Brake system
Brake system
Brake system ................................................................................................................................................... P-1
General steps .................................................................................................................................................... P-2
Conventional brake system .............................................................................................................................. P-2
Air exhaust ............................................................................................................................................... P-2
Inspection and adjustment of brake pedal ................................................................................................ P-3
Removal/disassembly/installation of brake pedal .................................................................................... P-4
Service of brake switch ............................................................................................................................ P-5
Disassembly/installation of brake master cylinder ................................................................................... P-5
Service of liquid level sensor ................................................................................................................... P-6
Disassembly/assembly of brake master cylinder ...................................................................................... P-6
Check of vacuum booster ......................................................................................................................... P-7
Removal/installation of vacuum booster .................................................................................................. P-9
Check of front disc brakes .............................................................................................................................. P-10
Introduction to the repair tips of brake judder ........................................................................................ P-10
Removal and installation of front disc brakes ........................................................................................ P-11
Removal and installation of the rear disc brake ..................................................................................... P-14
Parking Brake System .................................................................................................................................... P-17
Removal and Installation of Parking Brake Handle ............................................................................... P-17
Removal and installation of rear parking brake ..................................................................................... P-18
Check the parking brake handle ............................................................................................................. P-20
Adjustment of parking brake handle ...................................................................................................... P-20
Anti-lock brake system (ABS control unit) .................................................................................................... P-21
Check of ABS control unit and control unit ........................................................................................... P-21
Steps prior to determine the replacement of the ABS control unit ......................................................... P-23
Exhaust braking ...................................................................................................................................... P-26
Removal and installation of HU/CM of ABS control unit ..................................................................... P-29
Removal and installation of HU/CM of ABS control unit ..................................................................... P-30
Brake line connection diagram of ABS control unit 8 ........................................................................... P-31
Diagram of hydraulic pressure regulator of ABS control unit with ECU............................................... P-32
Definition of hydraulic pressure regulator pins of ABS control unit with ECU .................................... P-32
Removal and installation of wheel speed sensor on the rear ABS control unit ...................................... P-34
Check of Front/rear ABS control unit wheel speed sensor .................................................................... P-35
OBD ....................................................................................................................................................... P-36
ECU faults ...................................................................................................................................................... P-44
Brake system
P-2
General steps
Removal and installation of wheels and tires
1. This chapter does not include the removal and installation steps of wheels and tires. If necessary to
remove the wheel, they shall be retightened up at the installation time, to the specified torque in
88-127N.m {9.0-13.0kgf.m,65-94ft.lbf}.
Disconnection and connection of brake line
Attention
The brake fluid will damage the paint surface, thus, if the brake fluid stained the paint surface, please wipe it
up immediately
1. Use the SST(49 0259 770B ) to screw up the flare nut of brake line, the tightening torque of flare nut on
the brake line has to be adjusted to match with the use of combination tool——joint torque wrench
-SST(See——Moment Equation G1).
2. If the brake line used to be disconnected during the operation, the brake fluid shall be added, air in the
brake system exhausted, then check for any system leakage after the completion of work.
Disconnection of plug
Attention
1. Prior to the connector operation, the negative connection of battery shall be disconnected, the negative
connection can be remade up only after the completion of work.
Precautions to the operation of ABS control unit component
1. After the work of ABS control unit component completed, no fault codes shall exist in the ABS control
unit system. If there are fault codes in the diagnostic system, eliminate them(See——Fault Diagnostic
Function, ABS Control Unit System, steps to clean up the fault codes).
Conventional brake system
Air exhaust
Attention:
Whenever, the brake system shall exhaust, when
the brake line disconnected. If the hydraulic
piping is disconnected at the brake master
cylinder, the braking shall exhaust by starting
from the farthest slave cylinder, and then further
wheel cylinder until the exhaust of four
sub-cylinders completed. If the point of
disconnection is not located at the brake master
cylinder, then the exhaust shall start from the
nearest disconnection point from the brake slave
cylinders, and then the further wheel cylinder
until the exhaust braking 4 of cylinders completed.
Standard of brake fluid:
FMVSS DOT-3
1. Shore up with a jack a vehicle on a level ground
and hold the vehicle on a safe platform.
