Brake - Brake System

Precautions

This Manual does not include all necessary terms and conditions of repair and service. This Manual is intended for
those who have special skills and corresponding certificates. Any one shall not be allowed to repair vehicles based
on this Manual until he/she possesses special skills and corresponding certificates or is armed with special
equipments and tools. Otherwise, a serious injury may be caused to him/her or other people around and the
customer’s vehicle may get seriously damaged.

For the purpose of avoiding dangerous operation as well as damage to customer’s vehicle, always stick to the
following precautions:

● Read this Manual carefully and pay special attention to precautions in Chapter “Introduction”.

● The service methods specified in this Manual are very practical in repair and service. When carrying out any
operation in accordance with the procedure specified in this Manual, be sure to use the recommended special
tools. If any non-special tool or service method or that not recommended in this Manual is to be used, prior to
the operation, be sure to confirm whether the technology is safe and whether the operation may cause
personal injury or damage to customer’s vehicle.

● Always replace parts with those of the same specifications or their equivalents. Any parts of inferior quality
shall not be used. Please pay attention to the hints “Cautions” and “Tips” in this Manual, which are aimed at
avoiding personal injury and damage to vehicle owing to incorrect service or repair. Always understand their
meanings. Please note that these tips are not all-inclusive. Too redundant operation tips may also cause
dangerous results.
Brake - Brake System

Brake

Brake System ............................................................. 9-1

Troubleshooting .......................................................... 9-2

Brake Fluid .................................................................. 9-3

Brake Pedal ................................................................ 9-5

Parking Brake Handle ................................................. 9-8

Master Brake Cylinder ................................................ 9-9

Brake Booster Assembly .......................................... 9-12

Front Brake Pad........................................................ 9-16

Front Brake Caliper................................................... 9-18

Rear Drum Brake ...................................................... 9-23

ABS Control Unit....................................................... 9-32

Front Wheel Speed Sensor ...................................... 9-36

Rear Wheel Speed Sensor ....................................... 9-39

9-0
 Brake - Brake System

Brake System

Cautions:
· Replace each component correctly, otherwise the braking performance will get affected and thus traffic
accident may occur. Replacement shall be of the same part number as the original one.

· When maintaining or repairing the brake system, be sure to keep all components and the ground clean.

· For vehicles equipped with the mobile communication system, please refer to relative tips.

9-1
 Brake - Brake Fluid

Troubleshooting

Table of Failure Phenomena

The table below will help you identify failure causes. Each item corresponds to possible failure causes. Please
check in order. If necessary, carry out replacement.

Phenomena Possible Causes

1. Brake system (insufficient brake fluid)
2. Brake system (air)
3. Leather cup of piston (worn or damaged)
The brake pedal is too low or too soft 4. Clearance between rear brake shoe linings
(improperly adjusted)
5. Master cylinder (broken down)
6. Booster push rod (improperly adjusted)
1. Free stroke of pedal (too short)
2. Stroke of parking brake pull rod (improperly
adjusted)
3. Parking brake cable (jammed)
4. Clearance of the rear brake shoe (improperly
adjusted)
The braking effect is delayed 5. Brake pad or lining (cracked or twisted)
6. Piston (blocked up)
7. Piston (frozen)
8. Return spring (broken down)
9. Booster push rod (improperly adjusted)
10. Booster system (vacuum leakage)
11. Master cylinder (broken down)
1. Piston (blocked up)
2. Brake pad or lining (oil stain)
The vehicle pulls up to one side when brake is applied 3. Piston (frozen)
4. Brake disc (scratched)
5. Brake pad or lining (cracked or twisted)
1. Brake system (insufficient brake fluid)
2. Brake system (air)
3. Brake pad or lining (worn)
4. Brake pad or lining (cracked or twisted)
5. Clearance of the rear brake shoe (improperly
The brake pedal is too low or rebounds adjusted)
6. Brake pad or lining (oil stain)
7. Brake pad or lining (hard spot)
8. Brake disc (scratched)
9. Booster push rod (improperly adjusted)
10. Booster system (vacuum leakage)
1. Brake pad or lining (cracked or twisted)
2. Fixing bolt (loosened)
3. Brake disc (scratched)
4. Brake pad support (loosened)
5. Sliding pin (worn)
Abnormal noise appears when brake is applied
6. Brake pad or lining (dirty)
7. Brake pad or lining (hard spot)
8. Return spring (ineffective)
9. Sound damping washer (damaged)
10. Brake shoe locating spring (damaged)

9-2
Brake - Brake Fluid

Brake Fluid

Air Discharging

Tip:

Discharge air from it when repairing the brake system or

doubt that there is air in the brake line

Cautions:

Don’t get any painted surface stained with the brake

fluid; otherwise immediately wipe away the brake fluid.

