Wheel and Tire

Brake system

I. Overview
(I) Structure Summary
Brake system diagram (front & rear plate models)

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1. Left front brake caliper assembly
2. Right front brake caliper assembly
3. Front brake discs
4. Rear brake disc
5. Left rear brake caliper assembly
6. Right rear brake caliper assembly
7. Master cylinder flow lines assembly
8. Front brake exhaust pipe assembly
9. Right front brake pipe assembly
10. Rear brake exhaust pipe assembly
11. Left front brake hose assembly
12. Right front brake hose assembly
13. Left rear brake hose assembly Ⅱ
14. Right rear brake hose assembly Ⅱ
15. Vacuum booster with brake master pump assembly
16. Brake pedal assembly

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Rear disc brake caliper structure (Front & Rear plate models)

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1. The guide seat
2. Strut nut
3. The torsion spring
4. Strut
5. Guide seat bolt
6. Plug
7. Hex head bolt
8. Cylinder
9. The Under-pin
10. The bushing
11. Piston composition
12. Dust cover
13. The yoke spring
14. The inner brake assembly
15. Bracket
16. Bleeder screw and nut
17. The outer brake assemblyVacuum booster assembly diagram

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1. The vacuum booster

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2. The master cylinder
3. Brake fluid reservoirHydraulic line chart

1. Brake master cylinder 2. ABS / ESP module assembly

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(II) Maintenance data and Specifications

Item Specifications
master cylinder type Cascade
cylinder bore 22.22mm
brake booster type vacuum
Size (size) 10 inches
assist ratio 7.3:1
type Floating type/ventilated disc
Front brake (front Brake disc diameter 256mm
disc rear drum
type) Brake disc thickness 22mm
Friction block thickness 10.8mm
cylinder bore 54mm
Rear brake (front type Drum brake
disc rear drum type) Sub brake disc diameter 17.46mm

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Brake disc thickness 204mm
Friction block thickness 4mm
type Floating type/ventilated disc
Front brake (front Brake disc diameter 294mm
disc rear disc type) 25mm
Brake disc thickness
Friction block thickness 9.5mm
cylinder bore 54mm
Rear brake (front type Floating type/ventilated disc
disc rear disc type) Brake disc diameter 275mm
Brake disc thickness 9mm
Friction block thickness 8mm
cylinder bore 34mm
(III) Torque parameters
No. Item Torque (N • m) Remarks
1 front brake caliper and knuckle connecting bolt 75~85
2 rear brake caliper and torsion beam bolt 65~75
3 rear brake and rear hub connecting bolt 65~85
4 front and rear brake caliper bleeder screw 7~13
5 brake pedal upper bracket bolt 20~25
6 brake pedal fixing nut 20~25
7 brake hose and brake caliper bolt 25~30
8 brake hardware fittings 16~18

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(IV) Maintenance Precautions

1. All brake lines should not be excessive bending, twisting and stretching.
2. Verify that all vehicle brake lines do not interfere with other parts at ease or during steering.
3. The brake lines is an important safety part, always tighten its fixture. If found damaged parts, replace
the applicable component.
4. When disconnecting the brake pipe, please seal the connector end to avoid dust entering.
5. "DOT 4" brake fluid is recommended.
6. Do not reuse drained brake fluid.
7. Be careful not to splash brake fluid on painting, to avoid damaging the paint. If splashed on painted
areas, wash clean immediately with water.
8. Please wash with clean brake fluid all parts in the brake cylinder.
9. Do not use gasoline or kerosene and other mineral oil, to avoid damaging the rubber parts of the
hydraulic system.
10. Please use a dedicated pipe wrench when removing and installing tube, during brake tube
installation, be sure to check tightening torque.
11. After repairing or replacing brake discs, brake shoes, or appear lack of brake with a very short

