Disc & Drum: Removal & Installation Daewoo Nubira II

Removal & Installation

1. Raise and support vehicle. Disconnect brake line from disc brake hose at wheel housing bracket on each side of vehicle. (Scheme 5) Remove brake hose retainer. Remove rear disc brake hose retainer and brake hose from bracket on steering knuckle shaft. Remove rear disc brake hose from caliper.
2. Remove rear drum brake line from brake hose bracket on wheel housing and steering knuckle shaft. Remove brake hose retainers and then brake hose from wheel housing bracket and bracket on steering knuckle shaft.
3. Install rear drum brake hose to wheel housing bracket, and to steering knuckle shaft bracket on each side of vehicle. Connect brake line to brake hose. Tighten brake line to 16 N.m (12 ft. lbs.). Install rear disc brake hose to caliper. Tighten rear disc brake hose-to-caliper bolt to 32 N.m (24 ft. lbs.).
4. Install rear disc brake hose and retainer on bracket on steering knuckle shaft. Install rear disc brake line to brake hose on wheel housing bracket. Tighten brake line to 16 N.m (12 ft. lbs.). Lower vehicle. Bleed brake system. Check brake system for leaks.

Scheme 5

1. Raise and support vehicle. Disconnect brake line from brake hose support bracket on wheel housing on each side of vehicle. Remove retainer. Disconnect brake hose from "C" bracket on steering knuckle shaft. (Scheme 6) Remove bolt from brake caliper. Remove seal rings and disc brake hose. (Scheme 7)
2. Install new disc brake hose to caliper with new seal rings and bolt. Tighten front disc brake hose-to-caliper bolt to 40 N.m (30 ft. lbs.). Slide brake hose on steering knuckle shaft "C"bracket. Connect brake line to brake hose on wheel housing bracket on each side of vehicle.
3. Tighten brake line to 16 N.m (12 ft. lbs.). Lower vehicle. Bleed brake system. Check brake system for leaks.

Scheme 6

Scheme 7

1. Disconnect negative battery cable. Disconnect connector from stoplamp switch. Rotate switch and remove it from brake pedal bracket. (Scheme 8)
2. To install, insert stoplamp switch into brake pedal bracket and rotate switch to lock it. (Scheme 9) Connect electrical connector to stoplamp switch. Press brake pedal and pull switch plunger to its maximum setting to adjust switch. Release plunger and pull up on pedal. Connect negative battery cable. (Scheme 10)(Scheme 13).

Scheme 8

Scheme 9

Scheme 10

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Scheme 12

Scheme 13

1. Remove stoplamp switch. Notice how brake pedal return spring is installed so that it can be reinstalled same way. Move end of brake return spring away from clevis retainer on brake pedal. Remove clip, retainer, and clevis pin from brake pedal. Remove retaining clip from brake pedal shaft and remove nut and washer from shaft. Remove pedal shaft and brake pedal. (Scheme 14)
2. To install, coat pedal shaft with grease. Place brake pedal and return spring in brake pedal bracket, and install shaft, washer, and nut. Tighten shaft nut to 18 N.m (13 ft. lbs.). Install retaining clip into hole in pedal shaft. Align clevis with holes in brake pedal, and install clevis pin, clevis retainer, and clip. Install stoplamp switch. (Scheme 15)

Scheme 14

Scheme 15

1. Disconnect electrical connector from reservoir cap. For vehicles with ABS braking system, disconnect brake lines from master cylinder body. For vehicles with non-ABS braking system, disconnect brake lines from proportioning valves. For vehicles with manual transaxle, disconnect clip to clutch hose connection to master cylinder and move clip out of way.
2. Remove clutch hose from master cylinder if equipped. Plug opening to brake lines to prevent fluid loss and contamination. Remove attaching nuts from power booster. Remove master cylinder assembly. Drain brake fluid.
3. Install master cylinder assembly with new attaching nuts. Tighten master cylinder attaching nuts to 18 N.m (13 ft. lbs.). For vehicles with ABS braking system (as shown), connect brake lines to cylinder body. For vehicles with non-ABS braking system, connect brake lines to proportioning valves.
4. Tighten brake lines to 16 N.m (12 ft. lbs.). For vehicles with manual transaxle, connect clip to clutch hose connection to master cylinder reservoir if equipped. Connect electrical connector on reservoir cap. Add brake fluid. Check for leaks and recheck fluid level. Bleed brake system.

