Specifications

Specifications

Item		Specification
Master cylinder	Type	Tandem
	Cylinder I.D.	22.22 mm
	Piston stroke	45 ± 1 mm (1.77 ± 0.039 in)
	Fluid level switch	Provided
Brake booster	Type	10" Single
	Boosting ratio	8.0 : 1
Front disc brake	Type	Ventilated disc
	Disc O.D.	O 280 mm (11.02 in)
	Disc thickness	23 mm (0.91 in)
	Caliper piston	Single
	Cylinder I.D.	O 57.2 mm (2.25 in)
Rear disc brake	Type	Solid disc
	Disc O.D.	O  262 mm (10.31in)
	Disc thickness	10 mm (0.39 in)
	Caliper piston	Single
	Cylinder I.D.	O 33.96 mm (1.34 in)
Rear drum brake	Type	Leading trailing
	Drum I.D	O 203.2 mm (8 in)
	Brake lining thickness	4.2 mm (0.17 in)
	Clearance adjustment	Automatic
Parking brake	Type	BIR (Ball-in-Ramp)
	Actuation	Lever

Specification (ABS)

Part	Item	Standard value	Remark
HECU	System	4 Channel 4 Sensor (Solenoid)
	Type	Motor, valve relay intergrated type
	Operating Voltage	8 ~ 16 V
	Operating Temperature	-40 ~ 120 °C (-40 ~ 248°F)
	Motor power	195 W
Active Wheel speed sensor (ABS)	Supply voltage	DC 4.5 ~ 20 V
	Output current low	5.9 ~ 8.4 mA
	Output current high	11.8  ~ 16.8 mA
	Output range	1 ~ 2500 Hz
	Tone wheel	Front : 46 teeth, Rear : 47 teeth
	Air gap	0.4 ~ 1.0 mm

Specification(ESP)

Part	Item	Standard value	Remark
HECU	System	4 Channel 4 Sensor (Solenoid)	Total control (ABS, EBD, TCS, ESP)
	Type	Motor, valve relay intergrated type
	Operating Voltage	8 ~ 16 V
	Operating Temperature	-40 ~ 120 °C (-40 ~ 248°F)
	Motor power	290 W
Active Wheel speed sensor	Supply voltage	DC 4.5 ~ 20 V
	Output current low	5.9 ~ 8.4 mA
	Output current high	11.8~ 16.8 mA
	Output range	1 ~ 2,500 Hz
	Tone wheel	Front : 46 teeth, Rear : 47 teeth
	Air gap	0.4 ~ 1.0 mm

Service Standard

Items	Standard value
Brake pedal height	182 mm (7.17 in)
Brake pedal Full stroke	135 mm (5.31 in)
Stop lamp switch clearance	1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
Brake pedal free play	2 ~ 4 mm (0.08 in ~ 0.16 in)
Front brake disc thickness	23 mm (0.90 in)
Front brake disc service limit	21.4 mm(0.84 in)
Front brake disc pad thickness	11 mm (0.43 in)
Front brake disc pad service limit	2.0 mm (0.78 in)
Rear brake disc thickness	10 mm (0.39 in)
Rear brake disc service limit	8.4 mm (0.33 in)
Rear brake disc pad thickness	10 mm (0.39 in)
Rear brake disc pad service limit	2.0 mm (0.78 in)
Rear drum brake lining thickness	4.2 mm (0.17 in)
Rear drum brake lining service limit	1.0 mm (0.04 in)

