torque DAEWOO MATIZ 2003 Service User Guide

1F–242 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F280
DIAGNOSTIC TROUBLE CODE (DTC) – P0501 VEHICLE SPEED NO SIGNAL
(M/T ONLY)
Circuit Description
Vehicle speed information is provided to the engine con-
trol module (ECM) by the voltage speed sensor (VSS) is
a permanent magnet generator that is mounted in the
transaxle and produces a pulsing voltage whenever ve-
hicle speed is over 3 mph (5km/h). The A/C voltage level
and the number of pulses increase with vehicle speed.
The ECM converts the pulsing voltage into mph (km/h)
and than supplies the necessary signal to the instrument
panel for speedometer / odometer operation and to the
cruise control module and multi-function alarm module
operation. The Diagnostic Trouble Code (DTC) will de-
tect if vehicle speed is reasonable according to engine
rpm and load.
Conditions for Setting the DTC

Vehicle speed is not change at least 10 seconds.

Engine speed is greater than 2,100rpm.

MAF is greater than 152mg/tdc.
Action taken when The DTCs Sets

The Malfunction Indicator Lamp (MIL) will illuminate.

The ECM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Freeze Frame and failure records buffers.

A history DTC is stored.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.

Using the scan tool can clear DTC(s).
Diagnostic Aids
An Intermittent problem may be caused by a poor con-
nection, rubbed through wire insulation, or wire that is
broken inside the insulation.
VSS signal circuit should be thoroughly checked for the
following conditions

Backed-out terminals

Improper mating

Broken locks

Improperly formed

Damaged terminals

Poor terminals to wire connection

Physical damage to the wiring harness
Ensure the VSS is correctly torqued to the trnasaxle
housing.
Refer to “intermittents” in this Section.

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
–

FRONT SUSPENSION 2C–5
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
STRUT DAMPENER
A strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand
than are shock absorbers. Strut dampeners are used only on the front in most vehicles, including this vehicle. Shock
absorbers are used on the rear wheels.
Condition Probable cause Correction
Struts Seem Weak
Improper tire pressures.
Adjust the tire pressures to the speci-
fications on the tire placard.

Abnormal load conditions.
Consult with the owner to confirm the
owner’s understanding of normal load
conditions.

Improper compression and rebound
effectiveness of the strut dampener.
Quickly push down and then lift up on
the corner of the bumper nearest the
strut dampener being tested.

Compare the compression and re-
bound with those of a similar vehicle
that has an acceptable ride quality.

Replace the strut dampener, if need-
ed.
Struts are Noisy
Loose or damaged mountings.
Tighten the strut dampener.

Replace the strut dampener if need-
ed.

Improper compression and rebound
effectiveness of the strut dampener.
Quickly push down and then lift up on
the corner of the bumper nearest the
strut dampener being tested.

Compare the compression and re-
bound with those of a similar vehicle
that has an acceptable ride quality.

Replace the strut dampener, if need-
ed.
Leaks
A slight trace of fluid.
The strut dampener is OK.

Leaks of the seal cover on the fully
extended strut.
Replace the strut dampener.

Excessive leaks of fluid on the strut
dampener.
Replace the strut dampener.
BALL JOINT AND KNUCKLE
Ball Joint Inspection
1. Raise the front of the vehicle to allow the front sus-
pension to hang free.
2. Grasp the tire at the top and the bottom.
3. Move the top of the tire in an in-and-out motion.
4. Look for any horizontal movement of the knuckle rela-
tive to the control arm.
5. Control arms assembly must be replaced if the follow-
ing conditions exist:

The joint is loose.

The ball seal is cut.

The ball stud is disconnected from the knuckle.
The ball stud is loose at the knuckle.

The ball stud can be twisted in its socket with finger
pressure.Ball Stud Inspection
Make sure to check the tightness of the ball stud in the
knuckle boss during each inspection of the ball joint.
One way to inspect the ball stud for wear is to shake the
wheel and feel for movement of the stud end or the cas-
tellated nut at the knuckle boss.
Another way to inspect the ball stud for wear is to check
the fastener torque at the castellated nut. A loose nut can
indicate a stressed stud or a hole in the knuckle boss.
Worn or damaged ball joints and knuckles must be re-
placed.

2C –6 FRONT SUSPENSION
DAEWOO M-150 BL2
FRONT WHEEL BEARING
Bearing Axial End Play Inspection
D107B303
1. Lift and suitably support the vehicle.
2. Inspect the end play of the bearing.
3. If excessive play is defeeted, free shoes from the disc
or remove the calipers.4. Check the standard torque of the drive nut (spec. :
210 Nm (155 lb-ft)).
5. Check the bearing end play according to the following
method.

Place a dial guage against the disc surface, grasp
the disc.

