Hub DAEWOO LACETTI 2004 Service Owner's Guide

SECTION : 4D
FRONT DISC BRAKES
TABLE OF CONTENTS
SPECIFICATIONS4D–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specirications 4D–1. . . . . . . . . .
DIAGNOSIS4D–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lining Inspection 4D–1. . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Inspection 4D–1. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR4D–3 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 4D–3. . . . . . . . . . . . . . . . . . . . .
Shoe and Lining 4D–3. . . . . . . . . . . . . . . . . . . . . . . . . . Caliper Assembly 4D–3. . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor 4D–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Splash Shield 4D–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 4D–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caliper Overhaul 4D–6. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION4D–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc Brake Caliper Assembly 4D–9. . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIRICATIONS
ApplicationNSmLb–FtLb–In
Brake Hose Inlet Fitting–to–Caliper Bolt4030–
Caliper Bleeder Valve8–71
Caliper–to–Steering Knuckle Mounting Bolts9570–
Retaining Frame–to–Caliper Housing Bolts2720–
Rotor–to–Front Wheel Hub Detent Screw4–35
Splash Shield–to–Steering Knuckle Screws4–35
DIAGNOSIS
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 inner or the
outer pad is 7 mm (0.28 inch).
5. Install the brake pads 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 cir-
cumference of the rotor. All measurements must be made
at the same distance in from the edge of the rotor.
A rotor that varies by more than 0.01 mm (0.0004 inch) can
cause pedal pulsations and/or front end vibration during
brake applications. A rotor that does not meet these speci-
fications should be refinished to specifications or re-
placed.

4D – 2IFRONT DISC BRAKES
DAEWOO V–121 BL4
During manufacturing, the brake rotor and the tolerances
of the braking surface regarding flatness, thickness varia-
tion, and lateral runout are held very close. The mainte-
nance of close tolerances on the shape of the braking sur-
faces is necessary to prevent brake roughness.
In addition to these tolerances, the surface finish must be
held to a specified range. The control of the braking sur-
face finish is necessary to avoid pulls and erratic perfor-
mance and to extend lining life.
Using a commercially available dial indicator, check lateral
runout as follows:
Notice : Permissible lateral runout is a maximum 0.03 mm
(0.0012 inch). If lateral runout exceeds the specification,
ensure that there is no dirt between the rotor and the hub
and that contact surfaces are smooth and free from burrs.
1. Position the shift lever in NEUTRAL.2. Remove the rotor. Refer to ”Rotor” in this section.
3. Fasten the brake rotor to the wheel hub with two
wheel bolts.
4. Fasten a dial indicator to the brake caliper.
5. Set the gauge probe tip to approximately 10 mm
(0.39 inch) from the outer edge of the brake rotor,
perpendicular to the disc and under slight preload.
6. Remove the dial indicator and the wheel bolts con-
necting the rotor to the hub.
Important : Since accurate control of the rotor tolerances
is necessary for proper performance of the disc brakes, re-
finishing of the rotor should be done only with precision
equipment.
7. Refinish the rotor, if required, with precision equip-
ment. Discard the rotor if it fails to meet the above
specifications after refinishing.
8. Install the rotor. Refer to ”Rotor” in this section.

FRONT DISC BRAKES 4D – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
SHOE AND LINING
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E,
Tires and Wheels.
3. Remove the lower bolt of the caliper assembly re-
taining frame.
Important : Caliper assembly removal is not necessary to
service the brake pads.
4. Pull the caliper piston housing up.
5. Remove the brake pads.
Installation Procedure
1. Measure the minimum lining thickness. Refer to
”Lining Inspection” in this section.
2. Install the brake pads into the caliper.
3. Push the piston inward, if needed.
Notice : Take care not to damage the piston seal when the
piston housing frame is pulled down.
4. Pull down the caliper piston housing and secure it
to the retaining frame with the lower bolt.
Tighten
Tighten the retaining frame–to–caliper housing bolts
to 27 NSm (20 lb–ft).
5. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
6. Lower the vehicle.
CALIPER ASSEMBLY
Removal Procedure
1. Raise and suitably support the vehicle.
2. Mark the position of the front wheels relative to the
wheel hubs and remove the wheels. Refer to Sec-
tion 2E, Tires and Wheels.
3. Remove the bolt and the washers attaching the
brake hose to the caliper.
4. Disconnect the brake hose, and plug the openings
in the caliper and the brake hose to prevent fluid
loss and contamination.
5. Remove the caliper mounting bolts from the steer-
ing knuckle, and remove the caliper assembly.

