2003 DAEWOO MATIZ brake sensor

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

1F–106 ENGINE CONTROLS
DAEWOO M-150 BL2
DIAGNOSTIC TROUBLE CODE (DTC) – P0171 FUEL TRIM SYSTEM TOO LEAN
System Description
To provide the best possible combination of driveability,
fuel economy, and emission control, a Closed Loop air/
fuel metering system is used. While in Closed Loop, the
Engine Control Module (ECM) monitors the oxygen sen-
sor (O2S) signal voltage and adjusts fuel delivery based
on signal voltage. A change made to fuel delivery will be
indicated by the long and short term fuel trim values
which can be monitored with the scan tool. Ideal fuel trim
values are around 128 (0%). If the O2S signal is indicat-
ing a lean condition, the ECM will add fuel resulting in
fuel trim values above 128 (0% to 100%). If a rich condi-
tion is detected, the fuel trim values will be below 128
(0% to –100%), indicating that the ECM is reducing the
amount of fuel delivered. If exhaust emissions reach an
excessive level due to a lean or rich condition, a fuel trim
Diagnostic Trouble Code (DTC) is set.
Conditions for Setting the DTC

No intrusive tests active.

DTCs P0106, P0107, P0108, P0112, P0113, P0117,
P0118, P0122, P0123, P0125, P0131, P0132,
P0133, P0134, P0137, P0138, P0140, P0141,
P1167, P1171, P0201, P0202, P0203, P0204,
P0300, P0336, P0337, P0341, P0342, P0402,
P0404, P1404, P0405, P0406, P0443, P0506, and
P0507are not set.

The average of short term fuel trim value is greater
than or equal to 120.

Throttle Position (TP) is less than 95%.

Engine speed is between 700 and 6000 rpm.

Barometric Pressure (BARO) is greater than 92.0
kPa (10.4 psi).

Coolant temperature is between 80°C (176°F) and
11 5°C (239°F).

Manifold Absolute Pressure (MAP) is more than 90
kPa (10.2 psi).

System is in closed loop.

Adaptive index is ready.
Action Taken when the DTC Sets

Emission related.

“Armed” after two trip with a fail.

“Disarmed” after one trip with a pass.

MIL on if failure is detected in three consecutive trips.

Stores a History DTC on the third consecutive with a
fail (The DTC will be armed after the second fail).
Stores a Freeze Frame on the third consecutive trip
with a fail (if empty).
Conditions for Clearing the MIL/DTC

The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.

A history DTC will clear after 40 consecutive warm up
cycles without a fault.

DTC(s) can be cleared by using the scan tool.
Diagnostic Aids
Important: After repairs, use the scan tool Fuel Trim
Reset function to reset the long-term fuel trim to 128
(0%).

Fuel pressure – The system will be lean if the pres-
sure is too low. It may be necessary to monitor fuel
pressure while driving the vehicle at various road
speeds and/or loads to confirm.

Map sensor – An output that causes the ECM to
sense a lower than normal manifold pressure (high
vacuum) can cause the system to go lean. Discon-
necting the MAP sensor will allow the ECM to substi-
tute a fixed (default) value for the MAP sensor. If the
lean condition is gone when the sensor is discon-
nected, substitute a known good sensor and recheck.

Fuel contamination – Water, in even small amounts,
near the in-tank fuel pump inlet can be delivered to
the injector. The water causes a lean exhaust and
can set DTC P0171.
Check for poor O2S or MAP sensor connection at the
ECM. Inspect the harness connectors for the following
conditions:

Backed-out terminals

Improper mating

Broken locks

Improperly formed

Damaged terminals

Poor terminal-to-wire connection
Inspect the wiring harness for damage. If the harness
appears to be OK, observe the O2S display on the scan
tool while moving the connectors and the wiring harness
related to the engine harness. A change in the display
will indicate the location of the fault.
Check the brake power booster check valve for possible
leaks.

FRONT SUSPENSION 2C–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D16B501A
STRUT ASSEMBLY
Removal Procedure
1. Open the hood.
2. Remove the top of the strut assembly at passenger
seat side.

For vehicle with power steering, remove the power
steering fluid reservoir (1).

Remove the nuts (2).
D16B502A
3. Remove the top of the strut assembly at driver side.

Remove the bolt and the fuse box (1, 2).

Remove the nuts (3).
D106B503
4. Remove the lower of the strut assembly.

Raise and suitably support the vehicle.

Remove the wheel. Refer to Section 2E, Tires and
Wheels.

Remove the ABS front speed sensor electrical wire
from the bracket, if applicable (1).

Disconnect the brake hose from the bracket (2).

Remove the strut bracket bolts (3).
5. Remove the strut bracket assembly from the vehicle.

2C –8 FRONT SUSPENSION
DAEWOO M-150 BL2
D16B504A
70–90 Nm
Installation Procedure
1. Install the strut assembly to the vehicle with the strut
assembly–to–strut bracket bolts.
Tighten
Tighten the strut assembly–to–strut bracket bolts to
70–90 Nm (52–66 lb-ft).
2. Connect the brake hose to the bracket.
3. Install the ABS front speed sensor electrical wire to
the bracket, if applicable.
D16B505A
18–28 Nm
18–28 Nm4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
6. Install the nuts.

