air bleeding DAEWOO MATIZ 2003 Service Repair Manual

DAEWOO M-150 BL2
SECTION 4A
HYDRAULIC BRAKES
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.
TABLE OF CONTENTS
Description and Operation 4A-2. . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A-2. . . . . . . . . . . . . . . . . . .
Component Locator 4A-3. . . . . . . . . . . . . . . . . . . . . . . .
Brake System (Non-ABS) 4A-3. . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4A-4. . . . .
Brake System Testing 4A-4. . . . . . . . . . . . . . . . . . . . . .
Brake Hose Inspection 4A-4. . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A-5. . . . . . . . . . . . . . . . . . .
Brake System Fault 4A-5. . . . . . . . . . . . . . . . . . . . . . . .
Manual Bleeding the Brakes 4A-6. . . . . . . . . . . . . . . .
Pedal Travel Check 4A-6. . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Free Play Inspection 4A-7. . . . . . . . . . . Repair Instructions 4A-8. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4A-8. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose (Front) 4A-8. . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose (Rear) 4A-9. . . . . . . . . . . . . . . . . . . . . . . .
Stoplamp Switch 4A-9. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal 4A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4A-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4A-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4A-13. . . . . . . . . .
Schematic and Routing Diagrams 4A-14. . . . . . . . . .
Brake Lamp Warning Circuit 4A-14. . . . . . . . . . . . . . .
Stoplamp Switch Circuit 4A-14. . . . . . . . . . . . . . . . . . .

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 –6 HYDRAULIC BRAKES
DAEWOO M-150 BL2
MANUAL BLEEDING THE BRAKES
Important: The bleeding sequence is as follows; right
rear, left rear, right front, and left front.
Important: Check the fluid level and add the fluid during
the bleeding operation.
1. Raise the vehicle.
2. Remove the bleeder screw and cap.
D17B703B
3. Attach a transparent tube over the valve. Allow the
tube to hang submerged in brake fluid in a transpar-
ent container.
D107A303
4. Slowly push the brake pedal several times and hold
the brake pedal.5. Tighten the bleeder screw after loosening the bleeder
screw and draining the fluid.
Caution: Hold the brake pedal until tightening the
bleeder screw.
6. Repeat the step 5, 6 until all the air is removed.
7. Check the leaks for the bleeder screw.
PEDAL TRAVEL CHECK
1. Start the engine.
2. Push the pedal three times.
3. With brake pedal depressed with a about 30Kg (66.15
lb) load, measure the clearance between the pedal
pad and the lower dash panel.
Unit : mm (in.)

Specification

60 (2.36)
D107A304
4. If clearance is less than 60mm (2.36 in.), the most
possible cause is either rear drum brake shoes are
worn out beyond the specification value or air is in
lines. Clearance still remains less than 60mm (2.36
in.) even after replacement of brake shoes and bleed-
ing of the brake system, other possible but infrequent
cause is malfunction of rear drum brake shoe adjust-
ers or booster push rod length out of adjustment.
5. Automatic clearance adjuster check is performed af-
ter removing brake drums. If the faulty is found, repair
or replace it.

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.

