belt DAEWOO MATIZ 2003 Service Owner's Manual

1E–16 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D12E508A
35–41 Nm
68–83 Nm
Installation Procedure
1. Install in the reverse order of removal except genera-
tor driver velt.
2. Install the engine mounting lower bracket bolts and
nut.
Tighten

Tighten the engine mounting lower bracket bolts to
35–41 Nm (25–30 lb-ft) (a).

Tighten the engine mounting lower bracket, attach-
ing reaction rod bolt and nut to 68–83 Nm (50–61
lb-ft) (b).
D12E509A
4–7 Nm
18–28 Nm3. Install the bolts and nut.Tighten

Tighten the generator adjusting bolt to 4–7 Nm
(35–62 lb-in) (a).

Tighten the generator lower bracket bolt and nut to
18–28 Nm (13–21 lb-ft) (b).

Inspect the generator drive belt tension.
D12E511A
BATTERY
Removal Procedure
1. Disconnect the negative battery cable and then dis-
connect the positive battery cable.

Remove the battery cable nut to disconnect the
negative battery cable (1).

Remove the battery terminal cap (2).

Remove the battery cable nut to disconnect the
positive battery cable (3).
D102E512
2. Remove the battery.

Remove the battery rod nut (1).

Remove the battery rod (2).

Remove the battery (3).

1E–42 ENGINE ELECTRICAL
DAEWOO M-150 BL2
BATTERY SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
BatteryType–MF–
CapacityAH35–
Cold Cranking AmpsCCA246–
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Distributor Bolts10–16–89–142
Battery Retainer Clamp–to–Battery Rod Nuts6–8–53–71
Battery Carrier Tray Bolts9–12–80–106
Battery Cable Nuts9–12–80–106
Starter field Connector Nut9–12–80–106
Starter Through–Bolts4–6–35–53
Starter Mounting Bolts55–6541–48–
Starter Solenoid Assembly Screws6–8–53–71
Starter Solenoid Nuts9–12–80–106
Spark Plug20–3015–22–
Generator Through–Bolts4–6–35–53
Generator Drive End Nut80–11 059–81–
Generator Battery Lead Connector Nut4–7–35–62
Generator Bearing Plate Bolt6–8–53–71
Generator Brush Holder / Rectifier Screw9–12–80–106
Generator Belt Tension Adjusting Bolt18–2813–21–
Generator Shackle Bracket Bolt45–5533–41–
Generator Lower Bracket–to–Generator Bolt/Nut18–2813–21–
Ground Bolt35–4126–30–
Ignition Coil Screw4–7–35–62
Ignition Coil Bracket Bolt9–12–80–106

ENGINE CONTROLS 1F–25
DAEWOO M-150 BL2
ENGINE CRANKS BUT WILL NOT RUN
Caution: Use only electrically insulated pliers when
handling ignition wires with the engine running to
prevent an electrical shock.
Caution: Do not pinch or restrict nylon fuel lines.
Damage to the lines could cause a fuel leak, result-
ing in possible fire or personal injury.Important: If a no start condition exists, ensure the fuel
cutoff switch has not been tripped prior to further diagno-
sis.
Engine Cranks But Will Not Run
StepActionValue(s)YesNo
1
Perform an Euro On-Board Diagnostic (EOBD)
System Check.
Is the check complete.
–
Go to Step 2
Go to “Euro
On-Board
Diagnostic
System Check”
2Crank the engine.
Does the engine start and continue to run?–System OkGo to Step 3
3
Perform a cylinder compression test.
Is the cylinder compression for all of the cylinders at
or above the value specified?
1250 kPa
(181 psi)
Go to Step 7Go to Step 4
4Inspect the timing belt alignment.
Is the timing belt in alignment?–Go to Step 6Go to Step 5
5Align or replace the timing belt as needed.
Is the repair complete?–Go to Step 2–
6Repair internal engine damage as needed.
Is the repair complete?–Go to Step 2–
7Inspect the fuel pump fuse.
Is the problem found?–Go to Step 8Go to Step 9
8Replace the fuse.
Is the repair complete?–Go to Step 2–
9
Check for the presence of spark from all of the
ignition wires while cranking the engine.
Is spark present from all of the ignition wires?
–
Go to Step 23Go to Step 10
10
1. Measure the resistance of the ignition wires.
2. Replace any of the ignition wire(s) with a
resistance above the value specified.
3. Check for the presence of spark from all of the
ignition wire.
Is spark present from all of the ignition wires?
5 kΩGo to Step 2Go to Step 11
11
1. Turn the ignition OFF.
2. Disconnect the crankshaft position (CKP) sensor
connector.
3. Turn the ignition ON.
4. Measure the voltage between following terminals:

Terminal 1 and 3 of the CKP sensor connector.