4D – 4IFRONT DISC BRAKES
DAEWOO V–121 BL4
Installation Procedure
1. Install the caliper assembly with the mounting bolts.
Tighten
Tighten the caliper–to–steering knuckle mounting
bolts to 95 NSm(70 lb–ft).
2. Connect the brake hose.
Tighten
Tighten the brake hose inlet fitting–to–caliper bolt and
washers to 40 NSm (30 lb–ft).
3. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
4. Lower the vehicle.
5. Fill the master cylinder to the proper level with
clean brake fluid.
6. Bleed the caliper. Refer to Section 4A, Hydraulic
Brakes.
7. Recheck the fluid level.
Notice : Do not move the vehicle until a firm pedal is ob-
tained, or improper braking action will result.
8. Repeatedly press the brake pedal to bring the pads
in contact with the rotor.
ROTOR
Removal Procedure
Notice : Do not hang the caliper assembly from the brake
hose. Any resulting internal hose restriction will impede
uniform braking action.
Important : To guarantee uniform braking on both sides,
both rotors must have identical surfaces regarding
smoothness and scoring depth. For this reason, always
replace both rotors.
1. Remove the caliper assembly without disconnecting
the brake hoses. Refer to ”Caliper Assembly” in this
section.
2. Remove the rotor–to–front wheel hub detent
screws.
3. Pull off the rotor.
Installation Procedure
1. Inspect the rotor. Refer to ”Rotor Inspection”in this
section.
2. Install the rotor to the front wheel hub by tightening
the detent screw.
Tighten
Tighten the rotor–to–front wheel hub detent screw to
4 NSm (35 lb–in).
3. Install the caliper assembly. Refer to ”Caliper As-
sembly” in this section.

SECTION : 4E1
REAR DISC BRAKES
TABLE OF CONTENTS
SPECIFICATIONS4E1–1 . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4E1–1. . . . . . . . . .
DIAGNOSIS4E1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lining Inspection 4E1–1. . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Inspection 4E1–1. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR4E1–3 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 4E1–3. . . . . . . . . . . . . . . . . . . .
Shoe and Lining 4E1–3. . . . . . . . . . . . . . . . . . . . . . . . . . Caliper 4E1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor 4E1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub and Parking Brake Shoe/Backplate 4E1–6. . . . .
UNIT REPAIR 4E1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caliper Overhaul 4E1–10. . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION4E1–12 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc Brake Caliper Assembly 4E1–12. . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Brake Hose Inlet Bolt and Ring Seals3224–
Caliper Mounting Bolts5641–
Lower Caliper Mounting Bolt2720–
Parking Brake Shoe Hold–Down Spring As-
sembly Screw4–35
Rotor Detent Screw4–35
Hub Bolts6548–
DIAGNOSIS
LINING INSPECTION
1. Raise and suitably support the vehicle.
2. Remove the rear wheels. Refer to Section 2E, Tires
and Wheels.
3. Visually check the brake shoe linings for minimum
thickness and wear.
4. Measure the thickness.
Important : The minimum discard thickness of the brake
shoe lining is 2 mm (0.08 inch).
5. Install the shoes in axle sets only.
6. Install the rear wheels. Refer to Section 2E, Tires
and Wheels.
7. Lower the vehicle.
ROTOR INSPECTION
Brake rotors are manufactured with close tolerances for
thickness variation, flatness, and lateral runout, but pits
and grooves are created in rotors during usage. Lack of
uniformity of the braking surfaces of the rotor can cause
inadequate braking and a pulsating pedal during braking.
The surface finish of the rotor is also important because
an unsuitable surface finish can cause pulling and rapid
wear of the brake shoe lining. If a rotor does not meet the
specification, it should be refinished to specification or re-
placed. Refinishing of the rotor should only be done with
precision equipment.
Thickness variation can be checked by measuring the
thickness of the rotor at four or more points around the cir-
cumference of the rotor. All measurements must be made
at the same distance from the edge of the rotor. A rotor that
varies by more than. 1.0 mm (0.04 inch) can cause pedal