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distance, be sure to run-brake joint surface.
12. Make sure there is no brake fluid on the brake disc, do not spill brake fluid on the brake disc,
otherwise it will lead to brake failure.
II. Fault diagnosis
(I) Fault diagnosis table
Common braking system fault finding chart
No. Failure Cause Failure Analysis Solution Remark
when braking insufficient left & right tire pressure adjust
1 the vehicle Front wheel adjusted incorrectly adjust
deviate to one
Brake shoe has poor contact adjust
side
Brake shoe surface has grease or oil replace
brake drum eccentric or unevenly replace
worn
Brake cylinder assembly adjusted adjust
incorrectly
Self-adjusting mechanism is faulty adjust
2 insufficient lack of brake fluid or contaminated Refill to replace
braking force Brake system has air Drain the system
The brake booster is faulty Adjust
Brake shoe has poor contact Adjust
Brake shoe surface has grease or oil Replace
Self-adjusting mechanism is faulty Adjust
Dragging brake shoe and brake Adjust
rotating parts cause overheating
brake lines limits Adjust
Increase the Brake system has air Drain the system
3 pedal stroke Brake fluid leak Adjust

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(pedal to the Self-adjusting mechanism is faulty Adjust

floor to reduce Pushrod to the brake master cylinder Adjust
the distance) gap is too big

No. Failure Failure Analysis Solution Remark

Cause
Brake parking brake is not fully liberalized liberalize
4 hysteresis parking brake improperly adjusted adjust
Brake pedal return spring worn replace
Brake master cylinder reservoir port adjust
restrictions
Rear drum brake return spring damaged replace
lading parts insufficient lubrication lubricate
One-way valve or the master cylinder replace
piston return spring defective

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master cylinder pushrod and gap is too lubricate
small
parking rear brake shoe damage adjust
5 brake The surface of rear brake shoe has grease replace
function is or oil
insufficient
Parking brake fastener jammed adjust
Self-adjusting mechanism is faulty adjust
The parking brake lever stroke is too big adjust
6 Braking pipe joints or brake cylinder cups leak wipe clean and tighten or
force is Pipeline residual exhaust air is not replace
drain
insufficient drained
Shoe drum gap is too large retune
Hoof surface sticky oil or hardened friction or replace
The drum overheating, pipe vapor Replace, cooling, drain
resistance
7 brake is brake cylinder cups back to the hole expansion or replace
hard to blocked or gap
drum shoe remove
is too small retune
release
Shoe return spring elastic weakened or replace
broken
Hoof or floor deformation, return Adjust or replace
8 noise blocked
rear brake shoe severely worn replace
Brake drum out of round Cut and need balance
performance verification

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Rear brake shoe surface is too smooth, After clearing the foreign
when friction coefficient is small and the object, use sandpaper to polish
brake pressure is high, the noise will be brake shoe
generated when friction and slipping the
smooth surface or when there is foreign
object between the extrusion friction
surface

9 Brake brake gap and pedal free travel遇此情况

is too readjust the brake timing and
dragging small, when release the brake pedal, the gap according to the request
caused braking force is not fully liberated, so
brake drum that the friction lasts a long time; cause
heating start difficulties, driving weakness, when
touches the surface of the drum, it is hot

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brake handle is not fully liberalized, If necessary adjustments
caused by negligent operation or according to specifications
improper adjustment, resulting in a long
time friction and heat

The heat generated by braking causes

应检修或更 repair or replace the return
return spring thermal deformation, the spring to eliminate failure
elastic force decline or disappear, which
makes that it after braking it cannot
guarantee that brake shoe assembly
return in time, the heat of the brake and
brake drum cannot be completely
removed

10 Parking Common brush or jacket rust, traction Check whether there is injury
failure spring break, fall off or elasticity of the brake systems and brake
disappear, causing parking brake control parts drawing surface, handle
drawing or brake drawing is not flexible maneuvers whether flexible
in its coat, which makes the parking and without jam, the
brake does not release and cause failure. connection of drawing is loose
and the fixed portion is
damaged, repair or replace
parts if necessary.

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III. Front brake pad friction plate

(I) Remove
△ Note To maintain wheel balance, before removing the
tire, mark the relative positions of the wheel.
1. Remove wheels refers to the wheels
2. Remove the front brake caliper friction plate group
1). Remove mounting bolts of the brake caliper assembly
positioning pin.
2). Flip caliper clamp body assembly.
△ Note avoid pulling the brake hose

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S2-w3085b

3). Remove the inner and outer brake pads.

