2003 DAEWOO MATIZ Service Repair Manual

HYDRAULIC BRAKES 4A–7
DAEWOO M-150 BL2
BRAKE PEDAL FREE PLAY
INSPECTION
1. Push the brake pedal several times to discharge the
vacuum of the power booster.
2. Measure the pedal movement until the hardness is
felt when pushing the brake pedal by hand.
Unit : mm (in.)

Specification

6–10 (0.24–0.31)
3. Brake pedal free play can not be adjusted.
D107A305

4A –8 HYDRAULIC BRAKES
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D107A528
BRAKE HOSE (FRONT)
Removal Procedure
1. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
2. Remove the brake hose.

Remove the fitting (1).

Remove the E–ring retainer (2).

Disconnect the brake hose mounting from the strut
(3).

Remove the coupling bolt (4).

Plug the opening in the brake pipe and caliper to
prevent fluid loss or contamination.
D17A529B
Installation Procedure
1. Connect the brake lines to the brake hose (1).
Tighten
Tighten the brake pipe–to–hose fitting to 16 Nm (12
lb-ft).
2. Install the brake hose coupling bolt (2).
Tighten
Tighten the bolt to 25.5 Nm (19.1 lb-ft).
Important: Use only Daewoo recommended brake
fluid.
3. Bleed the brake system. Refer to “Manual Bleeding
the Brakes” in this section.
4. Check the brake system for leaks.
5. Install the wheels. Refer to Section 2E, Tires and
Wheels.

HYDRAULIC BRAKES 4A–9
DAEWOO M-150 BL2
D107A530
BRAKE HOSE (REAR)
Removal Procedure
1. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
2. Remove the brake hose.

Remove the fittings (1).

Remove the E–rings (2).

Plug the opening in the brake pipe to prevent fluid
loss or contamination.
D17A531A
Installation Procedure
1. Connect the brake lines to the brake hose.
2. Install the fitting and E–rings.
Tighten
Tighten the fitting to 16 Nm (12 lb-ft).
Important: Use only Daewoo recommended brake fluid.
3. Bleed the brake system. Refer to “Manual Bleeding
the Brakes” in this section.
4. Check the brake system for leaks.
5. Install the wheels. Refer to Section 2E, Tires and
Wheels.
D107A523
STOPLAMP SWITCH
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the stoplamp switch.

Disconnect the connector (1).

Turn the stoplamp switch (2).
D107A524
Installation Procedure
1. Install the stoplamp switch.
2. Connect the electrical connector.
3. Connect the negative battery cable.
Important: After installing the stoplamp switch, pull the
lever completely.

4A –10 HYDRAULIC BRAKES
DAEWOO M-150 BL2
D107A525
BRAKE PEDAL
(LEFT–HAND DRIVE)
Removal Procedure
1. Remove the stoplamp switch. Refer to “Stoplamp
Switch” in this section.
2. Disconnect the brake pedal from the power booster.
Refer to Section 4C, Power Booster.
3. Remove the brake pedal.

Remove the bolt (1).
D107A526

Remove the brake pedal spring (2).

Remove the bushing (3).

Remove the cushion (4).

Remove the brake pedal pad (5).
D17A527A
Installation Procedure
1. Install the pad to the brake pedal.
2. Install the brake pedal with spring, bushing, and cush-
ion.
3. Connect the brake pedal to the power booster.
Tighten
Tighten the brake pedal–to–pedal bracket bolt to 18
Nm (13 lb-ft).
4. Install the stoplamp switch. Refer to “Stoplamp
Switch” in this section.
D24C001A
BRAKE PEDAL
(RIGHT–HAND DRIVE)
Removal Procedure
1. Remove the instrument panel assembly. Refer to
Section 9E, Instrument/Driver Information.
2. Disconnect the brake pedal rod from the power
booster. Refer to Section 4C, Power Booster.

HYDRAULIC BRAKES 4A–11
DAEWOO M-150 BL2
D24D001
3. Remove the stoplamp switch.

Remove the stoplamp switch (1).

Remove the bolts (2).

Remove the stoplamp switch bracket (3).
D24D002
4. Remove the bolts mounting brake pedal bracket (1).
5. Remove the nuts mounting brake pedal bracket (2).
D24D003
6. Remove the canister. Refer to Section 1F, Engine
Controls.
7. Remove the bolt mounting brake pedal bracket in the
engine compartment (1).
D24D004
8. Remove the brake pedal.

Remove the snap rings (1).

Remove the bushings (2).

Remove the brake pedal spring (3).

Remove the cushion (4).

Remove the brake pedal pad (5).

4A –12 HYDRAULIC BRAKES
DAEWOO M-150 BL2
D24D005
Installation Procedure
1. Install the brake pedal with pad, spring, bushings, and
cushion.
2. Install the bolt mounting brake pedal bracket in the
engine compartment.
Tighten
Tighten the bolt to 18–26 Nm (13–20 lb-ft).
3. Install the canister. Refer to Section 1F, Engine Con-
trols.
D24D006
4. Install the brake pedal with the snap rings.
5. Install the bolts and nuts mounting brake pedal brack-
et.
Tighten

Tighten the bolts mounting brake pedal bracket to
18–26 Nm (13–20 lb-ft).

Tighten the nuts mounting brake pedal bracket to
18–26 Nm (13–20 lb-ft).
D24D007
6. Install the stoplamp switch with the bracket and the
bolts.
Tighten
Tighten the mounting bolts to 9–12 Nm (80–106 lb-
in.)
7. Connect the brake pedal rod to the power booster.
Refer to Section 4C, Power Booster.
8. Install the instrument panel assembly. Refer to Sec-
tion 9E, Instrument/Driver Information.

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

4A –14 HYDRAULIC BRAKES
DAEWOO M-150 BL2
SCHEMATIC AND ROUTING DIAGRAMS
BRAKE LAMP WARNING CIRCUIT
D17A201B
STOPLAMP SWITCH CIRCUIT
D17A202B