SERVICE TRAINING MANUAL

ENGINE
Matiz 1.0L
2002. 11. 25.
CONTENTS
1. OBD General 3

2. General Information 27

3. Engine Mechanical 34

4. Engine Lubrication.47

5. Engine Intake . 49

6. Engine Exhaust 53

7. Engine Cooling 56

8. Fuel Supply System 60

9. Engine Control (General Area)... 67

10. Engine Control (Euro stage III)... 105
MATIZ 1.0L
3
GENERAL
INFORMATION
VEHICLE IDENTIFICATION NUMBER
K L A 4 M 1 1 C E Y C 000000
9. Production Serial Number
: 000001 ~ 999999

8. Plant Code
C : Changwon

7. Model Year
Y : 2000
1 : 2001
2 : 2002
3 : 2003

6. Transaxle Type
D : Five-speed Manual Transaxle, LHD
E : Five-speed Manual Transaxle, RHD

5. Purpose
1B : Export Purpose Usage
(70/220-96/69/EC)
1C : Export Purpose Usage
(70/220-1999/102/EC)

4. Body Type
1 : 4 Door Hatchback

3. Daewoo Trade Marks
M : Matiz

2. Engine Code
4 : 0.8 SOHC MPFI
0 : 1.0 SOHC MPFI
2 : 1.2 SOHC MPFI

1. Maker Identification
K : Asia
L : Korea
A : Daewoo Motor Co. Ltd
---------- -- --- --- ----- --- --- --- -----------
MATIZ 1.0L
4
GENERAL
INFORMATION
ENGINE NUMBER
MATIZ 1.0L
5
GENERAL
INFORMATION
ENGINE and ECM TYPE
0.8 L SOHC FENIX 5MR SASCO Unleaded/Leaded
1.0 L SOHC SIRIUS D4 SIEMENS Unleaded/Leaded
0.8 L SOHC
SIRIUS D3
(2000. 9 ~ )
SIEMENS Euro stage III
1.0 L SOHC SIRIUS D4 SIEMENS Euro stage III
0.8 L SOHC SIRIUS D3 SIEMENS Euro stage III
1.0 L SOHC SIRIUS D4 SIEMENS Euro stage III
Western
Europe
Mexico
Emission ECM Source
Engine
Area
Engine
General
1. FENIX 5MR : SASCO (SIEMENS family) , 55 pins
2. SIRIUS D3/D4 : SIEMENS , 90 pins
SIRIUS D3/D4
MATIZ 1.0L
6
GENERAL
INFORMATION
SPECIFICATION
1.0L SOHC
152
0.42
46.5 (63.2) / 5400
8.9 (64.4) / 4200
Overhead Cam L4
68.5 x 67.5
995
9.3 : 1
Overlap 18
Intake 12 BTDC / 48 ABDC
Exhaust 50 BBDC / 6 ATDC
At warm-up 850 RPM
A/C ON 900 RPM
Engine type
Bore(mm) stroke(mm)
Total displacement (cc)
Idle Speed
Compression ratio
Valve timing
Maximum torque. kg.m (lb.ft)/rpm
Application
Maximun speed (km/h)
Gradeability (tan )
Maximun Power.kw (ps)/rpm
Application Unleaded Leaded
Ignition type Direct ignition system Direct ignition system
Ignition timing (BTDC) 12 12
Ignition sequence 1-3-4-2 1-3-4-2
Spark plug type Golden : BPR5EY-11 Golden : BPR5EY
Spark plug gap 1.1 mm 0.8 mm
MATIZ 1.0L
7
GENERAL
INFORMATION
1.0L SOHC
Lubricating Type Forced Feed
Oil Pump Type Rotary (Trochoid)
Oil Filter Type Full Flow
Oil Capacity W/Oil Filter 3.5 L
Cooling Type Forced Water Circulation
Radiator Type Cross Flow
Water Pump Type Centrifugal
Thermostat Type Pellet Type
Coolant Capacity 4.0 L
Battery 12V-35AH, 275CCA
Generator 65A
Starter 0.8 KW
Fuel Delivery Type MPI
Fuel Pump Type Electric Motor Pump
Fuel Filter Type Cartridge
Fuel Capacity
. Plastic : 35 L
. Steel : 38 L (Euro stage III)
Type Single Dry Plate
Outside Diameter 184 mm
Inside Diameter 127 mm
Thickness 7.65 mm
Maker DWMC
Model Y4M
Gear ratio
1st 3.417
2nd 1.950
3rd 1.280
4th 0.914
5th 0.758
Reverse 3.273
Final gear ratio 4.444
Oil capacity (L) 2.1 L
Clutch
M/T
Lubrication
Application
Cooling
Fuel
