brake rotor DAEWOO MATIZ 2003 Service Repair Manual

1A–6 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
 Condition Probable cause Correction
Hard Starting (WithOthers
Broken timing belt.
Replace the belt.
normal cranking)
Malfunction of Positive
Crankcase Ventilation (PCV)
valve.
Check and replace Positive
Crankcase Ventilation (PCV)
valve if needed.

Loosening, damage or
leakage of the vacuum hose.
Connect the hose correctly
or replace it.

Leakage of intake system.
Replace intake system.
Lack of Engine PowerDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Improper ignition timing.
Adjust the ignition timing.
Ignition System
Faulty spark plug.
Adjust or replace the spark
plug.

Malfunction of the distributor.
Repair or replace the
distributor. Check the rotor.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.
Malfunction of
Clogged fuel pipe.
Clean the pipe.
Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.
Others
Clogged exhaust system.
Check and repair the
system.

Clogged or contaminated air
cleaner element.
Clean or replace the air
cleaner element.

Leak of the intake manifold
gasket.
Replace the gasket.

Dragging brakes.
Repair or replace the
brakes.

Slipping clutch.
Adjust or replace the clutch.
Rough Engine IdlingDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Clogged fuel pipe.
Clean the pipe.
Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.

Malfunction of the fuel
pressure regulator.
Replace the regulator.
Malfunction of
Ignition System
Malfunction of the spark
plug.
Adjust or replace the spark
plug.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.

Worn distributor cap terminal
or accumulated carbon in
the distributor cap.
Replace or clean the
distributor cap.

1E–4 ENGINE ELECTRICAL
DAEWOO M-150 BL2
3. In both vehicles, apply the parking brake firmly.
Notice: Make sure the cables are not on or near pulleys,
fans, or other parts that will move when the engine
starts, damaging the parts.
4. Shift a manual transaxle to NEUTRAL.
Caution: Do not use cables that have loose or miss-
ing insulation, or injury could result.
5. Clamp one end of the first jumper cable to the positive
terminal on the battery. Make sure it does not touch
any other metal parts. Clamp the other end of the
same cable to the positive terminal on the other bat-
tery. Never connect the other end to the negative ter-
minal of the discharged battery.
Caution: Do not attach the cable directly to the neg-
ative terminal of the discharged battery. Doing so
could cause sparks and possible battery explosion.
6. Clamp one end of the second cable to the negative
terminal of the booster battery. Make the final con-
nection to a solid engine ground, such as the engine
lift bracket, at least 450 millimeters (18 inches) from
the discharged battery.
7. Start the engine of the vehicle with the good battery.
Run the engine at a moderate speed for several min-
utes. Then start the engine of the vehicle which has
the discharged battery.
8. Remove the jumper cables by reversing the above
sequence exactly. Remove the negative cable from
the vehicle with the discharged battery first. While re-
moving each clamp, take care that it does not touch
any other metal while the other end remains at-
tached
.
GENERATOR
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator lamination.
CS generators are equipped with internal regulators.
The Y connection (A-type) or Delta (B-type) stator, a
rectifier bridge, and a rotor with slip rings and brushes
are electrically similar to earlier generators. A conven-
tional pulley and fan are used. There is no test hole.
Unlike three-wire generators, the ∅114D (A-type) or
CS114D (B-type) may be used with only two connec-
tions: battery positive and an ‘‘L’’ terminal to the charge
indicator lamp.
As with other charging systems, the charge indicator
lamp lights when the ignition switch is turned to ON, and
goes out when the engine is running. If the charge indi-
cator is on with the engine running, a charging system
defect is indicated.
The regulator voltage setting varies with temperature
and limits the system voltage by controlling the rotorfield current. The regulator switches rotor field current
on and off. By varying the on-off time, correct average
field current for proper system voltage control is ob-
tained. At high speeds, the on-time may be 10 percent
and the off-time 90 percent. At low speeds, with high
electrical loads, on-time may be 90 percent and the off-
time 10 percent.
CHARGING SYSTEM
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator laminations.
CS generators use a new type of regulator that incorpo-
rates a diode trio. The Y connection (A-type) or Delta (B-
type) stator, a rectifier bridge, and a rotor with slip rings
and brushes are electrically similar to earlier generators.
A conventional pulley and fan are used. There is no test
hole.
STARTER
Wound field starter motors have pole pieces, arranged
around the armature, which are energized by wound
field coils.
Enclosed shift lever cranking motors have the shift lever
mechanism and the solenoid plunger enclosed in the
drive housing, protecting them from exposure to dirt, icy
conditions, and splashes.
In the basic circuit, solenoid windings are energized
when the switch is closed. The resulting plunger and
shift lever movement causes the pinion to engage the
engine flywheel ring gear. The solenoid main contacts
close. Cranking then takes place.
When the engine starts, pinion overrun protects the ar-
mature from excessive speed until the switch is opened,
at which time the return spring causes the pinion to dis-
engage. To prevent excessive overrun, the switch
should be released immediately after the engine starts.
STARTING SYSTEM
The engine electrical system includes the battery, the
ignition, the starter, the generator, and all the related wir-
ing. Diagnostic tables will aid in troubleshooting system
faults. When a fault is traced to a particular component,
refer to that component section of the service manual.
The starting system circuit consists of the battery, the
starter motor, the ignition switch, and all the related elec-
trical wiring. All of these components are connected
electrically
.
DISTRIBUTOR
Distributor distributes the high tension voltage induced
from ignition coil, to each spark plug of each cylinder in

2A–2 SUSPENSION DIAGNOSIS
DAEWOO M-150 BL2
Condition Probable Cause Correction
Car Lead/Pull
Mismatched or uneven tires.
Replace the tires.

