run flat DAEWOO MATIZ 2003 Service Repair Manual

DAEWOO M-150 BL2
SECTION 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
Diagnostic Information and Procedures 2A-1. . . . .
General Diagnosis 2A-1. . . . . . . . . . . . . . . . . . . . . . . . . Wheel Bearing Diagnosis 2A-6. . . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires, and
the wheels involve several systems. Consider all sys-
tems when you diagnose a complaint. Some problems,
such as abnormal or excessive tire wear and scuffed
tires, may be the result of hard driving. Always road testthe vehicle first. If possible, do this road test with the
customer.
Proceed with the following preliminary checks. Correct
any substandard conditions.
Application Checks Correction
Preliminary Checks
Inspect the tires for improper pressure
and uneven wear.
Inflate the tires to the proper pressure.

Inspect the joint from the steering
column to the intermediate shaft for
loose connections or wear.

Inspect the joint from the intermediate
shaft to the steering gear for loose
connections or wear.
Tighten the coupling flange pinch
bolts.

Replace the intermediate shaft as
needed.

Inspect the front and the rear
suspension, the steering gear, and the
linkage for loose or damaged parts.
Tighten the front and the rear
suspension.

Tighten the steering gear mounting
bracket bolts.

Replace the front and the rear
suspension as needed.

Replace the steering gear as needed.

Replace the coupling flange as
needed.

Inspect for out–of–round tires.
Perform free runout test.

Match–mount the tires.

Inspect for out–of–balance tires, bent
wheels, and worn or loose wheel
bearings.
Balance the wheels.

Replace the wheels.

Replace the wheel bearings.

Check the power steering pump drive
belt tension.
Tighten the power steering pump drive
belt.

Inspect the power steering system.
Also, check the power steering fluid
level.
Repair any leaks.

Perform a power steering gear test.

Add power steering fluid.

2A–2 SUSPENSION DIAGNOSIS
DAEWOO M-150 BL2
Condition Probable Cause Correction
Car Lead/Pull
Mismatched or uneven tires.
Replace the tires.

A broken or a sagging coil spring.
Replace the coil spring.

A improperly radial tire lateral force.
Check the wheel alignment.

Switch the tire and wheel assemblies.

Replace the tires as needed.

The front–wheel alignment is
out–of–align.
Align the front wheels.

Off–center steering gear.
Reseat the pinion valve assembly.

Replace the pinion valve assembly as
needed.

Front–brake dragging.
Adjust the front brakes.
Abnormal or Excessive
Tire Wear
The front–wheel and rear–wheel
alignment is out–of–align.
Align the front and the rear wheels.

Excessive toe.
Adjust the toe.

A broken or a sagging coil spring.
Replace the coil spring.

Out–of–balance tires.
Balance the tires.

Worn strut dampeners.
Replace the strut dampeners.

A failure to rotate tires.
Rotate the tires.

Replace the tires as needed.

Overloaded vehicle.
Maintain the proper load weight.

Low tire inflation.
Inflate the tires to the proper pressure.
Scuffed Tires
Incorrect toe.
Adjust the toe.

A twisted or a bent suspension arm.
Replace the suspension arm.
Wheel Tramp
An out–of–balance tire or wheel.
Balance the tire or the wheel.

Improper strut dampener action.
Replace the strut dampeners.
Shimmy, Shake, or
An out–of–balance tire or wheel.
Balance the tire or the wheel.
Vibration
Excessive wheel hub runout.
Measure the hub flange runout.

Replace the hub as needed.

Excessive brake drum or brake rotor
imbalance.
Adjust the brakes.

Replace the brake rotor or the brake
drum as needed.

Worn tie rod ends.
Replace the tie rod ends.

Wheel trim imbalance.
Balance the wheel.

A worn ball joint.
Replace the control arm and ball joint
assembly.

Excessive wheel runout.
Measure the wheel runout.

Replace the wheel as needed.

Excessive loaded radial runout on the
tire and wheel assembly.
Match–mount the tire and wheel
assembly.

