M31a General Engine Information

7/31/2019 M31a General Engine Information

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DAEWOO M-150 BL2

SECTION 1A

GENERAL ENGINE INFORMATION

TABLE OF CONTENTSDescription 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. . . . . . . . . . . . . . . .


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1A2 GENERAL ENGINE INFORMATION

DAEWOO M-150 BL2

DESCRIPTION AND SYSTEMOPERATION

CLEANLINESS AND CAREAn automobile engine is a combination of many ma-chined, honed, polished and lapped surfaces with toler-ances that are measured in the tenthousandths of an

inch. When any internal engine parts are serviced, careand 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 machinedsurfaces and friction areas is part of the repair proce-

dure. This is considered standard shop practice even ifnot specifically stated.

Whenever valve train components are removed for ser-vice, they should be kept in order. They should beinstalled 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 isperformed on the engine. Failure to disconnect cables

may result in damage to wire harness or other electricalparts.

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 anddamage to the vehicle. The ignition must also be inB unless otherwise noted.

Notice: Any time the air cleaner is removed, the intakeopening should be covered. This will protect against ac-

cidental entrance of foreign material, which could followthe intake passage into the cylinder and cause exten-

sive damage when the engine is started.


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GENERAL ENGINE INFORMATION 1A3

DAEWOO M-150 BL2

COMPONENT LOCATOR

ENGINE COMPARTMENT (TYPICAL)

(LeftHand Drive Shown, RightHand Drive Similar)

D102A401

1 Power Steering Oil Reservoir2 Coolant Reservoir

3 Canister

4 Canister Solenoid5 Manifold Absolute Pressure (MAP) Sensor6 Intake Manifold7 Ignition Coil8 Idle Air Control (IAC) Valve

9 Throttle Position (TP) Sensor10 Throttle Body11 Brake Fluid Reservoir

12 Wiper Motor

13 Battery14 Fuse Box

15 Air Cleaner Housing

16 Resonator17 PCV Hose18 Distributor19 Exhaust Manifold20 Snorkel

21 Engine22 Washer Fluid Reservoir23 Oil Level Gauge

24 Oil Filler Cap


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DAEWOO M-150 BL2

ENGINE COMPARTMENT (EURO III)

(LeftHand Drive Shown, RightHand Drive Similar)

MAA1A010

1 Power Steering Oil Reservoir2 Coolant Reservoir3 Canister Purge Solenoid

4 Manifold Absolute Pressure (MAP) Sensor5 Intake Manifold6 Throttle Position (TP) Sensor

7 Throttle Body8 Idle Air Control (IAC) Valve9 Brake Fluid Reservoir

10 Wiper Motor

11 Battery12 Fuse Box13 Air Cleaner Housing

14 Resonator15 Electronic Ignition System Ignition Coil16 Exhaust Manifold

17 Snorkel18 Engine20 Washer Fluid Reservoir19 Oil Level Gauge

21 Oil Filler Cap


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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 orreplace.

D Electric leakage at the hightension cable.

D Replace the cable.

D Poor connection of the hightension cable or lead wires.

D Replace the cable or wires.

D Worn distributor cap oraccumulated carbon in thedistributor cap.

D Replace or clean thedistributor cap.

D Damaged distributor rotor orcap.

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 fuelinjector.

D Replace the injector.

D The foreign material in thefuel tank.

D Clean the fuel tank.

Decline ofCompression

D Poor tightening spark plug. D Tighten to the specifiedtorque.

PressureD Cracked cylinder head

gasket.D Replace the gasket.

D Inadequate the valveclearance.

D Adjust the clearance.

D Leakage of the valveclearance.

D Repair the valve.

DInterference of the valvestem.

DReplace the valve or thevalve guide.

D Low elasticity or damage ofthe valve spring.

D Replace the valve spring.

D Abnormal interference ofpistons and cylinders.

D Replace the piston ring.

D Excessive wear of pistons,rings, or cylinders.

D Replace the ring or thepiston and boring or replacethe cylinder.


