BRAKE SYSTEM CONVENTIONAL BRAKE SYSTEM AIR BLEEDING BRAKE FLUID, CHECK VALVE sn. BRAKE HYDRAULIC LINE .... BRAKE PEDAL .. BRAKE PEDAL . CALIPER .. DESCRIPTION AND OPERATION ... FRONT DISC BRAKE .... MASTER CYLINDER POWER BRAKE UNIT POWER BRAKE UNIT PROPORTIONING VALVI REAR DRUM BRAKE ‘TROUBLESHOOTING GUIDE ...... WHEEL CYLINDER ..... PARKING BRAKE SYSTEM DESCRIPTION AND OPERATION ... PARKING BRAKE CABLE PARKING BRAKE LEVER SERVICE SPECIAL TOOL SPECIFICATIONS .. TROUBLESHOOTING GUIDEDESCRIPTION AND OPERATION BRAKE SYSTEM 52- DESCRIPTION AND OPERATION The hydraulic brake system uses the principles of fluid power to apply the front and rear brakes. The hy- draulic brake system operates as follows: + The brake pedal is connected to a hydraulic servo called the master cylinder. + When the pedal is pushed, a solid column of fluid is pushed from the master cylinder through metal tubing and flexible hoses to the rear brake wheel cylinders and front disc brake calipers. +The wheel cylinders and calipers are hydraulic actuators where the hydraulic pressure produced in the ‘master oylinder is converted into motion. + The pistons in the rear wheel cylinders are forced outward against brake shoes which contact a metal braking surface on the brake drum. ‘+ The front brake caliper pistons move inward against the brake pads and contact the metal braking surface of the brake rotor. + When the brake pedal is released, the pressure in the system is relieved and the brake shoes and pistons return to their neutral or unapplied position. ‘The brake lines are arranged to form a split diagonal hydraulic system. Although the physical layout of the brake lines do not indicate it, they are arranged to form an "X". One side of the “X" supplies hydraulic pres- sure to the left front and right rear. The remaining circuit supplies pressure to the right front and left rear. The hydraulic system is split in this manner as a safety precaution. If hydraulic pressure is lost in one circuit, the remaining circuit can provide less efficient but balanced braking. If brake fluid is lost from one or both circuits, a low fluid level sensor in the master cylinder wil illuminate an indicator lamp in the instrument cluster. The lamp comes on when a float in the master oylinder drops below a specified level and completes the circuit. Once the circuit is closed, the lamp will come on and remain on whenever the ignition switch is in the ON or START position. If the lamp is ON, make sure the parking brake is in the fully released position. The same lamp indicates when the brake fluid level is low and when the park- ing brake has been applied. A proportioning valve is installed in the system to balance front to rear brake application. The valve reduces hydraulic pressure to the rear brake wheel cylinders to prevent rear wheel lock-up. Internally, the valve con- tains plungers that are shifted by hydraulic pressure to limit the output pressure to the rear wheels.52-4 BRAKE SYSTEM DESCRIPTION AND OPERATION DESCRIPTION AND OPERATION (continued) OnaeNe Brake hydraulic line Brake pedal . Master cylinder Power brake unit Dual proportioning valve Front brake (Disc) 00 7. Caliper 8. Rear brake (Drum) 9. Wheel oylinder 10. Parking brake (Lever type) 11. Parking brake cable 12, Parking brake leverTROUBLESHOOTING GUIDE BRAKE SYSTEM 52-5 TROUBLESHOOTING GUIDE eer Pena wai Fils aroma] + aie > Riga cee Sear EASA otnarsiay |? SHRM SHERI Sl “Hite Boencumramns [+ BEE pau sonst eng i eae ‘ rarguievergaene, |» itneentienee zPanmuatscemmaeses |: RERCEAME ti a Thetsoetagssret |) Gece amey mses aaa eo = + Caliper piston or sie pins + BEBAIR or REPLACE caliper or anal Bea Oey ircpreguien tse, |» HO ess Pacing « Ebacecomauscins SEED aor | odie eee «Wet a «Renate les rs Tp gonnansnyamase [SRL A ‘terial * noe meg « gocaeracprorenar |» HEE ase rom tes © snap meas creape: |» STERIL arenice wo ETERS cum |. SRE i + Caliper or whee! cylinder pistons | « OVERHAUL or REPLACE calipers frozen. ‘or whee! cylinders. {EeGieunanganve | «SERB Ce an = eueiteea «+ Brake orvon(600) switen + ADJUST Brake On/OM(BOO) SO et, | Ee ate EERCRS” |) nownomemmepes—, | snare bo Mereetinivneges, |? Reeecete iE aa = [Beem | Bibacewmammen52-6 BRAKE SYSTEM TROUBLESHOOTING GUIDE Condition ‘Action = Brake(s) Pull to One Side ‘Womn/damaged brake pad. Foreign material on brake pad, + Abnormal wear or distortion of rotor. + Caliper piston malfunction, = Improper wheel alignment adjustment. ‘+ Improper tire air pressure, ‘+ Loose or damaged dust cover ‘mounting bot ‘+ Improper whoe! bearing preload agjustment. REPLACE brake pad. CLEAN or REPLACE brake pad. + REPAIR or REPLACE rotor. REPLACE caliper piston. PERFORM wheel alignment adjustment. REFER to Section «INFLATE tie to proper air vessure, « TESTEN or REPLACE dust cover mounting bo ROJUSY preload or REPLACE ‘hoo besning ‘+ Brakes Do Not Release No brake pedal play, ‘= Improper push rod ciearance adjustment. + Master cynderrtum post ‘+ Caliper piston malfunction Excessive rotor runout. Brake pad not returning properly + Improper whee! bearing preload adjustment, '* ADJUST brake pedal play. ‘+ ADJUST push rod for proper