2003 DAEWOO MATIZ sensor

FRONT SUSPENSION 2C–9
DAEWOO M-150 BL2
D106B507
4. Remove the control arm from the knuckle assembly.

Remove the stud bolt (1).

Separate the control arm from the knuckle assem-
bly (2).
D106B508
5. Remove the brake caliper from the knuckle assembly.
Refer to Section 4D, Front Disc Brakes.
6. Remove the ABS wheel speed sensor from the
knuckle assembly, if applicable. Refer to Section 4F,
Anti–lock Brake System.
7. Remove the steering knuckle assembly from the ve-
hicle.

Remove the strut bracket bolts (1).

Separate the knuckle assembly from the drive
shaft by pulling the steering knuckle assembly (2).
D16B509A
70–90 Nm
50–70 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the steering knuckle assembly in the vehicle
with strut bracket bolts (1).
Tighten
Tighten the strut bracket bolts to 70–90 Nm (52–66
lb-ft).
3. Install the brake caliper from the knuckle assembly.
4. Install the control arm into the knuckle assembly with
the stud bolt (2).
Tighten
Tighten the stud bolt to 50–70 Nm (36–52 lb-ft).
D16B510B
5. Install the tie rod end to the knuckle assembly.
6. Install the tie rod end–to–knuckle castellated nut (1)
and the cotter pin.
Tighten
Tighten the castellated nut to 30–55 Nm (22–41 lb-
ft).
7. Install the caulking nut (2).

Bend the caulking nut flange (3).
Tighten
Tighten the caulking nut to 210 Nm (155 lb-ft).

FRONT SUSPENSION 2C–23
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Suspension Type – Mcpherson (Strut)
Maximum Length mm (in.) 475–481 (18.7–18.94) Shock Absorber Minimum Length mm (in.) 321–327 (12.64–12.87)
Stroke

mm (in.)

154 (6.06)
Stabilizer Shaft Diammeter

mm (in.)

24 (0.94)
Coil Spring Height (No Load) mm (in.) 374 (14.72 )
Grease Type (Front Wheel Bearing and Hub) – M–8143 ANTIF BRG GREASE
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Strut Assembly–to–Body Nuts 18 – 28 13 – 21 –
Strut Closure Nut 50 – 60 36 – 44 – Strut Assembly–to–Knuckle Bolts 70 – 90 52 – 66 –
Control Arm Mounting Bolt

55 – 70

41 – 52

–
Control Arm Ball Stud Bolt

50 – 70

36 – 52

–
Stabilizer Shaft Castellated Nut 40 – 50 30 – 36 –
Stabilizer Shaft Mounting Bolt 30 – 50 22 – 36 –
Front Under Longitudinal Frame Bolts 10 – 14 – 89 – 124
Front Under Longitudinal Frame Nut 65 – 80 48 – 59 – Drive Axle–to–Hub Caulking Nut 210 155 – Crossmember Bolt 17 – 27 13 – 20 –
Strut Bar Bolts

35 – 55

25 – 41

–
ABS Front Speed Sensor Retaining Bolt 18 – 28 13 – 21 –
Wheel Hub–to–Brake Disc Bolt 55 – 75 41 – 55 –

REAR SUSPENSION 2D–15
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Unit Description
Suspension Type– Isolated Trailing Link
Maximum Lengthmm (in.) 394.5 ± 3 (15.53 ± 0.12)
Shock Absorber Minimum Lengthmm (in.) 257.5 ± 3 (10.14 ± 0.12)

Shock Absorber
Strokemm (in.) 137 (5.39)
Clearancemm (in.) 0
Rear Wheel Bearing No LoadNm (lb-in.) 0.137 – 0.422 (0.9 – 3.7)
Coil Spring Height (No Load)mm (in.) 291 (11.46)
Grease Type (Rear Wheel Bearing and Hub)–M–8143 ANTIF BRG GREASE
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In Shock Absorber–to–Body Bracket Nut 45 – 70 33 – 52 – Shock Absorber–to–Rear Axle Bolt 45 – 70 33 – 52 – Trailing Arm–to–Rear Axle Bolt 80 – 90 59 – 66 – Trailing Arm–to–Body Bracket Bolt 70 – 90 55 – 66 – Lateral Rod–to–Body Bracket Bolt 50 – 70 37 – 52 – Lateral Rod–to–Rear Axle Nut 35 – 55 25 – 41 – Rear Axle Castellated Nut* – – – ABS Rear Speed Sensor Retaining Bolt 9 – 13 – 80 – 11 5

Rear Axle Castellated Nut : Refer to Section 4E, Rear Drum Brakes

HYDRAULIC BRAKES 4A–5
DAEWOO M-150 BL2
WARNING LAMP OPERATION
This brake system uses a BRAKE warning lamp located
in the instrument panel cluster. When the ignition switch
is in the III position, the BRAKE warning lamp should
glow and then go OFF when the ignition switch returns
to the II position.The following conditions will activate the BRAKE lamp:

Parking brake applied. The light should be on when-
ever the parking brake is applied and the ignition
switch is II.