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DAEWOO M-150 BL2

GENERAL DIAGNOSIS (Contd)


Hard Starting (With Others D Broken timing belt. D Replace the belt.normal cranking)

D Malfunction of PositiveCrankcase Ventilation (PCV)valve.

D Check and replace PositiveCrankcase Ventilation (PCV)valve if needed.

D Loosening, damage orleakage of the vacuum hose.

D Connect the hose correctlyor replace it.

D Leakage of intake system. D Replace intake system.

Lack of Engine Power Decline ofCompressionPressure

D Refer to Page 1A5. D Refer to Page 1A5.

Malfunction of D Improper ignition timing. D Adjust the ignition timing.Ignition System

D Faulty spark plug. D Adjust or replace the sparkplug.

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

D Electric leakage or poorconnection of the hightension cable.

D Connect the cable correctlyor replace it.

Malfunction of D Clogged fuel pipe. D Clean the pipe.Fuel System

D Clogged or contaminatedfuel filter.

D Replace the filter.

Others D Clogged exhaust system. D Check and repair thesystem.

D Clogged or contaminated aircleaner element.

D Clean or replace the aircleaner element.

DLeak of the intake manifoldgasket.

DReplace the gasket.

D Dragging brakes. D Repair or replace thebrakes.

D Slipping clutch. D Adjust or replace the clutch.

Rough Engine Idling Decline ofCompressionPressure


Malfunction of D Clogged fuel pipe. D Clean the pipe.Fuel System

D Clogged or contaminatedfuel filter.

D Replace the filter.

D Malfunction of the fuelpressure regulator.

D Replace the regulator.

Malfunction ofIgnition System

D Malfunction of the sparkplug.

D Adjust or replace the sparkplug.



D Worn distributor cap terminalor accumulated carbon inthe distributor cap.

D Replace or clean thedistributor cap.


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DAEWOO M-150 BL2



Rough Engine Idling Malfunction ofIgnition System

D Loosening or damage of thedistributor rotor or cap.

D Replace the rotor or cap.

D Poor ignition timing. D Adjust the ignition timing.

D Malfunction of the ignitioncoil.

D Replace the ignition coil.

Others D Clogged or contaminated aircleaner element.

D Clean or replace the aircleaner element.

D Leak of the intake manifoldgasket.

D Replace the gasket.

D Malfunction of PositiveCrankcase Ventilation (PCV)valve.

D Check the valve or replace itif needed.

D Poor connection or damageor leakage of the vacuumhose.

D Connect the hose correctlyor replace it.

Engine Hesitate (Uponpressing acceleratingpedal, the engine

Decline ofCompressionPressure


makes delayedresponse. This Malfunction of D Poor ignition timing. D Adjust the ignition timing.response. Thissituation is remarkablewhen cruising or

Ignition SystemD Poor spark plug or poor

adjustment of the plug gap.D Replace the plug or adjust

the gap.starting.)



Others D Malfunction of the air cleanersystem.

D Clean or replace the aircleaner system.

D Leak of the intake manifoldgasket.


Engine Surging(Engine power makesfluctuation in a fixed



speed and speedchanges without Malfunction of D Clogged fuel pipe. D Clean the pipe.changes withoutoperating theaccelerating pedal.)

Fuel SystemD Clogged or contaminated

fuel filter.D Replace the filter.

D Malfunction of the fuelpressure regulator.

D Replace the fuel pressureregulator.

Malfunction of

Ignition System

D Malfunction of the spark

plug.

D Adjust or replace the spark

plug.



D Worn distributor cap terminalor accumulated carbon inthe distributor cap.

D Clean or replace thedistributor cap.

D Loosening or damage of thedistributor rotor or the cap.

D Replace the distributor rotoror the cap.

D Poor ignition timing. D Adjust the ignition timing.


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DAEWOO M-150 BL2



Engine Surging(Engine power makesfluctuation in a fixed

Others D Leak of the intake manifoldgasket.

D Clean or replace the gasket.

speed and speedchanges withoutoperating theaccelerating pedal.)

