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Brake System

GENERAL
MECHANICAL SPECIFICATIONS . . . . . . . BR - 2

VACUUM ASSISTED HYDRAULIC BRAKE


BRAKE BOOSTER
BRAKE PEDAL
BRAKE MASTER CYLINDER
LOAD
SENSING
PROPORTIONING
VALVE(L.S.P.V)

FRONT BRAKE ASSEMBLY


DISC BRAKE
DRUM BRAKE

REAR BRAKE ASSEMBLY


DRUM BRAKE

EXHAUST BRAKE
PARKING BRAKE SYSTEM
ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION
ABS MODULATER
ABS CONTROL MODULE
WHEEL SPEED SENSOR

BR -2

BRAKE SYSTEM

GENERAL
MECHANICAL SPECIFICATIONS

SPECIFICATIONS

E7FA724A

FRONT WHEEL BRAKE (DRUM TYPE)


Item

Specifications

Brake type

2-leading Brake

Wheel cylinder

Inner diameter

31.75mm

Brake drum

Inner diameter

320mm

Brake lining

Width x Thickness (mm)

85 x 10(Standard), 110 x 11(Option)

FRONT WHEEL BRAKE (DISK TYPE)


Item

Specifications

Brake type

Disc brake with hydraulic vacuum booster

I.D (mm)

76

Effective radius (mm)

118

Pad area (cm)

83

Disc size (O.DI.Dthickness)

304 16830

Bore
size

REAR WHEEL BRAKE


Item

Specifications

Brake type

2-leading Brake

Wheel cylinder

Inner diameter

28.57mm

Brake drum

Inner diameter

320mm

Brake lining

Width x Thickness (mm)

8510 (standard)
11011 (option)

BRAKE SYSTEM
Item
Brake Pedal

Total Stroke

Booster

Power Cylinder

Specification
162
Diaphragm Diameter
Total Stroke

Master Cylinder

Inner Diameter
Stroke

Capacity of Brake Tank

228/251mm
32mm
31.75mm

Front

17mm

Rear

14mm
505(cc)

GENERAL

BR -3

EXHAUST BRAKE
Item

Specification

Control System

Combination of Electric and Vacuum Type

Exhaust Brake Valve Type

Butterfly Valve

Exhaust Brake
Chamber

76.2mm

Diaphragm Effective Diameter


With Installing N(kg)
In operation N(kg)

Spring Tension

90~110 (9.18~11.22)

Rod Tensile Force

142.1(14.5): Vacuum Pressure-400mmHg

Spring Tension

125~153 (12.78~15.62)

Rod Tensile Force

103(10.5) Vacuum Pressure-400mmHg

Excluded from D4AE, D4AF

Intake shutter

Included with D4DA, D4DB, D4DC, D4AL, D4DD

PARKING BRAKE
Item

Specification

Type

Internal expansion type acting on propller shft

Control

Mechanical cable

Parking lever

Normal stroke

7~8 clicks(20 kgf)

Parking brake size

Drum i.d. x Lining width


x Lining thickness

180 x 35 x 5 (T/M : M2S5, M3S5)


190 x 45 x 4 (T/M : M035S5, D4DA, D4DB, D4DD)

ABS SPECIFICATION
Item
ABSCM(ABS Control Module)
Operating voltage
Power consumption
Inoperation
Operation
Operating temperature range

24V
16~32V
12W or below
18W or below
-40 ~ 65 C

Modulator
Operating voltage range
On-board voltage
Operating temperature range

18.9 ~ 32.8 V
24V
-40 ~ 120 C

Motor relay
On-board voltage
Operation voltage
On-board current

DC24V
15V
20A

Valve relay
On-board voltage
Operating voltage

DC24V
13V

BR -4

BRAKE SYSTEM

SERVICE STANDARDS
Description
Brake
pedal

Bushing to collar clearance


Brake pedal play
Stop lamp switch installation clearance

Nominal value
(Basic diameter
in [ ])

Limit

Correction
and
remarks

[16]0.02 ~ 0.26

0.5

Replace
bushing

3-8

Adjust

0 ~ 1

Replace

0.03-0.089

0.2

Brake
master
cylinder

Primary and secondary piston to cylinder body clearance

Front
disc
brake

Brake drum

I.D.

320

322

Replace

Brake lining

Thickness

10.0

4.0

Replace

303/227

19/227

Replace

[31.75]0.03 to
0.13

0.2

Replace

Primary spring deterioration

Free length

54

Replace

Secondary spring
deterioration

Free length

70.3

Replace

Return spring
Wheel cylinder body to piston clearance
Brake shoe clearance(No. of notches returned of
wheel cylinder adjuster)

Rear
wheelbrake

Replace

4 ~ 6

Adjust

Brake drum

I.D.

320

322

Replace

Brake lining

Thickness

10.0

4.0

Replace

Return
spring

Load N(kgf)/installed length

303/227

19/227

Replace

Wheel
cylinder

Body to piston clearance

0.02-0.11

0.2

Replace

Brake drum

Out of roundness

0.05

Replace

Brake shoe clearance (number of return notches


of wheel cylinder adjuster)

4 ~ 6

Adjust

GENERAL

BR -5
Nominal value
(Basic diameter
in [ ])

Description
Exhaust
brake

Limit

Correction
and
remarks

Power chamber air tightness [15 seconds after application


of -67 kPa (-500 mmHg) negative pressure]

-63 kPa (-475


mmHg) or more

Replace

Valve to body clearance when butterfly valve is fully closed [at


power chamber vacuum -87 to -93 kPa(-650 to -700 mmHg)

0.1 to 0.25mm

Replace

When -100 kPa (-750 mmHg)


negative pressure is applied from
vacuum tank side to operate
valve with exhaust brake unit
side plugged tightly

No air to be
sucked in from
atmosphere side

Replace

When 98 kPa (1 kgf/cm


air pressure is applied from
atmosphere side to operate
valve with exhaust brake unit
side plugged tightly

No air to leak from


vacuum tank side

Replace

3-way
magnet
valve

Air tightness

Minimum
operating
voltage

When -100
kPa(-750
mmHg) negative
pressure is
applied to
vacuum tank side

24V type
unit

22V or less

Replace

When 98 kPa
(1 kgf/cm air
pressure is
applied from
atmosphere side
with exhaust
brake unit side
plugged tightly

24V type
unit

22V or less

Replace

BR -6

BRAKE SYSTEM

SERVICE STANDARDS (PARKING BRAKE)


Description
Brake drum

I.D.

Nominal value
(Basic diameter
in [])

Limit

180

181

190

192

Squareness

0.05 or less

Concentricity

0.1 or less

Cylindricity

0.1 or less

Static roation imbalance

0.49N cm (50 gf
cm)or less

Model with M2S5


T/M

3.85 ~ 5.15

Brake shoe clearance

Model with M2S5


T/M

0.25 ~ 0.35

Brake shoe return


spring

Free length

Model with M2S5


T/M

98

Load N
(kgf)/installed
length

Model with M2S5


T/M

67 ~ 86 (6.8 ~
8.8)/104

104.364
(6.5)/104

Spring A(longer
one of free
length)

Free length

Spring B(shorter
one of freel
ength)

Free length

Load N
(kgf)/installed
length
Load N
(kgf)/installed
length

Correct to limit,
replace when
limit is reached.
Correct or replace

Brake lining thickness

Shoe hold down


spring

Correction and
remarks

2.0

Adjust

34.1
59 ~ 69 (6.0 to
7.0)/13.7

Replace
Replace

59 (6.0)/13.7

23.6
59 ~ 69 (6.0 to
7.0)/10.5

Replace

59 (6.0)/10.5

GENERAL

BR -7

TIGHTENING TORQUE TABLE


Tightening torque

Description

Nm

Kgf.m

Lb-ft

Oil tank attaching bolt

3.9 ~ 5.9

0.4 ~ 0.6

2.8 ~ 4.3

Brake booster support attaching bolt

23 ~ 27

2.3 ~ 2.7

16.6 ~ 19.5

Brake pedal attaching bolt

34 ~ 54

3.5 ~ 5.5

25.3 ~ 39.7

Brake booster and brake pedal


support assembly attaching bolt

23 ~ 27

2.3 ~ 2.8

16.6 ~ 20.2

Brake pedal support assembly


to floor attaching bolt

8.8 ~ 14

0.9 ~ 1.4

6.5 ~ 10.1

Brake master
cylinder

Set bolt tightening

13 ~ 15

1.3 ~ 1.5

9.4 ~ 10.8

Brake booster

Clevis lock nut tightening

19 ~ 23

1.9 ~ 2.3

13.7 ~ 16.6

Front wheel brake

Connector attaching

20 ~ 28

2.0 ~ 2.9

14.4 ~ 20.9

Brake tube nut tightening

13 ~ 18

1.3 ~ 1.8

9.4 ~ 13

34.5 ~ 50

3.45 ~ 5.1

24.9 ~ 36.8

Screw tightening

7 ~ 13

0.7 ~ 1.3

5 ~ 9.4

Brake tube nut tightening

13 ~ 18

1.3 ~ 1.8

9.4 ~ 13

Wheel cylinder attaching bolt

13 ~ 18

1.3 ~ 1.8

9.4 ~ 13

245 ~ 340

25 ~ 35

181 ~ 253

Backing plate tightening bolt

52 ~ 67

5.3 ~ 6.8

38.3 ~ 49.1

Brake drum and propeller shaft


flange yoke tightening nut

59 ~ 74

6.0 ~ 7.5

43.3 ~ 54.2

Main cable bracket bolt

38 ~ 59

3.9 ~ 6.0

28.2 ~ 43.3

Intermediate lever bracket bolt

38 ~ 59

3.9 ~ 6.0

28.2 ~ 43.3

Balancer bracket bolt

38 ~ 59

3.9 ~ 6.0

28.2 ~ 43.3

Hanger bolt

33 ~ 36

3.4 ~ 3.7

24.5 ~ 26.7

Cable assembly adjusting nut

18 ~ 29

1.9 ~ 2.8

13.7 ~ 20.2

Exhaust brake valve cover


attaching bolt

4.9 ~ 6.9

0.5 ~ 0.7

3.6 ~ 5.0

Power chamber attaching bolt

9.8 ~ 16

1.0 ~ 1.6

7.2 ~ 11.5

Push rod fixing nut

9.8 ~ 16

1.0 ~ 1.6

7.2 ~ 11.5

Front

8 ~ 9

0.8 ~ 0.9

5.7 ~ 6.5

Rear

15 ~ 16

1.5 ~ 1.6

10.8 ~ 11.5

Hydraulic unit mounting bolt

17 ~ 26

1.7 ~ 2.6

12.2 ~ 18.8

Hydraulic unit mounting bracket bolt

18 ~ 22

1.8 ~ 2.2

13 ~ 15.9

Six brake tubes on the Hydraulic Unit

13 ~ 17

1.3 ~ 1.7

9.4 ~ 12.2

Brake control

Wheel cylinder attaching bolt


Rear wheel brake
Parking brake

Exhaust brake

ABS

Transmission main shaft rear lock nut

Sensor mounting
bolt on the brake
plate

BR -8

BRAKE SYSTEM

COMPONENTS

E4450706

10

9
7
8

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Vacuum tank
Vacuum hose
Brake booster
Master cylinder
3-Way connector
Front wheel brake
Reservoir tank
ABS modulator
LSP valve
Rear wheel brake

4
NOTE:
1. Clean tube inside with compressed air when assembling.
2. Tighten tube nut of brake tube contacting tube flare portion by mating seat face.
3. Tightening torque of brake tube nut to be 1.3-1.7kgm
4. Install brake hose without twist and interference with near parts.
And Tightening torque to be 2.5-3.0kgm
5. Tube must not assemble with electric harness.
6. Perform air bleeding securely.(Perform LSPV side securely)
7. Tightening torque of brake bleed screw to be 0.7-0.9kgm
8. Junction to be free from oil and vaccum leaking.
9. Contact shoe to drum by turning wheel cylinder piston.
And adjust lining clearance by turning adjuster piston to opposite direction of arrow. This time, drawing tolerance
between drum and lining to be 50kgcm
10. Assemble brake assembly to axle with same color LH, RH marking in lining side.

