M34d Front Disc Brakes.pdf part of Daewoo Matiz 796cc (My 2003).part01.rar, Service Manual, Wiring Diagram - 16 Part File

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SECTION 4D

FRONT DISC BRAKES
TABLE OF CONTENTS
Description and Operation . . . . . . . . . . . . . . . . . . Disc Brake Caliper Assembly . . . . . . . . . . . . . . . Clearance Calibration . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . Lining Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 4D-2 4D-2 4D-3 4D-3 4D-4 4D-4 4D-5 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe and Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-6 4D-6 4D-7 4D-7

Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-8 Caliper Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-11 General Specifications . . . . . . . . . . . . . . . . . . . . 4D-11 Fastener Tightening Specifications . . . . . . . . . . 4D-11

Rotor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . 4D-6

DAEWOO M-150 BL2

4D ґ 2 FRONT DISC BRAKES

DESCRIPTION AND OPERATION
DISC BRAKE CALIPER ASSEMBLY
This caliper has a single bore and is mounted to the steering knuckle with two mounting bolts. Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force. This force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to slide the caliper inward, resulting in a clamping action on the rotor. This clamping action forces the linings against the rotor, creating friction to stop the vehicle.

CLEARANCE CALIBRATION
When the hydraulic pressure is applied to the piston, the piston moves leftward. The piston seal, which extent considerable pressure against the piston, moves with cylinder. However, as a part of the piston seal is fixed into a grove in the cylinder shape of the seal is as shown in below figure, distorted toward the piston moving direction. When the pressure is taken off from the brake pedal and the hydraulic pressure is released from the piston, a restoring elastic force is generated at the seal and pushes the piston rightward and back it in original position. As the pads wear away and the clearance between rotor and pads becomes larger, the piston moves larger. The seal then could change in shape further, but since end of the seal is fixed into the groove in the cylinder, the distortion is limited to the same amount as previously described. The piston moves further to cover the distance of clearance. As the piston returns by the same distance and the rubber seal recovers its original shape, the clearance between the rotor and pads is maintained in original condition.

D17B001A

Important: D Replace all components included in the repair kits used to service this caliper. D Lubricate the rubber parts with clean brake fluid to ease assembly. D Do not use lubricated shop air on brake parts, as damage to the rubber components may result. D If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. D Replace the pads in axle sets only. D The torque values specified are for dry, unlubricated fasteners. D Perform the service operations on a clean bench, free from all mineral oil materials. 1. 2. 3. a. Piston Piston Seal Pads Clearance

D107B002

DAEWOO M-150 BL2

FRONT DISC BRAKES 4D ґ 3

COMPONENT LOCATOR
FRONT DISC BRAKES

D17B401A

1. 2. 3. 4. 5. 6. 7.

Front Brake Caliper Assembly Front Brake Boot Assemblies Pins Pin Boots Front Brake Pads Carrier Pad Spring

8. 9. 10. 11. 12. 13.

Piston Boot Piston Piston Seal Cylinder Bleeder Screw Cap Bleeder Screw

DAEWOO M-150 BL2

4D ґ 4 FRONT DISC BRAKES

DIAGNOSTIC INFORMATION AND PROCEDURES
FRONT DISC BRAKE

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Condition Probable cause Correction Uneven Braking D Inoperative carrier. D Replace the carrier. D Sticked caliper piston. D Sticked caliper piston. D Excessive rotor run out. D Interference of the dust cover. D Loose caliper mounting bolts. D Repair the caliper piston or replace the caliper assembly, if needed. D Repair the caliper piston or replace the caliper assembly if needed. D Replace the rotor. D Repair the dust cover. D Tighten the mounting bolts. Dragging Brake Noise and Vibration When Brake Applied
DAEWOO M-150 BL2

FRONT DISC BRAKES 4D ґ 5

LINING INSPECTION
1. Raise and suitably support the vehicle. 2. Remove the front wheels. Refer to Section 2E, Tires and Wheels. 3. Visually check the linings for minimum thickness and wear. 4. Measure the thickness. Important: The minimum thickness of the shoe and lining together is 8 mm (0.31 in.).

D107B302

In addition to these tolerances, the surface finish must be held to a specified range. The control of the braking surface finish is necessary to avoid pulls and erratic performance and to extend lining life. Using a commercially-available dial indicator, check lateral runout as follows: Notice: Permissible lateral runout is a maximum 0.05 mm (0.002 in.). If lateral runout exceeds the specification, ensure there is no dirt between the rotor and the hub and that contact surfaces are smooth and free from burrs. 1. Position the transaxle in NEUTRAL. 2. Remove the rotor. Refer to "Rotor" in this section. 3. Fasten a dial indicator to the strut. 4. Set the gauge probe tip to approximately 10 mm (0.4 in.) from the outer edge of the brake rotor, perpendicular to the disc and under slight preload. 5. Remove the dial indicator. Important: Since accurate control of the rotor tolerances is necessary for proper performance of the disc brakes, refinishing of the rotor should be done only with precision equipment. 6. Refinish the rotor, if required, with precision equipment. Discard the rotor if it fails to meet the above specifications after refinishing. 7. Install the rotor. Refer to "Rotor" in this section.

