Manual de Mantenimiento: Chevrolet Spark 800cc/Daewoo Matiz est protegido por las

Leyes Nacionales e Internacionales de Derechos de Autor.

Queda prohibida la reproduccin o distribucin de los contenidos de este libro por

cualquier medio mecnico o electrnico, ya sean fotocopias, distribucin va e-mail,
enlaces de descargas, sitios Web no autorizados o similares sin autorizacin del autor.

Jorge E. Penagos P.

Todos los Derechos Reservados

ISBN: 978-9942-02-587-6

Ao 2009

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2
Todos los Derechos Reservados 2009

Jorge E. Penagos P.

CONSEJOS PARA USAR EL MANUAL

Empieza por el captulo que te resulte ms fcil de entender y aplicar en

tu caso, dedica algunos minutos a revisar todo el contenido del manual ya que
te servir de mucho cualquier detalle que observes y asimiles.
No te frustres intentando hacer todo a la vez, realizando una cosa por
vez tomars confianza y destreza, conocers tu automvil poco a poco lo que
te dar confianza y satisfaccin.
No importa si desconoces totalmente la mecnica de tu automvil, con
este manual, tu intuicin y dedicacin logrars en poco tiempo poner tu
vehculo a punto AHORRANDO TIEMPO, DINERO Y MOLESTIAS.
Te felicito por haber adquirido este manual y dejo en tus manos una
gua til, sencilla y prctica.

Atentamente,

Jorge E. Penagos P.

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Todos los Derechos Reservados 2009

Jorge E. Penagos P.

NDICE
Captulo 1: Cambio de pastillas de frenos

1.1.- Introduccin
1.2.- Herramientas para el cambio de pastillas de freno
1.3.- Cambio de pastillas de freno en neumtico delantero izquierdo
1.4.- Cambio de pastillas de freno en neumtico derecho

10
12
12
17

Captulo 2.- Lquido de frenos

22

2.1.- Cundo se debe reemplazar el lquido de frenos?

2.2.- Cambio de lquido de frenos: procedimiento
2.3.- Drenaje en frenos posteriores
2.4.- Drenaje en freno delantero derecho
2.5.- Drenaje en freno delantero izquierdo
2.6.- Qu resultados debo esperar?

23
25
26
28
30
31

Captulo 3.- Freno de tambor

32

3.1.- Introduccin
3.2.- Revisin ajuste y calibracin del freno de tambor izquierdo
3.3.- Revisin, ajuste y calibracin del freno de tambor derecho

33
33
38

Captulo 4.- Freno de mano

40

4.1.- Introduccin
4.2.- Desmontaje del freno de mano
4.3.- Inspeccin del sistema de freno de mano
4.4.- Inspeccin del interruptor de freno de mano
4.5.- Tensado del cable del freno de mano

41
41
44
45
47

Captulo 5.- Cambio y limpieza del distribuidor de alta tensin

49

5.1.- Introduccin
5.2.- Herramientas necesarias
5.3.- Mantenimiento del distribuidor, ubicacin
5.4.- Desmontaje de tapa de distribuidor y rotor
5.5.- Limpieza y cambio de tapa de distribuidor

50
50
51
52
55

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Jorge E. Penagos P.

Captulo 6.- Refrigerante (Coolant)

59

6.1.- Introduccin
6.2.- Proporcin agua/etilenglicol
6.3.- Materiales para el cambio de lquido refrigerante
6.4.- Cuidados al drenar el refrigerante caliente
6.5.- Drenaje y cambio del lquido refrigerante

60
62
63
63
63

Captulo 7.- Cambio y limpieza de bujas

66

7.1.- Introduccin
7.2.- Funcin de la buja
7.3.- Composicin de una buja
7.4.- Bujas para Chevrolet Spark 800/Daewoo Matiz
7.5.- Medicin y calibracin de holgura de las bujas
7.6.- Cambio de bujas
7.7.- Cambio de bujas BPR5EY-11(GM#:94535748) en imgenes

67
67
67
68
71
72
74

Captulo 8.- Limpieza de inyectores

75

8.1.- Inyectores
8.2.- Limpia-inyectores en el combustible
8.3.- Limpieza de inyectores
8.4.- Desmontaje de riel de inyectores
8.5.- Limpieza de los inyectores y riel
8.6.- Pruebas con multmetro
8.6.1.- Prueba de inyectores con batera
8.7.- Mantenimiento de inyectores en imgenes
8.7.1.- Desconexin de la batera

76
77
78
79
79
80
81
82
82

Captulo 9.- Cambio de filtro de aire

87

9.1.- Introduccin
9.2.- Limpieza y/o cambio del filtro de aire

88
88

Captulo 10.- Filtro de gasolina

91

10.1.- Introduccin
10.2.- Cambio de filtro de gasolina

92
92

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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 the oil pan.
2. After pulling out the oil level gauge (a), check the oil
level.
3. Clean the oil level gauge and insert the gauge into
guide.
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 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 3040 NSm (2230 lb-ft).
5. Replace the oil filter using the oil filter wrench
0991547341 (d).
D Remove the air cleaner/resonator/snorkel assembly.
D After removing the bolts, remove the heat
shield.
D Loosen the power steering pump cap screw and
pull 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 on
oil filter sealing.

