Brake Brake System

Brake
Specifications
Torque
Description Value
Nut - Master Cylinder to Vacuum Booster 21-29 Nm
-Brake Hard Tube Brake Master Cylinder 20-24 Nm
Nut - Vacuum Booster to Body 8-18 Nm
-Brake Hard Tube to Master cylinder 20-24 Nm
Bolt - Pedal Mounting Bracket 8-18 Nm
Nut - Pedal Assembly to Dash Lower Panel 8-18 Nm
Bolt -Accelerator Pedal Secured to Dash Panel 4-8 Nm
Bolt - Stop Lamp Switch secured to Brake Pedal 8-12 Nm
Bolt -Brake Caliper Assembly 90-110 Nm
-Front Brake Hose to Brake Caliper Housing 20-30 Nm
Screw - Front Brake Exhaust 9-11 Nm

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Screw - Front Brake Ventilated Disc to Front Hub Flange 5-7 Nm
Bolt - Front Brake Caliper to Front Hub 85-105 Nm
Screw - Rear Brake Ventilated Disc to Rear Bearing 5-7 Nm
Bolt - Rear Brake Caliper to Rear Hub 85-105 Nm
-Rear Brake Hose to Brake Caliper Housing 20-30 Nm
Screw - Rear Brake Exhaust 9-11 Nm
Bolt -Electronic Vacuum Pump Support to Longitudinal 19-25 Nm
Member
Bolt -Electronic Vacuum Pump to Mount Support 8.8 Nm

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Brake System Brake

Parameter
Model
Front Single Piston Floating Type Caliper Brake Construction
of Ventilated Disc
Rear Integrated Rear Brake CaliperBrake Construction of Solid Disc
Diameter of Brake Caliper Piston
Front 54 mm
Rear 34mm
Diameter of Brake Disc
Front 280mm
Rear 255mm
Minimum Thickness of Brake Disc
New (Nominal Value) 24mm
Limited Service Value 21mm

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Minimum Thickness of Rear Brake Disc

New (Nominal Value) 9mm

Limited Service Value 7mm
Maximum Disc Runout (Equipped with Wheels) 0.05
Types of Brake Line Diagonal Line, Double Lines, w/4ABS Sensors

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Brake Brake System
Description and Operation
System Component Layout
Brake Fluid Pressure System Component Layout

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1. Front Brake Caliper Assembly 8. Rear Brake Disc Protector
2. Front Brake Ventilated Hole Disc 9. Rear Brake Hose
3. ABS Adjuster 10. Rear Brake Solid Disc
4. Front Disc 11. Front Brake Disc Protector
5. Brake Booster Assembly 12. Brake Reservoir
6. Booster Vacuum Pipe and Check Valve 13. Intake Manifold
7. Rear Brake Caliper Assembly

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Brake System Brake

Front Brake Caliper Exploded View

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1. Front Brake Disc Protector 7. Bleed Screw
2. Front Brake Ventilated Hole Disc 8. Small Bleed Screw Cap
3. Guide Pin Trim Cover 9. Brake Caliper Guide Bracket
4. Front Friction Lining Set 10. Spring Washer - Front Brake Mounting Bolt
5. Front Brake Caliper Housing Assembly 11. Brake Guide Pin
6. Bolt - Front Brake Caliper to Universal Joint

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Brake Brake System
Rear Brake Caliper Exploded View

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1. Rear Brake Disc Protector 6. Bolt-Rear Brake Caliper to Universal Joint
2. Rear Brake Solid Disc 7. Small Bleed Screw Cap
3. Brake Guide Pin 8. Bleed Screw
4. Brake Guide Pin Pad 9. Brake Caliper Guide Bracket
5. Rear Brake Caliper Housing Assembly 10. Brake Pad Set

