BRAKE

GENERAL INFORMATION 26-3 Brake Pedal Assembly 26-23

Description 26-3 On-vehicle Inspection 26-23
Specifications 26-5 Removal 26-24
Tools 26-7 Inspection 26-26
Circuit Diagram 26-8 Installation 26-26
Front Disc Brake Assembly 26-27
DIAGNOSIS & TESTING 26-9
On-vehicle Inspection 26-28
Problem Symptoms Table 26-9
Removal 26-28
Inspection 26-11
Disassembly 26-30
ON-VEHICLE SERVICE 26-12 Inspection 26-32
Brake Bleeding 26-12 Assembly 26-34
Brake Fluid Replacement 26-13 Installation 26-37
Brake Fluid Reservoir Assembly 26-14 Front Brake Hose Assembly 26-38
On-vehicle Inspection 26-14 Removal 26-38
Removal 26-14 Installation 26-39
Installation 26-15 Rear Disc Brake Assembly 26-40
Brake Master Cylinder Assembly 26-16 On-vehicle Inspection 26-41
Removal 26-16 Removal 26-41
Installation 26-18 Disassembly 26-42
Vacuum Booster with Brake  Inspection 26-45
Master Cylinder Assembly 26-19 Assembly 26-46
On-vehicle Inspection 26-19 Installation 26-50
Removal 26-20 Rear Brake Hose Assembly 26-51
Inspection 26-22 Removal 26-51
Installation 26-22 Installation 26-52

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GENERAL INFORMATION
BRAKE

Description
Front Disc Brake Assembly

3
4

×4

RT21260010

1 - Front Steering Knuckle 2 - Front Wheel Mudguard

3 - Front Hub Bearing 4 - Front Hub Assembly
5 - Front Brake Disc 6 - Front Brake Caliper Assembly

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Rear DIH (Drum-in-hat)

1
2

3 5

RT21260020

1 - Connecting Plate Assembly 2 - Rear Brake Bottom Board

3 - Rear Brake Assembly 4 - Rear Hub Bearing Unit
5 - Rear Brake Caliper Assembly 6 - Rear Brake Disc

Brake system uses following configuration: disc brake is used for front wheels, and DIH (Drum-in-hat) is used
for rear wheels (disc brake is used for driving brake, and drum brake is used for parking brake).
Using lever principle, brake pedal pushes pushrod into vacuum booster, which boosts the force of pushrod by
using vacuum and then transmits the force to brake master cylinder assembly. Hydraulic pressure, produced
in the brake master cylinder assembly, is transmitted to ABS Hydraulic Control Unit (HCU) through brake
tube, and then distributed to individual brake calipers. The brake calipers apply force to brake linings using
hydraulic pressure. The brake linings will cause wheel speed to decrease or stop depending on amount of
brake pressure applied.

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Specifications
Torque Specifications

Description Torque (N·m)

Wheel Mounting Bolt 110 ± 10
Coupling Nut Between Brake Fluid Reservoir
9±1
Assembly and Body
Coupling Plug Between Brake Master Cylinder
16 ± 2
Assembly and Brake Pipe
Coupling Nut Between Brake Master Cylinder
21 - 25
Assembly and Vacuum Booster Assembly
Coupling Bolt Between Brake Fluid Reservoir
3-5
Assembly and Brake Master Cylinder Assembly
Coupling Nut Between Vacuum Booster Assembly
25 ± 3
and Brake Pedal Assembly
Coupling Nut Between Brake Pedal Assembly and
25 ± 3
Body
Coupling Bolt Between Front Brake Caliper
27 ± 2
Assembly and Front Brake Hose Assembly
Coupling Bolt Between Front Brake Caliper
100 ± 10
Assembly and Front Steering Knuckle Assembly
Front Brake Disc Positioning Screw 10 ± 1
Front Brake Caliper Bleeder Plug 9 - 11
Locating Bolt Between Front Brake Caliper Fixing
25 ± 3
Bracket and Front Brake Cylinder Assembly
Coupling Plug Between Front Brake Hose Assembly
16 ± 2
and Front Brake Pipe
Coupling Bolt Between Rear Brake Caliper
20 ± 2
Assembly and Rear Brake Hose Assembly
Coupling Bolt Between Rear Brake Caliper
100 ± 10
Assembly and Rear Brake Bottom Board Assembly
Rear Brake Disc Positioning Screw 10 ± 1
Rear Brake Caliper Bleeder Plug 9 - 11
Locating Bolt Between Rear Brake Caliper Fixing
25 ± 3
Bracket and Rear Brake Cylinder Assembly
Coupling Plug Between Rear Brake Hose Assembly
16 ± 2
and Brake Pipe

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Front Disc Brake

Standard Thickness Minimum Thickness

Description Maximum Runout (mm)
(mm) (mm)
Front Brake Disc 25 23 0.06
Front Brake Lining 9.2 2 -

Rear DIH (Drum-in-hat)

Standard Thickness Minimum Thickness

Description Maximum Runout (mm)
(mm) (mm)
Rear Brake Disc 10 8 0.06
Rear Brake Lining 8.2 2 -

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Tools
Special Tool

Brake Caliper Piston Pressing Tool

RCH0000053

General Tools

20
10

30
0

40
90

50
80
Dial Indicator and Magnetic Holder

60
70
RCH0000023

Vernier Caliper

RCH0000019

Digital Multimeter

RCH0000002

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Circuit Diagram
Brake System

BATTERY IGNITION SWITCH

ON OR START

INSTRUMENT
RF23 RF06 PANEL
FUSE AND
10A 10A RELAY BOX
I-007
23 6
R

P
11 13

INSTRUMENT
CLUSTER
I-015

26 3 5
Br
B
Y

2 I-004
E-071
Y

I-003
1

BREAK
FLUID LEVEL
CLOSE SENSOR
E-082
OPEN
2
B

E-078

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
I-015 13 14 15 16 17 18 19 20 21 22 23 24
L
27 25 26
87
85 86 86 86
6 5 4 3 2 1 87 30 87 30
30 85 85
14 13 12 11 10 9 8 7 1 2

E-082 I-007
I-004 B B
W

26
ET21260010

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DIAGNOSIS & TESTING

Problem Symptoms Table
HINT:
Use the table below to help determine the cause of the problem symptoms. Check each suspected area in
sequence. Repair or replace the faulty components, or adjust as necessary.