ECOBR5001A

GENERAL

BR -9

1
2

AIR

3
7
8
6

Vacuum Tube
Vacuum Hose
Oil Tube
Oil hose

1.
2.
3.
4.
5.
6.
7.
8.

Vacuum pump
Vacuum tank
3-way magntic valve
Exhaust brake valve
Booster
Master cylinder
Oil reservoir
Check valve

ECOBR5002A

BR -10

BRAKE SYSTEM

10

AIR

3
7

10

6
5

Vacuum Tube
Vacuum Hose
Oil Tube
Oil hose

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Vacuum pump
Vacuum tank
3-way magntic valve
Exhaust brake valve
Booster
Master cylinder
Oil reservoir
ABS modulator valve
Speed wheel sensor
Check valve

ECOBR5003A

GENERAL

BR -11

1
9

AIR

3
7
9
6

Vacuum Tube
Vacuum Hose
Oil Tube
Oil hose

1.
2.
3.
4.
5.
6.
7.
8.
9.

Vacuum pump
Vacuum tank
3-way magntic valve
Exhaust brake valve
Booster
Master cylinder
Oil reservoir
L.S.P.V
Check valve

ECOBR5004A

BR -12

BRAKE SYSTEM

To vacuum tank

Diaphragm plate

Vacuum valve
Valve body
Input rod

Silencer
Valve plunger
Air valve

Output rod

Diaphragm

ECOBR5005A

GENERAL
DESCRIPTION

BR -13
EBB7B828

BRAKE SYSTEM
The service brakes are internally expanding type hydraulic brakes acting on all wheels. The brakes for the
front wheels are 2-leading type and those for the rear
wheels are duo-servo or dual 2-leading type.
The brake booster gives faster hydraulic pressure buildup.
Tandem type brake master cylinder also contributes to
safety. The brake pedal, which is easy-to-operate pendant
type, transmits depression force via operating rod, etc.
to the BRAKE BOOSTER, which boosts it and drives the
master cylinder.
The BRAKE BOOSTER vacuum line is equipped with a
vacuum tank which minimizes negative pressure change
even in the case of repeated and frequent braking operation.
BRAKE BOOSTER
1.

When not in Operation


When not in operation, no force acts on the operating
rod and hence the valve plunger is seated on the poppet to open the negative pressure valve and to close
the atmospheric valve.
Negative pressure generated by the engine draws
out air from the chamber on the left side of the diaphragm plate. And as the chamber on the right side
of the diaphragm plate is also evacuated via the vacuum channel and the negative pressure valve that is
opened. As a result, the diaphragm plate is pressed
tightly onto the rear shell surface by the diaphragm
plate return spring. Atmosphere goes through the air
filter into space around the operating rod but does
not flow further as the atmospheric valve of the valve
plunger is closed.

2.

When in Operation
When the brake pedal depression force overcomes
the valve return spring force, the operating rod, valve
plunger and poppet now move to the left and the
poppet is pressed tightly onto the valve plunger seat
by the poppet spring, closing the negative pressure
valve. When the brake pedal is further depressed following closure of this valve, the valve plunger clears
the poppet to open the atmospheric valve and atmosphere now flows through the channel into the chamber
on the right side of the diaphragm.
This flow of atmosphere produces the pressure difference across the diaphragm and the force resulting
from such pressure difference overcomes the piston
return spring force. As a result, the diaphragm pushes
the push rod as it moves from right to left. The push
rod thus pushes the master cylinder piston, generating high fluid pressure from low pedal depression
force.

KMTBR5501A

BRAKE MASTER CYLINDER


1.

Normal Operation
The tandem type brake master cylinder has independent hydraulic systems for front and rear brakes.
Should one of the two hydraulic systems fail, braking by survived system (front or rear wheels) ensures
safety. When the brake pedal is depressed, the primary piston is pushed to left, developing hydraulic
pressure in the pressure chamber on the primary side.
This pressure directly acts on the secondary piston
to push the secondary piston to left, developing hydraulic pressure also in the pressure chamber on the
secondary side. As a result, each piston pressurizes
brake fluid to generate hydraulic pressure in both front
and rear brake systems.

Primary piston

Secondary piston

EMTBR5002A

2.

When fluid leaks are caused in front brake system


In this case, depression of the brake pedal to push the
push rod does not develop hydraulic pressure as the
brake fluid leaks from the front brake system. Therefore, the primary piston compresses the primary return spring and the retainer pushes the secondary piston, which then pressurizes brake fluid in space between the secondary piston and cylinder body, thus
generating hydraulic pressure in the rear brake system only.

BR -14

BRAKE SYSTEM
friction between the lining and drum causes the shoe to
try to turn with the drum, thus boosting the braking force.

Piston

Primary piston

Brake
drum

Wheel
cylinder

Secondary piston

Lining
Shoe
EMTBR5003A

3.

When fluid leaks are caused in rear brake system


In this case, when the brake pedal is depressed to
push out the push rod, the secondary piston end
comes into contact with the cylinder body since brake
fluid in the rear brake system leaks. When the push
rod is further pushed, the primary piston pressurizes
brake fluid in the space between the primary and
secondary pistons, generating hydraulic pressure in
the front brake system only.

FRONT AND REAR WHEEL BRAKES


FRONT WHEEL BRAKES
The wheel cylinder is so constructed that the piston extends in one direction only to push the shoes which are
held down to the backing plate by the shoe hold down pin.
The return springs mounted on the shoe fixed and moving
sides cause contraction of the shoe and wheel cylinder
piston when the brake is released.
When the vehicle is running forward, both shoes work as
leading shoes.

REAR WHEEL BRAKE


DUAL 2-LEADING BRAKE
The wheel cylinders are installed at front and rear and the
pistons extend in both upward and downward directions to
push the shoes from both directions. The shoes are held
down to the backing plate by shoe hold down pins and the
return springs mounted on the shoes causing contraction
of the shoe and wheel cylinder piston when the brake is
released. During both forward and reverse operation of
the vehicle, the shoes work as leading shoes.
Shoe

Shoe return
spring

Shoe return
spring

Wheel
cylinder
assembly

Shoe

Shoe return
spring

EMTBR5005A

Shoe return
spring

Shoe inspection hole


EMTBR5004A

Wheel
cylinder
assembly

When the pedal is depressed, brake fluid supplied under


pressure from the master cylinder enters the wheel cylinder, of which piston causes the shoe to expand in both directions to press the lining against the drum inside. Resultant friction between the lining and drum causes the shoe
to try to turn with the drum, thus boosting the braking force.

Shoe inspection hole


EMTBR5004A

When the pedal is depressed, brake fluid supplied under


pressure from the master cylinder enters the wheel cylinder, of which piston moves the shoe moving side so that
the lining is pressed against the drum inside. Resultant

GENERAL

BR -15
Brake drum
Shoe

Lining
Piston
Wheel
cylinder

Lining
Piston

Shoe

Piston cup

Brake drum
EMTBR5006A

WHEEL CYLINDER

EMTBR5008A

2.

The wheel cylinder driven by hydraulic pressure generated by the brake master cylinder presses the shoe (lining)
against the brake drum.
There are following two types of wheel cylinder according
to the method of pushing the shoe.

Dual 2-reeding type : rear brake


Brake drum
Shoe

Lining

Piston cup
Adjusting screw

Piston

Spring sheet

Piston cup
EMTBR5009A

Adjuster

Piston

BRAKE FLUID LEVEL SENSOR

EMTBR5007A

1.

2-reeding type : Front brake


In pedaling brake, oil pressure rising is master cylinder goes into wheel cylinder and pushes piston. Shoe
contacting with the end of piston sticks to brake drum
and generates frictional force.

The brake fluid level sensor installed in the brake fluid tank
senses the brake fluid level in the tank. When the fluid level
drops to a preset level, the sensor operates to turn on the
warning lamp in the cluster to warn low brake fluid level.
Cap

Float

Reed switch
EMTBR5010A

BR -16

BRAKE SYSTEM

EXHAUST BRAKE

OFF
Vacuum chamber

Vacuum tank
3-way magnet
valve in ON
Exhaust brake

Intake shutter

Exhaust brake valve


Engine

Accelerator pedal switch ON


Accelerator pedal switch OFF

Fuse
Battery
1 : Clutch switch
Clutch switch ON in not pedaling clutch
Clutch switch OFF in pedaling clutch

Exhaust brake switch


Cold-start switch

NOTE:
Intake shutter system

ECOBR5006A

The exhaust brake system, as an assistant function of the


service brake, comprises of the exhaust brake device installed at the middle portion of the exhaust pipe and the
intake shutter installed at the intake manipulate to reduce
the intake air noise.
When the exhaust brake device close the butterfly valve,
the pressure inside of the pipe increases. This increased
pressure influences to the piston to get the braking force.
At that time, the intake shutter is also closed. When the
clutch pedal, the accelerator pedal or the exhaust brake
switch is released, the electric circuit is OFF and the exhaust brake is released.
The exhaust brake is the vacuum type assistant device
which uses the negative pressure.

GENERAL

BR -17

INTAKE SHUTTER

2.

When the exhaust brake is operating, the intake shutter(A)


reduces the amount of the intake air through the intake
manipulate so as that the exhaust pressure is operated to
the piston effectively. As a result, the noise will be reduced
and the brake will be more effective.

At releasing
If the exhaust brake switch, the clutch switch and the
accelerator switch are OFF, the 3-way magnetic valve
closes the circuit to the vacuum tank and opens the
atmosphere circuit.
Therefore, the atmospheric pressure is applied to the
exhaust brake unit. Due to the spring tension, the butterfly valve is opened. The exhaust brake is released.

A
Connector

Spring
Diaphragm plate
Retainer
Push rod
Adjusting bolt
(When close,
adjust space correctly)
KMTBR5513A

Adjusting bolt
(When open with maximum)
EMTBR5013A

EXHAUST BRAKE UNIT


1.

Butterfly
valve

At Working
If the exhaust brake switch is ON, the three-way magnetic valve is opened. The vacuum pressure of the
vacuum tank is applied to the exhaust brake unit so
as to pull the piston.
As a result, the butterfly valve linked to the push rod
is closed so that the exhaust brake is working.

Butterfly valve

EMTBR5012A

BR -18

BRAKE SYSTEM

THE 3-WAY MAGNETIC VALVE


1.

At working
If the exhaust brake switch is ON, an electric current
will flow through the coil and then a magnetic field
is formed. The magnetic force pulls the plunge to
upward. At that time, the valve seat at the plunger
closes the way to the atmosphere pressure while it
opens the way linking the vacuum tank and the brake
chamber.

Magnetic coil

Plunger

From exhaust
brake unit

To vacuum tank
(negative pressure)

EMTBR5014A

2.

At releasing
If the exhaust brake switch is OFF, the electric current flowing through the coil is shut down. Due to the
spring tension, the plunger will be pushed so as to
close the way to vacuum tank while the way to the atmosphere pressure and the brake chamber.
Atmosphere

Plunger spring

Exhaust brake
unit

EMTBR5060A

GENERAL

BR -19

LOAD SENSING PROPORTIONING VALVE

3
2

1. LSPV assembly
2. Bleeder screw
3. Bracket

4. Lever assembly
5. Sensor spring
6. Spring guide

7. Adjusting nut
8. Operating lever
9. Connecting link assembly
EMTBR5015A

BR -20

BRAKE SYSTEM
2.

LSPV is consist of sensor part and pressure controller


part.
1.

2.

Sensor part
It consists of spring, operating lever, link. It senses the
height of vehicle with varing according to the amount
loads
Pressure controller part
It consists of valve stem mechanism for proportioning
control of sensor force.

