Ignition DAEWOO MATIZ 2003 Service Repair Manual

4F–52 ANTILOCK BRAKE SYSTEM
DAEWOO M-150 BL2
D17E305B
DIAGNOSTIC TROUBLE CODE (DTC) 0601
LEFT FRONT DUMP SHORTED OR DRIVER OPEN
Circuit Description
EBCM proceeds the self–test about the dump valve or
the motor driver, if the EBCM senses the brake signal.
Diagnosis
If the EBCM proceeds the self–test about the dump
valve or the motor driver and senses the fault, the
EBCM may make the fault code.
Cause(s)

EBCM internal fault (Left front dump voltage shorted
or ground open).Warning Lamp Operation

ABS warning lamp ON.

ABS warning lamp OFF if the ignition switch ON/OFF.
Fail Action
This is a critical operational fault. The ABS is disabled
and the ABS warning lamp is turned on. The proportion-
ing is operation.

ANTILOCK BRAKE SYSTEM 4F–53
DAEWOO M-150 BL2
DTC 0601 – Left Front Dump Shorted or Drive Open
 Step Action Value(s) Yes No
 
 
 1
 
 
 
1. Turn the ignition switch to OFF.
2. Remove the fuse Ef1 in the engine fuse block.
3. Check for an open in fuse Ef1.
Is the fuse open? 
 
 –
 
 
 
Go to Step 3
 
 
 
Go to Step 2 
 2
 
 Replace the fuse Ef1.
Is the repair complete?
 
 –
 
 System OK
 
 –
 
 
 
 
 
 
3
 
 
 
 
 
 
1. Disconnect the EBCM harness connector.
2. Turn the ignition switch to ON.
3. Use a digital voltmeter (DVM) to measure the
voltage between ground and terminal 18 of the
EBCM connector.
Is the voltage within the specified value? 
 
 
 
 
 10.5 v to
13.5 v
 
 
 
 
 
 Go to Step 5
 
 
 
 
 
 Go to Step 4
 
 
 
 
4
 
 
 
 
Repair the short to voltage between terminal 18 of
the EBCM connector and engine fuse block Ef1 out-
put.
Is the repair complete? 
 
 
 
–
 
 
 
 System OK
 
 
 
 
–
 
 
 
5
 
 
 
Use a DVM to measure the voltage between termi-
nal 18 and terminal 19 of the EBCM connector.
Is the voltage within the specified value? 
 
 10.5 v to
13.5 v
 
 
 Go to Step 7
 
 
 Go to Step 6
 
 
 
6
 
 
 
Repair the open between terminal 19 of the EBCM
connector and ground G101.
Is the repair complete? 
 
 
–
 
 
 System OK
 
 
 
–
 7 Replace the EBCM.
Is the repair complete? – 
System OK
 –

4F–54 ANTILOCK BRAKE SYSTEM
DAEWOO M-150 BL2
D17E305B
DIAGNOSTIC TROUBLE CODE (DTC) 0602
LEFT FRONT DUMP OPEN OR DRIVER SHORTED
Circuit Description
EBCM proceeds the self–test about the dump valve or
the motor driver, if the EBCM senses the brake signal.
Diagnosis
If the EBCM proceeds the self–test about the dump
valve or the motor driver and senses the fault, the
EBCM may make the fault code.
Cause(s)

EBCM internal fault (Left front dump voltage open or
ground shorted).Warning Lamp Operation

ABS warning lamp ON.

ABS warning lamp OFF if the ignition switch ON/OFF.
Fail Action
This is a critical operational fault. The ABS is disabled
and the ABS warning lamp is turned on. The proportion-
ing is operation.

ANTILOCK BRAKE SYSTEM 4F–55
DAEWOO M-150 BL2
DTC 0602 – Left Front Dump Open or Driver Shorted
 Step Action Value(s) Yes No
 
 
 1
 
 
 
1. Turn the ignition switch to OFF.
2. Remove the fuse Ef1 in the engine fuse block.
3. Check for an open in fuse Ef1.
Is the fuse open? 
 
