DAEWOO MATIZ 2003 Service Repair Manual

REAR DRUM BRAKES 4E–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
REAR DRUM BRAKES
D107C401
1. Bleeder Screw
2. Bleeder Screw
3. Rear Brake Assembly
4. Rear Brake Plate
5. Wheel Cylinder
6. Strut Assembly
7. Brake Leading Shoe
8. Middle Return Spring9. Upper Return Spring
10. Brake Shoe Retain Spring Pin
11. Trailing Shoe
12. Brake Shoe Retain Spring
13. Brake Shoe Retain Spring Cap
14. Lower Return Spring
15. Hub Bolt
16. Rear Brake Drum

4E –4 REAR DRUM BRAKES
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
REAR DRUM BRAKE

Condition

Probable cause

Correction
Not Enough Braking
Badly worn brake shoe lining.
Replace the lining.
Force
Lining stained with oil.
Check the wheel cylinder leaks and
then replace the wheel cylinder or the
lining, if needed.

Wheel cylinder condition faulty.
Replace the wheel cylinder.

Malfunctioning self–adjustment
feature.
Repair the self–adjustment feature.
Uneven Braking
Lining stained with oil.
Check the wheel cylinder leaks and
then replace the wheel cylinder or the
lining, if needed.

Wheel cylinder condition faulty.
Replace the wheel cylinder.

Malfunctioning self–adjustment
feature.
Repair the self–adjustment feature.
Dragging Brakes After
Pedal is Released
Weakened brake shoe return spring.
Replace the brake shoe return
spring.

Wheel cylinder condition faulty.
Replace the wheel cylinder.
Excessive Pedal Travel
Excessively worn lining.
Replace the lining.

Malfunctioning self–adjustment
feature.
Repair the self–adjustment feature.
Braking Noise or
Foreign material stuck to drum.
Clean the rear drum brake.
Vibration
Loosen brake plate bolt.
Tighten the brake plate bolt.

Damaged drum.
Replace the drum.
Poor Braking Force of
Parking Brake
Lining stained with oil.
Check the wheel cylinder leaks and
then replace the wheel cylinder or the
lining, if needed.

Damaged self–adjustment feature.
Repair the self–adjustment feature.

Poor adjustment of parking brake
cable.
Adjust the parking brake cable.

REAR DRUM BRAKES 4E–5
DAEWOO M-150 BL2
DRUMS
Inspect the brake drum as follows ;
1. Inspect the drum for crack or damage.
2. Measure the inside diameter.
Unit : mm (in.)

Inside Diameter Wear Limit Value

182 (7.165)
D107C301
3. If the measured value is over the limit value, or if the
defect is found, replace the drum.
LINING
Inspect the brake drum as follows ;
1. Inspect the lining for wear or stain with oil.
2. Measure the thickness.
Unit : mm (in.)

Lining Wear Limit Value

1 (0.039)
D107C302
3. If the measured value is within the limit value, or if the
defect is found, replace the lining.

4E –6 REAR DRUM BRAKES
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D107C501
D17C502A
REAR BRAKE DRUM
Removal Procedure
1. Remove the rear wheels. Refer to Section 6E, Tires
and Wheels.
2. Release the parking brake.
3. Remove the brake drum.

Remove the spindle cap (1).

Remove the cotter pin and do not reuse it (2).

Remove the castellated nut (3).

Remove the rear axle washer (4).

Remove the bearing, race and oil seal. Refer to
Section 2D, Rear Suspension.

Remove the hub bolts using a hammer (5).
Important: Do not reuse removed hub bolts.
D107C503
Installation Procedure
1. Install the brake drum.

Insert the new hub bolts using a hammer.

Install the bearing, race, oil seal and rear axle
washer.

REAR DRUM BRAKES 4E–7
DAEWOO M-150 BL2
D17C504A

Tighten the castellated nut to 25 Nm (18 lb-ft).

Loosen the castellated nut to 180.

Retighten the castellated nut to 2.5 Nm (22 lb-in).

Install the new cotter pin and spindle cap.
2. Adjust the parking brake.
3. Install the rear wheels. Refer to Section 6E, Tires and
Wheels.
D107C505
BRAKE SHOE
Removal Procedure
1. Remove the brake drum. Refer to “Brake Drum” in
this section.
2. Remove the return spring.

Remove the upper return spring (1).

