2003 DAEWOO MATIZ coolant level

GENERAL ENGINE INFORMATION 1A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
ENGINE COMPARTMENT (TYPICAL)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
D102A401
1 Power Steering Oil Reservoir
2 Coolant Reservoir
3 Canister
4 Canister Solenoid
5 Manifold Absolute Pressure (MAP) Sensor
6 Intake Manifold
7 Ignition Coil
8 Idle Air Control (IAC) Valve
9 Throttle Position (TP) Sensor
10 Throttle Body
11 Brake Fluid Reservoir
12 Wiper Motor13 Battery
14 Fuse Box
15 Air Cleaner Housing
16 Resonator
17 PCV Hose
18 Distributor
19 Exhaust Manifold
20 Snorkel
21 Engine
22 Washer Fluid Reservoir
23 Oil Level Gauge
24 Oil Filler Cap

1A–4 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
ENGINE COMPARTMENT (EURO III)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
MAA1A010
1 Power Steering Oil Reservoir
2 Coolant Reservoir
3 Canister Purge Solenoid
4 Manifold Absolute Pressure (MAP) Sensor
5 Intake Manifold
6 Throttle Position (TP) Sensor
7 Throttle Body
8 Idle Air Control (IAC) Valve
9 Brake Fluid Reservoir
10 Wiper Motor11 Battery
12 Fuse Box
13 Air Cleaner Housing
14 Resonator
15 Electronic Ignition System Ignition Coil
16 Exhaust Manifold
17 Snorkel
18 Engine
20 Washer Fluid Reservoir
19 Oil Level Gauge
21 Oil Filler Cap

1A–14 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
 Application Description
  Maximum Speed 144 km/h (90 mph)
 Vehicle Capacity Gradeability 0.420 tan θ
 
Vehicle Capacity
 Minimum Turning Radius 4.5 m (14.8 ft)
  Bore × Stroke 68.5 × 72.0 mm (2.70 × 2.83 inch)
  Displacement 796 cm3 (48.6 in3)
  Compression Ratio 9.3 : 1
  Maximum Power 37.5 KW (6,000 rpm)
 
Engine Information
 Maximum Torque 68.6 Nm (50.59 lb-ft) (at 4,600 rpm)
Ignition Timing (Ignition Sequence)5 BTDC (1–3–2) / 10 BTDC (1–3–2)   
Air Conditioning System (ON)
 
1,000 ± 50 rpm  Idle Speed Air Conditioning System (OFF) 950 rpm  Engine Overhead Cam L–3 
 
 
 Ignition Type
 
 Direct Ignition System (DIS) /
High Energy Ignition (HEI)
  Distributor Optical Sensor Type
  Starter SD 80
   Unleaded BPR5EY–11, RN9YC4, WR8DCX
  Spark–Plug Leaded BPR5EY, RN9YC, WR8DC
  Fuel Injection Type MPI
  Fuel Pump Electric Motor Pump
Engine Part TypeFuel FilterCartridge Engine Part Type 
Lubricating Type
 
Forced Feed Type  Oil Pump Rotary Pump Type  Cooling Type Forced Water Circulation  Radiator Cross – Flow  Water Pump Centrifugal  Thermostat Pellet Type
  Air Cleaner Element Non Woven Fablic
  Muffler Catalytic Converter, Closed Circuit
  Battery MF
Engine PartEngine OilSJ Grade
SAE 5W30, SAE 10W30, SAE 15W40
CapacityRefrigerantFour Seasons   
Engine Disassembly
 
3.0 L (3.17 qt)   Oil Change (Including filter) 2.7 L (2.85 qt)  Engine Oil Oil Change (Not including filter) 2.5 L (2.64 qt)   Oil Level Gauge 1 L (1.06 qt) (MIN to MAX)  Coolant 3.8 L (4.02 qt) Engine Information Battery 12V–35 AH, 246 CCA
 Engine Information  

