DAEWOO MATIZ 2003 Service Repair Manual

CLUTCH 5C–11
DAEWOO M-150 BL2
D103C519
2. Remove the clutch release arm.

Remove the bolt and nut (1).

Remove the release arm (2).
D13C520A
Installation Procedure
1. Install in the reverse order of removal.
2. Install the clutch release arm.

Install the clutch release arm matching to punched
mark (1).
Tighten
Tighten the bolt and nut to 10–16 Nm (7.5–12 lb-ft).
3. Adjust the clutch cable. Refer to “Diagnosis” in this
section.
D103B506
CLUTCH CABLE
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the clutch cable from the transaxle.

Remove the adjusting nut (1).

Disconnect the cable from the wire clip (2).

Pull and remove the cable from the transaxle
mount hole (3).
D13C5211
2. Disconnect the clutch cable from the pedal.

Pull upward and disconnect the cable from the
pedal hook (1).

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.

CLUTCH 5C–13
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Description Unit Standard Limit
Type – Single Dry Plate –
Outside Diameter mm (in.) 170 (6.7) –
Inside Diameter mm (in.) 110 (4.3) –Clutch Disc Thickness mm (in.) 7.15 (0.281) –
Rivet Head Depth mm (in.) 1.2 (0.047) 0.5 (0.020)
Disc Runout Limit in Rotational Direction mm (in.) – 0.7 (0.028)
Pedal Free Travel mm (in.) 0 (0) –
Clutch Pedal Pedal Travel mm (in.) 100 – 11 0
(3.9 – 4.3) –Clutch Pedal
Clearance between pedal and floor just
before clutch connection
mm (in.)

–

30 – 40
(1.2 – 1.6)
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Pressure Plate Bolt

18 – 28

13 – 21

–
Clutch Release Arm Bolt and Nut

10 – 16

7.5 – 12

–

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

DAEWOO M-150 BL2
SECTION 6B
POWER STEERING PUMP
TABLE OF CONTENTS
Description and Operation 6B-2. . . . . . . . . . . . . . . . . .
Power Steering Pump 6B-2. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6B-3. . . . .
Power Steering Pump 6B-3. . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 6B-4. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Belt 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Pulley 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . Pump Assembly 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 6B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6B-8. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6B-8. . . . . . . . . . .
Special Tools and Equipment 6B-9. . . . . . . . . . . . . . .
Special Tools Table 6B-9. . . . . . . . . . . . . . . . . . . . . . . .

6B – 2 POWER STEERING PUMP
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
POWER STEERING PUMP
The pump has a remote fluid reservoir. A pressure-relief
valve inside the flow control valve limits pump pressure.

POWER STEERING PUMP 6B–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER STEERING PUMP
ConditionProbable CauseCorrection
Foaming, Milky
Power Steering Fluid,
Insufficient power steering fluid level.
Fill the power steering fluid
reservoir.
Low Fluid Level, and
Possible Low
Contaminated air in the power steering
fluid.
Bleed the power steering system.
Pressure

Internal leaks and overflow of the power
steering pump.
Replace the power steering pump.

Leaks of the power steering pump housing
and the soft plug.
Replace the power steering pump.
Low Pressure Due to
Steering Pump
Stuck and improperly operated power
steering pump flow control valve.
Replace the power steering pump.

Worn power steering pump seats.
Replace the power steering pump.

Scores, cracks, or breaks of the pressure
plate, the pump ring, the thrust plate, and
the rotor.
Replace the power steering pump.

Sticking of the vanes in the rotor slots.
Replace the power steering pump.

Internal leaks and overflow of the power
steering pump.
Replace the power steering pump.
Growling Noise in
Steering Pump
Restricted flow of the pump hoses and the
steering gear pipes.
Clean out the pipes and the hoses.

Replace the pipes and the hoses as
needed.

Scores, cracks, or breaks of the pressure
plate, the pump ring, the thrust plate, and
the rotor.
Replace the power steering pump.

