Daewoo Nubira. Service manual - part 45

FRONT DISC BRAKES  4D – 9

DAEWOO V–121 BL4

UNIT REPAIR

CALIPER OVERHAUL

Disassembly Procedure

1.  Remove the caliper. Refer to ”Caliper” in this sec-

tion.

CAUTION :  Do not attempt to catch the piston when
attempting to remove the piston with compressed air.
The piston will pop out of its bore with enough force
to damage a hand or fingers.

Important : When removing the caliper piston with com-
pressed air, insert a piece of hardwood into the caliper to
prevent damage to the piston.

2.  Apply unlubricated compressed air at the hose inlet

of the caliper.

3.  Remove the piston from its bore, and remove the

piston dust seal.

4D – 10

I

FRONT DISC BRAKES

DAEWOO V–121 BL4

4.  Remove the inner seal from the bore.
5.  Remove the bleeder valve protector and the bleed-

er valve.

Assembly Procedure

1.  Clean all parts in denatured alcohol or brake fluid.

Dry the parts with unlubricated compressed air and
blow out all passages in the housing and bleeder
valve.

2.  Inspect the piston and caliper for scoring, nicks, or

corrosion. Replace any components which show
these conditions.

3.  Install the caliper bleeder valve.

Important : Do not use a hone or any other procedure to
remove material from the caliper bore or piston.

4.  Lubricate a new piston inner seal with brake fluid.
5.  Install the piston inner seal into the groove in the

caliper bore.

6.  Install the piston dust seal in its groove.
7.  Lubricate the piston with brake fluid.
8.  Push the piston inward until it is properly seated.

Make sure that the dust seal is in the correct
groove in the piston and caliper.

9.  Reinstall the caliper. Refer to”Caliper”in this section.
10.  Bleed the brake system. Refer toSection 4A, Hy-

draulic brakesor Section 4F, Antilock Brakes, if ap-
plicable.

FRONT DISC BRAKES  4D – 11

DAEWOO V–121 BL4

GENERAL DESCRIPTION

AND SYSTEM OPERATION

DISC BRAKE CALIPER ASSEMBLY

This caliper has a single bore and is mounted to the steer-
ing knuckle with two mounting bolts. Hydraulic pressure,
created by pressing 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. It moves the
piston outward and slides 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 ve-
hicle.

S

 

Replace all components included in the repair kits
used to service the caliper.

S

 

Lubricate the rubber parts with clean brake fluid to
ease assembly.

S

 

Do not use lubricated shop air on brake parts, as
damage to the rubber components may result.

S

 

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of
the brake system.

S

 

Replace the pads in axle sets only.

S

 

The torque values specified are for dry, unlubri-
cated fasteners.

S

 

Perform the service operations on a clean bench,
free from all mineral oil materials.

SECTION : 4G

PARKING BRAKE

CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

TABLE OF CONTENTS

SPECIFICATIONS

4G–1

. . . . . . . . . . . . . . . . . . . . . . . . . . 

FASTENER TIGHTENING SPECIFICATIONS

4G–1

. 

MAINTENANCE AND REPAIR

4G–2

. . . . . . . . . . . . . . . 

ON–VEHICLE SERVICE

4G–2

. . . . . . . . . . . . . . . . . . . . . 

PARKING BRAKE ADJUSTMENT

4G–2

. . . . . . . . . . . 

PARKING BRAKE LEVER

4G–3

. . . . . . . . . . . . . . . . . . 

PARKING BRAKE CABLE

4G–5

. . . . . . . . . . . . . . . . . . 

PARKING BRAKE HANDLE

4G–10

. . . . . . . . . . . . . . . . 

GENERAL DESCRIPTION AND SYSTEM

OPERATION

4G–11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PARKING BRAKE

4G–11

. . . . . . . . . . . . . . . . . . . . . . . . 

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Application

N

S

m

Lb–Ft

Lb–In

Fuel Tank Retaining Strap Nut

12.5

–

111

Parking Brake Cable–to–Underbody Side Bracket Nuts

12

–

106

Parking Brake Lever Assembly–to–Vehicle Underbody Bolts

22

16

–

Parking Brake Switch–to–Parking Brake Lever Screw

4

–

35