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File information:
File name:796cc (My 2003).part16.rar
Size:1043 kB
Extension:PDF
MD5 Checksum:4fe49f8aaebe893d1514a933b6573e7d
Mfg:Daewoo
Model:Matiz
Original no||Chassis||Ordercode:M-150 BL2
Description:Service Manual, Wiring Diagram - 16 Part File - 62 File
Group:Electronics > Automobile >
Uploaded:2006-11-09 18:46:00
User:salvacolnome
Multipart: 0  1  2  3  4  5  6  7  8  9  10  11  12  13  14  15

Information about the files in archive:
Decompress result:OK
Extracted files:61
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7b1 Heating, Ventilation and AC 1-20.pdfSECTION 7B MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . System Components Functional . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Refrigerant System . . . . . . . . . . . . . . Insufficient Cooling "Quick Check" Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 7B-2 7B-3 7B-3 7B-5 7B-5 7B-5 7B-
M31a General Engine Information.pdfSECTION 1A GENERAL ENGINE INFORMATION TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Cleanliness and Care . . . . . . . . . . . . . . . . . . . . . . On-Engine Service . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Engine Compartment (Typical) . . . . . . . . . . . . . . Engine Compartment (Euro III) . . . . . . . . . . . . . . Diagnoctic Information and Procedure . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 1A-2 1A-2 1A-3 1A-3 1A-4 1A-5 1A-5 Checking Engine Timing Belt . . . . . . . . . . . . . . . Checking Accessory Belt . . . . . . . . . . . . . . . . . . Checking Spark Plug . . . . . . . . . . . . . . . . . . . . . Checking Air Cleaner Element . . . . . . . . . . . . . Checking Fuel Filter . . . . . . . . . . . . . . . . . . . . . . Checking Fuel System . . . . . . . . . . . . . . . . . . . . Checking Hose System . . . . . . . . . . . . . .
M31b1 SOHC Engine Mechanical.pdfSECTION 1B SOHC ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Engine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Valve Train . . . . . . . . . . . . . . Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston, Piston Ring and Piston Pin . . . . . . . . . . . 1B-2 1B-2 1B-2 1B-2 1B-3 1B-3 1B-3 1B-3 Air Filter Assembly . . . . . . . . . . . . .
M31d Engine Cooling.pdfSECTION 1D ENGINE COOLING CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant Temperature Sensor . . . . . . . . . 1D-2 1D-2 1D-2 1D-2 1D-3 1D-3 1D-3 1D-4 Cooling System Diagnosis . . . . . . . . . .
M31e1 Engine Electrical 1-18.pdfSECTION 1E ENGINE ELECTRICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . . . Cold Cranking Amperage . . . . . . . . . . . . . . . . . . . Built-In Hydrometer . . . . . . . . . . . . . . . . . . . . . . . . Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . Charging Time Required . . . . . . . . . . . . . . . . . . . . Charging a Completely Discharged Battery (Off the Vehicle) . . . . . . . . . . .
M31e2 Engine Electrical 19-42.pdfENGINE ELECTRICAL 1E 19 REPAIR INSTRUCTIONS UNIT REPAIR STARTER MOTOR Inspection / Measurement (Before the Overhaul) 1. Remove the starter. Refer to "Starter" in this section. 2. Pinion clearance inspection. D Disconnect the starter motor terminal M (1). D Connect the 12-volt battery lead to the starter motor terminals M and S. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds) D Switch on to move the pinion gear (2). D Now check the clearance between the pinion and the stopper with the filler gauge (3). D If the clearance does not fall within the limits, check for improper installation and replace all worn parts. D102E701 D102E702 3. Magnetic switch pull-in test. D Disconnect the starter motor terminal M (1). D Connect the 12-volt battery lead to the starter motor terminals M and S. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds) D10
M31f1 Engine Controls 1-54.pdfSECTION 1F ENGINE CONTROLS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Ignition System Operation . . . . . . . . . . . . . . . . . . Electronic Ignition System Ignition Coil . . . . . . . Crankshaft Position Sensor . . . . . . . . . . . . . . . . . Camshaft Position Sensor . . . . . . . . . . . . . . . . . . Idle Air System Operation . . . . . . . . . . . . . . . . . . Fuel Control System Operation . . . . . . . . . . . . . . Evaporative Emission Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controlled Charcoal Canister . . . . . . . . . . . . . . . . Positive Crankcase Ventilation C
