service DAEWOO MATIZ 2003 Service Manual PDF

ANTILOCK BRAKE SYSTEM 4F–5
DAEWOO M-150 BL2
D107E001
WHEEL SPEED SENSORS AND
RINGS
Front wheel speed sensors are installed to the front
knuckle and rear wheel speed sensors are installed to
the backing plate.
Wheel speed sensors are no serviceable. And the air
cap is not adjusted. Front wheel speed sensor ring is
pressed onto the drive axle shaft. Each ring contains 40
equally spaced teeth. Exercise care during service pro-
cedures to avoid prying or contacting this ring. Exces-
sive contact may cause damage to one or more teeth.
Rear wheel speed sensor rings are incorporated into the
hub drum.
D107E007
D107E008
ELECTRONIC BRAKE DISTRIBUTION
ABS features an enhanced algorithm which includes
control of the brake force distribution between the front
and rear axles. This is called Electronic Brake Distribu-
tion or Dynamic Rear Proportioning valve. In an unladen
car condition the brake efficiency is comparable to the
conventional system but for a fully loaden vehicle the ef-
ficiency of the Dynamic Rear Proportioning System is
higher due to the better use of rear axle braking capabili-
ty.
No indication is given to the driver when Dynamic Rear
Proportioning is activated. Also, DRP remains active
even in such cases where the anti-lock function of the
ABS is disabled.
D17E009A
Critical Brake Points
Ideal Distribution
Fully Laden Vehicle
Ideal Distribution
Lightly Loaded
Vehicle
Advanced Distribution with ABS
Regular Distribution without Dynamic
Rear Proportioning
Relative Front Brake Force
INDICATOR
It illuminates for four seconds immediately after the igni-
tion has been turned on to show that the anti-lock sys-
tem self-test is being carried out. If the light does not go
off after this time it means that there may be a problem
and ABS operation is not available.
If any malfunction or error, including an unplugged
EBCM connector, is detected during vehicle operation,
the light will come on, warning the driver that the ABS is
not operative and brake operation is in conventional,
non-ABS mode.
D17E010A

DAEWOO M-150 BL2
SECTION 4G
PARKING BRAKE
TABLE OF CONTENTS
Description and Operation 4G-2. . . . . . . . . . . . . . . . . .
Parking Brake 4G-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 4G-3. . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake 4G-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 4G-4. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4G-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever 4G-4. . . . . . . . . . . . . . . . . . . . . . . Parking Brake Warning Lamp Switch 4G-5. . . . . . . . .
Parking Brake Cable 4G-6. . . . . . . . . . . . . . . . . . . . . . .
Specifications 4G-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4G-8. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4G-8. . . . . . . . . . .
Schematic and Routing Diagrams 4G-9. . . . . . . . . . .
Parking Brake System 4G-9. . . . . . . . . . . . . . . . . . . . .

4G–4 PARKING BRAKE
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
D107D501
PARKING BRAKE LEVER
Removal Procedure
1. Remove the parking brake lever cover. Refer to Sec-
tion 9G, Interior Trim.
2. Remove the parking brake cable cover. Refer to Sec-
tion 9G, Interior Trim.
3. Remove the parking brake lever.

Disconnect the brake warning lamp switch (1).

Remove the brake warning switch lamp screw (2).
Important: The brake warning lamp switch screw should
be removed with the lever fixed.
D107D502

Remove the bolts (3).

Remove the nut (4).
D107D503

Remove the cotter pin (5).

Remove the pin (6).

