Brake System

Specifications

Specifications

Item		Specification
Master Cylinder	Type	Single
	Cylinder Inner Diameter	Ø 20.64 mm (0.812 in.)
	Piston Stroke	33 ± 1 mm (1.29 ± 0.039 in.)
	Fluid Level Sensor	Provided
Brake booster	Type	9-inch single
	Booster Ratio	7,5 : 1
Front Disc Brake
		13 in.	14 in.
Type		Ventilated Disc	Ventilated Disc
Rear Disc		241 mm (9.4882 in.)	256 mm (10.0787 in.)
Disc Thickness		18 mm (0.7087 in.)	20 mm (0.7874 in.)
Disc Service Limit		16.0 mm (0.6299 in.)	18.0 mm (0.7087 in.)
Cylinder Type		Single piston	Single piston
Rear Disc Brake
Type		Solid Disc
Disc O.D.		234 mm (9.2126 in.)
Disc Thickness		10.0 mm (0.3937 in.)
Disc Service Limit		8.4 mm (0.3307 in.)
Cylinder Type		Single piston
Drum Brake
Type		Leading Trailing
Drum (Disc) ID		Ø 203.2 mm (8.0000 in.)
Lining Thickness		4.0–4.7 mm (0.1575–0.1850 in.)

Specifications (ABS)

Part	Item	Standard Value	NOTE
HECU	System	4-Channel 4-Sensor (Solenoid)
	Type	Motor, Integrated Valve Relay Type
	Operating Voltage	9.7–17.4 V
	Operating Temperature	-40 to 120 °C
	Engine Power	230 W
Active Wheel Speed Sensor (ABS)	Supply Voltage	4.5–20 V DC
	Low Output Current	5.9–8.4 mA
	High Output Current	11.8–16.8 mA
	Output range	1 - 2500 Hz
	Tone wheel	48 teeth
	Air gap	0.4 - 1.0 mm

Specifications (ESC)

Part	Item	Standard Value	NOTE
HECU	System	4-Channel 4-Sensor (Solenoid)	Full Control
	Type	Motor, Integrated Valve Relay Type	(ABS, TCS, VSM, ESC)
	Operating Voltage	9.7–17.4 V
	Operating Temperature	-40 to 120 °C
	Engine Power	270 W
Active wheel speed sensor	Supply Voltage	4.5–20 V DC
	Low Output Current	5.9–8.4 mA
	High Output Current	11.8-16.8 mA
	Output range	1 - 2500 Hz
	Tone wheel	48 teeth
	Air gap	0.4 - 1.0 mm

Service Standard

Items	Standard Value
Brake pedal height	182 mm (7.29 in.)
Brake pedal full travel	108 mm (4.25 in)
Stop Lamp Switch Clearance	1.0–2.0 mm (0.04–0.08 in.)
Front brake disc thickness (13 in.)	18 mm (0.70 in)
Front brake disc thickness (14 in.)	20 mm (0.7874 in.)
Front brake pad thickness	11 mm (0.4331 in.)
Rear brake disc thickness	10 mm (0.39 in.)
Rear brake pad thickness	10 mm (0.39 in.)

Tightening Torque

Items		N·m	kgf·m	lbf·ft
Master Cylinder to Brake Booster Nut		9,8 - 15,7	1,0 - 1,6	7,2 - 11,6
Brake Tube Flare Nuts at Master Cylinder	ABS	13,7 - 16,7	1,4 - 1,7	10,1 - 12,3
	ESC	18,6 - 22,6	1,9 - 2,3	13,7 - 16,6
Front caliper guide rod bolts		21,6 - 31,4	2,2 - 3,2	15,9 - 23,1
Rear caliper guide rod bolts		21,6 - 31,4	2,2 - 3,2	15,9 - 23,1
Front caliper assembly to steering knuckle		78,5 - 98,1	8,0 - 10,0	57,9 - 72,3
Rear caliper assembly to steering knuckle		78,5 - 98,1	8,0 - 10,0	57,9 - 72,3
Brake pedal bracket bolts		16,7 - 25,5	1,7 - 2,6	12,3 - 18,8
Wheel speed sensor mounting bolt		7,8 - 11,8	0,8 - 1,2	5,8 - 8,7
HECU Bracket Mounting Bolts		16,7 - 25,5	1,7 - 2,6	12,3 - 18,8
HECU Brake Tube Flare Nuts		13,7 - 16,7	1,4 - 1,7	10,1 - 12,3

