2003 DAEWOO MATIZ horn

BODY AND ACCESSORIES
CONTENTS
SECTION 9A BODY WIRING SYSTEM
SECTION 9B LIGHTING SYSTEMS
SECTION 9C HORNS
SECTION 9D WIPERS / WASHER SYSTEMS
SECTION 9E INSTRUMENTATION / DRIVER INFORMATION
SECTION 9F AUDIO SYSTEMS
SECTION 9G INTERIOR TRIM
SECTION 9H SEATS
SECTION 9I WATERLEAKS
SECTION 9J WINDNOISE
SECTION 9K SQUEAKS AND RATTLES
SECTION 9L GLASS AND MIRRORS
SECTION 9M EXTERIOR TRIM
SECTION 9N FRAME AND UNDERBODY
SECTION 9O BUMPERS AND FASCIAS
SECTION 9P DOORS
SECTION 9Q ROOF
SECTION 9R BODY FRONT END
SECTION 9S BODY REAR END
SECTION 9T IMMOBILIZER ANTI–THEFT SYSTEM

SOHC ENGINE MECANICAL 1B–3
DAEWOO M-150 BL2
parts are installed in the cross flow arrangement. The
rocker arm (i) operates in seesaw motion to close and
open the intake and exhaust valves (j) with camshaft by
turning the rocker arm shaft of each intake and exhaust
part.
ENGINE BLOCK
As the largest part of the engine components. the block
(l) has all the necessary parts attached to outer surface
of it.
On the inside surface of block, there are bore surfaces
by horning, which are cylinders, and on the periphery of
the cylinders, there are the passages to prevent the
over-heated and to lubricate the engine block.
CRANKSHAFT
The crankshaft (m) is to convert the rectilinear motion
into the rotation motion through the connecting rod (n)
which transmits the power generated by combustion.
On the one side of it, oil pump, crankshaft pulley and
timing belt pulley are attached, and oil seal housing and
flywheel are on the other side.
A special steel of high grade cast iron is used for the ma-
terial to stand the bending load and distortion. The mate-
rial of the main bearing (o) is aluminum alloy. The split
thrust bearings (p) are inserted in the journal bearing
part (No.3).
D102B004
CONNECTING ROD
The connecting rods (n) are made of forged steel, and
its section is typed “I” with its big end connected tocrankshaft (m) and its small end to piston pin to transmit
the power.
The big end is detachable, and its upper and lower parts
are fastened by bolting after the metal bearings (q) are
inserted.
PISTON, PISTON RING AND PISTON
PIN
Piston
The piston (r) is of the open skirt type and its crown is
exposed in the combustion chamber to generate power.
Its land and skirt parts are made of coat aluminum alloy
which is light and has excellent heat conductivity in order
to meet its continuous and high speed reciprocation
movement.
Piston Ring
It is composed of two compression rings (s) and one oil
ring (t) and installed between the grooves of the piston
to make the high speed reciprocating movement main-
taining a remarkable air tightness as well as cylinders. It
is a critical parts to affect the compression pressure, oil
consumption, compression, blow by pressure and en-
gine performance.
Piston Pin
The pin (u) is not fixed to the piston or connecting rod
and its both ends are assembled by the circlip (v) in the
full floating type. The pin is used to transmit the power
from the crown part of piston to connecting rod.
D102B005

STEERING WHEEL AND COLUMN 6E–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
STEERING WHEEL AND COLUMN
D15A401A
1. Horn Cover (Airbag Module)
2. Steering Wheel Nut
3. Locking Plate
4. Steering Wheel
5. Steering Column Upper Cover
6. Steering Column Lower Cover
7. Turn Signal Switch
8. Windshield Wiper Switch
9. Steering Column Assembly
10. Retaining Ring
11. Washer
12. Spring
13. Switch Housing
14. Bolt15. Support Bolt
16. Steering Column Housing
17. Steering Column Jacket
18. Ignition Switch Retaining Screw
19. Ignition Switch
20. Steering Lock Housing Assembly
21. Steering Column Shaft
22. Pinch Bolt
23. Intermediate Shaft
24. Steering Column Upper Nut
25. Steering Column Lower Nut

STEERING WHEEL AND COLUMN 6E–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D105A501
D15A502A
DW310–010
STEERING WHEEL
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Tools Required
DW310–010, Steering Wheel Puller
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the SIR module. Refer to Section 8B, Sup-
plemental Inflatable Restraints. (For vehicle with SIR)
3. Remove the steering wheel.
4. Remove the steering wheel horn cover (For vehicle
without SIR) (1).

