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Daewoo Matiz (2003 year). Manual - part 9

1D – 6 ENGINE COOLING

RADIATOR/FAN

D12D4021

1 Radiator Assembly

2 Electric Cooling Fan Assembly

ENGINE COOLING 1D – 7

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

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

COOLING SYSTEM DIAGNOSIS

ÁÁÁÁÁÁÁÁÁÁ

Condition

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Probable Cause

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Correction

Engine Overheats

A 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 Coolant

A 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 Operating

Thermostat 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 Heater

The 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.

ENGINE COOLING 1D – 9

REPAIR INSTRUCTIONS

ON–VEHICLE SERVICE

D12D5011

DRAINING AND REFILLING THE
COOLING SYSTEM

Caution: Do not remove the surge tank cap while
the engine and the radiator are hot. Scalding fluid
and steam may be blown out under pressure.

1. Place a pan below the vehicle to catch the draining

coolant.

2. Drain the coolant.

Remove the surge tank cap (1).

Disconnect the lower radiator hose (2).

Caution: Dispose of the used coolant to a used
coolant holding tank to be picked up with the used
oil for disposal. Never pour the used coolant down
the drain. Ethylene glycol antifreeze is an extremely
toxic chemical. Disposing of it into the sewer sys-
tem or the ground water can contaminate the local
environment.

D102D502

3. Connect the lower radiator hose.

4. Clean the cooling system.

Remove all sludge and dirt from inside the surge
tank. And install the surge tank. Refer to “Surge
Tank” in this section (1).

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