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Brake System Brake

Description in the bushing of the centre plate. There is a return spring

Brake Pedal and Stop Lamp Switch on the guide opening end. The double-deck diaphragm and
the centre plate divide the inner space of the round housing
Brake pedal is fitted on rotor shaft which located on brake
into 4 sealed chambers. Connect the chambers in front
pedal mounting bracket of the dash panel, and the brake
of the diaphragm together through the retaining passage of
booster input lever is connected to the brake pedal with the
control valve assembly. Connect the chambers in the back of
lever pin and clevis clip. The brake booster input lever on the
the diaphragm together through the inner of the secondary
top of brake pedal controls the Hall-effect stop lamp switch
diaphragm of the retaining bolt.
which is on the brake pedal mounting bracket. The stop lamp
switch provides two kinds of brake pedal status output: One Brake Master Cylinder Assembly
is connected toABS ECU; The second is connected to cruise
control system (if equipped), automatic transmissionECU and
the internal lock is used for automatic transmission shifting.
ECU.The stop lamp switch contains a built-in sensor in the
outer mounting spool. To ensure the correct fitting direction
of the built-in sensor, the built-in sensor is fitted in mounting
spool in a key-connected way; The mounting spool is also
fitted on the brake pedal mounting bracket in a key-connected
way; The built-in sensor stays in the right position in the spool

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due to the serration interacting between the mounting spool
and the sensor. When the brake is released, the top of the
brake pedal is against the end of the sensor; when the brake
pedal is pressed, the top of the brake pedal is far from the
sensor, and cause the output voltage of the sensor to change. 1. Secondary Pressure Chamber
If the brake switch is invalid, at least one of the following 2. Secondary Piston
conditions may occur: one is that the cruise is invalid, and the
3. Secondary Inlet
other is that the stop lamp does not illuminate.
4. Brake Reservoir Interface
Vacuum Booster Assembly
5. Brake Master Cylinder
When the brake is applied, the vacuum booster provides the
6. Main Inlet
assist force to decrease the required pedal force with braking.
If the vacuum booster assembly is invalid, the hydraulic 7. Main Centre Valve
pressure system is still provided with the function of braking, 8. Main piston
but it needs a larger brake pedal force due to the lack of 9. Main Spring
vacuum boost. Connect the vacuum booster assembly to 10. Main Pressure Chamber
the dash panel with 4 stud bolts. Connect the brake master
11. Secondary Centre Valve
cylinder assembly to the 2 retaining bolts of the front end
of vacuum booster assembly. The vacuum booster assembly 12. Valve Pin
consists of round housing with 2-layer diaphragm, centre plate, 13. Secondary Spring
control valve assembly, input push rod, output push rod and
When the brake pedal is pressed, the brake master cylinder
filter. The input push rod is connected to the brake pedal, and
assembly generates hydraulic pressure to operate the brakes.
the output push rod is located inside the main piston of the
The assembly is fitted in front of the vacuum booster assembly,
brake master cylinder. The rubber gaiter is fitted at the rear
containing a pump body, and two pistons are fitted in the
housing extending area from the control valve on the control
front and rear of the pump body. The rear piston generates
valve assembly. The hole of the front housing is connected to
brake pressure for the main circuit, and the front piston
the vacuum tube with the check valve from the engine. The
generates brake pressure for the secondary circuit. The brake
control valve assembly consists of valve body with the vacuum
reservoir is fitted at the top of the master cylinder. The
valve, piston, vacuum valve spring and input push rod spring.
interior of the reservoir is divided to provide fluid for each
There are vacuum holes on the vacuum valve body. The
brake circuit independently, so it can avoid a case that neither
piston controls the air inlet hole between the vacuum valve
of the main and secondary brake circuits can operate due to
and piston. The reaction disc and proportioning disc separate
brake fluid leakage in one place. If one of the brake circuits
the piston from the output push rod. The guide in the front of
has malfunction, the remaining brake circuits still operate
the valve body is fitted on the front diaphragm, and supports
effectively, but the brake pedal trips and the brake distance of

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Brake Brake System
the entire vehicle will increase. If the brake fluid level in the hub. There is a protector inside the brake disc. On the right
reservoir is too low, the brake fluid level switch turns on to brake, a brake pad wear sensor is connected to the inside
cut off the circuit betweenABS adjuster and instrument panel of the brake pad, and it is connected with rear brake pad
and illuminate the brake warning light. The brake fluid level wear sensor in series by the wire. The connector of the
switch contains a spring plate switch which is located in the sensor connecting lead is located on the inner splash shield
plastic gaiter securing on lower side of the reservoir. There of the engine bay. When the hydraulic pressure is transmitted
is a permanent magnet on a float inside the reservoir. When to the brake caliper, the piston extends outward, forcing the
the brake fluid level is in a proper height, this magnet makes inner brake pad to lean against the brake disc. When the
the brake fluid level switch remain closed. When the height brake caliper housing is subject to the reactive force, slides
of brake fluid level is too low, the float subsides, and causes along the guide pin and makes the outer brake pad contact the
the spring plate switch to open. brake disc.If the brake pad is excessive worn, the wear sensor
Front Brakes connecting lead will turn the circuit off by the brake pad wear
sensor due to the worn right brake disc, causing the brake pad
Each of the front brakes consists of a single piston, coast brake
wear warning light on the instrument panel to illuminate.
caliper assembly and a brake disc with ventilator fitted on the