1. Brake fluid: HZY4 as specified in GB12981-2003

Fill the storage tank with brake fluid.

2. Discharge air away from the master cylinder

Tip:

If the master cylinder has been disassembled or the

storage tank is empty, be sure to discharge air away
from the master cylinder.

(a) Disconnect the joint of oil line from the master

cylinder.

(b) Push down the brake pedal slowly and hold it.

9-3
Brake - Brake Fluid

(c) Block up the holes with your fingers from outside,

and then release the brake pedal.

(d) Repeat steps b and c for 3 or 4 times.

3. Discharge air away from the brake line

(a) Connect the plastic pipe to the brake caliper and

the wheel cylinder.

(b) Push down the brake pedal for several times and
then hold it there, and thereafter loosen the
bleeding screw.

(c) When no brake fluid flows out, tighten up the

bleeding screw and release the brake pedal.

(d) Repeat the operations (b) and (c) until all air in the
brake fluid has been discharged away.

(e) Repeat the steps above, so as to discharge air

away from each wheel cylinder.

Tightening torque: (bleeding screw) 8. 0N·m

(85kgf·cm, 73in. 1bf)

4. Check the level of the brake fluid in the fluid

reservoir

Check the level of fluid, and if necessary, add the brake

fluid.

Brake fluid: HZY4 as specified in GB12981-2003

9-4
 Brake - Brake Pedal

Brake Lamp Switch Brake Pedal

Push Rod
Check and Adjustment
1. Check the height of brake pedal
Height between brake pedal and floor:
124.3-134.3mm (4.894-5.287.in)
If the height of the pedal is inconsistent with the value
mentioned above, please carry out adjustment.

2. If necessary, adjust the height of pedal

(a) Dismount the brake lamp switch plug.
(b) Screw off the brake lamp switch locking nut, and
then dismount the brake lamp switch.

Height of (c) Screw off the push rod locking nut.

Pedal (d) Rotate the pedal push rod, so as to adjust the
height of the brake pedal.
(e) Tighten up the push rod locking nut.
Tightening torque: 26N·m (265kgf.cm, 20ft.1bf)
(f) Install the brake lamp switch.
(g) Connect the brake lamp switch plug.
(h) Push down the pedal by 5-15mm, rotate the brake
lamp switch, and locate the locking nut at the
position whereby the brake lamp goes out.
(i) Push down the pedal by 5-15mm, and then check
whether the brake lamp goes on.
(j) After adjusting the height of the pedal, check the
free stroke of the pedal.
3. Check the free stroke of the pedal

(a) Shut down the engine; push down the brake pedal
repeatedly until there is no vacuum in the booster.
(b) Push down the pedal until resistance is felt, and
then measure the clearance as indicated in the
figure.

Free stroke of pedal: 1-3mm

If the free stroke is abnormal, check the clearance of
the brake lamp switch;
If the clearance is normal, please carry out diagnosis for
the brake system.
Clearance of brake lamp switch: 0.5-2.4mm
(0.020-0.094in)

Free stroke of pedal

9-5
 Brake - Brake Pedal

4. Check the reserve stroke of brake pedal

Reserve Stroke of Pedal
Loosen the parking brake pull rod.

Keep the engine running and push down the pedal as

indicated in the figure to measure the reserve stroke.

When the pedal is pushed down using a force of 490N

(50kgf.110.21bf), the distance between the front wall
and the pedal must be more than 55mm.

If the reserve stroke is inconsistent with the value

mentioned above, please carry out diagnosis for the
brake system.

9-6
 Brake - Brake Pedal

Components

U-shaped Joint of Master Brake Pedal Bracket

Cylinder Push Rod

Brake Lamp Switch

Brake Pedal Bush

Brake Pedal Return Spring

Push Rod Pin

Vibration Damping Cushion

Brake Pedal
Bush
Clip

Rubber Pad on Brake Pedal

Brake Pedal

Specified Torque

One-off Parts

Lithium-based Ethylene Lubricating Grease

9-7
 Brake - Parking Brake Handle

Parking Brake Handle

On-board Check
1. Check the stroke of the parking brake handle

Pull up the parking brake handle and then record the

number of teeth.

When subjected to a pulling force of 196N, the number

of teeth must be 6 to 9.

If the number recorded is inconsistent with the value

mentioned above, please adjust the parking brake.

