2003 DAEWOO MATIZ Oil specification

1F–54 ENGINE CONTROLS
DAEWOO M-150 BL2
FUEL INJECTOR BALANCE TEST
A fuel injector tester is used to energize the injector for a
precise amount of time, thus spraying a measured
amount of fuel into the intake manifold. This causes adrop in the fuel rail pressure that can be recorded and
used to compare each of the fuel injectors. All of the fuel
injectors should have the same pressure drop.
Fuel Injector Balance Test Example
Cylinder123
First Reading380 kPa
(55 psi)380 kPa
(55 psi)380 kPa
(55 psi)
Second Reading215 kPa
(31 psi)201 kPa
(29 psi)230 kPa
(33 psi)
Amount Of Drop165 kPa
(24 psi)179 kPa
(26 psi)151 kPa
(22 psi)
Average Range: 156-176 kPa
(22.5-25.5 psi)Injector OKFaulty Injector –
Too Much
Pressure DropFaulty Injector –
Too Little
Pressure Drop
Caution: The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pres-
sure before disconnecting the fuel lines.
Caution: Do not pinch or restrict fuel lines. Damage
to the lines could cause a fuel leak, resulting in pos-
sible fire or personal injury.
Notice: In order to prevent flooding of the engine, do not
perform the Injector Balance Test more than once (in-
cluding any retest on faulty fuel injectors) without run-
ning the engine.
Test
Notice: An engine cool down period of 10 minutes is
necessary in order to avoid irregular readings due to hot
soak fuel boiling.
1. Connect the fuel pressure gauge carefully to avoid
any fuel spillage.
2. The fuel pump should run about 2 seconds after the
ignition is turned to the ON position.
3. Insert a clear tube attached to the vent valve of the
fuel pressure gauge into a suitable container.
4. Bleed the air from the fuel pressure gauge and hose
until all of the air is bled from the fuel pressure gauge.
5. The ignition switch must be in the OFF position at
least 10 seconds in order to complete the electronic
control module (ECM) shutdown cycle.6. Turn the ignition ON in order to get the fuel pressure
to its maximum level.
7. Allow the fuel pressure to stabilize and then record
this initial pressure reading. Wait until there is no
movement of the needle on the fuel pressure gauge.
8. Follow the manufacturer’s instructions for the use of
the adapter harness. Energize the fuel injector test-
er once and note the fuel pressure drop at its lowest
point. Record this second reading. Subtract it from
the first reading to determine the amount of the fuel
pressure drop.
9. Disconnect the fuel injector tester from the fuel in-
jector.
10. After turning the ignition ON, in order to obtain maxi-
mum pressure once again, make a connection at
the next fuel injector. Energize the fuel injector test-
er and record the fuel pressure reading. Repeat this
procedure for all the injectors.
11. Retest any of the fuel injectors that the pressure
drop exceeds the 10 kPa (1.5 psi) specification.
12. Replace any of the fuel injectors that fail the retest.
13. If the pressure drop of all of the fuel injectors is with-
in 10 kPa (1.5 psi), then the fuel injectors are flowing
normally and no replacement should be necessary.
14. Reconnect the fuel injector harness and review the
symptom diagnostic tables.

ENGINE CONTROLS 1F–319
DAEWOO M-150 BL2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Camshaft Position Sensor Bolts10–14–89–124
Engine Coolant Temperature (ECT) Sensor8–12–71–106
Crankshaft Position (CKP) Sensor Retaining Bolt5–8–44–71
Electronic Ignition (EI) System Ignition Coil Retaining
Bolts8–12–71–106
Evaporative Emission Canister Protective Cover8–71
Electric Exhaust Gas Recirculation (EEGR) Valve
Retaining Bolts20–3015–22–
Fuel Rail Retaining Bolts18–2213–16–
Fuel Tank Strap Retaining Nuts18–2213–16–
Knock Sensor Bolt15–2511–18–
Intake Air Temperature (IAT) Sensor20–3015–22–
Manifold Absolute Pressure (MAP) Sensor Retaining
Bolt8–12–71–106
Oxygen Sensor35–4426–33–
Heated Oxygen Sensor35–4426–33–
Throttle Body Retaining Bolt9–12–80–106
ECM Mounting Bolts6–8–53–71
SPECIAL TOOLS
SPECIAL TOOLS TABLE
D102F101
Scan Tool
D12F102A
DW–140–010A
Fuel Pump Lock Ring
Remover/Installer

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.

