length DAEWOO MATIZ 2003 Service Repair Manual

1E–2 ENGINE ELECTRICAL
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
BATTERY
The battery has three major functions in the electrical
system. First, the battery provides a source of energy
for cranking the engine. Second, the battery acts as a
voltage stabilizer for the electrical system. Finally, the
battery can, for a limited time, provide energy when the
electrical demand exceeds the output of the generator.
The sealed battery is standard on all cars. There are no
vent plugs in the cover. The battery is completely
sealed, except for two small vent holes in the sides.
These vent holes allow the small amount of gas pro-
duced in the battery to escape.
The sealed battery has the following advantages over
conventional batteries:

No water need be added for the life of the battery.

It is protected against overcharge. If too much volt-
age is applied to the battery, it will not accept as much
current as a conventional battery. In a conventional
battery, the excess voltage will still try to charge the
battery, leading to gassing, which causes liquid loss.

It is not as liable to self-discharge as a conventional
battery. This is particularly important when a battery
is left standing for long periods of time.

It has more power available in a lighter and a smaller
case.
RATINGS
A battery has two ratings: (1) A reserve capacity rating
designated at 27C (81F), which is the time a fully
charged battery will provide 25 amperes current flow at
or above 10.5 volts; (2) A cold cranking amp rating de-
termined under testing at -18C (0F), which indicates
the cranking load capacity.
RESERVE CAPACITY
The reserve capacity is the maximum length of time it is
possible to travel at night with the minimum electrical
load and no generator output. Expressed in minutes,
Reserve Capacity (or RC rating) is the time required for
a fully charged battery, at a temperature of 27C (81F)
and being discharged at a current of 25 amperes, to
reach a terminal voltage of 10.5 volts.
COLD CRANKING AMPERAGE
The cold cranking amperage test is expressed at a bat-
tery temperature of -18C (0F). The current rating is
the minimum amperage, which must be maintained by
the battery for 30 seconds at the specified temperature,
while meeting a minimum voltage requirement of
7.2 volts. This rating is a measure of cold cranking ca-
pacity.The battery is not designed to last indefinitely. However,
with proper care, the battery will provide many years of
service.
If the battery tests well, but fails to perform satisfactorily
in service for no apparent reason, the following factors
may point to the cause of the trouble:

Vehicle accessories are left on overnight.

Slow average driving speeds are used for short peri-
ods.

The vehicle’s electrical load is more than the genera-
tor output, particularly with the addition of aftermarket
equipment.

Defects in the charging system, such as electrical
shorts, a slipping generator belt, a faulty generator, or
a faulty voltage regulator.

Battery abuse, including failure to keep the battery
cable terminals clean and tight, or a loose battery
hold-down.

Mechanical problems in the electrical system, such
as shorted or pinched wires.
BUILT-IN HYDROMETER
The sealed battery has a built-in, temperature-compen-
sated hydrometer in the top of the battery. This hydrom-
eter is to be used with the following diagnostic
procedure:
1. When observing the hydrometer, make sure that the
battery has a clean top.
2. Under normal operation, two indications can be ob-
served:

GREEN DOT VISIBLE – Any green appearance is
interpreted as a “green dot,” meaning the battery is
ready for testing.

DARK GREEN DOT IS NOT VISIBLE – If there is
a cranking complaint, the battery should be tested.
The charging and electrical systems should also
be checked at this time.
3. Occasionally, a third condition may appear:

CLEAR OR BRIGHT YELLOW – This means the
fluid level is below the bottom of the hydrometer.
This may have been caused by excessive or pro-
longed charging, a broken case, excessive tipping,
or normal battery wear. Finding a battery in this
condition may indicate high charging by a faulty
charging system. Therefore, the charging and the
electrical systems may need to be checked if a
cranking complaint exists. If the cranking com-
plaint is caused by the battery, replace the battery.

