Daewoo Matiz (2003 year). Manual - part 132

POWER BOOSTER  4C – 7

D24C003

Installation Procedure

1. Install the power booster with the new cotter pin, cle-

vis pin and nuts.

Tighten

Tighten the nuts to 16 N

S

m (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 evaporator unit with the screws. Refer to

Section 7B, Manual Control Heating, Ventilation, and
Air Conditioning System.

3. Install the instrument panel assembly. Refer to Sec-

tion 9E, Instrument/Driver Information.

4. Connect the vacuum hose to the power booster.

5. Install the master cylinder assembly. Refer to Section

4B, Master Cylinder.

4C – 8  POWER BOOSTER

SPECIFICATIONS

GENERAL SPECIFICATIONS

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Application

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Unit

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Description

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

Type

–

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Vacuum–Suspended

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

Diameter

mm (inch)

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

177.8 (7)

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

Power Booster

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

Servo Force Ratio

–

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

3.7 : 1

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

Distance from the booster to
the center of the clevis bore

mm (inch)

96(3.78)

FASTENER TIGHTENING SPECIFICATIONS

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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Application

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

N

S

m

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Lb-Ft

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

Lb-In

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Booster–to-Dash Panel Nuts

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

16

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

12

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

–

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Master Cylinder Attaching Nuts

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

16

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

12

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

–

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

. . . . . . . . . . 

4D – 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 con-
verted 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.

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 discon-
nected, 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.

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 re-
storing 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 clear-
ance. As the piston returns by the same distance and
the rubber seal recovers its original shape, the clear-
ance between the rotor and pads is maintained in origi-
nal condition.

1. Piston
2. Piston Seal
3. Pads
a. Clearance

D107B002