4F – 2 ANTILOCK BRAKE SYSTEM
DAEWOO M-150 BL2
DTC 0951 Right Rear Isolation Shorted or
Driver Open 4F-80. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0952 Right Rear Isolation Open or
Driver Shorted 4F-82. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 1102 Return Pump Motor Circuit Open 4F-84. .
DTC 1103 Return Pump Motor Relay Fault 4F-86. . .
DTC 1104 Return Pump Motor Circuit
Shorted 4F-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 1211 EBCM Main Relay Shorted 4F-90. . . . . . .
DTC 1212 EBCM Main Relay Open 4F-92. . . . . . . . .
DTC 1213 EBCM Main Relay Fault 4F-94. . . . . . . . .
DTC 1610 Stoplamp Switch Circuit Open 4F-96. . . .
DTC 2321 ABS (Amber) Indicator Shorted
to Battery 4F-100. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 2322 ABS (Amber) Indicator Shorted
to Ground 4F-104. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 2458 Wheel Speed Sensor
Intermittent Error 4F-107. . . . . . . . . . . . . . . . . . . . . .
DTC 2459 Wheel Speed Sensor Excessive
Wheel Speed Variation 4F-108. . . . . . . . . . . . . . . . .
DTC 2520 EBCM Internal Fault 4F-110. . . . . . . . . . .
DTC 5501 Vehicle Inhibit Code 4F-112. . . . . . . . . . . .
DTC 5502 Isolation Valve Time–Out 4F-114. . . . . . .
DTC 5503 CPU Loop Time Error 4F-115. . . . . . . . . .
DTC 5504 Excessive Dump Valve Time 4F-116. . . .
DTC 5560 Inoperative External Watch–Dog 4F-117.
DTC 5610 RAM/ROM Error 8 Bit 4F-118. . . . . . . . . .
DTC 5630 ROM Error 16 Bit 4F-119. . . . . . . . . . . . . . DTC 5640 RAM Error 16 Bit 4F-120. . . . . . . . . . . . . .
DTC 8001 Battery High Voltage Fault
(More Than 16V) 4F-122. . . . . . . . . . . . . . . . . . . . . .
DTC 8002 Battery Low Voltage Fault
(Less Than 9V) 4F-124. . . . . . . . . . . . . . . . . . . . . . .
DTC 8003 Battery Low Voltage Fault
(Less Than 9.5V) 4F-126. . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 4F-128. . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4F-128. . . . . . . . . . . . . . . . . . . . . . . .
Service Precautions 4F-128. . . . . . . . . . . . . . . . . . . . .
Bleeding System 4F-128. . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Speed Sensor 4F-129. . . . . . . . . . . . . . .
Rear Wheel Speed Sensor 4F-130. . . . . . . . . . . . . . .
Front Wheel Speed Ring 4F-131. . . . . . . . . . . . . . . . .
Rear Wheel Speed Ring 4F-131. . . . . . . . . . . . . . . . . .
Hydraulic Modulator and Upper/Lower
Mounting Bracket 4F-132. . . . . . . . . . . . . . . . . . . . . .
EBCM (Electronic Brake Control Module) 4F-134. . .
Specifications 4F-136. . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4F-136. . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4F-136. . . . . . . . .
Special Tools and Equipment 4F-136. . . . . . . . . . . . .
Special Tools Table 4F-136. . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 4F-137. . . . . . . . .
ABS Circuit 4F-137. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS Block Diagram 4F-140. . . . . . . . . . . . . . . . . . . . . .

6B –6 POWER STEERING PUMP
DAEWOO M-150 BL2
D105C531

Remove the bolt (3).
18–22 Nm
D15C532A
Installation Procedure
1. Install the power steering pump with the bolt.
Tighten
Tighten the bolt to 18–22 Nm (13–16 lb-ft).
2. Connect the power steering pressure switch connec-
tor. Refer to Section 6A, Power Steering System.
3. Install the pump drive belt. Refer to “Pump Drive Belt”
in this section.
20–24 Nm
20–24 Nm 21–35 Nm
D15C533A
4. Install the bolts.
Tighten

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (1).

Tighten the power steering bolt to 20–24 Nm
(15–18 lb-ft) (2).
5. Connect the pressure line pipe to the outlet connec-
tion on the steering pump.
Tighten
Tighten the pressure line pipe fitting to 21–35 Nm
(16–26 lb-ft) (3).
6. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
Notice: When adding fluid or making a complete fluid
change, always use DEXRON-II or DEXRON-III pow-
er steering fluid. Failure to use the proper fluid will cause
hose and seal damage and fluid leaks.
7. Refill the pump with new fluid and bleed the air from
the system. Refer to Section 6A, Bleeding the Power
Steering System.
8. Inspect for leaks. If leaks are found, correct the cause
of the leak and bleed the system.