Remove the upper return spring bracket (2).

Remove the lower return spring (3).
D107C506

Remove the adjust lever (4).

Remove the middle return spring (5).
D107C507
3. Remove the brake shoe.

Remove the readjusting unit (1).

Turn the brake shoe retaining spring pin rectangu-
larly by the pliers (2).

Remove the brake shoe retain spring cap (3).

Remove the retaining spring (4).

Remove the retaining spring pin (5).

Remove the leading shoe (6).

4E –8 REAR DRUM BRAKES
DAEWOO M-150 BL2
D107C508
4. Disconnect the parking brake cable from the trailing
shoe and remove the trailing shoe (7).
D107C509
Installation Procedure
1. Install in the reverse of removal.
2. Clean the adjust assembly and apply grease.
3. Connect the parking brake cable from the trailing
shoe.
4. Install the brake shoe.
5. Install the return spring.

Install the middle return spring and adjust lever.

Install the lower return spring.

Install the upper return spring bracket.

Install the upper return spring.
6. Install the brake drum. Refer to “Brake Drum” in this
section.
D107C510
WHEEL CYLINDER ASSEMBLY
Removal Procedure
1. Remove the brake drum. Refer to “Rear Brake Drum”
in this section.
2. Remove the wheel cylinder.

Remove the brake shoe upper spring (1).

Widen the leading shoe and trailing shoe (2).
D107C511

Disconnect the brake line fitting (3).

Plug the opening in the brake line to prevent fluid
loss or contamination.

Remove the wheel cylinder–to–backing plate bolt
(4).

REAR DRUM BRAKES 4E–9
DAEWOO M-150 BL2
D17C512A
Installation Procedure
1. Install the wheel cylinder to the backing plate with the
wheel cylinder bolt (1).
Tighten
Tighten the wheel cylinder–to–backing plate bolt to 10
Nm (89 lb-in).
2. Connect the brake line fitting (2).
Tighten
Tighten the brake line fitting to 16 Nm (12 lb-ft).
3. Install the brake shoe. Refer to “Brake Shoe” in this
section.
4. Install the brake drum. Refer to “Rear Brake Drum” in
this section.
D107C513
BACKING PLATE
Removal Procedure
1. Remove the brake drum. Refer to “Rear Brake Drum”
in this section.
2. Remove the brake shoe components. Refer to “Brake
Shoe” in this section.
3. Remove the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.
4. Remove the bolts and the backing plate.
D17C514A
Installation Procedure
1. Install the bolts and the backing plate.
Tighten
Tighten the backing plate–to–rear axle bolts to 24
Nm (18 lb-ft).
2. Install the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.
3. Install the brake shoe components. Refer to “Brake
Shoe” in this section.
4. Install the brake drum.

4E –10 REAR DRUM BRAKES
DAEWOO M-150 BL2
UNIT REPAIR
D107C701
WHEEL CYLINDER
Disassembly Procedure
1. Remove the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.
2. Disassemble wheel cylinder assembly.

Remove the dust boots and do not reuse them (1).

Remove the piston (2).

Remove the piston cup and do not reuse it (3).

Remove the spring assembly (4).

Remove the bleeder screw (5).
3. Clean all parts with denatured alcohol. Dry the parts
with unlubricated compressed air.
D17C702A
Assembly Procedure
Important: Lubricate the new seals, the piston, the pis-
ton cup and the wheel cylinder bore with clean brake
fluid before assembly.
1. Assemble wheel cylinder assembly.

Insert the bleeder screw.
Tighten
Tighten the bleeder screw to 6 Nm (53 lb-in).

Install the spring and the new piston cup.

Install the piston and the new boots.
2. Inspect the piston for free movement.
3. Install the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.

REAR DRUM BRAKES 4E–11
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Inside Diameter mm (in.) 180 (7.086)
Wear Limit mm (in.) 182 (7.165)
Drum Out of Round mm (in.) 0.04 (0.001)
Cylindricty mm (in.) 0.02 (0.0008)
Thickness mm (in.) 4 (0.157)
Brake Lining Wear Limit mm (in.) 1 (0.039)

Brake Lining
Distance Between Lining and Drum mm (in.) 0.3 (0.011)
Wheel Cylinder Inside Diameter mm (in.) 17.46 (0.687)
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Castellated Nut* – – –
Wheel Cylinder Bolt 10 – 89
Brake Backing Plate Bolt 24 18 –
Brake Pipe Fitting 16 12 –
Bleeder Screw 6 – 53

Castellated Nut : 25 Nm – 180 + 2.5 Nm (18 lb-ft – 180 + 22 lb-in.)

