Brake PDF

Brake System
GENERAL
MECHANICAL SPECIFICATIONS . . . . . . . BR - 2
VACUUM ASSISTED HYDRAULIC BRAKE

BRAKE BOOSTER
BRAKE PEDAL
BRAKE MASTER CYLINDER
LOAD
SENSING
PROPORTIONING
VALVE(L.S.P.V)
FRONT BRAKE ASSEMBLY

DISC BRAKE
DRUM BRAKE
REAR BRAKE ASSEMBLY

DRUM BRAKE
EXHAUST BRAKE
PARKING BRAKE SYSTEM
ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION
ABS MODULATER
ABS CONTROL MODULE
WHEEL SPEED SENSOR
BR -2
BRAKE SYSTEM
GENERAL
MECHANICAL SPECIFICATIONS
SPECIFICATIONS
E7FA724A
FRONT WHEEL BRAKE (DRUM TYPE)

Item
Specifications
Brake type
2-leading Brake
Wheel cylinder
Inner diameter
31.75mm
Brake drum
Inner diameter
320mm
Brake lining
Width x Thickness (mm)
85 x 10(Standard), 110 x 11(Option)
FRONT WHEEL BRAKE (DISK TYPE)

Item
Specifications
Brake type
Disc brake with hydraulic vacuum booster
I.D (mm)
76
Effective radius (mm)
118
Pad area (cm)
83
Disc size (O.DI.Dthickness)
304 16830
Bore
size
REAR WHEEL BRAKE

Item
Specifications
Brake type
2-leading Brake
Wheel cylinder
Inner diameter
28.57mm
Brake drum
Inner diameter
320mm
Brake lining
Width x Thickness (mm)
8510 (standard)
11011 (option)
BRAKE SYSTEM
Item
Brake Pedal
Total Stroke
Booster
Power Cylinder
Specification
162
Diaphragm Diameter
Total Stroke
Master Cylinder
Inner Diameter
Stroke
Capacity of Brake Tank
228/251mm
32mm
31.75mm
Front
17mm
Rear
14mm
505(cc)
GENERAL
BR -3
EXHAUST BRAKE
Item
Specification
Control System
Combination of Electric and Vacuum Type
Exhaust Brake Valve Type
Butterfly Valve
Exhaust Brake
Chamber
76.2mm
Diaphragm Effective Diameter

With Installing N(kg)
In operation N(kg)
Spring Tension
90~110 (9.18~11.22)
Rod Tensile Force
142.1(14.5): Vacuum Pressure-400mmHg
Spring Tension
125~153 (12.78~15.62)
Rod Tensile Force
103(10.5) Vacuum Pressure-400mmHg
Excluded from D4AE, D4AF
Intake shutter
Included with D4DA, D4DB, D4DC, D4AL, D4DD
PARKING BRAKE
Item
Specification
Type
Internal expansion type acting on propller shft
Control
Mechanical cable
Parking lever
Normal stroke
7~8 clicks(20 kgf)
Parking brake size
Drum i.d. x Lining width

x Lining thickness
180 x 35 x 5 (T/M : M2S5, M3S5)

190 x 45 x 4 (T/M : M035S5, D4DA, D4DB, D4DD)
ABS SPECIFICATION
Item
ABSCM(ABS Control Module)
Operating voltage
Power consumption
Inoperation
Operation
Operating temperature range
24V
16~32V
12W or below
18W or below
-40 ~ 65 C
Modulator
Operating voltage range
On-board voltage
Operating temperature range
18.9 ~ 32.8 V
24V
-40 ~ 120 C
Motor relay
On-board voltage
Operation voltage
On-board current
DC24V
15V
20A
Valve relay
On-board voltage
Operating voltage
DC24V
13V
BR -4
BRAKE SYSTEM
SERVICE STANDARDS
Description
Brake
pedal
Bushing to collar clearance

Brake pedal play
Stop lamp switch installation clearance
Nominal value
(Basic diameter
in [ ])
Limit
Correction
and
remarks
[16]0.02 ~ 0.26
0.5
Replace
bushing
3-8
Adjust
0 ~ 1
Replace
0.03-0.089
0.2
Brake
master
cylinder
Primary and secondary piston to cylinder body clearance
Front
disc
brake
Brake drum
I.D.
320
322
Replace
Brake lining
Thickness
10.0
4.0
Replace
303/227
19/227
Replace
[31.75]0.03 to
0.13
0.2
Replace
Primary spring deterioration
Free length
54
Replace
Secondary spring
deterioration
Free length
70.3
Replace
Return spring
Wheel cylinder body to piston clearance
Brake shoe clearance(No. of notches returned of
wheel cylinder adjuster)
Rear
wheelbrake
Replace
4 ~ 6
Adjust
Brake drum
I.D.
320
322
Replace
Brake lining
Thickness
10.0
4.0
Replace
Return
spring
Load N(kgf)/installed length
303/227
19/227
Replace
Wheel
cylinder
Body to piston clearance
0.02-0.11
0.2
Replace
Brake drum
Out of roundness
0.05
Replace
Brake shoe clearance (number of return notches

of wheel cylinder adjuster)
4 ~ 6
Adjust
GENERAL
BR -5
Nominal value
(Basic diameter
in [ ])
Description
Exhaust
brake
Limit
Correction
and
remarks
Power chamber air tightness [15 seconds after application

of -67 kPa (-500 mmHg) negative pressure]
-63 kPa (-475

mmHg) or more
Replace
Valve to body clearance when butterfly valve is fully closed [at

power chamber vacuum -87 to -93 kPa(-650 to -700 mmHg)
0.1 to 0.25mm
Replace
When -100 kPa (-750 mmHg)

negative pressure is applied from
vacuum tank side to operate
valve with exhaust brake unit
side plugged tightly
No air to be
sucked in from
atmosphere side
Replace
When 98 kPa (1 kgf/cm

air pressure is applied from
atmosphere side to operate
valve with exhaust brake unit
side plugged tightly
No air to leak from

vacuum tank side
Replace
3-way
magnet
valve
Air tightness
Minimum
operating
voltage
When -100
kPa(-750
mmHg) negative
pressure is
applied to
vacuum tank side
24V type
unit
22V or less
Replace
When 98 kPa
(1 kgf/cm air
pressure is
applied from
atmosphere side
with exhaust
brake unit side
plugged tightly
24V type
unit
22V or less
Replace
BR -6
BRAKE SYSTEM
SERVICE STANDARDS (PARKING BRAKE)

Description
Brake drum
I.D.
Nominal value
(Basic diameter
in [])
Limit
180
181
190
192
Squareness
0.05 or less
Concentricity
0.1 or less
Cylindricity
0.1 or less
Static roation imbalance
0.49N cm (50 gf
cm)or less
Model with M2S5

T/M
3.85 ~ 5.15
Brake shoe clearance
Model with M2S5

T/M
0.25 ~ 0.35
Brake shoe return

spring
Free length
Model with M2S5

T/M
98
Load N
(kgf)/installed
length
Model with M2S5

T/M
67 ~ 86 (6.8 ~
8.8)/104
104.364
(6.5)/104
Spring A(longer
one of free
length)
Free length
Spring B(shorter
one of freel
ength)
Free length
Load N
(kgf)/installed
length
Load N
(kgf)/installed
length
Correct to limit,
replace when
limit is reached.
Correct or replace
Brake lining thickness
Shoe hold down

spring
Correction and
remarks
2.0
Adjust
34.1
59 ~ 69 (6.0 to
7.0)/13.7
Replace
Replace
59 (6.0)/13.7
23.6
59 ~ 69 (6.0 to
7.0)/10.5
Replace
59 (6.0)/10.5
GENERAL
BR -7
TIGHTENING TORQUE TABLE

Tightening torque
Description
Nm
Kgf.m
Lb-ft
Oil tank attaching bolt
3.9 ~ 5.9
0.4 ~ 0.6
2.8 ~ 4.3
Brake booster support attaching bolt
23 ~ 27
2.3 ~ 2.7
16.6 ~ 19.5
Brake pedal attaching bolt
34 ~ 54
3.5 ~ 5.5
25.3 ~ 39.7
Brake booster and brake pedal

support assembly attaching bolt
23 ~ 27
2.3 ~ 2.8
16.6 ~ 20.2
Brake pedal support assembly

to floor attaching bolt
8.8 ~ 14
0.9 ~ 1.4
6.5 ~ 10.1
Brake master
cylinder
Set bolt tightening
13 ~ 15
1.3 ~ 1.5
9.4 ~ 10.8
Brake booster
Clevis lock nut tightening
19 ~ 23
1.9 ~ 2.3
13.7 ~ 16.6
Front wheel brake
Connector attaching
20 ~ 28
2.0 ~ 2.9
14.4 ~ 20.9
Brake tube nut tightening
13 ~ 18
1.3 ~ 1.8
9.4 ~ 13
34.5 ~ 50
3.45 ~ 5.1
24.9 ~ 36.8
Screw tightening
7 ~ 13
0.7 ~ 1.3
5 ~ 9.4
Brake tube nut tightening
13 ~ 18
1.3 ~ 1.8
9.4 ~ 13
Wheel cylinder attaching bolt
13 ~ 18
1.3 ~ 1.8
9.4 ~ 13
245 ~ 340
25 ~ 35
181 ~ 253
Backing plate tightening bolt
52 ~ 67
5.3 ~ 6.8
38.3 ~ 49.1
Brake drum and propeller shaft

flange yoke tightening nut
59 ~ 74
6.0 ~ 7.5
43.3 ~ 54.2
Main cable bracket bolt
38 ~ 59
3.9 ~ 6.0
28.2 ~ 43.3
Intermediate lever bracket bolt
38 ~ 59
3.9 ~ 6.0
28.2 ~ 43.3
Balancer bracket bolt
38 ~ 59
3.9 ~ 6.0
28.2 ~ 43.3
Hanger bolt
33 ~ 36
3.4 ~ 3.7
24.5 ~ 26.7
Cable assembly adjusting nut
18 ~ 29
1.9 ~ 2.8
13.7 ~ 20.2
Exhaust brake valve cover

attaching bolt
4.9 ~ 6.9
0.5 ~ 0.7
3.6 ~ 5.0
Power chamber attaching bolt
9.8 ~ 16
1.0 ~ 1.6
7.2 ~ 11.5
Push rod fixing nut
9.8 ~ 16
1.0 ~ 1.6
7.2 ~ 11.5
Front
8 ~ 9
0.8 ~ 0.9
5.7 ~ 6.5
Rear
15 ~ 16
1.5 ~ 1.6
10.8 ~ 11.5
Hydraulic unit mounting bolt
17 ~ 26
1.7 ~ 2.6
12.2 ~ 18.8
Hydraulic unit mounting bracket bolt
18 ~ 22
1.8 ~ 2.2
13 ~ 15.9
Six brake tubes on the Hydraulic Unit
13 ~ 17
1.3 ~ 1.7
9.4 ~ 12.2
Brake control
Wheel cylinder attaching bolt

