2003 DAEWOO MATIZ Service Repair Manual

9I–6 WATERLEAKS
DAEWOO M-150 BL2
D109A504
6. Prime the trimmed area with the primer.
7. Using a sharp knife, trim off the uneven edges of the
adhesive material around the leak 75 to 100 mm (3 to
4 inches) on both sides of the leak.
D109A505
8. Allow the primer to dry for 5 minutes.
9. Apply the adhesive over the leak and for a distance
of 75 to 100 mm (3 to 4 inches) on both sides of the
leak.
D109A506
10. Immediately after applying the adhesive, use a flat
stick or a similar tool to work the adhesive into the
leak area and into the joint between the original ma-
terial and the vehicle body in order to ensure a wa-
tertight seal.
11. Spray warm or hot water over the repaired area in
order to determine if the leak was repaired. Do not
run a heavy stream of water directly on the freshly
applied adhesive.
12. Install the trim strip lace if it was removed.
13. Install the garnish molding if it was removed.
14. Install the reveal molding.
D109A304
Important: After the completion of any waterleak repair,
re–test the area using the watertest stands. Do not use
localized testing procedures on the newly–repaired
areas, as the repair material may dislodge under abnor-
mal pressure.

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

DAEWOO M-150 BL2
SECTION 9J
WINDNOISE
TABLE OF CONTENTS
Diagnostic Information and Procedures 9J-1. . . . .
Windnoise Diagnosis 9J-1. . . . . . . . . . . . . . . . . . . . . . . Repair Instructions 9J-2. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9J-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Windnoise Repair 9J-2. . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
WINDNOISE DIAGNOSIS
Caution: An assistant should drive the vehicle while
the technician checks for the location of the wind-
noise, in order to prevent personal injury or vehicle
damage.
A test drive in the vehicle is necessary to accurately de-
termine the location of the windnoise. Often there is a
primary leak and secondary leaks. Failure to repair all
leaks will only reduce the windnoise, not eliminate it.
During the test drive the technician should bring the fol-
lowing items to aid in determining the location of the
windnoise.

A mechanics stethoscope or vacuum hose

Masking tape

Strip caulk

A china marking pencil

A screwdriver
Perform the following steps in order to conduct the road
test:
1. Choose a route that includes smooth straight streets
that run in all four directions (north, south, east, and
west).
2. Choose streets with little traffic or noise that would in-
terfere with the test.
3. Drive the vehicle at the speeds at which the noise
was noticed by the customer or until the noise is pro-
duced. Do not exceed legal speed limits.
4. The windnoise is external if any of the following condi-
tions occur:

The windnoise is caused by the wind.

The windnoise can be heard with the door glass
lowered and while the vehicle is being driven.

The windnoise is eliminated when tape is placed
over various moldings and gaps.5. Internal windnoise is air leaving the vehicle and
should be repaired in the following manner.

In order to locate the leak, tape off the body lock
pillar pressure relief valves. This will cause air
pressure to build up inside the vehicle and en-
hance the windnoise.

Use a stethoscope or a vacuum hose to locate the
leak.

Temporarily repair the leak with masking tape.
D109A307

Continue testing in order to determine if the noise
has been eliminated or if other leaks exist.

When all leaks have been found, return to the shop
and make permanent repairs with the proper align-
ment techniques and sealing materials.

9J – 2 WINDNOISE
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
WINDNOISE REPAIR
Windnoise leak repairs are very similar to waterleak re-
pairs. Refer to Section 9I, Waterleaks. The actual proce-
dure depends on the type of seal being repaired. Leaks
around the door opening weatherstrips do not always in-
dicate a faulty weatherstrip. A door or window adjust-
ment may resolve the condition. Refer to Section 9L,
Glass and Mirrors.

DAEWOO M-150 BL2
SECTION 9K
SQUEAKS AND RATTLES
TABLE OF CONTENTS
Diagnostic Information and Procedures 9K-1. . . . .
Squeak and Rattle Diagnosis 9K-1. . . . . . . . . . . . . . . Repair Instructions 9K-3. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9K-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Squeak and Rattle Repair 9K-3. . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
SQUEAK AND RATTLE DIAGNOSIS
ConditionProbable CauseCorrection
Rattle Coming From the
Side Rail
Improperly connected brake
lines.
Tap lightly on the brake lines and listen for a
rattle.

Install plastic tie straps to secure the brake
lines tightly together.
Rattle Under Vehicle at
Higher RPM
The heat shield contacts with
the underbody.
Raise the vehicle and perform a visual
inspection.

