2003 DAEWOO MATIZ light

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–5
DAEWOO M-150 BL2
D105C527
PUMP DRIVE PULLEY
Tools Required
DW310–020 Power Steering Pulley Remove Holder
Removal Procedure
1. Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Remove the steering pump pulley.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Fix the pulley using the power steering pulley re-
move holder DW310–020 (1).

Remove the pump drive pulley nut (2).
55–69 Nm
D15C528A
Installation Procedure
1. Install the pump drive pulley. Install the steering pump
pulley nut.
2. Install the pump drive belt.
3. Tighten the steering pump pulley nut using the power
steering pulley remove holder DW310–020.
Tighten
Tighten the steering pump pulley nuts to 55–69 Nm
(41–51 lb-ft).
4. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
D105C529
PUMP ASSEMBLY
Removal Procedure
1.Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Disconnect the pipe line from the pump.

Disconnect the supply line pipe hose (1).

Disconnect the pressure line pipe fitting (2).
D105C530
3. Remove the power steering pump.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Disconnect the power steering pressure switch
connector (1). Refer to Section 6A, Power Steering
Systems.

Remove the bolts (2).

6B –6 POWER STEERING PUMP
DAEWOO M-150 BL2
D105C531

Remove the bolt (3).
18–22 Nm
D15C532A
Installation Procedure
1. Install the power steering pump with the bolt.
Tighten
Tighten the bolt to 18–22 Nm (13–16 lb-ft).
2. Connect the power steering pressure switch connec-
tor. Refer to Section 6A, Power Steering System.
3. Install the pump drive belt. Refer to “Pump Drive Belt”
in this section.
20–24 Nm
20–24 Nm 21–35 Nm
D15C533A
4. Install the bolts.
Tighten

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (1).

Tighten the power steering bolt to 20–24 Nm
(15–18 lb-ft) (2).
5. Connect the pressure line pipe to the outlet connec-
tion on the steering pump.
Tighten
Tighten the pressure line pipe fitting to 21–35 Nm
(16–26 lb-ft) (3).
6. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
Notice: When adding fluid or making a complete fluid
change, always use DEXRON-II or DEXRON-III pow-
er steering fluid. Failure to use the proper fluid will cause
hose and seal damage and fluid leaks.
7. Refill the pump with new fluid and bleed the air from
the system. Refer to Section 6A, Bleeding the Power
Steering System.
8. Inspect for leaks. If leaks are found, correct the cause
of the leak and bleed the system.

6E – 2 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
STEERING WHEEL AND COLUMN
In addition to the steering function, the steering column
provides safety and security.
Caution: To ensure energy-absorbing action, it is
important to use only the specified screws, bolts,
and nuts, tightened to the specified torque.
The energy-absorbing column is designed to compress
in a front-end collision to lessen the chance of driver in-
jury.
The ignition switch and the lock are mounted on the col-
umn, allowing the ignition and steering operations to be
locked to inhibit theft of the car.
The column levers trigger the turn signals, the headlight
beams, and the windshield washer and wipers.
Notice: Apply a thin coat of lithium grease to all friction
points when reassembling to ensure proper operation.
The column may be easily disassembled and assembled.
D15A001A

Safety Device
A. Steering Column Upper Bracket.
B. Steering Column.
C. Steering Column Shaft.

7A–10 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
BLOWER ELECTRICAL
Step Action Value(s) Yes No
1

Verify the customer’s complaint.
Are the customer’s concerns verified.
–

Go to Step 2

System OK
2

Check the blower.
Does the blower run at any speed?
–

System OK

Go to Step 3







3







1. Disconnect the power connector from the blower
motor under the dashboard on the passenger side
of the vehicle.
2. Use an ohmmeter check the resistance between
the 1 terminal of the blower motor connector and
each step with the blower switch place each
position.
Does the ohmmeter show the specified value of the
each position?






Refer to
“Specifica-
tions” in this
section.






