position DAEWOO MATIZ 2003 Service Owners Manual

1F–316 ENGINE CONTROLS
DAEWOO M-150 BL2
D21F010
Installation Procedure
1. Install the knock sensor with the bolt.
Tighten
Tighten the knock sensor retaining bolt to 15–25 Nm
(11–18 lb-ft).
2. Connect the electrical connector to the knock sensor.
3. Install the starter. Refer to Section 1E, Engine Electri-
cal.
4. Connect the negative battery cable.
MAA1F490
ELECTRONIC IGNITION (EI) SYSTEM
IGNITION COIL
Removal Procedure
1. Disconnect the negative battery cable.
2. Note the ignition wire location and disconnect the
ignition wires from the EI system ignition coil.
3. Disconnect the EI system ignition coil connector.
4. Remove the EI system ignition coil retaining bolts.
5. Remove the EI system ignition coil.
MAA1F500
Installation Procedure
1. Install the EI system ignition coil.
2. Tighten the EI system ignition coil to 8–12 Nm
(71–106 lb-in).
UAA1F2C0
CRANKSHAFT POSITION (CKP)
SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly.
3. Disconnect the crankshaft position (CKP) sensor
connector.
4. Remove the CKP sensor retaining bolt.

ENGINE CONTROLS 1F–317
DAEWOO M-150 BL2
MAA1F550
Installation Procedure
1. Install the CKP sensor.
2. Tighten the CKP sensor retaining bolt to 5–8 Nm
(44–71 lb-in).
UAA1F2E0
CAMSHAFT POSITION (CMP)
SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the camshaft position (CMP) sensor con-
nector.
3. Remove the CMP sensor retaining bolt.
4. Remove the CMP sensor.
MAA1F540
Installation Procedure
1. Install the CMP sensor.
2. Tighten the CMP sensor retaining bolt to 10–14 Nm
(89–124 lb-in).
MAA1F510
ENGINE CONTROL MODULE (ECM)
Removal Procedure
1. Disconnect the ECM connector.

ENGINE CONTROLS 1F–319
DAEWOO M-150 BL2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Camshaft Position Sensor Bolts10–14–89–124
Engine Coolant Temperature (ECT) Sensor8–12–71–106
Crankshaft Position (CKP) Sensor Retaining Bolt5–8–44–71
Electronic Ignition (EI) System Ignition Coil Retaining
Bolts8–12–71–106
Evaporative Emission Canister Protective Cover8–71
Electric Exhaust Gas Recirculation (EEGR) Valve
Retaining Bolts20–3015–22–
Fuel Rail Retaining Bolts18–2213–16–
Fuel Tank Strap Retaining Nuts18–2213–16–
Knock Sensor Bolt15–2511–18–
Intake Air Temperature (IAT) Sensor20–3015–22–
Manifold Absolute Pressure (MAP) Sensor Retaining
Bolt8–12–71–106
Oxygen Sensor35–4426–33–
Heated Oxygen Sensor35–4426–33–
Throttle Body Retaining Bolt9–12–80–106
ECM Mounting Bolts6–8–53–71
SPECIAL TOOLS
SPECIAL TOOLS TABLE
D102F101
Scan Tool
D12F102A
DW–140–010A
Fuel Pump Lock Ring
Remover/Installer

