DAEWOO MATIZ 2003 Service Repair Manual

FRAME AND UNDERBODY 9N–3
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
ALIGNMENT CHECKING
An accurate method of determining the alignment of the
underbody uses a measuring tram gauge. The tram
gauge set used to perform the recommended measuring
checks must include a vertical pointer able to reach
457 mm (18 inches).
Two types of measurements can be made with a tram
gauge: direct point-to-point measurements and mea-
surements calculated on a horizontal plane (datum line)
parallel to the underbody. Point-to-point measurements
are generally taken on steering and suspension engine
compartment parts and simply require the vertical point-
ers to be set equally.
For horizontal plane measurements, the vertical pointers
must be set as specified for each point to be measured.
Dimensions-to-gauge holes are measured to the center
of the holes and flush to the adjacent surface metal un-
less otherwise specified. It is recommended that the di-
agonal dimensions to the cross-body be checked on
both sides in order to verify the dimensional accuracy of
the vehicle underbody.
FLOOR PAN INSULATORS
The floor pan insulators have been designed for the
higher floor pan temperatures that result from the use
of the catalytic converter in the exhaust system. There-
fore, when servicing a vehicle, it is essential that any in-sulators that may have been disturbed or removed be
reinstalled in the original sequence and location. Also, if
an insulator needs to be replaced, use only the insula-
tion specified for that location on the floor pan.
When servicing or replacing interior insulators, observe
the following instructions.

Install the insulators in the original position and se-
quence. Butt the pieces together in order to avoid
gapping or overlapping.

If it is necessary to replace an insulator, use only the
specified insulation.

Use the original part to determine the amount of re-
placement material required and as a template for
cutting and fitting the new piece to the floor pan.

When installing the insulator, do not enlarge any cut-
outs or holes that are used for the attachment of interi-
or parts such as the instrument panel or the floor
console.

Route the cross-body harness for interior parts over
the floor pan insulators. Clip it in the original location.

Do not apply spray-on deadeners or trim adhesives to
the top of the floor pan at the area directly over the
catalytic converter or the muffler.
Any insulator service repair or replacement should be
the same thickness, size, and location as the original
installation in the vehicle.

9N –4 FRAME AND UNDERBODY
DAEWOO M-150 BL2
SPECIFICATIONS
UNDERBODY DIMENSIONS
Unit: mm (in.)
DBDM118A

FRAME AND UNDERBODY 9N–5
DAEWOO M-150 BL2
Unit: mm (in.)
DBDM119A
Unit: mm (in.)
DBDM120

9N –6 FRAME AND UNDERBODY
DAEWOO M-150 BL2
Unit: mm (in.)
DBDM117A

DAEWOO M-150 BL2
SECTION 9O
BUMPERS AND FASCIAS
TABLE OF CONTENTS
Description and Operation 9O-2. . . . . . . . . . . . . . . . . .
Bumpers 9O-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 9O-3. . . . . . . . . . . . . . . . . . . . . . . .
Bumpers and Fascias 9O-3. . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 9O-4. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 9O-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Bumper Fascia 9O-4. . . . . . . . . . . . . . . . . . . . . .
Front Bumper Impact Bar 9O-5. . . . . . . . . . . . . . . . . . .
Rear Bumper Fascia 9O-6. . . . . . . . . . . . . . . . . . . . . . .
Rear Bumper Bracket 9O-8. . . . . . . . . . . . . . . . . . . . . .

9O – 2 BUMPERS AND FASCIAS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
BUMPERS
The bumper systems are installed with the body color
bumper and the general bumper according to the vehicle
grade.
The bumper systems are designed to sustain a collision
into a fixed barrier at 4 km/h (2.5 mph) without damage.
After absorbing the energy of a collision, these bumpersystems restore themselves to their original position.
Both the front and the rear bumpers feature an internal
foam energy absorber and a polymer fascia cover. The
front bumper consists of the bumper fascia and the im-
pact bar. Remove the fascia before removing the impact
bar. The rear bumper consists of the bumper fascia and
the bracket. Removal of rear bumper brackets can be
possible without removing the bumper fascia.

BUMPERS AND FASCIAS 9O–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
BUMPERS AND FASCIAS
D19C401A
1. Front Towing Cover
2. Front Bumper
3. Front Bumper Impact Beam
4. Front Bumper Reinforcement5. Rear Bumper Reinforcement
6. Rear Bumper
7. Rear Bumper Bracket
8. Rear Towing Cover

9O –4 BUMPERS AND FASCIAS
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D19C501A
FRONT BUMPER FASCIA
Removal Procedure
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the front wheels.
4. Remove the front wheel house splash shields.

Remove the clip and bolts.
a. Bolt and clip.

Remove the wheel house splash shield.
b. Splash shield.
D109C502
5. Remove the bolts on the both side of the fascia.
a. Bolt.
D109C503
6. Remove the clips under the fascia.
a. Clip.

BUMPERS AND FASCIAS 9O–5
DAEWOO M-150 BL2
D19C504A
7. Lower the vehicle.
8 Remove the front bumper spacer from the bumper.
Refer to Section 9M, Exterior Trim.
9. Remove the front bumper fascia.

Remove the bolts (1).

Remove the clips (2).

Remove the front bumper fascia (3).
10 Remove the front fog lamps. Refer to Section 9B,
Lighting Systems.
D19C505A
Installation Procedure
Notice: Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use the correct
fasteners to prevent premature corrosion.
1. Install the front fog lamps. Refer to Section 9B,
Lighting Systems.
2. Install the bumper fascia.
3. Install the clips on the top of the fascia.
a. Fascia upper clip.
4. Install the bolts on the top of the fascia.
b. Fascia upper bolt.
5. Install the front bumper spacer. Refer to Section 9M,
Exterior Trim.
D109C506
6. Raise and suitably support the vehicle.
7. Install the clips under the fascia.
c. Fascia lower clip.
8. Install the bolts on the both side of the fascia.
9. Install the front wheelhouse splash shields with the
clips and the bolts.
10. Install the front wheels.
11. Lower the vehicle.
12. Connect the negative battery cable.
D19C507A
FRONT BUMPER IMPACT BAR
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the front bumper fascia. Refer to “Front
Bumper Fascia” in this section.
3. Remove the front wiring harness retaining clip from
the impact bar.

9O –6 BUMPERS AND FASCIAS
DAEWOO M-150 BL2
D19C508A
3. Remove the impact bar.

Remove the nuts (1).

Remove the impact bar (2).
D19C509A
Installation Procedure
Notice: Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use the correct
fasteners to prevent premature corrosion.
1. Install the impact bar with the nuts.
C19C507A
2. Install the front wiring harness retaining clip to the im-
pact bar.
3. Install the front bumper fascia. Refer to “Front Bump-
er Fascia” in this section.
4. Connect the negative battery cable.
D19C510A
REAR BUMPER FASCIA
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the bolts underneath the fascia.

Remove the bolts (1).