steering DAEWOO MATIZ 2003 Service User Guide

SUSPENSION DIAGNOSIS 2A–5
DAEWOO M-150 BL2
Condition Probable Cause Correction
Steering Wheel
Air in the power steering system.
Bleed the power steering system.
Kickback (Power)
A loose steering gear mounting.
Tighten the steering gear mounting
bracket bolts.

Loose connections or wear of the joint
from the steering column to the
intermediate shaft.

Loose connections or wear of the joint
from the intermediate shaft to the
steering gear.
Tighten the coupling pinch bolts.

Replace the intermediate shaft as
needed.

Loose tie rod ends.
Tighten the tie rod ends.

Replace the tie rods as needed.

Loose or worn wheel bearings.
Tighten the drive axle nut.

Replace the wheel bearing as needed.
Steering Wheel Surges
or Jerks (Power)
Low pressure in the power steering
system.
Replace the seals and the hoses as
needed.

A sluggish steering gear valve.
Clean the pinion valve assembly.

Replace the pinion valve assembly as
needed.

A loose power steering pump drive
belt.
Adjust the power steering pump drive
belt.
Cupped Tires
The front–wheel and the rear–wheel
alignment are out–of–align.
Align the front and the rear wheels.

Worn strut dampeners.
Replace the strut dampeners.

Worn or loose wheel bearing.
Tighten the drive axle nut.

Replace the wheel bearings as
needed.

Excessive tire or wheel runout.
Match–mount the tires.

Replace the tires as needed.

Replace the wheels as needed.

A worn ball joints.
Replace the control arm and ball joint
assembly.

The steering gear preload adjustment
is out–of–adjustment.
Perform a rack bearing preload
on–vehicle adjustment.

DAEWOO M-150 BL2

SECTION 2B
WHEEL ALIGNMENT
TABLE OF CONTENTS
Description and Operation 2B-2. . . . . . . . . . . . . . . . . .
Four Wheel Alignment 2B-2. . . . . . . . . . . . . . . . . . . . .
Toe 2B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caster 2B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camber 2B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Axis Inclination 2B-3. . . . . . . . . . . . . . . . . . . .
Included Angle 2B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scrub Radius 2B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setback 2B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turning Angle 2B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures 2B-4. . . . .
Tire Diagnosis 2B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Toe Adjustment 2B-5. . . . . . . . . . . . . . . . . . . . . .
Front Camber and Caster Check 2B-5. . . . . . . . . . . .
Rear Camber Check 2B-5. . . . . . . . . . . . . . . . . . . . . . .
Rear Toe Check 2B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 2B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Alignment Specifications 2B-6. . . . . . . . . . . . .
Fastener Tightening Specifications 2B-6. . . . . . . . . . .

2B – 2 WHEEL ALIGNMENT
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FOUR WHEEL ALIGNMENT
The first responsibility of engineering is to design safe
steering and suspension systems. Each component
must be strong enough to withstand and absorb extreme
punishment. Both the steering system and the front and
the rear suspension must function geometrically with the
body mass.
The steering and the suspension systems require that
the front wheels self-return and that the tire rolling effort
and the road friction be held to a negligible force in order
to allow the customer to direct the vehicle with the least
effort and the most comfort.
A complete wheel alignment check should include mea-
surements of the rear toe and camber.
Four-wheel alignment assures that all four wheels will be
running in precisely the same direction.
When the vehicle is geometrically aligned, fuel economy
and tire life are at their peak, and steering and perfor-
mance are maximized.
TOE
D16A006A
Toe–in is the turning in of the tires, while toe–out is the
turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the
wheel support system which occur when the vehicle is
rolling forward. The specified toe angle is the setting
which achieves–degrees (0
) of toe when the vehicle is
moving.
Incorrect toe-in or toe-out will cause tire wear and re-
duced fuel economy. As the individual steering and sus-
pension components wear from vehicle mileage,
additional toe will be needed to compensate for the
wear.
Always correct the toe dimension last.
CASTER
D16A008A
Caster is the tilting of the uppermost point of the steering
axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is
positive, and a forward tilt is negative. Caster influences
directional control of the steering but does not affect tire
wear. Weak springs or overloading a vehicle will affect
caster. One wheel with more positive caster will pull to-
ward the center of the car. This condition will cause the
car to move or lean toward the side with the least
amount of positive caster. Caster is measured in de-
grees and is not adjustable.
CAMBER
D16A007A
Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the
tires tilt outward, the camber is positive. When the tires
tilt inward, the camber is negative. The camber angle is
measured in degrees from the vertical. Camber in-
fluences both directional control and tire wear.
If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Camber is measured in degrees and is not adjustable.