Rear wheel brake
Parking brake
Exhaust brake
ABS
Transmission main shaft rear lock nut
Sensor mounting
bolt on the brake
plate
BR -8
BRAKE SYSTEM
COMPONENTS
E4450706
10
9
7
8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Vacuum tank
Vacuum hose
Brake booster
Master cylinder
3-Way connector
Front wheel brake
Reservoir tank
ABS modulator
LSP valve
Rear wheel brake
4
NOTE:
1. Clean tube inside with compressed air when assembling.
2. Tighten tube nut of brake tube contacting tube flare portion by mating seat face.
3. Tightening torque of brake tube nut to be 1.3-1.7kgm
4. Install brake hose without twist and interference with near parts.
And Tightening torque to be 2.5-3.0kgm
5. Tube must not assemble with electric harness.
6. Perform air bleeding securely.(Perform LSPV side securely)
7. Tightening torque of brake bleed screw to be 0.7-0.9kgm
8. Junction to be free from oil and vaccum leaking.
9. Contact shoe to drum by turning wheel cylinder piston.
And adjust lining clearance by turning adjuster piston to opposite direction of arrow. This time, drawing tolerance
between drum and lining to be 50kgcm
10. Assemble brake assembly to axle with same color LH, RH marking in lining side.
ECOBR5001A
GENERAL
BR -9
1
2
AIR
3
7
8
6
Vacuum Tube
Vacuum Hose
Oil Tube
Oil hose
1.
2.
3.
4.
5.
6.
7.
8.
Vacuum pump
Vacuum tank
3-way magntic valve
Exhaust brake valve
Booster
Master cylinder
Oil reservoir
Check valve
ECOBR5002A
BR -10
BRAKE SYSTEM
10
AIR
3
7
10
6
5
Vacuum Tube
Vacuum Hose
Oil Tube
Oil hose
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Vacuum pump
Vacuum tank
3-way magntic valve
Exhaust brake valve
Booster
Master cylinder
Oil reservoir
ABS modulator valve
Speed wheel sensor
Check valve
ECOBR5003A
GENERAL
BR -11
1
9
AIR
3
7
9
6
Vacuum Tube
Vacuum Hose
Oil Tube
Oil hose
1.
2.
3.
4.
5.
6.
7.
8.
9.
Vacuum pump
Vacuum tank
3-way magntic valve
Exhaust brake valve
Booster
Master cylinder
Oil reservoir
L.S.P.V
Check valve
ECOBR5004A
BR -12
BRAKE SYSTEM
To vacuum tank
Diaphragm plate
Vacuum valve
Valve body
Input rod
Silencer
Valve plunger
Air valve
Output rod
Diaphragm
ECOBR5005A
GENERAL
DESCRIPTION
BR -13
EBB7B828
BRAKE SYSTEM
The service brakes are internally expanding type hydraulic brakes acting on all wheels. The brakes for the
front wheels are 2-leading type and those for the rear
wheels are duo-servo or dual 2-leading type.
The brake booster gives faster hydraulic pressure buildup.
Tandem type brake master cylinder also contributes to
safety. The brake pedal, which is easy-to-operate pendant
type, transmits depression force via operating rod, etc.
to the BRAKE BOOSTER, which boosts it and drives the
master cylinder.
The BRAKE BOOSTER vacuum line is equipped with a
vacuum tank which minimizes negative pressure change
even in the case of repeated and frequent braking operation.
BRAKE BOOSTER
1.
When not in Operation

When not in operation, no force acts on the operating
rod and hence the valve plunger is seated on the poppet to open the negative pressure valve and to close
the atmospheric valve.
Negative pressure generated by the engine draws
out air from the chamber on the left side of the diaphragm plate. And as the chamber on the right side
of the diaphragm plate is also evacuated via the vacuum channel and the negative pressure valve that is
opened. As a result, the diaphragm plate is pressed
tightly onto the rear shell surface by the diaphragm
plate return spring. Atmosphere goes through the air
filter into space around the operating rod but does
not flow further as the atmospheric valve of the valve
plunger is closed.
2.
When in Operation
When the brake pedal depression force overcomes
the valve return spring force, the operating rod, valve
plunger and poppet now move to the left and the
poppet is pressed tightly onto the valve plunger seat
by the poppet spring, closing the negative pressure
valve. When the brake pedal is further depressed following closure of this valve, the valve plunger clears
the poppet to open the atmospheric valve and atmosphere now flows through the channel into the chamber
on the right side of the diaphragm.
This flow of atmosphere produces the pressure difference across the diaphragm and the force resulting
from such pressure difference overcomes the piston
return spring force. As a result, the diaphragm pushes
the push rod as it moves from right to left. The push
rod thus pushes the master cylinder piston, generating high fluid pressure from low pedal depression
force.
KMTBR5501A

1.
Normal Operation
The tandem type brake master cylinder has independent hydraulic systems for front and rear brakes.
Should one of the two hydraulic systems fail, braking by survived system (front or rear wheels) ensures
safety. When the brake pedal is depressed, the primary piston is pushed to left, developing hydraulic
pressure in the pressure chamber on the primary side.
This pressure directly acts on the secondary piston
to push the secondary piston to left, developing hydraulic pressure also in the pressure chamber on the
secondary side. As a result, each piston pressurizes
brake fluid to generate hydraulic pressure in both front
and rear brake systems.
Primary piston
Secondary piston
EMTBR5002A
2.
When fluid leaks are caused in front brake system

In this case, depression of the brake pedal to push the
push rod does not develop hydraulic pressure as the
brake fluid leaks from the front brake system. Therefore, the primary piston compresses the primary return spring and the retainer pushes the secondary piston, which then pressurizes brake fluid in space between the secondary piston and cylinder body, thus
generating hydraulic pressure in the rear brake system only.
BR -14
BRAKE SYSTEM
friction between the lining and drum causes the shoe to
try to turn with the drum, thus boosting the braking force.
Piston
Primary piston
Brake
drum
Wheel
cylinder
Secondary piston
Lining
Shoe
EMTBR5003A
3.
When fluid leaks are caused in rear brake system

In this case, when the brake pedal is depressed to
push out the push rod, the secondary piston end
comes into contact with the cylinder body since brake
fluid in the rear brake system leaks. When the push
rod is further pushed, the primary piston pressurizes
brake fluid in the space between the primary and
secondary pistons, generating hydraulic pressure in
the front brake system only.
FRONT AND REAR WHEEL BRAKES

FRONT WHEEL BRAKES
The wheel cylinder is so constructed that the piston extends in one direction only to push the shoes which are
held down to the backing plate by the shoe hold down pin.
The return springs mounted on the shoe fixed and moving
sides cause contraction of the shoe and wheel cylinder
piston when the brake is released.
When the vehicle is running forward, both shoes work as
leading shoes.
REAR WHEEL BRAKE

DUAL 2-LEADING BRAKE
The wheel cylinders are installed at front and rear and the
pistons extend in both upward and downward directions to
push the shoes from both directions. The shoes are held
down to the backing plate by shoe hold down pins and the
return springs mounted on the shoes causing contraction
of the shoe and wheel cylinder piston when the brake is
released. During both forward and reverse operation of
the vehicle, the shoes work as leading shoes.
Shoe
Shoe return
spring
Shoe return
spring
Wheel
cylinder
assembly
Shoe
Shoe return
spring
EMTBR5005A
Shoe return
spring
Shoe inspection hole

EMTBR5004A
Wheel
cylinder
assembly
When the pedal is depressed, brake fluid supplied under

pressure from the master cylinder enters the wheel cylinder, of which piston causes the shoe to expand in both directions to press the lining against the drum inside. Resultant friction between the lining and drum causes the shoe
to try to turn with the drum, thus boosting the braking force.
Shoe inspection hole

EMTBR5004A
When the pedal is depressed, brake fluid supplied under

pressure from the master cylinder enters the wheel cylinder, of which piston moves the shoe moving side so that
the lining is pressed against the drum inside. Resultant
GENERAL
BR -15
Brake drum
Shoe
Lining
Piston
Wheel
cylinder
Lining
Piston
Shoe
Piston cup
Brake drum
EMTBR5006A
WHEEL CYLINDER
EMTBR5008A
2.
The wheel cylinder driven by hydraulic pressure generated by the brake master cylinder presses the shoe (lining)
against the brake drum.
There are following two types of wheel cylinder according
to the method of pushing the shoe.
Dual 2-reeding type : rear brake

Brake drum
Shoe
Lining
Piston cup
Adjusting screw
Piston
Spring sheet
Piston cup
EMTBR5009A
Adjuster
Piston
BRAKE FLUID LEVEL SENSOR
EMTBR5007A
1.
2-reeding type : Front brake

In pedaling brake, oil pressure rising is master cylinder goes into wheel cylinder and pushes piston. Shoe
contacting with the end of piston sticks to brake drum
and generates frictional force.
The brake fluid level sensor installed in the brake fluid tank
senses the brake fluid level in the tank. When the fluid level
drops to a preset level, the sensor operates to turn on the
warning lamp in the cluster to warn low brake fluid level.
Cap
Float
Reed switch
EMTBR5010A
BR -16
BRAKE SYSTEM
EXHAUST BRAKE
OFF
Vacuum chamber
Vacuum tank
3-way magnet
valve in ON
Exhaust brake
Intake shutter
Exhaust brake valve

Engine
Accelerator pedal switch ON

Accelerator pedal switch OFF
Fuse
Battery
1 : Clutch switch
Clutch switch ON in not pedaling clutch
Clutch switch OFF in pedaling clutch
Exhaust brake switch

Cold-start switch
NOTE:
Intake shutter system
ECOBR5006A
The exhaust brake system, as an assistant function of the

service brake, comprises of the exhaust brake device installed at the middle portion of the exhaust pipe and the
intake shutter installed at the intake manipulate to reduce
the intake air noise.
When the exhaust brake device close the butterfly valve,
the pressure inside of the pipe increases. This increased
pressure influences to the piston to get the braking force.
At that time, the intake shutter is also closed. When the
clutch pedal, the accelerator pedal or the exhaust brake
switch is released, the electric circuit is OFF and the exhaust brake is released.
The exhaust brake is the vacuum type assistant device
which uses the negative pressure.
GENERAL
BR -17
INTAKE SHUTTER
2.
When the exhaust brake is operating, the intake shutter(A)

reduces the amount of the intake air through the intake
manipulate so as that the exhaust pressure is operated to
the piston effectively. As a result, the noise will be reduced
and the brake will be more effective.
At releasing
If the exhaust brake switch, the clutch switch and the
accelerator switch are OFF, the 3-way magnetic valve
closes the circuit to the vacuum tank and opens the
atmosphere circuit.
Therefore, the atmospheric pressure is applied to the
exhaust brake unit. Due to the spring tension, the butterfly valve is opened. The exhaust brake is released.
A
Connector
Spring
Diaphragm plate
Retainer
Push rod
Adjusting bolt
(When close,
adjust space correctly)
KMTBR5513A
Adjusting bolt
(When open with maximum)
EMTBR5013A
EXHAUST BRAKE UNIT

1.
Butterfly
valve
At Working
If the exhaust brake switch is ON, the three-way magnetic valve is opened. The vacuum pressure of the
vacuum tank is applied to the exhaust brake unit so
as to pull the piston.
As a result, the butterfly valve linked to the push rod
is closed so that the exhaust brake is working.
Butterfly valve
EMTBR5012A
BR -18
BRAKE SYSTEM
THE 3-WAY MAGNETIC VALVE

1.
At working
If the exhaust brake switch is ON, an electric current
will flow through the coil and then a magnetic field
is formed. The magnetic force pulls the plunge to
upward. At that time, the valve seat at the plunger
closes the way to the atmosphere pressure while it
opens the way linking the vacuum tank and the brake
chamber.
Magnetic coil
Plunger
From exhaust
brake unit
To vacuum tank
(negative pressure)
EMTBR5014A
2.
At releasing
If the exhaust brake switch is OFF, the electric current flowing through the coil is shut down. Due to the
spring tension, the plunger will be pushed so as to
close the way to vacuum tank while the way to the atmosphere pressure and the brake chamber.
Atmosphere
Plunger spring
Exhaust brake
unit
EMTBR5060A
GENERAL
BR -19
LOAD SENSING PROPORTIONING VALVE
3
2
1. LSPV assembly
2. Bleeder screw
3. Bracket
4. Lever assembly
5. Sensor spring
6. Spring guide
7. Adjusting nut
8. Operating lever
9. Connecting link assembly
EMTBR5015A
BR -20
BRAKE SYSTEM
2.
LSPV is consist of sensor part and pressure controller

part.
1.
2.
Sensor part
It consists of spring, operating lever, link. It senses the
height of vehicle with varing according to the amount
loads
Pressure controller part
It consists of valve stem mechanism for proportioning
control of sensor force.
Full Load Characteristic
Loaded status
The sensor spring presses the valve stem strongly, so
the brake fluid pressure is setted highly.
NOTE
Dont loose or dont retight the adjusting nut crimping.
Output Pressure
CONSTRUCTION
Pc
Input pressure
Output
Pressure
Empty Characteristic
EMTBR5017A
SERVICE AND INSPECTION OF THE LSPV
Input Pressure
Check the LSPV as below when replace the sensor spring,

valve body assembly or reinstall the rear axle,rear spring.
EMTBR5016A
OPERATING PRINCIPAL
LSPV body is mounted in the frame and the end of the
link is mounted in the rear axle. With varying of amout
of vehicle load changes the relative position of frame and
rear axle, so sensor spring force varies to the valve stem.
It controls the rear axle brake fluid pressure.
1.
Symptom
Braking force is
insufficient
Unloaded status
The sensor spring presses the valve stem slightly, so
the brake fluid pressure is setted weakly.
Rear brake is
lock too fast
Probable Cause
Remedy
Insufficient air
bleeding
Air bleeding
Maladjust
sensor spring
Readjust
Sensor spring
broken
Replace valve
assembly
Oil leakage in
the brake fluid
line or LSPV
assembly
Tighten brake
fluid line or
replace LSPV
assembly
Maladjust
sensor spring
Readjust
Inner fault the

