2003 DAEWOO MATIZ charging

ENGINE ELECTRICAL 1E–13
DAEWOO M-150 BL2
GENERATOR SYSTEM CHECK
When operating normally, the generator indicator lamp
will come on when the ignition switch is in the ON posi-
tion and go out when the engine starts. If the lamp oper-
ates abnormally or if an undercharged or overcharged
battery condition occurs, the following procedure may
be used to diagnose the charging system. Remember
that an undercharged battery is often caused by acces-
sories being left on overnight or by a defective switch
that allows a lamp, such as a trunk or glove box lamp, to
stay on.
Diagnose the generator with the following procedure:
1. Visually check the belt and wiring.
2. With the ignition switch in the ON position and the en-
gine stopped, the charge indicator lamp should be on.
If not, detach the harness at the generator and
ground the ‘‘L’’ terminal in the harness with a fused,
5-ampere jumper lead.
If the lamp lights, replace the generator. Refer to
“Generator” in the On-Vehicle Service section.

If the lamp does not light, locate the open circuit
between the ignition switch and the harness con-
nector. The indicator lamp bulb may be burned out.
3. With the ignition switch in the ON position and the en-
gine running at moderate speed, the charge indicator
lamp should be off. If not, detach the wiring harness
at the generator.

If the lamp goes off, replace the generator. Refer to
“Generator” in the On-Vehicle Service section.

If the lamp stays on, check for a short to ground in
the harness between the connector and the indica-
tor lamp.
Important: Always check the generator for output be-
fore assuming that a grounded ‘‘L’’ terminal circuit has
damaged the regulator. Refer to “Generator” in the Unit
Repair section.

1E–38 ENGINE ELECTRICAL
DAEWOO M-150 BL2
CHARGING SYSTEM
D12E2021

DAEWOO M-150 BL2

SECTION 7B
MANUAL CONTROL HEATING, VENTILATION,
AND AIR CONDITIONING SYSTEM
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.
TABLE OF CONTENTS
Description and Operation 7B-2. . . . . . . . . . . . . . . . . .
System Components – Functional 7B-2. . . . . . . . . . .
Component Locator 7B-3. . . . . . . . . . . . . . . . . . . . . . . .
A/C System 7B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 7B-5. . . . .
General Diagnosis 7B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Refrigerant System 7B-5. . . . . . . . . . . . . .
Insufficient Cooling “Quick Check”
Procedure 7B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Temperature Relationship
of R-134a 7B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing the Refrigerant System 7B-7. . . . . . . . .
Air Conditioning System Diagnosis 7B-8. . . . . . . . . . . . .
Insufficient Cooling Diagnosis 7B-8. . . . . . . . . . . . . . .
Symptom Diagnosis 7B-11. . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test Chart (R-134a System) 7B-11. . . . . . .
Repair Instructions 7B-13. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 7B-13. . . . . . . . . . . . . . . . . . . . . . . . .
General A/C System Service Procedures 7B-13. . . . . .
O-Ring Replacement 7B-13. . . . . . . . . . . . . . . . . . . . .
Handling Refrigerant 7B-13. . . . . . . . . . . . . . . . . . . . . .
Handling of Refrigerant Lines and Fittings 7B-13. . .
Maintaining Chemical Stability in the
Refrigeration System 7B-14. . . . . . . . . . . . . . . . . . .
Discharging, Adding Oil, Evacuating, and
Charging Procedures for A/C System 7B-14. . . . . Serviceable Components 7B-17. . . . . . . . . . . . . . . . . . . .
Control Assembly and Control Cables 7B-17. . . . . . .
Blower Motor and Cooling Hose 7B-17. . . . . . . . . . . .
Blower Resistor 7B-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Switch 7B-17. . . . . . . . . . . . . . . . . . . . . .
A/C Push Knob 7B-18. . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver–Dryer and Dual Cut Switch 7B-18. . . . . . . .
Receiver–Dryer Bracket 7B-20. . . . . . . . . . . . . . . . . . .
Compressor 7B-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser 7B-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C High Pressure Pipe Line 7B-22. . . . . . . . . . . . . . .
A/C Low Pressure Pipe Line 7B-25. . . . . . . . . . . . . . .
Evaporator Unit and Drain Hose 7B-26. . . . . . . . . . . .
Unit Repair 7B-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Core and Expansion Valve 7B-28. . . . . .
Compressor Overhaul 7B-29. . . . . . . . . . . . . . . . . . . . .
Specifications 7B-30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7B-30. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7B-30. . . . . . . . . .
Special Tools and Equipment 7B-31. . . . . . . . . . . . . .
Special Tools Table 7B-31. . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 7B-32. . . . . . . . . .
A/C Diagrams 7B-32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Airflow (Typical) 7B-33. . . . . . . . . . . . . . . . . . . . . .
A/C System (Typical) 7B-33. . . . . . . . . . . . . . . . . . . . .

