Hand brake DAEWOO LACETTI 2004 Service Repair Manual

GENERAL INFORMATION 0B – 15
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
S If a floor jack is used, the following precautions are
recommended.
S Park the vehicle on level ground,
block" the front
or rear wheels, set the jack against the frame, raise
the vehicle and support it with chassis stands and
then perform the service operation.
S Before performing the service operation, disconnect
the negative battery cable in order to reduce the
chance of cable damage and burning due to short–
circuiting.
S Use a cover on the body, the seats and the floor to
protect them against damage and contamination.
S Handle brake fluid and antifreeze solution with care
as they can cause paint damage.
S The use of proper tools, and the recommended es-
sential and available tools where specified, are im-
portant for efficient and reliable performance of the
service repairs.S Use genuine DAEWOO parts.
S Discard used cotter pins, gaskets, O–rings, oil
seals, lock washers and self–locking nuts. Prepare
new ones for installation. Normal function of these
parts cannot be maintained if these parts are re-
used.
S Keep the disassembled parts neatly in groups to
facilitate proper and smooth reassembly.
S Keep attaching bolts and nuts separated, as they
vary in hardness and design depending on the posi-
tion of the installation.
S Clean the parts before inspection or reassembly.
S Also clean the oil parts, etc. Use compressed air to
make certain they are free of restrictions.
S Lubricate rotating and sliding faces of parts with oil
or grease before installation.
S When necessary, use a sealer on gaskets to pre-
vent leakage.
S Carefully observe all specifications for bolt and nut
torques.
S When service operation is completed, make a final
check to be sure service was done properly and the
problem was corrected.

2A – 6ISUSPENSION DIAGNOSIS
DAEWOO V–121 BL4
S A high front trim height. This height would increase
the drive axle angle and could cause wobble at
speeds between 24 to 48 km/h (15 to 30 mph).
S Binding or a tight drive axle joint. A tight drive axle
joint or a high front trim height may also cause a
wobble at speeds between 24 to 48 km/h (15 to 30
mph).
S Incorrect, worn, or loose engine mounts causing
adverse drive angles.
Refer to ”General Diagnosis” in this section for actions to
remedy these problems.
Conditions that may produce an effect similar to torque
steer include:
S Incorrect front or rear alignment.
S Frame misalignment or defect.
S Front suspension damage.
S Incorrectly mounted rear crossmember.
TAPERED ROLLER BEARING
Perform the following test to check for looseness in the
hub and bearing assembly on vehicles equipped with rear
disc brakes:
1. Raise and suitably support the vehicle.
2. Remove the rear wheel. Refer to Section 2E, Tires
and Wheels.
3. Remove the brake disc caliper and the brake rotor.
Refer to Section 4E1, Rear Disc Brakes.4. Mount a dial indicator set with a magnetic base to a
control arm or any other stationary part of the ve-
hicle.
5. Push and pull the wheel hub by hand. If the wheel
hub movement exceeds 0.05 mm (0.002 inch), re-
place the wheel bearing. Refer to Section 2D, Rear
Suspension.
6. Install the brake disc caliper and the brake rotor.
Refer to Section 4E1, Rear Disc Brakes.
7. Install the rear wheel. Refer to Section 2E, Tires
and Wheels.
8. Lower the vehicle.

2C – 14IFRONT SUSPENSION
DAEWOO V–121 BL4
6. Remove the wheel bearing with the support bridge
J–37105–B–1, the bearing adapter J–37105–B–2,
the hex nut 500–20, and the forcing screw
J–36661–2.
7. Clean the bore of the knuckle.
Installation Procedure
1. Install the outer snap ring and push the wheel bear-
ing into place with the support bridge
J–37105–B–1, the bearing adapter J–37105–B–2,
the hex nut 500–20, and the forcing screw
J–36661–2.
2. Install the brake shield. Refer to Section 4D, Front
Disc Brakes.
3. Install the inner snap ring.
4. Push the wheel hub into place with the hub adapter
J–37105–B–3, the bearing adapter J–37105–B–2,
the hex nut 500–20, and the forcing screw
J–36661–2.
5. Install the drive axle into the front wheel hub. Refer
to Knuckle/Strut Assembly” in this section.
CONTROL ARM
Tools Required
KM–507–B Ball Joint Remover
Removal Procedure
1. Raise and suitably support the vehicle. Let the con-
trol arms hang free.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. Remove the pinch bolt and the nut from the ball
joint.
4. In case of right–hand side, remove the engine
mounting.