Symptom Suspected Area See page

Front brake lining (cracked, deformed, dirty
26-32
or burnished)
Rear brake lining (cracked, deformed, dirty
26-45
or burnished)
Front disc brake locating bolt guide pin
26-30
(worn)
Rear disc brake locating bolt guide pin
26-42
(worn)
Front brake caliper assembly fixing bolt
26-28
(loose)
Noise in brake Rear brake caliper assembly fixing bolt
26-41
(loose)
Front brake disc (scored) 26-32
Rear brake disc (scored) 26-45
Excessive brake disc runout 26-41
Brake shoe stopper spring (damaged) 27-17
Brake shoe return tension spring
27-17
(damaged or elasticity insufficient)
Foreign matter on front brake disc -
Foreign matter on rear brake disc -
Front brake lining (worn, cracked,
26-32
deformed, oily or burnished)
Rear brake lining (worn, cracked,
26-45
deformed, oily or burnished)

Hard pedal but brake inefficient Front brake disc (unevenly worn) 26-32
Rear brake disc (unevenly worn) 26-45
Vacuum booster pushrod position
26-23
(incorrect)
Vacuum leaks in booster system 26-19
Hard pedal (firm-depress unable to lock-up
Vacuum booster (bounce) 26-19
wheels)
Pedal overtravel (vehicle stops normally) Air in brake system 26-12
26-32
Pedal pulsates/bounces during braking Brake disc (unevenly worn) 26
26-45

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Symptom Suspected Area See page

Air in brake system 26-12
Brake system (leaked) -
Front brake piston seal (worn or damaged) 26-30

Low or spongy pedal Rear brake piston seal (worn or damaged) 26-42
Brake master cylinder assembly
26-16
(malfunctioning)
Vacuum booster pushrod position
26-23
(incorrect)
Front brake piston (stuck or frozen) 26-30
Rear brake piston (stuck or frozen) 26-42
Front brake lining (dirty, cracked or
26-32
deformed)
Vehicle pulls during braking
Rear brake lining (dirty, cracked or
26-45
deformed)
Front brake disc (unevenly worn) 26-32
Rear brake disc (unevenly worn) 26-45
Brake pedal free play (minimum) 26-23
Parking brake lever travel (in need of
27-8
adjustment)
Parking brake cable (stuck) 27-13
Parking brake shoe clearance (in need of
27-8
adjustment)
Front brake lining (cracked or deformed) 26-32
Rear brake lining (cracked or deformed) 26-45
Brake stuck Front brake piston (stuck or frozen) 26-30
Rear brake piston (stuck or frozen) 26-42
Brake shoe return tension spring (loose or
27-17
damaged)
Vacuum booster pushrod position
26-23
(incorrect)
Vacuum leaks in booster system 26-19
Brake master cylinder assembly
26-16
(malfunctioning)

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Inspection
CAUTION

 Use well-sealed brake fluid DOT4 or equivalent. DO NOT use oily solution, otherwise brake system seal
may be damaged.
 Brake fluid may damage paint surface. If brake fluid spills on paint surface, wash it off immediately with
water.
 DO NOT use gasoline, kerosene, alcohol, engine oil, transmission oil or any other fluid that contains
mineral oil to clean the system components. These kinds of fluid will damage rubber cover and seal.
 During servicing, make sure to clean grease or other foreign matter on the outer surface of brake caliper
assembly, brake lining, brake disc and wheel hub.
 When operating brake disc and brake caliper, be careful to prevent damaging brake disc and brake
caliper or scratching or cutting brake shoe linings.

1. Check conditions of tires and wheels. Damaged or worn wheels and tires can cause a pull, shudder,
vibration and a condition similar to sudden braking.
2. If noise occurs while braking, check suspension components. Bounce vehicle up and down several times
and check suspension or steering components for any looseness, wear or damage.
3. Check brake fluid level and condition.
a. If brake fluid level is low, check ABS control unit assembly, brake wheel cylinder, brake caliper, brake
line, brake master cylinder assembly and brake fluid reservoir, etc. for leakage.
b. If brake fluid is contaminated, drain an amount of fluid to check. Replace with new fluid as necessary.
HINT:
It is normal that brake fluid will become dark after being used for a period of time. Do not mistake this for
contamination.

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ON-VEHICLE SERVICE
Brake Bleeding
WARNING

 When bleeding brake system, wear safety glasses.

 Be careful when bleeding air, as brake fluid at high pressure may spray out of bleeder plug.

CAUTION

 Before removing brake fluid reservoir, wipe it off to prevent dust and other foreign matter from dropping
into the brake fluid reservoir.
 Use fresh, clear and well-sealed brake fluid of specified type or equivalent.
 DO NOT allow brake fluid to adhere to any paint surface, such as vehicle body. If brake fluid leaks onto
any paint surface, immediately wash it off.
 During bleeding, do not depress brake pedal repeatedly at any time with bleeder plug opened.
Otherwise, the amount of air in system will increase, and further bleeding is needed.
 DO NOT drain brake fluid in brake fluid reservoir while bleeding brake system.

HINT:
An assistant will be required to assist when bleeding brake system.
1. Fill the brake fluid reservoir with brake fluid to proper level.
2. Loosen the bleeder plug cap and connect a clear plastic hose to the bleeder plug. Submerge the end of
hose into the clear container filled with new brake fluid.
3. Have an assistant depress the brake pedal 3 to 4 times
repeatedly; depress and hold the brake pedal to a lower
position. Then loosen the bleeder plug, and rotate it at
least one turn.

RT21260030

4. Tighten the bleeder plug every time the brake pedal

moves down quickly. Then release the brake pedal.

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5. Repeat above steps, and bleed the brake lines of each wheel in the same manner in the order of rear left
wheel, front right wheel, rear right wheel and front left wheel, until all air are bled from the brake lines.
Empty sign: a stream of fresh brake fluid flows into the clear container without bubbles.
HINT:
During bleeding the brake system, make sure the brake
fluid level is always near the "MAX" mark. Check the
brake fluid level at all times during bleeding. Add brake
fluid as necessary.

RT21260050

6. Check and adjust the brake fluid level to the "MAX" mark.
7. Check brake pedal effect. If braking effect is improper or the pedal is spongy, air may still exist in the
system. Perform bleeding procedures again for brake system as necessary.
8. Have the vehicle tested to confirm that brake operates properly and pedal feel is correct.

