Brake System - Brake System 4-79

Chapter 9 Brake System

Section 1 Brake System
I. Precaution
1. It's very important to keep the parts and area clean when repairing the brake system.
2. Care must be taken to replace each part properly as it could affect the performance of the brake system and
result in a driving hazard.
3. Do not let brake fluid remain on a painted surface when repairing any parts. Wash it off immediately.
4. If any work is done on the brake system or air in the brake pipelines is suspected, bleed the system of air.
5. Check the brake system for leakage after repairing the brake system.
6. Use specified brake fluid. Do not mix with other brand of brake fluid.

II. Symptom table

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.

Symptom Suspected Area

1 Brake system (fluid leaks)
2 Brake system (air in)
3 Piston Cup in Sub-pump (worn or damaged)
4 Rear brake shoe clearance (out of adjustment)
Low brake pedal or recoil
5 Master cylinder (faulty)
6 Booster push rod (out of adjustment)
7 Brake shoe or lining (oily)
8 Disc/Drum scratched
1. Brake pedal free stroke is too small
2. Parking brake lever stroke (out of adjustment)
3. Parking brake cable (sticking)
4. Rear brake shoe clearance (out of adjustment)
Brake Stagnation 5. Brake pad or lining (cracked or distorted)
6. Wheel cylinder piston (stuck or frozen)
7. Return spring (faulty)
8. Vacuum booster (faulty)
9. Brake master cylinder (faulty)
4-80 Brake System - Brake System

Symptom Suspected Area

1. Wheel cylinder piston (stuck)
2. Brake shoe lining (oily)
3. Disc (scratched)
Brake Deviation
4. Brake shoes or lining (cracked or distorted)
5. Wheel hub bearing (worn or damaged)
6. Tire pressure (not as specified)
1. Brake shoe lining (damaged)
2. Installation bolt (loose)
3. Disc (scratched)
Noise from brake 4. Brake shoe (bad in quality)
5. Brake shoes lining (oily)
6. Sound isolating shim damaged
7. Hold spring of brake shoe (damage)
 Brake System - Brake Fluid 4-81

Section 2 Brake Fluid

Bleeding
1. Fill brake reservoir with brake fluid
Brake fluid: HZY4 complying with GB12981

2. Bleed brake pipeline system

(1) Connect the vinyl pipe to the wheel cylinder bleeder plug port
(2) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal held down.
(3) At the point when fluid stops flowing out, tighten the bleeder plug, and then release the brake pedal.
(4) Repeat (2) and (3) until all the air in the fluid has been bled out.
(5) Repeat the above procedure to bleed the brake pipeline of the air for each wheel cylinder.
Notice: Fill brake fluid into the reservoir all the time when bleeding.

3. Check fluid level in reservoir

Check the fluid level and fill fluid if necessary.
Tips: Do not mix and use with other brand of brake fluid.
4-82 Brake System - Brake Pedal

Section 3 Brake Pedal

Component View

Brake master cylinder

handspike U-connector Brake pedal bracket

Brake light switch

Brake pedal axis

25

Lubrication bushing

Brake pedal return spring

Brake light bushing

Handspike pin

Pad

Clip

Brake pedal pad

Brake pedal
Specified torque

Non-reusable parts
Lithium soap-base glycol lube
 Brake System - Brake Pedal 4-83

Adjustment
1. Check and adjust the height of brake pedal.
(1) Check the height of brake pedal.
Height from the floor: 124.3-134.3mm
Braking lamp switch
(2) Adjust the height of brake pedal.
a. Remove the cover of the console.
b. Remove the coupler from the brake light switch.
c. Loosen the lock nut of the brake light switch, and remove
the brake light switch.
d.Loosen the lock nub of the U-connector.
e.Turn the pedal push bar to adjust the height of brake
pedal. Push par

f. Tighten the lock nub of the push bar.

Torque: 26N.m
g. Install the brake light switch.
Braking pedel
h. Insert the connector of the brake light switch.
height
i. Push the brake pedal (5-15ram), and turn the brake light
switch till it goes out. Lock the nut in this position.
j. After installation, step down the brake pedal (5-15mm),
and check the brake light is bright.