WHEEL ALIGNMENT 2B–3
DAEWOO M-150 BL2
STEERING AXIS INCLINATION
Steering Axis Inclination (SAI) is the tilt at the top of the
steering knuckle from the vertical. Measure the SAI
angle from the true vertical to a line through the center of
the strut and the lower ball joint as viewed from the front
of the vehicle.
SAI helps the vehicle track straight down the road and
assists the wheel back into the straight ahead position.
SAI on front wheel drive vehicles should be negative.
INCLUDED ANGLE
The included angle is the angle measured from the cam-
ber angle to the line through the center of the strut and
the lower ball joints as viewed from the front of the ve-
hicle.
The included angle is calculated in degrees Most align-
ment racks will not measure the included angle directly.
To determine the included angle, subtract the negativeor add the positive camber readings to the Steering Axis
Inclination (SAI).
SCRUB RADIUS
The scrub radius is the distance between true vertical
and the line through the center of the strut and lower ball
joint to the road surface. Scrub radius is bulit into the de-
sign of the vehicle. Scrub radius is not adjustable.
SETBACK
The setback is the distance in which one front hub and
bearing assembly may be rearward of the other front
hub and bearing assembly. Setback is primarily caused
by a road hazard or vehicle collision.
TURNING ANGLE
The turning angle is the angle of each front wheel to the
vertical when the vehicle is making a turn.

2B–4 WHEEL ALIGNMENT
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
TIRE DIAGNOSIS

Condition

Probable cause

Correction
Irregular and Excessive
Tire WearIncorrect inflation pressure.Inflate the tires to the proper
pressure.
Inbalanced wheel.Balance the wheel.
Replace the wheel.
A lack of regular rotation.Rotate the tires.
Incorrect alignment.Align the front and rear wheels.
Premature Tire WearExcessive inflation pressure.Inflate the tires to the proper
pressure.
High speed driving with the low
inflation pressure.Inflate the tires to the proper
pressure.
Uneven BrakingInbalanced inflation pressure.Inflate the tires to the proper
pressure.
Irregular tire wear.Replace the tires.
Noise and Vibration of
The BodyLow inflation pressure.Inflate the tires to the proper
pressure.
Inbalanced wheel.Balance the wheel.
Replace the wheel.
Damaged wheel or tire.Replace the wheel and the tire.
Irregular tire wear.Replace the tire.
Vibration of The SteeringIrregular tire wear.Replace the tire.
WheelInbalanced inflation pressure.Inflate the tires to the proper
pressure.
Damaged tire.Replace the tire.
Bent or damaged wheel.Replace the wheel.

