2003 DAEWOO MATIZ hose system

DAEWOO M-150 BL2
SECTION 1A
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Description and Operation 1A-2. . . . . . . . . . . . . . . . . .
Cleanliness and Care 1A-2. . . . . . . . . . . . . . . . . . . . . .
On-Engine Service 1A-2. . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 1A-3. . . . . . . . . . . . . . . . . . . . . . . .
Engine Compartment (Typical) 1A-3. . . . . . . . . . . . . .
Engine Compartment (Euro III) 1A-4. . . . . . . . . . . . . .
Diagnoctic Information and Procedure 1A-5. . . . . . .
General Diagnosis 1A-5. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Fluid Level 1A-11. . . . . . . . . . . . . . .
Changing Engine Oil or Oil Filter 1A-11. . . . . . . . . . . . Checking Engine Timing Belt 1A-12. . . . . . . . . . . . . . .
Checking Accessory Belt 1A-12. . . . . . . . . . . . . . . . . .
Checking Spark Plug 1A-12. . . . . . . . . . . . . . . . . . . . .
Checking Air Cleaner Element 1A-13. . . . . . . . . . . . .
Checking Fuel Filter 1A-13. . . . . . . . . . . . . . . . . . . . . .
Checking Fuel System 1A-13. . . . . . . . . . . . . . . . . . . .
Checking Hose System 1A-13. . . . . . . . . . . . . . . . . . .
Specifications 1A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 1A-14. . . . . . . . . . . . . . . . . . . .
Engine Performance Curve 1A-15. . . . . . . . . . . . . . . .

1A–6 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
 Condition Probable cause Correction
Hard Starting (WithOthers
Broken timing belt.
Replace the belt.
normal cranking)
Malfunction of Positive
Crankcase Ventilation (PCV)
valve.
Check and replace Positive
Crankcase Ventilation (PCV)
valve if needed.

Loosening, damage or
leakage of the vacuum hose.
Connect the hose correctly
or replace it.

Leakage of intake system.
Replace intake system.
Lack of Engine PowerDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Improper ignition timing.
Adjust the ignition timing.
Ignition System
Faulty spark plug.
Adjust or replace the spark
plug.

Malfunction of the distributor.
Repair or replace the
distributor. Check the rotor.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.
Malfunction of
Clogged fuel pipe.
Clean the pipe.
Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.
Others
Clogged exhaust system.
Check and repair the
system.

Clogged or contaminated air
cleaner element.
Clean or replace the air
cleaner element.

Leak of the intake manifold
gasket.
Replace the gasket.

Dragging brakes.
Repair or replace the
brakes.

Slipping clutch.
Adjust or replace the clutch.
Rough Engine IdlingDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Clogged fuel pipe.
Clean the pipe.
Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.

Malfunction of the fuel
pressure regulator.
Replace the regulator.
Malfunction of
Ignition System
Malfunction of the spark
plug.
Adjust or replace the spark
plug.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.

Worn distributor cap terminal
or accumulated carbon in
the distributor cap.
Replace or clean the
distributor cap.

GENERAL ENGINE INFORMATION 1A–7
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
 Condition Probable cause Correction
Rough Engine IdlingMalfunction of
Ignition System
Loosening or damage of the
distributor rotor or cap.
Replace the rotor or cap.

Poor ignition timing.
Adjust the ignition timing.

Malfunction of the ignition
coil.
Replace the ignition coil.
Others
Clogged or contaminated air
cleaner element.
Clean or replace the air
cleaner element.

Leak of the intake manifold
gasket.
Replace the gasket.

Malfunction of Positive
Crankcase Ventilation (PCV)
valve.
Check the valve or replace it
if needed.

Poor connection or damage
or leakage of the vacuum
hose.
Connect the hose correctly
or replace it.
Engine Hesitate (Upon
pressing accelerating
pedal, the engineDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
makes delayed
response. ThisMalfunction of
Poor ignition timing.
Adjust the ignition timing.response. This
situation is remarkable
when cruising orIgnition System
Poor spark plug or poor
adjustment of the plug gap.
Replace the plug or adjust
the gap.
starting.)
Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.
Others
Malfunction of the air cleaner
system.
Clean or replace the air
cleaner system.

Leak of the intake manifold
gasket.
Replace the gasket.
Engine Surging
(Engine power makes
fluctuation in a fixedDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
speed and speed
changes withoutMalfunction of
Clogged fuel pipe.
Clean the pipe.changes without
operating the
accelerating pedal.)Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.

Malfunction of the fuel
pressure regulator.
Replace the fuel pressure
regulator.
Malfunction of
Ignition System
Malfunction of the spark
plug.
Adjust or replace the spark
plug.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.

Worn distributor cap terminal
or accumulated carbon in
the distributor cap.
Clean or replace the
distributor cap.

Loosening or damage of the
distributor rotor or the cap.
Replace the distributor rotor
or the cap.

Poor ignition timing.
Adjust the ignition timing.

1A–8 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
 
 Condition
 
 Probable cause
 
 Correction
Engine Surging
(Engine power makes
fluctuation in a fixedOthers
Leak of the intake manifold
gasket.
Clean or replace the gasket.
speed and speed
changes without
operating the
accelerating pedal.)
Leakage of the vacuum hose.
Connect the hose correctly
or replace it.
Excessive Detonation
(According to theOverheated
Engine
Refer to “Overheat” in this
page.
Refer to “Overheat” in this
page.
opening range of
throttle valve,Malfunction of
Abnormal spark plug.
Replace the spark plug.
knocking sound of
metallic is made withIgnition System
Poor ignition timing.
Adjust the ignition timing.metallic is made with
abnormal explosion.)