2. Check the pedal free stroke.

(1) Shut down the motor, and step on the brake pedal repeatedly
till the booster is not vacuum.
(2) Step down the pedal till resistance appears, and measure the
distance as shown in the figure.
Pedal free travel: 1-6mm
If the clearance does not meet the requirement, check the
clearance of the brake light switch. If the clearance is correct,
make diagnosis on the braking system.
Free travel for
Clearance: 0.5-2.4mm
braking pedal

3. Check the pedal reserved distance.

Loosen the parking brake extension rod.
When the motor is running, step down the pedal, and measure the
pedal reserved distance as shown in the figure.
When stepping on the pedal 490N, the reserved distance from the
asphalt floor is larger than 55mm
If the distance doesn't meet the requirement, make diagnosis on
Reverse of braking
the braking system.
pedal
4-84 Brake System - Brake Pedal

Removal
After the installation, check and adjust the height, free stroke and reserved distance of the brake pedal.
1. Remove the combination instrument component (see figure 1).
2. Unfix the brake master cylinder push bar U-connector.
Remove the clip and pin, and unfix the master cylinder handspike from the brake pedal.
3. Remove the brake pedal bracket.
(1) Remove the bolt from the brake pedal bracket (see figure 1).
(2) Unfix the brake light coupler.
(3) Remove the four nuts and brake pedal bracket (see figure 2).

4. Remove the brake pedal sub-assembly. 1

(1) Remove the bolt and nut from the brake pedal bracket.
(2) Remove the brake pedal and the two bushings.
5. Remove the brake light switch component.
(1) Loosen the lock nut of the brake light switch.
(2) Remove the brake light switch from the brake pedal bracket.
6. Remove the brake pedal pad.
Remove the brake pedal pad from the brake pedal.
7. Install the brake pedal pad. 2
Install the brake pedal pad on the brake pedal.
8. Install the brake light switch component.
Install the brake light switch on the brake pedal bracket.
9. Install the brake pedal.
(1) Apply lithium soap-base glycol lube on the end surface and side surface of the two new bushings.
(2) Install the brake pedal and the two bushings on the brake pedal bracket with bolts and nuts.
Torque: 37N.m
10. Install the brake pedal bracket.
(1) Install the brake pedal bracket with four nuts.
Torque: 25N.m
(2) Connect the connector of the brake light switch.
(3) Install the bolt on the brake pedal bracket (see figure 3).
Torque: 20N.m
11. Connect and install the brake cylinder push bar U-connector.
(1) Apply the lithium soap-base glycol lube on the handspike pin.
(2) Connect the master cylinder handspike with pins and clips.

12. Install the combination instrument components.

13. Check and adjust the brake pedal height.
14. Check the brake pedal's free travel.
15. Check the brake pedal's reserved distance. 3
 Brake System - Brake Master Cylinder Assembly 4-85

Section 4 Brake Master Cylinder Assembly

Component View

Brake master cylinder Vacuum booster

sub-assembly
Vacuum tube

No ABS

Manual Transmission Fluid level indicator lamp connector

#1 clutch fluidr tank pipe

N .m : specified torque
4-86 Brake System - Brake Master Cylinder Assembly

Component View

With ABS:
Cover
Brake fluid reservoir

Strainer Automatic Transmission

O-ring

Pin Retaining ring

Piston guide
Straight pin Hole
block
Cup
connector
Washer
Hole connector
#1 piston & Spring

Master cylinder #2 piston

Spring

Without ABS
Cover

Strainer

Pin Manual Transmission

O-ring
Retaining ring

Hole connector

Piston guide block

Cup
Hole connector

Master cylinder #1 piston & Spring

#2 piston & Spring

Washer

Piston limit bolt

Specified torque
Non-reusable parts
Lithium soap base glycol lube
 Brake System - Brake Master Cylinder Assembly 4-87

Repair
1. Discharge the brake fluid.
With ABS:
Note: Never spray the brake fluid on the paint surface, otherwise
wash it immediately.
2. Remove the brake master cylinder.
(1) Pull out the connector of the level alarm light switch.
(2) Slide the clip, and pull out #1 clutch storage tank pipe (manual
transaxle).
Without ABS
(3) Remove the two brake pipes from the brake master cylinder
with special tool.(with ABS)
(4) Remove the three brake pipes from the brake master cylinder
accessory with special tool. (without ABS)

(5) Remove the two lock nuts, and pull out the brake master
pump.

