2003 DAEWOO MATIZ radiator

1D–16 ENGINE COOLING
DAEWOO M-150 BL2
9–12 Nm
9–12 Nm
D12D520A
D12D521A
Installation Procedure
1. Install the coolant pump with the new gasket.
Tighten
Tighten the bolts and the nuts to 9–12 Nm (80–106
lb-in) (a).
2. Install the rear timing belt cover.
Tighten
Tighten the bolts to 9–12 Nm (80–106 lb-in) (b).
3. Install the timing belt. Refer to Section 1B, Engine
Mechanical.
4. Connect the lower radiator hose and drain the cool-
ant. Refer to “Draining and Refilling the Cooling Sys-
tem” in this section.
5. Connect the negative battery cable.

ENGINE COOLING 1D–17
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
Cooling
SystemCooling Type–Forced Water
Circulation
CoolantCoolant CapacityL/qt3.8/4.00
Thermostat Type–Pellet Type
Temperature(opened initially)°C(°F)82(180)
ThermostatTemperature(perfectly opened)°C(°F)95(203.4)
Temperature(perfectly closed)°C(°F)80(176.4)
Stroke(perfectly opened)mm(in.)8 (0.32)
Cooling Fan Type–Electric
Blade NumberEA6
Cooling Fan Diametermm(inch)300(11.8)
Electric CoolingTemperature At Low Speed ON°C(°F)93(199.8)Fan
Temperature At Low Speed OFF°C(°F)90(194.4)
Temperature At High Speed ON°C(°F)100(212.4)
Temperature At High Speed OFF°C(°F)97(207)
Surge TankOpen Pressure of The Pressure ValvekPa (psi)120–150
(17.4–21.8)
Surge Tank
Open Pressure of The Vacuum ValvekPa (psi)10 (1.5)
Water Pump Type–Centrifugal
Coolant PumpImpeller Diametermm(in.)60(2.36)
Impeller Blade NumberEA7
Radiator Type–Cross–Flow
Core Widthmm(in.)458(18.03)RadiatorCore Heightmm(in.)295(11.61)
Core Depth (Standard/Heavy Duty)mm(in.)16/27(0.63/1.06)
Resistance
(Coolant Temperature 50°C(122.4°F))Ω185.2
Coolant
TemperatureResistance
(Coolant Temperature 85°C(185.4°F))Ω49.2
SensorResistance
(Coolant Temperature 105°C(221.4°F))Ω27.5
Engine CoolantResistance
(Coolant Temperature 20°C(68.4°F))Ω3,520
Temperature
SensorResistance
(Coolant Temperature 80°C(176.4°F))Ω332

1D–18 ENGINE COOLING
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Engine Coolant Temperature Sensor10–89
Coolant Temperature Sensor2015–
Coolant Pipe Bolt8 – 15–71 – 130
Electric Cooling Fan Motor Nut3.0 – 3.2–27 – 28
Electric Cooling Fan Assembly Bolt3.5 – 4.5–31 – 40
Distributor Case Bolt/Nut8 – 12–71 – 106
Radiator Mounting Bracket Bolt3.5 – 4.5–31 – 40
Thermostat Housing Bolt8 – 15–71 – 130
Water Inlet Cap Bolt8 – 12–71 – 106
Coolant Pump Bolt/Nut9–12–80 – 106
Coolant Pump Stud Bolt9–12–80 – 106

