light DAEWOO MATIZ 2003 Service Manual PDF

1F–298 ENGINE CONTROLS
DAEWOO M-150 BL2
Rough, Unstable, or Incorrect Idle, Stalling (Cont’d)
StepActionValue(s)YesNo
12
Is the long term fuel trim reading below the value
specified?
–20%
Go to
“Diagnostic Aids
for DTC P0172”
Go to Step 13
13
Is the long term fuel trim reading above the value
specified?
25%
Go to
“Diagnostic Aids
for DTC P0171”
–
14
1. Disconnect all of the fuel injector harness
connectors at the fuel injectors.
2. Connect an injector test light between the
harness terminals of each fuel injector connector.
3. Note the test light while cranking the engine.
Does the test light blink for all of the fuel injectors?
–
Go to Step 16Go to Step 15
15
1. Repair or replace the faulty injector drive circuit
harness, the connector, or the connector
terminals as needed.
2. If the harness, the connectors, and the terminals
are OK, replace the Engine Control Module
(ECM).
Is the repair complete?
–
System OK
–
16
Measure the resistance of each of the fuel injectors.
Is the resistance within the value specified (the
resistance will increase slightly at higher
temperatures)?
11.6–12.4 ΩGo to Step 18Go to Step 17
17
Replace any fuel injectors with a resistance that is
out of specifications.
Is the repair complete?
–
System OK
–
18Perform an injector diagnosis.
Is the problem found?–Go to Step 19Go to Step 20
19Replace any leaking or restricted fuel injectors.
Is the repair complete?–System OK–
20
1. With the engine OFF, disconnect the fuel
pressure regulator vacuum hose.
2. Thoroughly inspect the fuel pressure regulator
vacuum port and the fuel pressure regulator
vacuum hose for the presence of fuel.
Is the problem found?
–
Go to Step 21Go to Step 22
21Replace the fuel pressure regulator as needed.
Is the repair complete?–System OK–
22
1. Check the ignition system output voltage for all of
the cylinders using a spark tester.
2. Inspect the spark plugs for excessive wear,
insulation cracks, improper gap, or heavy
deposits.
3. Inspect the ignition wires for cracking, hardness,
or improper connections.
4. Replace any ignition wires with a resistance over
the value specified.
Is the problem found?
30000 ΩGo to Step 23Go to Step 24
23
Repair or replace any ignition system components
as needed.
Is the repair complete?
–
System OK
–

FRONT SUSPENSION 2C–5
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
STRUT DAMPENER
A strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand
than are shock absorbers. Strut dampeners are used only on the front in most vehicles, including this vehicle. Shock
absorbers are used on the rear wheels.
Condition Probable cause Correction
Struts Seem Weak
Improper tire pressures.
Adjust the tire pressures to the speci-
fications on the tire placard.

Abnormal load conditions.
Consult with the owner to confirm the
owner’s understanding of normal load
conditions.

Improper compression and rebound
effectiveness of the strut dampener.
Quickly push down and then lift up on
the corner of the bumper nearest the
strut dampener being tested.

Compare the compression and re-
bound with those of a similar vehicle
that has an acceptable ride quality.

Replace the strut dampener, if need-
ed.
Struts are Noisy
Loose or damaged mountings.
Tighten the strut dampener.

Replace the strut dampener if need-
ed.

Improper compression and rebound
effectiveness of the strut dampener.
Quickly push down and then lift up on
the corner of the bumper nearest the
strut dampener being tested.

Compare the compression and re-
bound with those of a similar vehicle
that has an acceptable ride quality.

Replace the strut dampener, if need-
ed.
Leaks
A slight trace of fluid.
The strut dampener is OK.

Leaks of the seal cover on the fully
extended strut.
Replace the strut dampener.

Excessive leaks of fluid on the strut
dampener.
Replace the strut dampener.
BALL JOINT AND KNUCKLE
Ball Joint Inspection
1. Raise the front of the vehicle to allow the front sus-
pension to hang free.
2. Grasp the tire at the top and the bottom.
3. Move the top of the tire in an in-and-out motion.
4. Look for any horizontal movement of the knuckle rela-
tive to the control arm.
5. Control arms assembly must be replaced if the follow-
ing conditions exist:

The joint is loose.

