DAEWOO NUBIRA 2004 Service Repair Manual

4F – 70IANTILOCK BRAKE SYSTEM
DAEWOO V–121 BL4
ELECTRONIC BRAKE–FORCE DISTRIBUTION (EBD)
FAILURE MATRIX

ANTILOCK BRAKE SYSTEM 4F – 71
DAEWOO V–121 BL4
TIRES AND ABS/EBD
Replacement Tires
Tire size is important for proper performance of the ABS
system. Replacement tires should be the same size, load
range, and construction as the original tires. Replace tires
in axle sets and only with tires of the same tire perfor-
mance criteria (TPC) specification number. Use of any
other size or type may seriously affect the ABS operation.
TIRES AND ABS/EBD
Notice : There is no serviceable or removable EEPROM.
The EBCM must be replaced as an assembly.
The EBCM is attached to the hydraulic unit in the engine
compartment. The controlling element of ABS 5.3 is a mi-
croprocessor–based EBCM. Inputs to the system include
the four wheel speed sensors, the stoplamp switch, the
ignition switch, and the unswitched battery voltage. There
is an output to a bi–directional serial data link, located in
pin K of Data Link Connector (DLC) for service diagnostic
tools and assembly plant testing.
The EBCM monitors the speed of each wheel. If any wheel
begins to approach lockup and the brake switch is closed
(brake pedal depressed), the EBCM controls the sole-
noids to reduce brake pressure to the wheel approaching
lockup. Once the wheel regains traction, brake pressure
is increased until the wheel again begins to approach lock-
up. This cycle repeats until either the vehicle comes to a
stop, the brake pedal is released, or no wheels approach
lockup.
Additionally, the EBCM monitors itself, each input (except
the serial data link), and each output for proper operation.
If it detects any system malfunction, the EBCM will store
a DTC in nonvolatile memory (EEPROM) (DTCs will not
disappear if the battery is disconnected). Refer to ”Self
Diagnostics” in this section for more detailed information.
FRONT WHEEL SPEED SENSOR
The front wheel speed sensors are of a variable reluctance
type. Each sensor is attached to the steering knuckle,
close to a toothed ring. The result, as teeth pass by the
sensor, is an AC voltage with a frequency proportional to
the speed of the wheel. The magnitude of the voltage and
frequency increase with increasing speed. The sensor is
not repairable, nor is the air gap adjustable.
FRONT WHEEL SPEED SENSOR
RINGS
The toothed ring mentioned above is pressed onto the
wheel–side (outer) constant velocity joint. Each ring con-
tains 47 equally spaced teeth. Exercise care during ser-
vice procedures to avoid prying or contacting this ring. Ex-cessive contact may cause damage to one or more teeth.
If the ring is damaged, the wheel–side constant velocity
joint must be replaced.
REAR WHEEL SPEED SENSOR AND
RINGS
The rear wheel speed sensors operate in the same man-
ner as the front wheel speed sensors. They incorporate a
length of flexible harness with the connector attached to
the end of the harness. The rear wheel speed rings are in-
corporated into the hub assemblies and cannot be re-
placed separately, but require replacement of the rear
hub/bearing assembly.
VALUE RELAY AND PUMP MOTOR
RELAY
The valve relay and the motor pump relay are located in-
side the electronic brake control module (EBCM) and are
not replaceable. If one should fail, replace the EBCM.
WIRING HARNESS
The wiring harness is the mechanism by which the elec-
tronic brake control module (EBCM) is electrically con-
nected to power and to ground, to the wheel speed sen-
sors, the fuses, the switches, the indicators, and the serial
communications port. The components, considered part
of the wiring harness, are the wires that provide electrical
interconnection, and connectors (terminals, pins, con-
tacts, or lugs) that provide an electrical/mechanical inter-
face from the wire to a system component.
INDICATORS
The electronic brake control module (EBCM) continuously
monitors itself and the other ABS components. If the
EBCM detects a problem with the system, the amber ABS
indicator will light continuously to alert the driver to the
problem. An illuminated ABS indicator indicates that the
ABS system has detected a problem that affects the op-
eration of ABS. No antilock braking will be available. Nor-
mal, non–antilock brake performance will remain. In order
to regain ABS braking ability, the ABS must be serviced.
The red BRAKE indicator will be illuminated when the sys-
tem detects a low brake fluid level in the master cylinder
or when the parking brake switch is closed (the parking
brake is engaged) or EBD system is diabled.
WARNING : EBD INDICATOR LAMP WIRING IS CON-
NECTED TO THE PARKING BRAKE LAMP. IF THE
PARKING BRAKE LAMP IS TURNED ON WHEN YOU
DRIVING, CHECKING ON WHETHER THE PARKING
BRAKE LEVER IS ENAGED OR THE BRAKE FLUID
LEVEL IS LOW. IF THE SYSTEM HAS NO PROBLEM,
THE EBD SYSTEM IS WORKING IMPROPERLY. THE
EBD SYSTEM MUST BE SERVICED.

