torque DAEWOO MATIZ 2003 Service Owner's Manual

4E – 2 REAR DRUM BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRUM BRAKES
This drum brake assembly is a leading/trailing shoe de-
sign. Both brake shoes are held against the wheel cylin-
der pistons by the lower return spring and the fixed
anchor plate near the lower return spring. When the
brakes are applied, the wheel cylinder pistons move
both shoes out to contact the drum. With forward wheel
rotation, the forward brake shoe will wrap into the drum
and become self-energized. With reverse wheel rota-
tion, the rear brake shoe is self-energized. Force from
the brake shoes is transferred to the anchor plate
through the backing plate to the axle flange. Adjustment
is automatic and occurs on any service brake applica-
tion. Do not switch the position of shoes that have been
in service, as this may render the self-adjustment fea-
ture inoperative and result in increased pedal travel.Notice:

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

Do not use lubricated shop air on the 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
braking system.

The torque values specified are for dry, unlubricated
fasteners.

Perform service operations on a clean bench that is
free from all mineral oil materials.

5B – 2 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FIVE-SPEED MANUAL TRANSAXLE
This five-speed transaxle assembly adopts the synchro-
nized mesh type of 5 forward speed. The reverse speed
gear is driven by sliding idle gear without synchronizer.
REVERSE GEAR MISSHIFT
PREVENTING MECHANISM
It prevents the gear from directly being shifted from 5th
to reverse when shifting to reverse from 5th. Shift to the
reverse in neutral position to prevent the shift cam from
being interfered to the shift guide bolt.
D103B001
In case of shifting to 5th gear, shift and select shaft ro-
tates to right that shift cam aparts from guide bolt and
moves upwards by returning spring. Therefore, shifting
to reverse in this condition is impossible because of in-
terference of guide bolt.
D103B002
When shifting to reverse from neutral position between
5th and reverse, shift cam rotates to left and shifting is
possible.
D103B003
DIFFERENTIAL
Differential is integrated with transmission case and
installed on chassis together with engine. It changes the
direction of power and increase torque by reducing
speed.
Reduction gear is installed parallel to counter shaft and
is helical gear type. Differential gear is bevel gear type
and is integrated with reduction gear.

POWER STEERING GEAR 6C–5
DAEWOO M-150 BL2
ADJUST THE FREE LOAD OF THE
STEERING GEAR
1. Place the steering wheel in the straight-ahead posi-
tion.
2. Raise and suitably support the vehicle.
3. Remove the adjust plug locknut.
4. Check the torque of the adjuster plug.
5. Check the torque is below the specification value or
the measured torque is over the specification value,
adjust the tightening torque.

Place the rack gear in the straight-ahead position.

Tighten the adjust plug to 10 Nm (89 lb-in).

Turn the steering wheel all the way to the right and
the left about 5 times repeatedly.

Place the rack gear in the straight-ahead position.

Loosen the adjust plug.
D105C302

Tighten the adjust plug to 4.5–5.5 Nm (40–49 lb-
in).

Loosen the adjust plug to 67.5.
6. Tighten the adjust plug locknut.

6D –6 MANUAL STEERING GEAR
DAEWOO M-150 BL2
STEERING WHEEL RESTORATION
1. Turn the steering wheel fast to the right and left and
turn it slowly as the same way.
2. Check if the steering wheel restoration for the wheel
turning to right and the one to the left are same.
3. Turn the steering wheel to 90 about 1–2 seconds
and loosen the steering wheel during the low speed
driving.
4. If the steering wheel restores above 70%, the steer-
ing wheel restoration is OK.
5. If the restoration is poor, check the tire pressure,
steering gear preload, and steering gear operation.
And repair the fault.
CHECK THE TURNING RESISTANCE
OF THE TIE ROD END OR TIE ROD
1. Turn the ball joint of the tie rod end or the tie rod about
10 times.
2. Use a spring balance to check the turning resistance
of each ball joint.
D105B302
Application Specified Value
Tie Rod End Ball Joint0.49 – 3.43 Nm
(4.5 – 30 lb-in.)

