wheel bolts DAEWOO MATIZ 2003 Service Repair Manual

DAEWOO M-150 BL2
SECTION 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
Diagnostic Information and Procedures 2A-1. . . . .
General Diagnosis 2A-1. . . . . . . . . . . . . . . . . . . . . . . . . Wheel Bearing Diagnosis 2A-6. . . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires, and
the wheels involve several systems. Consider all sys-
tems when you diagnose a complaint. Some problems,
such as abnormal or excessive tire wear and scuffed
tires, may be the result of hard driving. Always road testthe vehicle first. If possible, do this road test with the
customer.
Proceed with the following preliminary checks. Correct
any substandard conditions.
Application Checks Correction
Preliminary Checks
Inspect the tires for improper pressure
and uneven wear.
Inflate the tires to the proper pressure.

Inspect the joint from the steering
column to the intermediate shaft for
loose connections or wear.

Inspect the joint from the intermediate
shaft to the steering gear for loose
connections or wear.
Tighten the coupling flange pinch
bolts.

Replace the intermediate shaft as
needed.

Inspect the front and the rear
suspension, the steering gear, and the
linkage for loose or damaged parts.
Tighten the front and the rear
suspension.

Tighten the steering gear mounting
bracket bolts.

Replace the front and the rear
suspension as needed.

Replace the steering gear as needed.

Replace the coupling flange as
needed.

Inspect for out–of–round tires.
Perform free runout test.

Match–mount the tires.

Inspect for out–of–balance tires, bent
wheels, and worn or loose wheel
bearings.
Balance the wheels.

Replace the wheels.

Replace the wheel bearings.

Check the power steering pump drive
belt tension.
Tighten the power steering pump drive
belt.

Inspect the power steering system.
Also, check the power steering fluid
level.
Repair any leaks.

Perform a power steering gear test.

Add power steering fluid.

SUSPENSION DIAGNOSIS 2A–3
DAEWOO M-150 BL2
Condition Probable Cause Correction
Hard Steering (Manual)
A lack of lubrication of the ball joints,
the tie rods and the steering gear.
Lubricate the ball joints, the tie rods,
and the steering gear.

Replace the control arm and ball joint
assembly, the tie rods, and the
steering gear as needed.

The front–wheel alignment is
out–of–align.
Align the front wheels.

Steering gear adjustment is
out–of–adjustment.
Adjust the steering gear.
Hard Steering (Power)
The steering preload adjustment is
out–of–adjustment.
Perform a rack bearing preload
on–vehicle adjustment.

The leaked hydraulic system.
Test the power steering system
pressure with a gauge.

Replace the seals and the hoses as
needed.

A loose steering gear mounting.
Tighten the steering gear mounting
bracket bolts.
Too Much Play in
Steering.
Worn or loose wheel bearings.
Tighten the drive axle nut.

Replace the wheel bearing as needed.

A loose steering gear mounting.
Tighten the steering gear mounting
bracket bolts.

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

Loose connections or wear of the joint
from the steering column to the
intermediate shaft.

Loose connections or wear of the joint
from the intermediate shaft to the
steering gear.
Tighten the coupling pinch bolts.

Replace the intermediate shaft as
needed.
Poor Returnability
Binding in the ball joints.
Replace the control arm and ball joint
assembly.

Binding in the steering column.
Lubricate the steering column.

Replace the steering column as
needed.

The front–wheel alignment is
out–of–align.
Align the front wheels.

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

A sticking valve.
Lubricate the pinion valve assembly.

Replace the pinion valve assembly as
needed.

Binding in the coupling on the
intermediate shaft.
Replace the intermediate shaft.
Abnormal Noise, Front
Suspension
Damaged suspension components.
Replace the damaged suspension
components.

Worn control arm bushings or tie rod
ends.
Replace the control arm bushings or
the tie rods.

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.

SUSPENSION DIAGNOSIS 2A–5
DAEWOO M-150 BL2
Condition Probable Cause Correction
Steering Wheel
Air in the power steering system.
Bleed the power steering system.
Kickback (Power)
A loose steering gear mounting.
Tighten the steering gear mounting
bracket bolts.

Loose connections or wear of the joint
from the steering column to the
intermediate shaft.

Loose connections or wear of the joint
from the intermediate shaft to the
steering gear.
Tighten the coupling pinch bolts.

Replace the intermediate shaft as
needed.

Loose tie rod ends.
Tighten the tie rod ends.

Replace the tie rods as needed.

Loose or worn wheel bearings.
Tighten the drive axle nut.

Replace the wheel bearing as needed.
Steering Wheel Surges
or Jerks (Power)
Low pressure in the power steering
system.
Replace the seals and the hoses as
needed.

A sluggish steering gear valve.
Clean the pinion valve assembly.

Replace the pinion valve assembly as
needed.

A loose power steering pump drive
belt.
Adjust the power steering pump drive
belt.
Cupped Tires
The front–wheel and the rear–wheel
alignment are out–of–align.
Align the front and the rear wheels.

Worn strut dampeners.
Replace the strut dampeners.

Worn or loose wheel bearing.
Tighten the drive axle nut.

Replace the wheel bearings as
needed.

Excessive tire or wheel runout.
Match–mount the tires.

Replace the tires as needed.

Replace the wheels as needed.

A worn ball joints.
Replace the control arm and ball joint
assembly.

