2003 DAEWOO MATIZ Ignition

STEERING WHEEL AND COLUMN 6E–11
DAEWOO M-150 BL2
D105A515
STEERING COLUMN
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering Wheel”
in this section.
Caution: Disconnect the negative battery cable and
let the vehicle sit for 1 minute to deactivate the air-
bag (For vehicle with SIR)
2. Remove the turn signal switch and wiper switch. Re-
fer to “Turn Signal Switch and Lever/Wiper Switch
and Lever in this section.
3. Remove the switch housing. Refer to “Switch Hous-
ing” in this section.
D105A516
4. Remove the ignition switch. Refer to “Ignition Switch”
in this section.
5. Remove the ignition lock cylinder. Refer to “Ignition
Lock Cylinder” in this section.
6. Remove the steering column.

Match–mark on the intermediate shaft and the
steering column shaft (1).

Remove the intermediate shaft upper pinch bolt
(2).

Remove the steering column lower nuts (3).

Remove the steering column upper nuts (4).
D15A517B
D15A518B
Installation Procedure
Important: Align the match–mark on the intermediate
shaft and the steering column shaft.
1. Install the steering column.

Install the intermediate shaft upper pinch bolt (1).
Tighten
Tighten the pinch bolt to 21–29 Nm (16–22 lb-ft).

Install the steering column lower nuts (2).
Tighten
Tighten the nuts to 15–20 Nm (11–15 lb-ft).

Install the steering column upper nuts (3).
Tighten
Tighten the nuts to 15–20 Nm (11–15 lb-ft).
2. Install the ignition lock cylinder. Refer to “Ignition Lock
Cylinder” in this section.
3. Install the ignition switch. Refer to “Ignition Switch” in
this section.
4. Install the switch housing. Refer to “Switch Housing”
in this section.
5. Install the turn signal switch and wiper switch. Refer
to “Turn Signal Switch and Lever/Wiper Switch and
Lever” in this section.
6. Install the steering wheel. Refer to “Steering Wheel”
in this section.

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–6 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
HEATER SYSTEM
INSUFFICIENT HEATING OR DEFROSTING
Caution: The cooling system is pressurized when hot. Injury can result from removing the surge tank cap
before the engine is sufficiently cool.
Step Action Value(s) Yes No

1

Verify the customer’s complaint.
Are the customer’s concerns verified?
–
Go to Step 2

System OK
2 Check the coolant level.
Is the coolant level correct? – Go to Step 4 Go to Step 3
3

Add coolant as needed.
Is the repair complete?
–

System OK

Go to Step 4
4

Check the timing belt for tension or damage.
Is the timing belt OK?
–

Go to Step 6

Go to Step 5

5

Correct any problem with the drive belts.
Is the repair complete?
–
System OK

Go to Step 6

6

Check the coolant hoses for leaks or kinks.
Are the coolant hoses OK?
–
Go to Step 8

Go to Step 7
7 Repair any problem with the coolant hoses.
Is the repair complete? –
System OK

Go to Step 8

8



Check the surge tank cap. Refer to Section 1D,
Engine Cooling.
Is the surge tank cap OK?


–


Go to Step 10


Go to Step 9

9


Repair or replace the surge tank cap as needed.
Is the repair complete?
–

System OK

Go to Step 10






10






1. Set the A/C switch OFF on vehicles equipped
with air conditioning.
2. Set the blower motor switch on 4.
3. Set the heater control to full hot.
4. Turn the ignition ON.
5. Check for airflow from the heater outlet.
Is there heavy airflow from the heater outlet?





–





Go to Step 11





Go to Step 25



11



Check for a change in the airflow at various blower
speeds.
Does the blower speed increase as the switch is
turned from 1 to 4?


–


Go to Step 12


Go to ‘‘Blower
Electrical’’








12








1. Set the A/C switch to OFF, on vehicles equipped
with air conditioning.
2. Set the temperature lever to full hot.
3. Set the blower motor switch on 4.
4. With the engine sufficiently cool, remove the
surge tank cap.
5. Start the vehicle and idle the engine.
6. Watch for the flow of the coolant.
Is the coolant flow visible?







