2003 DAEWOO MATIZ brake

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

TIRES AND WHEELS 2E–3
DAEWOO M-150 BL2
Hydroplaning
The condition of driving a vehicle fast on the road surface
covered with water can cause tires to fail to rotate with a
good contact on the surface, so results in remaining them
afloat. This is so–called hydroplaning. It causes brake
failure, lower tractive force, and losing the steering per-
formance so it is very vulnerable condition.
D16A005A
Standing Wave
During running the rotating tire repeats deformation and
restoring movement generated in tread. But when the
wheel rotating speed reaches high, the next deformation
applied to tire before restoring last deformation so the
trembling wave appears in the tread portion. The lower
the tire pressure the severe the trembling wave appears.
And during the high speed.
D106A004
REPLACEMENT TIRES
A Tire Performance Criteria (TPC) specification number
is molded in the sidewall near the tire size of all original
equipment tires. This specification number assures that
the tire meets performance standards for traction, en-
durance, dimensions, noise, handling and rolling resist-
ance. Usually a specific TPC number is assigned to
each tire size.Caution: Do not mix different types of tires on the
same vehicle such as radial, bias and bias-belted
tires except in emergencies, because vehicle han-
dling may be seriously affected and may result in
loss of control.
Caution: Do not change 145/70 R13 tires or 155/65
R13 tires for 175/60 R13 tires, because vehicle
hancling may be seriously affected and may result
in loss of control. If you change 145/70 R13 tires or
155/65 R13 tires for 175/60 R13 tires, you have to
change the steering gear assembly.
Use only replacement tires with the same size, load
range, and construction as the original. The use of any
other tire size or construction type may seriously affect
ride, handling, speedometer/odometer calibration, ve-
hicle ground clearance, and tire clearance to the body
and the chassis. This does not apply to the spare tire fur-
nished with the vehicle.
It is recommended that new tires be installed in pairs on
the same axle.
If it is necessary to replace only one tire, pair it with the
tire having the most tread to equalize the braking action.
Although they may appear different in tread design, tires
built by different manufacturers with identical TPC speci-
fications may be used on the same vehicle.
ALL SEASON TIRES
Most vehicles are now equipped with steel-belted all
season radial tires as standard equipment. These tires
qualify as snow tires, with a 37 percent higher average
rating for snow traction than the non-all season radial
tires previously used. Other performance areas, such as
wet traction, rolling resistance, tread life, and air reten-
tion, have also been improved. This was done by im-
provements in both tread design and tread compounds.
These tires are identified by an “M + S” molded in the tire
sidewall following the size number. The suffix “MS” is
also molded in the sidewall after the TPC specification
number.
The optional handling tires used on some vehicles are
not all season tires. These will not have the “MS” mark-
ing after the tire size or the TPC specification number.
TIRE LABEL
The tire label is permanently located on the rear face of
the driver’s door and should be referred to for tire infor-
mation. It lists the maximum vehicle load, the tire size
(including the spare tire), and the cold inflation pressure
(including the spare tire).
SPARE TIRE
This vehicle comes equipped with a full-sized spare tire
and wheel.

2E –4 TIRES AND WHEELS
DAEWOO M-150 BL2
WHEELS
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, leak air through welds,
have elongated bolt holes, or if the wheel bolts won’t
stay tight or are heavily rusted. Wheels with excessive
runout may cause vehicle vibration. Replacement
wheels must be equivalent to the original equipment
wheels in load capacity, diameter, rim width, offset, and
mounting configuration. A wheel of improper size or type
may affect wheel and bearing life, brake cooling,
speedometer/odometer calibration, vehicle ground
clearance, and tire clearance to the body and the chas-
sis.
INFLATION OF TIRES
The pressure recommended for any vehicle line is care-
fully calculated to give a satisfactory ride, handling,
tread life, and load-carrying capacity.
Tire pressure should be checked monthly or before any
extended trip. Check the tires when they are cold, after
the vehicle has sat for 3 hours or more or has been driv-
en less than 1 mile. Set the tire pressure to the specifi-
cations on the tire label located on the rear face of the
driver’s door. Tire inflation pressure is also given under
“Tire Size and Pressure Specifications” in this section.
Valve caps or extensions should be on the valves to
keep dust and water out.
Higher than recommended tire pressure can cause:

Hard ride

Tire bruising or damage

Rapid tread wear at the center of the tire
Lower than recommended pressure can cause:

Tire squeal on turns

Hard steering

Rapid and uneven wear on the edges of the tread

Tire rim bruises and rupture

Tire cord breakage

High tire temperatures
Unequal tire pressures on same axle can cause:

Uneven braking

Steering lead
Reduced handling

Swerve on acceleration

Torque steer
ROTATION TIRES
Front and rear tires perform different jobs and can wear
differently depending on the tires of road driven, driving
habit, etc.
The front tires will wear faster than the rear ones.
To avoid uneven wear of tires and to prolong tire life, in-
spect and rotate the tires every 5,000 km (3,100 miles).
After rotating the tires, adjust the tire inflation pressures
and be sure to check wheel nuts tightness.
D16A304A
WHEEL BALANCE
Balance is the easiest procedure to perform and should
be done first if the vibration occurs at high speeds, or if
the tires or the wheels are replaced.
When proceeding the wheel balancing procedure regard
the belows.
1. Do not use the wheel weight over two at the inboard
and the outboard flanges.
2. The total weight of the wheel weights should not ex-
ceed the 100 grams (3.5 ounces).
3. Blanching the assemblies with factory aluminum
wheels requires the use of special nylon–coated,
clip–on wheel weights.

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.

MANUAL TRANSAXLE DRIVE AXLE 3B–5
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D106B506
DRIVE AXLE ASSEMBLY
Tool Required
KM–507–B Tie Rod End Joint Remover
Removal Procedure
1. Remove the drive axle shaft nut.
Fix the hub not to rotate by pressing the brake ped-
al.
Loosen the caulking (1).
Remove the nut (2).
Discard the nut.
Remove the washer (3).
D103B505
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Remove the transaxle under cover.
Remove the bolts (1).
Remove the under cover (2).
D104B501
4. Drain the transaxle fluid through the drain plug.
5. Remove the stabilizer bar. Refer to Section 2C, Front
Suspension.
6. Separate the control arm ball joint and the tie rod end
from the knuckle. Refer to Section 6D, Manual Steer-
ing gear and Section 2C, Front Suspension.
a. Control arm ball joint bolt.
b. Tie rod end joint castellated nut.
Notice: Use only the recommended tool for separating
the tie rod from the knuckle/strut assembly. Failure to
use the recommended tool may cause damage to the
knuckle/strut assembly or the tie rod end.

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 – 2 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
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 il-
luminate. It should go off when the ignition switch return
to II position. The following conditions will activate the
BRAKE warning lamp.

The lamp should be on whenever the parking brake
applied and the ignition switch is in the II position.

A low fluid level in the master cylinder will turn the
BRAKE warning lamp on.
D17A007A

HYDRAULIC BRAKES 4A–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
BRAKE SYSTEM (NON–ABS)
(Left–Hand Drive Shown, Right–Hand Drive Similar)
MAB4A001
1. Power Booster
2. Power Booster Boot
3. Cotter Pin
4. Clevis
5. Clevis Pin
6. Packing
7. Spacer
8. Master Cylinder Assembly
9. Fluid Reservoir Assembly
10. Reservoir Cap
11. Reservoir
12. Grommet Seal
13. Master Cylinder
14. Proportioning Valve
15. Stoplamp Switch
16. Brake Pedal Assembly
17. Clutch Pedal Spring18. Pedal Bracket Assembly
19. Clutch Pedal Pad
20. Clutch Pedal
21. Cushion
22. Bushing
23. Retaining Ring
24. Spring
25. Brake Pedal Pad
26. Brake Pedal
27. Brake Pedal Spring
28. Accelator Pedal Pad
29. Accelator Pedal
30. Rear Drum Brake Hose
31. E Ring
32. Front Disc Brake Hose
33. Brake Hose Coupling Bolt
34. Plain Washer