2003 DAEWOO MATIZ oil pressure

ANTILOCK BRAKE SYSTEM 4F–3
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
ABS SYSTEM COMPONENTS
The Antilock Braking System (ABS) consists of a con-
ventional hydraulic brake system plus antilock compo-
nents. The conventional brake system includes a
vacuum booster, master cylinder, front disc brakes, rear
drum brakes, interconnecting hydraulic brake pipes and
hoses, brake fluid level sensor and the BRAKE indicator.
The ABS components include a hydraulic unit, an elec-
tronic brake control module (EBCM), two system fuses,
four wheel speed sensors (one at each wheel), intercon-
necting wiring, the ABS indicator, and the rear drum
brake. See “ABS Component Locator” in this section for
the general layout of this system.
HYDRAULIC UNIT
The hydraulic unit with the attached EBCM is located
between the surge tank and the fire wall on the right side
of the vehicle. The basic hydraulic unit configuration
consists of return pump motor, return pump, four isola-
tion valves, four dump valves, two Low Pressure Accu-
mulators (LPA), two High Pressure Attenuators (HPA).
The hydraulic unit controls hydraulic pressure to the
front calipers and rear wheel cylinders by modulating hy-
draulic pressure to prevent wheel lockup.
Isolation valve
The isolation valve is placed in the brake fluid path from
the master cylinder to the relevant brake caliper and al-
lows free flow as commanded by the driver during nor-
mal braking and reapply phases.
In the isolation phase the coil moves the armature down,
which closes the normally open isolation orifice and pre-
vents any further increase of pressure in the brake. The
valve also remains closed during the dump phase.
The lip seal provides a one way return path for brake
fluid to flow through in:
1. Foot off pedal during isolation.
2. Residual LPA fluid.
D107E002
Dump Valve
The dump valve creates a flow path from the isolation
cartridge (brake side) to the low pressure accumulator
(LPA). The valve keeps this path permanently closed ex-
cept during the dump phase in the ABS mode. On ac-
tivation (dump phase), the coil moves up the armature
which opens the normally closed dump orifice and allow
to drain the pressure in the brake line with the brake fluid
flowing into the LPA.
The lip seal provides a return path for residual brake
fluid in the LPA.
D107E003
Low Pressure Accumulator (LPA)
LPA provides a variable chamber for brake fluid to be
quickly pushed in through the dump valve at the begin-
ning of a departure. This chamber then acts as a reser-
voir which buffers the pump.
D107E004
High Pressure Attenuator (HPA)
The HPA is in between the pump and the ISO valve
(master cylinder side) and uses the bulk mode of the
contained plastic damper and orifice size to dump out
the pressure oscillations from the pump to reduce the

4F–8 ANTILOCK BRAKE SYSTEM
DAEWOO M-150 BL2
Master Cylinder
High Pressure Attenuator
High Pressure Attenuator
Return Pump Motor
Return Pump Return Pump
Low
Pressure
Accumulator
Low Pressure
Accumulator
RRFL FR
RL
D17E206A
RR
Isolation ValveFL
Isolation Valve
RR Dump ValveFL
Dump
ValveFR
Isolation Valve
FR Dump ValveRL
Dump
ValveRL
Isolation
Valve
ISOLATION MODE (PRESSURE MAINTAIN)
If the information from the wheel speed sensors indicate excessive wheel deceleration (imminent lockup), the first step
in the antilock sequence is to isolate the brake pressure being applied by the driver. The EBCM sends a voltage to the
coil to energize and close the isolation valves by pulling down on the armature. This prevents any additional fluid pres-
sure applied by the driver from reaching the wheel. Though each channel of the 4-channel system can operate inde-
pendently, once any front channel (brake) sees excessive deceleration, both front isolation valves are energized and
close thus, with the isolation valves closed, further unnecessary increases in the brake pressure will be prohibited.