Terminal 2 and 3 of the CKP sensor connector.

Terminal 1 of the CKP sensor connector and
ground.

Terminal 2 of the CKP sensor connector and
ground.
Are the voltage measure within the value specified?
≈ 0.4 VGo to Step 13Go to Step 12

ENGINE CONTROLS 1F–303
DAEWOO M-150 BL2
BACKFIRE
Definition: Fuel ignites in the intake manifold, or in the
exhaust system, making a loud popping noise.Important: Before diagnosing the symptom, check ser-
vice bulletins for updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Inspect for crossed or crossfiring ignition wires.
2. Check the ignition system output voltage for all
cylinders using a spark tester.
3. Inspect the spark plugs for excessive wear,
burned electrodes, improper gap, or heavy
deposits.
Is the problem found?
–
Go to Step 3Go to Step 4
3
Repair or replace any ignition system components
as needed.
Is the repair complete?
–
System OK
–
4
1. Check the fuel system operation.
2. Check the fuel injectors by performing an injector
diagnosis.
Is the problem found?
–
Go to Step 5Go to Step 6
5
Repair or replace any fuel system components as
needed.
Is the repair complete?
–
System OK
–
6
1. Inspect the Electric Exhaust Gas Recirculation
(EEGR) gasket for a leak or a loose fit.
2. Check the EEGR valve for proper operation.
3. Inspect the intake manifold and the exhaust
manifold for a casting flash.
Is the problem found?
–
Go to Step 7Go to Step 8
7Repair or replace any components as needed.
Is the repair complete?–System OK–
8
1. Inspect the timing belt for proper installation and
tension.
2. Check the engine compression.
3. Inspect the intake manifold gasket and the
exhaust manifold gasket for leaks.
4. Check for sticking or leaking valves.
5. Repair or replace any components as needed.
Are all checks and corrections complete?
–
System OK
–

DAEWOO M-150 BL2
SECTION 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
Diagnostic Information and Procedures 2A-1. . . . .
General Diagnosis 2A-1. . . . . . . . . . . . . . . . . . . . . . . . . Wheel Bearing Diagnosis 2A-6. . . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires, and
the wheels involve several systems. Consider all sys-
tems when you diagnose a complaint. Some problems,
such as abnormal or excessive tire wear and scuffed
tires, may be the result of hard driving. Always road testthe vehicle first. If possible, do this road test with the
customer.
Proceed with the following preliminary checks. Correct
any substandard conditions.
Application Checks Correction
Preliminary Checks
Inspect the tires for improper pressure
and uneven wear.
Inflate the tires to the proper pressure.

Inspect the joint from the steering
column to the intermediate shaft for
loose connections or wear.

Inspect the joint from the intermediate
shaft to the steering gear for loose
connections or wear.
Tighten the coupling flange pinch
bolts.

Replace the intermediate shaft as
needed.

Inspect the front and the rear
suspension, the steering gear, and the
linkage for loose or damaged parts.
Tighten the front and the rear
suspension.

Tighten the steering gear mounting
bracket bolts.

Replace the front and the rear
suspension as needed.

Replace the steering gear as needed.

Replace the coupling flange as
needed.

Inspect for out–of–round tires.
Perform free runout test.

Match–mount the tires.

Inspect for out–of–balance tires, bent
wheels, and worn or loose wheel
bearings.
Balance the wheels.

Replace the wheels.

Replace the wheel bearings.

Check the power steering pump drive
belt tension.
Tighten the power steering pump drive
belt.

Inspect the power steering system.
Also, check the power steering fluid
level.
Repair any leaks.

Perform a power steering gear test.

Add power steering fluid.

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.

2E – 2 TIRES AND WHEELS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
TIRE
Tread
A part (that contacts) road surfaces directly is fixed on
the outside of carcass and breaker. It is a strong rubber
coat made of high anti–abrasion rubber. Its running per-
formance depends on is surface profile.
Breaker
A cord belt between tread and carcass prevents dam-
ages of inner code due to outer shock and vibration.
Carcass
This major part made by pilling code papers of strong
synthetic fiber forms a structure of tire. Since it main-
tains tire pressure and endures applied load and shock
to tire, it should have a high anti–fatigue characteristic.
Bead
A steel wire winding the ending part of carcass code,
coated with rubber film and wrapped with nylon cord pa-
pers. It fixes tire to a rim.
Tube
Tires used in mostly current vehicle are mostly tubeless
tires.
Side Wall
It is provided to improve the comfortable driving by pro-
tecting carcass and cushion movement.
Structure of Tubeless Tube
D16A001A
Nomenclature
D16A002A
175 Width (mm)