FRONT SUSPENSION 2C–23
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Suspension Type – Mcpherson (Strut)
Maximum Length mm (in.) 475–481 (18.7–18.94) Shock Absorber Minimum Length mm (in.) 321–327 (12.64–12.87)
Stroke

mm (in.)

154 (6.06)
Stabilizer Shaft Diammeter

mm (in.)

24 (0.94)
Coil Spring Height (No Load) mm (in.) 374 (14.72 )
Grease Type (Front Wheel Bearing and Hub) – M–8143 ANTIF BRG GREASE
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Strut Assembly–to–Body Nuts 18 – 28 13 – 21 –
Strut Closure Nut 50 – 60 36 – 44 – Strut Assembly–to–Knuckle Bolts 70 – 90 52 – 66 –
Control Arm Mounting Bolt

55 – 70

41 – 52

–
Control Arm Ball Stud Bolt

50 – 70

36 – 52

–
Stabilizer Shaft Castellated Nut 40 – 50 30 – 36 –
Stabilizer Shaft Mounting Bolt 30 – 50 22 – 36 –
Front Under Longitudinal Frame Bolts 10 – 14 – 89 – 124
Front Under Longitudinal Frame Nut 65 – 80 48 – 59 – Drive Axle–to–Hub Caulking Nut 210 155 – Crossmember Bolt 17 – 27 13 – 20 –
Strut Bar Bolts

35 – 55

25 – 41

–
ABS Front Speed Sensor Retaining Bolt 18 – 28 13 – 21 –
Wheel Hub–to–Brake Disc Bolt 55 – 75 41 – 55 –

REAR SUSPENSION 2D–15
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Suspension Type– Isolated Trailing Link
Maximum Lengthmm (in.) 394.5 ± 3 (15.53 ± 0.12)
Shock Absorber Minimum Lengthmm (in.) 257.5 ± 3 (10.14 ± 0.12)

Shock Absorber
Strokemm (in.) 137 (5.39)
Clearancemm (in.) 0
Rear Wheel Bearing No LoadNm (lb-in.) 0.137 – 0.422 (0.9 – 3.7)
Coil Spring Height (No Load)mm (in.) 291 (11.46)
Grease Type (Rear Wheel Bearing and Hub)–M–8143 ANTIF BRG GREASE
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In Shock Absorber–to–Body Bracket Nut 45 – 70 33 – 52 – Shock Absorber–to–Rear Axle Bolt 45 – 70 33 – 52 – Trailing Arm–to–Rear Axle Bolt 80 – 90 59 – 66 – Trailing Arm–to–Body Bracket Bolt 70 – 90 55 – 66 – Lateral Rod–to–Body Bracket Bolt 50 – 70 37 – 52 – Lateral Rod–to–Rear Axle Nut 35 – 55 25 – 41 – Rear Axle Castellated Nut* – – – ABS Rear Speed Sensor Retaining Bolt 9 – 13 – 80 – 11 5

Rear Axle Castellated Nut : Refer to Section 4E, Rear Drum Brakes

3B –12 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Description

Unit

Standard

Limit
Inner

–Tripot Joint

– Type
Outer

–Rzeppa Joint

–
Right

mm (in.)553.5(21.79)

– Length
Left

mm (in.)386.5(15.22)

– Drive AxleShaft Diameter

mm (in.)22 (0.87)

–


Inner

g (ounce)90 – 100
(3.2 – 3.5)

–


Grease Capacity
Outer

g (ounce)80 – 90
(2.8 – 3.2)
–
FASTENER TIGHTENING SPECIFICATIONS
Application N
m Lb-Ft Lb-In
Control Arm Ball Joint Bolt 50 – 70 36 – 52 –
Tie Rod End Joint castellated Nut 30 – 55 21 – 41 –
Stabilizer Bar Bolt 33 – 53 24 – 39 –
Stabilizer Bar Castellated Nut40 – 5030 – 36–
Drive Axle Shaft Nut 210 155 –
Wheel Nut 90 – 11 0 66 – 81 –
Transaxle Under Cover Bolt35 – 5525 – 41–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–

