2003 DAEWOO MATIZ lock

1B –8 SOHC ENGINE MECANICAL
DAEWOO M-150 BL2
TIMING BELT & ENGINE MOUNT
D12B4041
1 Engine Mount Damping Block
2 Engine Mount Intermediate Bracket
3 Engine Mount Brace Bracket
4 Transaxle Mount Bracket
5 Transaxle Mount Damping Block
6 Engine Mount Front Bracket
7 Engine Mount Front Damping Bush
8 Timing Belt9 Timing Belt Tensioner
10 Crankshaft Gear
11 Timing Belt Upper Front Cover
12 Timing Belt Lower Front Cover
13 Crankshaft Pulley
14 Engine Mount Lower Bracket
15 Engine Mount Upper Bracket

SOHC ENGINE MECANICAL 1B–9
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURE
COMPRESSION PRESSURE CHECK
Tools Required
09915–64510 Compression Pressure Gauge
Check the compression pressure in the following proce-
dures:
1. Warm up the engine to the normal operating tempera-
ture (Cooling temperature : 80–90C (176–194F)).
2. Stop the engine and then remove the high tension
cable and the spark plug.
3. Disconnect the distributor optical sensor connector.
4. Install the compression pressure gauge 09915–64510
(a) in the hole of spark plug.
D12B301A
5. Disengage the clutch in Neutral (to lighten starting
load on engine upon cranking), and depress the ac-
celerator all the way to make the throttle fully open.
6. Crank the engine with the starting motor, and read the
highest pressure on the compression pressure gauge.
The difference of measured value between cylinders
is 98.06kPa (14.22 psi) and less.
On checking, make the connection perfectly airtight
between the hole of spark plug and compression pres-
sure gauge.
Unit Standard Limit



Compression
Pressure
– 400 rpm
kPa(psi)1,225.75
(177.73)
1,176.72–
1,274.78
(170.62–
184.84)
7. After checking, remove the gauge and install the re-
moved parts.
OIL PRESSURE CHECK
Tools Required
09915–77310 Oil Pressure Gauge
Prior to check oil pressure, check the followings:
Check oil level and add if required.
Replace the discolored, deteriorated or diluted oil.
Check any oil leakage and repair the defective parts.
Check the compression pressure in the following proce-
dures:
1. Remove the oil pressure switch (b) from the cylinder
block.
2. Install the oil pressure gauge 09915–77310 (c) to the
mounting place of the oil pressure switch.
D12B302A
3. Start the engine and warm up to the normal operating
temperature.
4. Raise the engine speed up to 2,000rpm and then
read oil pressure.
Item Unit Standard
Oil Pressure – 2000rpmkPa
(psi)245.15–294.18
(35.55–42.66)
5. After checking, wrap the threads of oil pressure
switch with a seal tape and tighten it to the specified
torque 12–16 N
m (106–144 lb-in).
6. Start the engine and check oil pressure switch for oil
leakage.

1B –12 SOHC ENGINE MECANICAL
DAEWOO M-150 BL2
D102B310
5. If the ignition timing exceeds the specified value,
loosen the distributor bolts and adjust it to the speci-
fied ignition timing by turning the distributor body (s).
D102B311
VA LV E T I M I N G C H E C K A N D
ADJUSTMENT
Check the valve timing in the following procedures:
1. After removing the high headlamp, loosen the bolts
(a) and remove the timing belt front upper cover (b).
D102B312
2. Turning the crankshaft clockwise twice, align the
notch (d) on the crankshaft pulley (c) with the mark 0
(e) for the timing check on the timing belt front lower
cover.
D102B313
3. Check if the notch (f) on the camshaft sprocket is
aligned with the triangle pointer (g) on the timing belt
rear cover.
Important: Notch (f) should be aligned with pointer (g)
to set the valve timing normally.
D102B314

SOHC ENGINE MECANICAL 1B–13
DAEWOO M-150 BL2
Adjust the valve timing in the following procedures:
1. Loosen the bolt and remove the timing belt pulley (c).
In loosening the bolt, use the driver (h) in the picture
shown.
D102B315
2. Remove the oil level gauge guide tube (i) and the tim-
ing belt front lower cover (j).
D102B316
3. Remove the timing belt tensioner (k) and the timing
belt (l).
D102B317
4. Using the bolt, turn the crankshaft clockwise to align
the mark (m) on the crankshaft sprocket with the
pointer (n) on the oil pump housing. Then, turn the
camshaft to align the notch (f) with the pointer (g).
D102B318
5. Install the timing belt (l) and the tensioner (k). (Do not
tighten the tensioner bolt completely.)
Turning the crankshaft clockwise twice, align the
mark (m) with the pointer (n) and tighten the tensioner
bolt to 15–23 N
m (11–17 lb-ft).
D12B319A
6. Install all removed parts.