Straighten the bending locking plate (2).

Remove the nut (3).

Remove the locking plate (4).

In order to install the steering wheel correctly,
match–mark the steering column shaft to the
steering wheel (5).

Remove the steering wheel using the steering
wheel puller DW310–010 (6).
Important: Be careful not to hit the top of steering col-
umn shaft with hammer during repair work.
D15A503A
Installation Procedure
1. Install the SIR module. Refer to Section 8B, Supple-
mental Inflatable Restraints (For vehicle with SIR).
Important: Align the match marks on the steering wheel
and the steering column shaft.
2. Install the steering wheel with the nut and the locking
plate.
Tighten
Tighten the steering wheel nut to 23–33 Nm (17–24
lb-ft).
3. Bend the tabs to secure the locking plate.
4. Install the steering wheel horn cover (For vehicle
without SIR).
5. Connect the negative battery cable.

6E –10 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
D105A511

Remove the lock cylinder by pressing down the
detent spring with a 2.5MM allen wrench, or other
suitable tool, and pulling the lock cylinder out of the
switch cylinder housing (2).
D105A512
Installation Procedure
Important: To install the ignition lock cylinder the igni-
tion position should be designated I.
1. Install the ignition lock cylinder.
2. Connect the electrical connector for the immobilizer
detection coil.
3. Install the steering wheel. Refer to “Steering Wheel”
in this section.
D105A513
SWITCH HOUSING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
2. Remove the turn signal switch and windshield wiper
switch. Refer to “Turn Signal Switch and Lever/Wiper
Switch and Lever” in this section.
3. Remove the switch housing.

Disconnect the horn electrical connector (1).

Remove the screws retaining the switch housing
(2).
D105A514
Installation Procedure
1. Install the switch housing with the screws.
2. Connect the horn electrical connector.
3. Install the turn signal switch and windshield wiper
switch. Refer to “Turn Signal Switch and Lever/Wiper
switch and Lever” in this section.
4. Install the steering wheel. Refer to “Steering Wheel”
in this section.

8B–4 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO M-150 BL2
If there is a failure of the sensing and diagnostic module
or the external circuits, the SIR warning lamp in the in-
strument cluster turns ON.
As a system check, the SIR warning lamp also turns ON
when the ignition is first switched to the ON position.
Correct Functioning
The system is working properly if:

The SIR warning lamp turns OFF after approximately
four seconds.
Faulty Functioning
The system is not working properly, meaning one of the
SIR components or the wiring connector is faulty, if:

The SIR warning lamp fails to turn ON when the
ignition is first switched ON.

The SIR warning lamp remains ON.
D110B009A
CLOCK SPRING
The clock spring:

Is on the steering column.

Contains a coil that is the electrical contact between
the steering column wiring harness and the driver
side airbag module.

Is part of the circuit for the horn.
Notice: Turning the steering wheel more than three and
one-quarter turns may damage the clock spring.
Turning the steering wheel:

In one direction tightens the coil.

In the opposite direction loosens the coil.

More than three and one-quarter turns may damage
the clock spring.
Caution: Disassembling the clock spring can cause
injury and vehicle damage.The clock spring should never be disassembled.
The clock spring must be replaced if the airbags have
been deployed.
D110B008A
WIRING HARNESS/CONNECTORS
The connector for the sensing and diagnostic module
(SDM) has a built-in shorting bar that will turn ON the
warning lamp if there is a poor connection at the SDM.
As an anti-deployment mechanism, additional shorting
bars are in the

Connector for the clock spring at the lower steering
column.