2E – 2 TIRES AND WHEELS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
TIRE
Tread
A part (that contacts) road surfaces directly is fixed on
the outside of carcass and breaker. It is a strong rubber
coat made of high anti–abrasion rubber. Its running per-
formance depends on is surface profile.
Breaker
A cord belt between tread and carcass prevents dam-
ages of inner code due to outer shock and vibration.
Carcass
This major part made by pilling code papers of strong
synthetic fiber forms a structure of tire. Since it main-
tains tire pressure and endures applied load and shock
to tire, it should have a high anti–fatigue characteristic.
Bead
A steel wire winding the ending part of carcass code,
coated with rubber film and wrapped with nylon cord pa-
pers. It fixes tire to a rim.
Tube
Tires used in mostly current vehicle are mostly tubeless
tires.
Side Wall
It is provided to improve the comfortable driving by pro-
tecting carcass and cushion movement.
Structure of Tubeless Tube
D16A001A
Nomenclature
D16A002A
175 Width (mm)

60Flatness ratio 60%
(Height/Width) ×100
175/60R13RRadial
77H13Rim diameter (= Tire I.D, Inch)
77Max. load index
HMax. speed symbol

TIRES AND WHEELS 2E–3
DAEWOO M-150 BL2
Hydroplaning
The condition of driving a vehicle fast on the road surface
covered with water can cause tires to fail to rotate with a
good contact on the surface, so results in remaining them
afloat. This is so–called hydroplaning. It causes brake
failure, lower tractive force, and losing the steering per-
formance so it is very vulnerable condition.
D16A005A
Standing Wave
During running the rotating tire repeats deformation and
restoring movement generated in tread. But when the
wheel rotating speed reaches high, the next deformation
applied to tire before restoring last deformation so the
trembling wave appears in the tread portion. The lower
the tire pressure the severe the trembling wave appears.
And during the high speed.
D106A004
REPLACEMENT TIRES
A Tire Performance Criteria (TPC) specification number
is molded in the sidewall near the tire size of all original
equipment tires. This specification number assures that
the tire meets performance standards for traction, en-
durance, dimensions, noise, handling and rolling resist-
ance. Usually a specific TPC number is assigned to
each tire size.Caution: Do not mix different types of tires on the
same vehicle such as radial, bias and bias-belted
tires except in emergencies, because vehicle han-
dling may be seriously affected and may result in
loss of control.
Caution: Do not change 145/70 R13 tires or 155/65
R13 tires for 175/60 R13 tires, because vehicle
hancling may be seriously affected and may result
in loss of control. If you change 145/70 R13 tires or
155/65 R13 tires for 175/60 R13 tires, you have to
change the steering gear assembly.
Use only replacement tires with the same size, load
range, and construction as the original. The use of any
other tire size or construction type may seriously affect
ride, handling, speedometer/odometer calibration, ve-
hicle ground clearance, and tire clearance to the body
and the chassis. This does not apply to the spare tire fur-
nished with the vehicle.
It is recommended that new tires be installed in pairs on
the same axle.
If it is necessary to replace only one tire, pair it with the
tire having the most tread to equalize the braking action.
Although they may appear different in tread design, tires
built by different manufacturers with identical TPC speci-
fications may be used on the same vehicle.
ALL SEASON TIRES
Most vehicles are now equipped with steel-belted all
season radial tires as standard equipment. These tires
qualify as snow tires, with a 37 percent higher average
rating for snow traction than the non-all season radial
tires previously used. Other performance areas, such as
wet traction, rolling resistance, tread life, and air reten-
tion, have also been improved. This was done by im-
provements in both tread design and tread compounds.
These tires are identified by an “M + S” molded in the tire
sidewall following the size number. The suffix “MS” is
also molded in the sidewall after the TPC specification
number.
The optional handling tires used on some vehicles are
not all season tires. These will not have the “MS” mark-
ing after the tire size or the TPC specification number.
TIRE LABEL
The tire label is permanently located on the rear face of
the driver’s door and should be referred to for tire infor-
mation. It lists the maximum vehicle load, the tire size
(including the spare tire), and the cold inflation pressure
(including the spare tire).
SPARE TIRE
This vehicle comes equipped with a full-sized spare tire
and wheel.

