wheel alignment DAEWOO MATIZ 2003 Service User Guide

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 –

4A –4 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DIAGNOSITIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily
braked, but turning, wheels will stop the vehicle in less
distance than locked brakes. More tire-to-road friction is
present with a heavily braked, turning tire than with a
sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:

Tires having unequal contact and grip of the road will
cause unequal braking. Tires must be equally in-
flated, and the tread pattern of the right and the left
tires must be approximately equal.

Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.

Misalignment of the wheels, particularly conditions of
excessive camber and caster, will cause the brakes
to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and the
shift lever in NEUTRAL. If the pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking. Perform a visual check to confirm any sus-
pected leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an
abnormally low level indicates a leak in the system. The
hydraulic system may be leaking either internally or ex-
ternally. Refer to the procedure below to check the mas-
ter cylinder. Also, the system may appear to pass this
test while still having a slight leak. If the fluid level is nor-
mal, check the vacuum booster pushrod length. If an in-
correct pushrod length is found, adjust or replace the
rod.Check the master cylinder using the following proce-
dure:

Check for a cracked master cylinder casting or brake
fluid leaking around the master cylinder. Leaks are in-
dicated only if there is at least one drop of fluid. A
damp condition is not abnormal.

Check for a binding pedal linkage and for an incorrect
pushrod length. If both of these parts are in satisfac-
tory condition, disassemble the master cylinder and
check for an elongated or swollen primary cylinder or
piston seals. If swollen seals are found, substandard
or contaminated brake fluid should be suspected. If
contaminated brake fluid is found, all the components
should be disassembled and cleaned, and all the rub-
ber components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, then the rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston seals on the
drum brake wheels.
If rubber deterioration is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep al-
cohol out of the system. Replace all the rubber parts in
the system, including the hoses. Also, when working on
the brake mechanisms, check for fluid on the linings. If
excessive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush the
master cylinder with brake fluid, refill the master cylin-
der, and bleed the system. Refer to “Manual Bleeding
the Brakes” in this section.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of the
outer cover, and for leaks or blisters. Inspect the hoses
for proper routing and mounting. A brake hose that rubs
on a suspension component will wear and eventually
fail. A light and a mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as neces-
sary.

6D –8 MANUAL STEERING GEAR
DAEWOO M-150 BL2
D15B504B
Installation Procedure
1. Install the tie rod end.
2. Install the tie rod lock nut (1).
Tighten
Tighten the tie rod end lock nut to 35–55 Nm (25–41
lb-ft).
3. Connect the tie rod end to the knuckle.
4. Install the tie rod end castellated nut (2).
Tighten
Tighten the castellated nut to 30–55 Nm (21–41 lb-
ft).
5. Install the split pin.
6. Install the wheel. Refer to Section 2E, Tires and
Wheels.
7. Make the toe–in adjustment by turning the tie rod ad-
juster. Refer to Section 2B, Wheel Alignment.
D105B505
RACK AND PINON BOOT
Removal Procedure
1. Remove the tie rod end. Refer to “Tie Rod End” in this
section.
2. Remove the tie rod end lock nut.
D105B506
3. Remove the rack and pinion boot.

Remove the boot clamp (1).

Cut off the boot wire clamp (2).

6E –4 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
STEERING COLUMN DIAGNOSIS
Lock System
ConditionProbable CauseCorrection
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Unlock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Lock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
High Lock Effort
Damaged lock cylinder.
Replace the lock cylinder.

The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Extreme misalignment of the housing to the
cover.
Realign the cover on the housing.

Replace the cover as needed.
Key Cannot Be
The ignition switch to be set incorrectly.
Reset the ignition switch.
Removed in the B
Position
Damaged lock cylinder.
Replace the lock cylinder.
Column
ConditionProbable CauseCorrection
Noise in the Column
Improperly installed intermediate shaft–to–
column joints.
Tighten the coupling pinch bolts.

Replace the intermediate shaft as
needed.

Column misalignment.
Replace the alignment spacer.

The lack of lubrication for the joint.
Lubricate the joint.

The lack of lubrication for the steering shaft.
Lubricate the steering shaft bearing.

Improperly seated shaft lock snap ring.
Adjust the shaft lock snap ring.

Replace the shaft lock snap ring as
needed.

Improperly installed intermediate shaft
pinch bolt.
Tighten the pinch bolt.
High Steering Shaft
Column misalignment.
Replace the alignment spacer.
Effort
A damaged bearing.
Replace the steering column
housing.

The lack of free movement for the steering
shaft universal joint.
Lubricate the steering shaft
universal joint.

Replace the steering column shaft
as needed.

STEERING WHEEL AND COLUMN 6E–13
DAEWOO M-150 BL2
UNIT REPAIR
D105A701
D15A702A
D15A703A
STANDARD STEERING COLUMN
Disassembly Procedure
1. Remove the steering column from the vehicle. Refer
to “Steering Column” in this section.
Caution: Be careful not to impact on the steering
column shaft. Plastic sleeve may be broken that is
installed to secure the driver at the accident.
2. Remove the steering column shaft from the steering
column.

Remove the retaining ring (1).

Remove the washer (2).

Remove the spring (3).

Remove the washer (4).

Remove the locking of the alignment spacer (5).

Push strongly the steering column shaft downward
(6).

6E –14 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
D15A704A
Assembly Procedure
Important: Position the alignment spacer on the lower
column shaft to install the spacer in the steering column
jacket easily.
1. Install the steering column shaft to the steering col-
umn.

Position the locking of the alignment spacer on the
groove of the steering column.

Install the washer.

Install the spring.

Install the washer.

Install the retaining ring.
2. Install the steering column to the vehicle. Refer to
“Steering Wheel” in this section.

8B–70 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO M-150 BL2
D110B504
CLOCK SPRING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable. Wait 1 minute
until the capacitor inside the sensing and diagnostic
module has discharged.
2. Remove the driver airbag module. Refer to “Driver
Airbag Module” in this section.
3. Remove the steering wheel. Refer to Section 6E,
Steering Wheel and Column.
4. Remove the lower/upper steering column cover.

Remove the screws (1).

Remove the lower/upper steering column cover(2).
D110B505
5. Disconnect the clock spring and the horn terminal
connector.
6. Disconnect the clock spring and the horn terminal
connector which are banded on the steering column.
7. Remove the clock spring.

Remove the screws (1).

Remove the clock spring (2).
3 Nm
D1AB506A
D110B507
Installation Procedure
Caution: If the clock spring is not properly aligned,
the steering wheel may not be able to rotate com-
pletely during a turn. Restricted turning ability can
cause the vehicle to crash. Improper alignment of
the clock spring also may make the supplemental
inflatable restraints (SIR) system inoperative, pre-
venting the airbags from deploying during a crash.
Both of these outcomes can result in injury.
Notice: Turning the clock spring more than three turns
clockwise or more than three turns counterclockwise
can damage the spring.
1. Turn the front wheels straight ahead.
2. Install the clock spring with the screws.
Tighten
Tighten the clock spring mounting screws to 3 Nm
(27 lb-in)
Important: The clock spring may come packed in mate-
rial used to prevent damage to the spring during ship-
ping or storage. Avoid installing any of the packing
material with the clock spring.
3. Turn the label of the clock spring clockwise to lock.
4. Turn the label of the clock spring counterclockwise
approximately three turns to the neutral positions with
the front wheels ahead.