2B–6 WHEEL ALIGNMENT
DAEWOO M-150 BL2
SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS

Application

Front

Rear
Camber0
30′ ± 0
30′0

20′
Caster–Manual Steering2
48′ ± 30′–
Caster–Power Steering2
48′ ± 30′–
To e–in (2–person load)10′ ± 10′20′
20′
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In Tie Rod End Lock Nut 45 33 –

2C – 2 FRONT SUSPENSION
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FRONT SUSPENSION
The front suspension for this vehicle is a combination
knuckle/strut and spring design.
The control arms pivot from the body. The lower control
arm pivots use rubber bushing. The upper end of the
strut is isolated by a rubber mount and contains a bear-
ing to allow the wheel to turn.
The lower end of the steering knuckle pivots on a ball
joint bolted to the control arm. The ball joint is fastened
to the steering knuckle with a bolt.When servicing the control arm-to-body attachment and
the stabilizer shaft-to-body insulators, make sure the at-
taching bolts are loose until the control arms are moved
to the trim height, which is curb height. Trim height is the
normal position to which the control arms move when
the vehicle is sitting on the ground. Refer to “General
Specifications” in this section.

2C –4 FRONT SUSPENSION
DAEWOO M-150 BL2
1. Strut Bar
2. Front Suspension Strut Assembly
3. Strut Inner Support
4. Strut Mount Assembly
5. Strut Mount Seat
6. Strut Bearing Seat
7. Strut Bearing
8. Coil Spring Upper Seat
9. Coil Spring Seat
10. Bumper Stopper
11. Coil Spring
12. Strut
13. Inner Bearing Oil Seal
14. Inner Hub Bearing
15. Steering Knuckle
16. Dust Cover
17. Hub Bearing Spacer
18. Outer Hub Bearing19. Outer Bearing Oil Seal
20. Rotor
21. Wheel Hub
22. Hub Bolt
23. Hub Assembly
24. Drive Axle–to–Hub Caulking Nut
25. Control Arm Ball Stud Bolt
26. Cotter Pin
27. Castellated Nut
28. Washer
29. Stabilizer Shaft Bushing
30. Control Arm Dust Seal
31. Clip
32. Control Arm Bushing
33. Control Arm Assembly
34. Stabilizer Shaft
35. Stabilizer Shaft Mount
36. Front Under Longitudinal Frame

FRONT SUSPENSION 2C–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D16B501A
STRUT ASSEMBLY
Removal Procedure
1. Open the hood.
2. Remove the top of the strut assembly at passenger
seat side.

For vehicle with power steering, remove the power
steering fluid reservoir (1).

Remove the nuts (2).
D16B502A
3. Remove the top of the strut assembly at driver side.

Remove the bolt and the fuse box (1, 2).

Remove the nuts (3).
D106B503
4. Remove the lower of the strut assembly.

Raise and suitably support the vehicle.

Remove the wheel. Refer to Section 2E, Tires and
Wheels.

Remove the ABS front speed sensor electrical wire
from the bracket, if applicable (1).

Disconnect the brake hose from the bracket (2).

Remove the strut bracket bolts (3).
5. Remove the strut bracket assembly from the vehicle.

2C –8 FRONT SUSPENSION
DAEWOO M-150 BL2
D16B504A
70–90 Nm
Installation Procedure
1. Install the strut assembly to the vehicle with the strut
assembly–to–strut bracket bolts.
Tighten
Tighten the strut assembly–to–strut bracket bolts to
70–90 Nm (52–66 lb-ft).
2. Connect the brake hose to the bracket.
3. Install the ABS front speed sensor electrical wire to
the bracket, if applicable.
D16B505A
18–28 Nm
18–28 Nm4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
6. Install the nuts.

Install the nuts at passenger side (1).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).

Install the nuts at driver side (2).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).
7. Install the power steering fluid reservoir.
8. Install the fuse box and bolt.
D106B506
KNUCKLE ASSEMBLY
Tools Required
KM 507–B Ball Joint Remover
Removal Procedure
1. Remove the caulking nut.

Straighten the bent flange caulking nut (1).

Remove the caulking nut (2).

Remove the washer (3).
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
D105B501
3. Separate the tie rod end from the knuckle assembly.

Remove the cotter pin (1).

Remove the castellated nut (2).

Install the ball joint remover KM 507–B.

Separate the tie rod end from the knuckle assem-
bly using a ball joint remover KM 507–B (3).