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

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–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D16B501A
STRUT ASSEMBLY
Removal Procedure
1. Open the hood.
2. Remove the top of the strut assembly at passenger
seat side.

For vehicle with power steering, remove the power
steering fluid reservoir (1).

Remove the nuts (2).
D16B502A
3. Remove the top of the strut assembly at driver side.

Remove the bolt and the fuse box (1, 2).

Remove the nuts (3).
D106B503
4. Remove the lower of the strut assembly.

Raise and suitably support the vehicle.

Remove the wheel. Refer to Section 2E, Tires and
Wheels.

Remove the ABS front speed sensor electrical wire
from the bracket, if applicable (1).

Disconnect the brake hose from the bracket (2).

Remove the strut bracket bolts (3).
5. Remove the strut bracket assembly from the vehicle.

2C –8 FRONT SUSPENSION
DAEWOO M-150 BL2
D16B504A
70–90 Nm
Installation Procedure
1. Install the strut assembly to the vehicle with the strut
assembly–to–strut bracket bolts.
Tighten
Tighten the strut assembly–to–strut bracket bolts to
70–90 Nm (52–66 lb-ft).
2. Connect the brake hose to the bracket.
3. Install the ABS front speed sensor electrical wire to
the bracket, if applicable.
D16B505A
18–28 Nm
18–28 Nm4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
6. Install the nuts.

Install the nuts at passenger side (1).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).

Install the nuts at driver side (2).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).
7. Install the power steering fluid reservoir.
8. Install the fuse box and bolt.
D106B506
KNUCKLE ASSEMBLY
Tools Required
KM 507–B Ball Joint Remover
Removal Procedure
1. Remove the caulking nut.

Straighten the bent flange caulking nut (1).

Remove the caulking nut (2).

Remove the washer (3).
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
D105B501
3. Separate the tie rod end from the knuckle assembly.

Remove the cotter pin (1).

Remove the castellated nut (2).

Install the ball joint remover KM 507–B.

Separate the tie rod end from the knuckle assem-
bly using a ball joint remover KM 507–B (3).

FRONT SUSPENSION 2C–9
DAEWOO M-150 BL2
D106B507
4. Remove the control arm from the knuckle assembly.

Remove the stud bolt (1).

Separate the control arm from the knuckle assem-
bly (2).
D106B508
5. Remove the brake caliper from the knuckle assembly.
Refer to Section 4D, Front Disc Brakes.
6. Remove the ABS wheel speed sensor from the
knuckle assembly, if applicable. Refer to Section 4F,
Anti–lock Brake System.
7. Remove the steering knuckle assembly from the ve-
hicle.

Remove the strut bracket bolts (1).

Separate the knuckle assembly from the drive
shaft by pulling the steering knuckle assembly (2).
D16B509A
70–90 Nm
50–70 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the steering knuckle assembly in the vehicle
with strut bracket bolts (1).
Tighten
Tighten the strut bracket bolts to 70–90 Nm (52–66
lb-ft).
3. Install the brake caliper from the knuckle assembly.
4. Install the control arm into the knuckle assembly with
the stud bolt (2).
Tighten
Tighten the stud bolt to 50–70 Nm (36–52 lb-ft).
D16B510B
5. Install the tie rod end to the knuckle assembly.
6. Install the tie rod end–to–knuckle castellated nut (1)
and the cotter pin.
Tighten
Tighten the castellated nut to 30–55 Nm (22–41 lb-
ft).
7. Install the caulking nut (2).

Bend the caulking nut flange (3).
Tighten
Tighten the caulking nut to 210 Nm (155 lb-ft).

2C –10 FRONT SUSPENSION
DAEWOO M-150 BL2
D106B511
FRONT LONGITUDINAL FRAME AND
STABILIZER SHAFT
Removal Procedure
1. Removed the front under longitudinal frame.

Raise and suitably support the vehicle.

Remove the front wheel. Refer to Section 2E, Tires
and Wheels.

Remove the transaxle under cover. Refer to Sec-
tion 5B, Manual Transaxle.

Remove the front under longitudinal frame bolt (1).

Remove the front under longitudinal frame nut (2).
D16B512A

Remove the stabilizer shaft mounting bolts (3).

Remove the front under longitudinal frame.
D106B513
2. Remove the stabilizer shaft from the vehicle.

Remove the cotter pin (1).

Remove the castellated nut (2).

Remove the washer (3).

Remove the rear bushing with separating the sta-
bilizer shaft from the control arm (4).
D16B514A

Remove the bushing (5).

Remove the wire clamps (6).

Remove the mountings (7).

2C –16 FRONT SUSPENSION
DAEWOO M-150 BL2
UNIT REPAIR
D106B701
HUB BEARING AND KNUCKLE
Tools Required
DW 220–020A–01 Differential Bearing Puller.
DW 220–020A–04 Differential Bearing Plate Adapter.
DW 340–010 Front Wheel Hub Remover.
DW 340–020 Front Wheel Bearing Race Installer.
DW 340–030 Front Wheel Bearing Installer.
09940–71430 Front Spring Compressor.
Disassembly Procedure
1. Remove the steering knuckle assembly. Refer to
“Knuckle Assembly” in this section.
2. Remove the bolts from the wheel hub.
D106B702
3. Remove the wheel hub from the knuckle assembly
using the front wheel hub remover DW 340–010.

Remove the wheel hub using the front wheel hub
remover DW 340–010 (1).

Remove the bearing spacer (2).

Remove the brake rotor (3).