(II) Check
1. Check the thickness of brake shoe (disc brakes)
1). Check brake shoe thickness with the scale.
Front brake caliper Standard lining thickness (front disc rear drum models): 11mm
Front brake caliper pad wear limit thickness (front disc rear drum models): 2mm
Front brake caliper standard lining thickness (front disc rear disc models): 9.5mm
Front brake caliper pad wear limit thickness (front disc rear disc models): 2mm
Rear caliper standard lining thickness (front disc rear disc models): 8mm
Front brake caliper pad wear limit thickness (front disc rear disc models): 2mm
△ Note that if the brake shoe thickness less than the
thickness of the wear limit, replace the brake shoe

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S2-w3087b
(III) Installation
1. Install the caliper lining
1). Mount the caliper brake friction plate on the caliper
bracket.

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2) Install front brake caliper assembly positioning pin
fixing bolts and tighten.
Tightening torque 35 ~ 45N • m
3). Fix brake disc, tread the brake pedal until the brake
respond.
4) Check the rotation resistance of brake caliper.

5) Install the wheel

IV. Front brake caliper assembly
(I) Remove
1. Remove the wheels refers to the wheels
2. Discharge brake fluid refers to brake fluid
3. Remove the front brake caliper assembly
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1). Remove the brake hose bolts and copper washer

connecting brake hose and front brake caliper.
△ Note attention not to drop copper washer on both ends
of the bolt

2). Remove the two mounting bolts connecting the front

brake caliper assembly and steering knuckle.
3) Remove the front brake caliper assembly.

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(II) Installation
1. Install the front brake caliper assembly
1). Place the caliper assembly to the mounting position,
pre-tightening two mounting bolts connecting clamp
caliper assembly and steering knuckle.
2) Tighten two mounting bolts connecting clamp caliper
assembly and steering knuckle.
Tightening torque 75 ~ 85N • m

3) Install the caliper bolts and copper washers connecting

the front brake hose and front brake hose.

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Tightening torque 25 ~ 30N • m

2. Fill brake fluid refers to brake fluid
3. Drain brake system exhaust refers to the brake system exhaust
4. Install the wheel

V. Front brake discs

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(I) Remove
1. Remove the wheels refers to the wheels.
2. Remove the front brake caliper assembly refers to front brake caliper assembly.
3. Remove the front brake disc.
1). Remove the brake discs on the front cross screws.
2) Remove the front brake discs.

(II) Check
1. Visually check
Check whether there is front brake disc surface uneven
wear, cracks and badly damaged. If yes, please replace it.
2. Check run out
1) Fix front brake disc to the hub.
△ Note before measurement, make sure the wheel bearing
axial clearance should not be too large.
2) Use a dial indicator to check run out. It can be
measured at 10mm inside edge of the brake disc
Run out limit: 0.05mm
3) If the run out exceeds the limit, replace the brake disc
or make the necessary processing.

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3. Check the thickness

1) Use a micrometer to check the brake disc thickness. If
the thickness is less than wear limit, replace the brake disc.
Standard thickness (front disc rear drum models): 22mm wear limit (front disc rear drum models):
20.4mm standard thickness (front disc rear disc models): 25mm wear limit (front disc rear disc models):
23mm

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(III) Installation
1. Install the front brake discs
1) Install the front brake discs.
2) Tighten the cross-shaped screws.
Tightening torque 10 ~ 15N • m
2. Install the front brake caliper assembly
3. Install the wheel

VI. Rear brake pad lining

(I) Remove
△ Note To maintain wheel balance, before removing the
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tire, mark the relative positions of the wheel.

1. Remove the rear wheel refers to wheels.
2. Remove the rear brake caliper lining
1). Lower the parking brake.
2) Demolition two mounting bolts of rear caliper
positioning pin.
3) Flip rear caliper clamp body assembly.
△ Note avoid pulling the brake hose

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4). Remove the inner and outer brake pad lining.

