height DAEWOO MATIZ 2003 Service Repair Manual

ENGINE COOLING 1D–17
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
Cooling
SystemCooling Type–Forced Water
Circulation
CoolantCoolant CapacityL/qt3.8/4.00
Thermostat Type–Pellet Type
Temperature(opened initially)°C(°F)82(180)
ThermostatTemperature(perfectly opened)°C(°F)95(203.4)
Temperature(perfectly closed)°C(°F)80(176.4)
Stroke(perfectly opened)mm(in.)8 (0.32)
Cooling Fan Type–Electric
Blade NumberEA6
Cooling Fan Diametermm(inch)300(11.8)
Electric CoolingTemperature At Low Speed ON°C(°F)93(199.8)Fan
Temperature At Low Speed OFF°C(°F)90(194.4)
Temperature At High Speed ON°C(°F)100(212.4)
Temperature At High Speed OFF°C(°F)97(207)
Surge TankOpen Pressure of The Pressure ValvekPa (psi)120–150
(17.4–21.8)
Surge Tank
Open Pressure of The Vacuum ValvekPa (psi)10 (1.5)
Water Pump Type–Centrifugal
Coolant PumpImpeller Diametermm(in.)60(2.36)
Impeller Blade NumberEA7
Radiator Type–Cross–Flow
Core Widthmm(in.)458(18.03)RadiatorCore Heightmm(in.)295(11.61)
Core Depth (Standard/Heavy Duty)mm(in.)16/27(0.63/1.06)
Resistance
(Coolant Temperature 50°C(122.4°F))Ω185.2
Coolant
TemperatureResistance
(Coolant Temperature 85°C(185.4°F))Ω49.2
SensorResistance
(Coolant Temperature 105°C(221.4°F))Ω27.5
Engine CoolantResistance
(Coolant Temperature 20°C(68.4°F))Ω3,520
Temperature
SensorResistance
(Coolant Temperature 80°C(176.4°F))Ω332

2A–4 SUSPENSION DIAGNOSIS
DAEWOO M-150 BL2
Condition Probable Cause Correction
Abnormal Noise, Front
A loose stabilizer shaft link.
Tighten the stabilizer shaft link.
Suspension
Loose wheel nuts.
Tighten the wheel nuts.

Loose suspension bolts or nuts.
Tighten the suspension bolts or the
nuts.

Loose wheel covers.
Tighten the wheel covers.

Worn strut dampeners or strut
mountings.
Replace the strut dampeners.

Tighten the strut mounting nuts.

An improperly positioned strut spring.
Adjust the strut spring to the proper
position.
Wander or Poor
Mismatched or uneven tires.
Replace the tires.
Steering Ability
Worn strut dampeners.
Replace the strut dampeners.

A loose stabilizer shaft link.
Tighten the stabilizer shaft link.

A broken or a sagging coil spring.
Replace the coil spring.

The steering preload adjustment is
out–of–adjustment.
Perform a rack bearing preload
on–vehicle adjustment.

The front–wheel and the rear–wheel
alignment are out–of–align.
Align the front and the rear end
wheels.
Erratic Steering when
Worn or loose wheel bearings.
Replace the wheel bearings.
Braking
A broken or a sagging coil spring.
Replace the coil spring.

A leaking caliper.
Replace the caliper.

Warped rotors.
Replace the rotors.

An incorrect or an uneven caster.
If the caster is beyond specifications,
check the frame and repair it as
needed.
Low or Uneven Trim
A broken or a sagging coil spring.
Replace the coil spring.
Height
An overloaded vehicle.
Maintain the proper load weight.

An incorrect or weak coil spring.
Replace the coil spring.
Ride Too Soft
Worn strut dampeners.
Replace the strut dampeners.

A broken or a sagging coil spring.
Replace the coil spring.
Ride Too Harsh
Incorrect strut dampeners.
Replace the strut dampeners.

An incorrect coil spring.
Replace the coil spring.
Body Leans or Sways
A loose stabilizer shaft link.
Tighten the stabilizer shaft link.
in Corners
Worn strut dampeners or strut
mountings.
Replace the strut dampeners.

Tighten the strut assembly mounting
nuts.

an overloaded vehicle.
Maintain the proper load weight.

A broken or a sagging coil spring.
Replace the coil spring.
Suspension Bottoms
Worn strut dampeners.
Replace the strut dampeners.

