brake light DAEWOO NUBIRA 2004 Service User Guide

4A – 8IHYDRAULIC BRAKES
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
16Check for a short to ground in the wiring between the
instrument cluster terminal A19(B15) and the EBCM
connector terminal 21.
Is the problem found?–Go to Step 17Go to Step 18
17Repair the wiring as needed.
Is the repair complete?–System OK–
18Check the brake lamp after doing each of the follow-
ing functions:
S Apply the parking brake.
S Remove the cap from the brake fluid reservoir.
S On vehicles equipped with ABS, command the
lamp on using a scan tool.
Does the brake warning lamp operate for all of these
conditions?–System OKGo to Step 19
19When the operations listed in step 18 were per-
formed, the brake warning lamp did not function.
Did the brake warning lamp fail to light for all of the
operations listed in step 18?–Go to Step 20Go to Step 27
201. Turn the ignition OFF.
2. Inspect the kick panel fuse F4.
Is the fuse OK?–Go to Step 22Go to Step 21
21Replace the fuse.
Is the repair complete?–System OK–
22Inspect the brake warning lamp bulb.
Is the bulb OK?–Go to Step 24Go to Step 23
23Replace the bulb.
Is the repair complete?–System OK–
241. Disconnect the instrument cluster connector.
2. Turn the ignition ON.
3. Measure the voltage at the instrument cluster
connector terminal A19(B15).
Does the voltage measure within the value speci-
fied?11–14 vGo to Step 25Go to Step 26
251. Turn the ignition OFF.
2. Repair the open in the instrument cluster.
Is the repair complete?–System OK–
261. Turn the ignition OFF.
2. Repair the open in the wiring between the in-
strument cluster connector terminal A19(B15)
and the ignition switch.
Is the repair complete?–System OK–
27Apply the parking brake again.
Does the parking brake warning lamp operate with
the parking brake applied?–Go to Step 28Go to Step 30
28Remove the brake fluid reservoir cap.
Does the parking brake warning lamp operate with
the cap from the brake fluid reservoir removed?–Go to Step 29Go to Step 32
29Check for an open between the instrument cluster
connector terminal A1 and the EBCM connector ter-
minal 21.
Is the problem found?–Go to Step 17Go to Step 13

HYDRAULIC BRAKES 4A – 9
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
301. Turn the ignition ON.
2. Disconnect the parking brake switch.
3. Jumper the parking brake switch connector
terminal to ground.
Is the lamp on?–Go to Step 10Go to Step 31
311. Turn the ignition OFF.
2. Repair the open in the wire between the instru-
ment cluster connector terminal A1 and the
parking brake switch connector terminal.
3. Is the repair complete?
Is the repair complete?–System OK–
321. Disconnect the brake fluid level switch.
2. Turn the ignition ON.
3. Jumper the brake fluid level switch connector
terminals.
Is the lamp on?–Go to Step 8Go to Step 33
331. Turn the ignition OFF.
2. Connect a test light between battery positive
and the BRN/WHT wire terminal of the brake
fluid level switch.
Is the test light on?–Go to Step 34Go to Step 35
34Repair the open in the wiring between ground and
the brake fluid level switch.
Is the repair complete?–System OK–
35Repair the open in the wiring between the instrument
cluster connector terminal A1 and the brake fluid lev-
el switch.
Is the repair complete?–System OK–

MASTER CYLINDER 4B – 9
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
MASTER CYLINDER
The master cylinder is designed for use in a diagonal–split
system. One front and one diagonally opposite rear brake
are served by the primary piston. The opposite front and
rear brakes are served by the secondary piston. The mas-
ter cylinder incorporates the functions of the standard dual
master cylinder, plus a low fluid level indicator and the pro-
portioning valves in the non–antilock braking system. The
proportioning valves limit the outlet pressure to the rear
brakes after a predetermined master cylinder pressure
has been reached.
Important :
S Replace all the components included in the repair
kits used to service this master cylinder.S Lubricate rubber parts with clean brake fluid to ease
assembly.
S Do not use lubricated shop air on brake parts, as
this may damage rubber components.
S If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of
the brake system.
S The torque values specified are for dry, unlubri-
cated fasteners.
S Perform all service operations on a clean bench,
free from all traces of mineral oil.
FLUID LEVEL SENSOR
The master cylinder is equipped with a fluid level sensor.
This sensor will activate the BRAKE light if a low fluid level
condition is detected. Once the fluid level is corrected, the
BRAKE light will go out.

