2003 DAEWOO MATIZ electric circuit

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)

DAEWOO M-150 BL2
SECTION 1E
ENGINE ELECTRICAL
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 1E-2. . . . . . . . . . . . . . . . . .
Battery 1E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratings 1E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reserve Capacity 1E-2. . . . . . . . . . . . . . . . . . . . . . . . .
Cold Cranking Amperage 1E-2. . . . . . . . . . . . . . . . . . .
Built-In Hydrometer 1E-2. . . . . . . . . . . . . . . . . . . . . . . .
Charging Procedure 1E-3. . . . . . . . . . . . . . . . . . . . . . .
Charging Time Required 1E-3. . . . . . . . . . . . . . . . . . . .
Charging a Completely Discharged Battery
(Off the Vehicle) 1E-3. . . . . . . . . . . . . . . . . . . . . . . . .
Jump Starting Procedure 1E-3. . . . . . . . . . . . . . . . . . .
Generator 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 1E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug 1E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 1E-6. . . . . . . . . . . . . . . . . . . . . . . .
Starting System 1E-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System (A-type: MANDO) 1E-7. . . . . . . . . .
Charging System (B-type: DAC) 1E-8. . . . . . . . . . . . .
Ignition System 1E-9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 1E-10. . . . . .
Ignition System 1E-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Load Test 1E-12. . . . . . . . . . . . . . . . . . . . . . . . Generator Output Test 1E-12. . . . . . . . . . . . . . . . . . . .
Generator System Check 1E-13. . . . . . . . . . . . . . . . . .
Repair Instructions 1E-14. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1E-14. . . . . . . . . . . . . . . . . . . . . . . . .
Starter 1E-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator 1E-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 1E-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor 1E-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 1E-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 1E-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor 1E-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator (A-type: MANDO) 1E-24. . . . . . . . . . . . . . .
Generator (B-type: DAC) 1E-29. . . . . . . . . . . . . . . . . .
Distributor Assembly 1E-34. . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 1E-37. . . . . . . . . .
Starting System 1E-37. . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1E-38. . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System Circuit – Tipical 1E-39. . . . . . . . . . . .
Ignition System Circuit – Euro III 1E-40. . . . . . . . . . .
Specifications 1E-41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Specifications 1E-41. . . . . . . . . . . . . . . . . . . . .
Generator Specifications 1E-41. . . . . . . . . . . . . . . . . .
Ignition System Specifications 1E-41. . . . . . . . . . . . . .
Battery Specifications 1E-41. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1E-42. . . . . . . . . .

ENGINE ELECTRICAL 1E–3
DAEWOO M-150 BL2
CHARGING PROCEDURE
1. Batteries with the green dot showing do not require
charging unless they have just been discharged, such
as in cranking a vehicle.
2. When charging sealed-terminal batteries out of the
vehicle, install the adapter kit. Make sure all the char-
ger connections are clean and tight. For best results,
batteries should be charged while the electrolyte and
the plates are at room temperature. A battery that is
extremely cold may not accept current for several
hours after starting the charger.
3. Charge the battery until the green dot appears. The
battery should be checked every half-hour while
charging. Tipping or shaking the battery may be nec-
essary to make the green dot appear.
4. After charging, the battery should be load tested. Re-
fer to “Starter Motor” in this section.
CHARGING TIME REQUIRED
The time required to charge a battery will vary depend-
ing upon the following factors:

Size of Battery – A completely discharged large
heavy-duty battery requires more than twice the re-
charging as a completely discharged small passenger
car battery.

Temperature – A longer time will be needed to
charge any battery at -18C (0F) than at 27C
(81F). When a fast charger is connected to a cold
battery, the current accepted by the battery will be
very low at first. The battery will accept a higher cur-
rent rate as the battery warms.

Charger Capacity – A charger which can supply only
5 amperes will require a much longer charging period
than a charger that can supply 30 amperes or more.

State-of-Charge – A completely discharged battery
requires more than twice as much charge as a one-
half charged battery. Because the electrolyte is nearly
pure water and a poor conductor in a completely dis-
charged battery, the current accepted by the battery
is very low at first. Later, as the charging current
causes the electrolyte acid content to increase, the
charging current will likewise increase.
CHARGING A COMPLETELY
DISCHARGED BATTERY
(OFF THE VEHICLE)
Unless this procedure is properly followed, a perfectly
good battery may be needlessly replaced.
The following procedure should be used to recharge a
completely discharged battery:
1. Measure the voltage at the battery terminals with an
accurate voltmeter. If the reading is below 10 volts,
the charge current will be very low, and it could take
some time before the battery accepts the current inexcess of a few milliamperes. Refer to “Charging
Time Required” in this section, which focuses on the
factors affecting both the charging time required and
the rough estimates in the table below. Such low cur-
rent may not be detectable on ammeters available in
the field.
2. Set the battery charger on the high setting.
Important: Some chargers feature polarity protection
circuitry, which prevents charging unless the charger
leads are correctly connected to the battery terminals. A
completely discharged battery may not have enough
voltage to activate this circuitry, even though the leads
are connected properly, making it appear that the bat-
tery will not accept charging current. Therefore, follow
the specific charger manufacturer’s instruction for by-
passing or overriding the circuitry so that the charger will
turn on and charge a low-voltage battery.
3. Battery chargers vary in the amount of voltage and
current provided. The time required for the battery to
accept a measurable charger current at various volt-
ages may be as follows:
VoltageHours
16.0 or moreUp to 4 hours
14.0–15.9Up to 8 hours
13.9 or lessUp to 16 hours

If the charge current is not measurable at the end
of the above charging times, the battery should be
replaced.