Brake Fluid Replacement

1. Drain the brake fluid.
a. Start the engine and run it at idle.
b. Remove the filler cap of brake fluid reservoir assembly. Remove the bleeder plug cap and connect a
clear plastic hose to the bleeder plug, and submerge the end of hose into the clear container filled with
new brake fluid.
c. Loosen the bleeder plug, and depress the brake pedal
continuously until the brake fluid stops coming out.

RT21260030

2. Add brake fluid.

a. Tighten the bleeder plug after confirming that brake fluid is drained. Fill the brake fluid reservoir with
new brake fluid to the proper level.
3. Perform bleeding procedures.
a. After replacing with new brake fluid, make sure to bleed the brake system for normal operation. See
page 26-12 for detail information about brake bleeding.

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Brake Fluid Reservoir Assembly

On-vehicle Inspection
1. Check the brake fluid level warning switch.
a. Remove the brake fluid reservoir filler cap.
b. Disconnect the brake fluid level warning switch wire + -
harness connector.
c. Using ohm band of digital multimeter, check for
continuity between brake fluid level warning switch 1 2
terminals according to conditions shown in the table
below.
Standard Condition

Multimeter Specified RT21260060

Condition
Connection Condition
Terminal 1 - Float upward
No continuity
Terminal 2 (switch ON)
Terminal 1 - Float downward
Continuity
Terminal 2 (switch OFF)

HINT:
 There is a float in the fluid reservoir. The position of float changes according to increasing or decreasing
brake fluid level.
 If result is not as specified, replace brake fluid reservoir assembly.
d. Add brake fluid to the "MAX" mark.

Removal
1. Drain the brake fluid (See page 26-13).

ENVIRONMENTAL PROTECTION

 Drained brake fluid should be well kept in a container. Never discard it at will.

CAUTION

 Wash off brake fluid immediately if it comes in contact with any paint surface.

2. Remove the brake fluid reservoir assembly.

a. Disconnect the brake fluid level warning switch
connector (arrow).

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b. Remove the coupling nuts (arrow) between brake fluid

reservoir assembly and body. 
(Tightening torque: 9 ± 1 N·m)

RT21260080

c. Loosen the brake fluid tube fixing clamp (arrow) and

disengage the brake fluid tube from brake fluid
reservoir assembly.

RT21260090

d. Remove the brake fluid reservoir assembly.

Installation
Installation is in the reverse order of removal.
HINT:
Perform bleeding procedures for brake system and add brake fluid to the proper level after completing
installation.

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Brake Master Cylinder Assembly

Removal

CAUTION

 Remove the vacuum remained in vacuum booster before removing brake master cylinder assembly to
avoid damaging brake master cylinder assembly and prevent booster from sucking in any pollutant.
 When engine is not running, remove vacuum by depressing brake pedal repeatedly until the brake pedal
can be depressed firmly.
 When removing brake line, sealing measures should be taken to prevent foreign matter from entering.

1. Drain the brake fluid (See page 26-13).

CAUTION

 Wash off brake fluid immediately if it comes in contact with any paint surface.

ENVIRONMENTAL PROTECTION

 Drained brake fluid should be well kept in a container. Never discard it at will.

2. Remove the air filter assembly (See page 10-17).

3. Remove the brake master cylinder assembly.
a. Loosen the brake fluid tube fixing clamp (arrow) and
disengage the brake fluid tube from brake fluid
reservoir assembly.

RT21260100

b. Loosen the clutch hose fixing clamp (arrow) and

disengage the clutch hose from brake fluid reservoir
assembly (for only MT model).

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c. Loosen 2 coupling plugs (arrow) between brake

master cylinder assembly and brake pipes.
(Tightening torque: 16 ± 2 N·m)

RT21260120

d. Loosen 2 coupling nuts (arrow) between brake master

cylinder assembly and vacuum booster. 
(Tightening torque: 21 - 25 N·m)

RT21260130

e. Carefully and vertically slide the brake master cylinder assembly out of vacuum booster.
f. Remove the coupling bolt (arrow) between brake fluid
reservoir assembly and brake master cylinder
assembly.
(Tightening torque: 3 - 5 N·m)

RT21260140

g. Disengage the connection between brake fluid

reservoir assembly and brake master cylinder
assembly, and remove the brake fluid reservoir
assembly.

RT21260150

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CAUTION

 Brake master cylinder assembly and piston are designed to make piston fall out easily. To prevent this,
make sure brake master cylinder is horizontal or end surface downward (piston surface facing upward)
when handling the brake master cylinder assembly.
 Make sure that no foreign matter adheres to brake master cylinder assembly piston. If foreign matter
adheres, clean it off with a piece of clean cloth. Then, apply grease to entire outer edge contact surface
of master cylinder piston.
 Master cylinder should be handled carefully. Avoid any impact to the master cylinder, such as falling. The
fallen master cylinder cannot be reused.
 DO NOT tap or pinch master cylinder piston, and avoid damaging master cylinder piston in any other
ways.

Installation
Installation is in the reverse order of removal.

CAUTION

 Make sure to tighten coupling plugs and nuts to the specified torque during installation.
 Perform bleeding procedures for brake system and add brake fluid to the proper level after completing
installation.

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Vacuum Booster with Brake Master Cylinder Assembly

On-vehicle Inspection
1. Check vacuum booster assembly.
a. Air tightness check.
 Start engine and stop it after 1 or 2 minutes. Slowly depress brake pedal several times.
 Make sure that booster is airtight. Check that distance every time the pedal depressed is gradually
decreased compare to the previous operation.
If pedal operation is not as specified, check the check valve. If check valve is normal, replace the
vacuum booster assembly.
 Start engine. Depress and hold pedal, then stop engine.
 Make sure that booster is airtight. Depress and hold pedal for 30 seconds, and check that pedal
reserve distance does not change.
If pedal operation is not as specified, check the check valve. If check valve is normal, replace the
vacuum booster assembly.
b. Operation check.
 Stop engine.
 Depress pedal several times and check that pedal
reserve distance does not change.

RT21260160

 Depress and hold pedal, and then start engine.

Check that pedal can only be depressed lightly.
If pedal operation is not as specified, check the
check valve. If check valve is normal, replace the
vacuum booster assembly.

RT21260170

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Removal
1. Drain the brake fluid (See page 26-13).

CAUTION

 Wash off brake fluid immediately if it comes in contact with any paint surface.