Tie Rod Ball Joint0.49 – 3.43 Nm
(4.5 – 30 lb-in.)
3. If the values exceed the specified values, replace the
tie rod end or the tie rod.
4. But, If the ball joint of the tie rod end or the tie rod falls
down of itself, replace it.
ADJUST THE FREE LOAD OF THE
STEERING GEAR
1. Place the steering wheel in the straight–ahead posi-
tion.
2. Raise and suitably support the vehicle.
3. Check the torque of the adjuster plug.
4 When the measured torque is below the specification
value or the measured torque is over the specification
value, adjust the tightening torque.

Place the rack gear in the straight–ahead position.

Tighten the adjust plug to 95 Nm (70 lb-ft).

Turn the steering wheel all the way to the right and
the left about 5 times repeatedly.

Place the rack gear in the straight–ahead position.

Loosen the adjust plug.

Tighten the adjust plug to 8 Nm (71 lb-in.).

Set the torque in the 0.8–1.3 Nm (8–12 lb-in.) by
loosening the adjust plug to 0 − 90.
D105B303

6E – 2 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
STEERING WHEEL AND COLUMN
In addition to the steering function, the steering column
provides safety and security.
Caution: To ensure energy-absorbing action, it is
important to use only the specified screws, bolts,
and nuts, tightened to the specified torque.
The energy-absorbing column is designed to compress
in a front-end collision to lessen the chance of driver in-
jury.
The ignition switch and the lock are mounted on the col-
umn, allowing the ignition and steering operations to be
locked to inhibit theft of the car.
The column levers trigger the turn signals, the headlight
beams, and the windshield washer and wipers.
Notice: Apply a thin coat of lithium grease to all friction
points when reassembling to ensure proper operation.
The column may be easily disassembled and assembled.
D15A001A

Safety Device
A. Steering Column Upper Bracket.
B. Steering Column.
C. Steering Column Shaft.

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–7
DAEWOO M-150 BL2
LEAK TESTING THE REFRIGERANT
SYSTEM
Test for leaks whenever you suspect a refrigerant leak in
the system. You should also test for leaks whenever you
perform a service operation which results in disturbing
the lines or the connections. Leaks are commonly found
at the refrigerant fittings or at the connections. Leaks are
commonly caused by the following problems:
Improper torque.
Damaged O-ring seals.
Dirt or lint on the O-ring seals.
Liquid Leak Detectors
Use a liquid leak detector solution on locations such as
fittings. Apply the solution to the area in question with
the swab that is supplied with the solution. Look for
bubbles to appear. This will indicate the existence and
location of any leak.
For areas where this is not practical, such as sections of
the evaporator and the condenser, an electronic leak de-
tector is more useful.
Electronic Leak Detectors
Follow the manufacturer’s instructions for calibration,
operation, and maintenance of an electronic leak detec-
tor. Battery condition is especially important to the accu-
racy of a portable model. Set the detector to R-134a
before beginning the test.
Important: Electronic leak detectors are sensitive to
windshield washing solutions, solvents and cleaners,
and certain vehicle adhesives.
Surfaces must be clean to prevent false readings. Make
sure that all surfaces are dry to prevent damage to the
detector.
General Testing Instructions
Follow the entire path of the refrigerant system.
Completely circle each joint at 25 to 50 mm (1 to 2
inches) per second.
Hold the probe tip within 6 mm (1/4 inch) of the sur-
face.
Do not block the air intake.The audible tone changes from 1 to 2 clicks per second
into a solid alarm if there is a leak. Adjust the balance
control to maintain 1 to 2 clicks per second.
Test all of the following areas, even after one leak has
been confirmed:
Evaporator inlet and outlet.
Receiver-drier inlet and outlet.
Condenser inlet and outlet.
Brazed and welded areas.
Damaged areas.
Hose couplings.
Compressor rear head.
All fittings and joints.
Testing Service Ports/Access Valves
The sealing cap is the primary seal for the service ports.
This cap contains a special leak-free O-ring. Make sure
that this cap is not missing or loose. Always use the cor-
rect cap.
Testing the Evaporator Core
Leaks in the evaporator core are difficult to find. Test the
evaporator core using the following procedure:
1. Run the blower fan at speed setting 4 for at least
15 minutes.
2. Turn the blower to the OFF position.
3. Wait for 10 minutes.
4. Remove the blower motor resistor. Refer to “Blower
Motor Resistor” in this section.
5. Insert the leak detector probe as close as possible to
the evaporator core. The detector will indicate a leak
with a solid alarm.
6. Use a flashlight to search for refrigerant oil in the core
surface.
Testing the Compressor Shaft Seal
1. Blow shop air behind and in front of the compressor
clutch/pulley for at least 15 seconds.
2. Wait 1 to 2 minutes.
3. Probe the area in front of the pulley. If the detector
emits a solid alarm, there is a leak.

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–13
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
GENERAL A/C SYSTEM
SERVICE PROCEDURES
O-RING REPLACEMENT
Important: Even though O-rings may look identical, it is
extremely important that only recommended service re-
placement air conditioning O-rings be used, or exces-
sive leakage of refrigerant may occur.
Important: Always slip the O-ring onto the flange tube
to ensure proper locating and sealing.
Install new DAEWOO-approved service replacement air
conditioning O-rings whenever a joint or a fitting is disas-
sembled, except when the O-rings are provided on new
components.
When replacing O-rings on an air conditioning compo-
nent or a joint connection, the fitting design should be
identified to ensure installation of the correct air condi-
tioning service replacement O-ring.
Before installation, verify that both O-rings and fittings
have not been nicked or deformed. Deformed or nicked
parts must be replaced. Failure to use the proper service
replacement parts and procedures may result in exces-
sive refrigerant leakage.
HANDLING REFRIGERANT
Caution: Always work in a well-ventilated area and
avoid breathing any refrigerant fumes. If you have
difficulty breathing, seek medical attention immedi-
ately. If refrigerant comes in contact with any part of
your body, flush the exposed area with water. If a
rash or pain develops, seek medical attention.
Air conditioning systems contain refrigerant. This is a
chemical mixture which requires special handling proce-
dures to avoid personal injury.
Always wear goggles and wrap a clean cloth around the
fittings, the valves and the connections when performing
work that involves opening the refrigerant system. Do
not weld or steam clean on or near any vehicle-installed
air conditioning lines or components.
All refrigerant drums are shipped with a heavy metal
screw cap. The purpose of the cap is to protect the valve
and the safety plug from damage. It is good practice to
replace the cap after each use of the drum.
If it is necessary to transport or carry any container of
refrigerant in a vehicle, do not carry it in the passenger
compartment.
HANDLING OF REFRIGERANT LINES
AND FITTINGS
Notice: Using too low or too high torque when tightening
a fitting can result in loose joints or deformed joint parts.
Both conditions can result in refrigerant leakage.
Keep all metal tubing lines free of dents or kinks. Any
line restrictions will cause the loss of system capacity.
Never bend a flexible hose line to a radius of less than
four times the diameter of the hose.
Never allow a flexible hose line to come near the ex-
haust manifold.
Inspect flexible hose lines regularly for leaks or brittle-
ness.
Replace flexible hose lines with new lines if you find
signs of deterioration or leaking.
Discharge the refrigeration system of all refrigerant
before disconnecting any fitting in the refrigeration
system.
Proceed very cautiously regardless of the gauge
readings.
Open the fittings very slowly.
Keep your face and your hands away from the fitting
so that you will not be injured if there happens to be
liquid refrigerant in the line.
If you notice pressure when you loosen a fitting, allow
the pressure to bleed off as described under “Dis-
charging, Adding Oil, Evacuating and Charging Pro-
cedures for A/C System” in this section.
Cap or tape any refrigerant line immediately after it is
opened. This will prevent the entrance of moisture
and dirt, which can cause internal compressor wear
or plugged lines in the condenser, the evaporator
core, the expansion valve or the compressor inlet
screens.
Important: Use two proper wrenches to connect the O-
ring fittings.
Back up the opposing fitting to prevent distortion of
the connecting lines or the components.
Back up both the swaged fitting on the flexible hose
connections and the coupling to which it is attached
with two wrenches to prevent turning the fitting and
damaging the ground seat.
Keep the O-rings and the seats in perfect condition. A
burr or a piece of dirt may cause a refrigerant leak.
Dip new O-rings in clean PAG refrigerant oil before
installation.

