2003 DAEWOO MATIZ engine

HEATING AND VENTILATION SYSTEM 7A–11
DAEWOO M-150 BL2
IMPROPER AIR DELIVERY OR NO MODE SHIFT
This procedure provides a test of all functions of the heater/defroster unit.
1. Warm up the vehicle.
2. Keep the engine running.
3. Perform the tests outlined in the table below and look for the results indicated.
CONTROL SETTINGS CORRECT RESULTS



MODE
KNOB



TEMP.
CONTROL



BLOWER
MOTOR
SWITCH


BLOWER
SPEED



POWER
VENT
OUTLET


FLOOR
OUTLET



DEFROST
OUTLET



SIDE
WINDOW
OUTLET
Vent Cold Off Off No
Airflow No
Airflow No
Airflow No
Airflow



Vent

Cold

4

High

Ambient
Airflow
No
Airflow
No
Airflow
No
Airflow



Floor

Cold to Hot

4

High

No
Airflow
Cold to Hot
Airflow

Minimum
Cold to Hot
Airflow

Minimum
Cold to Hot
Airflow




Defroster


Cold to Hot


4


High



No
Airflow



Minimum
Cold to Hot
Airflow



Cold to Hot
Airflow



Minimum
Cold to Hot
Airflow
If any of these settings does not produce the correct results, perform the following diagnostic procedure.

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





Examine the affected door in the unit for proper
cable attachment.

Check the cable connection to the door.

Check that the cable sheath is properly re-
tained.
Is the cable connected properly?




–




Go to Step 4




Go to Step 3
3

Repair as necessary.
Is the repair complete?
–

System OK

–





4





1. Disconnect the cable at the door.
2. Check the range of the door travel and the effort
required to move it.
Does the door move freely through its entire range
of travel so that it can close at both ends of the
range?




–




Go to Step 5




Go to Step 3

5


Check the travel of the Bowden cable by turning the
control knob.
Is the cable travel OK?
–

Go to Step 6

Go to Step 7



6




1. Reinstall the cable.
2. Recheck the system using the “Control
Settings/Correct Results” tests in this procedure.
Does the system perform properly?




–



System OK



Go to Step 9



7



1. Check the cable attachment at the control.
2. Check for a broken control.
Is there a problem with the cable attachment or the
control?


–


Go to Step 8


Go to Step 9

7A–14 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
Too Much Heat (Cont’d)
Step Action Value(s) Yes No




14




1. Check the temperature door travel, the cables,
and the linkage.
2. Verify that the temperature door goes to full cold.
3. Check the temperature door for full hot.
Is the temperature door travel correct?



–



System OK




–




15




1. Check for hot air leaks from the engine
compartment to the blower inlet.
2. Repair as needed.
Is the repair complete?



–



System OK




–

7A–22 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
D18A515A
HEATER HOSES
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Tool Required
DW100–020 Hose Remover/Installer.
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the coolant.
3. Remove the heater inlet hoses.

Remove the air cleaner housing.

Raise and suitably support the vehicle.

Disconnect the hose from the heater module using
a hose remover DW100–020 (1).
D108A516

Lower the vehicle.

Disconnect the hose from the thermostat (2).
D18A517A
4. Remove the heater outlet hoses.

Raise and suitably support the vehicle.

Disconnect the hose from the heater module using
a hose remover DW100–020 (1).

Disconnect the B
+ terminal from the starter. Refer
to Section 1E, Engine Electrical.
D108A518

Disconnect the heater hose from the engine (2).

HEATING AND VENTILATION SYSTEM 7A–23
DAEWOO M-150 BL2
D108A521
Installation Procedure
1. Install the heater outlet hoses.

Connect the heater hose to the engine (1).

Connect the B
+ terminal to the starter. Refer to
Section 1E, Engine Electrical.
D18A522A

Connect the hose to the heater module using a
hose installer DW100–020 (2).

Lower the vehicle.
D108A519
2. Install the heater inlet hoses.

Connect the hose to the thermostat (1).

Raise and suitably support the vehicle.
DW100–020
D18A520A

Connect the hose to the heater module using a
hose installer DW100–020 (2).

Lower the vehicle.

Install the air cleaner housing.
3. Refill the coolant. Refer to Section 1D, Engine Cool-
ing.
4. Connect the negative battery cable.

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.

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–5
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
TESTING THE REFRIGERANT
SYSTEM
If you suspect a problem in the refrigerant system,
check for the following conditions:
1. Check the outer surfaces of the radiator and the con-
denser cores to be sure that the airflow is not blocked
by dirt, leaves, or other foreign material. Check be-
tween the condenser and the radiator, as well as all
outer surfaces.
2. Check for restrictions or kinks in the condenser core,
the hoses, and the tubes.
3. Check the operation of the blower fan.
4. Check all the air ducts for leaks or restrictions. A low
airflow rate may indicate a restricted evaporator core.
5. Check for slippage of the compressor clutch.
6. Check the drive belt tension.
INSUFFICIENT COOLING “QUICK
CHECK” PROCEDURE
Perform the following “hand-feel” procedure to get a
quick idea of whether the air conditioning (A/C) system
has the proper charge of Refrigerant-134a.
1. Warm up the engine. Run the engine at idle.
2. Open the hood and all the doors.
3. Turn the A/C switch ON.
4. Set the temperature control to the full cold position.
5. Set the blower speed switch on 4.
6.“Hand-feel” the temperature of the evaporator outlet
pipe. The pipe should be cold.
7. Check for other problems. Refer to “Testing the Re-
frigerant System” in this section.
8. Leak check the system. Refer to “Leak Testing the
Refrigerant System” in this section. If you find a leak,
discharge the system and repair the leak as required.
After completing the repair, evacuate and charge the
system.
9. If there is no leak, refer to “Insufficient Cooling Diag-
nosis” in this section.