Lubricants

Items	Recommended	Quantity
Brake fluid	DOT 3 or DOT 4	419.5 cm3 ± 20 cm3
Brake pedal bushing and bolt	Chassis grease	As required
Parking brake shoe and backing plate contact surface	Heat-resistant grease	As required

Special Service Tools

Special Service Tools

		Use
09581-11000 Piston Expander		Front Disc Brake Piston Compression
09964-C1100 SCC Reflector		SCC Radar Alignment Reflector
09964-C1200 Calibration Beam		Laser for determining vehicle center.
09964-C1300 Stand		SCC reflector or vertical/horizontal laser support.

Troubleshooting

Troubleshooting

Symptom Table

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

Symptom	Possible Cause	Countermeasure
Low or Spongy Pedal	Brake System (Fluid Leak)	Repair
	Brake System (Air Intrusion)	Bleeding Procedure
	Piston Seal (Worn or Damaged)	Replace
	Rear Brake Shoe Clearance (Incorrect Adjustment)	Adjust
	Master Cylinder (Malfunction)	Replace
Brake Drag	Brake Pedal Free Travel (Minimum)	Adjust
	Parking Brake Cable Length (Adjustment Problem)	Adjust
	Parking Brake Cable (Seized)	Repair
	Rear Brake Pad Separation (Adjustment Problems)	Adjust
	Lining and Backing Plate (Twisted or Cracked)	Replace
	Piston (Trapped)	Replace
	Piston (Seized)	Replace
	Anchor or Return Spring (Malfunction)	Replace
	Brake Booster (Vacuum Leak)	Repair
	Master Cylinder (Malfunction)	Replace
Uneven Braking	Piston (Trapped)	Replace
	Lining and Backing Plate (Oil Stains, Cracks or Warpage)	Replace
Heavy Pedal Effort and Brake Problems	Brake System (Fluid Leak, Air Intrusion)	Perform the Bleeding Procedure
	Brake Shoe or Lining (Worn)	Replace
	Pad Shim or Backing Plate (Cracked or Twisted)	Replace
	Rear Brake Pad Separation (Adjustment Problems)	Adjust
	Pad Shim or Backing Plate (Oil Stain)	Replace
	Pad Shim or Backing Plate (Slippery)	Replace
	Disc (Scored)	Replace
	Brake Booster (Vacuum Leak)	Repair
Brake noise	Pad Shim or Backing Plate (Cracked or Twisted)	Replace
	Loose Wheel Bolt and Caliper	Adjust
	Pad Sliding Problems (Uneven Pad Wear)	Replace
	Lining or Backing Plate (Dirty)	Cleaning
	Pad Shim or Backing Plate (Slippery)	Brake Pad Replacement
	Anchor or Return Spring (Malfunction)	Replace
	Brake Pad Shim (Damaged)	Replace
	Retaining Spring (Damaged)	Replace
	Foreign Object Caught Between Disc and Pad	Cleaning
	Corrosion on Disc	Brake Road Test and Cleaning * Remove friction corrosion by performing a brake road test
	Cave-in Disc	Replace
Brakes Not Fully Effective (at high driving speed)	Brake Shoe or Lining (Worn)	Replace
	Master Cylinder (Malfunction)	Replace
Brake Vibration	Brake Booster (Vacuum Leak)	Repair
	Pedal Free Separation	Adjust
	Master Cylinder (Malfunction)	Replace
	Master Cylinder Cap Damaged	Replace
	Brake Line Damaged	Replace
	Caliper Return Problem (while wheel rotates, check for noise)	Replace
	Converted Disc	Replace