If the charge current is measurable during the
charging time, the battery is good, and charging
should be completed in the normal manner.
Important: It is important to remember that a complete-
ly discharged battery must be recharged for a sufficient
number of ampere hours (AH) to restore the battery to a
usable state. As a general rule, using the reserve capac-
ity rating (RC) as the number of ampere hours of charge
usually brings the green dot into view.

If the charge current is still not measurable after
using the charging time calculated by the above
method, the battery should be replaced.

If the charge current is measurable during the
charging time, the battery is good, and charging
should be completed in the normal manner.
JUMP STARTING PROCEDURE
1. Position the vehicle with the good (charged) battery
so that the jumper cables will reach from one battery
to the other.
2. Turn off the ignition, all the lights, and all the electrical
loads in both vehicles. Leave the hazard flasher on if
there may be other traffic and any other lights needed
for the work area.

1E–4 ENGINE ELECTRICAL
DAEWOO M-150 BL2
3. In both vehicles, apply the parking brake firmly.
Notice: Make sure the cables are not on or near pulleys,
fans, or other parts that will move when the engine
starts, damaging the parts.
4. Shift a manual transaxle to NEUTRAL.
Caution: Do not use cables that have loose or miss-
ing insulation, or injury could result.
5. Clamp one end of the first jumper cable to the positive
terminal on the battery. Make sure it does not touch
any other metal parts. Clamp the other end of the
same cable to the positive terminal on the other bat-
tery. Never connect the other end to the negative ter-
minal of the discharged battery.
Caution: Do not attach the cable directly to the neg-
ative terminal of the discharged battery. Doing so
could cause sparks and possible battery explosion.
6. Clamp one end of the second cable to the negative
terminal of the booster battery. Make the final con-
nection to a solid engine ground, such as the engine
lift bracket, at least 450 millimeters (18 inches) from
the discharged battery.
7. Start the engine of the vehicle with the good battery.
Run the engine at a moderate speed for several min-
utes. Then start the engine of the vehicle which has
the discharged battery.
8. Remove the jumper cables by reversing the above
sequence exactly. Remove the negative cable from
the vehicle with the discharged battery first. While re-
moving each clamp, take care that it does not touch
any other metal while the other end remains at-
tached
.
GENERATOR
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator lamination.
CS generators are equipped with internal regulators.
The Y connection (A-type) or Delta (B-type) stator, a
rectifier bridge, and a rotor with slip rings and brushes
are electrically similar to earlier generators. A conven-
tional pulley and fan are used. There is no test hole.
Unlike three-wire generators, the ∅114D (A-type) or
CS114D (B-type) may be used with only two connec-
tions: battery positive and an ‘‘L’’ terminal to the charge
indicator lamp.
As with other charging systems, the charge indicator
lamp lights when the ignition switch is turned to ON, and
goes out when the engine is running. If the charge indi-
cator is on with the engine running, a charging system
defect is indicated.
The regulator voltage setting varies with temperature
and limits the system voltage by controlling the rotorfield current. The regulator switches rotor field current
on and off. By varying the on-off time, correct average
field current for proper system voltage control is ob-
tained. At high speeds, the on-time may be 10 percent
and the off-time 90 percent. At low speeds, with high
electrical loads, on-time may be 90 percent and the off-
time 10 percent.
CHARGING SYSTEM
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator laminations.
CS generators use a new type of regulator that incorpo-
rates a diode trio. The Y connection (A-type) or Delta (B-
type) stator, a rectifier bridge, and a rotor with slip rings
and brushes are electrically similar to earlier generators.
A conventional pulley and fan are used. There is no test
hole.
STARTER
Wound field starter motors have pole pieces, arranged
around the armature, which are energized by wound
field coils.
Enclosed shift lever cranking motors have the shift lever
mechanism and the solenoid plunger enclosed in the
drive housing, protecting them from exposure to dirt, icy
conditions, and splashes.
In the basic circuit, solenoid windings are energized
when the switch is closed. The resulting plunger and
shift lever movement causes the pinion to engage the
engine flywheel ring gear. The solenoid main contacts
close. Cranking then takes place.
When the engine starts, pinion overrun protects the ar-
mature from excessive speed until the switch is opened,
at which time the return spring causes the pinion to dis-
engage. To prevent excessive overrun, the switch
should be released immediately after the engine starts.
STARTING SYSTEM
The engine electrical system includes the battery, the
ignition, the starter, the generator, and all the related wir-
ing. Diagnostic tables will aid in troubleshooting system
faults. When a fault is traced to a particular component,
refer to that component section of the service manual.
The starting system circuit consists of the battery, the
starter motor, the ignition switch, and all the related elec-
trical wiring. All of these components are connected
electrically
.
DISTRIBUTOR
Distributor distributes the high tension voltage induced
from ignition coil, to each spark plug of each cylinder in

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.

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–20 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E704

Inspect the pinion gear’s moving to the outside (2).

If the pinion gear does not move outside, replace
the magnetic switch.
D102E705
4. Solenoid hold-in test.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminal S and body.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
D102E706

Check the pinion gear’s moving to the outside (2).

If the pinion gear move to the inside, the circuit is
open. Replace the magnetic switch.
D102E707
5. Solenoid return test.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminal S and body.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.