LSPV
Replace LSPV
assembly
GENERAL
BR -21
PARKING BRAKE GENERAL
Adjusting nut
Parking brake cable assembly
(M035S5 T/M)
Parking brake drum
Parking brake cable assembly (M2S5, M3S5 T/M)
Parking brake lever assembly
ECOBR5007A
The parking brake installed behind the transmission is an

internal expansion type acting on the propeller shaft.
It controls propeller shaft rotation to work as a parking
brake.
The control is wire mechanical type; brake shoes are
pressed via a wire to controll the propeller shaft.
BR -22
BRAKE SYSTEM
PARKING BRAKE PROPER

When the lever at the drivers seat is pulled, the cam lever
is actuated via a wire cable and resultant cam rotation
causes the brake shoes to expand and be forced against
the brake drum. The braking force is thus obtained by friction between the shoes and drum. When the lever is released, the cam lever returns to the initial position and the
braking force is released by the brake shoe return springs.
Cam lever
EMTBR5019A
GENERAL
DIAGNOSIS
Symptom
Irregular
Braking Force
After releasing
the brake
pedal, the
braking force is
release too late.
Unbalance at
the right and left
braking force
BR -23
E6F72854
Remedy
Causes
The air pressures of tire are different.
Adjust the air pressure of tire
The sizes of the right and left tires are different.
Replace the tire.
The adjustment of the wheel bearing

is defective.
Adjust (Check the wheel bearing)
The sizes of the right and left wheel

bases are different.
Check and adjust the loosening the

U-bolt or damages on center bolt.
The wheel alignment is defective.
Adjust
The vertical surface of the back plate is rough.
Replace the back plate or check

the lining.
The operation of the wheel cylinder

is defective.
Check the contacting, the piston

cup and wearing status. If needed,
replace it. Check the lining.
The return spring is damaged
Replace the spring
The surface of the lining is contaminated

by the oil, grease or water.
If it is contaminated by oil or grease,

then replace it. If it is contaminated
by water, dry it.
The lining is defective or The material

of lining is improper.
Replace or adjust.
The wear is irregular. The surface is rough.
Replace the lining. Check the inside

of the drum, if needed, replace it.
The lining contact is defective.
Adjust the lining with being installed.
The brake drum is worn irregularly.
Adjust or replace it.
Unstable
braking force
The brake drum is deformed.
Replace
The back plate is deformed or loosened.

The vertical surface of it is rough.
If it is loosened, tighten with specified

torque. Otherwise, replace
Improper Lock
Point
The drum is worn.
Adjust or Replace
The lining is worn irregularly.
Adjust
The lining contact is defective
Adjust with being installed.

(Temperature of lining should be
less than 100 C)
Remark
Drum
limit STD
:
Dia+2mm
BR -24
BRAKE SYSTEM
Symptom
Low Braking
Force
The clearance
between the
pedal and the
floor is too
narrow.
During braking,
the noise and
shock are made
abnormally.
Remedy
Causes
The clearance between the brake
pedal and floor is 45mm or more (at
Pressure-600mmHg, Pressure 50kg)
Refer to the item for decreasing

the clearance between the brake
pedal and floor.
The lining contact is defective
Adjust with being installed not being

disassembled (Temperature should
be 100 C or less)
The surface of the lining is contaminated

by the oil, grease or water
If it is contaminated by oil or grease,

then replace it. If it is contaminated
by water, dry it.
The lining is deteriorated.
Replace the lining.
The vacuum force is too low.
Check the pipe or the vacuum pump.

If needed, replace.
The drum surface is rough.
Adjust or Replace
The brake booster is defective.
Adjust or Replace
The brake oil level is too low.
Refill
The air intrudes.
Air Exhausting
Vapor lock
Referring to the brake drawn item, adjust

or replace. And then exhaust the air.
The adjustment on pedal is defective.

The clearance is too large.
Adjust the pedal clearance. Check

the total stroke.
The shoe clearance is too large.
Adjust the shoe clearance.

If the wear exceeds the limit, replace.
The cup of the master cylinder is defective.
If the tightening does not satisfy the

specifications, replace the kit.
The brake shoe is deformed or damaged
Replace
The brake booster is defective.
Replace
When the wheel is

rotating with being
lifted by jack, there
are some noises.
Foreign materials
in drum
Check that the brake is damaged.

Remove the foreign materials.
Return spring is
damaged.
Check that the parts are damaged by

broken parts. If needed, replace.
Hold down cup is

damaged
Check that the parts are damaged by

broken parts. If needed, replace.
Improper adjustment
on wheel bearing
Check the rotating surface. Adjust
The lining is worn
Replace
During braking (at

low speed), noise is
made continually.
The grease is deficiency in sliding parts.
Apply the grease.
The drum inside surface is rough.
Modify the inner surface with

sand paper.
The drum is cracked.
Replace
Remark
GENERAL
Symptom
The drum is
overheated.
BR -25
The outlet of the brake master cylinder

is clogged.
If the booster operating rod is not

properly adjusted, adjust the pedal
clearance of the rod clevis to 10~15mm.
The brake does not return.
Check the burst of the return spring, the

bearing lubricant, the stop lamp switch
adjustment. If needed, adjust.
The booster is defective.
Replace
The vertical surface of the back plate

is scratched.
If the surface is too rough, replace.

If it is too dry, apply the grease.
The wheel cylinder piston cu is defective.
Replace
The oil return has problems due to the

over tight of the brake pipe nut.
Check the connector hole diameter.

If it is reduced, replace.
When the wheel is

rotating with being
lifted by jack, the
wheel is hard to
rotate.
The pedal
returning is
defective.
Brake is
vibrating.
Brake is drawn.
Remedy
Causes
The wheel bearing

clearance is too large.
Replace bearing or adjust.
Shoe clearance is
improper.
Adjust
Return spring is
defective.
Check the part damages due to the

spring over working. If needed replace.
Brake shoe is worn
Replace
The pedal linkage is rusted or deformed
Disassemble. Adjust or replace.

Oil the grease.
It is bursting due to the defectives on

the pedal return spring.
Replace
The booster operating rod is pushed.
Adjust the pedal clearance with

10~15mm.
The drum is eccentrically centered.
Replace
The drum is deformed.
Replace
The king pin bushing is worn
Replace the bushing
The hub bearing is worn.
Adjust (Check the rolling surface)

or replace.
The pedal clearance is too narrow.
Adjust the booster working rod.
The shoe clearance is improper.
Adjust
The back plate vertical surface is rough
Replace the back plate
The shoe spring is burst.
Replace
The master cylinder or wheel cylinder piston

cup is deteriorated and swelled.
Replace
Remark
Specific
wheel
is over
heated.
BR -26
BRAKE SYSTEM
Symptom
Brake makes
noises.
Exhaust brake
does not work.
Exhaust brake
can not be
released.
Remedy
Causes
Brake shoe contacting is defective.
Adjust the lining with being installed

not being disassembled (Temperature
should be 100 C or less)
Lining is deformed.
Replace the lining. Replace the drum

if it has hardened surface.
Drum has hardened surface.
Replace.
Shoe is deformed.
Replace.
Back plate is deformed or installed improperly.
Replace or adjust
Front bearing is loosened.
Adjust (Check the rolling surface)
Powder from the wear of the lining is adhered.
Clear
Lining is worn.
Replace.
Vacuum pressure is improper.
Check the vacuum pump or piping.

If needed repair.
Electric circuit is defective.
Check the clutch switch, the micro

switch and the exhaust brake circuit.
If needed, repair.
Vacuum pipe is damaged.
Replace.
3-way magnetic valve does not work.
Replace.
Exhaust brake valve does not work.
Replace.
Exhaust brake valve shaft is adhered.
Replace.
Power chamber is defective.
Disassemble and check.
3-way magnetic valve does not work.
Replace.
Exhaust brake valve does not work.
Replace.
Exhaust brake valve shaft is adhered.
Replace.
Electric circuit is defective.
Check the clutch switch, the micro

switch and the exhaust brake circuit.
If needed, repair.
Remark
GENERAL
BR -27
DIAGNOSIS (PARKING BRAKE)

Symptom
Parking brake
does not work.
Causes
Operating
mechanism has
a problem.
When pulling the parking brake

with 30kg, there is no lever stroke
clearance and shoe clearance.
Adjust the shoe clearance and cable
The locking status between

the lever lock latch and Rachet
pull is improper.
Adjust the Rachet pull lock status.

Replace it
Wire is broken or elongated.
Replace the cable.
Tolerance between the shoe

clearance and the brake lever
pulling is too large.
Drum inner surface is deformed

or twisted.
Repair the drum inner surface.

Replace the lining.
Lining is irregularly worn. Drum

inner surface is contacted
irregularly.
Replace the lining.
The oil of drum and lining

is contaminated.
Clear the inner surface of the drum.

Replace the lining.
Operating
mechanism has
a problem.
Return spring is damaged.

The tension of the return
spring is inferior.
Replace the return spring.
The inner cable does not

move smoothly.
Replace the cable.
After the parking brake is

released, the brake is operating.
Adjust the pulling tolerance limit.
Parking
brake is
defective.
Return spring is damaged.

The tension of the return
spring is inferior.
Replace the return spring.
The shoe clearance is too narrow.
Parking
brake is
defective.
Parking brake
can not be
relesed.
Remedy
Remark
ON-VEHICLE INSPECTION AND

ADJUSTMENT E274E72C
AIR BLEEDING OF THE BRAKE
1.
Fill up the brake oil tank with the brake oil at the maximum level. During the air bleeding, if the level is lowered, refill the brake oil.
CAUTION
Be careful that the brake oil does not drop on
the painted surface. If the brake oil contacts the
painted surface, immediately wash it by water.
KMTBR5518A
2.
Connecting an end of transparent vinyl tubes at the

air breather of the front wheel cylinder and the rear
wheel cylinder, put the other end of the tubes into the
transparent container having the brake oil.
BR -28
3.
BRAKE SYSTEM
Step on the brake pedal several times. Pressing the

brake pedal at half, loosen the air bleeder screw to
evacuate the air with the brake oil.
And then, pressing the pedal until it reaches to the
floor, tighten the air bleeder screw. Release the pedal.
There procedures should be repeated until any air
bubble is not shown in the brake oil.
ADJUSTMENT OF BRAKE SHOE GAP

1.
Using the screw driver(A), turn the wheel cylinder

adjuster(B) to the shoe expansion direction until
the drum is not rotate anymore. Turn the adjuster
reversely with the following notch number. (At that
time, the drag torque between the lining and the drum
should be less than 50kgf.m).
KMTBR5519A
4.
KMTBR5521A
Tighten the bleeder screw
The Notch Number for reverse rotation of the Adjuster.

