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    Romeo Belko
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    © All Rights Reserved
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    3 views64 pages

    Hyndai BR

    Uploaded by

    Romeo Belko

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 64
    Brake System GENERAL cscs stseentnenetntnesene BR-2 BRAKE SYSTEM... -BR- 9 LSPV (LOAD SENSING PROPORTIONING VALVE) ......:s.essss BR 26 PARKING BRAKE SYSTEM BR-28 [ABS (ANTI-LOCK BRAKE SYSTEM) . BR-30 BR2 GENERAL SPECIFICATIONS exes Masi finder Te 1D. mm tn) Becstng rato Front brake 8 Dee 00. ise tckness| Oxtnde 1.0. rake 18 Etectve da, oxtngr 1.0. Cearanco adjustment Paring brake ecuston Pe 00. = Outer dameter 10, = tar ameter Mechanical brake acing BRAKE SYSTEM Spoateaton| Tandem type 254 (19) Provided \acaum type with tandem beoter 70:1 Disc pe 2545 (1002 in): 20.2765 men (1088) : 4D 24 rem (0965 in} 10 mem (0304 in) 429 mm (1.69 mn) 0) Leading wrling rum 270 mim (1.63 in} 2223 me (088 In} GENERAL BR SERVICE STANDARD cn Service it Slanded aloe ‘rake posal height 170 mm (65916) Clearance beeen sop lamp sch outer 080 and pedal stesper Brake pods! roe pay Clearance between brake pel and aor boars Peking brake lower sroko (non oor ascomby | puted wah 196N 20k, 4) ore Front ese brake pa hikes Front thickness (minimum) Front ie runout Fear cram 1D. esr broke ning teks TIGHTENING TORQUE. eon 05:1.0mm(0020-0.028in) 38mm (01203in) 70 rm (273) 79 ke 20mm (07s n) 10mm (0304 ny 24 mm (088in) 26 mm (0845 n) 0.05 mem (0.002 n) (2.005 mm (0.0082 in) 272mm (1071) 270ne (10850 in) 1.5 mm (0059in) 4.7mm (185 in) ro Koon ‘aster cylinder to booster mounting nut B12 ‘80-120 rake booster mounting nut 136 120-160 oats ‘Brake toosor vacuum hos ting fo surge tank 1518 150-180 m9 Front teed scr 79 70-90 566 Brake fare mit, brake hose sa7 10-170 eae Fear bleed sew on 7-130 594 Caliper guide rad tot zoe 220-220 1628 Calpe assem to knee eo100 | e00-r000 5073, ‘rake hoes to font caliper 25.20 zsosuo | 1e5222 Wee! eynder mounting bot re18 120-180 sa13 Parking take mounting tat wr28 170-280 219 Wes! speed sensor meuntng bot Frontost) e207 297 5768 Hysraue & etetonie cont unt mounting bot 2510 5-100 67 Hygraue &olcroni canto! unt mounting bracket bal 25-0 85-100 67 ‘Sx brake tubs on the Hyaue Unit [tsar 120-170 oe G cauTion ‘Replace te soltlocking nuts with new ones ater BRA BRAKE SYSTEM LUBRICANTS: sane ne Recomended Wicd ‘ausnity | [rae 2OT8 e Dore soo ‘rake peal buting anda pdalbok | Gases aso SAE J10, NGI HOO fees [ies in Whee beste see SAE INO, NLGINE® [A eed raking brake sa and basing plate | Beang grease, NLGI No 7e equ SPECIAL TOOLS. esas “oo! (Wurber and Name) ee ‘ase - 17000 Pushing back of he Font dis and veer Piston expander fase wake ison TROUBLESHOOTING esse Todo ym Probate caus ened ] fig oc viaton when caper imoropery mouried onteet Looe caliper mounting tote thon Uneven worn orcrachod baka drum ortrakedise | Replace Foign material a brake darn ean ‘Seued pad or ning contact sutaco pace pase dose ean pat as coed Uneven pad contact onset Lack of Wexieaton in sng parts ubicate Loose suspension pars atighon Excneshe se runout epace diss ‘orci pal To ane ade | Dilerence in and right re nfatonprossuwe | Ads when brakes ae apples | magequate contacto pa er ning ‘coneet ‘Grease or lon pad o ring srace pace ‘rum warpod or uneven wear piace Incooet wheel clndsrnsallaton ‘conet ‘Auto adie maluncion Conect Rs GENERAL Toube syrpiom Probabe enue Femedy Trefcon raking power | Low or detovoraed brake id ello change Ain tho bra syste Blood He syst