FIVE-SPEED MANUAL TRANSAXLE 5B–9
DAEWOO M-150 BL2
CHECKING FLUID LEVEL
Check for a leak in the area of transaxle case and seal-
ing and then check fluid level and condition after remov-
ing oil level plug.
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Remove the oil level plug and check the fluid level.
4. The fluid should slightly flow out from the oil level plug
hole.
5. If the level is low, add the recommended fluid through
the oil level plug hole until the fluid begins to run out.
6. If the fluid is contaminated or discolored, replace it
with the recommended fluid.
7. Reinstall the oil level plug and tighten it securely.
D103B301
CHANGING FLUID
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Drain the fluid after removing the drain plug.
4. Reinstall the drain plug and tighten it securely after
coating sealant.
5. Remove the oil level plug and replenish the fluid until
it begins to run out.
a. Oil drain plug.
b. Oil level plug.
6. Reinstall the oil level plug and tighten it securely.Fluid Specification
75W-85(GL-4)
Fluid Capacity2.1L(2.21qt)
Service intervalRefer to Owner’s Manual
CHECKING TRANSAXLE NOISE
Many noises that appear to come from the transaxle
may actually originate with other sources such as tires,
road surfaces, wheel bearings, or engine and exhaust
system.
Identify the cause of any noise before attempting to re-
pair the clutch, the transaxle, or their related linkages.
To verify suspected transaxle noises,
1. Select a smooth, level asphalt road to reduce tyre
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lubri-
cants thoroughly.
3. Record the speed and the gear range of the transaxle
when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle oper-
ates in.

Drive – Under a light acceleration or a heavy pull.

Float – Maintaining a constant speed with a light
throttle on a level road.

Coast – With the transaxle in gear and the throttle
partly or fully closed.

All of the above.
CHECKING BEARING NOISE
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre-
loaded, a differential side bearing noise should not di-
minish much when the differential/transaxle is run with
the wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre-loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.

FIVE-SPEED MANUAL TRANSAXLE 5B–53
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
5th/Reverse Gear Shift Shaft Bolt10 – 167 – 12–
Back Up Light Switch Nut15 – 1811 – 13–
Counter Shaft 5th Gear Nut60 – 8044 – 59–
Crankshaft Position Sensor Bolt5 – 8–44 – 70
Differential Ring Gear Bolt80 – 10059 – 74–
Engine Mounting Front Bracket Bolt
(Cylinder Block Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolt
(Crossmember Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolts
(Crossmember Side)45 – 5533 – 41–
Engine Mounting Front Damping Bush Bolt/Nut
(Bracket Side)68 – 8351 – 61–
Front Exhaust Pipe Nut
(Exhaust Manifold Side/Muffler Side)25 – 3518 – 25–
Gear Shift Control Case Bolt18 – 2813 – 21–
Gear Shift Lever Bolt4 – 7–35 – 62
High Speed Shift Shaft Bolt10 – 167 – 12–
Low Speed Shift Shaft Bolt10 – 167 – 12–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–
Radiator Lower Hose Bracket Bolts8 – 15–70 – 132
Reverse Idle Gear Shaft Bolt18 – 2813 – 21–
Reverse Shift Lever Bolt18 – 2813 – 21–
Select Cable Nut(Shift Lever Side)8 – 12–71 – 106
Select Lever Bolt18 – 2813 – 21–
Side Cover Plate Screw6 – 7–53 – 62
Shift Guide Bolt18 – 2813 – 21–
Shift Interlock Bolt18 – 2813 – 21–
Side Cover Bolt8 – 12–71 – 106
Speedometer Driven Gear Bolt4 – 7–35 – 62
Starter Motor Bolt18 – 2813 – 21–
Transaxle Case Bolt15 – 2211 – 16–
Transaxle Case(left) Cap Bolt8 – 12–71 – 106
Transaxle Lower Bolt and Nut(Engine Side)55 – 6541 – 48–
Transaxle Mounting Bolt(Body Side)45 – 5533 – 41–
Transaxle Mounting Bolt and Nut(Transaxle Side)55 – 6541 – 48–
Transaxle Upper Bolt(Engine Side)55 – 6541 – 48–
Transaxle Under Cover Bolt35 – 5525 – 41–