ABS DAEWOO MATIZ 2003 Service Manual PDF

REAR SUSPENSION 2D–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
REAR SUSPENSION
D106C401
1. Shock Absorber
2. Bumper Stopper
3. Coil Spring Upper Seat
4. Coil Spring
5. Washer
6. Bushing
7. Lateral Rod
8. Rear Axle9. Oil Seal
10. Wheel Bearing Inner
11. ABS Wheel Speed Ring
12. Wheel Bearing Outer
13. Cotter Pin
14. Castellated Nut
15. Spindle Cap
16. Trailing Arm

2D –4 REAR SUSPENSION
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
REAR SUSPENSION

Condition

Probable cause

Correction
Noise
The loosened joints.
Tighten the joints.

Wheel bearing is worn or damaged.
Replace the wheel bearing.

Faulty shock absorber.
Replace the shock absorber.
Uncomfortable
Faulty shock absorber.
Replace the shock absorber.

Faulty coil spring.
Replace the coil spring.

Lateral rod bushing is worn or
damaged.
Replace the lateral rod bushing.

Trailing arm bushing is worn or
damaged.
Replace the trailing arm bushing.
Vehicle Leans Toward
Rear axle deformation.
Replace the rear axle.
the Side
Lateral rod deformation.
Replace the lateral rod.

Trailing arm deformation.
Replace the trailing arm.

Faulty coil spring.
Replace the coil spring.

Lateral rod bushing is worn or
damaged.
Replace the lateral rod bushing.

Trailing arm bushing is worn or
damaged.
Replace the trailing arm bushing.

2D –6 REAR SUSPENSION
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D106C501
SHOCK ABSORBER
Removal Procedure
1. Support the rear axle with adjustable jack stands.

Raise the vehicle and support the rear axle assem-
bly (1, 2).
D106C502
2. Remove the shock absorber.

Remove the bolt (1).

Remove the nut (2).
D16C503B
Installation Procedure
1. Install the shock absorber.

Install the shock absorber–to–rear axle bolt (1).
Tighten
Tighten the bolt to 45–70 Nm (33–52 lb-ft).

Install the shock absorber–to–body bracket nut (2).
Tighten
Tighten the shock absorber nut to 45–70 Nm (33–52
lb-ft).
2. Remove the jack stand and lower the vehicle.

2D –8 REAR SUSPENSION
DAEWOO M-150 BL2
D16C508B
3. Install the lateral rod–to–body bracket bolt.
Tighten
Tighten the lateral rod–to–body bracket bolt to 50–70
Nm (37–52 lb-ft).
D106C509
TRAILING ARM
Removal Procedure
1. Raise and suitably support the vehicle.
2. Support the rear axle with adjustable jack stands.
3. Separate the rear shock absorber from the rear axle
assembly.

Loosen the shock absorber–to–body bracket nut
(1).

Remove the shock absorber–to–rear axle bolt (2).
D106C510
4. Remove the trailing arm.

Remove the trailing arm–to–rear axle bolts (1).
D106C511

Remove the trailing arm–to–body bracket bolt (2).

REAR SUSPENSION 2D–9
DAEWOO M-150 BL2
D16C515A
Installation Procedure
1. Install the trailing arm.

Install the trailing arm–to–body bracket bolt (1).
Tighten
Tighten the trailing arm–to–body bracket bolt to 70–
90 Nm (55–66 lb-ft).

Install the trailing arm–to–rear axle bolts (2).
Tighten
Tighten the trailing arm–to–rear axle bolts to 80–90
Nm (59–66 lb-ft).
2. Install the rear shock absorber. Refer to “Shock Ab-
sorber” in this section.
D106C516
D106C517
REAR AXLE ASSEMBLY
(INCLUDING COIL SPRING)
Removal Procedure
1. Remove the rear brake drum, shoe and brake plate.
Refer to Section 4E, Rear Drum Brakes.
2. Remove the lateral rod. Refer to “Lateral Rod” in this
section.
3. Disconnect the rear axle and the trailing arm.

