2003 DAEWOO MATIZ brake

4B –6 MASTER CYLINDER
DAEWOO M-150 BL2
Notice: Brake fluid may damage paintwork, if spillage
onto paintwork, wash with cold water immediately.
MAB4B004
Installation procedure
1. Install the proportioning valve (1).
Tighten
Tighten the proportioning valve to 22 Nm (16 lb-ft).
2. Install the brake pipe fitting (2).
Tighten
Tighten the brake pipe fitting–to–proportioning valve
to 16 Nm (12 lb-ft).
3. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.
D107A504
BRAKE FLUID LEVEL SWITCH
Removal procedure
1. Remove the vacuum hose from the power booster.
Refer to Section 4C, Power Booster.
2. Remove the brake fluid level switch.

Remove the brake fluid level switch locking system
by the flathead screwdriver (1).
D107A505

Disconnect the electrical connector (2).

MASTER CYLINDER 4B–7
DAEWOO M-150 BL2
D107A506
Installation procedure
1. Install the brake fluid level switch.
2. Connect the electrical connector.
3. Install the vacuum hose to the power booster. Refer
to Section 4C, Power Booster.

4B –8 MASTER CYLINDER
DAEWOO M-150 BL2
UNIT REPAIR
D24B001
MASTER CYLINDER
(ABS Type Master Cylinder is Shown,
Non–ABS Type Master Cylinder is Similar)
Disassembly Procedure
1. Remove the master cylinder. Refer to “Master Cylin-
der Assembly” in this section.
2. Remove the brake fluid reservoir. Refer to “Brake
Fluid Reservoir” in this section.
3. Remove the reservoir seals (1).
4. Remove the washer (2).
5. Remove the stop pin (3).
D24B002
6. Remove the boot (1).
7. Remove the retaining ring (2).
Notice: When removing the retaining ring, avoid dam-
aging the piston or the cylinder wall.
8. Remove the primary piston (3).
9. Carefully remove the secondary piston assembly
and the spring from the master cylinder bore (4).
D24B003
Assembly Procedure
1. Install the secondary piston assembly .
2. Install the stop pin.
3. Install the primary piston.
4. Install the retaining ring.
5. Install the boot.
6. Install the washer.
7. Install the reservoir seals.
8. Install the brake fluid reservoir. Refer to “Brake Fluid
Reservoir” in this section.
9. Install the master cylinder. Refer to “Master Cylinder
Assembly” in this section.
10. Raise and suitably support the vehicle.
11. Bleed the braking system. Refer to Section 4A, Hy-
draulic Brakes.
12. Lower the vehicle.

MASTER CYLINDER 4B–9
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Unit

Description
Type – Tandem
Master Cylinder Bore Diameter mm (in.) 20.64 (0.81)
Cut–In Pressure kPa (psi) 3,000(435.1)

Proportioning Valve
Pressure Ratio

–

0.25 : 30
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Fluid Reservoir Screw 4 – 35
Master Cylinder Attaching Nuts 16 12 –
Brake Pipe Fittings to Master Cylinder

16

12

–
Brake Pipe Fittings to Proportioning Valve 16 12 –
Brake Pipe Fittings to Rear Wheel Cylinder 16 12 –
Brake Pipe Fittings to Front Caliper 16 12 –
Proportioning Valve

22

16

–

4C – 2 POWER BOOSTER
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
POWER BOOSTER
This booster is a single diaphragm, vacuum-suspended
unit. In a normal operating mode, with the service brakes
in the release position, a vacuum-suspended booster
operates with a vacuum on both sides of its diaphragm.
When the brakes are applied, air at atmospheric pres-
sure is admitted to one side of the diaphragm to pro-vide the power assist. When the brakes are released, at-
mospheric air is shut off from that side of the diaphragm.
The air is then drawn from the booster through the vacu-
um check valve by the vacuum source.
Important: If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or part of
the brake system.

POWER BOOSTER 4C–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER BOOSTER FUNCTIONAL
CHECK
1. With the engine stopped, eliminate the vacuum in the
booster by pumping the brake pedal several times.
2. Push the pedal down and hold it in this position.
3. Start the engine.
4. The booster is OK if the pedal drops further because
of extra force produced.
If the brake pedal does not drop, the vacuum system
(vacuum hoses, check valve, etc.) is probably defective
and should be checked.
If no defect is revealed by checking the vacuum system,
the defect is in the booster itself.
CHECK VALVE FUNCTIONAL CHECK
1. Remove the vacuum hose.
2. Suck the vacuum hose to power booster. And also,
suck the vacuum hose to engine.
3. If the air pass through the check valve or not, replace
the check valve. And if the vacuum hose to engine isonly sucked, the check valve OK.
D17A301B

POWER BOOSTER 4C–5
DAEWOO M-150 BL2
D107A519
POWER BOOSTER ASSEMBLY
(LEFT–HAND DRIVE)
Removal Procedure
1. Remove the master cylinder assembly. Refer to Sec-
tion 4B, Master Cylinder.
2. Disconnect the vacuum hose from the power booster.
3. Remove the power booster.

Straighten the cotter pin and remove it (1).

Remove the clevis pin (2).
D107A520

Remove the nuts (3).
D107A521

Remove the power booster (4).
D17A522A
Installation Procedure
1. Install the power booster with the new cotter pin, cle-
vis pin and nuts.
Tighten
Tighten the nuts to 16 Nm (12 lb-ft).
Important: Make sure the distance from the booster
to the center of the clevis bore should be 100mm
(3.94 in.).
2. Install the master cylinder assembly. Refer to Section
4B, Master Cylinder.
3. Connect the vacuum hose to the power booster.
4. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.

DAEWOO M-150 BL2
SECTION 4D
FRONT DISC BRAKES
TABLE OF CONTENTS
Description and Operation 4D-2. . . . . . . . . . . . . . . . . .
Disc Brake Caliper Assembly 4D-2. . . . . . . . . . . . . . .
Clearance Calibration 4D-2. . . . . . . . . . . . . . . . . . . . . .
Component Locator 4D-3. . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brakes 4D-3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 4D-4. . . . .
Front Disc Brake 4D-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Lining Inspection 4D-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Inspection 4D-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 4D-6. . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 4D-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Shoe and Lining 4D-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Caliper Assembly 4D-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor 4D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 4D-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caliper Overhaul 4D-8. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 4D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 4D-11. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4D-11. . . . . . . . . .