6 Brake System

6.1 Warnings and Notices.....................6-3

6.1.1 Warnings and Notices...........................................6-3

6.2 Front Brake.....................................6-4

6.2.1 Specifications...........................................6-4

6.2.1.1 Fastener Tightening Specifications....................6-4
6.2.1.2 Front Disc Brake Parts Specifications................6-4

6.2.2 Description and Operation........................6-5

6.2.2.1 Description and Operation..................................6-5

6.2.3 Disassemble View....................................6-6

6.2.3.1 Disassemble View..............................................6-6

6.2.4 Diagnostic Information and Procedures.....6-
7

6.2.4.1 Brake Pad Inspection.........................................6-7
6.2.4.2 Brake Caliper Inspection....................................6-7
6.2.4.3 Brake Guide Inspection......................................6-7
6.2.4.4 Floating Brake Caliper Pin Inspection................6-7
6.2.4.5 Brake Disc Surface and Worn Inspection...........6-8
6.2.4.6 Brake Disc Thickness Measurement..................6-8
6.2.4.7  Brake  Disc  Assembly  Rear  Face  Run  Out
Measurement.................................................................6-8

6.2.5 Removal and Installation........................6-10

6.2.5.1 Brake Pad Replacement - Front.......................6-10
6.2.5.2 Brake Caliper Replacement - Front..................6-12
6.2.5.3 Brake Disc Replacement..................................6-14
6.2.5.4 Disc Brake Dust Cover Replacement...............6-16

6.3 Rear Brake....................................6-18

6.3.1 Specifications.........................................6-18

6.3.1.1 Fastener Tightening Specifications..................6-18
6.3.1.2 Rear Disc Brake Parts Specifications...............6-18

6.3.2 Description and Operation......................6-19

6.3.2.1 Description and Operation................................6-19

6.3.3 Disassemble View..................................6-20

6.3.3.1 Disassemble View............................................6-20

6.3.4 Diagnostic Information and Procedures.....6-
21

6.3.4.1 Diagnostic Information and Procedures...........6-21

6.3.5 Removal and Installation........................6-22

6.3.5.1 Brake Pad Replacement - Rear.......................6-22
6.3.5.2 Brake Caliper Replacement - Rear..................6-24
6.3.5.3 Brake Disc Replacement - Rear.......................6-26

6.4 Hydraulic Brake.............................6-29

6.4.1 Specifications.........................................6-29

6.4.1.1 Fastener Tightening Specifications..................6-29

6.4.2 Description and Operation......................6-30

6.4.2.1 Description and Operation................................6-30

6.4.3 Component Locator................................6-31

6.4.3.1 Component Locator..........................................6-31

6.4.4 Diagnostic Information and Procedures.....6-
32

6.4.4.1 Diagnostic Notes..............................................6-32
6.4.4.2 Fault Symptom Table.......................................6-32
6.4.4.3 Brake Warning Lamp Always On.....................6-34

6.4.5 Removal and Installation........................6-37

6.4.5.1 Brake Master Cylinder Tank Replacement.......6-37
6.4.5.2 Brake Master Cylinder Replacement................6-37
6.4.5.3 Brake Hose Replacement (Front).....................6-40
6.4.5.4 Brake Hose Replacement (Rear).....................6-42
6.4.5.5 Hydraulic Brake System Exhaust Procedure.......6-
43
6.4.5.6 Vacuum Booster Replacement.........................6-46
6.4.5.7 Brake Fluid Level Sensor Replacement...........6-48
6.4.5.8 Brake Pedal Replacement................................6-49

6.5 Parking System.............................6-51

6.5.1 Specifications.........................................6-51

6.5.1.1 Fastener Tightening Specifications..................6-51

6.5.2 Description and Operation......................6-52

6.5.2.1 Description and Operation................................6-52

6.5.3 Component Locator................................6-53

6.5.3.1 Component Locator..........................................6-53

6.5.4 Diagnostic Information and Procedures.....6-
54

6.5.4.1 Fault Symptom Table.......................................6-54

Brake System

Table of Contents

6-1

6.5.4.2 Park Brake Warning Lamp Malfunction............6-55

6.5.5 Removal and Installation........................6-58

6.5.5.1  Park  Brake  Control  Mechanism  Switch
Replacement................................................................6-58
6.5.5.2  Park  Brake  Control  Mechanism  Assembly
Replacement................................................................6-59
6.5.5.3  Park  Brake  Control  Mechanism  Cable  Assembly
Replacement................................................................6-61
6.5.5.4 Park Brake Control Mechanism Adjustment.....6-67

6.6 ABS / TCS / EBD / ESP................6-69

6.6.1 Specifications.........................................6-69

6.6.1.1 Fastener Tightening Specifications..................6-69
6.6.1.2 Wheel Speed Sensor Technical Specifications....6-
69

6.6.2 Description and Operation......................6-70

6.6.2.1 Description and Operation................................6-70

6.6.3 System Working Principle.......................6-71

6.6.3.1 System Working Principle................................6-71

6.6.4 Component Locator................................6-73

6.6.4.1 Component Locator..........................................6-73

6.6.5 Schematic...............................................6-74

6.6.5.1 Schematic.........................................................6-74

6.6.6 Diagnostic Information and Procedures.....6-
75

6.6.6.1 Diagnosis Description.......................................6-75
6.6.6.2 Visual Inspection..............................................6-75
6.6.6.3 DTC Code (DTC) List.......................................6-75
6.6.6.4 Scan Tool and The Vehicle Can Not Communicate
6-76
6.6.6.5 Fault Symptom Table.......................................6-76
6.6.6.6 Active Test and Data Flow...............................6-78
6.6.6.7 ABS Control Module Terminal List...................6-79
6.6.6.8 ABS Warning Lamp Always On........................6-81
6.6.6.9 ABS Warning Lamp Always Off........................6-84
6.6.6.10  Power  Failure  and  Hydraulic  Electronic  Control
Unit Assembly Internal Fault Diagnosis........................6-86
6.6.6.11 Wheel Speed Sensor Fault Diagnosis............6-88

