2003 DAEWOO MATIZ brake

SECTION INDEX
FRONT MATTER
0A
GENERAL INFORMATION
0B
ENGINE1
SERVICE
MATIZ
FOREWORD
This manual includes procedure for maintenance,
adjustment, service operation and removal and
installation of components.
All information, illustrations and specifications con-
tained in this manual are based on the latest prod-
uct information available at the time of manual ap-
proval.
The right is reserved to make changes at any time
without notice.
DAEWOO MOTOR CO., LTD.
INCHON, KOREA
MANUAL
SUSPENSION
2
DRIVELINE/AXLE 3
BRAKES
4
TRANSAXLE
5
STEERING
6
RESTRAINTS
8
BODY AND ACCESSORIES9 7 HVAC
(HEATING, VENTILATION,
AND AIR CONDITIONING)
(MY2003)

BRAKES
CONTENTS
SECTION 4A HYDRAULIC BRAKES
SECTION 4B MASTER CYLINDER
SECTION 4C POWER BOOSTER
SECTION 4D FRONT DISC BRAKES
SECTION 4E REAR DRUM BRAKES
SECTION 4F ANTILOCK BRAKE SYSTEM
SECTION 4G PARKING BRAKE

GENERAL ENGINE INFORMATION 1A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
ENGINE COMPARTMENT (TYPICAL)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
D102A401
1 Power Steering Oil Reservoir
2 Coolant Reservoir
3 Canister
4 Canister Solenoid
5 Manifold Absolute Pressure (MAP) Sensor
6 Intake Manifold
7 Ignition Coil
8 Idle Air Control (IAC) Valve
9 Throttle Position (TP) Sensor
10 Throttle Body
11 Brake Fluid Reservoir
12 Wiper Motor13 Battery
14 Fuse Box
15 Air Cleaner Housing
16 Resonator
17 PCV Hose
18 Distributor
19 Exhaust Manifold
20 Snorkel
21 Engine
22 Washer Fluid Reservoir
23 Oil Level Gauge
24 Oil Filler Cap

1A–4 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
ENGINE COMPARTMENT (EURO III)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
MAA1A010
1 Power Steering Oil Reservoir
2 Coolant Reservoir
3 Canister Purge Solenoid
4 Manifold Absolute Pressure (MAP) Sensor
5 Intake Manifold
6 Throttle Position (TP) Sensor
7 Throttle Body
8 Idle Air Control (IAC) Valve
9 Brake Fluid Reservoir
10 Wiper Motor11 Battery
12 Fuse Box
13 Air Cleaner Housing
14 Resonator
15 Electronic Ignition System Ignition Coil
16 Exhaust Manifold
17 Snorkel
18 Engine
20 Washer Fluid Reservoir
19 Oil Level Gauge
21 Oil Filler Cap

1A–6 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
 Condition Probable cause Correction
Hard Starting (WithOthers
Broken timing belt.
Replace the belt.
normal cranking)
Malfunction of Positive
Crankcase Ventilation (PCV)
valve.
Check and replace Positive
Crankcase Ventilation (PCV)
valve if needed.

Loosening, damage or
leakage of the vacuum hose.
Connect the hose correctly
or replace it.

Leakage of intake system.
Replace intake system.
Lack of Engine PowerDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Improper ignition timing.
Adjust the ignition timing.
Ignition System
Faulty spark plug.
Adjust or replace the spark
plug.

Malfunction of the distributor.
Repair or replace the
distributor. Check the rotor.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.
Malfunction of
Clogged fuel pipe.
Clean the pipe.
Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.
Others
Clogged exhaust system.
Check and repair the
system.

Clogged or contaminated air
cleaner element.
Clean or replace the air
cleaner element.

Leak of the intake manifold
gasket.
Replace the gasket.

Dragging brakes.
Repair or replace the
brakes.

Slipping clutch.
Adjust or replace the clutch.
Rough Engine IdlingDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Clogged fuel pipe.
Clean the pipe.
Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.

Malfunction of the fuel
pressure regulator.
Replace the regulator.
Malfunction of
Ignition System
Malfunction of the spark
plug.
Adjust or replace the spark
plug.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.

Worn distributor cap terminal
or accumulated carbon in
the distributor cap.
Replace or clean the
distributor cap.

