2003 DAEWOO MATIZ Service Repair Manual

ENGINE ELECTRICAL 1E–9
DAEWOO M-150 BL2
IGNITION SYSTEM
D102E404
1 Ignition Coil
2 Spark Pulg
3 Ignitoin Wire (#0)
4 Ignition Wires (#1, #2, #3)
5 Support Clamp
6 Mounting Clamp
7 Distributor Assembly
8 Coupling
9 Distributor Oil Seal
10 Distributor Housing
11 Distributor Shaft12 Plate
13 Optical Sensor Unit
14 Plate
15 Bushing
16 Disc Wheel
17 Inner Cover
18 Outer Cover
19 Distributor Rotor
20 Distributor Cap Seal
21 Distributor Cap

1E–10 ENGINE ELECTRICAL
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURE
IGNITION SYSTEM
ConditionProbable CauseCorrection
No Crank
Low battery voltage.
Charging the battery or Replace
the battery.

Battery cable is loose, corroded,
or damaged.
Repair or Replace the battery
cable.

Faulty starter motor or starter
motor circuit is open.
Repair or Replace the starter
motor/starter motor circuit.

Faulty ignition switch or fuse Ef2
is blown.
Replace the ignition switch or fuse
Ef2.

Ground short.
Repair the ground short.
Crank OK, But Too Slow
Low battery voltage.
Charging the battery or Replace
the battery.

Batter.

Battery cables is loose, corroded,
or damaged.
Repair or Replace the battery
cable.

Faulty starter motor.
Repair or Replace the starter
motor.
Starter Motor Does Not Stop
Faulty starter motor.
Repair or Replace the starter
motor.

Faulty ignition switch.
Replace the ignition switch.
Starter Motor Running, But Not
Cranking
Broken the clutch pinion gear or
faulty starter motor.
Replace the starter motor.

Broken the flywheel ring gear.
Replace the flywheel.

Connected circuit is open.
Repair the open circuit.
Overcharging Battery
Faulty the IC regulator.
Replace the IC regulator.
Battery Discharge
Loosen the generator drive belt.
Adjust the belt tension or Replace
the belt.

The circuit is open or a short.
Repair the open or a short circuit.

Faulty IC regulator.
Replace the IC regulator.

Battery run down.
Replace the battery.

Open ground circuit.
Repair the open ground circuit.
Charging Indicator Lamp
Fault IC regulator.
Replace the IC regulator.
Does Not Work When the
Ignition Switch ON
Charging indicator lamp is blown
or fuse F8 is blown.
Repair or Replace the charging
indicator lamp/fuse F8.
(Engine Does Not Work)
Faulty ignition switch.
Replace the ignition switch.

Generator ground circuit is open
or a short.
Repair the circuit.
Charging Indicator Lamp
Faulty IC regulator.
Replace the IC regulator.
Does Not Put Out Lights After
Starting the Engine
Battery cable is corroded or
damaged.
Repair or Replace the battery
cable.

Loosen the generator drive belt.
Adjust the belt tension or Replace
the belt.

Faulty wiring harness.
Repair the wiring harness.

ENGINE ELECTRICAL 1E–11
DAEWOO M-150 BL2
IGNITION SYSTEM (Cont’d)
ConditionProbable CauseCorrection
Hard to Starting the Engine
Faulty ignition coil.
Replace the ignition coil.

Faulty distributor (include the
optical sensor).
Replace the distributor or the
optical sensor.

Faulty spark plug.
Replace the spark plug or Adjust
the gap.

Poor ignition timing.
Reset the valve timing.
Engine Idling State is Unstable
Faulty spark plug.
Replace the spark plug or Adjust
the gap.

Faulty ignition coil.
Replace the ignition coil.

Poor ignition timing.
Reset the valve timing.
Poor Engine Accelerating
Poor ignition timing.
Reset the valve timing.