(II) Inspection
1. Check thickness of the brake pads friction plates
1). Check the thickness with the caliper scale lining. Brake
caliper lining standard thickness (front disc rear disc
models): 8mm rear brake caliper pad wear limit thickness
(front disc rear disc models): 2mm
△ Note that if the brake shoe thickness less than the
thickness of the wear limit, replace the brake caliper lining

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(III) Installation
1. Install the caliper lining
1). Mount the brake caliper friction disc to the brake
caliper mounting bracket.
△ Note install in accordance with the friction plate pad and
friction plate retaining ring direction

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2) Install rear brake caliper assembly positioning pin
fixing bolts and tighten
Tightening torque 22 ~ 32N • m
3). Fix brake disc, tread the brake pedal until the brake
respond.
4) Check the rotation resistance of brakes.
2. Install the rear wheels

VII Rear brake caliper assembly

(I) Remove
1. Remove the wheels refers to wheels
2. Discharge brake fluid refer to brake fluid
3. Remove the rear brake caliper assembly
1). Lower the parking brake.
2) Remove the brake hose bolts and copper washers
connecting to the rear brake hose and the rear brake
caliper.
△ Note attention not to drop copper washer at both ends of

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the bolt

3) Demolition two mounting bolts connecting rear caliper

assembly and rear torsion beam assembly.

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4) Remove fixing nuts and cards connecting rear brake
caliper assembly and rear parking brake drawing;
disengage the rear brake caliper assembly and rear parking
brake drawing.
5) Remove the rear brake caliper assembly.

(II) Installation
1. Install the rear brake caliper assembly
1). Place the rear caliper assembly to the mounting
position, pre tighten brake caliper mounting bracket bolts.
2). Tighten two mounting bolts connecting the rear caliper
assembly and torsion beam assembly.
Tightening torque 65 ~ 75N • m

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3) Install brake hose bolts and copper washers connecting

the rear brake hose and brake pad.
Tightening torque 25 ~ 30N • m
4) Install rear brake caliper assembly and rear parking
brake drawing connections.
2. Fill brake fluid refers to brake fluid.

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3. Drain brake system exhaust refers to brake system exhaust.
4. Install the wheel

VIII Rear brake disc

(I) Remove
1. Remove the wheels refers to wheels
2. Remove the rear brake caliper assembly refers to the rear brake caliper assembly
3. Remove the rear brake disc
1). Remove the brake disc rear cross screws.
2). Remove the brake disc

(II) Check

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1. Visually check
Check that whether there is the rear brake disc surface uneven wear, cracks and badly damaged. If there is,
replace it.
2. Check run out
1) Fix the rear brake disc to the hub.
△ Note before measurement, make sure the wheel bearing
axial clearance should not be too large.
2) Use a dial indicator to check run out. It can be
measured at the10mm inside edge of the brake disc
Run out limit: 0.05mm
3) If the run out exceeds the limit, replace the brake disc
or make the necessary processing

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3. Check the thickness
1) Use a micrometer to check the brake disc thickness. If
the thickness is less than wear limit, replace the brake disc.
Standard rear brake disc thickness (front disc rear disc
models): 9mm
Rear brake disc wear limit (front disc rear disc models):
8mm

(III) Installation
1. Install the brake disc
1) Install the rear brake disc.
2) Tighten the cross screws.
Tightening torque 10 ~ 15N • m

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2. Install the rear brake caliper assembly

3. Install the wheel

IX Brake fluid
(I) Check
1. Check the brake fluid level
1) Verify whether the brake fluid level oiler height is

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within a predetermined range
Standard size between mark MAX and MIN
2) If the level is too low, Check whether brake system and
surrounding oiler leaks.

(II) Brake fluid discharge

1. Drain brake fluid
1) Open the brake fluid filler cap.
2) Place drip pan.
3). Empty brake fluid
4) Install the brake fluid filler cap.
△ Note cover with a cloth or piece of cloth on the painted
surface to prevent brake fluid adhesion.
(III) Fill brake fluid
1. Fill brake fluid
1). Depress the brake pedal several times until the
complete elimination of the vacuum booster pressure.
2) Open the brake fluid filler cap.
3). Fill the brake fluid.
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△ Note clean before open the front tank cover, only use
brake fluid stored in a sealed container.
X. Front brake hose
(I) Remove
1. Drain brake fluid refers to brake fluid
2. Remove the wheels refers to wheels
3. Remove the front brake hose
1). Remove brake hose bolt and copper washers
connecting the front brake hose and front brake caliper.
△ Note attention not to drop copper washers

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2). Remove the connector between the brake hose and
brake hardware with a pipe wrench, disengage the card.
3). Remove fixing bolts connecting the central of brake
hose and the front shock absorber.
4) Remove the front brake hose.

