length DAEWOO MATIZ 2003 Service User Guide

4A –6 HYDRAULIC BRAKES
DAEWOO M-150 BL2
MANUAL BLEEDING THE BRAKES
Important: The bleeding sequence is as follows; right
rear, left rear, right front, and left front.
Important: Check the fluid level and add the fluid during
the bleeding operation.
1. Raise the vehicle.
2. Remove the bleeder screw and cap.
D17B703B
3. Attach a transparent tube over the valve. Allow the
tube to hang submerged in brake fluid in a transpar-
ent container.
D107A303
4. Slowly push the brake pedal several times and hold
the brake pedal.5. Tighten the bleeder screw after loosening the bleeder
screw and draining the fluid.
Caution: Hold the brake pedal until tightening the
bleeder screw.
6. Repeat the step 5, 6 until all the air is removed.
7. Check the leaks for the bleeder screw.
PEDAL TRAVEL CHECK
1. Start the engine.
2. Push the pedal three times.
3. With brake pedal depressed with a about 30Kg (66.15
lb) load, measure the clearance between the pedal
pad and the lower dash panel.
Unit : mm (in.)

Specification

60 (2.36)
D107A304
4. If clearance is less than 60mm (2.36 in.), the most
possible cause is either rear drum brake shoes are
worn out beyond the specification value or air is in
lines. Clearance still remains less than 60mm (2.36
in.) even after replacement of brake shoes and bleed-
ing of the brake system, other possible but infrequent
cause is malfunction of rear drum brake shoe adjust-
ers or booster push rod length out of adjustment.
5. Automatic clearance adjuster check is performed af-
ter removing brake drums. If the faulty is found, repair
or replace it.

FIVE-SPEED MANUAL TRANSAXLE 5B–19
DAEWOO M-150 BL2
D13B530A
3. Install the gear shift control case and the select lever.
Tighten

Tighten the gear shift control case bolts to 18–28
Nm (13–21 lb-ft).
a. Gear shift control case bolt.

Tighten the select lever bolts to 18–28 Nm (13–21
lb-ft).
b. Select lever bolt.
Important: Make sure a correct bolt. There is length dif-
ference between select lever bolts.
D13B531A
4. Install the shift interlock bolt.
Tighten
Tighten the shift interlock bolt to 18–28 Nm (13–21
lb-ft).
D103B532
SPEEDOMETER DRIVEN GEAR AND
CABLE
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the speedometer driven gear assembly.

Loosen the nut. (1).

Disconnect the cable (2).

Remove the bolt (3).

Remove the speedometer driven gear assembly
(4).
D103B533

Disconnect the vehicle speed sensor connector (If
equipped).
a. Vehicle speed sensor connector.

Disconnect the vehicle speed sensor.
b. Vehicle speed sensor.
Caution: Be careful to prevent personal injury while
the exhaust pipe is hot.

5C – 2 CLUTCH
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRIVING MEMBERS
The driving members consist of two flat surfaces ma-
chined to a smooth finish. One of these is the rear face
of the engine flywheel, and the other is the pressure
plate. The pressure plate is fitted into a steel cover,
which is bolted to the flywheel.
DRIVEN MEMBERS
The driven member is the clutch disc with a splined hub
which is free to slide lengthwise along the splines of the
input shaft, but which drives the input shaft through
these same splines.The driving and driven members are held in contact by
spring pressure. This pressure is exerted by a dia-
phragm spring in the pressure plate assembly.
OPERATING MEMBERS
The clutch release system consists of the clutch pedal,
the clutch release shaft, the clutch cable, the release
arm and the release bearing. When pressure is applied
to the clutch pedal, the clutch release shaft pushes
against the release bearing by rotating. The bearing
then pushes against the diaphragm spring in the pres-
sure plate assembly, thereby releasing the clutch.