3. Remove the storage tank.

(1) Put the brake master cylinder on the bench clamp.
(2) Remove the pin from the brake master cylinder body with
punch and hammer.
(3) Pull out the Brake fluid reservoir.
(4) Remove the cover and strainer from the storage tank.
(5) Remove the storage tank and the two hole connectors.

4. Remove the brake master cylinder.

(1) Put the brake master cylinder on the bench clamp.
(2) Remove the O-ring.
(3) Push the piston with hand, and remove the snap ring with
snap ring pliers.
4-88 Brake System - Brake Master Cylinder Assembly

(4) Push the piston with hand, and turn the cylinder body to
remove the straight pin. (with ABS)

(5) Push the piston with hand, and remove the piston bolt and
washer. (without ABS)

(6) Pull out #1 piston, piston guide block, spring, cup and washer
straightly.
Note: If angle appears in the pulling process, it may cause
damage to the cylinder wall.

(7) Put two blocks and cloth on the workbench. Put the flange of
the master cylinder against the block edge and knock it till #2
piston and spring get out of the cylinder.
Tips:
Make sure the distance (A) between the working cloth and the block's top is at least 100mm.
Note:
If angle appears in the pulling process, it may cause damage to the cylinder wall.
5. Check the brake master cylinder.
(1) Check the cylinder wall whether there is any rust or nick.
(2) Check the cylinder wall whether there is any abrasion or damage.
Note:
If necessary, clean or replace the brake master cylinder.
Tips:
Clean the assembled parts with compressed air.
6. Install the brake master cylinder.
(1) Fix the brake master cylinder on the bench clamp.
(2) Apply the lithium soap-base glycol lube on the rubber parts with arrow.
(3) Install # 2 and # 1 pistons, spring, piston guide block, cup and washer.
Note:
If angle appears in the installation process, it may cause damage to the cylinder wall. Be careful not to
damage the edge of the cup on the piston.
 Brake System - Brake Master Cylinder Assembly 4-89

(4) Push the piston, and install the straight pin on the cylinder
body. (with ABS)

(5) Push the piston, and install the new washer and piston bolt.
Torque: 10N.m

(6) Push the piston, and install the snap ring with snap ring pliers.
(7) Install the O-ring on the brake master cylinder.

7. Install the Brake fluid reservoir.

(1) Apply the lithium soap-base glycol lube on the Brake fluid reservoir connector, and install it on the brake
master scylinder.
(2) Install the pin on the brake master cylinder with punch and hammer.

8. Check and adjust the vacuum booster push bar.

(1) Install a special tool on the brake master cylinder,and lower
the special tool mandril till it touches the piston.

(2) Mark the mandril top surface of the special tool with chalk.
(3) Overturn the special tool, and leave a clearance between the
special tool and the vacuum booster.

Tips:
If there is clearance between the special tool body and the booster hull, it means that the clearance is
standard value. If there is no chalk trace on the booster push bar, it means that the clearance exceeds the
standard value.
4-90 Brake System - Brake Master Cylinder Assembly

(4) Adjust the length of the vacuum booster push bar with the
special tool till the push bar touches the mandril head.

9. Install the brake master cylinder.

(1) Install the brake master cylinder on the booster with two bolts.
Torque: 13N.m

(2) Connect the two brake oil pipes to the brake master cylinder
with a special tool. (with ABS)
With ABS:
Torque: 15N.m
(3) Connect the three brake oil pipes to the brake master cylinder
with a special tool. (without ABS)
Torque: 15N.m
(4) Connect # 1 clutch storage tank oil pipe with clip. (Manual
transaxle type)
(5) Insert the brake fluid level alarm switch connector. Without ABS

10. Add the brake fluid to the Brake fluid reservoir.

11. Discharge the air in the brake master cylinder.
12. Discharge the air in the brake pipeline.
13. Check the level height in the Brake fluid reservoir.
14. Check the brake fluid whether there is any leakage.
 Brake System - Vacuum Booster 4-91

