2003 DAEWOO MATIZ Service Repair Manual

4D –8 FRONT DISC BRAKES
DAEWOO M-150 BL2
UNIT REPAIR
D107B701
CALIPER OVERHAUL
Disassembly Procedure
1. Remove the caliper assembly. Refer to “Caliper As-
sembly” in this section.
2. Separate the cylinder assembly and the carrier.

Remove the pin bolts (1).

Separate the cylinder assembly and the carrier (2).
D107B702
3. Disassemble the carrier.

Remove the front brake pad set (1).

Remove the springs (2).

Remove the guide pins and boots (3).
Refer to “Shoe and Lining” in this section.
D17B703C

Remove the bleeder plug (1).

Remove the bleeder plug cap (2).

FRONT DISC BRAKES 4D–9
DAEWOO M-150 BL2
D107B704

Remove the piston boot (3).
Caution: Do not face in the direction of removing.
D107B705

Using compressed air, blow out the piston from the
cylinder (4).

Remove the piston (5).
D107B706

Remove the piston seal (6).

4D –10 FRONT DISC BRAKES
DAEWOO M-150 BL2
D17B708B
D17B707A
26
Assembly Procedure
Important: Clean all parts in denatured alcohol. Dry the
parts with unlubricated compressed air.
Important: Lubricate the piston with brake fluid.
1. Assembly the cylinder assembly.

Install the piston seal.

Push the piston inward until it is properly seated.

Install the piston boot.

Install the bleeder plug.
Tighten
Tighten the bleeder plug to 6 Nm (53 lb-in).

Install the bleeder plug cap.
2. Assemble the carrier.

Install the guide pin and boot.

Install the spring.

Install the pads.
3. Install the pin bolt connecting the cylinder assembly
and carrier.
Tighten
Tighten the pin bolt to 26 Nm (19 lb-ft).
4. Install the caliper assembly. Refer to “Caliper Assem-
bly” in this section.

FRONT DISC BRAKES 4D–11
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Unit

Description
Outer Diameter

mm (in.)

236 (9.3)
Thickness

mm (in.)

12.7 (0.5) Rotor
Discard Thickness

mm (in.)

10 (0.4)
Runout

mm (in.)

0.05 (0.002)
Pad Thickness

mm (in.)

10 (0.40)
Caliper

Pad Discard Thickness

mm (in.)

8 (0.31)
Diameter of the Position

mm (in.)

48 (1.89)
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In Rotor Bolts 65 48 – Caliper Mounting Bolts 95 70 – Pin Bolts 26 19 – Brake Hose Coupling Bolt 25.5 19.1 – Bleeder Screw 6 – 53

DAEWOO M-150 BL2
SECTION 4E
REAR DRUM BRAKES
TABLE OF CONTENTS
Description and Operation 4E-2. . . . . . . . . . . . . . . . . .
Drum Brakes 4E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 4E-3. . . . . . . . . . . . . . . . . . . . . . . .
Rear Drum Brakes 4E-3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4E-4. . . . .
Rear Drum Brake 4E-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Drums 4E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lining 4E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 4E-6. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 4E-6. . . . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Drum 4E-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shoe 4E-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder Assembly 4E-8. . . . . . . . . . . . . . . . . .
Backing Plate 4E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 4E-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder 4E-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4E-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4E-11. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4E-11. . . . . . . . . .

4E – 2 REAR DRUM BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRUM BRAKES
This drum brake assembly is a leading/trailing shoe de-
sign. Both brake shoes are held against the wheel cylin-
der pistons by the lower return spring and the fixed
anchor plate near the lower return spring. When the
brakes are applied, the wheel cylinder pistons move
both shoes out to contact the drum. With forward wheel
rotation, the forward brake shoe will wrap into the drum
and become self-energized. With reverse wheel rota-
tion, the rear brake shoe is self-energized. Force from
the brake shoes is transferred to the anchor plate
through the backing plate to the axle flange. Adjustment
is automatic and occurs on any service brake applica-
tion. Do not switch the position of shoes that have been
in service, as this may render the self-adjustment fea-
ture inoperative and result in increased pedal travel.Notice:

Replace all the components included in the repair kits
used to service this drum brake.

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

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
braking system.

The torque values specified are for dry, unlubricated
fasteners.

Perform service operations on a clean bench that is
free from all mineral oil materials.

REAR DRUM BRAKES 4E–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
REAR DRUM BRAKES
D107C401
1. Bleeder Screw
2. Bleeder Screw
3. Rear Brake Assembly
4. Rear Brake Plate
5. Wheel Cylinder
6. Strut Assembly
7. Brake Leading Shoe
8. Middle Return Spring9. Upper Return Spring
10. Brake Shoe Retain Spring Pin
11. Trailing Shoe
12. Brake Shoe Retain Spring
13. Brake Shoe Retain Spring Cap
14. Lower Return Spring
15. Hub Bolt
16. Rear Brake Drum

4E –4 REAR DRUM BRAKES
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
REAR DRUM BRAKE

Condition

Probable cause

Correction
Not Enough Braking
Badly worn brake shoe lining.
Replace the lining.
Force
Lining stained with oil.
Check the wheel cylinder leaks and
then replace the wheel cylinder or the
lining, if needed.

Wheel cylinder condition faulty.
Replace the wheel cylinder.

Malfunctioning self–adjustment
feature.
Repair the self–adjustment feature.
Uneven Braking
Lining stained with oil.
Check the wheel cylinder leaks and
then replace the wheel cylinder or the
lining, if needed.

Wheel cylinder condition faulty.
Replace the wheel cylinder.

Malfunctioning self–adjustment
feature.
Repair the self–adjustment feature.
Dragging Brakes After
Pedal is Released
Weakened brake shoe return spring.
Replace the brake shoe return
spring.

Wheel cylinder condition faulty.
Replace the wheel cylinder.
Excessive Pedal Travel
Excessively worn lining.
Replace the lining.

Malfunctioning self–adjustment
feature.
Repair the self–adjustment feature.
Braking Noise or
Foreign material stuck to drum.
Clean the rear drum brake.
Vibration
Loosen brake plate bolt.
Tighten the brake plate bolt.

Damaged drum.
Replace the drum.
Poor Braking Force of
Parking Brake
Lining stained with oil.
Check the wheel cylinder leaks and
then replace the wheel cylinder or the
lining, if needed.

Damaged self–adjustment feature.
Repair the self–adjustment feature.

Poor adjustment of parking brake
cable.
Adjust the parking brake cable.