M31f2 Engine Controls 55-151.pdfENGINE CONTROLS 1F 55 DIAGNOSTIC TROUBLE CODE DIAGNOSIS CLEARING TROUBLE CODES Notice: To prevent Engine Control Module (ECM) damage, the key must be OFF when disconnecting or reconnecting the power to the ECM (for example battery cable, ECM pigtail connector, ECM fuse, jumper cables, etc.).When the ECM sets a Diagnostic Trouble Code (DTC), the Malfunction Indicator Lamp (MIL) lamp will be turned on only for type A, B and E but a DTC will be stored in the ECM's memory for all types of DTC. If the problem is intermittent, the MIL will go out after 10 seconds if the fault is no longer present. The DTC will stay in the ECM's memory until cleared by scan tool. Removing battery voltage for 10 seconds will clear some stored DTCs. DTCs should be cleared after repairs have been completed. Some diagnostic tables will tell you to clear the codes before using the chart. This allows the ECM to set the DTC while going through the chart, which will help to find the cause of the problem more quick
M31f3 Engine Controls 152-279.pdf1F 152 ENGINE CONTROLS MAA1F180 DIAGNOSTIC TROUBLE CODE (DTC) P0336 58X CRANKSHAFT POSITION SENSOR NO PLAUSIBLE SIGNAL Circuit Description The 58X reference signal is produced by the crankshaft position (CKP) sensor. During one crankshaft revolution, 58 crankshaft pulses will be produced. The engine control module(ECM) uses the 58X reference signal to calculate engine rpm and CKP. The ECM constantly monitors the number of pulses on the 58X reference circuit and compares them to the number of camshaft position (CKP) signal pulses being received. If the ECM receive and incorrect number of pulses on the 58X reference circuit, DTC P0336 will set. Conditions for Setting the DTC D This DTC can be stored in "key-on" status. D Detected number of teeth is differs by 3 or higher. Action Taken When the DTC Sets D The Malfunction Indicator Lamp (MIL) will illuminate. D The ECM will record operating conditions at the time the diagnostic fails. This information will be stored in the Freeze Fra
M31f4 Engine Controls 280-324.pdf1F 280 ENGINE CONTROLS SYMPTOM DIAGNOSIS IMPORTANT PRELIMINARY CHECKS Important: Several symptom procedures call for a careful visual/physical inspection. Always perform the visual/ physical test first. Visual inspections may lead to Step 1 Action Perform the On-Board Diagnostic (EOBD) System Check. Are any Diagnostic Trouble Code(s) (DTCs) stored in the Engine Control Module (ECM) memory? 1. Inspect all of the ECM ground connections. 2. Inspect all of the vacuum hoses for splits, kinks, and proper connections. 3. Check for air leaks at all of the mounting areas of the intake manifold sealing surfaces. 4. Inspect the ignition wires for cracking, hardness, proper routing, and carbon tracking. 5. Inspect the wiring for proper connections, pinches, and cuts. Are all checks complete? correcting a problem without further checks and can save valuable time. Value(s) Yes Go to Appropriate DTC Table No Go to Step 2 2 Go to Appropriate Symptom Table DAEWOO M-150 BL2 ENGINE CONT
M31g Engine Exhaust.pdfSECTION 1G ENGINE EXHAUST TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . 1G-2 1G-2 1G-2 1G-2 Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Pipe/Catalytic Converter . . . . . . . . . . . . Pup-up Catalitic Converter . . . . . . . . . . . . . . . . . . Front Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . . 1G-4 1G-4 1G-4 1G-5 1G-7 1G-8 1G-9 1G-9 Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 1G-3 Exhaust
M32a Suspension Diagnostics.pdfSECTION 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 systems 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 test the 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 D Inspect the tires for improper pressure and uneven wear. D Inspect the joint from the steering column to the intermediate shaft for loose connec
M32b Wheel Alignment.pdfSECTION 2B WHEEL ALIGNMENT TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Four Wheel Alignment . . . . . . . . . . . . . . . . . . . . . Toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Axis Inclination . . . . . . . . . . . . . . . . . . . . Included Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scrub Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 2B-2 2B-2 2B-2 2B-2 2B-3 2B-3 2B-3 Diagnostic Information and Procedures . . . . . Tire Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . Front Camber and Caster Check . . . . . . . . . . . . Rear Camber Check . . . . . . . . . . . . . . . . . . . . . . . Rear Toe Check . . . . . . . . . . . . . . . .
