2003 DAEWOO MATIZ washer 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

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).

MANUAL TRANSAXLE DRIVE AXLE 3B–5
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D106B506
DRIVE AXLE ASSEMBLY
Tool Required
KM–507–B Tie Rod End Joint Remover
Removal Procedure
1. Remove the drive axle shaft nut.
Fix the hub not to rotate by pressing the brake ped-
al.
Loosen the caulking (1).
Remove the nut (2).
Discard the nut.
Remove the washer (3).
D103B505
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Remove the transaxle under cover.
Remove the bolts (1).
Remove the under cover (2).
D104B501
4. Drain the transaxle fluid through the drain plug.
5. Remove the stabilizer bar. Refer to Section 2C, Front
Suspension.
6. Separate the control arm ball joint and the tie rod end
from the knuckle. Refer to Section 6D, Manual Steer-
ing gear and Section 2C, Front Suspension.
a. Control arm ball joint bolt.
b. Tie rod end joint castellated nut.
Notice: Use only the recommended tool for separating
the tie rod from the knuckle/strut assembly. Failure to
use the recommended tool may cause damage to the
knuckle/strut assembly or the tie rod end.

HYDRAULIC BRAKES 4A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
BRAKE SYSTEM (NON–ABS)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
MAB4A001
1. Power Booster
2. Power Booster Boot
3. Cotter Pin
4. Clevis
5. Clevis Pin
6. Packing
7. Spacer
8. Master Cylinder Assembly
9. Fluid Reservoir Assembly
10. Reservoir Cap
11. Reservoir
12. Grommet Seal
13. Master Cylinder
14. Proportioning Valve
15. Stoplamp Switch
16. Brake Pedal Assembly
17. Clutch Pedal Spring18. Pedal Bracket Assembly
19. Clutch Pedal Pad
20. Clutch Pedal
21. Cushion
22. Bushing
23. Retaining Ring
24. Spring
25. Brake Pedal Pad
26. Brake Pedal
27. Brake Pedal Spring
28. Accelator Pedal Pad
29. Accelator Pedal
30. Rear Drum Brake Hose
31. E Ring
32. Front Disc Brake Hose
33. Brake Hose Coupling Bolt
34. Plain Washer

4B –8 MASTER CYLINDER
DAEWOO M-150 BL2
UNIT REPAIR
D24B001
MASTER CYLINDER
(ABS Type Master Cylinder is Shown,
Non–ABS Type Master Cylinder is Similar)
Disassembly Procedure
1. Remove the master cylinder. Refer to “Master Cylin-
der Assembly” in this section.
2. Remove the brake fluid reservoir. Refer to “Brake
Fluid Reservoir” in this section.
3. Remove the reservoir seals (1).
4. Remove the washer (2).
5. Remove the stop pin (3).
D24B002
6. Remove the boot (1).
7. Remove the retaining ring (2).
Notice: When removing the retaining ring, avoid dam-
aging the piston or the cylinder wall.
8. Remove the primary piston (3).
9. Carefully remove the secondary piston assembly
and the spring from the master cylinder bore (4).
D24B003
Assembly Procedure
1. Install the secondary piston assembly .
2. Install the stop pin.
3. Install the primary piston.
4. Install the retaining ring.
5. Install the boot.
6. Install the washer.
7. Install the reservoir seals.
8. Install the brake fluid reservoir. Refer to “Brake Fluid
Reservoir” in this section.
9. Install the master cylinder. Refer to “Master Cylinder
Assembly” in this section.
10. Raise and suitably support the vehicle.
11. Bleed the braking system. Refer to Section 4A, Hy-
draulic Brakes.
12. Lower the vehicle.

5B–16 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5032
8. Install the radiator lower hose and crank position
(CKP) sensor.
Tighten
Tighten the radiator lower hose bolt to 8–15 Nm
(70–132 lb-in).
Tighten the CKP sensor bolt to 5–8 Nm (44–70 lb-
in).
D13B520A
9. Refill the transaxle fluid.

Tighten the drain plug to 25–30 Nm (18–22 lb-ft)
(a).

Remove the oil level plug (1).

Refill recommended fluid to the proper level.
Classification 75W – 85 (GL–4) Capacity2.1L (2.21 qt)

Tighten the oil level plug to 36–54 Nm (26–40 lb-ft)
(b).
D13B521A
10. Adjust the clutch cable. Refer to Section 5C, Clutch.

Adjust the clutch cable by the clutch cable adjust
nut.
11. Install the transaxle under cover.
Tighten
Tighten the transaxle under cover bolts to 35–55
Nm (25–41 lb-ft).
D103B501
GEAR SHIFT CONTROL CASE
ASSEMBLY
Removal Procedure
1. Remove the air hose (air cleaner to throttle body).
Refer to Section 1B, SOHC Engine Mechanical.
2. Remove the battery.
3. Disconnect the select and the shift control cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift control cable
(3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.

5B–50 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B795
Side Gear Play Inspection
1. Measure the axle direction play of side gear and re-
place a side gear washer if it exceeds limit.
UNIT : mm (in.)


Thrust Free Play of
Differential Side

0.05–0.33
(0.0020–0.0130)
UNIT : mm (in.)
0.90 (0.0354) 0.95 (0.0374)
Thrust Adjusting 1.00 (0.0394) 1.05 (0.0413)

Thrust Adjusting
Shim
1.10 (0.0433) 1.15 (0.0453)
1.20 (0.0472)
D103B796
2. After checking for worn or scratched thrust adjusting
shim, replace it if necessary.
a. Side gear.
b. Driver.
D103B797
Assembly Procedure
1. Install the differential left side bearing.

Insert the left side bearing (1).

Install the left side bearing using the bushing, seal
installer 09913–76010 and a hammer.
Important: Coat the inner parts; bearing, washer, shim
etc. with gear fluid.
D103B798
2. Install the speedometer drive gear and differential
right side bearing.

Insert the speedometer drive gear(1).

Insert the differential right side bearing (2).

Install the right side bearing using the bushing,
seal installer 09913–76010 and a hammer.