clearance. CLEAN return port on the master oylinder. «REPLACE caliper piston, 3 REPLACE rotor ‘CHECK and REPLACE brake pad it necessary. «ADJUST preload or REPLACE wheel bearing, ‘* Abnormal Noise or Vibration During Braking Worn / damaged brake pad. ‘Loose caliper mounting bolt. ‘Insufficient grease on sliding parts. ‘Foreign material or scratches on fotor contact surface. ‘+ Damaged rotor contact surface. REPLACE brake pad. TIGHTEN caliper mounting bot. + APPLY grease where necessary. + CLEAN rotor contact surface. * REPLACE rotor. ‘+ Low or Hard Pedal Lack of vacuum to the power booster. = Vacuum check valve restricted. ‘+ stricted vacuum hose. '* REPAIR vacuum supply to power booster. «TEST and REPLACE check valve as necessary, + REPAIR or REPLACE hose as necessary. ‘* Groaning Noise ‘+ Diy oF rough brake cable holders. ‘+ LUBRICATE cable and cable holders. ‘© Brake Pedal Pulsates ‘+ Brake drums out-of-round. {Disc rotors have excessive lateral runout. + Loose whee! bearings. Bont front /rear spindles. Bent or distorted hub mounting flange. REPLACE drums MACHINE rotors, REPLACE it mocossa «INSPECT and ADJUST whee! REPLACE spindle REPLACE hub. ‘> Brake Noise ‘= Worn brake linings. Bent, cracked brake lining iatforms on backing plate. +» Foreign objects in linings. ‘+ Cracked or heat checked drums or rotors. + Broken or loose rear brake hhold-down or return springs. ‘Diy or rough backing plate slide pads. + Loose or missing disc brake anti-rattle springs. ‘+ Loose caliper mounting bolts, ‘> REPLACE linings. 2 REPLACE linings, REPLACE backing plate. + BEPLACE linings, CHECK drums REPLACE drums or rotors. CHECK pads / shoes. «+ REPLACE notedown or tum + SANB and LUBRICATE side pads. «REPAIR or REPLACE antivatle + BTIGRTEN mounting bots, CHECK | * force elongationAIR BLEEDING 1, Jack up the vehicle and support it with a safety stands. Caution + The brake fluid reservoir must be kept 3/4 full during air bleeding. 2. Remove the bleeder cap and attach a vinyl hose to the bleeder plug. 3. Place the other end of the vinyl tube in a clear container. 4. One person should depress the brake pedal a few times, and then hold it in the depressed position. 5. A-second person should loosen the bleeder screw, drain out the fluid, and retighten the screw with the SST. Caution + Be sure the pedal remains depressed until the bleed screw is tightened. 6. Repeat Steps 4 and 5 until no air bubbles are seen. 7. Check for the correct brake operation. 8. Verify that there is no fluid leakage. Clean away any spilled fluid with rags. 9. After bleeding the air, add a brake fluid to the reservoir up to the specified level. Tightening torque : 5.9-8.8 N.m (60-90 kg-cm, 52-78 Ib-in) Note + Air bleeding must be started from the bleeder screw furthest from the master cylinder. BRAKE HYDRAULIC LINE AIR BLEEDING BRAKE SYSTEM 52-7 oO CSET rr 1. Brake pipe 2, Flexible hose52-8 BRAKE SYSTEM BRAKE HYDRAULIC LINE INSPECTION (ON-VEHICLE) Brake pipe TUBE SEAT Check for cracks, damage, and corrosion of the brake pipe. Replace the pipe or flare nut if necessary. Flexible hose Check for scars, cracks, and swelling of the flexible hose. Re- place the hose if necessary. Removal 1, Remove the brake pipe with the SST. 2. Disconnect the clip and remove the flexible hose from the bracket. ouBLe FLARE DOUBLE FLARE FLARE NUT Installation 1. Fix the flexible hose in the bracket and install the clip, 2. Connect the flexible hose to the brake pipe and tighten the flare nut with the SST. Caution + Verify that the hose is not twisted. + Verify that the hose does not contact other parts when the vehicle bounces or when the steering wheel is turned fully right or left. Tightening torque : 13-22 N.m (1.3-2.2 kg-m, 9~16 lb-ft)BRAKE FLUID, CHECK VALVE BRAKE SYSTEM 52-9 BRAKE FLUID INSPECTION Leakage inspection Depress the brake pedal several times, and inspect for leakage of the brake lines and system BRAKE FLUID LEVEL Leakage check Verify that the fluid level in the reservoir is between the MAX and MIN lines on the reservoir. ‘Add fluid if itis below MAX. Replacement 1. Follow the procedure outlined in “Air Bleeding”. 2. Continue bleeding and replacing the brake fluid until only clean fluid is expelled. 3. Fill the reservoir to the MAX level. CHECK VALVE INSPECTION Note + The check valve is pressed into the vacuum hose. + The arrow on the hose indicates the direction of hose installation (toward engine). 1. Remove the clamps and remove the hose (with the internal check valve). 2. Apply a suction and pressure to the hose from the engine side. Verify that air flows only toward the engine. If the air passes in both directions or not at all, replace the vacuum hose (along with the check valve). a7 mon wae52-10 BRAKE SYSTEM BRAKE PEDAL BRAKE PEDAL INSPECTION (ON-VEHICLE) BRAKE PEDAL HEIGHT Inspection Verify that the distance from the center on the pedal pad to the dash lower panel mat is as specified. Specification : 205 mm (8.07 in) Adjustment 1. Disconnect the stoplight switch connector. 2. Loosen the locknut @ and turn the switch @ until it does not contact the pedal. 3. Loosen the locknut ® and turn the rod © to adjust the height of the brake pedal. 