Ignition DAEWOO MATIZ 2003 Service Repair Manual

DAEWOO M-150 BL2
SECTION 6D
MANUAL 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 6D-2. . . . . . . . . . . . . . . . . .
Manual Rack and Pinion 6D-2. . . . . . . . . . . . . . . . . . . .
Component Locator 6D-3. . . . . . . . . . . . . . . . . . . . . . . .
Manual Rack and Pinion Steering Gear 6D-3. . . . . . .
Diagnostic Information and Procedures 6D-4. . . . .
Manual Rack and Pinion Steering Gear 6D-4. . . . . . .
Straight-Ahead Check 6D-5. . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Restoration 6D-6. . . . . . . . . . . . . . . . .
Check The Turning Resistance of the
Tie Rod End or Tie Rod 6D-6. . . . . . . . . . . . . . . . . . . .
Adjust the Free Load of the Steering Gear 6D-6. . . .
Repair Instructions 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Boot 6D-8. . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Steering Gear Assembly 6D-9. . . .
Unit Repair 6D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Boot 6D-11. . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion 6D-11. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 6D-17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6D-17. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6D-17. . . . . . . . . .
Special Tools and Equipment 6D-18. . . . . . . . . . . . . .
Special Tools Table 6D-18. . . . . . . . . . . . . . . . . . . . . . .

DAEWOO M-150 BL2
SECTION 6E
STEERING WHEEL AND COLUMN
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 6E-2. . . . . . . . . . . . . . . . . .
Steering Wheel and Column 6E-2. . . . . . . . . . . . . . . .
Component Locator 6E-3. . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel and Column 6E-3. . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6E-4. . . . .
Steering Column Diagnosis 6E-4. . . . . . . . . . . . . . . . .
Repair Instructions 6E-7. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6E-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel 6E-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column Cover 6E-8. . . . . . . . . . . . . . . . . . . .
Turn Signal Switch and Lever/
Wiper Switch and Lever 6E-8. . . . . . . . . . . . . . . . . .
Ignition Switch 6E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Lock Cylinder and Switch
with Immobilizer 6E-9. . . . . . . . . . . . . . . . . . . . . . . . .
Switch Housing 6E-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column 6E-11. . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Shaft cover and
Intermediate Shaft 6E-12. . . . . . . . . . . . . . . . . . . . . .
Unit Repair 6E-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Steering Column 6E-13. . . . . . . . . . . . . . . . .
Specifications 6E-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6E-15. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6E-15. . . . . . . . . .
Special Tools and Equipment 6E-16. . . . . . . . . . . . . .
Special Tools Table 6E-16. . . . . . . . . . . . . . . . . . . . . . .

6E – 2 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
STEERING WHEEL AND COLUMN
In addition to the steering function, the steering column
provides safety and security.
Caution: To ensure energy-absorbing action, it is
important to use only the specified screws, bolts,
and nuts, tightened to the specified torque.
The energy-absorbing column is designed to compress
in a front-end collision to lessen the chance of driver in-
jury.
The ignition switch and the lock are mounted on the col-
umn, allowing the ignition and steering operations to be
locked to inhibit theft of the car.
The column levers trigger the turn signals, the headlight
beams, and the windshield washer and wipers.
Notice: Apply a thin coat of lithium grease to all friction
points when reassembling to ensure proper operation.
The column may be easily disassembled and assembled.
D15A001A

Safety Device
A. Steering Column Upper Bracket.
B. Steering Column.
C. Steering Column Shaft.

STEERING WHEEL AND COLUMN 6E–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
STEERING WHEEL AND COLUMN
D15A401A
1. Horn Cover (Airbag Module)
2. Steering Wheel Nut
3. Locking Plate
4. Steering Wheel
5. Steering Column Upper Cover
6. Steering Column Lower Cover
7. Turn Signal Switch
8. Windshield Wiper Switch
9. Steering Column Assembly
10. Retaining Ring
11. Washer
12. Spring
13. Switch Housing
14. Bolt15. Support Bolt
16. Steering Column Housing
17. Steering Column Jacket
18. Ignition Switch Retaining Screw
19. Ignition Switch
20. Steering Lock Housing Assembly
21. Steering Column Shaft
22. Pinch Bolt
23. Intermediate Shaft
24. Steering Column Upper Nut
25. Steering Column Lower Nut

6E –4 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
STEERING COLUMN DIAGNOSIS
Lock System
ConditionProbable CauseCorrection
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Unlock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Lock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
High Lock Effort
Damaged lock cylinder.
Replace the lock cylinder.

