service DAEWOO MATIZ 2003 Service Repair Manual

GLASS AND MIRRORS 9L–5
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D19E501
WINDSHIELD
Tool Required
J–24402 Glass Sealant Remover
Removal Procedure
1. Remove the cowl vent grille. Refer to Section 9R,
Body Front End.
2. Remove the inside rearview mirror. Refer to “Inside
Rearview Mirror” in this section.
3. Remove the weatherstrip around the windshield.
D19E502
4. Using the glass sealant remover J–24402, cut the
adhesive around the windshield.
D19E503
5. Remove the windshield from the vehicle.
6. Using a knife, remove the adhesive from the wind-
shield.

DAEWOO M-150 BL2
SECTION 9M
EXTERIOR TRIM
TABLE OF CONTENTS
Description and Operation 9M-2. . . . . . . . . . . . . . . . . .
Emblems and Lettering 9M-2. . . . . . . . . . . . . . . . . . . . .
Mud Guards 9M-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 9M-3. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9M-3. . . . . . . . . . . . . . . . . . . . . . . . . . Roof Molding 9M-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Spoiler 9M-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Bumper Spacer 9M-4. . . . . . . . . . . . . . . . . . . . . .
Tailgate Handle 9M-5. . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTERIOR TRIM 9M–3
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D109E586
ROOF MOLDING
Removal Procedure
1. Remove the roof molding from the plastic clips (1).
D109E587
Installation Procedure
1. Press the roof molding onto the plastic clips.
D19E588A
REAR SPOILER
Removal Procedure
1. Open the tailgate.
2. Remove the spoiler seals.

DAEWOO M-150 BL2
SECTION 9N
FRAME AND UNDERBODY
TABLE OF CONTENTS
Description and Operation 9N-2. . . . . . . . . . . . . . . . . .
General Body Construction 9N-2. . . . . . . . . . . . . . . . .
Transaxle Under Covers 9N-2. . . . . . . . . . . . . . . . . . . .
Repair Instructions 9N-3. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9N-3. . . . . . . . . . . . . . . . . . . . . . . . . . Alignment Checking 9N-3. . . . . . . . . . . . . . . . . . . . . . .
Floor Pan Insulators 9N-3. . . . . . . . . . . . . . . . . . . . . . .
Specifications 9N-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Underbody Dimensions 9N-4. . . . . . . . . . . . . . . . . . . .

9N – 2 FRAME AND UNDERBODY
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
GENERAL BODY CONSTRUCTION
This vehicle is constructed with a unitized body which in-
corporates integral front and rear frame side rails.
The front suspension lower control arms are bolted to
and retained by supports, one each on the right and left
sides. The front suspension lower control arm supports
are attached to the underbody with three bolts at two
locations. The engine is bolted to the integral front side
rails. The suspension strut towers must be dimensional-
ly correct in relation to the remainder of the underbody in
order to maintain specified suspension strut and caster/
camber angles.
Since the individual underbody parts contribute directly
to the overall strength of the body, it is essential to ob-
serve proper welding techniques during service repairoperations. The underbody parts should be properly
sealed and rustproofed whenever body repair operations
destroy or damage the original sealing and rustproof-
ing. When rustproofing critical underbody parts, use a
good-quality type of air-dry primer, such as a corrosion-
resistant chromate or an equivalent material. Combina-
tion-type primer/surfacers are not recommended.
TRANSAXLE UNDER COVER
The transaxle under cover is one piece of steel that
serve as shields for the underside of the transaxle. The
covers help protect the engine from small rocks, gravel
and other objects that would otherwise come into con-
tact with the transaxle during normal driving conditions.

FRAME AND UNDERBODY 9N–3
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
ALIGNMENT CHECKING
An accurate method of determining the alignment of the
underbody uses a measuring tram gauge. The tram
gauge set used to perform the recommended measuring
checks must include a vertical pointer able to reach
457 mm (18 inches).
Two types of measurements can be made with a tram
gauge: direct point-to-point measurements and mea-
surements calculated on a horizontal plane (datum line)
parallel to the underbody. Point-to-point measurements
are generally taken on steering and suspension engine
compartment parts and simply require the vertical point-
ers to be set equally.
For horizontal plane measurements, the vertical pointers
must be set as specified for each point to be measured.
Dimensions-to-gauge holes are measured to the center
of the holes and flush to the adjacent surface metal un-
less otherwise specified. It is recommended that the di-
agonal dimensions to the cross-body be checked on
both sides in order to verify the dimensional accuracy of
the vehicle underbody.
FLOOR PAN INSULATORS
The floor pan insulators have been designed for the
higher floor pan temperatures that result from the use
of the catalytic converter in the exhaust system. There-
fore, when servicing a vehicle, it is essential that any in-sulators that may have been disturbed or removed be
reinstalled in the original sequence and location. Also, if
an insulator needs to be replaced, use only the insula-
tion specified for that location on the floor pan.
When servicing or replacing interior insulators, observe
the following instructions.

Install the insulators in the original position and se-
quence. Butt the pieces together in order to avoid
gapping or overlapping.

If it is necessary to replace an insulator, use only the
specified insulation.

Use the original part to determine the amount of re-
placement material required and as a template for
cutting and fitting the new piece to the floor pan.

When installing the insulator, do not enlarge any cut-
outs or holes that are used for the attachment of interi-
or parts such as the instrument panel or the floor
console.