Full Load Characteristic

Loaded status
The sensor spring presses the valve stem strongly, so
the brake fluid pressure is setted highly.
NOTE
Dont loose or dont retight the adjusting nut crimping.

Output Pressure

CONSTRUCTION

Pc

Input pressure
Output
Pressure

Empty Characteristic

EMTBR5017A

SERVICE AND INSPECTION OF THE LSPV

Input Pressure

Check the LSPV as below when replace the sensor spring,


valve body assembly or reinstall the rear axle,rear spring.
EMTBR5016A

OPERATING PRINCIPAL
LSPV body is mounted in the frame and the end of the
link is mounted in the rear axle. With varying of amout
of vehicle load changes the relative position of frame and
rear axle, so sensor spring force varies to the valve stem.
It controls the rear axle brake fluid pressure.
1.

Symptom
Braking force is
insufficient

Unloaded status
The sensor spring presses the valve stem slightly, so
the brake fluid pressure is setted weakly.
Rear brake is
lock too fast

Probable Cause

Remedy

Insufficient air
bleeding

Air bleeding

Maladjust
sensor spring

Readjust

Sensor spring
broken

Replace valve
assembly

Oil leakage in
the brake fluid
line or LSPV
assembly

Tighten brake
fluid line or
replace LSPV
assembly

Maladjust
sensor spring

Readjust

Inner fault the


LSPV

Replace LSPV
assembly

GENERAL

BR -21

PARKING BRAKE GENERAL

Adjusting nut
Parking brake cable assembly
(M035S5 T/M)
Parking brake drum

Parking brake cable assembly (M2S5, M3S5 T/M)

Parking brake lever assembly

ECOBR5007A

The parking brake installed behind the transmission is an


internal expansion type acting on the propeller shaft.
It controls propeller shaft rotation to work as a parking
brake.
The control is wire mechanical type; brake shoes are
pressed via a wire to controll the propeller shaft.

BR -22

BRAKE SYSTEM

PARKING BRAKE PROPER


When the lever at the drivers seat is pulled, the cam lever
is actuated via a wire cable and resultant cam rotation
causes the brake shoes to expand and be forced against
the brake drum. The braking force is thus obtained by friction between the shoes and drum. When the lever is released, the cam lever returns to the initial position and the
braking force is released by the brake shoe return springs.
Cam lever

EMTBR5019A

GENERAL
DIAGNOSIS
Symptom
Irregular
Braking Force

After releasing
the brake
pedal, the
braking force is
release too late.

Unbalance at
the right and left
braking force

BR -23
E6F72854

Remedy

Causes
The air pressures of tire are different.

Adjust the air pressure of tire

The sizes of the right and left tires are different.

Replace the tire.

The adjustment of the wheel bearing


is defective.

Adjust (Check the wheel bearing)

The sizes of the right and left wheel


bases are different.

Check and adjust the loosening the


U-bolt or damages on center bolt.

The wheel alignment is defective.

Adjust

The vertical surface of the back plate is rough.

Replace the back plate or check


the lining.

The operation of the wheel cylinder


is defective.

Check the contacting, the piston


cup and wearing status. If needed,
replace it. Check the lining.

The return spring is damaged

Replace the spring

The surface of the lining is contaminated


by the oil, grease or water.

If it is contaminated by oil or grease,


then replace it. If it is contaminated
by water, dry it.

The lining is defective or The material


of lining is improper.

Replace or adjust.

The wear is irregular. The surface is rough.

Replace the lining. Check the inside


of the drum, if needed, replace it.

The lining contact is defective.

Adjust the lining with being installed.

The brake drum is worn irregularly.

Adjust or replace it.

Unstable
braking force

The brake drum is deformed.

Replace

The back plate is deformed or loosened.


The vertical surface of it is rough.

If it is loosened, tighten with specified


torque. Otherwise, replace

Improper Lock
Point

The drum is worn.

Adjust or Replace

The lining is worn irregularly.

Adjust

The lining contact is defective

Adjust with being installed.


(Temperature of lining should be
less than 100 C)

Remark

Drum
limit STD
:
Dia+2mm

BR -24

BRAKE SYSTEM

Symptom
Low Braking
Force

The clearance
between the
pedal and the
floor is too
narrow.

During braking,
the noise and
shock are made
abnormally.

Remedy

Causes
The clearance between the brake
pedal and floor is 45mm or more (at
Pressure-600mmHg, Pressure 50kg)

Refer to the item for decreasing


the clearance between the brake
pedal and floor.

The lining contact is defective

Adjust with being installed not being


disassembled (Temperature should
be 100 C or less)

The surface of the lining is contaminated


by the oil, grease or water

If it is contaminated by oil or grease,


then replace it. If it is contaminated
by water, dry it.

The lining is deteriorated.

Replace the lining.

The vacuum force is too low.

Check the pipe or the vacuum pump.


If needed, replace.

The drum surface is rough.

Adjust or Replace

The brake booster is defective.

Adjust or Replace

The brake oil level is too low.

Refill

The air intrudes.

Air Exhausting

Vapor lock

Referring to the brake drawn item, adjust


or replace. And then exhaust the air.

The adjustment on pedal is defective.


The clearance is too large.

Adjust the pedal clearance. Check


the total stroke.

The shoe clearance is too large.

Adjust the shoe clearance.


If the wear exceeds the limit, replace.

The cup of the master cylinder is defective.

If the tightening does not satisfy the


specifications, replace the kit.

The brake shoe is deformed or damaged

Replace

The brake booster is defective.

Replace

When the wheel is


rotating with being
lifted by jack, there
are some noises.

Foreign materials
in drum

Check that the brake is damaged.


Remove the foreign materials.

Return spring is
damaged.

Check that the parts are damaged by


broken parts. If needed, replace.

Hold down cup is


damaged

Check that the parts are damaged by


broken parts. If needed, replace.

Improper adjustment
on wheel bearing

Check the rotating surface. Adjust

The lining is worn

Replace

During braking (at


low speed), noise is
made continually.

The grease is deficiency in sliding parts.

Apply the grease.

The drum inside surface is rough.

Modify the inner surface with


sand paper.

The drum is cracked.

Replace

Remark

GENERAL
Symptom
The drum is
overheated.

BR -25

The outlet of the brake master cylinder


is clogged.

If the booster operating rod is not


properly adjusted, adjust the pedal
clearance of the rod clevis to 10~15mm.

The brake does not return.

Check the burst of the return spring, the


bearing lubricant, the stop lamp switch
adjustment. If needed, adjust.

The booster is defective.

Replace

The vertical surface of the back plate


is scratched.

If the surface is too rough, replace.


If it is too dry, apply the grease.

The wheel cylinder piston cu is defective.

Replace

The oil return has problems due to the


over tight of the brake pipe nut.

Check the connector hole diameter.


If it is reduced, replace.

When the wheel is


rotating with being
lifted by jack, the
wheel is hard to
rotate.

The pedal
returning is
defective.

Brake is
vibrating.

Brake is drawn.

Remedy

Causes

The wheel bearing


clearance is too large.

Replace bearing or adjust.

Shoe clearance is
improper.

Adjust

Return spring is
defective.

Check the part damages due to the


spring over working. If needed replace.

Brake shoe is worn

Replace

The pedal linkage is rusted or deformed

Disassemble. Adjust or replace.


Oil the grease.

It is bursting due to the defectives on


the pedal return spring.

Replace

The booster operating rod is pushed.

Adjust the pedal clearance with


10~15mm.

The drum is eccentrically centered.

Replace

The drum is deformed.

Replace

The king pin bushing is worn

Replace the bushing

The hub bearing is worn.

Adjust (Check the rolling surface)


or replace.

The pedal clearance is too narrow.

Adjust the booster working rod.

The shoe clearance is improper.

Adjust

The back plate vertical surface is rough

Replace the back plate

The shoe spring is burst.

Replace

The master cylinder or wheel cylinder piston


cup is deteriorated and swelled.

Replace

Remark

Specific
wheel
is over
heated.

BR -26

BRAKE SYSTEM

Symptom
Brake makes
noises.

Exhaust brake
does not work.

Exhaust brake
can not be
released.

Remedy

Causes
Brake shoe contacting is defective.

Adjust the lining with being installed


not being disassembled (Temperature
should be 100 C or less)

Lining is deformed.

Replace the lining. Replace the drum


if it has hardened surface.

Drum has hardened surface.

Replace.

Shoe is deformed.

Replace.

Back plate is deformed or installed improperly.

Replace or adjust

Front bearing is loosened.

Adjust (Check the rolling surface)

Powder from the wear of the lining is adhered.

Clear

Lining is worn.

Replace.

Vacuum pressure is improper.

Check the vacuum pump or piping.


If needed repair.

Electric circuit is defective.

Check the clutch switch, the micro


switch and the exhaust brake circuit.
If needed, repair.

Vacuum pipe is damaged.

Replace.

3-way magnetic valve does not work.

Replace.

Exhaust brake valve does not work.

Replace.

Exhaust brake valve shaft is adhered.

Replace.

Power chamber is defective.

Disassemble and check.

3-way magnetic valve does not work.

Replace.

Exhaust brake valve does not work.

Replace.

Exhaust brake valve shaft is adhered.

Replace.

Electric circuit is defective.

Check the clutch switch, the micro


switch and the exhaust brake circuit.
If needed, repair.

Remark

GENERAL

BR -27

DIAGNOSIS (PARKING BRAKE)


Symptom
Parking brake
does not work.

Causes
Operating
mechanism has
a problem.

When pulling the parking brake


with 30kg, there is no lever stroke
clearance and shoe clearance.

Adjust the shoe clearance and cable

The locking status between


the lever lock latch and Rachet
pull is improper.

Adjust the Rachet pull lock status.


Replace it

Wire is broken or elongated.

Replace the cable.

Tolerance between the shoe


clearance and the brake lever
pulling is too large.

Adjust the shoe clearance.

Drum inner surface is deformed


or twisted.

Repair the drum inner surface.


Replace the lining.

Lining is irregularly worn. Drum


inner surface is contacted
irregularly.

Replace the lining.

The oil of drum and lining


is contaminated.

Clear the inner surface of the drum.


Replace the lining.

Operating
mechanism has
a problem.

Return spring is damaged.


The tension of the return
spring is inferior.

Replace the return spring.

The inner cable does not


move smoothly.

Replace the cable.

After the parking brake is


released, the brake is operating.

Adjust the pulling tolerance limit.

Parking
brake is
defective.

Return spring is damaged.


The tension of the return
spring is inferior.

Replace the return spring.

The shoe clearance is too narrow.

Adjust the shoe clearance.

Parking
brake is
defective.

Parking brake
can not be
relesed.

Remedy

Remark

ON-VEHICLE INSPECTION AND


ADJUSTMENT E274E72C
AIR BLEEDING OF THE BRAKE
1.

Fill up the brake oil tank with the brake oil at the maximum level. During the air bleeding, if the level is lowered, refill the brake oil.
CAUTION
Be careful that the brake oil does not drop on
the painted surface. If the brake oil contacts the
painted surface, immediately wash it by water.
KMTBR5518A

2.

Connecting an end of transparent vinyl tubes at the


air breather of the front wheel cylinder and the rear
wheel cylinder, put the other end of the tubes into the
transparent container having the brake oil.

BR -28
3.

BRAKE SYSTEM

Step on the brake pedal several times. Pressing the


brake pedal at half, loosen the air bleeder screw to
evacuate the air with the brake oil.
And then, pressing the pedal until it reaches to the
floor, tighten the air bleeder screw. Release the pedal.
There procedures should be repeated until any air
bubble is not shown in the brake oil.

ADJUSTMENT OF BRAKE SHOE GAP


1.

Using the screw driver(A), turn the wheel cylinder


adjuster(B) to the shoe expansion direction until
the drum is not rotate anymore. Turn the adjuster
reversely with the following notch number. (At that
time, the drag torque between the lining and the drum
should be less than 50kgf.m).

