engine DAEWOO MATIZ 2003 Service Repair Manual

HYDRAULIC BRAKES 4A–13
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
0.8 SOHC Engine
Application Millimeters Inches



Brake Drums:
Inside Diameter
Maximum Rebore Diameter
Out-of-Round


180
182
0.04


7.09
7.17
0.0016




Brake Rotors:
Discard Thickness
Lateral Runout (Installed)
Rotor Diameter
Rotor Thickness (New)



10
0.05
236
12.7




0.4
0.002
9.3
0.5
Master Cylinder:
Bore Diameter 20.64 0.81
Caliper:
Piston Diameter
48

1.89
Wheel Cylinder Diameter: 17.46 0.69



Brake Pedal:
Free Play
Height
Stroke


6 – 10
200
30



0.24 – 0.31
7.87
1.18
Type DOT–3 or DOT–4 Brake Fluid Capacity 0.45 L (0.48 qt.)
FASTENER TIGHTENING SPECIFICATIONS

Application

Nm

Lb-Ft

Lb-In
Brake Pipe Fittings 16 12 –
Front Brake Hose-to-Caliper Bolt 25.5 19.1 –
Brake Pedal–to–Pedal Bracket Hex Bolt

18

13

–
Brake Pedal Bracket Mounting Bolts 18 – 26 13 – 20 –
Brake Pedal Bracket Mounting Nuts 18 – 26 13 – 20 –
Stoplamp Switch Mounting Bracket Bolts

9 – 12

–

80 – 106

4B –4 MASTER CYLINDER
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
MAB4B001
D107A514
MASTER CYLINDER ASSEMBLY
Removal Procedure
1. Remove the air filter assembly. Refer to Section 1B,
Engine Mechanical.
2. For vehicles with the non–ABS braking system, re-
move the proportioning valve. Refer to “Proportioning
Valve” in this section.
3. Remove the master cylinder.

Disconnect the electrical connector.

Loosen the brake pipe fittings.

Plug the opening in the master cylinder to prevent
fluid loss or contamination.
Notice: Brake fluid may damage paintwork, if spillage
onto paintwork, wash with cold water immediately.

Remove the nuts mounting the master cylinder (3).
D17A515A
Installation Procedure
Important: Use only Daewoo recommended brake
fluid.
1. Install the master cylinder assembly with the nuts.
Tighten
Tighten the attaching nuts to 16 Nm (12 lb-ft).

POWER BOOSTER 4C–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER BOOSTER FUNCTIONAL
CHECK
1. With the engine stopped, eliminate the vacuum in the
booster by pumping the brake pedal several times.
2. Push the pedal down and hold it in this position.
3. Start the engine.
4. The booster is OK if the pedal drops further because
of extra force produced.
If the brake pedal does not drop, the vacuum system
(vacuum hoses, check valve, etc.) is probably defective
and should be checked.
If no defect is revealed by checking the vacuum system,
the defect is in the booster itself.
CHECK VALVE FUNCTIONAL CHECK
1. Remove the vacuum hose.
2. Suck the vacuum hose to power booster. And also,
suck the vacuum hose to engine.
3. If the air pass through the check valve or not, replace
the check valve. And if the vacuum hose to engine isonly sucked, the check valve OK.
D17A301B

4F–4 ANTILOCK BRAKE SYSTEM
DAEWOO M-150 BL2
feed back to the master cylinder and brake pedal.
D107E005
Return Pump Motor
The motor drives two pump elements through the ec-
centric wheel on its shaft.
Return Pump
Description: Each pump element consists of a fixed
displacement piston driven by an eccentric on the end of
the eccentric motor. It has two check valves (inlet and
outlet) and is fed with fluid by the low pressure accumu-
lator.
Operation:
Compression stroke: the pump is filled via the inlet ball
seat, then the motor eccentric rotates moving the piston
to displace the fluid. After the pressure build-up closes
the inlet valve the piston displacement increases the
pressure until the outlet ball opens. The outlet pressure
will continue to increase for the rest of the piston stroke.
Return Stroke: The piston retracts, forced by its spring,
as the motor eccentric returns to its low end position.
The pressure at the inlet side of the outlet ball then de-
creases due to the displaced volume and the pressure
difference across this ball holds it closed.
The pressure at the outlet side of the inlet ball seat,
which is set to open at a certain pressure level also de-
creases until this valve opens. With the outlet ball
closed, the pump is filled with additional fluid from the
low pressure accumulator.
The pressure will continue until a stall point is reached
and compression of the piston cannot generate enough
differential pressure anymore to open the outlet ball
seat.
D17E006A
Return Pump
Return Pump
Motor(0.12~0.16 in.)
EBCM (ELECTRONIC BRAKE
CONTROL MODULE)
Notice: There is no serviceable. The EBCM must be re-
placed as an assembly.
The EBCM is attached to the hydraulic unit in the engine
compartment. The controlling element of ABS is a mi-
croprocessor-based EBCM. Inputs to the system in-
clude the four wheel speed sensors, the stoplamp
switch, the ignition switch, and the unswitched battery
voltage. There is an output to a bi-directional serial data
link, located in pin M of the assembly line diagnostic link
(ALDL), for service diagnostic tools and assembly plat
testing.
The EBCM monitors the speed of each wheel. If any
wheel begins to approach lockup and the brake switch is
closed (brake pedal depressed), the EBCM controls the
dump valve to reduce brake pressure to the wheel ap-
proaching lockup. Once the wheel regains traction,
brake pressure is increased until the wheel again begins
to approach lockup. The cycle repeats until either the
vehicle comes to a stop, the brake pedal is released or
no wheels approach lockup.
Additionally, the EBCM monitors itself, each input (ex-
cept the serial data link), and each output for proper op-
eration. If it detects any system malfunction, the EBCM
will store a DTC in nonvolatile memory (DTCs will not
disappear if the battery is disconnected).