2E –4 TIRES AND WHEELS
DAEWOO M-150 BL2
WHEELS
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, leak air through welds,
have elongated bolt holes, or if the wheel bolts won’t
stay tight or are heavily rusted. Wheels with excessive
runout may cause vehicle vibration. Replacement
wheels must be equivalent to the original equipment
wheels in load capacity, diameter, rim width, offset, and
mounting configuration. A wheel of improper size or type
may affect wheel and bearing life, brake cooling,
speedometer/odometer calibration, vehicle ground
clearance, and tire clearance to the body and the chas-
sis.
INFLATION OF TIRES
The pressure recommended for any vehicle line is care-
fully calculated to give a satisfactory ride, handling,
tread life, and load-carrying capacity.
Tire pressure should be checked monthly or before any
extended trip. Check the tires when they are cold, after
the vehicle has sat for 3 hours or more or has been driv-
en less than 1 mile. Set the tire pressure to the specifi-
cations on the tire label located on the rear face of the
driver’s door. Tire inflation pressure is also given under
“Tire Size and Pressure Specifications” in this section.
Valve caps or extensions should be on the valves to
keep dust and water out.
Higher than recommended tire pressure can cause:

Hard ride

Tire bruising or damage

Rapid tread wear at the center of the tire
Lower than recommended pressure can cause:

Tire squeal on turns

Hard steering

Rapid and uneven wear on the edges of the tread

Tire rim bruises and rupture

Tire cord breakage

High tire temperatures
Unequal tire pressures on same axle can cause:

Uneven braking

Steering lead
Reduced handling

Swerve on acceleration

Torque steer
ROTATION TIRES
Front and rear tires perform different jobs and can wear
differently depending on the tires of road driven, driving
habit, etc.
The front tires will wear faster than the rear ones.
To avoid uneven wear of tires and to prolong tire life, in-
spect and rotate the tires every 5,000 km (3,100 miles).
After rotating the tires, adjust the tire inflation pressures
and be sure to check wheel nuts tightness.
D16A304A
WHEEL BALANCE
Balance is the easiest procedure to perform and should
be done first if the vibration occurs at high speeds, or if
the tires or the wheels are replaced.
When proceeding the wheel balancing procedure regard
the belows.
1. Do not use the wheel weight over two at the inboard
and the outboard flanges.
2. The total weight of the wheel weights should not ex-
ceed the 100 grams (3.5 ounces).
3. Blanching the assemblies with factory aluminum
wheels requires the use of special nylon–coated,
clip–on wheel weights.

4A –4 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DIAGNOSITIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily
braked, but turning, wheels will stop the vehicle in less
distance than locked brakes. More tire-to-road friction is
present with a heavily braked, turning tire than with a
sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:

Tires having unequal contact and grip of the road will
cause unequal braking. Tires must be equally in-
flated, and the tread pattern of the right and the left
tires must be approximately equal.

Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.

Misalignment of the wheels, particularly conditions of
excessive camber and caster, will cause the brakes
to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and the
shift lever in NEUTRAL. If the pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking. Perform a visual check to confirm any sus-
pected leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an
abnormally low level indicates a leak in the system. The
hydraulic system may be leaking either internally or ex-
ternally. Refer to the procedure below to check the mas-
ter cylinder. Also, the system may appear to pass this
test while still having a slight leak. If the fluid level is nor-
mal, check the vacuum booster pushrod length. If an in-
correct pushrod length is found, adjust or replace the
rod.Check the master cylinder using the following proce-
dure:

Check for a cracked master cylinder casting or brake
fluid leaking around the master cylinder. Leaks are in-
dicated only if there is at least one drop of fluid. A
damp condition is not abnormal.