4C – 2IPOWER BOOSTER
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
VACUUM HOSE
Removal Procedure
1. Spread the clip on the vacuum hose connection at
the intake manifold and move the clip slightly to-
ward the brake booster.
2. Pull the hose from the union nut connection. If the
hose does not remove easily or is deteriorated, pry
off and discard the hose.
3. Spread the clip on the vacuum hose connection to
the brake booster, and move the clip clear of the
booster.
4. Remove the vacuum hose.
Installation Procedure
1. Mount the vacuum hose and ensure the connec-
tions are tight on each end.
2. Check the function of the booster. Refer to the
”Power Booster Functional Check” in this section.
POWER BOOSTER ASSEMBLY
Removal Procedure
1. Remove the master cylinder. Refer to Section 4B,
Master Cylinder Assembly.

4D – 2IFRONT DISC BRAKES
DAEWOO V–121 BL4
During manufacturing, the brake rotor and the tolerances
of the braking surface regarding flatness, thickness varia-
tion, and lateral runout are held very close. The mainte-
nance of close tolerances on the shape of the braking sur-
faces is necessary to prevent brake roughness.
In addition to these tolerances, the surface finish must be
held to a specified range. The control of the braking sur-
face finish is necessary to avoid pulls and erratic perfor-
mance and to extend lining life.
Using a commercially available dial indicator, check lateral
runout as follows:
Notice : Permissible lateral runout is a maximum 0.03 mm
(0.0012 inch). If lateral runout exceeds the specification,
ensure that there is no dirt between the rotor and the hub
and that contact surfaces are smooth and free from burrs.
1. Position the shift lever in NEUTRAL.2. Remove the rotor. Refer to ”Rotor” in this section.
3. Fasten the brake rotor to the wheel hub with two
wheel bolts.
4. Fasten a dial indicator to the brake caliper.
5. Set the gauge probe tip to approximately 10 mm
(0.39 inch) from the outer edge of the brake rotor,
perpendicular to the disc and under slight preload.
6. Remove the dial indicator and the wheel bolts con-
necting the rotor to the hub.
Important : Since accurate control of the rotor tolerances
is necessary for proper performance of the disc brakes, re-
finishing of the rotor should be done only with precision
equipment.
7. Refinish the rotor, if required, with precision equip-
ment. Discard the rotor if it fails to meet the above
specifications after refinishing.
8. Install the rotor. Refer to ”Rotor” in this section.

4E1 – 2IREAR DISC BRAKES
DAEWOO V–121 BL4
pulsation and/or front end vibration during braking. Thick-
ness can be measured with a commercially available mi-
crometer and should be 10 mm(0.39 inch) or over.
Light scoring of the rotor surfaces is acceptable if it does
not exceed 0.40 mm (0.016 inch) in depth. Scoring mea-
surements can be made with a commercially available
brake micrometer.
Lateral runout cannot exceed 0.8 mm (0.03 inch). If lateral
runout exceeds the specification, make sure that there is
no dirt between the rotor and the hub and that hub–to–ro-
tor contact surfaces are smooth and free from burrs. Use
a commercially available dial indicator to check the lateral
runout according to the following procedure.
1. Position the shift lever in NEUTRAL and raise the
vehicle.2. To preserve wheel balance, mark the relative posi-
tions of the wheel and hub, and remove the rear
wheel.
3. Fasten the brake rotor to the wheel hub.
4. Mount a dial indicator on the brake caliper.
5. Place the indicator tip approximately 10 mm (0.39
inch) from the outer edge of the brake rotor, per-
pendicular to the disc and under slight preload. Ob-
serve the indicator gauge while rotating the rotor.
6. After measuring is completed, remove the dial indi-
cator and the wheel nuts.
7. If necessary, refinish the rotor with precision equip-
ment. Measure the runout again after refinishing. If
the runout exceeds 0.8 mm (0.03 inch) after refin-
ishing, the rotor should be replaced.
8. Align the marks that were made before wheel re-
moval, and install the rear wheel.
9. Lower the vehicle.

