4850-01 09-3

1. SPECIFICATION
Unit Description Specification
Front brake Type Ventilated disc
Outer diameter of disc Ø294 mm
Inner diameter of caliper cylinder Ø43.0 x 2 mm
Thickness of disc 28 mm (wear limit: 25.4 mm)
Area of brake pad Above 60 cm2
Pad wear indicator Mechanical type
Rear brake Type Solid disc
Outer diameter of disc Ø299 m
Thickness of disc 10.4 mm (wear limit: 8.5 mm)
Area of brake pad Above 28.8 cm2
Pad wear indicator Mechanical type
Brake booster Type Vacuum assist type
Size 8” + 9” (Tandem)
Master cylinder Type Tandem type(integrated level sensor)
Inner diameter of cylinder Ø26.99 mm
Brake pedal Maximum operating stroke 150 mm
Pedal ratio 4:1
Free play 3 to 10 mm
Parking brake Type Mechanically expanded rear lining
Operating type Hand operated type
Inner diameter of drum Ø190 mm
Brake oil Specification DOT 4
Capacity As required

Service Interval: Change the brake oil at every 2 years

DOT?
It is the quality grade of brake fluid established by US Department of Transportation.
09-4

2. SYSTEM OVERVIEW
1) Terms and Definition
- CBS: Conventional Brake System
- ABS: Anti-Lock Brake System
- EBD: Electronic brake-Force Distribution
- ESP: Electronic Stability Program
- ABD: Automatic Braking Differential
- ASR: Acceleration Slip Regulation
- AYC: Active Yaw Control (Understeer and Oversteer Control)
- HBA: Hydraulic Brake Assistant
- ARP: Active Rollover Protection
- HSA: Hill Start Assistant
- Brake pad: Brake pad is a component of disk brakes used in automotive and other applications.
Brake pad is steel backing plates with friction material bound to the surface that faces the brake disc.
Brake disc: The brake disc is a device for slowing or stopping the rotation of a wheel while it is in
- motion.
Brake caliper: To stop the wheel, friction material in the form of brake pads (mounted on a device
- called a brake caliper) is forced hydraulically against both sides of the disc. Friction causes the disc
and attached wheel to slow or stop.
Brake master cylinder: The brake master cylinder is a control device that converts non-hydraulic
- pressure (commonly from a driver's foot) into hydraulic pressure, in order to move other device(s)
which are located at the other end of the hydraulic system, such as one or more slave cylinders. As
piston(s) move along the bore of the master cylinder, this movement is transferred through the
hydraulic fluid, to result in a movement of the slave cylinder(s). The hydraulic pressure created by
moving a piston (inside the bore of the master cylinder) toward the slave cylinder(s) compresses the
fluid evenly, but by varying the comparative surface-area of the master cylinder and/or each slave
cylinder, one will vary the amount of force and displacement applied to each slave cylinder (relative to
the amount of force and displacement that was applied to the master cylinder).

2) Functions
Function Vehicle with CBS Vehicle with ABS/EBD Vehicle with ESP
ABS Applied
EBD Applied
ABD
ASR Not applied Applied
AYC Not applied
HBA
ARP
 4850-01 09-5

3) Parts Arrangement
Part name Vehicle with Vehicle with ABS/EBD Vehicle with ESP
CBS
HECU
Front wheel speed sensor
Applied
Rear wheel speed sensor Applied

ABS warning lamp

EBD indicator
Longitudinal G sensor 2WD: N/A, 4WD: Applied Not applied
Not applied
Sensor cluster
(Yaw rate sensor,
lateral/longitudinal G sensor)
Not applied Applied
ESP indicator
ESP OFF switch and warning
lamp
Steering wheel angle sensor

4) Components
ABS ESP+ARP
2WD 4WD 2WD 4WD
Whhel speed sensor 4 4 4 4
Sensor cluster N/A N/A Applied Applied
G-sensor N/A Applied N/A N/A
2H G-sensor - Operating - -
4H G-sensor - Operating - -
4L G-sensor - Operating - -
2H sensor cluster - - Operating Operating
4H sensor cluster - - Operating Operating
4L sensor cluster - - Operating Operating
09-6