4, Tighten the stoplight switch until it contacts the pedal then tum it an additional 1/2 turn. Tighten the locknuts @ and O. Tightening torque : 23,5~34.3 Nem (2.4~3.5 kg-m, 17.4-25.3 lb-ft) 5. Verify the operation of the stoplight. Pedal Play Inspection 1. Depress the pedal a few times to eliminate the vacuum in the system. 2. Gently depress the pedal by hand and check the free play (until resistance is felt) Free play : 4-7 mm (0.16~0.28 in) Agjustment 1. Loosen the locknut ® and tum the rod © to adjust the free play. 2, Verity the pedal height and the stoplight operation. 3. Tighten a lock nut ©. Tightening torque = 23.5-34,3 Nem (2.4-3.5 kg-m, 17.4-25.3 lb-ft) 4, Check the height of dedal and the lightening of stop lamp af- ter the adjustment. Pedal-To-Floor Clearance Inspection Verty thatthe distance from the floor panel to the center of the pedal pad is as specified when the pedal is depressed with a force of 490.33 N (50 kg) MIN. Pedal-to-floor clearance : 74 mm (2.9 in) If the distance is less than specified, check for the following problems: 1. Air in brake system 2. Malfunction of automatic adjuster (rear drum brakes) 3. Worn shoes or pads PEDAL-TO-FLOOR ‘CLEARANCE. PEDAL PU AY odPOWER BRAKE UNIT BRAKE SYSTEM 52-11 POWER BRAKE UNIT QUICK INSPECTION (ON-VEHICLE) Power brake unit function check (Simple method) Step 1 1. With the engine stopped, depress the pedal a few times. 2. With the pedal depressed, start the engine. 3. Ifimmediately after the engine starts the pedal moves down slightly, the unit is operating, Step 2 Start the engine. Stop the engine after it has run for 1 or 2 minutes. Depress the pedal with the usual force. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating, 5. Ifa problem is found, inspect for damage of the check valve or vacuum hose and examine the installation. Repair if nec- essary, and inspect it once again. pene Step 3 . Start the engine Depress the pedal with the usual force. . Stop the engine with the pedal held depressed. . Hold the pedal down for about 30 seconds. . If the pedal height does not change, the unit is operating. . If there is a problem, check for damage to the check valve or vacuum hose, and check the connection. Repair if neces- sary and check once again. eoseNe If the nature of the problem is stil not clear after the 3 steps above, follow the more detailed check described in the “Method-using tester” below. (Method-using tester) Connect the SST, vacuum gauge ®, and pedal depression force gauge ® as shown in the figure. After bleeding the air from the SST, conduct the test as described in the 3 steps be- low. Note + Use a commercially available vacuum gauge and pedal depression force gauge. a) Checking for vacuum loss Unloaded condition 1. Start the engine. 2, Stop the engine when the vacuum gauge reading reaches 66.7 kPa (500 mmHg, 19.7 inHg). 3. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3~66.7 kPa (475~500 mmHg, 18.7~19.7 inHg), the unit is operating, G FOR 30 ‘SECONDS. ie52-12 BRAKE SYSTEM POWER BRAKE UNIT Loaded condition 1. Start the engine. 2. Depress the brake pedal with a force of 196 N (20 kg, 44 Ib). 3. With the brake pedal depressed, stop the engine when the vacuum gauge reading reaches 66.7 kPa (500 mmHg, 19.7 inHg). 4, Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3~66.7 kPa (475~500 mmHg, 18.7~19.7 inHg), the unit is operating. b) Checking for hydraulic pressure 1. If with the engine stopped (vacuum 0 kPa (0 mmHg, 0 in- Hg)) the fluid pressure is within the specification, the unit is operating. Pedal force N (ke, 16) | Fluid pressure kPa kglem psi) ~ B3 MT | 1,470 (15, 213) | 198 20,48) ‘AT | 1.280 (13, 185) es [4.17 02, 7) 2. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa (500 mmHg, 19.7 inHg). If the fluid pres- sure is within the specification, the unit will operate, [7 Pedalforce N(kg,lb) | Fluid pressure kPa (kg/em?, psi) 1 po | MT_| 8.040 (62, 1.165) 196 (20, 44) ‘AMT_| 6,440 (86, 1,223) BS | 7,068 (72, 1,024) 29 @ 77196 N (20 kg, 44 1b) a @ ») ae ® ea7iea ong ema \ aPROPORTIONING VALVE BRAKE SYSTEM 52-13 INSPECTION 1. Connect the SST to the brake pipes with adapters as shown PROPORTIONING VALVE c | in the figure. | Adapter and flare nut tightening torque : 12,8-21.5 N.m (130-220 kg-cm, 113~190 tb-in) Note | + Disconnect and connect the brake pipes with SST. 2, Bleed the air from the brake system. 3. Depress the brake pedal until the master cylinder pressure equals to A; then record the rear brake pressure A’ 4. Depress the brake pedal again, apply the additional pressure until the pressure equals to B; thenrecord the pressure B’ Fluid pressure | | kPa (kglome, psi) i | a Te ! 