boot DAEWOO MATIZ 2003 Service Repair Manual

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.

MANUAL TRANSAXLE DRIVE AXLE 3B–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
DRIVE AXLE ASSEMBLY
D104B401
1. Outer Joint (Rzeppa)
2. Outer Large Boot Clamp
3. Outer Boot
4. Outer Small Boot Clamp
5. Drive Axle Shaft6. Inner Small Boot Clamp
7. Inner Boot
8. Inner Large Boot Clamp
9. Inner Joint (Tripot)
10. Inner Joint Housing

3B –4 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
Condition Probable Cause Correction
Noise
Bent drive axle shaft.
Replace drive axle.





Worn the spline of drive axle shaft or joint
shaft.


Replace drive axle.

Worn joint by grease leakage.
Replace drive axle.
Steering Wheel
Bent drive axle shaft.
Replace drive axle.


Vibration


Worn the spline of drive axle shaft or joint
shaft.


Replace drive axle.
Car Lead / Pull
Worn joint by grease leakage.
Replace drive axle.
Boot Leak
Poor assembly of boot clamp.
Replace boot clamp.

Torn boot.
Replace Boot.

3B –6 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
D104B502
7. Pull the drive axle shaft (1) from the wheel hub.
Important: Support the unfastened end of the drive
axle. Do not allow the drive axle to dangle freely from the
transaxle for any length of time after it has been re-
moved from the wheel hub.
D104B503
8. Remove the drive axle from the transaxle.
Insert a flathead screwdriver between the trans-
axle case and the drive axle joint case (1).
Remove the drive axle (2).
Important: Cap the transaxle drive opening after the
drive axle has been removed to keep any contamination
out.
D104B504
Inspection Procedure
1. Inspect for worn or damaged spline of drive axle (1).
2. Inspect for a leaking boot (2).
3. Inspect for a bent shaft (3).
D14B502A
Installation Procedure
1. Clean the transaxle seal.
2. Install the drive axle into the transaxle.
3. Install the wheel hub onto the drive axle shaft.
4. Mount the knuckle onto the control arm ball joint.

MANUAL TRANSAXLE DRIVE AXLE 3B–9
DAEWOO M-150 BL2
UNIT REPAIR
D104B701
INNER JOINT (TRANSAXLE SIDE)
Tool Required
J–35566 Boot Clamp Pliers
Disassembly Procedure
1. Remove the drive axle. Refer to “Drive Axle Assem-
bly” in this section.
2. Remove the clamps on the joint boot.
Remove the boot clamp (large) using the boot
clamp pliers J–35566 (1).
Remove the boot clamp (small) (2).
D104B702
3. Remove the joint housing from boot.
a. Boot.
b. Joint housing.
D104B703
4. Degrease the joint assembly.
5. Remove the tripot joint.
Remove the circlip (1).
Remove the tripot joint (2).

3B –10 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
D104B704
6. Remove the drive axle shaft boot.
D104B705
Assembly Procedure
1. Install in the reverse order of removal.
2. Fill the joint housing with recommended grease when
installing.
Capacity 90–100 g (3.2–3.5 ounces)
Notice: Always use the recommended grease. If not,
joint and boot can be damaged.
Important: Always use new clamps.
Inspection Procedure
1. Inspect the operation of joint.
2. Inspect for a leaking boot through the clamp side.
D104B706
OUTER JOINT (WHEEL SIDE)
Disassembly Procedure
1. Remove the drive axle. Refer to “Drive Axle Assem-
bly” in this section.
2. Remove the clamps on the joint boot.
Remove the boot clamps (1,2).
D104B707
3. Degrease the joint assembly.
4. Remove the joint assembly.
Widen the circlip (1).
Remove the joint assembly while widening the cir-
clip (2).

MANUAL TRANSAXLE DRIVE AXLE 3B–11
DAEWOO M-150 BL2
D104B704
5. Remove the drive axle shaft boot.
D104B708
Assembly Procedure
1. Install in the reverse order of removal.
2. Install the joint assembly.
Pre–install the joint assembly by pushing to the
drive axle shaft to widen the circlip.
Keep the circlip widened (1).
Push the joint assembly to the drive axle shaft (2).
D104B709
3. Fill the joint housing with recommended grease when
installing.
Capacity 80–90 g (2.8–3.2 ounces)
Notice: Always use the recommended grease. If not,
joint and boot can be damaged.
Important: Always use new clamps.
D104B710
Inspection Procedure
1. Inspect the operation of joint.
2. Inspect for a leaking boot through the clamp side.
Important: Do not disassemble the outer joint assem-
bly. Parts are match fit and can not be serviced sepa-
rately. Improper reassembly will adversely affect both
performance and safety.

MANUAL TRANSAXLE DRIVE AXLE 3B–13
DAEWOO M-150 BL2
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
D104B101
KM–507–B
Tie Rod End
Joint Remover
D105B101
J–35566
Boot Clamp Pliers

HYDRAULIC BRAKES 4A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
BRAKE SYSTEM (NON–ABS)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
MAB4A001
1. Power Booster
2. Power Booster Boot
3. Cotter Pin
4. Clevis
5. Clevis Pin
6. Packing
7. Spacer
8. Master Cylinder Assembly
9. Fluid Reservoir Assembly
10. Reservoir Cap
11. Reservoir
12. Grommet Seal
13. Master Cylinder
14. Proportioning Valve
15. Stoplamp Switch
16. Brake Pedal Assembly
17. Clutch Pedal Spring18. Pedal Bracket Assembly
19. Clutch Pedal Pad
20. Clutch Pedal
21. Cushion
22. Bushing
23. Retaining Ring
24. Spring
25. Brake Pedal Pad
26. Brake Pedal
27. Brake Pedal Spring
28. Accelator Pedal Pad
29. Accelator Pedal
30. Rear Drum Brake Hose
31. E Ring
32. Front Disc Brake Hose
33. Brake Hose Coupling Bolt
34. Plain Washer

4B –8 MASTER CYLINDER
DAEWOO M-150 BL2
UNIT REPAIR
D24B001
MASTER CYLINDER
(ABS Type Master Cylinder is Shown,
Non–ABS Type Master Cylinder is Similar)
Disassembly Procedure
1. Remove the master cylinder. Refer to “Master Cylin-
der Assembly” in this section.
2. Remove the brake fluid reservoir. Refer to “Brake
Fluid Reservoir” in this section.
3. Remove the reservoir seals (1).
4. Remove the washer (2).
5. Remove the stop pin (3).
D24B002
6. Remove the boot (1).
7. Remove the retaining ring (2).
Notice: When removing the retaining ring, avoid dam-
aging the piston or the cylinder wall.
8. Remove the primary piston (3).
9. Carefully remove the secondary piston assembly
and the spring from the master cylinder bore (4).
D24B003
Assembly Procedure
1. Install the secondary piston assembly .
2. Install the stop pin.
3. Install the primary piston.
4. Install the retaining ring.
5. Install the boot.
6. Install the washer.
7. Install the reservoir seals.
8. Install the brake fluid reservoir. Refer to “Brake Fluid
Reservoir” in this section.
9. Install the master cylinder. Refer to “Master Cylinder
Assembly” in this section.
10. Raise and suitably support the vehicle.
11. Bleed the braking system. Refer to Section 4A, Hy-
draulic Brakes.
12. Lower the vehicle.