(II) Installation
1. Install the front brake hose assembly
1) Install the card, install the brake hose and brake
hardware connector with a pipe wrench.
Tightening torque 16 ~ 18N • m
2) Install fixing bolts connecting the central of the brake
hose and the front shock absorber.
Tightening torque 20 ~ 25N • m

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3) Install brake hose bolts and copper washers connecting

the front brake hose and front brake pads.
Tightening torque 25 ~ 30N • m
△ Note Do not reuse gaskets and tubing cards.

△ Note pay attention to the brake hose installation

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direction.
2. Install the wheel
3. Fill brake fluid refers to brake fluid
4. Drain brake system exhaust refers to brake system exhaust

XI. Rear brake hose assembly

(I) Remove
1. Drain brake fluid refers to brake fluid
2. Remove wheel refers to wheels
3. Remove the rear brake hose
1) Remove bolts and copper washers connecting the rear
brake hose and rear brake caliper Ⅱ.

△ Note attention not to drop copper washers

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2). Remove the connector between rear brake hose

assemblies Ⅱ and the brake hardware with a wrench.
Disengage the card.
3) Remove the rear brake hose assembly Ⅱ.

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(II) Installation
1. Install the rear brake hose assemblies Ⅱ
1) Install the card, the connector between rear brake hose
assemblies Ⅱ and the brake hardware with a wrench.
Tightening torque 16 ~ 18N • m

2) Install bolts and copper washers connecting the rear

brake hose and rear brake caliper Ⅱ..
Tightening torque 25 ~ 30N • m
△ Note Do not reuse gaskets and tubing cards.

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△ Note pay attention to the brake hose installation

direction.
2. Install the wheel
3. Fill brake fluid refers to brake fluid
4. Drain brake system exhaust refers to brake system exhaust

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XII. Brake pedal (MT)
(I) Check and adjust
1. Adjust the clearance between the brake pedal and the brake limit switch bolt
1). Remove guard assembly under the driving side.
2) Disconnect the brake lamp switch harness connector.

3) Loosen the lock nut of brake limit switches, release the

brake pedal.
4). Rotate switch bolt, keep the gap of switch bolt and the
brake pedal between 0.5 ~ 1mm
Tightening torque 8 ~ 10N • m

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2. Check brake pedal free travel

1) When the engine stalls state, depress the brake pedal 2
or 3 times.
2) confirm the vacuum brake booster vacuum-elimination,
pressed pedal with hand.
3) Before verify resistance occurs, check the brake pedal

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free travel is within the standard range.
Standard value: 3mm ~ 8mm
△ Note that if the free travel is not within the standard,
replace the damaged parts.

3. Adjust the brake pedal free travel

1) Release the brake limit switch nut, relax the brake pedal,
rotate switch bolt, and keep the gap of switch bolt and the
brake pedal in 0.5mm ~ 1mm.
Free travel standard value: 3mm ~ 8mm

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(II) Remove
1. Open the engine hatch
2. Disconnect the negative battery cable
3. Remove the lower part of the dashboard fender refers to the lower part of the dashboard fender
4. Remove the brake pedal
1) Disconnect the stop lamp switch harness connector.

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2). Remove lock pin connecting the brake pedal and the
brake booster vacuum, disconnect the brake pedal and the
brake booster vacuum

3) Remove the two fixing nuts connecting the brake pedal

and the body.

4). Remove four fixing nuts connected the brake pedal and
the vacuum booster to the vehicle body
5) Remove the brake pedal.

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(III) Installation
1. Install the brake pedal
1) Install four fixing nuts connected the brake pedal and
the vacuum booster to the vehicle body and pre-tighten.
Tightening torque 20 ~ 25N • m

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2). Install the two fixing nuts connecting the brake pedal
and the body and tighten.
Tightening torque 20 ~ 25N • m

3) Install the brake pedal and the brake booster vacuum

plastic ring, cotter pins, the main pump latch locking.
△ Note the main pump kingpin should be normally
moving in the mounting hole with no jam phenomenon.
△ Note when the main pump kingpin cannot be installed
according to requirements, adjust the pedal length of the
bolt to ensure kingpin correctly fit, but do not adjust the
length of vacuum booster pushrod, or keep the vacuum
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booster pushrod in a compressed state.

