2003 DAEWOO MATIZ power steering fluid

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

GENERAL ENGINE INFORMATION 1A–11
DAEWOO M-150 BL2
CHECKING ENGINE FLUID LEVEL
Check the engine fluid level or condition. If needed, refill
or replace the oil.
Check the engine oil level within engine normal operat-
ing temperature as follows ;
1. After stopping the engine, wait for a few minutes to
accumulate oil into the oil pan.
2. After pulling out the oil level gauge (a), check the oil
level.
3. Clean the oil level gauge and insert the gauge into
guide.
4. After pulling out the oil level gauge again, recheck the
oil level and insert the gauge into guide again.
Important: Oil level should be between “MIN” mark and
“MAX” mark.
5. If oil level is below the “MIN” mark, refill engine oil as
much as the demanded quantify.
Important: If checking oil level under the engine cold
condition, oil is not accumulated into oil pan quickly and
correct level checking can not be performed. Therefore,
wait until temperature reaches the normal operating
condition and check the engine oil level.
D102A301
CHANGING ENGINE OIL OR OIL
FILTER
Tools Required
09915–47341 Oil Filter Wrench.
When checking engine oil level or condition, if needed,
change engine oil (including the filter) as follows ;
1. After stopping the engine, wait for a few minutes to
accumulate oil into the oil pan.
2. Remove the oil filter cap (b).3. Remove the oil drain plug (c) and draw oil off.
D102A302
4. After drawing oil completely, tighten the oil drain plug
to 30–40 Nm (22–30 lb-ft).
5. Replace the oil filter using the oil filter wrench
09915–47341 (d).

Remove the air cleaner/resonator/snorkel as-
sembly.

After removing the bolts, remove the heat
shield.

Loosen the power steering pump cap screw and
pull the power steering hose into the front.

Remove the oil filter.
Important: Whenever changing engine oil, replace the
oil filter. When replacing new oil filter, apply engine oil on
oil filter sealing.
D102A303

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.

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).

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.

POWER STEERING PUMP 6B–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER STEERING PUMP
ConditionProbable CauseCorrection
Foaming, Milky
Power Steering Fluid,
Insufficient power steering fluid level.
Fill the power steering fluid
reservoir.
Low Fluid Level, and
Possible Low
Contaminated air in the power steering
fluid.
Bleed the power steering system.
Pressure

Internal leaks and overflow of the power
steering pump.
Replace the power steering pump.

Leaks of the power steering pump housing
and the soft plug.
Replace the power steering pump.
Low Pressure Due to
Steering Pump
Stuck and improperly operated power
steering pump flow control valve.
Replace the power steering pump.

Worn power steering pump seats.
Replace the power steering pump.

Scores, cracks, or breaks of the pressure
plate, the pump ring, the thrust plate, and
the rotor.
Replace the power steering pump.

Sticking of the vanes in the rotor slots.
Replace the power steering pump.

Internal leaks and overflow of the power
steering pump.
Replace the power steering pump.
Growling Noise in
Steering Pump
Restricted flow of the pump hoses and the
steering gear pipes.
Clean out the pipes and the hoses.

Replace the pipes and the hoses as
needed.

Scores, cracks, or breaks of the pressure
plate, the pump ring, the thrust plate, and
the rotor.
Replace the power steering pump.

Improperly contacted power steering hose
with the body.
Secure the pump hose in a clamp
away from the body.

Insufficient power steering fluid level.
Fill the power steering pump
reservoir.
Ratting Noise in the
Steering Pump
Contaminated air in the power steering
fluid.
Bleed the power steering system.

Improperly contacted power steering hose
with the body.
Secure the pump hose in a clamp
away from the body.

Insufficient power steering fluid level.
Fill the power steering pump
reservoir.

Improperly installed pump mounting.
Tighten the power steering pump
attachment bolts.
Swishing Noise in the
Steering Pump
Damaged power steering pump flow control
valve.
Replace the power steering pump.
Whining Noise in the
Scores of the pressure plate and the vanes.
Replace the power steering pump.
Steering Pump
Scores of the pump shaft bearing
Replace the power steering pump.