tow DAEWOO MATIZ 2003 Service Repair Manual

1F–42 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F070
IDLE AIR CONTROL SYSTEM CHECK
Circuit Description
The Engine Control Module (ECM) controls the engine
idle speed with the Idle Air Control (IAC) valve. To in-
crease the idle speed, the ECM pulls the IAC pintle
away from its seat, allowing more air to pass by the
throttle body. To decrease the idle speed, it extends the
IAC valve pintle toward its seat, reducing bypass air
flow. A scan tool will read the ECM commands to the
IAC valve in counts. The higher counts indicate more air
bypass (higher idle). The lower counts indicate less air is
allowed to bypass (lower idle).
Diagnostic Aids
If the idle is too high, stop the engine. Fully extend the
Idle Air Control (IAC) valve with a IAC driver. Start the
engine. If the idle speed is above 950 rpm, locate and
repair the vacuum leak. Also, check for a binding throttle
plate or throttle linkage or an incorrect base idle setting.
Idle Air Control Valve Reset Procedure
Whenever the battery cable or the Engine Control Mod-
ule (ECM) connector or the ECM fuse EF6 is discon-nected or replaced, the following idle learn procedure
must be performed:
1. Turn the ignition ON for 5 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON for 5 seconds.
4. Start the engine in park/neutral.
5. Allow the engine to run until the engine coolant is
above 85C (185F ).
6. Turn the A/C ON for 10 seconds, if equipped.
7. Turn the A/C OFF for 10 seconds, if equipped.
8. If the vehicle is equipped with an automatic trans-
axle, apply the parking brake. While pressing the
brake pedal, place the transaxle in D (drive).
9. Turn the A/C ON for 10 seconds, if equipped.
10. Turn the A/C OFF for 10 seconds, if equipped.
11. Turn the ignition OFF. The idle learn procedure is
complete.

1F–246 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F070
DIAGNOSTIC TROUBLE CODE (DTC) 0505
IDLE AIR CONTROL VALVE (IACV) CIRCUIT FAULT
Circuit Description
The Engine Control Module (ECM) controls the air en-
tering into the engine with an Idle Air Control (IAC)
Valve. To increase the idle rpm, the ECM commands the
pintle inside the IAC valve away from the throttle body
seat. This allows more air to bypass through the throttle
blade. To decrease the rpm the ECM commands the
pintle towards the throttle body seat. This reduces the
amount of air bypassing the throttle blade. A scan tool
will read the IAC valve pintle position in counts. The
higher the counts, the more air that is allowed to bypass
the throttle blade. This Diagnostic Trouble Code (DTC)
determines if a low idle condition exists as defined as
100 rpm below the desired idle rpm.
Conditions for Setting the DTC

No intrusive tests are active.

DTC(s) P0106, P0107, P0108, P0112, P0113,
P0117, P0118, P0122, P0123, P0131, P0132,
P0133, P1133, P1134, P0171, P1171, P0172, P0201,
P0202, P0203, P0204, P0300, P0336, P0337,
P0341, P0342, P0351, P0352, P0402, P0404,
P1404, P0405, P0406, P0443, and P0502 are not
set.

Engine is running more than 60 seconds.

Barometric Pressure (BARO) is greater than 72 kPa
(10.4 psi).

Engine Coolant Temperature (ECT) is greater than
60C (140F).

Ignition voltage is between 11 and 16 volts.

The Intake Air Temperature (IAT) is greater than
–20C (–4F).

Manifold Absolute Pressure is less than 60 kPa (8.7
psi).
IAC valve is controlled fully opened.

All of the above must be met for greater than 5 sec-
onds.
Action Taken When the DTC Sets

The Malfunction Indicator Lamp (MIL) will illuminate.

The ECM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Freeze Frame and Failure Records buffers.

A history DTC is stored.
Conditions for Clearing the MIL/DTC

The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.

A history DTC will clear after 40 consecutive warm-up
cycles without a fault.

DTC(s) can be cleared by using the scan tool.

Disconnecting the ECM battery feed for more than 10
seconds.
Diagnostic Aids
Inspect the IAC valve electrical connection for proper
mating.
Inspect the wiring harness for damage.
Inspect the throttle stop screw for signs of tampering.
Inspect the throttle linkage for signs of binding or exces-
sive wear.
A slow or unstable idle may be caused by one of the fol-
lowing conditions:

Fuel system too rich or too lean.

