22 Basic Brake System 22 - SM
22 Basic Brake System 22 - SM
SYSTEM
Click on the applicable bookmark to selected the required model year
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35A-2
BASIC BRAKE
SYSTEM
CONTENTS
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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 Brake Fluid Level Sensor Check . . . . . . . . . . . . . 10
Disc Brake Pad Check and Replacement . . . . . . 11
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4
Disc Brake Rotor Check . . . . . . . . . . . . . . . . . . . . . 12
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake Disc Thickness Check . . . . . . . . . . . . . . . . . 12
Brake Disc Run-out Check and Correction . . . . 13
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MASTER CYLINDER AND BRAKE
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6 BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Brake Pedal Check and Adjustment . . . . . . . . . . . . 6 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Brake Booster Operating Test . . . . . . . . . . . . . . . . . . 7
FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . . 20
Check Valve Operation Check . . . . . . . . . . . . . . . . . 8
Load Sensing Spring Length Check and REAR DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . 25
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Load Sensing Proportioning Valve Function LOAD SENSING PROPORTIONING
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BASIC BRAKE SYSTEM – General Information 35A-3
GENERAL INFORMATION
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.
Items Specifications
I.D. mm 22.2
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Disc effective dia. × thickness mm 236 × 22
CONSTRUCTION DIAGRAM
Load sensing
proportioning
valve
Hydraulic unit
Brake booster
Master cylinder
35A-4 BASIC BRAKE SYSTEM – Service Specifications
SERVICE SPECIFICATIONS
Items Standard value Limit
Brake pedal to floorboard clearance when the brake pedal is depressed mm 105 or more –
Brake booster push rod protrusion amount mm L.H. drive vehicles with ABS 22.7 – 22.9 –
Load sensing proportion- When load sensing spring length is 199 mm (when 4.2 – 6.0 (9.8) –
ing valve output fluid unladen)
pressure
pressure (I
(Innpu
putt fluid
fluid pres-
pres-
sure) MPa When load sensing spring length is 217 mm (when 9.7 – 10.5 (9.8) –
laden)
laden)
14.5 – 16.3 (16.7) –
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Output fluid pressure difference between left and right – 0.39
MPa
Load sensing spring length <Distance between spring ends> mm 194 – 198 –
Disc
Di sc thickness
thickness mm 22.0 20.4
Drag force N 69 –
Drag force N 34 –
SEALANT
Items Specified sealant Remarks
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SPECIAL TOOLS
Tool Number Name Use
MB991568 Push rod adjusting Adjustment of the brake booster push rod
socket protrusion amount
35A-6 BASIC BRAKE SYSTEM – On-vehicle Service
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
Operating rod
BRAKE PEDAL HEIGHT
Stop lamp switch
1. Turn up the carpet, etc. under the brake pedal.
Operating 2. Measure the brake pedal height as illustrated.
rod lock nut
Standard value (A):
A <L.H. drive vehicles> 201 – 204 mm
<R.H. drive vehicles> 201.7 – 204.7 mm
3. If the brake pedal height is not within the standard value,
follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch by turning it approx.
1/4 turns anticlockwise.
(3) Remove the pin, and then adjust so that the brake
pedal height meets the standard value by turning the
clevis.
NOTE
When the clevis is turned 180°, the pedal height is
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changed approximately 2.3 mm.
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air trapped in the brake line, thickness of the disc brake
pad or the drum brake lining and dragging in the parking
brake.
Adjust and replace defective parts as required.
4. Return the carpet, etc.
Good No good
BRAKE BOOSTER OPERATING TEST
For simple checking of the brake booster operation, carry
out the following tests:
1. Run the engine for one or two minutes, and then stop
it.
If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly. If the pedal height remains
unchanged, the booster is defective.
Good No good 3. With the engine running, step on the brake pedal and
then stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good condition.
If the pedal rises, the booster is defective.
If the above three tests are okay, the booster performance
can be determined as good.
If one of the above three tests is not okay at least, the check
valve, vacuum hose, or booster will be defective.
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Vacuum pump Accept/reject criteria
connection
Connection at the brake A negative pressure (vacuum) is
Valve Spring booster side (A) created and held.
Connection at the intake A negative pressure (vacuum) is
Booster A B Intake manifold side (B) not created.
side manifold
side Caution
If the check valve is defective, always replace it as
an assembly unit together with the vacuum hose.
