service DAEWOO MATIZ 2003 Service Repair Manual

9G –4 INTERIOR TRIM
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D109E532
FRONT DOOR TRIM PANEL
(STANDARD)
Tool Required
KM 475–B Trim Remover.
Removal Procedure
1. Remove the door pull from the front door.

Remove the screws (1).

Remove the door pull (2).
D109E533
2. Remove the inside door handle.

Remove the screw (1).

Disconnect the inside door handle rod (2).

Pry off the inside door handle (3).
D109E534
3. Remove the window regulator handle from the front
door.

Using a cloth, pull out the clip (1).

Remove the regulator handle (2).

DAEWOO M-150 BL2
SECTION 9H
SEATS
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.
TABLE OF CONTENTS
Description and Operation 9H-2. . . . . . . . . . . . . . . . . .
Seats 9H-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 9H-3. . . . . . . . . . . . . . . . . . . . . . . .
Front Seat 9H-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Seat 9H-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 9H-5. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9H-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Seats 9H-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Restraint 9H-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Seatback 9H-6. . . . . . . . . . . . . . . . . . . . . . . . . . . Front Seat Cushion 9H-7. . . . . . . . . . . . . . . . . . . . . . . .
Front Seats Guide Rail 9H-9. . . . . . . . . . . . . . . . . . . .
Front Seat Cushion Frame 9H-9. . . . . . . . . . . . . . . . . .
Rear Seatback 9H-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Seat Cushion 9H-11. . . . . . . . . . . . . . . . . . . . . . .
Rear Seatback Latch 9H-11. . . . . . . . . . . . . . . . . . . . .
Rear Seatback Hinge 9H-12. . . . . . . . . . . . . . . . . . . . .
Specifications 9H-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 9H-13. . . . . . . . . .

SEATS 9H–5
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D109B528
FRONT SEATS
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the front seat.

Remove the bolts (1).

Disconnect the seat belt warning lamp connector
(2).

Remove the seat (3).
23–28 Nm
D19B529A
Installation Procedure
1. Connect the seat belt warning lamp connector.
2. Install the front seat with the bolts.
Tighten
Tighten the seat bolt to 23–28 Nm (17–21 lb-ft).
a. Seat bolt.
3. Connect the negative battery cable.
D109B530
HEAD RESTRAINT
Removal Procedure
1. Pull the head restraint up to the stop position.
2. Insert a small flathead screwdriver in the notch in the
left guide sleeve and pull up the head restraint by
pushing the head restraint left.

DAEWOO M-150 BL2
SECTION 9I
WATERLEAKS
TABLE OF CONTENTS
Diagnostic Information and Procedures 9I-2. . . . . .
Waterleak Diagnosis 9I-2. . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 9I-5. . . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9I-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Waterleak Repair 9I-5. . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications 9I-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Materials for
Waterleak Repairs 9I-7. . . . . . . . . . . . . . . . . . . . . . . .
Watertest Stand Specifications 9I-7. . . . . . . . . . . . . .

WATERLEAKS 9I–5
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D109A501
D109A502
WATE R LE A K RE PA IR
Some waterleaks around the glass can be repaired with-
out removing the glass.
Important: This type of repair may be used only for ure-
thane–installed glass.
1 Remove the reveal molding in the area of the leak. It
may be necessary to remove the garnish molding or
the trim strip lace in order to locate the leak.
2. While spraying water over leak area, carefully push
the glass outward in order to determine the size of the
leak.
3. Mark the location of the leak.
4. Use water to clean any dirt frame the area. Dry the
area with an air hose.
D109A503
5. Using a sharp knife, trim off the uneven edges of the
adhesive caulking material around the leak for a dis-
tance of 75 to 100 mm (3 to 4 inches) on both side of
the leak.

DAEWOO M-150 BL2
SECTION 9J
WINDNOISE
TABLE OF CONTENTS
Diagnostic Information and Procedures 9J-1. . . . .
Windnoise Diagnosis 9J-1. . . . . . . . . . . . . . . . . . . . . . . Repair Instructions 9J-2. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9J-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Windnoise Repair 9J-2. . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
WINDNOISE DIAGNOSIS
Caution: An assistant should drive the vehicle while
the technician checks for the location of the wind-
noise, in order to prevent personal injury or vehicle
damage.
A test drive in the vehicle is necessary to accurately de-
termine the location of the windnoise. Often there is a
primary leak and secondary leaks. Failure to repair all
leaks will only reduce the windnoise, not eliminate it.
During the test drive the technician should bring the fol-
lowing items to aid in determining the location of the
windnoise.

A mechanics stethoscope or vacuum hose

Masking tape

Strip caulk

A china marking pencil

A screwdriver
Perform the following steps in order to conduct the road
test:
1. Choose a route that includes smooth straight streets
that run in all four directions (north, south, east, and
west).
2. Choose streets with little traffic or noise that would in-
terfere with the test.
3. Drive the vehicle at the speeds at which the noise
was noticed by the customer or until the noise is pro-
duced. Do not exceed legal speed limits.
4. The windnoise is external if any of the following condi-
tions occur:

The windnoise is caused by the wind.

The windnoise can be heard with the door glass
lowered and while the vehicle is being driven.

The windnoise is eliminated when tape is placed
over various moldings and gaps.5. Internal windnoise is air leaving the vehicle and
should be repaired in the following manner.