M32c Front Suspension.pdfSECTION 2C FRONT SUSPENSION TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Strut Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Joint and Knuckle . . . . . . . . . . . . . . . . . . . . . Front Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . 2C-2 2C-2 2C-3 2C-3 2C-5 2C-5 2C-5 2C-6 Front Longitudinal Frame and Stabilizer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 2C-10 Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-12 Strut Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-12 Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-13 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M32d Rear Suspension.pdfSECTION 2D REAR SUSPENSION TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Rear Wheel Bearing End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Bearing Free Load . . . . . . . . . . . . . . 2D-2 2D-2 2D-3 2D-3 2D-4 2D-4 2D-5 2D-5 Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . Lateral Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub and Bearing A
M32e Tires and Wheels.pdfSECTION 2E TIRES AND WHEELS TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Tires . . . . . . . . . . . . . . . . . . . . . . . . All Season Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inflation of Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2 2E-2 2E-3 2E-3 2E-3 2E-3 2E-4 2E-4 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Balancing . . . . . . . . . . . . . . . . . . . . . . 2E-7 2E-7 2E-7 2E-8 Off-Vehicle Balancing . . . . .
M33b Manual Transaxle Drive Axle.pdfSECTION 3B MANUAL TRANSAXLE DRIVE AXLE TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 3B-2 3B-3 3B-3 3B-4 3B-4 3B-5 3B-5 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-9 Inner Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-9 Outer Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-12 General Specifications . . . . . . . . . . . . . . . .
M34a Hydraulic Brakes.pdfSECTION 4A HYDRAULIC BRAKES CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Warning Lamp Operation . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Brake System (Non-ABS) . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Brake System Testing . . . . . . . . . . . . . . . . . . . . . . Brake Hose Inspection . . . . . . . . . . . . . . . . . . . . . Warning Lamp Operation . . . . . . . . . . . . . . . . . . . 4A-2 4A-2 4A-3 4A-3 4A-4 4A-4 4A-4 4A-5 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . .
M34b Master Cylinder.pdfSECTION 4B MASTER CYLINDER TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . Proportioning Valve . . . . . . . . . . . . . . . . . . . . . . . . Fluid Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Checking the Brake Fluid Level . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 4B-2 4B-2 4B-2 4B-3 4B-3 4B-4 4B-4 Brake Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . Proportioning Valve (For Vehicle With the NonABS Braking System) . . . . . . . . . . . . . . . Brake Fluid Level Switch . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-5 4B-5 4B-6 4B-8 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-
M34c Power Booster.pdfSECTION 4C POWER BOOSTER TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Power Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Power Booster Functional Check . . . . . . . . . . . . 4C-2 4C-2 4C-3 4C-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose and Check Valve . . . . . . . . . . . . . Power Booster Assembly . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 4C-4 4C-5 4C-8 Check Valve Functional Check . . . . . . . . . . . . . . 4C-3 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 General Specifications . . . . . . . . . . . . . . . . . . . . . 4C-8 Fastener Tightening Specifications . . . . . . . . . . . 4C-8 DAEWOO M-150 BL2 4C 2 POWER BOOSTER DESCRIPTION AND OPERATION POWER BOOSTER This booster is a single diaphragm, vacuum-suspended unit. In a normal
M34d Front Disc Brakes.pdfSECTION 4D FRONT DISC BRAKES TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Disc Brake Caliper Assembly . . . . . . . . . . . . . . . Clearance Calibration . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . Lining Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 4D-2 4D-2 4D-3 4D-3 4D-4 4D-4 4D-5 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe and Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-6 4D-6 4D-7 4D-7 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-8 Caliper Overh
M34e Rear Drum Brakes.pdfSECTION 4E REAR DRUM BRAKES TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Rear Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Rear Drum Brake . . . . . . . . . . . . . . . . . . . . . . . . . . Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-2 4E-2 4E-3 4E-3 4E-4 4E-4 4E-5 4E-5 Rear Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Cylinder Assembly . . . . . . . . . . . . . . . . . . Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Cylinder . . . . . . .
M34f1 ABS.pdfSECTION 4F ANTILOCK BRAKE SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. CAUTION: Don't diagnosis the Antilock Brake System (ABS) under the vehicle moving status. Because the ABS function will be stopped. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . ABS System Components . . . . . . . . . . . . . . . . . . Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EBCM (Electronic Brake Control Module) . . . . . Wheel Speed Sensors and Rings . . . . . . . . . . . . Electronic Brake Distribution . . . . . . . . . . . . . . . . Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EBCM Connector . . . . . . . . . . . . . . . . . .
M34g Parking Brake.pdfSECTION 4G PARKING BRAKE TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2 4G-2 4G-3 4G-3 Parking Brake Warning Lamp Switch . . . . . . . . . Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . 4G-5 4G-6 4G-8 4G-8 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4G-4 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-4 Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . 4G-4 Fastener Tightening Specifications . . . . . . . . . . . 4G-8 Schematic and Routing Diagrams . . . . . . . . . . . 4G-9 Parking Brake System . . . . . . . . . . . .
