service DAEWOO MATIZ 2003 Service Manual PDF

6B –4 POWER STEERING PUMP
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D105C524
PUMP DRIVE BELT
Removal Procedure
1. Remove the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.
2. Remove the pump drive belt.

Loosen the rear bracket adjusting bolt (1).

Loosen the bolt (2).
D105C525

Loosen the front bracket adjusting bolts (3).

Push the pump forward (4).
18–22 Nm
20–24 Nm
20–24 Nm
D15C526A
Installation Procedure
1. Install the pump drive belt with the bolts.
Tighten

Tighten the front bracket adjusting bolt to 18–22
Nm (13–16 lb-ft) (1).

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (2).

Tighten the power steering pump bolt to 20–24
Nm (15–18 lb-ft) (3).
2. Install the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.

POWER STEERING PUMP 6B–7
DAEWOO M-150 BL2
UNIT REPAIR
PUMP
The power steering pump in this vehicle is not service-
able. A faulty pump must be replaced.

DAEWOO M-150 BL2
SECTION 6C
POWER STEERING GEAR
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 6C-2. . . . . . . . . . . . . . . . . .
Power Rack and Pinion 6C-2. . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6C-3. . . . .
Power Rack and Pinion Steering Gear 6C-3. . . . . . .
Adjust the Free Load of the Steering Gear 6C-5. . .
Repair Instructions 6C-6. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6C-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Assembly 6C-6. . . . . . . . . . . . . . . . .
Power Steering Gear Rack and Pinion Boot 6C-7. . . Unit Repair 6C-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Boot 6C-8. . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Cylinder Lines 6C-8. . . . . . . . . . . . . . . . . . . .
Rack and Pinion Steering Gear 6C-9. . . . . . . . . . . . . .
Assembly
Specifications 6C-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6C-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6C-13. . . . . . . . . .

6C –6 POWER STEERING GEAR
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
RACK AND PINION ASSEMBLY
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the intermediate shaft lower pinch bolt. Re-
fer to Section 6E, Steering Wheel and Column.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. Remove the tie rod ends. Refer to Section 6D, Manu-
al Steering Gear.
4. Remove the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
D105C534
5. Remove the rack and pinion assembly.

Disconnect the return line pipe from the steering
gear (1).

Disconnect the pressure inlet line pipe from the
steering gear (2).

Plug the opening in the power steering pipe line to
prevent fluid loss and contamination.
D105C535

Remove the power steering gear retaining bracket
tighten bolts (3).

Remove the power steering gear retaining bracket
(4).
Important: After moving the gear toward the passenger
side and pulling the gear of the driver side into the un-
derbody hole, remove the steering gear.

6C –10 POWER STEERING GEAR
DAEWOO M-150 BL2
D105C706
Important: Hit the drift using a hammer when the lower
pinion is vertical with the drift.

Remove the bearing by hitting the bearing with the
flated drift and rubber hammer (6).
D105C707

Remove the pinion shaft seal (7).

Remove the needle bearing (8).

Remove the retaining ring (9).
Important: The power steering gear housing and the
rack gear in this vehicle is not serviceable as unit.
The faulty parts must be replaced as whole units.
D105C708
Inspection Procedure
1. Inspect the tie rod ends and the ball joints for dam-
age. Refer to Section 6D, Manual Steering Gear.
2. Inspect the tie rod ends and the rack/pinion boot for
cracks or abnormal wear. Refer to Section 6D, Manu-
al Steering Gear.
3. Inspect the metal part for damage.

Inspect the pinion gear for damage or wear (1).
D105C709

Inspect the rack gear for damage or wear (2).

Inspect the steering gear housing for damage or
wear(3).

DAEWOO M-150 BL2
SECTION 6D
MANUAL STEERING GEAR
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 6D-2. . . . . . . . . . . . . . . . . .
Manual Rack and Pinion 6D-2. . . . . . . . . . . . . . . . . . . .
Component Locator 6D-3. . . . . . . . . . . . . . . . . . . . . . . .
Manual Rack and Pinion Steering Gear 6D-3. . . . . . .
Diagnostic Information and Procedures 6D-4. . . . .
Manual Rack and Pinion Steering Gear 6D-4. . . . . . .
Straight-Ahead Check 6D-5. . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Restoration 6D-6. . . . . . . . . . . . . . . . .
Check The Turning Resistance of the
Tie Rod End or Tie Rod 6D-6. . . . . . . . . . . . . . . . . . . .
Adjust the Free Load of the Steering Gear 6D-6. . . .
Repair Instructions 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Boot 6D-8. . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Steering Gear Assembly 6D-9. . . .
Unit Repair 6D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Boot 6D-11. . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion 6D-11. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 6D-17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6D-17. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6D-17. . . . . . . . . .
Special Tools and Equipment 6D-18. . . . . . . . . . . . . .
Special Tools Table 6D-18. . . . . . . . . . . . . . . . . . . . . . .