Install the nuts at passenger side (1).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).

Install the nuts at driver side (2).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).
7. Install the power steering fluid reservoir.
8. Install the fuse box and bolt.
D106B506
KNUCKLE ASSEMBLY
Tools Required
KM 507–B Ball Joint Remover
Removal Procedure
1. Remove the caulking nut.

Straighten the bent flange caulking nut (1).

Remove the caulking nut (2).

Remove the washer (3).
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
D105B501
3. Separate the tie rod end from the knuckle assembly.

Remove the cotter pin (1).

Remove the castellated nut (2).

Install the ball joint remover KM 507–B.

Separate the tie rod end from the knuckle assem-
bly using a ball joint remover KM 507–B (3).

FRONT SUSPENSION 2C–9
DAEWOO M-150 BL2
D106B507
4. Remove the control arm from the knuckle assembly.

Remove the stud bolt (1).

Separate the control arm from the knuckle assem-
bly (2).
D106B508
5. Remove the brake caliper from the knuckle assembly.
Refer to Section 4D, Front Disc Brakes.
6. Remove the ABS wheel speed sensor from the
knuckle assembly, if applicable. Refer to Section 4F,
Anti–lock Brake System.
7. Remove the steering knuckle assembly from the ve-
hicle.

Remove the strut bracket bolts (1).

Separate the knuckle assembly from the drive
shaft by pulling the steering knuckle assembly (2).
D16B509A
70–90 Nm
50–70 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the steering knuckle assembly in the vehicle
with strut bracket bolts (1).
Tighten
Tighten the strut bracket bolts to 70–90 Nm (52–66
lb-ft).
3. Install the brake caliper from the knuckle assembly.
4. Install the control arm into the knuckle assembly with
the stud bolt (2).
Tighten
Tighten the stud bolt to 50–70 Nm (36–52 lb-ft).
D16B510B
5. Install the tie rod end to the knuckle assembly.
6. Install the tie rod end–to–knuckle castellated nut (1)
and the cotter pin.
Tighten
Tighten the castellated nut to 30–55 Nm (22–41 lb-
ft).
7. Install the caulking nut (2).

Bend the caulking nut flange (3).
Tighten
Tighten the caulking nut to 210 Nm (155 lb-ft).

FRONT SUSPENSION 2C–23
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Suspension Type – Mcpherson (Strut)
Maximum Length mm (in.) 475–481 (18.7–18.94) Shock Absorber Minimum Length mm (in.) 321–327 (12.64–12.87)
Stroke

mm (in.)

154 (6.06)
Stabilizer Shaft Diammeter

mm (in.)

24 (0.94)
Coil Spring Height (No Load) mm (in.) 374 (14.72 )
Grease Type (Front Wheel Bearing and Hub) – M–8143 ANTIF BRG GREASE
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Strut Assembly–to–Body Nuts 18 – 28 13 – 21 –
Strut Closure Nut 50 – 60 36 – 44 – Strut Assembly–to–Knuckle Bolts 70 – 90 52 – 66 –
Control Arm Mounting Bolt

55 – 70

41 – 52

–
Control Arm Ball Stud Bolt

50 – 70

36 – 52

–
Stabilizer Shaft Castellated Nut 40 – 50 30 – 36 –
Stabilizer Shaft Mounting Bolt 30 – 50 22 – 36 –
Front Under Longitudinal Frame Bolts 10 – 14 – 89 – 124
Front Under Longitudinal Frame Nut 65 – 80 48 – 59 – Drive Axle–to–Hub Caulking Nut 210 155 – Crossmember Bolt 17 – 27 13 – 20 –
Strut Bar Bolts

35 – 55

25 – 41

–
ABS Front Speed Sensor Retaining Bolt 18 – 28 13 – 21 –
Wheel Hub–to–Brake Disc Bolt 55 – 75 41 – 55 –

REAR SUSPENSION 2D–15
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Suspension Type– Isolated Trailing Link
Maximum Lengthmm (in.) 394.5 ± 3 (15.53 ± 0.12)
Shock Absorber Minimum Lengthmm (in.) 257.5 ± 3 (10.14 ± 0.12)

Shock Absorber
Strokemm (in.) 137 (5.39)
Clearancemm (in.) 0
Rear Wheel Bearing No LoadNm (lb-in.) 0.137 – 0.422 (0.9 – 3.7)
Coil Spring Height (No Load)mm (in.) 291 (11.46)
Grease Type (Rear Wheel Bearing and Hub)–M–8143 ANTIF BRG GREASE
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In Shock Absorber–to–Body Bracket Nut 45 – 70 33 – 52 – Shock Absorber–to–Rear Axle Bolt 45 – 70 33 – 52 – Trailing Arm–to–Rear Axle Bolt 80 – 90 59 – 66 – Trailing Arm–to–Body Bracket Bolt 70 – 90 55 – 66 – Lateral Rod–to–Body Bracket Bolt 50 – 70 37 – 52 – Lateral Rod–to–Rear Axle Nut 35 – 55 25 – 41 – Rear Axle Castellated Nut* – – – ABS Rear Speed Sensor Retaining Bolt 9 – 13 – 80 – 11 5

Rear Axle Castellated Nut : Refer to Section 4E, Rear Drum Brakes