M35b Five Speed Manual Transaxle.pdfSECTION 5B FIVE-SPEED MANUAL TRANSAXLE CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Five-Speed Manual Transaxle . . . . . . . . . . . . . . . Reverse Gear Misshift Preventing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locators . . . . . . . . . . . . . . . . . . . . . . . Gear Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . Input Shaft and Counter Shaft Gear . . . . . . . . . . Gear Shift Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential and Case . . . . . . . . . . . . . . . .
M35c Clutch.pdfSECTION 5C CLUTCH CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Driving Members . . . . . . . . . . . . . . . . . . . . . . . . . . Driven Members . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Members . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Clutch Components . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 5C-2 5C-2 5C-2 5C-3 5C-3 5C-4 5C-4 Pressure Plate, Clutch Disc and Input Shaft Bearing . . . . . . . . . . . . . . . .
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M36b Power Steering Pump.pdfSECTION 6B POWER STEERING PUMP TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 6B-2 6B-3 6B-3 6B-4 6B-4 6B-4 6B-5 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specificatio
M36c Power Steering Gear.pdfSECTION 6C POWER STEERING GEAR CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Power Rack and Pinion . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Power Rack and Pinion Steering Gear . . . . . . . Adjust the Free Load of the Steering Gear . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Rack and Pinion Assembly . . . . . . . . . . . . . . . . . 6C-2 6C-2 6C-3 6C-3 6C-5 6C-6 6C-6 6C-6 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tie Rod End Boot . . . . . . .
M36d Manual Sterring Gear.pdfSECTION 6D MANUAL STEERING GEAR CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Manual Rack and Pinion . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Manual Rack and Pinion Steering Gear . . . . . . . Diagnostic Information and Procedures . . . . . Manual Rack and Pinion Steering Gear . . . . . . . Straight-Ahead Check . . . . . . . . . . . . . . . . . . . . . . Steering Wheel Restoration . . . . . . . . . . . . . . . . . 6D-2 6D-2 6D-3 6D-3 6D-4 6D-4 6D-5 6D-6 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Tie Rod End . . . . . . . . . . . . . .
M36e Steering Wheel and Column.pdfSECTION 6E STEERING WHEEL AND COLUMN CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Steering Wheel and Column . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel and Column . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Steering Column Diagnosis . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Column Cover . . . . . . . . . . . . . . .
M37a1 Heating and Ventilation System 1-17.pdfSECTION 7A HEATING AND VENTILATION SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . 7A-2 Heating and Ventilation Systems . . . . . . . . . . . . 7A-2 Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 7A-3 Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3 Blower Module Assembly . . . . . . . . . . . . . . . . . . . 7A-4 Air Distributor and Heater Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-5 Diagnostic Informatin and Procedures . . . . . . . 7A-6 Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-6 Insufficient Heating or Defr
M37a2 Heating and Ventilation System 18-32.pdf7A 18 HEATING AND VENTILATION SYSTEM REPAIR INSTRUCTIONS ON-VEHICLE SERVICE CONTROL ASSEMBLY AND CONTROL CABLES (LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the instrument cluster housing trim panel. Refer to Section 9E, Instrumentation/Driver information. 3. Remove the control assembly. D108A501 D Remove the control assembly retaining screws (1). D Separate the control assembly from the instrument panel (2). D Disconnect the electrical connectors (3). D Disconnect the mode control cable from the heater module (4). D Disconnect the temperature control cable from the heater module (5). D Remove the glove box from the instrument panel. Refer to Section 9E, Instrumentation/Driver Information. D108A502 D Disconnect the recirculating/fresh air door cable from the blower module (6). D108A503 DAEWOO M-150 BL2 HEATING AND VENTILATION SYSTEM 7A 19 D108A504 4. Disconnect the control cables from the control as
M37b2 Heating, Ventilation and AC 21-33.pdfMANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 21 Installation Procedure 1. Install the compressor with the mounting bolts. Tighten D Tighten the compressor--to--bracket upper bolt to 20 NSm (15 lb-ft) (1). D Tighten the compressor--to--bracket lower bolts to 22 NSm (16 lb-ft) (2). 2. Connect the electrical connector. D18B511B 3. Install the A/C high pressure pipe line to the compressor with the bolt. Tighten Tighten the A/C high pressure pipe line bolt to 23 NSm (17 lb-ft) (3). 4. Install the A/C low pressure pipe line to the compressor with the bolt. Tighten Tighten the A/C low pressure pipe line bolt to 23 NSm (17 lb-ft) (4). 5. Evacuate and charge the system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedure for A/C System" in this section. 6. Install the A/C belt. Refer to Section 6B, Power Steering Pump. 7. Install the receiver dryer. Refer to "Receiver Dryer and Dual Cut Switch" in this section. D18B512A CONDENSER 1. Disconnect
