steering DAEWOO MATIZ 2003 Service Repair Manual

SECTION INDEX
FRONT MATTER
0A
GENERAL INFORMATION
0B
ENGINE1
SERVICE
MATIZ
FOREWORD
This manual includes procedure for maintenance,
adjustment, service operation and removal and
installation of components.
All information, illustrations and specifications con-
tained in this manual are based on the latest prod-
uct information available at the time of manual ap-
proval.
The right is reserved to make changes at any time
without notice.
DAEWOO MOTOR CO., LTD.
INCHON, KOREA
MANUAL
SUSPENSION
2
DRIVELINE/AXLE 3
BRAKES
4
TRANSAXLE
5
STEERING
6
RESTRAINTS
8
BODY AND ACCESSORIES9 7 HVAC
(HEATING, VENTILATION,
AND AIR CONDITIONING)
(MY2003)

STEERING
CONTENTS
SECTION 6A POWER STEERING SYSTEM
SECTION 6B POWER STEERING PUMP
SECTION 6C POWER STEERING GEAR
SECTION 6D MANUAL STEERING GEAR
SECTION 6E STEERING WHEEL AND COLUMN

GENERAL ENGINE INFORMATION 1A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
ENGINE COMPARTMENT (TYPICAL)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
D102A401
1 Power Steering Oil Reservoir
2 Coolant Reservoir
3 Canister
4 Canister Solenoid
5 Manifold Absolute Pressure (MAP) Sensor
6 Intake Manifold
7 Ignition Coil
8 Idle Air Control (IAC) Valve
9 Throttle Position (TP) Sensor
10 Throttle Body
11 Brake Fluid Reservoir
12 Wiper Motor13 Battery
14 Fuse Box
15 Air Cleaner Housing
16 Resonator
17 PCV Hose
18 Distributor
19 Exhaust Manifold
20 Snorkel
21 Engine
22 Washer Fluid Reservoir
23 Oil Level Gauge
24 Oil Filler Cap

1A–4 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
ENGINE COMPARTMENT (EURO III)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
MAA1A010
1 Power Steering Oil Reservoir
2 Coolant Reservoir
3 Canister Purge Solenoid
4 Manifold Absolute Pressure (MAP) Sensor
5 Intake Manifold
6 Throttle Position (TP) Sensor
7 Throttle Body
8 Idle Air Control (IAC) Valve
9 Brake Fluid Reservoir
10 Wiper Motor11 Battery
12 Fuse Box
13 Air Cleaner Housing
14 Resonator
15 Electronic Ignition System Ignition Coil
16 Exhaust Manifold
17 Snorkel
18 Engine
20 Washer Fluid Reservoir
19 Oil Level Gauge
21 Oil Filler Cap

GENERAL ENGINE INFORMATION 1A–11
DAEWOO M-150 BL2
CHECKING ENGINE FLUID LEVEL
Check the engine fluid level or condition. If needed, refill
or replace the oil.
Check the engine oil level within engine normal operat-
ing temperature as follows ;
1. After stopping the engine, wait for a few minutes to
accumulate oil into the oil pan.
2. After pulling out the oil level gauge (a), check the oil
level.
3. Clean the oil level gauge and insert the gauge into
guide.
4. After pulling out the oil level gauge again, recheck the
oil level and insert the gauge into guide again.
Important: Oil level should be between “MIN” mark and
“MAX” mark.
5. If oil level is below the “MIN” mark, refill engine oil as
much as the demanded quantify.
Important: If checking oil level under the engine cold
condition, oil is not accumulated into oil pan quickly and
correct level checking can not be performed. Therefore,
wait until temperature reaches the normal operating
condition and check the engine oil level.
D102A301
CHANGING ENGINE OIL OR OIL
FILTER
Tools Required
09915–47341 Oil Filter Wrench.
When checking engine oil level or condition, if needed,
change engine oil (including the filter) as follows ;
1. After stopping the engine, wait for a few minutes to
accumulate oil into the oil pan.
2. Remove the oil filter cap (b).3. Remove the oil drain plug (c) and draw oil off.
D102A302
4. After drawing oil completely, tighten the oil drain plug
to 30–40 Nm (22–30 lb-ft).
5. Replace the oil filter using the oil filter wrench
09915–47341 (d).

Remove the air cleaner/resonator/snorkel as-
sembly.

After removing the bolts, remove the heat
shield.

Loosen the power steering pump cap screw and
pull the power steering hose into the front.

Remove the oil filter.
Important: Whenever changing engine oil, replace the
oil filter. When replacing new oil filter, apply engine oil on
oil filter sealing.
D102A303

1A–12 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
CHECKING ENGINE TIMING BELT
After checking the timing belt for looseness, crack, wear
or tension, replace the belt if necessary.
CHECKING ACCESSORY BELT
After checking the alternator belt (e), air conditioning/
power steering belt (f), air conditioning belt (g), power
steering belt (h), for looseness, crack, wear or tension,
replace the belt if necessary.
D102A304
CHECKING SPARK PLUG
After checking the spark plug for bad clearance, exces-
sive carbon deposit, worn electrode or damaged insula-
tor, replace the new one if necessary.
Remove and check the spark plug as follows ;
1. Pull the high tension cable cap portion (i), and discon-
nect the high tension cable from the spark plug.
If pulling the high tension cable (j), circuit could be
disconnected. Therefore, the cap portion should be
used.
D102A305
2. Remove the spark plugs from cylinder head using a
wrench.
3. Measure the spark plug clearance (k) with the filler
gauge. If measured value is not within the specified
value, adjust the grounding electrode.
When installing new spark plug, check the clearance
for equality and install it.
D102A306

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.