Electric
SPECIFICATION
MATIZ 1.0L
8
GENERAL
INFORMATION
RECOMMENDED FLUIDS & LUBRICANT
Capacity Fluid/Lubricant
Engine disassembly 3.5 L
Oil change W/filter 3.2 L
Oil change W/O filter 3.0 L
Oil Level Gage
(Min to Max)
1.0 L
4.0 L
Water + Ethylene glycol base antifreeze
(Year round coolant ; 50:50 mixing ratio)
0.45 L DOT-3 / DOT-4
1.0 L DEXRON II / DEXRON III
2.1 L SAE 75W-85 (GL-4)
As Required
Multi-purpose grease
(Requirement : NLGI No. 1 or 2)
As Required Silicone Lubricant
As Required Grease
As Required Grease
As Required Grease
As Required Spray grease
As Required Silicone grease
Usage
Engine coolant
Brake Fluid
Power steering
Engine oil
Weatherstrips
Manual transaxle
Manual transaxle shift linkage
Key lock cylinder
Clutch linkage pivot points
API SL Grade SAE 10W-30
(Cold area : SAE 5W-30)
(Hot area : SAE15W-40/10W-30)
Parking brake cable
Hood latch assembly
Hood and Door hinges
Fuel door hinge
Rear compartment lid hinges
MATIZ 1.0L
9
ENGINE OVER VIEW
ENGINE
MECHANICAL
MATIZ 1.0L
10
ENGINE EXPLODED VIEW
ENGINE
MECHANICAL
1. Oil Filler Cap
2. Cylinder Head Cover
3. Valve Spring
4. Water Outlet Case
5. Camshaft
6. Rocker Arm
7. Cylinder Head Gasket
8. Cylinder Head
9. Exhaust Valve
10. Intake Valve
11. Exhaust Rocker Arm Shaft
12. Intake Rocker Arm Shaft
MATIZ 1.0L
11
ENGINE EXPLODED VIEW
ENGINE
MECHANICAL
1. Oil Level Gauge Stick
2. Piston
3. Connecting Rod
4. Engine Block
5. Oil Filter
6. Flywheel
7. Crankshaft
8. Oil Pan
9. Oil Pump Strainer
10. Oil Pump Assembly
MATIZ 1.0L
12
ENGINE MOUNTING
ENGINE
MECHANICAL
4 Point Engine Mounting
1. Engine Mount Damping Block
2. Engine Mount Intermediate Bracket
3. Engine Mount Brace Bracket
4. Transaxle Mount Bracket
5. Transaxle Mount Damping Block
6. Engine Mount Front Bracket
7. Engine Mount Front Damping Bush
8. Engine Mount Lower Bracket
9. Engine Mount Upper Bracket
MATIZ 1.0L
13
PISTON RING INSTALLATION
ENGINE
MECHANICAL
Piston Ring Installation
Piston Ring Cut-away
MATIZ 1.0L
14
TIMING BELT
ENGINE
MECHANICAL
Model Part number ID Length Maintenance Remarks
Matiz 1.0L 12761A78B00 White (A-475) 851.6 mm
I : 30,000 km
R : 90,000 km
HNBR
Timing Belt
Timing Belt
Tensioner
Timing Belt Upper Front Cover
Timing Belt Lower Front Cover
MATIZ 1.0L
15
TIMING BELT ADJUSTMENT
ENGINE
MECHANICAL
1. Align the both marks on the cam
sprocket and the cover
2. Align the both marks on the crankshaft
sprocket and the cover
3. Install the timing belt
4. Tighten tensioner bolt
MATIZ 1.0L
16
VALVE-CLEARANCE ADJUSTMENT
ENGINE
MECHANICAL
1. Remove the cylinder head cover hexagon bolts and remove the cover.

2. Turn over the crankshaft to make No.1 cylinder matched with the compression top dead
center.
(When the camshaft sprocket notch (d) is aligned with the timing belt rear cover
triangle pointer (e) and the crankshaft sprocket point (f) is aligned with the oil
pump housing point (g), the compression top dead center is on the ignition sequence
for No. 1 cylinder).
3. Check the valve clearance for No. 1 cylinder compression top dead center.