8A –2 SEAT BELTS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRIVER SEAT BELT WARNING
The driver’s safety belt incorporates a safety belt re-
minder light in the instrument cluster to remind the driver
if the safety belt is not fastened when the ignition is
turned ON.
THREE-POINT PRETENSIONER
FRONT SEAT BELT (W/EUROPE
ONLY)
The pretensioner front seat belt is optional. It contains a
electrically-controlled pyrotechnical retractor, which re-
duces seat belt slack when it is activated in a head-on or
angled front collision. The pretensioner front seat belt
must be replaced after an accident that causes its ac-
tivation.
THREE-POINT WLR FRONT SEAT
BELT
The three-point web locking retractor (WLR) seat belt
will limit the movement of the driver and offer better
protection in an accident.
THREE-POINT ELR FRONT SEAT
BELT
The three-point emergency locking retractor (ELR) front
seat belt is always unlocked, allowing the passenger
freedom of movement, except in emergencies (rapid de-
celeration, rapid acceleration, or hard cornering maneu-
vers).
THREE-POINT ELR REAR
OUTBOARD SEAT BELT
The rear outboard seating positions use the three-point
emergency locking retractor (ELR) seat belts. The
three-point emergency locking retractor (ELR) seat beltis always unlocked, allowing the passenger freedom of
movement, except in emergencies (rapid deceleration,
rapid acceleration, or hard cornering maneuvers).
TWO-POINT LAP REAR CENTER
SEAT BELT
The two-point lap rear center seat belt is a single contin-
uous length of webbing. The webbing is routed from the
anchor through a latch plate and into a single retractor.
OPERATIONAL AND FUNCTIONAL
CHECKS
Caution:

Keep sharp objects and potentially damaging ob-
jects away from the seat belts.

Avoid bending or damaging any portion of the
buckle or the latch plate.

Do not bleach or dye the belt webbing. Use only
mild soap and water in order to clean the belts.

When installing the seat belt anchor bolts and
the screws, start the bolts and the screws by
hand in order to prevent crossthreading.

Do not attempt any repairs on the retractor mech-
anisms or the covers. Replace any defective as-
semblies with new assemblies.

Replace any belts that are cut or damaged in any
way.
1. Inspect all seat belt anchor bolts and the screws in or-
der to verify that they are secure.
2. Inspect the seat belt buckle. The buckle must lock
and unlock easily.
3. After inserting the latch into the buckle, tug sharply on
the belt. The buckle must remain locked.
4. Fully extend the shoulder belt portion to make sure
that there is no twisting or tears in the belt.
5. Let the shoulder belt retract fully. The belt should re-
tract easily.

9T–2 REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
REMOTE KEYLESS ENTRY AND
ANTI-THEFT SYSTEM
The remote keyless entry and anti-theft system can per-
form the following functions:

Remotely lock and unlock the vehicle doors with a
hand-held high-frequency transmitter.

Sense intrusion into the vehicle through the doors,
the tailgate, or the hood.

Activate a warning to signal an intrusion.

Help the driver find the vehicle in a parking area.

Automatically re-lock the doors if a door or the trunk is
not opened within 30 seconds after the vehicle has
been unlocked by the remote keyless entry.

Communicate serial data to a scan tool to help diag-
nose system faults.
The remote keyless entry and anti-theft system consists
of the following components:

Keyless entry and anti-theft control module/receiver.

Security indicator.

Tailgate open switch.

Door open switches.

Central locking unit.

Flashing turn signal lamps.

Siren.

Hood open switch.
REMOTE LOCKING AND UNLOCKING
The hand-held transmitter locks and unlocks the vehicle
doors by sending radio waves to the control module/re-
ceiver in the vehicle. The effective range of the transmit-
ter varies between 5 and 10 meters (approximately 16 to
32 feet), depending on whether or not objects such as
other vehicles are blocking the path of the radio waves.
The transmitter has a LOCK button and an UNLOCK
button which only function when the ignition is OFF.
Pressing the UNLOCK button has the following effects:

The doors are unlocked.

The turn signal lamps flash twice.

The control module is disarmed.
Pressing the LOCK button has the following effects:

The doors are locked.

The turn signal lamps flash once.

The control module is armed.
The transmitter has a replaceable battery. The battery is
designed to last at least two years before replacement is
necessary.
SECURITY INDICATOR
There is a security indicator on the instrument panel. Af-
ter the LOCK button of the transmitter is pressed, the
module is placed in the armed mode, and the security
indicator flashes. The security indicator turns ON for 1/8
second and OFF for 7/8 second. It then flashes at that
frequency until the control module/receiver is disarmed.
INTRUSION SENSING
The anti-theft function is armed if the transmitter sends
the LOCK message to the control module/receiver when
the ignition is OFF.
When the hood, the door, or the tailgate is opened, the
hood open switch, the door open switch, or the tailgate
open switch will change its input to ground. The alarm
will be activated if the hood open sensor, the door open
sensor, or the tailgate open sensor changes its input to
ground before either of the following conditions occurs:

An UNLOCK message is received from the transmit-
ter.
SIREN
The remote keyless entry system is armed when the
LOCK message is received from the transmitter when
the ignition is OFF. When the system is armed, it will ac-
tivate the siren and flash the turn signals for 28 seconds
if any of the following conditions occurs:

A door is opened (front door open switch input is
changed to ground).