2. With the lever pressed all the way to the load sensing
Load sensing spring proportioning valve side, check whether or not the length
Spring support (shown in the figure) of the spring (the length between
Lever its ends) is the standard value.
Standard value (A): 194 – 198 mm
A 3. If the spring length is not within the standard value, loosen
the bolt attaching the support and adjust the distance by
moving the support.
BASIC BRAKE SYSTEM – On-vehicle Service 35A-9
Pressure gauge LOAD SENSING PROPORTIONING VALVE
FUNCTION TEST
1. Connect pressure gauges to the input and output ports
of the load sensing proportioning valve.
2. Bleed the system. (Refer to P.35A-10.)
3. Disconnect the spring at the support side.
Load sensing pro- 4. Place the spring so that it is in parallel with the load sensing
portioning valve Load sensing spring proportioning valve, and then pull in the direction indicated
A by arrow A so that its length H shown in the figure (the
Parallel
length between its ends) is as noted below.
NOTE
At this time the lever is pressed all the way to the load
sensing proportioning valve side.
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Lever
BLEEDING
Caution
Specified brake fluid: DOT3 or DOT4
Always use the specified brake fluid. Avoid using a mixture
of the specified brake fluid and other fluid.
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4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2 – 4 three or four times to fill the inside
of the master cylinder with brake fluid.
2 (4) 3 (1)
( ): R.H. drive vehicles
FRONT REAR 1. Check the brake pad thickness through the caliper body
check port.
Standard value: 10.0 mm
Limit: 2.0 mm
2. When the thickness is less than the limit, always replace
the pads at an axle set.
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3. Remove the guide lock pin bolt. Pivot the caliper assembly
and hold it with wires.
FRONT REAR 4. Remove the following parts from the caliper support.
3 3 1. Pad and wear indicator assembly
2. Pad assembly
2 1
2
3. Clip
4
5
4 4. Inner shim
5 5. Outer shim
1
3 3
Scratches, rust, saturated lining materials D If the vehicle is not driven for a certain period, the sections of
and wear the discs that are not in contact with lining will become rusty, causing
noise and shuddering.
D If grooves resulting from excessive disc wear and scratches are
not removed prior to installing a new pad assembly, there will
momentarily be inappropriate contact between the disc and the
lining (pad).
Run-out or drift Excessive run-out or drift of the discs will increase the pedal depression
resistance due to piston knock-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause pedal pulsation,
shuddering and surging.
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Inset or warping (flatness) Overheating and improper handling while servicing will cause inset or
warping.
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(2) Remove the brake disc. Then place a dial gauge as
shown, and measure the end play by pushing and
pulling the wheel hub.
Limit: <Front> 0.2 mm, <Rear> 0.025 mm
(3) If the end play exceeds the limit, disassemble the
hub and knuckle assembly to check each part.
(4) If the end play does not exceed the limit, dephase
the brake disc and secure it. Then recheck the brake
disc run-out.
BRAKE PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Brake Pedal Adjustment (Refer to P.35A-6.)
14 Nm
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10
3 2 1
4
7 8 9
12 Nm
Removal steps
1. Harness connector 7. Split pin <A/T>
2. Stop lamp switch 8. Shift lock cable connection <A/T>
3. Adjuster 9. Pedal pad
4. Pedal stopper 10. Brake pedal and pedal support
5. Snap pin member
6. Pin assembly
INSPECTION
STOP LAMP SWITCH CHECK
1. Connect an ohmmeter between the stop lamp switch
connector terminals.
No continuity Continuity 2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.
4 mm
BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster 35A-15
MASTER CYLINDER AND BRAKE BOOSTER
REMOVAL AND INSTALLATION
<L.H. drive vehicles with ABS>
Pre-removal Operation Post-installation Operation
Brake Fluid Draining D Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
D Brake Pedal Adjustment (Refer to P.35A-6.)
