Daewoo MATIZ User manual

SECTION INDEX
FRONT MATTER 0A
GENERAL INFORMATION 0B
ENGINE 1
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 ACCESSORIES 9
7
HVAC
(HEATING, VENTILATION,
AND AIR CONDITIONING)
(MY2003)

ENGINE
CONTENTS
SECTION 1A GENERAL ENGINE INFORMATION
SECTION 1B SOHC ENGINE MECHANICAL
SECTION 1D ENGINE COOLING
SECTION 1E ENGINE ELECTRICAL
SECTION 1F ENGINE CONTROLS
SECTION 1G ENGINE EXHAUST

SUSPENSION
CONTENTS
SECTION 2A SUSPENSION DIAGNOSIS
SECTION 2B WHEEL ALIGNMENT
SECTION 2C FRONT SUSPENSION
SECTION 2D REAR SUSPENSION
SECTION 2E TIRES AND WHEELS

DRIVELINE/AXLE
CONTENTS
SECTION 3B MANUAL TRANSAXLE DRIVE AXLE

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

TRANSAXLE
CONTENTS
SECTION 5B FIVE–SPEED MANUAL TRANSAXLE
SECTION 5C CLUTCH

STEERING
CONTENTS
SECTION 6A POWER STEERING SYSTEM
SECTION 6B POWER STEERING PUMP
SECTION 6C POWER STEERING GEAR
SECTION 6D MANUAL STEERING GEAR
SECTION 6E STEERING WHEEL AND COLUMN

HVAC (HEATING, VENTILATION,
AND AIR CONDITIONING)
CONTENTS
SECTION 7A HEATING AND VENTILATION SYSTEM
SECTION 7B MANUAL CONTROL HEATING,
VENTILATION, AND AIR CONDITIONING
SYSTEM

RESTRAINTS
CONTENTS
SECTION 8A SEAT BELTS
SECTION 8B SUPPLEMENTAL INFLATABLE RESTRAINTS
(SIR)

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

DAEWOO M-150 BL2
SECTION 1A
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Description and Operation 1A-2. . . . . . . . . . . . . . . . . .
Cleanliness and Care 1A-2. . . . . . . . . . . . . . . . . . . . . .
On-Engine Service 1A-2. . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 1A-3. . . . . . . . . . . . . . . . . . . . . . . .
Engine Compartment (Typical) 1A-3. . . . . . . . . . . . . .
Engine Compartment (Euro III) 1A-4. . . . . . . . . . . . . .
Diagnoctic Information and Procedure 1A-5. . . . . . .
General Diagnosis 1A-5. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Fluid Level 1A-11. . . . . . . . . . . . . . .
Changing Engine Oil or Oil Filter 1A-11. . . . . . . . . . . .
Checking Engine Timing Belt 1A-12. . . . . . . . . . . . . . .
Checking Accessory Belt 1A-12. . . . . . . . . . . . . . . . . .
Checking Spark Plug 1A-12. . . . . . . . . . . . . . . . . . . . .
Checking Air Cleaner Element 1A-13. . . . . . . . . . . . .
Checking Fuel Filter 1A-13. . . . . . . . . . . . . . . . . . . . . .
Checking Fuel System 1A-13. . . . . . . . . . . . . . . . . . . .
Checking Hose System 1A-13. . . . . . . . . . . . . . . . . . .
Specifications 1A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 1A-14. . . . . . . . . . . . . . . . . . . .
Engine Performance Curve 1A-15. . . . . . . . . . . . . . . .

