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SECTION 4B

MASTER CYLINDER

DESCRIPTION AND OPERATION

MASTER CYLINDER

The master cylinder is designed for use in a direct-split system. Front right brake and rear left brake are served by the primary piston. Front left brake and rear right brake are served by the secondary piston.
The master cylinder incorporates the functions of the standard dual master cylinder, plus a low fluid level indicator and the proportioning valve in the non-antilock braking system.
The proportioning valves limit the outlet pressure to the rear brakes after a predetermined master cylinder has been reached.
Important :

PROPORTIONING VALVE

The proportioning valve limits the outlet pressure to the rear brakes on the non-ABS after a predetermined master cylinder pressure has been reached. This is used when less rear apply force is needed to obtain optimum braking and is usually found on disc/drum brake configurations. On ABS-equipped vehicles, refer to Section 4F, Antilock Brake System.

FLUID LEVEL SENSOR

Fluid level sensor is attached at the brake fluid reservoir. This sensor will activate the BRAKE light if a low fluid level condition is detected. Once the fluid level is corrected, the BRAKE light will go out.

DIAGNOSTIC INFORMATION AND PROCEDURES

CHECKING THE BRAKE FLUID LEVEL

  1. Check the fluid level.
  2. If the fluid level is below MAX, refill the fluid to MAX.

D107A302
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REPAIR INSTRUCTIONS

ON-VEHICLE SERVICE

MASTER CYLINDER ASSEMBLY



MAB4B001
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Removal Procedure

  1. Remove the air filter assembly. Refer to Section 1B, Engine Mechanical.
  2. For vehicles with the non-ABS braking system, remove the proportioning valve. Refer to "Proportioning Valve" in this section.
  3. Remove the master cylinder.


  4. D107A514
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    Notice : Brake fluid may damage paintwork, if spillage onto paintwork, wash with cold water immediately.



D107A515A
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Installation Procedure

    Important : Use only Daewoo recommended brake fluid.

  1. Install the master cylinder assembly with the nuts.
  2. Tighten
    Tighten the attaching nuts to 16 N•m (12 lb-ft).



    MAB4B002
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  3. Install the brake pipe fittings to the master cylinder.
  4. Tighten
    Tighten the fittings to 16 N•m (12 lb-ft).

  5. Connect the electrical connector.
  6. For vehicles with the non-ABS braking system, install the proportioning valve. Refer to "Proportioning Valve" in this section.
  7. Install the air filter assembly. Refer to Section 1B, Engine Mechanical.
  8. Bleed the brake system. Refer to Section 4A, Hydraulic Brakes.


D17A517A
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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.
  3. Notice : Do not force one side strongly to prevent damage of reservoir when removing the reservoir.



D17A518A
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Installation Procedure

    Important : Use only Daewoo recommended brake fluid.

  1. Install the reservoir with the screw
  2. Tighten
    Tighten the screw to 4 N•m (35 lb-ft).

  3. Install the fluid level switch connector. Refer to "Brake Fluid Level Switch" in this section.
  4. Add brake fluid.
  5. Bleed the brake system. Refer to Section 4A, Hydraulic Brakes.


MAB4B003
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PROPORTIONING VALVE (FOR VEHICLE WITH THE NON-ABS BRAKING SYSTEM)

  1. Remove the proportioning valve.
  2. Notice : Brake fluid may damage paintwork, if spillage onto paintwork, wash with cold water immediately.



MAB4B004
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Installation procedure

  1. Install the proportioning valve (1).
  2. Tighten
    Tighten the proportioning valve to 22 N•m (16 lb-ft).

  3. Install the brake pipe fitting (2).
  4. Tighten
    Tighten the brake pipe fitting-to-proportioning valve to 16 N•m (12 lb-ft).

  5. Bleed the brake system. Refer to Section 4A, Hydraulic Brakes.


D107A504
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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.


  3. D107A505
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D107A506
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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.

UNIT REPAIR



D24B001
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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 Cylinder 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).


  6. D24B002
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  7. Remove the boot (1).
  8. Remove the retaining ring (2).
  9. Notice : When removing the retaining ring, avoid damaging the piston or the cylinder wall.

  10. Remove the primary piston (3).
  11. Carefully remove the secondary piston assembly and the spring from the master cylinder bore (4).


D24B003
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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, Hydraulic Brakes.
  12. Lower the vehicle.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Application
Unit
Description
Master Cylinder
Type
-
Tandem
Bore Diameter
mm (in.)
20.64 (0.81)
Proportioning Valve
Cut-In Pressure
kPa (psi)
3,000(435.1)
Pressure Ratio
-
0.25 : 30

FASTENER TIGHTENING SPECIFICATIONS

Application
N•m
Lb-Ft
Lb-In
Fluid Reservoir Screw
4
-
35
Master Cylinder Attaching Nuts
16
12
-
Brake Pipe Fittings to Master Cylinder
16
12
-
Brake Pipe Fittings to Proportioning Valve
16
12
-
Brake Pipe Fittings to Rear Wheel Cylinder
16
12
-
Brake Pipe Fittings to Front Caliper
16
12
-
Proportioning Valve
22
16
-


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