ANTILOCK BRAKE SYSTEM 4F–9
DAEWOO M-150 BL2
Master Cylinder
High Pressure Attenuator
High Pressure Attenuator
Return Pump Motor
Return Pump Return Pump
Low
Pressure
Accumulator
Low Pressure
Accumulator
RRFL FR
RL
D17E207A
RR
Isolation ValveFL
Isolation Valve
RR Dump ValveFL
Dump
ValveFR
Isolation Valve
FR Dump ValveRL
Dump
ValveRL
Isolation
Valve
DUMP MODE (PRESSURE DECREASE)
Once the pressure is isolated, it must be reduced to get the wheels rolling once again. This is accomplished by dump-
ing a portion of the brake fluid pressure into a low pressure accumulator (LPA).
The EBCM energizes the dump cartage coil(s) to open the dump cartridge, allowing fluid from the wheels to be
dumped into the LPA. This done with very short activation pulses opening and closing the dump cartridge passageway.
Brake pressure is lowered at the wheel and allows the wheel to begin spinning again.
The fluid taken from the wheels forces the spring back and is stored in the LPA. A portion of the fluid also primes the
pump. The dump cartridges are operated independently to control the deceleration of the wheel.

5B–8 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURE
GENERAL DIAGNOSIS
ConditionProbable CauseCorrection
Gear Slipping Out of Mesh
Worn shift fork.
Replace shift fork.

Worn synchronizer sleeve or gear.
Replace sleeve or gear.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Weakened or damaged location
spring.
Replace spring.

Loose or damaged synchronizer
spring.
Replace synchronizer spring.

Excessive back-lash of gear.
Adjust back-lash of gear.
Gear Catching
Bent or distorted shift shaft or shift
fork.
Replace shift shaft or shift fork.

Weakened or damaged
synchronizer spring.
Replace spring.
Hard Shifting
Worn synchronizer ring.
Replace synchronizer ring.

Worn synchronizer sleeve or gear.
Replace sleeve or gear.

Bent or distorted shift shaft.
Replace shift shaft.

Excessive free travel of all gears
in axial direction.
Replace gear.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Poor adjustment of clutch cable.
Adjust clutch cable.

Distorted or broken clutch disc.
Replace clutch disc.

Damaged pressure plate.
Replace pressure plate.
Noise in the Neutral Gear
Insufficient lubricant.
Supply lubricant.

Worn input shaft gear.
Replace gear.

Worn bearings on the input shaft
gears.
Replace bearing.

Worn clutch release bearing.
Replace clutch release bearing.
Noise in the All Gears
Insufficient lubricant.
Supply lubricant.

Worn bearings on input shaft or
counter shaft.
Replace bearing.

Worn input shaft or counter shaft
gear.
Replace gear.

Worn or damaged synchronizer
ring.
Replace synchronizer ring.

Worn or damaged synchronizer
sleeve.
Replace synchronizer sleeve.

Worn differential gear or bearing.
Replace gear or bearing.
Noise in the Peculiar Gear
Worn or damaged synchronizer
ring in the peculiar gear.
Replace synchronizer ring.

Worn or damaged gear in the
peculiar gear.
Replace gear.

Worn or damaged bearing in the
peculiar gear.
Replace bearing.
Leak of Lubricant
Damaged gasket, oil seal or
O-ring.
Replace gasket, oil seal or O-ing.

5C –4 CLUTCH
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
ConditionProbable CauseCorrection
Slipping Clutch
Improper clutch cable adjustment.
Adjust clutch cable.

Worn or oily contamination on clutch disc
surface.
Replace clutch disc.

Worn or oily contamination on pressure
plate, flywheel surface.
Replace pressure plate, flywheel.

Damaged or weakened diaphragm spring.
Replace pressure plate.

Rusted clutch cable.
Replace clutch cable.
Dragging Clutch
Improper clutch cable adjustment.
Adjust clutch cable.

Worn or weakened diaphragm spring.
Replace pressure plate.

Worn or rusted splines of input shaft or
clutch disc.
Replace input shaft or clutch disc.

Excessively wobbly clutch disc.
Replace clutch disc.

Worn clutch disc.
Replace clutch disc.
Fails to Release
Bent or damaged clutch disc.
Replace clutch disc.

Worn or rusted splines of input shaft or
clutch disc.
Replace input shaft or clutch disc.