An overloaded vehicle.
Maintain the proper load weight.

A broken or a sagging coil spring.
Replace the coil spring.

2C – 2 FRONT SUSPENSION
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FRONT SUSPENSION
The front suspension for this vehicle is a combination
knuckle/strut and spring design.
The control arms pivot from the body. The lower control
arm pivots use rubber bushing. The upper end of the
strut is isolated by a rubber mount and contains a bear-
ing to allow the wheel to turn.
The lower end of the steering knuckle pivots on a ball
joint bolted to the control arm. The ball joint is fastened
to the steering knuckle with a bolt.When servicing the control arm-to-body attachment and
the stabilizer shaft-to-body insulators, make sure the at-
taching bolts are loose until the control arms are moved
to the trim height, which is curb height. Trim height is the
normal position to which the control arms move when
the vehicle is sitting on the ground. Refer to “General
Specifications” in this section.

FRONT SUSPENSION 2C–23
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Suspension Type – Mcpherson (Strut)
Maximum Length mm (in.) 475–481 (18.7–18.94) Shock Absorber Minimum Length mm (in.) 321–327 (12.64–12.87)
Stroke

mm (in.)

154 (6.06)
Stabilizer Shaft Diammeter

mm (in.)

24 (0.94)
Coil Spring Height (No Load) mm (in.) 374 (14.72 )
Grease Type (Front Wheel Bearing and Hub) – M–8143 ANTIF BRG GREASE
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Strut Assembly–to–Body Nuts 18 – 28 13 – 21 –
Strut Closure Nut 50 – 60 36 – 44 – Strut Assembly–to–Knuckle Bolts 70 – 90 52 – 66 –
Control Arm Mounting Bolt

55 – 70

41 – 52

–
Control Arm Ball Stud Bolt

50 – 70

36 – 52

–
Stabilizer Shaft Castellated Nut 40 – 50 30 – 36 –
Stabilizer Shaft Mounting Bolt 30 – 50 22 – 36 –
Front Under Longitudinal Frame Bolts 10 – 14 – 89 – 124
Front Under Longitudinal Frame Nut 65 – 80 48 – 59 – Drive Axle–to–Hub Caulking Nut 210 155 – Crossmember Bolt 17 – 27 13 – 20 –
Strut Bar Bolts

35 – 55

25 – 41

–
ABS Front Speed Sensor Retaining Bolt 18 – 28 13 – 21 –
Wheel Hub–to–Brake Disc Bolt 55 – 75 41 – 55 –

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

2E – 2 TIRES AND WHEELS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
TIRE
Tread
A part (that contacts) road surfaces directly is fixed on
the outside of carcass and breaker. It is a strong rubber
coat made of high anti–abrasion rubber. Its running per-
formance depends on is surface profile.
Breaker
A cord belt between tread and carcass prevents dam-
ages of inner code due to outer shock and vibration.
Carcass
This major part made by pilling code papers of strong
synthetic fiber forms a structure of tire. Since it main-
tains tire pressure and endures applied load and shock
to tire, it should have a high anti–fatigue characteristic.
Bead
A steel wire winding the ending part of carcass code,
coated with rubber film and wrapped with nylon cord pa-
pers. It fixes tire to a rim.
Tube
Tires used in mostly current vehicle are mostly tubeless
tires.
Side Wall
It is provided to improve the comfortable driving by pro-
tecting carcass and cushion movement.
Structure of Tubeless Tube
D16A001A
Nomenclature
D16A002A
175 Width (mm)

60Flatness ratio 60%
(Height/Width) ×100
175/60R13RRadial
77H13Rim diameter (= Tire I.D, Inch)
77Max. load index
HMax. speed symbol

HYDRAULIC BRAKES 4A–13
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
0.8 SOHC Engine
Application Millimeters Inches



Brake Drums:
Inside Diameter
Maximum Rebore Diameter
Out-of-Round


180
182
0.04


7.09
7.17
0.0016




Brake Rotors:
Discard Thickness
Lateral Runout (Installed)
Rotor Diameter
Rotor Thickness (New)



10
0.05
236
12.7




0.4
0.002
9.3
0.5
Master Cylinder:
Bore Diameter 20.64 0.81
Caliper:
Piston Diameter
48