2,450 (25,960) 2,450 (2,380) | | nasrencvunoerbressune kPa atone eh _ +200 (2,90) ——vKrKervr'—— Caution «+ Do not attempt to adjust the dual proportioning valve. + After the inspection, bleed the air from the brake sys- tem and check for the fluid leakage. « If the measurements are not within the specification, replace the valve assembly.52-14 BRAKE SYSTEM BRAKE PEDAL Pa EE BRAKE PEDAL REMOVAL AND INSTALLATION Bi 1. Split pin 7. Spacer 2. Clevis pin 8. Bushing 3. Retum spring 9. Brake pedal 4, Nut 10. Stopper rubber 5. Washer 11. Brake pedal pad 6. Bolt 12. Stoplight switchBRAKE PEDAL BRAKE SYSTEM 52-15 Removal Disconnect the negative battery cable. Remove the split pin from the brake pedal clevis pin and re- move the pin. Remove the pivot bolt attaching nut, lockwasher, and spring washer. Remove the spacer from the pivot bolt. Slide the pivot bolt to the right and remove. Remove the brake pedal, brake pedal return spring, and spacers. If necessary, remove the brake pedal bushings, foot pad, and stop bumper. Par o Vo N Installation 1. If necessary, install the brake pedal stop bumper, foot pad, and bushings. Position the brake pedal spacer and slide the pivot bolt through to hold it in position. Position the return spring on the brake pedal. Position the clutch pedal, if equipped, and slide the pivot bolt through to hold it in position, Install the clutch pedal spacer, if equipped. Install the pivot bolt attaching washers and nut. Install the brake pedal clevis pin and split pin. . Connect the negative battery cable. se Pp ero52-16 BRAKE SYSTEM MASTER CYLINDER MASTER CYLINDER REMOVAL / INSTALLATION co 41. Brake fluid level sensor connector 3, Nut and washer 2. Brake pipe 4, Master cylinder assembly Removal —_ 1. Disconnect the low fluid level sensor wiring connector. 2. Disconnect the brake lines. Cap the tubes and plug the master cylinder ports to prevent the entry of contaminants. 3. Remove the two master cylinder attaching nuts and wash- ors. 4, Remove the master cylinder from the mounting studs on the brake booster. Installation 1. Position the master cylinder on the brake booster. Refer be- low to check push rod length. Piston to push rod clearance Standard type a) Place the SST on the master cylinder. Turn the adjusting bolt until it bottoms in the push rod hole in the piston. Fa ADJUSTING BOLT =e aMASTER CYLINDER BRAKE SYSTEM 52-17 b) Apply 500 mmHg (19.7 inHg) vacuum to the power brake unit with a vacuum pump. c) Invert the adjustment gauge used in Step 1 and place it on the power brake unit. d) Measure the clearance between the end of the gauge and the push rod of the power brake unit. If it is not © mm (0 in), loosen the push rod locknut and tum the push rod to make the adjustment. Note + By making the above adjustment, the clearance be- tween the push rod and piston (after installation of the brake master cylinder to the power brake unit) will be as shown in the table below. Ea Vacuum applie Push rod-to-piston clearance (mmHg (0 inkig) 124 in) ‘Approx. 500 mmHg (19.7 inHg) (0.10.4 mm (0,004-0.016 in) 2, Install the master cylinder attaching washers and nuts. Tighten the master cylinder attaching nuts. Tightening torque : 9.81~15.7 Nem (1.0~1.6 kg-m, 7~12 lb-ft) Brake pipe 3. Tighten the brake pipe flare nut with the SST. Tightening torque : 13-22 N-m (1.3-2.2 kg-m, 10~16 lb-ft) 4. Connect the low fluid level sensor wiring 5. Bleed the brakes. aoa52-18 BRAKE SYSTEM MASTER CYLINDER Disassembly / Inspection / Assembly Caution ‘Secure the master cylinder flange in a vise when necessary. + Replace the piston assembly, if necessary. aie 1. Cap Set 9. O-ring 2. Float 10. Piston guide 3. Fluid level sensor 41. Cup 4, Sorew 12. Stopper 5. Reservoir 13. Primary piston assembly 6. Joint bushing 14. Secondary piston assembly 7. Snap ting 15. Master cylinder body 8. SpacerMASTER CYLINDER BRAKE SYSTEM 52-19 Disassembly 1. Remove the cap and drain the master cylinder reservoir. Remove the master cylinder. 2. Remove the reservoir attaching screw. 3. Carefully pry the reservoir out of the master cylinder. 4, Remove the reservoir seals from the master cylinder. 5. Push the primary piston into the master cylinder bore to ease the snap ring removal. Remove the primary piston snap ring and the primary piston. 6. Push the secondary piston into the master cylinder bore be- fore removing the stop screw. Remove the secondary piston stop screw. 7. Remove the secondary piston assembly by gradually apply- ing the compressed air into the cylinder. Caution + Use a rag to stop the secondary piston assembly. + Do not use a petroleum based solvent, kerosene, or gasoline for cleaning the master cylinder parts. Their use as a cleaning agent can leave residues which can damage the rubber seals. ‘ATTACHING ‘SCREW RESERVOIR 1] RESERVOIR 7 ‘SECONDARY PISTON STOP SCREW, PUSH PISTON INTO BORE wo 205 ST52-20 BRAKE SYSTEM MASTER CYLINDER ‘Assembly Note + As the master cylinder parts are assembled, they must be lubricated with a clean brake fluid. 1. Install new seals on the primary and secondary pistons. 2. Lubricate the secondary piston with a brake fluid and install. 3. Install the secondary piston stop screw and O-ring such like below. Stopper screw and O-ring a) Push the secondary piston assembly in fully. b) Install and tighten a new O-ring and stop screw. c) Push and release the piston to verify that it is held by the stop sorew. Install the primary piston. Install the primary piston snap ring. Push the piston into the master cylinder bore to ease snap ring installation. Install new reservoir seals. Install the reservoir. Install the master cylinder in the vehicle and bleed the sys- tem. PND OePROPORTIONING VALVE BRAKE SYSTEM 5; PROPORTIONING VALVE REPLACEMENT 1. Remove the brake pipe shown in the figure. 