Section 5 Vacuum Booster

Component View

Battery

#2 relay box, engine chamber

Return spring
Pin
Master cylinder

Vacuum tube
15 Clip 26

Clip
Without ABS
15
Push bar
U-connector
25
Vacuum booster assembly
Manual Transmission
#1 clutch fluid tank oil pipe Gasket
13 Fluid level indicator lamp connector

15 15

19

Clip

19 HECU assembly

Specified torque
Non-reusable parts
Lithium soap base glycol lube
4-92 Brake System - Vacuum Booster

Check
1. Check the brake booster.
(1) Air tightness check Good Poor

a. Start the motor, and shut it down after one or two minutes,
then step on the pedal several times slowly.
Tips:
If the pedal goes down greatly at the first step, but it gradually Positiom 3
Positiom 2
goes up after the second and third steps, it means the air Positiom 1
tightness is good.
b. When the motor is running, step down the brake pedal, and then shut down the motor.
Tips:
If the reserved distance does not change thirty seconds after
the pedal is stepped down, it means the air tightness is good.
(2) Operation check
a. When the ignition switch stays in OFF position, step on the
pedal several times, and then check that the reserved
distance should not change.
b. Step down the pedal, and start the motor.
Tips:
If the pedal goes down a little, it means the operation is ok.

2. Check the vacuum one-way valve.

(1) Check the vacuum one-way valve. ON OFF

a. Slide the clip to unfix the vacuum tube.

b. Remove the vacuum one-way valve.
c. Check the booster is ventilated to the motor.
d. In case of any failure, replace the vacuum one-way valve.
 Brake System - Vacuum Booster 4-93

Replacement
1. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash it immediately.
2. Unfix the clutch fluid tank pipe (manual transaxle).
3. Remove the brake master cylinder.
4. Remove the HECU assembly (with ABS).
5. Remove the vacuum booster.
(1) Unfix the vacuum tube from the brake booster.
(2) Remove the return spring, clip and pin.
(3) Remove the four nuts and U-clip.
(4) Pull out the vacuum booster and washer.

6. Install the vacuum booster.

(1) Install the vacuum booster and new washer.
(2) Install and fasten the vacuum booster nut.
Torque: 25N.m
(3) Install the return spring, clip and pin.

7. Install the vacuum booster push bar.

8. Install the brake actuator. (with ABS)
9. Install the brake master cylinder.
10. Connect the clutch fluid pipe.
11. Add the brake fluid to the reservoir.
12. Discharge the air in the brake master cylinder.
13. Discharge the air in the brake pipeline.
14. Check and adjust the height of the brake pedal.
15. Check the free stroke of the pedal.
16. Check the reserved distance of the pedal.
17. Discharge the air in the clutch tank pipe (manual transmission).
18. Check and adjust the clutch pedal (manual transmission).
19. Check the level height in the brake reservoir.
20. Check the brake fluid whether there is any leakage.
21. Check the clutch fluid whether there is any leakage (manual transmission).
4-94 Brake System - Front Brake Disc

Section 6 Front Brake Disc

Component View

88

Front disc brake cylinder

sliding pin Dust shield
Left cylinder support

88

Front disc brake

cylinder sliding pin #1 muffle pad

Dust shield #2 muffle pad

#2 muffle pad

Tube #1 muffle pad

Brake pad
Connector bolt 8
30 Brake pad
34
Left front disc
brake cylinder accessory

Support piece
Front brake pad I
Washer Support piece
Piston oil seal
Front brake pad II
Discharge screw
plug cap
Dust shield
34
Set ring

N . m : specified torque Front disc brake piston

Non-reusable parts
Lithium soap base glycol lube
Disc brake lube
 Brake System - Front Brake Disc 4-95

Repair
1. Remove the front wheel.
2. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash it immediately.
3. Remove the front disc brake cylinder.
(1) Remove the connector bolt and washer from the front disc
bake cylinder, and unfix the tube.

(2) Fasten the sliding pin on the front disc brake cylinder, and
remove the two bolts.

4. Remove the front brake pad package (only the pad).

(1) Remove the two brake pads with muffle washers.
(2) Remove muffle and heat isolation washers from the brake
pads.
5. Remove the support pad of the front brake pad.
Remove the two friction block from the brake cylinder support.
6. Remove the sliding pin of the front disc brake cylinder.
7. Remove the two dust shields
Braking Disc Cylinder Bracket
Remove the two dust shields from brake cylinder support.

