2003 DAEWOO MATIZ Service Repair Manual

DOORS 9P–21
DAEWOO M-150 BL2
D19C608A
Installation Procedure
Notice: Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use the correct
fastener to prevent premature corrosion.
1. Connect the body–to–door rubber grommet.
2. With the aid of another technician, lightly secure the
front door with the bolts.
3. Adjust the door for proper fit.
4. Tighten the hinge–to–body bolts.
5. Install the door hold open link with the bolt.
6. Install the fender. Refer to Section 9R, Body Front
End.
7. Connect the electrical connector.
8. Connect the negative battery cable.
9. Perform the waterleak test. Refer to Section 9I, Wa-
terleak.
10. Check for windnoise. Refer to Section 9J, Wind-
noise.
D109C609
REAR DOOR ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Pry off the lower B–pillar trim panel. Refer to Section
9G, Interior Trim.
3. Disconnect the rear door electrical connector.
a. Rear door electrical connector.
D109C610
4. Remove the rear door assembly.

Remove the door hinge bolts (1).

Remove the door hold open link bolt (2).

Disconnect the body–to–door rubber grommet (3).

Remove the rear door assembly (4).

9P –22 DOORS
DAEWOO M-150 BL2
D19C611A
Installation Procedure
Notice: Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use the correct
fastener to prevent premature corrosion.
1.Connect the body–to–door rubber grommet.
2. With the aid of another technician, lightly secure the
rear door with the bolts.
3. Adjust the door for proper fit.
4. Install the door hold open link with the bolt.
5. Connect the rear door electrical connector.
6. Connect the negative battery cable.
7. Perform the waterleak test. Refer to Section 9I, Wa-
terleaks.
8. Check for windnoise. Refer to Section 9J, Windnoise.
D109C612
TA I L G AT E
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the luggage compartment wheelhouse trim
panel. Refer to Section 9G, Interior Trim.
3. Disconnect the tailgate electrical connector.
a. Tailgate electrical connector.
D109C636
4. Remove the tailgate strut. Refer to “Tailgate Strut” in
this section.
5. Remove the tailgate.

Remove the hinge bolts.

Disconnect the body–to–tailgate rubber grommet.

Remove the tailgate.
D19C613A

DOORS 9P–23
DAEWOO M-150 BL2
D19C614A
Installation Procedure
Notice: Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use the correct
fastener to prevent premature corrosion.
1. Connect the body–to–tailgate rubber grommet.
2. With the aid of another technician, lightly secure the
tailgate with the bolts.
3. Adjust the tailgate for proper fit.
4. Install the tailgate strut. Refer to “Tailgate Strut” in this
section.
5. Connect the tailgate electrical connector.
6. Install the luggage compartment wheelhouse trim pan-
el. Refer to Section 9G, Interior Trim.
7. Connect the negative battery cable.
D209B113
TAILGATE LOCK CYLINDER
Removal Procedure
1. Disconnect the negative battery cable.
2. Open the tailgate.
3. Remove the rear window wiper motor assembly. Re-
fer to Section 9D, Wipers/Washer Systems.
4. Remove the tailgate lock cylinder.

Disconnect the tailgate lock rod (1).

Remove the nuts from the tailgate lock cylinder (2).

Remove the tailgate lock cylinder (3).
D209B114
Installation Procedure
1. Install the tailgate lock cylinder.
2. Install the rear window wiper motor assembly. Refer
to Section 9D, Wipers/Washer Systems.
3. Connect the negative battery cable.
D109C615
DOOR HINGE
Removal Procedure
1. With the aid of another technician, remove the door
hinge.

Remove the hinge–to–body bolts (1).

Remove the hinge–to–door bolts (2).

Remove the door hinge (3).

9P –24 DOORS
DAEWOO M-150 BL2
D109C616
Installation Procedure
Notice: Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use the correct
fastener to prevent premature corrosion.
1. With the aid of another technician, install the hinge to
the door and the body with the bolts.
D109C617
DOOR HOLD OPEN LINK
Removal Procedure
1. Remove the door seal trim. Refer to “Door Seal Trim”
in this section.
2. Remove the door hold open link.

