service DAEWOO MATIZ 2003 Service Service Manual

TIRES AND WHEELS 2E–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
D106A501
D106A502
WHEEL
Removal Procedure
1. Remove the wheel cover on the vehicle equipped
with steel wheel.
2. Loosen the wheel nuts.
3. Raise and suitably support the vehicle.
4. Remove the wheel nuts.
Notice: Never use heat to loosen a tight wheel. It can
shorten the life of the wheel, the wheel nuts and the
wheel bearings. Excessive force, such as hammering
the wheel or tire, can also cause damage and is not rec-
ommended. Slight tapping of the wheel sidewall with
one’s hand or with a rubber mallet is acceptable.
5. Remove the wheel.
Difficulty in removing the wheels from the vehicle can be
due to foreign material or to a tight fit between the wheel
centerhole and the hub or the rotor. These wheels can
be removed by
1. Retightening the wheel nuts on the affected wheel
and then loosening the wheel nuts by two turns.
2. Lowering the vehicle and rocking it from side to side
as hard as possible, using one or more person’s body
weight to loosen the wheel.
3. Raising the vehicle and removing the wheel.
Caution: Do not allow the penetrating oil to get on
the vertical surfaces between the wheel and the
drum (or rotor) because penetrating oil in this area
could cause the wheel to work loose as the vehicle
is driven, resulting in loss of control and an injury
accident.
Penetrating oil is not effective in removing tight wheels.
If it is used, however, apply it sparingly and only to the
wheel’s centerhole area.

DAEWOO M-150 BL2
SECTION 3B
MANUAL TRANSAXLE DRIVE AXLE
TABLE OF CONTENTS
Description and Operation 3B-2. . . . . . . . . . . . . . . . . .
Front Drive Axle 3B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 3B-3. . . . . . . . . . . . . . . . . . . . . . . .
Drive Axle Assembly 3B-3. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 3B-4. . . . .
Diagnosis 3B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 3B-5. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 3B-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Axle Assembly 3B-5. . . . . . . . . . . . . . . . . . . . . . . Unit Repair 3B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Joint 3B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Joint 3B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 3B-12. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 3B-12. . . . . . . . . .
Special Tools and Equipment 3B-13. . . . . . . . . . . . . .
Special Tools Table 3B-13. . . . . . . . . . . . . . . . . . . . . . .

MANUAL TRANSAXLE DRIVE AXLE 3B–5
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D106B506
DRIVE AXLE ASSEMBLY
Tool Required
KM–507–B Tie Rod End Joint Remover
Removal Procedure
1. Remove the drive axle shaft nut.
Fix the hub not to rotate by pressing the brake ped-
al.
Loosen the caulking (1).
Remove the nut (2).
Discard the nut.
Remove the washer (3).
D103B505
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Remove the transaxle under cover.
Remove the bolts (1).
Remove the under cover (2).
D104B501
4. Drain the transaxle fluid through the drain plug.
5. Remove the stabilizer bar. Refer to Section 2C, Front
Suspension.
6. Separate the control arm ball joint and the tie rod end
from the knuckle. Refer to Section 6D, Manual Steer-
ing gear and Section 2C, Front Suspension.
a. Control arm ball joint bolt.
b. Tie rod end joint castellated nut.
Notice: Use only the recommended tool for separating
the tie rod from the knuckle/strut assembly. Failure to
use the recommended tool may cause damage to the
knuckle/strut assembly or the tie rod end.

MANUAL TRANSAXLE DRIVE AXLE 3B–11
DAEWOO M-150 BL2
D104B704
5. Remove the drive axle shaft boot.
D104B708
Assembly Procedure
1. Install in the reverse order of removal.
2. Install the joint assembly.
Pre–install the joint assembly by pushing to the
drive axle shaft to widen the circlip.
Keep the circlip widened (1).
Push the joint assembly to the drive axle shaft (2).
D104B709
3. Fill the joint housing with recommended grease when
installing.
Capacity 80–90 g (2.8–3.2 ounces)
Notice: Always use the recommended grease. If not,
joint and boot can be damaged.
Important: Always use new clamps.
D104B710
Inspection Procedure
1. Inspect the operation of joint.
2. Inspect for a leaking boot through the clamp side.
Important: Do not disassemble the outer joint assem-
bly. Parts are match fit and can not be serviced sepa-
rately. Improper reassembly will adversely affect both
performance and safety.