Sliding Pin Dust Shields

8. Remove the left front disc brake cylinder support.

Remove the two bolts, and then take out the left front disc brake
cylinder support.
9. Remove the dust shield of the brake cylinder.
Remove the retaining ring and dust shield with screwdriver.
4-96 Brake System - Front Brake Disc

11. Remove the front brake piston.

(1) Put a piece of cloth or equivalent between the brake cylinder
and the piston.
(2) Blow the piston out of the brake cylinder with compressed air.
Warning:
In the blowing process, the finger shall not be placed before the
piston.
Note:
Don't spray the brake fluid.
12. Remove the piston oil seal.
Take out the oil seal from the brake cylinder with screwdriver.
13. Check the brake cylinder and piston.
Check the cylinder wall and piston whether there is rust or scar.

14. Check the lining thickness of the brake pad.

Measure the lining thickness with ruler.
Standard Thickness: 10.0mm
Minimum Thickness:1.0mm

15. Check the abrasion indicator steel strap of the front brake.
Make sure the abrasion indicator steel strap has adequate flexibility and has no deformation, crack or damage.
All rust, dirt and other impurities shall be cleaned out.

16. Check the thickness of the brake disc.

Measure the thickness of the brake disc with screw micrometer.
Standard Thickness: 20.0mm
Minimum Thickness: 18.0mm

17. Remove the front brake disc.

(1) Make mark on the brake disc and wheel hub.
(2) Remove the brake disc.

18. Install the brake disc.

Tips:
Install the disc at the minimum swing position.
 Brake System - Front Brake Disc 4-97

19. Check the swing of the brake disc.

(1) Fasten the brake disc temporarily.
Torque: 103N.m
(2) Measure the swing of the brake disc at the 10mm from the disc
edge with a dial test indicator.
Maximum Swing: 0.05 mm
(3) If the swing of the brake disc reaches or exceeds the limit,
check the bearing's axial clearance and the wheel hub's swing.
If the bearing and wheel hub run normally, adjust the swing
of the brake disc, or finish it with onboard finishing machine.

20. Tighten the brake discharge bolt temporarily.

Tighten the brake discharge screw plug on the front brake cylinder temporarily.
21. Install the piston oil seal.
(1) Apply the lithium soap-base glycol lube on the new piston oil seal.
(2) Install the new piston oil seal on the brake cylinder.
22. Install the brake piston.
(1) Apply the lithium soap-base glycol lube on the brake piston.
(2) Install the piston on the front disc brake cylinder.
Note:
Don't tighten the piston into the brake cylinder forcefully.
23. Install the dust shield of the brake wheel cylinder.
(1) Apply the lithium soap-base glycol lube on the dust shield of
the new brake wheel cylinder, and install it on the brake
cylinder.
Tips:
Install the dust shield in the groove of the brake wheel cylinder
and piston reliably.

(2) Install the set ring with screwdriver.

Note:
Be careful not to damage to the dust shield of the brake wheel cylinder.

24. Install the left front disc brake wheel cylinder support.
Fasten the front disc brake wheel cylinder support with two blots.
Torque: 88N.m
25. Install the dust shield of the front disc brake bushing.
Apply the lithium soap-base glycol lube on the surface of the two new dust shields.
Install the two dust shields on the front disc brake cylinder support.
26. Install the sliding pin of the front dist brake cylinder.
Apply the lithium soap-base glycol lube on the surface of the two sliding pin and oil seal.
Install the two sliding pins on the front disc brake cylinder support.
4-98 Brake System - Front Brake Disc

27. Install the support piece of the front brake pad.

Remove the two support pieces of the brake pad from the front disc brake cylinder support.

28. Install the brake lining block component.

Note:
When replace the abrasion brake lining block, replace the muffle
pad simultaneously.
(1) Apply the disc brake lube on both sides of all muffle pads
(2) Install muffle pads on all brake lining blocks.
(3) The abrasion indicator face upwards. Install a inner brake
lining block, then install a outer lining block.
Note:
Don't apply the oil or lube on the friction surface of the brake pad and brake disc.

