boot DAEWOO MATIZ 2003 Service User Guide

FRONT DISC BRAKES 4D–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
FRONT DISC BRAKES
D17B401A
1. Front Brake Caliper Assembly
2. Front Brake Boot Assemblies
3. Pins
4. Pin Boots
5. Front Brake Pads
6. Carrier
7. Pad Spring8. Piston Boot
9. Piston
10. Piston Seal
11. Cylinder
12. Bleeder Screw Cap
13. Bleeder Screw

4D –8 FRONT DISC BRAKES
DAEWOO M-150 BL2
UNIT REPAIR
D107B701
CALIPER OVERHAUL
Disassembly Procedure
1. Remove the caliper assembly. Refer to “Caliper As-
sembly” in this section.
2. Separate the cylinder assembly and the carrier.

Remove the pin bolts (1).

Separate the cylinder assembly and the carrier (2).
D107B702
3. Disassemble the carrier.

Remove the front brake pad set (1).

Remove the springs (2).

Remove the guide pins and boots (3).
Refer to “Shoe and Lining” in this section.
D17B703C

Remove the bleeder plug (1).

Remove the bleeder plug cap (2).

FRONT DISC BRAKES 4D–9
DAEWOO M-150 BL2
D107B704

Remove the piston boot (3).
Caution: Do not face in the direction of removing.
D107B705

Using compressed air, blow out the piston from the
cylinder (4).

Remove the piston (5).
D107B706

Remove the piston seal (6).

4D –10 FRONT DISC BRAKES
DAEWOO M-150 BL2
D17B708B
D17B707A
26
Assembly Procedure
Important: Clean all parts in denatured alcohol. Dry the
parts with unlubricated compressed air.
Important: Lubricate the piston with brake fluid.
1. Assembly the cylinder assembly.

Install the piston seal.

Push the piston inward until it is properly seated.

Install the piston boot.

Install the bleeder plug.
Tighten
Tighten the bleeder plug to 6 Nm (53 lb-in).

Install the bleeder plug cap.
2. Assemble the carrier.

Install the guide pin and boot.

Install the spring.

Install the pads.
3. Install the pin bolt connecting the cylinder assembly
and carrier.
Tighten
Tighten the pin bolt to 26 Nm (19 lb-ft).
4. Install the caliper assembly. Refer to “Caliper Assem-
bly” in this section.

4E –10 REAR DRUM BRAKES
DAEWOO M-150 BL2
UNIT REPAIR
D107C701
WHEEL CYLINDER
Disassembly Procedure
1. Remove the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.
2. Disassemble wheel cylinder assembly.

Remove the dust boots and do not reuse them (1).

Remove the piston (2).

Remove the piston cup and do not reuse it (3).

Remove the spring assembly (4).

Remove the bleeder screw (5).
3. Clean all parts with denatured alcohol. Dry the parts
with unlubricated compressed air.
D17C702A
Assembly Procedure
Important: Lubricate the new seals, the piston, the pis-
ton cup and the wheel cylinder bore with clean brake
fluid before assembly.
1. Assemble wheel cylinder assembly.

Insert the bleeder screw.
Tighten
Tighten the bleeder screw to 6 Nm (53 lb-in).

Install the spring and the new piston cup.

Install the piston and the new boots.
2. Inspect the piston for free movement.
3. Install the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.

5B–6 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
GEAR SHIFT FORK
D13B4021
1 Shift and Select Shaft
2 Shift Interlock Bolt
3 Shift Lever
4 Select Lever
5 Shift and Select Shaft Boot
6 Gearshift Control Case
7 Shift Guide Bolt
8 Gearshift Control Case Guide Plate
9 Gearshift Control Case Gasket
10 Low Speed Shift Fork
11 Low Speed Shift Shaft
12 Low Speed Shift Shaft Spring/Ball
13 Low Speed Shift York14 High Speed Shift York
15 High Speed Shaft Spring/Ball
16 High Speed Shift Shaft
17 High Speed Shift Fork
18 Reverse Shift Arm
19 5th/Reverse Shift Ball
20 5th/Reverse Shift Shaft Spring/Ball
21 Reverse Shift Shaft Guide Spring/Ball
22 5th/Reverse Shift Shaft
23 5th/Reverse Shift York
24 5th/Shift Fork Guide Ball
25 5th/Shift Fork
26 Reverse Shift Lever

FIVE-SPEED MANUAL TRANSAXLE 5B–17
DAEWOO M-150 BL2
D103B522
4. Remove the select lever.