ENVIRONMENTAL PROTECTION

 Drained brake fluid should be well kept in a container. Never discard it at will.

2. Remove the air filter assembly (See page 10-17).

3. Remove the vacuum booster with brake master cylinder assembly.
a. Loosen the brake fluid tube fixing clamp (arrow) and
disengage the brake fluid tube from brake fluid
reservoir assembly.

RT21260100

b. Loosen the clutch hose fixing clamp (arrow) and

disengage the clutch hose from brake fluid reservoir
assembly (for only MT model).

RT21260110

c. Loosen 2 coupling plugs (arrow) between brake

master cylinder assembly and brake pipes.
(Tightening torque: 16 ± 2 N·m)

RT21260120

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d. Disengage the vacuum hose assembly with check

valve (arrow) from vacuum booster assembly.

RT21260180

e. Using needle-nose pliers, remove the locking pin

(arrow) and pushrod pin (1) from vacuum booster
pushrod, and detach the brake pedal assembly.

RT21260190

f. Remove 4 coupling nuts (arrow) between vacuum

booster assembly and brake pedal assembly.
(Tightening torque: 25 ± 3 N·m)

RT21260200

g. Remove the vacuum booster with brake master

cylinder assembly from engine compartment.

RT21260210

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Inspection
1. Check the check valve.
a. Remove the check valve from vacuum hose assembly.
b. Check that there is airflow (A) from vacuum booster to
engine, and no airflow (B) from engine to vacuum A B
booster.
If result is not as specified, replace vacuum hose
assembly.

RT21260220

Installation
Installation is in the reverse order of removal.

CAUTION

 Make sure to tighten fixing plugs and nuts to the specified torque during installation.
 Perform bleeding procedures for brake system and add brake fluid to proper level after completing
installation.

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Brake Pedal Assembly

On-vehicle Inspection
1. Check brake pedal free play.
a. Stop engine. Depress brake pedal several times until no vacuum is left in vacuum booster, and then
release brake pedal.
b. Depress brake pedal until resistance is felt.
c. As shown in the illustration, check the brake pedal
free play by measuring distance between pedal
position in above step and pedal position when it is
released.
Standard brake pedal free play: 1 - 9 mm

Pedal Free Play

RT21260230

2. Adjust brake pedal free play.

a. As shown in the illustration, loosen the vacuum booster
pushrod locking nut (arrow) and rotate the vacuum
booster pushrod clockwise or counterclockwise to
adjust the brake pedal free play to the specified value.

RT21260240

3. Check brake pedal height.

a. As shown in the illustration, turn over the carpet and
measure distance between brake pedal center and
dash panel, which is the brake pedal height.
Standard brake pedal height: 176 - 186 mm

Pedal Height
RT21260250

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4. Adjust brake pedal height.

a. As shown in the illustration, loosen the vacuum booster
pushrod locking nut (arrow) and rotate the vacuum
booster pushrod clockwise or counterclockwise to
adjust brake height to the specified value.

RT21260240

Removal
1. Remove the brake light switch assembly.
a. Disconnect the brake light switch assembly wire
harness connector (arrow).

RT21260260

b. Remove the brake light switch assembly by rotating it

90° clockwise or counterclockwise.

RT21260270

2. Remove the brake pedal assembly.

a. Using needle-nose pliers, remove the locking pin
(arrow) and pushrod pin (1) from vacuum booster
pushrod, and detach the brake pedal assembly.

RT21260190

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b. Remove 4 coupling nuts (arrow) between vacuum

booster assembly and brake pedal assembly.
(Tightening torque: 25 ± 3 N·m)

RT21260200

c. Remove 2 coupling nuts (arrow) between brake pedal

assembly and body.
(Tightening torque: 25 ± 3 N·m)

RT21260280

d. Remove the brake pedal assembly from the inside of

vehicle.

RT21260290

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Inspection
1. Check brake light switch assembly.
a. Using ohm band of digital multimeter, check for
continuity between brake light switch assembly
+ -
terminals according to the table below. 1 2
Standard Condition 3 4

Multimeter Switch Specified

Connection Condition Condition
Brake pedal
Terminal 1 -
depressed (switch Continuity
Terminal 3
pin released) RT21260300

Brake pedal
Terminal 2 -
depressed (switch No continuity
Terminal 4
pin released)
Brake pedal
Terminal 1 -
released (switch No continuity
Terminal 3
pin pushed)
Brake pedal
Terminal 2 -
released (switch Continuity
Terminal 4
pin pushed)

If result is not as specified, replace brake light switch

assembly.

Installation
Installation is in the reverse order of removal.

CAUTION

 Make sure to tighten fixing nuts to the specified torque during installation.
 Check that brake light operates properly after completing installation.

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Front Disc Brake Assembly

1
2
3
4

5 8
14 6
7 9

13

10
11

12

RT21260310

1 - Brake Caliper Locating Bolt 2 - Brake Caliper Locating Bolt Guide Pin
3 - Brake Caliper Guide Pin Rubber Dust Boot 4 - Front Disc Brake Cylinder
5 - Front Disc Brake Piston Seal Ring 6 - Front Disc Brake Piston
7 - Front Disc Brake Piston Dust Boot 8 - Front Disc Brake Caliper Fixing Bracket
9 - Upper Support Gasket 10 - Inner Brake Lining
11 - Outer Brake Lining 12 - Lower Support Gasket
13 - Bleeder Plug 14 - Bleeder Plug Cap

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On-vehicle Inspection
1. Check brake disc runout.
a. Remove the front wheel (See page 24-9).
b. Secure the dial indicator (1) to the proper position.
Position the dial indicator pointer approximately 10 2
mm from the outer edge of brake disc.
c. Slowly rotate the brake disc (2) and check the runout.
Mark the lowest and highest points and record these
measurements.

RT21260320

d. Check the runout on the opposite side of brake disc in the same way. Mark the lowest and highest
points and record these measurements.
e. Compare the recorded runout value and limit value.
Maximum runout for front brake disc: 0.06 mm
f. If runout exceeds the maximum value, replace the brake disc.

Removal
HINT:
 Use the same procedures for the right side and left side.
 Procedures listed below are for the left side.
1. Drain the brake fluid (See page 26-13).

CAUTION

 Wash off brake fluid immediately if it comes in contact with any paint surface.