Foreign material in the throttle body bore or in the air
induction system.

A leaking or restricted intake manifold.

1F–292 ENGINE CONTROLS
DAEWOO M-150 BL2
HESITATION, SAG, STUMBLE
Definition: Momentary lack of response as the accelera-
tor is pushed down. This can occur at any vehicle speed.
It is usually the most severe when first trying to make the
vehicle move, as from a stop. Hesitation, sag, or
stumble may cause the engine to stall if severe enough.Important: Before diagnosing this condition, check ser-
vice bulletins for PROM updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Check the fuel system pressure. If the pressure is
not within the value specified, service the fuel
system as needed.
2. Inspect the Throttle Position (TP) sensor for
binding or sticking. The TP sensor voltage should
increase at a steady rate as the throttle is moved
toward Wide Open Throttle (WOT).
Is the problem found?
380 kPa
(55 psi)
Go to Step 3Go to Step 4
3Repair or replace any components as needed.
Is the repair complete?–System OK–
4
1. Check the Manifold Absolute Pressure (MAP)
sensor response and accuracy.
2. Inspect the fuel for water contamination.
3. Check the Evaporative Emission (EVAP) Canister
Purge System for proper operation.
Is the problem found?
–
Go to Step 5Go to Step 6
5Repair or replace any components as needed.
Is the repair complete?–System OK–
6
1. Disconnect all of the fuel injector harness
connectors.
2. Connect an injector test light between the
harness terminals of each fuel injector.
3. Note the test light while cranking the engine.
Does the test light blink on all connectors?
–
Go to Step 8Go to Step 7
7
1. Repair or replace the faulty fuel injector drive
harness, the connector, or the connector terminal.
2. If the connections and the harnesses are good,
replace the Engine Control Module (ECM).
Is the repair complete?
–
System OK
–
8
Measure the resistance of each fuel injector.
Is the fuel injector resistance within the value
specified (the resistance will increase slightly at
higher temperatures)?
11.6–12.4 ΩGo to Step 10Go to Step 9
9
Replace any of the fuel injectors with a resistance
that is out of specifications.
Is the repair complete?
–
System OK
–
10Perform an injector diagnosis.
Is the problem found?–Go to Step 11Go to Step 12
11Replace any restricted or leaking fuel injectors.
Is the repair complete?–System OK–
12
Check the fuel system pressure after a cold start or
during moderate or full throttle acceleration.
Is the fuel pressure within specifications?
380 kPa
(55 psi)
Go to Step 14Go to Step 13

2B – 2 WHEEL ALIGNMENT
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FOUR WHEEL ALIGNMENT
The first responsibility of engineering is to design safe
steering and suspension systems. Each component
must be strong enough to withstand and absorb extreme
punishment. Both the steering system and the front and
the rear suspension must function geometrically with the
body mass.
The steering and the suspension systems require that
the front wheels self-return and that the tire rolling effort
and the road friction be held to a negligible force in order
to allow the customer to direct the vehicle with the least
effort and the most comfort.
A complete wheel alignment check should include mea-
surements of the rear toe and camber.
Four-wheel alignment assures that all four wheels will be
running in precisely the same direction.
When the vehicle is geometrically aligned, fuel economy
and tire life are at their peak, and steering and perfor-
mance are maximized.
TOE
D16A006A
Toe–in is the turning in of the tires, while toe–out is the
turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the
wheel support system which occur when the vehicle is
rolling forward. The specified toe angle is the setting
which achieves–degrees (0
) of toe when the vehicle is
moving.
Incorrect toe-in or toe-out will cause tire wear and re-
duced fuel economy. As the individual steering and sus-
pension components wear from vehicle mileage,
additional toe will be needed to compensate for the
wear.
Always correct the toe dimension last.
CASTER
D16A008A
Caster is the tilting of the uppermost point of the steering
axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is
positive, and a forward tilt is negative. Caster influences
directional control of the steering but does not affect tire
wear. Weak springs or overloading a vehicle will affect
caster. One wheel with more positive caster will pull to-
ward the center of the car. This condition will cause the
car to move or lean toward the side with the least
amount of positive caster. Caster is measured in de-
grees and is not adjustable.
CAMBER
D16A007A
Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the
tires tilt outward, the camber is positive. When the tires
tilt inward, the camber is negative. The camber angle is
measured in degrees from the vertical. Camber in-
fluences both directional control and tire wear.
If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Camber is measured in degrees and is not adjustable.