2. Remove the bolt. 3, Remove the proportioning valve. 4, Install in the reverse order of removal. 5. After the installation, add a brake fluid, bleed air and check for the fluid leakage. BRAKE LINE ‘RIGHT FRONT BRAKE LINE SLEFT FRONT. PROPORTIONING VALVE52-22 BRAKE SYSTEM PROPORTIONING VALVE Removal / Installation Note Brake pipe Loosen and tighten the brake pipe by using the SST. Tightening torque : 13-22 N-m (1.3-2.2 kg-m, 10-16 lb-ft) Installation Note Dual proportioning valve Install the dual proportioning valve with R marks facing the right side. EdPOWER BRAKE UNIT BRAKE SYSTEM 52-23 POWER BRAKE UNIT REMOVAL AND INSTALLATION Caution Take the following steps after the installation: ‘Add a fluid and bleed the air. + Check all parts for the fluid leakage. + Adjust and check the brake pedal operation. + Make an on-vehicle check of the unit. POWER BRAKE UNIT COTTER PIN LEVIS PIN RESERVE TANK. _ nur BRAKE PIPE. s \ Removal 1. Disconnect the fluid level warning connector. Remove the brake pipes. Remove the master cylinder Disconnect the vacuum supply hose from the power brake unit. From inside the vehicle, remove the cotter pin securing the levis pin. Remove the clevis pin from the clevis. Have a second technician support the brake booster in the engine compartment. Remove the four brake booster mounting nuts securing the brake booster to the bulkhead Remove the brake booster. Remove the gasket between the brake booster and the bulkhead. © 2 ND 7 SoM 3 Installation Note + Lubricate the clevis pin with white lithium grease. To install, reverse the removal procedure. Tighten the four brake booster mounting nuts. Tightening torque 18.6-25.5 Nem (1. 2.6 kg-m, 13.7~18.8 lb-ft)52-24 BRAKE SYSTEM FRONT DISC BRAKE FRONT DISC BRAKE DESCRIPTION AND OPERATION The front disc brake system consists of a full-floating caliper and ventilated rotor. The caliper is attached to the steering knuckle with two attaching bolts that also serve as the caliper slide pins. The single piston caliper applies brake pads that are held in position by a wire clip and two pins. The brake shoes are prevented from rattling against the caliper and pins by an M-shaped anti-rattle spring that main- tains a constant pressure on the shoes. A flexible hose is used to connect the caliper to the hydraulic system. Leakage at the hose connection is pre- vented by the copper washers installed on either side of the hydraulic fitting. oy 1. M-spring 7. Guide plate 2. Pin retainer 8. Brake hose bolt 3. Pad pin 9. Brake hose 4, Disc pad 10. Caliper bolts 5. Brake pad shims (Inner) 11. Caliper 6. Brake pad shim (Outer)FRONT DISC BRAKE_BRAKE SYSTEM 52-25 Replacement Disc pad 1. Raise and support the vehicle. 2. Remove the wheel. Caution + Do not use a screwdriver or similar tool to pry the piston away from the rotor. 3. Remove the brake pad pin retainer. 4, Disengage the anti-rattle spring from the brake pads. 5. Remove the brake pad pins and the anti-rattle spring. Note * Do not discard the shims found behind the brake pads. 6. Remove the brake pads and shims. Inspection Disc pad 1. Check for the oil or grease on the facing, abnormal wear or cracks, and deterioration or damage from heat. 2, Measure the thickness of the lining, ‘Specified thickness : 10 mm (0.39 in) Minimum + 2.0 mm (0.08 in) 3. Check visually for the damage or wear of the guide plate. BBAKE PAD PIN BRAKE PAD PIN) RETAINER ANTLRATTLE ‘SPRING BRAKE PADS. 08 ANT-RATTLE SPRING BRAKE PAD PIN 3206652-26 BRAKE SYSTEM FRONT DISC BRAKE Installation 1. Push the piston back into the caliper bore. 2. Apply the grease supplied with the brake pad set to both ‘surfaces of the inner shim and to the back of the brake pad Note + Ensure the shims are installed with the inner and outer pads. Install the brake pads and shims. Install the brake pad pins. Install the anti-rattle spring. Install the brake pad pin retainer. Install the wheel and tire assembly. Tighten the wheel at- taching bolts. Tightening torque : 88-118 N.m (9. 8. Lower the vehicle. 9. Check the master cylinder fluid level. Add a fluid as necessary. Noga 12.0 kg-m, 65-87 Ib-ft) Removal and Installation Caliper Removal 1. Remove the brake pads. 2. Remove the caliper brake hose bolt. Discard the seal wash- ers. 3. Remove the caliper bolts and the caliper. 