KMTBR5519A

4.

KMTBR5521A

Tighten the bleeder screw

The Notch Number for reverse rotation of the Adjuster.


Tightening Torque for the bleeder Screw
Front: 6.9~8.8Nm(0.7~0.9kgf.m, 5.1~6.5lb-ft)
Rear : 6.9~8.8Nm(0.7~0.9kgf.m, 5.1~6.5lb-ft)
5.

Step on the brake pedal several times. Pressing the


brake pedal at half, loosen the air breather screw to
evacuate the air with the brake oil.
And then, pressing the pedal until it reaches to the
floor, tighten the air breather screw. Release the
pedal. There procedures should be repeated until any
air bubble is not shown in the brake oil.

KMTBR5520A

Front Wheel Cylinder

4 ~ 6

Rear Wheel Cylinder

4 ~ 6

VACUUM ASSISTED HYDRAULIC BRAKE

BR -29

VACUUM ASSISTED
HYDRAULIC BRAKE
BRAKE BOOSTER
COMPONENTS

EC3D367F

1
5
2

17.7~21.6(1.8~2.2, 13.0~15.9)

Tightening torque : Nm(kgf.m, lb-ft)

1. Clevis pin
2. Hose connector
3. Grommet
4. Master cylinder

5. Booster
6. Pedal assembly
7. Return spring

EMTBR5059A

BR -30

BRAKE SYSTEM

REMOVAL

4.

E38736B6

1.

Loosen the bolt for mounting of the steering column


assembly. Put the steering column down.

2.

Loosen the bolt(A), Remove the instrument panel(B).

Loosen the 2 bolts for mounting the master cylinder.


Disassemble the reservoir hose and the brake tube.
Remove the master cylinder.

KMTBR5524A

A
KMTBR5003A

3.

Taking out the brake hose linking between the brake


oil and the master cylinder, evacuate the brake oil.
Also, taking out the clutch hose of the clutch master
cylinder, evacuate the brake oil.

5.

Remove the brake booster and the master cylinder.

6.

Remove the booster clevis pin (A) installed at the


brake pedal assembly.
Loosen the booster mounting nut (C) from the pedal
support member (B). Remove the booster.

CAUTION

As the brake oil could be harmful to the painted


surface, if the body is contaminated by the brake
oil, clean it out with water or soap water.

KMTBR5004A

KMTBR5523A

VACUUM ASSISTED HYDRAULIC BRAKE


INSTALLATION
1.

E11406D5

Insert the clevis pin (A) into the brake pedal. Fix the
split pin firmly.

KMTBR5004A

2.

Tighten the booster mounting nut (C) at the pedal support member (B).

3.

Connect the vacuum hose to the booster.

4.

Assemble the master cylinder to the booster. Connect


the reservoir hose and the brake tube.

5.

Assemble the instrument panel. Install the steering


column.
CAUTION
-

After installing the brake booster, adjust the


height of the brake pedal and the free play
clearance.
When installing, the snap pin and the clevis
pin are should be replaced new ones.
Apply the recommended grease on the clevis
pin and the washer.

6.

Fill the reservoir with the brake oil. Perform the brake
air bleeding.

7.

Check the brake oil leakage.

BR -31

BR -32

BRAKE SYSTEM

INSPECTION

EF7805A9

There are two methods for inspecting the booster. The one
is not to use the tester, the other is to use a simple tester for
inspecting the characteristics. These two methods can be
performed on vehicle. Before the inspection, check if the
brake pipe and the hose are connected tightly or damaged.

KMTBR5525A

Engine Start

Engine Stop

Just after the engine is stop, remove the pipe and vacuum hose clamp.

Put the hose to your mouth

During sucking, you feel


the air flow when the
pedal is pressed.

Yes
Normal

(opened valve) (closed valve)

No
Defective

When blowing air into


hose, air flow is stop.
(closed valve)

Yes
Normal

No
Defective

EMTBR5020A

CAUTION
Be careful that a sharpen material does not
intrude into the check valve.
Check at the opened sate and at the closed
state of the valve.
If it is replaced with kit, do not replace the
check valve.

VACUUM ASSISTED HYDRAULIC BRAKE

BR -33
1.

TEST FOR TEMPORARILY OPERATING OF


BOOSTER
The followings are for checking the general functions of the
booster.
CAUTION
If the booster has problem, it should be replaced in assembly because it can not be disassembled for repair.

Method without tester


After checking the following three-items, if they are
all normal, then most functions of booster would be
normal. If one of following items has a problem, the
booster may have been damaged.
Check Valve
Vacuum Hose
Booster

Engine Start

After running for 2~3 minutes, stop the engine

Press the brake pedal with regular force.

At the first pressing, the stroke is the longest. After that,


the stroke will be getting shorter.
Yes

No

Normal

Defective

Engine is stop

Engine is running

Press the brake pedal several times

Step on the brake pedal

With pressing the pedal, start the engine

Stop the engine

Pedal is pressed down slightly.


Yes
Normal

Press the pedal for 30 seconds.


No

Defective

The height of pedal is changed.


Yes
Normal

No
Defective

EMTBR5021A

BR -34
2.

BRAKE SYSTEM

Method for test using a simple tester


As shown in following figures, connect the vacuum
gauge, the pressure gauge and the stepping (foot
pressing) power gauge. Test in the following sequence.
If it lease one of two among the gauges shows abnormal valve, the following components may have a
problem.

Vacuum hose
Booster
Check Valve

Engine Start

When the vacuum gauge is 67kmmHg, press the pedal

Measure the oil pressure of the stepping force gauge and the pressure gauge

Pressure of the Stepping


Force Gauge

Pressure of the Pressure


Gauge

Remark

10kg

31kg/cm

Booster: 257.8mm

30kg

81kg/cm

Booster: 257.8mm

Yes

No
Defective

Normal

Engine Stop

When the vacuum gauge is 0kmmHg, press the pedal

Measure the oil pressure of the stepping force gauge and the pressure gauge

Pressure of the Stepping


Force Gauge

Pressure of the Pressure


Gauge

Remark

10kg

4kg/cm

Booster: 257.8mm

30kg

17kg/cm

Booster: 257.8mm

Yes
Normal

No
Defective
EMTBR5022A

VACUUM ASSISTED HYDRAULIC BRAKE

BR -35

BRAKE PEDAL
COMPONENT

EBE8BA10

1
5
2

17.7~21.6(1.8~2.2, 13.0~15.9)

Tightening torque : Nm(kgf.m, lb-ft)

1. Clevis pin
2. Hose connector
3. Grommet
4. Master cylinder

5. Booster
6. Pedal assembly
7. Return spring

EMTBR5059A

BR -36

BRAKE SYSTEM

REMOVAL

INSTALLATION

E628D2F9

1.

Loosen the steering column assembly mounting bolt.


Pull down the steering column.

2.

Loosen the bolt(A), Remove the instrument panel(B).

1.

Install the brake pedal assembly(A) to the bracket(B).


CAUTION
Before the assembling, apply the grease inside of
the brake pedal assembly pipe.

E94CBB4D

A
B

A
KMTBR5003A

3.

Remove the master cylinder (Refer to the BR-"Master


cylinder")

4.

Remove the
BR-"Booster")

brake

booster

(Refer

to

the

5.

Remove the brake light switch.

6.

Remove the shaft bolt(A) connected to the bracket.

KMTBR5527A

2.

Install the brake light switch.

3.

Install the booster and the master cylinder.


CAUTION

KMTBR5040A

Apply the grease on the clevis pin and the washer

VACUUM ASSISTED HYDRAULIC BRAKE


ADJUSTMENT

GAP BETWEEN THE BRAKE PEDAL AND THE


FLOOR.

E45B8B7B

ADJUST THE HEIGHT OF THE BRAKE PEDAL


1.

BR -37

1.

Turn the booster operating rod so that the distance


from the center of the brake pedal pad to the A point
of the instrument panel lower portion is the 2493mm.
After adjusting, fix the clevis with the nut. Check that
the maximum stroke of the pedal is more than 180mm
(before filling the brake oil)

After cranking the engine, check if the gap between


the floor and the pedal is more than 45mm by pressing
the pedal with 50kg.

45mm or More

A
249

EMTBR5023A

BRAKE LIGHT SWITCH


1.
162

Adjusting the gap between the end of the brake. Light


switch screw and the pedal stopper to 0~1mm, tighten
the locknut.

KMTBR5528B

Stopper

FREE PLAY CLEARANCE OF THE BRAKE PEDAL


1.

Setting the brake pedal to the original position, check


if the free play(B) clearance is 5mm at least by pressing the pedal(A).
If the clearance excesses the reference, re-adjust the
position of the brake pedal.

Pedal

Locknut

CAUTION
When checking the free play clearance of the
brake pedal, the master back negative pressure
should be 0.

0~1mm

Stop tamp switch

EMTBR5024A

KMTBR5005A

BR -38

BRAKE SYSTEM

BRAKE MASTER CYLINDER


COMPONENTS

ED050718

15

16
17

19

14

18

13
12
11
9
4

10

5
6
7
8
2
1

1.
2.
3.
4.
5.
6.
7.

Cir-clip
Primary piston
Seal
Stem
Spring sheet
Primary spring
Spring sheet

8.
9.
10.
11.
12.
13.
14.

Recup seal
Secondary piston
Seal
Seal
Spring sheet
Secondary spring
Cylinder body

15.
16.
17.
18.
19.

Connector
Oil seal
Stop pin
Screw
Washer

EMTBR5025A

VACUUM ASSISTED HYDRAULIC BRAKE


REMOVAL

BR -39
5.

EC4A3E6C

1.

Loosen the steering column assembly mounting bolt.


Put down the steering column.

2.

Loosen the bolt(A), Remove the instrument panel(B).

Remove the 2 of master cylinder bracket nuts connecting to the booster.

A
A

KMTBR5042A

KMTBR5003A

3.

6.

Disassemble the 1st piston assembly.

Take out the brake hose installed between the brake


oil tank and the master cylinder. Evacuate the brake
oil. Take out the clutch hose of the clutch master cylinder. Evacuate the brake oil.
CAUTION
If the painted surface is contaminated by the
brake oil, the painted surface may be damaged.
Clean out the brake oil from the body with water
or soap water. Be careful that the brake oil does
not contact you.

Primary Spring
Primary piston
EMTBR5026A

7.

Taking off the stopping, disassemble the 2nd piston


assembly.
CAUTION
Check if the master cylinder inner surface and the
piston surface. If any one is damaged, replace it
in assembly unit.

KMTBR5524A

4.

Remove the tubes connecting to the front brake and


the rear brake.

BR -40

BRAKE SYSTEM

INSTALLATION
1.

EC1A8112

After assembling the 2nd piston assembly(A), fix it


with the stop pin(B).
CAUTION
Clear the inside of the cylinder or piston with the
brake oil or alcohol. When assembling, apply the
brake oil at piston and seal.

KMTBR5044A

2.

Assemble the 1st piston assembly(C). When assembling piston, assemble the retainer seal and recup
seal align with the arrow direction to prevent the recup seal from being damaged. (Use only DOT3 for
the brake oil.)

KMTBR5531A

3.

Install the master cylinder at the booster.

4.

Connect the two brake tubes. Connect the two brake


tubes to the reservoir tank.

5.

After installing the master cylinder, perform the air


bleeding.

VACUUM ASSISTED HYDRAULIC BRAKE

BR -41

LOAD SENSING PROPORTIONING


VALVE(L.S.P.V)
COMPONENTS

E871B7DC

3
2

1. LSPV assembly
2. Bleeder screw
3. Bracket

4. Lever assembly
5. Sensor spring
6. Spring guide

7. Adjusting nut
8. Operating lever
9. Connecting link assembly
EMTBR5015A

BR -42

BRAKE SYSTEM

REMOVAL
1.

E1B9538C

Remove the brake tube(A) connecting to the LSP


valve.
A

KMTBR5557A

2.