5) Indicators and Warning Lamps for ABS/ESP

Indicator/Warning Lamp
Lamp Description

EBD warning lamp ON when EBD function is failed

ABS warning lamp ON when ABS function is failed

ESP indicator Blinking when ESP function is operating

ESP OFF indicator ON when the ESP OFF switch is pressed

ESP warning lamp ON when ESP function is failed

ESP buzzer Sound when ESP function is operating

 4850-01 09-7

3. TROUBLESHOOTING
Problem Possible Cause Action
Noise or vehicle Incorrectly mounted back plate or caliper Repair
vibration when applied
Loosened bolt of back plate or caliper Retighten
Uneven wear of brake disc Replace
Brake pad contamination Clean or replace
Sticking brake pad on contact surface Replace
Wear or hardening of brake pad Replace
Excessive clearance between caliper and pad Repair
Uneven contact of pad Repair
Lack of lubrication in sliding parts Lubricate
Improper operation of caliper Replace
Dust cover missing Repair
Loosened suspension mounting bolt Retighten
Pulls to one side when Unbalanced tire pressure between left and right Adjust
braking
Poor contact of brake pad Repair
Oil or grease on brake pad Replace
Scratch, uneven wear, distortion of brake disc Replace
Improperly installed brake caliper Repair
Improper operation of auto adjuster Repair
Crack or distortion of brake pad Replace
Poor braking Oil leak or contamination Repair or replace
Air in brake line Bleed air
Improper operation of brake booster Repair
Poor contact of brake pad Repair
Oil or grease on brake pad Replace
Improper operation of auto adjuster Repair
Clogged brake line Repair
Improper operation of proportioning valve Repair
09-8

Problem Possible Cause Action

Increased pedal stroke Air in brake line Bleed air
Oil leak Repair
Worn brake pad Replace
Excessive clearance between push rod and master Adjust
cylinder
Worn or damaged piston seal Replace
Brake dragging Parking brake is not fully released Release
Incorrect adjustment of parking brake Adjust
Incorrectly adjusted clearance of parking brake shoe Adjust

Faulty brake pedal return spring Replace

Incorrectly adjusted free play of brake pedal Adjust
Faulty master cylinder Replace
Lack of lubrication in sliding parts Lubricate
Faulty brake booster (vacuum leak) Repair

Poor parking Wear, hardening or poor contact of brake pad Replace

brake Oil or water on lining Repair or replace
Fixed or broken parking brake cable Replace
Excessive stroke of brake lever Adjust notch
Faulty auto clearance adjuster Repair
Increased stroke of Loosened parking brake cable Adjust or replace
parking brake lever
Incorrectly adjusted parking brake cable Adjus
Defective automatic lining clearance adjuster Repair or replace
Worn brake lining Replace
 4850-01 09-9

Problem Cause Action

Burning smell around Too frequent braking in high driving speed Reduce the use of
tire foot brake/use
Used only foot brake during downhill driving engine brake
properly

Driving with foot on brake pedal Get off the foot from
pedal
Foreign materials such as dirt or sand in brake system Replace: caliper,
wheel cylinder,
master cylinder,
return spring

Broken return spring in shoe assembly Replace

Incorrectly adjusted parking brake cable Adjust
Incorrect wheel or wheel cover Replace
(generating the heat)
09-10

▶ BRAKE OPERATION AND NOISE

This section describes the noise phenomena occurred possibly in the brake system operation.
Distinguish between the information given below and the actual problems and then, inspect the vehicle
and take appropriate measures.

- Noise symptoms and Causes

Symptom 1. If depressing the brake pedal when the engine is cold, "screeching" sound always
occurs and, after driving for a while, the sound disappears..

This usually occurs in the morning. When the temperature goes down, the dew condensation
phenomenon sets moisture on the brake disc as the window frost forms. Due to this moisture, the iron
within the brake disc and pad oxidizes, forming undetectable micro-rusts on the disc surface. When
starting the engine under this condition, noise may sound due to the friction of micro-rusts. When
operating the brake several times, the disc temperature goes up and the micro-rusts come off and the
noise goes away. Depending on the driving conditions, noise gets louder when slightly depressing the
brake pedal and oppositely, noise is smaller when deeply depressing the brake pedal. This is simply a
physical phenomenon, called "morning effect" in professional terms, and does not imply any problems
with the brake system.

Symptom 2. Slip or screech after the brake pad replacement.

This usually occurs when the bed-in is not made between the disc and the pad's friction material. The
bed-in is a state that the brake system normally works and gives no noise out, when, after about 300 km
city driving, the contact area of the pad friction material is enlarged and the disk is in complete contact
with the pad's friction material. Therefore, for some time after the brake disk/pad replacement, the brake
system poorly operates or noise (abnormal sound) occurs due to the partial contact.

