DAEWOO MATIZ 2003 Service Repair Manual

HYDRAULIC BRAKES 4A–5
DAEWOO M-150 BL2
WARNING LAMP OPERATION
This brake system uses a BRAKE warning lamp located
in the instrument panel cluster. When the ignition switch
is in the III position, the BRAKE warning lamp should
glow and then go OFF when the ignition switch returns
to the II position.The following conditions will activate the BRAKE lamp:

Parking brake applied. The light should be on when-
ever the parking brake is applied and the ignition
switch is II.

Low fluid level. A low fluid level in the master cylinder
will turn the BRAKE lamp ON.
BRAKE SYSTEM FAULT
Condition Probable cause Correction
Brake Warning Lamp ON
Brake fluid leaks.
Repair the leaks or add th fluid.

Parking brake switch shorted to
ground.
Repair the short ground.

Faulty the fluid level sensor.
Replace the sensor.
Stoplamp ON
Faulty the stoplamp switch.
Replace the stoplamp switch.

Push rod length is short.
Adjust the push rod length of the
power booster.

Stoplamp switch circuit shorted to
battery.
Repair or Replace the wiring harness.
Poor Braking
Brake fluid lacks or leaks.
Repair the leaks or add the fluid.

Brake fluid contamination.
Replace the fluid.

Air in the brake system.
Bleed the brake system.

Damaged brake lines.
Replace the brake lines.

Damaged vacuum hose or faulty
check valve.
Replace the vacuum hose or check
value.
Dragging Brake
No free play at the brake pedal.
Adjust the free play.

Weakened the brake pedal return
spring.
Replace the return spring.

Faulty master cylinder.
Replace the master cylinder.

Air in the brake system.
Bleed the brake system.
Pedal Over Stroke
Brake fluid lacks or leaks.
Repair the leaks or add the fluid.

Poor adjustment of the brake pedal
free play.
Adjust the push rod length of the
power booster.

4A –6 HYDRAULIC BRAKES
DAEWOO M-150 BL2
MANUAL BLEEDING THE BRAKES
Important: The bleeding sequence is as follows; right
rear, left rear, right front, and left front.
Important: Check the fluid level and add the fluid during
the bleeding operation.
1. Raise the vehicle.
2. Remove the bleeder screw and cap.
D17B703B
3. Attach a transparent tube over the valve. Allow the
tube to hang submerged in brake fluid in a transpar-
ent container.
D107A303
4. Slowly push the brake pedal several times and hold
the brake pedal.5. Tighten the bleeder screw after loosening the bleeder
screw and draining the fluid.
Caution: Hold the brake pedal until tightening the
bleeder screw.
6. Repeat the step 5, 6 until all the air is removed.
7. Check the leaks for the bleeder screw.
PEDAL TRAVEL CHECK
1. Start the engine.
2. Push the pedal three times.
3. With brake pedal depressed with a about 30Kg (66.15
lb) load, measure the clearance between the pedal
pad and the lower dash panel.
Unit : mm (in.)

Specification

60 (2.36)
D107A304
4. If clearance is less than 60mm (2.36 in.), the most
possible cause is either rear drum brake shoes are
worn out beyond the specification value or air is in
lines. Clearance still remains less than 60mm (2.36
in.) even after replacement of brake shoes and bleed-
ing of the brake system, other possible but infrequent
cause is malfunction of rear drum brake shoe adjust-
ers or booster push rod length out of adjustment.
5. Automatic clearance adjuster check is performed af-
ter removing brake drums. If the faulty is found, repair
or replace it.

HYDRAULIC BRAKES 4A–7
DAEWOO M-150 BL2
BRAKE PEDAL FREE PLAY
INSPECTION
1. Push the brake pedal several times to discharge the
vacuum of the power booster.
2. Measure the pedal movement until the hardness is
felt when pushing the brake pedal by hand.
Unit : mm (in.)

Specification

6–10 (0.24–0.31)
3. Brake pedal free play can not be adjusted.
D107A305

4A –8 HYDRAULIC BRAKES
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D107A528
BRAKE HOSE (FRONT)
Removal Procedure
1. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
2. Remove the brake hose.

Remove the fitting (1).

Remove the E–ring retainer (2).

Disconnect the brake hose mounting from the strut
(3).

Remove the coupling bolt (4).

Plug the opening in the brake pipe and caliper to
prevent fluid loss or contamination.
D17A529B
Installation Procedure
1. Connect the brake lines to the brake hose (1).
Tighten
Tighten the brake pipe–to–hose fitting to 16 Nm (12
lb-ft).
2. Install the brake hose coupling bolt (2).
Tighten
Tighten the bolt to 25.5 Nm (19.1 lb-ft).
Important: Use only Daewoo recommended brake
fluid.
3. Bleed the brake system. Refer to “Manual Bleeding
the Brakes” in this section.
4. Check the brake system for leaks.
5. Install the wheels. Refer to Section 2E, Tires and
Wheels.

HYDRAULIC BRAKES 4A–9
DAEWOO M-150 BL2
D107A530
BRAKE HOSE (REAR)
Removal Procedure
1. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
2. Remove the brake hose.

Remove the fittings (1).

Remove the E–rings (2).