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Brake System Brake

Service Procedures Brake Master Cylinder and Reservoir Assembly

Brake Fluid Level Indication Switch Caution: The brake fluid can damage the painted surface.
Caution: The brake fluid can damage the painted surface. If the fluid spills, immediately remove the fluid and clean
If the fluid spills, immediately remove the fluid and clean this area with water.
this area with water. Removal
Removal 1. Place the cloth under theABS adjuster to absorb the
1. Disconnect the connector from the brake fluid level overflowing fluid.
switch. Caution: The brake fluid can damage the painted surface.
2. Loosen the snap fit securing the brake fluid level switch If the fluid spills, immediately remove the fluid and clean
to brake reservoir, and remove the switch. this area with water.
2. Disconnect the connector from the brake fluid level
switch.
3. Loosen the 2 brake hard tubes from the brake master
cylinder.

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Caution: The brake fluid can damage the painted surface.
If the fluid spills, immediately remove the fluid and clean
this area with water.
Refit
1. Fit the brake fluid level switch to the brake reservoir, 4. Loosen the clip securing the connector to the battery
and secure it with the snap fit. box support, and loosen the connector.
2. Connect the connector to the brake fluid level switch. 5. Loosen the engine bay wire harness from the battery
box bracket, and disconnect the connector main wire.
6. Remove the 2 nuts and gasket securing the master
cylinder to the vacuum booster, and discard the nuts.
7. Remove the master cylinder and the reservoir assembly.
Refit
1. Position the brake master cylinder onto the vacuum
booster, and secure it with the 2 new nuts. Tighten the
nuts to 21-29 Nm.
2. Clean the brake hard tube joint.
3. Fit the brake hard tube to the brake master cylinder,
and tighten to 20-24 Nm.
4. Position the engine bay wire harness connector to
battery box bracket and connect it to the main wire.
Secure the wire harness connector to the bracket.
5. PositionECM wire harness and connect the connector.
6. Connect the connector on the brake fluid level switch.
7. Drain the brake system.

Drain Brake System

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Brake Brake System
Vacuum Booster Assembly pedal and secure it with pin lever and spring plate nuts.
Removal 5. Fit the driver side lower cover plate assembly.
1. Remove the battery box cover. 6. Connect the vacuum pipe to the vacuum booster.
Battery Box Cover 7. Clean the brake hard tube joint.
2. Disconnect the connector from the brake fluid level 8. Fit the brake hard tube to the brake master cylinder,
switch. and tighten to 20-24 Nm.
3. Place the cloth under the reservoir to absorb the 9. Connect the connector to the brake fluid level switch.
overflowing fluid.
10. Drain the brake system.
Caution: The brake fluid can damage the painted surface.
If the fluid spills, immediately remove the fluid and clean Drain Brake System
this area with water. 11. Fit the battery box cover.

4. Loosen the 2 brake hard tubes from the brake master Battery Box Cover
cylinder.
Caution: Before disconnecting or removing brake
lines, ensure that the centre area around lines and
connections are clean. Plug opened connection to
prevent contamination entering.

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5. Disconnect the vacuum pipe from the vacuum booster.
6. Remove the driver side lower cover plate assembly.
7. Remove the spring plate nut and pin lever securing the
vacuum booster to brake pedal.
8. Remove 4 nuts securing the vacuum booster to dash
lower panel, and remove the vacuum booster and brake
master cylinder assembly.