M38a Seat Belts.pdfSECTION 8A SEAT BELTS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Driver Seat Belt Warning . . . . . . . . . . . . . . . . . . . Three-Point Pretensioner Front Seat Belt (W/EUROPE Only) . . . . . . . . . . . . . . . . . . . . . . Three-Point WLR Front Seat Belt . . . . . . . . . . . . Three-Point ELR Front Seat Belt . . . . . . . . . . . . Three-Point ELR Rear Outboard Seat Belt . . . . Two-Point Lap Rear Center Seat Belt . . . . . . . . Operational and Functional Checks . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front and Rear Seat Belt . . . . . . . . . . . . . . . . . . . Diagnos
M38b1 Airbags 1-6.pdfSECTION 8B SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Airbag Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensing and Diagnostic Module (SDM) . . . . . . . SIR Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . Clock Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness/Connectors . . . . . . . . . . . . . . . . . SIR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . . . . . . . 8B-3 8B-3 8B-3 8B-3 8B-4 8B-4 8B-4 8B-5 DTC 10 Driver Pretensioner Circuit, Resis
M38b2 Airbags 7-79.pdfSUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B 7 COMPONENT LOCATOR SIR COMPONENT (LeftHand Drive Shown, RightHand Drive Similar) D110B401 1. Driver Airbag Module 2. Passenger Airbag Module 3. Clock Spring 4. Sensing and Diagnostic Module (SDM) 5. Wiring Harness DAEWOO M-150 BL2 8B 8 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) DIAGNOSTIC INFORMATION AND PROCEDURES A scan tool connected to the data link connector (DLC): D Reveals the fault codes. D Receives serial data transmission through the terminal J (13) of the DLC. D Receives ground through the terminal A (4) of the DLC. CLEARING FAULT CODES When the sensing and diagnostic module (SDM) receives the CODE ERASE command from the scan tool, the SDM: D Clears the entire fault memory. D Turns OFF the warning lamp. D Resets for fault detection. D110B009A External Fault Service personnel can reset the SDM and turn OFF the warning lamp if the fault is an external fault. Internal Fault An internal fault of the SDM or a CRASH RECORDE
M39a Body Wiring System.pdfSECTION 9A BODY WIRING SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . How to Read Electrical Wiring Diagram . . . . . . . How to Check Terminal Number of Connector . Special Tools and Equipment . . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . Schematic and Routing Diagrams . . . . . . . . . . . Wire Color Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Power Distribution Schematic . . . . . . . . . . . . . . . 9A-2 9A-2 9A-4 9A-5 9A-5 9A-6 9A-6 9A-7 Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Harness Routing . . . . . . . . . . .
M39b Lighting Systems.pdfSECTION 9B LIGHTING SYSTEMS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Headlamps and Parking Lamps . . . . . . . . . . . . . Front Turn Signal Lamps . . . . . . . . . . . . . . . . . . . Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . Taillamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . Interior Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . Backup Lamp(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . Daytime Running Lamps (DRL) (W/Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . Diagnos
M39c Horns.pdfSECTION 9C HORNS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9C-2 9C-2 9C-3 9C-3 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C-3 Schematic and Routing Diagrams . . . . . . . . . . . 9C-4 Horn Wiring System . . . . . . . . . . . . . . . . . . . . . . . 9C-4 DAEWOO M-150 BL2 9C 2 HORN DESCRIPTION AND OPERATION HORN The horn is located under the hood. It is attached near
M39d Wipers - Washer Systems.pdfSECTION 9D WIPERS / WASHER SYSTEMS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Windshield Wiper System . . . . . . . . . . . . . . . . . . Windshield Washer System . . . . . . . . . . . . . . . . . Rear Window Wiper/Washer System . . . . . . . . . Diagnostic Information and Procedures . . . . . Windshield/Rear Window Wiper and Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper Arm . . . . . . . . . . . . . . . . . . . . . Rear Window Wip
M39e1 Instrumentation - Driver Information 1-14.pdfSECTION 9E INSTRUMENTATION/DRIVER INFORMATION CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Vents . . . . . . . . . . . . . . . . . . . . Glove Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . Speedometer/Odometer/Trip Odometer . . . . . . 9E-2 9E-2 9E-2 9E-2 9E-2 9E-2 9E-2 9E-2 Ashtray . . . . . . . . . .
M39e2 Instrumentation - Driver Information 15-26.pdfINSTRUMENT/DRIVER INFORMATION 9E 15 6. Remove the defroster duct from the cowl upper panel. D Remove the screws (1). D Remove the defroster duct (2). D109B523 7. Remove the bolts and the tiebar. a. Tie bar. D109B524 8. Remove the bolts and the tiebar center. b. Tie bar center. D109B525 Installation Procedure 1. Install the tiebar with the bolts. 2. Install the tiebar center with the bolts. 3. Install the defroster duct to the cowl upper panel with the screws. D109B526 DAEWOO M-150 BL2 9E 16 INSTRUMENT/DRIVER INFORMATION 4. 5. 6. 7. 8. 9. 10. 11. Connect the electrical wiring harness. Connect the blow motor resistance connector. Connect the blow motor connector. Connect the thermostat connector. Connect the brake switch connector. Bind the electrical wiring harness strip. Install the steering column with the nuts. Install the defroster duct hose with the screws. 12. Install the instrument panel assembly. Refer to "Instrument Panel" in this section. 13. Connect the nega
M39f Audio.pdfSECTION 9F AUDIO SYSTEMS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . 9F-2 Stereo Cassette AM/FM Radio with CD Changer and RDS/Audio Security System . . . . . . . . . . . . . 9F-2 Front and Rear Speakers . . . . . . . . . . . . . . . . . . . 9F-2 Roof Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-2 Tape Player and Cassette Care . . . . . . . . . . . . . Compact Disc Care . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Audio Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-2 9F-2 9F-3 9F-3 Repair Instructions . . . . . .
M39g Interior Trim.pdfSECTION 9G INTERIOR TRIM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Interior Trim Panels . . . . . . . . . . . . . . . . . . . . . . . . Pressure Relief Vent . . . . . . . . . . . . . . . . . . . . . . . Floor Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Cable Cover . . . . . . . . . . . . . . . . . Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G-2 9G-2 9G-2 9G-2 9G-2 9G-2 9G-3 9G-3 Tailgate Trim Panel . . . . . . . . . . .
M39h Seats.pdfSECTION 9H SEATS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Front Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H-2 9H-2 9H-3 9H-3 9H-4 9H-5 9H-5 9H-5 Front Seat Cushion . .
M39i Waterleaks.pdfSECTION 9I WATERLEAKS TABLE OF CONTENTS Diagnostic Information and Procedures . . . . . . Waterleak Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I-2 9I-2 9I-5 9I-5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I-7 Recommended Materials for Waterleak Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9I-7 Watertest Stand Specifications . . . . . . . . . . . . . . 9I-7 Waterleak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I-5 DAEWOO M-150 BL2 9I 2 WATERLEAKS DIAGNOSTIC INFORMATION AND PROCEDURES WATERLEAK DIAGNOSIS The repair of waterleaks in the body requires proper testing and diagnosis. Repair waterleaks by adjusting the misaligned parts and using the proper repair materials. First, determine what conditions cause the leak. For example, the leak may occur only when the
M39j Windnoise.pdfSECTION 9J WINDNOISE TABLE OF CONTENTS Diagnostic Information and Procedures . . . . . 9J-1 Windnoise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 9J-1 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9J-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9J-2 Windnoise Repair . . . . . . . . . . . . . . . . . . . . . . . . . 9J-2 DIAGNOSTIC INFORMATION AND PROCEDURES WINDNOISE DIAGNOSIS Caution: An assistant should drive the vehicle while the technician checks for the location of the windnoise, in order to prevent personal injury or vehicle damage. A test drive in the vehicle is necessary to accurately determine the location of the windnoise. Often there is a primary leak and secondary leaks. Failure to repair all leaks will only reduce the windnoise, not eliminate it. During the test drive the technician should bring the following items to aid in determining the location of the windnoise. D D D D A mechanics stethoscope or vacuum
M39k Squeaks and Rattles.pdfSECTION 9K SQUEAKS AND RATTLES TABLE OF CONTENTS Diagnostic Information and Procedures . . . . . 9K-1 Squeak and Rattle Diagnosis . . . . . . . . . . . . . . . 9K-1 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9K-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9K-3 Squeak and Rattle Repair . . . . . . . . . . . . . . . . . . 9K-3 DIAGNOSTIC INFORMATION AND PROCEDURES SQUEAK AND RATTLE DIAGNOSIS Condition Rattle Coming From the Side Rail Probable Cause D Improperly connected brake lines. Correction D Tap lightly on the brake lines and listen for a rattle. D Install plastic tie straps to secure the brake lines tightly together. D Raise the vehicle and perform a visual inspection. D Bend the heat shield slightly to gain clearance from the underbody. D While the vehicle is cold, perform a test drive and achieve full front suspension travel by driving through a dip in the road. D Remove the insulators and wrap teflon tape around the stabil
M39l Glass and Mirrors.pdfSECTION 9L GLASS AND MIRRORS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and System Operation . . . . . . . . . . Stationary Glass . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Rearview Mirror . . . . . . . . . . . . . . . . . . . . . Outside Rearview Mirrors . . . . . . . . . . . . . . . . . . . Components Locator . . . . . . . . . . . . . . . . . . . . . . . Glass and Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Testing Rear Window Defogger Grid Line . . . . . 9L-2 9L-2 9L-2 9L-2 9L-3 9L-3 9L-4 9L-4 Rear Window Defogger Braided Lead Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .
M39m Exterior Trim.pdfSECTION 9M EXTERIOR TRIM TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . 9M-2 Emblems and Lettering . . . . . . . . . . . . . . . . . . . . . 9M-2 Mud Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-2 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9M-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-3 Roof Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-3 Rear Spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-3 Front Bumper Spacer . . . . . . . . . . . . . . . . . . . . . . 9M-4 Tailgate Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-5 DAEWOO M-150 BL2 9M 2 EXTERIOR TRIM DESCRIPTION AND OPERATION EMBLEMS AND LETTERING The emblems and lettering on the vehicle are attached by adhesive. The company emblem appears on the hood. The lettering, which appears in several places on the body of the vehicle, features the model, the
M39n Frame and Underbody.pdfSECTION 9N FRAME AND UNDERBODY TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . General Body Construction . . . . . . . . . . . . . . . . . Transaxle Under Covers . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9N-2 9N-2 9N-2 9N-3 Alignment Checking . . . . . . . . . . . . . . . . . . . . . . . Floor Pan Insulators . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Underbody Dimensions . . . . . . . . . . . . . . . . . . . . 9N-3 9N-3 9N-4 9N-4 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9N-3 DAEWOO M-150 BL2 9N 2 FRAME AND UNDERBODY DESCRIPTION AND OPERATION GENERAL BODY CONSTRUCTION This vehicle is constructed with a unitized body which incorporates integral front and rear frame side rails. The front suspension lower control arms are bolted to and retained by supports, one each on the right a
M39o Bumpers and Facials.pdfSECTION 9O BUMPERS AND FASCIAS TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Bumpers and Fascias . . . . . . . . . . . . . . . . . . . . . . 9O-2 9O-2 9O-3 9O-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Front Bumper Fascia . . . . . . . . . . . . . . . . . . . . . . Front Bumper Impact Bar . . . . . . . . . . . . . . . . . . . Rear Bumper Fascia . . . . . . . . . . . . . . . . . . . . . . . 9O-4 9O-4 9O-5 9O-6 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9O-4 Rear Bumper Bracket . . . . . . . . . . . . . . . . . . . . . . 9O-8 DAEWOO M-150 BL2 9O 2 BUMPERS AND FASCIAS DESCRIPTION AND OPERATION BUMPERS The bumper systems are installed with the body color bumper and the general bumper according to the vehicle grade. The bumper systems are designed to susta
M39p Doors.pdfSECTION 9P DOORS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Door Lock Striker . . . . . . . . . . . . . . . . . . . . . . . . . . Childproof Rear Door Lock . . . . . . . . . . . . . . . . . . Power Door Locks . . . . . . . . . . . . . . . . . . . . . . . . . Power Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P-2 9P-2 9P-2 9P-2 9P-2 9P-2 9P-3 9P-3 Outside Front Door Handle . . . . . . . . . . . . .
M39q Roof.pdfSECTION 9Q ROOF TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual SunRoof . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Visors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Passenger Assist Handles . . . . . . . . . . . . . . . . . . Coat Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q-2 9Q-2 9Q-2 9Q-2 9Q-2 9Q-2 9Q-3 9Q-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Formed Headliner . . . . . . . . . . . . . . . . . . . . . . . . . Manual SunRoof . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Visors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q-4 9Q-4 9Q-5 9Q-6 Passenger Assist Handle and the Coat Hook . . . . . . . . . . . .
