wheel DAEWOO MATIZ 2003 Service Manual Online

4A –4 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DIAGNOSITIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily
braked, but turning, wheels will stop the vehicle in less
distance than locked brakes. More tire-to-road friction is
present with a heavily braked, turning tire than with a
sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:

Tires having unequal contact and grip of the road will
cause unequal braking. Tires must be equally in-
flated, and the tread pattern of the right and the left
tires must be approximately equal.

Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.

Misalignment of the wheels, particularly conditions of
excessive camber and caster, will cause the brakes
to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and the
shift lever in NEUTRAL. If the pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking. Perform a visual check to confirm any sus-
pected leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an
abnormally low level indicates a leak in the system. The
hydraulic system may be leaking either internally or ex-
ternally. Refer to the procedure below to check the mas-
ter cylinder. Also, the system may appear to pass this
test while still having a slight leak. If the fluid level is nor-
mal, check the vacuum booster pushrod length. If an in-
correct pushrod length is found, adjust or replace the
rod.Check the master cylinder using the following proce-
dure:

Check for a cracked master cylinder casting or brake
fluid leaking around the master cylinder. Leaks are in-
dicated only if there is at least one drop of fluid. A
damp condition is not abnormal.

Check for a binding pedal linkage and for an incorrect
pushrod length. If both of these parts are in satisfac-
tory condition, disassemble the master cylinder and
check for an elongated or swollen primary cylinder or
piston seals. If swollen seals are found, substandard
or contaminated brake fluid should be suspected. If
contaminated brake fluid is found, all the components
should be disassembled and cleaned, and all the rub-
ber components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, then the rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston seals on the
drum brake wheels.
If rubber deterioration is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep al-
cohol out of the system. Replace all the rubber parts in
the system, including the hoses. Also, when working on
the brake mechanisms, check for fluid on the linings. If
excessive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush the
master cylinder with brake fluid, refill the master cylin-
der, and bleed the system. Refer to “Manual Bleeding
the Brakes” in this section.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of the
outer cover, and for leaks or blisters. Inspect the hoses
for proper routing and mounting. A brake hose that rubs
on a suspension component will wear and eventually
fail. A light and a mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as neces-
sary.

4A –8 HYDRAULIC BRAKES
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D107A528
BRAKE HOSE (FRONT)
Removal Procedure
1. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
2. Remove the brake hose.

Remove the fitting (1).

Remove the E–ring retainer (2).

Disconnect the brake hose mounting from the strut
(3).

Remove the coupling bolt (4).

Plug the opening in the brake pipe and caliper to
prevent fluid loss or contamination.
D17A529B
Installation Procedure
1. Connect the brake lines to the brake hose (1).
Tighten
Tighten the brake pipe–to–hose fitting to 16 Nm (12
lb-ft).
2. Install the brake hose coupling bolt (2).
Tighten
Tighten the bolt to 25.5 Nm (19.1 lb-ft).
Important: Use only Daewoo recommended brake
fluid.
3. Bleed the brake system. Refer to “Manual Bleeding
the Brakes” in this section.
4. Check the brake system for leaks.
5. Install the wheels. Refer to Section 2E, Tires and
Wheels.

HYDRAULIC BRAKES 4A–9
DAEWOO M-150 BL2
D107A530
BRAKE HOSE (REAR)
Removal Procedure
1. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
2. Remove the brake hose.

Remove the fittings (1).

Remove the E–rings (2).

Plug the opening in the brake pipe to prevent fluid
loss or contamination.
D17A531A
Installation Procedure
1. Connect the brake lines to the brake hose.
2. Install the fitting and E–rings.
Tighten
Tighten the fitting to 16 Nm (12 lb-ft).
Important: Use only Daewoo recommended brake fluid.
3. Bleed the brake system. Refer to “Manual Bleeding
the Brakes” in this section.
4. Check the brake system for leaks.
5. Install the wheels. Refer to Section 2E, Tires and
Wheels.
D107A523
STOPLAMP SWITCH
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the stoplamp switch.

Disconnect the connector (1).