Remove the LSP valve mounting bolt and nut.

SERVICE AND INSPECTION OF THE


LSPV E69981E8
1.

Check the LSPV as below when replace the sensor spring, valve body assembly or reinstall the rear
axle,rear spring.
1)

Braking force is insufficient


Remedy

Probable Cause
Insufficient air bleeding

Air bleeding

Maladjust sensor spring

Readjust

Sensor spring broken

Replace valve assembly

Oil leakage in the brake


fluid line or LSPV assembly

Tighten brake fluid line or


replace LSPV assembly

2)

Rear brake is lock too fast

Probable Cause

Remedy

Maladjust sensor spring

Readjust

Inner fault the LSPV

Replace LSPV assembly

FRONT BRAKE ASSEMBLY

BR -43

FRONT BRAKE ASSEMBLY


DISC BRAKE
COMPONENTS

ED4FC603

6.9~12.7
(0.7~1.3, 5.1~9.4)
9

10
11
12

3
4

13

5
6
8

14
15
16
17

18

19

Tightening torque : Nm(kgf.m, lb-ft)

1.
2.
3.
4.
5.
6.
7.

Brake disk
Hub
Bearing
Clow washer
Nut
Nut cab
Cottor pin

8.
9.
10.
11.
12.
13.
14.

Grease cap
Sleeve plug
Sleeve bolt
Sleeve boot
Sleeve
Piston seal
Caliper bridge

20
15.
16.
17.
18.
19.
20.
21.

21
Caliper housing
Piston
Boot
Retaining ring
Retaining pin
Brake pad
Pad spring
EMTBR5027A

BR -44
REMOVAL

BRAKE SYSTEM
E37F8626

1.

Parking the car, remove the front tire. (Refer to the


PA-"Front Axle")

2.

After taking off the clip(A), remove the retaining


pin(B).

KMTBR5535A

5.

CAUTION
Fix the hose to prevent the brake oil from flowing
out.

KMTBR5533A

3.

Loosen the bolt. Remove the flexible hose(A) from the


caliper.

Remove the pad spring(A).

KMTBR5536A
KMTBR5534A

4.

Remove the pad and the spacer(A) from the caliper


housing.

6.

After loosening the 4 bolts(A), remove the bridge from


the caliper housing.

KMTBR5537A

FRONT BRAKE ASSEMBLY


7.

BR -45

Loosing the fixing bolt(A) of the caliper housing, remove the housing.

3.

After inserting the retaining ring, install the clip.

4.

Install the caliper housing(A) to the knuckle.

B
KMTBR5538A
KMTBR5538A

INSTALLATION
1.

5.

EAA60C6D

Install the bridge(A) to the caliper housing.

Install the pad to the caliper housing with being the


warning indicator to the lower portion.
CAUTION
Do not contaminate the surfaces of the pad and
disk with oil and dust.

2.

Install a new pad spring and a new retaining pin(A).

A
KMTBR5537A

KMTBR5533B

BR -46
6.

BRAKE SYSTEM

Install the flexible hose(A).

2.

Using a driver, remove the cylinder boot.

CAUTION
When installing, be careful that the hose is
not twisted.
If the brake oil is leaked, clear it perfectly.

KMTBR5540A

3.
A

KMTBR5536A

7.

Assemble the clip, the retaining pin, the pad spring


and the pad.

8.

Install the front wheel.

DISASSEMBLY
1.

Insert a cloth for preventing from damage between the


piston and the cylinder. Using an air gun(A), remove
the piston from the cylinder.
A

E787872C

Using a driver, remove the retaining ring(A).

KMTBR5541A

4.

Remove the piston seal(A) using a driver.

KMTBR5539A

KMTBR5542A

FRONT BRAKE ASSEMBLY


REASSEMBLY

BR -47

E8656B05

1.

Clear the piston and the cylinder with the brake oil.

2.

Insert a new piston seal(A) into the caliper cylinder


groove.

KMTBR5545A

5.

Assemble a new retaining ring(A) to the cylinder boot.


CAUTION
Be careful that the boot is not damaged.

KMTBR5543A

3.

Assemble the piston to the cylinder boot careful that


the piston(A) is not twisted.

CAUTION
When assembling the piston, be careful that the
piston seal is not damaged.
A

KMTBR5546A

6.

Assemble a new dust boot(A) to the caliper housing(B).


Install a bushing at the dust boot.
Check if the bushing can slip slightly.
B

KMTBR5544A

4.

Assemble a new cylinder boot(A) to the caliper cylinder along to the direction as shown in figure.
CAUTION
Insert the boot correctly into the cylinder groove.

KMTBR5547A

BR -48
INSPECTION

BRAKE SYSTEM
2.

E100B737

CHECK THE CALIPER PAD


1.

Remove the front wheel

2.

Check the pad thickness.

Reference Value

12.5mm

Limit Value

2.0mm

Check the disk vibration


1)

Before checking the disk vibration, firstly check


the clearance of the wheel bearing.

2)

Using a dial gauge, check the disk vibration at the


10mm position from the disk to outside.

Limit Value

0.12mm

KMTBR5548A

KMTBR5550A

CHECK THE DISK


1.

3)

If the disk vibration exceeds the limit, check the


vibration of the front axle.

4)

If the front axle vibration is less than limit, adjust


the disk vibration within the limit.

5)

If the disk vibration exceeds the limit, replace the


disk.

Check the thickness of the disk

Reference Value

35mm

Limit Value

33mm

3.

KMTBR5549A

Replace the front disk


1)

Disassemble the disk from the axle hub.

2)

Loosening the 10 bolts, disassemble the axle


lower part and the disk.

3)

Install a new disk to the axle hub.

4)

Install the axle hub to the steering knuckle.

5)

Adjust the free rod of the front wheel bearing.

FRONT BRAKE ASSEMBLY

BR -49

DRUM BRAKE
COMPONENTS

11

E582B58B

Lining thickness
NV 10.0
L 4.0

10

Wear, rough surface


(if severe, correct by grinding)

5
6
4

7
8
3

15

Score, uneven
wear, cracks of
inside surface

2
13
14

Deterioration

1
12

Installed load N (kgf)/


installed length

NV 195 to 235
(19.8 to 24.2)/190
L 175 (18)/190

Deformed shoe,
rough ledge surface

NOTE:
Use alcohol, brake fluid, or other vegetable
oil to clean rubber parts.
When alcohol is used, do not immerse for
more than 30 seconds.

Item

NV

I.D.

320mm

322mm

Out of
0.05mm
roundness

Repair kit
Brake lining kit
1.
2.
3.
4.
5.
6.
7.
8.

Return spring
Shoe hold down cup
Shoe hold down spring
Shoe hold down pin
Shoe and lining assembly
Rivet
Lining
Shoe

9.
10.
11.
12.
13.
14.
15.

Pipe
Rubber
Connector
Wheel cylinder assembly
Cover
Backing plate
Brake drum

EMTBR5028A

BR -50

BRAKE SYSTEM

REMOVAL
1.

3.

E5ABD4A3

Remove the washer (A), the outer bearing (B) and the
hub knuckle (C) from the knuckle (D).

Parking the car, remove the front tire. (Refer to the


PA-"Front Axle").
CAUTION

When removing the wheel and tire (A), be careful


that the hub bolt (B) is not damaged.
B
A
B

KMTBR5008A

4.
C

Remove the shoe hold down spring and the shoe hold
down pin. Removing the return spring, remove the
shoe and lining assembly.

Shoe

KCOWT5006A

2.

After removing the wheel cap (A), remove the split pin
(B) and the lock nut (C).
CAUTION
When removing the lock nut (C), be careful that
the washer and the outer bearing are not drop
down to the ground.

Shoe Hold
Down Pin
Shoe
Return
Spring
Wheel
Cylinder
Assembly

Shoe Return
Spring
Shoe Hold
Down Washer
Shoe Hold
Down Spring
Shoe Inspection Hole

EMTBR5029A

C
B

KMTBR5007A

FRONT BRAKE ASSEMBLY


REPLACEMENT

BR -51
2.

E454BDF1

WHEEL CYLINDER
1.

2.

After running 64,000km, check if the inside of the adjuster piston and the wheel cylinder have rusts.
Check that the dust boot is damaged. Check that the
piston cup has been worn, cracked and swelled. After
checking, if needed, replace the damaged parts.

Assemble the lining


1)

Clear the lining mounting surface of the shoe with


the specific oil.

2)

Perform the riveting with the pressure of 2100


100kg.

Loosening the screw, disassemble the adjuster piston.

Spring

Piston cup
Adjuster piston

Boot

Adjustng screw

Side end surface


Bleeder screw
KMTBR5554B

EMTBR5030A

3)

When performing the riveting, at the 0.4mm position of the side end surface, the shoe lining gap
should be 0.3mm or less. At the around of the
rivet, it should be 0.5mm or less.

4)

After checking that the brake drum and the lining


are contacted, if there is any defective, modify it
with the brake lining grinder.

Bleeder Screw Tightening Torque:


6.9~8.9Nm(0.7 ~ 0.9 kgf.m, 5.1~6.5lb-ft)
LINING
1.

Using a drill machine, drill the jointing part of the shoe


side rivet. Remove the lining.

CAUTION
Lining should be replaced in a kit.
Use the same size of the lining
Do not contaminate the lining surface with oil
or grease.

KMTBR5553A

BR -52

BRAKE SYSTEM

INSTALLATION

EA4A2729

1.

After assembling the wheel cylinder assembly, install


the shoe return spring.

2.

Install the shoe hold down spring.

Shoe
Shoe Hold
Down Pin
Shoe
Return
Spring
Wheel
Cylinder
Assembly

Shoe Return
Spring
Shoe Hold
Down Washer
Shoe Hold
Down Spring
Shoe Inspection Hole

EMTBR5029A

3.

Apply the grease at each part.

4.

For installing the drum brake, refer to the PA-"Front


Axle."

REAR BRAKE ASSEMBLY

BR -53

REAR BRAKE ASSEMBLY


DRUM BRAKE
COMPONENTS

EA680F90

Lining thickness
N 10.0
L 4.0
10

Wear,
rough surface
(if severe, correct by grinding)

6
7
8

12

Item
I.D.
Out of
roundness

NV

12.6

12.7

0.002

14

Score, uneven
wear, cracks of
inside surface

4
12
13

11

Deterioration Installed load N


(kgf)/installed length
NV 195 to 235
(19.8 to 24.2)/190
L 175 (18)/190

1.
2.
3.
4.
5.
6.
7.

Shoe hold down cup


Shoe hold down spring
Shoe hold down pin
Return spring
Shoe and lining assembly
Rivet
Lining

Deformed shoe, rough


ledge surface

8.
9.
10.
11.
12.
13.
14.

Shoe
Pipe
Rubber
Wheel cylinder assembly
Cover
Backing plate
Brake drum

L ....... Limit
NV ..... Nominal Value
NOTE:
Use alcohol, brake fluid, or other vegetable
oil to clean rubber parts.
When alcohol is used, do not immerse for
more than 30 seconds.

EMTBR5031A

BR -54

BRAKE SYSTEM

REMOVAL
1.

E92594B1

CAUTION
When removing the wheel and tire (B), be careful
that the hub bolt (B) is not damaged.

Place the wooden blocks (A) at the front and rear


sides of the front wheel.
4.

After taking off the hub bolt (A), remove the axle shaft
(B).

B
KCOWT5007A

C
A

2.

Loosen the wheel nut. Lift up the axle with the garage
jack (A) and support the frame stand (B).

KMTBR5013A

CAUTION
If the axle shaft (B) is hard to remove, insert the
hub bolt (A) into the removing screw hole (C) and
then try to remove it.
5.

Remove the oil seal (A)

A
KCOWT5008A

3.

After taking off the wheel nut (A), remove the wheel
and tire (B) from the hum (C).