ENVIRONMENTAL PROTECTION

 Drained brake fluid should be well kept in a container. Never discard it at will.

2. Remove the front left wheel (See page 24-9).

3. Remove the front left brake caliper assembly.
a. Remove the coupling bolt and washer (arrow)
between front left brake caliper assembly and front left
brake hose assembly.
(Tightening torque: 27 ± 2 N·m)

26 RT21260330

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CAUTION

 DO NOT allow brake fluid to be sprayed on your clothes or skin when removing brake hose, as brake
fluid is corrosive.

b. Remove the coupling bolts (arrow) between front left

brake caliper assembly and front left steering knuckle.
(Tightening torque: 100 ± 10 N·m)

RT21260340

c. Remove the front left brake caliper assembly.

4. Remove the front left brake disc.
a. Remove 2 positioning screws (arrow) from front left
brake disc, and remove the front left brake disc.
(Tightening torque: 10 ± 1 N·m)

RT21260350

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Disassembly
HINT:
 Use the same procedures for the right side and left side.
 Procedures listed below are for the left side.

WARNING

 Never use high pressure when removing piston from the bore of brake caliper. Otherwise this may cause
personal injuries.
 If it is needed to remove piston with compressed air. DO NOT face the piston to yourself or place your
hands around the brake caliper and piston.

1. Remove the bleeder plug (w/ bleeder plug cap).

a. Remove the bleeder plug (w/ bleeder plug cap)
(arrow) from brake caliper assembly.

RT21260360

2. Remove the brake cylinder assembly.

a. Remove 2 locating bolts (arrow) between brake
caliper fixing bracket and brake cylinder assembly.

RT21260370

b. Detach the brake cylinder assembly and brake caliper fixing bracket.
3. Remove the front brake caliper locating bolt guide pin (w/ dust boot).
a. Remove 2 brake caliper locating bolt guide pins (w/
dust boot) (arrow) from brake caliper fixing bracket.

26 RT21260380

26–30 Chery Automobile Co., Ltd.

 26 - BRAKE

4. Remove the front brake lining.

a. Remove the inner brake lining and outer brake lining
(arrow) from brake caliper fixing bracket.

RT21260390

5. Remove the brake lining support gasket.

a. Remove 2 brake lining support gaskets (arrow) from
brake caliper fixing bracket.

RT21260400

6. Remove the brake cylinder dust boot.

a. Using a flat tip screwdriver wrapped with protective
tape, pry out the dust boots (arrow) on both sides
carefully.

RT21260410

CAUTION

 Be careful not to damage brake piston and brake cylinder.

26

Chery Automobile Co., Ltd. 26–31

 26 - BRAKE

7. Remove the front disc brake piston.

a. Place a wooden board (1) between front disc brake
piston and front disc brake cylinder.
1
b. Use compressed air (2) to carefully press out the
piston from front disc brake cylinder through the
attachment hole.
2

RT21260420

CAUTION

 Be careful not to splash brake fluid.

 DO NOT hold piston by hands to prevent injury.
 DO NOT remove or install brake piston casually, and always perform these operations by professional.

c. Clean the piston bore with alcohol or proper solution. Then wipe it with a piece of lint.
8. Remove the front disc brake piston seal ring.
a. Using a screwdriver wrapped with protective tape,
carefully pry out the seal rings (arrow) on both sides of
front disc brake piston from brake cylinder rear ring
groove.

RT21260430

Inspection
1. Check brake cylinder and piston.
a. Check piston and bore for scratches or corrosion. If there are scratches or corrosion, remove them with
fine sand cloth.
b. Remove dirt on piston with a soft brass wire brush and coarse cloth. Do not clean the piston with
polishing cloth or sand cloth, as this may damage its surface. If surface of piston is damaged, replace it.
If piston is stuck or bore is worn or corroded, replace entire brake caliper assembly. Use polishing cloth
to remove small corrosion points inside the bore.
2. Check brake caliper fixing bracket and brake caliper guide pin set.
a. Clean the contact surface of brake caliper fixing bracket and brake lining support gasket with brake
cleaner. Check for deformation, cracks, rust and foreign matter which is difficult to remove.
b. Check brake caliper guide pin rubber dust boot for deformation, cracks, worn and foreign matter which
is difficult to remove.
c. Install brake caliper guide pin and brake caliper guide pin rubber dust boot to brake caliper fixing
bracket. The brake caliper guide pin set should move smoothly without being stuck when pushing it with
26 hand; otherwise replace it.
d. After installing the brake lining, check if it is easy to fall out (due to insufficient elasticity of support
gasket). Replace as necessary.

26–32 Chery Automobile Co., Ltd.

 26 - BRAKE

3. Check brake lining.

a. Visually check brake lining for flatness, and also check for excessive wear. If condition of lining cannot
be confirmed accurately only by visual inspection, a physical check will be used as necessary.
b. Measure the minimum brake lining thickness. When
the minimum thickness of brake lining is 2 mm or less,
replace the brake lining.

RT21260440

c. When replacing excessively worn brake linings (inner and outer), it is also necessary to replace linings
on the opposite side of vehicle as well as unchecked linings to maintain proper braking performance. If
it is unnecessary to replace brake linings, be sure to reinstall brake linings to the original positions.
4. Check brake disc.
a. Minor scratch or wear on brake disc surface is acceptable. If severe scratch or deformation exists, the
brake disc must be replaced.
b. Excessive wear of brake disc may cause poor contact between brake lining and surface of brake disc. If
protrusion on the disc is not removed before installing new brake lining, abnormal wear of brake disc
will be caused.
c. It is normal that the surface of brake disc is worn when replacing brake lining. If cracks or burned spots
exist, the brake disc must be replaced.
5. Check brake disc thickness.
a. Using a vernier caliper, measure the brake disc
thickness at the center of brake lining contact surface
as shown in the illustration.
Standard thickness: 25 mm
Minimum thickness: 23 mm

RT21260450

b. If it is less than the minimum thickness due to wear of brake disc, replace brake disc.

CAUTION

 DO NOT machine brake disc, because it may make the brake disc thickness less than the minimum
thickness.

26

Chery Automobile Co., Ltd. 26–33

 26 - BRAKE

Assembly
HINT:
 Use the same procedures for the right side and left side.
 Procedures listed below are for the left side.

CAUTION

 When assembling brake caliper assembly, always keep your hands clean.
 When assembling brake caliper assembly, always use clean new brake fluid.
 Never use old seal ring for front disc brake piston.