1F–290 ENGINE CONTROLS
DAEWOO M-150 BL2
DETONATION/SPARK KNOCK
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Fill the fuel tank with a known good grade of
gasoline that has the octane rating of the value
specified.
2. Reevaluate the vehicle’s performance.
Does the detonation problem still exist?
91 octaneGo to Step 3System OK
3
1. Inspect for low engine coolant level.
2. Check for restricted airflow to the radiator or
restricted coolant flow.
3. Check for a faulty thermostat.
4. Check for an incorrect coolant solution.
Is the problem found?
–
Go to Step 4Go to Step 5
4
Repair or replace any cooling system components
as needed.
Is the repair complete?
–
System OK
–
5
1. Check the engine coolant temperature using the
scan tool.
2. Replace the Engine Coolant Temperature (ECT)
sensor if the resistance is not within specifications
as listed in the Diagnostic Aids for diagnostic
trouble code P0118.
Is the problem found?
–
Go to Step 6Go to Step 7
6
Replace the ECT sensor or repair the circuit as
needed.
Is the repair complete?
–
System OK
–
7
1. Check the ignition system output with a spark
tester.
2. Inspect the spark plugs for the proper heat range
and gap.
3. Check for the proper operation of the ignition
controls.
Is the ignition system operating properly?
–
Go to Step 9Go to Step 8
8
Repair or replace the ignition system components as
needed.
Is the repair complete?
–
System Ok
–
9
1. Connect the scan tool to the Data Link Connector
(DLC).
2. Road test the vehicle at the speed of the
complaint.
3. Monitor the long term fuel trim reading from the
scanner data stream.
Is the long term fuel trim reading above the value
specified?
25%
Go to
“Diagnostic Aids
for DTC P0171”
Go to Step 10
10Check the fuel system pressure.
Is the problem found?380 kPa
(55 psi)
Go to Step 11Go to Step 12
11
Repair or replace the fuel system components as
needed.
Is the repair complete?
–
System OK
–

FIVE-SPEED MANUAL TRANSAXLE 5B–11
DAEWOO M-150 BL2
D13B5031
6. Disconnect the radiator lower hose.

Remove the bolts (1).

Disconnect the radiator lower hose (2).
7. Remove crankshaft position (CKP) sensor.

Remove the bolt (3).

Disconnect the CKP sensor connector

Remove the CKP sensor.
D103B507
8. Disconnect the speedometer cable.

Loosen the nut (1).

Disconnect the cable (2).
9. Remove the vehicle speed sensor (VSS) if
equipped.

Disconnect VSS connector.

Remove the VSS.
D102E502
10. Remove the starter motor.

Remove upper two bolts that securing starter mo-
tor to transaxle.
D13B5041
11. Fix the engine assembly.

Remove the cowl panel weatherstrip.

Position the engine support fixture DW110–021
on the cowl panel and the front upper panel.

Tighten the engine fixture joint with a bolt after re-
moving exhaust manifold bolt (No.4).

5B–16 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5032
8. Install the radiator lower hose and crank position
(CKP) sensor.
Tighten
Tighten the radiator lower hose bolt to 8–15 Nm
(70–132 lb-in).
Tighten the CKP sensor bolt to 5–8 Nm (44–70 lb-
in).
D13B520A
9. Refill the transaxle fluid.

Tighten the drain plug to 25–30 Nm (18–22 lb-ft)
(a).

Remove the oil level plug (1).

Refill recommended fluid to the proper level.
Classification 75W – 85 (GL–4) Capacity2.1L (2.21 qt)

Tighten the oil level plug to 36–54 Nm (26–40 lb-ft)
(b).
D13B521A
10. Adjust the clutch cable. Refer to Section 5C, Clutch.

Adjust the clutch cable by the clutch cable adjust
nut.
11. Install the transaxle under cover.
Tighten
Tighten the transaxle under cover bolts to 35–55
Nm (25–41 lb-ft).
D103B501
GEAR SHIFT CONTROL CASE
ASSEMBLY
Removal Procedure
1. Remove the air hose (air cleaner to throttle body).
Refer to Section 1B, SOHC Engine Mechanical.
2. Remove the battery.
3. Disconnect the select and the shift control cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift control cable
(3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.