KMTBR5014A

A
B
EMTBR5064A

REAR BRAKE ASSEMBLY


6.

BR -55

Loosening the lock nut tightening bolt (A), remove the


lock washer (B).

CAUTION
Be careful that the outer hub bearing(C) is not torn
off.
9.

Remove the shoe hold down spring and the shoe hold
down pin. Remove the return spring. Remove the
lining assembly.

Shoe
Shoe Hold
Down Pin
Shoe
Return
Spring

A
B
KMTBR5015A

7.

Shoe Return
Spring
Shoe Hold
Down Washer

Wheel
Cylinder
Assembly

Using the special tool (09527-47000), remove the lock


nut (A).

Shoe Hold
Down Spring
Shoe Inspection Hole

EMTBR5029A

REPLACEMENT

EA177866

WHEEL CYLINDER
A

1.

After running 64,000km, check if the inside of the adjuster piston and the wheel cylinder have rusts. Check
that the dust boot is damaged. Check that the piston
cup has been worn, cracked and swelled. After checking, if needed, replace the damaged parts.

2.

Loosening the screw, remove the adjuster piston.

KMTBR5016A

8.

Remove the rear wheel hub (B) with the outer bearing
(C) from the axle housing (A).

Spring

Piston cup
A

Adjuster piston
B

Boot

Adjustng screw

Bleeder screw

EMTBR5030A

KMTBR5017A

Bleeder Screw Tightening Torque: 6.9~8.9Nm(0.7


~ 0.9 kgf.m, 5.1~6.5lb-ft)

BR -56

BRAKE SYSTEM

LINING
1.

CAUTION

Using a drill machine, drill the joining part of the shoe


side rivet. Remove the lining.

Lining should be replaced in a kit.


Use the same size of the lining
Do not contaminate the lining surface with oil
or grease.

INSTALLATION

E2E68B53

1.

After assembling the wheel cylinder assembly, install


the shoe return spring.

2.

Install the shoe hold down spring.

Shoe
Shoe Hold
Down Pin
Shoe
Return
Spring

KMTBR5553A

2.

Assemble the lining


1)
2)

Clear the lining mounting surface of the shoe with


the specific oil.

Shoe Return
Spring
Shoe Hold
Down Washer

Wheel
Cylinder
Assembly

Perform the riveting with the pressure of 2100


100kg.

Shoe Hold
Down Spring
Shoe Inspection Hole

EMTBR5029A

3.

Apply the grease at each part.

4.

Inject the recommended grease at the inside of the


wheel hub (A).

Recommended Grease: RETINAX 0434 of


Hankook Shell Oil Co., Ltd
RETINAX 0419 of Hankook Shell Oil Co., Ltd
KO-GW02 of CheonMa Mineral Oil Co., Ltd

A
KMTBR5554A

3)

4)

When performing the riveting, at the 0.4mm position of the side end surface, the shoe lining gap
should be 0.3mm or less. At the around of the
rivet, it should be 0.5mm or less.

After checking that the brake drum and the lining


are contacted, if there is any defective, modify it
with the brake lining grinder.
KMTBR5017A

REAR BRAKE ASSEMBLY


5.

Install the rear wheel hub (B) and the outer bearing
(C) at the axle housing (A).
CAUTION
Use only the set comprising the bearing and the
bearing race.

6.

For the next step of installation, refer to the PA-"Rear


Axle."

BR -57

BR -58

BRAKE SYSTEM

EXHAUST BRAKE
COMPONENT LOCATION

ECDDE8C6

7
6

2
3
5

1.
2.
3.
4.
5.
6.
7.
8.

Air tube
D4AL
D4DA, D4DB
D4DC
Vacuum tube
Vacuum hose
Magnetic valve
Vacuum tank

1.
2.
3.
4.
5.

Vacuum tank
Vacuum hose
Magnetic valve
Exhaust valve assembly
Exhaust pipe

1.
2.
3.
4.

Vacuum tank
Magnetic valve
Exhaust valve assembly
Exhaust pipe

<D4AL, D4DA, D4DC>

2
3
4

<D4AF>

5
1

2
3

<D4AE>

ECOBR5008A

EXHAUST BRAKE
COMPONENTS (1)

BR -59
E16B0353

Atmosphere
5
4

1.
2.
3.
4.
5.

Magnetic valve-3way
Exhaust pipe
Exhaust brake assembly
Vacuum hose
Air hose

ECOBR5009A

BR -60

BRAKE SYSTEM

COMPONENT (2)

[Exhaust brake unit]

2
[Caution]
The power chamber is non-disassembly type.
Do not attempt to disassemble.
1.
2.
3.
4.

Cover
Clevis
Power chamber
Exhaust brake valve
EMTBR5033A

EXHAUST BRAKE

BR -61

COMPONENT (3)

[ Power Chamber ]
11
Disassembly Sequence
1. Rear shell
2. Nut
3. Diaphragm retainer
4. Diaphragm
5. Diaphragm plate
6. O-ring
7. Piston washer
8. Push rod
9. Washer
10. Nut
11. Spring
12. Front shell

10
9
8
7
6
5
4
3
2

For disassembly and reassembly of parts


with an encircled number, see Diassembly
and Reassembly given later

3
9.8~16 (1.0, 1.6)
4
9.8~16 (1.0, 1.6)

37.5
2

37.5
Reassembly Sequence

Full opening

4 3 2 1
Tightening Torque : Nm (kgf.m, Ib-ft)

4.9~6.9 (0.5, 0.7)

ECOBR5010A

BR -62

BRAKE SYSTEM

COMPONENT (4)

[ Intake shutter ]
1

4
5

3
1.
2.
3.
4.
5.

Coupler
Actuator assembly
Butterfly valve
Valve shaft
Bushing

Clearance
NV : 0.021~1.01mm
L : 0.15mm
Press bushing into coupler.

8Nm (0.8kgfm)

Mark V
(0 30)

Apply grease

Close
Open
Clearance between valve and
coupler when closed
NV 1.5-2 mm
Adjust actuator bracket

Tightening Torque : Nm (kgf.m, Ib-ft)

Reassembly Sequence
5

NV ... Nominal value

ECOBR5012A

EXHAUST BRAKE
REMOVAL
1.

BR -63
DISASSEMBLY

E938FC15

Remove the vacuum pipe(B) connected to the exhaust brake unit(A).

1.

E1F97DF2

Remove the power chamber (A).


CAUTION

Do not try to disassemble the power chamber because it can not be disassembled.

KMTBR5579A

2.

Remove the exhaust brake mounting bolt connected


to the exhaust pipe.

3.

Remove the power chamber (B) from exhaust brake


unit(A).

C
KMTBR5581A

CAUTION
Do not try to disassemble the power chamber because it can not be disassembled.

2.

Remove the exhaust brake cover (B).

3.

Remove the clevis (C).

REASSEMBLY
1.

E2F3E12B

With opening the butterfly valve, adjust the adjusting


bolt(B) to fix the lever(A) and tighten the lock nut.

Butterfly valve

A
B
KMTBR5580A

EMTBR5034A

BR -64
2.

BRAKE SYSTEM

Fixing the rod of the power chamber in the state of


press-in with 2~4mm, tighten the lock nut(A).

INSPECTION
1.

E060470A

Apply the vacuum pressure of 500mmHg or more


to the power chamber(A) so as that the vacuum
gauge(B) indicates the -500mmHg. After 15 seconds, check that the vacuum gauge indicates the
specific valve.
B
Vacuum

A
KMTBR5561A

3.

Adjust the adjusting bolt(A) so as that the gap between the body is 0.1~0.4mm, when the butterfly
valve is fully closed due to the -650~-750mmHg of
the vacuum pressure applied to the power chamber.
And then tighten the lock nut.
Check that the opening and closing of the brake valve
is smoothly working when the power chamber is applied the vacuum pressure of -400~-600mmHg or atmospheric pressure.

Vacuum
-650~
-750mmHg

Gap
0.1~
0.4mm

EMTBR5036A

2.

3-way Magnetic Valve


1)

Check for air tightness


1. Closing the valve of the exhaust brake unit
side with a plug and applying the vacuum
pressure of -750mmHg to the vacuum tank
side valve, there should be no air leakage to
the atmosphere side valve.

EMTBR5035A

Plug

Compressed air
EMTBR5037A

EXHAUST BRAKE
2.

BR -65

Closing the valve to the exhaust brake unit


side and applying the air pressure of 1kg/cm
to the valve of the atmosphere side, there
should be no air leakage to the vacuum tank
side valve.
Compressed air

EMTBR5061A

2)

Operating Inspection
1. Applying the -750mmHg vacuum pressure to
the vacuum tank side valve, check that the
valve is working at the voltage of 22V or less.

Vacuum

EMTBR5038A

2.

Closing the exhaust brake unit side valve


with a plug and applying the 1kg/cm air
pressure to the atmosphere side valve,
check that the valve is working at the voltage of 22V or less.

BR -66

BRAKE SYSTEM

PARKING BRAKE SYSTEM


COMPONENT LOCATION

E0FC7C8F

Adjusting nut
Parking brake cable assembly
(M035S5 T/M)
Parking brake drum

Parking brake cable assembly (M2S5, M3S5 T/M)

Parking brake lever assembly

ECOBR5007A

PARKING BRAKE SYSTEM


COMPONENTS

BR -67

E2E093D6

15

17

16
L...... Limit
NV... Nominal Value
Item
I.D
Squareness

NV

180/190

181/191

13

0.05 or less

Concentricity 0.1 or less


Cylindricity

0.05 or less

Static rotary

0.49 Ncm

imbalance

(50 gf.cm)

6
4

11

or less

3
12
8
7

14

10

Lining Thickness
8
7

NV : 5.15~5.45 mm
L : 2 mm

18

1. Return Spring

7. Spring Seat

13. Parking Brake Cable

2. Return Spring

8. Hold Spring

14. Shoe Assembly

3. Shoe Guide Plate

9. Spring Srat

15. Parking Brake Lever

4. Strut Spring

10. Adjuster

16. Cable

5. Adjuster Spring

11. Shoe Assembly

17. Parking Brake Assembly

6. Shoe Hold Pin

12. Strut

18. Parking Brake Drum


ECOBR5015A

BR -68

BRAKE SYSTEM

REMOVAL
1.

3.

E9CE8DC9

Remove the front propeller shaft(A).

Make an alignment marking(C) to the flange yoke


(A) of the front propeller shaft and the parking brake
drum(B). Remove the tightening nut (D) of the propeller shaft.
B

A
A

KMTBR5023A

4.

Remove the parking brake cable clip (A).

C
KMTBR5021A

2.

Remove the tightening bolt (A) of the center bearing


bracket.

KMTBR5568A

5.

Using a companion flange puller, remove the companion flange from the main shaft.

A
KMTBR5022A

Companion flange

NOTE
For short axis, the center bearing is one. For longaxis, the center bearing are two.

Companion flange pulley


EMTBR5040A

PARKING BRAKE SYSTEM


6.

BR -69

Using a socket wrench, remove the flange bolt. Remove the shoe and lining assembly.

INSTALLATION
1.

E7B9186A

Install the shoe and lining assembly(B) to the back


plate(A).

Back plate

CAUTION

Shoe and lining

Do not contaminate the lining surface with


foreign materials.
The outer diameter of the lining should be
180.
Apply the grease at the following portions.
Contacting surface between the back
plate and the shoe.
Contacting surface between the shoe and
the anchor pin.
Contacting surface between the adjuster
thread and the nut and sleeve.

EMTBR5041A

7.

Remove the shoe hold pin and spring.

8.

Taking off the return spring(A), remove the shoe assembly(B).

9.

Remove the parking brake cable(C).

C
B

KMTBR5045A

2.

After installing the parking brake cable, install the


shoe hold pin and spring.

KMTBR5024A

KMTBR5046A

BR -70
3.

BRAKE SYSTEM

Aligning the align markings(C) of the rear axle companion flange (A) and the flange yoke (B) of the rear
propeller shaft, install the tightening bolt (D) of the propeller shaft.