1D – 2 ENGINE COOLING
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION
The cooling system maintains the engine temperature at
an efficient level during all engine operating conditions.
When the engine is cold the cooling system cools the
engine slowly or not at all. This slow cooling of the en-
gine allows the engine to warm up quickly.
The cooling system includes a radiator(a) and cooling
fan(b), a thermostat and housing(c), a coolant pump(d),
a coolant pump drive belt and coolant hose. The timing
belt drives the coolant pump.
All components must function properly in order for the
cooling system to operate. The coolant pump draws the
coolant from the radiator. The coolant then circulates
through water jackets in the engine block and the cylin-
der head, distributor case(e), throttle body(f). When the
coolant reaches the operating temperature of the ther-
mostat, the thermostat opens. The coolant then goes
back to the radiator where it cools.
This system directs some coolant through the hoses to
the heater core(g). This provides for heating and de-
frosting. The surge tank(h) is connected to the radiator
and throttle body to recover the coolant displaced by ex-
pansion from the high temperatures. The surge tank
maintains the correct coolant level.
The cooling system for this vehicle has no radiator cap
and drain cock. The coolant is added to the cooling sys-tem through the surge tank. To drain the cooling system,
disconnect the lower radiator hose and drain the cool-
ant.
RADIATOR
This vehicle has a lightweight tube-and-fin aluminum ra-
diator.
SURGE TANK
The surge tank is a transparent plastic reservoir, similar
to the windshield washer reservoir.
The surge tank is connected to the radiator and throttle
body by a hose. As the vehicle is driven, the engine cool-
ant heats and expands. The portion of the engine cool-
ant displaced by this expansion flows from the radiator
into the surge tank. The air trapped in the radiator is de-
gassed into the surge tank.
When the engine is stops, the engine coolant cools and
contracts. The displaced engine coolant is then drawn
back into the radiator. This keeps the radiator filled with
the coolant to the desired level at all times and increases
the cooling efficiency.
Maintain the coolant level between the MIN and the
MAX marks on the surge tank when the system is cold.
D102D001

1D–8 ENGINE COOLING
DAEWOO M-150 BL2
COOLING SYSTEM DIAGNOSIS
Condition Probable Cause Correction
Engine OverheatsA loss of the coolant.Add the coolant.
A weak coolant solution.Confirm that the coolant solution is a
50/50 mixture of ethylene glycol and
water.
Any dirt, any leaves, or any insects
on the front of the radiator.Clean the front of the radiator.
The leakage from the hoses, the
coolant pump, the heater, the
thermostat housing, the radiator, the
heater core, or the head gasket.Replace any damaged components.
A faulty thermostat.Replace a damaged thermostat.
Retarded ignition timing.Perform an ECM code diagnosis.
Confirm the integrity of the timing
belt.
An improperly operating electric
cooling fan.Replace the electric cooling fan.
Plugged or rotted radiator hoses.Replace any damaged radiator
hoses.
A faulty water pump.Replace a faulty water pump.
A faulty surge tank cap.Replace a faulty surge tank cap.
A cracked or plugged cylinder head
or engine block.Repair the damaged cylinder head or
the damaged engine block.
A faulty radiator.Replace a faulty radiator.
Loss of CoolantA leak in the radiator.Replace a damaged radiator.
A leak in the surge tank or the hose.Replace the surge tank or the hose.
Looseness or damage of radiator
hoses, heater hoses, or connections.Reseat the hoses.
Replace the hoses or the clamps.
Leaks in the coolant pump seal.Replace the coolant pump seal.
Leaks in the coolant pump gasket.Replace the coolant pump gasket.
An improper cylinder head torque.Tighten the cylinder head bolts to
specifications.
Replace the cylinder head gasket, if
needed.
Leaks in the intake manifold, cylinder
head gasket, heater core.Repair or replace any components,
as needed to correct the leak.
Engine Fails to Reach
Normal OperatingThermostat to be stuck open or to be
wrong type.Install a new thermostat of the
correct type and heat range.
Temperature or Cool Air
from the HeaterThe coolant level below the MIN
mark on the surge tank.Add sufficient coolant to raise the
fluid to the specified mark on the
surge tank.

1E–18 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E517
IGNITION COIL
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ignition wires and ignition coil connec-
tor.

Disconnect the ignition wire (1).

Disconnect the ignition coil connector by pushing
the connector’s lock(2).
D102E518
3. Remove the ignition coil.