The ball seal is cut.

The ball stud is disconnected from the knuckle.
The ball stud is loose at the knuckle.

The ball stud can be twisted in its socket with finger
pressure.Ball Stud Inspection
Make sure to check the tightness of the ball stud in the
knuckle boss during each inspection of the ball joint.
One way to inspect the ball stud for wear is to shake the
wheel and feel for movement of the stud end or the cas-
tellated nut at the knuckle boss.
Another way to inspect the ball stud for wear is to check
the fastener torque at the castellated nut. A loose nut can
indicate a stressed stud or a hole in the knuckle boss.
Worn or damaged ball joints and knuckles must be re-
placed.

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.

4A –4 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DIAGNOSITIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily
braked, but turning, wheels will stop the vehicle in less
distance than locked brakes. More tire-to-road friction is
present with a heavily braked, turning tire than with a
sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:

Tires having unequal contact and grip of the road will
cause unequal braking. Tires must be equally in-
flated, and the tread pattern of the right and the left
tires must be approximately equal.

Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.

Misalignment of the wheels, particularly conditions of
excessive camber and caster, will cause the brakes
to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and the
shift lever in NEUTRAL. If the pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking. Perform a visual check to confirm any sus-
pected leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an
abnormally low level indicates a leak in the system. The
hydraulic system may be leaking either internally or ex-
ternally. Refer to the procedure below to check the mas-
ter cylinder. Also, the system may appear to pass this
test while still having a slight leak. If the fluid level is nor-
mal, check the vacuum booster pushrod length. If an in-
correct pushrod length is found, adjust or replace the
rod.Check the master cylinder using the following proce-
dure:

Check for a cracked master cylinder casting or brake
fluid leaking around the master cylinder. Leaks are in-
dicated only if there is at least one drop of fluid. A
damp condition is not abnormal.

Check for a binding pedal linkage and for an incorrect
pushrod length. If both of these parts are in satisfac-
tory condition, disassemble the master cylinder and
check for an elongated or swollen primary cylinder or
piston seals. If swollen seals are found, substandard
or contaminated brake fluid should be suspected. If
contaminated brake fluid is found, all the components
should be disassembled and cleaned, and all the rub-
ber components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, then the rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston seals on the
drum brake wheels.
If rubber deterioration is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep al-
cohol out of the system. Replace all the rubber parts in
the system, including the hoses. Also, when working on
the brake mechanisms, check for fluid on the linings. If
excessive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush the
master cylinder with brake fluid, refill the master cylin-
der, and bleed the system. Refer to “Manual Bleeding
the Brakes” in this section.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of the
outer cover, and for leaks or blisters. Inspect the hoses
for proper routing and mounting. A brake hose that rubs
on a suspension component will wear and eventually
fail. A light and a mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as neces-
sary.

HYDRAULIC BRAKES 4A–5
DAEWOO M-150 BL2
WARNING LAMP OPERATION
This brake system uses a BRAKE warning lamp located
in the instrument panel cluster. When the ignition switch
is in the III position, the BRAKE warning lamp should
glow and then go OFF when the ignition switch returns
to the II position.The following conditions will activate the BRAKE lamp:

Parking brake applied. The light should be on when-
ever the parking brake is applied and the ignition
switch is II.

Low fluid level. A low fluid level in the master cylinder
will turn the BRAKE lamp ON.
BRAKE SYSTEM FAULT
Condition Probable cause Correction
Brake Warning Lamp ON
Brake fluid leaks.
Repair the leaks or add th fluid.

Parking brake switch shorted to
ground.
Repair the short ground.

Faulty the fluid level sensor.
Replace the sensor.
Stoplamp ON
Faulty the stoplamp switch.
Replace the stoplamp switch.

Push rod length is short.
Adjust the push rod length of the
power booster.

Stoplamp switch circuit shorted to
battery.
Repair or Replace the wiring harness.
Poor Braking
Brake fluid lacks or leaks.
Repair the leaks or add the fluid.

Brake fluid contamination.
Replace the fluid.

Air in the brake system.
Bleed the brake system.

Damaged brake lines.
Replace the brake lines.

