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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–2 GENERAL ENGINE INFORMATION DAEWOO M-150 BL2 DESCRIPTION AND SYSTEMOPERATION CLEANLINESS AND CARE An automobile engine is a combination of many ma- chined, honed, polished and lapped surfaces with toler- ances that are measured in the ten–thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of en- gine oil should be applied to friction areas during assem- bly, to protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas is part of the repair proce- dure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for ser- vice, they should be kept in order. They should be installed in the same locations, and with the same mat- ing surfaces, as when they were removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. ON-ENGINE SERVICE Caution: Disconnect the negative battery cable be- fore removing or installing any electrical unit, or when a tool or equipment could easily come in con- tact with exposed electrical terminals. Disconnect- ing this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. Notice: Any time the air cleaner is removed, the intake opening should be covered. This will protect against ac- cidental entrance of foreign material, which could follow the intake passage into the cylinder and cause exten- sive damage when the engine is started. 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 Motor 13 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 Motor 11 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 GENERAL ENGINE INFORMATION 1A– 5 DAEWOO M-150 BL2 DIAGNOSTIC INFORMATION PROCEDURE GENERAL DIAGNOSIS Condition Probable cause Correction Hard Starting (With Malfunction of D Faulty fuse. D Replace the fuse. normal cranking) Ignition System D Faulty spark plug. D Clean, adjust the plug gap or replace. D Electric leakage at the high tension cable. D Replace the cable. D Poor connection of the high tension cable or lead wires. D Replace the cable or wires. D Worn distributor cap or accumulated carbon in the distributor cap. D Replace or clean the distributor cap. D Damaged distributor rotor or cap. D Replace the rotor or the cap. D Improper ignition timing. D Adjust the ignition timing. D Faulty ignition coil. D Replace the ignition coil. Malfunction of Fuel D Lock of fuel in the fuel tank. D Feed the fuel. System D Dirty or clogged fuel filter. D Replace the filter. D Clogged fuel pipe. D Clean the fuel pipe. D Malfunction of the fuel pump. D Replace the fuel pump. D Malfunction of the fuel injector. D Replace the injector. D The foreign material in the fuel tank. D Clean the fuel tank. Decline of Compression D Poor tightening spark plug. D Tighten to the specified torque. Pressure D Cracked cylinder head gasket. D Replace the gasket. D Inadequate the valve clearance. D Adjust the clearance. D Leakage of the valve clearance. D Repair the valve. D Interference of the valve stem. D Replace the valve or the valve guide. D Low elasticity or damage of the valve spring. D Replace the valve spring. D Abnormal interference of pistons and cylinders. D Replace the piston ring. D Excessive wear of pistons, rings, or cylinders. D Replace the ring or the piston and boring or replace the cylinder. 1A–6 GENERAL ENGINE INFORMATION DAEWOO M-150 BL2 GENERAL DIAGNOSIS (Cont’d) Condition Probable cause Correction Hard Starting (With Others D Broken timing belt. D Replace the belt. normal cranking) D Malfunction of Positive Crankcase Ventilation (PCV) valve. D Check and replace Positive Crankcase Ventilation (PCV) valve if needed. D Loosening, damage or leakage of the vacuum hose. D Connect the hose correctly or replace it. D Leakage of intake system. D Replace intake system. Lack of Engine Power Decline of Compression Pressure D Refer to “Page 1A–5”. D Refer to “Page 1A–5”. Malfunction of D Improper ignition timing. D Adjust the ignition timing. Ignition System D Faulty spark plug. D Adjust or replace the spark plug. D Malfunction of the distributor. D Repair or replace the distributor. Check the rotor. D Electric leakage or poor connection of the high tension cable. D Connect the cable correctly or replace it. Malfunction of D Clogged fuel pipe. D Clean the pipe. Fuel System D Clogged or contaminated fuel filter. D Replace the filter. Others D Clogged exhaust system. D Check and repair the system. D Clogged or contaminated air cleaner element. D Clean or replace the air cleaner element. D Leak of the intake manifold gasket. D Replace the gasket. D Dragging brakes. D Repair or replace the brakes. D Slipping clutch. D Adjust or replace the clutch. Rough Engine Idling Decline of Compression Pressure D Refer to “Page 1A–5”. D Refer to “Page 1A–5”. Malfunction of D Clogged fuel pipe. D Clean the pipe. Fuel System D Clogged or contaminated fuel filter. D Replace the filter. D Malfunction of the fuel pressure regulator. D Replace the regulator. Malfunction of Ignition System D Malfunction of the spark plug. D Adjust or replace the spark plug. D Electric leakage or poor connection of the high tension cable. D Connect the cable correctly or replace it. D Worn distributor cap terminal or accumulated carbon in the distributor cap. D 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 Idling Malfunction of Ignition System D Loosening or damage of the distributor rotor or cap. D Replace the rotor or cap. D Poor ignition timing. D Adjust the ignition timing. D Malfunction of the ignition coil. D Replace the ignition coil. Others D Clogged or contaminated air cleaner element. D Clean or replace the air cleaner element. D Leak of the intake manifold gasket. D Replace the gasket. D Malfunction of Positive Crankcase Ventilation (PCV) valve. D Check the valve or replace it if needed. D Poor connection or damage or leakage of the vacuum hose. D Connect the hose correctly or replace it. Engine Hesitate (Upon pressing accelerating pedal, the engine Decline of Compression Pressure D Refer to “Page 1A–5”. D Refer to “Page 1A–5”. makes delayed response. This Malfunction of D Poor ignition timing. D Adjust the ignition timing. response. This situation is remarkable when cruising or Ignition System D Poor spark plug or poor adjustment of the plug gap. D Replace the plug or adjust the gap. starting.) D Electric leakage or poor connection of the high tension cable. D Connect the cable correctly or replace it. Others D Malfunction of the air cleaner system. D Clean or replace the air cleaner system. D Leak of the intake manifold gasket. D Replace the gasket. Engine Surging (Engine power makes fluctuation in a fixed Decline of Compression Pressure D Refer to “Page 1A–5”. D Refer to “Page 1A–5”. speed and speed changes without Malfunction of D Clogged fuel pipe. D Clean the pipe. changes without operating the accelerating pedal.) Fuel System D Clogged or contaminated fuel filter. D Replace the filter. D Malfunction of the fuel pressure regulator. D Replace the fuel pressure regulator. Malfunction of Ignition System D Malfunction of the spark plug. D Adjust or replace the spark plug. D Electric leakage or poor connection of the high tension cable. D Connect the cable correctly or replace it. D Worn distributor cap terminal or accumulated carbon in the distributor cap. D Clean or replace the distributor cap. D Loosening or damage of the distributor rotor or the cap. D Replace the distributor rotor or the cap. D Poor ignition timing. D 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 fixed Others D Leak of the intake manifold gasket. D Clean or replace the gasket. speed and speed changes without operating the accelerating pedal.) D Leakage of the vacuum hose. D Connect the hose correctly or replace it. Excessive Detonation (According to the Overheated Engine D Refer to “Overheat” in this page. D Refer to “Overheat” in this page. opening range of throttle valve, Malfunction of D Abnormal spark plug. D Replace the spark plug. knocking sound of metallic is made with Ignition System D Poor ignition timing. D Adjust the ignition timing. metallic is made with abnormal explosion.) D Electric leakage or poor connection of the high tension cable. D Connect the cable correctly or replace it. Malfunction of Fuel System D Clogged or contaminated fuel filter and fuel pipe. D Clean or replace the fuel filter and the fuel pipe. Others D Leak of the intake manifold gasket. D Replace the gasket. D Excessive carbon deposit due to