Brake--Remove malfunction

Remove malfunction

Malfunction phenomenon table

Use following table to help you find the reason of malfunction, the number in table indicates the preferred

sequence of possible reasons of malfunction. Please check every part by sequence, if necessary, change

this part.

Malfunction phenomenon

Possible malfunction part

Reference page

1. Brake system (leaking oil).

-

The height of brake pedal is too

2. Brake system (entering air).

135

low or brake pedal is loose.

3. Piston oil seal (abraded or damaged).

141, 144

4. Brake main pump (invalid)

138

5. Vacuum booster lever (adjusted badly)

138

1. Brake pedal free travel (too small).

136

2. Parking brake handle travel (adjusted badly).

154

3. Parking brake pull cable (lag).

156, 158

4. Brake block (damaged or distorted).

141, 144

Brake lag

5. Piston (locked).

141, 144

6. Piston (freezed).

141, 144

7. Tensility or return spring (invalid).

161

8. Vacuum booster lever (adjusted badly).

138

9. Vacuum boosting system (vacuum leakage).

138

10. Brake main pump (invalid).

138

1. Piston (locked).

141, 144

2. Brake block (oil dirt).

141, 144

Brake offset

3. Piston (freezed).

141, 144

4. Brake disk (scratched).

141, 144

5. Brake block (abraded or distorted).

141, 144

1. Brake system (leaking oil).

2. Brake system (entering air).

135

3. Brake block (abraded).

141, 144

4. Brake block (damaged or distorted).

141, 144

Brake pedal is too hard to make power lack.

5. Brake block (oil dirt).

141, 144

6. Brake block (sclerosesed).

141, 144

7. Brake disk (scratched).

141, 144

8. Vacuum booster lever (adjusted badly).

138

9. Vacuum boosting system (vacuum leakage).

138

133

Brake--Remove malfunction

1. Brake block (damaged or distorted).

141, 144

2. Assembled nut (loose).

141, 144

3. Brake disk (scratched).

141, 144

4. Support sheet of brake block (loose).

141, 144

Brake noise

5. Sliding pin (abraded).

141, 144

6. Brake block (oil dirt).

141, 144

7. Brake block(sclerosesed).

141, 144

8. Support pin or return spring (invalid).

161

9. Muffle gasket (damaged).

141, 144

10. Localizing spring (damaged).

161

Malfunction phenomenon

Possible malfunction part

Reference page

134

Brake--Remove malfunction

1. Add brake liquid in storage tank.

Brake liquid: DOT-4

2. Discharge the air in brake main pump.

Hint: if brake main pump or liquid storage tank is

disassembled, it is necessary to discharge the air in

brake main pump.

(a) Disassemble brake pipeline of brake main pump.

(b) Step down brake pedal slowly and keep this state.

(c) Plug oil hole with finger, then release brake pedal.

(d) Repeat (b) and (c) three times or four times.

3. Discharge the air in brake pipeline.

(a) Connect plastic pipe on exhaust bolt of brake branch pump.

(b) After stepping brake pedal several times, and step down

brake pedal, then release inflating bolt to discharge air.

(c) Lock exhaust bolt until brake liquid stops flowing out, then

release brake pedal.

(d) Repeat (b) and (c) until air is discharged completely.

(e) Repeat the procedure above, and release the air in brake

pipeline of every wheel.

Torque: 12.7-17.6 N

⋅⋅⋅⋅⋅m

4. Check the brake liquid storage tank

Check the liquid level in storage tank, if necessary, add brake

liquid.

Brake liquid: DOT-4.

Brake liquid

Discharge the air in brake system

Hint: if any part of brake system has been damaged or

you disbelieve whether there is any air in brake pipeline,

it is necessary to discharge the air in brake system

completely.

Note: do not make brake liquid spill on paint surface, if

having, wash it cleanly.

135

Brake--Remove malfunction

2. Check the free travel of pedal.

(a) Extinguish the engine, and step brake pedal repeatedly until

there is no vacuum in vacuum booster.

(b) Press down pedal with hand until feeling the resistance,

then measure the distance of this section, liking that shown

in figure.

Free travel of pedal: 1-6mm.

If it is wrong, check the clearance of brake light switch.

Clearance of brake light switch: 0.5-2.4mm

If the clearance accords with the regulation, remove the

malfunction in brake system.

3. Check the distance from pedal to floor.

Release parking brake drag lever

When engine is running, step down brake pedal, then mea-

sure the distance from pedal to floor, liking that shown in figure,

Force 490 N on pedal, its distance from floor should be:

over 60mm.

If it is wrong, remove the malfunction in brake system.

Brake pedal assembly

Adjustment

1. Check and adjust the height of brake pedal.

(a) Check the height of brake pedal.

Pedal distance from floor: 136.0-146.0mm

(b) Adjust the height of brake pedal.

(1) Disassemble lower trim board of panel.

(2) Disassemble switch joint of brake light.

(3) Loosen locking nut of brake switch, and disassemble

the switch of brake light.

(4) Loosen U-shaped clasp fixing nut of pedal lever.

(5) Turn pedal lever to adjust the height of pedal.

(6) Lock the fixing nut of lever.

Torque: 26

±±±±±2 N

⋅⋅⋅⋅⋅

m

(7) Assemble the switch of brake switch.

(8) Connect the switch joint of brake light.
(9) Press down the brake pedal for 5-15mm, and turn the switch of brake light to illuminate brake light,

then lock the nut.

(10) After assembling, press down the brake pedal for 5-15mm again, and confirm brake light has

illuminated.

Pedal distance

from floor

Free travel of

pedal

Height of pedal

Push rod

Brake light switch

136