1A–2 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
DESCRIPTION AND SYSTEMOPERATION
CLEANLINESS AND CARE
An automobile engine is a combination of many ma-
chined, honed, polished and lapped surfaces with toler-
ances that are measured in the ten–thousandths of an
inch. When any internal engine parts are serviced, care
and cleanliness are important. A liberal coating of en-
gine oil should be applied to friction areas during assem-
bly, to protect and lubricate the surfaces on initial
operation. Proper cleaning and protection of machined
surfaces and friction areas is part of the repair proce-
dure. This is considered standard shop practice even if
not specifically stated.
Whenever valve train components are removed for ser-
vice, they should be kept in order. They should be
installed in the same locations, and with the same mat-
ing surfaces, as when they were removed. Battery
cables should be disconnected before any major work is
performed on the engine. Failure to disconnect cables
may result in damage to wire harness or other electrical
parts.
ON-ENGINE SERVICE
Caution: Disconnect the negative battery cable be-
fore removing or installing any electrical unit, or
when a tool or equipment could easily come in con-
tact with exposed electrical terminals. Disconnect-
ing this cable will help prevent personal injury and
damage to the vehicle. The ignition must also be in
B unless otherwise noted.
Notice: Any time the air cleaner is removed, the intake
opening should be covered. This will protect against ac-
cidental entrance of foreign material, which could follow
the intake passage into the cylinder and cause exten-
sive damage when the engine is started.

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 Motor
13 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 Motor
11 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–5
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION PROCEDURE
GENERAL DIAGNOSIS
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Condition
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Probable cause
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Correction
Hard Starting (With Malfunction of DFaulty fuse. DReplace the fuse.
normal cranking) Ignition System DFaulty spark plug. DClean, adjust the plug gap or
replace.
DElectric leakage at the high
tension cable. DReplace the cable.
DPoor connection of the high
tension cable or lead wires. DReplace the cable or wires.
DWorn distributor cap or
accumulated carbon in the
distributor cap.
DReplace or clean the
distributor cap.
DDamaged distributor rotor or
cap. DReplace the rotor or the cap.
DImproper ignition timing. DAdjust the ignition timing.
DFaulty ignition coil. DReplace the ignition coil.
Malfunction of Fuel DLock of fuel in the fuel tank. DFeed the fuel.
System DDirty or clogged fuel filter. DReplace the filter.
DClogged fuel pipe. DClean the fuel pipe.
DMalfunction of the fuel pump. DReplace the fuel pump.
DMalfunction of the fuel
injector. DReplace the injector.
DThe foreign material in the
fuel tank. DClean the fuel tank.
Decline of
Compression DPoor tightening spark plug. DTighten to the specified
torque.
Pressure DCracked cylinder head
gasket. DReplace the gasket.
DInadequate the valve
clearance. DAdjust the clearance.
DLeakage of the valve
clearance. DRepair the valve.
DInterference of the valve
stem. DReplace the valve or the valve guide.
DLow elasticity or damage of
the valve spring. DReplace the valve spring.
DAbnormal interference of
pistons and cylinders. DReplace the piston ring.
DExcessive wear of pistons,
rings, or cylinders. DReplace the ring or the piston and boring or replace
the cylinder.

1A–6 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
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Condition
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Probable cause
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Correction
Hard Starting (With Others DBroken timing belt. DReplace the belt.
normal cranking) DMalfunction of Positive
Crankcase Ventilation (PCV)
valve.
DCheck and replace Positive
Crankcase Ventilation (PCV)
valve if needed.
DLoosening, damage or
leakage of the vacuum hose. DConnect the hose correctly or replace it.
DLeakage of intake system. DReplace intake system.
Lack of Engine Power Decline of
Compression
Pressure
DRefer to “Page 1A–5”.DRefer to “Page 1A–5”.
Malfunction of DImproper ignition timing. DAdjust the ignition timing.
Ignition System DFaulty spark plug. DAdjust or replace the spark
plug.
DMalfunction of the distributor. DRepair or replace the
distributor. Check the rotor.
DElectric leakage or poor
connection of the high
tension cable.
DConnect the cable correctly
or replace it.
Malfunction of DClogged fuel pipe. DClean the pipe.
Fuel System DClogged or contaminated
fuel filter. DReplace the filter.
Others DClogged exhaust system. DCheck and repair the
system.
DClogged or contaminated air
cleaner element. DClean or replace the air cleaner element.
DLeak of the intake manifold
gasket. DReplace the gasket.
DDragging brakes. DRepair or replace the
brakes.
DSlipping clutch. DAdjust or replace the clutch.
Rough Engine Idling Decline of
Compression
Pressure
DRefer to “Page 1A–5”.DRefer to “Page 1A–5”.
Malfunction of DClogged fuel pipe. DClean the pipe.
Fuel System DClogged or contaminated
fuel filter. DReplace the filter.
DMalfunction of the fuel
pressure regulator. DReplace the regulator.
Malfunction of
Ignition System DMalfunction of the spark
plug. DAdjust or replace the spark plug.
DElectric leakage or poor
connection of the high
tension cable.
DConnect the cable correctly
or replace it.
DWorn distributor cap terminal
or accumulated carbon in
the distributor cap.
DReplace or clean the
distributor cap.