 –
 
 
 
Go to Step 3
 
 
 
Go to Step 2 
 2
 
 Replace the fuse Ef1.
Is the repair complete?
 
 –
 
 System OK
 
 –
 
 
 
 
 
 
3
 
 
 
 
 
 
1. Disconnect the EBCM harness connector.
2. Turn the ignition switch to ON.
3. Use a digital voltmeter (DVM) to measure the
voltage between ground and terminal 18 of the
EBCM connector.
Is the voltage within the specified value? 
 
 
 
 
 10.5 v to
13.5 v
 
 
 
 
 
 Go to Step 5
 
 
 
 
 
 Go to Step 4
 
 
 
 
4
 
 
 
 
Repair the short to voltage between terminal 18 of
the EBCM connector and engine fuse block Ef1 out-
put.
Is the repair complete? 
 
 
 
–
 
 
 
 System OK
 
 
 
 
–
 
 
 
5
 
 
 
Use a DVM to measure the voltage between termi-
nal 18 and terminal 19 of the EBCM connector.
Is the voltage within the specified value? 
 
 10.5 v to
13.5 v
 
 
 Go to Step 7
 
 
 Go to Step 6
 
 
 
6
 
 
 
Repair the open between terminal 19 of the EBCM
connector and ground G101.
Is the repair complete? 
 
 
–
 
 
 System OK
 
 
 
–
 7 Replace the EBCM.
Is the repair complete? – 
System OK
 –

4F–56 ANTILOCK BRAKE SYSTEM
DAEWOO M-150 BL2
D17E305B
DIAGNOSTIC TROUBLE CODE (DTC) 0651
LEFT FRONT ISOLATION SHORTED OR DRIVER OPEN
Circuit Description
EBCM proceeds the self–test about the dump valve or
the motor driver, if the EBCM senses the brake signal.
Diagnosis
If the EBCM proceeds the self–test about the dump
valve or the motor driver and senses the fault, the
EBCM may make the fault code.
Cause(s)

EBCM internal fault (Left front isolation voltage
shorted or ground open).Warning Lamp Operation

ABS warning lamp ON.

ABS warning lamp OFF if the ignition switch ON/OFF.
Fail Action
This is a critical operational fault. The ABS is disabled
and the ABS warning lamp is turned on. The proportion-
ing is operation.

ANTILOCK BRAKE SYSTEM 4F–57
DAEWOO M-150 BL2
DTC 0651 – Left Front Isolation Shorted or Driver Open
 Step Action Value(s) Yes No
 
 
 1
 
 
 
1. Turn the ignition switch to OFF.
2. Remove the fuse Ef1 in the engine fuse block.
3. Check for an open in fuse Ef1.
Is the fuse open? 
 
 –
 
 
 
Go to Step 3
 
 
 
Go to Step 2 
 2
 
 Replace the fuse Ef1.
Is the repair complete?
 
 –
 
 System OK
 
 –
 
 
 
 
 
 
3
 
 
 
 
 
 
1. Disconnect the EBCM harness connector.
2. Turn the ignition switch to ON.
3. Use a digital voltmeter (DVM) to measure the
voltage between ground and terminal 18 of the
EBCM connector.
Is the voltage within the specified value? 
 
 
 
 
 10.5 v to
13.5 v
 
 
 
 
 
 Go to Step 5
 
 
 
 
 
 Go to Step 4
 
 
 
 
4
 
 
 
 
Repair the short to voltage between terminal 18 of
the EBCM connector and engine fuse block Ef1 out-
put.
Is the repair complete? 
 
 
 
–
 
 
 
 System OK
 
 
 
 
–
 
 
 
5
 
 
 
Use a DVM to measure the voltage between termi-
nal 18 and terminal 19 of the EBCM connector.
Is the voltage within the specified value? 
 
 10.5 v to
13.5 v
 
 
 Go to Step 7
 
 
 Go to Step 6
 
 
 
6
 
 
 
Repair the open between terminal 19 of the EBCM
connector and ground G101.
Is the repair complete? 
 