2. Remove the exhaust valve cap from the calipers
and fit up a vinyl pipe, transparent and not
corroded by brake fluid on the exhaust bolt.
3. Place another end of plastic pipe in a clean fluid
container.
4. The operator A steps down the brake pedal
several times, and then hold it on the depressed
position. The operator B unscrews the exhaust
bolt, drains the liquid, the operator A may release
the brake pedal, after the bleed bolt has been
retightened by the operator B with SST.
5. Repeat the steps 4 and 5 until bubbles appear
again.
6. During the air exhaust process, the fluid reservoir
shall be held at the 3/4 liquid level to prevent air
reentry again into the pipe.
Tightening torque: 5.9-8.8N·m (60-90kgf·cm)
Brake system
P-3
7. Check whether the brake is in normal operation.
8. Verify whether there is any spilled fluid, if yes,
wipe it off.
9. When exhausting of the brake is finished, fill the
brake with the brake fluid to the highest liquid
level.
Inspection and adjustment of brake pedal
Check of brake pedal height
Confirm that the distance between the central surface
of pedal pad and the carpet is within the designated
range
Pedal height (reference value): 250mm
Adjustment of brake pedal height
1. Disconnect the joint of brake switch.
2. Unscrew the lock nut A and turn the brake light
switch B until the thread section on the switch
just gets in contact with the pedal limit block.
3. Screw up the lock nut A so that the clearance
between the thread section of switch B and pedal
limit block is within the scope of the technique
requirements.
Technique requirements: 0.1-1.0mm
{0.004-0.039 in}
Tightening torque 14-17 N⋅m {140-180
kgf⋅cm, 122-156 in.lbf}
5. Connect the joint of brake switch.
6. After the adjustment, check whether the pedal
free travel and brake light are in normal
operation.
Check of free travel of brake pedal
1. Step down the pedal several times to clean up
the vacuum from the system.
2. Press down, with hand, the pedal to check the
free travel (until the resistance is felt).
Pedal free travel 6-10mm.
Height of brake pedal
Brake system
P-4
Check of the clearance between the pedal
and floor
1. Start the engine and then confirm that the
distance between the floor to the center of pedal
pad remains within the specified range, when the
pedal is depressed with the force in 147N
{15kgf}.
Specified vale: 130mm (min)
2. If the distance from the floor to the center of
pedal pad is less than the specified value, check
whether there is air in the Brake system.
Removal/disassembly/installation of brake pedal
1. Dismantle in the order of 6-7-8-9-10-11-2-3-5-1.
2. Install in the reversing order of removal.
1. Dismantle in the order of
4-12-13-15-14-16-17-19-18
2. Install in the reversing order of removal.
1 Brake switch plug 6 Flange nut
2 Stop pin 7 Flange nut
3 Spacer 8 Flange nut
4 Bushing 9 Flange nut
5 Vacuum booster push
rod
10
Flange nut
11 Locking bolt 16
Pedal swing arm
12
M10 Hexagonal nut 17
Limit block
13
Bolt pin 18
Brake light switch
14
Return spring 19
Lock nut M8
15
Spring sleeve
Clearance between the
brake pedal and the floor
Brake system
P-5
Service of brake switch
1. Disconnect the connection of brake switch plug.
2. Connect an ohmmeter between two terminals of
brake switch plug to check whether the circuit is
put through.
3. If inconsistent to the case as specified in the
table, replace the brake switch.
Disassembly/installation of brake master
cylinder
1. Remove in the order of 1-2-3-4-5-6-7-8.
2. Install in the reversing order of removal.
1
Liquid level sensor plug
2
Pipe clamp
3
Inlet hose of clutch master cylinder
4
Front cavity pipe of brake master cylinder
5
Rear cavity pipe of brake master cylinder
6
Flange nut
7
Flange nut
8
Brake master cylinder
Circuit put through
Terminal
Conditions
When the brake is stepped down
When the brake is not stepped down
Brake system
P-6
Service of liquid level sensor
1. Pull out the sensor plug;
2. Connect an ohmmeter on the plug;
3. Start measuring when the liquid level is more
than the max. value, and confirm the circuit is
not through at this moment.
4. Drain out the brake liquid and confirm that the
circuit is through when the liquid level is below
the min. value.
5. If inconsistent to the case as specified in the
table, replace the sensor.
