Daewoo Matiz (2003 year). Manual — part 129
4B – 4 MASTER CYLINDER
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
MAB4B001
D107A514
MASTER CYLINDER ASSEMBLY
Removal Procedure
1. Remove the air filter assembly. Refer to Section 1B,
Engine Mechanical.
2. For vehicles with the non–ABS braking system, re-
move the proportioning valve. Refer to “Proportioning
Valve” in this section.
3. Remove the master cylinder.
D
Disconnect the electrical connector.
D
Loosen the brake pipe fittings.
D
Plug the opening in the master cylinder to prevent
fluid loss or contamination.
Notice: Brake fluid may damage paintwork, if spillage
onto paintwork, wash with cold water immediately.
D
Remove the nuts mounting the master cylinder (3).
D17A515A
Installation Procedure
Important: Use only Daewoo recommended brake
fluid.
1. Install the master cylinder assembly with the nuts.
Tighten
Tighten the attaching nuts to 16 N
S
m (12 lb-ft).
MASTER CYLINDER 4B – 5
MAB4B002
2. Install the brake pipe fittings to the master cylinder.
Tighten
Tighten the fittings to 16 N
S
m (12 lb-ft).
3. Connect the electrical connector.
4. For vehicles with the non–ABS braking system, install
the proportioning valve. Refer to “Proportioning
Valve” in this section.
5. Install the air filter assembly. Refer to Section 1B, En-
gine Mechanical.
6. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.
D17A517A
BRAKE FLUID RESERVOIR
Removal Procedure
1. Remove the fluid level switch connector. Refer to
“Brake Fluid Level Switch” in this section.
2. Remove the reservoir.
D
Drain the brake fluid.
D
Remove the screw (1).
D
Remove the fluid reservoir using a flathead screw-
driver (2).
Notice: Do not force one side strongly to prevent dam-
age of reservoir when removing the reservoir.
D17A518A
Installation Procedure
Important: Use only Daewoo recommended brake fluid.
1. Install the reservoir with the screw.
Tighten
Tighten the screw to 4 N
S
m (35 lb-ft).
2. Install the fluid level switch connector. Refer to “Brake
Fluid Level Switch” in this section.
3. Add brake fluid.
4. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.
MAB4B003
PROPORTIONING VALVE (FOR
VEHICLE WITH THE NON–ABS
BRAKING SYSTEM)
1. Remove the proportioning valve.
D
Loosen the brake pipe fittings–to–proportioning
valve (1).
D
Remove the proportioning valve (2).
D
Plug the opening in the proportioning valve and
brake pipe fitting to prevent fluid loss or contamina-
tion.
4B – 6 MASTER CYLINDER
Notice: Brake fluid may damage paintwork, if spillage
onto paintwork, wash with cold water immediately.
MAB4B004
Installation procedure
1. Install the proportioning valve (1).
Tighten
Tighten the proportioning valve to 22 N
S
m (16 lb-ft).
2. Install the brake pipe fitting (2).
Tighten
Tighten the brake pipe fitting–to–proportioning valve
to 16 N
S
m (12 lb-ft).
3. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.
D107A504
BRAKE FLUID LEVEL SWITCH
Removal procedure
1. Remove the vacuum hose from the power booster.
Refer to Section 4C, Power Booster.
2. Remove the brake fluid level switch.
D
Remove the brake fluid level switch locking system
by the flathead screwdriver (1).
D107A505
D
Disconnect the electrical connector (2).
MASTER CYLINDER 4B – 7
D107A506
Installation procedure
1. Install the brake fluid level switch.
2. Connect the electrical connector.
3. Install the vacuum hose to the power booster. Refer
to Section 4C, Power Booster.
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