Symptom 3. "Groaning" sound occurs in the automatic transmission vehicle when slightly taking the foot
off the brake pedal to slowly start after waiting for the signal, or slightly depressing the brake pedal.

This is the noise "Creep groan" that occurs when, in both the automatic and manual transmission,
slightly releasing the brake pedal in the neutral gear at downhill roads.
It frequently occurs at the low braking power and low speed, through the following process. When
operating the brake system at low speed and low pressure, adhesion and slip repeatedly take place
between the brake disk and the friction material, and this makes the braking power inconstant, instantly
increasing or decreasing, and gives out the brake noise.
It is also a physical phenomenon and has no relation with the brake performance.
 4850-01 09-11

4. AIR BLEEDING

- Never reuse the used brake fluid.

- Use only specifies brake fluid (DOT 4). Add brake fluid between MAX and MIN lines on the
reservoir (0.7 to 0.8 liters).
- Be careful not to splash the brake fluid on painted area or body.
- Make sure that any foreign material does not get into brake line.
- Always work with another staff.

1. Fill up the brake fluid up to "MAX" line on the

reservoir.

2. Fill the reservoir with brake fluid and pump the

brake pedal several times. Then keep it
depressed.

3. Loosen the bleed screw and collect the

bleeding brake fluid from the brake line with
the order in the figure.

Fill the reservoir with the brake fluid as much

as it bleeded, and continue to bleeding
operation.
09-12

Air bleed screw at rear brake 4. Air bleed screw at rear brake

Air bleed screw at front brake 5. Air bleed screw at front brake

Air bleeding completed 6. Repeat the air bleeding procedures until clear
brake fluid comes out of air bleed screw.
Air in brake
fluid

Deteriorated
fluid 7. Check for oil leaks from the brake lines.
 4850-01 09-13

5. BRAKE SYSTEM CHECK

▶ Maximum Stroke of Brake Pedal
- Check the brake pedal with below procedures:

1. Start the engine.

2. Pump the brake pedal around 3 times.
3. Depress the brake pedal with approx. 30 kg
and measure the distance (A) between the
upper surface of pedal pad and the lower
dash panel.
4. If the measured value is out of the specified
value, adjust the length.

Specified value (A) 150mm

Over the specified value

Cause Action
Worn brake pad Replace
Worn brake shoe Replace
Improper stroke of hand
Adjust
brake
Air in brake line Air bleeding
Oil leak Repair or replace
Brake booster push rod Replace or adjust

Improperly adjusted
Adjust
stopper bolt

Below the specified value

Cause Action
Brake booster push rod Replace or adjust

Air in brake fluid Replace

Improperly adjusted
stopper bolt Adjust
09-14

▶ Pedal Height
- Check the pedal height with below procedures:

Push rod
1. Start the engine and measure the length (A)
Stop lamp
between floor mat and pedal.
switch
2. If the measured value is out of the specified
value, adjust the length.

Specified value (B) 155mm

- Adjust the pedal height with below procedures:

1. Disconnect the stop lamp switch connector.

Unscrew the lock nut and remove the stop
2. lamp switch assembly.
Loosen the lock nut on the pedal push rod.
3. Turn the pedal push rod to adjust the pedal
4. height.
Tighten the lock nut.
5. Install the stop lamp switch assembly.
6. Connect the stop lamp switch connector.
7. Check if the stop lamps come on when
8. pressing the brake pedal around 5 mm.
If the stop lamp dpes not come on, adjust the
9. stop lamp switch assembly again.
If the stop lamps come on, tighten the lock nut
10.and measure the pedal height again.
 4850-01 09-15

▶ Pedal Free Play

- Check the pedal free play with below
procedures:

1. Stop the engine.

2. Depress the brake pedal several times to
discharge the vacuum pressure of the brake
booster.
3. Depress the brake pedal until you feel the
resistance, and measure the movement (A).

Specified value (A) 3 ~ 10mm

- Below the specified value: Check if the

distance between the outer case of stop lamp
switch and the brake pedal.
- Over the specified value: It may be caused by
bigger clearance between the clevis pin and
the brake pedal arm. Replace the
components if necessary.