Remove the screws (1).

Remove the ignition coil (2).
D12E519A
4–7 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the ignition coil screws.
Tighten
Tighten the ignition coil screws to 4–7 Nm (35–62 lb-
in).

DAEWOO M-150 BL2
SECTION 1F
ENGINE CONTROLS
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 LOCK unless
otherwise noted.
TABLE OF CONTENTS
Description and Operation 1F-4. . . . . . . . . . . . . . . . . .
Ignition System Operation 1F-4. . . . . . . . . . . . . . . . . .
Electronic Ignition System Ignition Coil 1F-4. . . . . . .
Crankshaft Position Sensor 1F-4. . . . . . . . . . . . . . . . .
Camshaft Position Sensor 1F-4. . . . . . . . . . . . . . . . . .
Idle Air System Operation 1F-4. . . . . . . . . . . . . . . . . .
Fuel Control System Operation 1F-4. . . . . . . . . . . . . .
Evaporative Emission Control System
Operation 1F-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controlled Charcoal Canister 1F-5. . . . . . . . . . . . . . . .
Positive Crankcase Ventilation Control System
Operation 1F-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor 1F-6. . . . . . . . .
Throttle Position Sensor 1F-6. . . . . . . . . . . . . . . . . . . .
Catalyst Monitor Oxygen Sensors 1F-6. . . . . . . . . . .
Electric Exhaust Gas Recirculation Valve 1F-6. . . . .
Intake Air Temperature Sensor 1F-7. . . . . . . . . . . . . .
Idle Air Control Valve 1F-7. . . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure Sensor 1F-7. . . . . . . . . .
Engine Control Module 1F-8. . . . . . . . . . . . . . . . . . . . .
Fuel Injector 1F-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Cutoff Switch (Inertia Switch) 1F-8. . . . . . . . . . .
Knock Sensor 1F-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable Reluctance (VR) Sensor 1F-8. . . . . . . . . . . .
Octane Number Connector 1F-8. . . . . . . . . . . . . . . . .
Strategy-Based Diagnostics 1F-9. . . . . . . . . . . . . . . .
EOBD Serviceability Issues 1F-9. . . . . . . . . . . . . . . . .
Serial Data Communications 1F-10. . . . . . . . . . . . . . .
Euro On-Board Diagnostic (EOBD) 1F-10. . . . . . . . .
Comprehensive Component Monitor Diagnostic
Operation 1F-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common EOBD Terms 1F-11. . . . . . . . . . . . . . . . . . . .
DTC Types 1F-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading Diagnostic Trouble Codes 1F-13. . . . . . . . .
Primary System-Based Diagnostics 1F-15. . . . . . . . Diagnostic Information and Procedures 1F-17. . . .
System Diagnosis 1F-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 1F-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Learn Procedure 1F-17. . . . . . . . . . . . . . . . . . . . .
Euro On-Board Diagnostic (EOBD) System
Check 1F-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECM Output Diagnosis 1F-20. . . . . . . . . . . . . . . . . . . .
Multiple ECM Information Sensor DTCs Set 1F-21. .
Engine Cranks But Will Not Run 1F-25. . . . . . . . . . . .
No Malfunction Indicator Lamp 1F-30. . . . . . . . . . . . .
Malfunction Indicator Lamp On Steady 1F-32. . . . . .
Fuel System Diagnosis 1F-34. . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay Circuit Check 1F-36. . . . . . . . . . . .
Main Relay Circuit Check 1F-38. . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure Check 1F-40. . . . . . . . . .
Idle Air Control System Check 1F-42. . . . . . . . . . . . .
Ignition System Check 1F-45. . . . . . . . . . . . . . . . . . . .
Engine Cooling Fan Circuit Check 1F-48. . . . . . . . . .
Data Link Connector Diagnosis 1F-52. . . . . . . . . . . . .
Fuel Injector Balance Test 1F-54. . . . . . . . . . . . . . . . .
Diagnostic Trouble Code Diagnosis 1F-55. . . . . . . .
Clearing Trouble Codes 1F-55. . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes 1F-55. . . . . . . . . . . . . . . . .
DTC P0107 Manifold Absolute Pressure Sensor
Low Voltage 1F-58. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0108 Manifold Pressure Sensor High
Voltage 1F-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0112 Intake Air Temperature Sensor Low
Voltage 1F-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0113 Intake Air Temperature Sensor High
Voltage 1F-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0117 Engine Coolant Temperature Sensor
Low Voltage 1F-72. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0118 Engine Coolant Temperature Sensor
High Voltage 1F-74. . . . . . . . . . . . . . . . . . . . . . . . . . .