In order to locate the leak, tape off the body lock
pillar pressure relief valves. This will cause air
pressure to build up inside the vehicle and en-
hance the windnoise.

Use a stethoscope or a vacuum hose to locate the
leak.

Temporarily repair the leak with masking tape.
D109A307

Continue testing in order to determine if the noise
has been eliminated or if other leaks exist.

When all leaks have been found, return to the shop
and make permanent repairs with the proper align-
ment techniques and sealing materials.

9J – 2 WINDNOISE
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
WINDNOISE REPAIR
Windnoise leak repairs are very similar to waterleak re-
pairs. Refer to Section 9I, Waterleaks. The actual proce-
dure depends on the type of seal being repaired. Leaks
around the door opening weatherstrips do not always in-
dicate a faulty weatherstrip. A door or window adjust-
ment may resolve the condition. Refer to Section 9L,
Glass and Mirrors.

DAEWOO M-150 BL2
SECTION 9K
SQUEAKS AND RATTLES
TABLE OF CONTENTS
Diagnostic Information and Procedures 9K-1. . . . .
Squeak and Rattle Diagnosis 9K-1. . . . . . . . . . . . . . . Repair Instructions 9K-3. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9K-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Squeak and Rattle Repair 9K-3. . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
SQUEAK AND RATTLE DIAGNOSIS
ConditionProbable CauseCorrection
Rattle Coming From the
Side Rail
Improperly connected brake
lines.
Tap lightly on the brake lines and listen for a
rattle.

Install plastic tie straps to secure the brake
lines tightly together.
Rattle Under Vehicle at
Higher RPM
The heat shield contacts with
the underbody.
Raise the vehicle and perform a visual
inspection.

Bend the heat shield slightly to gain
clearance from the underbody.
Squeak From the Front
of the Vehicle in Cold
Weather
Poor front stabilizer shaft
insulators taping.
While the vehicle is cold, perform a test drive
and achieve full front suspension travel by
driving through a dip in the road.

Remove the insulators and wrap teflon tape
around the stabilizer shaft. Reinstall the
insulators over the tape.
Thump From Rear of
Vehicle on Bumps
Improperly secured spare tire in
the rear compartment.
Open the rear compartment and perform a
visual inspection of the spare tire and the
tools.

Tightly secure the spare tire and all tools.

Perform a road test to verify that the noise is
eliminated.
Glass Knock Coming
From the Rear of the
Vehicle When Driving
Over Bumps
An out-of-adjustment hatchback
latch.
Test drive the vehicle in order to verify this
condition.

Loosen the latch nuts and adjust the latch
downward.
Rattle Coming From
Door
The door lock solenoid is loose.
Remove the door trim panel and check if the
solenoid is loose.

Tighten the solenoid bolts.

Rattling electrical connectors
inside the door trim panel.
Tap on the trim panel and listen for a rattle.

Remove the trim panel and wrap foam
padding around the connectors as required.
Squeak When
Operating Doors
A lack of lubrication of the door
hinge pins.
Operate the doors and listen for squeaks.

Lubricate the door hinge pins with light oil
and coat with lithium grease.

A lack of lubrication of the door
hold open link arm.
Lubricate the door hold open link arm with
light oil and coat with lithium grease.

SQUEAKS AND RATTLES 9K–3
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
SQUEAK AND RATTLE REPAIR
Squeaks and rattles are caused by the unwanted move-
ment between parts of a vehicle. There are three means
to prevent squeaks or rattles.

Attach the parts securely so that there is no rela-
tive motion during the operation of the vehicle.

Separate the parts so that there is no contact dur-
ing operation.

Insulate the parts so that no squeaks or rattles oc-
cur with the movement of the parts. Low uniform
friction surfaces can be used to eliminate “stick–
slip” motion.

DAEWOO M-150 BL2
SECTION 9L
GLASS AND MIRRORS
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.
TABLE OF CONTENTS
Description and System Operation 9L-2. . . . . . . . . .
Stationary Glass 9L-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Inside Rearview Mirror 9L-2. . . . . . . . . . . . . . . . . . . . .
Outside Rearview Mirrors 9L-2. . . . . . . . . . . . . . . . . . .
Components Locator 9L-3. . . . . . . . . . . . . . . . . . . . . . .
Glass and Mirror 9L-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 9L-4. . . . .
Testing Rear Window Defogger Grid Line 9L-4. . . . .
Repair Instructions 9L-5. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9L-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield 9L-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Glass 9L-7. . . . . . . . . . . . . . . . . . . . . . .
Rear Window Defogger Grid Line Repair 9L-9. . . . . Rear Window Defogger Braided Lead
Wire Repair 9L-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Glass 9L-10. . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Quarter Glass 9L-12. . . . . . . . . . . . . . . . .
Rear Door Glass 9L-13. . . . . . . . . . . . . . . . . . . . . . . . .
Inside Rearview Mirror 9L-13. . . . . . . . . . . . . . . . . . . .
Outside Rearview Mirror (Manual) 9L-14. . . . . . . . . .
Outside Rearview Mirror (Cable) 9L-15. . . . . . . . . . . .
Outside Rearview Mirror (Electric) 9L-16. . . . . . . . . .
Special Tools and Equipment 9L-17. . . . . . . . . . . . . .
Special Tools Table 9L-17. . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 9L-18. . . . . . . . . .
Rear Window Defogger 9L-18. . . . . . . . . . . . . . . . . . .