Note. Remove reservoir only when replacing a damaged or a leaking reservoir. (Scheme 16)

1. Disconnect electrical connector from reservoir cap. For vehicles with manual transaxle, disconnect clip to clutch hose connection to master cylinder, and move clip out of way. Remove clutch hose from master cylinder.
2. Gently pry upwards with a screwdriver to release reservoir. Tilt reservoir and pull it upward in order to remove it. Remove reservoir seals from master cylinder body. (Scheme 17)
3. To install, lubricate new seals with clean brake fluid. Install seals into cylinder body. Install reservoir on master cylinder body. For vehicles with manual transaxle, connect clip to clutch hose connection to master cylinder.
4. Add brake fluid. Raise and support vehicle. Bleed braking system. Bleed clutch master cylinder. Lower vehicle. Connect reservoir electrical connector.

Scheme 16

Scheme 17

1. Disconnect brake lines from proportioning valves. Remove valves from master cylinder body. (Scheme 18) NOTE: Since these valves are adjusted in pairs to correct control range, they must be replaced in pairs.
2. Install proportioning valves to cylinder body. Tighten proportioning valves to 22 N.m (16 ft. lbs.). Connect brake lines to valves. Tighten brake lines to 16 N.m (12 ft. lbs.). Raise and support vehicle. Bleed braking system. Lower vehicle.

Scheme 18

1. To remove, spread clip on vacuum hose connection at intake manifold and move clip slightly toward brake booster. Pull hose from union nut connection. If hose does not remove easily or is deteriorated, pry off and discard hose. Spread clip on vacuum hose connection to brake booster, and move clip clear of booster. Remove vacuum hose.
2. To install, mount vacuum hose and ensure connections are tight on each end. Install vacuum hose clips. Check function of booster.

1. Remove master cylinder. Remove brake lines to hydraulic modulator for vehicles equipped with ABS. (Scheme 19) Remove shaft and rubber O-ring. (Scheme 20) Remove clip on vacuum hose connection on booster. Disconnect brake stoplamp switch from brake pedal bracket. Remove brake pedal spring. Disconnect clip and pushrod pin from pedal bracket assembly.
2. Remove booster mounting nuts from studs protruding from dash panel and remove booster. (Scheme 21) Remove rubber boot. (Scheme 22) Holding hex nut, twist off pushrod clevis. Remove hex nut from pushrod.
3. To install, check pushrod and pushrod clevis for damage and proper fit. Install hex nut and pushrod clevis on booster shaft. Tighten booster hex nut and pushrod clevis to 18 N.m (13 ft. lbs.). Measure distance from booster to center of fork pin bore. (Scheme 23) NOTE: Measurement should be 201 mm (7.9").
4. Install rubber boot on booster. Install booster and mounting nuts to dash panel. Tighten booster-to-dash panel nuts to 22 N.m (16 ft. lbs.). Insert shaft and rubber O-ring into power booster. Connect master cylinder to booster. Connect brake line fittings to hydraulic modulator, if applicable.
5. Tighten brake line fittings to 16 N.m (12 ft. lbs.). Install new vacuum hose to booster. Install hose clamps on vacuum hose, and snap vacuum hose in revolving clip. Install pushrod pin to brake pedal bracket assembly and connect clip and spring. Install brake stoplamp switch onto brake pedal bracket.

