clutch DAEWOO MATIZ 2003 Service User Guide

ENGINE CONTROLS 1F–139
DAEWOO M-150 BL2
DIAGNOSTIC TROUBLE CODE (DTC) – P0300 MULTIPLE CYLINDER MISFIRE
System Description
The Engine Control Module (ECM) monitors the crank-
shaft and camshaft positions to detect if the engine is
misfiring. The ECM looks for a quick drop in crankshaft
speed. This test is executed in blocks of 100 engine rev-
olution tests. It may take between one to several tests to
store a Diagnostic Trouble Code (DTC) and illuminate
the Malfunction Indicator Lamp (MIL). Under light misfire
conditions, it may also take more than one trip to set a
DTC. Severe misfire will flash the MIL, indicating that
catalyst damage is possible.
Conditions for Setting the DTC

Emission threshold is 3.0% for automatic transaxle
and 3.0% for manual transaxle.

20 engine cycles have occurred since cranking has
started.

A/C compressor clutch has not just engaged or disen-
gaged.

Engine load and engine speed are in a detectable re-
gion and are at or above zero torque.

Camshaft Position (CMP) sensor is in synchroniza-
tion.

Electric Exhaust Gas Recirculation (EEGR) flow
diagnostic is not in progress.

Fuel level is greater than or equal to 20% of rated
tank capacity.

Decel Fuel Cutoff (DFCO) not active.

Fuel is not shutoff from high engine speed of 6500
rpm for manual transaxle vehicle or 6500 rpm in drive
and 6250 rpm in park for automatic transaxle ve-
hicles.

Fuel is not shutoff at 255 km/h (158 mph).

An automatic transmission is not shifting.

Throttle position change is less than 3% per 125 ms.

Vehicle has not encountered an abusive engine
speed of 7000 rpm.

Crankshaft speed patters are normal.
Throttle position is less than 4% when vehicle speed
is greater than 10 km/h (6 mph).

Engine speed is between 600 and 4500 rpm.

Vehicle voltage is between 11 and 16 volts.

Engine Coolant Temperature (ECT) is between –7°C
(20°F) and 120°C (248°F).

The engine speed is less than or equal to 1800 rpm or
the crank angle sensing error has not been learned.

There is the correct ratio between Crankshaft Posi-
tion (CKP) sensor pulses and CMP sensor pulses.

DTCs P0106, P0107, P0108, P0117, P0118, P0122,
P0123, P0320, P0337, P0341, P0342 and P0502 are
not set.
Action Taken when the DTC Sets

Emission related.

“Armed” after two trip with a fail.

“Disarmed” after one trip with a pass.

MIL on if failure is detected in three consecutive trips.

Stores a History DTC on the third consecutive with a
fail (The DTC will be armed after the second fail).

Stores a Freeze Frame on the third consecutive trip
with a fail (if empty).
Conditions for Clearing the MIL/DTC

The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.

A history DTC will clear after 40 consecutive warm up
cycles without a fault.

DTC(s) can be cleared by using the scan tool.

Disconnecting the ECM battery feed for 10 seconds.
Diagnostic Aids
An intermittent can also be the result of a defective re-
luctor wheel. Remove the CKP sensor and inspect the
reluctor wheel through the sensor mount hole. Check for
porosity and the condition of wheel. If the DTC is inter-
mittent refer to “Symptoms Diagnosis” in this section.
DTC P0300 – Multiple Cylinder Misfire
StepActionValue(s)YesNo
1
Perform an Euro On-Board Diagnostic (EOBD)
System Check.
Was the check performed?
–
Go to Step 2
Go to
“On-Board
Diagnostic
System Check”
2
1. Install a scan tool to the Data Link Connector
(DLC).
2. Turn the ignition ON, with the engine OFF.
3. Request Diagnostic Trouble Codes (DTCs)
Are DTCs P0201, P0202, P0203, P0204 set?
–Go to
Applicable DTC
table
Go to Step 3

1F–282 ENGINE CONTROLS
DAEWOO M-150 BL2
Intermittent (Cont’d)
StepActionValue(s)YesNo
9
1. Turn the ignition OFF.
2. Replace the ECM.
Is the repair complete?
–
System OK
–
10Does the vehicle stall while driving?–Go to Step 11Go to Step 12
11
Monitor the oxygen sensor and the injector base
pulse width with the scan tool.
Does the scan tool display a steady low voltage
(about 0 millivolts) for the oxygen sensor with the
control module commanding an injector base pulse
width of the value specified?
8 msGo to Step 9Go to Step 12
12
1. Check for an open diode across the A/C clutch
and for other open diodes.
2. Repair or replace any components as needed.
Is the repair complete?
–
System OK
–

ENGINE CONTROLS 1F–289
DAEWOO M-150 BL2
Lack of Power, Sluggishness, or Sponginess (Cont’d)
StepActionValue(s)YesNo
15
Repair or replace any engine components as
needed.
Is the repair complete?
–
System OK
–
16
1. Check the Engine Control Module (ECM) grounds
for being clean, tight, and in their proper location.
2. Check the exhaust recirculation valve for being
open or partially open all the time.
3. Check the torque converter clutch operation.
4. Check the A/C system operation.
5. Check the generator output.
6. Repair the generator if the output is not within the
specified range.
Are all checks and repairs complete?
12–16 VSystem OK
–

ENGINE CONTROLS 1F–291
DAEWOO M-150 BL2
Detonation/Spark Knock (Cont’d)
StepActionValue(s)YesNo
12
1. Inspect for carbon buildup inside the engine.
2. Remove the carbon with a top engine cleaner.
Follow the instructions supplied with the product.
3. Check the basic engine parts such as the
camshaft, the cylinder head, the pistons, etc. for
excessive wear.
4. Replace any excessively worn parts.
Is the procedure complete?
–
Go to Step 13
–
13
1. Check the exhaust gas recirculation valve for
proper operation.
2. Check the air intake system for proper operation.
3. Check the torque converter clutch operation and
transaxle shift points.
4. Check the service bulletins for Programmable
Read Only Memory (PROM) updates.
5. Check the cylinder compression.
6. Repair or replace any faulty components.
Are all checks and repairs complete?
–
System OK
–

HYDRAULIC BRAKES 4A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
BRAKE SYSTEM (NON–ABS)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
MAB4A001
1. Power Booster
2. Power Booster Boot
3. Cotter Pin
4. Clevis
5. Clevis Pin
6. Packing
7. Spacer
8. Master Cylinder Assembly
9. Fluid Reservoir Assembly
10. Reservoir Cap
11. Reservoir
12. Grommet Seal
13. Master Cylinder
14. Proportioning Valve
15. Stoplamp Switch
16. Brake Pedal Assembly
17. Clutch Pedal Spring18. Pedal Bracket Assembly
19. Clutch Pedal Pad
20. Clutch Pedal
21. Cushion
22. Bushing
23. Retaining Ring
24. Spring
25. Brake Pedal Pad
26. Brake Pedal
27. Brake Pedal Spring
28. Accelator Pedal Pad
29. Accelator Pedal
30. Rear Drum Brake Hose
31. E Ring
32. Front Disc Brake Hose
33. Brake Hose Coupling Bolt
34. Plain Washer

5B–8 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURE
GENERAL DIAGNOSIS
ConditionProbable CauseCorrection
Gear Slipping Out of Mesh
Worn shift fork.
Replace shift fork.

Worn synchronizer sleeve or gear.
Replace sleeve or gear.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Weakened or damaged location
spring.
Replace spring.

Loose or damaged synchronizer
spring.
Replace synchronizer spring.

Excessive back-lash of gear.
Adjust back-lash of gear.
Gear Catching
Bent or distorted shift shaft or shift
fork.
Replace shift shaft or shift fork.

Weakened or damaged
synchronizer spring.
Replace spring.
Hard Shifting
Worn synchronizer ring.
Replace synchronizer ring.

Worn synchronizer sleeve or gear.
Replace sleeve or gear.

Bent or distorted shift shaft.
Replace shift shaft.

Excessive free travel of all gears
in axial direction.
Replace gear.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Poor adjustment of clutch cable.
Adjust clutch cable.

Distorted or broken clutch disc.
Replace clutch disc.

Damaged pressure plate.
Replace pressure plate.
Noise in the Neutral Gear
Insufficient lubricant.
Supply lubricant.

Worn input shaft gear.
Replace gear.

Worn bearings on the input shaft
gears.
Replace bearing.

Worn clutch release bearing.
Replace clutch release bearing.
Noise in the All Gears
Insufficient lubricant.
Supply lubricant.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Worn input shaft or counter shaft
gear.
Replace gear.

Worn or damaged synchronizer
ring.
Replace synchronizer ring.

Worn or damaged synchronizer
sleeve.
Replace synchronizer sleeve.

Worn differential gear or bearing.
Replace gear or bearing.
Noise in the Peculiar Gear
Worn or damaged synchronizer
ring in the peculiar gear.
Replace synchronizer ring.

Worn or damaged gear in the
peculiar gear.
Replace gear.

Worn or damaged bearing in the
peculiar gear.
Replace bearing.
Leak of Lubricant
Damaged gasket, oil seal or
O-ring.
Replace gasket, oil seal or O-ing.

