Engine DAEWOO MATIZ 2003 Service Repair Manual

5C –4 CLUTCH
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
ConditionProbable CauseCorrection
Slipping Clutch
Improper clutch cable adjustment.
Adjust clutch cable.

Worn or oily contamination on clutch disc
surface.
Replace clutch disc.

Worn or oily contamination on pressure
plate, flywheel surface.
Replace pressure plate, flywheel.

Damaged or weakened diaphragm spring.
Replace pressure plate.

Rusted clutch cable.
Replace clutch cable.
Dragging Clutch
Improper clutch cable adjustment.
Adjust clutch cable.

Worn or weakened diaphragm spring.
Replace pressure plate.

Worn or rusted splines of input shaft or
clutch disc.
Replace input shaft or clutch disc.

Excessively wobbly clutch disc.
Replace clutch disc.

Worn clutch disc.
Replace clutch disc.
Fails to Release
Bent or damaged clutch disc.
Replace clutch disc.

Worn or rusted splines of input shaft or
clutch disc.
Replace input shaft or clutch disc.

Improper operation of clutch release shaft.
Replace clutch release shaft.
Pedal Stays on Floor
When Disengaged
Interfered clutch release bearing.
Lubricate and adjust clutch release
bearing.

Weakened diaphragm spring.
Replace pressure plate.
Clutch Vibration
Clutch facing with oily contamination.
Replace clutch disc.

Release bearing slides unsmoothly on input
shaft bearing retainer.
Lubricate retainer release bearing.

Wobbly clutch disc or poor facing contact.
Replace clutch disc.

Loose clutch disc rivets.
Replace clutch disc.

Weakened clutch disc torsion spring.
Replace clutch disc.

Distorted pressure plate or flywheel
surface.
Replace pressure plate or flywheel.

Weakened engine mounting or loosened
installing bolt or nut.
Retighten or replace mounting.
Clutch Noise
Worn or broken release bearing.
Replace release bearing.

Worn input shaft bearing.
Replace input shaft bearing.

Cracked clutch disc.
Replace clutch disc.

Pressure plate and diaphragm spring
rattling.
Replace pressure plate.

Improper clutch cable adjustment.
Adjust clutch cable.
Grabbing Clutch
Clutch disc facing with oily contamination.
Replace clutch disc.

Excessively worn on clutch disc facing.
Replace clutch disc.

Rivet head showing out of facing.
Replace clutch disc.

Weakened clutch torsion spring.
Replace clutch disc.

CLUTCH 5C–5
DAEWOO M-150 BL2
CLUTCH PEDAL OPERATION
D103C301
Clutch pedal free travel
It is designed that there is no clutch pedal free travel.
Clutch pedal travel (A)

Pedal Travel

100–110 mm (3.9–4.3 in.)
Clearance between pedal and floor just
before clutch connection (B)
After starting the engine, check if the clearance between
pedal and floor is within specified range in condition of
idling, lifting, parking brake and drawing out clutch ped-
al.

Clearance Between Pedal and Floor
just Before Clutch Connection
30–40 mm
(1.2–1.6 in.)
Caution: During inspection, take care on sudden
departure.
CLUTCH CABLE ADJUSTMENT
D103C302
If clutch connection / disconnection is operated un-
smoothly, adjust the clutch cable by adjusting clutch
cable adjust nut.

5C –6 CLUTCH
DAEWOO M-150 BL2
INSTRUCTION REPAIR
ON–VEHICLE SERVICE
D13B5151
D103B516
PRESSURE PLATE, CLUTCH DISC
AND INPUT SHAFT BEARING
Tools Required
09917–58010 Input Shaft Bearing Remover
09924–17810 Flywheel Holder
09925–98210 Input Shaft Bearing Installer
DW110–021 Engine Fixture
DW210–010 Clutch Center Guide
Removal Procedure
1. Remove the transaxle from the vehicle. Refer to Sec-
tion 5B, Manual Transaxle.
2. Support the engine to normal position using the en-
gine fixture DW110–021.
Notice: The abnormal position of the engine may dam-
age to the related parts and interfere with them. You
must support the engine to normal position after remov-
ing the transaxle.
D13C5021
3. Remove the pressure plate and the clutch disc.

Fix the fly wheel using the fly wheel holder 09924–
17810.

Remove the pressure plate bolts (1).

Remove the pressure plate and the clutch disc (2).

5C –12 CLUTCH
DAEWOO M-150 BL2
D103C522
3. Remove the battery. Refer to Section 1E, Engine
Electrical.
4. Remove the clutch cable.

Remove the nuts (1).

Remove the cable grommet (2).

Remove the cable from the pedal (3).
D103C302
Installation Procedure
1. Install the clutch cable.
2 Install the battery.
3. Connect the clutch cable to the pedal.
4. Connect the clutch cable to the transaxle.
5. Adjust the clutch cable. Refer to “Diagnosis” in this
section.
D103C524
CLUTCH PEDAL
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the clutch cable. Refer to “Clutch Cable”
in this section.
2. Remove the clutch pedal.

Release the pedal return spring.

Remove the nut (1).

Remove the clutch pedal (2).

Remove the bushing (3).

Remove the pedal return spring (4).
D103C302
Installation Procedure
1. Install the pedal return spring.
2. Install the bushings.
3. Install the clutch pedal.
4. Install the nut.
5. Fix the pedal return spring.
6. Connect the clutch cable.
7. Adjust the clutch cable. Refer to “Diagnosis” in this
section.

