2003 DAEWOO MATIZ check engine

1F–308 ENGINE CONTROLS
DAEWOO M-150 BL2
D102F516
6. Remove the fuel tank.
Lower slowly the jack to remove the fuel tank easi-
ly (1).
Disconnect the canister hose which is connected
to the roll over valve from the fuel tank removed
(2).
Inspect the fuel tank for clacks, damages, and con-
taminations.
Inspect the fuel lines for cracks and damages.
D12F517A
Installation Procedure
1. Install in the reverse order of removal.
After the installation is complete, start the engine
to prevent the vapor lock and check the hoses for
leaks.
2. Install the fuel tank strap bolts.
Tighten
Tighten the fuel tank strap bolts to 18–22 Nm (13–16
lb-ft).
D102F519
D102F518
FUEL RAIL AND INJECTORS
Removal Procedure
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.
1. Relieve the fuel system pressure.
Refer to “Fuel Pump” in this section.
2. Remove the canister from the engine room. Refer to
“Evaporative Emission Canister” in this section.
3. Disconnect the fuel inlet line (1).
4. Disconnect the fuel injector harness connectors (2).

ENGINE CONTROLS 1F–309
DAEWOO M-150 BL2
D102F520
5. Remove the fuel rail with the fuel injectors attached.
Remove the bolts (1).
Remove the fuel rail with the fuel injectors attached
(2).
Notice: Before removal, the fuel rail assembly may be
cleaned with a spray–type cleaner, following package in-
structions. Do not immerse the fuel rails in liquid clean-
ing solvent. Use care in removing the fuel rail assembly
to prevent damage to the electrical connectors and the
injector spray tips. Prevent dirt and other contaminants
from entering open lines and passages. Fittings should
be capped and holes plugged during service.
D102F521
6. Remove the injectors from the fuel rail.
Remove the fuel injector retainer clips (1).
Remove the fuel injectors by pulling them down
and out (2).
Discard the fuel injector O–rings (3).
Important: Different fuel injectors are calibrated for dif-
ferent flow rates. When ordering new fuel injectors, be
certain to order the identical part number that is in-
scribed on the old fuel injector.
D12F522A
18–22 Nm
Installation Procedure
1. Install in the reverse order of removal.
Important: If a fuel injector becomes separated from
the fuel rail and remains in the cylinder head, replace the
fuel injector O–ring seals and the retaining clip.
Lubricate the new fuel injector O–rings with engine
oil. Install the new O–rings on the fuel injectors.
2. Install the fuel rail retaining bolts.
Tighten
Tighten the fuel rail retaining bolts to 18–22 Nm
(13–16 lb-ft).
3. Perform a leak check of the fuel rail and the fuel injec-
tors.
MAA1F400
EVAPORATIVE EMISSION CANISTER
Removal Procedure
Caution: Canister and vacuum hoses contain fuel
vapors. Do not smoke in the area or permit an open
flame.
1. Disconnect the negative battery cable.
2. Remove the canister.
Remove the bolt (1).
Remove the nut, then remove the cover (2).

1F–312 ENGINE CONTROLS
DAEWOO M-150 BL2
D102F539
4. Disconnect the coolant hoses and vacuum hoses
from the throttle body.
Loosen the clamps from the coolant hoses (1).
Disconnect the coolant hoses from the throttle
body (2).
Disconnect the vacuum hoses (3).
D102F541
5. Remove the throttle body from the intake manifold.
Remove the throttle body bolts (1).
Remove the throttle body (2).
Discard the throttle body gasket (3).
Inspect the throttle body gasket for the deforma-
tion and the damages.
9–12 Nm
D12F542A
Installation Procedure
1. Install in the reverse order of removal.
Important: Make sure the throttle control cable do not
hold the throttle open. With the engine OFF, check to
see that the accelerator pedal is free.
2. Install the throttle body with the bolts.
Tighten
Tighten the throttle body bolts to 9–12 Nm (80–106
lb-in).
D12F543A
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
Removal Procedure
1. Remove the engine coolant temperature (ECT) sen-
sor. Refer to Section 1D, Engine Coolings.