2. If necessary, adjust the parking brake.

Tip:

Before adjusting the parking brake, make sure that the

clearance of the rear brake shoe has been adjusted.

Adjust the clearance of rear brake shoe.

Locking Nut
Adjusting Nut (a) Dismount the passage box.

(b) Screw off the locking nut, and rotate the adjusting
nut until the stroke is normal.

(c) Tighten up the locking nut.

Tightening torque: 5.4N·m (55kgf.cm, 48in)

(d) Properly mount the passage box.

9-8
 Brake - Parking Master Cylinder

Master Cylinder

Components

Washer

Storage Tank
Cover Brake Hose and Clamp

Spacer

Limiter

Level Warning Lamp Switch Plug

Sealing Ring

Storage Tank

Master Cylinder

Specified Torque

One-off Parts

Lithium-based Ethylene Lubricating Grease

9-9
Brake - Parking Master Cylinder

Dismount
1. Dismount the level warning lamp switch plug.

2. Use a suction pipe to suck out the brake fluid

Cautions: Don’t get any painted surface of the body

stained with the brake fluid; otherwise immediately wipe
away the brake fluid.

3. Dismount the brake oil line

(a) Use the special service tool to dismount the brake

oil line from the master cylinder.

SST: 09023-00700

(b) Dismount the brake hose from the storage tank.

4. Dismount the master cylinder

Remove 2 fixing nuts, and then dismount the master

cylinder and washer.

Torque: 13N·m (127kgf.cm, 9ft·Ibf)

9-10
 Brake - Parking Master Cylinder

Installation:
Carry out the installation in accordance with the procedure reversed to that for dismounting

Tip:

* Before the installation, adjust the length of booster push rod.

* After the installation, add brake fluid and discharge air.

* Check for leakage. Check and adjust the brake pedal.

9-11
 Brake - Brake Booster Assembly

Brake Booster Assembly

On-board Check
1. Check the performance

(a) Keep the engine off, push down the brake pedal for
several times and carry out check, the reserve
stroke of the pedal must remain unchanged.

(b) Push down the brake pedal and start the engine. If
the pedal sinks slightly, it means that the
performance is normal.

2. Check the air tightness

Good Bad
(a) Start the engine, make it run for 1-2 minutes, and
then shut it down. Slowly push down the brake
pedal for several times. If the largest stroke is
obtained at the first time, and the position of the
pedal rises up gradually at the second and third
times, it means that no leakage occurs to the
booster.

(b) Push down the brake pedal when the engine is

running, and then shut down the engine. If the
reserve stroke of the pedal remains unchanged 30
seconds after the pedal is pushed down, it means
that no leakage occurs to the booster.

3. Check the vacuum check valve

(a) Slide the clamp so as to loosen the vacuum pipe.

Clear Not Clear (b) Dismount the vacuum check valve.

(c) Carry out check and make sure that air can flow
from booster to engine rather than from engine to
booster.

(d) If any trouble is found, please replace the vacuum

check valve.

9-12
 Brake - Brake Booster Assembly

Components

Return Spring

Push Rod Limit

Vacuum Hose Brake Booster Assembly
Booster Fixing
Master Cylinder Clamp Washer U-shape
d Push
Joint
Rod

Booster Fixing Clip

Washer

Level Warning Lamp Switch Plug

Specified Torque
One-off Parts

9-13
Brake - Brake Booster Assembly

Dismounting:
1. Discharge the brake fluid.

Cautions: Don’t get any painted surface stained

with the brake fluid; otherwise immediately wipe
away the brake fluid.

2. Dismount the brake oil pipe. Torque: 15N·m

(155kgf·cm, 11ft·1bf)

3. Dismount the brake master cylinder.

4. Dismount the vacuum hose from the booster.

5. Dismount the pedal return spring.

6. Dismount the clip and pin.

7. Dismount the booster.

(a) Dismount 4 nuts

(b) Remove the brake booster and washer.

9-14
 Brake - Brake Booster Assembly

Installation
1. Install the brake booster.
(a) Install the booster, and replace the washer with a
new one.
(b) Mount and tighten up the booster fixing nuts.
Tightening torque: 13N·m (130kgf·cm)

(c) Insert the pin into the U-shaped clamp and the
brake pedal, and mount the clip onto the pin.
(d) Install the brake pedal return spring.
2. Adjust the length of push rod.
Master Brake (a) Place the special repair tool on the master cylinder,
Cylinder
and make its screw just contacts with the master
cylinder piston.
SST: 09737-00011

(b) Turn upside down the special repair tool, and then
place it on the booster.
SST: 09737-0011.
(c) Measure the clearance between the booster push
rod and the screw end (SST).
Clearance: 0mm

(d) Use the special service tool to adjust the length of

booster push rod until the booster push rod just
contacts with the screw end.
SST: 09737-00020
3. Install the master cylinder.
4. Connect the vacuum hose to the brake booster.
5. Add brake fluid and discharge air away from the
brake system.
6. Carry out check for leakage.
7. Check and adjust the brake pedal.
8. Carry out the performance check.

