2003 DAEWOO MATIZ tow

FIVE-SPEED MANUAL TRANSAXLE 5B–33
DAEWOO M-150 BL2
D13B735A
13. Install the counter shaft bearing shim.

Measure clearance between the transaxle case
surface and the bearing outer race using a
straight ruler and gauge.

Select shim in order that clearance is within stan-
dard.
Unit : mm (in.)
Measured value (A) Shim thickness
0.33 − 0.37 (0.0130 – 0.0146) 0.45 (0.0177)
0.38 − 0.42 (0.0147 – 0.0165) 0.50 (0.0197)
0.43 − 0.47 (0.0169 – 0.0185) 0.55 (0.0217)
0.48 − 0.52 (0.0189 – 0.0205) 0.60 (0.0236)
0.53 − 0.57 (0.0209 – 0.0224) 0.65 (0.0256)
0.58 − 0.62 (0.0228 – 0.0244) 0.70 (0.0276)
0.63 − 0.67 (0.0248 – 0.0264) 0.75 (0.0295)
0.68 − 0.72 (0.0268 – 0.0283) 0.80 (0.0315)
0.73 − 0.77 (0.0287 – 0.0303) 0.85 (0.0335)
0.78 − 0.82 (0.0307 – 0.0323) 0.90 (0.0354)
0.83 − 0.87 (0.0327 – 0.0343) 0.95 (0.0374)
0.88 − 0.92 (0.0346 – 0.0362) 1.00 (0.0394)
0.93 − 0.97 (0.0366 – 0.0382) 1.05 (0.0413)
0.98 – 1.02 (0.0386 – 0.0402) 1.10 (0.0433)
1.03 – 1.07 (0.0406 – 0.0421) 1.15 (0.0453)
a. Straight ruler
b. Bearing outer race
c. Case surface
D13B736A
14. Install the side cover plate and the counter shaft fifth
gear.

Install the side cover plate (1).
Tighten
Tighten the screws to 6–7 N.m (53–62 lb–in).
Important: Use only new screws.

Install the counter shaft fifth gear (2).
Important: Position the machined boss side toward the
side cover plate.

5B–34 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B737A
15. Install the counter shaft fifth gear nut.

Shift the shift yoke using a screwdriver to engage
the first–gear and the third–gear or the second–
gear and the fourth–gear (1).
Tighten
Tighten the fifth gear nut to 60–80 Nm (44–59 lb-ft).

Caulk the nut using a chisel and a hammer (2).
D103B710
16. Install the input shaft fifth gear bearing and the fifth
gear / synchronizer ring.

Insert the bearing into the input shaft.

Install the fifth gear, wave spring and synchroniz-
er ring matching synchronizer’s oil groove and in-
put shaft punched mark (1).
D103B738
17. Install the fifth gear synchronizer hub assembly.

Install the synchronizer springs to hub (1).

Install the synchronizer key (2).
Important: In case of assembling synchronizer sleeve
and hub, let A=B.

Position the longer boss side of hub toward inner
side (3).

Position the chamfered spline of sleeve toward
inner side and install the hub to the sleeve (4).
D103B739
18. Install the fifth gear fork to the synchronizer hub as-
sembly.
19. Install the fifth gear fork and the synchronizer hub
assembly to the input shaft.
Important: Position the longer boss side of hub toward
inner side and match the synchronizer key and the hub
groove with the input shaft punched mark.

FIVE-SPEED MANUAL TRANSAXLE 5B–35
DAEWOO M-150 BL2
D103B740
20. Install the fifth gear shift fork pin.

Push the shift fork toward the fifth gear.

Install the shift fork pin using a pin punch and a
hammer(1).
Important: Use only new shift fork pin.
D103B741
21. Install the input shaft fifth gear snap ring, the fifth
gear shift fork snap ring and guide ball.

Install the fifth gear synchronizer plate.

Install the fifth gear snap ring (1).

Install the fork snap ring (2).
Important: Use only new snap ring.

Tighten the fork plug after inserting the guide ball
into the fork hole.
D13B742A
22. Install the side cover(1).