M39r Body Front End.pdfSECTION 9R BODY FRONT END TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Body Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anticorrosion Materials . . . . . . . . . . . . . . . . . . . . . Front End Sealing . . . . . . . . . . . . . . . . . . . . . . . . . 9R-2 9R-2 9R-3 9R-3 9R-3 9R-3 9R-3 9R-4 Cowl Vent Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M39s Body Rear End.pdfSECTION 9S BODY REAR END TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9S-2 9S-2 9S-3 9S-3 Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S-3 Fuel Filler Door Remote Cable and Handle . . . . 9S-3 Tailgate Remote Cable and Handle . . . . . . . . . . 9S-5 DAEWOO M-150 BL2 9S 2 BODY REAR END DESCRIPTION AND OPERATION FUEL FILLER DOOR The fuel filler door attaches to the fuel tank pocket on the right side of the vehicle. DAEWOO M-150 BL2 BODY REAR END 9S 3 REPAIR INSTRUCTIONS ONVEHICLE SERVICE FUEL FILLER DOOR Removal Procedure 1. Pull the fuel filler door opening lever and open the fuel filler door. 2. Remove the fuel filler door. D Remove the bolts (1). D Remove the fuel filler door (2). D109C546 Installatio
M39t1 Remote Keyless Entry and Anti-theft System.pdfREMOTE KEYLESS ENTRY AND ANTITHEFT SYSTEM 9T i SECTION 9T REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Remote Keyless Entry and Anti-Theft System . . . . . . . . . . . . . . . . . . . . . . . Remote Locking and Unlocking . . . . . . . . . . . . . . Security Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . Intrusion Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . Autolocking (Safety Lock) . . . . . . . . . . . . . . . . . . 9T-2 9T-2 9T-2 9T-2 9T-2 9T-2 9T-2 9T-3 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Programming . . . . . . . . . . . . . . . . . . .
M39t2 Remote Keyless Entry and Anti-theft System.pdfREMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM 9T 1 SECTION 9T REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Remote Keyless Entry and Anti-Theft System . . . . . . . . . . . . . . . . . . . . . . . Remote Locking and Unlocking . . . . . . . . . . . . . . Security Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . Intrusion Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . Autolocking (Safety Lock) . . . . . . . . . .
M39t3 Imobiliser Anti-theft System.pdfIMMOBILIZER ANTI-THEFT SYSTEM 9T 9 SECTION 9T IMMOBILIZER ANTI-THEFT SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . Immobilizer System . . . . . . . . . . . . . . . . . . . . . . . Electronically Coded Keys . . . . . . . . . . . . . . . . . Detection Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer Control Unit . . . . . . . . . . . . . . . . . . . Serial Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module (ECM) . . . . . . . . . . . Security Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 9T-10 9T-10 9T-10 9T-10 9T-10 9T-11 9T-11 9T-12 Key Statu
M3CONTS.PDFSECTION INDEX SERVICE MANUAL FRONT MATTER 0A MATIZ (MY2003) FOREWORD This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of manual approval. The right is reserved to make changes at any time without notice. GENERAL INFORMATION 0B ENGINE 1 SUSPENSION 2 DRIVELINE/AXLE 3 BRAKES 4 TRANSAXLE 5 STEERING HVAC (HEATING, VENTILATION, AND AIR CONDITIONING) RESTRAINTS 6 7 8 DAEWOO MOTOR CO., LTD. INCHON, KOREA BODY AND ACCESSORIES 9
SECTION.PDFENGINE CONTENTS SECTION 1A SECTION 1B SECTION 1D SECTION 1E SECTION 1F SECTION 1G GENERAL ENGINE INFORMATION SOHC ENGINE MECHANICAL ENGINE COOLING ENGINE ELECTRICAL ENGINE CONTROLS ENGINE EXHAUST SUSPENSION CONTENTS SECTION 2A SECTION 2B SECTION 2C SECTION 2D SECTION 2E SUSPENSION DIAGNOSIS WHEEL ALIGNMENT FRONT SUSPENSION REAR SUSPENSION TIRES AND WHEELS DRIVELINE/AXLE CONTENTS SECTION 3B MANUAL TRANSAXLE DRIVE AXLE BRAKES CONTENTS SECTION 4A SECTION 4B SECTION 4C SECTION 4D SECTION 4E SECTION 4F SECTION 4G HYDRAULIC BRAKES MASTER CYLINDER POWER BOOSTER FRONT DISC BRAKES REAR DRUM BRAKES ANTILOCK BRAKE SYSTEM PARKING BRAKE TRANSAXLE CONTENTS SECTION 5B SECTION 5C FIVESPEED MANUAL TRANSAXLE CLUTCH STEERING CONTENTS SECTION 6A SECTION 6B SECTION 6C SECTION 6D SECTION 6E POWER STEERING SYSTEM POWER STEERING PUMP POWER STEERING GEAR MANUAL STEERING GEAR STEERING WHEEL AND COLUMN HVAC (HEATING, VENTILATION, AND AIR CONDITIONING) CONTENTS SECTION 7A SECTION 7B HEATING AND VENTILATION

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