9. Remove the 2 nuts and gaskets securing the master

cylinder to the vacuum booster, and discard the nuts.
10. Remove the vacuum booster assembly.
Refit
1. Position the brake master cylinder onto the vacuum
booster, and secure it with the 2 new nuts. Tighten the
nuts to 21-29 Nm.
2. Clean the mating surface of the vacuum booster and
body.
3. Fit vacuum booster assembly and secure it to the body
dash panel with the nuts. Tighten the nuts to 8-18 Nm.
4. Position the vacuum booster push rod to the brake

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Brake System Brake

Break Pedal
Removal
1. Disconnect the battery earth lead.
2. Remove the steering column lower cover plate.
Steering Column Lower Cover Plate
3. Remove the stop lamp assembly.
Stop Lamp Switch Assembly
4. Loosen a stud and 2 bolts securing the accelerator
pedal to the dash panel.

10. Loosen the 2 nuts securing the clutch pedal to the dash
panel.
11. Remove the clutch pedal.
Refit
1. Pass the clutch pedal bolt through the dash panel so

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that it fits the clutch master cylinder bore.
2. Fit the nut to the clutch pedal stud, and tighten it to
8-18 Nm.
3. Fit the clutch pedal arm onto the clutch push rod clevis,
insert the pin, and fit the snap fit at last.
5. Remove the accelerator pedal. 4. Adjust the clutch master cylinder push rod clevis to
6. Loosen the nuts securing the vacuum booster push rod place the clutch pedal in the proper position.
to the brake pedal. 5. Pass the vacuum booster stud through the dash panel
7. Loosen the 2 bolts securing the brake pedal to the so that it fits the brake pedal bore.
dash panel. 6. Tighten the nuts in the order of bottom RH, bottom
8. Remove the brake pedal. LH, and the two nuts in the middle to 8-18 Nm.
7. Pass the brake pedal bolts through the dash panel, and
tighten them to 8-18 Nm.
8. Secure the accelerator pedal to the dash panel with 2
bolts and a stud, and tighten them to 4-8 Nm.
9. Fit the stop lamp assembly.

Stop Lamp Switch Assembly

10. Fit the steering column lower cover plate.
Steering Column Lower Cover Plate

9. Loosen the pin and the snap fit securing the clutch
pedal to the clutch master cylinder.

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Brake Brake System
Stop Lamp Switch Assembly Front Brake Caliper Housing Assembly
Removal Removal
1. Disconnect the battery earth lead. 1. Raise the vehicle on a lift.
2. Remove the steering column lower cover plate. 2. Remove the front wheel.
Steering Column Lower Cover Plate Wheel
3. Loosen the set nuts of stop lamp switch, and detach 3. Remove the service bolt and gasket from the brake
the switch. hose to brake caliper.
4. Disconnect the brake hose, block the brake caliper and
brake hose opening to prevent the brake fluid from
running off and being polluted.
Caution: Before disconnecting or removing brake
lines, ensure that the centre area around lines and
connections are clean. Plug opened connection to
prevent contamination entering.
5. Remove the brake caliper mounting bolt from the
steering knuckle, and then remove the brake caliper

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assembly.

Refit
1. Connect the connector to brake switch.
2. Fit the stop lamp switch retaining bolts to the brake
pedal, and tighten them to 8-12 Nm.
3. Release the brake pedal, be sure to contact the brake
switch with operation point on the brake pedal.
4. Fit steering pipe lower plate assembly.

Steering Column Lower Cover Plate

5. Connect the battery earth lead.

Refit
1. Clean the brake components.
Warning: DO NOT clean the brake components with
compressed air. Dust from friction materials are
hazardous to your health, DO NOT inhale it by mistake.
2. Fit the brake caliper assembly with mounting bolt, and
tighten the bolt to 90-110 Nm.
3. Connect the brake hose, tighten the brake hose inlet
union to the brake caliper bolt and gasket to 20-30
Nm.
4. Drain the brake system.
Drain Brake System
5. Fit the wheels.
6. Lower the vehicle.

