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Section 3 Brake Pedal

Components

1. Vacuum Booster Assembly

2. Liner

3. Spacer

4. Torsion Spring

5. Brake Pedal Arm

6. Cushion Gasket

7. Brake Pedal Mat

Replacement:

1. Separate the vacuum booster with brake master cylinder assembly

Remove the cotter pin, flat washer and pivot, separate the vacuum booster with brake master cylinder

assembly from the brake pedal

2. Remove the clutch and brake pedal assembly

(1) Remove 4 nuts connecting the vacuum booster with brake master cylinder assembly and brake

pedal support bracket.

(2) Remove 3 bolts connecting the clutch and brake pedal assembly and front cowl panel cross member.

Remove the clutch and brake pedal assembly.

3.Remove the brake pedal

Remove the bolt and nut, Torsion Spring, liner, brake pedal arm assembly , spacer

4. Remove the brake pedal arm assembly

Remove brake pedal mat and cushion gasket from the brake pedal arm.

5. The installation is in the reverse order of removal.

Notice:

(1) Apply No 3 molybdenum disulphide lithium base grease to the relatively moving faces.

(2) After assembling the brake pedal and the brake pedal support bracket, make sure the

brake pedal can turn freely.

Nut

Bolt

Brake Pedal Bracket

Brake Pedal

142

(3) The 3 bolts connecting the brake pedal support bracket and cowl panel cross member

Torque : 16-20N.m

(4) The 4 bolts connecting the brake pedal support bracket and the vacuum booster with

brake master cylinder assembly

Torque: 16-20N.m

Check the brake pedal

1. Check and adjust brake pedal height

(a) Brake pedal height from the ground: normal height is 176~181 mm.

(b) Adjust brake pedal height

(1) Loosen the brake lamp switch lock nut

(2) Adjust the brake lamp switch to the right position

(3) Check the brake lamp switch

Make sure the brake lamp is light by depressing the brake pedal for5~15mm

(4) Tighten the brake lamp switch lock nut

2. Check pedal freestroke

(1) Shut off the engine and depress the brake pedal several times until there is no more vacuum left in

the booster.

(2) Depress the pedal until the resistance begins to be felt

Pedal freestroke should be: 10~30mm

Worn Or Damaged

Worn Or Damaged

Worn Or
Damaged

Worn Or 
Damaged

Worn Or Damaged

Worn Or Damaged

Distorted Or Damaged

Distorted Or Damaged

Bent Or Distorted

Freestroke

143

Section 4 Vacuum Booster with Brake Master Cylinder Assembly

Notice: The vacuum booster with brake master cylinder assembly must be repaired by

manufacturer. Replace it if it is faulty.

On-vehicle inspection

1. Check vacuum booster

(a)  Air tightness check

(1) start the engine, run 1 or 2 minutes then shut off. Depress the brake pedal several times slightly.

Hint: if the pedal rises gradually after depressing the pedal, the booster is airtight.

(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 stroke after holding the pedal for 30 seconds, 

the booster is air--tight.

(b) Operating check

Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal.

2. Check the vacuum check valve

(1) Remove the connecting pipe with the check valve

(2) Check the direction from the booster to the engine. Check valve for ventilation. It should not

ventilate in the reverse order.

(3) Replace it if it is faulty.

Notice: Pay attention to the matchmark on the connecting hose when connecting 
the hose with vacuum check valve. Do not install it in reverse order.

Replacement

1. Remove the brake pipe on the brake master cylinder (master cylinder)

2. Refer to Brake Pedal Replacement for other operation

Notice:

 (1) The torque of the union thread on the brake master cylinder (master cylinder ) 

and brake pipe: 12-16 N.m

 (2) Bleed all the air in the brake system after installation

Good

Poor

Third

Second

First

144

Section 5 Front Brake Assembly

Components

Repairing

1. Remove the front wheel

2. Drain the brake fluid. Remove the brake hose

3. Remove the front brake caliper

(1) Remove the brake hose union thread from the front brake cylinder. Disconnect the hose

(2) Remove 2 installing bolts

4. Remove the front brake pad

5. Remove the front left disc caliper

6. Remove the sliding pin boot

Disk Brake Wheel 
Cylinder Bracket

Sliding Pin Boot

Inner Floating Clip Plate

Screw Plug

Brake Caliper 
Housing

Inner 
Damper

Inner Pad 
Backing 
Plate

Inner Pad

Outer Pad

Outer Pad 
Backing Plate

Outer 
Damper

Outer Floating

Clip Plate

Alarm 

Plate

Wheel 

Cylinder 

Piston

Wheel 

Cylinder 

Piston Seal

Wheel 

Cylinder 

Boot

Steel Wire 

Snap Ring

Short Pin 

Set Bolt

Short Bushing

Guide Boot (II)

Splash Shield

Front Ring Gear Retaining 

Ring

Wheel Hub Bolt Front Wheel 

Hub Bearing

Wheel Hub

Disc