DAEWOO MATIZ 2003 Service Repair Manual

ENGINE EXHAUST 1G–9
DAEWOO M-150 BL2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Front Exhaust Pipe-to-Front Muffler Pipe Nuts25 – 3518 – 25–
Front Exhaust Pipe-to-Exhaust Manifold Nuts25 – 3518 – 25–
Front Exhaust Pipe-to-Pup-up Catalytic Converter25 – 3518 – 25–
Front Muffler-to-Rear Muffler nuts25 – 3518 – 25–
Pup-up Catalytic Convertor-to-Exhaust Manifold Bolt25 – 3518 – 25–
Muffler Clamp Nut24 – 2818 – 21–
Catalytic Converter Heat Shield8 – 12–71 – 106
Rear Muffler Heat Shield8 – 12–71 – 106

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.

2A–2 SUSPENSION DIAGNOSIS
DAEWOO M-150 BL2
Condition Probable Cause Correction
Car Lead/Pull
Mismatched or uneven tires.
Replace the tires.

A broken or a sagging coil spring.
Replace the coil spring.

A improperly radial tire lateral force.
Check the wheel alignment.

Switch the tire and wheel assemblies.

Replace the tires as needed.

The front–wheel alignment is
out–of–align.
Align the front wheels.

Off–center steering gear.
Reseat the pinion valve assembly.

Replace the pinion valve assembly as
needed.

Front–brake dragging.
Adjust the front brakes.
Abnormal or Excessive
Tire Wear
The front–wheel and rear–wheel
alignment is out–of–align.
Align the front and the rear wheels.

Excessive toe.
Adjust the toe.

A broken or a sagging coil spring.
Replace the coil spring.

Out–of–balance tires.
Balance the tires.

Worn strut dampeners.
Replace the strut dampeners.

A failure to rotate tires.
Rotate the tires.

Replace the tires as needed.

Overloaded vehicle.
Maintain the proper load weight.

Low tire inflation.
Inflate the tires to the proper pressure.
Scuffed Tires
Incorrect toe.
Adjust the toe.

A twisted or a bent suspension arm.
Replace the suspension arm.
Wheel Tramp
An out–of–balance tire or wheel.
Balance the tire or the wheel.

Improper strut dampener action.
Replace the strut dampeners.
Shimmy, Shake, or
An out–of–balance tire or wheel.
Balance the tire or the wheel.
Vibration
Excessive wheel hub runout.
Measure the hub flange runout.

Replace the hub as needed.

Excessive brake drum or brake rotor
imbalance.
Adjust the brakes.

Replace the brake rotor or the brake
drum as needed.

Worn tie rod ends.
Replace the tie rod ends.

Wheel trim imbalance.
Balance the wheel.

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

Excessive wheel runout.
Measure the wheel runout.

Replace the wheel as needed.

Excessive loaded radial runout on the
tire and wheel assembly.
Match–mount the tire and wheel
assembly.

SUSPENSION DIAGNOSIS 2A–3
DAEWOO M-150 BL2
Condition Probable Cause Correction
Hard Steering (Manual)
A lack of lubrication of the ball joints,
the tie rods and the steering gear.
Lubricate the ball joints, the tie rods,
and the steering gear.

Replace the control arm and ball joint
assembly, the tie rods, and the
steering gear as needed.

The front–wheel alignment is
out–of–align.
Align the front wheels.

Steering gear adjustment is
out–of–adjustment.
Adjust the steering gear.
Hard Steering (Power)
The steering preload adjustment is
out–of–adjustment.
Perform a rack bearing preload
on–vehicle adjustment.

The leaked hydraulic system.
Test the power steering system
pressure with a gauge.

Replace the seals and the hoses as
needed.

A loose steering gear mounting.
Tighten the steering gear mounting
bracket bolts.
Too Much Play in
Steering.
Worn or loose wheel bearings.
Tighten the drive axle nut.

Replace the wheel bearing as needed.

A loose steering gear mounting.
Tighten the steering gear mounting
bracket bolts.

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

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.
Poor Returnability
Binding in the ball joints.
Replace the control arm and ball joint
assembly.