Bend the heat shield slightly to gain
clearance from the underbody.
Squeak From the Front
of the Vehicle in Cold
Weather
Poor front stabilizer shaft
insulators taping.
While the vehicle is cold, perform a test drive
and achieve full front suspension travel by
driving through a dip in the road.

Remove the insulators and wrap teflon tape
around the stabilizer shaft. Reinstall the
insulators over the tape.
Thump From Rear of
Vehicle on Bumps
Improperly secured spare tire in
the rear compartment.
Open the rear compartment and perform a
visual inspection of the spare tire and the
tools.

Tightly secure the spare tire and all tools.

Perform a road test to verify that the noise is
eliminated.
Glass Knock Coming
From the Rear of the
Vehicle When Driving
Over Bumps
An out-of-adjustment hatchback
latch.
Test drive the vehicle in order to verify this
condition.

Loosen the latch nuts and adjust the latch
downward.
Rattle Coming From
Door
The door lock solenoid is loose.
Remove the door trim panel and check if the
solenoid is loose.

Tighten the solenoid bolts.

Rattling electrical connectors
inside the door trim panel.
Tap on the trim panel and listen for a rattle.

Remove the trim panel and wrap foam
padding around the connectors as required.
Squeak When
Operating Doors
A lack of lubrication of the door
hinge pins.
Operate the doors and listen for squeaks.

Lubricate the door hinge pins with light oil
and coat with lithium grease.

A lack of lubrication of the door
hold open link arm.
Lubricate the door hold open link arm with
light oil and coat with lithium grease.

9K – 2 SQUEAKS AND RATTLES
DAEWOO M-150 BL2
SQUEAK AND RATTLE DIAGNOSIS (Cont’d)
ConditionProbable CauseCorrection
Squeak Coming From
Console When Shifting
Manual Transaxle
(Condition Occurs In
Cold Weather with a
Cold Engine)
The faulty manual transaxle
control lever lower boot.
Move the control lever between gears and
listen for squeaks.

Remove the floor console and replace the
lower shift boot or apply talcum powder to
the lower shift boot.
Squeak Coming From
Instrument Cluster Trim
Plate
Rubbing of the cluster trim plate
on the instrument panel.
Test drive the vehicle in order to verify this
condition.

Remove the instrument cluster trim plate and
install felt tape to the edges.

SQUEAKS AND RATTLES 9K–3
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
SQUEAK AND RATTLE REPAIR
Squeaks and rattles are caused by the unwanted move-
ment between parts of a vehicle. There are three means
to prevent squeaks or rattles.

Attach the parts securely so that there is no rela-
tive motion during the operation of the vehicle.

Separate the parts so that there is no contact dur-
ing operation.

Insulate the parts so that no squeaks or rattles oc-
cur with the movement of the parts. Low uniform
friction surfaces can be used to eliminate “stick–
slip” motion.

DAEWOO M-150 BL2
SECTION 9L
GLASS AND MIRRORS
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.
TABLE OF CONTENTS
Description and System Operation 9L-2. . . . . . . . . .
Stationary Glass 9L-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Inside Rearview Mirror 9L-2. . . . . . . . . . . . . . . . . . . . .
Outside Rearview Mirrors 9L-2. . . . . . . . . . . . . . . . . . .
Components Locator 9L-3. . . . . . . . . . . . . . . . . . . . . . .
Glass and Mirror 9L-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 9L-4. . . . .
Testing Rear Window Defogger Grid Line 9L-4. . . . .
Repair Instructions 9L-5. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9L-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield 9L-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Glass 9L-7. . . . . . . . . . . . . . . . . . . . . . .
Rear Window Defogger Grid Line Repair 9L-9. . . . . Rear Window Defogger Braided Lead
Wire Repair 9L-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Glass 9L-10. . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Quarter Glass 9L-12. . . . . . . . . . . . . . . . .
Rear Door Glass 9L-13. . . . . . . . . . . . . . . . . . . . . . . . .
Inside Rearview Mirror 9L-13. . . . . . . . . . . . . . . . . . . .
Outside Rearview Mirror (Manual) 9L-14. . . . . . . . . .
Outside Rearview Mirror (Cable) 9L-15. . . . . . . . . . . .
Outside Rearview Mirror (Electric) 9L-16. . . . . . . . . .
Special Tools and Equipment 9L-17. . . . . . . . . . . . . .
Special Tools Table 9L-17. . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 9L-18. . . . . . . . . .
Rear Window Defogger 9L-18. . . . . . . . . . . . . . . . . . .