Tightening Torque for the bleeder Screw
Front: 6.9~8.8Nm(0.7~0.9kgf.m, 5.1~6.5lb-ft)
Rear : 6.9~8.8Nm(0.7~0.9kgf.m, 5.1~6.5lb-ft)
5.
Step on the brake pedal several times. Pressing the

brake pedal at half, loosen the air breather screw to
evacuate the air with the brake oil.
And then, pressing the pedal until it reaches to the
floor, tighten the air breather screw. Release the
pedal. There procedures should be repeated until any
air bubble is not shown in the brake oil.
KMTBR5520A
Front Wheel Cylinder
4 ~ 6
Rear Wheel Cylinder
4 ~ 6
BR -29
VACUUM ASSISTED
HYDRAULIC BRAKE
BRAKE BOOSTER
COMPONENTS
EC3D367F
1
5
2
17.7~21.6(1.8~2.2, 13.0~15.9)
Tightening torque : Nm(kgf.m, lb-ft)
1. Clevis pin
2. Hose connector
3. Grommet
4. Master cylinder
5. Booster
6. Pedal assembly
7. Return spring
EMTBR5059A
BR -30
BRAKE SYSTEM
REMOVAL
4.
E38736B6
1.
Loosen the bolt for mounting of the steering column

assembly. Put the steering column down.
2.
Loosen the bolt(A), Remove the instrument panel(B).
Loosen the 2 bolts for mounting the master cylinder.

Disassemble the reservoir hose and the brake tube.
Remove the master cylinder.
KMTBR5524A
A
KMTBR5003A
3.
Taking out the brake hose linking between the brake

oil and the master cylinder, evacuate the brake oil.
Also, taking out the clutch hose of the clutch master
cylinder, evacuate the brake oil.
5.
Remove the brake booster and the master cylinder.
6.
Remove the booster clevis pin (A) installed at the

brake pedal assembly.
Loosen the booster mounting nut (C) from the pedal
support member (B). Remove the booster.
CAUTION
As the brake oil could be harmful to the painted

surface, if the body is contaminated by the brake
oil, clean it out with water or soap water.
KMTBR5004A
KMTBR5523A

INSTALLATION
1.
E11406D5
Insert the clevis pin (A) into the brake pedal. Fix the
split pin firmly.
KMTBR5004A
2.
Tighten the booster mounting nut (C) at the pedal support member (B).
3.
Connect the vacuum hose to the booster.
4.
Assemble the master cylinder to the booster. Connect

the reservoir hose and the brake tube.
5.
Assemble the instrument panel. Install the steering

column.
CAUTION
-
After installing the brake booster, adjust the

height of the brake pedal and the free play
clearance.
When installing, the snap pin and the clevis
pin are should be replaced new ones.
Apply the recommended grease on the clevis
pin and the washer.
6.
Fill the reservoir with the brake oil. Perform the brake
air bleeding.
7.
Check the brake oil leakage.
BR -31
BR -32
BRAKE SYSTEM
INSPECTION
EF7805A9
There are two methods for inspecting the booster. The one
is not to use the tester, the other is to use a simple tester for
inspecting the characteristics. These two methods can be
performed on vehicle. Before the inspection, check if the
brake pipe and the hose are connected tightly or damaged.
KMTBR5525A
Engine Start
Engine Stop
Just after the engine is stop, remove the pipe and vacuum hose clamp.
Put the hose to your mouth
During sucking, you feel

the air flow when the
pedal is pressed.
Yes
Normal
(opened valve) (closed valve)
No
Defective
When blowing air into

hose, air flow is stop.
(closed valve)
Yes
Normal
No
Defective
EMTBR5020A
CAUTION
Be careful that a sharpen material does not
intrude into the check valve.
Check at the opened sate and at the closed
state of the valve.
If it is replaced with kit, do not replace the
check valve.
BR -33
1.
TEST FOR TEMPORARILY OPERATING OF

BOOSTER
The followings are for checking the general functions of the
booster.
CAUTION
If the booster has problem, it should be replaced in assembly because it can not be disassembled for repair.
Method without tester

After checking the following three-items, if they are
all normal, then most functions of booster would be
normal. If one of following items has a problem, the
booster may have been damaged.
Check Valve
Vacuum Hose
Booster
Engine Start
After running for 2~3 minutes, stop the engine
Press the brake pedal with regular force.
At the first pressing, the stroke is the longest. After that,

the stroke will be getting shorter.
Yes
No
Normal
Defective
Engine is stop
Engine is running
Press the brake pedal several times
Step on the brake pedal
With pressing the pedal, start the engine
Stop the engine
Pedal is pressed down slightly.

Yes
Normal
Press the pedal for 30 seconds.

No
Defective
The height of pedal is changed.

Yes
Normal
No
Defective
EMTBR5021A
BR -34
2.
BRAKE SYSTEM
Method for test using a simple tester

As shown in following figures, connect the vacuum
gauge, the pressure gauge and the stepping (foot
pressing) power gauge. Test in the following sequence.
If it lease one of two among the gauges shows abnormal valve, the following components may have a
problem.
Vacuum hose
Booster
Check Valve
Engine Start
When the vacuum gauge is 67kmmHg, press the pedal
Measure the oil pressure of the stepping force gauge and the pressure gauge
Pressure of the Stepping

Force Gauge
Pressure of the Pressure

Gauge
Remark
10kg
31kg/cm
Booster: 257.8mm
30kg
81kg/cm
Booster: 257.8mm
Yes
No
Defective
Normal
Engine Stop
When the vacuum gauge is 0kmmHg, press the pedal
Measure the oil pressure of the stepping force gauge and the pressure gauge
Pressure of the Stepping

Force Gauge
Pressure of the Pressure

Gauge
Remark
10kg
4kg/cm
Booster: 257.8mm
30kg
17kg/cm
Booster: 257.8mm
Yes
Normal
No
Defective
EMTBR5022A
BR -35
BRAKE PEDAL
COMPONENT
EBE8BA10
1
5
2
17.7~21.6(1.8~2.2, 13.0~15.9)
1. Clevis pin
2. Hose connector
3. Grommet
4. Master cylinder
5. Booster
6. Pedal assembly
7. Return spring
EMTBR5059A
BR -36
BRAKE SYSTEM
REMOVAL
INSTALLATION
E628D2F9
1.
Loosen the steering column assembly mounting bolt.

Pull down the steering column.
2.
1.
Install the brake pedal assembly(A) to the bracket(B).

CAUTION
Before the assembling, apply the grease inside of
the brake pedal assembly pipe.
E94CBB4D
A
B
A
KMTBR5003A
3.
Remove the master cylinder (Refer to the BR-"Master

cylinder")
4.
Remove the
BR-"Booster")
brake
booster
(Refer
to
the
5.
Remove the brake light switch.
6.
Remove the shaft bolt(A) connected to the bracket.
KMTBR5527A
2.
Install the brake light switch.
3.
Install the booster and the master cylinder.

CAUTION
KMTBR5040A
Apply the grease on the clevis pin and the washer

ADJUSTMENT
GAP BETWEEN THE BRAKE PEDAL AND THE

FLOOR.
E45B8B7B
ADJUST THE HEIGHT OF THE BRAKE PEDAL

1.
BR -37
1.
Turn the booster operating rod so that the distance

from the center of the brake pedal pad to the A point
of the instrument panel lower portion is the 2493mm.
After adjusting, fix the clevis with the nut. Check that
the maximum stroke of the pedal is more than 180mm
(before filling the brake oil)
After cranking the engine, check if the gap between

the floor and the pedal is more than 45mm by pressing
the pedal with 50kg.
45mm or More
A
249
EMTBR5023A
BRAKE LIGHT SWITCH

1.
162
Adjusting the gap between the end of the brake. Light

switch screw and the pedal stopper to 0~1mm, tighten
the locknut.
KMTBR5528B
Stopper
FREE PLAY CLEARANCE OF THE BRAKE PEDAL

1.
Setting the brake pedal to the original position, check

if the free play(B) clearance is 5mm at least by pressing the pedal(A).
If the clearance excesses the reference, re-adjust the
position of the brake pedal.
Pedal
Locknut
CAUTION
When checking the free play clearance of the
brake pedal, the master back negative pressure
should be 0.
0~1mm
Stop tamp switch
EMTBR5024A
KMTBR5005A
BR -38
BRAKE SYSTEM

COMPONENTS
ED050718
15
16
17
19
14
18
13
12
11
9
4
10
5
6
7
8
2
1
1.
2.
3.
4.
5.
6.
7.
Cir-clip
Primary piston
Seal
Stem
Spring sheet
Primary spring
Spring sheet
8.
9.
10.
11.
12.
13.
14.
Recup seal
Secondary piston
Seal
Seal
Spring sheet
Secondary spring
Cylinder body
15.
16.
17.
18.
19.
Connector
Oil seal
Stop pin
Screw
Washer
EMTBR5025A

REMOVAL
BR -39
5.
EC4A3E6C
1.
Loosen the steering column assembly mounting bolt.

Put down the steering column.
2.
Remove the 2 of master cylinder bracket nuts connecting to the booster.
A
A
KMTBR5042A
KMTBR5003A
3.
6.
Disassemble the 1st piston assembly.
Take out the brake hose installed between the brake

oil tank and the master cylinder. Evacuate the brake
oil. Take out the clutch hose of the clutch master cylinder. Evacuate the brake oil.
CAUTION
If the painted surface is contaminated by the
brake oil, the painted surface may be damaged.
Clean out the brake oil from the body with water
or soap water. Be careful that the brake oil does
not contact you.
Primary Spring
Primary piston
EMTBR5026A
7.
Taking off the stopping, disassemble the 2nd piston

assembly.
CAUTION
Check if the master cylinder inner surface and the
piston surface. If any one is damaged, replace it
in assembly unit.
KMTBR5524A
4.
Remove the tubes connecting to the front brake and

the rear brake.
BR -40
BRAKE SYSTEM
INSTALLATION
1.
EC1A8112
After assembling the 2nd piston assembly(A), fix it

with the stop pin(B).
CAUTION
Clear the inside of the cylinder or piston with the
brake oil or alcohol. When assembling, apply the
brake oil at piston and seal.
KMTBR5044A
2.
Assemble the 1st piston assembly(C). When assembling piston, assemble the retainer seal and recup
seal align with the arrow direction to prevent the recup seal from being damaged. (Use only DOT3 for
the brake oil.)
KMTBR5531A
3.
Install the master cylinder at the booster.
4.
Connect the two brake tubes. Connect the two brake

tubes to the reservoir tank.
5.
After installing the master cylinder, perform the air

bleeding.
BR -41
LOAD SENSING PROPORTIONING

VALVE(L.S.P.V)
COMPONENTS
E871B7DC
3
2
1. LSPV assembly
2. Bleeder screw
3. Bracket
4. Lever assembly
5. Sensor spring
6. Spring guide
7. Adjusting nut
8. Operating lever
9. Connecting link assembly
EMTBR5015A
BR -42
BRAKE SYSTEM
REMOVAL
1.
E1B9538C
Remove the brake tube(A) connecting to the LSP

valve.
A
KMTBR5557A
2.
Remove the LSP valve mounting bolt and nut.
SERVICE AND INSPECTION OF THE

LSPV E69981E8
1.
Check the LSPV as below when replace the sensor spring, valve body assembly or reinstall the rear
axle,rear spring.
1)
Braking force is insufficient

Remedy
Probable Cause
Insufficient air bleeding
Air bleeding
Maladjust sensor spring
Readjust
Sensor spring broken
Replace valve assembly
Oil leakage in the brake

fluid line or LSPV assembly
Tighten brake fluid line or

replace LSPV assembly
2)
Rear brake is lock too fast
Probable Cause
Remedy
Maladjust sensor spring
Readjust
Inner fault the LSPV
Replace LSPV assembly
BR -43