1G – 2 ENGINE EXHAUST
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
EXHAUST SYSTEM
Notice: When you are inspecting or replacing exhaust
system components, make sure there is adequate clear-
ance from all points on the underbody to avoid possible
overheating of the floor pan and possible damage to the
passenger compartment insulation and trim materials.
Check the complete exhaust system and the nearby
body areas and tailgate for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connec-
tions or other deterioration which could permit exhaust
fumes to seep into the luggage or passenger compart-
ment. Dust or water in the luggage may be an indication
of a problem in one of these areas. Any defects should
be corrected immediately.
MUFFLER
The muffler reduces the temperature, pressure, and
noise of the exhaust gas.
Aside from the exhaust manifold connection, the ex-
haust system uses a flange and seal joint design op-
posed to a slip joint coupling design with clamp. If holes,
open seams or any deterioration is discovered upon in-
spection of the front muffler and pipe assembly, thecomplete assembly should be replaced. The same pro-
cedure is applicable to the rear muffler assembly.
Heat shields in the front and rear muffler assembly posi-
tions, as well as for the catalytic converter and front ex-
haust pipe, protect the vehicle and the environment from
high temperatures the exhaust system develops.
CATALYTIC CONVERTER
Notice: When jacking or lifting the vehicle from the body
side rails, be certain that the lift pads do not contact the
catalytic converter as this could damage the catalytic
converter.
Notice: The catalytic converter requires the use of un-
leaded fuel only, or damage to the catalyst will result.
The catalytic converter is an emission control device
added to the exhaust system to reduce pollutants from
the exhaust pipes.
The oxidation catalyst is coated with a catalytic material
containing platinum and palladium, which reduces levels
of hydrocarbon (HC) and carbon monoxide (CO) from
the exhaust gas. The three-way catalyst has coatings
which contain platinum and rhodium, which additionally
lower the levels of oxides of nitrogen (NOx).

2A–4 SUSPENSION DIAGNOSIS
DAEWOO M-150 BL2
Condition Probable Cause Correction
Abnormal Noise, Front
A loose stabilizer shaft link.
Tighten the stabilizer shaft link.
Suspension
Loose wheel nuts.
Tighten the wheel nuts.

Loose suspension bolts or nuts.
Tighten the suspension bolts or the
nuts.

Loose wheel covers.
Tighten the wheel covers.

Worn strut dampeners or strut
mountings.
Replace the strut dampeners.

Tighten the strut mounting nuts.

An improperly positioned strut spring.
Adjust the strut spring to the proper
position.
Wander or Poor
Mismatched or uneven tires.
Replace the tires.
Steering Ability
Worn strut dampeners.
Replace the strut dampeners.

A loose stabilizer shaft link.
Tighten the stabilizer shaft link.

A broken or a sagging coil spring.
Replace the coil spring.

The steering preload adjustment is
out–of–adjustment.
Perform a rack bearing preload
on–vehicle adjustment.

The front–wheel and the rear–wheel
alignment are out–of–align.
Align the front and the rear end
wheels.
Erratic Steering when
Worn or loose wheel bearings.
Replace the wheel bearings.
Braking
A broken or a sagging coil spring.
Replace the coil spring.

A leaking caliper.
Replace the caliper.

Warped rotors.
Replace the rotors.

An incorrect or an uneven caster.
If the caster is beyond specifications,
check the frame and repair it as
needed.
Low or Uneven Trim
A broken or a sagging coil spring.
Replace the coil spring.
Height
An overloaded vehicle.
Maintain the proper load weight.

An incorrect or weak coil spring.
Replace the coil spring.
Ride Too Soft
Worn strut dampeners.
Replace the strut dampeners.

A broken or a sagging coil spring.
Replace the coil spring.
Ride Too Harsh
Incorrect strut dampeners.
Replace the strut dampeners.

An incorrect coil spring.
Replace the coil spring.
Body Leans or Sways
A loose stabilizer shaft link.
Tighten the stabilizer shaft link.
in Corners
Worn strut dampeners or strut
mountings.
Replace the strut dampeners.

Tighten the strut assembly mounting
nuts.

an overloaded vehicle.
Maintain the proper load weight.

A broken or a sagging coil spring.
Replace the coil spring.
Suspension Bottoms
Worn strut dampeners.
Replace the strut dampeners.

An overloaded vehicle.
Maintain the proper load weight.

A broken or a sagging coil spring.
Replace the coil spring.