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–13
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
GENERAL A/C SYSTEM
SERVICE PROCEDURES
O-RING REPLACEMENT
Important: Even though O-rings may look identical, it is
extremely important that only recommended service re-
placement air conditioning O-rings be used, or exces-
sive leakage of refrigerant may occur.
Important: Always slip the O-ring onto the flange tube
to ensure proper locating and sealing.
Install new DAEWOO-approved service replacement air
conditioning O-rings whenever a joint or a fitting is disas-
sembled, except when the O-rings are provided on new
components.
When replacing O-rings on an air conditioning compo-
nent or a joint connection, the fitting design should be
identified to ensure installation of the correct air condi-
tioning service replacement O-ring.
Before installation, verify that both O-rings and fittings
have not been nicked or deformed. Deformed or nicked
parts must be replaced. Failure to use the proper service
replacement parts and procedures may result in exces-
sive refrigerant leakage.
HANDLING REFRIGERANT
Caution: Always work in a well-ventilated area and
avoid breathing any refrigerant fumes. If you have
difficulty breathing, seek medical attention immedi-
ately. If refrigerant comes in contact with any part of
your body, flush the exposed area with water. If a
rash or pain develops, seek medical attention.
Air conditioning systems contain refrigerant. This is a
chemical mixture which requires special handling proce-
dures to avoid personal injury.
Always wear goggles and wrap a clean cloth around the
fittings, the valves and the connections when performing
work that involves opening the refrigerant system. Do
not weld or steam clean on or near any vehicle-installed
air conditioning lines or components.
All refrigerant drums are shipped with a heavy metal
screw cap. The purpose of the cap is to protect the valve
and the safety plug from damage. It is good practice to
replace the cap after each use of the drum.
If it is necessary to transport or carry any container of
refrigerant in a vehicle, do not carry it in the passenger
compartment.
HANDLING OF REFRIGERANT LINES
AND FITTINGS
Notice: Using too low or too high torque when tightening
a fitting can result in loose joints or deformed joint parts.
Both conditions can result in refrigerant leakage.
Keep all metal tubing lines free of dents or kinks. Any
line restrictions will cause the loss of system capacity.
Never bend a flexible hose line to a radius of less than
four times the diameter of the hose.
Never allow a flexible hose line to come near the ex-
haust manifold.
Inspect flexible hose lines regularly for leaks or brittle-
ness.
Replace flexible hose lines with new lines if you find
signs of deterioration or leaking.
Discharge the refrigeration system of all refrigerant
before disconnecting any fitting in the refrigeration
system.
Proceed very cautiously regardless of the gauge
readings.
Open the fittings very slowly.
Keep your face and your hands away from the fitting
so that you will not be injured if there happens to be
liquid refrigerant in the line.
If you notice pressure when you loosen a fitting, allow
the pressure to bleed off as described under “Dis-
charging, Adding Oil, Evacuating and Charging Pro-
cedures for A/C System” in this section.
Cap or tape any refrigerant line immediately after it is
opened. This will prevent the entrance of moisture
and dirt, which can cause internal compressor wear
or plugged lines in the condenser, the evaporator
core, the expansion valve or the compressor inlet
screens.
Important: Use two proper wrenches to connect the O-
ring fittings.
Back up the opposing fitting to prevent distortion of
the connecting lines or the components.
Back up both the swaged fitting on the flexible hose
connections and the coupling to which it is attached
with two wrenches to prevent turning the fitting and
damaging the ground seat.
Keep the O-rings and the seats in perfect condition. A
burr or a piece of dirt may cause a refrigerant leak.
Dip new O-rings in clean PAG refrigerant oil before
installation.