Plug the opening in the brake pipe to prevent fluid
loss or contamination.
D17A531A
Installation Procedure
1. Connect the brake lines to the brake hose.
2. Install the fitting and E–rings.
Tighten
Tighten the fitting to 16 Nm (12 lb-ft).
Important: Use only Daewoo recommended brake fluid.
3. Bleed the brake system. Refer to “Manual Bleeding
the Brakes” in this section.
4. Check the brake system for leaks.
5. Install the wheels. Refer to Section 2E, Tires and
Wheels.
D107A523
STOPLAMP SWITCH
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the stoplamp switch.

Disconnect the connector (1).

Turn the stoplamp switch (2).
D107A524
Installation Procedure
1. Install the stoplamp switch.
2. Connect the electrical connector.
3. Connect the negative battery cable.
Important: After installing the stoplamp switch, pull the
lever completely.

4A –10 HYDRAULIC BRAKES
DAEWOO M-150 BL2
D107A525
BRAKE PEDAL
(LEFT–HAND DRIVE)
Removal Procedure
1. Remove the stoplamp switch. Refer to “Stoplamp
Switch” in this section.
2. Disconnect the brake pedal from the power booster.
Refer to Section 4C, Power Booster.
3. Remove the brake pedal.

Remove the bolt (1).
D107A526

Remove the brake pedal spring (2).

Remove the bushing (3).

Remove the cushion (4).

Remove the brake pedal pad (5).
D17A527A
Installation Procedure
1. Install the pad to the brake pedal.
2. Install the brake pedal with spring, bushing, and cush-
ion.
3. Connect the brake pedal to the power booster.
Tighten
Tighten the brake pedal–to–pedal bracket bolt to 18
Nm (13 lb-ft).
4. Install the stoplamp switch. Refer to “Stoplamp
Switch” in this section.
D24C001A
BRAKE PEDAL
(RIGHT–HAND DRIVE)
Removal Procedure
1. Remove the instrument panel assembly. Refer to
Section 9E, Instrument/Driver Information.
2. Disconnect the brake pedal rod from the power
booster. Refer to Section 4C, Power Booster.

HYDRAULIC BRAKES 4A–11
DAEWOO M-150 BL2
D24D001
3. Remove the stoplamp switch.

Remove the stoplamp switch (1).

Remove the bolts (2).

Remove the stoplamp switch bracket (3).
D24D002
4. Remove the bolts mounting brake pedal bracket (1).
5. Remove the nuts mounting brake pedal bracket (2).
D24D003
6. Remove the canister. Refer to Section 1F, Engine
Controls.
7. Remove the bolt mounting brake pedal bracket in the
engine compartment (1).
D24D004
8. Remove the brake pedal.

Remove the snap rings (1).

Remove the bushings (2).

Remove the brake pedal spring (3).

Remove the cushion (4).

Remove the brake pedal pad (5).

4A –12 HYDRAULIC BRAKES
DAEWOO M-150 BL2
D24D005
Installation Procedure
1. Install the brake pedal with pad, spring, bushings, and
cushion.
2. Install the bolt mounting brake pedal bracket in the
engine compartment.
Tighten
Tighten the bolt to 18–26 Nm (13–20 lb-ft).
3. Install the canister. Refer to Section 1F, Engine Con-
trols.
D24D006
4. Install the brake pedal with the snap rings.
5. Install the bolts and nuts mounting brake pedal brack-
et.
Tighten

Tighten the bolts mounting brake pedal bracket to
18–26 Nm (13–20 lb-ft).

Tighten the nuts mounting brake pedal bracket to
18–26 Nm (13–20 lb-ft).
D24D007
6. Install the stoplamp switch with the bracket and the
bolts.
Tighten
Tighten the mounting bolts to 9–12 Nm (80–106 lb-
in.)
7. Connect the brake pedal rod to the power booster.
Refer to Section 4C, Power Booster.
8. Install the instrument panel assembly. Refer to Sec-
tion 9E, Instrument/Driver Information.

HYDRAULIC BRAKES 4A–13
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
0.8 SOHC Engine
Application Millimeters Inches



Brake Drums:
Inside Diameter
Maximum Rebore Diameter
Out-of-Round


180
182
0.04


7.09
7.17
0.0016




Brake Rotors:
Discard Thickness
Lateral Runout (Installed)
Rotor Diameter
Rotor Thickness (New)



10
0.05
236
12.7




0.4
0.002
9.3
0.5
Master Cylinder:
Bore Diameter 20.64 0.81
Caliper:
Piston Diameter
48

1.89
Wheel Cylinder Diameter: 17.46 0.69



Brake Pedal:
Free Play
Height
Stroke


6 – 10
200
30



0.24 – 0.31
7.87
1.18
Type DOT–3 or DOT–4 Brake Fluid Capacity 0.45 L (0.48 qt.)
FASTENER TIGHTENING SPECIFICATIONS

Application

Nm

Lb-Ft

Lb-In
Brake Pipe Fittings 16 12 –
Front Brake Hose-to-Caliper Bolt 25.5 19.1 –
Brake Pedal–to–Pedal Bracket Hex Bolt

18

13

–
Brake Pedal Bracket Mounting Bolts 18 – 26 13 – 20 –
Brake Pedal Bracket Mounting Nuts 18 – 26 13 – 20 –
Stoplamp Switch Mounting Bracket Bolts

9 – 12

–

80 – 106

4A –14 HYDRAULIC BRAKES
DAEWOO M-150 BL2
SCHEMATIC AND ROUTING DIAGRAMS
BRAKE LAMP WARNING CIRCUIT
D17A201B
STOPLAMP SWITCH CIRCUIT
D17A202B