2003 DAEWOO MATIZ heating

1F–48 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F090
ENGINE COOLING FAN CIRCUIT CHECK
Circuit Description
The engine cooling fan circuit operates the cooling fan.
The cooling fan is controlled by the engine control mod-
ule (ECM) based on input from the coolant temperature
sensor (CTS) and the A/C ON/OFF. The ECM controls
the low speed cooling fan operation by internally ground-
ing the ECM connector terminal 39. This energizes the
low speed cooling fan relay and operates the cooling fan
at low speed. The low speed cooling fan operation is
achieved by the cooling fan resistor causing a drop in
the voltage supplied to the cooling fan. The ECM con-
trols the high speed cooling fan operation by internally
grounding the ECM connector terminal 5. This ener-
gizes the high speed cooling fan relay, bypassing the ra-
diator fan resistor. This results in high speed cooling fan
operation.
Diagnostic Aids

If the owner complained of an overheating problem, it
must be determined if the complaint was due to anactual boil over, or the engine coolant temperature
gauge indicated overheating. If the engine is over-
heating and the cooling fans are on, the cooling sys-
tem should be checked.

If the engine fuse block fuse EF15 become open
(blown) immediately after installation, inspect for a
short to ground in the wiring of the appropriate circuit.
If the fuse become open (blown) when the cooling
fans are to be turned on by the Engine Control Mod-
ule (ECM), suspect a faulty cooling fan motor.

The ECM will turn the cooling fan on at low speed
when the coolant temperature is 93C (199F). The
ECM will turn the cooling fans off when the coolant
temperature is 90C (194F).

The ECM will turn the cooling fans on at high speed
when the coolant temperature is 100C (212F). The
ECM will change the cooling fans from high speed to
low speed when the coolant temperature is 97C
(207F).

1G – 2 ENGINE EXHAUST
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
EXHAUST SYSTEM
Notice: When you are inspecting or replacing exhaust
system components, make sure there is adequate clear-
ance from all points on the underbody to avoid possible
overheating of the floor pan and possible damage to the
passenger compartment insulation and trim materials.
Check the complete exhaust system and the nearby
body areas and tailgate for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connec-
tions or other deterioration which could permit exhaust
fumes to seep into the luggage or passenger compart-
ment. Dust or water in the luggage may be an indication
of a problem in one of these areas. Any defects should
be corrected immediately.
MUFFLER
The muffler reduces the temperature, pressure, and
noise of the exhaust gas.
Aside from the exhaust manifold connection, the ex-
haust system uses a flange and seal joint design op-
posed to a slip joint coupling design with clamp. If holes,
open seams or any deterioration is discovered upon in-
spection of the front muffler and pipe assembly, thecomplete assembly should be replaced. The same pro-
cedure is applicable to the rear muffler assembly.
Heat shields in the front and rear muffler assembly posi-
tions, as well as for the catalytic converter and front ex-
haust pipe, protect the vehicle and the environment from
high temperatures the exhaust system develops.
CATALYTIC CONVERTER
Notice: When jacking or lifting the vehicle from the body
side rails, be certain that the lift pads do not contact the
catalytic converter as this could damage the catalytic
converter.
Notice: The catalytic converter requires the use of un-
leaded fuel only, or damage to the catalyst will result.
The catalytic converter is an emission control device
added to the exhaust system to reduce pollutants from
the exhaust pipes.
The oxidation catalyst is coated with a catalytic material
containing platinum and palladium, which reduces levels
of hydrocarbon (HC) and carbon monoxide (CO) from
the exhaust gas. The three-way catalyst has coatings
which contain platinum and rhodium, which additionally
lower the levels of oxides of nitrogen (NOx).

4C –6 POWER BOOSTER
DAEWOO M-150 BL2
D24C001
POWER BOOSTER ASSEMBLY
(RIGHT–HAND DRIVE)
Removal Procedure
1. Remove the master cylinder assembly. Refer to Sec-
tion 4B, Master Cylinder.
2. Disconnect the vacuum hose from the power booster.
3. Remove the instrument panel assembly. Refer to
Section 9E, Instrument/Driver Information.
4. Remove the evaporator unit mounting screws and
take off the evaporator unit a little. Refer to Section
7B, Manual Control Heating, Ventilation, and Air Con-
ditioning System.
5. Remove the power booster.

Straighten the cotter pin and remove it (1).

Remove the clevis pin (2).
D24C002

Remove the nuts (3).
D107A521

Remove the power booster (4).

POWER BOOSTER 4C–7
DAEWOO M-150 BL2
D24C003
Installation Procedure
1. Install the power booster with the new cotter pin, cle-
vis pin and nuts.
Tighten
Tighten the nuts to 16 Nm (12 lb-ft).
Important: Make sure the distance from the booster
to the center of the clevis bore should be 100mm
(3.94 in.).
2. Install the evaporator unit with the screws. Refer to
Section 7B, Manual Control Heating, Ventilation, and
Air Conditioning System.
3. Install the instrument panel assembly. Refer to Sec-
tion 9E, Instrument/Driver Information.
4. Connect the vacuum hose to the power booster.
5. Install the master cylinder assembly. Refer to Section
4B, Master Cylinder.