4) Connect the brake lamp switch harness connector.

2. Install the lower part of the dashboard fender
3. Connect the negative battery cable
4. Turn off the engine hatch

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XIII. Brake light switch
(I) Disassembly
1. Open the engine hood
2. Disconnect the battery’s negative cable
3. Remove the dashboard’s bottom cover. Please refer to
“dashboard’s bottom cover”
4. Disassemble the brake light switch
1). Disconnect the harness connector of brake light switch

2). Remove the fixed bolt of light switch

3). Remove the brake light switch

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(II) Check

1. Check the brake light switch

1). Use multimeter to check the two terminals of light
switch, and confirm whether it’s brakeover when you turn
on or off the light switch
2). If the terminals do not brake over when the switch is
pushed more than 4mm in depth, and restore brake-over
when you turn off the switch, then the brake light switch
is functional
(III) Installation

1. Install brake light switch

1). Install the fixed bolt of brake light switch (tightening
torque: 20~25N.m)

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2). Link the harness connector of brake light switch
2. Install the dashboard’s bottom cover
3. Connect the battery’s negative cable
4. Close the engine hood

XIV. Unit assembly of vacuum booster with master

cylinder (MT)
(I) Check on the car

1. Check fluid leakage

1). Check whether leakage exists on the fitting surface of
master cylinder, oilcan or brake hose’s joint
(II) Disassembly

1. Open the engine hood.

2. Disconnect the battery’s negative cable
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3. Drain the brake fluid (please refer to “brake fluid”)

4. Remove the liquid level sensor of brake fluid (please refer to “liquid level sensor of brake fluid”)
5. Remove the vacuum booster with master cylinder
1). Remove the lockpin that connects vacuum booster and
brake pedal

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2). Remove the girdle clamp and disconnect vacuum
booster and hose
3). Disconnect the master cylinder and its outlet tube
assembly

4). Remove the girdle clamp and disconnect brake master

cylinder and the hose of clutch master cylinder

5). Remove the four screws that connect vacuum booster

and brake pedal

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(III) Installation

1. Install the unit assembly of vacuum booster with

master cylinder
1). Install the four screws that connect vacuum booster
and brake pedal.
(tightening torque: 20~25N.m)

2). Install the connection of master cylinder and its outlet

tube

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(tightening torque: 16~18N.m)
3). Install the girdle clamp to connect vacuum booster
and its hose

4). Install the girdle clamp to connect the hose that links
brake master cylinder and clutch cylinder

5). Install the lockpin and cotter that connect vacuum

booster and brake pedal

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2. Install the liquid level sensor of brake fluid

3. Add the brake fluid (please refer to “brake fluid”)
4. Exhaust air inside the brake system (please refer to air-removal of brake system)
5. Connect the battery’s negative cable
6. Close the engine hood
XV. Unit assembly of vacuum booster with master cylinder (AT)
(I) Check on the car
1. Check fluid leakage
1). Check whether leakage exists on the fitting surface of
master cylinder, oil can or brake hose’s joint
(II) Disassembly
1. Open the engine hood
2. Disconnect the battery’s negative cable
3. Drain the brake fluid (please refer to “brake fluid”)
4. Remove the liquid level sensor of brake fluid (please refer to “liquid level sensor of brake fluid”)
5. Remove the vacuum booster with master cylinder

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1). Remove the lockpin that connects vacuum booster
and brake pedal

2). Remove the girdle clamp and disconnect vacuum

booster and hose
3). Disconnect the master cylinder and its outlet tube
assembly

4). Remove the four screws that connect vacuum

booster and brake pedal

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(III) Installation

1. Install the unit assembly of vacuum booster with master

cylinder
1). Install the four screws that connect vacuum booster
and brake pedal
(tightening torque: 20~25N.m)

2). Install the joint between master cylinder and its outlet
tube assembly

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(tightening torque: 16~18N.m)
3). Install the girdle clamp to connect the vacuum booster
and its hose