▶ Stop Lamp Switch

- Connect the multimeter to stop lamp switch
connector and check if the continuity exists
when pushing in the plunger. If the continuity
doesn't exist, the stop lamp switch is normal.
09-16

▶ Brake Booster
1. Let the engine run for 1 to 2 minutes and
stop it. If the brake pedal stroke is shortened
as pumping the brake pedal, the system is
normal. If not, the system is defective.
Depress the brake pedal several times with
2. engine off. If the brake goes down when
starting engine with pedal depressed, the
system is normal. If not, the system is
defective.
Depress the brake pedal when the engine is
3. running. If the pedal height is not changed for
30 seconds after stopping the engine, the
system is normal. If not, the system is
defective.

If the above three checks are OK, the system is

normal. If any condition is not met, check the
valve, vacuum hose and brake booster.
 4850-01 09-17

▶ Brake Fluid

1. Color
- Ligh gold (New oil) → Brown → Black

2. Service Interval/Type
- Change: every 2 years, Type: DOT4
The water in the brake fluid has an adverse effect to the brake system. If the fluid contains
around 3% of water, the boiling point of the brake fluid goes down by 25%. It will cause the vapor
lock frequently.
Water content in fluid: around 3% after 18 months, around 7~10% after few years
The water ib fluid makes the corrosion in the brake lines, deforms and deteriorates the rubber
components, brake calipers and pistons.

▶ Brake Fluid Type

DOT4: Brake fluid for premium vehicle. Lower water absorbing rate AND higher boiling point than
DOT3

▶ Brake Fluid Level Check

The brake fluid level should be between "MAX"

and "MIN" on the reservoir. If it is below "MIN"
mark, check for oil leaks and refill the reservoir
with the specified fluid.
09-18

▶ Front Brake

1. Pad Thickness
- Measure the pad thickness and replace it if
it is below the wear limit.

New pad Wear limit

10.5 mm 2 mm

- Wera limit point

2. Disc Thickness
- Measure the disc thickness at over four
points.
- If any of measured points is below the wear
limit, replace the brake disc with new one.

New disc Wear limit

28 mm 25.4 mm

3. Disc Run-Out

- Install the dial gauge on the side of brake

disc and measure the run-out while rotating
the brake disc.
- If the measured value exceeds the limit,
replace the brake disc with new one.
Otherwise, it may cause the pedal vibration
and shimmy when braking.

Limit 0.03 mm (before installation)

0.07 mm (when installed)
 4850-01 09-19

Clean the dissembled components and visually check the followings:

4. Damage and tear on boot

5. Uneven wear and oil contamination

6. Damage, crack and wear on cylinder body (A)

and guide pin (B)

7. Wear, rust and damage on the cylinder and

piston
8. Scratch and bending on disc plate
09-20

▶ Rear Brake
Pad Thickness
1. Remove the front tire.
2. 2. Measure the pad thickness and replace it if
it is below the wear limit.

New pad Wear limit

10 mm 2mm

Disc thickness
1. Measure the disc thickness at over four
points.
2. If any of measured points is below the wear
limit, replace the brake disc with new one.

New disc Wear limit

10.4mm 8.5mm

Disc Run-Out
1. Install the dial gauge on the side of brake disc
and measure the run-out while rotating the
brake disc.
2. If the measured value exceeds the limit,
replace the brake disc with new one.
Otherwise, it may cause the pedal vibration
and shimmy when braking.

0.03 mm (before installation)

Limit
0.07 mm (when installed)
 4850-01 09-21

▶ Parking Brake

Check the brake force with below procedures:

1. Count the number of the clicks (notches)

when pulling up the parking brake with 19 kg
of force.

Specified notches 5

2. If the clicks are over or below the specified

value, adjust the clicks to the specified value
with the parking brake adjusting nut.
Check the parking brake force after
3. adjustment.

4. If the parking brake force is not enough,

check the parking brake lever and cable.
Replace the components if needed.

Never park the vehicle only with the parking

brake on the stiff hill. It may cause roll down of
the vehicle due to release of the parking
brake. Place the wheel chocks under the
wheels.
09-22

6. COMPONENTS
▶ Brake Pedal, Master Cylinder and Booster

1. Brake master cylinder assembly 17.Nut - Brake pedal

2. Brake booster assembly 18.Stop lamp switch
3. Brake master cylinder 19.Stopper
6. Nut (12.8~16.7 Nm) 20.Clevis pin
7. Booster mounting seal 21.Snap pin
8. O-ring 22.Bolt - Brake pedal assembly
11.Brake pedal assembly (17.6~21.6 Nm)
12.Brake pedal 23.Nut - Brake booster
13.Brake pedal return spring (17.6~21.6 Nm)
 4850-01 09-23