ENGINE ELECTRICAL 1E–41
DAEWOO M-150 BL2
SPECIFICATIONS
STARTER SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
Starter MotorType–SD 80–
Output(Capacity)kW0.8–
No Load Test @ 9 volts
Drive Pinion SpeedA
RPM150
2,000–
Brushes Lengthmm (in.)11.3–11.5
(0.445–0.453)7.0–7.25
(0.275–0.285)
GENERATOR SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
GeneratorTypeA-Type–J114D(MANDO)–GeneratorTypeA-Type
B-Type–J114D(MANDO)
CS114D(DAC)–
RegulatorA-TypeV14.4–15.0–Regulator
VoltageA-Type
B-TypeV14.4–15.0
14.3–4.9–
Brushes
LengthA-Type
B-Typemm (in.)18.5 (0.728)
20.0 (0.787)13.5 (0.531)
14 (0.551)
OutputA-Type–12V, 65A–Output
(Capacity)A-Type
B-Type–12V, 65A
12V, 65A–
IGNITION SYSTEM SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
Ignition CoilType–Closed
Magnetic Type–
First Coil ResistanceΩ1.2
10%–
Second Coil ResistanceKΩ12.1
15%–
DistributorType–Optical Sensor
Type–
Spark PlugTypeUnlead–BPR5EY-11–
RN9YC4–
WR8DCX–
TypeLead–BPR5EY–
RN9YC–
WR8DC–
Spark PlugGapUnleadmm (in.)1.1 (0.043)–
1.2 (0.047)–
Leadmm (in.)0.8 (0.031)–
Ignition WireIgnition Wire ResistanceKΩ/m2.5–12.0–

1F–10 ENGINE CONTROLS
DAEWOO M-150 BL2
fuels use alcohol to increase the octane rating of the
fuel. Although alcohol-enhanced fuels may raise the oc-
tane rating, the fuel’s ability to turn into vapor in cold
temperatures deteriorates. This may affect the starting
ability and cold driveability of the engine.
Low fuel levels can lead to fuel starvation, lean engine
operation, and eventually engine misfire.
Non-OEM Parts
The EOBD system has been calibrated to run with Origi-
nal Equipment Manufacturer (OEM) parts. Something
as simple as a high performance-exhaust system that
affects exhaust system back pressure could potentially
interfere with the operation of the Electric Exhaust Gas
Recirculation (EEGR) valve and thereby turn on the
MIL. Small leaks in the exhaust system near the heated
oxygen sensor (HO2S) can also cause the MIL to turn
on.
Aftermarket electronics, such as cellular phones, ster-
eos, and anti-theft devices, may radiate Electromagnet-
ic Interference (EMI) into the control system if they are
improperly installed. This may cause a false sensor
reading and turn on the MIL.
Environment
Temporary environmental conditions, such as localized
flooding, will have an effect on the vehicle ignition sys-
tem. If the ignition system is rain-soaked, it can tempo-
rarily cause engine misfire and turn on the MIL.
Vehicle Marshaling
The transportation of new vehicles from the assembly
plant to the dealership can involve as many as 60 key
cycles within 2 to 3 miles of driving. This type of opera-
tion contributes to the fuel fouling of the spark plugs and
will turn on the MIL with a set DTC P0300.
Poor Vehicle Maintenance
The sensitivity of the EOBD will cause the MIL to turn on
if the vehicle is not maintained properly. Restricted air fil-
ters, fuel filters, and crankcase deposits due to lack of oil
changes or improper oil viscosity can trigger actual ve-
hicle faults that were not previously monitored prior to
EOBD. Poor vehicle maintenance can not be classified
as a “non-vehicle fault,” but with the sensitivity of the
EOBD, vehicle maintenance schedules must be more
closely followed.
Severe Vibration
The Misfire diagnostic measures small changes in the
rotational speed of the crankshaft. Severe driveline
vibrations in the vehicle, such as caused by an exces-
sive amount of mud on the wheels, can have the same
effect on crankshaft speed as misfire and, therefore,
may set DTC P0300.
Related System Faults
Many of the EOBD system diagnostics will not run if the
Engine Control Module (ECM) detects a fault on a re-
lated system or component. One example would be thatif the ECM detected a Misfire fault, the diagnostics on
the catalytic converter would be suspended until the
Misfire fault was repaired. If the Misfire fault is severe
enough, the catalytic converter can be damaged due to
overheating and will never set a Catalyst DTC until the
Misfire fault is repaired and the Catalyst diagnostic is al-
lowed to run to completion. If this happens, the custom-
er may have to make two trips to the dealership in order
to repair the vehicle.
SERIAL DATA COMMUNICATIONS
Keyword 2000 Serial Data
Communications
Government regulations require that all vehicle
manufacturers establish a common communication sys-
tem. This vehicle utilizes the “Keyword 2000” commu-
nication system. Each bit of information can have one of
two lengths: long or short. This allows vehicle wiring to
be reduced by transmitting and receiving multiple sig-
nals over a single wire. The messages carried on Key-
word 2000 data streams are also prioritized. If two
messages attempt to establish communications on the
data line at the same time, only the message with higher
priority will continue. The device with the lower priority
message must wait. The most significant result of this
regulation is that it provides scan tool manufacturers
with the capability to access data from any make or
model vehicle that is sold.
The data displayed on the other scan tool will appear the
same, with some exceptions. Some scan tools will only
be able to display certain vehicle parameters as values
that are a coded representation of the true or actual val-
ue. On this vehicle, the scan tool displays the actual val-
ues for vehicle parameters. It will not be necessary to
perform any conversions from coded values to actual
values.
EURO ON-BOARD DIAGNOSTIC
(EOBD)
Euro On-Board Diagnostic Tests
A diagnostic test is a series of steps, the result of which
is a pass or fail reported to the diagnostic executive.
When a diagnostic test reports a pass result, the diag-
nostic executive records the following data:

The diagnostic test has been completed since the last
ignition cycle.