1G – 2 ENGINE EXHAUST
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
EXHAUST SYSTEM
Notice: When you are inspecting or replacing exhaust
system components, make sure there is adequate clear-
ance from all points on the underbody to avoid possible
overheating of the floor pan and possible damage to the
passenger compartment insulation and trim materials.
Check the complete exhaust system and the nearby
body areas and tailgate for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connec-
tions or other deterioration which could permit exhaust
fumes to seep into the luggage or passenger compart-
ment. Dust or water in the luggage may be an indication
of a problem in one of these areas. Any defects should
be corrected immediately.
MUFFLER
The muffler reduces the temperature, pressure, and
noise of the exhaust gas.
Aside from the exhaust manifold connection, the ex-
haust system uses a flange and seal joint design op-
posed to a slip joint coupling design with clamp. If holes,
open seams or any deterioration is discovered upon in-
spection of the front muffler and pipe assembly, thecomplete assembly should be replaced. The same pro-
cedure is applicable to the rear muffler assembly.
Heat shields in the front and rear muffler assembly posi-
tions, as well as for the catalytic converter and front ex-
haust pipe, protect the vehicle and the environment from
high temperatures the exhaust system develops.
CATALYTIC CONVERTER
Notice: When jacking or lifting the vehicle from the body
side rails, be certain that the lift pads do not contact the
catalytic converter as this could damage the catalytic
converter.
Notice: The catalytic converter requires the use of un-
leaded fuel only, or damage to the catalyst will result.
The catalytic converter is an emission control device
added to the exhaust system to reduce pollutants from
the exhaust pipes.
The oxidation catalyst is coated with a catalytic material
containing platinum and palladium, which reduces levels
of hydrocarbon (HC) and carbon monoxide (CO) from
the exhaust gas. The three-way catalyst has coatings
which contain platinum and rhodium, which additionally
lower the levels of oxides of nitrogen (NOx).

1G–4 ENGINE EXHAUST
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
MAA1G010
EXHAUST PIPE/CATALYTIC
CONVERTER
Caution : Make sure to confirm that the components
is cool. And do work.
Removal Procedure
1. Remove the floor console. Refer to Section 9G, Inte-
rior Trim, if equipped Heated Oxygen Sensor (HO2S).
2. Disconnect HO2S connector.
D102G501
3. Remove the front exhaust pipe from the exhaust
manifold or pup-up catalytic converter.

Remove the nuts (1).

Remove the gasket (2).
4. Check the gasket for damage or crack.
D102G502
5. Remove the front exhaust pipe from the front muffler
pipe.

Remove the nuts (1).

ENGINE EXHAUST 1G–5
DAEWOO M-150 BL2
D102G503
6. Remove the front exhaust pipe and the catalytic con-
verter assembly.
a. Front exhaust pipe.
b. Catalytic converter.
7. Clean the sealing surfaces on the front exhaust pipe
flange and the exhaust manifold.
8. Check the exhaust pipe and the catalytic coverter for
holes, damage, open seams, or other deterioration
which could permit exhaust fumes to seep into the
passenger compartment.
D12G504A
25–35 Nm
25–35 Nm
Installation Procedure
1. Using the nuts and the gasket, secure the front ex-
haust pipe and the catalytic converter assembly to
the exhaust manifold.
Tighten
Tighten the nuts to 25–35 Nm (18–25 lb-ft).
a. Front exhaust pipe nut.
2. Install the front exhaust pipe and the catalytic con-
verter assembly to the front muffler pipe flange. Use
the nuts to secure the front exhaust pipe and the cat-
alytic converter assembly.
Tighten
Tighten the nuts to 25–35 Nm (18–25 lb-ft).
b. Front muffler pipe nut.
Notice : Make sure not to contact the components with
the underbody.
3. Connect the Heated Oxygen Sensor (HO2S) connec-
tor.
4. Install the floor console. Refer to Section 9G, Interior
Trim.
D102G501
PUP-UP CATALITIC CONVERTER
Removal Procedure
1. Remove the front exhaust pipe from the pup-up cata-
litic converter.

Remove the nuts (1).