–







Go to Step 14







Go to Step 13

HEATING AND VENTILATION SYSTEM 7A–7
DAEWOO M-150 BL2
Insufficient Heating or Defrosting (Cont’d)
Step Action Value(s) Yes No





13





1. Check for a

Restriction in the cooling system.

Failed water pump impeller.

Faulty thermostat.
2. Make repairs to the cooling system, as needed.
Are the repairs complete?




–




System OK





–






14






1. Check the vehicle for cold air leaks at the

Dash.

Heater cases.

Vents.
2. Check under the seat for obstructions.
3. Repair any leaks or obstructions.
Are the repairs complete?





–





System OK






–






15






1. Turn the ignition OFF.
2. Turn the temperature control knob to full cold,
then rapidly to full hot.
3. Listen for the sound of the temperature door slam
just before reaching the end of the travel range of
the control knob.
Did the door slam?





–





Go to Step 17





Go to Step 16







16







1. Check the temperature door

Travel.

Cables.

Linkage.
2. Verify the accuracy of the temperature controls at
full hot.
3. Verify the accuracy of the temperature controls at
full cold.
Is the repair complete?






–






System OK







–





17





1. Set the temperature door to full hot.
2. Start the vehicle.
3. Check the temperature of the heater inlet hose
and the heater outlet hose by feel.
Is the heater inlet hose hot and the heater outlet
hose warm?




–




Go to Step 18




Go to Step 21


18



Check the thermostat. Refer to Section 1D, Engine
Cooling.
Is the thermostat installed and seated properly?


–


Go to Step 19


Go to Step 20

19


Replace the thermostat. Refer to Section 1D, Engine
Cooling.
Is the repair complete?
–

System OK

–

20

Reinstall the thermostat.
Is the repair complete?
–

System OK

–

21


Inspect the heater hoses for proper installation.
Are heater hoses reversed?
–

Go to Step 22

Go to Step 23

22

Reinstall the heater hoses properly.
Is the repair complete?
–
System OK

–

7A–10 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
BLOWER ELECTRICAL
Step Action Value(s) Yes No
1

Verify the customer’s complaint.
Are the customer’s concerns verified.
–

Go to Step 2

System OK
2

Check the blower.
Does the blower run at any speed?
–

System OK

Go to Step 3







3







1. Disconnect the power connector from the blower
motor under the dashboard on the passenger side
of the vehicle.
2. Use an ohmmeter check the resistance between
the 1 terminal of the blower motor connector and
each step with the blower switch place each
position.
Does the ohmmeter show the specified value of the
each position?






Refer to
“Specifica-
tions” in this
section.






Go to Step 4






Go to Step 5

4

Replace the blower motor.
Is the repair complete?
–
System OK

Go to Step 7

5

Check the fuse Ef6.
Is the fuse blown?
–
Go to Step 6

Go to Step 7






6






1. Turn the ignition ON.
2. Use a short detector to locate a possible short.

From the fuse Ef6 to the blower switch.

From the blower swtich to the blower resistor.

From the blower resistor to the blower motor.
3. Repair any short.
4. Replace any blown fuse.
Is the repair complete?





–






System OK






–











7











1. Turn the ignition ON.
2. Disconnect the power connector from the blower
motor.
3. Use a test lamp to locate a possible short.

From the terminal 2 of the motor connector to
the terminal 3 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 4 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 5 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 6 of the motor switch connector.
Does the test lamp light ON?











–










Go to Step 9










Go to Step 8

8

Replace the blower resistor.
Is the repair complete?
–
System OK

Go to Step 10

9

Replace the blower motor switch.
Is the repair complete?
–
System OK

–

10


1. Check the ground of the blower motor.
2. Repair the ground of the blower motor.
Is the repair complete?
–

System OK

–

HEATING AND VENTILATION SYSTEM 7A–13
DAEWOO M-150 BL2
TOO MUCH HEAT
Step Action Value(s) Yes No

1

Verify the customer’s complaint.
Are the customer’s concerns verified?
–
Go to Step 2

System OK

2


Set the mode switch to the floor position.
Is there too much heat when the mode switch is in
the floor position?
–

Go to Step 3

Go to Step 9
3

Check for defroster bleed.
Is there objectionable defroster bleed?
–

Go to Step 4

Go to Step 5



4




1. Check the door travel, the cables, the controls,
and the linkage for the heater and the defroster.
2. Adjust or repair, as required.
Is the repair complete?