Electric leakage or poor
connection of the high tension
cable.
Connect the cable correctly
or replace it.
Malfunction of
Fuel System
Clogged or contaminated fuel
filter and fuel pipe.
Clean or replace the fuel
filter and the fuel pipe.
Others
Leak of the intake manifold
gasket.
Replace the gasket.

Excessive carbon deposit due
to abnormal combustion.
Remove the carbon.
OverheatMalfunction of
Lack of coolant.
Refill coolant.
Cooling System
Malfunction of the thermostat.
Replace the thermostat.

Malfunction of the cooling fan.
Check or replace the cooling
fan.

Poor water pump
performance.
Replace the pump.

Clogged or leaky radiator.
Clean, repair or replace the
radiator.
Malfunction of
Lubrication
Poor engine oil.
Replace engine oil with the
specified one.
System
Blocking oil filter or strainer.
Clean or replace the oil filter
or the strainer.

Lack of engine oil.
Refill oil.

Poor oil pump performance.
Replace or repair the pump.

Leakage of oil.
Repair.
Other
Damaged cylinder head
gasket.
Replace the gasket.
Poor Fuel
ConsumptionDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Fuel System
Leakage of the fuel tank or
the fuel pipe.
Repair or replace the fuel
tank or the fuel pipe.

GENERAL ENGINE INFORMATION 1A–13
DAEWOO M-150 BL2
CHECKING AIR CLEANER ELEMENT
If the air cleaner element becomes dirty, engine efficien-
cy could be deteriorated.
Be sure to check the element often.
Especially, if a vehicle frequently runs on a dusty road,
check and replace the element often.
CHECKING FUEL FILTER
If fuel filter is used over the specified period, engine effi-
ciency is deteriorated by dust or foreign material.
Therefore, replace a new one within the specified peri-
od.
CHECKING FUEL SYSTEM
Check the fuel system as follows ;

Check the fuel line or line connection portion for dam-
age or leakage.

Check the fuel hose surface for damage.

Check the fuel cap for looseness.
CHECKING HOSE SYSTEM
Check the engine vacuum hose, PCV hose or canister
hose as follows ;

Check the hose surface for damage by heat or ma-
chine.

Check the hose for hardening, crack, tear, or coming
off.

DAEWOO M-150 BL2
SECTION 1B
SOHC ENGINE MECHANICAL
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 1B-2. . . . . . . . . . . . . . . . . .
Engine Type 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 1B-2. . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train 1B-2. . . . . . . . . . . . . .
Engine Block 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Piston Pin 1B-3. . . . . . . . . . .
Timing Belt and Pulley 1B-4. . . . . . . . . . . . . . . . . . . . .
Engine Mount 1B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 1B-5. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold & Air Flow System 1B-7. . . . . . . . . . . . . . . . .
Timing Belt & Engine Mount 1B-8. . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 1B-9. . . . . . .
Compression Pressure Check 1B-9. . . . . . . . . . . . . . .
Oil Pressure Check 1B-9. . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of Valve Clearance 1B-10. . . . . . . . . . . . .
Ignition Timing Check and Adjustment
(Typical) 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Timing Check and Adjustment 1B-12. . . . . . . .
Repair Instructions 1B-14. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1B-14. . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Assembly 1B-14. . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element 1B-15. . . . . . . . . . . . . . . . . . . . . . . . .
Positive Crankcase Ventilation (PCV) Hose
and Valve 1B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1B-16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold (Typical) 1B-18. . . . . . . . . . . . . . . . .
Exhaust Manifold (Euro III) 1B-20. . . . . . . . . . . . . . . .
Timing Belt 1B-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1B-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor Case 1B-26. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1B-28. . . . . . . . . . . . . . . . .
Engine Mount Damping Block 1B-32. . . . . . . . . . . . . .
Engine Mount Front Damping Bush 1B-34. . . . . . . . .
Engine Assembly 1B-35. . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 1B-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train
Components 1B-47. . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block Components 1B-59. . . . . . . . . . . . . . . . .
Specifications 1B-71. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1B-71. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1B-73. . . . . . . . . .
Special Tools 1B-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1B-75. . . . . . . . . . . . . . . . . . . . . . .

DAEWOO M-150 BL2
SECTION 1D
ENGINE COOLING
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 1D-2. . . . . . . . . . . . . . . . . .
General Description 1D-2. . . . . . . . . . . . . . . . . . . . . . .
Radiator 1D-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank 1D-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Pump 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan 1D-3. . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor 1D-4. . . . . . . . .
Coolant Temperature Sensor 1D-4. . . . . . . . . . . . . . . .
Component Locator 1D-5. . . . . . . . . . . . . . . . . . . . . . . .
Coolant Hose and Components 1D-5. . . . . . . . . . . . .
Radiator/Fan 1D-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 1D-7. . . . . . .
Coolant Leaks Test 1D-7. . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank Cap Test 1D-7. . . . . . . . . . . . . . . . . . . . . . .
Thermostat Test 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Diagnosis 1D-8. . . . . . . . . . . . . . . . . .
Repair Instructions 1D-9. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1D-9. . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Refilling the Cooling System 1D-9. . . .
Surge Tank 1D-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan 1D-11. . . . . . . . . . . . . . . . . . . . . .
Radiator 1D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat (Typical) 1D-12. . . . . . . . . . . . . . . . . . . . . .
Thermostat (Euro III) 1D-13. . . . . . . . . . . . . . . . . . . . . .
Coolant Temperature Sensor 1D-14. . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor 1D-15. . . . . . . .
Coolant Pump 1D-15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 1D-17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 1D-17. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1D-18. . . . . . . . . .

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