Using a push–pull movement, note gage readings.
Specification
0.130mm
or less
(0.005 in)Standard tighting torque
of drive shaft nut :
210 Nm (155 lb-ft)
6. If the axial end play of the front wheel bearing exceed
0.130mm torque the drive shaft nut successively
(Max. allowance : 240 Nm (177 lb-ft))
7. Check the axial end play again.
8. If the axial end play is above spec., replace the front
wheel bearing.

REAR SUSPENSION 2D–5
DAEWOO M-150 BL2
CHECKING THE REAR WHEEL
BEARING END PLAY
1. Release the parking brake.
2. Raise the vehicle.
3. Check the wheel bearing play by moving the top and
the down of the tire in an in–and–out motion.
D106C301

Rear Wheel Bearing Play

0 mm (0 in.)
4. If the bearing play is high, tighten the castellated nut.
5. If the bearing play is high after tightening, replace the
wheel bearing.
REAR WHEEL BEARING FREE LOAD
1. Release the parking brake.
2. Raise the vehicle and rotate the wheel.
3. Remove the wheels.
4. Check the torque when the hub moves by a spring
scale.

Standard (No Load)

0.137 – 0.422 Nm
(0.9 – 3.7 lb-in)
D106C302
5. If the checked torque exceeds the specification, tight-
en the castellated nut.
6. If the checked torque exceeds the specification after
tightening, replace the wheel bearing.

2E –4 TIRES AND WHEELS
DAEWOO M-150 BL2
WHEELS
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, leak air through welds,
have elongated bolt holes, or if the wheel bolts won’t
stay tight or are heavily rusted. Wheels with excessive
runout may cause vehicle vibration. Replacement
wheels must be equivalent to the original equipment
wheels in load capacity, diameter, rim width, offset, and
mounting configuration. A wheel of improper size or type
may affect wheel and bearing life, brake cooling,
speedometer/odometer calibration, vehicle ground
clearance, and tire clearance to the body and the chas-
sis.
INFLATION OF TIRES
The pressure recommended for any vehicle line is care-
fully calculated to give a satisfactory ride, handling,
tread life, and load-carrying capacity.
Tire pressure should be checked monthly or before any
extended trip. Check the tires when they are cold, after
the vehicle has sat for 3 hours or more or has been driv-
en less than 1 mile. Set the tire pressure to the specifi-
cations on the tire label located on the rear face of the
driver’s door. Tire inflation pressure is also given under
“Tire Size and Pressure Specifications” in this section.
Valve caps or extensions should be on the valves to
keep dust and water out.
Higher than recommended tire pressure can cause:

Hard ride

Tire bruising or damage

Rapid tread wear at the center of the tire
Lower than recommended pressure can cause:

Tire squeal on turns

Hard steering

Rapid and uneven wear on the edges of the tread

Tire rim bruises and rupture

Tire cord breakage

High tire temperatures
Unequal tire pressures on same axle can cause:

Uneven braking

Steering lead
Reduced handling

Swerve on acceleration

Torque steer
ROTATION TIRES
Front and rear tires perform different jobs and can wear
differently depending on the tires of road driven, driving
habit, etc.
The front tires will wear faster than the rear ones.
To avoid uneven wear of tires and to prolong tire life, in-
spect and rotate the tires every 5,000 km (3,100 miles).
After rotating the tires, adjust the tire inflation pressures
and be sure to check wheel nuts tightness.
D16A304A
WHEEL BALANCE
Balance is the easiest procedure to perform and should
be done first if the vibration occurs at high speeds, or if
the tires or the wheels are replaced.
When proceeding the wheel balancing procedure regard
the belows.
1. Do not use the wheel weight over two at the inboard
and the outboard flanges.
2. The total weight of the wheel weights should not ex-
ceed the 100 grams (3.5 ounces).
3. Blanching the assemblies with factory aluminum
wheels requires the use of special nylon–coated,
clip–on wheel weights.