DISC BRAKE
COMPONENTS
ED4FC603
6.9~12.7
(0.7~1.3, 5.1~9.4)
9
10
11
12
3
4
13
5
6
8
14
15
16
17
18
19
1.
2.
3.
4.
5.
6.
7.
Brake disk
Hub
Bearing
Clow washer
Nut
Nut cab
Cottor pin
8.
9.
10.
11.
12.
13.
14.
Grease cap
Sleeve plug
Sleeve bolt
Sleeve boot
Sleeve
Piston seal
Caliper bridge
20
15.
16.
17.
18.
19.
20.
21.
21
Caliper housing
Piston
Boot
Retaining ring
Retaining pin
Brake pad
Pad spring
EMTBR5027A
BR -44
REMOVAL
BRAKE SYSTEM
E37F8626
1.
Parking the car, remove the front tire. (Refer to the

PA-"Front Axle")
2.
After taking off the clip(A), remove the retaining

pin(B).
KMTBR5535A
5.
CAUTION
Fix the hose to prevent the brake oil from flowing
out.
KMTBR5533A
3.
Loosen the bolt. Remove the flexible hose(A) from the

caliper.
Remove the pad spring(A).
KMTBR5536A
KMTBR5534A
4.
Remove the pad and the spacer(A) from the caliper

housing.
6.
After loosening the 4 bolts(A), remove the bridge from

the caliper housing.
KMTBR5537A

7.
BR -45
Loosing the fixing bolt(A) of the caliper housing, remove the housing.
3.
After inserting the retaining ring, install the clip.
4.
Install the caliper housing(A) to the knuckle.
B
KMTBR5538A
KMTBR5538A
INSTALLATION
1.
5.
EAA60C6D
Install the bridge(A) to the caliper housing.
Install the pad to the caliper housing with being the

warning indicator to the lower portion.
CAUTION
Do not contaminate the surfaces of the pad and
disk with oil and dust.
2.
Install a new pad spring and a new retaining pin(A).
A
KMTBR5537A
KMTBR5533B
BR -46
6.
BRAKE SYSTEM
Install the flexible hose(A).
2.
Using a driver, remove the cylinder boot.
CAUTION
When installing, be careful that the hose is
not twisted.
If the brake oil is leaked, clear it perfectly.
KMTBR5540A
3.
A
KMTBR5536A
7.
Assemble the clip, the retaining pin, the pad spring

and the pad.
8.
Install the front wheel.
DISASSEMBLY
1.
Insert a cloth for preventing from damage between the

piston and the cylinder. Using an air gun(A), remove
the piston from the cylinder.
A
E787872C
Using a driver, remove the retaining ring(A).
KMTBR5541A
4.
Remove the piston seal(A) using a driver.
KMTBR5539A
KMTBR5542A

REASSEMBLY
BR -47
E8656B05
1.
Clear the piston and the cylinder with the brake oil.
2.
Insert a new piston seal(A) into the caliper cylinder

groove.
KMTBR5545A
5.
Assemble a new retaining ring(A) to the cylinder boot.

CAUTION
Be careful that the boot is not damaged.
KMTBR5543A
3.
Assemble the piston to the cylinder boot careful that

the piston(A) is not twisted.
CAUTION
When assembling the piston, be careful that the
piston seal is not damaged.
A
KMTBR5546A
6.
Assemble a new dust boot(A) to the caliper housing(B).

Install a bushing at the dust boot.
Check if the bushing can slip slightly.
B
KMTBR5544A
4.
Assemble a new cylinder boot(A) to the caliper cylinder along to the direction as shown in figure.
CAUTION
Insert the boot correctly into the cylinder groove.
KMTBR5547A
BR -48
INSPECTION
BRAKE SYSTEM
2.
E100B737
CHECK THE CALIPER PAD

1.
Remove the front wheel
2.
Check the pad thickness.
Reference Value
12.5mm
Limit Value
2.0mm
Check the disk vibration

1)
Before checking the disk vibration, firstly check

the clearance of the wheel bearing.
2)
Using a dial gauge, check the disk vibration at the

10mm position from the disk to outside.
Limit Value
0.12mm
KMTBR5548A
KMTBR5550A
CHECK THE DISK

1.
3)
If the disk vibration exceeds the limit, check the

vibration of the front axle.
4)
If the front axle vibration is less than limit, adjust

the disk vibration within the limit.
5)
If the disk vibration exceeds the limit, replace the

disk.
Check the thickness of the disk
Reference Value
35mm
Limit Value
33mm
3.
KMTBR5549A
Replace the front disk

1)
Disassemble the disk from the axle hub.
2)
Loosening the 10 bolts, disassemble the axle

lower part and the disk.
3)
Install a new disk to the axle hub.
4)
Install the axle hub to the steering knuckle.
5)
Adjust the free rod of the front wheel bearing.
BR -49
DRUM BRAKE
COMPONENTS
11
E582B58B
Lining thickness
NV 10.0
L 4.0
10
Wear, rough surface

(if severe, correct by grinding)
5
6
4
7
8
3
15
Score, uneven
wear, cracks of
inside surface
2
13
14
Deterioration
1
12
Installed load N (kgf)/

installed length
NV 195 to 235
(19.8 to 24.2)/190
L 175 (18)/190
Deformed shoe,
rough ledge surface
NOTE:
Use alcohol, brake fluid, or other vegetable
oil to clean rubber parts.
When alcohol is used, do not immerse for
more than 30 seconds.
Item
NV
I.D.
320mm
322mm
Out of
0.05mm
roundness
Repair kit
Brake lining kit
1.
2.
3.
4.
5.
6.
7.
8.
Return spring
Shoe hold down cup
Shoe hold down spring
Shoe hold down pin
Shoe and lining assembly
Rivet
Lining
Shoe
9.
10.
11.
12.
13.
14.
15.
Pipe
Rubber
Connector
Wheel cylinder assembly
Cover
Backing plate
Brake drum
EMTBR5028A
BR -50
BRAKE SYSTEM
REMOVAL
1.
3.
E5ABD4A3
Remove the washer (A), the outer bearing (B) and the
hub knuckle (C) from the knuckle (D).
Parking the car, remove the front tire. (Refer to the

PA-"Front Axle").
CAUTION
When removing the wheel and tire (A), be careful

that the hub bolt (B) is not damaged.
B
A
B
KMTBR5008A
4.
C
Remove the shoe hold down spring and the shoe hold
down pin. Removing the return spring, remove the
shoe and lining assembly.
Shoe
KCOWT5006A
2.
After removing the wheel cap (A), remove the split pin
(B) and the lock nut (C).
CAUTION
When removing the lock nut (C), be careful that
the washer and the outer bearing are not drop
down to the ground.
Shoe Hold
Down Pin
Shoe
Return
Spring
Wheel
Cylinder
Assembly
Shoe Return
Spring
Shoe Hold
Down Washer
Shoe Hold
Down Spring
Shoe Inspection Hole
EMTBR5029A
C
B
KMTBR5007A

REPLACEMENT
BR -51
2.
E454BDF1
WHEEL CYLINDER
1.
2.
After running 64,000km, check if the inside of the adjuster piston and the wheel cylinder have rusts.
Check that the dust boot is damaged. Check that the
piston cup has been worn, cracked and swelled. After
checking, if needed, replace the damaged parts.
Assemble the lining

1)
Clear the lining mounting surface of the shoe with

the specific oil.
2)
Perform the riveting with the pressure of 2100

100kg.
Loosening the screw, disassemble the adjuster piston.
Spring
Piston cup
Adjuster piston
Boot
Adjustng screw
Side end surface

Bleeder screw
KMTBR5554B
EMTBR5030A
3)
When performing the riveting, at the 0.4mm position of the side end surface, the shoe lining gap
should be 0.3mm or less. At the around of the
rivet, it should be 0.5mm or less.
4)
After checking that the brake drum and the lining

are contacted, if there is any defective, modify it
with the brake lining grinder.
Bleeder Screw Tightening Torque:

6.9~8.9Nm(0.7 ~ 0.9 kgf.m, 5.1~6.5lb-ft)
LINING
1.
Using a drill machine, drill the jointing part of the shoe

side rivet. Remove the lining.
CAUTION
Lining should be replaced in a kit.
Use the same size of the lining
Do not contaminate the lining surface with oil
or grease.
KMTBR5553A
BR -52
BRAKE SYSTEM
INSTALLATION
EA4A2729
1.
After assembling the wheel cylinder assembly, install

the shoe return spring.
2.
Install the shoe hold down spring.
Shoe
Shoe Hold
Down Pin
Shoe
Return
Spring
Wheel
Cylinder
Assembly
Shoe Return
Spring
Shoe Hold
Down Washer
Shoe Hold
Down Spring
EMTBR5029A
3.
Apply the grease at each part.
4.
For installing the drum brake, refer to the PA-"Front

Axle."
REAR BRAKE ASSEMBLY
BR -53
REAR BRAKE ASSEMBLY

DRUM BRAKE
COMPONENTS
EA680F90
Lining thickness
N 10.0
L 4.0
10
Wear,
rough surface
(if severe, correct by grinding)
6
7
8
12
Item
I.D.
Out of
roundness
NV
12.6
12.7
0.002
14
Score, uneven
wear, cracks of
inside surface
4
12
13
11
Deterioration Installed load N

(kgf)/installed length
NV 195 to 235
(19.8 to 24.2)/190
L 175 (18)/190
1.
2.
3.
4.
5.
6.
7.
Shoe hold down cup

Shoe hold down spring
Shoe hold down pin
Return spring
Shoe and lining assembly
Rivet
Lining
Deformed shoe, rough

ledge surface
8.
9.
10.
11.
12.
13.
14.
Shoe
Pipe
Rubber
Wheel cylinder assembly
Cover
Backing plate
Brake drum
L ....... Limit
NV ..... Nominal Value
NOTE:
Use alcohol, brake fluid, or other vegetable
oil to clean rubber parts.
When alcohol is used, do not immerse for
more than 30 seconds.
EMTBR5031A
BR -54
BRAKE SYSTEM
REMOVAL
1.
E92594B1
CAUTION
When removing the wheel and tire (B), be careful
that the hub bolt (B) is not damaged.
Place the wooden blocks (A) at the front and rear

sides of the front wheel.
4.
After taking off the hub bolt (A), remove the axle shaft
(B).
B
KCOWT5007A
C
A
2.
Loosen the wheel nut. Lift up the axle with the garage
jack (A) and support the frame stand (B).
KMTBR5013A
CAUTION
If the axle shaft (B) is hard to remove, insert the
hub bolt (A) into the removing screw hole (C) and
then try to remove it.
5.
Remove the oil seal (A)
A
KCOWT5008A
3.
After taking off the wheel nut (A), remove the wheel
and tire (B) from the hum (C).
KMTBR5014A
A
B
EMTBR5064A
REAR BRAKE ASSEMBLY

6.
BR -55
Loosening the lock nut tightening bolt (A), remove the

lock washer (B).
CAUTION
Be careful that the outer hub bearing(C) is not torn
off.
9.
Remove the shoe hold down spring and the shoe hold
down pin. Remove the return spring. Remove the
lining assembly.
Shoe
Shoe Hold
Down Pin
Shoe
Return
Spring
A
B
KMTBR5015A
7.
Shoe Return
Spring
Shoe Hold
Down Washer
Wheel
Cylinder
Assembly
Using the special tool (09527-47000), remove the lock

nut (A).
Shoe Hold
Down Spring
EMTBR5029A
REPLACEMENT
EA177866
WHEEL CYLINDER
A
1.
After running 64,000km, check if the inside of the adjuster piston and the wheel cylinder have rusts. Check
that the dust boot is damaged. Check that the piston
cup has been worn, cracked and swelled. After checking, if needed, replace the damaged parts.
2.
Loosening the screw, remove the adjuster piston.
KMTBR5016A
8.
Remove the rear wheel hub (B) with the outer bearing
(C) from the axle housing (A).
Spring
Piston cup
A
Adjuster piston
B
Boot
Adjustng screw
Bleeder screw
EMTBR5030A
KMTBR5017A
Bleeder Screw Tightening Torque: 6.9~8.9Nm(0.7

~ 0.9 kgf.m, 5.1~6.5lb-ft)
BR -56
BRAKE SYSTEM
LINING
1.
CAUTION
Using a drill machine, drill the joining part of the shoe

side rivet. Remove the lining.
Lining should be replaced in a kit.