Support the rear axle with adjustable jack stands
(1).

Remove the shock absorber–to–rear axle bolt (2).

Loosen the shock absorber–to–body bracket nut
(3).

Remove the trailing arm–to–rear axle bolt (4).
Caution: When disconnecting the rear axle and the
trailing arm, coil spring tension may cause the ad-
justable jack stand to slip from the rear axle. This
may result in personal injury. Carry out the opera-
tion with co–worker.
D106C518
4. Remove the rear axle from the vehicle.

Remove the coil spring by lowering the jack stand
slowly (1).

Lower the support jack and remove the rear axle
(2).

REAR SUSPENSION 2D–11
DAEWOO M-150 BL2
D16C517C
3. Install the trailing arm and the shock absorber to the
rear axle.

Install the trailing arm–to–rear axle bolt (1).
Tighten
Tighten the trailing arm–to–rear axle bolt to 80–90
Nm (59–66 lb-ft).
D16C516C

Install the shock absorber–to–rear axle bolt (2).
Tighten
Tighten the shock absorber–to–rear axle bolt to 45–70
Nm (33–52 lb-ft).
4. Install the lateral rod. Refer to “Lateral Rod” in this
section.
5. Install the rear brake drum, shoe and brake plate. Re-
fer to Section 4E, Rear Drum Brake.

REAR SUSPENSION 2D–15
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Suspension Type– Isolated Trailing Link
Maximum Lengthmm (in.) 394.5 ± 3 (15.53 ± 0.12)
Shock Absorber Minimum Lengthmm (in.) 257.5 ± 3 (10.14 ± 0.12)

Shock Absorber
Strokemm (in.) 137 (5.39)
Clearancemm (in.) 0
Rear Wheel Bearing No LoadNm (lb-in.) 0.137 – 0.422 (0.9 – 3.7)
Coil Spring Height (No Load)mm (in.) 291 (11.46)
Grease Type (Rear Wheel Bearing and Hub)–M–8143 ANTIF BRG GREASE
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In Shock Absorber–to–Body Bracket Nut 45 – 70 33 – 52 – Shock Absorber–to–Rear Axle Bolt 45 – 70 33 – 52 – Trailing Arm–to–Rear Axle Bolt 80 – 90 59 – 66 – Trailing Arm–to–Body Bracket Bolt 70 – 90 55 – 66 – Lateral Rod–to–Body Bracket Bolt 50 – 70 37 – 52 – Lateral Rod–to–Rear Axle Nut 35 – 55 25 – 41 – Rear Axle Castellated Nut* – – – ABS Rear Speed Sensor Retaining Bolt 9 – 13 – 80 – 11 5

Rear Axle Castellated Nut : Refer to Section 4E, Rear Drum Brakes

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

HYDRAULIC BRAKES 4A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
BRAKE SYSTEM (NON–ABS)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
MAB4A001
1. Power Booster
2. Power Booster Boot
3. Cotter Pin
4. Clevis
5. Clevis Pin
6. Packing
7. Spacer
8. Master Cylinder Assembly
9. Fluid Reservoir Assembly
10. Reservoir Cap
11. Reservoir
12. Grommet Seal
13. Master Cylinder
14. Proportioning Valve
15. Stoplamp Switch
16. Brake Pedal Assembly
17. Clutch Pedal Spring18. Pedal Bracket Assembly
19. Clutch Pedal Pad
20. Clutch Pedal
21. Cushion
22. Bushing
23. Retaining Ring
24. Spring
25. Brake Pedal Pad
26. Brake Pedal
27. Brake Pedal Spring
28. Accelator Pedal Pad
29. Accelator Pedal
30. Rear Drum Brake Hose
31. E Ring
32. Front Disc Brake Hose
33. Brake Hose Coupling Bolt
34. Plain Washer

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. . . . . . . . . . .