2003 DAEWOO MATIZ Service Repair Manual

ENGINE EXHAUST 1G–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
EXHAUST SYSTEM
D12G4011
1 Pup-up Catalytic Converter
2 Front Exhaust Pipe/Catalytic Converter
Assembly3 Front Muffler Pipe
4 Rear Muffler Pipe

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.

1G–6 ENGINE EXHAUST
DAEWOO M-150 BL2
MAA1B010
3. Remove the air cleaner assembly. Refer to Section
1B, SOHC Engine Mechanical.
4. Disconnect Oxygen Sensor (O2S) connector.
5. Remove the exhaust manifold heat shield.
6. Remove the exhaust manifold. Refer to Section 1B,
SOHC Engine Mechanical.
MAA1B040
7. Remove pup-up catalytic convertor.

Remove the bolts.
MAA1B041
Installation Procedure
1. Install pup-up catalytic convertor to exhaust pipe.
Tighten
Tighten the bolts to 25–35 Nm (18–25 lb-ft).
MAA1B011
2. Install exhaust manifold. Refer to Section 1B, SOHC
Engine Mechanical.
Tighten
Tighten the bolts and nuts to 17–27 Nm (13–20 lb-ft).
Tighten the exhaust manifold heat shield bolts to
8–12 Nm (71–106 lb-in).

ENGINE EXHAUST 1G–7
DAEWOO M-150 BL2
D12G504B
3. Install the front exhaust pipe to pup-up catalytic con-
vertor.
Tighten
Tighten the bolts to 25–35 Nm (18–25 lb-ft).

D102G502
FRONT MUFFLER
Removal Procedure
1. Remove the front exhaust pipe-to-front muffler nuts.

Remove the nuts (1).

MAA1G030
2. Remove the front muffler-to-rear muffler nuts.
3. Detach the front muffler from rubber hanger and re-
move the front muffler.

MAA1G031
Installation Procedure
1. Hang the front muffler to rubber hanger.
2. Install the front muffler-to-rear muffler nuts.
Tighten
Tighten the nuts to 25–35 Nm (18–25 lb-ft).
3. Install the exhaust pipe-to-front muffler nuts.
Tighten
Tighten the nuts to 25–35 Nm (18–25 lb-ft) (a).

1G–8 ENGINE EXHAUST
DAEWOO M-150 BL2
MAA1G030
REAR MFFLER
Removal Procedure
1. Remove the front muffler-to rear muffler nuts.
Tighten
Tighten the nuts to 25–35 Nm (18–25 lb-ft).
2. Detach the rear muffler from the rubber hangers.
MAA1G040
3. Remove the rear muffler.
4. Installation should flow the removal procedure in re-
verse order.

ENGINE EXHAUST 1G–9
DAEWOO M-150 BL2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Front Exhaust Pipe-to-Front Muffler Pipe Nuts25 – 3518 – 25–
Front Exhaust Pipe-to-Exhaust Manifold Nuts25 – 3518 – 25–
Front Exhaust Pipe-to-Pup-up Catalytic Converter25 – 3518 – 25–
Front Muffler-to-Rear Muffler nuts25 – 3518 – 25–
Pup-up Catalytic Convertor-to-Exhaust Manifold Bolt25 – 3518 – 25–
Muffler Clamp Nut24 – 2818 – 21–
Catalytic Converter Heat Shield8 – 12–71 – 106
Rear Muffler Heat Shield8 – 12–71 – 106

DAEWOO M-150 BL2
SECTION 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
Diagnostic Information and Procedures 2A-1. . . . .
General Diagnosis 2A-1. . . . . . . . . . . . . . . . . . . . . . . . . Wheel Bearing Diagnosis 2A-6. . . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires, and
the wheels involve several systems. Consider all sys-
tems when you diagnose a complaint. Some problems,
such as abnormal or excessive tire wear and scuffed
tires, may be the result of hard driving. Always road testthe vehicle first. If possible, do this road test with the
customer.
Proceed with the following preliminary checks. Correct
any substandard conditions.
Application Checks Correction
Preliminary Checks
Inspect the tires for improper pressure
and uneven wear.
Inflate the tires to the proper pressure.

Inspect the joint from the steering
column to the intermediate shaft for
loose connections or wear.

Inspect the joint from the intermediate
shaft to the steering gear for loose
connections or wear.
Tighten the coupling flange pinch
bolts.

Replace the intermediate shaft as
needed.

Inspect the front and the rear
suspension, the steering gear, and the
linkage for loose or damaged parts.
Tighten the front and the rear
suspension.

Tighten the steering gear mounting
bracket bolts.

Replace the front and the rear
suspension as needed.

Replace the steering gear as needed.

Replace the coupling flange as
needed.

Inspect for out–of–round tires.
Perform free runout test.

Match–mount the tires.

Inspect for out–of–balance tires, bent
wheels, and worn or loose wheel
bearings.
Balance the wheels.

Replace the wheels.

Replace the wheel bearings.

Check the power steering pump drive
belt tension.
Tighten the power steering pump drive
belt.

Inspect the power steering system.
Also, check the power steering fluid
level.
Repair any leaks.

Perform a power steering gear test.

Add power steering fluid.