Wheel

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Brake System Brake

Front Brake Pad 6. Secure the draining screw dust cover to the draining
Removal screw.
Warning: DO NOT work under the vehicle supported only 7. Fit the brake pad to the brake caliper housing assembly.
with a jack. It is essential to support the vehicle on safety 8. Use proper anti-sticking grease to lubricate the front
stands. brake guide.
1. Raise the vehicle on a lift. Caution: If the brake pad warning light was illuminated
2. Remove the front wheel. before replacing brake pads, replace the brake pad wear
Wheel sensor with a new one, otherwise, the warning light will
still be illuminated.
3. Remove the front brake caliper assembly.
9. Secure the front brake caliper housing to front brake
Front Brake Caliper Assembly
caliper bracket and align it. Fit front brake caliper guide
4. Remove the 2 trim caps from the front brake caliper and tighten it.
guide dust cover.
10. Fit the trim cover cap to the front brake caliper guide
5. Remove the 2 front brake caliper guides from the front dust cover.
brake caliper housing.
11. Inspect/Add the brake reservoir.
6. Remove the front brake caliper housing assembly from
the front brake caliper bracket. Caution: Never reuse the brake fluid that has been bled

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from the brake system.
Caution: DO NOT hang the brake caliper on brake hose.
12. Fit the wheels.
7. Remove the front brake pad from the front brake
caliper housing assembly. Wheel
13. Lower the vehicle.
14. Press the brake pedal several times to fit the front
brake pad.
Tip: The pedal trips may be longer than normal during
the first brake application.

Refit
1. Remove any dirt and corrosives from the front disc
edge.
2. Clean the front brake caliper housing and the front
brake caliper bracket. Check the front brake caliper
and seal for damage.
Warning: DO NOT clean the brake components with
compressed air. Dust from friction materials are
hazardous to your health, DO NOT inhale it by mistake.
3. Hold the drain bottle, connect the drain hose to the
draining screw, and loose the screws (each side).
4. press the front brake caliper piston into the front
brake caliper housing, and tighten the draining screw
again to 9-11 Nm.
5. Disconnect the drain hose, and take away the drain
bottle.

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Brake Brake System
Front Disc Inspection of Thickness and Round Runout -
Removal Front Disc
Caution: Brake discs must be replaced in pairs, unless the
Inspection
disc is just changed with a new one and the vehicle drive 1. Raise the vehicle on a lift.
less than 1,500 miles. Warning: DO NOT work under the vehicle supported only
1. Raise the vehicle on a lift. with a jack. It is essential to support the vehicle on safety
stands.
Warning: DO NOT work under the vehicle supported only
with a jack. It is essential to support the vehicle on safety 2. Remove the front wheel.
stands. Wheel
2. Remove the front wheel. 3. Remove the front brake caliper assembly.
Wheel Front Brake Caliper Assembly
3. Remove the front brake caliper assembly. 4. Using differential gauge/micrometer, measure the
Front Brake Caliper Assembly thickness of the front disc along 4 evenly distributed
points on its surface, and the measuring points should
4. Remove the countersunk head screw securing the front
be located at 10 mm away from its edge. The thickness
disc to the front drive wheel flange.
of brake disc is at least 20.0 mm. If it exceeds the limits,

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the front disc must be replaced.

5. Remove the front disc assembly.

Refit
Caution: Brake discs must be replaced in pairs, unless the
1. Make sure the mating surface of the front disc and front
disc is just changed with a new one and the vehicle drive
drive wheel flange is clean.
less than 1,500 miles.
2. Fit the front disc to the front drive wheel flange, and
then fit the countersunk head screw and tighten it to 5. Fit a dial test indicator (DTI), and secure it to the inside
5-7 Nm. of the front hub with the bolt hole of the front brake
caliper assembly.
3. Inspect the runout of front disc.
6. Set the probe of DTI on the brake disc with 5 mm
Inspection of Thickness and Round Runout - away from its edge.
Front Disc
7. Zero the DTI, turn the wheel in a complete circle to
4. Inspect the front brake pad, and replace it as necessary. measure the runout of brake disc. The runout of brake
5. Fit the front brake caliper to front hub, then fit the bolt disc is less than 0.05 mm.
and tighten it to 85-105 Nm. 8. If the runout of brake disc exceeds the limits:
Front Brake Caliper Assembly • Remove the countersunk head screw securing the front
6. Fit the wheels. disc to the front hub and then remove the front disc.
Wheel • Make sure the mating surface from the front disc to front
7. Lower the vehicle. hub flange is clean.
• Fit the front disc to the front hub, then fit countersunk
head screw and tighten to 5-7 Nm.