Improperly contacted power steering hose
with the body.
Secure the pump hose in a clamp
away from the body.

Insufficient power steering fluid level.
Fill the power steering pump
reservoir.
Ratting Noise in the
Steering Pump
Contaminated air in the power steering
fluid.
Bleed the power steering system.

Improperly contacted power steering hose
with the body.
Secure the pump hose in a clamp
away from the body.

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

Improperly installed pump mounting.
Tighten the power steering pump
attachment bolts.
Swishing Noise in the
Steering Pump
Damaged power steering pump flow control
valve.
Replace the power steering pump.
Whining Noise in the
Scores of the pressure plate and the vanes.
Replace the power steering pump.
Steering Pump
Scores of the pump shaft bearing
Replace the power steering pump.

6B –4 POWER STEERING PUMP
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D105C524
PUMP DRIVE BELT
Removal Procedure
1. Remove the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.
2. Remove the pump drive belt.

Loosen the rear bracket adjusting bolt (1).

Loosen the bolt (2).
D105C525

Loosen the front bracket adjusting bolts (3).

Push the pump forward (4).
18–22 Nm
20–24 Nm
20–24 Nm
D15C526A
Installation Procedure
1. Install the pump drive belt with the bolts.
Tighten

Tighten the front bracket adjusting bolt to 18–22
Nm (13–16 lb-ft) (1).

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (2).

Tighten the power steering pump bolt to 20–24
Nm (15–18 lb-ft) (3).
2. Install the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.

POWER STEERING PUMP 6B–5
DAEWOO M-150 BL2
D105C527
PUMP DRIVE PULLEY
Tools Required
DW310–020 Power Steering Pulley Remove Holder
Removal Procedure
1. Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Remove the steering pump pulley.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Fix the pulley using the power steering pulley re-
move holder DW310–020 (1).

Remove the pump drive pulley nut (2).
55–69 Nm
D15C528A
Installation Procedure
1. Install the pump drive pulley. Install the steering pump
pulley nut.
2. Install the pump drive belt.
3. Tighten the steering pump pulley nut using the power
steering pulley remove holder DW310–020.
Tighten
Tighten the steering pump pulley nuts to 55–69 Nm
(41–51 lb-ft).
4. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
D105C529
PUMP ASSEMBLY
Removal Procedure
1.Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Disconnect the pipe line from the pump.

Disconnect the supply line pipe hose (1).

Disconnect the pressure line pipe fitting (2).
D105C530
3. Remove the power steering pump.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Disconnect the power steering pressure switch
connector (1). Refer to Section 6A, Power Steering
Systems.

Remove the bolts (2).

6B –6 POWER STEERING PUMP
DAEWOO M-150 BL2
D105C531

Remove the bolt (3).
18–22 Nm
D15C532A
Installation Procedure
1. Install the power steering pump with the bolt.
Tighten
Tighten the bolt to 18–22 Nm (13–16 lb-ft).
2. Connect the power steering pressure switch connec-
tor. Refer to Section 6A, Power Steering System.
3. Install the pump drive belt. Refer to “Pump Drive Belt”
in this section.
20–24 Nm
20–24 Nm 21–35 Nm
D15C533A
4. Install the bolts.
Tighten

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (1).

Tighten the power steering bolt to 20–24 Nm
(15–18 lb-ft) (2).
5. Connect the pressure line pipe to the outlet connec-
tion on the steering pump.
Tighten
Tighten the pressure line pipe fitting to 21–35 Nm
(16–26 lb-ft) (3).
6. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
Notice: When adding fluid or making a complete fluid
change, always use DEXRON-II or DEXRON-III pow-
er steering fluid. Failure to use the proper fluid will cause
hose and seal damage and fluid leaks.
7. Refill the pump with new fluid and bleed the air from
the system. Refer to Section 6A, Bleeding the Power
Steering System.
8. Inspect for leaks. If leaks are found, correct the cause
of the leak and bleed the system.