4). Install the lockpin and cotter that connect vacuum

booster and brake pedal

2. Install the liquid level sensor of brake fluid

3. Add the brake fluid (please refer to “brake fluid”)
4. Exhaust air inside the brake system (please refer to air-removal of brake system)
5. Connect the battery’s negative cable
6. Close the engine hood
XVI. Vacuum hose assembly
(I) Disassembly
1. Open the engine hood
2. Disassemble the vacuum hose assembly
1). Remove the girdle clamp to disconnect vacuum hose
and booster

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2). Remove the girdle clamp to disconnect vacuum hose

and vacuum power steel pipe

(II) Installation

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1. Install the vacuum hose assembly
1). Install the girdle clamp to connect vacuum hose and
booster

2). Install the girdle clampto connect vacuum hose and

power steel pipe
2. Close the engine hood

XVII Liquid sensor of brake fluid

(I) Disassembly

1. Open the engine hood

2. Disconnect the battery’s negative cable
3. Remove the liquid sensor
1). Remove the clamp to disconnect sensor’s harness
connector

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2). Take out the sensor from the side face of storage tank
△Notice No need to discharge the brake fluid

(II) Installation

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1. Install the liquid sensor of brake fluid
1). Install the sensor into the correct position of the liquid
tank

2). Connect the harness connector of sensor

2. Connect the battery’s negative cable
3. Close the engine hood

XVIII Air-removal of brake system

(I) System’s air-exhaust

△Notice Air cannot be exhausted from hydraulic brake on

MT type. If the air is mixed in ABS hydraulic brake, or
unfilled ABS hydraulic brake is installed, it is necessary to
use fault diagnosis tester to exhaust air from the brake
system. The situation of ABS brake when the car goes off-
line is filled without air, and air will not enter the ABS
brake during normal service process. Under this situation,
please use manual air-removal process.

1. Preparation
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1). Keep the engine shut down, and stamp the brake pedal
for several times till no assist power exists.
2). Add brake fluid into fluid storage of master cylinder,
and ensure the liquid level more than half during air-
removal process

2. Exhaust air from master cylinder

△Notice If the master cylinder is re-installed, or the
liquid storage is empty, please exhaust the air from the
master cylinder
1). Stamp and hold the brake pedal till the end side
2). Loosen one brake oil pipe from the master cylinder,
and fasten the joint after the brake fluid runs off
3). Loosen the other brake oil pipe from the master
cylinder, and fasten the joint after the brake fluid runs off

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△Notice Cover the painting side with rag to prevent fluid
adhesion
4). Repeat step 1) to 3) for 3~4 times
3. Exhaust air from brake pipe
1). Remove the dust cover of bleeder screw on the brake
2). Connect a transparent tube with the bleeder screw on
the left-rear brake, and soak
△Notice Exhaust air from brake pipe consecutively from
far to near ABS brake
3). Stamp the brake pedal slowly for several times till the
pedal is on the end side
△Notice Do not stamp the pedal quickly
4). Loosen the bleeder screw and exhaust air from brake
while holding the brake pedal
5). Tighten the bleeder screw and slowly loosen the brake
pedal when the brake fluid stops overflowing
6). Repeat step 3) to 5) till the air in the brake fluid is
completely exhausted
7). If no air bubble appears in the tank when loosen the
bleeder screw, it means the air is completely exhausted
△Notice ensure the liquid level is more than half during
air-removal process
8). Tighten the bleeder screw
Tightening torque 7~13N.m
9). Exhaust air in other brakes by following step 1) to 8)
10). Check whether the brake pedal is stamped softly or
not after exhausting air from all brakes. If yes, please
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repeat the whole process till it works normally.

XIX Oil outlet tube of master cylinder

(I) Disassembly
1. Open the engine hood
2. Drain the brake fluid (please refer to “brake fluid”)
3. Remove the assembly of master cylinder’s fuel outlet pipe
1). Loosen the screw on fuel pipe to disconnect pipe
assembly and brake master cylinder

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2). Remove the oil pipe screw to disconnect fuel outlet
pipe assembly and ABS/ESP controller

3). Loosen the two pipe clamps and 2 front pipe clamps
that fix the oil outlet pipe assembly

(II) