brakes DAEWOO MATIZ 2003 Service Owner's Guide

DAEWOO M-150 BL2
SECTION 4D
FRONT DISC BRAKES
TABLE OF CONTENTS
Description and Operation 4D-2. . . . . . . . . . . . . . . . . .
Disc Brake Caliper Assembly 4D-2. . . . . . . . . . . . . . .
Clearance Calibration 4D-2. . . . . . . . . . . . . . . . . . . . . .
Component Locator 4D-3. . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brakes 4D-3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4D-4. . . . .
Front Disc Brake 4D-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Lining Inspection 4D-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Inspection 4D-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 4D-6. . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 4D-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Shoe and Lining 4D-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Caliper Assembly 4D-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor 4D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 4D-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caliper Overhaul 4D-8. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4D-11. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4D-11. . . . . . . . . .

4D – 2 FRONT DISC BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DISC BRAKE CALIPER ASSEMBLY
This caliper has a single bore and is mounted to the
steering knuckle with two mounting bolts. Hydraulic
pressure, created by applying the brake pedal, is con-
verted by the caliper to a stopping force. This force acts
equally against the piston and the bottom of the caliper
bore to move the piston outward and to slide the caliper
inward, resulting in a clamping action on the rotor. This
clamping action forces the linings against the rotor,
creating friction to stop the vehicle.
D17B001A
Important:

Replace all components included in the repair kits
used to service this caliper.

Lubricate the rubber parts with clean brake fluid to
ease assembly.

Do not use lubricated shop air on brake parts, as
damage to the rubber components may result.

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake system.

Replace the pads in axle sets only.

The torque values specified are for dry, unlubricated
fasteners.

Perform the service operations on a clean bench, free
from all mineral oil materials.
CLEARANCE CALIBRATION
When the hydraulic pressure is applied to the piston, the
piston moves leftward. The piston seal, which extent
considerable pressure against the piston, moves with
cylinder.
However, as a part of the piston seal is fixed into a grove
in the cylinder shape of the seal is as shown in below
figure, distorted toward the piston moving direction.
When the pressure is taken off from the brake pedal and
the hydraulic pressure is released from the piston, a re-
storing elastic force is generated at the seal and pushes
the piston rightward and back it in original position.
As the pads wear away and the clearance between rotor
and pads becomes larger, the piston moves larger.
The seal then could change in shape further, but since
end of the seal is fixed into the groove in the cylinder, the
distortion is limited to the same amount as previously
described.
The piston moves further to cover the distance of clear-
ance. As the piston returns by the same distance and
the rubber seal recovers its original shape, the clear-
ance between the rotor and pads is maintained in origi-
nal condition.
1. Piston
2. Piston Seal
3. Pads
a. Clearance
D107B002

FRONT DISC BRAKES 4D–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
FRONT DISC BRAKES
D17B401A
1. Front Brake Caliper Assembly
2. Front Brake Boot Assemblies
3. Pins
4. Pin Boots
5. Front Brake Pads
6. Carrier
7. Pad Spring8. Piston Boot
9. Piston
10. Piston Seal
11. Cylinder
12. Bleeder Screw Cap
13. Bleeder Screw

4D –4 FRONT DISC BRAKES
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
FRONT DISC BRAKE

Condition

Probable cause

Correction
Uneven Braking
Inoperative carrier.
Replace the carrier.

Sticked caliper piston.
Repair the caliper piston or replace
the caliper assembly, if needed.
Dragging Brake
Sticked caliper piston.
Repair the caliper piston or replace
the caliper assembly if needed.
Noise and Vibration
Excessive rotor run out.
Replace the rotor.
When Brake Applied
Interference of the dust cover.
Repair the dust cover.

Loose caliper mounting bolts.
Tighten the mounting bolts.

FRONT DISC BRAKES 4D–5
DAEWOO M-150 BL2
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 shoe and lin-
ing together is 8 mm (0.31 in.).
D107B301
5. Install the shoe and linings 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
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the rotor.
If the thickness of the rotor is below 10 mm (0.40 in.),
replace the brake rotor.
During manufacturing, the brake rotor and the toler-
ances of the braking surface regarding flatness and lat-
eral runout are held very close. The maintenance of
close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
D107B302
In addition to these tolerances, the surface finish must
be held to a specified range. The control of the braking
surface finish is necessary to avoid pulls and erratic per-
formance and to extend lining life.
Using a commercially-available dial indicator, check lat-
eral runout as follows:
Notice: Permissible lateral runout is a maximum 0.05 mm
(0.002 in.). If lateral runout exceeds the specification,
ensure there is no dirt between the rotor and the hub and
that contact surfaces are smooth and free from burrs.
1. Position the transaxle in NEUTRAL.
2. Remove the rotor. Refer to “Rotor” in this section.
3. Fasten a dial indicator to the strut.
4. Set the gauge probe tip to approximately 10 mm
(0.4 in.) from the outer edge of the brake rotor, per-
pendicular to the disc and under slight preload.
5. Remove the dial indicator.
Important: Since accurate control of the rotor toler-
ances is necessary for proper performance of the disc
brakes, refinishing of the rotor should be done only with
precision equipment.
6. Refinish the rotor, if required, with precision equip-
ment. Discard the rotor if it fails to meet the above
specifications after refinishing.
7. Install the rotor. Refer to “Rotor” in this section.
D107B303