D Leakage of the vacuum hose. D Connect the hose correctlyor replace it.

Excessive Detonation(According to the

OverheatedEngine

D Refer to Overheat in thispage.

D Refer to Overheat in thispage.

opening range ofthrottle valve, Malfunction of D Abnormal spark plug. D Replace the spark plug.

knocking sound ofmetallic is made with

Ignition SystemD Poor ignition timing. D Adjust the ignition timing.metallic is made with

abnormal explosion.)D Electric leakage or poor

connection of the high tensioncable.


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 manifoldgasket.


D Excessive carbon deposit dueto 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 coolingfan.

DPoor water pumpperformance.

DReplace the pump.

D Clogged or leaky radiator. D Clean, repair or replace theradiator.

Malfunction ofLubrication

D Poor engine oil. D Replace engine oil with thespecified one.

SystemD Blocking oil fil ter 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 headgasket.


Poor FuelConsumption



Malfunction ofFuel System

D Leakage of the fuel tank orthe fuel pipe.

D Repair or replace the fueltank or the fuel pipe.


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DAEWOO M-150 BL2



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 Connect the cable normallyor replace it.

Malfunction ofCooling System

D Malfunction of thethermostat.

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 ofEngine Oil

Engine OilD Loosened oil pan bolt. D Tighten the bolt.Engine Oil

D Loosened oil filter. D Tighten the filter.

D Loosened oil pressureswitch.

D Tighten the switch.

D Leakage of camshaft front oilseal.

D Replace the seal.

D Leakage of crankshaft frontoil seal.

D Replace the seal.

D Leakage at the cylinder headcover gasket.


D Damage of the cylinder headgasket.


Oil Mixing inCombustion

D Stuck piston ring. D Remove carbon and replacethe ring.

ChamberD Worn piston or cylinder. D Replace the piston or the

cylinder.

D Worn piston ring or ringgroove.

D Replace the piston or ring.

D Inadequate position of thepiston ring cutting part.

D Adjust the position.

D Abrasion or damage of thevalve system.

D Replace the valve system.

Low Oil Pressure Malfunction ofLubrication

D Inadequate oil viscosity. D Replace with the specifiedone.

SystemD 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.


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DAEWOO M-150 BL2



Low Oil Pressure Malfunction ofLubrication

D Lowered function of the oilpump.

D Replace the pump.

SystemD 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 orguide.

D Replace the valve stem orthe guide.

D Weak valve spring. D Replace the spring.

Piston, Ring,Cylinder Noise

D Abrasion of the piston, thering or the cylinder.

D Boring the cylinder orreplace the piston, the ringor the cylinder.

Connecting RodNoise

D Abrasion of the connectingrod bearing.

D Replace the bearing.

D Loosened the connecting rod

nut.

D Tighten to the specified

torque.CrankshaftNoise

D Abrasion of the crankshaftbearing.

D Replace the bearing.

D Abrasion of the crankshaftjournal.

D Grind or replace thecrankshaft journal.

D Loosened bearing cap bolt. D Tighten to the specifiedtorque.

D Excessive clearance of thecrankshaft thrust bearing.

D Adjust or replace.

D Low oil pressure. D Refer to Low Oil Pressurein this section.


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DAEWOO M-150 BL2

CHECKING ENGINE FLUID LEVELCheck the engine fluid level or condition. If needed, refillor replace the oil.

Check the engine oil level within engine normal operat-ing temperature as follows ;

1. After stopping the engine, wait for a few minutes toaccumulate oil into the oil pan.

2. After pulling out the oil level gauge (a), check the oillevel.

3. Clean the oil level gauge and insert the gauge intoguide.

4. After pulling out the oil level gauge again, recheck the

oil level and insert the gauge into guide again.

Important: Oil level should be between MIN mark and

MAX mark.

5. If oil level is below the MIN mark, 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 andcorrect level checking can not be performed. Therefore,wait until temperature reaches the normal operating

condition and check the engine oil level.

D102A301

CHANGING ENGINE OIL OR OILFILTER

Tools Required

0991547341 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 oil into the oil pan.