1E–12 ENGINE ELECTRICAL
DAEWOO M-150 BL2
BATTERY LOAD TEST
1. Check the battery for obvious damage, such as a
cracked or broken case or cover, which could permit
the loss of electrolyte. If obvious damage is noted, re-
place the battery.
Caution: Do not charge the battery if the hydrometer
is clear or light yellow. Instead, replace the battery. If
the battery feels hot or if violent gassing or spewing
of electrolyte through the vent hole occurs, discontin-
ue charging or reduce the charging rate to avoid inju-
ry.
2. Check the hydrometer. If the green dot is visible, go to
the load test procedure. If the indicator is dark but
green is not visible, charge the battery. For charging a
battery removed from the vehicle, refer to “Charging a
Completely Discharged Battery” in this section.
3. Connect a voltmeter and a battery load tester across
the battery terminals.
4. Apply a 300-ampere load for 15 seconds to remove
any surface charge from the battery.
5. Remove the load.
6. Wait 15 seconds to let the battery recover, and apply
a 270-ampere load.
Important: The battery temperature must be estimated
by touch and by the temperature condition the battery
has been exposed to for the preceding few hours.
7. If the voltage does not drop below the minimum
listed, the battery is good and should be reinstalled. If
the voltage is less than the minimum listed, replace
the battery. Refer to “Battery Specifications” in this
section.
GENERATOR OUTPUT TEST
1. Perform the generator system test. Refer to “Gener-
ator System Check” in this section.
2. Replace the generator if it fails that test. Refer to
“Generator” in the On-Vehicle Service section. If it
passes the test, perform the on-vehicle output
check which follows.
Important: Always check the generator for output be-
fore assuming that a grounded “L” terminal circuit has
damaged the regulator.
3. Attach a digital multimeter (a), an ammeter (b), and
a carbon pile load (c) to the battery (d) and the gen-
erator (e) of the rehicle.
D102E301
Important: Be sure the vehicle battery is fully charged,
and the carbon pile load is turned off.
4. With the ignition switch in the OFF position, check
and record the battery voltage.
5. Remove the harness connector from the generator.
6. Turn the ignition switch to the ON position with the
engine not running. Use a digital multimeter to
check for voltage in the harness connector “L” termi-
nal.
7. The reading should be near the specified battery
voltage of 12 volts. If the voltage is too low, check
the indicator “L” terminal circuits for open and
grounded circuits causing voltage loss. Correct any
open wires, terminal connections, etc., as neces-
sary. Refer to “Charging System” in this section.
8. Attach the generator harness connector.
9. Run the engine at a moderate idle, and measure the
voltage across the battery terminals. The reading
should be above that recorded in Step 4 but less
than 15 volts. If the reading is over 15 volts or below
the previous reading, replace the generator. Refer to
“Generator” in the On-Vehicle Service section.
10. Run the engine at a moderate idle, and measure the
generator amperage output.
11. Turn on the carbon pile, and adjust it to obtain the
maximum amps while maintaining the battery volt-
age above 13 volts.
12. If the reading is within 15 amps of the generator’s
rating noted on the generator, the generator is good.
If not, replace the generator. Refer to “Generator”
in the On-Vehicle Service section.
13. With the generator operating at the maximum out-
put, measure the voltage between the generator
housing and the battery negative terminal. The volt-
age drop should be 0.5 volt or less. If the voltage
drop is more than 0.5 volt, check the ground path
from the generator housing to the negative battery
cable.
14. Check, clean, tighten, and recheck all of the ground
connections.

ENGINE ELECTRICAL 1E–13
DAEWOO M-150 BL2
GENERATOR SYSTEM CHECK
When operating normally, the generator indicator lamp
will come on when the ignition switch is in the ON posi-
tion and go out when the engine starts. If the lamp oper-
ates abnormally or if an undercharged or overcharged
battery condition occurs, the following procedure may
be used to diagnose the charging system. Remember
that an undercharged battery is often caused by acces-
sories being left on overnight or by a defective switch
that allows a lamp, such as a trunk or glove box lamp, to
stay on.
Diagnose the generator with the following procedure:
1. Visually check the belt and wiring.
2. With the ignition switch in the ON position and the en-
gine stopped, the charge indicator lamp should be on.
If not, detach the harness at the generator and
ground the ‘‘L’’ terminal in the harness with a fused,
5-ampere jumper lead.
If the lamp lights, replace the generator. Refer to
“Generator” in the On-Vehicle Service section.