DAEWOO M-150 BL2
SECTION 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 4F-3. . . . . . . . . . . . . . . . . .
ABS System Components 4F-3. . . . . . . . . . . . . . . . . .
Hydraulic Unit 4F-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EBCM (Electronic Brake Control Module) 4F-4. . . . .
Wheel Speed Sensors and Rings 4F-5. . . . . . . . . . . .
Electronic Brake Distribution 4F-5. . . . . . . . . . . . . . . .
Indicator 4F-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EBCM Connector 4F-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fluid Flow Diagrams 4F-7. . . . . . . . . . . . . .
Normal Braking Mode 4F-7. . . . . . . . . . . . . . . . . . . .
Isolation Mode (Pressure Maintain) 4F-8. . . . . . . .
Dump Mode (Pressure Decrease) 4F-9. . . . . . . . .
Reapply Mode (Pressure Increase) 4F-10. . . . . . .
Proportioning Function 4F-11. . . . . . . . . . . . . . . . . .
Visual Identification 4F-12. . . . . . . . . . . . . . . . . . . . . . .
EBCM Connector Face View 4F-12. . . . . . . . . . . . . . .
Component Locator 4F-13. . . . . . . . . . . . . . . . . . . . . . .
ABS 4F-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4F-16. . . .
DTC 0354 Left Front Wheel Speed Sensor
Circuit Open or Shorted 4F-16. . . . . . . . . . . . . . . . .
DTC 0355 Left Front Wheel Speed Sensor
Poor Air Gap or Missing Tooth Ring 4F-20. . . . . . .
DTC 0356 Left Front Wheel Speed Sensor
Circuit Intermittent Shorted 4F-22. . . . . . . . . . . . . .
DTC 0404 Right Front Wheel Speed Sensor
Circuit Open or Shorted 4F-24. . . . . . . . . . . . . . . . .
DTC 0405 Right Front Wheel Speed Sensor
Poor Air Gap or Missing Tooth Ring 4F-28. . . . . . .
DTC 0406 Right Front Wheel Speed Sensor
Circuit Intermittent Shorted 4F-30. . . . . . . . . . . . . .
DTC 0454 Left Rear Wheel Speed Sensor
Circuit Open or Shorted 4F-32. . . . . . . . . . . . . . . . .
DTC 0455 Left Rear Wheel Speed Sensor
Poor Air Gap or Missing Tooth Ring 4F-36. . . . . . . DTC 0456 Left Rear Wheel Speed Sensor
Circuit Intermittent Shorted 4F-38. . . . . . . . . . . . . .
DTC 0504 Right Rear Wheel Speed Sensor
Circuit Open or Shorted 4F-42. . . . . . . . . . . . . . . . .
DTC 0505 Right Rear Wheel Speed Sensor
Poor Air Gap or Missing Tooth Ring 4F-46. . . . . . .
DTC 0506 Right Rear Wheel Speed Sensor
Circuit Intermittent Shorted 4F-48. . . . . . . . . . . . . .
DTC 0601 Left Front Dump Shorted or
Driver Open 4F-52. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0602 Left Front Dump Open or
Driver Shorted 4F-54. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0651 Left Front Isolation Shorted or
Driver Open 4F-56. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0652 Left Front Isolation Open or
Driver Shorted 4F-58. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0701 Right Front Dump Shorted or
Driver Open 4F-60. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0702 Right Front Dump Open or
Driver Shorted 4F-62. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0751 Right Front Isolation Shorted or
Driver Open 4F-64. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0752 Right Front Isolation Open or
Driver Shorted 4F-66. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0801 Left Rear Dump Shorted or
Driver Open 4F-68. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0802 Left Rear Dump Open or
Driver Shorted 4F-70. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0851 Left Rear Isolation Shorted or
Driver Open 4F-72. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0852 Left Rear Isolation Open or
Driver Shorted 4F-74. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0901 Right Rear Dump Shorted or
Driver Open 4F-76. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0902 Right Rear Dump Open or
Driver Shorted 4F-78. . . . . . . . . . . . . . . . . . . . . . . . .