2004 DAEWOO LACETTI brake

4–2WUSAGE AND CAPACITY OF FUSES IN FUSE BLOCK
1. ENGINE ROOM RELAY AND FUSE BLOCK
1) POSITION OF RELAY AND FUSE
2) USAGE OF FUSE IN ENGINE FUSE BLOCK
Power
Supply
ClassificationFuse
NoCapacityUsage
Ef130ABattery Main(F13~F16, F21~F24)
Ef260AEBCM, Oil Feeding Conenctor
Ef330ABlower Relay
30SBEf430AIgnition Switch–2
BAT (+)(Slow–BlownEf530AIgnition Switch–1
Fuse)Ef620ACooling Fan Low Relay
Ef730ADefog Relay
Ef830ACooling Fan HI Relay
IGN2 (15A)Ef920APower Window Switch
IGN1 (15)Ef1015AFuel Connector, ECM (MR–140), LEGR, EI
System
30Ef1110AECM, Main Relay (Sirius D4)
BAT(+)Ef1225AHead lamp Relay, ILLUM. Relay
Ef1315ABrake Switch
IGN2 (15A)Ef1420APower Window Switch
56 LIGHTEf1515AHead Lamp HI
30Ef1615AHorn Relay, siren, Hood Contact Switch
BAT(+)Ef1710AA/C Comp. Relay
IGN1 (15)Ef1815AFuel Pump
30 BAT(+)Ef1915ACluster, Key Remind S/W, Folding Mirror Unit, MAP
Lamp, Room Lamp, Trunk Open lamp, Trunk
Open S/W
56 LIGHTBlade TypeEf2010AHead Lamp Low
IGN1 (15)/FuseEf2115AEVAP Canister Purge Solenoid, HO2S, Cooling
Fan Relay
30 BAT(+)Ef2215Ainjector, EGR, EEGR
ILLUM. (58)Ef2310ALicense Plate Lamp, Chime Bell, Tail Lamp, Head
Lamp
30 BAT (+)Ef2415AFog Lamp Relay
IGN2 (15A)Ef2510AElectric OSRV Mirror
30 BAT (+)Ef2615ACentral Door Lock Unit
56 LIGHTEf2710AHead Lamp Low
ILLUM. (58)Ef2810AILLUM. Circuit, Head Lamp, Tail Lamp
SPAREEf2910ANot Used
Ef3015ANot Used
Ef3125ANot Used

USAGE AND CAPACITY OF FUSES IN FUSE BLOCKW4–3
2. I.P FUSE BLOCK
1) POSITION OF FUSE AND RELAY
2) USAGE OF FUSE IN I.P FUSE BLOCK
Power
Supply
ClassificationFuse
NoCapacityUsage
IGN1 (15)Blade TypeF110ASDM
FuseF210ATCM, ECM, Generator, VGIS,VSS
F315AHazard Switch
F410ACluster, Chime Bell, Brake Switch, SSPS Module,
A/C Control Switch
–F5––
IGN2 (15A)F610AA/C Comp. Relay, Defog Relay, Power Window
Relay, Head Lamp Relay
F720ABlower Relay, A/C Control Switch, FATC
F815AElectric Mirror Switch, Folding Mirror, Sun Roof
Module
IGN1 (15)F925AWiper Motor, Wiper Switch
–F10––
IGN1 (15)F1110AEBCM, Oil Feeding Connector
F1210AImmobilizer, Anti Theft Control Unit, Rain Sensor
Unit
30 BAT(+)F1310ATCM
F1415AHazard Switch
F1515AAnti Theft Control Unit
F1610ADLC
ACC (15C)F1710AAudio, Clock
F1815AExtra Power Jack
F1915ACigar Lighter
IGN1 (15)F2010AReverse Lamp Switch, PNP Switch
30 BAT(+)F2115ARear Fog Relay
F2215AClock, FATC, A/C Control Switch
F2315AAudio
F2410AImmobilizer

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 LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS4A–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifcations 4A–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4A–2. . . . . . . . . .
COMPONENT LOCATOR4A–3 . . . . . . . . . . . . . . . . . . . .
Brake System (ABS) 4A–3. . . . . . . . . . . . . . . . . . . . . . .
Brake System (NON–ABS) 4A–4. . . . . . . . . . . . . . . . .
DIAGNOSIS4A–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake System Testing 4A–5. . . . . . . . . . . . . . . . . . . . .
Brake Hose Inspection 4A–5. . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A–5. . . . . . . . . . . . . . . . . . .
Stop Lamp Warning Circuit Diagnosis 4A–6. . . . . . . . MAINTENANCE AND REPAIR4A–10 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 4A–10. . . . . . . . . . . . . . . . . . . .
Manual Bleeding the Brakes 4A–10. . . . . . . . . . . . . . .
Pressure Bleeding the Brakes 4A–12. . . . . . . . . . . . . .
Brake Hose Rear 4A–13. . . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose Front 4A–14. . . . . . . . . . . . . . . . . . . . . . . . .
Stoplamp Switch 4A–15. . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal 4A–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION4A–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A–17. . . . . . . . . . . . . . . . . .