2E –8 TIRES AND WHEELS
DAEWOO M-150 BL2
D16A503A
90–11 0 Nm
Installation Procedure
Notice: Before installing the wheels, remove any build-
up of corrosion on the wheel mounting surface and the
brake drum or the rotor mounting surface by scraping
and brushing them with a wire brush. Installing the
wheels without good metal-to-metal contact at the
mounting surfaces can cause the wheel nuts to loosen,
which can later allow a wheel to come off while the ve-
hicle is moving. Wheel nuts must be tightened in se-
quence and to the proper torque to avoid bending the
wheel, the brake drum or the rotor.
1. Mount the wheel.
2. Install the wheel nuts in the diagonally. Do not tighten
the wheel nuts.
3. Lower the vehicle.
Tighten
Tighten the wheel nuts to 90–110 Nm (66–81 lb-ft).
ON-VEHICLE BALANCING
On-vehicle balancing will help correct vibrations due to
brake drum, rotor, and wheel cover imbalances.
Notice: Do not allow the front suspension to hang free.
When the drive axle is run at an extreme angle, extra
vibrations can occur, as well as damage to seals and
joints.
1. During on-vehicle balancing, do not remove the bal-
ance weights from the off-vehicle dynamic balance.
2. If more than 1 ounce of additional weight is required,
split the weight between the inner and the outer rim
flanges.
3. Spin the driven tire and wheel assemblies using the
engine.
OFF-VEHICLE BALANCING
Perform wheel balancing with an electronic off-vehicle
balancer. The balancer is easy to use and gives both a
static and a dynamic balance. Unlike on-vehicle balanc-
ing, the off-vehicle balancer does not correct for drum or
rotor imbalance. This drawback is overcome by its accu-
racy. Secure the wheel on the balancer with a cone
through the back side of the centerhole, not through the
wheel nut holes.
CORRECTING NON-UNIFORM TIRES
There are two ways to correct properly balanced tires
which still vibrate. One method uses an automatic
machine which loads the tire and buffs small amounts of
rubber from high spots on the outer two tread rows.
Correction by this method is usually permanent and, if it
is done properly, does not significantly affect the
appearance or the tread life of the tire. Tire truing with a
blade-type machine is not recommended because it
substantially reduces the tread life and often does not
correct the problem permanently.

4B –2 MASTER CYLINDER
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
MASTER CYLINDER
The master cylinder is designed for use in a direct–split
system. Front right brake and rear left brake are served
by the primary piston. Front left brake and rear right
brake are served by the secondary piston.
The master cylinder incorporates the functions of the
standard dual master cylinder, plus a low fluid level indi-
cator and the proportioning valve in the non–antilock
braking system.
The proportioning valves limit the outlet pressure to the
rear brakes after a predetermined master cylinder has
been reached.
Important:

Replace all the components included in the repair kits
used to service this master cylinder.

Lubricate rubber parts with clean brake fluid to ease
assembly.

Do not use lubricated shop air on brake parts, as this
may damage rubber components.

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake system.
The torque values specified are for dry, unlubricated
fasteners.

Perform all service operations on a clean bench, free
from all traces of mineral oil.
PROPORTIONING VALVE
The proportioning valve limits the outlet pressure to the
rear brakes on the non-ABS after a predetermined mas-
ter cylinder pressure has been reached. This is used
when less rear apply force is needed to obtain optimum
braking and is usually found on disc/drum brake configu-
rations. On ABS-equipped vehicles, refer to Section 4F,
Antilock Brake System.
FLUID LEVEL SENSOR
Fluid level sensor is attached at the brake fluid reservoir.
This sensor will activate the BRAKE light if a low fluid
level condition is detected. Once the fluid level is cor-
rected, the BRAKE light will go out.

4D – 2 FRONT DISC BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DISC BRAKE CALIPER ASSEMBLY
This caliper has a single bore and is mounted to the
steering knuckle with two mounting bolts. Hydraulic
pressure, created by applying the brake pedal, is con-
verted by the caliper to a stopping force. This force acts
equally against the piston and the bottom of the caliper
bore to move the piston outward and to slide the caliper
inward, resulting in a clamping action on the rotor. This
clamping action forces the linings against the rotor,
creating friction to stop the vehicle.
D17B001A
Important:

Replace all components included in the repair kits
used to service this caliper.

Lubricate the rubber parts with clean brake fluid to
ease assembly.

Do not use lubricated shop air on brake parts, as
damage to the rubber components may result.

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake system.

Replace the pads in axle sets only.

The torque values specified are for dry, unlubricated
fasteners.

Perform the service operations on a clean bench, free
from all mineral oil materials.
CLEARANCE CALIBRATION
When the hydraulic pressure is applied to the piston, the
piston moves leftward. The piston seal, which extent
considerable pressure against the piston, moves with
cylinder.
However, as a part of the piston seal is fixed into a grove
in the cylinder shape of the seal is as shown in below
figure, distorted toward the piston moving direction.
When the pressure is taken off from the brake pedal and
the hydraulic pressure is released from the piston, a re-
storing elastic force is generated at the seal and pushes
the piston rightward and back it in original position.
As the pads wear away and the clearance between rotor
and pads becomes larger, the piston moves larger.
The seal then could change in shape further, but since
end of the seal is fixed into the groove in the cylinder, the
distortion is limited to the same amount as previously
described.
The piston moves further to cover the distance of clear-
ance. As the piston returns by the same distance and
the rubber seal recovers its original shape, the clear-
ance between the rotor and pads is maintained in origi-
nal condition.
1. Piston
2. Piston Seal
3. Pads
a. Clearance
D107B002