9-15
 Brake - Front Brake Pad

Front Brake Pad

Components

Outer Sound
Damping Washer
Inner Sound
Damping Washer Sound Damping
Inner Brake Washer
Pad Outer
Brake Pad

Front Brake Pad Supporting Bracket

Specified Torque
Sound Damping Washer
Disc Brake Lubricating Grease

9-16
Brake - Front Brake Pad

Replacement
1. Dismount the front wheel.
2. Check the thickness of the brake pad.
Through the check hole on the brake caliper, check the
thickness of front brake pad. If the thickness is beyond
the standard, please carry out replacement.
Minimum thickness: 1.0 mm

3. Lift up the brake caliper.

(a) Hold the lower guide pin, loosen and dismount the
fixing bolt.
(b) Lift up the brake caliper and get it suspended.
Tip: Don’t disconnect the brake hose from the brake
caliper.
4. Dismount the brake pad together with the vibration
damping plate.
5. Dismount the 2 front brake pad supporting plates.
Cautions: If the supporting plates have sufficient
elasticity and are free from deformation, crack or wear,
they may be re-used after the rust, dust and foreign
materials are cleaned away.
6. Check the thickness and run-out of the brake disc.
7. Install 2 brackets.
8. Install the new brake pad.
(a) Apply some disc brake lubricating grease onto the
vibration damping plate.
(b) Mount 2 sound damping washers onto the outer
brake pad.
(c) Mount the sound damping plate onto the inner
brake pad.
(d) Install the inner brake pad in such a way that the
side with warning indication plate faces upwards.
(e) Mount the outer brake pad.
Cautions:
Don't get the friction surfaces of brake pad and of
brake disc stained with oil or lubricating grease.
9. Install the caliper body.
(a) Use a hammer or similar article to press in the
piston.
Tip:
If it is difficult to press in the piston, loosen the bleeding
screw so as to let some brake fluid flow out when
pressing the piston.
(b) Install the brake caliper.
(c) Hold the guide pin, and then mount the fixing bolt.
Tightening torque: 34N·m (347kgf·cm)
10. Install the front wheel.
11. Check whether the level of brake fluid reaches the
upper limit

9-17
 Brake - Front Brake Caliper

Front Brake Caliper

Components

Guide Pin

Dust Cap
Caliper Body
Supporting Bracket
Inner Brake Pad
Inner Sound
Guide Pin
Damping Washer
Dust Cap
Outer Sound
Bleeding Damping
Screw Washer
Inner Sound
Damping Washer Outer Sound
Damping Washer
Brake Outer Brake Pad
Caliper
Piston Sealing Ring

Dust Cap of
Sealing Wheel Cylinder
Washer
Front Brake Pad Supporting Plate

Specified Torque
One-off Parts Piston
Applying Lithium-based Ethylene
Lubricating Grease snap spring
Disc Brake Lubricating Grease

9-18
Brake - Front Brake Caliper

Dismounting
1. Dismount the front wheel
Dismount the wheel temporarily
fix the brake disc with the hub nut.
Tightening torque: 103N·m (1,050kgf·cm)
2. Discharge the brake fluid
Cautions: Don’t get any painted surface of the body
stained with the brake fluid; otherwise immediately wipe
away the brake fluid.
3. Dismount the brake hose
Dismount the connecting bolt and sealing washer from
the brake caliper, and then disconnect the brake hose.
Tightening torque: 30N·m (310kgf·cm)
Tip:
In the course of installation, make sure that the brake
hose is firmly mounted into the lock hole of the caliper
body.
4. Dismount the caliper body
(a) Hold the guide pin and then remove the 2 fixing
bolts.
Tightening torque: 34N·m (347kgf·cm)
(b) Dismount the brake caliper from the caliper body
supporting bracket.
5. Dismount the brake pad together with the sound
damping washer
6. Dismount the 2 brake pad supporting plates

9-19
Brake - Front Brake Caliper

Disassembly
1. Dismount the steel snap spring and the dust cap of
wheel cylinder caliper

Use a screwdriver to dismount the steel snap spring

and the dust cap.