Use the same size of the lining
Do not contaminate the lining surface with oil
or grease.
INSTALLATION
E2E68B53
1.
After assembling the wheel cylinder assembly, install

the shoe return spring.
2.
Install the shoe hold down spring.
Shoe
Shoe Hold
Down Pin
Shoe
Return
Spring
KMTBR5553A
2.
Assemble the lining

1)
2)
Clear the lining mounting surface of the shoe with

the specific oil.
Shoe Return
Spring
Shoe Hold
Down Washer
Wheel
Cylinder
Assembly
Perform the riveting with the pressure of 2100

100kg.
Shoe Hold
Down Spring
EMTBR5029A
3.
Apply the grease at each part.
4.
Inject the recommended grease at the inside of the

wheel hub (A).
Recommended Grease: RETINAX 0434 of

Hankook Shell Oil Co., Ltd
RETINAX 0419 of Hankook Shell Oil Co., Ltd
KO-GW02 of CheonMa Mineral Oil Co., Ltd
A
KMTBR5554A
3)
4)
When performing the riveting, at the 0.4mm position of the side end surface, the shoe lining gap
should be 0.3mm or less. At the around of the
rivet, it should be 0.5mm or less.
After checking that the brake drum and the lining

are contacted, if there is any defective, modify it
with the brake lining grinder.
KMTBR5017A
REAR BRAKE ASSEMBLY

5.
Install the rear wheel hub (B) and the outer bearing
(C) at the axle housing (A).
CAUTION
Use only the set comprising the bearing and the
bearing race.
6.
For the next step of installation, refer to the PA-"Rear

Axle."
BR -57
BR -58
BRAKE SYSTEM
EXHAUST BRAKE
COMPONENT LOCATION
ECDDE8C6
7
6
2
3
5
1.
2.
3.
4.
5.
6.
7.
8.
Air tube
D4AL
D4DA, D4DB
D4DC
Vacuum tube
Vacuum hose
Magnetic valve
Vacuum tank
1.
2.
3.
4.
5.
Vacuum tank
Vacuum hose
Magnetic valve
Exhaust valve assembly
Exhaust pipe
1.
2.
3.
4.
Vacuum tank
Magnetic valve
Exhaust valve assembly
Exhaust pipe
<D4AL, D4DA, D4DC>
2
3
4
<D4AF>
5
1
2
3
<D4AE>
ECOBR5008A
EXHAUST BRAKE
COMPONENTS (1)
BR -59
E16B0353
Atmosphere
5
4
1.
2.
3.
4.
5.
Magnetic valve-3way
Exhaust pipe
Exhaust brake assembly
Vacuum hose
Air hose
ECOBR5009A
BR -60
BRAKE SYSTEM
COMPONENT (2)
[Exhaust brake unit]
2
[Caution]
The power chamber is non-disassembly type.
Do not attempt to disassemble.
1.
2.
3.
4.
Cover
Clevis
Power chamber
Exhaust brake valve
EMTBR5033A
EXHAUST BRAKE
BR -61
COMPONENT (3)
[ Power Chamber ]
11
Disassembly Sequence
1. Rear shell
2. Nut
3. Diaphragm retainer
4. Diaphragm
5. Diaphragm plate
6. O-ring
7. Piston washer
8. Push rod
9. Washer
10. Nut
11. Spring
12. Front shell
10
9
8
7
6
5
4
3
2
For disassembly and reassembly of parts

with an encircled number, see Diassembly
and Reassembly given later
3
9.8~16 (1.0, 1.6)
4
9.8~16 (1.0, 1.6)
37.5
2
37.5
Reassembly Sequence
Full opening
4 3 2 1
Tightening Torque : Nm (kgf.m, Ib-ft)
4.9~6.9 (0.5, 0.7)
ECOBR5010A
BR -62
BRAKE SYSTEM
COMPONENT (4)
[ Intake shutter ]
1
4
5
3
1.
2.
3.
4.
5.
Coupler
Actuator assembly
Butterfly valve
Valve shaft
Bushing
Clearance
NV : 0.021~1.01mm
L : 0.15mm
Press bushing into coupler.
8Nm (0.8kgfm)
Mark V
(0 30)
Apply grease
Close
Open
Clearance between valve and
coupler when closed
NV 1.5-2 mm
Adjust actuator bracket
Tightening Torque : Nm (kgf.m, Ib-ft)
Reassembly Sequence
5
NV ... Nominal value
ECOBR5012A
EXHAUST BRAKE
REMOVAL
1.
BR -63
DISASSEMBLY
E938FC15
Remove the vacuum pipe(B) connected to the exhaust brake unit(A).
1.
E1F97DF2
Remove the power chamber (A).

CAUTION
Do not try to disassemble the power chamber because it can not be disassembled.
KMTBR5579A
2.
Remove the exhaust brake mounting bolt connected

to the exhaust pipe.
3.
Remove the power chamber (B) from exhaust brake

unit(A).
C
KMTBR5581A
CAUTION
Do not try to disassemble the power chamber because it can not be disassembled.
2.
Remove the exhaust brake cover (B).
3.
Remove the clevis (C).
REASSEMBLY
1.
E2F3E12B
With opening the butterfly valve, adjust the adjusting

bolt(B) to fix the lever(A) and tighten the lock nut.
Butterfly valve
A
B
KMTBR5580A
EMTBR5034A
BR -64
2.
BRAKE SYSTEM
Fixing the rod of the power chamber in the state of

press-in with 2~4mm, tighten the lock nut(A).
INSPECTION
1.
E060470A
Apply the vacuum pressure of 500mmHg or more

to the power chamber(A) so as that the vacuum
gauge(B) indicates the -500mmHg. After 15 seconds, check that the vacuum gauge indicates the
specific valve.
B
Vacuum
A
KMTBR5561A
3.
Adjust the adjusting bolt(A) so as that the gap between the body is 0.1~0.4mm, when the butterfly
valve is fully closed due to the -650~-750mmHg of
the vacuum pressure applied to the power chamber.
And then tighten the lock nut.
Check that the opening and closing of the brake valve
is smoothly working when the power chamber is applied the vacuum pressure of -400~-600mmHg or atmospheric pressure.
Vacuum
-650~
-750mmHg
Gap
0.1~
0.4mm
EMTBR5036A
2.
3-way Magnetic Valve

1)
Check for air tightness

1. Closing the valve of the exhaust brake unit
side with a plug and applying the vacuum
pressure of -750mmHg to the vacuum tank
side valve, there should be no air leakage to
the atmosphere side valve.
EMTBR5035A
Plug
Compressed air
EMTBR5037A
EXHAUST BRAKE
2.
BR -65
Closing the valve to the exhaust brake unit

side and applying the air pressure of 1kg/cm
to the valve of the atmosphere side, there
should be no air leakage to the vacuum tank
side valve.
Compressed air
EMTBR5061A
2)
Operating Inspection
1. Applying the -750mmHg vacuum pressure to
the vacuum tank side valve, check that the
valve is working at the voltage of 22V or less.
Vacuum
EMTBR5038A
2.
Closing the exhaust brake unit side valve

with a plug and applying the 1kg/cm air
pressure to the atmosphere side valve,
check that the valve is working at the voltage of 22V or less.
BR -66
BRAKE SYSTEM

COMPONENT LOCATION
E0FC7C8F
Adjusting nut
Parking brake cable assembly
(M035S5 T/M)
Parking brake drum
Parking brake cable assembly (M2S5, M3S5 T/M)
Parking brake lever assembly
ECOBR5007A

COMPONENTS
BR -67
E2E093D6
15
17
16
L...... Limit
NV... Nominal Value
Item
I.D
Squareness
NV
180/190
181/191
13
0.05 or less
Concentricity 0.1 or less

Cylindricity
0.05 or less
Static rotary
0.49 Ncm
imbalance
(50 gf.cm)
6
4
11
or less
3
12
8
7
14
10
Lining Thickness
8
7
NV : 5.15~5.45 mm
L : 2 mm
18
1. Return Spring
7. Spring Seat
13. Parking Brake Cable
2. Return Spring
8. Hold Spring
14. Shoe Assembly
3. Shoe Guide Plate
9. Spring Srat
15. Parking Brake Lever
4. Strut Spring
10. Adjuster
16. Cable
5. Adjuster Spring
11. Shoe Assembly
17. Parking Brake Assembly
6. Shoe Hold Pin
12. Strut
18. Parking Brake Drum

ECOBR5015A
BR -68
BRAKE SYSTEM
REMOVAL
1.
3.
E9CE8DC9
Remove the front propeller shaft(A).
Make an alignment marking(C) to the flange yoke

(A) of the front propeller shaft and the parking brake
drum(B). Remove the tightening nut (D) of the propeller shaft.
B
A
A
KMTBR5023A
4.
Remove the parking brake cable clip (A).
C
KMTBR5021A
2.
Remove the tightening bolt (A) of the center bearing

bracket.
KMTBR5568A
5.
Using a companion flange puller, remove the companion flange from the main shaft.
A
KMTBR5022A
Companion flange
NOTE
For short axis, the center bearing is one. For longaxis, the center bearing are two.
Companion flange pulley

EMTBR5040A

6.
BR -69
Using a socket wrench, remove the flange bolt. Remove the shoe and lining assembly.
INSTALLATION
1.
E7B9186A
Install the shoe and lining assembly(B) to the back

plate(A).
Back plate
CAUTION
Shoe and lining
Do not contaminate the lining surface with

foreign materials.
The outer diameter of the lining should be
180.
Apply the grease at the following portions.
Contacting surface between the back
plate and the shoe.
Contacting surface between the shoe and
the anchor pin.
Contacting surface between the adjuster
thread and the nut and sleeve.
EMTBR5041A
7.
Remove the shoe hold pin and spring.
8.
Taking off the return spring(A), remove the shoe assembly(B).
9.
Remove the parking brake cable(C).
C
B
KMTBR5045A
2.
After installing the parking brake cable, install the

shoe hold pin and spring.
KMTBR5024A
KMTBR5046A
BR -70
3.
BRAKE SYSTEM
Aligning the align markings(C) of the rear axle companion flange (A) and the flange yoke (B) of the rear
propeller shaft, install the tightening bolt (D) of the propeller shaft.
Tightening Torque :
98~117.6Nm(10~12kgf.m, 72.7~87.2lb-ft)
A
5.
Aligning the align marking (C) of the flange yoke (A) of

the front propeller shaft and that of the parking brake
drum (B), install the tightening nut (D) of the propeller
shaft.
Tightening Torque :
97~117.6Nm(10~12kgf.m, 72.7~87.2lb-ft)
C
KMTBR5025A
4.
Install the tightening bolt (A) of the center bearing

bracket.
Tightening Torque :
68.6~93.1Nm(7.0~9.5kgf.m, 50.9~69.1lb-ft)
KMTBR5021A
6.
Inject the recommended grease to the grease nipple

(A) until the grease is leaked out oil seal. Clear the
leaked grease.
Recommended Grease: ALVANIA EP#2
A
KMTBR5022A
NOTE
For short-axis, the center bearing is one. For longaxis, the center bearings are two.
KMTBR5026A

ADJUSTMENT
BR -71
ADJUSTING THE PARKING BRAKE
E03829FE
METHOD FOR ADJUSTING THE LINING GAP.
1.
Release the parking brake.
1.
Turn the adjuster to the shoe expansion direction until

the shoe contacts the drum.
2.
Pulling the out cable with the 6~10kgf force, locate the
nut (A) at the position at which the gap is 3~7mm.
2.
Turn the adjust to the reverse direction of the shoe

expansion direction with 8~10 notch.
Out cable
3~7mm
Adjuster
ECOBR5016A
EMTBR5042A
CS58033B
3.
After operating the parking brake lever several times,

turn the drum with hand. At that time, the lining should
not contact with the drum.
3.
Returning the out cable. Tighten the nut (B) near the
nut (A) with the specified torque.
Tightening Torque:
38.2~50Nm(3.9~5.1kgf.m, 28.2~36.9lb-ft)
4.
After the initial adjusting of the cable, check the following items.
1)
Check the click number of the parking brake and

hand force.
Hand force
Number of lever click
20kg or more
8~9 notch
2)
Check that the parking brake warning Lamp is

normally working.
3)
Tighten the parking brake bracket flange bolt with

the specified torque.
Tightening Torque:
11.8~14.7Nm(1.2~1.5kgf.m, 8.7~10.9lb-ft)
BR -72
BRAKE SYSTEM
ANTI-LOCK BRAKE
SYSTEM/ACCELERATION
SLIP REGULATION
COMPONENTS
E88E723C
1
2
1.
2.
3.
4.
5.
ABS control module

Master cylinder and brake booster
Modulate assembly
Front wheel speed sensor
Rear wheel speed sensor
ECOBR5017A

GENERALS
SRI CODE CHECK
EAE94BE4
ABS SYSTEM
The Anti-Lock Brake System (ABS) protects the locking of
the wheel by controlling the oil pressure of the 4 wheels
when the driver brakes the car suddenly or on the slide
road.
The ABS suggests the following advantages.
1.
2.
BR -73
When the car is turn around an object suddenly or

when the car is stopped suddenly, it is possible to
control the car.
During sudden braking time, or even running in curved
way, it is possible to drive in safe and to ensure the
excellent controlling so as to stop the car safely.
In order to ensure the good service when it has a
problem, the ABS system includes the self diagnosis
and the fail safe device.
With the ignition switch turned ON and "L" terminal of Data

link connector shorted to ground, diagnostic trouble code
No. can be checked, if faults are detected, with the reading
of SRI lamp flash.
1.
Ground the "L" terminal (Pin No.6) of data link connector with suitable wire, otherwise fault code cannot
be accessed.
2.
Turn the ignition switch ON.
3.
SRI lamp will be illuminated for 2 seconds and then

read the following "Diagnostic trouble code."
4.
First digit of Diagnostic trouble code is determined by

the number of long flashes (1.5 sec.) and after the
following 2 seconds break second digit is determined
by the number of short flashes (0.5 sec.)
5.
Once the SRI lamp flashing is completed, next active

trouble code or history trouble code stored at ABSCM
will be followed after 3 sec. break while the "L" terminal is shorted to ground or the ignition switch is ON.
CHECKING THE SYSTEM DIAGNOSIS INDICATOR.

When turning the ignition switch ON, check that the ABS
warning lamp turns on for 2 seconds. If the warning lamp
does not turn on immediately when the ignition switch is
ON, the ABS fail safe may be damaged.
2 3 4 5 6 7
9 10 11 12 13 14 15 16
Ground
K-line
Power
ECOBR5019A
ECOBR5018A
SYSTEM DIAGNOSIS STEP

The ABSCM continuously checks the state of the electrical
integrity of ABS and if detects a failure, it inform the fault
codes in SRI lamp flash code.
L-line
IG
ON
OFF
SRI
ON
OFF
ECOBR5020A
BR -74
6.
BRAKE SYSTEM
Diagnostic Trouble code will be retained in the ABSCM until the ignition has been switched ON and the
vehicle speed exceeded 8km/h 20 times.
SRI lamp flash pattern
Remarks
System normal or
fault code is stored
at ABSCM
ABSCM has active
fault
L-line
ground
OFF
ECOBR5021A
System Normal
L-line
(Pin No.6)
Shorted to
ground
ECOBR5022A
Active fault No.22

flashes after check-in
period and followed
by history fault code
No.23
ECOBR5023A
CONNECTOR CHECK
1.
Remove the battery negative (-) terminal.
2.
Disconnect the connectors and check terminals follow

the troubleshooting procedure.
NOTE
When you check terminals, be sure to use enough
small pin which is not damage to the connector terminals.
BR -75
OIL PRESSURE CIRCUIT DIAGRAM
RESERVOIR
I/V
O/V
DC
M
:
:
:
:
RESERVOIR
Inlet Valve
Outlet Valve
Damper Chamber
Plunger pump
VT58003
BR -76
BRAKE SYSTEM
ELECTRIC CIRCUIT DIAGRAM
EB94E529
HOT AT ON
FUSE
BOX
FUSE 11
5A
FUSE 2
10A
FUSE 10
5A
0.5L
1.25G/R
0.5L
0.85R/G
7 M41-1
0.5L/W
3 M13
DBR
RELAY
(Open with
ABS operated)
RELAY
BOX
See Exhaust
Brake System
on page SD-50
ABS
7 M41-3
0.5L/W
0.5B/R
1.25G/R
0.85R/L
12
0.85G
See Exhaust
Brake System
on page SD-50
1.25G/R
28
39
ON
input
DBR
relay
control
16
0.5B/R
0.85R/L
0.5B/R
0.85R/L
To ABS Relay Box

53 M87 on page SD-53
ABS
ABS
CONTROL
indicator
MODULE
control
10
Exhaust
brake
Ground
13
38
55
54
29
0.5G/R
0.85Y/W
0.85Y/R
1.25B
1.25B
1.25B
11
1.25B
1.25B
C H E C K
MM05
0.85R/L
Check connector
A B S
INSTRUMENT
CLUSTER
ABS
IND.
5 M13
0.5G
15
0.85R/G
See Fuse Box Details

on page SD-10, SD-14
1 M87
1.25B
3 M57
C O N N E C T O R
8 M57
0.5B
G04
Q8SD011A
ECOBR5024A
BR -77
ELECTRIC CIRCUIT DIAGRAM (2)
HOT AT ALL TIMES
HOT AT ALL TIMES
FUSE
BOX
FUSIBLE
LINK
BOX
FUSE 35
15A
ABS
40A
1.25L/W
From
ABS Control Module
on page SD-52
18
A
3.0L/W
1.25L/W
0.85R/L
2 M82-2 1
MM05
M82-1 2 M82-3
1 M82-2
ABS
RELAY
BOX
0.85W/B
35
0.85Lg/B 0.85L/R
0.85
Lg/W
22
49
3 M82-3
1.25B
G03
47 M87
ABS
CONTROL
MODULE
ABS relay control
F/L
EV
3.0R
2.0R
2 M77-1
F/L
AV
F/R
EV
F/R
AV
R/L
EV
R/L
AV
R/R
EV
24
51
30
31
23
1.25B/W
1.25G
1.25R
1.25Y
1.25L
1.25Br
1.25O
R/R
AV
50 M87
1.25W/Br
7 M77-2
HYDRAULIC
UNIT
Q8SD011B
ECOBR5025A
BR -78
BRAKE SYSTEM
SCHEMATIC DIAGRAM (3)

FUSE
BOX
FUSE 36
10 A
0.85L/G
MM01
3
0.85L/G
2
M49
STOP
LAMP
SWITCH
1
M49
0.85G
4
MM01
0.85G
5
MM06
0.85G
See Stop Lamps
on page SD-94
0.5G
36 M87
ABS
CONTROL
MODULE
Stop lamp switch input
Wheel speed input

15
16
20
19
44
45
18
0.5B
0.5Br
0.5Br
0.5B
0.5B
0.5Br
0.5Br
LEFT FRONT
WHEEL SENSOR
M66
RIGHT FRONT
WHEEL SENSOR
M58
LEFT REAR
WHEEL SENSOR
M85
17 M87
0.5B
M84
RIGHT REAR
WHEEL SENSOR
Q8SD011C
ECOBR5026A
BR -79
CONNECTOR ID DIAGRAM
ABSCM CONNECTOR (A01, ABSCM HARNESS
SIDE CONNECTOR)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
ECOBR5027A
Pin No.
Plug Assignment
Pin No.
Plug Assignment
Ignition "ON"
30
Ground
Front left inlet solenoid v/v control
31
ABS indicator control
Rear right inlet solenoid v/v control
33
Front left outlet solenoid v/v control
ABS relay control
34
Rear right outlet solenoid v/v control
Front left wheel speed sensor
35
ABS relay control
10
Front left wheel speed sensor
37
ABS relay control
11
Rear right wheel speed sensor
39
Rear left wheel speed sensor
12
40
Rear left wheel speed sensor
13
45
ABS relay control
14
46
Data link connector
16
Data link connector
48
BLS
19
Exhaust brake main valve
49
Pump motor monitor
25
Rear left outlet solenoid v/v control
53
Rear left inlet solenoid v/v control
26
Front right outlet solenoid v/v control
54
Front right inlet solenoid v/v control
28
Ground
55
Ground
29
Ground
MODULATOR CONNECTOR (A05, HARNESS SIDE)
4 3 2 1
8 7 6 5
ECOBR5028A
Pin no.
Plug Assignment
Pin no.
Plug Assignment
Front Left Inlet Valve GND
Front Left Outlet Valve GND
Front Right Inlet Valve GND
Front Right Outlet Valve GND
Rear Right Inlet Valve GND
Rear Right Outlet Valve GND
Rear Left Inlet Valve GND
Rear Left Outlet Valve GND
BR -80
BRAKE SYSTEM
TROUBLESHOOTING
EDFD7A0E
STANDARD FLOW OF DIAGNOSTIC

TROUBLESHOOTING
Gathering information from customer

Reoccurs
Does not reoccur
Check diagnostic code

No trouble code
Check diagnostic code

Trouble code displayed
Trouble code
displayed
No trouble
code
Recheck trouble code(s) then erase
Basic brake system is normal or not
Recheck trouble symptom
Abnomal
Refer to
Brake - Troubleshooting
Check trouble codes
No trouble code
Trouble code displayed

Inspection chart for diagnostic trouble
codes
Intermittent malfunction
Using the customer problem analysis check sheet for reference, ask the customer in as much detail as
possible about the problem.
EMTBR5046A
NOTES WITH REGARD TO DIAGNOSIS

The phenomena listed in the following table are not abnormal.
Phenomenon
Explanation of phenomenon
ABS operation sound
1.
2.
Sound is generated along with vibration of the brake pedal (scraping).

When ABS operates, sound is generated from the vehicle chassis due to
repeated brake application and release.
(Thump : suspension; squeak: tires)
ABS operation
(Long braking
distance)
For road surfaces such as snow-covered roads and gravel roads, the braking
distance for vehicles with ABS can sometimes be longer than that for other vehicle.
Accordingly, advise the customer to drive safely on such roads by lowering the
vehicle speed and not being too overconfident.
Diagnosis detection condition can vary depending on the

diagnosis code.
Make sure that checking requirements listed in the "Comment" are satisfied when checking the trouble symptom
again after the diagnosis code has been erased.
ABS Check Sheet
BR -81
Inspectors
Name
Registration No.
Registration Year
Customers Name
VIN.
Data Vehicle
Brought In
Km
Miles
Odometer
Data Probelm First Occurred

Frequency Problem Occurs
Continuous
Intermittent (
times a day)
Intermittent (
times a day)
ABS does not operate.

Symptoms
Diagnostic
Trouble Code
Check
ABS does not operate efficiently.