TIRES AND WHEELS 2E – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
WHEEL
Removal Procedure
1. Loosen the wheel bolts.
2. Raise and suitably support the vehicle.
3. Remove the wheel bolts.
Notice : Never use heat to loosen a tight wheel. It can
shorten the life of the wheel, the wheel nuts and the wheel
bearings. Excessive force, such as hammering the wheel
or tire, can also cause damage and is not recommended.
Slight tapping of the wheel sidewall with one’s hand or with
a rubber mallet is acceptable.
4. Remove the wheel.
Difficulty in removing the wheels from the vehicle can be
due to foreign material or to a tight fit between the wheel
centerhole and the hub or the rotor. These wheels can be
removed by
5. Retightening the wheel bolts on the affected wheel
and then loosening the wheel bolts by two turns.
6. Lowering the vehicle and rocking it from side to side
as hard as possible, using one or more person’s
body weight to loosen the wheel.
7. Raising the vehicle and removing the wheel.
CAUTION : Do not allow the penetrating oil to get on
the vertical surfaces between the wheel and the drum
(or rotor) because penetrating oil in this area could
cause the wheel to work loose as the vehicle is driven,
resulting in loss of control and an injury accident.
Penetrating oil is not effective in removing tight wheels. If
it is used, however, apply it sparingly and only to the
wheel’s centerhole area.
Installation Procedure
Notice : Before installing the wheels, remove any buildup
of corrosion on the wheel mounting surface and the brake
drum or the rotor mounting surface by scraping and brush-
ing them with a wire brush. Installing the wheels without
good metal–to–metal contact at the mounting surfaces
can cause the wheel nuts to loosen, which can later allow
a wheel to come off while the vehicle is moving. Wheel
bolts must be tightened in sequence and to the proper
torque to avoid bending the wheel, the brake drum or the
rotor.
1. Mount the wheel.
2. Install the wheel bolts in the sequence shown. Do
not tighten the wheel bolts.
3. Lower the vehicle.
Tighten
Tighten the wheel bolts to 100 NSm (74 lb–ft).

2E – 6ITIRES AND WHEELS
DAEWOO V–121 BL4
S Amchem Alodine No. 1001. Stock No. DX50T or
equivalent coating chemical for alloys.
S Ditzler Delclear Acrylic Urethane Clear, Stock No.
DAU–75 or equivalent.
S Ditzler Delthane Ultra–Urethane Additive, Stock No.
DXR–80 or equivalent.
Before repairing the alloy damage or the clear coat dam-
age, prepare the wheels and the tires.
1. Remove the wheel from the vehicle.
2. Mark the location of the outboard weights and re-
move them.
3. Wash the wheel inside and out with a water–based,
all–purpose cleaner. Remove the grease and oil
with a solvent cleaner.
4. Mask the tire prior to painting.
5. Using a 400–grit wet or dry sandpaper, sand over
the painted areas that will not require recoloring.
Sanding will promote the adhesion of the clear coat.
Alloy Damage on Wheel Surface
1. Mount the wheel on a brake lathe and spin the as-
sembly slowly.
2. Sand the wheel with a backing block or pad. Hold
the backing block or pad flat to the surface of the
wheel and sand slowly back and forth from the cen-
ter to the outer edge of the tire to remove the dam-
age. Use the following sandpaper grits in the order
listed:
1) 80 grit.
2) 150 grit.
3) 240 grit.
Clear Coat Damage on Unpainted Wheels
1. Apply the chemical stripper Amchem Alumi Prep
No. 33. Use a small 1/4–inch detail brush to apply
the stripper around the perimeter and spoke–like
areas.
2. Remove the stripper according to the manufactur-
er’s recommendations.
CAUTION : To avoid serious personal injury, do not
use engine power to rotate the wheel while sanding.
3. Sand the wheel with 240–grit sandpaper by rotating
the wheel on a slow–spinning brake lathe or by
mounting the wheel on the car and spinning it by
hand. Sanding restores the machined appearance
and promotes adhesion.
After repairing the alloy or clear coat damage, the wheels
must be recoated.

