2003 DAEWOO MATIZ suspension

FRONT SUSPENSION 2C–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D16B501A
STRUT ASSEMBLY
Removal Procedure
1. Open the hood.
2. Remove the top of the strut assembly at passenger
seat side.

For vehicle with power steering, remove the power
steering fluid reservoir (1).

Remove the nuts (2).
D16B502A
3. Remove the top of the strut assembly at driver side.

Remove the bolt and the fuse box (1, 2).

Remove the nuts (3).
D106B503
4. Remove the lower of the strut assembly.

Raise and suitably support the vehicle.

Remove the wheel. Refer to Section 2E, Tires and
Wheels.

Remove the ABS front speed sensor electrical wire
from the bracket, if applicable (1).

Disconnect the brake hose from the bracket (2).

Remove the strut bracket bolts (3).
5. Remove the strut bracket assembly from the vehicle.

2C –8 FRONT SUSPENSION
DAEWOO M-150 BL2
D16B504A
70–90 Nm
Installation Procedure
1. Install the strut assembly to the vehicle with the strut
assembly–to–strut bracket bolts.
Tighten
Tighten the strut assembly–to–strut bracket bolts to
70–90 Nm (52–66 lb-ft).
2. Connect the brake hose to the bracket.
3. Install the ABS front speed sensor electrical wire to
the bracket, if applicable.
D16B505A
18–28 Nm
18–28 Nm4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
6. Install the nuts.

Install the nuts at passenger side (1).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).

Install the nuts at driver side (2).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).
7. Install the power steering fluid reservoir.
8. Install the fuse box and bolt.
D106B506
KNUCKLE ASSEMBLY
Tools Required
KM 507–B Ball Joint Remover
Removal Procedure
1. Remove the caulking nut.

Straighten the bent flange caulking nut (1).

Remove the caulking nut (2).

Remove the washer (3).
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
D105B501
3. Separate the tie rod end from the knuckle assembly.

Remove the cotter pin (1).

Remove the castellated nut (2).

Install the ball joint remover KM 507–B.

Separate the tie rod end from the knuckle assem-
bly using a ball joint remover KM 507–B (3).

FRONT SUSPENSION 2C–9
DAEWOO M-150 BL2
D106B507
4. Remove the control arm from the knuckle assembly.

Remove the stud bolt (1).

Separate the control arm from the knuckle assem-
bly (2).
D106B508
5. Remove the brake caliper from the knuckle assembly.
Refer to Section 4D, Front Disc Brakes.
6. Remove the ABS wheel speed sensor from the
knuckle assembly, if applicable. Refer to Section 4F,
Anti–lock Brake System.
7. Remove the steering knuckle assembly from the ve-
hicle.

Remove the strut bracket bolts (1).

Separate the knuckle assembly from the drive
shaft by pulling the steering knuckle assembly (2).
D16B509A
70–90 Nm
50–70 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the steering knuckle assembly in the vehicle
with strut bracket bolts (1).
Tighten
Tighten the strut bracket bolts to 70–90 Nm (52–66
lb-ft).
3. Install the brake caliper from the knuckle assembly.
4. Install the control arm into the knuckle assembly with
the stud bolt (2).
Tighten
Tighten the stud bolt to 50–70 Nm (36–52 lb-ft).
D16B510B
5. Install the tie rod end to the knuckle assembly.
6. Install the tie rod end–to–knuckle castellated nut (1)
and the cotter pin.
Tighten
Tighten the castellated nut to 30–55 Nm (22–41 lb-
ft).
7. Install the caulking nut (2).

Bend the caulking nut flange (3).
Tighten
Tighten the caulking nut to 210 Nm (155 lb-ft).

2C –10 FRONT SUSPENSION
DAEWOO M-150 BL2
D106B511
FRONT LONGITUDINAL FRAME AND
STABILIZER SHAFT
Removal Procedure
1. Removed the front under longitudinal frame.

Raise and suitably support the vehicle.

Remove the front wheel. Refer to Section 2E, Tires
and Wheels.

Remove the transaxle under cover. Refer to Sec-
tion 5B, Manual Transaxle.

Remove the front under longitudinal frame bolt (1).

Remove the front under longitudinal frame nut (2).
D16B512A

Remove the stabilizer shaft mounting bolts (3).

Remove the front under longitudinal frame.
D106B513
2. Remove the stabilizer shaft from the vehicle.

Remove the cotter pin (1).

Remove the castellated nut (2).

Remove the washer (3).