SECTION : 4G
PARKING BRAKE
TABLE OF CONTENTS
SPECIFICATIONS4G–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4G–1. . . . . . . . . .
MAINTENANCE AND REPAIR4G–2 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 4G–2. . . . . . . . . . . . . . . . . . . . .
Parking Brake Adjustment Rear Drum Brakes 4G–2.
Parking Brake Adjustment Rear Disc Brakes 4G–2. . Parking Brake Lever 4G–3. . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Cable 4G–5. . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Handle 4G–8. . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION4G–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake 4G–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Parking Brake Cable–to–Underbody Side
Bracket bolts6–53
Parking Brake Lever Assembly–to–Vehicle
Underbody Bolts2216–
Parking Brake Switch–to–Parking Brake Le-
ver Screw4–35
Rear Brake Drum Detent Screw4–35

4G – 2IPARKING BRAKE
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
PARKING BRAKE ADJUSTMENT
REAR DRUM BRAKES
Adjustment Procedure
1. Adjust the rear brakes. Refer to Section 4E1, Rear
Disc Brakes.
2. Release the parking brake.
3. Raise and suitably support the vehicle.
4. Check the parking brake cables for free movement.
5. Lower the vehicle
6. Remove the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
7. Partially raise the vehicle.
8. Turn the self–locking nut on the parking brake lever
assembly until the wheels are difficult to turn.
9. Back off the nut until the rear wheels are just free to
turn.
10. Lower the vehicle
11. Install the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
PARKING BRAKE ADJUSTMENT
REAR DISC BRAKES
Adjustment Procedure
1. Release the parking brake.
2. Raise and suitably support the vehicle.
3. Remove the rear wheels. Refer to Section 2E, Tires
and Wheels.
4. Remove the caliper and rotor assemblies. Refer to
Section 4E1, Rear Disc Brakes.
5. Remove the brake rotors on each side of the ve-
hicle. Refer to Section 4E1, Rear Disc Brakes.
6. Disconnect the parking brake cable from the back-
plate operating lever on each side of the vehicle.

PARKING BRAKE 4G – 3
DAEWOO V–121 BL4
7. Inspect and replace any parts of doubtful strength
or quality. This can be shown by discoloration from
heat or stress.
8. Using a vernier caliper, adjust the shoe assembly to
167.6 to 167.8 mm (6.60 to 6.61 inches) by turning
the adjuster nut clockwise to increase the diameter.
Measure the shoe assembly diameter as closely as
possible to the center of the lining material.
9. Inspect and install the rotors and calipers. Refer to
Section 4E1, Rear Disc Brakes.
10. Install the parking brake cable to the backplate le-
ver on each side of the vehicle.
11. In the vehicle cabin, pull on the parking brake han-
dle. Stop after hearing two clicks.
12. Turn the rear wheel by hand until the wheel begins
to drag.
13. Release the parking brake.
14. Turn the rear wheel by hand to check the drag. Re-
adjust the cable, if necessary.
15. Repeat the process for the other rear wheel.
16. Lower the vehicle.
PARKING BRAKE LEVER
Removal Procedure
1. Release the parking brake.
2. Remove the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
3. Measure the thread length from the end of the pull
rod to the hex nut.
4. Remove the hex nut.
5. Remove the parking brake warning lamp switch.
Notice : The parking brake switch should be replaced if
the BRAKE warning light in the instrument panel cluster
did not glow when the parking brake was applied with the
ignition switch ON.