1E–4 ENGINE ELECTRICAL
DAEWOO M-150 BL2
3. In both vehicles, apply the parking brake firmly.
Notice: Make sure the cables are not on or near pulleys,
fans, or other parts that will move when the engine
starts, damaging the parts.
4. Shift a manual transaxle to NEUTRAL.
Caution: Do not use cables that have loose or miss-
ing insulation, or injury could result.
5. Clamp one end of the first jumper cable to the positive
terminal on the battery. Make sure it does not touch
any other metal parts. Clamp the other end of the
same cable to the positive terminal on the other bat-
tery. Never connect the other end to the negative ter-
minal of the discharged battery.
Caution: Do not attach the cable directly to the neg-
ative terminal of the discharged battery. Doing so
could cause sparks and possible battery explosion.
6. Clamp one end of the second cable to the negative
terminal of the booster battery. Make the final con-
nection to a solid engine ground, such as the engine
lift bracket, at least 450 millimeters (18 inches) from
the discharged battery.
7. Start the engine of the vehicle with the good battery.
Run the engine at a moderate speed for several min-
utes. Then start the engine of the vehicle which has
the discharged battery.
8. Remove the jumper cables by reversing the above
sequence exactly. Remove the negative cable from
the vehicle with the discharged battery first. While re-
moving each clamp, take care that it does not touch
any other metal while the other end remains at-
tached
.
GENERATOR
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator lamination.
CS generators are equipped with internal regulators.
The Y connection (A-type) or Delta (B-type) stator, a
rectifier bridge, and a rotor with slip rings and brushes
are electrically similar to earlier generators. A conven-
tional pulley and fan are used. There is no test hole.
Unlike three-wire generators, the ∅114D (A-type) or
CS114D (B-type) may be used with only two connec-
tions: battery positive and an ‘‘L’’ terminal to the charge
indicator lamp.
As with other charging systems, the charge indicator
lamp lights when the ignition switch is turned to ON, and
goes out when the engine is running. If the charge indi-
cator is on with the engine running, a charging system
defect is indicated.
The regulator voltage setting varies with temperature
and limits the system voltage by controlling the rotorfield current. The regulator switches rotor field current
on and off. By varying the on-off time, correct average
field current for proper system voltage control is ob-
tained. At high speeds, the on-time may be 10 percent
and the off-time 90 percent. At low speeds, with high
electrical loads, on-time may be 90 percent and the off-
time 10 percent.
CHARGING SYSTEM
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator laminations.
CS generators use a new type of regulator that incorpo-
rates a diode trio. The Y connection (A-type) or Delta (B-
type) stator, a rectifier bridge, and a rotor with slip rings
and brushes are electrically similar to earlier generators.
A conventional pulley and fan are used. There is no test
hole.
STARTER
Wound field starter motors have pole pieces, arranged
around the armature, which are energized by wound
field coils.
Enclosed shift lever cranking motors have the shift lever
mechanism and the solenoid plunger enclosed in the
drive housing, protecting them from exposure to dirt, icy
conditions, and splashes.
In the basic circuit, solenoid windings are energized
when the switch is closed. The resulting plunger and
shift lever movement causes the pinion to engage the
engine flywheel ring gear. The solenoid main contacts
close. Cranking then takes place.
When the engine starts, pinion overrun protects the ar-
mature from excessive speed until the switch is opened,
at which time the return spring causes the pinion to dis-
engage. To prevent excessive overrun, the switch
should be released immediately after the engine starts.
STARTING SYSTEM
The engine electrical system includes the battery, the
ignition, the starter, the generator, and all the related wir-
ing. Diagnostic tables will aid in troubleshooting system
faults. When a fault is traced to a particular component,
refer to that component section of the service manual.
The starting system circuit consists of the battery, the
starter motor, the ignition switch, and all the related elec-
trical wiring. All of these components are connected
electrically
.
DISTRIBUTOR
Distributor distributes the high tension voltage induced
from ignition coil, to each spark plug of each cylinder in

1F–42 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F070
IDLE AIR CONTROL SYSTEM CHECK
Circuit Description
The Engine Control Module (ECM) controls the engine
idle speed with the Idle Air Control (IAC) valve. To in-
crease the idle speed, the ECM pulls the IAC pintle
away from its seat, allowing more air to pass by the
throttle body. To decrease the idle speed, it extends the
IAC valve pintle toward its seat, reducing bypass air
flow. A scan tool will read the ECM commands to the
IAC valve in counts. The higher counts indicate more air
bypass (higher idle). The lower counts indicate less air is
allowed to bypass (lower idle).
Diagnostic Aids
If the idle is too high, stop the engine. Fully extend the
Idle Air Control (IAC) valve with a IAC driver. Start the
engine. If the idle speed is above 950 rpm, locate and
repair the vacuum leak. Also, check for a binding throttle
plate or throttle linkage or an incorrect base idle setting.
Idle Air Control Valve Reset Procedure
Whenever the battery cable or the Engine Control Mod-
ule (ECM) connector or the ECM fuse EF6 is discon-nected or replaced, the following idle learn procedure
must be performed:
1. Turn the ignition ON for 5 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON for 5 seconds.
4. Start the engine in park/neutral.
5. Allow the engine to run until the engine coolant is
above 85C (185F ).
6. Turn the A/C ON for 10 seconds, if equipped.
7. Turn the A/C OFF for 10 seconds, if equipped.
8. If the vehicle is equipped with an automatic trans-
axle, apply the parking brake. While pressing the
brake pedal, place the transaxle in D (drive).
9. Turn the A/C ON for 10 seconds, if equipped.
10. Turn the A/C OFF for 10 seconds, if equipped.
11. Turn the ignition OFF. The idle learn procedure is
complete.

1F–52 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F010
DATA LINK CONNECTOR DIAGNOSIS
Circuit Description
The provision for communicating with the Engine Con-
trol Module (ECM) is the Data Link Connector (DLC). It
is located under the instrument panel. The DLC is used
to connect the scan tool. Battery power and ground is
supplied for the scan tool through the DLC. The Key-
word 2000 serial data circuit to the DLC allows the ECM
to communicate with the scan tool. A Universal Asyn-
chronous Receiver Transmitter (UART) serial data line
is used to communicate with the other modules such as
the Electronic Brake Control Module (EBCM), the Sup-
plemental Inflatable Restraint (SIR) system. and the In-
strument Panel Cluster.
Diagnostic Aids
Ensure that the correct application (model line, car year,
etc.) has been selected on the scan tool. If communica-
tion still cannot be established, try the scan tool onanother vehicle to ensure that the scan tool or cables
are not the cause of the condition.
An intermittent may be caused by a poor connection,
rubbed through wire insulation, or a broken wire inside
the insulation.
Any circuitry that is suspected of causing an intermittent
complaint should be thoroughly checked for the follow-
ing conditions:

Backed-out terminals.

Improper mating of terminals.

Broken locks.

Improperly formed or damaged terminals.

Poor terminal-to-wiring connection.

Physical damage to the wiring harness.

Corrosion.