Remove the gasket (2).
2. Check the gasket for damage or leak.

2B – 2 WHEEL ALIGNMENT
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
FOUR WHEEL ALIGNMENT
The first responsibility of engineering is to design safe
steering and suspension systems. Each component
must be strong enough to withstand and absorb extreme
punishment. Both the steering system and the front and
the rear suspension must function geometrically with the
body mass.
The steering and the suspension systems require that
the front wheels self-return and that the tire rolling effort
and the road friction be held to a negligible force in order
to allow the customer to direct the vehicle with the least
effort and the most comfort.
A complete wheel alignment check should include mea-
surements of the rear toe and camber.
Four-wheel alignment assures that all four wheels will be
running in precisely the same direction.
When the vehicle is geometrically aligned, fuel economy
and tire life are at their peak, and steering and perfor-
mance are maximized.
TOE
D16A006A
Toe–in is the turning in of the tires, while toe–out is the
turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the
wheel support system which occur when the vehicle is
rolling forward. The specified toe angle is the setting
which achieves–degrees (0
) of toe when the vehicle is
moving.
Incorrect toe-in or toe-out will cause tire wear and re-
duced fuel economy. As the individual steering and sus-
pension components wear from vehicle mileage,
additional toe will be needed to compensate for the
wear.
Always correct the toe dimension last.
CASTER
D16A008A
Caster is the tilting of the uppermost point of the steering
axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is
positive, and a forward tilt is negative. Caster influences
directional control of the steering but does not affect tire
wear. Weak springs or overloading a vehicle will affect
caster. One wheel with more positive caster will pull to-
ward the center of the car. This condition will cause the
car to move or lean toward the side with the least
amount of positive caster. Caster is measured in de-
grees and is not adjustable.
CAMBER
D16A007A
Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the
tires tilt outward, the camber is positive. When the tires
tilt inward, the camber is negative. The camber angle is
measured in degrees from the vertical. Camber in-
fluences both directional control and tire wear.
If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Camber is measured in degrees and is not adjustable.

4A –4 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DIAGNOSITIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily
braked, but turning, wheels will stop the vehicle in less
distance than locked brakes. More tire-to-road friction is
present with a heavily braked, turning tire than with a
sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:

Tires having unequal contact and grip of the road will
cause unequal braking. Tires must be equally in-
flated, and the tread pattern of the right and the left
tires must be approximately equal.

Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.

Misalignment of the wheels, particularly conditions of
excessive camber and caster, will cause the brakes
to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and the
shift lever in NEUTRAL. If the pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking. Perform a visual check to confirm any sus-
pected leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an
abnormally low level indicates a leak in the system. The
hydraulic system may be leaking either internally or ex-
ternally. Refer to the procedure below to check the mas-
ter cylinder. Also, the system may appear to pass this
test while still having a slight leak. If the fluid level is nor-
mal, check the vacuum booster pushrod length. If an in-
correct pushrod length is found, adjust or replace the
rod.Check the master cylinder using the following proce-
dure:

Check for a cracked master cylinder casting or brake
fluid leaking around the master cylinder. Leaks are in-
dicated only if there is at least one drop of fluid. A
damp condition is not abnormal.

Check for a binding pedal linkage and for an incorrect
pushrod length. If both of these parts are in satisfac-
tory condition, disassemble the master cylinder and
check for an elongated or swollen primary cylinder or
piston seals. If swollen seals are found, substandard
or contaminated brake fluid should be suspected. If
contaminated brake fluid is found, all the components
should be disassembled and cleaned, and all the rub-
ber components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, then the rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston seals on the
drum brake wheels.
If rubber deterioration is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep al-
cohol out of the system. Replace all the rubber parts in
the system, including the hoses. Also, when working on
the brake mechanisms, check for fluid on the linings. If
excessive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush the
master cylinder with brake fluid, refill the master cylin-
der, and bleed the system. Refer to “Manual Bleeding
the Brakes” in this section.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of the
outer cover, and for leaks or blisters. Inspect the hoses
for proper routing and mounting. A brake hose that rubs
on a suspension component will wear and eventually
fail. A light and a mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as neces-
sary.