2. Dismount the piston

(a) Place a piece of cotton cloth or similar material

between the piston and the caliper body.

(b) Use compressed air to blow out the piston from the
caliper body.

Tip:

When using compressed air, don’t place your finger in

front of the piston.

3. Dismount the piston sealing ring

Use a screwdriver to dismount the piston sealing ring

from the caliper body.

9-20
Brake - Front Brake Caliper

Check
1. Measure the thickness of the inner layer of the
brake pad
Use a ruler to measure the thickness of the inner layer
of the brake pad
Standard thickness: 11.0mm (0.433in)
Minimum thickness: 1.0mm (0.039in)
If the brake pad is uneven or seriously worn, or the
thickness is less than the minimum value, replace it.

2. Measure the thickness of the brake disc

Use a screw micrometer to measure the thickness of
the brake disc
Standard thickness: 18.0mm (0.709 in)
Minimum thickness: 16.0mm (0.630 in)
If the thickness of the brake disc is less than the
minimum value, please replace it. If the brake disc is
seriously scratched or worn, please grind it with turning
lathe or replace it.

3. Measure the run-out of brake disc

Use a dial indicator to measure the run-out at the
position which is 10mm away from the outer edge of the
brake disc.
Maximum run-out: 0.05mm
If the run-out of the brake disc is equivalent to or
exceeds the maximum value, please check the axial
clearance of the bearing and the run-out of the hub. If
both the bearing and the hub are normal, please adjust
the run-out of the brake disc or grind the brake disc
directly with turning lathe.
4. If necessary, adjust the run-out of the brake disc
(a) Dismount 2 fixing bolts and caliper body supporting
bracket from the steering knuckle.
(b) Dismount the hub nuts and the brake disc, turn the
disc until it is 1/4 round away from the original
position, re-install the brake disc and then mount
and tighten up the hub nuts.
Tightening torque: 88N·m (900kgf·cm)
(c) Measure the run-out of the brake disc again, and
left a mark at the position on the brake disc
corresponding to the hub. Repeat Step (b) until
only the position of two hub nuts is left.
If the minimum run-out measured in Steps (b) and (c) is
less than 0.05mm, just install the brake disc at this
position.
If the minimum run-out measured in Steps (b) and (c)
exceeds 0.05mm, please replace the brake disc in
accordance with Step 3.
(d) Mount the caliper body supporting bracket and 2
fixing bolts.
Tightening torque: 88N·m (900kgf·cm)

9-21
Brake - Front Brake Caliper

Installation
Carry out the installation in accordance with the
procedure reversed to that for dismounting

Tip:

* After the installation, add brake fluid and

discharge air

* Carry out check for leakage

9-22
 Brake - Rear Brake Drum

Rear Drum Brake

Components

Bleeding Plug Cap

Bleeding Plug
Piston
Dust Boot
Dust Boot
Hole Plug
Pin Plug
Pin Piston
Leather
Cup Boot
Spring
Brake Cylinder
Parking Brake Pull Rod
Leather
Cup Boot

Rear Brake Shoe

Left Supporter of Parking
C-shaped
Brake Shoe
Washer

Brake Shoe
Parking Brake Locating Spring
Cable
Back Plate
Pin

Return Spring
Tension Spring

Automatic Adjusting Front Brake Shoe

Rod of Rear Brake

Adjusting Rod Spring

Brake Shoe Locating
Spring Cover
Brake Shoe
Locating Spring

Rear Brake Drum

Specified Torque

Part which can only be used for once

Lithium-based Ethylene Lubricating Grease
Anti-heat Lubricating Grease

9-23
 Brake - Rear Brake Drum

Overhaul
Tip:
Overhaul the right side in accordance with the same
procedures as those for the left side.

1. Check the thickness of brake shoe lining

(a) Remove the hole plug, and through the hole check
the thickness of brake shoe lining.
If the thickness is less than the minimum value, please
replace the brake shoe.
Minimum thickness: 1.0mm (0.039 in.)

2. Dismount the rear wheel

3. Discharge the brake fluid
Cautions:
Don’t get any painted surface of the body stained
with the brake fluid; otherwise immediately wipe
away the brake fluid.

4. Dismount the rear brake drum

(a) After releasing the parking brake handle, dismount
the brake drum.
Tip:
If it is difficult to dismount the brake drum, please
Turn carry out the following operations.
(b) Remove the hole plug, insert a screwdriver along
the back plate and use it to separate the automatic
brake adjusting rod from the adjuster.
(c) Use another screwdriver to turn the adjusting
pulley, so as to reduce the length of the adjuster.