4, Remove the anti-squeak caps. Inspection Disc plate 1, Measure the thickness of the disc plate. Standard ‘AIT : 22 mm (0.86 in) MT: 18 mm (0.71 in) Minimum AIT : 20 mm (0.78 in) WT: 16 mm (0.63 in) 2. Measure the runout at the outer edge of the contact surface of the disc pad. Runout : 0.1 mm (0.004 in) max. Caution + There must be no wheel bearing looseness. CALIPER BRAKE. HOSE BOLT EyFRONT DISC BRAKE_ BRAKE SYSTEM 52-27 Installation 1, Install the anti-squeak caps. GAuPER 2, Position the caliper on the steering knuckle and install the caliper bolts and tighten. Tightening torque : 39-49 Nem (4.0-5.0 kg-m, 29-36 Ib-ft) 3. Connect the caliper brake hose. Be sure to use new seal washers. Tighten the caliper brake hose bolt. Tightening torque : 22-29 Nem (2.2-3.0 kg-m, 16-22 lb-ft) 4, Install the brake pads. 5, Bleed the brakes. Refer to the procedure in this section. CALIPER BRAKE HOSE BOLT52-28 BRAKE SYSTEM CaLiPER CALIPER DISASSEMBLY / ASSEMBLY ® © S—Op © ® - sare 1. Retaining ring 6. Bleeder sorew 2. Piston 7. Bushing 3, Dust boot 8. Seal 4, Piston seal 9. Caliper 5. Cap 1. Loosen the bleeder screw and drain the brake fluid out of the caliper. Install the bleeder screw. ust Boor 2. Remove the dust boot retaining ring. 076CALIPER BRAKE SYSTEM 52-29 . Position a block of wood or a roll of shop towels between the piston and the caliper. Warning + Do not use an excessive amount of air pressure to remove the piston. Excessive pressure can force the piston out of the caliper bore with enough force to cause personal injury. Never attempt to catch the piston by hand as it comes out of the caliper bore. Note + A compressed air can be used as an alternative to removing the caliper piston. Apply the air pressure through the fluid inlet port. Apply only enough pressure to ease the piston out of the bore. Remove the piston Remove the dust boot from the piston and discard, Caution + Do not use a screwdriver or other metal tool. A met- al tool can scratch or nick the seal groove resulting in a possible leak. .. Remove the piston seal from the caliper bore. Use a plastic or wooden stick to remove the seal, Remove the bleeder screw. Remove the caliper bushings and the bushing seals. Caution * Do not use petroleum based solvent, kerosene, or gasoline for cleaning caliper parts. Their use as a cleaning agent can leave residues which can dam- ‘age the rubber seals. Wash the parts in clean denatured alcohol and dry with a compressed air AIR PRESSURE NOZZLE 07 DUST,BOOT | Piston | | NON-METALIC TOOL, 2078 BUSHING SEAL SEAL BUSHING re52-30 BRAKE SYSTEM CALIPER Assembly 1. Install the piston seal. ny LUBRICATE WITH PINK GREASE Ed Lubricate the piston seal with the pink grease and install tin the caliper. 2081 2. Lubricate the piston with brake fluid and partially install the piston. The dust bot groove must remain above the caliper ore. ‘3. Lubricate the dust boot with the pink grease then install it on the piston. 4, Press the piston into the caliper unti it bottoms in the bore. 5. Install a new dust boot retaining ring. bust soar seAL MUST REMAIN AGOVE PISTON LUBRICATE CALIPER BORE WITH BRAKE FLUID CR 6. Install the bleeder screw. 7. Install the caliper bushings and new bushing seals. 8. Lubricate the inside surface of the bushings with the pink grease contained in the overhaul kit. Do not allow the grease to enter the bushing bore. wuenicars ITH PINR| ‘GREASE, usT BCoTREAR DRUM BRAKE BRAKE SYSTEM 52-31 REAR DRUM BRAKE ‘Stopping power is provided by front disc brakes and rear drum brakes. The rear brakes are a standard non- servo, selt-energizing design. The brakes are applied by a double-acting wheel cylinder mounted at the top of the backing plate. The self-adjuster is mounted on the parking brake strut. When the clearance between linings and drum be- comes excessive, the brake shoe pulls the adjuster cam, disengaging the teeth on the cam and strut. A spring rotates the cam to a new position that holds the brake shoes closer to the drum. ‘SPRING PULLS CAM JO NEW PISTON. BRAKE SHOE MOVES CAM MOVES 70, "TOWARD DRUM NEW PISTON: cam(6 putteo ALONG WITH DRUM PARK BRAKE LEVER, PARK BRAKE STRUT BRAKE SHOE SELF-ADJUSTER CaM Ea52-32 BRAKE SYSTEM REAR DRUM BRAKE Removal and Installation se 1. Hub cap 8. Upper retum spring 2, Look nut 9. Anti-rattle spring 3. Brake drum 10. Leading shoe 4. Lower retum spring 11. Operating lever assembly 5. Hold pin 12, Wheel cylinder assembly 6. Hold spring 13, Backing plate 7. Trailing shoe Removal 1. Remove the grease cap. 2, Remove and discard the spit pin. Remove the attaching nut. 3. Remove the drum, washer and bearings as an assembly from the spindle. J 3 4, Remove the brake shoe hold-down springs and pins.REAR DRUM BRAKE BRAKE SYSTEM 52-33 5, Remove the brake shoe return springs. Pull the brake shoes away from the backing plate and remove. Brake Drum 1. Inspect the inside of the brake drum for scratches and un- even or abnormal wear. 2. Repair minor damage or replace if damage is excessive. 3. Measure the inside diameter of the brake drum using Brake Drum Micrometer or equivalent. 4, The standard inner drum diameter is 200 mm (7.87 inches). ‘The maximum diameter is 201 mm (7.91 in). Caution + Be sure to check the drum-to-shoe contact after re- pairing or replacing the brake drum. 5. Check the brake linings for peeling, cracks, or extremely un- ‘even wear. 6. If the brake lining thickness is less than 1.0 mm (0.04 inch), replace the brake shoes. Installation 1. Clean the backing plate with an approved vacuum cleaner. 2. Lubricate the backing plate shoe pads. ‘SECONDARY BRAKE SHOE | BRAKE SHOE RETURN SPRING, 32088 MAXIMUM DIAMETER woe52-34 BRAKE SYSTEM REAR DRUM BRAKE 3. Install the brake shoe upper return spring on the primary brake shoe. 4, Position the primary brake shoe on the backing plate and in- stall the hold-down pin and spring. 