Scheme 19

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Scheme 21

Scheme 22

Scheme 23

1. Raise and support vehicle. To preserve wheel balance, mark position of front wheel relative to wheel hub. Remove front wheel. Remove lower caliper mounting bolt. (Scheme 24) NOTE: Caliper removal is not necessary to service brake shoes.
2. Pivot caliper upward. Remove brake shoes. (Scheme 25)
3. Install brake shoes. If new brake shoes are being installed, they will be thicker than worn pads that were removed. Push caliper piston inward, if necessary. Pull caliper downward and install lower mounting bolt. NOTE: Do not damage piston dust seal when caliper is pulled downward to reinstall lower mounting bolt.
4. Tighten caliper mounting bolt to 22-32 N.m (16-24 ft. lbs.). Align marks that were made when removing front wheel, and install wheel. Lower vehicle.

Scheme 24

Scheme 25

1. Raise and support vehicle. To preserve wheel balance, mark position of front wheel relative to wheel hubs. Remove wheel. Remove bolt which attaches brake hose to caliper. Remove washers.
2. Plug openings at caliper inlet and brake hose to prevent fluid loss or contamination. Remove caliper mounting bolts. Remove caliper.
3. Install caliper. Install caliper mounting bolts. Tighten caliper mounting bolts to 22-32 N.m (16-24 ft. lbs.). Connect caliper inlet hose with bolt and washers. Tighten brake hose-to-caliper bolt to 40 N.m (30 ft. lbs.).
4. Align marks that were made when removing front wheel, and install wheel. Lower vehicle. Fill master cylinder to proper level with clean brake fluid. Bleed air out of brake system. Recheck fluid level in master cylinder. Repeatedly press brake pedal to bring pads into contact with rotor. Do not move vehicle until a firm pedal is obtained.

1. Remove caliper. Remove brake pads. Remove caliper mounting bracket. Remove rotor detent screw. Remove rotor. NOTE: To guarantee uniform braking, always refinish both rotors even if only one rotor is defective. If a rotor is being replaced, use a new rotor on both skies of vehicle.
2. Install rotor on front wheel hub and install detent screw. Tighten rotor detent screw to 4 N.m (35 INCH lbs.). Apply a few drops of thread-locking compound to bolts and install caliper bracket.
3. Tighten caliper bracket-to-steering knuckle mounting bolts to 95 N.m (70 ft. lbs.). Install brake pads and caliper.

1. Remove rotor. Remove screws for splash shield from steering knuckle. (Scheme 26) Remove splash shield.
2. Install splash shield. Secure splash shield to steering knuckle with screws. Tighten splash shield screws to 5 N.m (44 INCH lbs.). Install rotor.

Scheme 26

1. Raise and support vehicle. To preserve wheel balance, mark position of rear wheels relative to wheel hubs and remove wheels. Remove lower caliper mounting bolt.
2. Pivot caliper upward. Remove brake shoes. NOTE: It is not necessary to remove caliper to service brake shoes.
3. To install, measure minimum shoe lining thickness. Install brake shoes. Push piston inward, if needed.
4. Pivot caliper downward and install lower bolt. Tighten lower caliper mounting bolt to 31 N.m (23 ft. lbs.). Align match marks that were made before removal and install rear wheels. Lower vehicle. NOTE: Do not damage piston seal when caliper is pivoted downward.

1. Raise and support vehicle. To preserve wheel balance, mark position of rear wheels relative to wheel hubs and remove wheels. Remove brake hose caliper inlet bolt and washers. (Scheme 27) Plug openings in caliper and brake hose to prevent fluid loss and contamination. Remove caliper mounting bolts and caliper.
2. Install caliper with mounting bolts. Tighten caliper mounting bolts to 31 N.m (23 ft. lbs.). Connect brake hose and washers with mounting bolt. Tighten brake hose caliper inlet bolt to 32 N.m (24 ft. lbs.). Align match marks that were made before removal and install rear wheels. Fill master cylinder to proper level with clean brake fluid.
3. Bleed caliper. Recheck fluid level. Repeatedly press brake pedal to bring pads into contact with rotor. Do not move vehicle until a firm pedal is obtained.