Coat the side cover with recommended sealant.
Side Cover Sealant THREE BOND 1215
Tighten
Tighten the side cover bolts to 8–12 Nm (71–106
lb-in).
D13B743A
23. Install the gear shift control case assembly.

Install the case gasket.

Install the gear shift control case.
Tighten

Tighten the bolts to 18–28 Nm (13–21 lb-ft) (a).

Tighten the shift interlock bolt to 18–28 Nm (13–
21 lb-ft) (b).

Install the select lever.
Tighten
Tighten the bolts to 18–28 Nm (13–21 lb-ft) (c).

5B–40 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B759
2. Assemble the third–fourth synchronizer hub assem-
bly.

Install the synchronizer springs to the hub.

Install the synchronizer key to the hub.
Important: In case of assembling the synchronizer
sleeve and the hub, let A=B.

Install the hub to the sleeve.
a. Sleeve.
b. Hub.
D103B760
3. Install the third–fourth synchronizer hub assembly.

Insert the hub assembly into the input shaft (1).
Important: Position the longer flange of hub toward the
third gear and match the key and the ring groove.

Install the hub assembly using a hammer and the
gear, bearing installer DW09940–53111.
D13B761A
Notice: When installing gear, bearing and hub assem-
bly, install them slowly using the gear, bearing installer
DW09940–53111 and a hammer. If overpressed, the
gear teeth may be damaged.
D103B749
4. Install the third–fourth synchronizer circlip.
5. Install the fourth synchronizer ring and wave spring.
Important: Match the ring groove to the key of hub.

6C –6 POWER STEERING GEAR
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
RACK AND PINION ASSEMBLY
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the intermediate shaft lower pinch bolt. Re-
fer to Section 6E, Steering Wheel and Column.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. Remove the tie rod ends. Refer to Section 6D, Manu-
al Steering Gear.
4. Remove the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
D105C534
5. Remove the rack and pinion assembly.

Disconnect the return line pipe from the steering
gear (1).

Disconnect the pressure inlet line pipe from the
steering gear (2).

Plug the opening in the power steering pipe line to
prevent fluid loss and contamination.
D105C535

Remove the power steering gear retaining bracket
tighten bolts (3).

Remove the power steering gear retaining bracket
(4).
Important: After moving the gear toward the passenger
side and pulling the gear of the driver side into the un-
derbody hole, remove the steering gear.

MANUAL STEERING GEAR 6D–13
DAEWOO M-150 BL2
D105B708
4. Remove the rack bearing.

Remove the adjuster plug (1).

Remove the adjuster spring (2).
D105B709
5. Remove the pinion and bearing assembly.

Remove the dust cover (1).

Remove the pinion plug (2).
Important: Do not reuse the removed pinion plug.
D105B710

Remove the pinion and bearing assembly (3).
D105B711
6. Remove the rack gear toward the driver side of the
steering gear.
a. Rack gear.
Notice: Remove the rack gear toward the driver side of
the steering gear to prevent the bulk head in the steering
gear housing from damaging in installing and removing
the rack gear.

7A–2 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
DESCRIPTION AND SYSTEM OPERATION
HEATING AND VENTILATION
SYSTEMS
The base heater system is designed to provide heating,
ventilation, windshield defrosting, and side window de-
fogging.
The heater and fan assembly blower regulates the air-
flow from the air inlet for further processing and distribu-
tion.
The heater core transfers the heat from the engine cool-
ant to the inlet air.
The temperature door regulates the amount of the air
that passes through the heater core. The temperature
door also controls the temperature of the air by control-
ling the mix of the heated air and the ambient air.
The mode door regulates the flow and the distribution
of the processed air to the heater ducts and to the de-
froster ducts.
This console-mounted heating and ventilation panel
contains the following:
Three Rotary Control Knobs
1. The Rotary Temperature Control Knob

Actuates by cable.

Raises the temperature of the air entering the ve-
hicle by rotation toward the right, or the red portion
of the knob.
2. The Rotary Blower Control Knob

Turns on to operate the blower motor at four speeds.

Turns
to stop the blower.