Go to Step 4






Go to Step 5

4

Replace the blower motor.
Is the repair complete?
–
System OK

Go to Step 7

5

Check the fuse Ef6.
Is the fuse blown?
–
Go to Step 6

Go to Step 7






6






1. Turn the ignition ON.
2. Use a short detector to locate a possible short.

From the fuse Ef6 to the blower switch.

From the blower swtich to the blower resistor.

From the blower resistor to the blower motor.
3. Repair any short.
4. Replace any blown fuse.
Is the repair complete?





–






System OK






–











7











1. Turn the ignition ON.
2. Disconnect the power connector from the blower
motor.
3. Use a test lamp to locate a possible short.

From the terminal 2 of the motor connector to
the terminal 3 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 4 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 5 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 6 of the motor switch connector.
Does the test lamp light ON?











–










Go to Step 9










Go to Step 8

8

Replace the blower resistor.
Is the repair complete?
–
System OK

Go to Step 10

9

Replace the blower motor switch.
Is the repair complete?
–
System OK

–

10


1. Check the ground of the blower motor.
2. Repair the ground of the blower motor.
Is the repair complete?
–

System OK

–

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–7
DAEWOO M-150 BL2
LEAK TESTING THE REFRIGERANT
SYSTEM
Test for leaks whenever you suspect a refrigerant leak in
the system. You should also test for leaks whenever you
perform a service operation which results in disturbing
the lines or the connections. Leaks are commonly found
at the refrigerant fittings or at the connections. Leaks are
commonly caused by the following problems:
Improper torque.
Damaged O-ring seals.
Dirt or lint on the O-ring seals.
Liquid Leak Detectors
Use a liquid leak detector solution on locations such as
fittings. Apply the solution to the area in question with
the swab that is supplied with the solution. Look for
bubbles to appear. This will indicate the existence and
location of any leak.
For areas where this is not practical, such as sections of
the evaporator and the condenser, an electronic leak de-
tector is more useful.
Electronic Leak Detectors
Follow the manufacturer’s instructions for calibration,
operation, and maintenance of an electronic leak detec-
tor. Battery condition is especially important to the accu-
racy of a portable model. Set the detector to R-134a
before beginning the test.
Important: Electronic leak detectors are sensitive to
windshield washing solutions, solvents and cleaners,
and certain vehicle adhesives.
Surfaces must be clean to prevent false readings. Make
sure that all surfaces are dry to prevent damage to the
detector.
General Testing Instructions
Follow the entire path of the refrigerant system.
Completely circle each joint at 25 to 50 mm (1 to 2
inches) per second.
Hold the probe tip within 6 mm (1/4 inch) of the sur-
face.
Do not block the air intake.The audible tone changes from 1 to 2 clicks per second
into a solid alarm if there is a leak. Adjust the balance
control to maintain 1 to 2 clicks per second.
Test all of the following areas, even after one leak has
been confirmed:
Evaporator inlet and outlet.
Receiver-drier inlet and outlet.
Condenser inlet and outlet.
Brazed and welded areas.
Damaged areas.
Hose couplings.
Compressor rear head.
All fittings and joints.
Testing Service Ports/Access Valves
The sealing cap is the primary seal for the service ports.
This cap contains a special leak-free O-ring. Make sure
that this cap is not missing or loose. Always use the cor-
rect cap.
Testing the Evaporator Core
Leaks in the evaporator core are difficult to find. Test the
evaporator core using the following procedure:
1. Run the blower fan at speed setting 4 for at least
15 minutes.
2. Turn the blower to the OFF position.
3. Wait for 10 minutes.
4. Remove the blower motor resistor. Refer to “Blower
Motor Resistor” in this section.
5. Insert the leak detector probe as close as possible to
the evaporator core. The detector will indicate a leak
with a solid alarm.
6. Use a flashlight to search for refrigerant oil in the core
surface.
Testing the Compressor Shaft Seal
1. Blow shop air behind and in front of the compressor
clutch/pulley for at least 15 seconds.
2. Wait 1 to 2 minutes.
3. Probe the area in front of the pulley. If the detector
emits a solid alarm, there is a leak.