abnormal combustion. D Remove the carbon. Overheat Malfunction of D Lack of coolant. D Refill coolant. Cooling System D Malfunction of the thermostat. D Replace the thermostat. D Malfunction of the cooling fan. D Check or replace the cooling fan. D Poor water pump performance. D Replace the pump. D Clogged or leaky radiator. D Clean, repair or replace the radiator. Malfunction of Lubrication D Poor engine oil. D Replace engine oil with the specified one. System D Blocking oil filter or strainer. D Clean or replace the oil filter or the strainer. D Lack of engine oil. D Refill oil. D Poor oil pump performance. D Replace or repair the pump. D Leakage of oil. D Repair. Other D Damaged cylinder head gasket. D Replace the gasket. Poor Fuel Consumption Decline of Compression Pressure D Refer to “Page 1A–5”. D Refer to “Page 1A–5”. Malfunction of Fuel System D Leakage of the fuel tank or the fuel pipe. D Repair or replace the fuel tank or the fuel pipe. GENERAL ENGINE INFORMATION 1A– 9 DAEWOO M-150 BL2 GENERAL DIAGNOSIS (Cont’d) Condition Probable cause Correction Poor Fuel Malfunction of D Improper ignition timing. D Adjust the ignition timing. Consumption Ignition System D Abnormal spark plug (Excessive carbon deposit, inadequate gap, burnt electrode). D Replace the plug. D Electric leakage or poor connection of the high tension cable. D Connect the cable normally or replace it. Malfunction of Cooling System D Malfunction of the thermostat. D Replace the thermostat. Others D Improperly installed valve. D Repair or replace the valve. D Slipping clutch. D Repair or replace the clutch. D Low pressure of tires. D Adjust the pressure of tires. Excessive Leakage of D Loosened oil drain plug. D Tighten the plug. Consumption of Engine Oil Engine Oil D Loosened oil pan bolt. D Tighten the bolt. Engine Oil D Loosened oil filter. D Tighten the filter. D Loosened oil pressure switch. D Tighten the switch. D Leakage of camshaft front oil seal. D Replace the seal. D Leakage of crankshaft front oil seal. D Replace the seal. D Leakage at the cylinder head cover gasket. D Replace the gasket. D Damage of the cylinder head gasket. D Replace the gasket. Oil Mixing in Combustion D Stuck piston ring. D Remove carbon and replace the ring. Chamber D Worn piston or cylinder. D Replace the piston or the cylinder. D Worn piston ring or ring groove. D Replace the piston or ring. D Inadequate position of the piston ring cutting part. D Adjust the position. D Abrasion or damage of the valve system. D Replace the valve system. Low Oil Pressure Malfunction of Lubrication D Inadequate oil viscosity. D Replace with the specified one. System D Loosening of the oil pressure switch. D Tighten the switch. D Lack of engine oil. D Refill oil. D Blocking oil strainer. D Clean the strainer. 1A–10 GENERAL ENGINE INFORMATION DAEWOO M-150 BL2 GENERAL DIAGNOSIS (Cont’d) Condition Probable cause Correction Low Oil Pressure Malfunction of Lubrication D Lowered function of the oil pump. D Replace the pump. System D Abrasion or damage of the oil pump relief valve. D Replace the valve. Engine Noise Valve Noise D Inadequate valve clearance. D Adjust the valve clearance. D Abrasion of valve stem or guide. D Replace the valve stem or the guide. D Weak valve spring. D Replace the spring. Piston, Ring, Cylinder Noise D Abrasion of the piston, the ring or the cylinder. D Boring the cylinder or replace the piston, the ring or the cylinder. Connecting Rod Noise D Abrasion of the connecting rod bearing. D Replace the bearing. D Loosened the connecting rod nut. D Tighten to the specified torque. Crankshaft Noise D Abrasion of the crankshaft bearing. D Replace the bearing. D Abrasion of the crankshaft journal. D Grind or replace the crankshaft journal. D Loosened bearing cap bolt. D Tighten to the specified torque. D Excessive clearance of the crankshaft thrust bearing. D Adjust or replace. D Low oil pressure. D Refer to “Low Oil Pressure” in this section. [...]... 