Page 1025 of 2643

HYDRAULIC BRAKES 4A – 9
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
301. Turn the ignition ON.
2. Disconnect the parking brake switch.
3. Jumper the parking brake switch connector
terminal to ground.
Is the lamp on?–Go to Step 10Go to Step 31
311. Turn the ignition OFF.
2. Repair the open in the wire between the instru-
ment cluster connector terminal A1 and the
parking brake switch connector terminal.
3. Is the repair complete?
Is the repair complete?–System OK–
321. Disconnect the brake fluid level switch.
2. Turn the ignition ON.
3. Jumper the brake fluid level switch connector
terminals.
Is the lamp on?–Go to Step 8Go to Step 33
331. Turn the ignition OFF.
2. Connect a test light between battery positive
and the BRN/WHT wire terminal of the brake
fluid level switch.
Is the test light on?–Go to Step 34Go to Step 35
34Repair the open in the wiring between ground and
the brake fluid level switch.
Is the repair complete?–System OK–
35Repair the open in the wiring between the instrument
cluster connector terminal A1 and the brake fluid lev-
el switch.
Is the repair complete?–System OK–
Page 1026 of 2643
4A – 10IHYDRAULIC BRAKES
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
MANUAL BLEEDING THE BRAKES
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
1. Remove the booster reserve by applying the brakes
several times with the engine OFF until all the re-
serve is depleted.
Important : If the master cylinder is known or suspected
to have air in the bore, then it must be bled before any
wheel cylinder or caliper is bled.
2. Fill the master cylinder reservoir with brake fluid.
Keep the master cylinder at least one–half full of
fluid during the bleeding operation.
3. Disconnect the front brake line(s) at the master cyl-
inder.
4. Allow the brake fluid to fill the master cylinder until it
begins to flow from the front pipe connector port.
5. Connect the front brake line(s) to the master cylin-
der.
Tighten
Tighten the brake lines to 16 NSm (12 lb–ft).
Page 1027 of 2643

HYDRAULIC BRAKES 4A – 11
DAEWOO V–121 BL4
6. Slowly push and hold the brake pedal one time.
7. Loosen the front brake line at the master cylinder to
purge air from the cylinder.
8. Tighten the brake line (as in step 5), and then re-
lease the brake pedal slowly. Wait 15 seconds be-
fore proceeding to the next step.
9. Repeat the sequence, including the 15–second
wait, until all the air is removed from the master
cylinder bore.
Notice : Care must be taken to prevent brake fluid from
contacting any painted surface to prevent damage to the
paint finish.
10. After all the air has been removed at the forward
connection(s), bleed the master cylinder at the rear
(cowl) connection(s) in the same manner as with
the front connections.
Important : For vehicles equipped with a non–antilock
braking system, the bleeding sequence is as follows: right
rear, left rear, left front and right front. For ABS vehicles,
refer to Section 4F, Antilock Brake System for the correct
sequence and bleeding procedure.
11. Attach a transparent tube over the valve. Allow the
tube to hang submerged in brake fluid in a transpar-
ent container.
Page 1028 of 2643

