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Brake system introduction for maintenance.pdf

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BRAKE SYSTEM INTRODUCTION FOR MAINTENANCE
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BRAKE – BRAKE SYSTEM BR–1 BR BRAKE SYSTEM PRECAUTION 1. Necessary care must be taken to replace each part properly as it could affect the brake system performance. This could cause driving hazards. Replace each part with an identical part with the same number. 2. It is very important to keep parts and the area clean when repairing the brake system. 3. If the vehicle is equipped with a mobile communication system, refer to the precautions in the INTRODUCTION section.BR–2 BRAKE – BRAKE SYSTEM BR SYSTEM DIAGRAM A A A A A A A A A A A A A A A A B B Brake Tube Flexible Hose A B Union Bolt Torque: 30 N*m (310 kgf*cm, 22 ft*lbf) w/ ABS: Brake Tube Way BRAKE MASTER CYLINDER BRAKE ACTUATOR for use without SST: Union Nut Torque: 15 N*m (155 kgf*cm, 11 ft*lbf) for use with SST: Union Nut Torque: 14 N*m (143 kgf*cm, 10 ft*lbf) A A AA C130323E03BRAKE – BRAKE SYSTEM BR–3 BR w/o ABS: BRAKE MASTER CYLINDER BRAKE TUBE WAY PROPORTIONING VALVE Brake Tube Flexible Hose Brake Tube Way for use without SST: Union Nut Torque: 15 N*m (155 kgf*cm, 11 ft*lbf) for use with SST: Union Nut Torque: 14 N*m (143 kgf*cm, 10 ft*lbf) Union Bolt Torque: 30 N*m (310 kgf*cm, 22 ft*lbf) A B B A A A A A A A A A A A A A A A A A A A A A A B C133161E01BR–4 BRAKE – BRAKE SYSTEM BR PROBLEM SYMPTOMS TABLE HINT: Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in the order suggested. If necessary, replace the applicable parts. Symptom Suspected area See page Low pedal or spongy pedal 1. Fluid leakage in brake system - 2. Air in brake system BR-10 3. Piston seal (Worn or damaged) BR-50 4. Wheel cylinder cup (Damaged) BR-62 5. Brake master cylinder (Faulty) BR-29 Brake drag 1. Brake pedal free play (Minimum) BR-8 2. Parking brake lever travel (Out of adjustment) PB-2 3. Rear drum brake shoe clearance (Out of adjustment) BR-67 4. Pad (Cracked or distorted) BR-51 5. Brake shoe (Cracked or distorted) BR-62 6. Front disc brake piston (Stuck) BR-50 7. Piston (Stuck) BR-62 8. Front disc brake piston (Frozen) BR-50 9. Piston (Frozen) BR-62 10. Tension or return spring (Faulty) BR-60 11. Booster system (Vacuum leakage) BR-5 12. Brake master cylinder (Faulty) BR-29 Brake pull 1. Front disc brake piston (Stuck) BR-50 2. Piston (Stuck) BR-62 3. Pad (Oily) BR-51 4. Brake shoe (Oily) BR-62 5. Front disc brake piston (Frozen) BR-50 6. Piston (Frozen) BR-62 7. Front disc (Scored) BR-51 8. Rear brake drum (Scored) BR-62 9. Pad (Cracked or distorted) BR-51 10. Brake shoe (Cracked or distorted) BR-62 Hard pedal but braking inefficient 1. Fluid leakage in brake system - 2. Air in brake system BR-10 3. Front disc brake piston (Stuck) BR-50 4. Piston (Stuck) BR-62 5. Pad (Cracked or distorted) BR-51 6. Brake shoe (Cracked or distorted) BR-62 7. Pad (Oily) BR-51 8. Brake shoe (Oily) BR-62 9. Pad (Glazed) BR-51 10. Brake shoe (Glazed) BR-62 11. Front disc (Scored) BR-51 12. Rear brake drum (Scored) BR-62 13. Booster system (Vacuum leakage) BR-5BRAKE – BRAKE SYSTEM BR–5 BR ON-VEHICLE INSPECTION 1. INSPECT BRAKE BOOSTER (a) Check the air tightness. (1) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. HINT: ? If the pedal can be depressed to the floor on the 1st time, but cannot be depressed as far on the 2nd or 3rd times, the booster is airtight. If not, inspect the vacuum check valve. ? If the vacuum check valve is normal, replace the brake booster assembly. (2) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. HINT: ? If there is no change in the pedal reserve distance after holding the pedal for 30 seconds, the booster is airtight. If not, inspect the vacuum check valve. ? If the vacuum check valve is normal, replace the brake booster assembly. (b) Check the operation. (1) Depress the brake pedal several times with the engine stopped and check that there is no change in the pedal reserve distance. (2) Depress the brake pedal and start the engine. HINT: ? If the pedal goes down slightly, the operation is normal. If not, inspect the vacuum check valve. ? If the vacuum check valve is normal, replace the brake booster assembly. Noise from brakes 1. Pad (Cracked or distorted) BR-51 2. Brake shoe (Cracked or distorted) BR-62 3. Installation bolt (Loose) BR-48 4. Front disc (Scored) BR-51 5. Rear brake drum (Scored) BR-62 6. Pad support plate (Loose) BR-51 7. Sliding pin (Worn) BR-48 8. Pad (Dirty) BR-51 9. Brake shoe (Dirty) BR-62 10. Pad (Glazed) BR-51 11. Brake shoe (Glazed) BR-62 12. Tension or return spring (Faulty) BR-60 13. Anti-squeal shim (Damaged) BR-48 14. Shoe hold down spring (Damaged) BR-60 Symptom Suspected area See page NO GOOD GOOD 3rd 2nd 1st BR02238E02 C121844BR–6 BRAKE – BRAKE SYSTEM BR 2. INSPECT VACUUM CHECK VALVE (a) Check the vacuum check valve. (1) Slide the clip and disconnect the vacuum hose. (2) Remove the vacuum check valve from the brake booster. (3) Check that there is ventilation from the booster to the engine, and no ventilation from the engine to the booster. If any fault is found, replace the vacuum hose assembly. (4) Install the vacuum check valve onto the brake booster. (5) Connect the vacuum hose with the clip. 3. INSPECT PROPORTIONING VALVE (w/o ABS) (a) Remove the bleeder plug from the front brake caliper and rear wheel cylinder. (b) for Hatchback: (1) Install SST and the bleed the air. SST 09709-29018 (2) Raise the front brake caliper pressure and inspect the rear wheel cylinder pressure. Standard fluid pressure Ventilation No Ventilation C099180E01 SST SST SST SST C121838E01 Front Brake Caliper Pressure Rear Wheel Cylinder Pressure 1,500 kPa (15.3 kgf/cm 2 , 218 psi) 1,500 kPa (15.3 kgf/cm 2 , 218 psi) 5,000 kPa (51.0 kgf/cm 2 , 725 psi) 2,350 kPa (24.0 kgf/cm 2 , 341 psi)BRAKE – BRAKE SYSTEM BR–7 BR HINT: When inspecting the fluid pressure, inspect the left front and right rear together, and the right front and left rear together. If the rear wheel cylinder pressure is incorrect, replace the proportioning valve. (3) Remove SST. (c) for Sedan: (1) Install SST and the bleed the air. SST 09709-29018 (2) Raise the front brake caliper pressure and inspect the rear wheel cylinder pressure. Standard fluid pressure HINT: When inspecting the fluid pressure, inspect the left front and right rear together, and the right front and left rear together. 8,000 kPa (81.6 kgf/cm 2 , 1,160 psi) 3,100 kPa (31.6 kgf/cm 2 , 450 psi) Front Brake Caliper Pressure Rear Wheel Cylinder Pressure SST SST SST SST C133122E01 Front Brake Caliper Pressure Rear Wheel Cylinder Pressure 1,500 kPa (15.3 kgf/cm 2 , 218 psi) 1,500 kPa (15.3 kgf/cm 2 , 218 psi) 5,000 kPa (51.0 kgf/cm 2 , 725 psi) 2,350 kPa (24.0 kgf/cm 2 , 341 psi) 8,000 kPa (81.6 kgf/cm 2 , 1,160 psi) 3,100 kPa (31.6 kgf/cm 2 , 450 psi)BR–8 BRAKE – BRAKE SYSTEM BR If the rear wheel cylinder pressure is incorrect, replace the proportioning valve. (3) Remove SST. (d) Install the bleeder plug onto the front brake caliper and rear wheel cylinder. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) (e) Bleed the brake fluid (See page BR-10). (f) Check the brake fluid leakage.BRAKE – BRAKE SYSTEM BR–9 BR ADJUSTMENT 1. REMOVE INSTRUMENT PANEL UNDER COVER SUB- ASSEMBLY Hatchback: (See page IP-67) Sedan: (See page IP-44) 2. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Hatchback: (See page IP-69) Sedan: (See page IP-45) 3. INSPECT AND ADJUST BRAKE PEDAL (a) Inspect the brake pedal height. Pedal height from floor If the pedal height is incorrect, adjust it. (b) Adjust the brake pedal height. (1) Disconnect the connector from the stop light switch. (2) Turn the stop light switch counterclockwise, and remove the stop light switch. (3) Loosen the push rod lock nut. (4) Adjust the pedal height by turning the pedal push rod. Pedal height from floor (5) Tighten the push rod lock nut. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) (6) Insert the stop light switch into the adjuster until it just touches the brake pedal. NOTICE: Do not depress the brake pedal. (7) Make a quarter turn clockwise to install the stop light switch. NOTICE: Do not depress the brake pedal. HINT: The turning torque for installing the stop light switch: Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less Stop Light Switch Push Rod Push Rod Lock Nut Pedal Height C116874E01 w/ ABS w/o ABS 107.3 to 117.3 mm (4.224 to 4.618 in.) 107.8 to 117.8 mm (4.244 to 4.638 in.) w/ ABS w/o ABS 107.3 to 117.3 mm (4.224 to 4.618 in.) 107.8 to 117.8 mm (4.244 to 4.638 in.) Adjuster Stop Light Switch Brake Pedal F049043E01 Shaft Stop Light Switch 0.5 to 2.6 mm (0.020 to 0.102 in.) F049044E08BR–10 BRAKE – BRAKE SYSTEM BR (8) Check the stop light switch clearance. Stop light switch clearance: 0.5 to 2.6 mm (0.020 to 0.102 in.) (9) Connect the connector to the stop light switch. (c) Inspect the brake pedal free play. (1) Stop the engine and depress the brake pedal several times until there is no vacuum left in the booster. (2) Push in the pedal until the beginning of the resistance is felt. Measure the distance as shown. Pedal free play: 1.0 to 6.0 mm (0.039 to 0.236 in.) If incorrect, troubleshoot the brake system. (d) Inspect the brake pedal reserve distance. (1) Release the parking brake lever. With the engine running, depress the pedal and measure the pedal reserve distance as shown. Pedal reserve distance from floor at 294 N (30 kgf, 66.1 lbf) HINT: Sound and resistance from the brake booster when the brake pedal is depressed without a vacuum does not indicate a problem. If incorrect, troubleshoot the brake system. 4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Hatchback: (See page IP-78) Sedan: (See page IP-54) 5. INSTALL INSTRUMENT PANEL UNDER COVER SUB- ASSEMBLY Hatchback: (See page IP-80) Sedan: (See page IP-55) Pedal Free Play F048932E01 Pedal Reserve Distance R000934E02 w/ ABS w/o ABS More than 73 mm (2.87 in.) More than 70 mm (2.75 in.)BR–10 BRAKE – BRAKE FLUID BR BRAKE FLUID BLEEDING NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces. HINT: If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system. 1. FILL RESERVOIR WITH BRAKE FLUID (a) Disengage the 3 clips and separate the hood to cowl top seal. (b) Remove the cowl top ventilator louver. (c) Set the brake fluid can upside down on the reservoir. Fluid: SAE J1703 or FMVSS No. 116 DOT3 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. for Hatchback: for Sedan: C133138E01 for Hatchback: for Sedan: C133139E01BRAKE – BRAKE FLUID BR–11 BR (a) Using SST, disconnect the brake tubes from the master cylinder. SST 09023-00100 (b) Slowly depress the brake pedal and hold it there (Step A). (c) Block the outer holes with your fingers, and release the brake pedal (Step B). (d) Repeat step A and B 3 or 4 times. (e) Using SST, connect the brake tubes to the master cylinder. SST 09023-00100 Torque: for use without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) for use with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) HINT: ? Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). ? This torque value is effective when SST is parallel to a torque wrench. SST C121690E01 C121826 C121827 SST C121690E01BR–12 BRAKE – BRAKE FLUID BR 3. BLEED BRAKE LINE (a) Connect the vinyl tube to the bleeder plug. (b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed (Step C). (c) At the point where the fluid stops coming out, tighten the bleeder plug, then release the brake pedal (Step D). (d) Repeat step C and D until all the air in the fluid is completely bled out. (e) Tighten the bleeder plug. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) (f) Repeat the above procedure to bleed the air out of the brake line for each wheel. 4. CHECK FLUID LEVEL IN RESERVOIR (a) Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 C116913BRAKE – BRAKE PEDAL SUPPORT BR–13 BR BRAKE BRAKE BRAKE PEDAL SUPPORT COMPONENTS COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL INSTRUMENT PANEL FINISH PANEL END LH INSTRUMENT PANEL FINISH PANEL END RH for Hatchback: E107796E03BR–14 BRAKE – BRAKE PEDAL SUPPORT BR COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL INSTRUMENT PANEL FINISH PANEL END LH INSTRUMENT PANEL FINISH PANEL END RH for Sedan: CENTER LOWER INSTRUMENT PANEL FINISH PANEL E116817E02BRAKE – BRAKE PEDAL SUPPORT BR–15 BR FRONT DOOR OPENING TRIM WEATHERSTRIP LH FRONT DOOR OPENING TRIM WEATHERSTRIP RH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH RH GLOVE COMPARTMENT DOOR ASSEMBLY CLIP CLIP N*m (kgf*cm, ft.*lbf) : Specified torque w/ Curtain Shield Airbag: 20 (204, 15) Non-reusable part CLIP FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH CLIP UPPER INSTRUMENT PANEL SUB-ASSEMBLY NO. 1 SWITCH HOLE BASE for Hatchback: B108209E02BR–16 BRAKE – BRAKE PEDAL SUPPORT BR FRONT DOOR OPENING TRIM WEATHERSTRIP LH FRONT DOOR OPENING TRIM WEATHERSTRIP RH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH RH UPPER INSTRUMENT PANEL SUB-ASSEMBLY FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH RH Non-reusable part N*m (kgf*cm, ft*lbf) : Specified torque 20 (204, 15) w/ Curtain Shield Airbag: SPECIAL CLIP SPECIAL CLIP for Sedan: GLOVE COMPARTMENT DOOR ASSEMBLY B132310E04BRAKE – BRAKE PEDAL SUPPORT BR–17 BR COLUMN HOLE COVER SILENCER SHEET N*m (kgf*cm, ft*lbf) : Specified torque 28 (290, 21) 28 (290, 21) CLIP CLIP 28 (290, 21) STEERING INTERMEDIATE SHAFT ASSEMBLY for Hatchback: for Sedan: INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY C133140E01BR–18 BRAKE – BRAKE PEDAL SUPPORT BR 9.0 (92, 80 in.*lbf) 24 (241, 17) 37 (375, 27) BRAKE MASTER CYLINDER PUSH ROD CLEVIS BRAKE PEDAL BRAKE PEDAL BUSH BRAKE PEDAL PAD BRAKE PEDAL SUPPORT STOP LIGHT SWITCH Lithium soap base glycol grease BRAKE PEDAL BUSH N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part BRAKE PEDAL PAD BRAKE PEDAL for Manual Transaxle: STOP LIGHT SWITCH MOUNTING ADJUSTER x4 BRAKE PEDAL SHAFT BRAKE PEDAL RETURN SPRING CLIP PUSH ROD PIN C116876E01BRAKE – BRAKE PEDAL SUPPORT BR–19 BR REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL (for Sedan) (See page ME-138) 3. REMOVE INSTRUMENT PANEL FINISH PANEL END LH Hatchback: (See page IP-19) Sedan: (See page IP-5) 4. REMOVE INSTRUMENT PANEL FINISH PANEL END RH Hatchback: (See page IP-19) Sedan: (See page IP-5) 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL Hatchback: (See page IP-19) Sedan: (See page IP-5) 6. REMOVE COMBINATION METER ASSEMBLY Hatchback: (See page IP-19) S
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