DAEWOO M-150 BL2

SECTION 5B
FIVE-SPEED MANUAL TRANSAXLE
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 5B-2. . . . . . . . . . . . . . . . . .
Five-Speed Manual Transaxle 5B-2. . . . . . . . . . . . . . .
Reverse Gear Misshift Preventing
Mechanism 5B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locators 5B-3. . . . . . . . . . . . . . . . . . . . . . .
Gear Shift Control 5B-3. . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft and Counter Shaft Gear 5B-4. . . . . . . . . .
Gear Shift Fork 5B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential and Case 5B-7. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 5B-8. . . . . . .
General Diagnosis 5B-8. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 5B-9. . . . . . . . . . . . . . . . . . . . . . .
Changing Fluid 5B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Transaxle Noise 5B-9. . . . . . . . . . . . . . . . . .
Checking Bearing Noise 5B-9. . . . . . . . . . . . . . . . . . . .
Repair Instruction 5B-10. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 5B-10. . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transaxle Assembly 5B-10. . . . . . . . . . . . . . .
Gear Shift Control Case Assembly 5B-17. . . . . . . . . .
Speedometer Driven Gear and Cable 5B-19. . . . . . .
Gear Shift Control Cable 5B-21. . . . . . . . . . . . . . . . . .
Gear Shift Control Lever 5B-23. . . . . . . . . . . . . . . . . . .
Unit Repair 5B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Unit 5B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft 5B-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Shaft 5B-41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Shift Fork 5B-46. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5B-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 5B-52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5B-52. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5B-53. . . . . . . . . .
Special Tools 5B-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5B-54. . . . . . . . . . . . . . . . . . . . . . .

FIVE-SPEED MANUAL TRANSAXLE 5B–9
DAEWOO M-150 BL2
CHECKING FLUID LEVEL
Check for a leak in the area of transaxle case and seal-
ing and then check fluid level and condition after remov-
ing oil level plug.
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Remove the oil level plug and check the fluid level.
4. The fluid should slightly flow out from the oil level plug
hole.
5. If the level is low, add the recommended fluid through
the oil level plug hole until the fluid begins to run out.
6. If the fluid is contaminated or discolored, replace it
with the recommended fluid.
7. Reinstall the oil level plug and tighten it securely.
D103B301
CHANGING FLUID
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Drain the fluid after removing the drain plug.
4. Reinstall the drain plug and tighten it securely after
coating sealant.
5. Remove the oil level plug and replenish the fluid until
it begins to run out.
a. Oil drain plug.
b. Oil level plug.
6. Reinstall the oil level plug and tighten it securely.Fluid Specification
75W-85(GL-4)
Fluid Capacity2.1L(2.21qt)
Service intervalRefer to Owner’s Manual
CHECKING TRANSAXLE NOISE
Many noises that appear to come from the transaxle
may actually originate with other sources such as tires,
road surfaces, wheel bearings, or engine and exhaust
system.
Identify the cause of any noise before attempting to re-
pair the clutch, the transaxle, or their related linkages.
To verify suspected transaxle noises,
1. Select a smooth, level asphalt road to reduce tyre
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lubri-
cants thoroughly.
3. Record the speed and the gear range of the transaxle
when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle oper-
ates in.

Drive – Under a light acceleration or a heavy pull.

Float – Maintaining a constant speed with a light
throttle on a level road.

Coast – With the transaxle in gear and the throttle
partly or fully closed.

All of the above.
CHECKING BEARING NOISE
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre-
loaded, a differential side bearing noise should not di-
minish much when the differential/transaxle is run with
the wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre-loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.

5B–10 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
REPAIR INSTRUCTION
ON–VEHICLE SERVICE
D103B501
MANUAL TRANSAXLE ASSEMBLY
Tools Required
DW110–021 Engine Support Fixture
DW220–031 Transaxle Remove/Install Support
Removal Procedure
1. Remove the air cleaner assembly. Refer to Section
1B, SOHC Engine Mechanical.
2. Remove the battery and battery tray. Refer to Section
1E, Engine Electrical.
3. Disconnect the select and the shift cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift cable (3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.
D103B502
4. Remove the engine wiring harness bending strap.
5. Disconnect the ground wire and the backup lamp
switch connector.

Remove the ground wire bolt (1).

Disconnect the ground wire (2).

Disconnect the backup lamp switch connector (3).