▶ Brake Pipe

1. Master cylinder primary tube assembly 13.Brake tube mounting clip

2. Master cylinder secondary tube assembly 14.Brake tube mounting holder
3. Front tube assembly 20.Brake tube 2-way connector
4. Front tube assembly 21.Screw
5. 2-way connector tube assembly 22.Rear hose 2-way connector
7. Front brake hose assembly 24.3-way connector hose tube assembly
8. Front brake hose mounting holder 25.Rear brake hose assembly
9. Flexible hose clip 26.Rear brake hose assembly
11.Caliper eye bolt (19.6~29.4 Nm) 27.Bolt (9.8~11.8 Nm)
12.Brake tube mounting clip
09-24

▶ Front/Rear Brake Assembly

1. Rear brake caliper assembly 21.Front brake caliper assembly

2. Rear brake pad 22.Front brake pad
3. Washer 23.Washer
4. Bolt (52.9~63.7 Nm) 24.Front caliper mounting bolt
5. Rear brake disc (25.5~30.4 Nm)
6. Rear disc brake dust shield 25.Caliper clip set
7. Bolt
12.Rear drum brake assembly
15.Parking brake shoe
16.Parking brake repair kit
17.Rear axle shaft grommet
 4850-01 09-25

▶ Parking Brake

1. Parking brake lever assembly

3. Equalizer
4. Nut (9.8~12.7 Nm)
5. Front brake mounting bracket
6. Bolt
10.Parking brake rear cable assembly
11.Parking brake rear cable assembly
12.Bolt (9.8~12.7 Nm)
13.Parking brake cable retaining ring
09-26

1. OVERVIEW
Even though a driver cuts off the power, while driving, the vehicle continues to move due to the law of
inertia. Therefore, a braking device is needed to stop the vehicle. The brake system normally uses the
frictional discs that converts the kinetic energy to the thermal energy by frictional operation. The brake
system consists of the brake disc (front wheel), brake disc or drum (rear wheel), parking brake
(mechanical type), master cylinder, booster, pedal and supply lines (pipes and hoses).

▶ Hydraulic Brake

This system uses the leverage effect and

Pascal's principle. When depressing the brake
pedal, the pedal pressure is increased by
booster and is delivered to master cylinder to
generate hydraulic pressure. The hydraulic
pressure generated by the master cylinder is
delivered to the brake caliper through the brake
pipes or hoses. This hydraulic pressure pushes
the brake calipers, accordingly the caliper pads
are contacted to brake disc to generate the
braking force.

▶ Brake Pedal

Brake pedal uses the leverage effect to apply

bigger force to the brake master cylinder.
 4850-01 09-27

▶ Braking distance & stopping distance

Stopping distance = free running distance + braking distance

What is stopping distance?

A certain distance (free running distance + braking distance) is needed from the moment an obstacle
appears ahead until you bring your vehicle to a complete stop. This is called as stopping distance.
What is braking distance?
Tire slip occurs until the vehicle stops completely when the the brake is applied.
This slip is what we call a braking distance.

What is free running distance?

The free running distance is the time from the driver sees the obstacles and begins to prepare for
depressing the brake pedal until the moment the brake pedal is depressed.
09-28

2. SYSTEM LAYOUT

Master Cylinder and Booster

HECU

Brake Pedal

Front Brake Assembly Front Wheel Speed Sensor (4WD)

 4850-01 09-29

ABS/EBD Indicators

Parking Brake Lever

Rear Brake Assembly

Parking Brake Rear Wheel Speed Sensor (4WD)

09-30

3. PARKING BRAKE
▶ Front Disc Brake

Brake caliper

Brake pad

Air breather

Brake disc

Drive shaft

Brake hub

Lower arm ball joint

Upper arm connection

2-way piston

Brake caliper

Tie rod end connection

Knuckle

Backing plate

Lower arm connection

 4850-01 09-31

▶ Rear Disc Brake

Air breather

Brake caliper

Brake pad

Brake disc

Brake hub

Rear shock absorber

Brake hose

Brake caliper

one-way piston

Air breather

Backing plate
09-32

4. HYDRAULIC CIRCUIT

1. Brake booster 4. HECU (Hydraulic & Electric Control Unit)

2. Brake fluid reservoir and master cylinder 5. Rear disc brake and caliper
3. Front disc brake and caliper
 4850-01 09-33

5. CIRCUIT DIAGRAM OF STOP LAMP