7B–14 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
MAINTAINING CHEMICAL STABILITY
IN THE REFRIGERATION SYSTEM
The efficient operation and life of the air conditioning
system is dependent upon the chemical stability of the
refrigeration system. When foreign materials, such as
dirt, air, or moisture, contaminate the refrigeration sys-
tem, they will change the stability of the refrigerant and
the PAG compressor oil. They will also affect the pres-
sure-temperature relationship, reduce efficient opera-
tion, and can possibly cause interior corrosion and
abnormal wear of moving parts.
Observe the following practices to ensure chemical sta-
bility in the system:
Wipe away dirt or oil at and near any connection be-
fore opening that connection. This will reduce the
chance of dirt entering the system.
Cap, plug, or tape both sides of a connection as soon
as possible after opening the connection. This will
prevent the entry of dirt, foreign material, and mois-
ture.
Keep all tools clean and dry, including the manifold
gauge set and all replacement parts.
Use a clean and dry transfer device and container to
add PAG refrigerant oil. This will ensure that the oil
remains as moisture-free as possible. Refer to “Dis-
charging, Adding Oil, Evacuating and Charging Pro-
cedures for A/C System” in this section.
Have everything you need ready to allow you to per-
form all operations quickly when opening an A/C sys-
tem. Do not leave the A/C system open any longer
than necessary.
Evacuate and recharge any A/C system that has
been opened. Refer to “Discharging, Adding Oil, Eva-
cuating and Charging Procedures for A/C System” in
this section for the instructions to perform this proce-
dure properly.
All service parts are dehydrated and sealed before ship-
ping. They should remain sealed until just before making
connections. All the parts should be at room tempera-
ture before uncapping. This prevents condensation of
moisture from the air from entering the system. Reseal
all parts as soon as possible if the caps have been re-
moved but the connections cannot be made promptly.
DISCHARGING, ADDING OIL,
EVACUATING, AND CHARGING
PROCEDURES FOR A/C SYSTEMS
Caution: Use only refillable refrigerant tanks that
are authorized for the charging station being used.
The use of other tanks may cause personal injury or
void the warranty. Refer to the manufacturer’s in-
structions for the charging station.Caution: To avoid personal injury, always wear
goggles and gloves when performing work that in-
volves opening the refrigeration system.
A charging station discharges, evacuates, and re-
charges an air conditioning system with one hook-up.
Filtering during the recovery cycle together with filtering
during the evacuation cycle ensures a supply of clean,
dry refrigerant for A/C system charging.
Notice:
Never use the R-134a charging station on a system
charged with R-12. The refrigerants and the oils are
not compatible and must never be mixed in even the
smallest amount. Mixing refrigerant residue will dam-
age the equipment.
Never use adapters which convert from one size fit-
ting to another. This will allow contamination which
may cause system failure.
Charging Station Setup and Maintenance
Refer to the manufacturer’s instructions for all initial set-
up procedures and all maintenance procedures. There
are many charging stations available. All perform the
various tasks required to discharge the system and re-
cover refrigerant, evacuate the system, add a measured
amount of oil, and recharge an air conditioning system
with a measured amount of refrigerant.
Control Panel Functions
A charging station will have controls and indicators to al-
low the operator to control and monitor the operation in
progress. Refer to the manufacturer’s instructions for
details. These can be expected to include:
1. Main Power Switch: The main power switch supplies
electrical power to the control panel.
2. Display: The display shows the time programmed for
vacuum and the weight of the refrigerant pro-
grammed for recharging. Refer to the manufacturer’s
instructions for detailed programming information.
3. Low Side Manifold Gauge: This gauge shows the
system’s low side pressure.
4. High Side Manifold Gauge: This gauge shows the
system’s high side pressure.
5. Controls: This will contain the controls that control
various operating functions.
6. Low Side Valve: This valve connects the low side of
the A/C system to the unit.
7. Moisture Indicator: This indicator shows if the refrig-
erant is wet or dry.
8. High Side Valve: This valve connects the high side of
the A/C system to the unit.