4G – 4IPARKING BRAKE
DAEWOO V–121 BL4
6. Remove the parking brake lever assembly–to–ve-
hicle underbody bolts.
Installation Procedure
Notice : If the parking brake lever is bent or damaged, re-
place the complete parking brake lever assembly, which
includes a new parking brake switch.
1. Fasten the parking brake switch to the parking
brake lever assembly with the screw.
Tighten
Tighten the parking brake switch–to–parking brake
lever screw to 4 NSm (35 lb–in).
2. Install the parking brake lever bolts, and fasten the
parking brake lever assembly to the vehicle under-
body.
Tighten
Tighten the parking brake lever assembly–to–vehicle
underbody bolts to 22 NSm (16 lb–ft).
3. Install the hex nut on the end of pull rod.
4. Check the parking brake adjustment referring to the
original removal adjustment nut measurement tak-
en in the removal procedure. Refer to ”Parking
Brake Adjustment – Rear Drum Brakes” or ”Park-
ing Brake Adjustment – Rear Disc Brakes” in this
section.
5. Install the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.

PARKING BRAKE 4G – 5
DAEWOO V–121 BL4
PARKING BRAKE CABLE
Removal Procedure
1. Remove the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
2. Release the parking brake lever and the hex nut on
the end of pull rod.
3. Remove the parking brake cable ends from the
equalizer.
4. Raise and suitably support the vehicle.
5. Remove the rear wheels. Refer to Section 2E, Tires
and Wheels.
6. For vehicles with rear drum brakes, remove the det-
ent screw of the rear brake drum and remove the
brake drum.
7. Remove the retaining ring for the parking brake
cable.
8. Remove the plastic sleeve.
9. Remove the parking brake cable from the brake
trailing shoe lever and from the backing plate.

4G – 6IPARKING BRAKE
DAEWOO V–121 BL4
10. For vehicles with rear disc brakes, remove the rear
hub assembly.
11. Remove the retaining pin.
12. Remove the parking brake cable from the trailing
shoe.
13. Remove the bolts securing the parking brake cable
to the underbody clip on both the driver and pas-
senger sides of the vehicle.
14. Remove the parking brake cable from the clip near
the fuel tank strap.
15. Remove the parking brake cables from the vehicle.
Installation Procedure
1. Install the new parking brake cable (if necessary)
through the rear drum brake backing plate and at-
tach to the brake trailing shoe lever.
2. Insert the plastic sleeve in the rear drum backing
plate and press in the retaining ring. Ensure the
parking brake cable is routed correctly.

PARKING BRAKE 4G – 7
DAEWOO V–121 BL4
3. Install the rear brake drums by fastening the detent
screw.
Tighten
Tighten the rear brake drum detent screw to 4 NSm
(35 lb–in).
4. Install the parking brake cable to the trailing shoe.
5. Install the retaining pin.
6. For vehicles with rear disc brakes, install the rear
hub assembly.
7. Install the bolts securing the parking brake cable to
a bracket on both the driver and passenger sides of
the vehicle.
Tighten
Tighten the parking brake cable–to–underbody side
bracket bolts to 6 NSm (53 lb–in).
8. Install the parking brake cable to the clip near the
fuel tank strap.

4G – 8IPARKING BRAKE
DAEWOO V–121 BL4
9. Attach the parking brake cable ends to the equaliz-
er.
10. Adjust the hex nut on the end of pull rod. Refer to
”Parking Brake Adjustment” in this section.
11. Install the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
PARKING BRAKE HANDLE
Removal Procedure
1. Remove the parking brake/gearshift console hood,
detaching the parking brake lever boot. Refer to
Section 9G, Interior Trim.
2. Slip the parking brake handle off of the parking
brake lever.
Installation Procedure
1. Push the parking brake handle as far as it will go on
the parking brake lever.
2. Install the parking brake/gearshift console hood
with the parking brake lever boot. Refer to Section
9G, Interior Trim.