Disassembly/assembly of brake master cylinder
Caution:
If the brake master cylinder body is damaged, the master cylinder shall be replaced. When the master
cylinder is fixed on a bench vice, only the flange disc of master cylinder is to be fixed.
1. Disassembly as per the order shown in the Table.
2. Assembly in the reversing order of disassembly.
1 Cover component
2 Screw
3 Fluid tank
4 Bushing
5 Bushing
6 Liquid level sensor
7 Retaining ring
8 Butterfly film
9 Piston sleeve
10 Retaining ring
11 1
st
stop pin
12 1
st
piston
13 2
nd
stop pin
14 2
nd
piston
15 Return spring
16 Master cylinder gasket
Circuit put through
Terminal
Conditions
Below the Min value
Above the Max value
Brake system
P-7
Installation instructions of stop pin
1. Aim the piston bore at the stop pin and fit on the
2nd piston and return spring.
2. Fit on the stop pin.
3. Push in and release the piston to confirm that the
piston can be locked by the stop pin.
Check of vacuum booster
Check the function of vacuum booster (simple method)
Attention:
Replace the vacuum booster when necessary.
Method 1
1. Shut down the engine; step down the brake pedal several times.
2. Hold pressed the brake pedal and start the engine.
3. If the pedal displaces slight downward after the engine started, it means that the vacuum booster is in
normal operation.
Method 2
1. Start the engine.
2. After the engine run for 1 or 2mins., shut down the engine.
3. Step down the brake pedal by the normal force, and hold it for 3-5s, so to allow the pressure difference
between the front and rear cavities equal to zero.
4. If the 1
st
travel of stepped pedal is long, and the 2
nd
becomes shorter, it means that the vacuum booster is
in normal operation.
5. Attention:
If any problems found, inspect whether the check valve and vacuum booster hose are damaged and their
installation, repair or replace when necessary, and then check again.
Method 3
1. Start the engine.
2. Step down the brake pedal by normal force.
3. Hold the brake pedal on the depressed position and shut down the engine.
4. Hold the brake pedal on the depressed position for about 30s.
5. If there is no change in the height of brake pedal, it means that the vacuum booster is in normal
operation.
Brake system
P-8
(Check with a measuring instrument)
1. As shown in Fig., connect respectively with the SST vacuum gauge and pedal pressure detector.
Attention: Exhaust the air in the SST at the instrument A with a special instrument and a pedal pressure
detector.
2. After the air exhausted from the SST, detect as per the following steps:
a) Check the vacuum leakage
Under no-load:
1. Start the engine.
2. When the vacuum gauge reading reached 66.7kPa{500mmHg}, shut down the engine.
3. Shut down the vacuum gauge for 15s. If the vacuum indicates 63.3-66.7kPa {475-500mmHg}, it means
that the vacuum booster is in normal operation.
Under loading conditions
1. Start the engine.
2. Step down the brake pedal with the force in 196N {20kgf}.
3. Hold depressed the brake pedal, and shut down the engine when the vacuum gauge reading reached
66.7kPa {500mmHg}.
4. Observe the vacuum gauge for 15s. If the vacuum degree indicates 63.3-66.7kPa {475-500mmHg}, it
means that the vacuum booster is in normal operation.
b) Check the hydraulic pressure
1. Shut down the engine (vacuum degree: 0kPa {0mmHg}. If the fluid pressure is now within the specified
range, it means that the vacuum booster is in normal operation.
Pedal pressure Fluid pressure
196N{20kgf} 790kPa{8kgf/ cm
2
}min
Vacuum gauge
Pedal dynamometer
Brake system
P-9
2. Start the engine and step down the brake pedal when the vacuum degree achieved 66.7kPa{500mmHg}.
If the fluid pressure is within the specified range, it means that the brake device is in normal operation.
Pedal pressure
Fluid pressure
MTX
196N
{20kgf}
7100kPa{72kgf/cm
2
}min
ATX
8820kPa{90kgf/cm
2
}min
Removal/installation of vacuum booster
1. Remove the brake master cylinder
(See——Conventional brake system,
Removal/installation of brake master cylinder).