If the lamp does not light, locate the open circuit
between the ignition switch and the harness con-
nector. The indicator lamp bulb may be burned out.
3. With the ignition switch in the ON position and the en-
gine running at moderate speed, the charge indicator
lamp should be off. If not, detach the wiring harness
at the generator.

If the lamp goes off, replace the generator. Refer to
“Generator” in the On-Vehicle Service section.

If the lamp stays on, check for a short to ground in
the harness between the connector and the indica-
tor lamp.
Important: Always check the generator for output be-
fore assuming that a grounded ‘‘L’’ terminal circuit has
damaged the regulator. Refer to “Generator” in the Unit
Repair section.

1E–14 ENGINE ELECTRICAL
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D12E5011
STARTER
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector and clip around
the starter.

Remove the engine oil temperature sensor to dis-
connect the harness connector (1).

Remove the starter solenoid nut to disconnect the
electrical cable (2).

Remove the harness clip bolt to disconnect the
harness clip (3).

Remove the ground bolt (4).
D102E502
3. Remove the starter assembly.

Remove the starter mounting bolts (1).

Remove the starter assembly (2).
D12E5031
Installation procedure
1. Install in the reverse order of removal.
2. Install the starter mounting bolts and starter solenoid
nut.
Tighten

Tighten the starter mounting bolts to 55–65 Nm
(41–48 lb-ft) (a).

Tighten the starter solenoid nut to 9–12 Nm
(80–106 lb-in) (b).

Tighten the harness clip bolt to 9–12 Nm (80–106
lb-in) (c).

Tighten the ground bolt to 35–41 Nm (26–30 lb-ft)
(d).

ENGINE ELECTRICAL 1E–15
DAEWOO M-150 BL2
D102E504
GENERATOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the harness connector.

Remove the battery harness connector nut to dis-
connect the battery positive connector (1).

Disconnect the generator harness connector (2).
D102E505
3. Remove the generator drive belt.

Loosen the generator adjusting bolt (1).

Remove the lower bracket-to-generator bolt and
nut (2).

Separate the generator drive belt from the genera-
tor.
D102E506
4. Remove the engine mounting lower bracket.

Remove the engine mounting lower bracket, at-
taching reaction rod bolt and nut (1).

Remove the engine mounting lower bracket bolts
(2).

Remove the engine mounting lower bracket (3).
D102E507
5. Remove the generator.

Remove the generator adjusting bolt (1).

Carefully remove the genrator (2).

1E–16 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D12E508A
35–41 Nm
68–83 Nm
Installation Procedure
1. Install in the reverse order of removal except genera-
tor driver velt.
2. Install the engine mounting lower bracket bolts and
nut.
Tighten

Tighten the engine mounting lower bracket bolts to
35–41 Nm (25–30 lb-ft) (a).

Tighten the engine mounting lower bracket, attach-
ing reaction rod bolt and nut to 68–83 Nm (50–61
lb-ft) (b).
D12E509A
4–7 Nm
18–28 Nm3. Install the bolts and nut.Tighten

Tighten the generator adjusting bolt to 4–7 Nm
(35–62 lb-in) (a).

Tighten the generator lower bracket bolt and nut to
18–28 Nm (13–21 lb-ft) (b).

Inspect the generator drive belt tension.
D12E511A
BATTERY
Removal Procedure
1. Disconnect the negative battery cable and then dis-
connect the positive battery cable.

Remove the battery cable nut to disconnect the
negative battery cable (1).

Remove the battery terminal cap (2).

Remove the battery cable nut to disconnect the
positive battery cable (3).
D102E512
2. Remove the battery.

Remove the battery rod nut (1).

Remove the battery rod (2).

Remove the battery (3).