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
 –

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
 –

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–6 PARKING BRAKE
DAEWOO M-150 BL2
D107D508
PARKING BRAKE CABLE
Removal Procedure
1. Remove the parking brake lever. Refer to “Parking
Brake Lever” in this section.
2. Remove the parking brake cable.

Remove the cable pulley (1).

Loosen the adjustment nuts (2).

Remove the strengthener (3).
D107D509

Remove the grommet (4).
D107D510
3. Remove the rear brake drum assembly. Refer to Sec-
tion 2D, Rear Suspension.
4. Disconnect the parking brake cable from the rear
brake drum assembly.

Remove the clip from the brake plate (1).

Disconnect the parking brake cable from the trailing
shoe (2). Refer to Section 4E, Rear Drum Brake.
D107D511
5. Remove the parking brake cable.

Remove the clamp bolts fastening the brake cable
(RH Rear Brake Side) (1).

Remove the fuel filter. Refer to Section 1F, Engine
Controls.

5B – 2 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FIVE-SPEED MANUAL TRANSAXLE
This five-speed transaxle assembly adopts the synchro-
nized mesh type of 5 forward speed. The reverse speed
gear is driven by sliding idle gear without synchronizer.
REVERSE GEAR MISSHIFT
PREVENTING MECHANISM
It prevents the gear from directly being shifted from 5th
to reverse when shifting to reverse from 5th. Shift to the
reverse in neutral position to prevent the shift cam from
being interfered to the shift guide bolt.
D103B001
In case of shifting to 5th gear, shift and select shaft ro-
tates to right that shift cam aparts from guide bolt and
moves upwards by returning spring. Therefore, shifting
to reverse in this condition is impossible because of in-
terference of guide bolt.
D103B002
When shifting to reverse from neutral position between
5th and reverse, shift cam rotates to left and shifting is
possible.
D103B003
DIFFERENTIAL
Differential is integrated with transmission case and
installed on chassis together with engine. It changes the
direction of power and increase torque by reducing
speed.
Reduction gear is installed parallel to counter shaft and
is helical gear type. Differential gear is bevel gear type
and is integrated with reduction gear.

FIVE-SPEED MANUAL TRANSAXLE 5B–9
DAEWOO M-150 BL2
CHECKING FLUID LEVEL
Check for a leak in the area of transaxle case and seal-
ing and then check fluid level and condition after remov-
ing oil level plug.
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Remove the oil level plug and check the fluid level.
4. The fluid should slightly flow out from the oil level plug
hole.
5. If the level is low, add the recommended fluid through
the oil level plug hole until the fluid begins to run out.
6. If the fluid is contaminated or discolored, replace it
with the recommended fluid.
7. Reinstall the oil level plug and tighten it securely.
D103B301
CHANGING FLUID
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Drain the fluid after removing the drain plug.
4. Reinstall the drain plug and tighten it securely after
coating sealant.
5. Remove the oil level plug and replenish the fluid until
it begins to run out.
a. Oil drain plug.
b. Oil level plug.
6. Reinstall the oil level plug and tighten it securely.Fluid Specification
75W-85(GL-4)
Fluid Capacity2.1L(2.21qt)
Service intervalRefer to Owner’s Manual
CHECKING TRANSAXLE NOISE
Many noises that appear to come from the transaxle
may actually originate with other sources such as tires,
road surfaces, wheel bearings, or engine and exhaust
system.
Identify the cause of any noise before attempting to re-
pair the clutch, the transaxle, or their related linkages.
To verify suspected transaxle noises,
1. Select a smooth, level asphalt road to reduce tyre
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lubri-
cants thoroughly.
3. Record the speed and the gear range of the transaxle
when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle oper-
ates in.

Drive – Under a light acceleration or a heavy pull.

Float – Maintaining a constant speed with a light
throttle on a level road.

Coast – With the transaxle in gear and the throttle
partly or fully closed.

All of the above.
CHECKING BEARING NOISE
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre-
loaded, a differential side bearing noise should not di-
minish much when the differential/transaxle is run with
the wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre-loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.