SECTION : 4E2
REAR DRUM BRAKES
TABLE OF CONTENTS
SPECIFICATIONS4E2–1 . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4E2–1. . . . . . . . .
DIAGNOSIS4E2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lining Inspection 4E2–1. . . . . . . . . . . . . . . . . . . . . . . . .
Drums 4E2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR4E2–3 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 4E2–3. . . . . . . . . . . . . . . . . . . .
Brake Adjustment 4E2–3. . . . . . . . . . . . . . . . . . . . . . . . Shoe and Lining 4E2–4. . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder Assembly 4E2–7. . . . . . . . . . . . . . . . .
Backing Plate 4E2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 4E2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder 4E2–10. . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION4E2–12 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Brakes 4E2–12. . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Brake Line1612–
Brake Wheel Hub/Backing Plate–to–Rear
Axle Nuts2821–
Wheel Cylinder–to–Backing Plate Bolt8–71
DIAGNOSIS
LINING INSPECTION
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. Release the parking brake.
4. Remove the drum. Refer to ” Drum” in this section.
5. Measure the lining thickness. The minimum lining
thickness is 0.5 mm (0.02 inch).
CAUTION : To avoid injury when servicing brake
parts, do not create dust by grinding or sanding the
brake linings or by cleaning the wheel brake parts
with a dry brush or with compressed air.
Important : Replace the shoe and lining assembly in axle
sets only.
6. Install the drum, if removed. Refer to ”One–Piece
Drum” or ”Two–Piece Drum” in this section.
7. Install the wheel, if removed. Refer to Section 2E,
Tires and Wheels.
8. Lower the vehicle.
DRUMS
Whenever brake drums are removed, they should be thor-
oughly cleaned and inspected to see if the drums are
cracked, scored, deeply grooved, or beyond the specified
out–of–round limit.
S A cracked drum is unsafe for further service and-
must be replaced. Do not attempt to weld a cracked
drum. Smooth out any slight scores.
S Heavy or extensive scoring will cause excessive
brake lining wear and may require refinishing the
drum braking surface.
S If the brake linings are slightly worn but are still re-
usable and the drum is grooved, polish the drum
with a fine emery cloth but do not refinish it. Elimi-
nating all grooves in the drum and smoothing the
ridges on the lining would remove too much metal
and lining. If left alone, the grooves and ridges
match, and satisfactory service can be obtained. If
the brake linings need to be replaced, refinish a
grooved drum. A grooved drum, used with a new

4E2 – 10IREAR DRUM BRAKES
DAEWOO V–121 BL4
UNIT REPAIR
WHEEL CYLINDER
Disassembly Procedure
1. Remove the wheel cylinder assembly from the
backing plate. Refer to ”Wheel Cylinder Assembly”
in this section.
2. Twist off the boots, the pistons, and the seals from
each end of the wheel cylinder.
3. Remove the spring assembly.
4. Remove the bleeder cap and the bleeder valve.
Assembly Procedure
1. Inspect the wheel cylinder bore and the pistons for
scoring, nicks, corrosion, and wear.
2. Use a crocus cloth to polish out light corrosion in
the wheel cylinder bore.
Important : If the bore will not clean up with a crocus cloth,
replace the assembly.
3. Clean all the parts in clean denatured alcohol or
brake fluid. Dry all the parts with unlubricated com-
pressed air and lubricate the new seals, the pis-
tons, and the wheel cylinder bore with clean brake
fluid before assembly.
4. Thinly coat all the parts except the dust caps with
brake cylinder fluid.
5. Fasten the bleeder valve and the cap to the wheel
cylinder.

4F – 8IANTILOCK BRAKE SYSTEM
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
31. Turn the ignition switch to LOCK for 10 sec-
onds.
2. Turn the ignition switch to ON and observe the
ABS indicator.
Does the indicator light for 4 seconds and then go
off?–Go to Step 5Go to Step 4
4Check the ABS indicator.
Did the ABS indicator turn on and stay on?–Go to ”ABS In-
dicator Lamp Il-
luminated
Constantly”Go to ”ABS In-
dicator Lamp
Inoperative”
51. Turn the ignition switch to LOCK for 10 sec-
onds.
2. Turn the ignition switch to ON and observe the
parking brake / EBD indicator.
Does the indicator light for 4 seconds and then go
off?–Go to Step 12Go to ”EBD
System Indica-
tor Lamp Inop-
erative”
61. Turn the ignition switch to LOCK.
2. Disconnect the EBCM harness connector.
3. Turn the ignition switch to ON.
4. Use a digital voltmeter (DVM) to measure the
voltage from ground to terminal 15, 17, and 18
of EBCM harness connector.
Is the voltage within the specified value on each ter-
minal?11–14 vGo to Step 7Go to ”Power
Supply to Con-
trol Module, No
DTCs Stored”
71. Turn the ignition switch to LOCK.
2. Use a DVM to measure the resistance from the
EBCM harness connector, terminals 16 and 19
to ground.
Is the resistance equal to the specified value?
0 WGo to Step 9Go to Step 8
8Repair the open in the circuit BLK and BLK/WHT
that failed.
Is the repair complete?–System OK–
9Use a DVM to measure the resistance between ter-
minal 11 of the EBCM harness connector and termi-
nal 12 of the Data Link Connector (DLC). Is the re-
sistance below the specified value?2 WGo to Step 10Go to Step 11
10Replace the ABS unit assembly.
Is the repair complete?–System OK–
11Repair the open or high resistance in circuit DK BLU
between terminal 11 of the EBCM harness connec-
tor and terminal 12 of the DLC jack.
Is the repair complete?–Go to Step 1–
12Perform the road test described above.
Are any DTCs set?–Go to the table
for the DTC–

ANTILOCK BRAKE SYSTEM 4F – 47
DAEWOO V–121 BL4
J3B14F10
EBCM
ORN/
BLK
LT BLULT B L U
BLK/ WHT
C201 C202
141
40
19
61
G1062
4
15A Ef13
6
C10211
S30114
C201C110
76
C202 11
DIAGNOSTIC TROUBLE CODE (DTC) C0161
ABS BRAKE SWITCH CIRCUIT MALFUNCTION
Circuit Description
When the brake pedal is depressed, the contacts on the
brake light switch close to illuminate the brake lights. Bat-
tery voltage is also applied to terminal 14 of the electronic
brake control module (EBCM), which signals the ABS con-
troller that the brakes are applied and ABS may be need-
ed. Without this, signals from a wheel speed sensor that
may indicate need for ABS intervention are questionable.
When the brake pedal is not depressed, the EBCM termi-
nal 14 is grounded through the brake lights.
Diagnosis
This procedure will check whether there is no output or
constant output from the brake light switch and will deter-
mine the cause as a faulty switch or a problem in the cir-
cuitry.
Cause(s)
S The ground connection or the positive connection at
the EBCM has failed.
S There is an open, short to ground, or short to posi-
tive in the vehicle wiring.S The brake light switch has failed.
Fail Action
The system records a DTC C0161. ABS and EBD opera-
tion is enabled and ABS / EBD warning lamp don’t turn on.
Test Description
The number(s) below refer to step(s) on the diagnostic
table.
1. This simple test will isolate the problem to the fuse–
brake light switch–splice 301 area or the splice
301–EBCM area.
3. This is the first step in identifying an open, a short
to ground, a short to voltage, or a faulty brake light
switch.
11. This step begins the process of finding an open, a
defective connector, or a faulty EBCM.
Diagnostic Aids
Inspect wiring and connectors carefully and thoroughly.
Failure to do so could result in misdiagnosis, causing part
replacement with reappearance of the malfunction.