DAEWOO MATIZ 2003 Service Repair Manual

4D –4 FRONT DISC BRAKES
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
FRONT DISC BRAKE

Condition

Probable cause

Correction
Uneven Braking
Inoperative carrier.
Replace the carrier.

Sticked caliper piston.
Repair the caliper piston or replace
the caliper assembly, if needed.
Dragging Brake
Sticked caliper piston.
Repair the caliper piston or replace
the caliper assembly if needed.
Noise and Vibration
Excessive rotor run out.
Replace the rotor.
When Brake Applied
Interference of the dust cover.
Repair the dust cover.

Loose caliper mounting bolts.
Tighten the mounting bolts.

FRONT DISC BRAKES 4D–5
DAEWOO M-150 BL2
LINING INSPECTION
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E, Tires
and Wheels.
3. Visually check the linings for minimum thickness and
wear.
4. Measure the thickness.
Important: The minimum thickness of the shoe and lin-
ing together is 8 mm (0.31 in.).
D107B301
5. Install the shoe and linings in axle sets only.
6. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
7. Lower the vehicle.
ROTOR INSPECTION
Thickness variation can be checked by measuring the
thickness of the rotor at four or more points around the
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the rotor.
If the thickness of the rotor is below 10 mm (0.40 in.),
replace the brake rotor.
During manufacturing, the brake rotor and the toler-
ances of the braking surface regarding flatness and lat-
eral runout are held very close. The maintenance of
close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
D107B302
In addition to these tolerances, the surface finish must
be held to a specified range. The control of the braking
surface finish is necessary to avoid pulls and erratic per-
formance and to extend lining life.
Using a commercially-available dial indicator, check lat-
eral runout as follows:
Notice: Permissible lateral runout is a maximum 0.05 mm
(0.002 in.). If lateral runout exceeds the specification,
ensure there is no dirt between the rotor and the hub and
that contact surfaces are smooth and free from burrs.
1. Position the transaxle in NEUTRAL.
2. Remove the rotor. Refer to “Rotor” in this section.
3. Fasten a dial indicator to the strut.
4. Set the gauge probe tip to approximately 10 mm
(0.4 in.) from the outer edge of the brake rotor, per-
pendicular to the disc and under slight preload.
5. Remove the dial indicator.
Important: Since accurate control of the rotor toler-
ances is necessary for proper performance of the disc
brakes, refinishing of the rotor should be done only with
precision equipment.
6. Refinish the rotor, if required, with precision equip-
ment. Discard the rotor if it fails to meet the above
specifications after refinishing.
7. Install the rotor. Refer to “Rotor” in this section.
D107B303

4D –6 FRONT DISC BRAKES
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D107B501
SHOE AND LINING
Removal Procedure
1. Remove the front wheels. Refer to Section 2E, Tires
and Wheels.
2. Remove the brake pads.

Remove the pin bolt (1).
D107B502

Lift up the cylinder assembly (2).
D17B503A
Installation Procedure
1. Install the brake pads and the cylinder assembly with
the pin bolt.
Tighten
Tighten the pin bolt to 26 Nm (19 lb-ft).
2. Install the front wheels. Refer to Section 2E, Tires
and Wheels.

FRONT DISC BRAKES 4D–7
DAEWOO M-150 BL2
D107B504
CALIPER ASSEMBLY
Removal Procedure
1. Remove the front wheels. Refer to Section 2E, Tires
and Wheels.
2. Remove the caliper assembly.

Remove the brake hose coupling bolt (1).

Plug the opening in the brake hose to prevent fluid
loss and contamination.

Remove the caliper mounting bolts (2).
D17B505B
Installation Procedure
1. Install the caliper assembly with the bolts (1).
Tighten
Tighten the caliper–to–steering knuckle bolts to 95
Nm (70 lb-ft).
2. Connect the brake hose (2).
Tighten
Tighten the brake hose inlet fitting–to–coupling bolt to
25.5 Nm (19.1 lb-ft).
3. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
4. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.
D117B506
ROTOR
Removal Procedure
1. Remove the steering knuckle. Refer to Section 2C,
Front Suspension.
2. Remove the rotor bolts from the front wheel hub.
3. Remove the rotor. Refer to Section 2C, Front Sus-
pension.
D17B507A
Installation Procedure
1. Install the rotor to the front wheel hub by tightening
the detent bolts.
Tighten
Tighten the rotor–to–front wheel hub detent bolts to
65 Nm (48 lb-ft).
2. Install the steering knuckle. Refer to Section 2C, Front
Suspension.

