2003 DAEWOO MATIZ position

5C –6 CLUTCH
DAEWOO M-150 BL2
INSTRUCTION REPAIR
ON–VEHICLE SERVICE
D13B5151
D103B516
PRESSURE PLATE, CLUTCH DISC
AND INPUT SHAFT BEARING
Tools Required
09917–58010 Input Shaft Bearing Remover
09924–17810 Flywheel Holder
09925–98210 Input Shaft Bearing Installer
DW110–021 Engine Fixture
DW210–010 Clutch Center Guide
Removal Procedure
1. Remove the transaxle from the vehicle. Refer to Sec-
tion 5B, Manual Transaxle.
2. Support the engine to normal position using the en-
gine fixture DW110–021.
Notice: The abnormal position of the engine may dam-
age to the related parts and interfere with them. You
must support the engine to normal position after remov-
ing the transaxle.
D13C5021
3. Remove the pressure plate and the clutch disc.

Fix the fly wheel using the fly wheel holder 09924–
17810.

Remove the pressure plate bolts (1).

Remove the pressure plate and the clutch disc (2).

POWER STEERING GEAR 6C–5
DAEWOO M-150 BL2
ADJUST THE FREE LOAD OF THE
STEERING GEAR
1. Place the steering wheel in the straight-ahead posi-
tion.
2. Raise and suitably support the vehicle.
3. Remove the adjust plug locknut.
4. Check the torque of the adjuster plug.
5. Check the torque is below the specification value or
the measured torque is over the specification value,
adjust the tightening torque.

Place the rack gear in the straight-ahead position.

Tighten the adjust plug to 10 Nm (89 lb-in).

Turn the steering wheel all the way to the right and
the left about 5 times repeatedly.

Place the rack gear in the straight-ahead position.

Loosen the adjust plug.
D105C302

Tighten the adjust plug to 4.5–5.5 Nm (40–49 lb-
in).

Loosen the adjust plug to 67.5.
6. Tighten the adjust plug locknut.

MANUAL STEERING GEAR 6D–5
DAEWOO M-150 BL2
STRAIGHT-AHEAD CHECK
After all the necessary operations on the steering gear
are completed, check the exact straight-ahead position
of the steering in each case.
With the vehicle on the floor, place the steering wheel in
the straight-ahead position. Mark the centerline of both
tires on the floor. Turn the steering wheel all the way to
the right and mark the new centerline of both tires on the
floor.
Application Tire Specified Valve
145, 15537.5 – 41.5
Inside Angle 17532.9 – 36.9
145, 15531.5 – 35.5
Outside Angle 17528.5 – 32.5
D105B301
Front Outside Angle
Inside Angle
Straight Ahead Check Table
Step Action Value(s) Yes No



1



Place the steering wheel in the straight-ahead posi-
tion.
Is the wheel in the correct position?


–


Go to Step 2



–


2

Is the steering wheel off center by more than 5 de-
grees?
–
Go to Step 4
Go to Step 5

3

The pinion is displaced on the rack. The steering
pinion position must be corrected.
Is the repair complete?
–
Go to Step 2

–



4



Remove steering wheel and center on the spindle
splines.
Is the repair complete?


–


Go to Step 2



–



5



Turn the steering wheel all the way to the right. Mea-
sure the inner and the outer angles of the tire cent-
erline compared to the straight-ahead centerline. Do
the angles match the value specified?


Refer to
“Straight–
Ahead Check”
in this section

System OK


Go to Step 6


6



The rack assembly was not assembled correctly.
Repair as needed.
Is the repair complete?


–


Go to Step 5



–

6D –6 MANUAL STEERING GEAR
DAEWOO M-150 BL2
STEERING WHEEL RESTORATION
1. Turn the steering wheel fast to the right and left and
turn it slowly as the same way.
2. Check if the steering wheel restoration for the wheel
turning to right and the one to the left are same.
3. Turn the steering wheel to 90 about 1–2 seconds
and loosen the steering wheel during the low speed
driving.
4. If the steering wheel restores above 70%, the steer-
ing wheel restoration is OK.
5. If the restoration is poor, check the tire pressure,
steering gear preload, and steering gear operation.
And repair the fault.
CHECK THE TURNING RESISTANCE
OF THE TIE ROD END OR TIE ROD
1. Turn the ball joint of the tie rod end or the tie rod about
10 times.
2. Use a spring balance to check the turning resistance
of each ball joint.
D105B302
Application Specified Value
Tie Rod End Ball Joint0.49 – 3.43 Nm
(4.5 – 30 lb-in.)

Tie Rod Ball Joint0.49 – 3.43 Nm
(4.5 – 30 lb-in.)
3. If the values exceed the specified values, replace the
tie rod end or the tie rod.
4. But, If the ball joint of the tie rod end or the tie rod falls
down of itself, replace it.
ADJUST THE FREE LOAD OF THE
STEERING GEAR
1. Place the steering wheel in the straight–ahead posi-
tion.
2. Raise and suitably support the vehicle.
3. Check the torque of the adjuster plug.
4 When the measured torque is below the specification
value or the measured torque is over the specification
value, adjust the tightening torque.

Place the rack gear in the straight–ahead position.

Tighten the adjust plug to 95 Nm (70 lb-ft).

Turn the steering wheel all the way to the right and
the left about 5 times repeatedly.

Place the rack gear in the straight–ahead position.

Loosen the adjust plug.

Tighten the adjust plug to 8 Nm (71 lb-in.).

Set the torque in the 0.8–1.3 Nm (8–12 lb-in.) by
loosening the adjust plug to 0 − 90.
D105B303

6E –4 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
STEERING COLUMN DIAGNOSIS
Lock System
ConditionProbable CauseCorrection
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Unlock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Lock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
High Lock Effort
Damaged lock cylinder.
Replace the lock cylinder.