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–15
DAEWOO M-150 BL2
Refrigerant Recovery
Important: Use only a refrigerant tank that is designed
for the charging station in use. The unit’s overfill limita-
tion mechanism is calibrated specifically for use with this
tank. The tank’s valves are also specifically for this unit.
1. Attach the high side hose with the quick disconnect
coupler to the high side fitting of the vehicle’s A/C
system.
2. Open the coupler valve after attachment.
3. Attach the low side hose with the quick disconnect
coupler to the low side fitting of the vehicle’s A/C
system.
4. Open the coupler valve after attachment.
5. Check the high side and the low side gauges on the
unit’s control panel in order to ensure that the A/C
system has pressure. If there is no pressure, there
is no refrigerant in the system to recover.
Important: If there is no refrigerant in the system, do
not continue with the recovery operation. This will draw
air into the recovery tank.
6. Open both the high side and the low side valves.
7. Open the gas and the liquid valves on the tank.
8. Drain any oil that may be in the oil separator.
9. Close the oil drain valve.
10. Plug the unit into the proper voltage outlet.
11. Turn on the main power switch.
Notice: Never reuse refrigerant oil. Damage to the A/C
system may result. Dispose of the refrigerant oil proper-
ly.
12. Begin the recovery process. Refer to the manufac-
turer’s instructions for the charging station in use.
Important: Some A/C system PAG lubricating oil may
be removed with the refrigerant during recovery. The
amount of oil removed varies. A charging station sepa-
rates the oil from the refrigerant and allows a means of
determining how much oil was removed. Replace the
same amount of oil when you recharge the system. Re-
fer to the manufacturer’s instructions for the charging
station in use.
13. Wait 5 minutes. Check the control panel low side
gauge. If the A/C has maintained vacuum, the re-
covery is complete.
14. There is more refrigerant in the system if the low
side gauge pressure rises above zero. Recover the
additional refrigerant. Repeat this step until the sys-
tem maintains vacuum for two minutes.
Important: If the control indicator shows that the refrig-
erant tank is full during the recovery process and the unit
shuts off, install an empty unit tank to store the refriger-
ant needed for steps later in the procedure. Do not use
any other type of tank.
Evacuation
The unit tank must contain a sufficient amount of R-134a
refrigerant for charging. Check the amount of refrigerant
in the tank. If there is less than 3.6 kg (8 pounds) of re-
frigerant, add new refrigerant to the tank. Refer to the
manufacturer’s instructions for adding refrigerant.
1. Verify that the high side and the low side hoses are
connected to the A/C system. Open both the high
side and the low side valves on the unit’s control pan-
el.
2. Open both the gas and the liquid valves on the tank.
Important: Refer to the manufacturer’s instructions for
the charging station in use. It is necessary to evacuate
the system before recharging it with new or recycled re-
frigerant.
3. Start the vacuum pump and begin the evacuation
process. Non-condensable gases (mostly air) are au-
tomatically vented from the tank during the recycling
process. You may hear the pressure being released.
4. Check for leaks in the system. Refer to the manufac-
turer’s instructions for the charging station in use.
Important:
Change the vacuum pump oil frequently. Refer to the
manufacturer’s instructions for the charging station in
use.
A/C System Oil Charge Replenishing
Any oil removed from the A/C system during the recov-
ery process must be replenished at this time.
1. Use the correct graduated bottle of polyalkaline glycol
(PAG) oil for the R-134a system.
Important:
Keep the oil bottles tightly capped at all times to pro-
tect the oil from moisture and contamination.
Never open the oil injection valve while there is posi-
tive pressure in the A/C system. This will result in oil
blow-back through the bottle vent. You must have
A/C system vacuum for this operation.
Never let the oil level drop below the pick-up tube
while charging or replenishing the system. This will
allow air into the A/C system.
2. Refer to the manufacturer’s instructions for the charg-
ing station in use. Add the proper amount of PAG oil
to the system.
3. Close the valve when the required oil charge has
been pulled into the system.
Charging
Important: Evacuate the air conditioning system before
charging.
1. Close the low side valve on the control panel.
2. Open the high side valve on the control panel.