4A – 2IHYDRAULIC BRAKES
DAEWOO V–121 BL4
SPECIFICATIONS
GENERAL SPECIFCATIONS
1.4/1.6/1.8/2.0 DOHC Engine
ApplicationMillimetersInches
Brake Drums:
Inside Diameter
Maximum Rebore Diameter
Out–of–Round200.00
201.00
0.047.87
7.91
0.0016
Front Brake Rotors:
Discard Thickness
Lateral Runout (Installed)
Rotor Diameter
Rotor Thickness (New)
Thickness Variation22.00
0.030
256
24.00
0.010.87
0.001
10.07
0.95
0.0004
Rear Brake Rotors:
Discard Thickness
Lateral Runout (Installed)
Rotor Diameter
Rotor Thickness (New)
Thickness Variation8
0.030
258
10.4
0.010.31
0.001
10.15
0.40
0.0004
Master Cylinder:
Bore Diameter (Nominal)
Bore Diameter (Maximum)22.22
22.290.875
0.878
Caliper:
Minimum Piston Diameter (Front)
Minimum Piston Diameter (Rear)54.00
322.126
1.260
Wheel Cylinder Diameter:
Maximum
Nominal20.7
20.640.815
0.812
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Bleeder Screw8–71
Brake Lines1612–
Brake Pedal–to–Pedal Bracket Hex Nut1813–
Front Disc Brake Hose–to–Caliper Bolt4030–
Rear Disc Brake Hose–to–Caliper Bol3224–

HYDRAULIC BRAKES 4A – 3
DAEWOO V–121 BL4
COMPONENT LOCATOR
BRAKE SYSTEM (ABS)
1. RH Rear Brake Hose
2. RH 3rd Rear Brake Pipe
3. Clip
4. 2nd Rear Brake Pipe (A)
5. 2nd Front Brake Pipe
6. RH Front Brake Hose
7. 2nd Rear Brake Pipe (B)
8. 1st Rear Brake Pipe (A)9. 1st Rear Brake Pipe (B)
10. Front Brake Pipe
11. LH Front Brake Hose
12. LHD Master Cylinder/Booster Assembly
13. ABS Modulator
14. LH Rear Brake Hose
15. LH 3rd Rear Brake Pipe

4A – 4IHYDRAULIC BRAKES
DAEWOO V–121 BL4
BRAKE SYSTEM (NON–ABS)
1. RH Rear Brake Hose
2. RH 3rd Rear Brake Pipe
3. Clip
4. 2nd Rear Brake Pipe
5. 2nd Front Brake Pipe
6. RH Front Brake Hose
7. 2nd Rear Brake Pipe
8. Front Brake Pipe9. LH Front Brake Hose
10. Connector
11. 1st Rear Brake Pipe (A)
12. 1st Front Brake Pipe
13. 1st Rear Brake Pipe (B)
14. LHD Master Cylinder/Booster Assembly
15. LH Rear Brake Hose
16. LH 3rd Rear Brake Pipe

