Engine DAEWOO MATIZ 2003 Service Repair Manual

ENGINE EXHAUST 1G–7
DAEWOO M-150 BL2
D12G504B
3. Install the front exhaust pipe to pup-up catalytic con-
vertor.
Tighten
Tighten the bolts to 25–35 Nm (18–25 lb-ft).

D102G502
FRONT MUFFLER
Removal Procedure
1. Remove the front exhaust pipe-to-front muffler nuts.

Remove the nuts (1).

MAA1G030
2. Remove the front muffler-to-rear muffler nuts.
3. Detach the front muffler from rubber hanger and re-
move the front muffler.

MAA1G031
Installation Procedure
1. Hang the front muffler to rubber hanger.
2. Install the front muffler-to-rear muffler nuts.
Tighten
Tighten the nuts to 25–35 Nm (18–25 lb-ft).
3. Install the exhaust pipe-to-front muffler nuts.
Tighten
Tighten the nuts to 25–35 Nm (18–25 lb-ft) (a).

1G–8 ENGINE EXHAUST
DAEWOO M-150 BL2
MAA1G030
REAR MFFLER
Removal Procedure
1. Remove the front muffler-to rear muffler nuts.
Tighten
Tighten the nuts to 25–35 Nm (18–25 lb-ft).
2. Detach the rear muffler from the rubber hangers.
MAA1G040
3. Remove the rear muffler.
4. Installation should flow the removal procedure in re-
verse order.

ENGINE EXHAUST 1G–9
DAEWOO M-150 BL2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Front Exhaust Pipe-to-Front Muffler Pipe Nuts25 – 3518 – 25–
Front Exhaust Pipe-to-Exhaust Manifold Nuts25 – 3518 – 25–
Front Exhaust Pipe-to-Pup-up Catalytic Converter25 – 3518 – 25–
Front Muffler-to-Rear Muffler nuts25 – 3518 – 25–
Pup-up Catalytic Convertor-to-Exhaust Manifold Bolt25 – 3518 – 25–
Muffler Clamp Nut24 – 2818 – 21–
Catalytic Converter Heat Shield8 – 12–71 – 106
Rear Muffler Heat Shield8 – 12–71 – 106

2B – 2 WHEEL ALIGNMENT
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FOUR WHEEL ALIGNMENT
The first responsibility of engineering is to design safe
steering and suspension systems. Each component
must be strong enough to withstand and absorb extreme
punishment. Both the steering system and the front and
the rear suspension must function geometrically with the
body mass.
The steering and the suspension systems require that
the front wheels self-return and that the tire rolling effort
and the road friction be held to a negligible force in order
to allow the customer to direct the vehicle with the least
effort and the most comfort.
A complete wheel alignment check should include mea-
surements of the rear toe and camber.
Four-wheel alignment assures that all four wheels will be
running in precisely the same direction.
When the vehicle is geometrically aligned, fuel economy
and tire life are at their peak, and steering and perfor-
mance are maximized.
TOE
D16A006A
Toe–in is the turning in of the tires, while toe–out is the
turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the
wheel support system which occur when the vehicle is
rolling forward. The specified toe angle is the setting
which achieves–degrees (0
) of toe when the vehicle is
moving.
Incorrect toe-in or toe-out will cause tire wear and re-
duced fuel economy. As the individual steering and sus-
pension components wear from vehicle mileage,
additional toe will be needed to compensate for the
wear.
Always correct the toe dimension last.
CASTER
D16A008A
Caster is the tilting of the uppermost point of the steering
axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is
positive, and a forward tilt is negative. Caster influences
directional control of the steering but does not affect tire
wear. Weak springs or overloading a vehicle will affect
caster. One wheel with more positive caster will pull to-
ward the center of the car. This condition will cause the
car to move or lean toward the side with the least
amount of positive caster. Caster is measured in de-
grees and is not adjustable.
CAMBER
D16A007A
Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the
tires tilt outward, the camber is positive. When the tires
tilt inward, the camber is negative. The camber angle is
measured in degrees from the vertical. Camber in-
fluences both directional control and tire wear.
If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Camber is measured in degrees and is not adjustable.