29. Install the front disc brake wheel cylinder.

(1) Install the front disc brake wheel cylinder with two bolts.
Torque: 34N.m

(2) Install the new washer and tube with bolt.

Torque: 30N.m
Tips: Fasten the tube in the lock hole of the brake wheel
cylinder reliably.

30. Add the brake fluid to the storage tank.

31. Discharge the air in the brake cylinder.
32. Discharge the air in the brake pipeline.
33. Check the level height in the storage tank.
34. Check the brake fluid whether there is any leakage.
35. Install the front wheel.
Torque: 103N.m
 Brake System - Rear Brake Drum 4-99

Section 7 Rear Brake Drum

Component View

Discharge plug
Piston Discharge plug
Dust Dust shield
cover
Hole plug
Pin plug
Pin Piston
Cup
Spring

Cvlinder
Extension rod
Cup

Rear bake shoe

Left parking brake shoe pad post C-ring

Parking brake Locating spring

inhaul cable
Pin Baseboard

Return spring
Extension spring
Rear brake automatic Front brake shoe
adjustment rod

Adjustment rod spring Shoe pad positioning spring cover

Shoe pad positioning spring cover

Shoe pad positioning spring

N . m : specified torque
Rear brake drum
Non-reusable parts
Lithium soap base glycol lube
Heat-resistant lube
4-100 Brake System - Rear Brake Drum

Repair
Repair the right side as the steps in the left side.
1. Check the thickness of the brake shoe lining.
Remove the hole plug, and check the thickness of the brake shoe
lining through the hole.
If the thickness is less than the minimum thickness, replace a new
brake shoe.
Minimum Thickness: 1.0mm
2. Remove the rear wheel.
3. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash
it immediately.

Rotate
4. Remove the rear brake drum.
(1) Loosen the parking brake rod, and remove the brake drum.
Tips: If the brake drum can't be removed easily, carry out the
following steps.
(2) Remove the hole plug, and insert a screwdriver through the
backboard to separate the brake automatic adjustment rod
and the adjustor.
(3) Rotate the adjustment wheel to reduce the length of the
adjustor with another screwdriver.
5. Check the inner diameter of the brake drum.
Measure the inner diameter of the brake drum with a brake drum
gauge or equivalent.
Standard Inner Diameter: 200.0mm
Maximum Inner Diameter: 201.0mm
6. Separate the left positioning post of the parking brake shoe.
Remove the extension spring from the front/rear brake shoe with
a special tool, and separate the left positioning post of the parking
brake shoe.
Note:
Be careful not to damage to the dust shield of the brake cylinder.

7. Remove the front brake shoe.

(1) Remove the end cap, set spring and pin with a special tool.
(2) Unfix the return spring, and remove the front brake shoe.
(3) Remove the left positioning post of the parking brake shoe.
 Brake System - Rear Brake Drum 4-101

8. Remove the left brake automatic adjustment rod.

Remove the brake adjustment rod and its spring.

9. Remove the return spring of the brake shoe.

Remove the return spring from the brake shoe.
10. Remove the rear brake shoe.
(1) Prize the end cover with a special tool, and remove the set
spring and pin.

(2) Remove the parking brake cable from the parking brake
extension rod with a pair of pinchers.

11. Remove the parking brake shoe extension rod accessory.

Remove the C-washer and parking brake shoe extension rod with
screwdriver.

12. Check the thickness of the brake shoe lining.

Measure the thickness of the brake shoe lining with ruler.
Standard Thickness: 5.0mm
Minimum Thickness: 1.0mm
If the thickness reaches the minimum thickness or below, or
serious/uneven abrasion occurs, replace a new brake shoe.
4-102 Brake System - Rear Brake Drum

13. Check the brake shoe and the brake shoe lining whether they
touch normally.
Mark the inner surface of the brake drum with chalk, joint and
abrade the brake shoe and the inner surface.
If the drum and the lining touch poorly, abrade the brake shoe or
replace a new one.

14. Remove the left front or top brake wheel cylinder.

(1) Unfix the brake oil pipe with a special tool, and collect the
brake fluid with a container.
(2) Remove the bolt and brake wheel cylinder.