5. Connect the upper return spring to the secondary brake shoe and position the shoe against the backing plate. 6. Install the secondary brake shoe hold-down pin and spring. 7. Install the parking brake retum spring. 8. Install the lower brake shoe return spring. 9. Set the self-adjuster to the fully released position 10.Place a screwdriver against the adjuster cam and push it to the released position. | ~9@ 11. Install the brake drum. | > 12. Push the brake pedal several times to set the selt-adjuster. primary [BRAKE SHOE LOWER BRAKE SHOE RETURN SPRING BebeREAR DRUM BRAKE_BRAKE SYSTEM 52-35 Wheel Cylinder Brake Hose Removal 1. Remove the rear wheel and tire assembly, 2, Remove the retaining clip from the body routing bracket. Disconnect the wheel cylinder hose from the body brake line. Remove the brake line retaining clip from the torsion beam routing bracket. Disconnect the wheel cylinder brake hose from the torsion beam brake line. Installation 1. Connect the wheel cylinder brake hose to the body and tor- sion beam brake lines. Install the routing bracket clips. Install the rear wheel and tire assembly. Tighten the wheel attaching bolts. 2 3. Tightening torque : 88~118 Nem (9.0~12.0 kg-m, 65-87 Ib-ft) 4, Bleed the brakes. Refer to the procedures in this section Wheel Cylinder Removal 1. Remove the rear brake shoes. 2. Disconnect the brake line from the wheel cylinder. 3. Remove the two wheel cylinder attaching bolts and the wheel cylinder. installation 1. Position the wheel cylinder on the backing plate and install the two wheel cylinder attaching bolts. Tighten the two wheel cylinder attaching bolts. Tightening torque : 10-13 N-m (1.0-1.3 kg-m, 7-9 Ib-ft) Connect the brake line, Install the rear brake shoes. Bleed the brakes. Refer to the procedure in this section, Se BRAKE LINE FITTING (” 7 BETBINING CLP — [PS ——— BRAKE HOSE52-36 BRAKE SYSTEM WHEEL CYLINDER WHEEL CYLINDER DISASSEMBLY / ASSEMBLY sgt 1, Dust boot 5. Rubber cap 2. Piston 6. Bleeder screw 3. Cup 7. Wheel cylinder body 4. Spring Disassembly 1. Remove the dust boots and discard. Remove the pistons and the retum spring. Remove the piston seals and discard. Remove the bleeder screw and the ball seal. -ON Caution + Do not use petroleum based solvent, kerosene, or gasoline for cleaning wheel cylinder parts. Their use as a cleaning agent can leave residues which can damage the rubber seals. 5. Wash the parts in clean denatured alcohol and dry with compressed air. Assembly 1. Install the seals on the pistons. 2. Lubricate the wheel cylinder bore and pistons with the specified brake fluid. 3. Install the return spring, pistons, and dust boots. 4, Install the ball seal and the bleeder screw.DESCRIPTION AND OPERATION BRAKE SYSTEM 52-37 PARKING BRAKE SYSTEM DESCRIPTION AND OPERATION The parking brake is a system of levers with an interconnecting metal cable used to mechanically apply the rear brakes. The hand lever used for application of the parking brake is mounted on the floor-panel between the two front seats. From this lever, the cable extends to an equalizer attached to the rear axle. The equalizer ‘serves as a dividing point where the cable splits and connects to a lever at each rear brake. When the parking brake lever is pulled upward, its motion is transferred through the cable to the equalizer. The action of the equalizer divides the force transferred through the cable to each rear brake. The lever at the. rear brake transfers its motion through a strut which pushes the brake shoes outward against the brake drum, Pressing the button on the end of the parking brake lever releases the lock paw holding the parking brake in the applied position. As the lever is lowered to the floor, springs in the rear brake assembly will pull the brake shces away from the brake drums, waive 1. Clevis pin 7. Tapping screw 2. Split pin 8. Parking cable 3. Clip 9. Clip 4, Bolt 10. Adjust screw 5. Clip 11. Parking brake lever 6. Parking cable cover52-38 BRAKE SYSTEM TROUBLESHOOTING GUIDE ——— TROUBLESHOOTING GUIDE Problem Possible cause ‘Action ~ Brakes do not Improper return of parking brake cable or improper Repair or adjust release adjustment Parking brake does Excessive lever stroke ‘Adjust | rot hold well Brake cable stuck or damaged | Repair or replace Brake fluid or oil on ining Clean or replace Hardening of lining surface or poor contact Grind or replace ADJUSTMENTS Parking Brake Cable 1. Ensure the parking brake lever is in the fully released posi- tion. 2, Remove the parking brake console access cover. 3, Remove the locking clip from the cable adjuster nut. 4, Raise the vehicle and ensure the rear wheels are free to tum. 5. Tighten the cable adjuster nut until there drag when the rear wheels are rotated. a slight brake 6. Loosen the cable adjuster nut in small increments until the brake drag disappears. Note + The rear brakes should lock when the parking brake lever is pulled upward 6~8 notches. . Check the operation of the parking brake. . Install the locking clip onto the cable adjuster nut. ). Install the parking brake console access cover. ©@Nn access \ ‘Cover PARKING BRake aalh CONSOLE 22104 ra | avidin A NSAES co.PARKING BRAKE LEVER BRAKE SYSTEM 52-39 PARKING BRAKE LEVER Removal / Installation =a 1. Access cover 8. Parking lever cover 2. Console 9. Retum spring 3. Parking brake switch 10. Adjuster nut 4, Parking brake cable 11. Attaching screw 5. Attaching bolts (2) 12. Attaching screw 6. Parking brake lever 13. Clip 7. Push button Removal 1, Remove the parking brake console. 