MANUAL STEERING GEAR 6D–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D105B501
TIE ROD END
Tools Required
KM–507–B Ball Joint Remover
Removal Procedure
1. Remove the wheel. Refer to Section 2E, Tires and
wheels.
2. Disconnect the tie rod and from the steering knuckle.

Remove the cotter pin (1).

Remove the castellated nut (2).

Use a ball joint remover KM–507–B, separate the
tie rod end (3).
D105B502
3. Remove the tie rod end.

Mark the tie rod, tie rod end lock nut and tie rod end
(1).

Loosen the tie rod end lock nut anticlockwise (2).

Loosen the tie rod end (3).
D105B503

DAEWOO M-150 BL2
SECTION 6E
STEERING WHEEL AND COLUMN
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 6E-2. . . . . . . . . . . . . . . . . .
Steering Wheel and Column 6E-2. . . . . . . . . . . . . . . .
Component Locator 6E-3. . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel and Column 6E-3. . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6E-4. . . . .
Steering Column Diagnosis 6E-4. . . . . . . . . . . . . . . . .
Repair Instructions 6E-7. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6E-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel 6E-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column Cover 6E-8. . . . . . . . . . . . . . . . . . . .
Turn Signal Switch and Lever/
Wiper Switch and Lever 6E-8. . . . . . . . . . . . . . . . . .
Ignition Switch 6E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Lock Cylinder and Switch
with Immobilizer 6E-9. . . . . . . . . . . . . . . . . . . . . . . . .
Switch Housing 6E-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column 6E-11. . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Shaft cover and
Intermediate Shaft 6E-12. . . . . . . . . . . . . . . . . . . . . .
Unit Repair 6E-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Steering Column 6E-13. . . . . . . . . . . . . . . . .
Specifications 6E-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6E-15. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6E-15. . . . . . . . . .
Special Tools and Equipment 6E-16. . . . . . . . . . . . . .
Special Tools Table 6E-16. . . . . . . . . . . . . . . . . . . . . . .

STEERING WHEEL AND COLUMN 6E–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D105A501
D15A502A
DW310–010
STEERING WHEEL
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Tools Required
DW310–010, Steering Wheel Puller
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the SIR module. Refer to Section 8B, Sup-
plemental Inflatable Restraints. (For vehicle with SIR)
3. Remove the steering wheel.
4. Remove the steering wheel horn cover (For vehicle
without SIR) (1).

Straighten the bending locking plate (2).

Remove the nut (3).

Remove the locking plate (4).

In order to install the steering wheel correctly,
match–mark the steering column shaft to the
steering wheel (5).

Remove the steering wheel using the steering
wheel puller DW310–010 (6).
Important: Be careful not to hit the top of steering col-
umn shaft with hammer during repair work.
D15A503A
Installation Procedure
1. Install the SIR module. Refer to Section 8B, Supple-
mental Inflatable Restraints (For vehicle with SIR).
Important: Align the match marks on the steering wheel
and the steering column shaft.
2. Install the steering wheel with the nut and the locking
plate.
Tighten
Tighten the steering wheel nut to 23–33 Nm (17–24
lb-ft).
3. Bend the tabs to secure the locking plate.
4. Install the steering wheel horn cover (For vehicle
without SIR).
5. Connect the negative battery cable.

DAEWOO M-150 BL2
SECTION 7A
HEATING AND VENTILATION SYSTEM
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 7A-2. . . . . . . . . . . . . . . . . .
Heating and Ventilation Systems 7A-2. . . . . . . . . . . .
Component Locator 7A-3. . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly 7A-3. . . . . . . . . . . . . . . . . . . . . . . . .
Blower Module Assembly 7A-4. . . . . . . . . . . . . . . . . . .
Air Distributor and Heater Module
Assembly 7A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Informatin and Procedures 7A-6. . . . . . .
Heater System 7A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insufficient Heating or Defrosting 7A-6. . . . . . . . . . . .
Blower Electrical 7A-10. . . . . . . . . . . . . . . . . . . . . . . . .
Improper Air Delivery or No Mode Shift 7A-11. . . . . .
Too Much Heat 7A-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 7A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Noise 7A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 7A-18. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 7A-18. . . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly and Control Cables 7A-18. . . . . . . Blower Motor and Cooling Hose 7A-20. . . . . . . . . . . .
Blower Resistor 7A-20. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Switch 7A-21. . . . . . . . . . . . . . . . . . . . . .
Heater Hoses 7A-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Module 7A-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Module 7A-25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Defroster Duct and Hoses 7A-26. . . . . . . . . . . . . . . . .
Ventilation Duct 7A-27. . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 7A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core 7A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 7A-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7A-29. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7A-29. . . . . . . . . .
Special Tools and Equipment 7A-30. . . . . . . . . . . . . .
Special Tools Table 7A-30. . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 7A-31. . . . . . . . . .
Non-A/C Diagrams 7A-31. . . . . . . . . . . . . . . . . . . . . . .
Air Flow Through Ducts (Non–A/C) 7A-32. . . . . . . . .