The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Extreme misalignment of the housing to the
cover.
Realign the cover on the housing.

Replace the cover as needed.
Key Cannot Be
The ignition switch to be set incorrectly.
Reset the ignition switch.
Removed in the B
Position
Damaged lock cylinder.
Replace the lock cylinder.
Column
ConditionProbable CauseCorrection
Noise in the Column
Improperly installed intermediate shaft–to–
column joints.
Tighten the coupling pinch bolts.

Replace the intermediate shaft as
needed.

Column misalignment.
Replace the alignment spacer.

The lack of lubrication for the joint.
Lubricate the joint.

The lack of lubrication for the steering shaft.
Lubricate the steering shaft bearing.

Improperly seated shaft lock snap ring.
Adjust the shaft lock snap ring.

Replace the shaft lock snap ring as
needed.

Improperly installed intermediate shaft
pinch bolt.
Tighten the pinch bolt.
High Steering Shaft
Column misalignment.
Replace the alignment spacer.
Effort
A damaged bearing.
Replace the steering column
housing.

The lack of free movement for the steering
shaft universal joint.
Lubricate the steering shaft
universal joint.

Replace the steering column shaft
as needed.

STEERING WHEEL AND COLUMN 6E–5
DAEWOO M-150 BL2
Column (Cont’d)
ConditionProbable CauseCorrection
Lash in the Steering
Column
Improperly installed steering column
bracket mounting nuts.
Tighten the steering column bracket
mounting nuts.

Loose steering column housing–to–steering
column jacket support bolts.
Tighten the support bolts.
Loose Steering
Wheel
The bearing to be seated incorrectly in the
housing.
Correctly seat the bearing.

Replace the column housing as
needed.

Loose steering column housing support
bolts.
Tighten the steering column housing
support bolts.
Turn Signal / Dimmer Switch
ConditionProbable CauseCorrection
Turn Signal Will Not
Stay in the Turn
Position
An improperly installed turn signal switch.
Remove and inspect the turn signal
switch.

Reinstall the switch.

The broken or missing components for the
cancelling mechanism.
Replace the turn signal switch.

Foreign material in the turn signal switch
housing.
Remove any foreign material.
Turn Signal Will Not
Cancel
Broken or missing components for the
cancelling mechanism.
Replace the turn signal switch.
Turn Signal/Dimmer
Switch Difficult to
Operate
Improperly installed turn signal/dimmer
switch and turn signal/dimmer switch lever.
Remove and inspect the turn
signal/dimmer switch and
signal/dimmer switch lever.

Reinstall the signal/dimmer switch
and signal/dimmer switch lever.

Foreign material in the signal/dimmer
switch housing.
Remove any foreign material.
Turn Signal Will Not
Indicate Lane
A broken lane change pressure pad or a
broken spring hanger.
Replace the turn signal switch.
Change
The improper functioning of the lane
change spring.
Replace the turn signal switch.

Improperly installed turn signal switch.
Replace the turn signal switch.
No Turn Signal
An inoperative turn signal flasher.
Replace the blinker unit.
Lamps
A faulty turn signal switch.
Replace the turn signal switch.

Improperly connected chassis–to–column
connector.
Reconnect the chassis–to–column
connector.
Turn Indicator Lamps
On, But Not Flashing
An inoperative blinker unit.
Replace the blinker unit.
Front or Rear Turn
Signal Lamps Not
Flashing
An inoperative blinker unit.
Replace the blinker unit.
Turn Signal Lamps
Flash Very Slowly
An inoperative blinker unit.
Replace the blinker unit.

STEERING WHEEL AND COLUMN 6E–9
DAEWOO M-150 BL2
D105A508
Installation Procedure
1. Install the wiper switch.
2. Install the turn signal switch.
3. Install the steering column cover. Refer to “Steering
Column Cover” in this section.
4. Connect the negative battery cable.
D105A509
IGNITION SWITCH
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
3. Remove the ignition switch.

Disconnect the electrical connector (1).

Remove the screw (2).
D105A510
Installation Procedure
1. Connect the electrical connector.
2. Install the ignition switch with the screw.
3, Install the steering wheel. Refer to “Steering Wheel”
in this section.
4. Connect the negative battery cable.
D105A511
IGNITION LOCK CYLINDER WITH
IMMOBILIZER
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
2. Disconnect the electrical connector for the immobiliz-
er detection coil.
3. Remove the lock cylinder.

With the key in the ignition, turn to the position des-
ignated I (1).

6E –10 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
D105A511

Remove the lock cylinder by pressing down the
detent spring with a 2.5MM allen wrench, or other
suitable tool, and pulling the lock cylinder out of the
switch cylinder housing (2).
D105A512
Installation Procedure
Important: To install the ignition lock cylinder the igni-
tion position should be designated I.
1. Install the ignition lock cylinder.
2. Connect the electrical connector for the immobilizer
detection coil.
3. Install the steering wheel. Refer to “Steering Wheel”
in this section.
D105A513
SWITCH HOUSING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
2. Remove the turn signal switch and windshield wiper
switch. Refer to “Turn Signal Switch and Lever/Wiper
Switch and Lever” in this section.
3. Remove the switch housing.

Disconnect the horn electrical connector (1).

Remove the screws retaining the switch housing
(2).
D105A514
Installation Procedure
1. Install the switch housing with the screws.
2. Connect the horn electrical connector.
3. Install the turn signal switch and windshield wiper
switch. Refer to “Turn Signal Switch and Lever/Wiper
switch and Lever” in this section.
4. Install the steering wheel. Refer to “Steering Wheel”
in this section.