2. Remove in the order as shown in the Table.
3. Assembly in the reversing order of disassembly.
1 Vacuum booster hose assembly
2 Spring pin
3 Axle pin
4 Nut
5 Vacuum booster pump
6 Check valve assembly
Check of front disc brakes
P-10
Check of front disc brakes
Introduction to the repair tips of brake judder
There are three features as shown below in the problems of brake judder:
(1) Vibration of steering wheel. The steering wheel vibrates in the direction of rotation and such feature is
the most notable when braked at the speed between 100～140 km/h {62～87 mph};
(2) Floor vibration. In braking, the bodywork vibrates forward and rearward, and the vibration intensity is
not subject of the speed effect;
(3) Vibration of brake pedal. When the brake applied, there is impulsive force trying to push back the brake
pad, and transferred on the brake pedal.
The followings are some key raisons possibly resulting in brake judder:
When the brake disc jittered too much, the swing thickness between the one side and another is uneven. If the
judder is over 0.05 mm {0.002 in} at 10 mm {0.39 in} away from the edge of brake disc, it means the uneven
wear on the disc occurred due to the contact of the unbalances of pad and disc, if it is less than 0.05 mm
{0.002 in}, it means that no uneven wear occurred.
Thermal deformation of disc The repeated violent brakes may enable the disc local temperature to increase up
to about 1000℃ {1832ºF}, resulting in the disc distortion.
The thickness and friction coefficient of disc will change due to corrosion. If the vehicle parked for longtime
in wet condition, the friction surface of disc will be corroded. When the corrosion thickness is uneven, it will
take the corrugated shape, resulting in the variation of friction coefficient and the reaction force.
Check and repair process
Check the lateral run-out
1. Screw up, in crosswise, the hub nut to assure that the disc and hub properly were installed or the washer
inserted between the hub bolt and hub nut with the spacer thickness in10mm {0.39 in} and the I/D more
than 12 mm {0.47 in}.
Note:
The part composed by SST 49 B017001 or 49 G019 003 may be use as the suitable washer.
Identify the complains of clients
Carry out the radial run-out check
Refer to Radial Run-Out Check
Less than
0.05mm
(0.002)
Less than 0.05mm
(0.002)
P
resence
C
onfirm whether there have
been any brake jitters
R
emove the disc plate,
reinstall at another phase and
make again the radial run-out
check.
C
heck the thickness variation
(see
below)
Verify the repair
U
se the mold on the vehicle to
process the disc plate
Tighten all rim nuts by the same
torque to fix the brake disc and
measure the radial run-out.
L
ess than 0.015mm (0.
0005in)
More than 0.015mm (0.0005in)
M
ore than
0.05mm
(0.002in)
U
se the mold on the vehicle.
[Less than 0.015mm (0.0005in)]
Work completed
Not presented
More than 0.05mm (0.002in)
Check of front disc brakes
P-11
2. After all hub nuts screwed up to the same torque, place the dial gauge on the friction surface of brake
disc, at ca.,10 mm{0.39 in} away from the edge of disc.
3. Turn once the brake disc and measure the lateral run-out.
Run-out limit: 0.05 mm {0.002 in}.
1. Clean up with brake cleaner the friction
surfaces of brake disc and brake pad.
2. Measure, with a micrometer calipers, the
thickness of each point as shown in the figure.
3. Subtract, with the measured maximum value the
minimum value. If the result is nonconforming
to the requirements, process the brake disc with
grinding tool.
Variation limit of thickness: 0.015 mm {0.0005
in}
Warning
Don’t surpass the requirements of minimal brake disc
thickness.
Check the variation of thickness
Check the thickness of brake disc
Attention
If the disc is removed from the vehicle for processing, it will result in excessive run-out, thus the disc shall be
processed when fitted up on the vehicle.
1. Measure the thickness of disc. Replace the disc when the disc thickness is not within the range of
technique requirements, then,
The minimal thickness limit of front brake disc: 24 mm {0.94 in}
The minimal thickness limit of rear brake disc: 10 mm {0.39 in}
Check the thickness of brake pad
1. Jack up the front part of vehicle and shore it up
with the safety bracket.
2. Remove the wheel.
3. Check the residual thickness of pad and replace
the pad by full set. As long as the thickness of
one lateral pad of R/L wheels is less than or
equal to the requirement of minimal thickness,
the pads at both sides should be replaced at the
same time.