TIRES AND WHEELS 2E – 11
DAEWOO V–121 BL4
pacity, diameter, rim width, offset, and mounting configu-
ration. A wheel of improper size or type may affect wheel
and bearing life, brake cooling, speedometer/odometer
calibration, vehicle ground clearance, and tire clearance
to the body and the chassis. The wheel offset is 49 ± 1 mm
(1.93 ± 0.04 inches). Steel wheels may be identified by a
two– or three–letter code stamped into the rim near the
valve stem. Alloy wheels should have the code, the part
number, and the manufacturer ID cast into the back side.
INFLATION O TIRES
The pressure recommended for any vehicle line is careful-
ly calculated to give a satisfactory ride, handling, tread life,
and load–carrying capacity.
Tire pressure should be checked monthly or before any
extended trip. Check the tires when they are cold, after the
vehicle has sat for 3 hours or more, or has been driven less
than 1 mile. Set the tire pressure to the specifications on
the tire label located on the rear face of the driver’s door.
Tire inflation pressure is also given under ”Tire Size and
Pressure Specifications” in this section.
Valve caps or extensions should be on the valves to keep
dust and water out.
For sustained driving at speeds up to 140 km/h (85 mph),
inflate the tires to the pressure recommended on the tire.
Sustained driving at speeds faster than 140 km/h (85mph), even if permitted by law, is not advised unless the
vehicle has special high–speed tires available from many
tire dealers. Tire pressures may increase as much as 41
kPa (6 psi) when the tires are hot.
Higher than recommended tire pressure can cause
S Hard ride.
S Tire bruising or damage.
S Rapid tread wear at the center of the tire.
Lower than recommended pressure can cause
S Tire squeal on turns.
S Hard steering.
S Rapid and uneven wear on the edges of the tread.
S Tire rim bruises and rupture.
S Tire cord breakage.
S High tire temperatures.
Unequal tire pressures on same axle can cause
S Uneven braking.
S Steering lead.
S Reduced handling.
S Swerve on acceleration.
S Torque steer.

4A – 10IHYDRAULIC BRAKES
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
MANUAL BLEEDING THE BRAKES
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
1. Remove the booster reserve by applying the brakes
several times with the engine OFF until all the re-
serve is depleted.
Important : If the master cylinder is known or suspected
to have air in the bore, then it must be bled before any
wheel cylinder or caliper is bled.
2. Fill the master cylinder reservoir with brake fluid.
Keep the master cylinder at least one–half full of
fluid during the bleeding operation.
3. Disconnect the front brake line(s) at the master cyl-
inder.
4. Allow the brake fluid to fill the master cylinder until it
begins to flow from the front pipe connector port.
5. Connect the front brake line(s) to the master cylin-
der.
Tighten
Tighten the brake lines to 16 NSm (12 lb–ft).

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.

4A – 16IHYDRAULIC BRAKES
DAEWOO V–121 BL4
BRAKE PEDAL
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Remove the instrument panel. Refer to Section 9E,
Instrumentation/Driver Information.
2. Remove the nuts from the brace.
3. Remove the brake pedal.
Installation Procedure
1. Install the brace with nuts.
Tighten
Tighten the brace with nuts to 22 NSm (16 lb–ft).
2. Install the brake pedal.
3. Install the instrument panel. Refer to Section 9E,
Instrumentation/Driver Information.

MASTER CYLINDER 4B – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
MASTER CYLINDER ASSEMBLY
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the electrical connector from the reser-
voir.
2. For vehicles with the ABS braking system, discon-
nect the brake lines from the master cylinder body.
3. For vehicles with the non–ABS braking system, dis-
connect the brake lines from the proportioning
valves.
4. For vehicles with the manual transaxle, disconnect
the clip to the clutch hose connection to the master
cylinder and move the clip out of the way.
5. Remove the clutch hose from the master cylinder if
equipped.
6. Plug the opening to the brake lines to prevent fluid
loss and contamination.
7. Remove the attaching nuts from the power booster.
8. Remove the master cylinder assembly.
9. Drain the brake fluid.