Improper operation of clutch release shaft.
Replace clutch release shaft.
Pedal Stays on Floor
When Disengaged
Interfered clutch release bearing.
Lubricate and adjust clutch release
bearing.

Weakened diaphragm spring.
Replace pressure plate.
Clutch Vibration
Clutch facing with oily contamination.
Replace clutch disc.

Release bearing slides unsmoothly on input
shaft bearing retainer.
Lubricate retainer release bearing.

Wobbly clutch disc or poor facing contact.
Replace clutch disc.

Loose clutch disc rivets.
Replace clutch disc.

Weakened clutch disc torsion spring.
Replace clutch disc.

Distorted pressure plate or flywheel
surface.
Replace pressure plate or flywheel.

Weakened engine mounting or loosened
installing bolt or nut.
Retighten or replace mounting.
Clutch Noise
Worn or broken release bearing.
Replace release bearing.

Worn input shaft bearing.
Replace input shaft bearing.

Cracked clutch disc.
Replace clutch disc.

Pressure plate and diaphragm spring
rattling.
Replace pressure plate.

Improper clutch cable adjustment.
Adjust clutch cable.
Grabbing Clutch
Clutch disc facing with oily contamination.
Replace clutch disc.

Excessively worn on clutch disc facing.
Replace clutch disc.

Rivet head showing out of facing.
Replace clutch disc.

Weakened clutch torsion spring.
Replace clutch disc.

CLUTCH 5C–7
DAEWOO M-150 BL2
D13C5031
4. Remove the transaxle input shaft bearing using the
input shaft bearing remover 09917–58010, the fly-
wheel holder 09924–17810 and a spanner.
D13C5041
Inspection Procedure – Pressure Plate
and Clutch Disc
1. Pressure plate inspection .

Check the weak and damaged diaphragm spring
(1).

Check the polluted face by the oil, grease (2).
D103C505
2. Clutch disc inspection

Measure rivet head depth from clutch disc surface
and replace if below limit.
Unit : mm (in.)
Standard Limit
Rivet Head Depth1.2 (0.047)0.5 (0.02)

Replace the clutch disc if clutch disc surface is
contaminated or clutch disc rivets are loosen.
D103C506
3. Clutch disc runout in rotational direction inspection.

Measure runout in rotational direction and replace
if runout exceeds limit.
Unit : mm (in.)


Disc Runout Limit in Rotational
Direction (Periphery)
0.7 (0.028)

6B –8 POWER STEERING PUMP
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Description
Lubricant

Power Steering Fluid DEXRON-II, DEXRON-III
Capacity

1.0 Liter (1.056 qt)
Type

Vane
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Power Steering Pump Bolt 20 – 24 15 – 18 –
Power Steering Pump Front Bracket Bolt 20 – 24 15 – 18 –
Power Steering Pump Front Bracket Adjusting Bolt 18 – 22 13 – 16 –
Power Steering Pump Rear Bracket Upper Bolt 35 – 45 26 – 33 –
Power Steering Pump Rear Bracket Lower Bolt 20 – 24 15 – 18 –
Power Steering Pump Rear Bracket Adjusting Bolt20 – 2415 – 18–
Power Steering Pump Pulley Nut55 – 6941– 51–
Power Steering Oil Pressure Line Fitting21 – 3516 – 26–

POWER STEERING GEAR 6C–13
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Power Steering FluidPower Steering Fluid DEXRON-II or DEXRON-III
Capacity1.0 L (1.056 qt)
TypeRack and Pinion
Overall Gear Ratio15.7 : 1
Power Steering Angle144, 155Inside39.5± 2
TireOutside33.5± 2
175 TireInside34.9± 2
Outside30.5± 2
GreaseRackPOLYUREAS
Ball JointSYNTHETICS OILS & LI SOAPS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Power Steering Gear Bracket Bolt50–5536–41–
Power Steering Gear Pinion Nut40–5030–36–
Power Steering Gear Pinion Dust Cover45–5533–41–
Power Steering Gear Pressure Line Fitting25–3518–25–
Power Steering Oil Pressure Pipe Fitting (Gear Side)21–3516–25–
Power Steering Gear Ajuster PlugRefer to “DIAGNOSIS” in this section.