steering DAEWOO LACETTI 2004 Service Manual PDF

HYDRAULIC BRAKES 4A – 15
DAEWOO V–121 BL4
Installation Procedure
1. Install the new disc brake hose to the caliper with
new seal rings and the bolt.
Tighten
Tighten the front disc brake hose–to–caliper bolt to 40
NSm (30 lb–ft).
2. Slide the brake hose on the steering knuckle shaft
”C” bracket.
3. Connect the brake pipe line to the brake hose on
the wheel housing bracket on each side of the ve-
hicle.
Tighten
Tighten the brake line to 16 NSm (12 lb–ft).
4. Lower the vehicle.
5. Bleed the brake system. Refer to ”Manual Bleeding
the Brakes” in this section.
6. Check the brake system for leaks.
STOPLAMP SWITCH
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the stoplamp switch from the plug con-
nector.
3. Turn the switch. Remove the switch from the brake
pedal bracket.
Installation Procedure
1. Place the stoplamp switch into the plug connector.
2. Twist the stoplamp switch into the brake pedal
bracket hole.
3. Depress the brake pedal and pull the switch plung-
er to its maximum setting to adjust the switch.
4. Release the plunger and pull up on the pedal.
5. Connect the negative battery cable.

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 – 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.

FRONT DISC BRAKES 4D – 5
DAEWOO V–121 BL4
SPLASH SHIELD
Removal Procedure
1. Remove the rotor. Refer to ”Rotor” in this section.
2. Remove the screws for the splash shield from the
steering knuckle.
3. Remove the splash shield.
Installation Procedure
1. Install the splash shield.
2. Secure the splash shield to the steering knuckle
with the screws.
Tighten
Tighten the splash shield–to–steering knuckle screws
to 4 NSm (35 lb–in).
3. Install the rotor. Refer to ”Rotor” in this section.

4F – 62IANTILOCK BRAKE SYSTEM
DAEWOO V–121 BL4
FRONT WHEEL SPEED SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the front wheel speed sensor electrical
connector.
3. Raise and suitably support the vehicle.
4. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
5. Turn the steering wheel to expose the speed sen-
sor. It is located at the rear of the steering knuckle
near the tie rod end.
6. Remove the bolt and the front wheel speed sensor
from the steering knuckle.
7. Free the feedthrough grommet for the speed sen-
sor harness and the hydraulic pipe from the strut
tower. Remove the speed sensor harness from it so
that the connector can pass through the hole in the
strut tower.
8. Free the sensor harness from the grommet holders
and the clamps and pull it through the fender.
Installation Procedure
1. Install the front wheel speed sensor to the steering
knuckle. Secure it with the bolt.
Tighten
Tighten the front wheel speed sensor bolt to 8 NSm
(71 lb–in).
2. Feed the sensor harness into the engine compart-
ment, insert it into the grommet, and secure the
grommet into the hole in the strut tower.
3. Secure the harness into the grommet holders and
the clamps under the fender.
4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
6. Connect the front wheel speed sensor electrical
connector.
7. Connect the negative battery cable.

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.

ELECTRICAL WIRING DIAGRAMSW5–3
4. ECM (ENGINE CONTROL MODULE) : SIRIUS D4 5–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM & CKP SENSOR CIRCUIT 5–34. . . . . . . . . . . . . . . . . . . . .
2) FUEL PUMP, INJECTOR, FUEL CONNECTOR & CMP SENSOR CIRCUIT 5–36. . . . . . . . . . . . . . . . . . . . . . . . .
3) MTIA, SENSOR(ECT, KNOCK, IAT, MAP, ACP & HO2S) & POWER STEERING PRESSURE SWITCH
CIRCUIT : EOBD5–38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4) MTIA, SENSOR(ECT, KNOCK, IAT, MAP, ACP & O2) & POWER STEERING PRESSURE SWITCH
CIRCUIT : NON EOBD5–40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5) EEGR VALVE, VR SENSOR, CLUSTER & FUEL PUMP CIRCUIT : EOBD 5–42. . . . . . . . . . . . . . . . . . . . . . . . . .
6) EGR VALVE, CLUSTER & FUEL PUMP CIRCUIT: NON EOBD 5–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7) EVAP CANISTER PURGE SOLENOID, VGIS, CLUSTER, VSS, TCM & RON SWITCH CIRCUIT 5–46. . . . . . .
8) DLC, MIL LAMP & IMMOBILIZER CONTROL CIRCUIT 5–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. TCM (TRANSMISSION CONTROL MODULE) : MR–140/HV–240 5–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) POWER SUPPLY, GROUND, PNP SWITCH, BRAKE SWITCH & SOLENOID VALVE CIRCUIT 5–50. . . . . . . .
2) SENSOR(INPUT SPEED,OUTPUT SPEED, TRANSMISSION FLUID TEMP.), CLUSTER, DLC, ECM &
HOLD MODE SWITCH CIRCUIT5–52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3) PNP SWITCH & CLUSTER CIRCUIT 5–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. TCM (TRANSMISSION CONTROL MODULE) : SIRIUS D4 5–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) POWER SUPPLY, GROUND, PNP SWITCH, CLUSTER & ECM CIRCUIT : NOTCH BACK 5–56. . . . . . . . . . . .
2) POWER SUPPLY, GROUND, PNP SWITCH, CLUSTER & ECM CIRCUIT : HATCH BACK 5–58. . . . . . . . . . . .
3) BRAKE SWITCH, BTSI SOLENOID, ISS SENSOR & TRANSAXLE CIRCUIT 5–60. . . . . . . . . . . . . . . . . . . . . . . .
4) HOLD MODE SWITCH, VSS & DLC CIRCUIT 5–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. AIR CONDITIONER5–64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) AIR CONDITIONER CONTROL SWITCH, BLOWER MOTOR RESISTER & BLOWER MOTOR
CIRCUIT5–64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) AIR CONDITIONER CONTROL, INTAKE MOTOR SWITCH & AIR CONDITIONER COMPRESSOR
CIRCUIT5–66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING DIAGRAMSW5–7
29. SUN ROOF CIRCUIT5–180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30. SSPS(SPEED SENSITIVE POWER STEERING) CIRCUIT 5–182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31. IMMOBILIZER SYSTEM CIRCUIT5–184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32. ANTI THEFT CONTROL SYSTEM CIRCUIT 5–186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) NOTCH BACK5–186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) HATCH BACK5–188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–38WELECTRICAL WIRING DIAGRAMS
3) MTIA, SENSOR (ECT, KNOCK, IAT, MAP, ACP & HO2S) & POWER STEERING PRESSURE
SWITCH CIRCUIT : EOBDa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C103 (10 Pin, White)Engine
Engine Fuse BlockEngine Fuse Block
C104 (24 Pin, White)Front
Engine Fuse BlockEngine Fuse Block
C106 (20 Pin, White)Engine
Engine Fuse BlockEngine Fuse Block
C109 (4 Pin, White)Engine
FrontUnder Engine Fuse Block
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
J3B1P016

5–40WELECTRICAL WIRING DIAGRAMS
4) MTIA, SENSOR (ECT, KNOCK, IAT, MAP, ACP & O2) & POWER STEERING PRESSURE
SWITCH CIRCUIT : NON EOBDa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C104 (24 Pin, White)Front
Engine Fuse BlockEngine Fuse Block
C106 (20 Pin, White)Engine
Engine Fuse BlockEngine Fuse Block
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
J3B1P017