6.6.7 Removal and Installation........................6-94

6.6.7.1 Hydraulic Electronic Control Unit Replacement. . .6-
94

6.6.7.2 Wheel Speed Sensor Replacement (Front).....6-96
6.6.7.3 Wheel Speed Sensor Replacement (Rear)......6-98

6.7 TPMS..........................................6-101

6.7.1 Specifications.......................................6-101

6.7.1.1 Fastener Tightening Specifications................6-101
6.7.1.2 Sensor Specifications.....................................6-101

6.7.2 Description and Operation....................6-102

6.7.2.1 Tire Pressure Monitoring System Overview.........6-
102
6.7.2.2  The  Composition  Of  Tire  Pressure  Monitoring
System.......................................................................6-102

6.7.3 System Working Principle.....................6-103

6.7.3.1 System Working Principle..............................6-103

6.7.4 Component Locator..............................6-104

6.7.4.1 Component Locator........................................6-104

6.7.5 Schematic.............................................6-105

6.7.5.1 Schematic.......................................................6-105

6.7.6 Diagnostic Information and Procedures.....6-
106

6.7.6.1 Sensor Learn..................................................6-106
6.7.6.2 TPMS Control Module Terminal List..............6-106
6.7.6.3 DTC Code (DTC) List.....................................6-107
6.7.6.4 Tire Pressure Monitoring System (TPMS) Indicator
Always On..................................................................6-109

6.7.7 Removal and Installation......................6-112

6.7.7.1 TPMS Control Unit Replacement...................6-112
6.7.7.2 TPMS Sensor Replacement...........................6-112

6.7.8 Special Tools and Equipment...............6-114

6.7.8.1 Trigger Tool....................................................6-114

6-2

Table of Contents

Brake System

6.1 Warnings and Notices

6.1.1 Warnings and Notices

ABS Component Handling Warning

Warning!

Warning:  Certain  components  in  the  Anti-lock  Brake
System  (ABS)  are  not  intended  to  be  serviced
individually. Attempting to remove or disconnect certain
system components may result in personal injury and/or
improper system operation. Only those components with
approved removal and installation procedures should be
serviced.

Brake Dust Warning

Warning!

Warning:  Avoid  taking  the  following  actions  when  you
service wheel brake parts:

–

Do not grind brake linings.

–

Do not sand brake linings.

–

Do not clean wheel brake parts with a dry brush or
with compressed air.

Warning!

Warning: Some models or aftermarket brake parts may
contain  fibers  which  can  become  airborne  in  dust.
Breathing  dust  with  fibers  may  cause  serious  bodily
harm. Use a water-dampened cloth in order to remove
any  dust  on  brake  parts.  Equipment  is  available
commercially in order to perform this washing function.
These  wet  methods  prevent  fibers  from  becoming
airborne.

Brake Fluid Warning

Warning!

Warning: Do not use fluid from an open container that
may  be  contaminated  with  water.  Incorrect  or
contaminated fluid could result in system failure, loss of
vehicle control and personal injury.

Brake Fluid Irritant Warning

Warning!

Warning: Brake fluid may be irritating to the skin or eyes.
In case of contact, take the following actions:

–

Eye contact--rinse eyes thoroughly with water.

–

Skin contact--wash skin with soap and water.

Brake Pipe Replacement Warning

Warning!

Warning: Carefully route and retain replacement brake
pipes.  Always  use  the  correct  fasteners  and  in  the
original location for replacement brake pipes. Failure to
properly  route  and  retain  brake  pipes  may  cause
damage to the brake pipes and brake system resulting
in personal injury.

Adding Fluid to the Brake System Notice

Note

Notice: When adding fluid to the brake master cylinder
reservoir,  use  DOT-4  brake  fluid  from  a  clean,  sealed
brake fluid container. The use of any type of fluid other
than  the  recommended  type  of  brake  fluid  may  cause
contamination  which  could  result  in  damage  to  the
internal rubber seals and/or rubber linings of hydraulic
brake system components.

Brake Caliper Notice

Note

Notice: Support the caliper with a piece of wire to prevent
damage to the brake line.

Brake System

Warnings and Notices

6-3

6.2 Front Brake

6.2.1 Specifications
6.2.1.1 Fastener Tightening Specifications

Applications

Model

Specifications

Metric (Nm)

US English (lb-ft)

Brake Hose Bolts

M10 × 15

11-20

8.1-14.8

Brake Caliper Bolts

M8 × 22

25-35

18.5-25.9

Brake Caliper Bracket Bolts

M10 × 23

100-110

74.0-81.4

6.2.1.2 Front Disc Brake Parts Specifications

Applications

Specifications

Metric (mm)

US English (in)

Scrapped Front Brake Disc Thickness

24.0

0.980

Front Brake Disc Acceptable Face Run
Out

0.05

0.002

Front Brake Disc Thickness - New

26.0

1.020

Front Brake Pads Standard Thickness

11.0

0.433

Front Brake Pads Minimum Thickness

2.0

0.078

6-4

Front Brake

Brake System