Damaged vacuum hose or faulty
check valve.
Replace the vacuum hose or check
value.
Dragging Brake
No free play at the brake pedal.
Adjust the free play.

Weakened the brake pedal return
spring.
Replace the return spring.

Faulty master cylinder.
Replace the master cylinder.

Air in the brake system.
Bleed the brake system.
Pedal Over Stroke
Brake fluid lacks or leaks.
Repair the leaks or add the fluid.

Poor adjustment of the brake pedal
free play.
Adjust the push rod length of the
power booster.

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.

FRONT DISC BRAKES 4D–5
DAEWOO M-150 BL2
LINING INSPECTION
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E, Tires
and Wheels.
3. Visually check the linings for minimum thickness and
wear.
4. Measure the thickness.
Important: The minimum thickness of the shoe and lin-
ing together is 8 mm (0.31 in.).
D107B301
5. Install the shoe and linings in axle sets only.
6. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
7. Lower the vehicle.
ROTOR INSPECTION
Thickness variation can be checked by measuring the
thickness of the rotor at four or more points around the
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the rotor.
If the thickness of the rotor is below 10 mm (0.40 in.),
replace the brake rotor.
During manufacturing, the brake rotor and the toler-
ances of the braking surface regarding flatness and lat-
eral runout are held very close. The maintenance of
close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
D107B302
In addition to these tolerances, the surface finish must
be held to a specified range. The control of the braking
surface finish is necessary to avoid pulls and erratic per-
formance and to extend lining life.
Using a commercially-available dial indicator, check lat-
eral runout as follows:
Notice: Permissible lateral runout is a maximum 0.05 mm
(0.002 in.). If lateral runout exceeds the specification,
ensure there is no dirt between the rotor and the hub and
that contact surfaces are smooth and free from burrs.
1. Position the transaxle in NEUTRAL.
2. Remove the rotor. Refer to “Rotor” in this section.
3. Fasten a dial indicator to the strut.
4. Set the gauge probe tip to approximately 10 mm
(0.4 in.) from the outer edge of the brake rotor, per-
pendicular to the disc and under slight preload.
5. Remove the dial indicator.
Important: Since accurate control of the rotor toler-
ances is necessary for proper performance of the disc
brakes, refinishing of the rotor should be done only with
precision equipment.
6. Refinish the rotor, if required, with precision equip-
ment. Discard the rotor if it fails to meet the above
specifications after refinishing.
7. Install the rotor. Refer to “Rotor” in this section.
D107B303

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

4F–6 ANTILOCK BRAKE SYSTEM
DAEWOO M-150 BL2
EBCM CONNECTOR
A Connector has 31 pins which are shown below figure.
And a connector includes a warning switch which
grounds and lights the ABS warning lamp if there is No
EBCM unit plugged in, so that an indication is given that
ABS is not available.
D17E011A
Mechanical Switch

4F–10 ANTILOCK BRAKE SYSTEM
DAEWOO M-150 BL2
Master Cylinder
High Pressure Attenuator
Return Pump Motor
Return Pump Return Pump
Low Pressure
Accumulator
RRFL FR
RL
D17E208A
RR
Isolation Valve
Low
Pressure
AccumulatorFL
Isolation Valve
RR Dump ValveFL
Dump
ValveFR
Isolation Valve
FR Dump ValveRL
Dump
ValveRL
Isolation
Valve High Pressure Attenuator
REAPPLY MODE (PRESSURE INCREASE)
This reapply sequence is initiated to obtain optimum braking. The isolation valve is momentarily pumped open to allow
master cylinder and pump pressure to reach the brakes. This controlled pressure rise continues unitl the wheel is at
optimum brake output or until the brake pressure is brough up to the master cylinder output pressure.
If more pressure is required, more fluid is drawn from the master cylinder and applied to the brakes. The driver may
feel slight pedal pulsations, or pedal drop, this is normal and expected.
As fluid is reapplied to the wheel, they begin to slow down. If they approach imminent lockup again, the EBCM will
isolate, dump and reapply again. The control cycle (isolation, dump, reapply) occurs in milli-second intervals, allowing
seveal cycles to occur each second.
It is a much faster and more controlled way of “pumping the pedal”.