7B–8 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
AIR CONDITIONING SYSTEM DIAGNOSIS
INSUFFICIENT COOLING DIAGNOSIS
Step Action Value(s) Yes No
1Can you verify the customer complaint?–Go to Step 2System OK
2
1. Check the fuses Ef14, Ef19, and Ef12.
2. Check the blower fan operation.
3. Check the engine cooling fan operation.
4. Check the A/C compressor belt.
5. Check the A/C condenser for restricted air flow.
6. Check the slippage of the compressor clutch.
7. Repair or replace any components as needed.
8. Check the A/C system operation.
Is the A/C system operation normal?
–
System OKGo to Step 3
3
1. Turn the ignition switch OFF.
2. Connect the high and the low pressure gauges.
Are both pressures within the value specified?
Low SideGo to Step 8Go to Step 6
4Are both pressures above the specified value?Pressure:Go to Step 5–
5Are both pressures within the specified value?200 kPa
(29 Psi)Go to Step 8–
6Are both pressure below the specified value?
(29 Psi)
Go to Step 7Go to Step 4
7
1. Add the refrigerant R–134a.
2. Check the A/C system for leaks.
3. Repair any refrigerant leaks as needed.
4. Recover, evacuate, and recharge the A/C system.
Are both pressure within the specified value?High Side
Pressure:
1,500 kPa
(217.5 Psi)
Go to Step 8
–
8
1. Start the engine and allow it to run at idle.
2. Set the A/C controls to following positions.
The A/C switch to the ON position.
The fresh air control switch to fresh air.
The blower motor to 4.
The temperature to full cold.
Does the A/C compressor clutch engage?
–
Go to Step 9Go to Step 11
9
1. Check for a knocking noise from the A/C
compressor.
2. Cycle the A/C compressor ON and OFF in order
to verify the source of the noise.
Do you hear a loud knocking noise?
–
Go to Step 10Go to Step 14
10
1. Recover the A/C system refrigerant.
2. Replace the A/C compressor.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the repair complete?
–
Go to Step 14
–
11
1. Turn the ignition switch OFF.
2. Disconnect the A/C compressor clutch coil
connector.
3. Connect a jumper wire from ground to one A/C
compressor clutch coil terminal.
4. Connect a fused jumper wire from the positive
battery terminal to the other A/C compressor
clutch coil terminal.
Does the A/C clutch engage?
–
Go to Step 12Go to Step 13

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–9
DAEWOO M-150 BL2
Insufficient Cooling Diagnosis (Cont’d)
Step Action Value(s) Yes No
12
Repair the electrical circuit to the A/C compressor
clutch coil.
Does the A/C clutch engage?
–
Go to Step 20Go to Step 13
13Replace the A/C compressor clutch coil.
Does the A/C clutch engage?–Go to Step 9Go to Step 10
14
Important: Perform this test under garage condi-
tions; 21-32
C (70-90
F) and no sun load. Follow
this test carefully for accurate results.
1. Close all of the windows and the doors of the
vehicle.
2. Set the A/C controls to the following positions:
The A/C switch to the ON position.
The fresh air control switch to fresh air.
The blower motor to 4.
The temperature to full cold.
3. Start the engine and follow it to run at idle for
5 minutes.
4. Feel the evaporator inlet and outlet pipes.
Is there a noticeable difference in the temperature of
the evaporator inlet and outlet pipes?
–
Go to Step 16Go to Step 15
15
1. Recover the A/C system refrigerant.
2. Replace the expansion valve as needed.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
5. Note the discharge air temperature with the A/C
ON.
Is the discharge temperature normal?
–
Go to Step16Go to Step 18
16
Feel the liquid pipe between the condenser and the
expansion valve.
Is the pipe cold?
–
Go to Step 19Go to Step 17
17
1. Remove the restriction of the high pressure side.
2. Check the A/C system for leaks.
Is the repair complete?
–
System OK
–
18
1. Recover the A/C system refrigerant.
2. Evacuate and recharge the A/C system.
3. Check the A/C system for leaks.
Is the repair complete?
–
System OK
–
19
1. Run the engine at 3,000 rpm.
2. Close all of the windows and doors of the vehicle.
3. Set the A/C controls to the following positions:
The A/C switch to the ON position.
The fresh air control switch to fresh air.
The blower motor to 4.
The temperature to full cold.
4. Turn the A/C switch ON and OFF every
20 seconds for 3 minutes.
Are the A/C compressor high and the low side
pressures within the specified value of each other?
Low Side
Pressure:
200 kPa
(29 psi)
High Side
Pressure:
1,500 kPa
(217.5 psi)
System OKGo to Step 22