1. Install the front disc brake piston seal ring.

a. Apply a light coat of grease to entire inner and outer
circumferences of new front disc brake piston seal
ring.
b. Install the front disc brake piston seal ring onto the
brake cylinder.

Grease RT21260460

CAUTION

 Securely install front disc brake piston seal ring into the rear ring groove of brake cylinder.

2. Install the front disc brake piston.

a. Apply a light coat of grease to the inner and outer
circumferences, and entire periphery of outer flange
top/bottom surfaces of new brake cylinder dust boot
as shown in the illustration.
b. Apply a light coat of grease to the entire outer
circumference (part contacting with the brake cylinder
dust boot and front disc brake cylinder) of front disc
brake piston.

Grease
RT21260470

c. Install the brake cylinder dust boot onto the front disc brake piston.
3. Install the brake cylinder dust boot.
a. Install the front disc brake piston to the front disc brake cylinder.

CAUTION

26  DO NOT install piston forcibly to brake cylinder.

26–34 Chery Automobile Co., Ltd.

 26 - BRAKE

b. Install the brake cylinder dust boot to the brake

cylinder.

RT21260480

CAUTION

 Securely install brake cylinder dust boots into front ring grooves (both sides) of disc brake cylinder.
 DO NOT damage brake cylinder dust boot.

4. Install the brake lining support gasket.

a. Securely install the upper and lower support gaskets
(arrow) onto the brake caliper fixing bracket.

RT21260400

5. Install the front brake lining.

a. Securely install the inner brake lining and outer brake
lining (arrow) onto the brake caliper fixing bracket.
Make sure they are clamped in place.

RT21260390

CAUTION

 Make sure the contact surface of lining and brake disc is free of oil and grease.

26

Chery Automobile Co., Ltd. 26–35

 26 - BRAKE

6. Install the front brake caliper locating bolt guide pin (w/ dust boot).
a. Apply a small amount of grease to the contact surface
between locating bolt guide pins and guide pin rubber
dust boots, and securely install the dust boots (arrow)
to the brake caliper fixing bracket.

RT21260380

7. Install the brake cylinder assembly.

a. Using brake cylinder piston pressing tool, slightly
retract the brake cylinder piston (both sides).

RT21260490

b. Align the brake caliper locating bolts (arrow) with the

guide pin hole and securely install the brake cylinder
assembly.
(Tightening torque: 25 ± 3 N·m)

RT21260370

8. Install the bleeder plug (w/ bleeder plug cap).

a. Securely install the bleeder plug (w/ bleeder plug cap)
(arrow) to the front brake caliper assembly.
(Tightening torque: 9 - 11 N·m)

RT21260360

26

26–36 Chery Automobile Co., Ltd.

 26 - BRAKE

Installation
Installation is in the reverse order of removal.

CAUTION

 Make sure to tighten fixing bolts and nuts to the specified torque during installation.
 Before installing brake linings, completely retract brake caliper piston back into the bore of brake caliper.
 Depress brake pedal several times to secure the brake linings to brake disc in order to ensure safety
after installing the brake linings and before moving vehicle.
 Replace brake linings in pairs. DO NOT replace it alone.
 DO NOT install inner brake lining and outer brake lining reversely.
 Be sure to check brake system for leakage after installation. Repair or replace malfunctioning parts as
necessary.
 Be sure to perform bleeding procedures for brake system after installation.
 Be sure to add brake fluid to the proper level after installation.

26

Chery Automobile Co., Ltd. 26–37

 26 - BRAKE

Front Brake Hose Assembly

Removal

CAUTION

 Be sure to wear necessary safety equipment to prevent accidents when repairing.

 Try to prevent body paint surface from being scratched during removal and installation.

HINT:
 Use the same procedures for the right side and left side.
 Procedures listed below are for the left side.
1. Remove the front left wheel (See page 24-9).
2. Drain the brake fluid (See page 26-13).

CAUTION

 Wash off brake fluid immediately if it comes in contact with any paint surface.

ENVIRONMENTAL PROTECTION

 Drained brake fluid should be well kept in a container. Never discard it at will.

3. Remove the front left brake hose assembly.

a. Disengage the fixing clamp (arrow) and loosen the
coupling plug (1) between front left brake hose
assembly and front left brake pipe.
1
(Tightening torque: 16 ± 2 N·m)

RT21260500

CAUTION

 DO NOT bend or damage brake tube.

 DO NOT allow any foreign matter such as dirt and dust to enter brake tube from joint parts.
 After removing brake line, perform sealing treatment to prevent foreign matter from entering.

26

26–38 Chery Automobile Co., Ltd.

 26 - BRAKE

b. Remove the front left brake hose assembly (arrow)

from front left shock absorber assembly.

RT21260510

c. Remove the coupling bolt and washer (arrow)

between front left brake caliper assembly and front left
brake hose assembly.
(Tightening torque: 27 ± 2 N·m)

RT21260330

CAUTION

 DO NOT allow brake fluid to be sprayed on your clothes or skin when removing brake hose, as the brake
fluid is corrosive.

d. Remove the front left brake hose assembly.

Installation
Installation is in the reverse order of removal.

CAUTION

 Make sure to tighten coupling bolts and plug to the specified torque during installation.
 Be sure to check brake system for leakage after installation. Repair or replace malfunctioning parts as
necessary.
 Be sure to perform bleeding procedures for brake system after installation.
 Be sure to add brake fluid to the proper level after installation.

26

Chery Automobile Co., Ltd. 26–39

 26 - BRAKE

Rear Disc Brake Assembly

5
6
2 3
7

9
10

12
11

RT21260520

1 - Support Gasket 2 - Outer Brake Lining

3 - Inner Brake Lining 4 - Rear Disc Brake Caliper Fixing Bracket
5 - Rear Disc Brake Piston Dust Boot 6 - Rear Disc Brake Piston
7 - Rear Disc Brake Piston Seal Ring 8 - Rear Brake Cylinder
9 - Brake Caliper Locating Bolt Guide Pin (w/ Dust 10 - Brake Caliper Locating Bolt
Boot)
11 - Bleeder Plug 12 - Bleeder Plug Cap

26

26–40 Chery Automobile Co., Ltd.