Low fluid level. A low fluid level in the master cylinder
will turn the BRAKE lamp ON.
BRAKE SYSTEM FAULT
Condition Probable cause Correction
Brake Warning Lamp ON
Brake fluid leaks.
Repair the leaks or add th fluid.

Parking brake switch shorted to
ground.
Repair the short ground.

Faulty the fluid level sensor.
Replace the sensor.
Stoplamp ON
Faulty the stoplamp switch.
Replace the stoplamp switch.

Push rod length is short.
Adjust the push rod length of the
power booster.

Stoplamp switch circuit shorted to
battery.
Repair or Replace the wiring harness.
Poor Braking
Brake fluid lacks or leaks.
Repair the leaks or add the fluid.

Brake fluid contamination.
Replace the fluid.

Air in the brake system.
Bleed the brake system.

Damaged brake lines.
Replace the brake lines.

Damaged vacuum hose or faulty
check valve.
Replace the vacuum hose or check
value.
Dragging Brake
No free play at the brake pedal.
Adjust the free play.

Weakened the brake pedal return
spring.
Replace the return spring.

Faulty master cylinder.
Replace the master cylinder.

Air in the brake system.
Bleed the brake system.
Pedal Over Stroke
Brake fluid lacks or leaks.
Repair the leaks or add the fluid.

Poor adjustment of the brake pedal
free play.
Adjust the push rod length of the
power booster.

DAEWOO M-150 BL2
SECTION 4B
MASTER CYLINDER
TABLE OF CONTENTS
Description and Operation 4B-2. . . . . . . . . . . . . . . . . .
Master Cylinder 4B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Proportioning Valve 4B-2. . . . . . . . . . . . . . . . . . . . . . . .
Fluid Level Sensor 4B-2. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4B-3. . . . .
Checking the Brake Fluid Level 4B-3. . . . . . . . . . . . . .
Repair Instructions 4B-4. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4B-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly 4B-4. . . . . . . . . . . . . . . . . . Brake Fluid Reservoir 4B-5. . . . . . . . . . . . . . . . . . . . . .
Proportioning Valve (For Vehicle With the
Non–ABS Braking System) 4B-5. . . . . . . . . . . . . . .
Brake Fluid Level Switch 4B-6. . . . . . . . . . . . . . . . . . .
Unit Repair 4B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder 4B-8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4B-9. . . . . . . . . . .

4B –2 MASTER CYLINDER
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
MASTER CYLINDER
The master cylinder is designed for use in a direct–split
system. Front right brake and rear left brake are served
by the primary piston. Front left brake and rear right
brake are served by the secondary piston.
The master cylinder incorporates the functions of the
standard dual master cylinder, plus a low fluid level indi-
cator and the proportioning valve in the non–antilock
braking system.
The proportioning valves limit the outlet pressure to the
rear brakes after a predetermined master cylinder has
been reached.
Important:

Replace all the components included in the repair kits
used to service this master cylinder.

Lubricate rubber parts with clean brake fluid to ease
assembly.

Do not use lubricated shop air on brake parts, as this
may damage rubber components.

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake system.
The torque values specified are for dry, unlubricated
fasteners.

Perform all service operations on a clean bench, free
from all traces of mineral oil.
PROPORTIONING VALVE
The proportioning valve limits the outlet pressure to the
rear brakes on the non-ABS after a predetermined mas-
ter cylinder pressure has been reached. This is used
when less rear apply force is needed to obtain optimum
braking and is usually found on disc/drum brake configu-
rations. On ABS-equipped vehicles, refer to Section 4F,
Antilock Brake System.
FLUID LEVEL SENSOR
Fluid level sensor is attached at the brake fluid reservoir.
This sensor will activate the BRAKE light if a low fluid
level condition is detected. Once the fluid level is cor-
rected, the BRAKE light will go out.

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