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Brake System Brake

• Recheck the runout of the brake disc according to the Rear Disc
previous detailed procedure. Removal
• If the runout still exceeds the limits, replace the front disc Caution: Brake discs must be replaced in pairs, unless the
or front hub. disc is just changed with a new one and the vehicle drive
9. Remove DTI from inside of front hub and TCH00022. less than 1,500 miles.
10. Fit the front brake caliper assembly to the front hub, 1. Raise the vehicle on a lift.
then fit the bolt and tighten it to 85-105 Nm.
Warning: DO NOT work under the vehicle supported only
Front Brake Caliper Assembly with a jack. It is essential to support the vehicle on safety
11. Fit the wheels. stands.

Wheel 2. Remove the rear wheel.

12. Press the brake pedal several times to adjust the front Wheel
brake pad. 3. Remove the rear brake caliper assembly.
13. Lower the vehicle. Rear Brake Caliper Assembly
Caution: DO NOT hang the brake caliper on brake hose.
4. Remove the countersunk head screw securing the rear

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brake disc.

5. Remove the rear disc assembly.

Refit
1. Make sure the mating surface of the rear disc and rear
drive wheel flange is clean.
2. Fit the rear disc to the rear wheel drive flange, then fit
the countersunk head screw and tighten it to 5-7 Nm.
3. Inspect the runout of rear disc.
Inspection of Thickness and Round Runout -
Rear Disc
4. Inspect the rear brake pad, and replace it as necessary.
5. Fit the rear brake caliper assembly to the rear hub, then
fit the bolt and tighten it to 85-105 Nm.
Rear Brake Caliper Assembly
6. Fit the wheels.
Wheel
7. Lower the vehicle.

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Brake Brake System
Inspection of Thickness and Round Runout - • Recheck the runout of the rear brake disc according to
Rear Disc the previous detailed procedure.
Inspection • If the runout still exceeds the limits, replace the rear disc
1. Raise the vehicle on a lift. or rear hub.
Warning: DO NOT work under the vehicle supported only 9. Remove DTI from inside of rear hub and TCH00022.
with a jack. It is essential to support the vehicle on safety 10. Fit the rear brake caliper assembly to the rear hub, then
stands. fit the bolt and tighten it to 85-105 Nm.
2. Remove the rear wheel.
Rear Brake Caliper Assembly
Wheel
11. Fit the wheels.
3. Remove the rear brake caliper assembly.
Wheel
Rear Brake Caliper Assembly
12. Press the brake pedal several times to adjust the rear
4. Using differential gauge/micrometer, measure the
brake pad.
thickness of the front disc along 4 evenly distributed
points on its surface, and the measuring points should 13. Lower the vehicle.
be located at 10 mm away from its edge. The thickness
of brake disc is at least 20.0 mm. If it exceeds the limits,
the front disc must be replaced.

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Caution: Brake discs must be replaced in pairs, unless the
disc is just changed with a new one and the vehicle drive
less than 1,500 miles.
5. Fit a dial test indicator (DTI), and secure it to the inside
of the rear hub with the bolt hole of the rear brake
caliper assembly.
6. Set the probe of DTI on the rear disc with 10 mm away
from its edge.
7. Zero the DTI, turn the wheel in a complete circle to
measure the runout of brake disc. The runout of brake
disc is less than 0.05 mm.
8. If the runout of brake disc exceeds the limits:
• Remove countersunk head screw securing the rear disc
to front hub and remove the rear disc.
• Be sure to clean the mating surface from the rear disc to
rear wheel flange.
• Fit the rear disc to the rear hub, then fit the countersunk
head screw and tighten it to 5-7 Nm.
• Fit the wheels

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Brake System Brake

Rear Brake Caliper Housing Assembly Rear Brake Pad

Removal Removal
1. Raise the vehicle on a lift. Warning: Brake pads must be replaced with axle in pairs,
Warning: DO NOT work under the vehicle supported only otherwise brake efficiency may be impaired.
with a jack. It is essential to support the vehicle on safety 1. Raise the vehicle on a lift.
stands. Warning: DO NOT work under the vehicle supported only
2. Remove the rear wheel. with a jack. It is essential to support the vehicle on safety
Wheel stands.

3. Remove the service bolt and gasket from the brake 2. Remove the rear wheel.
hose to brake caliper. Wheel
4. Disconnect the brake hose, block the brake caliper and 3. Remove the rear brake caliper assembly.
brake hose opening to prevent the brake fluid from
Rear Brake Caliper Assembly
running off and being polluted.
4. Unscrew the rear brake caliper guide mounting bolt.
Caution: Before disconnecting or removing brake
lines, ensure that the centre area around lines and 5. Remove the 2 front brake caliper guides from the rear
connections are clean. Plug opened connection to brake caliper housing.

