Daewoo Matiz (2003 year). Manual - part 134

FRONT DISC BRAKES  4D – 7

D107B504

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).

D17B505B

Installation Procedure

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

Tighten

Tighten the caliper–to–steering knuckle bolts to 95
N

S

m (70 lb-ft).

2. Connect the brake hose (2).

Tighten

Tighten the brake hose inlet fitting–to–coupling bolt to
25.5 N

S

m (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, Hy-

draulic Brakes.

D117B506

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 Sus-

pension.

D17B507A

Installation Procedure

1. Install the rotor to the front wheel hub by tightening

the detent bolts.

Tighten

Tighten the rotor–to–front wheel hub detent bolts to
65 N

S

m (48 lb-ft).

2. Install the steering knuckle. Refer to Section 2C, Front

Suspension.

4D – 8  FRONT DISC BRAKES

UNIT REPAIR

D107B701

CALIPER OVERHAUL

Disassembly Procedure

1. Remove the caliper assembly. Refer to “Caliper As-

sembly” 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).

D107B702

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.

D17B703C

D

Remove the bleeder plug (1).

D

Remove the bleeder plug cap (2).

FRONT DISC BRAKES  4D – 9

D107B704

D

Remove the piston boot (3).

Caution: Do not face in the direction of removing.

D107B705

D

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

D

Remove the piston (5).

D107B706

D

Remove the piston seal (6).

4D – 10  FRONT DISC BRAKES

D17B708B

D17B707A

26

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

Tighten the bleeder plug to 6 N

S

m (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.

Tighten

Tighten the pin bolt to 26 N

S

m (19 lb-ft).

4. Install the caliper assembly. Refer to “Caliper Assem-

bly” in this section.