Pad thickness required: minimum value: 2.0 mm
{0.08in}
Removal and installation of front disc brakes
1. Remove in the order as shown in the Table
2. Assemble in the reversing order of disassembly
3. After installation step down the brake pedal several times, turn manually the wheel to confirm that no
brake blocking exists.
Check of front disc brakes
P-12
1 Brake hose
7 Guide pin cover
2 Caliper bolt 8 Guide pin
3 Front caliper assembly 9 Guide pin bushing
4 Compressing spring 10 Front brake disc
5 Internal/external friction plate
See——P Essentials to Removal of
Brake Disc
See——P Essentials to the Installation of
Internal/External Friction Plates
See——P Essentials to Brake Disc
Installation
6 Support beam 11 Bleed screw and bleed screw cap
Essentials to removal of brake disc
1. Prior to the removal, make the mark on the hub
bolt and brake disc for the reference at the
installation time.
Essentials to the installation of brake disc
1. Clean up any rust or grime on the contact
surface of brake disc and hub.
2. Align with the mark made prior to the removal
and fit up the brake disc.
Essentials to the installation of internal
/external friction plate
1. Push down to the end the piston with SST
2. Install the brake pad
Replace the internal/external friction plate
1. Disassemble in the order as shown in the Table.
2. Assemble in the reversing order of disassembly
Mark
Wood plate
Check of front disc brakes
P-13
1 Guide pin cover
2 Guide pin
3 Compressing spring
4 Internal/external friction plate
5 Support beam
6 Brake caliper assembly
Disassembly and assembly of front brake
caliper
1. Disassemble as per the order shown in the
Table.
2. Assembly in the reversing order of disassembly
1 Piston dust cover
2 Piston
See——P Essentials to the
Disassembly of Piston
3 Piston gasket
See——P Essentials to the
Disassembly of Piston Gasket
4 Bleed screw cover
5 Bleed screw
6 Front caliper body
Essentials to the piston disassembly
Attention
Slowly blow the compressed air into the brake caliper
to prevent sudden run-out of piston.
1. Place the SST into the brake caliper and then
slowly blow the compressed air from the hole
into the brake caliper, enabling the piston to be
pushed out from the brake caliper.
Check of front disc brakes
P-14
Essentials to the Disassembly of Piston Seal
Ring:
1. Push out, with the SST, the piston seal ring from
brake calipers.
Removal and installation of the rear disc brake
1. Remove in the order as shown in the Table
2. Assemble in the reversing order of disassembly
3. After installation, step down the brake pedal several times, turn manually the wheel to confirm that no
brake blocking exists.
1 Hollow bolt
See——P Essentials to the Installation of
Internal/External Friction Plate
2 Rear brake hose 7 Rear brake disc
3 Guide pin cover
See——P Essentials to the Removal Brake
Disc
4 Guide pin
See——P Essentials to the Installation of
Brake Disc
5 Rear caliper assembly 8 Guide pin sleeve
6 Internal/external friction plate 9 Bleed screw and bleed screw cover
Check of front disc brakes
P-15
Brake disc removal essentials
Prior to the removal, mark on the hub bolt and brake
disc for reference at the installation time.
Essentials to the Installation of Brake Disc
1. Clean up any rust or grime on the contact
surface of brake disc and hub.
2. Align with the mark made prior to the removal
and fit up the brake disc.
Essentials to the Installation of
Internal/External Friction Plate
1. Push out, with the SST, the piston to the end.
2. Install the brake pad.
Replacement of the Internal and External
Friction Plate
1. Disassemble in the order as shown in the Table.
2. Assemble in the reversing order of disassembly
1 Guide pin cover
2 Guide pin
3 Internal/external friction plate
4 rear brake caliper
5 Guide pin sleeve
Mark
Wood plate
Check of front disc brakes
P-16
Disassembly/assembly of rear brake
calipers
1. Disassemble as per the order shown in the
Table.
2. Assembly in the reversing order of disassembly
1 Piston dust cover
2 Piston
See——P piston disassembly
essentials to the
3 Piston gasket:
See——P piston gasket disassembly
essentials to the
4 Bleed screw cover
5 Bleed screw
6 Rear caliper body
Piston disassembly essentials to the
Attention
Slowly blow the compressed air into brake caliper to
prevent sudden run-out of piston.
