Oil DAEWOO MATIZ 2003 Service Repair Manual

FIVE-SPEED MANUAL TRANSAXLE 5B–31
DAEWOO M-150 BL2
D13B727A
Tighten
Tighten the bolt to 8–12 Nm (71–106 lb-in).
b. Case cap retaining bolt.

Install the differential left side oil seal using the oil,
seal installer KM519.
D103B728
3. Install the differential assembly to the right side of
transaxle case.
a. Differential assembly.

When the differential ring gear surface is lower
than the right side of transaxle case surface, it is
installed correctly.
D103B729
4. Install the low and the high speed shift shaft assem-
bly to the gear unit.
5. Install the gear unit.

Push the gear unit by matching it with the input and
the counter shaft hole (1).
Notice: Be careful not to damage teeth of the counter
shaft pinion and the differential ring gear.
D13B730A
6. Install the fifth–reverse gear shift shaft.
7. Install the reverse idle gear shaft assembly and the
reverse gear shift lever.

Install the reverse idle gear shaft assembly (1).
Important: Match the marking of the reverse idle gear
shaft bolt hole with the protrusion of the transaxle case
(Right Side).

Install the reverse gear shift lever (2).
Tighten
Tighten the bolts to 18–28 Nm (13–21 lb-ft).

5B–34 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B737A
15. Install the counter shaft fifth gear nut.

Shift the shift yoke using a screwdriver to engage
the first–gear and the third–gear or the second–
gear and the fourth–gear (1).
Tighten
Tighten the fifth gear nut to 60–80 Nm (44–59 lb-ft).

Caulk the nut using a chisel and a hammer (2).
D103B710
16. Install the input shaft fifth gear bearing and the fifth
gear / synchronizer ring.

Insert the bearing into the input shaft.

Install the fifth gear, wave spring and synchroniz-
er ring matching synchronizer’s oil groove and in-
put shaft punched mark (1).
D103B738
17. Install the fifth gear synchronizer hub assembly.

Install the synchronizer springs to hub (1).

Install the synchronizer key (2).
Important: In case of assembling synchronizer sleeve
and hub, let A=B.

Position the longer boss side of hub toward inner
side (3).

Position the chamfered spline of sleeve toward
inner side and install the hub to the sleeve (4).
D103B739
18. Install the fifth gear fork to the synchronizer hub as-
sembly.
19. Install the fifth gear fork and the synchronizer hub
assembly to the input shaft.
Important: Position the longer boss side of hub toward
inner side and match the synchronizer key and the hub
groove with the input shaft punched mark.

FIVE-SPEED MANUAL TRANSAXLE 5B–39
DAEWOO M-150 BL2
D103B755
3. Inspecting key slot width of synchronizer ring.

Measure key slot width of synchronizer ring. Re-
place if it exceeds limit.
Unit : mm (in.)
Key Slot Width Standard Limit
1st gear8.2 (0.323)8.6 (0.339)
2nd, 3rd, 4th gear9.6 (0.378)10.0 (0.394)
5th gear9.4 (0.370)9.8 (0.386)
D103B756
4. Inspecting wear of synchronizer ring.

Check for worn or damaged synchronizer ring
teeth. Replace it if necessary.
D103B757
5. Inspecting synchronizer key and spring.

Check for worn synchronizer key (1).

Check for weak, damaged or broken spring (2).
D103B758
Assembly Procedure
1. Install the third gear bearing, the third gear / synchro-
nizer ring.
a. Third gear / synchronizer ring.
b. Third gear bearing.
Important: Coat the inner parts; gear, bearing, oil seal
etc. with gear fluid.

5B–44 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B773
Assembly Procedure
1. Install the related counter shaft first gear.

Install the first gear bearing (1).

Install the first gear (2).

Install the first gear synchronizer ring (3)
Important: Coat the inner parts; gear, bearing and oil
seal etc. with gear fluid.
Important: Be careful there is the difference of key
groove width between the first synchronizer ring and the
second synchronizer ring.
D103B774A
Unit : mm (in.)




First synchronizer ring (A)
: 8.2 (0.323)


Key Groove Width
Second synchronizer ring
(B) : 9.6 (0.378)
D103B775
2. Assemble the first–second synchronizer hub assem-
bly.

Install the synchronizer springs to hub.

Install the synchronizer keys to hub.
Important: Let (A)=(B) when installing the keys.

Install the hub to the sleeve.
a. Sleeve.
b. Hub.
D103B776
3. Install the first–second synchronizer hub assembly.

Insert the hub assembly into the counter shaft us-
ing the gear, bearing installer DW09940–53111,
the gear bearing remover/installer KM466–A and a
hammer (1).
Important: Position the synchronizer key to the first
gear synchronizer ring groove.