Route the cross-body harness for interior parts over
the floor pan insulators. Clip it in the original location.

Do not apply spray-on deadeners or trim adhesives to
the top of the floor pan at the area directly over the
catalytic converter or the muffler.
Any insulator service repair or replacement should be
the same thickness, size, and location as the original
installation in the vehicle.

DAEWOO M-150 BL2
SECTION 9O
BUMPERS AND FASCIAS
TABLE OF CONTENTS
Description and Operation 9O-2. . . . . . . . . . . . . . . . . .
Bumpers 9O-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 9O-3. . . . . . . . . . . . . . . . . . . . . . . .
Bumpers and Fascias 9O-3. . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 9O-4. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 9O-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Bumper Fascia 9O-4. . . . . . . . . . . . . . . . . . . . . .
Front Bumper Impact Bar 9O-5. . . . . . . . . . . . . . . . . . .
Rear Bumper Fascia 9O-6. . . . . . . . . . . . . . . . . . . . . . .
Rear Bumper Bracket 9O-8. . . . . . . . . . . . . . . . . . . . . .

9O –4 BUMPERS AND FASCIAS
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D19C501A
FRONT BUMPER FASCIA
Removal Procedure
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the front wheels.
4. Remove the front wheel house splash shields.

Remove the clip and bolts.
a. Bolt and clip.

Remove the wheel house splash shield.
b. Splash shield.
D109C502
5. Remove the bolts on the both side of the fascia.
a. Bolt.
D109C503
6. Remove the clips under the fascia.
a. Clip.

DAEWOO M-150 BL2
SECTION 9P
DOORS
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 9P-2. . . . . . . . . . . . . . . . . .
Door Lock Striker 9P-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Childproof Rear Door Lock 9P-2. . . . . . . . . . . . . . . . . .
Power Door Locks 9P-2. . . . . . . . . . . . . . . . . . . . . . . . .
Power Windows 9P-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Strut 9P-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 9P-3. . . . . . . . . . . . . . . . . . . . . . . .
Front Door 9P-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door 9P-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 9P-7. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9P-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Glass Run 9P-7. . . . . . . . . . . . . . . . . . . . . .
Rear Door Glass Run 9P-8. . . . . . . . . . . . . . . . . . . . . .
Door Lock Striker 9P-9. . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Lock Striker 9P-9. . . . . . . . . . . . . . . . . . . . . . .
Door Lock Striker Adjustment 9P-10. . . . . . . . . . . . . .
Tailgate Lock Striker Adjustment 9P-11. . . . . . . . . . . .
Front Door Lock 9P-13. . . . . . . . . . . . . . . . . . . . . . . . . .
Childproof Rear Door Lock 9P-14. . . . . . . . . . . . . . . . .
Central Door Lock Actuator 9P-16. . . . . . . . . . . . . . . .
Tailgate Lock 9P-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside Door Handle 9P-17. . . . . . . . . . . . . . . . . . . . . . . Outside Front Door Handle 9P-17. . . . . . . . . . . . . . . .
Outside Rear Door Handle 9P-18. . . . . . . . . . . . . . . . .
Door Lock Cylinder 9P-18. . . . . . . . . . . . . . . . . . . . . . .
Manual Window Regulator 9P-19. . . . . . . . . . . . . . . . .
Power Front Window Regulator 9P-19. . . . . . . . . . . .
Front Door Assembly 9P-20. . . . . . . . . . . . . . . . . . . . .
Rear Door Assembly 9P-21. . . . . . . . . . . . . . . . . . . . . .
Tailgate 9P-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Lock Cylinder 9P-23. . . . . . . . . . . . . . . . . . . . .
Door Hinge 9P-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Hold Open Link 9P-24. . . . . . . . . . . . . . . . . . . . .
Inside Channel Weatherstrip (Standard) 9P-24. . . . .
Inside Channel Weatherstrip (Deluxe) 9P-25. . . . . . .
Door Outside Channel Weatherstrip 9P-25. . . . . . . . .
Door Weatherstrip 9P-26. . . . . . . . . . . . . . . . . . . . . . . .
Door Seal Trim 9P-27. . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Opening Weatherstrip 9P-27. . . . . . . . . . . . . . . .
Manual Window Regulator Handle 9P-28. . . . . . . . . .
Tailgate Strut 9P-28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 9P-30. . . . . . . . . .
Power Door Locks 9P-30. . . . . . . . . . . . . . . . . . . . . . . .
Power Windows (Front Only) 9P-34. . . . . . . . . . . . . . .

DOORS 9P–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D109E521
FRONT DOOR GLASS RUN
Removal Procedure
1. Remove the front door seal trim from the front door.
Refer to “Door Seal Trim” in this section.
2. Remove the outside rearview mirror from the front
door. Refer to Section 9L, Glass and Mirrors.
3. Remove the guide rail from the door.

Remove the screws (1).

Remove the inside bolts (2).

Remove the outside bolts (3).

Remove the division bar (4).
D109E522
4. Remove the glass run.
a. Glass run.
D109E526
Installation Procedure
1. Install the glass run.
2. Install the division bar with the bolts and the screws.
3. Install the outside rearview mirror. Refer to Section
9L, Glass and Mirrors.
4. Install the front door seal trim. Refer to “Door Seal
Trim” in this section.