 26 - BRAKE

On-vehicle Inspection
1. Check brake disc runout.
a. Remove the rear wheel (See page 24-9).
b. Secure the dial indicator (1) to the proper position.
Position the dial indicator pointer approximately 10
mm from the outer edge of rear brake disc. 2

c. Slowly rotate the brake disc (2) and check the runout.
Mark the lowest and highest points and record these 1
measurements.

RT21260530

d. Check the runout on the opposite side of brake disc in the same way. Mark the lowest and highest
points and record these measurements.
e. Compare the recorded runout value and limit value.
Maximum runout for front brake disc: 0.06 mm
f. If the runout exceeds the maximum value, replace the brake disc.

Removal
HINT:
 Use the same procedures for the right side and left side.
 Procedures listed below are for the left side.
1. Drain the brake fluid (See page 26-13).

CAUTION

 Wash off brake fluid immediately if it comes in contact with any paint surface.

ENVIRONMENTAL PROTECTION

 Drained brake fluid should be well kept in a container. Never discard it at will.

2. Remove the rear left wheel (See page 24-9).

3. Remove the rear left brake caliper assembly.
a. Remove the coupling bolt and washer (arrow)
between rear left brake caliper assembly and rear left
brake hose assembly.
(Tightening torque: 20 ± 2 N·m)

RT21260540 26

Chery Automobile Co., Ltd. 26–41

 26 - BRAKE

CAUTION

 DO NOT allow brake fluid to be sprayed on your clothes or skin when removing brake hose, as the brake
fluid is corrosive.

b. Remove the coupling bolts (arrow) between rear left

brake caliper assembly and rear left brake bottom
board assembly.
(Tightening torque: 100 ± 10 N·m)

RT21260550

c. Remove the rear left brake caliper assembly.

4. Remove the rear left brake disc.
a. Remove the positioning screw (arrow) from rear left
brake disc, and remove the rear left brake disc. 
(Tightening torque: 10 ± 1 N·m)

RT21260560

Disassembly
HINT:
 Use the same procedures for the right side and left side.
 Procedures listed below are for the left side.

WARNING

 Never use high pressure when removing piston from the bore of brake caliper. Otherwise this may cause
personal injuries.
 If it is needed to remove piston with compressed air. DO NOT allow the piston to face yourself or place
your hands around the brake caliper and piston.

26

26–42 Chery Automobile Co., Ltd.

 26 - BRAKE

1. Remove the bleeder plug (w/ bleeder plug cap).

a. Remove the bleeder plug (w/ bleeder plug cap)
(arrow) from brake caliper assembly.

RT21260570

2. Remove the brake cylinder assembly.

a. Remove 2 locating bolts (arrow) between brake
caliper fixing bracket and brake cylinder assembly.

RT21260580

b. Detach the brake cylinder assembly and brake caliper fixing bracket.
3. Remove the rear brake caliper locating bolt guide pin (w/ dust boot).
a. Remove 2 brake caliper locating bolt guide pins (w/
dust boot) (arrow) from brake caliper fixing bracket.

RT21260590

4. Remove the rear brake lining.

a. Remove the inner brake lining and outer brake lining
(arrow) from brake caliper fixing bracket.

RT21260600

26

Chery Automobile Co., Ltd. 26–43

 26 - BRAKE

5. Remove the brake lining support gasket.

a. Remove 2 brake lining support gaskets (arrow) from
brake caliper fixing bracket.

RT21260610

6. Remove the brake cylinder dust boot.

a. Using a flat tip screwdriver wrapped with protective
tape, pry out the dust boot carefully.

RT21260620

CAUTION

 Be careful not to damage brake piston and brake cylinder.

7. Remove the rear disc brake piston.

a. Place a wooden board (1) between rear disc brake
piston and rear disc brake cylinder.
b. Use compressed air (2) to carefully press out the 1
piston from rear disc brake cylinder through the
attachment hole.

RT21260630

CAUTION

 Be careful not to splash brake fluid.

 DO NOT hold piston by hands to prevent injury.
 DO NOT remove or install brake piston casually, and always perform these operations by professional.

26
c. Clean the piston bore with alcohol or proper solution. Then wipe it with a piece of lint.

26–44 Chery Automobile Co., Ltd.

 26 - BRAKE

8. Remove the rear disc brake piston seal ring.

a. Using a screwdriver wrapped with protective tape,
carefully pry out the rear disc brake piston seal ring
(arrow) from brake cylinder rear ring groove.

RT21260640

Inspection
1. Check brake cylinder and the piston.
a. Check piston and bore for scratches or corrosion. If there are scratches or corrosion, remove them with
fine sand cloth.
b. Remove dirt on piston with a soft brass wire brush and coarse cloth. Do not clean the piston with
polishing cloth or sand cloth, as this may damage its surface. If surface of piston is damaged, replace it.
If piston is stuck or bore is worn or corroded, replace entire brake caliper assembly. Using polishing
cloth to remove small corrosion points inside the bore.
2. Check brake caliper fixing bracket and brake caliper guide pin set.
a. Clean the contact surface of brake caliper fixing bracket and brake lining support gasket with brake
cleaner. Check for deformation, cracks, rust and foreign matter which is difficult to remove.
b. Check brake caliper guide pin rubber dust boot for deformation, cracks, worn and foreign matter which
is difficult to remove.
c. Install brake caliper guide pin and brake caliper guide pin rubber dust boot to brake caliper fixing
bracket. The brake caliper guide pin set should move smoothly without being stuck when pushing it with
hand; otherwise replace it.
d. After installing the brake lining, check if it is easy to fall out (due to insufficient elasticity of support
gasket). Replace as necessary.
3. Check brake lining.
a. Visually check brake lining for flatness, and also check for excessive wear. If condition of lining cannot
be confirmed accurately only by visual inspection, a physical check will be used as necessary.
b. Measure the minimum brake lining thickness. When
the minimum thickness of brake lining is 2 mm or less,
replace the brake lining.

RT21260650

c. When replacing excessively worn brake linings (inner and outer), it is also necessary to replace linings
on the opposite side of vehicle as well as unchecked linings to maintain proper braking performance. If
it is unnecessary to replace brake linings, be sure to reinstall brake linings to the original positions.
4. Check brake disc.
a. Minor scratch or wear on brake disc surface is acceptable. If severe scratch or deformation exists, the 26
brake disc must be replaced.

