position DAEWOO MATIZ 2003 Service Repair Manual

MANUAL STEERING GEAR 6D–5
DAEWOO M-150 BL2
STRAIGHT-AHEAD CHECK
After all the necessary operations on the steering gear
are completed, check the exact straight-ahead position
of the steering in each case.
With the vehicle on the floor, place the steering wheel in
the straight-ahead position. Mark the centerline of both
tires on the floor. Turn the steering wheel all the way to
the right and mark the new centerline of both tires on the
floor.
Application Tire Specified Valve
145, 15537.5 – 41.5
Inside Angle 17532.9 – 36.9
145, 15531.5 – 35.5
Outside Angle 17528.5 – 32.5
D105B301
Front Outside Angle
Inside Angle
Straight Ahead Check Table
Step Action Value(s) Yes No



1



Place the steering wheel in the straight-ahead posi-
tion.
Is the wheel in the correct position?


–


Go to Step 2



–


2

Is the steering wheel off center by more than 5 de-
grees?
–
Go to Step 4
Go to Step 5

3

The pinion is displaced on the rack. The steering
pinion position must be corrected.
Is the repair complete?
–
Go to Step 2

–



4



Remove steering wheel and center on the spindle
splines.
Is the repair complete?


–


Go to Step 2



–



5



Turn the steering wheel all the way to the right. Mea-
sure the inner and the outer angles of the tire cent-
erline compared to the straight-ahead centerline. Do
the angles match the value specified?


Refer to
“Straight–
Ahead Check”
in this section

System OK


Go to Step 6


6



The rack assembly was not assembled correctly.
Repair as needed.
Is the repair complete?


–


Go to Step 5



–

6D –6 MANUAL STEERING GEAR
DAEWOO M-150 BL2
STEERING WHEEL RESTORATION
1. Turn the steering wheel fast to the right and left and
turn it slowly as the same way.
2. Check if the steering wheel restoration for the wheel
turning to right and the one to the left are same.
3. Turn the steering wheel to 90 about 1–2 seconds
and loosen the steering wheel during the low speed
driving.
4. If the steering wheel restores above 70%, the steer-
ing wheel restoration is OK.
5. If the restoration is poor, check the tire pressure,
steering gear preload, and steering gear operation.
And repair the fault.
CHECK THE TURNING RESISTANCE
OF THE TIE ROD END OR TIE ROD
1. Turn the ball joint of the tie rod end or the tie rod about
10 times.
2. Use a spring balance to check the turning resistance
of each ball joint.
D105B302
Application Specified Value
Tie Rod End Ball Joint0.49 – 3.43 Nm
(4.5 – 30 lb-in.)

Tie Rod Ball Joint0.49 – 3.43 Nm
(4.5 – 30 lb-in.)
3. If the values exceed the specified values, replace the
tie rod end or the tie rod.
4. But, If the ball joint of the tie rod end or the tie rod falls
down of itself, replace it.
ADJUST THE FREE LOAD OF THE
STEERING GEAR
1. Place the steering wheel in the straight–ahead posi-
tion.
2. Raise and suitably support the vehicle.
3. Check the torque of the adjuster plug.
4 When the measured torque is below the specification
value or the measured torque is over the specification
value, adjust the tightening torque.

Place the rack gear in the straight–ahead position.

Tighten the adjust plug to 95 Nm (70 lb-ft).

Turn the steering wheel all the way to the right and
the left about 5 times repeatedly.

Place the rack gear in the straight–ahead position.

Loosen the adjust plug.

Tighten the adjust plug to 8 Nm (71 lb-in.).

Set the torque in the 0.8–1.3 Nm (8–12 lb-in.) by
loosening the adjust plug to 0 − 90.
D105B303

6E –4 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
STEERING COLUMN DIAGNOSIS
Lock System
ConditionProbable CauseCorrection
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Unlock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Lock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
High Lock Effort
Damaged lock cylinder.
Replace the lock cylinder.

The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Extreme misalignment of the housing to the
cover.
Realign the cover on the housing.

Replace the cover as needed.
Key Cannot Be
The ignition switch to be set incorrectly.
Reset the ignition switch.
Removed in the B
Position
Damaged lock cylinder.
Replace the lock cylinder.
Column
ConditionProbable CauseCorrection
Noise in the Column
Improperly installed intermediate shaft–to–
column joints.
Tighten the coupling pinch bolts.

Replace the intermediate shaft as
needed.

Column misalignment.
Replace the alignment spacer.

The lack of lubrication for the joint.
Lubricate the joint.

The lack of lubrication for the steering shaft.
Lubricate the steering shaft bearing.

Improperly seated shaft lock snap ring.
Adjust the shaft lock snap ring.

Replace the shaft lock snap ring as
needed.

Improperly installed intermediate shaft
pinch bolt.
Tighten the pinch bolt.
High Steering Shaft
Column misalignment.
Replace the alignment spacer.
Effort
A damaged bearing.
Replace the steering column
housing.

The lack of free movement for the steering
shaft universal joint.
Lubricate the steering shaft
universal joint.

Replace the steering column shaft
as needed.

STEERING WHEEL AND COLUMN 6E–5
DAEWOO M-150 BL2
Column (Cont’d)
ConditionProbable CauseCorrection
Lash in the Steering
Column
Improperly installed steering column
bracket mounting nuts.
Tighten the steering column bracket
mounting nuts.

Loose steering column housing–to–steering
column jacket support bolts.
Tighten the support bolts.
Loose Steering
Wheel
The bearing to be seated incorrectly in the
housing.
Correctly seat the bearing.

Replace the column housing as
needed.

Loose steering column housing support
bolts.
Tighten the steering column housing
support bolts.
Turn Signal / Dimmer Switch
ConditionProbable CauseCorrection
Turn Signal Will Not
Stay in the Turn
Position
An improperly installed turn signal switch.
Remove and inspect the turn signal
switch.

Reinstall the switch.

The broken or missing components for the
cancelling mechanism.
Replace the turn signal switch.

Foreign material in the turn signal switch
housing.
Remove any foreign material.
Turn Signal Will Not
Cancel
Broken or missing components for the
cancelling mechanism.
Replace the turn signal switch.
Turn Signal/Dimmer
Switch Difficult to
Operate
Improperly installed turn signal/dimmer
switch and turn signal/dimmer switch lever.
Remove and inspect the turn
signal/dimmer switch and
signal/dimmer switch lever.

Reinstall the signal/dimmer switch
and signal/dimmer switch lever.

Foreign material in the signal/dimmer
switch housing.
Remove any foreign material.
Turn Signal Will Not
Indicate Lane
A broken lane change pressure pad or a
broken spring hanger.
Replace the turn signal switch.
Change
The improper functioning of the lane
change spring.
Replace the turn signal switch.

Improperly installed turn signal switch.
Replace the turn signal switch.
No Turn Signal
An inoperative turn signal flasher.
Replace the blinker unit.
Lamps
A faulty turn signal switch.
Replace the turn signal switch.

Improperly connected chassis–to–column
connector.
Reconnect the chassis–to–column
connector.
Turn Indicator Lamps
On, But Not Flashing
An inoperative blinker unit.
Replace the blinker unit.
Front or Rear Turn
Signal Lamps Not
Flashing
An inoperative blinker unit.
Replace the blinker unit.
Turn Signal Lamps
Flash Very Slowly
An inoperative blinker unit.
Replace the blinker unit.

STEERING WHEEL AND COLUMN 6E–9
DAEWOO M-150 BL2
D105A508
Installation Procedure
1. Install the wiper switch.
2. Install the turn signal switch.
3. Install the steering column cover. Refer to “Steering
Column Cover” in this section.
4. Connect the negative battery cable.
D105A509
IGNITION SWITCH
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
3. Remove the ignition switch.

Disconnect the electrical connector (1).

Remove the screw (2).
D105A510
Installation Procedure
1. Connect the electrical connector.
2. Install the ignition switch with the screw.
3, Install the steering wheel. Refer to “Steering Wheel”
in this section.
4. Connect the negative battery cable.
D105A511
IGNITION LOCK CYLINDER WITH
IMMOBILIZER
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
2. Disconnect the electrical connector for the immobiliz-
er detection coil.
3. Remove the lock cylinder.

With the key in the ignition, turn to the position des-
ignated I (1).

6E –10 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
D105A511

Remove the lock cylinder by pressing down the
detent spring with a 2.5MM allen wrench, or other
suitable tool, and pulling the lock cylinder out of the
switch cylinder housing (2).
D105A512
Installation Procedure
Important: To install the ignition lock cylinder the igni-
tion position should be designated I.
1. Install the ignition lock cylinder.
2. Connect the electrical connector for the immobilizer
detection coil.
3. Install the steering wheel. Refer to “Steering Wheel”
in this section.
D105A513
SWITCH HOUSING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
2. Remove the turn signal switch and windshield wiper
switch. Refer to “Turn Signal Switch and Lever/Wiper
Switch and Lever” in this section.
3. Remove the switch housing.

Disconnect the horn electrical connector (1).

Remove the screws retaining the switch housing
(2).
D105A514
Installation Procedure
1. Install the switch housing with the screws.
2. Connect the horn electrical connector.
3. Install the turn signal switch and windshield wiper
switch. Refer to “Turn Signal Switch and Lever/Wiper
switch and Lever” in this section.
4. Install the steering wheel. Refer to “Steering Wheel”
in this section.

6E –12 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
D105A520
INTERMEDIATE SHAFT COVER AND
INTERMEDIATE SHAFT
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the intermediate shaft.