9P –10 DOORS
DAEWOO M-150 BL2
D109C574
DOOR LOCK STRIKER ADJUSTMENT
Notice: The door lock striker is an important attaching
part that can affect the performance of vital components
and systems and can cause major repair expenses. If
replacement becomes necessary, the door lock striker
must be replaced by one with the same part number or
with an equivalent part if replacement becomes neces-
sary. Do not use a replacement part of lesser quality or
of a substitute design. The specified torque values must
be used during reassembly in order to ensure the proper
retention of the part.
The door lock striker consists of a striker with two
screws that are threaded into a tapped, floating cage
plate located in the appropriate body pillar. This floating
cage plate allows the striker to be easily adjusted in or
out and up or down. The door is secured in the closed
position when the door lock fork snaps over and en-
gages the striker.
D19C575A
Fore/Aft Adjustment
1. The door must be properly aligned.
2. Close the door until the lock fork contacts the striker.
3. Stand next to the door opening and move the door
slowly in and out, just touching the striker each time.
D109C576
4. The alignment of the lock fork and the striker can be
easily seen. The lock fork should be perpendicular to
and fall near the middle of the striker. The lock fork
should fall near the middle of the striker between the
B-pillar and the end of the striker.

DOORS 9P–11
DAEWOO M-150 BL2
D109C577
5. If a fore or aft adjustment is required, use the following
steps:

Remove the striker screws (1).

Remove the spacer in order to move the striker to-
ward the rear of the vehicle (2).

Add a 2 mm (0.08 inch) spacer in order to move
the striker toward the front of the vehicle.

Install the striker screws.
6. Perform the up/down or the in/out adjustment. Refer
to ‘‘Up/Down or In/Out Adjustment’’ in this section.
D109C574
Up/Down or In/Out Adjustment
An adjustment of the striker in the up and down or in and
out directions may be necessary for a number of reasons:
vehicle frame damage as the result of a collision, installa-
tion of new door weatherstripping, customer complaints
of excessive windnoise, or difficulty in opening or closing
the door. In order to adjust the door striker in an up and
down or in and out direction, perform the following proce-
dure:
1. The door must be properly aligned.
2. Loosen the striker screws.
3. The floating cage plate can be moved slightly using
the ends of the striker screws. Move the floating cage
plate to the desired position.
Notice: It is important to use a flat-end rotary file in or-
der not to damage the tapped floating cage plate. The
striker screws and the tapped floating cage plate are im-
portant attaching parts that could affect the performance
of vital components and systems.
4. If proper adjustment requires that the floating cage plate
be moved more than is possible, use an electric hand
drill and a 3/8- inch rotary file with a flat head in order to
enlarge the body opening in the direction required.
5. Tighten the striker screws to the correct position.
D109C578
TAILGATE LOCK STRIKER
ADJUSTMENT
Notice: The tailgate lock striker is an important attaching
part that can affect the performance of vital components
and systems and can cause major repair expenses. If re-
placement becomes necessary, the tailgate lock striker
must be replaced by one with the same part number or
with an equivalent part if replacement becomes neces-
sary. Do not use a replacement part of lesser quality or of
a substitute design. The specified torque values must be
used during reassembly in order to ensure the proper
retention of the part.