Passenger airbag module connector.

SDM connector.
When these connectors are separated, the shorting
bars will short circuit any current which is applied, pre-
venting the current from reaching the airbag modules.
SIR SYSTEM
The supplemental inflatable restraints (SIR) system is a
safety device used in conjunction with the seat belts.
The airbag does not replace the function of the seat belt.
The driver and the passengers must always fasten their
seat belts and adjust them for a proper fit.
The SIR is designed to protect the driver and the front
seat passenger in the event of a significant frontal im-
pact to the vehicle. The airbags deploy if the force is ap-
plied from a direction within 30 degrees of the vehicle’s
centerline and above 25 km/h (15 mph) speed.
The SIR consists of a

Driver airbag module.

Passenger airbag module.

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B–69
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D110B501
DRIVER AIRBAG MODULE
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Tool Required
DS 401 Torx Bolt Wrench
Removal Procedure
1. Disconnect the negative battery cable.
2. Position the steering wheel straight ahead.
3. Remove the driver airbag module mounting bolts.

Remove the airbag module bolt cover (1).

Remove the airbag module torx bolt using a torx
bolt wrench DS 401.
a. Airbag module torx bolt.
D110B502
Caution: When handling an airbag module, always
keep the top of the unit facing upward. This leaves
room for the module to expand if the module unex-
pectedly deploys. Without room for expansion, a
module suddenly propelled toward a person or ob-
ject can cause injury or vehicle damage.
4.Remove the driver airbag module.

Disconnect the driver airbag module connector (1).

Disconnect the horn terminal connector (2).

Remove the driver airbag module (3).
15 Nm
D1AB503A
Installation Procedure
Caution: When removing an airbag module or han-
dling a new airbag module, always keep the top of
the unit facing upward. This leaves room for the
module to expand if the module unexpectedly de-
ploys. Without room for expansion, a module sud-
denly propelled toward a person or object can
cause injury or vehicle damage.
1. Install the driver airbag module.
2. Connect the connectors to the horn terminal and the
driver airbag module.
3. Install the driver airbag module torx bolt using a torx
bolt wrench DS 401.
Tighten
Tighten the torx bolt to 15 Nm (11 lb-ft)
4. Connect the negative battery cable.

8B–70 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO M-150 BL2
D110B504
CLOCK SPRING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable. Wait 1 minute
until the capacitor inside the sensing and diagnostic
module has discharged.
2. Remove the driver airbag module. Refer to “Driver
Airbag Module” in this section.
3. Remove the steering wheel. Refer to Section 6E,
Steering Wheel and Column.
4. Remove the lower/upper steering column cover.

Remove the screws (1).

Remove the lower/upper steering column cover(2).
D110B505
5. Disconnect the clock spring and the horn terminal
connector.
6. Disconnect the clock spring and the horn terminal
connector which are banded on the steering column.
7. Remove the clock spring.

Remove the screws (1).

Remove the clock spring (2).
3 Nm
D1AB506A
D110B507
Installation Procedure
Caution: If the clock spring is not properly aligned,
the steering wheel may not be able to rotate com-
pletely during a turn. Restricted turning ability can
cause the vehicle to crash. Improper alignment of
the clock spring also may make the supplemental
inflatable restraints (SIR) system inoperative, pre-
venting the airbags from deploying during a crash.
Both of these outcomes can result in injury.
Notice: Turning the clock spring more than three turns
clockwise or more than three turns counterclockwise
can damage the spring.
1. Turn the front wheels straight ahead.
2. Install the clock spring with the screws.
Tighten
Tighten the clock spring mounting screws to 3 Nm
(27 lb-in)
Important: The clock spring may come packed in mate-
rial used to prevent damage to the spring during ship-
ping or storage. Avoid installing any of the packing
material with the clock spring.
3. Turn the label of the clock spring clockwise to lock.
4. Turn the label of the clock spring counterclockwise
approximately three turns to the neutral positions with
the front wheels ahead.