DAEWOO MATIZ 2003 Service Repair Manual

2B–4 WHEEL ALIGNMENT
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
TIRE DIAGNOSIS

Condition

Probable cause

Correction
Irregular and Excessive
Tire WearIncorrect inflation pressure.Inflate the tires to the proper
pressure.
Inbalanced wheel.Balance the wheel.
Replace the wheel.
A lack of regular rotation.Rotate the tires.
Incorrect alignment.Align the front and rear wheels.
Premature Tire WearExcessive inflation pressure.Inflate the tires to the proper
pressure.
High speed driving with the low
inflation pressure.Inflate the tires to the proper
pressure.
Uneven BrakingInbalanced inflation pressure.Inflate the tires to the proper
pressure.
Irregular tire wear.Replace the tires.
Noise and Vibration of
The BodyLow inflation pressure.Inflate the tires to the proper
pressure.
Inbalanced wheel.Balance the wheel.
Replace the wheel.
Damaged wheel or tire.Replace the wheel and the tire.
Irregular tire wear.Replace the tire.
Vibration of The SteeringIrregular tire wear.Replace the tire.
WheelInbalanced inflation pressure.Inflate the tires to the proper
pressure.
Damaged tire.Replace the tire.
Bent or damaged wheel.Replace the wheel.

WHEEL ALIGNMENT 2B–5
DAEWOO M-150 BL2
FRONT TOE ADJUSTMENT
1. Separate the clamps from the both rack and pinion
boots.
2. Loosen the right and the left tie rod end lock nuts.
3. Turn the right and the left tie rod to align the toe.
In this adjustment, the right and left tie rods must be
equal in length.
Front Toe–In 10′ ± 10′

Rotation Number of Tie Rod

Difference of Toe–In

1/2
0.75 mm (0.03 in.)
1 1.5 mm (0.06 in.)
D106A303
4. Tighten the tie rod end lock nut to 45 Nm (33 lb-ft).
5. Install the rack and pinion boots clamp.
FRONT CAMBER AND CASTER
CHECK
The front camber and caster are not adjustable. Refer to
“Wheel Alignment Specifications” in this section. Jounce
the bumper three times before measuring the camber or
the caster in order to prevent an incorrect reading. If the
front camber or caster measurements deviate from the
specifications, locate and replace or repair any dam-
aged, loose, bent, dented, or worn suspension part. If
the problem is body related, repair the body.
REAR CAMBER CHECK
The rear camber is not adjustable. Refer to “Wheel
Alignment Specifications” in this section. If the rear cam-
ber deviates from the specification, locate the cause and
correct it. If damaged, loose, bent, dented, or worn sus-
pension parts are found, they should be repaired or re-
placed. If the problem is body related, repair the body.
REAR TOE CHECK
The rear toe is not adjustable. Refer to “Wheel Align-
ment Specifications” in this section. If the toe deviates
from the specification, check the rear axle assembly and
the wheel spindle on vehicles without an anti–lock brak-
ing system (ABS) or the rear axle assembly and the hub
and bearing assembly on vehicles with ABS for possible
damage.

2B–6 WHEEL ALIGNMENT
DAEWOO M-150 BL2
SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS

Application

Front

Rear
Camber0
30′ ± 0
30′0

20′
Caster–Manual Steering2
48′ ± 30′–
Caster–Power Steering2
48′ ± 30′–
To e–in (2–person load)10′ ± 10′20′
20′
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In Tie Rod End Lock Nut 45 33 –

DAEWOO M-150 BL2
SECTION 2C
FRONT SUSPENSION
TABLE OF CONTENTS
Description and Operation 2C-2. . . . . . . . . . . . . . . . . .
Front Suspension 2C-2. . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 2C-3. . . . . . . . . . . . . . . . . . . . . . . .
Front Suspension 2C-3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 2C-5. . . . .
Strut Dampener 2C-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Joint and Knuckle 2C-5. . . . . . . . . . . . . . . . . . . . .
Front Wheel Bearing 2C-6. . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 2C-7. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 2C-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Strut Assembly 2C-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle Assembly 2C-8. . . . . . . . . . . . . . . . . . . . . . . . . Front Longitudinal Frame and
Stabilizer Shaft 2C-10. . . . . . . . . . . . . . . . . . . . . . . . .
Control Arm 2C-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strut Bar 2C-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crossmember 2C-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 2C-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub, Bearing and Knuckle 2C-16. . . . . . . . . . . . . . . . .
Front Strut 2C-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 2C-23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 2C-23. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 2C-23. . . . . . . . . .
Special Tools and Equipment 2C-24. . . . . . . . . . . . . .
Special Tools Table 2C-24. . . . . . . . . . . . . . . . . . . . . . .

2C – 2 FRONT SUSPENSION
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FRONT SUSPENSION
The front suspension for this vehicle is a combination
knuckle/strut and spring design.
The control arms pivot from the body. The lower control
arm pivots use rubber bushing. The upper end of the
strut is isolated by a rubber mount and contains a bear-
ing to allow the wheel to turn.
The lower end of the steering knuckle pivots on a ball
joint bolted to the control arm. The ball joint is fastened
to the steering knuckle with a bolt.When servicing the control arm-to-body attachment and
the stabilizer shaft-to-body insulators, make sure the at-
taching bolts are loose until the control arms are moved
to the trim height, which is curb height. Trim height is the
normal position to which the control arms move when
the vehicle is sitting on the ground. Refer to “General
Specifications” in this section.

