Daewoo Matiz (2003 year). Manual — part 130
4B – 8 MASTER CYLINDER
UNIT REPAIR
D24B001
MASTER CYLINDER
(ABS Type Master Cylinder is Shown,
Non–ABS Type Master Cylinder is Similar)
Disassembly Procedure
1. Remove the master cylinder. Refer to “Master Cylin-
der Assembly” in this section.
2. Remove the brake fluid reservoir. Refer to “Brake
Fluid Reservoir” in this section.
3. Remove the reservoir seals (1).
4. Remove the washer (2).
5. Remove the stop pin (3).
D24B002
6. Remove the boot (1).
7. Remove the retaining ring (2).
Notice: When removing the retaining ring, avoid dam-
aging the piston or the cylinder wall.
8. Remove the primary piston (3).
9. Carefully remove the secondary piston assembly
and the spring from the master cylinder bore (4).
D24B003
Assembly Procedure
1. Install the secondary piston assembly .
2. Install the stop pin.
3. Install the primary piston.
4. Install the retaining ring.
5. Install the boot.
6. Install the washer.
7. Install the reservoir seals.
8. Install the brake fluid reservoir. Refer to “Brake Fluid
Reservoir” in this section.
9. Install the master cylinder. Refer to “Master Cylinder
Assembly” in this section.
10. Raise and suitably support the vehicle.
11. Bleed the braking system. Refer to Section 4A, Hy-
draulic Brakes.
12. Lower the vehicle.
MASTER CYLINDER 4B – 9
SPECIFICATIONS
GENERAL SPECIFICATIONS
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Application
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Unit
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Description
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Type
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
–
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Tandem
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Master Cylinder
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Bore Diameter
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
mm (in.)
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
20.64 (0.81)
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Cut–In Pressure
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
kPa (psi)
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
3,000(435.1)
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Proportioning Valve
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Pressure Ratio
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
–
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
0.25 : 30
FASTENER TIGHTENING SPECIFICATIONS
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Application
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
N
S
m
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
Lb-Ft
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Lb-In
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Fluid Reservoir Screw
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
4
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
–
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
35
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Master Cylinder Attaching Nuts
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
16
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
12
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
–
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Brake Pipe Fittings to Master Cylinder
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
16
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
12
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
–
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Brake Pipe Fittings to Proportioning Valve
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
16
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
12
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
–
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Brake Pipe Fittings to Rear Wheel Cylinder
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
16
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
12
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
–
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Brake Pipe Fittings to Front Caliper
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
16
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
12
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
–
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Proportioning Valve
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
22
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
16
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
–
SECTION 4C
POWER BOOSTER
TABLE OF CONTENTS
Description and Operation
4C-2
. . . . . . . . . . . . . . . . . .
Power Booster
4C-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures
4C-3
. . . . .
Power Booster Functional Check
4C-3
. . . . . . . . . . . .
Check Valve Functional Check
4C-3
. . . . . . . . . . . . . .
Repair Instructions
4C-4
. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service
4C-4
. . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Hose and Check Valve
4C-4
. . . . . . . . . . . . .
Power Booster Assembly
4C-5
. . . . . . . . . . . . . . . . . . .
Specifications
4C-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications
4C-8
. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications
4C-8
. . . . . . . . . . .
4C – 2 POWER BOOSTER
DESCRIPTION AND OPERATION
POWER BOOSTER
This booster is a single diaphragm, vacuum-suspended
unit. In a normal operating mode, with the service brakes
in the release position, a vacuum-suspended booster
operates with a vacuum on both sides of its diaphragm.
When the brakes are applied, air at atmospheric pres-
sure is admitted to one side of the diaphragm to pro-
vide the power assist. When the brakes are released, at-
mospheric air is shut off from that side of the diaphragm.
The air is then drawn from the booster through the vacu-
um check valve by the vacuum source.
Important: If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or part of
the brake system.
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