Scheme 27

1. Raise and support vehicle. To preserve wheel balance, mark position of rear wheels relative to wheel hubs and remove wheels.
2. Remove caliper. Remove caliper bracket. Remove rotor detent screw. Remove rotor. NOTE: To prevent damage to brake hose, do not hang caliper from brake hose.
3. To install, inspect rotor. Install rotor with detent screw. Tighten rotor detent screw to 4 N.m (35 INCH lbs.). Install caliper bracket. Tighten caliper bracket mounting bolts to 56 N.m (41 ft. lbs.). Install caliper. Align match marks that were made before removal, and install rear wheels. Lower vehicle.

Removal

1. Remove rotor. Disconnect parking brake cable from brake backplate operating lever. (Scheme 28) Pry off shaft dust cover. (Scheme 29) Remove spindle shaft castle nut. Remove wheel hub assembly from spindle shaft. (Scheme 30) Remove bolts that secure splash shield/backplate/parking brake shoe assembly to steering knuckle. Remove splash shield/backplat/parking brake shoe assembly from steering knuckle.
2. Remove screw that secures parking brake shoe hold-down spring assembly to backplate. Remove parking brake shoe, sliding it away from actuation mechanism. Remove splash shield. (Scheme 31) Remove and discard adjuster screw and nut. (Scheme 32) Remove and discard tappet and pushrod. (Scheme 33)
3. Using a 3.5 mm (.14") drill, remove pop rivets holding dust cover assembly and adjuster pawl to backplate. (Scheme 34) Remove and discard dust cover. and dust cover retainer from backplate. Remove and discard lever and adjuster pawl. (Scheme 35)

Installation

1. To install, clean backing plate, ensuring actuation cavity is free from grease and any other contamination. Inspect shoe assembly position. The shoe should fit centered on splash shield with shoe tips located correctly in slots. Inspect splash shield for rust or any other damage. Replace splash shield, if necessary. Install new adjuster pawl to backing plate by securing it with a pop rivet. Slide new dust cover onto dust cover notches.
2. Insert new lever and dust cover assembly into backing plate. Secure new dust cover retainer using pop rivets. Lubricate actuation cavity and tappet with grease. Ensure that internal bore of cavity is covered with grease. Secure splash shield and backplate to steering knuckle with bolts, and secure parking brake shoe hold-down spring assembly with screw. Tighten splash shield bolts to 35 N.m (26 ft. lbs.). Tighten parking brake shoe hold-down spring assembly screw to 3.5 N.m (31 INCH lbs.).
3. Connect new parking brake adjustment screw to new adjustment nut. Tighten nut to where it meets screw, and then back off one-quarter of a turn. Install adjustment screw and adjustment nut into backing plate actuation mechanism on adjustment pawl side. (Scheme 36)
4. Keep shoe slot parallel with backing plate face. Install new pushrod into tappet. Ensure pushrod is set correctly in lever socket by holding lever into backing plate while inserting pushrod and tappet. Clean excess grease using a clean rag. NOTE: The shoe assembly must be resting on splash shield with brand side up. NOTE: Clean hands are required when handling parking brake shoe.
5. Install parking brake shoe engaging shoe tips in both adjusting screw and tappet slots. Install wheel hub assembly, and secure it with wheel hub assembly-to-spindle shaft castle nut. Tighten wheel hub assembly-to-spindle shaft castle nut to 25 N.m (18 ft. lbs.), plus 1 N.m (9 INCH lbs.). Install shaft dust cover. Install parking brake cable to parking brake lever on each side of vehicle. Adjust parking brake. Install rotor.

