drain bolt DAEWOO MATIZ 2003 Service User Guide

MANUAL TRANSAXLE DRIVE AXLE 3B–5
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D106B506
DRIVE AXLE ASSEMBLY
Tool Required
KM–507–B Tie Rod End Joint Remover
Removal Procedure
1. Remove the drive axle shaft nut.
Fix the hub not to rotate by pressing the brake ped-
al.
Loosen the caulking (1).
Remove the nut (2).
Discard the nut.
Remove the washer (3).
D103B505
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Remove the transaxle under cover.
Remove the bolts (1).
Remove the under cover (2).
D104B501
4. Drain the transaxle fluid through the drain plug.
5. Remove the stabilizer bar. Refer to Section 2C, Front
Suspension.
6. Separate the control arm ball joint and the tie rod end
from the knuckle. Refer to Section 6D, Manual Steer-
ing gear and Section 2C, Front Suspension.
a. Control arm ball joint bolt.
b. Tie rod end joint castellated nut.
Notice: Use only the recommended tool for separating
the tie rod from the knuckle/strut assembly. Failure to
use the recommended tool may cause damage to the
knuckle/strut assembly or the tie rod end.

MANUAL TRANSAXLE DRIVE AXLE 3B–7
DAEWOO M-150 BL2
D14B505B
5. Install the control arm ball joint bolt.
Tighten
Tighten the control arm ball joint bolt to 50–70 N
m
(36–52 lb-ft).
a. Control arm ball joint bolt
6. Install the tie rod into the knuckle and install the tie
rod end joint castellated nut.
Tighten
Tighten the tie rod end joint castellated nut to 30–55
N
m (21–41 lb-ft).
b. Tie rod end joint castellated nut.
D14B506A
33–53 N
m
40–50 N
m7. Install the stabilizer bar.Tighten
Tighten the stabilizer bar mounting bolts 33–53
N
m (24–39 lb-ft).
Tighten the stabilizer bar castellated nut to 40–50
N
m (30–36 lb-ft).
a. Stabilizer bar mounting bolt.
b. Stabilizer bar castellated nut.
D14B507A
8. Install the drive axle shaft nut.
Tighten
Tighten the drive axle shaft nut to 210 N
m (155 lb-ft)
Notice: Always use a new nut. Always peen the
caulking nut with a punch and a hammer until the nut
is locked into place on the wheel hub.
9. Install the wheels. Refer to Section 2E, Tires and
wheels.
D13BB520A
10. Refill the transaxle fluid to the proper level.
Tighten the drain plug to 25-30 N
m (18-22 lb-ft)
(a).
Remove the oil level plug (1).
Refill recommended fluid to the proper level.
Tighten the oil level plug to 36-54 N
m (26–40 lb-
ft) (b).
Classification 75W–85 (GL–4) Capacity2.1L (2.21 gt)

3B –12 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Description

Unit

Standard

Limit
Inner

–Tripot Joint

– Type
Outer

–Rzeppa Joint

–
Right

mm (in.)553.5(21.79)

– Length
Left

mm (in.)386.5(15.22)

– Drive AxleShaft Diameter

mm (in.)22 (0.87)

–


Inner

g (ounce)90 – 100
(3.2 – 3.5)

–


Grease Capacity
Outer

g (ounce)80 – 90
(2.8 – 3.2)
–
FASTENER TIGHTENING SPECIFICATIONS
Application N
m Lb-Ft Lb-In
Control Arm Ball Joint Bolt 50 – 70 36 – 52 –
Tie Rod End Joint castellated Nut 30 – 55 21 – 41 –
Stabilizer Bar Bolt 33 – 53 24 – 39 –
Stabilizer Bar Castellated Nut40 – 5030 – 36–
Drive Axle Shaft Nut 210 155 –
Wheel Nut 90 – 11 0 66 – 81 –
Transaxle Under Cover Bolt35 – 5525 – 41–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–

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.