FIVE-SPEED MANUAL TRANSAXLE 5B–53
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
5th/Reverse Gear Shift Shaft Bolt10 – 167 – 12–
Back Up Light Switch Nut15 – 1811 – 13–
Counter Shaft 5th Gear Nut60 – 8044 – 59–
Crankshaft Position Sensor Bolt5 – 8–44 – 70
Differential Ring Gear Bolt80 – 10059 – 74–
Engine Mounting Front Bracket Bolt
(Cylinder Block Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolt
(Crossmember Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolts
(Crossmember Side)45 – 5533 – 41–
Engine Mounting Front Damping Bush Bolt/Nut
(Bracket Side)68 – 8351 – 61–
Front Exhaust Pipe Nut
(Exhaust Manifold Side/Muffler Side)25 – 3518 – 25–
Gear Shift Control Case Bolt18 – 2813 – 21–
Gear Shift Lever Bolt4 – 7–35 – 62
High Speed Shift Shaft Bolt10 – 167 – 12–
Low Speed Shift Shaft Bolt10 – 167 – 12–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–
Radiator Lower Hose Bracket Bolts8 – 15–70 – 132
Reverse Idle Gear Shaft Bolt18 – 2813 – 21–
Reverse Shift Lever Bolt18 – 2813 – 21–
Select Cable Nut(Shift Lever Side)8 – 12–71 – 106
Select Lever Bolt18 – 2813 – 21–
Side Cover Plate Screw6 – 7–53 – 62
Shift Guide Bolt18 – 2813 – 21–
Shift Interlock Bolt18 – 2813 – 21–
Side Cover Bolt8 – 12–71 – 106
Speedometer Driven Gear Bolt4 – 7–35 – 62
Starter Motor Bolt18 – 2813 – 21–
Transaxle Case Bolt15 – 2211 – 16–
Transaxle Case(left) Cap Bolt8 – 12–71 – 106
Transaxle Lower Bolt and Nut(Engine Side)55 – 6541 – 48–
Transaxle Mounting Bolt(Body Side)45 – 5533 – 41–
Transaxle Mounting Bolt and Nut(Transaxle Side)55 – 6541 – 48–
Transaxle Upper Bolt(Engine Side)55 – 6541 – 48–
Transaxle Under Cover Bolt35 – 5525 – 41–

FIVE-SPEED MANUAL TRANSAXLE 5B–55
DAEWOO M-150 BL2
SPECIAL TOOLS TABLE (Cont’d)
D13B112A
DW220–020A–01
Differential Bearing
Puller
D13B113A
DW220–020A–02
Differential Bearing
Plate Adapter
D13B114A
DW220–020A–03
Differential Bearing
Plate Adapter
D103B102
DW220–031
Transaxle Remove/
Install Support
D103B108
KM466–A
Gear, Bearing Remover
/ Installer
D103B111
KM519
Oil Seal Installer

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–7
DAEWOO M-150 BL2
D13C5031
4. Remove the transaxle input shaft bearing using the
input shaft bearing remover 09917–58010, the fly-
wheel holder 09924–17810 and a spanner.
D13C5041
Inspection Procedure – Pressure Plate
and Clutch Disc
1. Pressure plate inspection .

Check the weak and damaged diaphragm spring
(1).

Check the polluted face by the oil, grease (2).
D103C505
2. Clutch disc inspection

Measure rivet head depth from clutch disc surface
and replace if below limit.
Unit : mm (in.)
Standard Limit
Rivet Head Depth1.2 (0.047)0.5 (0.02)

Replace the clutch disc if clutch disc surface is
contaminated or clutch disc rivets are loosen.
D103C506
3. Clutch disc runout in rotational direction inspection.

Measure runout in rotational direction and replace
if runout exceeds limit.
Unit : mm (in.)


Disc Runout Limit in Rotational
Direction (Periphery)
0.7 (0.028)

6B –8 POWER STEERING PUMP
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Description
Lubricant

Power Steering Fluid DEXRON-II, DEXRON-III
Capacity

1.0 Liter (1.056 qt)
Type

Vane
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Power Steering Pump Bolt 20 – 24 15 – 18 –
Power Steering Pump Front Bracket Bolt 20 – 24 15 – 18 –
Power Steering Pump Front Bracket Adjusting Bolt 18 – 22 13 – 16 –
Power Steering Pump Rear Bracket Upper Bolt 35 – 45 26 – 33 –
Power Steering Pump Rear Bracket Lower Bolt 20 – 24 15 – 18 –
Power Steering Pump Rear Bracket Adjusting Bolt20 – 2415 – 18–
Power Steering Pump Pulley Nut55 – 6941– 51–
Power Steering Oil Pressure Line Fitting21 – 3516 – 26–

POWER STEERING GEAR 6C–13
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Power Steering FluidPower Steering Fluid DEXRON-II or DEXRON-III
Capacity1.0 L (1.056 qt)
TypeRack and Pinion
Overall Gear Ratio15.7 : 1
Power Steering Angle144, 155Inside39.5± 2
TireOutside33.5± 2
175 TireInside34.9± 2
Outside30.5± 2
GreaseRackPOLYUREAS
Ball JointSYNTHETICS OILS & LI SOAPS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Power Steering Gear Bracket Bolt50–5536–41–
Power Steering Gear Pinion Nut40–5030–36–
Power Steering Gear Pinion Dust Cover45–5533–41–
Power Steering Gear Pressure Line Fitting25–3518–25–
Power Steering Oil Pressure Pipe Fitting (Gear Side)21–3516–25–
Power Steering Gear Ajuster PlugRefer to “DIAGNOSIS” in this section.