8A –2 SEAT BELTS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRIVER SEAT BELT WARNING
The driver’s safety belt incorporates a safety belt re-
minder light in the instrument cluster to remind the driver
if the safety belt is not fastened when the ignition is
turned ON.
THREE-POINT PRETENSIONER
FRONT SEAT BELT (W/EUROPE
ONLY)
The pretensioner front seat belt is optional. It contains a
electrically-controlled pyrotechnical retractor, which re-
duces seat belt slack when it is activated in a head-on or
angled front collision. The pretensioner front seat belt
must be replaced after an accident that causes its ac-
tivation.
THREE-POINT WLR FRONT SEAT
BELT
The three-point web locking retractor (WLR) seat belt
will limit the movement of the driver and offer better
protection in an accident.
THREE-POINT ELR FRONT SEAT
BELT
The three-point emergency locking retractor (ELR) front
seat belt is always unlocked, allowing the passenger
freedom of movement, except in emergencies (rapid de-
celeration, rapid acceleration, or hard cornering maneu-
vers).
THREE-POINT ELR REAR
OUTBOARD SEAT BELT
The rear outboard seating positions use the three-point
emergency locking retractor (ELR) seat belts. The
three-point emergency locking retractor (ELR) seat beltis always unlocked, allowing the passenger freedom of
movement, except in emergencies (rapid deceleration,
rapid acceleration, or hard cornering maneuvers).
TWO-POINT LAP REAR CENTER
SEAT BELT
The two-point lap rear center seat belt is a single contin-
uous length of webbing. The webbing is routed from the
anchor through a latch plate and into a single retractor.
OPERATIONAL AND FUNCTIONAL
CHECKS
Caution:

Keep sharp objects and potentially damaging ob-
jects away from the seat belts.

Avoid bending or damaging any portion of the
buckle or the latch plate.

Do not bleach or dye the belt webbing. Use only
mild soap and water in order to clean the belts.

When installing the seat belt anchor bolts and
the screws, start the bolts and the screws by
hand in order to prevent crossthreading.

Do not attempt any repairs on the retractor mech-
anisms or the covers. Replace any defective as-
semblies with new assemblies.

Replace any belts that are cut or damaged in any
way.
1. Inspect all seat belt anchor bolts and the screws in or-
der to verify that they are secure.
2. Inspect the seat belt buckle. The buckle must lock
and unlock easily.
3. After inserting the latch into the buckle, tug sharply on
the belt. The buckle must remain locked.
4. Fully extend the shoulder belt portion to make sure
that there is no twisting or tears in the belt.
5. Let the shoulder belt retract fully. The belt should re-
tract easily.

8A –8 SEAT BELTS
DAEWOO M-150 BL2
D1AA505B
4. Install the bolt on the lower B–pillar.

Install the bolt.
Tighten
Tighten the lower B–pillar bolt to 30–45 Nm (22–33
lb-ft).

Install the spacers and the fiber washer.

Install the plastic protector on the seat belt anchor.
5. Relocate the seatback.
D11A506A
FRONT SEAT BELT BUCKLE
Removal Procedure
1. Remove the front seat belt buckle

Remove the bolt (1).

Remove the buckle (2).

Remove the patch (3).

Before removing the driver seat belt buckle, dis-
connect the reminder light connector.
D1AA507B
Installation Procedure
1. Install the front seat belt buckle.

Connect the reminder light connector.

Install the patch.

Install the buckle.

Install the bolt.
Tighten
Tighten the seat belt buckle bolt to 30–45 Nm
(22–33 lb-ft).
D109E566
THREE–POINT ELR REAR
OUTBOARD SEAT BELT
Removal Procedure
1. Remove the rear seat cushion and the rear seatback.
2. Pry off the rear interior trim panel. Refer to Section
9G, Interior Trim.

Pry off the backshelf trim panel.

Pry off the luggage compartment side load trim
panel.