DAEWOO M-150 BL2
SECTION 4A
HYDRAULIC BRAKES
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.
TABLE OF CONTENTS
Description and Operation 4A-2. . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A-2. . . . . . . . . . . . . . . . . . .
Component Locator 4A-3. . . . . . . . . . . . . . . . . . . . . . . .
Brake System (Non-ABS) 4A-3. . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4A-4. . . . .
Brake System Testing 4A-4. . . . . . . . . . . . . . . . . . . . . .
Brake Hose Inspection 4A-4. . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A-5. . . . . . . . . . . . . . . . . . .
Brake System Fault 4A-5. . . . . . . . . . . . . . . . . . . . . . . .
Manual Bleeding the Brakes 4A-6. . . . . . . . . . . . . . . .
Pedal Travel Check 4A-6. . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Free Play Inspection 4A-7. . . . . . . . . . . Repair Instructions 4A-8. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4A-8. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose (Front) 4A-8. . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose (Rear) 4A-9. . . . . . . . . . . . . . . . . . . . . . . .
Stoplamp Switch 4A-9. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal 4A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4A-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4A-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4A-13. . . . . . . . . .
Schematic and Routing Diagrams 4A-14. . . . . . . . . .
Brake Lamp Warning Circuit 4A-14. . . . . . . . . . . . . . .
Stoplamp Switch Circuit 4A-14. . . . . . . . . . . . . . . . . . .

4A –8 HYDRAULIC BRAKES
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D107A528
BRAKE HOSE (FRONT)
Removal Procedure
1. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
2. Remove the brake hose.

Remove the fitting (1).

Remove the E–ring retainer (2).

Disconnect the brake hose mounting from the strut
(3).

Remove the coupling bolt (4).

Plug the opening in the brake pipe and caliper to
prevent fluid loss or contamination.
D17A529B
Installation Procedure
1. Connect the brake lines to the brake hose (1).
Tighten
Tighten the brake pipe–to–hose fitting to 16 Nm (12
lb-ft).
2. Install the brake hose coupling bolt (2).
Tighten
Tighten the bolt to 25.5 Nm (19.1 lb-ft).
Important: Use only Daewoo recommended brake
fluid.
3. Bleed the brake system. Refer to “Manual Bleeding
the Brakes” in this section.
4. Check the brake system for leaks.
5. Install the wheels. Refer to Section 2E, Tires and
Wheels.

DAEWOO M-150 BL2
SECTION 4B
MASTER CYLINDER
TABLE OF CONTENTS
Description and Operation 4B-2. . . . . . . . . . . . . . . . . .
Master Cylinder 4B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Proportioning Valve 4B-2. . . . . . . . . . . . . . . . . . . . . . . .
Fluid Level Sensor 4B-2. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4B-3. . . . .
Checking the Brake Fluid Level 4B-3. . . . . . . . . . . . . .
Repair Instructions 4B-4. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4B-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly 4B-4. . . . . . . . . . . . . . . . . . Brake Fluid Reservoir 4B-5. . . . . . . . . . . . . . . . . . . . . .
Proportioning Valve (For Vehicle With the
Non–ABS Braking System) 4B-5. . . . . . . . . . . . . . .
Brake Fluid Level Switch 4B-6. . . . . . . . . . . . . . . . . . .
Unit Repair 4B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder 4B-8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4B-9. . . . . . . . . . .

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.

4B –4 MASTER CYLINDER
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
MAB4B001
D107A514
MASTER CYLINDER ASSEMBLY
Removal Procedure
1. Remove the air filter assembly. Refer to Section 1B,
Engine Mechanical.
2. For vehicles with the non–ABS braking system, re-
move the proportioning valve. Refer to “Proportioning
Valve” in this section.
3. Remove the master cylinder.

Disconnect the electrical connector.

Loosen the brake pipe fittings.

Plug the opening in the master cylinder to prevent
fluid loss or contamination.
Notice: Brake fluid may damage paintwork, if spillage
onto paintwork, wash with cold water immediately.

Remove the nuts mounting the master cylinder (3).
D17A515A
Installation Procedure
Important: Use only Daewoo recommended brake
fluid.
1. Install the master cylinder assembly with the nuts.
Tighten
Tighten the attaching nuts to 16 Nm (12 lb-ft).

DAEWOO M-150 BL2
SECTION 4C
POWER BOOSTER
TABLE OF CONTENTS
Description and Operation 4C-2. . . . . . . . . . . . . . . . . .
Power Booster 4C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4C-3. . . . .
Power Booster Functional Check 4C-3. . . . . . . . . . . .
Check Valve Functional Check 4C-3. . . . . . . . . . . . . .
Repair Instructions 4C-4. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 4C-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Hose and Check Valve 4C-4. . . . . . . . . . . . .
Power Booster Assembly 4C-5. . . . . . . . . . . . . . . . . . .
Specifications 4C-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4C-8. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4C-8. . . . . . . . . . .