Tightening Torque :
98~117.6Nm(10~12kgf.m, 72.7~87.2lb-ft)
A

5.

Aligning the align marking (C) of the flange yoke (A) of


the front propeller shaft and that of the parking brake
drum (B), install the tightening nut (D) of the propeller
shaft.

Tightening Torque :
97~117.6Nm(10~12kgf.m, 72.7~87.2lb-ft)

C
KMTBR5025A

4.

Install the tightening bolt (A) of the center bearing


bracket.

Tightening Torque :
68.6~93.1Nm(7.0~9.5kgf.m, 50.9~69.1lb-ft)

KMTBR5021A

6.

Inject the recommended grease to the grease nipple


(A) until the grease is leaked out oil seal. Clear the
leaked grease.

Recommended Grease: ALVANIA EP#2

A
KMTBR5022A

NOTE
For short-axis, the center bearing is one. For longaxis, the center bearings are two.

KMTBR5026A

PARKING BRAKE SYSTEM


ADJUSTMENT

BR -71
ADJUSTING THE PARKING BRAKE

E03829FE

METHOD FOR ADJUSTING THE LINING GAP.

1.

Release the parking brake.

1.

Turn the adjuster to the shoe expansion direction until


the shoe contacts the drum.

2.

Pulling the out cable with the 6~10kgf force, locate the
nut (A) at the position at which the gap is 3~7mm.

2.

Turn the adjust to the reverse direction of the shoe


expansion direction with 8~10 notch.

Out cable

3~7mm
Adjuster
ECOBR5016A

EMTBR5042A
CS58033B

3.

After operating the parking brake lever several times,


turn the drum with hand. At that time, the lining should
not contact with the drum.

3.

Returning the out cable. Tighten the nut (B) near the
nut (A) with the specified torque.

Tightening Torque:
38.2~50Nm(3.9~5.1kgf.m, 28.2~36.9lb-ft)
4.

After the initial adjusting of the cable, check the following items.
1)

Check the click number of the parking brake and


hand force.

Hand force

Number of lever click

20kg or more

8~9 notch

2)

Check that the parking brake warning Lamp is


normally working.

3)

Tighten the parking brake bracket flange bolt with


the specified torque.

Tightening Torque:
11.8~14.7Nm(1.2~1.5kgf.m, 8.7~10.9lb-ft)

BR -72

BRAKE SYSTEM

ANTI-LOCK BRAKE
SYSTEM/ACCELERATION
SLIP REGULATION
COMPONENTS

E88E723C

1
2

1.
2.
3.
4.
5.

ABS control module


Master cylinder and brake booster
Modulate assembly
Front wheel speed sensor
Rear wheel speed sensor

ECOBR5017A

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION


GENERALS

SRI CODE CHECK

EAE94BE4

ABS SYSTEM
The Anti-Lock Brake System (ABS) protects the locking of
the wheel by controlling the oil pressure of the 4 wheels
when the driver brakes the car suddenly or on the slide
road.
The ABS suggests the following advantages.
1.

2.

BR -73

When the car is turn around an object suddenly or


when the car is stopped suddenly, it is possible to
control the car.
During sudden braking time, or even running in curved
way, it is possible to drive in safe and to ensure the
excellent controlling so as to stop the car safely.
In order to ensure the good service when it has a
problem, the ABS system includes the self diagnosis
and the fail safe device.

With the ignition switch turned ON and "L" terminal of Data


link connector shorted to ground, diagnostic trouble code
No. can be checked, if faults are detected, with the reading
of SRI lamp flash.
1.

Ground the "L" terminal (Pin No.6) of data link connector with suitable wire, otherwise fault code cannot
be accessed.

2.

Turn the ignition switch ON.

3.

SRI lamp will be illuminated for 2 seconds and then


read the following "Diagnostic trouble code."

4.

First digit of Diagnostic trouble code is determined by


the number of long flashes (1.5 sec.) and after the
following 2 seconds break second digit is determined
by the number of short flashes (0.5 sec.)

5.

Once the SRI lamp flashing is completed, next active


trouble code or history trouble code stored at ABSCM
will be followed after 3 sec. break while the "L" terminal is shorted to ground or the ignition switch is ON.

CHECKING THE SYSTEM DIAGNOSIS INDICATOR.


When turning the ignition switch ON, check that the ABS
warning lamp turns on for 2 seconds. If the warning lamp
does not turn on immediately when the ignition switch is
ON, the ABS fail safe may be damaged.

2 3 4 5 6 7

9 10 11 12 13 14 15 16

Ground

K-line

Power
ECOBR5019A

ECOBR5018A

SYSTEM DIAGNOSIS STEP


The ABSCM continuously checks the state of the electrical
integrity of ABS and if detects a failure, it inform the fault
codes in SRI lamp flash code.

L-line

IG

ON
OFF

SRI

ON
OFF

ECOBR5020A

BR -74
6.

BRAKE SYSTEM

Diagnostic Trouble code will be retained in the ABSCM until the ignition has been switched ON and the
vehicle speed exceeded 8km/h 20 times.
SRI lamp flash pattern

Remarks

System normal or
fault code is stored
at ABSCM
ABSCM has active
fault

L-line
ground
OFF

ECOBR5021A

System Normal

L-line
(Pin No.6)
Shorted to
ground

ECOBR5022A

Active fault No.22


flashes after check-in
period and followed
by history fault code
No.23

ECOBR5023A

CONNECTOR CHECK
1.

Remove the battery negative (-) terminal.

2.

Disconnect the connectors and check terminals follow


the troubleshooting procedure.
NOTE
When you check terminals, be sure to use enough
small pin which is not damage to the connector terminals.

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION

BR -75

OIL PRESSURE CIRCUIT DIAGRAM

RESERVOIR

I/V
O/V
DC
M

:
:
:
:

RESERVOIR

Inlet Valve
Outlet Valve
Damper Chamber
Plunger pump

VT58003

BR -76

BRAKE SYSTEM

ELECTRIC CIRCUIT DIAGRAM

EB94E529

HOT AT ON
FUSE
BOX
FUSE 11
5A

FUSE 2
10A

FUSE 10
5A

0.5L

1.25G/R

0.5L

0.85R/G
7 M41-1

0.5L/W

3 M13
DBR
RELAY
(Open with
ABS operated)

RELAY
BOX
See Exhaust
Brake System
on page SD-50

ABS

7 M41-3

0.5L/W

0.5B/R

1.25G/R

0.85R/L

12

0.85G

See Exhaust
Brake System
on page SD-50

1.25G/R

28

39

ON
input

DBR
relay
control

16

0.5B/R

0.85R/L

0.5B/R

0.85R/L

To ABS Relay Box


53 M87 on page SD-53
ABS
ABS
CONTROL
indicator
MODULE
control

10
Exhaust
brake

Ground

13

38

55

54

29

0.5G/R

0.85Y/W

0.85Y/R

1.25B

1.25B

1.25B

11

1.25B

1.25B

C H E C K

MM05

0.85R/L

Check connector

A B S

INSTRUMENT
CLUSTER

ABS
IND.

5 M13

0.5G
15

0.85R/G

See Fuse Box Details


on page SD-10, SD-14

1 M87

1.25B

3 M57

C O N N E C T O R
8 M57
0.5B

G04
Q8SD011A
ECOBR5024A

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION

BR -77

ELECTRIC CIRCUIT DIAGRAM (2)

HOT AT ALL TIMES

HOT AT ALL TIMES

FUSE
BOX

FUSIBLE
LINK
BOX

FUSE 35
15A

ABS
40A

1.25L/W
From
ABS Control Module
on page SD-52
18
A

3.0L/W

1.25L/W

0.85R/L
2 M82-2 1

MM05

M82-1 2 M82-3

1 M82-2

ABS
RELAY
BOX

0.85W/B

35

0.85Lg/B 0.85L/R

0.85
Lg/W

22

49

3 M82-3

1.25B

G03

47 M87

ABS
CONTROL
MODULE

ABS relay control

F/L
EV

3.0R

2.0R

2 M77-1

F/L
AV

F/R
EV

F/R
AV

R/L
EV

R/L
AV

R/R
EV

24

51

30

31

23

1.25B/W

1.25G

1.25R

1.25Y

1.25L

1.25Br

1.25O

R/R
AV
50 M87

1.25W/Br

7 M77-2
HYDRAULIC
UNIT

Q8SD011B

ECOBR5025A

BR -78

BRAKE SYSTEM

SCHEMATIC DIAGRAM (3)


FUSE
BOX
FUSE 36
10 A

0.85L/G
MM01

3
0.85L/G
2

M49

STOP
LAMP
SWITCH
1

M49

0.85G
4

MM01

0.85G
5

MM06

0.85G
See Stop Lamps
on page SD-94

0.5G
36 M87

ABS
CONTROL
MODULE

Stop lamp switch input

Wheel speed input


15

16

20

19

44

45

18

0.5B

0.5Br

0.5Br

0.5B

0.5B

0.5Br

0.5Br

LEFT FRONT
WHEEL SENSOR

M66

RIGHT FRONT
WHEEL SENSOR

M58

LEFT REAR
WHEEL SENSOR

M85

17 M87

0.5B

M84

RIGHT REAR
WHEEL SENSOR
Q8SD011C

ECOBR5026A

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION

BR -79

CONNECTOR ID DIAGRAM
ABSCM CONNECTOR (A01, ABSCM HARNESS
SIDE CONNECTOR)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

ECOBR5027A

Pin No.

Plug Assignment

Pin No.

Plug Assignment

Ignition "ON"

30

Ground

Front left inlet solenoid v/v control

31

ABS indicator control

Rear right inlet solenoid v/v control

33

Front left outlet solenoid v/v control

ABS relay control

34

Rear right outlet solenoid v/v control

Front left wheel speed sensor

35

ABS relay control

10

Front left wheel speed sensor

37

ABS relay control

11

Rear right wheel speed sensor

39

Rear left wheel speed sensor

12

Rear right wheel speed sensor

40

Rear left wheel speed sensor

13

Rear right wheel speed sensor

45

ABS relay control

14

Rear right wheel speed sensor

46

Data link connector

16

Data link connector

48

BLS

19

Exhaust brake main valve

49

Pump motor monitor

25

Rear left outlet solenoid v/v control

53

Rear left inlet solenoid v/v control

26

Front right outlet solenoid v/v control

54

Front right inlet solenoid v/v control

28

Ground

55

Ground

29

Ground

MODULATOR CONNECTOR (A05, HARNESS SIDE)

4 3 2 1
8 7 6 5
ECOBR5028A

Pin no.

Plug Assignment

Pin no.

Plug Assignment

Front Left Inlet Valve GND

Front Left Outlet Valve GND

Front Right Inlet Valve GND

Front Right Outlet Valve GND

Rear Right Inlet Valve GND

Rear Right Outlet Valve GND

Rear Left Inlet Valve GND

Rear Left Outlet Valve GND

BR -80

BRAKE SYSTEM

TROUBLESHOOTING

EDFD7A0E

STANDARD FLOW OF DIAGNOSTIC


TROUBLESHOOTING

Gathering information from customer


Reoccurs

Does not reoccur

Check diagnostic code


No trouble code

Check diagnostic code


Trouble code displayed

Trouble code
displayed

No trouble
code

Recheck trouble code(s) then erase

Basic brake system is normal or not

Recheck trouble symptom

Abnomal
Refer to
Brake - Troubleshooting

Check trouble codes

No trouble code

Trouble code displayed


Inspection chart for diagnostic trouble
codes

Intermittent malfunction
Using the customer problem analysis check sheet for reference, ask the customer in as much detail as
possible about the problem.
EMTBR5046A

NOTES WITH REGARD TO DIAGNOSIS


The phenomena listed in the following table are not abnormal.
Phenomenon

Explanation of phenomenon

ABS operation sound

1.
2.