5. Check the inside diameter of the brake drum

(a) Use a brake drum gauge or equivalent to measure
the inside diameter of the brake drum.
Standard inside diameter: 200.0mm (7.874 in.)
Maximum inside diameter: 201.0mm (7.913 in.)

9-24
Brake - Rear Brake Drum

6. Separate the left locating supporter from the

parking brake shoe
(a) Use the special tool to dismount the tension spring
from the front/rear brake shoe, and then separate
left locating supporter from the parking brake shoe.
Special service tool: 09703-30010
Cautions:
Be careful not to damage the dust boot of the brake
cylinder.
7. Dismount the front brake shoe
(a) Use the special tool to dismount the end cap, the
brake shoe locating spring and the pin.
Special tool: 09718-00010
(b) After removing the return spring, dismount the front
brake shoe.
(c) Dismount the left locating supporter from the
parking brake shoe.

8. Dismount the left automatic adjusting rod

(a) Dismount the brake adjusting pull rod spring and
the automatic adjusting rod

9. Dismount the brake shoe return spring

(a) Dismount the return spring from the brake shoe.

10. Dismount the rear brake shoe

(a) Use the special tool to pry out the end cover, and
then dismount the brake shoe locating spring and
pin.
Special service tool: 09718-00010

9-25
Brake - Rear Brake Drum

(b) Use sharp nosed pliers to dismantle the parking

brake cable from the parking brake pull rod.

11. Dismount the accessories of the parking brake

shoe pull rod
(a) Use a screwdriver to dismount the C-shaped
washer and the parking brake shoe pull rod.

12. Check the thickness of brake shoe lining

(a) Use a ruler to measure the thickness of brake shoe
lining.
Standard thickness: 4.0mm (0.154in.)
Minimum thickness: 1.0mm (0.039in.)
If the thickness of the lining is equivalent to or less than
the minimum value, or the lining is seriously or unevenly
worn, please replace the brake shoe.

13. Check whether the brake drum contacts with the

brake shoe lining normally
(a) Apply chalk to the inner surface of the brake drum,
and then fit the brake shoe with the inner surface of
the drum.
If poor contact occurs between the brake drum and the
brake shoe lining, grind or replace the brake shoe.

14. Dismount the left front or upper brake wheel

cylinder
(a) Use the special tool to disconnect the brake oil line,
and then use a container to hold the brake fluid.
Special service tool: 09023-00100
(b) Remove the bolts and dismount the brake wheel
cylinder.

9-26
Brake - Rear Brake Drum

15. Dismount the leather cup of brake

(a) Dismount the 2 dust boots from the brake cylinder.
(b) Dismount 2 pistons and spring.
(c) Dismount 2 brake cylinder caps from each piston.
16. Check the brake cylinder
(a) Check whether the cylinder wall or piston is rusted
or scratched.
17. Dismount the rear bleeding screw of the brake
drum
18. Preliminarily tighten up the rear bleeding screw of
the brake drum
19. Install the leather cup of brake wheel cylinder

(a) Apply some lithium-based ethylene lubricating

grease onto the 2 leather cups of brake wheel
cylinder and the 2 pistons.
(b) Mount 2 brake cylinder caps onto each piston.
(c) Mount the compression spring and 2 pistons into
the brake wheel cylinder.
(d) Mount 2 new dust boots onto the brake wheel
cylinder.

20. Install the left front or upper brake cylinder

(a) Use bolts to fix the brake cylinder.
Torque: 9.8N·m (100kgf·cm)
(b) Use the special tool to connect the brake oil line.
Special service tool: 09023-00100
Torque: 15N·m (155kgf·cm)
21. Apply anti-heat lubricating grease
(a) Apply some anti-heat lubricating grease onto the
surface of the backing plate which will contact with
the brake shoe.
22. Install the accessories of the parking brake shoe
pull rod
(a) Mount a new C-shaped washer, and then install the
parking brake pull rod.

9-27
Brake - Rear Brake Drum

23. Install the brake shoe

(a) Use sharp nosed pliers to connect the parking
brake cable with the parking brake pull rod.

(b) Use the special tool to install the brake shoe, pin,
brake shoe locating spring and brake shoe locating
spring cap.
Special service tool: 09718-00010

24. Install the brake shoe return spring

(a) Mount the return spring onto the brake shoe.
25. Install the automatic adjusting pull rod of left brake
(a) Mount the automatic adjusting pull rod and the
automatic adjusting pull rod spring onto the front
brake shoe.