Generator

65 A
  Starter 0.8 kW
   Output Capacity 90 – 133 Lph
  Fuel Pump Output Pressure 380 kPa (55.1 Psi)
  Fuel Tank Capacity 35 L (9.2 gal), 38 L (10 gal)

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

ENGINE COOLING 1D–7
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURE
COOLANT LEAKS TEST
1. Remove the surge tank cap after the engine cools.
2. Check the coolant level.
3. Install a suitable cooling system pressure tester(b) to
the surge tank filler neck using the adapter(a) and
pressurize (110–120 kPa (16.0–17.4 psi)).
4. Check the coolant leaks on the hoses and connec-
tions during 2 minutes.
5. If the leak is checked, replace the parts or repair the
connections.
D102D301
SURGE TANK CAP TEST
The surge tank cap(c) is equipped with the pressure
valve(d) and the vacuum valve(e). Therefore, the surge
tank cap maintains proper pressure. And The surge tank
cap protects the system from high-pressure by opening
a pressure valve, and protects the coolant hoses from
collapsing because of a vacuum.
1. Wash any sludge from the surge tank cap and the
valve seat of the vacuum pressure valve for the surge
tank cap.
2. Check for any damage or deformity to the vacuum
pressure valve for the surge tank cap. If any damage
or deformity is found, replace the cap.
3. Install a suitable cooling system pressure tester(b) to
the cap using the Adapter(a).
4. Pull the vacuum pressure valve to the open position.
If the surge tank cap does not seal properly, replace
the surge tank cap.
5. Pressurize the cap to 90 to 120kPa (13 to 17psi).
6. Wait 10 seconds and check the pressure held by the
tank cap tester.
7. If the pressure held by the cooling system pressure
tester falls below 80kPa (11.6psi) replace the surge
tank cap.
D102D302
THERMOSTAT TEST
1. Remove the thermostat(f) from the vehicle. Refer
to“Thermostat” in this section.
2. Make sure the valve spring is tight when the thermo-
stat is fully closed. If the spring is not tight, replace the
thermostat.
3. Suspend the thermostat and a thermometer in a pan
of 50/50mixture of ethylene glycol and water. Do not
let the thermostat or the thermometer rest on the bot-
tom of the pan because the uneven concentration of
heat on the bottom could result in inaccurate temper-
ature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature of
the heated solution.
6. The thermostat should begin to open at 82°C (180°F)
and it should be fully open at 95°C (203.4°F) and it
should be fully close at 80°C (176.4°F). If it does not
open or close at these temperature, replace the ther-
mostat. Also, the thermostat rod’s stroke from the ini-
tially open to the fully open should be 8mm (0.31 in.).
D102D303

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.

1D–10 ENGINE COOLING
DAEWOO M-150 BL2
D102D503
Add the clean water to the surge tank (2).
5. Run the engine until the thermostat opens. You can
tell the thermostat is open when both radiator hoses
are hot to the touch.
6. Stop the engine and disconnect the lower radiator
hose to drain the coolant.
7. Repeat steps 3 through 6 until the drained water is
clear and free of coolant and rust.
Notice: Never use an antifreeze mixture more concen-
trated than 60 percent antifreeze to 40 percent water.
The solution freezing point increases above this con-
centration.
8. Fill the cooling system through the surge tank with a
mixture of ethylene glycol antifreeze and water. The
mixture must be at least 50 percent antifreeze, but
not more than 60 percent antifreeze for cold weather
operation.
9. Fill the surge tank to the specified MAX fill mark on
the outside of the tank.
10. Install the surge tank cap.
D102D504
SURGE TANK
Removal Procedure
Caution: To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot, because the heat causes the system to re-
main under pressure scalding fluid and steam may
be blown out under pressure.
1. Drain the engine coolant to below the level of the
surge tank.
2. Remove the surge tank.
Loosen the overflow hose clamps and disconnect
the overflow hoses from the surge tank (1).
Remove the surge tank (2).
3. Clean the inside and the outside of the surge tank and
the surge tank cap with soap and water.
4. Rinse the surge tank and the cap thoroughly.
5. Check the surge tank and the cap for crack or other
damage.