Binding in the steering column.
Lubricate the steering column.

Replace the steering column as
needed.

The front–wheel alignment is
out–of–align.
Align the front wheels.

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

A sticking valve.
Lubricate the pinion valve assembly.

Replace the pinion valve assembly as
needed.

Binding in the coupling on the
intermediate shaft.
Replace the intermediate shaft.
Abnormal Noise, Front
Suspension
Damaged suspension components.
Replace the damaged suspension
components.

Worn control arm bushings or tie rod
ends.
Replace the control arm bushings or
the tie rods.

2A–4 SUSPENSION DIAGNOSIS
DAEWOO M-150 BL2
Condition Probable Cause Correction
Abnormal Noise, Front
A loose stabilizer shaft link.
Tighten the stabilizer shaft link.
Suspension
Loose wheel nuts.
Tighten the wheel nuts.

Loose suspension bolts or nuts.
Tighten the suspension bolts or the
nuts.

Loose wheel covers.
Tighten the wheel covers.

Worn strut dampeners or strut
mountings.
Replace the strut dampeners.

Tighten the strut mounting nuts.

An improperly positioned strut spring.
Adjust the strut spring to the proper
position.
Wander or Poor
Mismatched or uneven tires.
Replace the tires.
Steering Ability
Worn strut dampeners.
Replace the strut dampeners.

A loose stabilizer shaft link.
Tighten the stabilizer shaft link.

A broken or a sagging coil spring.
Replace the coil spring.

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

The front–wheel and the rear–wheel
alignment are out–of–align.
Align the front and the rear end
wheels.
Erratic Steering when
Worn or loose wheel bearings.
Replace the wheel bearings.
Braking
A broken or a sagging coil spring.
Replace the coil spring.

A leaking caliper.
Replace the caliper.

Warped rotors.
Replace the rotors.

An incorrect or an uneven caster.
If the caster is beyond specifications,
check the frame and repair it as
needed.
Low or Uneven Trim
A broken or a sagging coil spring.
Replace the coil spring.
Height
An overloaded vehicle.
Maintain the proper load weight.

An incorrect or weak coil spring.
Replace the coil spring.
Ride Too Soft
Worn strut dampeners.
Replace the strut dampeners.

A broken or a sagging coil spring.
Replace the coil spring.
Ride Too Harsh
Incorrect strut dampeners.
Replace the strut dampeners.

An incorrect coil spring.
Replace the coil spring.
Body Leans or Sways
A loose stabilizer shaft link.
Tighten the stabilizer shaft link.
in Corners
Worn strut dampeners or strut
mountings.
Replace the strut dampeners.

Tighten the strut assembly mounting
nuts.

an overloaded vehicle.
Maintain the proper load weight.

A broken or a sagging coil spring.
Replace the coil spring.
Suspension Bottoms
Worn strut dampeners.
Replace the strut dampeners.

An overloaded vehicle.
Maintain the proper load weight.

A broken or a sagging coil spring.
Replace the coil spring.

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.

2A–6 SUSPENSION DIAGNOSIS
DAEWOO M-150 BL2
WHEEL BEARING DIAGNOSIS
This vehicle with non–serviceable bearings in the rear
wheels. If any fault is found with a wheel bearing, it must
be replaced.
Wheel Bearing Noise
A road test usually reveals excessive wheel bearing
noise. Wheel bearings emit a howling sound when loose
or damaged. Wheel bearing noise is present only when
the vehicle is moving. It is constant and unwavering and
increases with the speed of the vehicle. If the wheel
bearing noise cannot be positively diagnosed, or if theorigin of the noise cannot be determined, perform the
following test :
1. Raise and suitably support the vehicle.
2. Spin the wheels using your hand. Check for out–of–
round or out–of–balance tires, bent rims, or loose
wheel bearings.
3. Spin the rear wheels using a commercial wheel spin-
er.
4. If a noise can be heard from the passenger compart-
ment, replace the noisy wheel bearings. Refer to Sec-
tion 2D, Rear Suspension.
5. Lower the vehicle.

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.