DAEWOO M-150 BL2
SECTION 7A
HEATING AND VENTILATION 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 7A-2. . . . . . . . . . . . . . . . . .
Heating and Ventilation Systems 7A-2. . . . . . . . . . . .
Component Locator 7A-3. . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly 7A-3. . . . . . . . . . . . . . . . . . . . . . . . .
Blower Module Assembly 7A-4. . . . . . . . . . . . . . . . . . .
Air Distributor and Heater Module
Assembly 7A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Informatin and Procedures 7A-6. . . . . . .
Heater System 7A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insufficient Heating or Defrosting 7A-6. . . . . . . . . . . .
Blower Electrical 7A-10. . . . . . . . . . . . . . . . . . . . . . . . .
Improper Air Delivery or No Mode Shift 7A-11. . . . . .
Too Much Heat 7A-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 7A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Noise 7A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 7A-18. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 7A-18. . . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly and Control Cables 7A-18. . . . . . . Blower Motor and Cooling Hose 7A-20. . . . . . . . . . . .
Blower Resistor 7A-20. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Switch 7A-21. . . . . . . . . . . . . . . . . . . . . .
Heater Hoses 7A-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Module 7A-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Module 7A-25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Defroster Duct and Hoses 7A-26. . . . . . . . . . . . . . . . .
Ventilation Duct 7A-27. . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 7A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core 7A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 7A-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7A-29. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7A-29. . . . . . . . . .
Special Tools and Equipment 7A-30. . . . . . . . . . . . . .
Special Tools Table 7A-30. . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 7A-31. . . . . . . . . .
Non-A/C Diagrams 7A-31. . . . . . . . . . . . . . . . . . . . . . .
Air Flow Through Ducts (Non–A/C) 7A-32. . . . . . . . .

7A–2 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
DESCRIPTION AND SYSTEM OPERATION
HEATING AND VENTILATION
SYSTEMS
The base heater system is designed to provide heating,
ventilation, windshield defrosting, and side window de-
fogging.
The heater and fan assembly blower regulates the air-
flow from the air inlet for further processing and distribu-
tion.
The heater core transfers the heat from the engine cool-
ant to the inlet air.
The temperature door regulates the amount of the air
that passes through the heater core. The temperature
door also controls the temperature of the air by control-
ling the mix of the heated air and the ambient air.
The mode door regulates the flow and the distribution
of the processed air to the heater ducts and to the de-
froster ducts.
This console-mounted heating and ventilation panel
contains the following:
Three Rotary Control Knobs
1. The Rotary Temperature Control Knob

Actuates by cable.

Raises the temperature of the air entering the ve-
hicle by rotation toward the right, or the red portion
of the knob.
2. The Rotary Blower Control Knob

Turns on to operate the blower motor at four speeds.

Turns
to stop the blower.

Operates completely independently both from the
mode control that regulates the defroster door and
from the temperature control knob.
Changes the fan speed in any mode and at any
temperature setting.
3. The Rotary Mode Control Knob:

Actuates by cable.

Regulates the air distribution between the wind-
shield, the instrument panel, and the floor vents.
Push Knobs
1. The Rear Window Defogger Push Knob

Controls the rear window defogger.

Turns ON the rear window defogger when the push
knob is pressed and the indicator lamp is illumi-
nated.
2. The A/C Push Knob (if the vehicle is equipped with air
conditioning)

Controls the A/C.

Turns the A/C ON when the push knob is down.
However, if the blower control knob is OFF, the A/C
system is OFF, regardless of the position of the
A/C knob.
One Lever
1. The Fresh Air Control Lever

Operates by cable.

Switches between recirculating passenger compart-
ment air and bringing outside air into the passenger
compartment.

Draws in outside air when the lever is moved to the
left.

Recirculates inside air when the lever is moved to
the right.

HEATING AND VENTILATION SYSTEM 7A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
CONTROL ASSEMBLY
(Left–Hand Drive Shown, Right–Hand Drive Similar)
D108A401
1. HVAC Control Assembly
2. Temperature Control Cable
3. Mode Select Cable
4. Rack
5. Bracket
6. Cable Clamp
7. Bulb Socket Assembly
8. Pinion Assembly
9. A/C Switch
10. Housing
11. Detent Cap12. Detent Spring
13. Blower Switch
14. Rear Defogger Switch
15. Recirculating/Fresh Air Door Cable
16. Panel
17. A/C Push Knob
18. Rotary Knob
19. Recirculating Knob
20. Rear Defogger Push Knob
21. Recirculation

7A–4 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
BLOWER MODULE ASSEMBLY
(Left–Hand Drive Shown, Right–Hand Drive Similar)
D18A402A
1. Blower Module Assembly
2. Plastic Washer
3. Blower Link
4. Blower Lever
5. Air Intake Case
6. Valve Retainer
7. Heater Duct Assembly
8. Blower Connector Duct9. Orifice Case
10. Cable Clamp
11. Blower Valve
12. Blower Resistor
13. Lower Case
14. Cooling Hose
15. Blower Motor