FIVE-SPEED MANUAL TRANSAXLE 5B–9
DAEWOO M-150 BL2
CHECKING FLUID LEVEL
Check for a leak in the area of transaxle case and seal-
ing and then check fluid level and condition after remov-
ing oil level plug.
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Remove the oil level plug and check the fluid level.
4. The fluid should slightly flow out from the oil level plug
hole.
5. If the level is low, add the recommended fluid through
the oil level plug hole until the fluid begins to run out.
6. If the fluid is contaminated or discolored, replace it
with the recommended fluid.
7. Reinstall the oil level plug and tighten it securely.
D103B301
CHANGING FLUID
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Drain the fluid after removing the drain plug.
4. Reinstall the drain plug and tighten it securely after
coating sealant.
5. Remove the oil level plug and replenish the fluid until
it begins to run out.
a. Oil drain plug.
b. Oil level plug.
6. Reinstall the oil level plug and tighten it securely.Fluid Specification
75W-85(GL-4)
Fluid Capacity2.1L(2.21qt)
Service intervalRefer to Owner’s Manual
CHECKING TRANSAXLE NOISE
Many noises that appear to come from the transaxle
may actually originate with other sources such as tires,
road surfaces, wheel bearings, or engine and exhaust
system.
Identify the cause of any noise before attempting to re-
pair the clutch, the transaxle, or their related linkages.
To verify suspected transaxle noises,
1. Select a smooth, level asphalt road to reduce tyre
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lubri-
cants thoroughly.
3. Record the speed and the gear range of the transaxle
when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle oper-
ates in.

Drive – Under a light acceleration or a heavy pull.

Float – Maintaining a constant speed with a light
throttle on a level road.

Coast – With the transaxle in gear and the throttle
partly or fully closed.

All of the above.
CHECKING BEARING NOISE
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre-
loaded, a differential side bearing noise should not di-
minish much when the differential/transaxle is run with
the wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre-loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.

5B–12 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B510
12. Remove the transaxle upper bolts.
a. Exhaust manifold side bolt.
b. Thermostat housing side bolt.
D103B505
13. Remove the transaxle under cover.

Remove the bolts (1).

Remove the transaxle under cover (2).
14. Remove the front tires and wheels.
D103B506
15. Drain the transaxle fluid.

Remove the drain plug and drain the fluid.
16. Disconnect the clutch cable.

Remove the cable adjust nut (1).

Disconnect the cable from the wire clip (2).

Disconnect the cable from the transaxle mount
hole (3).
D103B509
17. Remove the front under longitudinal frames and sta-
bilizer. Refer to Section 2C, Front Suspension.
18. Remove the drive axle (only transaxle side). Refer
to Section 3B, Manual Transaxle Drive Axle.
19. Remove the clutch housing lower plate.

Remove the bolts (1).

Remove the lower plate (2).

5B–16 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5032
8. Install the radiator lower hose and crank position
(CKP) sensor.
Tighten
Tighten the radiator lower hose bolt to 8–15 Nm
(70–132 lb-in).
Tighten the CKP sensor bolt to 5–8 Nm (44–70 lb-
in).
D13B520A
9. Refill the transaxle fluid.

Tighten the drain plug to 25–30 Nm (18–22 lb-ft)
(a).

Remove the oil level plug (1).

Refill recommended fluid to the proper level.
Classification 75W – 85 (GL–4) Capacity2.1L (2.21 qt)

Tighten the oil level plug to 36–54 Nm (26–40 lb-ft)
(b).
D13B521A
10. Adjust the clutch cable. Refer to Section 5C, Clutch.

Adjust the clutch cable by the clutch cable adjust
nut.
11. Install the transaxle under cover.
Tighten
Tighten the transaxle under cover bolts to 35–55
Nm (25–41 lb-ft).
D103B501
GEAR SHIFT CONTROL CASE
ASSEMBLY
Removal Procedure
1. Remove the air hose (air cleaner to throttle body).
Refer to Section 1B, SOHC Engine Mechanical.
2. Remove the battery.
3. Disconnect the select and the shift control cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift control cable
(3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.

5B–22 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B540
Installation Procedure
1. Install in the reverse order of removal.
2. Push the cables toward the engine compartment
through dash panel’s hole slightly.
3. Position the cables on the select and the shift lever.
D13B5411
4. Connect the transaxle side select and shift control
cable.
5. Connect the gear shift lever side shift control cable.
6. Connect the gear shift lever side select control cable.

Insert the select control cable eye ring to the select
arm pin (1).

Install the selector lever control cable clip (2).

Install the select control cable to gear shift lever
bracket with E–ring (3).

Insert a driver to the select arm adjustment hole to
prevent the movement of gear shift lever in NEU-
TRAL (4).
7. Tighten the adjust nuts.
Tighten
Tighten the select cable adjust nut to 8–12 Nm
(71–106 lb-in).
D103B543
GEAR SHIFT CONTROL LEVER
Removal Procedure
1. Remove the floor console. Refer to Section 9G, Inte-
rior Trim.
2. Disconnect the select and shift control cable. Refer to
“Gear Shift control cable” in this section.
3. Remove the gear shift control lever assembly.

Remove the bolts (1).

Remove the gear shift control lever assembly (2).

Remove the gear shift lever sensor connector.
(If equipped with auto clutch).