15. Remove the brake cup.

(1) Remove the two dust shields from the brake cylinder.
(2) Remove the two pistons and springs.
(3) Remove the two brake cylinder caps from every piston.
16. Check the brake cylinder.
Check the cylinder wall and piston whether there is any rust or nick.
17. Remove the rear discharge screw plug of the brake drum.
18. Tighten the rear discharge screw plug of the brake drum
temporarily.
19. Install the brake wheel cylinder cup.
(1) Apply the lithium soap-base glycol lube on the two brake
wheel cylinder cups and the piston.
(2) Install two brake cylinder caps on every piston.
(3) Install the compression spring and the two pistons on the
brake wheel cylinder.
(4) Install two new dust shields on the brake wheel cylinder.

20. Install the left front or top brake cylinder.

(1) Install the brake cylinder with bolt.
Torque: 9.8N.m
(2) Connect the brake oil pipe with a special tool.
Torque: 15N.m

21. Apply the heat-resistant lube.

Apply the heat-resistant lube on the touch surface of the brake
backboard and the brake shoe.
 Brake System - Rear Brake Drum 4-103

22. Install the parking brake shoe extension rod accessory.

Install a new C-washer, and install the parking brake shoe
extension rod.

23. Install the brake shoe.

(1) Connect the parking brake cable to the parking brake
extension rod with a pair of pinchers.

(2) Install the brake shoe, pin, set spring and set spring cap with
a special tool.

24. Install the return spring of the brake shoe.

Install the return spring on the brake shoe.
25. Install the left brake automatic adjustment rod.
Install the automatic adjustment rod and its spring on the front
brake shoe.

26. Install the parking brake shoe post.

(1) Apply the heat-resistant lube on the adjustment bolt.
4-104 Brake System - Rear Brake Drum

(2) As shown in the figure, install the parking brake left post.
Braking Plate

parking brake left post

27. Install the front brake shoe.

(1) Install the return spring on the front brake shoe.
(2) Install the front brake shoe, pin, set spring and set spring cap
with a special tool.

28. Connect the parking brake shoe left post.

Connect the extension spring to the front/rear brake shoe with a
special tool.
Note:
Be careful not to damage to the dust shield of the brake wheel
cylinder.

29. Check the installation of the brake drum.

(1) Check all parts whether they are installed properly.
 Brake System - Rear Brake Drum 4-105

(2) Measure the inner diameter of the brake drum and the
diameter of the brake shoe, and check the difference of them
whether it is a proper brake shoe clearance.
Brake Shoe Clearance: 0.3mm
Note:
Don't apply the oil or lube on the friction surface of the brake shoe
lining and brake drum.

30. Adjust the shoe clearance of the brake drum.

(1) Install two wheel hub nuts temporarily.
(2) Turn around eight teeth of the adjustor.
(3) Install the hole plug.

Extend

31. Install the rear brake drum sub-assembly.

32. Add the brake fluid to the storage tank.
33. Discharge the air in the master cylinder.
34. Discharge the air in the brake pipeline.
35. Check the level height in the storage tank.
36. Check the brake fluid whether there is any leakage.
37. Install the rear wheel.
Torque: 103N.m
38. Check the stroke of the parking brake extension rod.
39. Adjust he stroke of the parking brake extension rod.
4-106 Brake System - Parking Brake System

Section 8 Parking Brake System

Component View

Parking brake extension rod accessory

Parking brake switch component

Parking brake extension rod

Parking brake balance port

Inhaul cable #1 adjustment nut

#3 parking brake extension rod

Parking brake balance port

N . m : specified torque
Lithium soap base glycol lube
 Brake System - Parking Brake System 4-107

Parking Brake System

The table below can help you find out the possible failure reasons. The number means the possible sequence
of the reasons. Check the parts, and replace the corresponding parts if necessary.

Symptom Suspected location

1. The stroke of the parking brake extension rod is misadjusted.
2. The parking brake inhaul cable is trapped.
Brake is blocked. 3. The clearance of the parking brake shoe is misadjusted.
4. The parking brake lining is cracked or deformed.
5. The return or extension spring is damaged.