Tightening Torques

Items	N.m	kgf.m	lb-ft
Master cylinder to brake booster	12.7 ~ 16.7	1.3 ~ 1.7	9.4 ~ 12.3
Brake booster mounting nuts	16.7 ~ 25.5	1.7 ~ 2.6	12.3 ~ 18.8
Air bleeding screw	6.9 ~ 12.7	0.7 ~ 1.3	5.1 ~ 9.4
Brake tube flare nuts	12.7 ~ 16.7	1.3 ~ 1.7	9.4 ~ 12.3
Front caliper guide rod bolts	21.6 ~ 31.4	2.2 ~ 3.2	15.9 ~ 23.1
Rear caliper guide rod bolts	21.6 ~ 31.4	2.2 ~ 3.2	15.9 ~ 23.1
Front caliper assembly to knuckle	78.5 ~ 98.1	8.0 ~ 10.0	57.9 ~ 72.3
Rear caliper assembly to knuckle	63.7 ~ 73.5	6.5 ~ 7.5	47.0 ~ 54.2
Brake hose to caliper	24.5 ~ 29.4	2.5 ~ 3.0	18.1 ~ 21.7
Brake pedal member bracket bolts	16.7 ~ 25.5	1.7 ~ 2.6	12.3 ~ 18.8
Wheel speed sensor mounting bolt	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
HECU bracket mounting and nut	16.7 ~ 25.5	1.7 ~ 2.6	12.3 ~ 18.8

Lubricants

Items	Recommended	Quantity
Brake fluid	DOT 3 or DOT 4	As required
Brake pedal bushing and bolt	Chassis grease	As required
Parking brake shoe and backing plate contacting surface	Heat resistance grease	As required

Special Service Tools

Special Service Tools

Tool(Number and Name)	Illustration	Use
09581-2T100 Piston expander		Spreading the front disc brake piston.
09580-0U000 Brake piston adjuster		Removal and installtion of the rear disc brake piston.

Troubleshooting

Troubleshooting

Problem Symptoms Table

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the like cause of the problem. Check each part in order.

If necessary, replace these parts.

Symptom	Suspect Area	Reference
Lower pedal or spongy pedal	1. Brake system (Fluid leaks) 2. Brake system (Air in) 3. Piston seals (Worn or damaged) 4. Rear brake shoe clearance(Out of adjustment) 5. Master cylinder (Inoperative)	repair air·bleed replace adjust replace
Brake drag	1. Brake pedal free play (Minimum) 2. Parking brake lever travel (Out of adjustment) 3. Parking brake wire (Sticking) 4. Rear brake shoe clearance(Out of adjustment) 5. Pad or lining (Cracked or distorted) 6. Piston (Stuck) 7. Piston (Frozen) 8. Anchor or Return spring (Inoperative) 9. Booster system (Vacuum leaks) 10. Master cylinder (Inoperative)	adjust adjust repair adjust replace replace replace replace replace replace
Brake pull	1. Piston (Sticking) 2. Pad or lining (Oily) 3. Piston (Frozen) 4. Disc (Scored) 5. Pad or lining (Cracked or distorted)	replace replace replace replace replace
Hard pedal but brake inefficient	1. Brake system (Fluid leaks) 2. Brake system (Air in) 3. Pad or lining (Worn) 4. Pad or lining (Cracked or distorted) 5. Rear brake shoe clearance(Out of adjustment) 6. Pad or lining (Oily) 7. Pad or lining (Glazed) 8. Disc (Scored) 9. Booster system (Vacuum leaks)	repair air·bleed replace replace adjust replace replace replace replace
Noise from brake	1. Pad or lining (Cracked or distorted) 2. Installation bolt (Loosen) 3. Disc (Scored) 4. Sliding pin (Worn) 5. Pad or lining (Dirty) 6. Pad or lining (Glazed) 7. Anchor or Return spring (Faulty) 8. Brake pad shim (Damage) 9. Shoe hold-down spring (Damage)	replace adjust replace replace clean replace replace replace replace
Brake fades	1. Master cylinder (Inoperative)	replace
Brake vibration, pulsation	1. Brake booster (Vacuum leaks) 2. Pedal free play 3. Master cylinder (Inoperative) 4. Caliper (Damage) 5. Master cylinder cap seal 6. Damaged brake lines	replace adjust replace replace replace replace
Brake Chatter	Brake chatter is usually caused by loose or worn components, or glazed or burnt linings. Rotors with hard spots can also contribute to brake chatter. Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes, loose wheel bearings and contaminated brake lining.