Turn the stoplamp switch (2).
D107A524
Installation Procedure
1. Install the stoplamp switch.
2. Connect the electrical connector.
3. Connect the negative battery cable.
Important: After installing the stoplamp switch, pull the
lever completely.

HYDRAULIC BRAKES 4A–13
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
0.8 SOHC Engine
Application Millimeters Inches



Brake Drums:
Inside Diameter
Maximum Rebore Diameter
Out-of-Round


180
182
0.04


7.09
7.17
0.0016




Brake Rotors:
Discard Thickness
Lateral Runout (Installed)
Rotor Diameter
Rotor Thickness (New)



10
0.05
236
12.7




0.4
0.002
9.3
0.5
Master Cylinder:
Bore Diameter 20.64 0.81
Caliper:
Piston Diameter
48

1.89
Wheel Cylinder Diameter: 17.46 0.69



Brake Pedal:
Free Play
Height
Stroke


6 – 10
200
30



0.24 – 0.31
7.87
1.18
Type DOT–3 or DOT–4 Brake Fluid Capacity 0.45 L (0.48 qt.)
FASTENER TIGHTENING SPECIFICATIONS

Application

Nm

Lb-Ft

Lb-In
Brake Pipe Fittings 16 12 –
Front Brake Hose-to-Caliper Bolt 25.5 19.1 –
Brake Pedal–to–Pedal Bracket Hex Bolt

18

13

–
Brake Pedal Bracket Mounting Bolts 18 – 26 13 – 20 –
Brake Pedal Bracket Mounting Nuts 18 – 26 13 – 20 –
Stoplamp Switch Mounting Bracket Bolts

9 – 12

–

80 – 106

MASTER CYLINDER 4B–9
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Unit

Description
Type – Tandem
Master Cylinder Bore Diameter mm (in.) 20.64 (0.81)
Cut–In Pressure kPa (psi) 3,000(435.1)

Proportioning Valve
Pressure Ratio

–

0.25 : 30
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Fluid Reservoir Screw 4 – 35
Master Cylinder Attaching Nuts 16 12 –
Brake Pipe Fittings to Master Cylinder

16

12

–
Brake Pipe Fittings to Proportioning Valve 16 12 –
Brake Pipe Fittings to Rear Wheel Cylinder 16 12 –
Brake Pipe Fittings to Front Caliper 16 12 –
Proportioning Valve

22

16

–

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.

DAEWOO M-150 BL2
SECTION 4E
REAR DRUM BRAKES
TABLE OF CONTENTS
Description and Operation 4E-2. . . . . . . . . . . . . . . . . .
Drum Brakes 4E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 4E-3. . . . . . . . . . . . . . . . . . . . . . . .
Rear Drum Brakes 4E-3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4E-4. . . . .
Rear Drum Brake 4E-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Drums 4E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lining 4E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 4E-6. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4E-6. . . . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Drum 4E-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shoe 4E-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder Assembly 4E-8. . . . . . . . . . . . . . . . . .
Backing Plate 4E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 4E-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder 4E-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4E-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4E-11. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4E-11. . . . . . . . . .

4E – 2 REAR DRUM BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRUM BRAKES
This drum brake assembly is a leading/trailing shoe de-
sign. Both brake shoes are held against the wheel cylin-
der pistons by the lower return spring and the fixed
anchor plate near the lower return spring. When the
brakes are applied, the wheel cylinder pistons move
both shoes out to contact the drum. With forward wheel
rotation, the forward brake shoe will wrap into the drum
and become self-energized. With reverse wheel rota-
tion, the rear brake shoe is self-energized. Force from
the brake shoes is transferred to the anchor plate
through the backing plate to the axle flange. Adjustment
is automatic and occurs on any service brake applica-
tion. Do not switch the position of shoes that have been
in service, as this may render the self-adjustment fea-
ture inoperative and result in increased pedal travel.Notice:

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

Do not use lubricated shop air on the 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
braking system.

The torque values specified are for dry, unlubricated
fasteners.

Perform service operations on a clean bench that is
free from all mineral oil materials.