6 10
12
14 11
14.7 – 17.7 Nm 14
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Part No.8661 or equivalent
9
15 Nm
10
1 4 11
12 Nm
8
5
7
13
2 14 Nm
15 Nm
12
3 Silicon grease
35A-16 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster
10
11 12
14 4 12
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10
15 Nm 11
1 2
8
5 13
12 Nm 7
1
4
14 Nm
15 Nm
12
3
6 6
14.7 – 17.7 Nm 14
14 14.7 – 17.7 Nm
BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster 35A-17
Master cylinder removal steps
1. Brake pipe connection "AA 6. Vacuum hose
2. Brake fluid level sensor connector (With built-in check valve)
3. Bracket <L.H. drive vehicles> 7. Snap pin
4. Master cylinder 8. Pin assembly
"CA 5. Seal 9. Vacuum sensor connector
Brake booster removal steps 10. Vacuum sensor
11. Grommet
1. Brake pipe connection 12. Brake booster
2. Brake fluid level sensor connector 13. Sealer
3. Bracket <L.H. drive vehicles>
4. Master cylinder Fitting removal
"CA 5. Seal 14. Fitting
"BA D Push rod protrusion amount check and
adjustment
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"BA PUSH ROD PROTRUSION AMOUNT CHECK AND
ADJUSTMENT
1. Measure dimension (A).
Standard value (A) :
<L.H. drive vehicles with ABS> 22.7 – 22.9 mm
A <L.H. drive vehicles without ABS and R.H. drive
vehicles> 23.93 – 24.18 mm
NOTE
When a negative pressure of 66.7 kPa is applied to the
brake booster, the push rod should protrude 22.2 – 22.4
mm <L.H. drive vehicles with ABS>/23.48 – 23.73 mm
Measuring distance A <L.H. drive vehicles without ABS and R.H. drive vehicles>.
Block gauge
35A-18 BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster
Angle-nose pliers
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MB991568
Seal
Seal
INSPECTION
VACUUM SENSOR CHECK
Refer to GROUP 13A – Troubleshooting.
NOTE
The vacuum sensor is monitored by the engine-ECU. Diagnosis
code is output when the vacuum sensor has a malfunction.
BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster 35A-19
MASTER CYLINDER <L.H. drive vehicles without ABS and R.H. drive vehicles>
DISASSEMBLY AND REASSEMBLY
4 8 6
9
5
7
10
5 11
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12
12
10
11 10
6
9 8 7
11
12 Brake fluid: DOT3 or DOT4
Master cylinder kit
Disassembly steps
1. Reservoir cap 7. Piston guide
2. Pin 8. Cylinder cup
3. Reservoir tank 9. Plate
4. Brake fluid level sensor 10. Primary piston assembly
5. Reservoir seal 11. Secondary piston assembly
AA" 6. Stopper ring 12. Master cylinder body
49 Nm
90 – 110 Nm
2
1
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3
Removal steps
1. Brake hose connection
2. Gasket
"AA 3. Disc brake assembly
4. Brake disc
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guide pin slide smoothly.
35A-22 BASIC BRAKE SYSTEM – Front Disc Brake
15 15
13 12
26 Nm
1
11 15
2
Clip kit
3 15
26 Nm
9 14
8
7
10
6
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2
3
5
4
1 2
3 11 13 9
9 3
8 7
10 7 6
2
3
5 14 5
4 12 4
Brake caliper kit Pad set Shim kit Seal and boot kit
Disassembly steps
1. Guide pin lock bolt AA" 8. Piston
2. Guide pin AB" 9. Piston seal
3. Boot 10. Caliper body
4. Bushing 11. Pad and wear indicator assembly
5. Bushing retainer 12. Pad assembly
6. Caliper support (including pad, clip, 13. Inner shim
and shim) 14. Outer shim
AA" 7. Piston boot 15. Clip
BASIC BRAKE SYSTEM – Front Disc Brake 35A-23
LUBRICATION POINTS
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Caution
The piston seal inside the
seal and boot kit is coated
with special grease, so do
not wipe this grease off.
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INSPECTION
D Check the cylinder for wear, damage or rust.
D Check the piston surface for wear, damage or rust.
D Check the caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check the
backing metal for damage.
55 – 65 Nm
1
15 Nm
2
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3
Removal steps
1. Brake hose connection
"AA 2. Disc brake assembly
3. Brake disc
3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
MB990520
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guide pin slide smoothly.
