DAEWOO MATIZ 2003 Service Repair Manual

2E –8 TIRES AND WHEELS
DAEWOO M-150 BL2
D16A503A
90–11 0 Nm
Installation Procedure
Notice: Before installing the wheels, remove any build-
up of corrosion on the wheel mounting surface and the
brake drum or the rotor mounting surface by scraping
and brushing them with a wire brush. Installing the
wheels without good metal-to-metal contact at the
mounting surfaces can cause the wheel nuts to loosen,
which can later allow a wheel to come off while the ve-
hicle is moving. Wheel nuts must be tightened in se-
quence and to the proper torque to avoid bending the
wheel, the brake drum or the rotor.
1. Mount the wheel.
2. Install the wheel nuts in the diagonally. Do not tighten
the wheel nuts.
3. Lower the vehicle.
Tighten
Tighten the wheel nuts to 90–110 Nm (66–81 lb-ft).
ON-VEHICLE BALANCING
On-vehicle balancing will help correct vibrations due to
brake drum, rotor, and wheel cover imbalances.
Notice: Do not allow the front suspension to hang free.
When the drive axle is run at an extreme angle, extra
vibrations can occur, as well as damage to seals and
joints.
1. During on-vehicle balancing, do not remove the bal-
ance weights from the off-vehicle dynamic balance.
2. If more than 1 ounce of additional weight is required,
split the weight between the inner and the outer rim
flanges.
3. Spin the driven tire and wheel assemblies using the
engine.
OFF-VEHICLE BALANCING
Perform wheel balancing with an electronic off-vehicle
balancer. The balancer is easy to use and gives both a
static and a dynamic balance. Unlike on-vehicle balanc-
ing, the off-vehicle balancer does not correct for drum or
rotor imbalance. This drawback is overcome by its accu-
racy. Secure the wheel on the balancer with a cone
through the back side of the centerhole, not through the
wheel nut holes.
CORRECTING NON-UNIFORM TIRES
There are two ways to correct properly balanced tires
which still vibrate. One method uses an automatic
machine which loads the tire and buffs small amounts of
rubber from high spots on the outer two tread rows.
Correction by this method is usually permanent and, if it
is done properly, does not significantly affect the
appearance or the tread life of the tire. Tire truing with a
blade-type machine is not recommended because it
substantially reduces the tread life and often does not
correct the problem permanently.

TIRES AND WHEELS 2E–9
DAEWOO M-150 BL2
Another method is to dismount the tire and rotate it
180 degrees on the rim. Do this only on the tire and
wheel assemblies which are known to be causing a
vibration because this method is just as likely to cause
good assemblies to vibrate.
TIRE AND WHEEL
MATCH-MOUNTING
The tires and wheels are match-mounted at the assem-
bly plant. Match-mounting aligns the radially stiffest part
of the tire, or high spot, to the smallest radius, or low
spot, of the wheel.
The high spot of the tire is originally marked by a red
paint mark or an adhesive label on the outboard side-
wall.
The low spot of the wheel will be at the location of the
valve stem.
Before dismounting a tire from its wheel, scribe a line on
the tire at the valve stem to assure that it is remounted in
the same position.
Replacement tires that are of original equipment quality
will have their high and low spot marked in the same
manner.

2E –10 TIRES AND WHEELS
DAEWOO M-150 BL2
SPECIFICATIONS
TIRE SIZE AND PRESSURE SPECIFICATIONS
Inflation Pressure
FrontRearEngineTiresWheelkPapsikPapsi
0.8 SOHC145/70 R134.5Jx13 (Steel)207 (207)*30 (30)*207 (234)*30 (34)*
155/65 R134.5Jx13 (Alloy)207 (207)*30 (30)*207 (234)*30 (34)*
Important: ( )* : 4 – 5 occupants
INFLATION PRESSURE CONVERSION SPECIFICATIONS

kPa

psi

kPapsikPapsi
140

20

186

27

234

34
145

21

193

28

241

35
152

22

200

29

248

36
159

23

207

30

276

40
166

24

214

31

310

45
172

25

221

32

345

50
179

26

228

33

379

55
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Wheel Nuts (Aluminum Wheel)90 – 11 066 – 81–
Wheel Nuts (Steel Wheel)90 – 11 066 – 81–

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. . . . . . . . . . . . . . . . . . . . . . .