4. If the checking for the valve clearance of No.1 cylinder compression top dead center is
over, position No.1 cylinder on the exhaust top dead center as rotating the crankshaft
in a 360degree arc.
(When the camshaft sprocket point (h) is aligned with the timing belt rear cover triangle
pointer (e), the exhaust top dead center is on the ignition sequence for No. 1 cylinder.)

5. Check the valve clearance for the No. 1 cylinder exhaust top dead center.
MATIZ 1.0L
17
VALVE-CLEARANCE ADJUSTMENT
ENGINE
MECHANICAL
7. Check and adjust the valve clearance (i) using thickness gauge (j).
The measured value of valve clearance should meet the specified value. If not, adjust
the valve clearance.
8. When adjusting the valve clearance, loosen the adjust nut (k) and then tighten or
loosen the adjust rod (l) properly.

Important : In case of hot engine, warm up the engine until the electric cooling fan
begins to work and stop the engine to adjust the clearance with 2030 minutes there
from.
1 2 3 4
IN O O
EX O O
IN O O
EX O O
Cylinder Number
No. 1 Cyinder Condition
Compression Top Dead Center
Exhaust Top Dead Center
0.8L 1.0L
IN 0.15 0.02 0.15 0.02
EX 0.32 0.02 0.20 0.02
IN 0.25 0.02 0.25 0.02
EX 0.42 0.02 0.3 0.02
Application
Cold
Hot
Valve Clearance (mm)
MATIZ 1.0L
18
COMPRESSION PRESSURE CHECK
ENGINE
MECHANICAL
Pressure (kg/cm
2
)
0.8 L 1.0 L
Standard 12.5 13
Limit 12~13 12.5~13.5
Difference between cylinders 1.0 or less 1.0 or less
1. Warm up until normal operating temperature (80~90)
2. Stop the engine
3. Remove all spark plugs and high tension wires
4. Disconnect the intake air cleaner elbow hose
5. Put the compression gage in the spark plug hole
6. Disengage the clutch and depress accelerator all the way down
7. Crank the engine and read the highest pressure measure
MATIZ 1.0L
19
BELT
ENGINE
MECHANICAL
Belt Installation
No. Item Type
Length
(mm)
1 Alternator 635
2 Power Steering Belt 665
3 A/C Belt 735
4 A/C Belt + Power Steering Belt 910
Rib Belt
Rib Belt
3
2
1
4
MATIZ 1.0L
20
LUBRICATION
ENGINE
LUBRICATION
Application 0.8L SOHC 1.0L SOHC
Engine Oil
. SAE 10W-30, API SJ
. SAE 5W-30, API SJ (Cold Area)
. SAE 10W-30, API SL
. SAE 5W-30, API SL (Cold Area)
Oil Capacity w/oil filter 2.7 L 3.5L
Maintenance
- Normal Condition : 10,000 km
- Severe Condition : 5,000 km
- Normal Condition : 15,000 km
- Severe Condition : 7,500 km
MATIZ 1.0L
21
LUBRICATION
ENGINE
LUBRICATION
Application 1.0L SOHC
Oil Pump Pressure
- Idle : 1.73 kg/cm2
- 2000 rpm : 3.0~3.5 kg/cm2
Oil Pressure Switch
Tightening Torque
1.22~1.63 kgm
MATIZ 1.0L
22
ENGINE
INTAKE
INTAKE SYSTEM
1.0L SOHC
Filter element Non woven fabric
Capacity 6.0L
Element
Maintenance
- Inspect : Every 15,000 km
- Replace : Every 45,000 km
Volume 1.9L
Frequency 87Hz
Aux Resonator Frequency 450Hz
Material Plastic
Volume
1732 cm
3
Air cleaner
Main Resonator
Intake manifold
Application
1. Intake Manifold
2. Exhaust Gas Recirculation (EGR) Pipe
3. Exhaust Gas Recirculation (EGR) Valve
4. Throttle Body Assembly
5. Air Filter Assembly
6. Resonator
7. Snorkel
MATIZ 1.0L
23
EXHAUST SYSTEM
ENGINE
EXHAUST
Front catalyst
Downstream O
2
sensor
Main
catalyst
ECU
Pin 64
O
2
down
heater
Pin 14
Down
stream
O
2
sensor
Pin 66
Vbat after
main relay
Upstream
O
2
sensor
Pin 13
O
2
UP
ground
Pin 44
Up
stream
O
2
sensor
Pin 35
O
2
UP
heater
Pin 16
O
2
down
ground
Upstream O
2
sensor
Main