1.89
Wheel Cylinder Diameter: 17.46 0.69



Brake Pedal:
Free Play
Height
Stroke


6 – 10
200
30



0.24 – 0.31
7.87
1.18
Type DOT–3 or DOT–4 Brake Fluid Capacity 0.45 L (0.48 qt.)
FASTENER TIGHTENING SPECIFICATIONS

Application

Nm

Lb-Ft

Lb-In
Brake Pipe Fittings 16 12 –
Front Brake Hose-to-Caliper Bolt 25.5 19.1 –
Brake Pedal–to–Pedal Bracket Hex Bolt

18

13

–
Brake Pedal Bracket Mounting Bolts 18 – 26 13 – 20 –
Brake Pedal Bracket Mounting Nuts 18 – 26 13 – 20 –
Stoplamp Switch Mounting Bracket Bolts

9 – 12

–

80 – 106

9I – 2 WATERLEAKS
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
WATERLEAK DIAGNOSIS
The repair of waterleaks in the body requires proper
testing and diagnosis. Repair waterleaks by adjusting
the misaligned parts and using the proper repair materi-
als. First, determine what conditions cause the leak. For
example, the leak may occur only when the vehicle is
parked on an incline, or water may appear only in the
spare tire compartment. Second, test the area for the
source of the leak using the following testing methods. If
the general leak area is found, determine the exact entry
point of the leak by using a water hose or an air hose. If
the general leak area is not obvious, use the watertest
stands to determine the area of the leak. It may be nec-
essary to remove some interior trim panels or some
parts in order to locate the leaks.
Important: It is necessary to find the origin of all the
leaks before making any repairs. Random repairs may
stop the leak only temporarily and may make future re-
pairs more difficult. Continue localized testing in the gen-
eral area in order to ensure that all leaks are found.
Generalized Testing
1. Set up the watertest stands.
D109A301
1 1/2-inch by 36-inch Pipe
2 Full-jet Spray Nozzle #1/2 GG-25 or Equivalent
Nozzle Height at 1,600 mm to the Floor
3 1/2-inch Coupling
4 1/2-inch by 1/2-inch by 1/4-inch Reducing T
(Right Only)
5 1/2-inch Coupling (Left Only)
6 1/2-inch Cross (Right Only)
7 1/2-inch Tee (Left Only)
8 1/2-inch Pipe-to-Hose Nipple (Right Only)
9 5/8-inch Female Hose Coupling
10 5/8-inch Input Hose (2 Feet Long, Right Only)
11 1/2-inch Close Nipple
12 1/2-inch Cross with Weld-on 1/2-inch Cap
13 1/2-inch by 12-inch Nipple
14 1/2-inch Cap
15 5/8-inch Female Hose Coupling
16 5/8-inch Cross Hose (12 Feet Long)
17 5/8-inch Hose Quick Connect
18 1/2-inch Pipe-to-Hose Nipple
19 1/2-inch by 30-inch Pipe (Straight)
20 1/4-inch Water Pressure Gauge (Right Only)
2. Set up the watertest stand leak test.
D19A302A

WATERLEAKS 9I–7
DAEWOO M-150 BL2
SPECIFICATIONS
RECOMMENDED MATERIALS FOR WATERLEAK REPAIRS

Leak Areas

Repair Materials
Windshield, back window

Urethane adhesive, caulking kit, or the equivalent
Metal joints

Brushable seam sealer which can be painted
Ventilation ducts

3MTM Auto Bedding and Glazing Compound or the
equivalent
Small cracks and pin holes 3MTM Drip-Check Sealer or the equivalent Large holes 3MTM Automotive Joint and Seam Sealer Weatherstrips 3MTM 08011 Weatherstrip Adhesive or the equivalent Bolts, studs, and screws Strip caulk
WATERTEST STAND SPECIFICATIONS
Application Description
Nozzle Type
Full jet spray nozzle #1/2 GG-25 or equivalent with a
60° included angle
Nozzle Height Approximately 1,600 mm (63.0 in.) from the floor
Volume of Flow 14L (3.7 gal) per minute
Pressure 155 kPa (22.5 psi) measured at the nozzle


Windshield and A-Pillar Test Stand Position

Approximately 30° down, 45° toward the rear, and
aimed at the corner of the windshield
B-Pillar Test Stand Position Approximately 30° down, 45° toward the rear, and
aimed at the center of the rear door



Back Window and tailgate Test Stand Position


Approximately 30° down, 45° toward the front and
aimed approximately 610 mm (24.0 in.) from the
corner of the back window