2. Remove the locking clip from the cable adjuster nut.52-40 BRAKE SYSTEM PARKING BRAKE LEVER 3. Remove the cable adjuster nut. 4, Disconnect the wiring connector from the parking brake switch. HD 5. Remove the two attaching bolts and the parking brake lever. a Installation To install, reverse the removal procedure. Tighten the two parking brake lever attaching bolts. Tightening torque : 19-26 N-m (1.9-2.6 kg-m, 14.3-19.2 Ib-ft)PARKING BRAKE CABLE_BRAKE SYSTEM 52-41 PARKING BRAKE CABLE Removal / Installation 1. Clevis pin 7. Tapping screw 2. Split pin 8. Parking cable 3. Clip 9. Clip 4. Bolt 10. Adjust screw 5. Clip 11. Parking brake lever 6. Parking cable cover Removal 1. Remove the attaching screws and the parking brake con- sole bracket. 2, Remove the parking brake lever. 3. Remove the two rear seat hinge attaching bolts. nesgsexr |} (FOLDED. BACK) LE Q Y wai52-42 BRAKE SYSTEM PARKING BRAKE CABLE 4, Fold the rear seat forward and remove the two rear seat hinge attaching bolts. SESEAT ATTACHING (FOLDED “BOLT @) FORWARD) (REAN) 4 5. Remove the rear seat. 6. Remove the rear carpet push retainers and carefully pull the carpeting forward to expose the parking brake cable cover. CARPET RETAINER, REMOVAL 7. Remove the two parking brake cable cover attaching screws. Remove the parking brake cable cover. COVER wai Ea 8. Raise and support the vehicle. 9. Remove the rear wheel and tire assemblies, 10. Remove the split pin and clevis pin attaching the levers. | 11. Remove the parking brake cable retaining clips. 12, Disengage the parking brake routing sleeves from the tor- sion beam routing brackets ROUTING BRACKET. cues route \ \ SLEEVE) ROUTING sACKET YC _f-R ‘SPUTPIN| tevERPARKING BRAKE CABLE_BRAKE SYSTEM 52-43 13. Remove the nut or clip which attaching the parking brake routing bracket to the fuel tank. 14, Remove the parking brake cable equalizer attaching bolts. 15. Pull the lever end of the cable through the body hole and re- move from the vehicle. Installation 1. Position the lever end of the cable through the body hole. 2. Position the cable routing bracket or clip on the fuel tank and install the attaching bolt and nut. 3. Make sure the cable seal is properly seated in the floor-panel. 4. Position the cable equalizer and install the attaching bolts. Make sure the equalizer spacers are in position before in- stalling the attaching bolts. . Route the cable ends through the body brackets and install the retaining clips. ‘Seat the cable sleeves in the torsion beam routing brackets. Attach the cable ends to the brake levers using the clevis pins and new split pins. Install the wheels. Tighten the wheel attaching bolts. 2 ND w Tightening torque : 88~118 N-m (9.0~12.0 kg-m, 65~87 Ib-ft) 9. Lower the vehicle. 10. Route the end of the cable through the parking brake lever. 411. Position the cable cover and instal the attaching screws, 12. Position the carpet and install the push retainers. 1, Install the rear seat. Tighten the front and rear seat hinge at- taching bolts and nuts. Tightening torque : 38-51 Nem (3.8-5.1 kg-m, 28~38 lb-ft) 14. Position the console mounting bracket and install the attach- ing screws, 15. Install the parking brake lever. Refer to the procedure in this section.52-44 BRAKE SYSTEM SPECIFICATIONS SPECIFICATIONS Engine type BS BS Model wr ar WT and AT ftem Brake pedal | Type ‘Suspended ~ Pedal iever ratio 42:1 Max. stroke rm (in) 140 (6.52) Master Type ‘Tandem (with level sensor) oylinder ‘Oylinder inner diameter _mm (in) 20.64 (0.81) 122.22 (0.8748) — Front dsc | Type Ventilated dise brake ylinder bore ram (in) 50.8 (2.00) 5421) Pad dimensions (area x thickness) £3,800 (6 89) X 10 (0.39) 3,750 X11 rm? (int) mn (in) (681 X0.453) Dise plate dimensions mm (in) 235 18 285 X22 249.20 (outer diameter X thickness)| (8.25 X 0.70) (925 x 0.88) (9570.79) Roar Type Leading aling ‘drum brake | Wheel ojinder inner dametermam (in) 17.46 (0.6874) Lining dimensions mm (in) ‘30x 192X4 30x 1745X5 (wich x length X thickness) (1.27.56 X0.16) (1.2687 X02) Drum inner diameter mm (in) 200 (7.87) ‘Shoe clearance adjustment ‘Automatic adjuster Powerbrake | Type Vacuum multiplier Boost C3 Diameter in 3 3 8 Braking force | Type Dual Proportioning control device proportioning valve valve Brake fuid SAE J1708 or FMVSS 116, DOTS Parking brake | Type Mechanical two-rear-whee! control ‘Operation system Center leverSERVICE SPECIAL TOOLS BRAKE SYSTEM 52-45 SERVICE SPECIAL TOOL 0k130 430 019 For 993 420 032 For removal and adjustment ofthe Flare nutwrench GIS | instalation ot | Adjustment push rod gap brake pipe gauge 0130 430 017 For 0201 660 001 For assombly of disk assembly of Disk brake pad Sensor rotor | sensor sor expander installer | rotor | (0670 990 AAO For removal of Bearing installer sensor rotor set Ae €