The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Extreme misalignment of the housing to the
cover.
Realign the cover on the housing.

Replace the cover as needed.
Key Cannot Be
The ignition switch to be set incorrectly.
Reset the ignition switch.
Removed in the B
Position
Damaged lock cylinder.
Replace the lock cylinder.
Column
ConditionProbable CauseCorrection
Noise in the Column
Improperly installed intermediate shaft–to–
column joints.
Tighten the coupling pinch bolts.

Replace the intermediate shaft as
needed.

Column misalignment.
Replace the alignment spacer.

The lack of lubrication for the joint.
Lubricate the joint.

The lack of lubrication for the steering shaft.
Lubricate the steering shaft bearing.

Improperly seated shaft lock snap ring.
Adjust the shaft lock snap ring.

Replace the shaft lock snap ring as
needed.

Improperly installed intermediate shaft
pinch bolt.
Tighten the pinch bolt.
High Steering Shaft
Column misalignment.
Replace the alignment spacer.
Effort
A damaged bearing.
Replace the steering column
housing.

The lack of free movement for the steering
shaft universal joint.
Lubricate the steering shaft
universal joint.

Replace the steering column shaft
as needed.

6E –6 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
Ignition Switch
ConditionProbable CauseCorrection
Electrical System Will
Damaged ignition switch.
Replace the ignition switch.
Not Function
Improperly installed ignition switch.
Remove and inspect the ignition
switch.

Reinstall the ignition switch.

Improperly installed ignition switch electrical
connector.
Reconnect the ignition switch
electrical connector.

Replace the ignition switch electrical
connector.
Ignition Switch Will
Damaged ignition switch.
Replace the ignition switch.
Not Turn
Improperly installed ignition switch.
Remove and inspect the ignition
switch.

Reinstall the ignition switch.
Wiper Switch Lever
ConditionProbable CauseCorrection
Switch Inoperative :
Damaged wiper switch.
Replace the wiper switch.
No I, Low, High, Int
or Wash
Improperly installed wiper switch.
Remove and inspect the wiper
switch.

Reinstall the wiper switch.

STEERING WHEEL AND COLUMN 6E–9
DAEWOO M-150 BL2
D105A508
Installation Procedure
1. Install the wiper switch.
2. Install the turn signal switch.
3. Install the steering column cover. Refer to “Steering
Column Cover” in this section.
4. Connect the negative battery cable.
D105A509
IGNITION SWITCH
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
3. Remove the ignition switch.

Disconnect the electrical connector (1).

Remove the screw (2).
D105A510
Installation Procedure
1. Connect the electrical connector.
2. Install the ignition switch with the screw.
3, Install the steering wheel. Refer to “Steering Wheel”
in this section.
4. Connect the negative battery cable.
D105A511
IGNITION LOCK CYLINDER WITH
IMMOBILIZER
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
2. Disconnect the electrical connector for the immobiliz-
er detection coil.
3. Remove the lock cylinder.

With the key in the ignition, turn to the position des-
ignated I (1).

6E –10 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
D105A511

Remove the lock cylinder by pressing down the
detent spring with a 2.5MM allen wrench, or other
suitable tool, and pulling the lock cylinder out of the
switch cylinder housing (2).
D105A512
Installation Procedure
Important: To install the ignition lock cylinder the igni-
tion position should be designated I.
1. Install the ignition lock cylinder.
2. Connect the electrical connector for the immobilizer
detection coil.
3. Install the steering wheel. Refer to “Steering Wheel”
in this section.
D105A513
SWITCH HOUSING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
2. Remove the turn signal switch and windshield wiper
switch. Refer to “Turn Signal Switch and Lever/Wiper
Switch and Lever” in this section.
3. Remove the switch housing.

