Engine DAEWOO MATIZ 2003 Service Repair Manual

5B–10 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
REPAIR INSTRUCTION
ON–VEHICLE SERVICE
D103B501
MANUAL TRANSAXLE ASSEMBLY
Tools Required
DW110–021 Engine Support Fixture
DW220–031 Transaxle Remove/Install Support
Removal Procedure
1. Remove the air cleaner assembly. Refer to Section
1B, SOHC Engine Mechanical.
2. Remove the battery and battery tray. Refer to Section
1E, Engine Electrical.
3. Disconnect the select and the shift cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift cable (3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.
D103B502
4. Remove the engine wiring harness bending strap.
5. Disconnect the ground wire and the backup lamp
switch connector.

Remove the ground wire bolt (1).

Disconnect the ground wire (2).

Disconnect the backup lamp switch connector (3).

FIVE-SPEED MANUAL TRANSAXLE 5B–11
DAEWOO M-150 BL2
D13B5031
6. Disconnect the radiator lower hose.

Remove the bolts (1).

Disconnect the radiator lower hose (2).
7. Remove crankshaft position (CKP) sensor.

Remove the bolt (3).

Disconnect the CKP sensor connector

Remove the CKP sensor.
D103B507
8. Disconnect the speedometer cable.

Loosen the nut (1).

Disconnect the cable (2).
9. Remove the vehicle speed sensor (VSS) if
equipped.

Disconnect VSS connector.

Remove the VSS.
D102E502
10. Remove the starter motor.

Remove upper two bolts that securing starter mo-
tor to transaxle.
D13B5041
11. Fix the engine assembly.

Remove the cowl panel weatherstrip.

Position the engine support fixture DW110–021
on the cowl panel and the front upper panel.

Tighten the engine fixture joint with a bolt after re-
moving exhaust manifold bolt (No.4).

5B–14 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5141
24. Position the manual transaxle assembly in tilting.

To remove the manual transaxle side cover with-
out the interference with the front under longitudi-
nal panel (Left), tilt the engine/manual transaxle by
loosening the engine support fixture DW110– 021
joint with the wrench.
D13B5151
25. Remove the manual transaxle assembly.

Lower the transaxle assembly slowly by adjusting
jack.
a. Jack.
b. Transaxle assembly.

Tilt the transaxle assembly by adjusting jack.

Remove the transaxle assembly by pulling and
lowering it slowly.
D103B516
26. Support the engine to normal position using the en-
gine support fixture DW110–021.
Notice: The abnormal position of the engine may dam-
age to the related parts or interfere with them. You have
to support the engine to normal position when removing
the transaxle.
Important: If it is impossible to use the special tool, sup-
port the engine to normal position with the auto jack.
D13B5171
Installation Procedure
1. Install in the reverse order of removal.
2. Install the transaxle mounting bolts.
Tighten
Tighten the transaxle mounting bolts (body side) to
45–55 Nm (33–41 lb-ft).

5B–16 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5032
8. Install the radiator lower hose and crank position
(CKP) sensor.
Tighten
Tighten the radiator lower hose bolt to 8–15 Nm
(70–132 lb-in).
Tighten the CKP sensor bolt to 5–8 Nm (44–70 lb-
in).
D13B520A
9. Refill the transaxle fluid.

Tighten the drain plug to 25–30 Nm (18–22 lb-ft)
(a).

Remove the oil level plug (1).

Refill recommended fluid to the proper level.
Classification 75W – 85 (GL–4) Capacity2.1L (2.21 qt)

Tighten the oil level plug to 36–54 Nm (26–40 lb-ft)
(b).
D13B521A
10. Adjust the clutch cable. Refer to Section 5C, Clutch.

Adjust the clutch cable by the clutch cable adjust
nut.
11. Install the transaxle under cover.
Tighten
Tighten the transaxle under cover bolts to 35–55
Nm (25–41 lb-ft).
D103B501
GEAR SHIFT CONTROL CASE
ASSEMBLY
Removal Procedure
1. Remove the air hose (air cleaner to throttle body).
Refer to Section 1B, SOHC Engine Mechanical.
2. Remove the battery.
3. Disconnect the select and the shift control cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift control cable
(3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.

5B–20 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B534
2. Remove the battery. Refer to Section 1E, Engine
Electrical.
3. Disconnect the instrument cluster side cable. Refer to
Section 9E, Instrumentation/Driver Information.
4. Remove the speedometer cable.

Remove the cable grommet (1).

Pull out the speedometer cable from the dash pan-
el.
D103B535
Inspection Procedure
1. Remove the O–ring from the speedometer driven
gear housing.
2. Remove the driven gear pin and disconnect the driv-
en gear.

Check for a damaged or torn O–ring.

Check for a worn or damaged tooth of driven gear.
a. O–ring.
b. Driven gear pin.
c. Driven gear.
D103B536
Installation Procedure
1. Install in the reverse order of removal.
Important: Install the speedometer driven gear assem-
bly after connecting the speedometer cable with the
speedometer driven gear assembly completely.
D13B537A
2. Install the speedometer driven gear assembly to
transaxle housing.
Tighten
Tighten the speedometer driven gear assembly bolt
to 4–7 Nm (35–62 lb-in).

FIVE-SPEED MANUAL TRANSAXLE 5B–21
DAEWOO M-150 BL2
D103B501
GEAR SHIFT CONTROL CABLE
Removal Procedure
1. Remove the air hose (air cleaner to throttle body).
Refer to Section 1B, SOHC Engine Mechanical.
2. Remove the battery.
3. Disconnect the transaxle side select and shift control
cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and shift control cable (3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.
D19E573A
4. Remove the floor console. Refer to Section 9G, Inte-
rior Trim.