BASIC BRAKE SYSTEM – Rear Disc Brake 35A-27
DISASSEMBLY AND REASSEMBLY
15
43 Nm 1 15
8 Nm 11
12
13
5 14
15
Clip set
9 8
7
6
2 15
4
3
10
5
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5
1
9 11 14
10 7 5
9
3
2
3
5 8
7 13 6
6 12 Grease 5
Brake caliper kit Pad set Shim set Seal and boots kit
Disassembly steps
"AA 1. Guide pin AB" 9. Piston seal
"AA 2. Lock pin 10. Caliper body
3. Bushing 11. Pad and wear indicator assembly
4. Caliper support (pad, clip, shim) 12. Pad assembly
5. Pin boot 13. Inner shim
6. Boot ring 14. Outer shim
AA" 7. Piston boot 15. Clip
AA" 8. Piston
35A-28 BASIC BRAKE SYSTEM – Rear Disc Brake
LUBRICATION POINTS
Piston
seal
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Caution
The piston seal inside the seal
and boot kit is coated with
special grease, so do not wipe
this grease off.
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REASSEMBLY SERVICE POINT
Lock pin
"AA LOCK PIN/GUIDE PIN INSTALLATION
“L”
Install the guide pin and lock pin as illustrated that each head
mark of the guide pin and the lock pin matches the indication
Front mark (“G” or “L”) located on the caliper body.
Guide pin
“G”
INSPECTION
D Check the cylinder for wear, damage or rust.
D Check the piston surface for wear, damage or rust.
D Check the caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check the
backing metal for damage.
35A-30 BASIC BRAKE SYSTEM – Rear Disc Brake
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BASIC BRAKE SYSTEM – Load Sensing Proportioning Valve 35A-31
LOAD SENSING PROPORTIONING VALVE
REMOVAL AND INSTALLATION
Caution
Do not disassemble the load sensing proportioning valve.
2
5
1
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15 Nm 3
15 Nm
3 4
Removal steps
"AA 1. Spring support 4. Load sensing proportioning valve
2. Load sensing spring 5. Bracket
3. Brake pipe connection
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35A-1
BASIC BRAKE
SYSTEM
CONTENTS
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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE <1800-MPI> . . . . . . . . . 3
Outline of Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Lining Thickness Check . . . . . . . . . . . . . . . . . 3
Brake Drum Inside Diameter Check . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
Brake Lining and Brake Drum Contact Check . . . 3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
MASTER CYLINDER AND BRAKE
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BOOSTER <1800-MPI> . . . . . . . . . . . . . . . . . . . . . 4
GENERAL
OUTLINE OF CHANGE
The following service procedures have been established due to the adoption of the rear drum brake.
<1800-MPI>
GENERAL INFORMATION
Items 1800-MPI
SERVICE SPECIFICATIONS
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Items Standard value Limit
LUBRICANTS
Items Specified Lubricant Quantity
SPECIAL TOOL
Tool Number Name Use
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BRAKE DRUM INSIDE DIAMETER CHECK
1. Remove the brake drum.
2. Measure the inside diameter of the brake drum at two
A or more locations.
Standard value (A) : 228.6 mm
Limit (A) : 230.6 mm
3. Replace the brake drum when the inside diameter exceeds
the limit value or the brake drum is worn unevenly.
11 5 9
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1
15 ± 1 N·m 2
8
5 10
9.8 ± 2.0 N·m
1 7
4
14 ± 2 N·m
15 ± 1 N·m
9
3
NOTE
(1) *: Refer to PAJERO PININ ’00 Workshop Manual
(Pub. No. CKRE00E1).
(2) The installation service points are the same as before.
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35A-6 BASIC BRAKE SYSTEM – Rear Drum Brake
8
15 ± 1 N·m 16 7
6
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17
10 9 1
8
7
6 5
4
3 17
17 14 4
NOTE
*: Refer to PAJERO PININ ’00 Workshop Manual
(Pub. No. CKRE00E1).
BASIC BRAKE SYSTEM – Rear Drum Brake 35A-7
REMOVAL SERVICE POINT
Pin of shoe and lining assembly
AA" RETAINER REMOVAL
Use a flat-tipped screwdriver or the like to open up the retainer
joint, and remove the retainer.
Retainer
Pin
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Parking lever
Retainer
INSPECTION
BRAKE LINING THICKNESS CHECK
Refer to P.35A-3.
BRAKE DRUM INSIDE DIAMETER CHECK
Refer to P.35A-3.
BRAKE LINING AND BRAKE DRUM CONTACT CHECK
Refer to P.35A-3.