5B–52 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
GeneralTypeForward gear–Synchronized
mesh type–
Reverse gear–Sliding mesh
type–
Gear ratio1st–3.818–
2nd–2.210–
3rd–1.423–
4th–1.029–
5th–0.837–
Reverse–3.583–
Final drive ratio–4.444–
Fluid capacityL(qt)2.1 (2.21)–
Fluid classification–75W-85 (GL-4)–
ServiceKey groove width of1st gearmm(in.)8.2 (0.323)8.6 (0.339)
synchronizer ring2nd, 3rd, 4th gearmm(in.)9.6 (0.378)10.0 (0.394)
5th gearmm(in.)9.4 (0.370)9.8 (0.386)
Shift fork end
thicknessLow speed shift fork
(1st~2nd)mm(in.)8.7 (0.343)8.1 (0.319)
High speed shift fork
(3rd~4th)mm(in.)7.8 (0.307)7.2 (0.283)
5th gear shift forkmm(in.)7.8 (0.307)7.2 (0.283)
Clearance between gear and synchronizer
ringmm(in.)1.0 (0.039)0.5 (0.020)
Clearance between sleeve and shift forkmm(in.)0.2 – 0.6
(0.008 – 0.024)1.0 (0.039)
Thrust free play of differential side gearmm(in.)0.05 – 0.33
(0.002 – 0.013)–
Speedometer gear ratio(Driven/Drive)–17/18 (0.944)–

DAEWOO M-150 BL2
SECTION 5C
CLUTCH
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 5C-2. . . . . . . . . . . . . . . . . .
Driving Members 5C-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Driven Members 5C-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Members 5C-2. . . . . . . . . . . . . . . . . . . . . . .
Component Locator 5C-3. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Components 5C-3. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 5C-4. . . . .
General Diagnosis 5C-4. . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pedal Operation 5C-5. . . . . . . . . . . . . . . . . . . .
Clutch Cable Adjustment 5C-5. . . . . . . . . . . . . . . . . . .
Repair Instruction 5C-6. . . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 5C-6. . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Plate, Clutch Disc and
Input Shaft Bearing 5C-6. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Release Bearing, Shaft and Bushing 5C-8. . .
Clutch Release Arm 5C-10. . . . . . . . . . . . . . . . . . . . . .
Clutch Cable 5C-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pedal 5C-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 5C-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5C-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5C-13. . . . . . . . . .
Special Tools 5C-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5C-14. . . . . . . . . . . . . . . . . . . . . . .

5C –6 CLUTCH
DAEWOO M-150 BL2
INSTRUCTION REPAIR
ON–VEHICLE SERVICE
D13B5151
D103B516
PRESSURE PLATE, CLUTCH DISC
AND INPUT SHAFT BEARING
Tools Required
09917–58010 Input Shaft Bearing Remover
09924–17810 Flywheel Holder
09925–98210 Input Shaft Bearing Installer
DW110–021 Engine Fixture
DW210–010 Clutch Center Guide
Removal Procedure
1. Remove the transaxle from the vehicle. Refer to Sec-
tion 5B, Manual Transaxle.
2. Support the engine to normal position using the en-
gine fixture DW110–021.
Notice: The abnormal position of the engine may dam-
age to the related parts and interfere with them. You
must support the engine to normal position after remov-
ing the transaxle.
D13C5021
3. Remove the pressure plate and the clutch disc.

Fix the fly wheel using the fly wheel holder 09924–
17810.

Remove the pressure plate bolts (1).

Remove the pressure plate and the clutch disc (2).

DAEWOO M-150 BL2
SECTION 6B
POWER STEERING PUMP
TABLE OF CONTENTS
Description and Operation 6B-2. . . . . . . . . . . . . . . . . .
Power Steering Pump 6B-2. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6B-3. . . . .
Power Steering Pump 6B-3. . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 6B-4. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Belt 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Pulley 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . Pump Assembly 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 6B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6B-8. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6B-8. . . . . . . . . . .
Special Tools and Equipment 6B-9. . . . . . . . . . . . . . .
Special Tools Table 6B-9. . . . . . . . . . . . . . . . . . . . . . . .