–



System OK




–







5







1. In vehicles equipped with A/C, set the A/C switch
OFF.
2. In all vehicles, set the blower speed to 4.
3. Set the temperature to full hot.
4. Turn the ignition switch to ON.
5. Check for airflow from the floor outlets.
6. Check the floor outlet attachment.
Is the airflow high?







–






Go to Step 7






Go to Step 8



6




Check for a change in the airflow at different blower
speeds.
Does the airflow change as the setting for the
blower-speed switch is changed?



–



System OK




Go to ‘‘Blower
Electrical’’




7




1. Check the temperature door travel, the cables,
and the linkage.
2. Adjust to full cold.
3. Check for full hot.
Is the repair complete?



–



System OK




–

8


Adjust or repair the floor/defroster and/or the vent/
floor mode.
Is the repair complete?
–

System OK

–


9



Set the mode switch to the vent position.
In the vent position, is the problem objectionable
bleed?

–


Go to Step 10


Go to Step 15



10



1. Check the system case for leaks.
2. Check the floor outlet attachment.
Are any problems found?


–


Go to Step 11


Go to Step 12

11

Repair the system case or the floor outlet attach-
ment as required.
Is the repair complete?
–
System OK

Go to Step 12




12




1. Turn the ignition switch OFF.
2. Turn the temperature control knob to full hot, then
rapidly to full cold.
Do you hear the door slam just before you reached
the end of the control travel?



–



Go to Step 13



Go to Step 14
13

Adjust the vent door to vent more.
Is the repair complete?
–

System OK

–

7A–16 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
BLOWER NOISE
Step Action Value(s) Yes No

1

Verify the customer’s complaint.
Are the customer’s concerns verified?
–
Go to Step 2

System OK








2








1. Sit inside the vehicle.
2. Close the doors and windows.
3. Turn the ignition ON.
4. Set the blower speed to 4.
5. Set the temperature to full cold.
6. Cycle through the blower speeds, the modes, and
the temperature settings in order to find the noise.
Is the blower noise constant at high blower speeds
or certain modes, but absent at lower speeds or in
other modes?







–







Go to Step 11







Go to Step 3



3



Check for vibrations from the blower motor and fan
assembly at each blower speed by feeling the
blower motor housing.
Did you find excessive vibration?


–


Go to Step 6


Go to Step 4



4




1. Remove the blower motor and fan assembly.
Refer to ‘‘Blower Motor” in this section.
2. Check for foreign material at the opening of the
blower inlet.
Did you find any foreign material at the blower inlet?



–



Go to Step 5



Go to Step 6
5

Remove all foreign material.
Is the repair complete?
–

System OK

Go to Step 6



6




1. Examine the blower fan for wear spots, cracked
blades, a cracked hub, a loose fan retaining nut,
or bad alignment.
2. Examine the blower case for wear spots.
Did you find any problem?



–



Go to Step 7



Go to Step 9
7

Lubricate the motor.
Is the repair complete?
–

System OK

Go to Step 8

8


Replace the motor and fan assembly.
Is the repair complete?
–

System OK

Go to Step 9

9


If the noise is a click/tick or whine, replace the mo-
tor.
Is the repair complete?
–

System OK

Go to Step 10
10

Reinstall the original motor.
Is the problem still present?

–

Go to Step 11

System OK



11




1. Set the blower speed on 4.
2. Check full-hot to full-cold temperature positions in
the defrost, floor, and vent modes.
Is the noise present in the defrost mode only?



–



Go to Step 12



Go to Step 13





12





1. Check the ducts for obstructions or foreign
materials.
2. Remove any obstructions or foreign materials.
3. Check floor/defroster door seals.
4. Repair or replace, as needed.
Is the repair complete?




–




System OK





–
13 Is the noise present in the floor mode only? – Go to Step 12 Go to Step 14

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. . . . . . . . . . . . . . . . . . . . .