60Flatness ratio 60%
(Height/Width) ×100
175/60R13RRadial
77H13Rim diameter (= Tire I.D, Inch)
77Max. load index
HMax. speed symbol

TIRES AND WHEELS 2E–3
DAEWOO M-150 BL2
Hydroplaning
The condition of driving a vehicle fast on the road surface
covered with water can cause tires to fail to rotate with a
good contact on the surface, so results in remaining them
afloat. This is so–called hydroplaning. It causes brake
failure, lower tractive force, and losing the steering per-
formance so it is very vulnerable condition.
D16A005A
Standing Wave
During running the rotating tire repeats deformation and
restoring movement generated in tread. But when the
wheel rotating speed reaches high, the next deformation
applied to tire before restoring last deformation so the
trembling wave appears in the tread portion. The lower
the tire pressure the severe the trembling wave appears.
And during the high speed.
D106A004
REPLACEMENT TIRES
A Tire Performance Criteria (TPC) specification number
is molded in the sidewall near the tire size of all original
equipment tires. This specification number assures that
the tire meets performance standards for traction, en-
durance, dimensions, noise, handling and rolling resist-
ance. Usually a specific TPC number is assigned to
each tire size.Caution: Do not mix different types of tires on the
same vehicle such as radial, bias and bias-belted
tires except in emergencies, because vehicle han-
dling may be seriously affected and may result in
loss of control.
Caution: Do not change 145/70 R13 tires or 155/65
R13 tires for 175/60 R13 tires, because vehicle
hancling may be seriously affected and may result
in loss of control. If you change 145/70 R13 tires or
155/65 R13 tires for 175/60 R13 tires, you have to
change the steering gear assembly.
Use only replacement tires with the same size, load
range, and construction as the original. The use of any
other tire size or construction type may seriously affect
ride, handling, speedometer/odometer calibration, ve-
hicle ground clearance, and tire clearance to the body
and the chassis. This does not apply to the spare tire fur-
nished with the vehicle.
It is recommended that new tires be installed in pairs on
the same axle.
If it is necessary to replace only one tire, pair it with the
tire having the most tread to equalize the braking action.
Although they may appear different in tread design, tires
built by different manufacturers with identical TPC speci-
fications may be used on the same vehicle.
ALL SEASON TIRES
Most vehicles are now equipped with steel-belted all
season radial tires as standard equipment. These tires
qualify as snow tires, with a 37 percent higher average
rating for snow traction than the non-all season radial
tires previously used. Other performance areas, such as
wet traction, rolling resistance, tread life, and air reten-
tion, have also been improved. This was done by im-
provements in both tread design and tread compounds.
These tires are identified by an “M + S” molded in the tire
sidewall following the size number. The suffix “MS” is
also molded in the sidewall after the TPC specification
number.
The optional handling tires used on some vehicles are
not all season tires. These will not have the “MS” mark-
ing after the tire size or the TPC specification number.
TIRE LABEL
The tire label is permanently located on the rear face of
the driver’s door and should be referred to for tire infor-
mation. It lists the maximum vehicle load, the tire size
(including the spare tire), and the cold inflation pressure
(including the spare tire).
SPARE TIRE
This vehicle comes equipped with a full-sized spare tire
and wheel.

DAEWOO M-150 BL2
SECTION 6B
POWER STEERING PUMP
TABLE OF CONTENTS
Description and Operation 6B-2. . . . . . . . . . . . . . . . . .
Power Steering Pump 6B-2. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6B-3. . . . .
Power Steering Pump 6B-3. . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 6B-4. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Belt 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Pulley 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . Pump Assembly 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 6B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6B-8. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6B-8. . . . . . . . . . .
Special Tools and Equipment 6B-9. . . . . . . . . . . . . . .
Special Tools Table 6B-9. . . . . . . . . . . . . . . . . . . . . . . .

6B –4 POWER STEERING PUMP
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D105C524
PUMP DRIVE BELT
Removal Procedure
1. Remove the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.
2. Remove the pump drive belt.

Loosen the rear bracket adjusting bolt (1).

Loosen the bolt (2).
D105C525

Loosen the front bracket adjusting bolts (3).

Push the pump forward (4).
18–22 Nm
20–24 Nm
20–24 Nm
D15C526A
Installation Procedure
1. Install the pump drive belt with the bolts.
Tighten

Tighten the front bracket adjusting bolt to 18–22
Nm (13–16 lb-ft) (1).

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (2).

Tighten the power steering pump bolt to 20–24
Nm (15–18 lb-ft) (3).
2. Install the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.