Check for a binding pedal linkage and for an incorrect
pushrod length. If both of these parts are in satisfac-
tory condition, disassemble the master cylinder and
check for an elongated or swollen primary cylinder or
piston seals. If swollen seals are found, substandard
or contaminated brake fluid should be suspected. If
contaminated brake fluid is found, all the components
should be disassembled and cleaned, and all the rub-
ber components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, then the rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston seals on the
drum brake wheels.
If rubber deterioration is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep al-
cohol out of the system. Replace all the rubber parts in
the system, including the hoses. Also, when working on
the brake mechanisms, check for fluid on the linings. If
excessive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush the
master cylinder with brake fluid, refill the master cylin-
der, and bleed the system. Refer to “Manual Bleeding
the Brakes” in this section.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of the
outer cover, and for leaks or blisters. Inspect the hoses
for proper routing and mounting. A brake hose that rubs
on a suspension component will wear and eventually
fail. A light and a mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as neces-
sary.

FRONT DISC BRAKES 4D–5
DAEWOO M-150 BL2
LINING INSPECTION
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E, Tires
and Wheels.
3. Visually check the linings for minimum thickness and
wear.
4. Measure the thickness.
Important: The minimum thickness of the shoe and lin-
ing together is 8 mm (0.31 in.).
D107B301
5. Install the shoe and linings in axle sets only.
6. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
7. Lower the vehicle.
ROTOR INSPECTION
Thickness variation can be checked by measuring the
thickness of the rotor at four or more points around the
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the rotor.
If the thickness of the rotor is below 10 mm (0.40 in.),
replace the brake rotor.
During manufacturing, the brake rotor and the toler-
ances of the braking surface regarding flatness and lat-
eral runout are held very close. The maintenance of
close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
D107B302
In addition to these tolerances, the surface finish must
be held to a specified range. The control of the braking
surface finish is necessary to avoid pulls and erratic per-
formance and to extend lining life.
Using a commercially-available dial indicator, check lat-
eral runout as follows:
Notice: Permissible lateral runout is a maximum 0.05 mm
(0.002 in.). If lateral runout exceeds the specification,
ensure there is no dirt between the rotor and the hub and
that contact surfaces are smooth and free from burrs.
1. Position the transaxle in NEUTRAL.
2. Remove the rotor. Refer to “Rotor” in this section.
3. Fasten a dial indicator to the strut.
4. Set the gauge probe tip to approximately 10 mm
(0.4 in.) from the outer edge of the brake rotor, per-
pendicular to the disc and under slight preload.
5. Remove the dial indicator.
Important: Since accurate control of the rotor toler-
ances is necessary for proper performance of the disc
brakes, refinishing of the rotor should be done only with
precision equipment.
6. Refinish the rotor, if required, with precision equip-
ment. Discard the rotor if it fails to meet the above
specifications after refinishing.
7. Install the rotor. Refer to “Rotor” in this section.
D107B303

9I–6 WATERLEAKS
DAEWOO M-150 BL2
D109A504
6. Prime the trimmed area with the primer.
7. Using a sharp knife, trim off the uneven edges of the
adhesive material around the leak 75 to 100 mm (3 to
4 inches) on both sides of the leak.
D109A505
8. Allow the primer to dry for 5 minutes.
9. Apply the adhesive over the leak and for a distance
of 75 to 100 mm (3 to 4 inches) on both sides of the
leak.
D109A506
10. Immediately after applying the adhesive, use a flat
stick or a similar tool to work the adhesive into the
leak area and into the joint between the original ma-
terial and the vehicle body in order to ensure a wa-
tertight seal.
11. Spray warm or hot water over the repaired area in
order to determine if the leak was repaired. Do not
run a heavy stream of water directly on the freshly
applied adhesive.
12. Install the trim strip lace if it was removed.
13. Install the garnish molding if it was removed.
14. Install the reveal molding.
D109A304
Important: After the completion of any waterleak repair,
re–test the area using the watertest stands. Do not use
localized testing procedures on the newly–repaired
areas, as the repair material may dislodge under abnor-
mal pressure.