2. Remove the oil filter cap (b).

3. Remove the oil drain plug (c) and draw oil off.

D102A302

4. After drawing oil completely, tighten the oil drain plugto 3040 NSm (2230 lb-ft).

5. Replace the oil filter using the oil filter wrench0991547341 (d).

D Remove the air cleaner/resonator/snorkel as-sembly.

D After removing the bolts, remove the heatshield.

D Loosen the power steering pump cap screw andpull the power steering hose into the front.

D Remove the oil filter.

Important: Whenever changing engine oil, replace the

oil filter. When replacing new oil filter, apply engine oil onoil filter sealing.

D102A303


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DAEWOO M-150 BL2

CHECKING ENGINE TIMING BELTAfter checking the timing belt for looseness, crack, wearor tension, replace the belt if necessary.

CHECKING ACCESSORY BELTAfter checking the alternator belt (e), air conditioning/power steering belt (f), air conditioning belt (g), powersteering belt (h), for looseness, crack, wear or tension,

replace the belt if necessary.

D102A304

CHECKING SPARK PLUG

After checking the spark plug for bad clearance, exces-sive carbon deposit, worn electrode or damaged insula-

tor, replace the new one if necessary.

Remove and check the spark plug as follows ;

1. Pull the high tension cable cap portion (i), and discon-nect the high tension cable from the spark plug.If pulling the high tension cable (j), circuit could bedisconnected. Therefore, the cap portion should be

used.

D102A305

2. Remove the spark plugs from cylinder head using awrench.

3. Measure the spark plug clearance (k) with the fillergauge. If measured value is not within the specifiedvalue, adjust the grounding electrode.

When installing new spark plug, check the clearancefor equality and install it.

D102A306


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DAEWOO M-150 BL2

CHECKING AIR CLEANER ELEMENTIf 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 FILTERIf 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 SYSTEMCheck the fuel system as follows ;

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

D Check the fuel hose surface for damage.

D Check the fuel cap for looseness.

CHECKING HOSE SYSTEMCheck the engine vacuum hose, PCV hose or canister

hose as follows ;

D Check the hose surface for damage by heat or ma-

chine.

D Check the hose for hardening, crack, tear, or coming

off.


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DAEWOO M-150 BL2

SPECIFICATIONS

GENERAL SPECIFICATIONS

Application Description

Maximum Speed 144 km/h (90 mph)

Vehicle Capacity Gradeability 0.420 tan 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 NSm (50.59 lb-ft) (at 4,600 rpm)

Ignition Timing (Ignition Sequence) 5_ BTDC (132) / 10_ BTDC (132)

Air Conditioning System (ON) 1,000 50 rpmIdle Speed

Air Conditioning System (OFF) 950 rpm

Engine Overhead Cam L3

Ignition Type

Direct Ignition System (DIS) /

High Energy Ignition (HEI)Distributor Optical Sensor Type

Starter SD 80

Unleaded BPR5EY11, RN9YC4, WR8DCXSparkPlug

Leaded BPR5EY, RN9YC, WR8DC

Fuel Injection Type MPI

Fuel Pump Electric Motor Pump

Engine Part Type Fuel Filter CartridgeEngine Part TypeLubricating Type Forced Feed Type

Oil Pump Rotary Pump Type

Cooling Type Forced Water Circulation

Radiator CrossFlow

Water Pump Centrifugal

Thermostat Pellet Type

Air Cleaner Element Non Woven Fablic

Muffler Catalytic Converter, Closed Circuit

Battery MF

Engine Part Engine OilSJ Grade

SAE 5W30, SAE 10W30, SAE 15W40Capacity

Refrigerant Four 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 12V35 AH, 246 CCAEngine Information

Generator 65 A

Starter 0.8 kW

Output Capacity 90133 LphFuel Pump

Output Pressure 380 kPa (55.1 Psi)

Fuel Tank Capacity 35 L (9.2 gal), 38 L (10 gal)


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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

Documents

M31a General Engine Information