Remove the hinge–to–body bolt (1).

Remove the hinge–to–door bolts (2).

Remove the door hold open link (3).
D109C618
Installation Procedure
Notice: Dissimilar metals in direct contact with each
other may corrode rapidly. Make sure to use the correct
fastener to prevent premature corrosion.
1. Install the door hold open link to the door and the
body with the bolts.
2. Remove the door seal trim. Refer to “Door Seal Trim”
in this section.
D109C619
INSIDE CHANNEL WEATHERSTRIP
(STANDARD)
Removal Procedure
1. Remove the channel weatherstrip.
a. Weatherstrip.

DOORS 9P–25
DAEWOO M-150 BL2
D109C620
Installation Procedure
1. Install the channel weatherstrip.
D109C621
INSIDE CHANNEL WEATHERSTRIP
(DELUXE)
Removal Procedure
1. Remove the door trim. Refer to Section 9G, Interior
Trim.
2. Remove the channel weatherstrip from the door trim.

Straighten the retaining tabs (1).

Remove the channel weatherstrip (2).
D109C622
Installation Procedure
1. Install the channel weatherstrip onto the door trim
panel.
2. Bend the retaining tabs to secure the channel weath-
erstrip to the door trim panel.
3. Install the door trim panel. Refer to Section 9G, Interi-
or Trim.
D109C623
DOOR OUTSIDE CHANNEL
WEATHERSTRIP
Removal Procedure
1. Remove the channel weatherstrip.

Remove the screw (1).

Lift off the outside channel weatherstrip (2).

9P –26 DOORS
DAEWOO M-150 BL2
D109C624
Installation Procedure
1. Press the outside channel weatherstrip onto the door.
2. Install the weatherstrip screw.
D109C625
DOOR WEATHERSTRIP
Removal Procedure
1. Remove the door hold open link bolt.
D109C626
2. Remove the door weatherstrip.

Remove the clip (1).

Remove the weatherstrip pins (2).
D109C627
Installation Procedure
1. Install the door weatherstrip with the clip and the pins.
2. Install the door hold open link bolt.

DOORS 9P–27
DAEWOO M-150 BL2
D109C566
DOOR SEAL TRIM
Removal Procedure
1. Remove the door trim panel. Refer to Section 9G, In-
terior Trim.
2. Remove the door seal trim.
a. Door seal trim.
b. Door pocket handle bracket.
Important: In case of the deluxe trim, remove the door
pocket handle bracket in advance.
D109C628
Installation Procedure
1. Install the door seal trim.
2. Install the door pocket handle bracket for the deluxe
trim.
3. Install the door trim panel. Refer to Section 9G, Interi-
or Trim.
D109C629
DOOR OPENING WEATHERSTRIP
Removal Procedure
1. Mark the door opening weatherstrip edge by a soluble
pen.
D109C630
2. Remove the door opening weatherstrip.

Take off the rocker trim panel partially (1).

Take off the lower B–pillar trim panel partially (2).

Remove the door opening weatherstrip (3).

9P –28 DOORS
DAEWOO M-150 BL2
D109C631
Installation Procedure
1. Install the door opening weatherstrip to match the
marking.
2. Install the rocker panel trim and the lower B–pillar
panel trim.
D109E543
MANUAL WINDOW REGULATOR
HANDLE
Removal Procedure
1. Remove the window regulator handle.

Using a cloth, pull out the clip (1).

Remove the window regulator handle (2).
D109C632
Installation Procedure
1. Install the window regulator handle with the clip.
D19C634A
TAILGATE STRUT
Removal Procedure
1. Open the tailgate and suitably support it.
2. Remove the tailgate strut assembly.

Remove the end fitting nut from the ball studs (rear
body) (1).

Removethe end fitting nut from the ball studs (tail-
gate) (2).