Disconnect the horn electrical connector (1).

Remove the screws retaining the switch housing
(2).
D105A514
Installation Procedure
1. Install the switch housing with the screws.
2. Connect the horn electrical connector.
3. Install the turn signal switch and windshield wiper
switch. Refer to “Turn Signal Switch and Lever/Wiper
switch and Lever” in this section.
4. Install the steering wheel. Refer to “Steering Wheel”
in this section.

STEERING WHEEL AND COLUMN 6E–11
DAEWOO M-150 BL2
D105A515
STEERING COLUMN
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering Wheel”
in this section.
Caution: Disconnect the negative battery cable and
let the vehicle sit for 1 minute to deactivate the air-
bag (For vehicle with SIR)
2. Remove the turn signal switch and wiper switch. Re-
fer to “Turn Signal Switch and Lever/Wiper Switch
and Lever in this section.
3. Remove the switch housing. Refer to “Switch Hous-
ing” in this section.
D105A516
4. Remove the ignition switch. Refer to “Ignition Switch”
in this section.
5. Remove the ignition lock cylinder. Refer to “Ignition
Lock Cylinder” in this section.
6. Remove the steering column.

Match–mark on the intermediate shaft and the
steering column shaft (1).

Remove the intermediate shaft upper pinch bolt
(2).

Remove the steering column lower nuts (3).

Remove the steering column upper nuts (4).
D15A517B
D15A518B
Installation Procedure
Important: Align the match–mark on the intermediate
shaft and the steering column shaft.
1. Install the steering column.

Install the intermediate shaft upper pinch bolt (1).
Tighten
Tighten the pinch bolt to 21–29 Nm (16–22 lb-ft).

Install the steering column lower nuts (2).
Tighten
Tighten the nuts to 15–20 Nm (11–15 lb-ft).

Install the steering column upper nuts (3).
Tighten
Tighten the nuts to 15–20 Nm (11–15 lb-ft).
2. Install the ignition lock cylinder. Refer to “Ignition Lock
Cylinder” in this section.
3. Install the ignition switch. Refer to “Ignition Switch” in
this section.
4. Install the switch housing. Refer to “Switch Housing”
in this section.
5. Install the turn signal switch and wiper switch. Refer
to “Turn Signal Switch and Lever/Wiper Switch and
Lever” in this section.
6. Install the steering wheel. Refer to “Steering Wheel”
in this section.

DAEWOO M-150 BL2
SECTION 7A
HEATING AND VENTILATION SYSTEM
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 7A-2. . . . . . . . . . . . . . . . . .
Heating and Ventilation Systems 7A-2. . . . . . . . . . . .
Component Locator 7A-3. . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly 7A-3. . . . . . . . . . . . . . . . . . . . . . . . .
Blower Module Assembly 7A-4. . . . . . . . . . . . . . . . . . .
Air Distributor and Heater Module
Assembly 7A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Informatin and Procedures 7A-6. . . . . . .
Heater System 7A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insufficient Heating or Defrosting 7A-6. . . . . . . . . . . .
Blower Electrical 7A-10. . . . . . . . . . . . . . . . . . . . . . . . .
Improper Air Delivery or No Mode Shift 7A-11. . . . . .
Too Much Heat 7A-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 7A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Noise 7A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 7A-18. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 7A-18. . . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly and Control Cables 7A-18. . . . . . . Blower Motor and Cooling Hose 7A-20. . . . . . . . . . . .
Blower Resistor 7A-20. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Switch 7A-21. . . . . . . . . . . . . . . . . . . . . .
Heater Hoses 7A-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Module 7A-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Module 7A-25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Defroster Duct and Hoses 7A-26. . . . . . . . . . . . . . . . .
Ventilation Duct 7A-27. . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 7A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core 7A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 7A-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7A-29. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7A-29. . . . . . . . . .
Special Tools and Equipment 7A-30. . . . . . . . . . . . . .
Special Tools Table 7A-30. . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 7A-31. . . . . . . . . .
Non-A/C Diagrams 7A-31. . . . . . . . . . . . . . . . . . . . . . .
Air Flow Through Ducts (Non–A/C) 7A-32. . . . . . . . .