Operates completely independently both from the
mode control that regulates the defroster door and
from the temperature control knob.
Changes the fan speed in any mode and at any
temperature setting.
3. The Rotary Mode Control Knob:

Actuates by cable.

Regulates the air distribution between the wind-
shield, the instrument panel, and the floor vents.
Push Knobs
1. The Rear Window Defogger Push Knob

Controls the rear window defogger.

Turns ON the rear window defogger when the push
knob is pressed and the indicator lamp is illumi-
nated.
2. The A/C Push Knob (if the vehicle is equipped with air
conditioning)

Controls the A/C.

Turns the A/C ON when the push knob is down.
However, if the blower control knob is OFF, the A/C
system is OFF, regardless of the position of the
A/C knob.
One Lever
1. The Fresh Air Control Lever

Operates by cable.

Switches between recirculating passenger compart-
ment air and bringing outside air into the passenger
compartment.

Draws in outside air when the lever is moved to the
left.

Recirculates inside air when the lever is moved to
the right.

7B–2 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
SYSTEM COMPONENTS
–FUNCTIONAL
Compressor
All compressors are belt–driven from the engine crank-
shaft through the compressor clutch pulley. The com-
pressor pulley rotates without driving the compressor
shaft until on electromagnetic clutch coils energized.
When voltage is applied to energize the clutch coil, the
clutch plate and hub assembly are drawn toward the
pulley. The magnetic force locks the clutch plate and
pulley together as one unit to drive the compressor
shaft.
Condenser Core
The condenser assembly in front of the radiator consists
of coils which carry the refrigerant and cooling fins that
provide the rapid transfer of heat. The air passing
through the condenser cools the high–pressure refriger-
ant vapor and cause it to condense into a liquid.
Expansion Valve
The expansion valve is located on the passenger
compartment side of the dash panel. The expansion
valve can fail in three different positions: open, closed,
or restricted. An expansion valve that fails in the open
position will result in a noisy A/C compressor or no cool-
ing. The cause can be a broken spring, a broken ball, or
excessive moisture in the A/C system. If the spring or
the ball is found to be detective, replace the expansion
valve. If excessive moisture is found in the A/C system,
recycle the refrigerant. An expansion valve that fails in
the closed position will result in low suction pressure and
no cooling. This may be caused by a failed power done
or excessive moisture in the A/C system. If the power
dome on the expansion valve is found to be defective,
replace the expansion valve. If excessive moisture is
found in the A/C system, recycle the refrigerant.
A restricted expansion valve will result in low suction
pressure and no cooling. This may be caused by debrisin the refrigerant system. If debris is believed to be
cause, recycle the refrigerant, replace the expansion
valve, and replace the receiver/dryer.
Evaporator Core
The evaporator is device which cools and dehumidifies
the air before it enters the vehicle. High–pressure liquid
refrigerant flows through the expansion tube (orifice)
and becomes a low–pressure gas in the evaporator. The
heat in the air passing through the evaporator core is
transferred to the cooler surface of the core, which cools
the air. As the process of heat transfer from the air to the
evaporator core surface is taking place, any moisture
(humidity) in the air condenses on the outside surface of
the evaporator core and is drained off as water.
Receiver–Dryer
The sealed receiver–dryer assembly is connected to the
evaporator outlet pipe. It acts as a refrigerant storing
container, receiving liquid and some vapor and refriger-
ant oil from the evaporator.
At the bottom the receiver–dryer is the desiccant, which
acts as a drying agent for the moisture that may have
entered the system. The receiver–dryer is serviceable
only as an assembly.
Dual Cut Switch
The dual cut switch controls compressor operation when
the cycling refrigerant pressure is dropped or surged.
Evaporator Thermistor
A semiconductor which resistance is noticeably changed
as the change of temperature. When the refrigerant tem-
perature of the evaporator drops to 0
C (32
F) and be-
low, the evaporator cores get stuck with frost or ice,
reducing the airflow, lowering the cooling capacity. The
thermistor is a sensor which is used to prevent from frost-
ing or icing.
The thermistor is installed on the evaporator.