4D –8 FRONT DISC BRAKES
DAEWOO M-150 BL2
UNIT REPAIR
D107B701
CALIPER OVERHAUL
Disassembly Procedure
1. Remove the caliper assembly. Refer to “Caliper As-
sembly” in this section.
2. Separate the cylinder assembly and the carrier.

Remove the pin bolts (1).

Separate the cylinder assembly and the carrier (2).
D107B702
3. Disassemble the carrier.

Remove the front brake pad set (1).

Remove the springs (2).

Remove the guide pins and boots (3).
Refer to “Shoe and Lining” in this section.
D17B703C

Remove the bleeder plug (1).

Remove the bleeder plug cap (2).

FRONT DISC BRAKES 4D–9
DAEWOO M-150 BL2
D107B704

Remove the piston boot (3).
Caution: Do not face in the direction of removing.
D107B705

Using compressed air, blow out the piston from the
cylinder (4).

Remove the piston (5).
D107B706

Remove the piston seal (6).

4D –10 FRONT DISC BRAKES
DAEWOO M-150 BL2
D17B708B
D17B707A
26
Assembly Procedure
Important: Clean all parts in denatured alcohol. Dry the
parts with unlubricated compressed air.
Important: Lubricate the piston with brake fluid.
1. Assembly the cylinder assembly.

Install the piston seal.

Push the piston inward until it is properly seated.

Install the piston boot.

Install the bleeder plug.
Tighten
Tighten the bleeder plug to 6 Nm (53 lb-in).

Install the bleeder plug cap.
2. Assemble the carrier.

Install the guide pin and boot.

Install the spring.

Install the pads.
3. Install the pin bolt connecting the cylinder assembly
and carrier.
Tighten
Tighten the pin bolt to 26 Nm (19 lb-ft).
4. Install the caliper assembly. Refer to “Caliper Assem-
bly” in this section.

FRONT DISC BRAKES 4D–11
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Unit

Description
Outer Diameter

mm (in.)

236 (9.3)
Thickness

mm (in.)

12.7 (0.5) Rotor
Discard Thickness

mm (in.)

10 (0.4)
Runout

mm (in.)

0.05 (0.002)
Pad Thickness

mm (in.)

10 (0.40)
Caliper

Pad Discard Thickness

mm (in.)

8 (0.31)
Diameter of the Position

mm (in.)

48 (1.89)
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In Rotor Bolts 65 48 – Caliper Mounting Bolts 95 70 – Pin Bolts 26 19 – Brake Hose Coupling Bolt 25.5 19.1 – Bleeder Screw 6 – 53

DAEWOO M-150 BL2
SECTION 4E
REAR DRUM BRAKES
TABLE OF CONTENTS
Description and Operation 4E-2. . . . . . . . . . . . . . . . . .
Drum Brakes 4E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 4E-3. . . . . . . . . . . . . . . . . . . . . . . .
Rear Drum Brakes 4E-3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4E-4. . . . .
Rear Drum Brake 4E-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Drums 4E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lining 4E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 4E-6. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4E-6. . . . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Drum 4E-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shoe 4E-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder Assembly 4E-8. . . . . . . . . . . . . . . . . .
Backing Plate 4E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 4E-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder 4E-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4E-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4E-11. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4E-11. . . . . . . . . .

4E – 2 REAR DRUM BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRUM BRAKES
This drum brake assembly is a leading/trailing shoe de-
sign. Both brake shoes are held against the wheel cylin-
der pistons by the lower return spring and the fixed
anchor plate near the lower return spring. When the
brakes are applied, the wheel cylinder pistons move
both shoes out to contact the drum. With forward wheel
rotation, the forward brake shoe will wrap into the drum
and become self-energized. With reverse wheel rota-
tion, the rear brake shoe is self-energized. Force from
the brake shoes is transferred to the anchor plate
through the backing plate to the axle flange. Adjustment
is automatic and occurs on any service brake applica-
tion. Do not switch the position of shoes that have been
in service, as this may render the self-adjustment fea-
ture inoperative and result in increased pedal travel.Notice:

Replace all the components included in the repair kits
used to service this drum brake.

Do not use lubricated shop air on the brake parts, as
damage to the rubber components may result.

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
braking system.

The torque values specified are for dry, unlubricated
fasteners.

Perform service operations on a clean bench that is
free from all mineral oil materials.