Put aside the floor carpet in order to get the gear
shift cable shown.
D13B5381
5. Disconnect the gear shift lever side select and shift
control cable.

Remove the select control cable clip (1).

Ply off the eye ring (2).

Remove the select control cable E–ring (3).

Disconnect the select control cable (4).

Remove the shift control cable pin (5).

Remove the shift control cable E–ring (6).

Ply off the shift control cable (7).
D13B539A
6. Remove the select and shift control cable.

Remove the nuts (1).

Pull the cables out in the passenger room.

5B–22 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B540
Installation Procedure
1. Install in the reverse order of removal.
2. Push the cables toward the engine compartment
through dash panel’s hole slightly.
3. Position the cables on the select and the shift lever.
D13B5411
4. Connect the transaxle side select and shift control
cable.
5. Connect the gear shift lever side shift control cable.
6. Connect the gear shift lever side select control cable.

Insert the select control cable eye ring to the select
arm pin (1).

Install the selector lever control cable clip (2).

Install the select control cable to gear shift lever
bracket with E–ring (3).

Insert a driver to the select arm adjustment hole to
prevent the movement of gear shift lever in NEU-
TRAL (4).
7. Tighten the adjust nuts.
Tighten
Tighten the select cable adjust nut to 8–12 Nm
(71–106 lb-in).
D103B543
GEAR SHIFT CONTROL LEVER
Removal Procedure
1. Remove the floor console. Refer to Section 9G, Inte-
rior Trim.
2. Disconnect the select and shift control cable. Refer to
“Gear Shift control cable” in this section.
3. Remove the gear shift control lever assembly.

Remove the bolts (1).

Remove the gear shift control lever assembly (2).

Remove the gear shift lever sensor connector.
(If equipped with auto clutch).

FIVE-SPEED MANUAL TRANSAXLE 5B–53
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
5th/Reverse Gear Shift Shaft Bolt10 – 167 – 12–
Back Up Light Switch Nut15 – 1811 – 13–
Counter Shaft 5th Gear Nut60 – 8044 – 59–
Crankshaft Position Sensor Bolt5 – 8–44 – 70
Differential Ring Gear Bolt80 – 10059 – 74–
Engine Mounting Front Bracket Bolt
(Cylinder Block Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolt
(Crossmember Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolts
(Crossmember Side)45 – 5533 – 41–
Engine Mounting Front Damping Bush Bolt/Nut
(Bracket Side)68 – 8351 – 61–
Front Exhaust Pipe Nut
(Exhaust Manifold Side/Muffler Side)25 – 3518 – 25–
Gear Shift Control Case Bolt18 – 2813 – 21–
Gear Shift Lever Bolt4 – 7–35 – 62
High Speed Shift Shaft Bolt10 – 167 – 12–
Low Speed Shift Shaft Bolt10 – 167 – 12–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–
Radiator Lower Hose Bracket Bolts8 – 15–70 – 132
Reverse Idle Gear Shaft Bolt18 – 2813 – 21–
Reverse Shift Lever Bolt18 – 2813 – 21–
Select Cable Nut(Shift Lever Side)8 – 12–71 – 106
Select Lever Bolt18 – 2813 – 21–
Side Cover Plate Screw6 – 7–53 – 62
Shift Guide Bolt18 – 2813 – 21–
Shift Interlock Bolt18 – 2813 – 21–
Side Cover Bolt8 – 12–71 – 106
Speedometer Driven Gear Bolt4 – 7–35 – 62
Starter Motor Bolt18 – 2813 – 21–
Transaxle Case Bolt15 – 2211 – 16–
Transaxle Case(left) Cap Bolt8 – 12–71 – 106
Transaxle Lower Bolt and Nut(Engine Side)55 – 6541 – 48–
Transaxle Mounting Bolt(Body Side)45 – 5533 – 41–
Transaxle Mounting Bolt and Nut(Transaxle Side)55 – 6541 – 48–
Transaxle Upper Bolt(Engine Side)55 – 6541 – 48–
Transaxle Under Cover Bolt35 – 5525 – 41–

5B–54 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
SPECIAL TOOLS
SPECIAL TOOLS TABLE
D103B110
09913–76010
Bushing, Seal Installer
D103B106
DW09913–80112
Gear, Bearing Installer
D103B104
DW09921–57810
Gear, Bearing Remover
D103B107
DW09925–98221
Gear, Bearing Installer
D103B105
DW09940–53111
Gear, Bearing Installer
D103B109
DW09943–78210
Bushing, Seal Installer
D103B103
DW110–021
Engine Assembly
Support Fixture
D13B101A
DW220–010A
Transaxle Fixture

5C – 2 CLUTCH
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRIVING MEMBERS
The driving members consist of two flat surfaces ma-
chined to a smooth finish. One of these is the rear face
of the engine flywheel, and the other is the pressure
plate. The pressure plate is fitted into a steel cover,
which is bolted to the flywheel.
DRIVEN MEMBERS
The driven member is the clutch disc with a splined hub
which is free to slide lengthwise along the splines of the
input shaft, but which drives the input shaft through
these same splines.The driving and driven members are held in contact by
spring pressure. This pressure is exerted by a dia-
phragm spring in the pressure plate assembly.
OPERATING MEMBERS
The clutch release system consists of the clutch pedal,
the clutch release shaft, the clutch cable, the release
arm and the release bearing. When pressure is applied
to the clutch pedal, the clutch release shaft pushes
against the release bearing by rotating. The bearing
then pushes against the diaphragm spring in the pres-
sure plate assembly, thereby releasing the clutch.