D102A301

CHANGING ENGINE OIL OR OIL

FILTER
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).

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 belt (e), air conditioning/
power steering belt (f), air conditioning belt (g), power
steering belt (h), for looseness, crack, wear or tension,
replace the belt if necessary.

D102A305

2. Remove the spark plugs from cylinder head using a

wrench.
3. Measure the spark plug clearance (k) with the filler
gauge. If measured value is not within the specified
value, adjust the grounding electrode.
When installing new spark plug, check the clearance
for equality and install it.

D102A304

CHECKING SPARK PLUG

After checking the spark plug for bad clearance, excessive carbon deposit, worn electrode or damaged insulator, replace the new one if necessary.
Remove and check the spark plug as follows ;
1. Pull the high tension cable cap portion (i), and disconnect the high tension cable from the 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 frequently runs on a dusty road,

check and replace the element often.

D Check the fuel hose surface for damage.

D Check the fuel cap for looseness.

CHECKING FUEL FILTER

CHECKING HOSE SYSTEM

If 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 portion for damage or leakage.

1A 14 GENERAL ENGINE INFORMATION

SPECIFICATIONS
GENERAL SPECIFICATIONS

Vehicle Capacity

Engine Information

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
Ignition Type
Distributor
Starter

Unleaded
Leaded
Fuel Injection Type
Fuel Pump
Fuel Filter
Lubricating Type
Oil Pump
Cooling Type
Radiator
Water Pump
Thermostat
Air Cleaner Element
Muffler
Battery
SparkPlug

Engine Part Type

Engine Part
Capacity

Engine Oil

Refrigerant

Engine Oil

Engine Information

Engine Disassembly
Oil Change (Including filter)
Oil Change (Not including filter)
Oil Level Gauge

Coolant
Battery

Generator
Starter

Output Capacity
Output Pressure
Fuel Tank Capacity
Fuel Pump

Description
144 km/h (90 mph)
0.420 tan
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 (132) / 10_ BTDC (132)
1,000 50 rpm
950 rpm
Overhead Cam L3
Direct Ignition System (DIS) /
High Energy Ignition (HEI)
Optical Sensor Type
SD 80
BPR5EY11, RN9YC4, WR8DCX
BPR5EY, RN9YC, WR8DC
MPI
Electric Motor Pump
Cartridge
Forced Feed Type
Rotary Pump Type
Forced Water Circulation
Cross Flow
Centrifugal
Pellet Type
Non Woven Fablic
Catalytic Converter, Closed Circuit
MF
SJ Grade
SAE 5W30, SAE 10W30, SAE 15W40
Four Seasons
3.0 L (3.17 qt)
2.7 L (2.85 qt)
2.5 L (2.64 qt)
1 L (1.06 qt) (MIN to MAX)
3.8 L (4.02 qt)
12V35 AH, 246 CCA
65 A
0.8 kW
90 133 Lph
380 kPa (55.1 Psi)
35 L (9.2 gal), 38 L (10 gal)

DAEWOO M-150 BL2

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

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 . . . . . . . . . . . . . . . . . .
Engine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train . . . . . . . . . . . . . .

1B-2
1B-2
1B-2
1B-2

Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Piston Pin . . . . . . . . . . .

1B-3
1B-3
1B-3
1B-3

Timing Belt and Pulley . . . . . . . . . . . . . . . . . . . . . 1B-4

Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4
Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold & Air Flow System . . . . . . . . . . . . . . . . .
Timing Belt & Engine Mount . . . . . . . . . . . . . . . .

1B-5
1B-6
1B-7
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Timing Check and Adjustment . . . . . . . .
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . .

DAEWOO M-150 BL2

1B-11
1B-12
1B-14
1B-14

Air Filter Assembly . . . . . . . . . . . . . . . . . . . . . . .

Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . .
Positive Crankcase Ventilation (PCV) Hose
and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B-14
1B-15
1B-15
1B-16

Exhaust Manifold (Typical) . . . . . . . . . . . . . . . . .

Exhaust Manifold (Euro III) . . . . . . . . . . . . . . . .
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B-18
1B-20
1B-21
1B-23

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor Case . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket . . . . . . . . . . . . . . . . .
Engine Mount Damping Block . . . . . . . . . . . . . .

1B-24
1B-26
1B-28
1B-32

Engine Mount Front Damping Bush . . . . . . . . .

Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B-34
1B-35
1B-47
1B-47

Engine Block Components . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications . . . . . . . . . .

1B-59
1B-71
1B-71
1B-73

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-75

Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 1B-75

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