2003 DAEWOO MATIZ brake

REAR DRUM BRAKES 4E–7
DAEWOO M-150 BL2
D17C504A

Tighten the castellated nut to 25 Nm (18 lb-ft).

Loosen the castellated nut to 180.

Retighten the castellated nut to 2.5 Nm (22 lb-in).

Install the new cotter pin and spindle cap.
2. Adjust the parking brake.
3. Install the rear wheels. Refer to Section 6E, Tires and
Wheels.
D107C505
BRAKE SHOE
Removal Procedure
1. Remove the brake drum. Refer to “Brake Drum” in
this section.
2. Remove the return spring.

Remove the upper return spring (1).

Remove the upper return spring bracket (2).

Remove the lower return spring (3).
D107C506

Remove the adjust lever (4).

Remove the middle return spring (5).
D107C507
3. Remove the brake shoe.

Remove the readjusting unit (1).

Turn the brake shoe retaining spring pin rectangu-
larly by the pliers (2).

Remove the brake shoe retain spring cap (3).

Remove the retaining spring (4).

Remove the retaining spring pin (5).

Remove the leading shoe (6).

4E –8 REAR DRUM BRAKES
DAEWOO M-150 BL2
D107C508
4. Disconnect the parking brake cable from the trailing
shoe and remove the trailing shoe (7).
D107C509
Installation Procedure
1. Install in the reverse of removal.
2. Clean the adjust assembly and apply grease.
3. Connect the parking brake cable from the trailing
shoe.
4. Install the brake shoe.
5. Install the return spring.

Install the middle return spring and adjust lever.

Install the lower return spring.

Install the upper return spring bracket.

Install the upper return spring.
6. Install the brake drum. Refer to “Brake Drum” in this
section.
D107C510
WHEEL CYLINDER ASSEMBLY
Removal Procedure
1. Remove the brake drum. Refer to “Rear Brake Drum”
in this section.
2. Remove the wheel cylinder.

Remove the brake shoe upper spring (1).

Widen the leading shoe and trailing shoe (2).
D107C511

Disconnect the brake line fitting (3).

Plug the opening in the brake line to prevent fluid
loss or contamination.

Remove the wheel cylinder–to–backing plate bolt
(4).

REAR DRUM BRAKES 4E–9
DAEWOO M-150 BL2
D17C512A
Installation Procedure
1. Install the wheel cylinder to the backing plate with the
wheel cylinder bolt (1).
Tighten
Tighten the wheel cylinder–to–backing plate bolt to 10
Nm (89 lb-in).
2. Connect the brake line fitting (2).
Tighten
Tighten the brake line fitting to 16 Nm (12 lb-ft).
3. Install the brake shoe. Refer to “Brake Shoe” in this
section.
4. Install the brake drum. Refer to “Rear Brake Drum” in
this section.
D107C513
BACKING PLATE
Removal Procedure
1. Remove the brake drum. Refer to “Rear Brake Drum”
in this section.
2. Remove the brake shoe components. Refer to “Brake
Shoe” in this section.
3. Remove the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.
4. Remove the bolts and the backing plate.
D17C514A
Installation Procedure
1. Install the bolts and the backing plate.
Tighten
Tighten the backing plate–to–rear axle bolts to 24
Nm (18 lb-ft).
2. Install the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.
3. Install the brake shoe components. Refer to “Brake
Shoe” in this section.
4. Install the brake drum.

4E –10 REAR DRUM BRAKES
DAEWOO M-150 BL2
UNIT REPAIR
D107C701
WHEEL CYLINDER
Disassembly Procedure
1. Remove the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.
2. Disassemble wheel cylinder assembly.

Remove the dust boots and do not reuse them (1).

Remove the piston (2).

Remove the piston cup and do not reuse it (3).

Remove the spring assembly (4).

Remove the bleeder screw (5).
3. Clean all parts with denatured alcohol. Dry the parts
with unlubricated compressed air.
D17C702A
Assembly Procedure
Important: Lubricate the new seals, the piston, the pis-
ton cup and the wheel cylinder bore with clean brake
fluid before assembly.
1. Assemble wheel cylinder assembly.

Insert the bleeder screw.
Tighten
Tighten the bleeder screw to 6 Nm (53 lb-in).

Install the spring and the new piston cup.

Install the piston and the new boots.
2. Inspect the piston for free movement.
3. Install the wheel cylinder assembly. Refer to “Wheel
Cylinder Assembly” in this section.

REAR DRUM BRAKES 4E–11
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Inside Diameter mm (in.) 180 (7.086)
Wear Limit mm (in.) 182 (7.165)
Drum Out of Round mm (in.) 0.04 (0.001)
Cylindricty mm (in.) 0.02 (0.0008)
Thickness mm (in.) 4 (0.157)
Brake Lining Wear Limit mm (in.) 1 (0.039)

Brake Lining
Distance Between Lining and Drum mm (in.) 0.3 (0.011)
Wheel Cylinder Inside Diameter mm (in.) 17.46 (0.687)
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Castellated Nut* – – –
Wheel Cylinder Bolt 10 – 89
Brake Backing Plate Bolt 24 18 –
Brake Pipe Fitting 16 12 –
Bleeder Screw 6 – 53

Castellated Nut : 25 Nm – 180 + 2.5 Nm (18 lb-ft – 180 + 22 lb-in.)

DAEWOO M-150 BL2
SECTION 4F
ANTILOCK BRAKE SYSTEM
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.
CAUTION: Don’t diagnosis the Antilock Brake System (ABS) under the vehicle moving status. Because the
ABS function will be stopped.
TABLE OF CONTENTS
Description and Operation 4F-3. . . . . . . . . . . . . . . . . .
ABS System Components 4F-3. . . . . . . . . . . . . . . . . .
Hydraulic Unit 4F-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EBCM (Electronic Brake Control Module) 4F-4. . . . .
Wheel Speed Sensors and Rings 4F-5. . . . . . . . . . . .
Electronic Brake Distribution 4F-5. . . . . . . . . . . . . . . .
Indicator 4F-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EBCM Connector 4F-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fluid Flow Diagrams 4F-7. . . . . . . . . . . . . .
Normal Braking Mode 4F-7. . . . . . . . . . . . . . . . . . . .
Isolation Mode (Pressure Maintain) 4F-8. . . . . . . .
Dump Mode (Pressure Decrease) 4F-9. . . . . . . . .
Reapply Mode (Pressure Increase) 4F-10. . . . . . .
Proportioning Function 4F-11. . . . . . . . . . . . . . . . . .
Visual Identification 4F-12. . . . . . . . . . . . . . . . . . . . . . .
EBCM Connector Face View 4F-12. . . . . . . . . . . . . . .
Component Locator 4F-13. . . . . . . . . . . . . . . . . . . . . . .
ABS 4F-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4F-16. . . .
DTC 0354 Left Front Wheel Speed Sensor
Circuit Open or Shorted 4F-16. . . . . . . . . . . . . . . . .
DTC 0355 Left Front Wheel Speed Sensor
Poor Air Gap or Missing Tooth Ring 4F-20. . . . . . .
DTC 0356 Left Front Wheel Speed Sensor
Circuit Intermittent Shorted 4F-22. . . . . . . . . . . . . .
DTC 0404 Right Front Wheel Speed Sensor
Circuit Open or Shorted 4F-24. . . . . . . . . . . . . . . . .
DTC 0405 Right Front Wheel Speed Sensor
Poor Air Gap or Missing Tooth Ring 4F-28. . . . . . .
DTC 0406 Right Front Wheel Speed Sensor
Circuit Intermittent Shorted 4F-30. . . . . . . . . . . . . .
DTC 0454 Left Rear Wheel Speed Sensor
Circuit Open or Shorted 4F-32. . . . . . . . . . . . . . . . .
DTC 0455 Left Rear Wheel Speed Sensor
Poor Air Gap or Missing Tooth Ring 4F-36. . . . . . . DTC 0456 Left Rear Wheel Speed Sensor
Circuit Intermittent Shorted 4F-38. . . . . . . . . . . . . .
DTC 0504 Right Rear Wheel Speed Sensor
Circuit Open or Shorted 4F-42. . . . . . . . . . . . . . . . .
DTC 0505 Right Rear Wheel Speed Sensor
Poor Air Gap or Missing Tooth Ring 4F-46. . . . . . .
DTC 0506 Right Rear Wheel Speed Sensor
Circuit Intermittent Shorted 4F-48. . . . . . . . . . . . . .
DTC 0601 Left Front Dump Shorted or
Driver Open 4F-52. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0602 Left Front Dump Open or
Driver Shorted 4F-54. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0651 Left Front Isolation Shorted or
Driver Open 4F-56. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0652 Left Front Isolation Open or
Driver Shorted 4F-58. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0701 Right Front Dump Shorted or
Driver Open 4F-60. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0702 Right Front Dump Open or
Driver Shorted 4F-62. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0751 Right Front Isolation Shorted or
Driver Open 4F-64. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0752 Right Front Isolation Open or
Driver Shorted 4F-66. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0801 Left Rear Dump Shorted or
Driver Open 4F-68. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0802 Left Rear Dump Open or
Driver Shorted 4F-70. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0851 Left Rear Isolation Shorted or
Driver Open 4F-72. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0852 Left Rear Isolation Open or
Driver Shorted 4F-74. . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0901 Right Rear Dump Shorted or
Driver Open 4F-76. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 0902 Right Rear Dump Open or
Driver Shorted 4F-78. . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . .

ANTILOCK BRAKE SYSTEM 4F–3
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
ABS SYSTEM COMPONENTS
The Antilock Braking System (ABS) consists of a con-
ventional hydraulic brake system plus antilock compo-
nents. The conventional brake system includes a
vacuum booster, master cylinder, front disc brakes, rear
drum brakes, interconnecting hydraulic brake pipes and
hoses, brake fluid level sensor and the BRAKE indicator.
The ABS components include a hydraulic unit, an elec-
tronic brake control module (EBCM), two system fuses,
four wheel speed sensors (one at each wheel), intercon-
necting wiring, the ABS indicator, and the rear drum
brake. See “ABS Component Locator” in this section for
the general layout of this system.
HYDRAULIC UNIT
The hydraulic unit with the attached EBCM is located
between the surge tank and the fire wall on the right side
of the vehicle. The basic hydraulic unit configuration
consists of return pump motor, return pump, four isola-
tion valves, four dump valves, two Low Pressure Accu-
mulators (LPA), two High Pressure Attenuators (HPA).
The hydraulic unit controls hydraulic pressure to the
front calipers and rear wheel cylinders by modulating hy-
draulic pressure to prevent wheel lockup.
Isolation valve
The isolation valve is placed in the brake fluid path from
the master cylinder to the relevant brake caliper and al-
lows free flow as commanded by the driver during nor-
mal braking and reapply phases.
In the isolation phase the coil moves the armature down,
which closes the normally open isolation orifice and pre-
vents any further increase of pressure in the brake. The
valve also remains closed during the dump phase.
The lip seal provides a one way return path for brake
fluid to flow through in:
1. Foot off pedal during isolation.
2. Residual LPA fluid.
D107E002
Dump Valve
The dump valve creates a flow path from the isolation
cartridge (brake side) to the low pressure accumulator
(LPA). The valve keeps this path permanently closed ex-
cept during the dump phase in the ABS mode. On ac-
tivation (dump phase), the coil moves up the armature
which opens the normally closed dump orifice and allow
to drain the pressure in the brake line with the brake fluid
flowing into the LPA.
The lip seal provides a return path for residual brake
fluid in the LPA.
D107E003
Low Pressure Accumulator (LPA)
LPA provides a variable chamber for brake fluid to be
quickly pushed in through the dump valve at the begin-
ning of a departure. This chamber then acts as a reser-
voir which buffers the pump.
D107E004
High Pressure Attenuator (HPA)
The HPA is in between the pump and the ISO valve
(master cylinder side) and uses the bulk mode of the
contained plastic damper and orifice size to dump out
the pressure oscillations from the pump to reduce the