4D –6 FRONT DISC BRAKES
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D107B501
SHOE AND LINING
Removal Procedure
1. Remove the front wheels. Refer to Section 2E, Tires
and Wheels.
2. Remove the brake pads.

Remove the pin bolt (1).
D107B502

Lift up the cylinder assembly (2).
D17B503A
Installation Procedure
1. Install the brake pads and the cylinder assembly with
the pin bolt.
Tighten
Tighten the pin bolt to 26 Nm (19 lb-ft).
2. Install the front wheels. Refer to Section 2E, Tires
and Wheels.

FRONT DISC BRAKES 4D–7
DAEWOO M-150 BL2
D107B504
CALIPER ASSEMBLY
Removal Procedure
1. Remove the front wheels. Refer to Section 2E, Tires
and Wheels.
2. Remove the caliper assembly.

Remove the brake hose coupling bolt (1).

Plug the opening in the brake hose to prevent fluid
loss and contamination.

Remove the caliper mounting bolts (2).
D17B505B
Installation Procedure
1. Install the caliper assembly with the bolts (1).
Tighten
Tighten the caliper–to–steering knuckle bolts to 95
Nm (70 lb-ft).
2. Connect the brake hose (2).
Tighten
Tighten the brake hose inlet fitting–to–coupling bolt to
25.5 Nm (19.1 lb-ft).
3. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
4. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.
D117B506
ROTOR
Removal Procedure
1. Remove the steering knuckle. Refer to Section 2C,
Front Suspension.
2. Remove the rotor bolts from the front wheel hub.
3. Remove the rotor. Refer to Section 2C, Front Sus-
pension.
D17B507A
Installation Procedure
1. Install the rotor to the front wheel hub by tightening
the detent bolts.
Tighten
Tighten the rotor–to–front wheel hub detent bolts to
65 Nm (48 lb-ft).
2. Install the steering knuckle. Refer to Section 2C, Front
Suspension.

4D –8 FRONT DISC BRAKES
DAEWOO M-150 BL2
UNIT REPAIR
D107B701
CALIPER OVERHAUL
Disassembly Procedure
1. Remove the caliper assembly. Refer to “Caliper As-
sembly” in this section.
2. Separate the cylinder assembly and the carrier.

Remove the pin bolts (1).

Separate the cylinder assembly and the carrier (2).
D107B702
3. Disassemble the carrier.

Remove the front brake pad set (1).

Remove the springs (2).

Remove the guide pins and boots (3).
Refer to “Shoe and Lining” in this section.
D17B703C

Remove the bleeder plug (1).

Remove the bleeder plug cap (2).

FRONT DISC BRAKES 4D–9
DAEWOO M-150 BL2
D107B704

Remove the piston boot (3).
Caution: Do not face in the direction of removing.
D107B705

Using compressed air, blow out the piston from the
cylinder (4).

Remove the piston (5).
D107B706

Remove the piston seal (6).

4D –10 FRONT DISC BRAKES
DAEWOO M-150 BL2
D17B708B
D17B707A
26
Assembly Procedure
Important: Clean all parts in denatured alcohol. Dry the
parts with unlubricated compressed air.
Important: Lubricate the piston with brake fluid.
1. Assembly the cylinder assembly.

Install the piston seal.

Push the piston inward until it is properly seated.

Install the piston boot.

Install the bleeder plug.
Tighten
Tighten the bleeder plug to 6 Nm (53 lb-in).

Install the bleeder plug cap.
2. Assemble the carrier.

Install the guide pin and boot.

Install the spring.

Install the pads.
3. Install the pin bolt connecting the cylinder assembly
and carrier.
Tighten
Tighten the pin bolt to 26 Nm (19 lb-ft).
4. Install the caliper assembly. Refer to “Caliper Assem-
bly” in this section.