2E –8 TIRES AND WHEELS
DAEWOO M-150 BL2
D16A503A
90–11 0 Nm
Installation Procedure
Notice: Before installing the wheels, remove any build-
up of corrosion on the wheel mounting surface and the
brake drum or the rotor mounting surface by scraping
and brushing them with a wire brush. Installing the
wheels without good metal-to-metal contact at the
mounting surfaces can cause the wheel nuts to loosen,
which can later allow a wheel to come off while the ve-
hicle is moving. Wheel nuts must be tightened in se-
quence and to the proper torque to avoid bending the
wheel, the brake drum or the rotor.
1. Mount the wheel.
2. Install the wheel nuts in the diagonally. Do not tighten
the wheel nuts.
3. Lower the vehicle.
Tighten
Tighten the wheel nuts to 90–110 Nm (66–81 lb-ft).
ON-VEHICLE BALANCING
On-vehicle balancing will help correct vibrations due to
brake drum, rotor, and wheel cover imbalances.
Notice: Do not allow the front suspension to hang free.
When the drive axle is run at an extreme angle, extra
vibrations can occur, as well as damage to seals and
joints.
1. During on-vehicle balancing, do not remove the bal-
ance weights from the off-vehicle dynamic balance.
2. If more than 1 ounce of additional weight is required,
split the weight between the inner and the outer rim
flanges.
3. Spin the driven tire and wheel assemblies using the
engine.
OFF-VEHICLE BALANCING
Perform wheel balancing with an electronic off-vehicle
balancer. The balancer is easy to use and gives both a
static and a dynamic balance. Unlike on-vehicle balanc-
ing, the off-vehicle balancer does not correct for drum or
rotor imbalance. This drawback is overcome by its accu-
racy. Secure the wheel on the balancer with a cone
through the back side of the centerhole, not through the
wheel nut holes.
CORRECTING NON-UNIFORM TIRES
There are two ways to correct properly balanced tires
which still vibrate. One method uses an automatic
machine which loads the tire and buffs small amounts of
rubber from high spots on the outer two tread rows.
Correction by this method is usually permanent and, if it
is done properly, does not significantly affect the
appearance or the tread life of the tire. Tire truing with a
blade-type machine is not recommended because it
substantially reduces the tread life and often does not
correct the problem permanently.

2E –10 TIRES AND WHEELS
DAEWOO M-150 BL2
SPECIFICATIONS
TIRE SIZE AND PRESSURE SPECIFICATIONS
Inflation Pressure
FrontRearEngineTiresWheelkPapsikPapsi
0.8 SOHC145/70 R134.5Jx13 (Steel)207 (207)*30 (30)*207 (234)*30 (34)*
155/65 R134.5Jx13 (Alloy)207 (207)*30 (30)*207 (234)*30 (34)*
Important: ( )* : 4 – 5 occupants
INFLATION PRESSURE CONVERSION SPECIFICATIONS

kPa

psi

kPapsikPapsi
140

20

186

27

234

34
145

21

193

28

241

35
152

22

200

29

248

36
159

23

207

30

276

40
166

24

214

31

310

45
172

25

221

32

345

50
179

26

228

33

379

55
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Wheel Nuts (Aluminum Wheel)90 – 11 066 – 81–
Wheel Nuts (Steel Wheel)90 – 11 066 – 81–

4A –4 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DIAGNOSITIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily
braked, but turning, wheels will stop the vehicle in less
distance than locked brakes. More tire-to-road friction is
present with a heavily braked, turning tire than with a
sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:

Tires having unequal contact and grip of the road will
cause unequal braking. Tires must be equally in-
flated, and the tread pattern of the right and the left
tires must be approximately equal.

Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.

Misalignment of the wheels, particularly conditions of
excessive camber and caster, will cause the brakes
to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and the
shift lever in NEUTRAL. If the pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking. Perform a visual check to confirm any sus-
pected leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an
abnormally low level indicates a leak in the system. The
hydraulic system may be leaking either internally or ex-
ternally. Refer to the procedure below to check the mas-
ter cylinder. Also, the system may appear to pass this
test while still having a slight leak. If the fluid level is nor-
mal, check the vacuum booster pushrod length. If an in-
correct pushrod length is found, adjust or replace the
rod.Check the master cylinder using the following proce-
dure:

Check for a cracked master cylinder casting or brake
fluid leaking around the master cylinder. Leaks are in-
dicated only if there is at least one drop of fluid. A
damp condition is not abnormal.