2D –4 REAR SUSPENSION
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
REAR SUSPENSION

Condition

Probable cause

Correction
Noise
The loosened joints.
Tighten the joints.

Wheel bearing is worn or damaged.
Replace the wheel bearing.

Faulty shock absorber.
Replace the shock absorber.
Uncomfortable
Faulty shock absorber.
Replace the shock absorber.

Faulty coil spring.
Replace the coil spring.

Lateral rod bushing is worn or
damaged.
Replace the lateral rod bushing.

Trailing arm bushing is worn or
damaged.
Replace the trailing arm bushing.
Vehicle Leans Toward
Rear axle deformation.
Replace the rear axle.
the Side
Lateral rod deformation.
Replace the lateral rod.

Trailing arm deformation.
Replace the trailing arm.

Faulty coil spring.
Replace the coil spring.

Lateral rod bushing is worn or
damaged.
Replace the lateral rod bushing.

Trailing arm bushing is worn or
damaged.
Replace the trailing arm bushing.

4D – 2 FRONT DISC BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DISC BRAKE CALIPER ASSEMBLY
This caliper has a single bore and is mounted to the
steering knuckle with two mounting bolts. Hydraulic
pressure, created by applying the brake pedal, is con-
verted by the caliper to a stopping force. This force acts
equally against the piston and the bottom of the caliper
bore to move the piston outward and to slide the caliper
inward, resulting in a clamping action on the rotor. This
clamping action forces the linings against the rotor,
creating friction to stop the vehicle.
D17B001A
Important:

Replace all components included in the repair kits
used to service this caliper.

Lubricate the rubber parts with clean brake fluid to
ease assembly.

Do not use lubricated shop air on brake parts, as
damage to the rubber components may result.

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake system.

Replace the pads in axle sets only.

The torque values specified are for dry, unlubricated
fasteners.

Perform the service operations on a clean bench, free
from all mineral oil materials.
CLEARANCE CALIBRATION
When the hydraulic pressure is applied to the piston, the
piston moves leftward. The piston seal, which extent
considerable pressure against the piston, moves with
cylinder.
However, as a part of the piston seal is fixed into a grove
in the cylinder shape of the seal is as shown in below
figure, distorted toward the piston moving direction.
When the pressure is taken off from the brake pedal and
the hydraulic pressure is released from the piston, a re-
storing elastic force is generated at the seal and pushes
the piston rightward and back it in original position.
As the pads wear away and the clearance between rotor
and pads becomes larger, the piston moves larger.
The seal then could change in shape further, but since
end of the seal is fixed into the groove in the cylinder, the
distortion is limited to the same amount as previously
described.
The piston moves further to cover the distance of clear-
ance. As the piston returns by the same distance and
the rubber seal recovers its original shape, the clear-
ance between the rotor and pads is maintained in origi-
nal condition.
1. Piston
2. Piston Seal
3. Pads
a. Clearance
D107B002

5B–22 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B540
Installation Procedure
1. Install in the reverse order of removal.
2. Push the cables toward the engine compartment
through dash panel’s hole slightly.
3. Position the cables on the select and the shift lever.
D13B5411
4. Connect the transaxle side select and shift control
cable.
5. Connect the gear shift lever side shift control cable.
6. Connect the gear shift lever side select control cable.

Insert the select control cable eye ring to the select
arm pin (1).

Install the selector lever control cable clip (2).

Install the select control cable to gear shift lever
bracket with E–ring (3).

Insert a driver to the select arm adjustment hole to
prevent the movement of gear shift lever in NEU-
TRAL (4).
7. Tighten the adjust nuts.
Tighten
Tighten the select cable adjust nut to 8–12 Nm
(71–106 lb-in).
D103B543
GEAR SHIFT CONTROL LEVER
Removal Procedure
1. Remove the floor console. Refer to Section 9G, Inte-
rior Trim.
2. Disconnect the select and shift control cable. Refer to
“Gear Shift control cable” in this section.
3. Remove the gear shift control lever assembly.