26. Install the supporter of parking brake shoe

(a) Apply some anti-heat lubricating grease onto the
adjusting bolt.

9-28
 Brake - Rear Brake Drum

Back Plate (b) As indicated in the figure, install the left supporter
of parking brake shoe.

Left Supporter of Parking Brake Shoe

27. Install the front brake shoe

(a) Mount the return spring onto the front brake shoe.
(b) Use the special tool to mount the front brake shoe,
pin, brake shoe locating spring and locating spring
cap.
Special service tool: 09718-00010

28. Install the left supporter of parking brake shoe

(a) Use the special tool to connect the tension spring
to the front/rear brake shoe.
Special service tool: 09703-30010
Cautions:
Be careful not to damage the dust boot of brake
wheel cylinder.

9-29
Brake - Rear Brake Drum

29. Check the installation of brake drum

(a) Check whether each part is corrected installed.

(b) Measure the inside diameter of brake drum and the

diameter of brake shoe, and check whether the
difference between them is consistent with the correct
clearance of brake shoe.

Clearance of brake shoe: 0.6mm (0.024 in.)

Cautions:

Don't get the brake shoe lining and the friction surface
of brake drum stained with oil or lubricating grease.

9-30
 Brake - Rear Brake Drum

30. Adjust the clearance between brake drum and

brake shoe

(a) Preliminarily fix 2 hub nuts.

(b) Turn the adjuster by 8 teeth.

(c) Mount the hole plug.

Lengthen

31. Install the rear brake drum subassembly

32. Fill brake fluid into the fluid reservoir

33. Discharge air from the master cylinder

SST: 09032-00100

34. Discharge the air from the brake line

35. Check the level of brake fluid in the fluid reservoir

36. Check whether the brake fluid leaks

37. Install the rear wheel

Torque: 113N·m

38. Check the stroke of the parking brake pull rod

39. Adjust the stroke of the parking brake pull rod

9-31
 Brake - ABS Actuator

ABS Control Unit

On-board Check

Hand-holding
1 Connect the hand-holding type tester
Type Tester (a) Connect the tester to the DLC3.
(b) Turn the ignition switch to “ON” position
(c) Click the key “ABS” on the tester
(d) Click the key “Actuator Test”
(e) Click the key “Hydraulic Control Unit Test”
2. Carry out test for hydraulic control unit
(a) Carry out hydraulic pump test (to check whether there
is operating noise). Click the key “Confirm”.
(b) Carry out the test for left front wheel, push down and
hold the brake pedal. Click the key “Confirm”.
(1) Check whether the wheel is locked up when the
normally open valve is opened and the normally close
valve is closed. Click the key “Confirm”.
(2) Check whether the wheel is locked up when the
normally open valve is closed and the normally close
valve is closed. Click the key “Confirm”.
(3) Check whether the wheel can rotate freely when the
normally open valve is closed and the normally close
valve is opened. Click the key “Confirm”.
(4) Check whether the wheel can rotate freely when the
normally open valve is closed and the normally close
valve is closed. Click the key “Confirm”.
(5) Check whether the wheel is locked up when the
normally open valve is opened and the normally close
valve is closed. Click the key “Confirm”.
(6) After the test for left front wheel is completed, release
the brake pedal. Click the key “Confirm”.
(c) Carry out the test for the right front wheel (using the
same testing method as that mentioned above)
(d) Carry out the test for left rear wheel (using the same
testing method as that mentioned above)
(e) Carry out the test for right rear wheel (using the same
testing method as that mentioned above)
If the test result is abnormal, please replace the ABS
assembly.
3. Discharge air and add brake fluid
(a) Click the key “Add Fluid and Discharge Air” under the
“Actuator Operation”.
(b) Push down the brake pedal and make the pump
running, and then pedal will rebound. Click the key
“Confirm”.
(c) Release the brake pedal, and then screw off the brake
caliper bleeding bolt. Click the key “Confirm”.
(d) Push down the brake pedal for 10 times. Click the key
“Confirm”.
(e) Tighten up the brake caliper bleeding bolt. Click the
key “Confirm”.
(f) Complete the air discharging.
Cautions: Discharge air from each wheel brake line in
accordance with the method mentioned above.