35A-8 BASIC BRAKE SYSTEM – Rear Drum Brake
WHEEL CYLINDER
DISASSEMBLY AND REASSEMBLY
1 4 4 1
Grease
7
6
2
2
Brake fluid: DOT3 or DOT4 Grease: Repair kit grease Wheel cylinder repair kit
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3 4
2
Disassembly steps
1. Boots "AA 4. Piston cups
2. Piston assembly 5. Spring
"AA 3. Pistons 6. Wheel cylinder body
INFORMATION
O. Kai - E.V.P. & G.M.
After Sales Service Dept.
1. Description:
On 4G93-GDI engine-equipped vehicles for Europe, the vacuum nipple of the brake booster must
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be replaced and cleaned periodically. This Service Bulletin covers the replacement and cleaning
procedures which should be added in On-Vehicle Service as shown below.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
’98 CARISMA GDI PWDE9502-C (English) 35A-1
Workshop Manual chassis PWDS9503-C (Spanish) 35A-1
PWDF9504-C (French) 35A-1
PWDG9505-C (German) 35A-1
PWDD9505-C (Dutch) 35A-1
PWDW9506-C (Swedish) 35A-1
PWDI96E1-C (Italian) 35A-1
’99 SPACE STAR CMXE99E1 (English) 35A-14
Workshop Manual chassis CMXS99E1 (Spanish) 35A-14
CMXF99E1 (French) 35A-14
CMXG99E1 (German) 35A-14
CMXD99E1 (Dutch) 35A-14
CMXW99E1 (Swedish) 35A-14
CMXI99E1 (Italian) 35A-14
’00 PAJERO PININ CKRE00E1 (English) 35A-13
Workshop Manual chassis
’00 MONTERO io CKRS00E1 (Spanish) 35A-13
Workshop Manual chassis
’00 PAJERO PININ CKRF00E1 (French) 35A-13
Workshop Manual chassis CKRG00E1 (German) 35A-13
CKRD00E1 (Dutch) 35A-13
CKRW00E1 (Swedish) 35A-13
CKRI00E1 (Italian) 35A-13
3. Details: ’98 CARISMA GDI Workshop Manual chassis
35A-1 BASIC BRAKE SYSTEM - General /On-vehicle Service <Added>
GROUP 35A
BASIC BRAKE SYSTEM
GENERAL
OUTLINE OF CHANGES
The following maintenance service points have been established to correspond to the addition of a pressure
sensor. Maintenance service procedures not listed below are the same as before.
<Added>
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and tighten to 15 – 18 N.m
Caution
Take care when applying the thread sealant as too
much could block the nipple.
2
3. Details: ’99 SPACE STAR Workshop Manual chassis
35A-14 BASIC BRAKE SYSTEM - On-vehicle Service
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BRAKE DRUM INSIDE DIAMETER CHECK 35100320049
3
3. Details: ’00 PAJERO PININ Workshop Manual chassis
BASIC BRAKE SYSTEM - On-vehicle Service 35A-13
BRAKE DISC RUN-OUT CHECK AND CORRECTION
1. Remove the brake assembly, and then hold it with wire.
2. Place a dial gauge approximately 5 mm from the outer circumference
of the brake disc, and measure the run-out of the disc.
Limit: <Front> 0.06 mm or less,
<Rear> 0.08 mm or less
3. If the brake disc run-out exceeds the limit, correct it as follows:
14F812
(1) Chalk phase marks on the wheel stud and the brake disc, which
run-out is excessive as show
Chalk marks
A14A0398
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(2) Remove the brake disc. Then place a dial gauge as shown, and
measure the end play by pushing and pulling the wheel hub.
Limit: <Front> 0.2 mm, <Rear> 0.025 mm
(3) If the end play exceeds the limit, disassemble the hub and knuckle
assembly to check each part.
(4) If the end play does not exceed the limit, dephase the brake disc
and secure it. Then recheck the brake disc run-out.
14H0052
4. If the run-out cannot be corrected by changing the phase of the brake
disc, replace the brake disc or grind it with the on-the-car type brake
lathe (”MAD, DL-8700PF” or equivalent.
<Added>
BRAKE BOOSTER VACUUM NIPPLE
Intake minifold REPLACEMENT <SCREW TYPE NIPPLE>
1. Remove the brake booster hose from the intake manifold.
Brake booster hose 2. Replace the nipple with a new one, using a sealing agent and
tighten to 15 – 18 N.m.
Nipple Specified sealant:
3M ATD Part No.8661 or equivalent
Caution
AY0142BY
Take care when applying the thread sealant as too much
could block the nipple.
3. After replacement, re-install the brake booster hose.