5C –14 CLUTCH
DAEWOO M-150 BL2
SPECIAL TOOLS
SPECIAL TOOLS TABLE
D103C101
09917–58010
Input Shaft Bearing
Remover
D103C105
09923–46040
Bushing Joint Pipe
D102B116
09924–17810
Fly Wheel Holder
D103C104
09925–48220
Bushing Remover/
Installer
D103C102
09925–98210
Input Shaft Bearing
Installer
D103C106
09930–30102
Sliding Shaft
D103C107
09943–88211
Bushing, Bearing
Installer
D103B103
DW110–021
Engine Assembly
Support Fixture
D103C103
DW210–010
Clutch Center Guide

POWER STEERING GEAR 6C–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER RACK AND PINION STERING GEAR
ConditionProbable CauseCorrection
Hissing Noise
Loose steering coupling joints.
Tighten the steering coupling
joints.

Improperly contacted the power
steering hose with other
components.
Fit the power steerng hose into
the hose clips correctly.
Rattling Noise in Steering Gear
Improperly contacted the power
steering line with the body.
Fix the steering line correctly.

Insufficient lubricant.
Lubricate the steering gear.

Loose steering gear mounting.
Tighten the steering gear
mounting bracket bolts.

Improperly installed tie rod ends.
Tighten the tie rod joints and
replace the tie rod end as needed.
Poor Return of Steering Wheel
to Center
Improperly contacted the steering
wheel with the turn signal housing.
Adjust the turn signal housing.

Improper binding or looseness of
steering coupling.
Replace the intermediate shaft.

Stuck and improperly aligned
power steering pump flow control
valve.
Replace the power steering pump.

Improper binding or looseness of
tie rods and ball joints.
Tighten the tie rods and the ball
joints. Replace the tie rods and
the ball joints as needed.

Poor adjustments of the steering
gear.
Perform a straight-ahead check.
Momentary Increase in Effect
When Turning the Wheel
Internal leaks of the power
steering pump.
Replace the power steering pump.
Quickly
The damage or restricted flow of
the hoses.
Replace the power steering hoses
and pipes.

Insufficient power steering fluid.
Fill the power steering fluid
reservoir.

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.
Steering Surges or Jerks When
Turning with Engine Running
Insufficient pressure of the power
steering pump.
Replace the power steering pump.

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.

The slippage of the pump drive
belt.
Tighten the pump drive belt.

Contaminated air in the power
steering system.
Bleed the power steering system.

6C –6 POWER STEERING GEAR
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
RACK AND PINION ASSEMBLY
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the intermediate shaft lower pinch bolt. Re-
fer to Section 6E, Steering Wheel and Column.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. Remove the tie rod ends. Refer to Section 6D, Manu-
al Steering Gear.
4. Remove the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
D105C534
5. Remove the rack and pinion assembly.

Disconnect the return line pipe from the steering
gear (1).

Disconnect the pressure inlet line pipe from the
steering gear (2).

Plug the opening in the power steering pipe line to
prevent fluid loss and contamination.
D105C535

Remove the power steering gear retaining bracket
tighten bolts (3).

Remove the power steering gear retaining bracket
(4).
Important: After moving the gear toward the passenger
side and pulling the gear of the driver side into the un-
derbody hole, remove the steering gear.

MANUAL STEERING GEAR 6D–9
DAEWOO M-150 BL2
D105B507

Coat the greases on the tie rod to ease removal
(3).

Remove the boot (4).
D105B508
Installation Procedure
1. Install the rack and pinion boot with the clamp and the
wire clamp.
2. Install the tie rod end nut.
3. Install the tie rod end. Refer to “Tie Rod End” in this
section.
D105B509
D105B510
RACK AND PINION STEERING GEAR
ASSEMBLY
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the intermediate shaft lower pinch bolt. Re-
fer to Section 6E, Steering Wheel and Column.
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Disconnect the tie rod end from the steering knuckle.
Refer to “Tie Rod End” in this section.
4. Remove the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
5. Remove the steering gear assembly from the vehicle.

Remove the steering gear bracket bolts (1).

Remove the steering gear bracket (2).

Remove the steering gear assembly.

Remove the packing (3).

6D –10 MANUAL STEERING GEAR
DAEWOO M-150 BL2
D15B511A
Installation Procedure
1. Install the mounting to the steering gear assembly.
2. Install the steering gear assembly.
3. Install the steering gear bracket with the bolts.
Tighten
Tighten the steering gear bracket bolts to 50–55 Nm
(36–41 lb-ft).
4. Install the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
5. Connect the tie rod end to the steering knuckle. Refer
to “Tie Rod End” in this section.
6. Install the wheels. Refer to Section 2E, Tires and
Wheels.
7. Install the intermediate shaft lower pinch bolt. Refer
to Section 6E, Steering Wheel and Column.

STEERING WHEEL AND COLUMN 6E–15
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Unit

Description
With Airbagmm (in.)

380 (14.96)
Steering Wheel
DiameterWithout Airbagmm (in.)

370 (14.57) Steering Wheel
Free Play (Engine Stop)mm (in.)

0 ± 20 (0 ± 0.79)
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Steering Wheel Nut 23 – 33 17 – 24 –
Steering Column Upper Nuts 15 – 20 11 – 15 –
Steering Column Lower Nuts 15 – 20 11 – 15 –
Intermediate Shaft Upper Pinch Bolt 21 – 29 16 – 22 –
Intermediate Shaft Lower Pinch Bolt 21 – 29 16 – 22 –