D107B301

5. Install the shoe and linings in axle sets only. 6. Install the front wheels. Refer to Section 2E, Tires and Wheels. 7. Lower the vehicle.

ROTOR INSPECTION
Thickness variation can be checked by measuring the thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made at the same distance in from the edge of the rotor. If the thickness of the rotor is below 10 mm (0.40 in.), replace the brake rotor. During manufacturing, the brake rotor and the tolerances of the braking surface regarding flatness and lateral runout are held very close. The maintenance of close tolerances on the shape of the braking surfaces is necessary to prevent brake roughness.

D107B303

DAEWOO M-150 BL2

4D ґ 6 FRONT DISC BRAKES

REPAIR INSTRUCTIONS ONґVEHICLE SERVICE
SHOE AND LINING
Removal Procedure
1. Remove the front wheels. Refer to Section 2E, Tires and Wheels. 2. Remove the brake pads. D Remove the pin bolt (1).

D107B501

D Lift up the cylinder assembly (2).

D107B502

Installation Procedure
1. Install the brake pads and the cylinder assembly with the pin bolt.

Tighten
Tighten the pin bolt to 26 NSm (19 lb-ft). 2. Install the front wheels. Refer to Section 2E, Tires and Wheels.

D17B503A

DAEWOO M-150 BL2

FRONT DISC BRAKES 4D ґ 7

CALIPER ASSEMBLY
Removal Procedure
1. Remove the front wheels. Refer to Section 2E, Tires and Wheels. 2. Remove the caliper assembly. D Remove the brake hose coupling bolt (1). D Plug the opening in the brake hose to prevent fluid loss and contamination. D Remove the caliper mounting bolts (2).

D107B504

Installation Procedure
1. Install the caliper assembly with the bolts (1).

Tighten
Tighten the caliperґtoґsteering knuckle bolts to 95 NSm (70 lb-ft). 2. Connect the brake hose (2).

Tighten
Tighten the brake hose inlet fittingґtoґcoupling bolt to 25.5 NSm (19.1 lb-ft). 3. Install the front wheels. Refer to Section 2E, Tires and Wheels. 4. Bleed the brake system. Refer to Section 4A, Hydraulic Brakes.

D17B505B

ROTOR
Removal Procedure
1. Remove the steering knuckle. Refer to Section 2C, Front Suspension. 2. Remove the rotor bolts from the front wheel hub. 3. Remove the rotor. Refer to Section 2C, Front Suspension.

D117B506

Installation Procedure
1. Install the rotor to the front wheel hub by tightening the detent bolts.

Tighten
Tighten the rotorґtoґfront wheel hub detent bolts to 65 NSm (48 lb-ft). 2. Install the steering knuckle. Refer to Section 2C, Front Suspension.

D17B507A

DAEWOO M-150 BL2

4D ґ 8 FRONT DISC BRAKES

UNIT REPAIR
CALIPER OVERHAUL
Disassembly Procedure
1. Remove the caliper assembly. Refer to "Caliper Assembly" in this section. 2. Separate the cylinder assembly and the carrier. D Remove the pin bolts (1). D Separate the cylinder assembly and the carrier (2).

D107B701

3. Disassemble the carrier. D Remove the front brake pad set (1). D Remove the springs (2). D Remove the guide pins and boots (3). Refer to "Shoe and Lining" in this section.

D107B702

D Remove the bleeder plug (1). D Remove the bleeder plug cap (2).

D17B703C

DAEWOO M-150 BL2

FRONT DISC BRAKES 4D ґ 9
D Remove the piston boot (3). Caution: Do not face in the direction of removing.

D107B704

D Using compressed air, blow out the piston from the cylinder (4). D Remove the piston (5).

D107B705

D Remove the piston seal (6).

D107B706

DAEWOO M-150 BL2

4D ґ 10 FRONT DISC BRAKES 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. D Install the piston seal. D Push the piston inward until it is properly seated. D Install the piston boot. D Install the bleeder plug.

Tighten
D17B708B

Tighten the bleeder plug to 6 NSm (53 lb-in). D Install the bleeder plug cap. 2. Assemble the carrier. D Install the guide pin and boot. D Install the spring. D Install the pads. 3. Install the pin bolt connecting the cylinder assembly and carrier.

26

Tighten
Tighten the pin bolt to 26 NSm (19 lb-ft). 4. Install the caliper assembly. Refer to "Caliper Assembly" in this section.
D17B707A

DAEWOO M-150 BL2

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Bleeder Screw Brake Hose Coupling Bolt Pin Bolts Caliper Mounting Bolts Rotor Bolts Caliper Application Diameter of the Position Pad Discard Thickness

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Rotor Application Pad Thickness Runout Discard Thickness Thickness Outer Diameter

DAEWOO M-150 BL2

FASTENER TIGHTENING SPECIFICATIONS

GENERAL SPECIFICATIONS

SPECIFICATIONS

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

NSm

Unit

25.5 26 95 65

6

FRONT DISC BRAKES 4D ґ 11

Lb-Ft

19.1 19 70 48

ґ

Description

0.05 (0.002)

12.7 (0.5)

48 (1.89)

10 (0.40)

236 (9.3)

8 (0.31)

10 (0.4)

Lb-In

53 ґ ґ ґ ґ