Brake booster matuncton Conact Insdauate contact of pad ing Comoct {roase o ol on pad ining sutaco Replace Auto acuster matinetion Corot vemested brako oor cu to craging of padetning | Cvect Festictod baka Ine epace Proprtoning vale maltincton Ferlace Trereasod pedal soke [Arn the syst Blea he satan vagus rake Hid oaks Comost (Redveed clearance Dotween peda and Exoossivo push edt masta eyindertosranse | Ast ocr) rake crag Tnsamplie eaasa of paring baka or Incorrect parking brake ecjstment Adjust Worn brake pea! rtun spring Replace Festictod mastor cylinder rtun pct Comat {rokan rear cru bake shoe turn spring Replace Lack of ubeaton i ling parts Luareate Detective mastor clade check vave of Replace pon voir serng Insufcont push red master oynder cleanse | Acust {seen park brs | Worn kenge a lace Grease rollon tng orp suriace Replace Parking brake eae stcking Replace ‘te acjstr matunston ‘coret Excessive paring bake lever soko Aust he pang ra oer Soke of chook the pang brake eatie routing ‘SERVICE ADJUSTMENT PROCEDURES xem INSPECTION AND ADJUSTH prot oasur th baka pada eight the height ent win he standard vee, aust a tons ‘Standard value 170 nen (668m) . explerponn =a Rs 1) Disconet te sip lamp swtehconnactor and Teceen the stop lamp sen lock mat Move hows core he bake pod arm, 2) Loosen he operating rod ick rut and asthe Trane pec! height by turing the aperang rod ‘ith ples uni bs connect rake pedal aight aio 3) Tumthestoplam smc unt ip just ouchas the lab onthe Bake peaal Then trn back 12 to revolution and excrete lk nt 4) Connect ne stop lamp swich connor, 5) Chackthatne stop amp doesn’ Burnt whon tho brake po st dopressed. 2. Winthe onghe stopped, dopress te brake ped two ‘rv tes to eleate the vacuum in the power brake booster Then, press the pods dow by hand {o very thatthe oar of movement before ary ‘Stance (ree pay) switin spoceaton, ‘Standard vue 8 me (072052 1) 1 me tee pay Below the standard value, chee {hatin clearance bot he eur ease ofthe sop lamp svc andthe eke pada within the standard ‘alve, Ife fe plays atove the standard value he clear: ance betwoon te cles pn andthe rake peda ar ‘rosede te standard value necessary, check and rooice. 8. When te engine start! a the bre podal s ‘opressed wth about for, heck oo ak he ‘master oyncer, rake ne and connasons Titer ie oak eps STOP LAMP SWITCH INSPECTION Connect circu str'o the stop amp sich, Wan the ‘sith planers aushed check at eof carina. ter isn cont to stop lamp sch is goo. Nace catty ek pe BRAKE BOOSTER OPERATION TEST Forasimpechoccot bake booster operation, prerm the 1. Rune angie fo one ortwo minutes andthen shut Ct Depress the ako pedal seal mes anormal ‘cot pease. hore podal goes own compet {he rr ima, but ses gradual, ho brake book funstoning propery he haga he peda ost ‘change, he hoeste may be damaped 008 Not good Le GENERAL 22, Afar hesling that the halght ofthe peda changes ‘when doprossng to rako pod! soeraltnos wih the engine stopp, sat keeping the bra pedal Cepresens At he tine, ## ge donn eighty, he oostore good but the night a doesn change, ‘i camegne ‘When engines stopped | When engines stared 5. Whe engine running, depces the brake peal and then sop the engine Ho the pedal Copreesed or ‘0 second. ta pda eight dows nat range, he Soostr sm god cndton he ped ies os carsaged Wane oth above te tse fe not OK, check he ‘acuienhoeas, he ehesk av and brake bose Mane any necessrycorrectons. Hal tests ee OX ‘he unt in good eonston (CHECK VALVE OPERATION CHECK ‘non choskng the check vane brine vacuum hoe, 2p the check va tt 1 Remove th vacuum hoes, Wrote Tho chock vahe i pressed ise the vacuum hose athe poston othe marking. 2. Check ho aeration ofthe chock vale by using a vacuum pure. Vacuum sump | AcceptRojct erloria ‘connection ‘Connacton ee brake | A pogaive proseue booster ce (8) (vacuum) cates and ha ‘onnacon at fake | A nagatve presbure manta i 3) (acca) nat rested GS caumion Ihe check valve is defective, replace it fan a6- ‘sembly unt together wit the vacuum hose. ie Sea Se ( LN Ae BR. BRAKE SYSTEM BLEEDING THE BRAKE SYSTEM. cicnw 1. Removo th reservoir cap adil he brake reservir wih bra AS cauTion Bo not allow brake Mud to remain on a painted Surface. Wash Hof immediately. 2 Connect vinyl tbe to he whee! cylinder Howser Puganainsortthe othr endothe be nacontain rae sd wh a 9. Str he engine 4. Stow depose he brake padal several as, 5. Whe dopressing the brake pedal tly, oosen the ‘ood plug un id rune out ‘Then loss the boda sero and release ne brake pods ») 8. ‘Ropoa! step a8 uti hve ar na mee Bubbles ine 7. Tien te bode’ plug soem, "Bleeder screw lightning torque: 7..Nm (0-90 kgem, 566 bt) 8. Repeat the above prccseura foreach whee! in he soquce ston Inthe lust, BRAKE SYSTEM BR-2 BRAKE SYSTEM BRAKE BOOSTER COMPONENTS so 5, Vacuum nose (in bun ek vate) | exzaoia0.e5) Removal stops 1 Brake tube connection 8 Spitpin 2 Brae ud inv eencor connector 7. Washer 3. Chitchhoteconsacion 8 Clevispin 4 Master naar assombly 3. Brake Doster | ‘ndstrant ot stance beeen bake booster 10. Sealer pushrod and primary piston Spacer ccaTUION. = The cheok valve should not be removed from the vacuum hose. the cheek ve Is defective replace It togethor with the vacuur hose. BR-10 BRAKE SYSTEM BOOSTER PUSH ROD esc ‘Adjust th clerance) the brake Boos push oa ‘Standard value: 0.1258575 rim (00050-5915), 12. clearance i not win the stand value range, a [usb enanging te push od lenge ty tuning the scr ‘tbe push rod BRAKE SYSTEM BR-t MASTER CYLINDER DISASSEMBLY AND REASSEMBLY sxsw i Disassembly stops 1, Reeonoiteap 6 Piston topper ring 2. Reser sopper bls 7. Primary paton assomy { 3. Recent 8. Maser ender boay 4 Reser eos! 8. Secondary pston assertly 5. Fer ‘caution Do not cisassomble the primary and secondary plston assembly BRA2 DISASSEMBLY SERVICE POINTS amv: PISTON STOPPER PIN DISASSEMBLY Remove the piston soper pin, hile cepresing th ps- PISTON STOPPER RING DISASSEMBLY Remove he pton stopper ing, whe sprosing he pis: insPEcrion 1. Check te ine suas of master yinder boy for ster ping 2 Chosk he pimary and secondary pistons for us, Scorng wea, cage or Woe. 8. Chack he salto damage and wear [BRAKE FLUID LEVEL SENSOR CHECK 1 Connect rout tester to brake uae soso, 2. Sensors in good conton heros no eet cont uty wan uingeearoioverandcreut cont ‘hon retuned fo egal poston, BRAKE SYSTEM Gs 1. Apply gone brako fd tothe rubber pat ofthe binder ana rors oxo 2. Carty inset he springs and pistons inthe proper Sireston 3. Press agai he pistons with a srewerivr and she rtsnee tg. 4. Wn the pon pushod completly by a stems, Insta he cxinder pn, 5. Mount wo grommets 6. Install he reer on the eyinder BRAKE SYSTEM BRAKE PEDAL COMPONENTS: xin Removal steps 4. Stop lang ante connector 2. Chach cabo connection (Cable typo chch) 5. Chen tum aping (Cable type cach and hyraue cic in ptol his) 4 Spitpn 5 Washer & Cevapn 7, Caden master cnr mounting nuts Pyare eh) Brake bocetarmovrting nas 29, Pada suport mambo’ mounting bots $0 Brake and aah mb ‘TORQUE : im (kgem, 1) BRa4 COMPONENTS cases Removal steps ated (Ree fe @ROUP1 - Cha ea 12. Stap rg 18. Washer 14, Bake pedal 418. Retum sprog 38, Bush $7, Bee pa 18. Stop amp sien 18, Support member (LH) 25, Support member