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prevent contamination entering. 6. Remove the rear brake caliper housing assembly from
the rear brake caliper bracket.
5. Remove the brake caliper mounting bolt from the
steering knuckle, and then remove the brake caliper Caution: DO NOT hang the brake caliper on brake hose.
assembly. 7. Remove the rear brake pad from the rear brake caliper
housing assembly.

Refit
1. Clean the brake components. Refit
Warning: DO NOT clean the brake components with 1. Remove any dirt and corrosives from the rear disc edge.
compressed air. Dust from friction materials are 2. Clean the rear brake caliper housing and the rear brake
hazardous to your health, DO NOT inhale it by mistake. caliper bracket. Check the front brake caliper and seal
2. Fit the brake caliper assembly with mounting bolt, and for damage.
tighten the bolt to 85-105 Nm.
Warning: DO NOT clean the brake components with
3. Connect the brake hose, tighten the brake hose inlet compressed air. Dust from friction materials are
union to the brake caliper bolt and gasket to 20-30 hazardous to your health, DO NOT inhale it by mistake.
Nm.
3. Hold the drain bottle, connect the drain hose to the
4. Drain the brake system. draining screw, and loose the screws (each side).
Drain Brake System 4. Using the special tool TCH00015, press the rear brake
5. Fit the wheels. caliper piston into the rear brake caliper housing, and
tighten the draining screw again to 9-11 Nm.
Wheel
6. Lower the vehicle.

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Brake Brake System
Drain Brake System
Drain
Warning: DO NOT allow the brake fluid to contact your
eyes or skin.
Caution: Never reuse the brake fluid that has been bled
from the brake system.
The following steps include the drain methods for the
entire system, but if the main circuit or sub circuit becomes
an independent circuit, only operate the required drain
5. Disconnect the drain hose, and take away the drain circuit. Only when the brake hard tube or the brake hose is
bottle. disconnected, and a small amount of fluid loses, it is allowed
6. Secure the draining screw dust cover to the draining to drain the hydraulic pressure system.
screw.
1. Add the brake reservoir to MAX mark position.
7. Fit the brake pad to the brake caliper housing assembly.
Caution: Ensure the level of new brake fluid in the brake
8. Use proper anti-sticking grease to lubricate the rear
reservoir is between the MIN and MAX throughout the
brake guide.
whole bleed procedures.

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9. Secure the rear brake caliper housing to rear brake
2. Raise the vehicle on a lift.
caliper bracket and align it. Fit rear brake caliper guide
and tighten it. 3. Remove the drain screw dust cover from the rear brake
caliper RH (for LHD), and fit the hose to drain screw.
Caution: If the brake pad warning light was illuminated
Submerge the free end of the hose into a container
before replacing brake pads, replace the brake pad wear
full of new brake fluid.
sensor with a new one, otherwise, the warning light will
4. Apply the brake to brake pedal several times, and then
still be illuminated.
apply a steady pressure.
10. Fit the trim cover cap to the rear brake caliper guide
5. Loosen the drain screw to separate the brake fluid and
dust cover.
air. Allow the pedal to return without any external
11. Inspect/Add the brake reservoir. force.
12. Fit the wheels. 6. Smoothly press the brake pedal to maximum stroke,
Wheel and allow it to return without any external force.
Repeat the operation several times until the brake fluid
13. Lower the vehicle.
flows into the container without any air, and secure
14. Press the brake pedal several times to fit the rear brake the brake pedal to maximum stroke, then tighten the
pad. drain screw to 9-11 Nm.
Tip: The pedal trips may be longer than normal during • LHD Mode: Rear LH; Front RH; Front LH.
the first brake application.
• RHD Mode: Rear RH; Front LH; Front RH.
7. Remove the hose from the drain screw, and fit the
drain screw dust cover.