SUSPENSION DIAGNOSIS 2A–3
DAEWOO M-150 BL2
Condition Probable Cause Correction
Hard Steering (Manual)
A lack of lubrication of the ball joints,
the tie rods and the steering gear.
Lubricate the ball joints, the tie rods,
and the steering gear.

Replace the control arm and ball joint
assembly, the tie rods, and the
steering gear as needed.

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

Steering gear adjustment is
out–of–adjustment.
Adjust the steering gear.
Hard Steering (Power)
The steering preload adjustment is
out–of–adjustment.
Perform a rack bearing preload
on–vehicle adjustment.

The leaked hydraulic system.
Test the power steering system
pressure with a gauge.

Replace the seals and the hoses as
needed.

A loose steering gear mounting.
Tighten the steering gear mounting
bracket bolts.
Too Much Play in
Steering.
Worn or loose wheel bearings.
Tighten the drive axle nut.

Replace the wheel bearing as needed.

A loose steering gear mounting.
Tighten the steering gear mounting
bracket bolts.

The steering preload adjustment is
out–of–adjustment.
Perform a rack bearing preload
on–vehicle adjustment.

Loose connections or wear of the joint
from the steering column to the
intermediate shaft.

Loose connections or wear of the joint
from the intermediate shaft to the
steering gear.
Tighten the coupling pinch bolts.

Replace the intermediate shaft as
needed.
Poor Returnability
Binding in the ball joints.
Replace the control arm and ball joint
assembly.

Binding in the steering column.
Lubricate the steering column.

Replace the steering column as
needed.

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

The steering preload adjustment is
out–of–adjustment.
Perform a rack bearing preload
on–vehicle adjustment.

A sticking valve.
Lubricate the pinion valve assembly.

Replace the pinion valve assembly as
needed.

Binding in the coupling on the
intermediate shaft.
Replace the intermediate shaft.
Abnormal Noise, Front
Suspension
Damaged suspension components.
Replace the damaged suspension
components.

Worn control arm bushings or tie rod
ends.
Replace the control arm bushings or
the tie rods.

2A–4 SUSPENSION DIAGNOSIS
DAEWOO M-150 BL2
Condition Probable Cause Correction
Abnormal Noise, Front
A loose stabilizer shaft link.
Tighten the stabilizer shaft link.
Suspension
Loose wheel nuts.
Tighten the wheel nuts.

Loose suspension bolts or nuts.
Tighten the suspension bolts or the
nuts.

Loose wheel covers.
Tighten the wheel covers.

Worn strut dampeners or strut
mountings.
Replace the strut dampeners.

Tighten the strut mounting nuts.

An improperly positioned strut spring.
Adjust the strut spring to the proper
position.
Wander or Poor
Mismatched or uneven tires.
Replace the tires.
Steering Ability
Worn strut dampeners.
Replace the strut dampeners.

A loose stabilizer shaft link.
Tighten the stabilizer shaft link.

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

The steering preload adjustment is
out–of–adjustment.
Perform a rack bearing preload
on–vehicle adjustment.

The front–wheel and the rear–wheel
alignment are out–of–align.
Align the front and the rear end
wheels.
Erratic Steering when
Worn or loose wheel bearings.
Replace the wheel bearings.
Braking
A broken or a sagging coil spring.
Replace the coil spring.

A leaking caliper.
Replace the caliper.

Warped rotors.
Replace the rotors.

An incorrect or an uneven caster.
If the caster is beyond specifications,
check the frame and repair it as
needed.
Low or Uneven Trim
A broken or a sagging coil spring.
Replace the coil spring.
Height
An overloaded vehicle.
Maintain the proper load weight.

An incorrect or weak coil spring.
Replace the coil spring.
Ride Too Soft
Worn strut dampeners.
Replace the strut dampeners.

A broken or a sagging coil spring.
Replace the coil spring.
Ride Too Harsh
Incorrect strut dampeners.
Replace the strut dampeners.

An incorrect coil spring.
Replace the coil spring.
Body Leans or Sways
A loose stabilizer shaft link.
Tighten the stabilizer shaft link.
in Corners
Worn strut dampeners or strut
mountings.
Replace the strut dampeners.

Tighten the strut assembly mounting
nuts.

an overloaded vehicle.
Maintain the proper load weight.

A broken or a sagging coil spring.
Replace the coil spring.
Suspension Bottoms
Worn strut dampeners.
Replace the strut dampeners.

An overloaded vehicle.
Maintain the proper load weight.

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