Remove the bolts (1).

Remove the gear shift control lever assembly (2).

Remove the gear shift lever sensor connector.
(If equipped with auto clutch).

5B–28 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B716
17. Remove the transaxle case (Left).

Remove the bolts from the left side case (1).

Remove the bolts, stud bolts if equipped with
auto clutch.

Remove the bolts from the right side of case (2).

Remove the left side case by hitting with a rubber
hammer lightly.

Remove the sealant on the case.
D103B717
18. Remove the reverse gear shift lever.

Remove the bolts (1).

Remove the reverse gear shift lever (2).
D103B718
19. Remove the reverse idle gear shaft assembly.

Push the reverse idle gear toward inner case.

Pulling shaft and remove the reverse idle gear
and shaft (1).

Remove the reverse idle gear from the shaft.
D103B719
20. Remove the fifth–reverse gear shift shaft.
a. Fifth–reverse gear shift shaft.

FIVE-SPEED MANUAL TRANSAXLE 5B–33
DAEWOO M-150 BL2
D13B735A
13. Install the counter shaft bearing shim.

Measure clearance between the transaxle case
surface and the bearing outer race using a
straight ruler and gauge.

Select shim in order that clearance is within stan-
dard.
Unit : mm (in.)
Measured value (A) Shim thickness
0.33 − 0.37 (0.0130 – 0.0146) 0.45 (0.0177)
0.38 − 0.42 (0.0147 – 0.0165) 0.50 (0.0197)
0.43 − 0.47 (0.0169 – 0.0185) 0.55 (0.0217)
0.48 − 0.52 (0.0189 – 0.0205) 0.60 (0.0236)
0.53 − 0.57 (0.0209 – 0.0224) 0.65 (0.0256)
0.58 − 0.62 (0.0228 – 0.0244) 0.70 (0.0276)
0.63 − 0.67 (0.0248 – 0.0264) 0.75 (0.0295)
0.68 − 0.72 (0.0268 – 0.0283) 0.80 (0.0315)
0.73 − 0.77 (0.0287 – 0.0303) 0.85 (0.0335)
0.78 − 0.82 (0.0307 – 0.0323) 0.90 (0.0354)
0.83 − 0.87 (0.0327 – 0.0343) 0.95 (0.0374)
0.88 − 0.92 (0.0346 – 0.0362) 1.00 (0.0394)
0.93 − 0.97 (0.0366 – 0.0382) 1.05 (0.0413)
0.98 – 1.02 (0.0386 – 0.0402) 1.10 (0.0433)
1.03 – 1.07 (0.0406 – 0.0421) 1.15 (0.0453)
a. Straight ruler
b. Bearing outer race
c. Case surface
D13B736A
14. Install the side cover plate and the counter shaft fifth
gear.

Install the side cover plate (1).
Tighten
Tighten the screws to 6–7 N.m (53–62 lb–in).
Important: Use only new screws.

Install the counter shaft fifth gear (2).
Important: Position the machined boss side toward the
side cover plate.

5B–34 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B737A
15. Install the counter shaft fifth gear nut.

Shift the shift yoke using a screwdriver to engage
the first–gear and the third–gear or the second–
gear and the fourth–gear (1).
Tighten
Tighten the fifth gear nut to 60–80 Nm (44–59 lb-ft).

Caulk the nut using a chisel and a hammer (2).
D103B710
16. Install the input shaft fifth gear bearing and the fifth
gear / synchronizer ring.

Insert the bearing into the input shaft.

Install the fifth gear, wave spring and synchroniz-
er ring matching synchronizer’s oil groove and in-
put shaft punched mark (1).
D103B738
17. Install the fifth gear synchronizer hub assembly.

Install the synchronizer springs to hub (1).

Install the synchronizer key (2).
Important: In case of assembling synchronizer sleeve
and hub, let A=B.

Position the longer boss side of hub toward inner
side (3).

Position the chamfered spline of sleeve toward
inner side and install the hub to the sleeve (4).
D103B739
18. Install the fifth gear fork to the synchronizer hub as-
sembly.
19. Install the fifth gear fork and the synchronizer hub
assembly to the input shaft.
Important: Position the longer boss side of hub toward
inner side and match the synchronizer key and the hub
groove with the input shaft punched mark.