7B–16 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
3. Refer to the manufacturer’s instructions for the charg-
ing station in use.
Enter the amount of refrigerant needed to charge
the A/C. Be sure that you are using the correct sys-
tem of measurement (kg, lb).
Begin the charging process.
Successful Transfer Complete
1. Close the high side valve on the unit’s control panel.
Both valves should be closed.
2. Start the vehicle and the A/C system.
3. Let the engine run until the readings on the high side
and low side gauges stabilize.
4. Compare the readings to the system specifications.
5. Check the evaporator outlet temperature to ensure
that the A/C system is operating within the system
specifications.
6. Keep the A/C running.
7. Close the high side coupler valve.
8. Disconnect the high side hose from the vehicle.9. Open the high side and low side valves on the con-
trol panel.
10. The system will quickly draw in refrigerant from both
hoses through the low side hose.
11. Close the low side coupler valve.
12. Disconnect the low side hose from the vehicle.
Unsuccessful Transfer
Sometimes the total charge does not transfer into the
A/C system. There are two reasons why this may occur.
1. The pressure in the unit’s tank and the pressure in the
A/C system are roughly equal. This will cause the
transfer to proceed too slowly. Refer to the manufac-
turer’s instructions for the charging station in use.
2. There was not enough refrigerant in the unit’s tank to
transfer the full charge. It is necessary to recover the
partial charge of refrigerant from the vehicle and
evacuate and charge the A/C system again. Refer to
the manufacturer’s instructions for the charging sta-
tion in use.

7B–18 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
D108B501
A/C PUSH KNOB
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the instrument cluster housing trim panel.
Refer to Section 9E, Instrumentation/Driver Informa-
tion.
2. Remove the A/C push knob.
Disconnect the temperature control cable from the
heater module (1).
Disconnect the mode control cable from the heater
module (2).
D108B502
Remove the control assembly retaining screws (3).
Pull out the control assembly.
Remove the A/C push knob by pushing the knob
lock (4).
Disconnect the A/C push knob electrical connector
(5).
D108A506
Installation Procedure
1. Install the A/C push knob to the control assembly.
2. Connect the A/C push knob electrical connector.
3. Install the control assembly with the screws.
4. Connect the mode control cable to the heater mod-
ule.
5. Connect the temperature control cable to the heater
module.
6. Install the instrument cluster housing trim panel. Re-
fer to Section 9E, Instrumentation / Driver Informa-
tion.
D18B503A
RECEIVER DRYER AND DUAL CUT
SWITCH
Removal Procedure
1. Recover the refrigerant. Refer to “Discharging, Add-
ing Oil, Evaculating, and Charging Procedures for
A/C System” in this section.
2. Remove the front bumper fascia. Refer to Section
9O, Bumpers and Fascias.
3. Remove the receiver dryer.
Disconnect the dual cut switch connector (1).
Remove the receiver dryer flange nuts (2).
Remove the bracket bolt (3).
Discard the O–ring (4).