Sound is generated along with vibration of the brake pedal (scraping).


When ABS operates, sound is generated from the vehicle chassis due to
repeated brake application and release.
(Thump : suspension; squeak: tires)

ABS operation
(Long braking
distance)

For road surfaces such as snow-covered roads and gravel roads, the braking
distance for vehicles with ABS can sometimes be longer than that for other vehicle.
Accordingly, advise the customer to drive safely on such roads by lowering the
vehicle speed and not being too overconfident.

Diagnosis detection condition can vary depending on the


diagnosis code.
Make sure that checking requirements listed in the "Comment" are satisfied when checking the trouble symptom
again after the diagnosis code has been erased.

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION

ABS Check Sheet

BR -81

Inspectors
Name

Registration No.
Registration Year

Customers Name

VIN.
Data Vehicle
Brought In

Km
Miles

Odometer

Data Probelm First Occurred


Frequency Problem Occurs

Continuous

Intermittent (

times a day)

Intermittent (

times a day)

ABS does not operate.


Symptoms

Diagnostic
Trouble Code
Check

ABS does not operate efficiently.


ABS Warning
Light Abnormal

Remins ON

Does not Light UP

1st Time

Normal Code

Malfunction Code (Code

2nd Time

Normal Code

Malfunction Code (Code

EMTBR5047A

BR -82

BRAKE SYSTEM

INSPECTION CHART FOR DIAGNOSTIC TROUBLE


CODES
Inspect according to the inspection chart that is appropriate for the malfunction code.
Dtc No.

Description

Mil*

Memory

11

FR sensor open

12

FL sensor open

13

RR sensor open

14

RL sensor open

15

Speed sensor series malfunction


(Teeth number malfunction)

16

Voltage out of range

21

FR sensor short

22

FL sensor short

23

RR sensor short

24

RL sensor short

38

BLS (Brake Lamp Switch) malfunction

41

FR - Inlet valve malfunction

42

FL - Inlet valve malfunction

43

RR - Inlet valve malfunction

44

RL - Inlet valve malfunction

45

FR - Outlet valve malfunction

46

FL - Outlet valve malfunction

47

RR - Outlet valve malfunction

48

RL - Outlet valve malfunction

51

Valve relay malfunction

53

Pump motor malfunction

63

ECU error

* MIL : Malfunction Indication Lamp

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION

BR -83

INSPECTION PROCEDURE FOR DIAGNOSTIC


TROUBLE CODES
DTC No. 11, 12, 13, 14, 21, 22, 23, 24 Wheel speed
sensor open or short

Probable cause

[Comment]
The ABSCM determines that an open or short circuit occurs in
more than one line of wheel speed sensors.

Wheel speed sensor installation


inspection

NG

Malfunction of wheel speed sensor


Malfunction of wiring harness or connector
Malfunction of ABSCM

Repair

OK
Measure at the ABSCM connector
A01
Disconnect the connector and
measure from the harness side.
Resistance values between 9
and 10, 11 and 12, 13 and 14,
39 and 40.
OK : 1280 - 1920

NG

Check the following connectors.


AA01, AA02, A09, A04, A08, A03

NG

Repair

OK
Check trouble symptoms

NG

Check the harness wire between


each wheel speed sensor and
ABSCM, and repair if necessary

OK
Wheel speed sensor output voltage
inspection

NG

OK
Check the following connector
A01
OK
Check trouble symptoms

NG
Wheel speed sensor inspection

Replace the wheel speed sensor

OK
NG
Repair

Rotor inspection

NG

Replace the rotor

OK
Wheel bearing inspection

NG
Replace the ABSCM

EMTBR5048A

BR -84

BRAKE SYSTEM
Probable cause

DTC No. 15 (Speed sensor series malfunction)


[Comment]
A wheel speed sensor outputs an abnormal signal or no signal

Wheel speed sensor installation


inspection

NG

Improper installation of wheel speed sensor


Malfunction of wheel speed sensor
Malfunction of rotor
Malfunction of wiring harness or connector
Malfunction of ABSCM

Repair

OK
Wheel speed sensor output voltage
inspection

NG

Wheel speed sensor inspection

Replace the wheel speed sensor

OK

OK
Check the related connectors

NG

NG
Repair

Rotor inspection

OK

NG

Replace the rotor

OK

Check trouble symptoms

Check trouble symptoms

NG

OK

Check the harness wire between


each wheel speed sensor and
ABSCM, and repair if necessary

Replace the ABSCM

EMTBR5049A

Probable cause

DTC No. 38 BLS Malfunction


[Comment]
BLS (Brake Lamp Switch) outputs an abnormal signal

Check the BLS connector

NG

Improper installation of the connectors

Repair or replace

OK
Inspret the BLS terminal

NG

Replace

EMTBR5050A

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION

BR -85

DTC No. 41, 42, 43, 44, 45, 46, 47, 48(Inlet/outlet
solenoid valve malfunction)

Probable cause

[Comment]Inlet or outlet solenoid valve outputs no signal

Fuse inspection

NG

Malfunction of valve inner coil


Improper installation of wiring harness
or connector
Malfunction of valve relay
Malfunction of fuse (15A)

Replace

OK
Check the valve relay

NG

Replace

OK
Check the connector A05, A05-1,
AA02 and terminals

NG

Repair or replace

OK
Replace the ABSCM
EMTBR5051A

Check the connectors of hydraulic unit side a each valve.


(At ambient temperature 23 5 C)

4 3 2 1
8 7 6 5

2 1

EMTBR5052A

Connector name

Terminal

Terminal name

Check terminals

Modulator
connector

FR - Inlet valve

Unit : W

Basic value
24V

12V

2 + 2

24.66 0.5

8.54 0.5

FL - Inlet valve

1 + 2

24.66 0.5

8.54 0.5

RR - Inlet valve

3 + 2

24.66 0.5

8.54 0.5

RL - Inlet valve

4 + 2

24.66 0.5

8.54 0.5

FR - Outlet valve

6 + 2

18.3 0.5

4.29 0.5

FL -Outlet valve

5 + 2

18.3 0.5

4.29 0.5

RR -Outlet valve

7 + 2

18.3 0.5

4.29 0.5

RL -Outlet valve

8 + 2

18.3 0.5

4.29 0.5

BR -86

BRAKE SYSTEM
Probable cause

DTC No. 16 Voltage out of range (Under and over voltage)


[Comment]
The voltage of the ABSCM power supply drops lower or
rises higher than specified value.If the voltage returns to the
specified value, this code is no longer output.

Malfunction of wiring harness or connector


Malfunction of ABSCM

CAUTION
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to
standard value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
Measure at the ABSCM connector
A01
Disconnect the connector and
measure from the harness side
Start the engine. Voltage
between 1-Body earth
OK : System voltage

NG

Check the following connector


MA01

Repair

OK
Check trouble symptoms
OK

NG

Check the harness wire between


each wheel speed sensor and
ABSCM, and repair if necessary

Check the battery

OK
Check the following connector
MA01

NG

NG

Repair

OK
Check trouble symptoms

NG

Replace the ABSCM


EMTBR5053A

DTC No. 63 ECU (ABSCM) error


[Comment]
The ABSCM always monitors the solenoid valve drive circuit. It
determines that there is an open or short-circuit in the solenoid
coil or in a harness : When no current flows in the solenoid even
though the ABSCM turns on it, and vice versa.

Probable cause
Malfunction of ABSCM
Replace the ABSCM

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION

BR -87
Probable cause

DTC No. 51 Valve relay malfunction


[Comment]
When the ignition switch is turned to ON, the ABSCM switches
the valve relay off and on during the initial check. In that way,
the ABSCM compares the signals sent to the valve relay with the
voltage in the valve power monitor line. That is how to check if
the valve relay is operating normally. The ABSCM always checks
if current flows in the valve power monitor line, too.
It determines that there is an open circuit when no current
flows. If no current flows in the valve power monitor line,
this diagnosis code is output.

Malfunction of valve relay


Malfunction of wiring harness or connector
Malfunction of ABSCM
Malfunction of hydraulic unit

NOTE
Whenever reading the diagnosis codes using the ABS
warning lamp, this diagnosis code will be output.
Fuse (2EA) inspection

NG

Replace the fuse

OK
Check the connectors AA01,
A06-2, A06-1

NG

Repair or replace the connectors

OK
Check the relay

NG

Replace the relay

OK
Replace the ABSCM
EMTBR5054A

Probable cause

DTC No. 53 Motor pump malfunction


[Comment]
When the motor power line is normal but no signal is input to the
motor monitor line. When the motor power line is faulty.

Malfunction of wiring harness or connector


Malfunction of hydraulic unit
Malfunction of ABSCM

Motor power source inspection


Pin No. 49, A01
NG
Disconnect the connector A01
Check the voltage from P.49
OK : System voltage

OK

Replace the ABSCM

NG
Repair the harness or connector

EMTBR5055A

BR -88

BRAKE SYSTEM

ABS OPERATION CHECK


WHEEL SPEED SENSOR OUTPUT VOLTAGE
CHECK
1.

Lift up the vehicle and release the parking brake

2.

Disconnect the ABSCM harness connector and measure from the harness side connector.
CAUTION
Be sure to remove the connector lock and insert
the probe into the harness side. Inserting it into
the terminal side will result in a bad connection.

3.

Rotate the wheel to be measured at approximately


1/2-1 rotation per second, and check the output voltage using a circuit tester or an oscilloscope.
Wheel
speed
sensor

Terminal
No.

Front
left

Front
right

Rear left

Rear
right

54

53

33

26

25

34

Output voltage
When measuring with an oscilloscope :
120 mV p-p or more

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION

BR -89

ABS MODULATER
COMPONENTS

E83A6B5E

Modulator
Motor
relay(24V)

Valve relay(24V)
Relay box-ABS

ECOBR5029A

BR -90

BRAKE SYSTEM

REMOVAL

INSTALLATION

E3F430EB

1.

Disconnect motor pump and relay box harness and


remove the ABS relay box mounting nuts.

2.

Remove the relay box(A) from relay box mounting


bracket.

E7702A84

1.

Follow the reverse order of Removal.

2.

Tighten the modulator mouting bolts and brake tube


nuts to the specified torque.

Tightening torque
Modulator mounting nut
........................... 17-26 Nm (1.7~2.6kgf.m, 12-19 lb.ft)
Brake tube nut
............................. 13-17 Nm (1.3~1.7kgf.m, 9-12 lb.ft)
3.
A

KMTBR5574A

3.

Disconnect the brake tubes(A) from the ABS modulator.

4.

Remove the ABS modulator mounting bolts(B).


A

KMTBR5575A

CAUTION
1.
2.

Never attempt to disassemble the ABS modulator.


The modulator must be transported and
stored in upright position and with sealed
ports.
The modulator must not be drained.

Bleed the brake system.

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION

ABS CONTROL MODULE


REMOVAL

E0C1E64C

1.

Fold the seat of passenger side.

2.

Remove the ABSCM mounting bolts and ABSCM.

Passenger seat

ABSCM
(ABS control module)

EMTBR5057A

3.

Installation is the reverse of removal.

BR -91

BR -92

BRAKE SYSTEM

WHEEL SPEED SENSOR


REMOVAL

INSPECTION
1.

E5AE8F53

FRONT WHEEL SPEED SENSOR

E7F79880

Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.

Service standard : 1280 - 1920

1.

Remove the front wheel speed sensor mounting bolt.

2.

Disconnect the wheel speed sensor connector.

REAR WHEEL SPEED SENSOR


Remove the rear wheel speed sensor after disconnection
the wheel speed sensor connector.

KMTBR5578A

2.

Connect a voltmeter between the wheel speed sensor terminals, and measure the voltage by turning the
wheel.
NOTE

KCOBR5006A

Set the voltmeter to measure AC voltage.


Service standard : AC voltage detected.
Output voltage
Measurement by oscilloscope : 12mV P-P over.

ECOBR5030A