The diagnostic test has passed during the current
ignition cycle.

The fault identified by the diagnostic test is not cur-
rently active.
When a diagnostic test reports a fail result, the diagnos-
tic executive records the following data:

The diagnostic test has been completed since the last
ignition cycle.

WHEEL ALIGNMENT 2B–5
DAEWOO M-150 BL2
FRONT TOE ADJUSTMENT
1. Separate the clamps from the both rack and pinion
boots.
2. Loosen the right and the left tie rod end lock nuts.
3. Turn the right and the left tie rod to align the toe.
In this adjustment, the right and left tie rods must be
equal in length.
Front Toe–In 10′ ± 10′

Rotation Number of Tie Rod

Difference of Toe–In

1/2
0.75 mm (0.03 in.)
1 1.5 mm (0.06 in.)
D106A303
4. Tighten the tie rod end lock nut to 45 Nm (33 lb-ft).
5. Install the rack and pinion boots clamp.
FRONT CAMBER AND CASTER
CHECK
The front camber and caster are not adjustable. Refer to
“Wheel Alignment Specifications” in this section. Jounce
the bumper three times before measuring the camber or
the caster in order to prevent an incorrect reading. If the
front camber or caster measurements deviate from the
specifications, locate and replace or repair any dam-
aged, loose, bent, dented, or worn suspension part. If
the problem is body related, repair the body.
REAR CAMBER CHECK
The rear camber is not adjustable. Refer to “Wheel
Alignment Specifications” in this section. If the rear cam-
ber deviates from the specification, locate the cause and
correct it. If damaged, loose, bent, dented, or worn sus-
pension parts are found, they should be repaired or re-
placed. If the problem is body related, repair the body.
REAR TOE CHECK
The rear toe is not adjustable. Refer to “Wheel Align-
ment Specifications” in this section. If the toe deviates
from the specification, check the rear axle assembly and
the wheel spindle on vehicles without an anti–lock brak-
ing system (ABS) or the rear axle assembly and the hub
and bearing assembly on vehicles with ABS for possible
damage.

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

3B –6 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
D104B502
7. Pull the drive axle shaft (1) from the wheel hub.
Important: Support the unfastened end of the drive
axle. Do not allow the drive axle to dangle freely from the
transaxle for any length of time after it has been re-
moved from the wheel hub.
D104B503
8. Remove the drive axle from the transaxle.
Insert a flathead screwdriver between the trans-
axle case and the drive axle joint case (1).
Remove the drive axle (2).
Important: Cap the transaxle drive opening after the
drive axle has been removed to keep any contamination
out.
D104B504
Inspection Procedure
1. Inspect for worn or damaged spline of drive axle (1).
2. Inspect for a leaking boot (2).
3. Inspect for a bent shaft (3).
D14B502A
Installation Procedure
1. Clean the transaxle seal.
2. Install the drive axle into the transaxle.
3. Install the wheel hub onto the drive axle shaft.
4. Mount the knuckle onto the control arm ball joint.

3B –12 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Description

Unit

Standard

Limit
Inner

–Tripot Joint

– Type
Outer

–Rzeppa Joint

–
Right

mm (in.)553.5(21.79)

– Length
Left

mm (in.)386.5(15.22)

– Drive AxleShaft Diameter

mm (in.)22 (0.87)

–


Inner

g (ounce)90 – 100
(3.2 – 3.5)

–


Grease Capacity
Outer

g (ounce)80 – 90
(2.8 – 3.2)
–
FASTENER TIGHTENING SPECIFICATIONS
Application N
m Lb-Ft Lb-In
Control Arm Ball Joint Bolt 50 – 70 36 – 52 –
Tie Rod End Joint castellated Nut 30 – 55 21 – 41 –
Stabilizer Bar Bolt 33 – 53 24 – 39 –
Stabilizer Bar Castellated Nut40 – 5030 – 36–
Drive Axle Shaft Nut 210 155 –
Wheel Nut 90 – 11 0 66 – 81 –
Transaxle Under Cover Bolt35 – 5525 – 41–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–

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.