ENGINE CONTROLS 1F–3
DAEWOO M-150 BL2
DTC P1628 Immobilizer No Successful
Communication 1F-270. . . . . . . . . . . . . . . . . . . . . . .
DTC P1629 Immovilizer Wrong Computation 1F-272
DTC P0656 Fuel Level Gauge Circuit Fault 1F-274.
DTC P1660 Malfunction Indicator Lamp (MIL)
High Voltage 1F-276. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1661 Malfunction Indicator Lamp (MIL)
Low Voltage 1F-278. . . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis 1F-280. . . . . . . . . . . . . . . . . . . . . .
Important Preliminary Checks 1F-280. . . . . . . . . . . . .
Intermittent 1F-281. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hard Start 1F-283. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surges or Chuggles 1F-286. . . . . . . . . . . . . . . . . . . . .
Lack of Power, Sluggishness or Sponginess 1F-288
Detonation/Spark Knock 1F-290. . . . . . . . . . . . . . . . . .
Hesitation, Sag, Stumble 1F-292. . . . . . . . . . . . . . . . .
Cuts Out, Misses 1F-294. . . . . . . . . . . . . . . . . . . . . . . .
Poor Fuel Economy 1F-296. . . . . . . . . . . . . . . . . . . . . .
Rough, Unstable, or Incorrect Idle, Stalling 1F-297. .
Excessive Exhaust Emissions or Odors 1F-300. . . .
Dieseling, Run-on 1F-302. . . . . . . . . . . . . . . . . . . . . . .
Backfire 1F-303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Repair 1F-304. . . . . . . . . . . . . . . . . .
On-Vehicle Service 1F–304 . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump 1F–304 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Regulator 1F-305. . . . . . . . . . . . . . . . .
Fuel Filter 1F-306. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank 1F-307. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail and Injectors 1F-308. . . . . . . . . . . . . . . . . . .
Evaporator Emission Canister 1F-309. . . . . . . . . . . . . Evaporator Emission Canister Purge
Solenoid 1F-310. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor 1F-310. .
Throttle Body 1F-311. . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor 1F-312.
Intake Air Temperature (ECT) Sensor 1F-313. . . . . .
Oxygen Sensor (O2S 1) 1F-314. . . . . . . . . . . . . . . . . .
Heated Oxygen Sensor (HO2S 2) 1F-314. . . . . . . . .
Electric Exhaust Gas Recirculation (EEGR)
Valve 1F-315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knock Sensor 1F-315. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Ignition (EI) System Ignition Coil 1F-316.
Crankshaft Position (CKP) Sensor 1F-316. . . . . . . .
Camshaft Position (CMP) Sensor 1F-317. . . . . . . . . .
Engine Control Module (ECM) 1F-317. . . . . . . . . . . . .
Specifications 1F-319. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specification 1F-319. . . . . . . . . .
Special Tools 1F-319. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1F-319. . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 1F-320. . . . . . . . .
ECM Wiring Diagram
(Sirius D3 – 1 of 5) 1F-320. . . . . . . . . . . . . . . . . . . .
ECM Wiring Diagram
(Sirius D3 – 2 of 5) 1F-321. . . . . . . . . . . . . . . . . . . .
ECM Wiring Diagram
(Sirius D3 – 3 of 5) 1F-322. . . . . . . . . . . . . . . . . . . .
ECM Wiring Diagram
(Sirius D3 – 4 of 5) 1F-323. . . . . . . . . . . . . . . . . . . .
ECM Wiring Diagram
(Sirius D3 – 5 of 5) 1F-324. . . . . . . . . . . . . . . . . . . .