2.5 L (2.64 qt) 1 L (1.06 qt) (MIN to MAX) 3.8 L (4.02 qt) 12V–35 AH, 246 CCA GENERAL SPECIFICATIONS SPECIFICATIONS 1A – 14 GENERAL ENGINE INFORMATION GENERAL ENGINE INFORMATION 1A – 15 ENGINE PERFORMANCE CURVE D Maximum Power : 51 PS (37.5 KW) (at 6,000 rpm) D Maximum Torque : 7 KgSm (68.6 NSm) (at 4,600 rpm) D12A101A DAEWOO M-150 BL2 .. .GENERAL ENGINE INFORMATION 1A – 11 CHECKING ENGINE FLUID LEVEL 3 Remove the oil drain plug (c) and draw oil off Check the engine fluid level or condition If needed, refill or replace the oil Check the engine oil level within engine normal operating temperature as follows ; 1 After stopping the engine, wait for a few minutes to accumulate oil into... ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Ñ Engine Information Output Capacity Output Pressure Fuel Tank Capacity Fuel Pump Generator Starter Coolant Battery Engine Oil Engine Part Capacity Engine Part Type Engine Disassembly Oil Change (Including filter) Oil Change (Not including filter) Oil Level Gauge Refrigerant Engine Oil Unleaded Leaded Fuel Injection Type Fuel Pump Fuel Filter Lubricating Type Oil Pump Cooling... spark plug If pulling the high tension cable (j), circuit could be disconnected Therefore, the cap portion should be used D102A306 DAEWOO M-150 BL2 GENERAL ENGINE INFORMATION 1A – 13 CHECKING AIR CLEANER ELEMENT CHECKING FUEL SYSTEM If the air cleaner element becomes dirty, engine efficiency could be deteriorated Be sure to check the element often Check the fuel system as follows ; Especially, if a vehicle... oil filter Important: Whenever changing engine oil, replace the oil filter When replacing new oil filter, apply engine oil on oil filter sealing D102A301 CHANGING ENGINE OIL OR OIL FILTER Tools Required 09915–47341 Oil Filter Wrench When checking engine oil level or condition, if needed, change engine oil (including the filter) as follows ; 1 After stopping the engine, wait for a few minutes to accumulate... engine oil (including the filter) as follows ; 1 After stopping the engine, wait for a few minutes to accumulate oil into the oil pan 2 Remove the oil filter cap (b) DAEWOO M-150 BL2 D102A303 1A – 12 GENERAL ENGINE INFORMATION CHECKING ENGINE TIMING BELT After checking the timing belt for looseness, crack, wear or tension, replace the belt if necessary CHECKING ACCESSORY BELT After checking the alternator... Muffler Battery Spark–Plug Distributor Starter Ignition Type Engine Information Vehicle Capacity Application Maximum Speed Gradeability Minimum Turning Radius Bore × Stroke Displacement Compression Ratio Maximum Power Maximum Torque Ignition Timing (Ignition Sequence) Air Conditioning System (ON) Idle Speed Air Conditioning System (OFF) Engine DAEWOO M-150 BL2 65 A 0.8 kW 90 – 133 Lph 380 kPa (55.1 Psi) 35... refill engine oil as much as the demanded quantify Important: If checking oil level under the engine cold condition, oil is not accumulated into oil pan quickly and correct level checking can not be performed Therefore, wait until temperature reaches the normal operating condition and check the engine oil level D102A302 4 After drawing oil completely, tighten the oil drain plug to 30–40 NSm (22–30 lb-ft)... fuel filter is used over the specified period, engine efficiency is deteriorated by dust or foreign material Therefore, replace a new one within the specified period Check the engine vacuum hose, PCV hose or canister hose as follows ; D Check the hose surface for damage by heat or machine D Check the hose for hardening, crack, tear, or coming off DAEWOO M-150 BL2 D Check the fuel line or line connection... kPa (55.1 Psi) 35 L (9.2 gal), 38 L (10 gal) Description 144 km/h (90 mph) 0.420 tan θ 4.5 m (14.8 ft) 68.5 × 72.0 mm (2.70 × 2.83 inch) 796 cm3 (48.6 in3) 9.3 : 1 37.5 KW (6,000 rpm) 68.6 NSm (50.59 lb-ft) (at 4,600 rpm) 5_ BTDC (1–3–2) / 10_ BTDC (1–3–2) 1,000 ± 50 rpm 950 rpm Overhead Cam L–3 Direct Ignition System (DIS) / High Energy Ignition (HEI) Optical Sensor Type SD 80 BPR5EY–11, RN9YC4, WR8DCX . 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 fixed Others D Leak. Manifold 17 Snorkel 18 Engine 20 Washer Fluid Reservoir 19 Oil Level Gauge 21 Oil Filler Cap GENERAL ENGINE INFORMATION 1A– 5 DAEWOO M-150 BL2 DIAGNOSTIC INFORMATION PROCEDURE GENERAL DIAGNOSIS Condition. this section. GENERAL ENGINE INFORMATION 1A– 11 DAEWOO M-150 BL2 CHECKING ENGINE FLUID LEVEL Check the engine fluid level or condition. If needed, refill or replace the oil. Check the engine oil