Adjustment
1. Remove the rear wheel.
2. Adjust the clearance of the brake shoe.
3. Install the rear wheel.
Torque: 103N.m
4. Check the stroke of the parking brake extension rod.
Pull the parking brake extension rod, and count the number of sound.
Parking Brake Extension Rod Stroke: Pull with 196N force till 6-9 clicks.
5. Adjust the stroke of the parking brake extension rod.
(1) Remove the glove box cover.
(2) Turn #1 adjustment nut inhaul cable till the stroke is ok.
(3) Install the glove box cover.

#1 adjustment nut inhaul cable

Parking Brake Tension Rod Component

1. Remove the accessories of the console.
2. Remove the middle console.
3. Remove #1 adjustment nut wire.
Remove #1 adjustment nut wire.
4. Remove the accessories of the parking brake extension rod.
(1) Remove the connector of the parking brake extension rod
switch.
(2) Remove the two bolts, and remove the parking brake exten
sion rod.

5. Remove the parking brake switch component.

Remove the screw and parking brake switch component.
4-108 Brake System - Parking Brake System

6. Install the parking brake switch component.

Install the parking brake switch component with screw.
7. Install the accessories of the parking brake extension rod.
(1) Install the extension rod on the parking brake inhaul cable, and install #1 adjustment nut wire.
(2) Fasten the parking brake extension rod with two bolts.
Torque: 13N.m
(3) Connect the connector of the parking brake switch.
8. Install the accessories of the console.
9. Install the middle console.
10. Check the stroke of the parking brake extension rod.
11. Adjust the stroke of the parking brake extension rod.

Parking System Component

Brake shoe baseboard

Parking brake shoe Rear Brake shoe

Left positioning post

Left rear brake automatic Shoe pad set spring

Adjustment rod

Rear brake automatic adjustment Shoe pad set spring cap

rod spring

Shoe pad set spring Return spring

Rear brake shoe

Shoe pad set spring cap

Brake drum

Replacement
For left parking brake inhaul cable component, carry out the same steps as the right side.
1. Remove the accessories of the console.
 Brake System - Parking Brake System 4-109

2. Remove the middle console.

3. Loosen #1 inhaul cable adjustment nut.
Remove #1 inhaul cable adjustment nut.
4. Remove the front floor extension rod.
Remove the two bolts to take out the front floor extension rod.
5. Remove the front exhaust pipe component.
6. Remove #2 front floor hot pad.
Remove the two bolts to take out the front floor hot pad.
7. Remove #3 parking brake inhaul cable component.
(1) Remove the four bolts to remove # 3 parking brake inhaul cable from the body.
(2) Remove 3
# parking brake inhaul cable component from the parking brake balancer, and remove the inhaul
cable component.
8. Remove the rear wheel.
9. Remove the accessories of the brake drum.
10. Remove the front brake shoe.
11. Remove the left rear automatic adjustment rod.
12. Remove the rear brake shoe.
13. Remove parking brake inhaul cable component.
Remove the bolt, and remove parking brake inhaul cable
component from the baseboard.

14. Install parking brake inhaul cable component.

(1) Install parking brake inhaul cable component on the parking brake inhaul cable balancer.
(2) Fasten parking brake inhaul cable with four bolts.
Torque: 5.4N.m
4-110 Brake System - Parking Brake System

15. Install #3 parking brake inhaul cable component.

Fasten #3 parking brake inhaul cable component to the baseboard.
Torque: 7.8N.m
16. Apply the heat-resistant lube.
17. Install the brake shoe.
18. Install the return spring of the brake shoe.
19. Install the left rear brake automatic adjustment rod.
20. Install the front brake shoe.
21. Check the installation of the brake drum.
22. Install the accessories of the brake drum.
23. Adjust the clearance of the brake shoe.
24. Install the rear wheel.
Torque: 103N.m
25. Fasten #1 adjustment nut wire temporarily.
Install #1 adjustment nut wire.
26. Install #2 front floor hot pad.
Fasten #2 floor hot pad with two bolts.
Torque: 5.5N.m
27. Install the front exhaust pipe component.
28. Install the front floor extension rod.
Install the front floor extension rod with two bolts.
29. Check the stroke of the parking brake extension rod.
30. Adjust the stroke of the parking brake extension rod.