Scheme 28

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Scheme 35

Scheme 36

1. Release parking brake. Remove parking brake/gearshift console hood. Measure thread length from end of pull rod to hex nut. (Scheme 37) Remove split pin which holds eye bolt pull rod to parking brake lever assembly. (Scheme 38)
2. Detach eye bolt pull rod but leave pull rod connected to equalizer which is attached to parking brake cables. (Scheme 39) Remove bolts and washers which secure complete parking brake assembly to underbody. (Scheme 40) NOTE: The parking brake switch should be replaced if BRAKE warning light in instrument panel cluster did not glow when parking brake was applied with ignition switch ON.
3. If necessary, remove parking brake switch attached to parking brake lever assembly by a small screw, and remove switch.

Note. If parking brake lever is bent or damaged, replace complete parking brake lever assembly, which includes a new parking brake switch.

1. To install, fasten parking brake switch to parking brake lever assembly with screw. Tighten parking brake switch-to-parking brake lever screw to 4 N.m (35 INCH lbs.). Install parking brake lever bolts, and fasten parking brake lever assembly to vehicle underbody. Tighten parking brake lever assembly-to-vehicle underbody bolts to 22 N.m (16 ft. lbs.).
2. Install eye bolt pull rod to brake lever operating pawl fastening pull rod with a split pin. Check parking brake adjustment referring to original removal adjustment nut measurement taken in removal procedure. Install parking brake/gearshift console hood.

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. Remove parking brake/gearshift console hood. Remove split pin which holds eye bolt pull rod to parking brake lever assembly. Remove parking brake cable ends from equalizer. (Scheme 41) Raise and support vehicle. Remove rear wheels. For vehicles with rear drum brakes, remove detent screw of rear brake drum and remove brake drum. Remove retaining ring for parking brake cable. Remove plastic sleeve.
2. Remove parking brake cable from brake trailing shoe lever and from backing plate. For vehicles with rear disc brakes, unfasten parking brake cable from lever at rear of backing plate. Remove clip that holds cable into protruding hole on steering knuckle assembly. Remove nut securing parking brake cable to underbody clip on both driver and passenger sides of vehicle.
3. Remove parking brake cable from clip near fuel tank strap (passenger side). (Scheme 42) Suitably support fuel tank. Remove fuel tank retaining strap nut on driver side and remove parking brake cable. (Scheme 43) Pull cable through loop of welded underbody bracket.
4. Pull out parking brake cable (and rubber grommet) from its underbody access to parking brake/gearshift console.

1. Install new parking brake cable (if necessary) through rear drum brake backing plate and attach to brake trailing shoe lever. Insert plastic sleeve in rear drum backing plate and press in retaining ring. Ensure parking brake cable is routed correctly. Install rear brake drums by fastening detent screw.
2. Tighten rear brake drum detent screw to 4 N.m (35 INCH lbs.). For vehicles with rear disc brakes, route cable to protruding hole on steering knuckle assembly. Fasten parking brake cable to lever at rear of disc brake backing plate. Install clip that secures parking brake cable to protruding routing hole on steering knuckle assembly.
3. Install nut securing parking brake cable to a bracket on both driver and passenger sides of vehicle. Tighten parking brake cable-to-underbody side bracket nuts to 6 N.m (53 INCH lbs.). Install parking brake cable (passenger side) to clip near fuel tank strap. Route parking brake cable through loop of a welded underbody bracket and under fuel tank retaining strap (driver side).
4. Tighten fuel tank retaining strap nut to 12.5 N.m (111 INCH lbs.). Route parking brake cables through access holes to parking brake/gearshift console. Install rubber grommet for each cable. Install rear wheels. Lower vehicle. Attach parking brake cable ends to equalizer. Attach eye bolt pull rod to parking brake lever assembly and fasten split pin.Install parking brake/gearshift console hood. If parking brake shoe lever was pressed backward before removing brake drum, now press it forward and adjust parking brake.

Scheme 41

Scheme 42

Scheme 43

1. Remove parking brake/gearshift console hood, detaching parking brake lever boot. Slip parking brake handle off of parking brake lever.
2. To install, push parking brake handle as far as it will go on parking brake lever. Install parking brake/gearshift console hood with parking brake lever boot.