The tailgate is opened (tailgate open switch input is
changed to ground).

The hood is opened while the anti-theft system is
armed (hood open switch input is changed to
ground).
The siren is disarmed when any of the following condi-
tions occurs:

The ignition switch is turned ON with the key.

The UNLOCK button or the LOCK button on the re-
mote transmitter is pressed.
VEHICLE LOCATOR
The remote keyless entry system assists the driver in lo-
cating the vehicle. When the vehicle is unlocked with the
remote control, the turn signals flash twice to indicate
the location of the vehicle. The duration of the flashes
and the length of time between flashes is used to indi-
cate certain vehicle conditions. Refer to “Fault or Alarm
Indication” in this section.

9T–10 IMMOBILIZER ANTI-THEFT SYSTEM
DAEWOO M–150 BL2
DESCRIPTION AND OPERATION
IMMOBILIZER SYSTEM
The purpose of the Immobilizer system is to provide
additional theft deterrence to the vehicle in which it is
installed and to prevent it from being stolen or driven by
unauthorized users.
The verification of the user authorization is done by an
ignition key with integrated transponder.
The external LED displays the Immobilizer status and
has an additional theft deterrence function.
To secure the communication, the status is exchanged
between the Immobilizer and the ECM in a 5 byte of en-
coded data.
These 5 bytes are composed by a mixture of random
data and two types of fixed code

a vehicle model identification number : MIN

a vehicle specific identification : VIN
The MIN is known from the first supply of the system.
The VIN is realized by ICU on the special order from the
key coding (reading of transponder code and storing it
as valid key code in Immobilizer EEPROM).
A different random data is computed at each key transi-
tion.
All the immobilization communication between the ECM
and ICU is made on K-line (K line : Serial data line ’7’).
Due to the learning of the Vehicle specific identification
Number, both ICU and ECM can stay in 3 stable modes

Virgin mode (VIN not learnt)

Learnt mode (VIN learnt)

Neutral mode (for a new VIN learning)
In case of using valid key, the release message commu-
nication with the ECM take place and the LED displays
the Immobilizer status valid key In case of using invalid
key, the ECM disables the fuel injector circuit with coded
intervention and sets DTC(Diagnostic Trouble Code)
The above conditions are maintained until the ignition is
switched off.
An ECM without an immobilizer control unit cannot be
interchanged for an ECM that is used with an immobiliz-
er control unit system. The Immobilizer control unit and
ECM must have a matching ID code. ID coding and key
coding are accomplished by using Scanner–100
The Immobilizer system consists of

a maximum or 5 ignition keys with integrated trans-
ponder

the toroidal coil (Detection coil) for energizing and
reading the transponder mounted at the ignition lock.

the Immobilizer control unit(ICU) with :
– power supply
– ignition input circuit
– transponder modulation and demodulation unit – EEPROM
– driver electronic for the external status LED
– serial data link hardware

the external status LED for displaying the Immobilizer
status

the serial data link between Immobilizer and ECM
ELECTRONICALLY CODED KEYS
Each valid ignition key has an internal transponder
which is a read /write transponder.
The transponder contains an implementation of a cryp-
to-algorithm with 96 bits of user configurable s cret-key
contained in EEPROM and transmits data to the ICU by
modulating the amplitude of the ele tromagnetic field,
and receives data and commands in a similar way.
DETECTION COIL
The toroidal coil is mounted at the ignition lock in front of
the key barrel.
It is connected to the ICU with a four terminal connector
fixed at the body of the coil.
The length of the connection between coil and Immobi-
lizer is restricted to 50cm. The correct placement on the
ignition lock and the exact electrical data is very impor-
tant for the reading distance of transponder.
The toroidal coil and receiving coil inside the transpond-
er built a transformer. During the readingprocess the coil
induces energy into the transponder. The transponder
charges the field and generates an amplitude modulated
signal with the manchester coded data. This charge of
the field is demodulated inside the Immobilizer.
The Immobilizer contains the coil driver hardware for di-
rect connection of the toroidal coil.
IMMOBILIZER CONTROL UNIT
The function of the Immobilizer System is shared be-
tween the ICU and the ECM.
The task of the Immobilizer Electronic Control unit (ICU)
are:

Reading of the input information “ignition ON/OFF”

Controlling the states LED

Controlling the transponder read/write process (mod-
ulation, demodulation, decoding, comparison of the
read code with the code of the valid keys).

Communication with the ECM after ignition ON (re-
ceiving of the ECM-request and transmission of re-
lease message).

Special functions for calculation and handling of the
VIN-code.