4A – 12IHYDRAULIC BRAKES
DAEWOO V–121 BL4
12. Slowly push and hold the brake pedal one time.
13. Remove the bleeder valve dust cover and loosen
the bleeder screw to purge the air from the cylinder.
14. Tighten the bleeder screw.
Tighten
Tighten the bleeder screw to 8 NSm (71 lb–in).
15. Slowly release the brake pedal. Wait 15 seconds
before proceeding with the next step.
Important : Rapid pumping of the brake pedal pushes the
master cylinder secondary piston down the bore in a man-
ner that makes it difficult to bleed the system.
16. Repeat the sequence, including the 15–second
wait, until all the air is removed. It may be neces-
sary to repeat the sequence 10 or more times to
remove all the air.
17. Locate the front bleeder caps.
18. Proceed to bleed the front brakes following the ap-
propriate sequence, beginning with step 12.
19. Check the brake pedal for sponginess. Repeat the
entire bleeding procedure to correct this condition.
20. Replace the bleeder valve dust cover.
PRESSURE BLEEDING THE BRAKES
Notice : Pressure bleeding equipment must be of the dia-
phragm type. It must have a rubber diaphragm between
the air supply and the brake fluid to prevent air, moisture,
oil, and other contaminants from entering the hydraulic
system. Contamination could lead to deterioration of the
braking components and loss of braking action.
1. Disconnect the master cylinder electrical connector.
2. Remove the master cylinder reservoir cap.
3. Connect the bleeder with the adapter to the master
cylinder reservoir.
4. For vehicles with the antilock braking system
(ABS), locate and remove the hydraulic modulator
bleeder valves. Refer to Section 4F, Antilock Brake
System.
5. Charge the bleeder ball to 140 to 172 kPa (20 to 25
psi).
6. Connect the line to the adapter. Open the line
valve.
7. Raise and suitably support the vehicle.
Important : The bleeding sequence is as follows: right
rear, left front, left rear and right front.
Page 1029 of 2643
HYDRAULIC BRAKES 4A – 13
DAEWOO V–121 BL4
8. Attach the bleeder hose to the bleeder valve. Sub-
merge the opposite end of the hose in a clean con-
tainer partially filled with brake fluid.
9. Open the bleeder valve one–half to three–fourths
turn and allow the fluid to flow until no air is seen in
the fluid.
Notice : After the bleeding operation, the brake reservoir
may be pressurized. While disconnecting the bleeder
hose or the unthreaded adapter cap, cover the cap and the
connection with a shop towel to protect painted surfaces
from contact with the brake fluid.
10. Inspect the brake pedal for sponginess. Repeat the
entire bleeding procedure to correct this condition.
BRAKE HOSE REAR
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the brake hose retainer.
3. Disconnect the brake pipe line from the disc brake
hose.
4. Remove the rear disc brake hose retainer and the
brake hose from the bracket on the steering
knuckle shaft.
Page 1030 of 2643

4A – 14IHYDRAULIC BRAKES
DAEWOO V–121 BL4
5. Remove the rear disc brake hose from the caliper.
Installation Procedure
1. Connect the brake pipe line to the brake hose.
Tighten
Tighten the brake line to 16 NSm (12 lb–ft).
2. Install the retainer onto the rear brake hose bracket
from the wheel house.
3. Install the rear disc brake hose to the caliper.
Tighten
Tighten the rear disc brake hose–to–caliper bolt to 32
NSm (24 lb–ft).
4. Install the rear disc brake hose and retainer on the
bracket on the steering knuckle shaft.
5. Lower the vehicle.
6. Bleed the brake system. Refer to ”Manual Bleeding
the Brakes” in this section.
7. Check the brake system for leaks.
BRAKE HOSE FRONT
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the retainer.
3. Disconnect the brake pipe line from the brake hose
support bracket on the wheel housing on each side
of the vehicle.
4. Disconnect the brake hose from the ”C” bracket on
the steering knuckle shaft.
5. Remove the bolt from the brake caliper.
6. Remove the seal rings and the disc brake hose.
Page 1031 of 2643

HYDRAULIC BRAKES 4A – 15
DAEWOO V–121 BL4
Installation Procedure
1. Install the new disc brake hose to the caliper with
new seal rings and the bolt.
Tighten
Tighten the front disc brake hose–to–caliper bolt to 40
NSm (30 lb–ft).
2. Slide the brake hose on the steering knuckle shaft
”C” bracket.
3. Connect the brake pipe line to the brake hose on
the wheel housing bracket on each side of the ve-
hicle.
Tighten
Tighten the brake line to 16 NSm (12 lb–ft).
4. Lower the vehicle.
5. Bleed the brake system. Refer to ”Manual Bleeding
the Brakes” in this section.
6. Check the brake system for leaks.
STOPLAMP SWITCH
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the stoplamp switch from the plug con-
nector.
3. Turn the switch. Remove the switch from the brake
pedal bracket.
Installation Procedure
1. Place the stoplamp switch into the plug connector.
2. Twist the stoplamp switch into the brake pedal
bracket hole.
3. Depress the brake pedal and pull the switch plung-
er to its maximum setting to adjust the switch.
4. Release the plunger and pull up on the pedal.
5. Connect the negative battery cable.
Page 1032 of 2643
4A – 16IHYDRAULIC BRAKES
DAEWOO V–121 BL4
BRAKE PEDAL
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Remove the instrument panel. Refer to Section 9E,
Instrumentation/Driver Information.
2. Remove the nuts from the brace.
3. Remove the brake pedal.
Installation Procedure
1. Install the brace with nuts.
Tighten
Tighten the brace with nuts to 22 NSm (16 lb–ft).
2. Install the brake pedal.
3. Install the instrument panel. Refer to Section 9E,
Instrumentation/Driver Information.