GENERAL ENGINE INFORMATION 1A–7
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
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Condition
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Probable cause
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Correction
Rough Engine Idling Malfunction of
Ignition System DLoosening or damage of the
distributor rotor or cap. DReplace the rotor or cap.
DPoor ignition timing. DAdjust the ignition timing.
DMalfunction of the ignition
coil. DReplace the ignition coil.
Others DClogged or contaminated air
cleaner element. DClean or replace the air cleaner element.
DLeak of the intake manifold
gasket. DReplace the gasket.
DMalfunction of Positive
Crankcase Ventilation (PCV)
valve.
DCheck the valve or replace it
if needed.
DPoor connection or damage
or leakage of the vacuum
hose.
DConnect the hose correctly
or replace it.
Engine Hesitate (Upon
pressing accelerating
pedal, the engine
Decline of
Compression
Pressure
DRefer to “Page 1A–5”.DRefer to “Page 1A–5”.
makes delayed
response. This Malfunction of DPoor ignition timing. DAdjust the ignition timing. response. This
situation is remarkable
when cruising or Ignition System DPoor spark plug or poor
adjustment of the plug gap. DReplace the plug or adjust the gap.
starting.) DElectric leakage or poor
connection of the high
tension cable.
DConnect the cable correctly
or replace it.
Others DMalfunction of the air cleaner
system. DClean or replace the air cleaner system.
DLeak of the intake manifold
gasket. DReplace the gasket.
Engine Surging
(Engine power makes
fluctuation in a fixed
Decline of
Compression
Pressure
DRefer to “Page 1A–5”.DRefer to “Page 1A–5”.
speed and speed
changes without Malfunction of DClogged fuel pipe. DClean the pipe. changes without
operating the
accelerating pedal.) Fuel System DClogged or contaminated
fuel filter. DReplace the filter.
DMalfunction of the fuel
pressure regulator. DReplace the fuel pressure regulator.
Malfunction of
Ignition System DMalfunction of the spark
plug. DAdjust or replace the spark plug.
DElectric leakage or poor
connection of the high
tension cable.
DConnect the cable correctly
or replace it.
DWorn distributor cap terminal
or accumulated carbon in
the distributor cap.
DClean or replace the
distributor cap.
DLoosening or damage of the
distributor rotor or the cap. DReplace the distributor rotor or the cap.
DPoor ignition timing. DAdjust the ignition timing.

1A–8 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
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Condition
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Probable cause
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Correction
Engine Surging
(Engine power makes
fluctuation in a fixed
Others DLeak of the intake manifold
gasket. DClean or replace the gasket.
speed and speed
changes without
operating the
accelerating pedal.)
DLeakage of the vacuum hose. DConnect the hose correctly
or replace it.
Excessive Detonation
(According to the Overheated
Engine DRefer to “Overheat”in this
page. DRefer to “Overheat”in this page.
opening range of
throttle valve, Malfunction of DAbnormal spark plug. DReplace the spark plug.
knocking sound of
metallic is made with Ignition System DPoor ignition timing. DAdjust the ignition timing. metallic is made with
abnormal explosion.) DElectric leakage or poor
connection of the high tension
cable.
DConnect the cable correctly
or replace it.
Malfunction of
Fuel System DClogged or contaminated fuel
filter and fuel pipe. DClean or replace the fuel filter and the fuel pipe.
Others DLeak of the intake manifold
gasket. DReplace the gasket.
DExcessive carbon deposit due
to abnormal combustion. DRemove the carbon.
Overheat Malfunction of DLack of coolant. DRefill coolant.
Cooling System DMalfunction of the thermostat. DReplace the thermostat.
DMalfunction of the cooling fan. DCheck or replace the cooling
fan.
DPoor water pump
performance. DReplace the pump.
DClogged or leaky radiator. DClean, repair or replace the
radiator.
Malfunction of
Lubrication DPoor engine oil. DReplace engine oil with the
specified one.
System DBlocking oil filter or strainer. DClean or replace the oil filter
or the strainer.
DLack of engine oil. DRefill oil.
DPoor oil pump performance. DReplace or repair the pump.
DLeakage of oil. DRepair.
Other DDamaged cylinder head
gasket. DReplace the gasket.
Poor Fuel
Consumption Decline of
Compression
Pressure
DRefer to “Page 1A–5”.DRefer to “Page 1A–5”.
Malfunction of
Fuel System DLeakage of the fuel tank or
the fuel pipe. DRepair or replace the fuel tank or the fuel pipe.