Remove the bolts (1).

Remove the select lever (2).
D103B523
5. Remove the shift interlock bolt.
Important: Certainly remove the shift interlock bolt.
Otherwise, the gear shift control case can not be re-
moved.
D103B524
6. Remove the gear shift control case assembly.

Remove the bolts (1).
Important: Make sure the gear shift lever is in NEU-
TRAL.

Remove the gear shift control case assembly (2).

Remove the gasket (3).
D103B525
7. Remove the shift lever.

Position the gear shift control case assembly to the
vice with a protector.

Remove the lever pin with a pin punch and a ham-
mer (1).

Remove the shift lever (2).

Remove the boot (3).

DAEWOO M-150 BL2
SECTION 6C
POWER STEERING GEAR
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 6C-2. . . . . . . . . . . . . . . . . .
Power Rack and Pinion 6C-2. . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6C-3. . . . .
Power Rack and Pinion Steering Gear 6C-3. . . . . . .
Adjust the Free Load of the Steering Gear 6C-5. . .
Repair Instructions 6C-6. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6C-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Assembly 6C-6. . . . . . . . . . . . . . . . .
Power Steering Gear Rack and Pinion Boot 6C-7. . . Unit Repair 6C-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Boot 6C-8. . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Cylinder Lines 6C-8. . . . . . . . . . . . . . . . . . . .
Rack and Pinion Steering Gear 6C-9. . . . . . . . . . . . . .
Assembly
Specifications 6C-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6C-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6C-13. . . . . . . . . .

POWER STEERING GEAR 6C–7
DAEWOO M-150 BL2
D105C536
6. Remove the packing (5).
D15C537A
Installation Procedure
1. Install in the reverse order of removal.
2. Install the power steering gear bracket with the bolt.
Tighten
Tighten the bracket bolts to 50–55 Nm (36–41 lb-ft).
D15C512A
21–35 Nm21–35 Nm3. Connect the steering pipe. Refer to Section 6A, Pow-
er Steering System.
Tighten
Tighten the power steering pressure line fitting (1) to
21–35 Nm (16–25 lb-ft) (1).
Tighten the return line fitting to 21–35 Nm (16–25 lb-
ft) (2).
Important: When adding fluid or making a complete
fluid change, always use DEXRON II or III power
steering fluid. Failure to use the proper fluid will cause
hose and seal change and fluid leaks.
4. Fill the fluid reservoir with power steering fluid.
5. Inspect for leaks. If there are leaks, correct the cause
of the leaks and bleed the system. Refer to Section
6A, Power Steering System.
POWER STEERING GEAR RACK
AND PINION BOOT
Refer to Section 6D, Manual Steering Gear.

6C –8 POWER STEERING GEAR
DAEWOO M-150 BL2
UNIT REPAIR
TIE ROD END BOOT
Refer to Section 6D, Manual Steering Gear.
D105C701
HYDRAULIC CYLINDER LINES
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Disassembly Procedure
1. Remove the rack and pinion steering assembly from
the vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Disconnect the cylinder lines from the rack and pinion
housing.

Remove the fitting (1).

Remove the fitting (2).
D15C715A
Assembly Procedure
1. Connect the cylinder lines to the rack and pinion
housing.
2. Install the power steering line fittings at the pinion
valve end.
Tighten
Tighten the power steering line fittings to 25–35 Nm
(18–25 lb-ft) (1).
3. Install the power steering line fittings at the cylinder
end.
Tighten
Tighten the power steering line fittings to 25–35 Nm
(18–25 lb-ft) (2).
4. Install the rack and pinion steering assembly to the
vehicle. Refer to “Rack and Pinion Assembly” in this
section.