Check for a binding pedal linkage and for an incorrect
pushrod length. If both of these parts are in satisfac-
tory condition, disassemble the master cylinder and
check for an elongated or swollen primary cylinder or
piston seals. If swollen seals are found, substandard
or contaminated brake fluid should be suspected. If
contaminated brake fluid is found, all the components
should be disassembled and cleaned, and all the rub-
ber components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, then the rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston seals on the
drum brake wheels.
If rubber deterioration is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep al-
cohol out of the system. Replace all the rubber parts in
the system, including the hoses. Also, when working on
the brake mechanisms, check for fluid on the linings. If
excessive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush the
master cylinder with brake fluid, refill the master cylin-
der, and bleed the system. Refer to “Manual Bleeding
the Brakes” in this section.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of the
outer cover, and for leaks or blisters. Inspect the hoses
for proper routing and mounting. A brake hose that rubs
on a suspension component will wear and eventually
fail. A light and a mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as neces-
sary.

4A –6 HYDRAULIC BRAKES
DAEWOO M-150 BL2
MANUAL BLEEDING THE BRAKES
Important: The bleeding sequence is as follows; right
rear, left rear, right front, and left front.
Important: Check the fluid level and add the fluid during
the bleeding operation.
1. Raise the vehicle.
2. Remove the bleeder screw and cap.
D17B703B
3. Attach a transparent tube over the valve. Allow the
tube to hang submerged in brake fluid in a transpar-
ent container.
D107A303
4. Slowly push the brake pedal several times and hold
the brake pedal.5. Tighten the bleeder screw after loosening the bleeder
screw and draining the fluid.
Caution: Hold the brake pedal until tightening the
bleeder screw.
6. Repeat the step 5, 6 until all the air is removed.
7. Check the leaks for the bleeder screw.
PEDAL TRAVEL CHECK
1. Start the engine.
2. Push the pedal three times.
3. With brake pedal depressed with a about 30Kg (66.15
lb) load, measure the clearance between the pedal
pad and the lower dash panel.
Unit : mm (in.)

Specification

60 (2.36)
D107A304
4. If clearance is less than 60mm (2.36 in.), the most
possible cause is either rear drum brake shoes are
worn out beyond the specification value or air is in
lines. Clearance still remains less than 60mm (2.36
in.) even after replacement of brake shoes and bleed-
ing of the brake system, other possible but infrequent
cause is malfunction of rear drum brake shoe adjust-
ers or booster push rod length out of adjustment.
5. Automatic clearance adjuster check is performed af-
ter removing brake drums. If the faulty is found, repair
or replace it.

HYDRAULIC BRAKES 4A–11
DAEWOO M-150 BL2
D24D001
3. Remove the stoplamp switch.

Remove the stoplamp switch (1).

Remove the bolts (2).

Remove the stoplamp switch bracket (3).
D24D002
4. Remove the bolts mounting brake pedal bracket (1).
5. Remove the nuts mounting brake pedal bracket (2).
D24D003
6. Remove the canister. Refer to Section 1F, Engine
Controls.
7. Remove the bolt mounting brake pedal bracket in the
engine compartment (1).
D24D004
8. Remove the brake pedal.

Remove the snap rings (1).

Remove the bushings (2).

Remove the brake pedal spring (3).

Remove the cushion (4).

Remove the brake pedal pad (5).

4A –12 HYDRAULIC BRAKES
DAEWOO M-150 BL2
D24D005
Installation Procedure
1. Install the brake pedal with pad, spring, bushings, and
cushion.
2. Install the bolt mounting brake pedal bracket in the
engine compartment.
Tighten
Tighten the bolt to 18–26 Nm (13–20 lb-ft).
3. Install the canister. Refer to Section 1F, Engine Con-
trols.
D24D006
4. Install the brake pedal with the snap rings.
5. Install the bolts and nuts mounting brake pedal brack-
et.
Tighten

Tighten the bolts mounting brake pedal bracket to
18–26 Nm (13–20 lb-ft).

Tighten the nuts mounting brake pedal bracket to
18–26 Nm (13–20 lb-ft).
D24D007
6. Install the stoplamp switch with the bracket and the
bolts.
Tighten
Tighten the mounting bolts to 9–12 Nm (80–106 lb-
in.)
7. Connect the brake pedal rod to the power booster.
Refer to Section 4C, Power Booster.
8. Install the instrument panel assembly. Refer to Sec-
tion 9E, Instrument/Driver Information.