 
–
 
 
 System OK
 
 
 
–
 7 Replace the EBCM.
Is the repair complete? – 
System OK
 –

4G – 2 PARKING BRAKE
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
PARKING BRAKE
This braking system uses a BRAKE warning light lo-
cated in the instrument panel cluster. When the ignition
switch is in the III position, the BRAKE warning light
should glow and go OFF when the parking brake lever is
released. Whenever the parking brake is applied and theignition switch is II, the BRAKE warning light should
glow.
When the brake is firmly applied, the parking brake
should securely hold the vehicle with ample pedal travel
remaining. Check for frayed cables, rust, etc., or any
condition that may inhibit present (or future) free move-
ment of the parking brake lever assembly.

DAEWOO M-150 BL2

SECTION 5B
FIVE-SPEED MANUAL TRANSAXLE
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 5B-2. . . . . . . . . . . . . . . . . .
Five-Speed Manual Transaxle 5B-2. . . . . . . . . . . . . . .
Reverse Gear Misshift Preventing
Mechanism 5B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locators 5B-3. . . . . . . . . . . . . . . . . . . . . . .
Gear Shift Control 5B-3. . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft and Counter Shaft Gear 5B-4. . . . . . . . . .
Gear Shift Fork 5B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential and Case 5B-7. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 5B-8. . . . . . .
General Diagnosis 5B-8. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 5B-9. . . . . . . . . . . . . . . . . . . . . . .
Changing Fluid 5B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Transaxle Noise 5B-9. . . . . . . . . . . . . . . . . .
Checking Bearing Noise 5B-9. . . . . . . . . . . . . . . . . . . .
Repair Instruction 5B-10. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 5B-10. . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transaxle Assembly 5B-10. . . . . . . . . . . . . . .
Gear Shift Control Case Assembly 5B-17. . . . . . . . . .
Speedometer Driven Gear and Cable 5B-19. . . . . . .
Gear Shift Control Cable 5B-21. . . . . . . . . . . . . . . . . .
Gear Shift Control Lever 5B-23. . . . . . . . . . . . . . . . . . .
Unit Repair 5B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Unit 5B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft 5B-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Shaft 5B-41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Shift Fork 5B-46. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5B-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 5B-52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5B-52. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5B-53. . . . . . . . . .
Special Tools 5B-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5B-54. . . . . . . . . . . . . . . . . . . . . . .

DAEWOO M-150 BL2
SECTION 5C
CLUTCH
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 5C-2. . . . . . . . . . . . . . . . . .
Driving Members 5C-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Driven Members 5C-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Members 5C-2. . . . . . . . . . . . . . . . . . . . . . .
Component Locator 5C-3. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Components 5C-3. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 5C-4. . . . .
General Diagnosis 5C-4. . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pedal Operation 5C-5. . . . . . . . . . . . . . . . . . . .
Clutch Cable Adjustment 5C-5. . . . . . . . . . . . . . . . . . .
Repair Instruction 5C-6. . . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 5C-6. . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Plate, Clutch Disc and
Input Shaft Bearing 5C-6. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Release Bearing, Shaft and Bushing 5C-8. . .
Clutch Release Arm 5C-10. . . . . . . . . . . . . . . . . . . . . .
Clutch Cable 5C-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pedal 5C-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 5C-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5C-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5C-13. . . . . . . . . .
Special Tools 5C-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5C-14. . . . . . . . . . . . . . . . . . . . . . .

DAEWOO M-150 BL2
SECTION 6C
POWER STEERING GEAR
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 6C-2. . . . . . . . . . . . . . . . . .
Power Rack and Pinion 6C-2. . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6C-3. . . . .
Power Rack and Pinion Steering Gear 6C-3. . . . . . .
Adjust the Free Load of the Steering Gear 6C-5. . .
Repair Instructions 6C-6. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6C-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Assembly 6C-6. . . . . . . . . . . . . . . . .
Power Steering Gear Rack and Pinion Boot 6C-7. . . Unit Repair 6C-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Boot 6C-8. . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Cylinder Lines 6C-8. . . . . . . . . . . . . . . . . . . .
Rack and Pinion Steering Gear 6C-9. . . . . . . . . . . . . .
Assembly
Specifications 6C-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6C-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6C-13. . . . . . . . . .