FRONT SUSPENSION 2C–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
FRONT SUSPENSION
D16B401A

2C –4 FRONT SUSPENSION
DAEWOO M-150 BL2
1. Strut Bar
2. Front Suspension Strut Assembly
3. Strut Inner Support
4. Strut Mount Assembly
5. Strut Mount Seat
6. Strut Bearing Seat
7. Strut Bearing
8. Coil Spring Upper Seat
9. Coil Spring Seat
10. Bumper Stopper
11. Coil Spring
12. Strut
13. Inner Bearing Oil Seal
14. Inner Hub Bearing
15. Steering Knuckle
16. Dust Cover
17. Hub Bearing Spacer
18. Outer Hub Bearing19. Outer Bearing Oil Seal
20. Rotor
21. Wheel Hub
22. Hub Bolt
23. Hub Assembly
24. Drive Axle–to–Hub Caulking Nut
25. Control Arm Ball Stud Bolt
26. Cotter Pin
27. Castellated Nut
28. Washer
29. Stabilizer Shaft Bushing
30. Control Arm Dust Seal
31. Clip
32. Control Arm Bushing
33. Control Arm Assembly
34. Stabilizer Shaft
35. Stabilizer Shaft Mount
36. Front Under Longitudinal Frame

FRONT SUSPENSION 2C–5
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
STRUT DAMPENER
A strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand
than are shock absorbers. Strut dampeners are used only on the front in most vehicles, including this vehicle. Shock
absorbers are used on the rear wheels.
Condition Probable cause Correction
Struts Seem Weak
Improper tire pressures.
Adjust the tire pressures to the speci-
fications on the tire placard.

Abnormal load conditions.
Consult with the owner to confirm the
owner’s understanding of normal load
conditions.

Improper compression and rebound
effectiveness of the strut dampener.
Quickly push down and then lift up on
the corner of the bumper nearest the
strut dampener being tested.

Compare the compression and re-
bound with those of a similar vehicle
that has an acceptable ride quality.

Replace the strut dampener, if need-
ed.
Struts are Noisy
Loose or damaged mountings.
Tighten the strut dampener.

Replace the strut dampener if need-
ed.

Improper compression and rebound
effectiveness of the strut dampener.
Quickly push down and then lift up on
the corner of the bumper nearest the
strut dampener being tested.

Compare the compression and re-
bound with those of a similar vehicle
that has an acceptable ride quality.

Replace the strut dampener, if need-
ed.
Leaks
A slight trace of fluid.
The strut dampener is OK.

Leaks of the seal cover on the fully
extended strut.
Replace the strut dampener.

Excessive leaks of fluid on the strut
dampener.
Replace the strut dampener.
BALL JOINT AND KNUCKLE
Ball Joint Inspection
1. Raise the front of the vehicle to allow the front sus-
pension to hang free.
2. Grasp the tire at the top and the bottom.
3. Move the top of the tire in an in-and-out motion.
4. Look for any horizontal movement of the knuckle rela-
tive to the control arm.
5. Control arms assembly must be replaced if the follow-
ing conditions exist:

The joint is loose.

The ball seal is cut.

The ball stud is disconnected from the knuckle.
The ball stud is loose at the knuckle.

The ball stud can be twisted in its socket with finger
pressure.Ball Stud Inspection
Make sure to check the tightness of the ball stud in the
knuckle boss during each inspection of the ball joint.
One way to inspect the ball stud for wear is to shake the
wheel and feel for movement of the stud end or the cas-
tellated nut at the knuckle boss.
Another way to inspect the ball stud for wear is to check
the fastener torque at the castellated nut. A loose nut can
indicate a stressed stud or a hole in the knuckle boss.
Worn or damaged ball joints and knuckles must be re-
placed.

2C –6 FRONT SUSPENSION
DAEWOO M-150 BL2
FRONT WHEEL BEARING
Bearing Axial End Play Inspection
D107B303
1. Lift and suitably support the vehicle.
2. Inspect the end play of the bearing.
3. If excessive play is defeeted, free shoes from the disc
or remove the calipers.4. Check the standard torque of the drive nut (spec. :
210 Nm (155 lb-ft)).
5. Check the bearing end play according to the following
method.

Place a dial guage against the disc surface, grasp
the disc.

Using a push–pull movement, note gage readings.
Specification
0.130mm
or less
(0.005 in)Standard tighting torque
of drive shaft nut :
210 Nm (155 lb-ft)
6. If the axial end play of the front wheel bearing exceed
0.130mm torque the drive shaft nut successively
(Max. allowance : 240 Nm (177 lb-ft))
7. Check the axial end play again.
8. If the axial end play is above spec., replace the front
wheel bearing.

FRONT SUSPENSION 2C–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D16B501A
STRUT ASSEMBLY
Removal Procedure
1. Open the hood.
2. Remove the top of the strut assembly at passenger
seat side.

For vehicle with power steering, remove the power
steering fluid reservoir (1).

Remove the nuts (2).
D16B502A
3. Remove the top of the strut assembly at driver side.

Remove the bolt and the fuse box (1, 2).

Remove the nuts (3).
D106B503
4. Remove the lower of the strut assembly.

Raise and suitably support the vehicle.

Remove the wheel. Refer to Section 2E, Tires and
Wheels.

Remove the ABS front speed sensor electrical wire
from the bracket, if applicable (1).

Disconnect the brake hose from the bracket (2).

Remove the strut bracket bolts (3).
5. Remove the strut bracket assembly from the vehicle.