HYDRAULIC BRAKES 4A – 5
DAEWOO V–121 BL4
DIAGNOSIS
BRAKE SYSTEM TESTING
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily braked,
but turning, wheels will stop the vehicle in less distance
than locked brakes. More tire–to–road friction is present
with a heavily–braked, turning tire than with a sliding tire.
Because of the high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
There are three major external conditions that affect brake
performance:
S Tires having unequal contact and grip of the road
will cause unequal braking. Tires must be equally
inflated, and the tread pattern of the right and the
left tires must be approximately equal.
S Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.
S Misalignment of the wheels, particularly conditions
of excessive camber and caster, will cause the
brakes to pull to one side.
To check for brake fluid leaks, hold constant foot pressure
on the pedal with the engine running at idle and the shift
lever in NEUTRAL. If the pedal gradually falls away with
the constant pressure, the hydraulic system may be leak-
ing. Perform a visual check to confirm any suspected
leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an ab-
normally low level indicates a leak in the system. The hy-
draulic system may be leaking either internally or external-
ly. Refer to the procedure below to check the master
cylinder. Also, the system may appear to pass this test
while still having a slight leak. If the fluid level is normal,
check the vacuum booster pushrod length. If an incorrect
pushrod length is found, adjust or replace the rod.
Check the master cylinder using the following procedure:
S Check for a cracked master cylinder casting or
brake fluid leaking around the master cylinder.
Leaks are indicated only if there is at least one drop
of fluid. A damp condition is not abnormal.S Check for a binding pedal linkage and for an incor-
rect pushrod length. If both of these parts are in
satisfactory condition, disassemble the master cyl-
inder and check for an elongated or swollen primary
cylinder or piston seals. If swollen seals are found,
substandard or contaminated brake fluid should be
suspected. If contaminated brake fluid is found, all
the components should be disassembled and
cleaned, and all the rubber components should be
replaced. All of the pipes must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration of
the rubber components. If the primary piston cups in the
master cylinder are swollen, then the rubber parts have
deteriorated. This deterioration may also be evidenced by
swollen wheel cylinder piston seals on the drum brake
wheels.
If deterioration of rubber is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep alco-
hol out of the system. Replace all the rubber parts in the
system, including the hoses. Also, when working on the
brake mechanisms, check for fluid on the linings. If exces-
sive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory condi-
tion, check for leaks or excessive heat conditions. If these
conditions are not found, drain the fluid, flush the master
cylinder with brake fluid, refill the master cylinder, and
bleed the system. Refer to ”Manual Bleeding the Brakes”
or”Pressure Bleeding the Brakes” in this section.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be checked
for road hazard damage, cracks, chafing of the outer cov-
er, and for leaks or blisters. Inspect the hoses for proper
routing and mounting. A brake hose that rubs on a suspen-
sion component will wear and eventually fail. A light and
a mirror may be needed for an adequate inspection. If any
of the above conditions are observed on the brake hose,
adjust or replace the hose as necessary.
WARNING LAMP OPERATION
This brake system uses a BRAKE warning lamp located
in the instrument panel cluster. When the ignition switch
is in the START position, the BRAKE warning lamp should
glow and go OFF when the ignition switch returns to the
RUN position.
The following conditions will activate the BRAKE lamp:
S Parking brake applied. The light should be ON
whenever the parking brake is applied and the igni-
tion switch is ON.
S Low fluid level. A low fluid level in the master cylin-
der will turn the BRAKE lamp ON.
S EBD system is disabled. The light should be ON
when the EBD system is malfunctioning.

4A – 6IHYDRAULIC BRAKES
DAEWOO V–121 BL4
STOP LAMP WARNING CIRCUIT DIAGNOSIS
J3B14A03
10A30
F4
32
A19
A13 A14 A1 A2B15 C201
31C201IP/Fuse
Block C201
C202
C110C108 S301 WHT
BRN
BRN
Parking
Brake
SwitchBrake
Fluid
Switch
BLKBRN LT GRN
DK
GRN
DK
GRN LT GRN/
BLK
LT GRN/
BLKPPL/
WHT
PPL/
WHT
PPL/
WHTPPL/
WHT PPL/
WHT
PPL/
WHT ABS
Warning
Lamp TCS
Active
Warning
Lamp Parking
Brake
Warning
Lamp Charging
Warning
Hot in Run and Start
PNK
Cluster PNK
EBCM”L” Ter.
Generator 1 12
2
20 2222 16 41 13
3
4
11 1 215
8
21
G303
Test Description
The number(s) below refer to step(s) on the diagnostic
table.
1. When the ignition is turned ON, the brake warning
lamp should initially illuminate and then dim for ABS
equipped vehicles. This is done as a bulb check.
On vehicles that are not equipped with ABS, the
brake warning lamp should only illuminate when
either the brake fluid reservoir is low or the parking
brake is applied.
7. The brake fluid level switch is a normally open
switch. If the brake warning lamp is off after discon-
necting the switch, the brake fluid level switch is
stuck closed.9. If the brake warning lamp is still on after discon-
necting the parking brake switch, there is a short to
ground in the wire to the parking brake switch.
12. If the other checks have been properly performed
and the brake warning lamp is off after disconnect-
ing the electronic brake control module (EBCM) J1
connector, the EBCM is faulty.
19. If the brake warning lamp does not operate while
performing any of the functions, the fault should be
in the ignition feed to the circuit.
24. This step determines if the problem is in the ignition
feed to the circuit or in the instrument cluster.
30. The brake warning lamp should illuminate when
jumpering the parking brake connector to ground.
32. If the brake warning lamp is on after jumpering the
brake fluid level switch terminals, the switch is
faulty.