WHEEL ALIGNMENT 2B–3
DAEWOO M-150 BL2
STEERING AXIS INCLINATION
Steering Axis Inclination (SAI) is the tilt at the top of the
steering knuckle from the vertical. Measure the SAI
angle from the true vertical to a line through the center of
the strut and the lower ball joint as viewed from the front
of the vehicle.
SAI helps the vehicle track straight down the road and
assists the wheel back into the straight ahead position.
SAI on front wheel drive vehicles should be negative.
INCLUDED ANGLE
The included angle is the angle measured from the cam-
ber angle to the line through the center of the strut and
the lower ball joints as viewed from the front of the ve-
hicle.
The included angle is calculated in degrees Most align-
ment racks will not measure the included angle directly.
To determine the included angle, subtract the negativeor add the positive camber readings to the Steering Axis
Inclination (SAI).
SCRUB RADIUS
The scrub radius is the distance between true vertical
and the line through the center of the strut and lower ball
joint to the road surface. Scrub radius is bulit into the de-
sign of the vehicle. Scrub radius is not adjustable.
SETBACK
The setback is the distance in which one front hub and
bearing assembly may be rearward of the other front
hub and bearing assembly. Setback is primarily caused
by a road hazard or vehicle collision.
TURNING ANGLE
The turning angle is the angle of each front wheel to the
vertical when the vehicle is making a turn.

2C – 2 FRONT SUSPENSION
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FRONT SUSPENSION
The front suspension for this vehicle is a combination
knuckle/strut and spring design.
The control arms pivot from the body. The lower control
arm pivots use rubber bushing. The upper end of the
strut is isolated by a rubber mount and contains a bear-
ing to allow the wheel to turn.
The lower end of the steering knuckle pivots on a ball
joint bolted to the control arm. The ball joint is fastened
to the steering knuckle with a bolt.When servicing the control arm-to-body attachment and
the stabilizer shaft-to-body insulators, make sure the at-
taching bolts are loose until the control arms are moved
to the trim height, which is curb height. Trim height is the
normal position to which the control arms move when
the vehicle is sitting on the ground. Refer to “General
Specifications” in this section.

FRONT SUSPENSION 2C–11
DAEWOO M-150 BL2
D16B515A
Installation Procedure
1. Install in the reverse order of removal.
Important: When installing the mountings, position the
opened mountings forward.
D16B516A
40–50 Nm2. Install the stabilizer shaft to the vehicle.

Install the castellated nut.
Tighten
Tighten the stabilizer shaft–to–body castellated nut to
40–50 Nm (30–36 lb-ft).

Install the cotter pin.
D16B517C
3. Install the front under longitudinal frame.

Install the stabilizer shaft mounting bolts (1).
Tighten
Tighten the mounting bolts to 30–50 Nm (22–36 lb-
ft).
D16B518B
65 – 80 Nm
10 – 14 Nm
Install the front under longitudinal frame bolt (2).
Tighten
Tighten to bolt to 10–14 Nm (89–124 lb-in).

Install the front under longitudinal frame nut (3).
Tighten
Tighten to nut to 65–80 Nm (48–59 lb-ft).

TIRES AND WHEELS 2E–9
DAEWOO M-150 BL2
Another method is to dismount the tire and rotate it
180 degrees on the rim. Do this only on the tire and
wheel assemblies which are known to be causing a
vibration because this method is just as likely to cause
good assemblies to vibrate.
TIRE AND WHEEL
MATCH-MOUNTING
The tires and wheels are match-mounted at the assem-
bly plant. Match-mounting aligns the radially stiffest part
of the tire, or high spot, to the smallest radius, or low
spot, of the wheel.
The high spot of the tire is originally marked by a red
paint mark or an adhesive label on the outboard side-
wall.
The low spot of the wheel will be at the location of the
valve stem.
Before dismounting a tire from its wheel, scribe a line on
the tire at the valve stem to assure that it is remounted in
the same position.
Replacement tires that are of original equipment quality
will have their high and low spot marked in the same
manner.

4A – 2 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
WARNING LAMP OPERATION
This brake system uses a BRAKE warning lamp located
in the instrument panel cluster. When the ignition switch
is in the III position, the BRAKE warning lamp should il-
luminate. It should go off when the ignition switch return
to II position. The following conditions will activate the
BRAKE warning lamp.

The lamp should be on whenever the parking brake
applied and the ignition switch is in the II position.

A low fluid level in the master cylinder will turn the
BRAKE warning lamp on.
D17A007A