FH) ‘TORQUE : Nm (kgm, bt) BRAKE SYSTEM BRAKE SYSTEM FRONT DISC BRAKE REMOVAL AND INSTALLATION. ex:ae 100 (000000, 5:75) 100 (001000, 58.26 Removal steps 1 Bela ue 2. Front bake ssterty & Brakenoee brace, 4 Brake ase TORQUE : Nm (kom, ot) = Gi seine, 1039) £6 Fy eon BRAKE SYSTEM. |AKE SYSTEM, INSPECTION AND REPLACEMENT. =. GQuore ns bapa hve wear nscale hat conta! he inte ac wre ne take pad oscknss eco ‘rim, arsemt a saveeing sede war hae 1. Choc the brake pad tikrass though ho caliper booy mspecton nl “Pad lining thickness mm dn) rn (0.368 in) Standard valve Servo uit: 2.0 mm (0.079) CAUTION {tthe pad tng thickness Is out of speciie- ton, fet ana right pads must be replaced as ‘complete set 2. When the thickness diference between the lettpad and right padi large, cheek the sic Ing eoniion of the piston, the fek pn and the gulge in. 2. Renveteguse pn me caiperasendy wand &) caurion 'Be careful not to contaminate the lock pin and ‘ulae pin with grease. ‘3. Remove he ‘lowing parts om the caper super. 1) Pac endear sestor assay 2) Pas assonbly 3) ip 4) Outer stim INSPECTION cscs FRONT BRAKE DISC RUNOUT CHECK 1. Remove te cate: super then ase te cape a8 emely upward and suspend wih a we 2. Chack ne uae of tha dc for eracks and at ane {8 Paco a dal gaugo about Sm (0.2 in}. tom the the rurodt othe oe. Umit 608 mm (0524 in) o ess [FRONT BRAKE DISC RUN OUT CORRECTION 1. tthe runt tho rake ssc ouhalant to o ex ead than specteaton, ‘elace Ne dc arab. Srl then meesore te runout again, 1) Before removing the brake dc, hak both sito 's greatest BR-19 FRONT BRAKE DISC THICKNESS CHECK 1. Using cap, measure se tings at ight po- sions apprsnatey £5" apart and 10mm 0.39) ‘rom he oer eape ofthe de Brake dee Bid Standard value: 24 mm (0985 in} Umit: 22.4 mn (0882 in) cosas Thickness vartion (at last @ positions) 2) Remove the brake ds, ad then place a dal___Thedlerence between any boknees masses geugeas hommes, enmove he Shou ot te moe han 001mm (9008 4) the excuod the fit specication instal the 2. ‘tho disc tikes is beyond the it, apace with brake dsc ater turing't 160" tam th chalk 8 NEW On. ‘mark and then check to rn ou ofthe brake sc agan, DISASSEMBLY cme Front disc brakes should be csassombled seperate Dont mx nght-nan ane han parts. 1. Remove te gistonbootpeton tow compressa sr into th brake hose seating ole. Remove he piston Sand piston box 2 ttherunou cannot be caress by changing he po ‘ston ofthe baked, place he bre di. R20 2. Remove the piston so +) Ramave the piston ssl wa your tinge. caurion Don't use a screwuriver or another too! cause may damage the cylinder. 2). Clan he piston surtace and eynder using the ected bake Ho or leo Brake aia = BOT Ser DOT 4 INSPECTION exc 4. Check the ylnder for moar, damage and rus 2. Check he piston sutace fr woar, damage ad us. ‘Cheek ne calor boy and seo for wer BRAKE SYSTEM 4 Chacktha easois ppl, anathepasandtarking 5. Check the pd wear, Chock the pad icknest and Feplace tits Ine han he spectod vas ad thickness Speciation : 100 mm (0391) Servos eit: 20 mm (0.08) REASSEMBLY cnew 1. Clash all comsonens wah soap! aeote excopt for pad ana shim. 2. ntl ne piston sea 3. After spnyng the speci brake fd othe piston ‘outer aura, intl piston eto ha cy 4 natal ne ton boot and bot ng. 5, Insta he gue pn boots and guide pi. BRAKE SYSTEM INSTALLATION. ses 1. sate pads and bake oyincer. 2. In th brake hose tthe caper Tighioning torque Blosser soe “7-9 No (70-80 kp em, 8.6.6 Br) 2 Filthe brake reser wh rake fi 4. Bled tn ete, wy R22 BRAKE SYSTEM REAR DRUM BRAKE REMOVAL AND INSTALLATION.

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