ABS Warning
Light Abnormal
Remins ON
Does not Light UP
1st Time
Normal Code
Malfunction Code (Code
2nd Time
Normal Code
Malfunction Code (Code
EMTBR5047A
BR -82
BRAKE SYSTEM
INSPECTION CHART FOR DIAGNOSTIC TROUBLE

CODES
Inspect according to the inspection chart that is appropriate for the malfunction code.
Dtc No.
Description
Mil*
Memory
11
FR sensor open
12
FL sensor open
13
RR sensor open
14
RL sensor open
15
Speed sensor series malfunction

(Teeth number malfunction)
16
Voltage out of range
21
FR sensor short
22
FL sensor short
23
RR sensor short
24
RL sensor short
38
BLS (Brake Lamp Switch) malfunction
41
FR - Inlet valve malfunction
42
FL - Inlet valve malfunction
43
RR - Inlet valve malfunction
44
RL - Inlet valve malfunction
45
FR - Outlet valve malfunction
46
FL - Outlet valve malfunction
47
RR - Outlet valve malfunction
48
RL - Outlet valve malfunction
51
Valve relay malfunction
53
Pump motor malfunction
63
ECU error
* MIL : Malfunction Indication Lamp
BR -83
INSPECTION PROCEDURE FOR DIAGNOSTIC

TROUBLE CODES
DTC No. 11, 12, 13, 14, 21, 22, 23, 24 Wheel speed
sensor open or short
Probable cause
[Comment]
The ABSCM determines that an open or short circuit occurs in
more than one line of wheel speed sensors.
Wheel speed sensor installation

inspection
NG
Malfunction of wheel speed sensor

Malfunction of wiring harness or connector
Malfunction of ABSCM
Repair
OK
Measure at the ABSCM connector
A01
Disconnect the connector and
measure from the harness side.
Resistance values between 9
and 10, 11 and 12, 13 and 14,
39 and 40.
OK : 1280 - 1920
NG
Check the following connectors.

AA01, AA02, A09, A04, A08, A03
NG
Repair
OK
Check trouble symptoms
NG
Check the harness wire between

each wheel speed sensor and
ABSCM, and repair if necessary
OK
Wheel speed sensor output voltage
inspection
NG
OK
Check the following connector
A01
OK
NG
Wheel speed sensor inspection
Replace the wheel speed sensor
OK
NG
Repair
Rotor inspection
NG
Replace the rotor
OK
Wheel bearing inspection
NG
Replace the ABSCM
EMTBR5048A
BR -84
BRAKE SYSTEM
Probable cause
DTC No. 15 (Speed sensor series malfunction)

[Comment]
A wheel speed sensor outputs an abnormal signal or no signal
Wheel speed sensor installation

inspection
NG
Improper installation of wheel speed sensor

Malfunction of wheel speed sensor
Malfunction of rotor
Repair
OK
Wheel speed sensor output voltage
inspection
NG
Wheel speed sensor inspection
Replace the wheel speed sensor
OK
OK
Check the related connectors
NG
NG
Repair
Rotor inspection
OK
NG
Replace the rotor
OK
NG
OK

Replace the ABSCM
EMTBR5049A
Probable cause
DTC No. 38 BLS Malfunction

[Comment]
BLS (Brake Lamp Switch) outputs an abnormal signal
Check the BLS connector
NG
Improper installation of the connectors
Repair or replace
OK
Inspret the BLS terminal
NG
Replace
EMTBR5050A
BR -85
DTC No. 41, 42, 43, 44, 45, 46, 47, 48(Inlet/outlet
solenoid valve malfunction)
Probable cause
[Comment]Inlet or outlet solenoid valve outputs no signal
Fuse inspection
NG
Malfunction of valve inner coil

Improper installation of wiring harness
or connector
Malfunction of valve relay
Malfunction of fuse (15A)
Replace
OK
Check the valve relay
NG
Replace
OK
Check the connector A05, A05-1,
AA02 and terminals
NG
Repair or replace
OK
Replace the ABSCM
EMTBR5051A
Check the connectors of hydraulic unit side a each valve.

(At ambient temperature 23 5 C)
4 3 2 1
8 7 6 5
2 1
EMTBR5052A
Connector name
Terminal
Terminal name
Check terminals
Modulator
connector
FR - Inlet valve
Unit : W
Basic value
24V
12V
2 + 2
24.66 0.5
8.54 0.5
FL - Inlet valve
1 + 2
24.66 0.5
8.54 0.5
RR - Inlet valve
3 + 2
24.66 0.5
8.54 0.5
RL - Inlet valve
4 + 2
24.66 0.5
8.54 0.5
FR - Outlet valve
6 + 2
18.3 0.5
4.29 0.5
FL -Outlet valve
5 + 2
18.3 0.5
4.29 0.5
RR -Outlet valve
7 + 2
18.3 0.5
4.29 0.5
RL -Outlet valve
8 + 2
18.3 0.5
4.29 0.5
BR -86
BRAKE SYSTEM
Probable cause
DTC No. 16 Voltage out of range (Under and over voltage)

[Comment]
The voltage of the ABSCM power supply drops lower or
rises higher than specified value.If the voltage returns to the
specified value, this code is no longer output.

CAUTION
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to
standard value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
Measure at the ABSCM connector
A01
Disconnect the connector and
measure from the harness side
Start the engine. Voltage
between 1-Body earth
OK : System voltage
NG

MA01
Repair
OK
OK
NG

Check the battery
OK
MA01
NG
NG
Repair
OK
NG
Replace the ABSCM

EMTBR5053A
DTC No. 63 ECU (ABSCM) error

[Comment]
The ABSCM always monitors the solenoid valve drive circuit. It
determines that there is an open or short-circuit in the solenoid
coil or in a harness : When no current flows in the solenoid even
though the ABSCM turns on it, and vice versa.
Probable cause
Replace the ABSCM
BR -87
Probable cause
DTC No. 51 Valve relay malfunction

[Comment]
When the ignition switch is turned to ON, the ABSCM switches
the valve relay off and on during the initial check. In that way,
the ABSCM compares the signals sent to the valve relay with the
voltage in the valve power monitor line. That is how to check if
the valve relay is operating normally. The ABSCM always checks
if current flows in the valve power monitor line, too.
It determines that there is an open circuit when no current
flows. If no current flows in the valve power monitor line,
this diagnosis code is output.
Malfunction of valve relay

Malfunction of hydraulic unit
NOTE
Whenever reading the diagnosis codes using the ABS
warning lamp, this diagnosis code will be output.
Fuse (2EA) inspection
NG
Replace the fuse
OK
Check the connectors AA01,
A06-2, A06-1
NG
Repair or replace the connectors
OK
Check the relay
NG
Replace the relay
OK
Replace the ABSCM
EMTBR5054A
Probable cause
DTC No. 53 Motor pump malfunction

[Comment]
When the motor power line is normal but no signal is input to the
motor monitor line. When the motor power line is faulty.

Malfunction of hydraulic unit
Motor power source inspection

Pin No. 49, A01
NG
Disconnect the connector A01
Check the voltage from P.49
OK : System voltage
OK
Replace the ABSCM
NG
Repair the harness or connector
EMTBR5055A
BR -88
BRAKE SYSTEM
ABS OPERATION CHECK

WHEEL SPEED SENSOR OUTPUT VOLTAGE
CHECK
1.
Lift up the vehicle and release the parking brake
2.
Disconnect the ABSCM harness connector and measure from the harness side connector.
CAUTION
Be sure to remove the connector lock and insert
the probe into the harness side. Inserting it into
the terminal side will result in a bad connection.
3.
Rotate the wheel to be measured at approximately

1/2-1 rotation per second, and check the output voltage using a circuit tester or an oscilloscope.
Wheel
speed
sensor
Terminal
No.
Front
left
Front
right
Rear left
Rear
right
54
53
33
26
25
34
Output voltage
When measuring with an oscilloscope :
120 mV p-p or more
BR -89
ABS MODULATER
COMPONENTS
E83A6B5E
Modulator
Motor
relay(24V)
Valve relay(24V)
Relay box-ABS
ECOBR5029A
BR -90
BRAKE SYSTEM
REMOVAL
INSTALLATION
E3F430EB
1.
Disconnect motor pump and relay box harness and

remove the ABS relay box mounting nuts.
2.
Remove the relay box(A) from relay box mounting

bracket.
E7702A84
1.
Follow the reverse order of Removal.
2.
Tighten the modulator mouting bolts and brake tube

nuts to the specified torque.
Tightening torque
Modulator mounting nut
........................... 17-26 Nm (1.7~2.6kgf.m, 12-19 lb.ft)
Brake tube nut
............................. 13-17 Nm (1.3~1.7kgf.m, 9-12 lb.ft)
3.
A
KMTBR5574A
3.
Disconnect the brake tubes(A) from the ABS modulator.
4.
Remove the ABS modulator mounting bolts(B).

A
KMTBR5575A
CAUTION
1.
2.
Never attempt to disassemble the ABS modulator.

The modulator must be transported and
stored in upright position and with sealed
ports.
The modulator must not be drained.
Bleed the brake system.
ABS CONTROL MODULE

REMOVAL
E0C1E64C
1.
Fold the seat of passenger side.
2.
Remove the ABSCM mounting bolts and ABSCM.
Passenger seat
ABSCM
(ABS control module)
EMTBR5057A
3.
Installation is the reverse of removal.
BR -91
BR -92
BRAKE SYSTEM
WHEEL SPEED SENSOR

REMOVAL
INSPECTION
1.
E5AE8F53
FRONT WHEEL SPEED SENSOR
E7F79880
Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.
Service standard : 1280 - 1920
1.
Remove the front wheel speed sensor mounting bolt.
2.
Disconnect the wheel speed sensor connector.
REAR WHEEL SPEED SENSOR

Remove the rear wheel speed sensor after disconnection
the wheel speed sensor connector.
KMTBR5578A
2.
Connect a voltmeter between the wheel speed sensor terminals, and measure the voltage by turning the
wheel.
NOTE
KCOBR5006A
Set the voltmeter to measure AC voltage.

Service standard : AC voltage detected.
Output voltage
Measurement by oscilloscope : 12mV P-P over.
ECOBR5030A

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Brake System

VACUUM ASSISTED HYDRAULIC BRAKE

FRONT BRAKE ASSEMBLY

REAR BRAKE ASSEMBLY

FRONT WHEEL BRAKE (DRUM TYPE)

Width x Thickness (mm)

85 x 10(Standard), 110 x 11(Option)

FRONT WHEEL BRAKE (DISK TYPE)

Disc brake with hydraulic vacuum booster

Effective radius (mm)

Pad area (cm)

Disc size (O.DI.Dthickness)

REAR WHEEL BRAKE

Width x Thickness (mm)

Capacity of Brake Tank

Combination of Electric and Vacuum Type

Exhaust Brake Valve Type

Diaphragm Effective Diameter

Rod Tensile Force

142.1(14.5): Vacuum Pressure-400mmHg

Rod Tensile Force

103(10.5) Vacuum Pressure-400mmHg

Excluded from D4AE, D4AF

Included with D4DA, D4DB, D4DC, D4AL, D4DD

Internal expansion type acting on propller shft

7~8 clicks(20 kgf)

Parking brake size

Drum i.d. x Lining width

180 x 35 x 5 (T/M : M2S5, M3S5)

Bushing to collar clearance

Primary and secondary piston to cylinder body clearance

Primary spring deterioration

Load N(kgf)/installed length

Body to piston clearance

Brake shoe clearance (number of return notches

Power chamber air tightness [15 seconds after application

-63 kPa (-475

Valve to body clearance when butterfly valve is fully closed [at

When -100 kPa (-750 mmHg)

When 98 kPa (1 kgf/cm

No air to leak from

SERVICE STANDARDS (PARKING BRAKE)

Static roation imbalance

Model with M2S5

Brake shoe clearance

Model with M2S5

Brake shoe return

Model with M2S5

Model with M2S5

Brake lining thickness

Shoe hold down

TIGHTENING TORQUE TABLE

Oil tank attaching bolt

Brake booster support attaching bolt

Brake pedal attaching bolt

Brake booster and brake pedal

Brake pedal support assembly

Set bolt tightening

Clevis lock nut tightening

Front wheel brake

Brake tube nut tightening

Brake tube nut tightening