GENERAL ENGINE INFORMATION 1A–9
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
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Condition
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Probable cause
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Correction
Poor Fuel Malfunction of DImproper ignition timing. DAdjust the ignition timing.
Consumption Ignition System DAbnormal spark plug
(Excessive carbon deposit,
inadequate gap, burnt
electrode).
DReplace the plug.
DElectric leakage or poor
connection of the high
tension cable.
DConnect the cable normally
or replace it.
Malfunction of
Cooling System DMalfunction of the
thermostat. DReplace the thermostat.
Others DImproperly installed valve. DRepair or replace the valve.
DSlipping clutch. DRepair or replace the clutch.
DLow pressure of tires. DAdjust the pressure of tires.
Excessive Leakage of DLoosened oil drain plug. DTighten the plug.
Consumption of
Engine Oil Engine Oil DLoosened oil pan bolt. DTighten the bolt. Engine Oil
DLoosened oil filter. DTighten the filter.
DLoosened oil pressure
switch. DTighten the switch.
DLeakage of camshaft front oil
seal. DReplace the seal.
DLeakage of crankshaft front
oil seal. DReplace the seal.
DLeakage at the cylinder head
cover gasket. DReplace the gasket.
DDamage of the cylinder head
gasket. DReplace the gasket.
Oil Mixing in
Combustion DStuck piston ring. DRemove carbon and replace
the ring.
Chamber DWorn piston or cylinder. DReplace the piston or the
cylinder.
DWorn piston ring or ring
groove. DReplace the piston or ring.
DInadequate position of the
piston ring cutting part. DAdjust the position.
DAbrasion or damage of the
valve system. DReplace the valve system.
Low Oil Pressure Malfunction of
Lubrication DInadequate oil viscosity. DReplace with the specified
one.
System DLoosening of the oil pressure
switch. DTighten the switch.
DLack of engine oil. DRefill oil.
DBlocking oil strainer. DClean the strainer.

1A–10 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
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Condition
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Probable cause
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Correction
Low Oil Pressure Malfunction of
Lubrication DLowered function of the oil
pump. DReplace the pump.
System DAbrasion or damage of the
oil pump relief valve. DReplace the valve.
Engine Noise Valve Noise DInadequate valve clearance. DAdjust the valve clearance.
DAbrasion of valve stem or
guide. DReplace the valve stem or the guide.
DWeak valve spring. DReplace the spring.
Piston, Ring,
Cylinder Noise DAbrasion of the piston, the
ring or the cylinder. DBoring the cylinder or replace the piston, the ring
or the cylinder.
Connecting Rod
Noise DAbrasion of the connecting
rod bearing. DReplace the bearing.
DLoosened the connecting rod
nut. DTighten to the specified torque.
Crankshaft
Noise DAbrasion of the crankshaft
bearing. DReplace the bearing.
DAbrasion of the crankshaft
journal. DGrind or replace the crankshaft journal.
DLoosened bearing cap bolt. DTighten to the specified
torque.
DExcessive clearance of the
crankshaft thrust bearing. DAdjust or replace.
DLow oil pressure. DRefer to “Low Oil Pressure”
in this section.