FIVE-SPEED MANUAL TRANSAXLE 5B–53
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
5th/Reverse Gear Shift Shaft Bolt10 – 167 – 12–
Back Up Light Switch Nut15 – 1811 – 13–
Counter Shaft 5th Gear Nut60 – 8044 – 59–
Crankshaft Position Sensor Bolt5 – 8–44 – 70
Differential Ring Gear Bolt80 – 10059 – 74–
Engine Mounting Front Bracket Bolt
(Cylinder Block Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolt
(Crossmember Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolts
(Crossmember Side)45 – 5533 – 41–
Engine Mounting Front Damping Bush Bolt/Nut
(Bracket Side)68 – 8351 – 61–
Front Exhaust Pipe Nut
(Exhaust Manifold Side/Muffler Side)25 – 3518 – 25–
Gear Shift Control Case Bolt18 – 2813 – 21–
Gear Shift Lever Bolt4 – 7–35 – 62
High Speed Shift Shaft Bolt10 – 167 – 12–
Low Speed Shift Shaft Bolt10 – 167 – 12–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–
Radiator Lower Hose Bracket Bolts8 – 15–70 – 132
Reverse Idle Gear Shaft Bolt18 – 2813 – 21–
Reverse Shift Lever Bolt18 – 2813 – 21–
Select Cable Nut(Shift Lever Side)8 – 12–71 – 106
Select Lever Bolt18 – 2813 – 21–
Side Cover Plate Screw6 – 7–53 – 62
Shift Guide Bolt18 – 2813 – 21–
Shift Interlock Bolt18 – 2813 – 21–
Side Cover Bolt8 – 12–71 – 106
Speedometer Driven Gear Bolt4 – 7–35 – 62
Starter Motor Bolt18 – 2813 – 21–
Transaxle Case Bolt15 – 2211 – 16–
Transaxle Case(left) Cap Bolt8 – 12–71 – 106
Transaxle Lower Bolt and Nut(Engine Side)55 – 6541 – 48–
Transaxle Mounting Bolt(Body Side)45 – 5533 – 41–
Transaxle Mounting Bolt and Nut(Transaxle Side)55 – 6541 – 48–
Transaxle Upper Bolt(Engine Side)55 – 6541 – 48–
Transaxle Under Cover Bolt35 – 5525 – 41–

7B–2 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
SYSTEM COMPONENTS
–FUNCTIONAL
Compressor
All compressors are belt–driven from the engine crank-
shaft through the compressor clutch pulley. The com-
pressor pulley rotates without driving the compressor
shaft until on electromagnetic clutch coils energized.
When voltage is applied to energize the clutch coil, the
clutch plate and hub assembly are drawn toward the
pulley. The magnetic force locks the clutch plate and
pulley together as one unit to drive the compressor
shaft.
Condenser Core
The condenser assembly in front of the radiator consists
of coils which carry the refrigerant and cooling fins that
provide the rapid transfer of heat. The air passing
through the condenser cools the high–pressure refriger-
ant vapor and cause it to condense into a liquid.
Expansion Valve
The expansion valve is located on the passenger
compartment side of the dash panel. The expansion
valve can fail in three different positions: open, closed,
or restricted. An expansion valve that fails in the open
position will result in a noisy A/C compressor or no cool-
ing. The cause can be a broken spring, a broken ball, or
excessive moisture in the A/C system. If the spring or
the ball is found to be detective, replace the expansion
valve. If excessive moisture is found in the A/C system,
recycle the refrigerant. An expansion valve that fails in
the closed position will result in low suction pressure and
no cooling. This may be caused by a failed power done
or excessive moisture in the A/C system. If the power
dome on the expansion valve is found to be defective,
replace the expansion valve. If excessive moisture is
found in the A/C system, recycle the refrigerant.
A restricted expansion valve will result in low suction
pressure and no cooling. This may be caused by debrisin the refrigerant system. If debris is believed to be
cause, recycle the refrigerant, replace the expansion
valve, and replace the receiver/dryer.
Evaporator Core
The evaporator is device which cools and dehumidifies
the air before it enters the vehicle. High–pressure liquid
refrigerant flows through the expansion tube (orifice)
and becomes a low–pressure gas in the evaporator. The
heat in the air passing through the evaporator core is
transferred to the cooler surface of the core, which cools
the air. As the process of heat transfer from the air to the
evaporator core surface is taking place, any moisture
(humidity) in the air condenses on the outside surface of
the evaporator core and is drained off as water.
Receiver–Dryer
The sealed receiver–dryer assembly is connected to the
evaporator outlet pipe. It acts as a refrigerant storing
container, receiving liquid and some vapor and refriger-
ant oil from the evaporator.
At the bottom the receiver–dryer is the desiccant, which
acts as a drying agent for the moisture that may have
entered the system. The receiver–dryer is serviceable
only as an assembly.
Dual Cut Switch
The dual cut switch controls compressor operation when
the cycling refrigerant pressure is dropped or surged.
Evaporator Thermistor
A semiconductor which resistance is noticeably changed
as the change of temperature. When the refrigerant tem-
perature of the evaporator drops to 0
C (32
F) and be-
low, the evaporator cores get stuck with frost or ice,
reducing the airflow, lowering the cooling capacity. The
thermistor is a sensor which is used to prevent from frost-
ing or icing.
The thermistor is installed on the evaporator.