2003 DAEWOO MATIZ Service Repair Manual

CLUTCH 5C–9
DAEWOO M-150 BL2
D103C511

Insert the tap (M14X1.5) to the busing (No.1) (2).
D13C512A

Insert the bushing joint pipe 09923–46040 to the
tab.

Connect the sliding shaft 09930–30102 to the end
of the bushing joint pipe 09923–46040.

Remove the bushing (No.1) by pulling.
D103C513
Inspection Procedure – Release Bearing
and Shaft
1. Release bearing inspection

Check for noisy, worn and damaged release bear-
ing.

Check for a grabbing rotation of release bearing.

Replace the release bearing if necessary.
D103C514
2. Release shaft inspection

Check for a warped shaft (1).

Check for a worn fork (2).

Replace the shaft if necessary.

5C –10 CLUTCH
DAEWOO M-150 BL2
D103C515
Installation Procedure
1. Install in the reverse order of removal.
2. Install the release shaft bushing (No.1) using the
bushing joint pipe 09923–46040, bushing, bearing in-
staller 09943–88211 and a hammer.
D103C516
3. Install the release shaft bushing (No.2) and seal using
the bushing remover/installer 09925–48220 and a
hammer.
D103C517
4. Install the release bearing.

Coat the spline of transaxle input shaft with multi–
purpose grease (1).

Coat the release bearing bore and the connecting
of release shaft with multi–purpose grease (2).

Install the release bearing.
D103C518
CLUTCH RELEASE ARM
Removal Procedure
1. Disconnect the clutch cable.

Remove the adjusting nut (1).

Disconnect the cable (2).

CLUTCH 5C–11
DAEWOO M-150 BL2
D103C519
2. Remove the clutch release arm.

Remove the bolt and nut (1).

Remove the release arm (2).
D13C520A
Installation Procedure
1. Install in the reverse order of removal.
2. Install the clutch release arm.

Install the clutch release arm matching to punched
mark (1).
Tighten
Tighten the bolt and nut to 10–16 Nm (7.5–12 lb-ft).
3. Adjust the clutch cable. Refer to “Diagnosis” in this
section.
D103B506
CLUTCH CABLE
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the clutch cable from the transaxle.

Remove the adjusting nut (1).

Disconnect the cable from the wire clip (2).

Pull and remove the cable from the transaxle
mount hole (3).
D13C5211
2. Disconnect the clutch cable from the pedal.

Pull upward and disconnect the cable from the
pedal hook (1).

5C –12 CLUTCH
DAEWOO M-150 BL2
D103C522
3. Remove the battery. Refer to Section 1E, Engine
Electrical.
4. Remove the clutch cable.

Remove the nuts (1).

Remove the cable grommet (2).

Remove the cable from the pedal (3).
D103C302
Installation Procedure
1. Install the clutch cable.
2 Install the battery.
3. Connect the clutch cable to the pedal.
4. Connect the clutch cable to the transaxle.
5. Adjust the clutch cable. Refer to “Diagnosis” in this
section.
D103C524
CLUTCH PEDAL
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the clutch cable. Refer to “Clutch Cable”
in this section.
2. Remove the clutch pedal.

Release the pedal return spring.

Remove the nut (1).

Remove the clutch pedal (2).

Remove the bushing (3).

Remove the pedal return spring (4).
D103C302
Installation Procedure
1. Install the pedal return spring.
2. Install the bushings.
3. Install the clutch pedal.
4. Install the nut.
5. Fix the pedal return spring.
6. Connect the clutch cable.
7. Adjust the clutch cable. Refer to “Diagnosis” in this
section.

CLUTCH 5C–13
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Description Unit Standard Limit
Type – Single Dry Plate –
Outside Diameter mm (in.) 170 (6.7) –
Inside Diameter mm (in.) 110 (4.3) –Clutch Disc Thickness mm (in.) 7.15 (0.281) –
Rivet Head Depth mm (in.) 1.2 (0.047) 0.5 (0.020)
Disc Runout Limit in Rotational Direction mm (in.) – 0.7 (0.028)
Pedal Free Travel mm (in.) 0 (0) –
Clutch Pedal Pedal Travel mm (in.) 100 – 11 0
(3.9 – 4.3) –Clutch Pedal
Clearance between pedal and floor just
before clutch connection
mm (in.)

–

30 – 40
(1.2 – 1.6)
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Pressure Plate Bolt

18 – 28

13 – 21

–
Clutch Release Arm Bolt and Nut

10 – 16

7.5 – 12

–

5C –14 CLUTCH
DAEWOO M-150 BL2
SPECIAL TOOLS
SPECIAL TOOLS TABLE
D103C101
09917–58010
Input Shaft Bearing
Remover
D103C105
09923–46040
Bushing Joint Pipe
D102B116
09924–17810
Fly Wheel Holder
D103C104
09925–48220
Bushing Remover/
Installer
D103C102
09925–98210
Input Shaft Bearing
Installer
D103C106
09930–30102
Sliding Shaft
D103C107
09943–88211
Bushing, Bearing
Installer
D103B103
DW110–021
Engine Assembly
Support Fixture
D103C103
DW210–010
Clutch Center Guide

DAEWOO M-150 BL2
SECTION 6B
POWER STEERING PUMP
TABLE OF CONTENTS
Description and Operation 6B-2. . . . . . . . . . . . . . . . . .
Power Steering Pump 6B-2. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6B-3. . . . .
Power Steering Pump 6B-3. . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 6B-4. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Belt 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Pulley 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . Pump Assembly 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 6B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6B-8. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6B-8. . . . . . . . . . .
Special Tools and Equipment 6B-9. . . . . . . . . . . . . . .
Special Tools Table 6B-9. . . . . . . . . . . . . . . . . . . . . . . .

6B – 2 POWER STEERING PUMP
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
POWER STEERING PUMP
The pump has a remote fluid reservoir. A pressure-relief
valve inside the flow control valve limits pump pressure.