FIVE-SPEED MANUAL TRANSAXLE 5B–53
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
5th/Reverse Gear Shift Shaft Bolt10 – 167 – 12–
Back Up Light Switch Nut15 – 1811 – 13–
Counter Shaft 5th Gear Nut60 – 8044 – 59–
Crankshaft Position Sensor Bolt5 – 8–44 – 70
Differential Ring Gear Bolt80 – 10059 – 74–
Engine Mounting Front Bracket Bolt
(Cylinder Block Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolt
(Crossmember Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolts
(Crossmember Side)45 – 5533 – 41–
Engine Mounting Front Damping Bush Bolt/Nut
(Bracket Side)68 – 8351 – 61–
Front Exhaust Pipe Nut
(Exhaust Manifold Side/Muffler Side)25 – 3518 – 25–
Gear Shift Control Case Bolt18 – 2813 – 21–
Gear Shift Lever Bolt4 – 7–35 – 62
High Speed Shift Shaft Bolt10 – 167 – 12–
Low Speed Shift Shaft Bolt10 – 167 – 12–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–
Radiator Lower Hose Bracket Bolts8 – 15–70 – 132
Reverse Idle Gear Shaft Bolt18 – 2813 – 21–
Reverse Shift Lever Bolt18 – 2813 – 21–
Select Cable Nut(Shift Lever Side)8 – 12–71 – 106
Select Lever Bolt18 – 2813 – 21–
Side Cover Plate Screw6 – 7–53 – 62
Shift Guide Bolt18 – 2813 – 21–
Shift Interlock Bolt18 – 2813 – 21–
Side Cover Bolt8 – 12–71 – 106
Speedometer Driven Gear Bolt4 – 7–35 – 62
Starter Motor Bolt18 – 2813 – 21–
Transaxle Case Bolt15 – 2211 – 16–
Transaxle Case(left) Cap Bolt8 – 12–71 – 106
Transaxle Lower Bolt and Nut(Engine Side)55 – 6541 – 48–
Transaxle Mounting Bolt(Body Side)45 – 5533 – 41–
Transaxle Mounting Bolt and Nut(Transaxle Side)55 – 6541 – 48–
Transaxle Upper Bolt(Engine Side)55 – 6541 – 48–
Transaxle Under Cover Bolt35 – 5525 – 41–

7B -- 26 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
D18B530B
D18B531A
DTighten the bracket nut to 5 NSm (44 lb-in) (2).
DTighten the bolt securing the A/C low pressure pipe
line at the compressor to 23 NSm (17 lb-ft) (3).
2. Evacuate and recharge the system. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedure for A/C System” in this section.
3. Connect the negative battery cable.
D108B532
D108B533
EVAPORATOR UNIT AND DRAIN
HOSE
(Left -- Hand Drive Shown, Right -- Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedures for A/C System” in this section.
3. Loosen the high pressure pipe line (receiver dry-
er→evaporator) nut and the low pressure pipe line
(evaporator→compressor) nut.
4. Remove the glove box. Refer toSection 9E, Instru-
mentation/Driver information.
5. Remove the evaporator unit.
DRemove the drain hose (1).
DDisconnect the thermistor connector (2).
DRemove the screws (3).
DRemove the evaporator backward slowly (4).

WIPERS/WASHER SYSTEMS 9D–11
DAEWOO M-150 BL2
D19D537A
3. Raise and suitably support the vehicle.
4. Remove the front RH wheelhouse splash shield.

Remove the screws (1).

Remove the clips (2).

Remove the wheelhouse splash shield (3).
D109D538
5. Remove the washer reservoir assembly.

Drain the washer fluid.

Disconnect the washer hose connector (1).

Disconnect the washer pump electrical connector
(2).

Remove the bolts (3).

Remove the washer reservoir assembly (4).
D109D539
Installation Procedure
1. Install the washer reservoir assembly with the bolts.
2. Connect the washer pump electrical connector.
3. Connect the washer hose connector.
4. Install the front RH wheelhouse splash shield with the
screws and the clips.
5. Lower the vehicle.
6. Install the washer reservoir with the bolt.
7. Connect the negative battery cable.
D109D540
WASHER PUMP
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the washer reservoir assembly. Refer to
“Washer Reservoir” in this section.
3. Drain the washer fluid.
4. Remove the wiper motor from the washer reservoir
assembly.
a. Washer pump.