A broken or a sagging coil spring.
Replace the coil spring.

A improperly radial tire lateral force.
Check the wheel alignment.

Switch the tire and wheel assemblies.

Replace the tires as needed.

The front–wheel alignment is
out–of–align.
Align the front wheels.

Off–center steering gear.
Reseat the pinion valve assembly.

Replace the pinion valve assembly as
needed.

Front–brake dragging.
Adjust the front brakes.
Abnormal or Excessive
Tire Wear
The front–wheel and rear–wheel
alignment is out–of–align.
Align the front and the rear wheels.

Excessive toe.
Adjust the toe.

A broken or a sagging coil spring.
Replace the coil spring.

Out–of–balance tires.
Balance the tires.

Worn strut dampeners.
Replace the strut dampeners.

A failure to rotate tires.
Rotate the tires.

Replace the tires as needed.

Overloaded vehicle.
Maintain the proper load weight.

Low tire inflation.
Inflate the tires to the proper pressure.
Scuffed Tires
Incorrect toe.
Adjust the toe.

A twisted or a bent suspension arm.
Replace the suspension arm.
Wheel Tramp
An out–of–balance tire or wheel.
Balance the tire or the wheel.

Improper strut dampener action.
Replace the strut dampeners.
Shimmy, Shake, or
An out–of–balance tire or wheel.
Balance the tire or the wheel.
Vibration
Excessive wheel hub runout.
Measure the hub flange runout.

Replace the hub as needed.

Excessive brake drum or brake rotor
imbalance.
Adjust the brakes.

Replace the brake rotor or the brake
drum as needed.

Worn tie rod ends.
Replace the tie rod ends.

Wheel trim imbalance.
Balance the wheel.

A worn ball joint.
Replace the control arm and ball joint
assembly.

Excessive wheel runout.
Measure the wheel runout.

Replace the wheel as needed.

Excessive loaded radial runout on the
tire and wheel assembly.
Match–mount the tire and wheel
assembly.

2C –16 FRONT SUSPENSION
DAEWOO M-150 BL2
UNIT REPAIR
D106B701
HUB BEARING AND KNUCKLE
Tools Required
DW 220–020A–01 Differential Bearing Puller.
DW 220–020A–04 Differential Bearing Plate Adapter.
DW 340–010 Front Wheel Hub Remover.
DW 340–020 Front Wheel Bearing Race Installer.
DW 340–030 Front Wheel Bearing Installer.
09940–71430 Front Spring Compressor.
Disassembly Procedure
1. Remove the steering knuckle assembly. Refer to
“Knuckle Assembly” in this section.
2. Remove the bolts from the wheel hub.
D106B702
3. Remove the wheel hub from the knuckle assembly
using the front wheel hub remover DW 340–010.

Remove the wheel hub using the front wheel hub
remover DW 340–010 (1).

Remove the bearing spacer (2).

Remove the brake rotor (3).

FRONT SUSPENSION 2C–19
DAEWOO M-150 BL2
D106B711
2. Install the wheel hub to steering knuckle assembly.

Install the brake rotor (1).

Install the wheel hub to the steering knuckle as-
sembly temporary (2).

Press the outer wheel bearing into the wheel hub
using the front wheel hub remover DW 340–010
and the front wheel bearing installer DW 340–030
(3).
D16B712A

Tighten the bolts (4).
Tighten
Tighten the bolt to 65 Nm (48 lb-ft).
D106B713

Install the bearing spacer (5).
D106B714

Press the inner wheel bearing into the wheel hub
using the front wheel hub remover DW 340–010
and the front wheel bearing installer DW 340–030
(6).

2E –8 TIRES AND WHEELS
DAEWOO M-150 BL2
D16A503A
90–11 0 Nm
Installation Procedure
Notice: Before installing the wheels, remove any build-
up of corrosion on the wheel mounting surface and the
brake drum or the rotor mounting surface by scraping
and brushing 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 ve-
hicle is moving. Wheel nuts must be tightened in se-
quence and to the proper torque to avoid bending the
wheel, the brake drum or the rotor.
1. Mount the wheel.
2. Install the wheel nuts in the diagonally. Do not tighten
the wheel nuts.
3. Lower the vehicle.
Tighten
Tighten the wheel nuts to 90–110 Nm (66–81 lb-ft).
ON-VEHICLE BALANCING
On-vehicle balancing will help correct vibrations due to
brake drum, rotor, and wheel cover imbalances.
Notice: Do not allow the front suspension to hang free.
When the drive axle is run at an extreme angle, extra
vibrations can occur, as well as damage to seals and
joints.
1. During on-vehicle balancing, do not remove the bal-
ance weights from the off-vehicle dynamic balance.
2. If more than 1 ounce of additional weight is required,
split the weight between the inner and the outer rim
flanges.
3. Spin the driven tire and wheel assemblies using the
engine.
OFF-VEHICLE BALANCING
Perform wheel balancing with an electronic off-vehicle
balancer. The balancer is easy to use and gives both a
static and a dynamic balance. Unlike on-vehicle balanc-
ing, the off-vehicle balancer does not correct for drum or
rotor imbalance. This drawback is overcome by its accu-
racy. Secure the wheel on the balancer with a cone
through the back side of the centerhole, not through the
wheel nut holes.
CORRECTING NON-UNIFORM TIRES
There are two ways to correct properly balanced tires
which still vibrate. One method uses an automatic
machine which loads the tire and buffs small amounts of
rubber from high spots on the outer two tread rows.
Correction by this method is usually permanent and, if it
is done properly, does not significantly affect the
appearance or the tread life of the tire. Tire truing with a
blade-type machine is not recommended because it
substantially reduces the tread life and often does not
correct the problem permanently.

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

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

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.