catalyst
ECU
Pin 13
O
2
UP
ground
Pin 44
Up
stream
O
2
sensor
ECU
K line for CO adjustment
Catalyst
case w/o
catalyst
No catalyst
[ EOBD ]
[ Unleaded ]
[ Leaded ]
MATIZ 1.0L
24
EXHAUST SYSTEM
ENGINE
EXHAUST
1.0L SOHC
Type 3 way catalyst
Volume 0.34 L
Type 3 way catalyst
Volume 1.54 L
Front Muffler Volume 3.4 L
Rear Muffler Volume 9.0 L
Application
Front Catalyst
Main Catalyst
1. Pupup Catalytic Converter 3. Front Muffler Pipe
2. Front Exhaust Pipe/Catalytic Converter Assembly 4. Rear Muffler Pipe
MATIZ 1.0L
25
EXHAUST SYSTEM
ENGINE
EXHAUST
* In order to remove the Downstream
HO2S, Remove the floor console and
disconnect the HO2S connector.
MATIZ 1.0L
26
1. Surge Tank
2. Surge Tank Cap
3. Upper Radiator Hose
4. Lower Radiator Hose
5. Clip
6. Surge Tank Hose
7. Clip
8. Hose Bracket
9. Radiator Coolant Return Hose
10. Clamp
11. Throttle Body Outlet Hose
12. Clip
13. Surge Tank Return Hose
14. Clip
15. Clip
16. Water Inlet Cap
17. Bolt
18. Heater Inlet Hose
19. Heater Outlet Hose
20. Clip
21. Clip
22. Engine Coolant Temp Sensor
23. Coolant Temp Sensor
24. Strap
COOLING SYSTEM
ENGINE
COOLING
MATIZ 1.0L
27
COOLING SYSTEM
ENGINE
COOLING
ON OFF ON OFF
ECT 93 90 93 90
ECT sensor
ECT 100 97 100 97
A/C COMP.
Speed Application
Low
High
1.0 L SOHC
Malfunction
ON ON
Malfunction
0.8 L SOHC
MATIZ 1.0L
28
COOLING SYSTEM
ENGINE
COOLING
Thermostat Cooling fan
Application 0.8L SOHC 1.0L SOHC
Cooling fan size 320 mm, 14 A 300 mm, 14 A
Coolin fan resistance
70~90@23
95~125@125
Thermostat operation
* Open
- start to open : 82 dec 1.5
- Full open : 95 dec
* Close 80 dec
* Open
- start to open : 82 dec 1.5
- Full open : 95 dec
* Close 80 dec
Radiator size (mm)
(Width x Height x Thickness)
458 x 295 x 16 (STD)
458 x 295 x 27 (Heavy Duty)
458 x 295 x 27
MATIZ 1.0L
29
FUEL PUMP
FUEL SUPPLY
SYSTEM
Gage angle( ) Resistance(k) Remark
Full stop 36.5 L 89 34.1
3/4 27.3 L 65 71.1
1/2 18.4 L 45 114
1/4 9.14 L 15 201
Low 6.5 L 6 238 Warning lamp ON
Empty stop 3.0 L 0 299
Fuel quantity
The fuel pump is installed inside the fuel tank.
The fuel pump stays ON as long as the engine cranks or
runs while ECM receives reference pulses from the
optical sensor of the distributor.
If there is no reference pulse in ignition ON state or the
engine stops running, 2 seconds later the ECM will turn
OFF the fuel pump.
The fuel pump delivers fuel to the fuel rail and injector
and the fuel system pressure is regulated by the fuel
pressure regulator, which is located on the fuel pump
assembly in side the fuel tank.
The fuel pump contains the relief valve and the check
valve for safety.
Fuel Pressure regulator
a : Fuel pressure regulator b : Spring
c : Over flow valve d : Diaphragm
* Fuel Pressure : 3.88 kg/cm
2

* Fuel filter maintenance : Every 3 years or 45,000 km (installed on the fuel tank)
MATIZ 1.0L
30
The evaporative emission canister is an emission control device containing activated
charcoal granules. The evaporative emission canister is used to store fuel vapors from the
fuel tank.
Once certain conditions are met, the electronic control module (ECM) activates the
controlled canister purge solenoid allowing the fuel vapors to be drawn into the engine
cylinders and burned.

Capacity
0.8 SOHC : 900cc
1.0 SOHC : 1000cc : 48 g/min
Carbon Element : Activated Carbon
EVAPORATIVE EMISSION CANISTER
FUEL SUPPLY
SYSTEM
[ Canister ]
[ CCCP Solenoid ]