In order to install the intermediate shaft correctly,
match–mark the intermediate shaft to the steering
column. (1).

Remove the intermediate shaft upper pinch bolt
(2).

Remove the intermediate shaft lower pinch bolt
(3).
D15A521A
Installation Procedure
1. Install the intermediate shaft with the bolts.
Tighten

Tighten the intermediate shaft lower pinch bolt to
21–29 Nm (16–22 lb-ft) (1).

Tighten the intermediate shaft upper pinch bolt to
21–29 Nm (16–22 lb-ft) (2).
Notice: Check the lower pinch bolt position correctly.

6E –14 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
D15A704A
Assembly Procedure
Important: Position the alignment spacer on the lower
column shaft to install the spacer in the steering column
jacket easily.
1. Install the steering column shaft to the steering col-
umn.

Position the locking of the alignment spacer on the
groove of the steering column.

Install the washer.

Install the spring.

Install the washer.

Install the retaining ring.
2. Install the steering column to the vehicle. Refer to
“Steering Wheel” in this section.

7A–2 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
DESCRIPTION AND SYSTEM OPERATION
HEATING AND VENTILATION
SYSTEMS
The base heater system is designed to provide heating,
ventilation, windshield defrosting, and side window de-
fogging.
The heater and fan assembly blower regulates the air-
flow from the air inlet for further processing and distribu-
tion.
The heater core transfers the heat from the engine cool-
ant to the inlet air.
The temperature door regulates the amount of the air
that passes through the heater core. The temperature
door also controls the temperature of the air by control-
ling the mix of the heated air and the ambient air.
The mode door regulates the flow and the distribution
of the processed air to the heater ducts and to the de-
froster ducts.
This console-mounted heating and ventilation panel
contains the following:
Three Rotary Control Knobs
1. The Rotary Temperature Control Knob

Actuates by cable.

Raises the temperature of the air entering the ve-
hicle by rotation toward the right, or the red portion
of the knob.
2. The Rotary Blower Control Knob

Turns on to operate the blower motor at four speeds.

Turns
to stop the blower.

Operates completely independently both from the
mode control that regulates the defroster door and
from the temperature control knob.
Changes the fan speed in any mode and at any
temperature setting.
3. The Rotary Mode Control Knob:

Actuates by cable.

Regulates the air distribution between the wind-
shield, the instrument panel, and the floor vents.
Push Knobs
1. The Rear Window Defogger Push Knob

Controls the rear window defogger.

Turns ON the rear window defogger when the push
knob is pressed and the indicator lamp is illumi-
nated.
2. The A/C Push Knob (if the vehicle is equipped with air
conditioning)

Controls the A/C.

Turns the A/C ON when the push knob is down.
However, if the blower control knob is OFF, the A/C
system is OFF, regardless of the position of the
A/C knob.
One Lever
1. The Fresh Air Control Lever

Operates by cable.

Switches between recirculating passenger compart-
ment air and bringing outside air into the passenger
compartment.

Draws in outside air when the lever is moved to the
left.

Recirculates inside air when the lever is moved to
the right.

7A–10 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
BLOWER ELECTRICAL
Step Action Value(s) Yes No
1

Verify the customer’s complaint.
Are the customer’s concerns verified.
–

Go to Step 2

System OK
2

Check the blower.
Does the blower run at any speed?
–

System OK

Go to Step 3







3







1. Disconnect the power connector from the blower
motor under the dashboard on the passenger side
of the vehicle.
2. Use an ohmmeter check the resistance between
the 1 terminal of the blower motor connector and
each step with the blower switch place each
position.
Does the ohmmeter show the specified value of the
each position?






Refer to
“Specifica-
tions” in this
section.






Go to Step 4






Go to Step 5

4

Replace the blower motor.
Is the repair complete?
–
System OK

Go to Step 7

5

Check the fuse Ef6.
Is the fuse blown?
–
Go to Step 6

Go to Step 7






6






1. Turn the ignition ON.
2. Use a short detector to locate a possible short.

From the fuse Ef6 to the blower switch.

From the blower swtich to the blower resistor.

From the blower resistor to the blower motor.
3. Repair any short.
4. Replace any blown fuse.
Is the repair complete?





–






System OK






–











7











1. Turn the ignition ON.
2. Disconnect the power connector from the blower
motor.
3. Use a test lamp to locate a possible short.

From the terminal 2 of the motor connector to
the terminal 3 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 4 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 5 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 6 of the motor switch connector.
Does the test lamp light ON?











–










Go to Step 9










Go to Step 8

8

Replace the blower resistor.
Is the repair complete?
–
System OK

Go to Step 10

9

Replace the blower motor switch.
Is the repair complete?
–
System OK

–

10


1. Check the ground of the blower motor.
2. Repair the ground of the blower motor.
Is the repair complete?
–

System OK

–