Chery Automobile Co., Ltd. 26–45

 26 - BRAKE

b. Excessive wear of brake disc may cause poor contact between brake lining and surface of brake disc. If
protrusion on the disc is not removed before installing new brake lining, abnormal wear of brake disc
will be caused.
c. It is normal that the surface of brake disc is worn when replacing brake lining. If cracks or burned spots
exist, the brake disc must be replaced.
5. Check brake disc thickness.
a. Using a vernier caliper, measure the brake disc
thickness at the center of brake lining contact surface
as shown in the illustration.
Standard thickness: 10 mm
Minimum thickness: 8 mm

RT21260660

b. If it is less than the minimum thickness due to wear of brake disc, replace brake disc.

CAUTION

 DO NOT machine brake disc, because it may make the brake disc thickness less than the minimum
thickness.

Assembly
HINT:
 Use the same procedures for the right side and left side.
 Procedures listed below are for the left side.

CAUTION

 When assembling brake caliper assembly, always keep your hands clean.
 When assembling brake caliper assembly, always use clean new brake fluid.
 Never use old seal ring for front disc brake piston.

1. Install the rear disc brake piston seal ring.

a. Apply a light coat of grease to entire inner and outer
circumferences of new rear disc brake piston seal
ring.
b. Install the rear disc brake piston seal ring onto the
brake cylinder.

Grease RT21260670

26

26–46 Chery Automobile Co., Ltd.

 26 - BRAKE

CAUTION

 Securely install rear disc brake piston seal ring into the rear ring groove of brake cylinder.

2. Install the rear disc brake piston.

a. Apply a light coat of grease to the inner and outer
circumferences, and entire periphery of outer flange
top/bottom surfaces of new brake cylinder dust boot
as shown in the illustration.
b. Apply a light coat of grease to the entire outer
circumference (part contacting with the brake cylinder
dust boot and rear disc brake cylinder) of the rear disc
brake piston.

Grease
RT21260470

c. Install the brake cylinder dust boot onto the rear disc brake piston.
3. Install the brake cylinder dust boot.
a. Install the rear disc brake piston to the rear disc brake cylinder.

CAUTION

 DO NOT install piston forcibly to brake cylinder.

b. Install the brake cylinder dust boot to the brake

cylinder.

RT21260680

CAUTION

 Securely install brake cylinder dust boot into front ring groove of disc brake cylinder.
 DO NOT damage brake cylinder dust boot.

26

Chery Automobile Co., Ltd. 26–47

 26 - BRAKE

4. Install the brake lining support gasket.

a. Securely install the upper and lower support gaskets
onto the brake caliper fixing bracket.

RT21260610

5. Install the rear brake lining.

a. Securely install the inner brake lining and outer brake
lining (arrow) onto the brake caliper fixing bracket.
Make sure they are clamped in place.

RT21260600

CAUTION

 Make sure the contact surface of lining and brake disc is free of oil and grease.

26

26–48 Chery Automobile Co., Ltd.

 26 - BRAKE

6. Install the rear brake caliper locating bolt guide pin (w/ dust boot).
a. Apply a small amount of grease to the contact surface
between locating bolt guide pins and guide pin rubber
dust boots, and securely install the dust boots to the
brake caliper fixing bracket.

RT21260590

7. Install the brake cylinder assembly.

a. Using brake cylinder piston pressing tool, slightly
retract the brake cylinder piston (both sides).

RT21260690

b. Align the brake caliper locating bolts (arrow) with the

guide pin hole and securely install the brake cylinder
assembly.
(Tightening torque: 25 ± 3 N·m)

RT21260580

8. Install the bleeder plug (w/ bleeder plug cap).

a. Securely install the bleeder plug (w/ bleeder plug cap)
(arrow) to the rear brake caliper assembly.
(Tightening torque: 9 - 11 N·m)

RT21260570

26

Chery Automobile Co., Ltd. 26–49

 26 - BRAKE

Installation
Installation is in the reverse order of removal.

CAUTION

 Make sure to tighten fixing bolts and nuts to the specified torque during installation.
 Before installing brake linings, completely retract brake caliper piston back into the bore of brake caliper.
 Depress brake pedal several times to secure the brake linings to brake disc in order to ensure safety
after installing the brake linings and before moving vehicle.
 Replace brake linings in pairs. DO NOT replace it alone.
 DO NOT install inner brake lining and outer brake lining reversely.
 Be sure to check brake system for leakage after installation. Repair or replace malfunctioning parts as
necessary.
 Be sure to perform bleeding procedures for brake system after installation.
 Be sure to add brake fluid to the proper level after installation.

26

26–50 Chery Automobile Co., Ltd.

 26 - BRAKE

Rear Brake Hose Assembly

Removal

CAUTION

 Be sure to wear necessary safety equipment to prevent accidents when repairing.

 Try to prevent body paint surface from being scratched during removal and installation.

HINT:
 Use the same procedures for the right side and left side.
 Procedures listed below are for the left side.
1. Drain the brake fluid (See page 26-13).

CAUTION

 Wash off brake fluid immediately if it comes in contact with any paint surface.

ENVIRONMENTAL PROTECTION

 Drained brake fluid should be well kept in a container. Never discard it at will.

2. Remove the rear left brake hose assembly.

a. Remove the coupling bolt and washer (arrow)
between rear left brake caliper assembly and rear left
brake hose assembly.
(Tightening torque: 20 ± 2 N·m)

RT21260540

CAUTION

 DO NOT allow brake fluid to be sprayed on your clothes or skin when removing brake hose, as the brake
fluid is corrosive.

26

Chery Automobile Co., Ltd. 26–51

 26 - BRAKE

b. Disengage the fixing clamp (arrow) and loosen the

coupling plug (1) between rear brake hose assembly
and brake pipe.
(Tightening torque: 16 ± 2 N·m)
1

RT21260700

CAUTION

 DO NOT bend or damage brake tube.

 DO NOT allow any foreign matter such as dirt and dust to enter brake tube from joint parts.
 After removing brake line, perform sealing treatment to prevent foreign matter from entering.

c. Remove the rear brake hose assembly.

Installation
Installation is in the reverse order of removal.

CAUTION

 Make sure to tighten bolt and plug in place.

 Be sure to check brake system for leakage after installation. Repair or replace malfunctioning parts as
necessary.
 Be sure to perform bleeding procedures for brake system after installation.
 Be sure to add brake fluid to the proper level after installation.

26

26–52 Chery Automobile Co., Ltd.