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Brake System Brake

8. Repeat drain the other 3 brake calipers in the following Electronic Vacuum Pump - Aftermarket
order. Removal
• LHD Mode: Rear LH; Front RH; Front LH. 1. Disconnect the battery negative terminal.
• RHD Mode: Rear RH; Front LH; Front RH.
Warning: Brake efficiency may be seriously impaired, if
draining is in incorrect sequence.
9. Lower the vehicle.
10. Add the brake reservoir to MAX mark line.
11. Apply the brakes and check for leakage.
12. Test the vehicle on the road. When the brake operates,
check the minimum stroke of brake pedal.

2. Remove the air cleaner assembly.

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Air Cleaner Assembly Removal
3. Remove the upper cover and waterproof plate on the
engine compartment fuse box.

4. Disconnect the engine compartment fuse box positive

cable.

5. Remove the fuse box body, and the connector indicated

by the arrow in the illustration below is: BD054.

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Brake Brake System

6. Remove the vacuum hose assembly. A = 43 mm, B = 21 mm, C = 15 mm, D = 75 mm, E = 14 mm,
F = 3.5 mm, G = 3 mm, H = 7 mm
Caution: When drilling, DO NOT let the chips drop into
the hole, apply a coat of paint on the mounting hole to
protect paint.

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2. Using the special tool TCH00076, fit the 3 riveted nuts
into 3 holes.

Refit
1. Drill four holes in the front longitudinal member LH
with a drill using the dimension in the illustration below.
Three of the holes are used to fit the electronic vacuum
pump support and their sizes are M11; One of them is
used to fit the connector and the size is ф7.
Tip: Protect the contact surfaces between EVP bracket
and the body with paint.
3. Tighten the 3 bolts securing the electronic vacuum
pump bracket to the longitudinal member to 19-25
Nm.

A = 73 mm, B = 26 mm, C = 63 mm, D = 48 mm

4. Tighten the 2 bolts securing the electronic vacuum

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Brake System Brake

pump to the bracket to 8.8 Nm.

BD054
5. Connect the vacuum switch connector on the
electronic vacuum pump wire harness to the vacuum Cav Col Cav Col
switch. 1 White 11 White/Red
2 Dark 12 -

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Blue/White
3 Black/White 13 Purple
4 Orange 14 Red
5 - 15 Orange
6 - 16 -
7 Pink 17 -
8 White/Purple 18 -
9 Light Blue 19 Pink
10 Dark 20 Red/Yellow/Dark
6. Connect the vacuum hose assembly to the electronic Blue/Gray Green
vacuum pump.
Tip: Before inserting the PIN, release the white buckle
on the connector BD054.
9. Connect the vacuum pump connector of the electronic
vacuum pump wire harness to the connector of the
vacuum pump.

7. Connect the vacuum hose to the vacuum booster and

intake manifold.
8. Insert the 2 terminals of the electronic vacuum pump
wire harness into PIN7 PIN14 of the connector BD054:
the red terminal (Wire diameter: 1.25) is inserted into
PIN14, and the pink terminal (Wire diameter: 0.85) is 10. Secure the vacuum pump relay on the electronic
inserted into PIN7. vacuum pump wire harness to the body main wire with

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Brake Brake System
bands. Electronic Vacuum Pump
Removal
1. Disconnect the battery negative terminal.

11. Connect the ground strip connector of the electronic

vacuum pump wire harness to the position as shown in
the illustration.
2. Remove the air cleaner assembly.

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Air Cleaner Assembly Removal
3. Loosen the vacuum hose connected to the vacuum
booster.

12. Add brake fluid to the reservoir to the MAX mark line.
13. Fit the air cleaner assembly.
Air Cleaner Assembly Refit
14. Connect the battery negative terminal. 4. Loosen the wire harness connected to the vacuum
sensor.

5. Loosen the vacuum hose connected to the electronic

vacuum pump.

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Brake System Brake

5. Connect the vacuum hose assembly to the electronic

vacuum pump.
6. Fit the air cleaner assembly.
Air Cleaner Assembly Refit
7. Connect the battery negative terminal.

6. Loosen the 2 bolts securing the electronic vacuum

pump to the bracket.

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7. Loosen the 3 bolts securing the bracket to the body.

Refit
1. Tighten the 3 bolts securing the electronic vacuum
pump bracket to the longitudinal member to 19-25
Nm.
2. Tighten the 2 bolts securing the electronic vacuum
pump to the bracket to 8.8 Nm.
3. Connect the wire harness to the vacuum sensor.
4. Connect the vacuum hose assembly to the vacuum
booster.

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