9-32
 Brake - ABS Actuator

Components

ABS Control Unit with ECU

ABS Control Unit Bracket

9-33
 Brake - ABS Actuator

Dismounting
1. Discharge the brake fluid.
Cautions:
Don’t get any painted surface of the body stained with
the brake fluid; otherwise immediately wipe away the
brake fluid.
2. Dismount the battery (cut off the power supply)
3. Screw off the nuts on fuse box of engine
compartment, and then remove the fuse box
4. Pull out the plug from the ABS control unit
assembly
5. Dismount the brake oil lines
Use the special tool to dismount 6 brake oil lines from
the ABS control unit.
SST: 09023-00100
Tightening torque: 15N·m (155kgf·cm)
6. Dismount the ABS control unit assembly
Remove 3 bolts and then dismount the ABS control unit
assembly
Torque: 19N·m (194kgf·cm)

7. Dismount the ABS control unit

Right Front
Wheel Left Front (a) Remove 3 nuts and then dismount the ABS control
Left Rear Wheel
Wheel unit from the bracket 1.
Right Rear Torque: 4.7N·m (48kgf·cm)
Wheel
(b) Dismount 3 vibration-damping washers from the
ABS control unit
(c) Stick label or left mark, so as to facilitate the
Master Cylinder
re-installation
(d) Remove 3 bolts and then dismount the brake
actuator together with bracket

8. Dismount the brake actuator assembly

(a) Remove 3 bolts and then dismount the brake
actuator from its bracket

9-34
Brake - ABS Actuator

Installation
Carry out the installation in accordance with the
procedure reversed to that for dismounting

Tip:

· After the installation, add brake fluid and discharge

air

· Carry out check for leakage

· Use the tester to check the brake actuator

9-35
 Brake - Front Wheel Speed Sensor

Front Wheel Speed Sensor

Components

Speed Sensor Plug

Damper

Left Front Wheel Speed Sensor

Specified Torque

9-36
Brake - Front Wheel Speed Sensor

Dismounting
1. Pull out the plug of the speed sensor.

Pull out the plug of the speed sensor.

2. Dismount the front wheel.

Tightening torque: 103N·m (1.050kgf·cm)

3. Dismount the peed sensor

(a) Dismount two fixing bolts A and B as well as one

harness clip from the body and the damper.

Tightening torque for bolt A: 8.0N·m (82kgf·cm)

Tightening torque for bolt B: 29.0N·m (300kgf·cm)

(b) Dismount bolts and the sensor from the steering

knuckle

Tightening torque: 8.0N·m (82kgf·cm)

9-37
Brake - Front Wheel Speed Sensor

Installation
Carry out the installation in accordance with the
procedure reversed to that for dismounting

Tip:

After the installation, check the signal of ABS speed

sensor

9-38
 Brake - Rear Wheel Speed Sensor

Rear Wheel Speed Sensor

Components

Plug

ABS Speed Sensor

Shaft Hub Assembly

Rear Wheel Hub

Brake Drum

9-39
Brake - Rear Wheel Speed Sensor

Dismounting
1. Dismount the rear wheel
2. Pull out the plug of the ABS speed sensor
3. Dismount the ABS speed sensor together with the
rear wheel hub
(a) Use a punch and a hammer to dismount two pins,
and then dismount two connecting parts from the
special service tool.
SST: 09520-00031

(b) Fix the rear wheel hub onto the caliper.

Cautions:
If the hub is knocked or drops onto the ground, please
replace it with a new one.
(c) Use the special tool and 2 bolts (diameter: 12mm;
thread pitch: 1.5mm) to dismount the ABS speed
sensor.
SST: 09520-00031 (09520-00040), 09521-00020,
09950-00020
Cautions:
* If the toothed ring of the sensor is damaged,
please replace the rear wheel hub assembly.
* Don't scratch the contact surfaces of the rear
wheel hub assembly and of the speed sensor.

9-40
Brake - Rear Wheel Speed Sensor

Installation
1. Install the new ABS speed sensor.
(a) Clean up the surface of the rear wheel hub
assembly contacting with the ABS speed sensor.
Cautions:
Any foreign material on the toothed ring of the ABS
shall not be allowed.
(b) Mount the ABS speed sensor onto the rear wheel
hub assembly, and locate the joint of the sensor as
low as possible.

(c) Use the special tool and a pressing machine to

press the ABS speed sensor into the rear wheel
hub
SST: 09214-76011
Cautions:
· Don’t knock the ABS speed sensor directly with
hammer
· Check whether there is no foreign material around
the sensor
· Press down the ABS speed sensor slowly and
vertically
2. Mount the speed sensor onto the rear wheel hub.
3. Connect the plug of speed sensor.
4. Install the rear wheel. Tightening torque: 103N·m
(105kgfcm. 76ft.Ibf)
5. Check the signal of ABS speed sensor.

9-41