Remove the rear bushing with separating the sta-
bilizer shaft from the control arm (4).
D16B514A

Remove the bushing (5).

Remove the wire clamps (6).

Remove the mountings (7).

FRONT SUSPENSION 2C–11
DAEWOO M-150 BL2
D16B515A
Installation Procedure
1. Install in the reverse order of removal.
Important: When installing the mountings, position the
opened mountings forward.
D16B516A
40–50 Nm2. Install the stabilizer shaft to the vehicle.

Install the castellated nut.
Tighten
Tighten the stabilizer shaft–to–body castellated nut to
40–50 Nm (30–36 lb-ft).

Install the cotter pin.
D16B517C
3. Install the front under longitudinal frame.

Install the stabilizer shaft mounting bolts (1).
Tighten
Tighten the mounting bolts to 30–50 Nm (22–36 lb-
ft).
D16B518B
65 – 80 Nm
10 – 14 Nm
Install the front under longitudinal frame bolt (2).
Tighten
Tighten to bolt to 10–14 Nm (89–124 lb-in).

Install the front under longitudinal frame nut (3).
Tighten
Tighten to nut to 65–80 Nm (48–59 lb-ft).

2C –12 FRONT SUSPENSION
DAEWOO M-150 BL2
D106B519
CONTROL ARM
Removal Procedure
1. Remove the stabilizer shaft. Refer to “Front Longitu-
dinal Frame and Stabilizer Shaft” in this section.
2. Remove the control arm.

Remove the stud bolt (1).

Separate the control arm from the knuckle assem-
bly using a lever (2).
D106B520

Remove the bolt (3).

Remove the control arm.
D16B521B
Installation Procedure
1. Install the control arm onto the vehicle.

Install the control arm bolt (1).
Tighten
Tighten the control arm bolt to 55–70 Nm (41–52 lb-
ft).

Install the control arm to the knuckle assembly.

Install the stud bolt (2).
Tighten
Tighten the stud bolt to 50–70 Nm (36–52 lb-ft).
2. Install the stabilizer shaft.
D10B522A
STRUT BAR
Removal Procedure
1. Open the hood.
2. Remove the strut bar from the vehicle.

Remove the purge control valve (1).

Remove the A/C low pressure pipe bracket–to–
strut bar nut (2).

Remove the strut bar bolts at passenger side (3).

FRONT SUSPENSION 2C–13
DAEWOO M-150 BL2
D106B523

Remove the strut bar bolts at driver side (4).
Important: When removing the bolts using the tool,
do not contact the battery terminal.

Remove the strut bar at passenger side
D16B524B
Installation Procedure
1. Install the strut bar to the vehicle.

Install the strut bar at passenger side.

Install the strut bar bolts at driver side (1).
Important: When installing the bolts using the tool, do
not contact the battery terminal.

Install the strut bar bolts at passenger side (2).

Install the A/C low pressure pipe bracket–to–strut
bar nut.
Tighten
Tighten the strut bar bolts to 35–55 Nm (25–41 lb-ft).

Install the purge control valve to the strut bar.
D106B525
CROSSMEMBER
Removal Procedure
1. Remove the transaxle under cover. Refer to Section
5B, Five–Speed Manual Transaxle.
2. Remove the front under longitudinal frame. Refer to
“Stabilizer Shaft” in this section.
3. Remove the damping bush bolt and nut.
D106B526
4. Disconnect the power steering pressure line from the
crossmember. Refer to Section 6B, Power Steering
Pump.
5. Remove the crossmember from the vehicle.

Place support jack under the crossmember.

Remove the bumper fascia screws.

Remove the rear bolts (1).

Remove the side bolts (2).

Lower the support jack and remove the crossmem-
ber from the vehicle.

2C –14 FRONT SUSPENSION
DAEWOO M-150 BL2
D106B527
D106B528
6. Remove the front damping bush bolts and damping
bush from the crossmember.
D16B529A
35–41 Nm
45–55 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the front damping bush to the crossmember.
Tighten

Tighten the bolts to 45–55 Nm (33–41 lb-ft).
a. Front damping bush bolt.

Tighten the bolt to 35–41 Nm (25–30 lb-ft).
b. Front damping bush bolt.
D16B530A
17–27 Nm
17–27 Nm3. Install the crossmember to the vehicle with the bolts.
Tighten
Tighten the bolts to 17–27 Nm (13–20 lb-ft).
a. Crossmember right rear bolt.
b. Crossmember right side bolt.