1. Place the SST into the brake caliper and then
slowly blow the compressed air from the hole
into the brake caliper, enabling the piston to be
pushed out from the brake caliper.
Essentials to the Disassembly of Piston
Gasket
1. Remove with the SST the piston gasket from
the brake calipers.
Parking Brake System
P-17
Parking Brake System
Removal and Installation of Parking Brake Handle
1. Disassemble in the order as shown in the Table.
2. Assemble in the reversing order of disassembly.
3. Adjust the travel of parking brake handle.
1
Auxiliary instrument panel: See——S
Auxiliary Instrument Panel
9
Support spring and clamping pin of
brake shoe
2
Mounting bolts of parking handle and
bracket
10 Upper/lower return springs
3 Parking brake handle 11 Parking adjustment mechanism
4 Mounting bolt of parking cable 12 Push plate and brake plate assembly
5 Guide pin cover 13 Brake shoe
6 Guide pin
14
Front draw wire and rear parking
inhaul cable assemblies(L/R)
7 Rear brake calipers
8 Rear brake disc 15 Parking handle holder
Parking Brake System
P-18
Removal and installation of rear parking brake
1. Disassemble in the order as shown in the Table.
2. Assemble in the reversing order of disassembly.
3. After installation, adjust the brake shoe clearance and carry out the following jobs.
(1) Step the brake pedal several times and then confirm that no brake blocking exists
(2) Check the clearance between the pedal and floor.
(3) Check the travel of parking brake handle.
1 Rear brake disc
6 Parking adjustment mechanism
2 Clamping pin 7 Parking brake shoe assembly
3 Brake shoe support spring 8 Rear parking cable
4 Upper return spring 9 Push plate and brake plate assembly
5 Lower return spring 10 Rear mudguard
Parking Brake System
P-19
Check the thickness of parking brake shoe
1. Remove the lower brake disc;
2. Check the thickness of residual friction plate;
● As long as the thickness of one of R/L friction
plates is less than or equal to the minimal
thickness, the brake shoes at both sides should
be replaced at the same time.
Friction plate thickness:
Minimum value: 1.0 mm {0.04 in}
Check the inner drum head of rear brake
disc
1. Measure the I/D of the drum head of rear brake
disc.
I/D maximum value: 188 mm {7.40 in}
2. Check whether there are any scratches,
unevenness or abnormal wear on the inner
drumhead of rear brake disc.
3. Repair or replace the rear brake disc if
necessary.
4. Pay attention to check whether the drumhead is
in good contact with the brake shoe when the
rear brake disc is repaired or replaced.
Essentials to the removal of rear brake disc
removal
1. Prior to the removal, mark on the hub bolt and
rear brake disc for reference at the installation
time.
Mark
Parking Brake System
P-20
Essentials to the installation of parking
brake shoe
Note: Toggle up to tighten the parking adjustment
mechanism.
1. Clean up any rust and grime on the contact
interface of drum brake.
2. Align with the mark made prior to the removal
and fit up the brake drum.
3. As steps stated below, adjust the clearance of
brake shoe.
(1) Clean up any rust and grime on the contact
interface of inner drum of rear brake disc.
(2) Align with the mark made prior to the removal
and fit up the rear brake disc.
(3) Poke, with a screwdriver, the parking adjustment
mechanism, through the parking adjusting hole
on the rear brake disc until the parking shoe disc
fully got in tight contacted the brake disc.
(4) Poke downward the parking adjustment
mechanism for 3～5 teeth by the same method,
to assure the free rotation of brake disc.
Check the parking brake handle
1. Pull the parking brake handle several times.
2. Pull, by the force in 98 N {10 kgf, 72.3 ft.Ibf}, the parking brake handle and check the travel of parking
brake for 3－7 teeth.
Adjustment of parking brake handle
1. Pull apart the jacket zipper of parking handle.
2. Turn the adjusting nut on the front parking cable.
3. After the adjustment, check the following points:
(1) Turn on the ignition switch, pull the parking brake handle for one tooth to confirm that the parking brake
light is lit.
(2) Confirm that no brake blocking exists on the rear brake.
Parking adjustment mechanism
Parking adjustment hole
Adjusting nut
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