4E1 – 2IREAR DISC BRAKES
DAEWOO V–121 BL4
pulsation and/or front end vibration during braking. Thick-
ness can be measured with a commercially available mi-
crometer and should be 10 mm(0.39 inch) or over.
Light scoring of the rotor surfaces is acceptable if it does
not exceed 0.40 mm (0.016 inch) in depth. Scoring mea-
surements can be made with a commercially available
brake micrometer.
Lateral runout cannot exceed 0.8 mm (0.03 inch). If lateral
runout exceeds the specification, make sure that there is
no dirt between the rotor and the hub and that hub–to–ro-
tor contact surfaces are smooth and free from burrs. Use
a commercially available dial indicator to check the lateral
runout according to the following procedure.
1. Position the shift lever in NEUTRAL and raise the
vehicle.2. To preserve wheel balance, mark the relative posi-
tions of the wheel and hub, and remove the rear
wheel.
3. Fasten the brake rotor to the wheel hub.
4. Mount a dial indicator on the brake caliper.
5. Place the indicator tip approximately 10 mm (0.39
inch) from the outer edge of the brake rotor, per-
pendicular to the disc and under slight preload. Ob-
serve the indicator gauge while rotating the rotor.
6. After measuring is completed, remove the dial indi-
cator and the wheel nuts.
7. If necessary, refinish the rotor with precision equip-
ment. Measure the runout again after refinishing. If
the runout exceeds 0.8 mm (0.03 inch) after refin-
ishing, the rotor should be replaced.
8. Align the marks that were made before wheel re-
moval, and install the rear wheel.
9. Lower the vehicle.

4E1 – 4IREAR DISC BRAKES
DAEWOO V–121 BL4
Notice : Avoid damaging the piston seal when the piston
housing is pulled down.
4. Pivot the caliper downward and install the bolt.
Tighten
Tighten the lower caliper mounting bolt to 27 NSm (20
lb–ft).
5. Install the rear wheels. Refer to Section 2E, Tires
and Wheels.
6. Lower the vehicle.
CALIPER
Removal Procedure
1. Raise and suitably support the vehicle.
2. Mark the position of the rear wheels relative to the
wheel hubs and remove the wheels. Refer to Sec-
tion 2E, Tires and Wheels.
3. Remove the bolt and the ring seals that attach the
brake hose inlet fitting to the caliper.
4. Disconnect the brake hose. Plug the openings in
the caliper and the brake hose to prevent fluid loss
or contamination.
5. Remove the caliper mounting bolts from the steer-
ing knuckle.
6. Remove the caliper.
Installation Procedure
1. Install the caliper with the mounting bolts.
Tighten
Tighten the caliper mounting bolts to 56 NSm (41 lb–
ft).

REAR DISC BRAKES 4E1 – 5
DAEWOO V–121 BL4
2. Connect the brake hose with the bolt and ring
seals.
Tighten
Tighten the brake hose inlet bolt and ring seals to 32
NSm (24 lb–ft).
3. Install the rear wheels. Refer to Section 2E, Tires
and Wheels.
4. Lower the vehicle.
5. Fill the master cylinder to the proper level with
clean brake fluid.
6. Bleed the caliper. Refer to Section 4F, Antilock
Brake System and Traction Control System.
ROTOR
Removal Procedure
1. Remove the caliper. Refer to ”Caliper” in this sec-
tion.
2. Remove the brake shoes.
3. Remove the caliper mounting bracket.
4. Remove the rotor detent screw.
5. Remove the rotor.
Installation Procedure
Important : To guarantee uniform braking, always refinish
both rotors even if only one rotor is defective.
1. Install the rotor on the front wheel hub and install
the detent screw.
Tighten
Tighten the rotor detent screw to 4 NSm (35 lb–in)

4E1 – 6IREAR DISC BRAKES
DAEWOO V–121 BL4
2. Apply a few drops of thread–locking compound to
the caliper bracket mounting bolts and install the
caliper bracket.
Tighten
Tighten the caliper bracket mounting bolts to 56 NSm
(41 lb–ft).
3. Install the brake shoes and the caliper. See ”Cali-
per” in this section.
HUB AND PARKING BRAKE
SHOE/BACKPLATE
Removal Procedure
1. Remove the caliper mounting bracket.
2. Remove the rotor detent screw.
3. Remove the rotor.
4. Remove the rear ABS sensor connector.

REAR DISC BRAKES 4E1 – 7
DAEWOO V–121 BL4
5. Remove the hub bolts and hub.
6. Remove the upper return spring, lower return spring
and adjuster assembly.
7. Remove the retaining spring plate, spring and re-
taining spring pin.
8. Remove the parking brake shoe.
9. Remove the parking brake cable pin and cable from
the backing plate.