3B – 2 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FRONT DRIVE AXLE
Drive axles are flexible shaft assemblies that transmit a
rotational force from the transaxle to the front wheel as-
semblies. Each axle assembly consists of an inner
constant-velocity joint and an outer constant-velocity
joint connected to an axle shaft. The inner joint is com-pletely flexible and has the ability to move in and out.
The outer joint is also flexible, but it cannot move in and
out.
The drive axles use a Rzeppa–style joint on the out-
board side and a Tripot–style joint on the inboard side.

MANUAL TRANSAXLE DRIVE AXLE 3B–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
DRIVE AXLE ASSEMBLY
D104B401
1. Outer Joint (Rzeppa)
2. Outer Large Boot Clamp
3. Outer Boot
4. Outer Small Boot Clamp
5. Drive Axle Shaft6. Inner Small Boot Clamp
7. Inner Boot
8. Inner Large Boot Clamp
9. Inner Joint (Tripot)
10. Inner Joint Housing

3B –4 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
Condition Probable Cause Correction
Noise
Bent drive axle shaft.
Replace drive axle.





Worn the spline of drive axle shaft or joint
shaft.


Replace drive axle.

Worn joint by grease leakage.
Replace drive axle.
Steering Wheel
Bent drive axle shaft.
Replace drive axle.


Vibration


Worn the spline of drive axle shaft or joint
shaft.


Replace drive axle.
Car Lead / Pull
Worn joint by grease leakage.
Replace drive axle.
Boot Leak
Poor assembly of boot clamp.
Replace boot clamp.

Torn boot.
Replace Boot.

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.

3B –6 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
D104B502
7. Pull the drive axle shaft (1) from the wheel hub.
Important: Support the unfastened end of the drive
axle. Do not allow the drive axle to dangle freely from the
transaxle for any length of time after it has been re-
moved from the wheel hub.
D104B503
8. Remove the drive axle from the transaxle.
Insert a flathead screwdriver between the trans-
axle case and the drive axle joint case (1).
Remove the drive axle (2).
Important: Cap the transaxle drive opening after the
drive axle has been removed to keep any contamination
out.
D104B504
Inspection Procedure
1. Inspect for worn or damaged spline of drive axle (1).
2. Inspect for a leaking boot (2).
3. Inspect for a bent shaft (3).
D14B502A
Installation Procedure
1. Clean the transaxle seal.
2. Install the drive axle into the transaxle.
3. Install the wheel hub onto the drive axle shaft.
4. Mount the knuckle onto the control arm ball joint.

MANUAL TRANSAXLE DRIVE AXLE 3B–7
DAEWOO M-150 BL2
D14B505B
5. Install the control arm ball joint bolt.
Tighten
Tighten the control arm ball joint bolt to 50–70 N
m
(36–52 lb-ft).
a. Control arm ball joint bolt
6. Install the tie rod into the knuckle and install the tie
rod end joint castellated nut.
Tighten
Tighten the tie rod end joint castellated nut to 30–55
N
m (21–41 lb-ft).
b. Tie rod end joint castellated nut.
D14B506A
33–53 N
m
40–50 N
m7. Install the stabilizer bar.Tighten
Tighten the stabilizer bar mounting bolts 33–53
N
m (24–39 lb-ft).
Tighten the stabilizer bar castellated nut to 40–50
N
m (30–36 lb-ft).
a. Stabilizer bar mounting bolt.
b. Stabilizer bar castellated nut.
D14B507A
8. Install the drive axle shaft nut.
Tighten
Tighten the drive axle shaft nut to 210 N
m (155 lb-ft)
Notice: Always use a new nut. Always peen the
caulking nut with a punch and a hammer until the nut
is locked into place on the wheel hub.
9. Install the wheels. Refer to Section 2E, Tires and
wheels.
D13BB520A
10. Refill the transaxle fluid to the proper level.
Tighten the drain plug to 25-30 N
m (18-22 lb-ft)
(a).
Remove the oil level plug (1).
Refill recommended fluid to the proper level.
Tighten the oil level plug to 36-54 N
m (26–40 lb-
ft) (b).
Classification 75W–85 (GL–4) Capacity2.1L (2.21 gt)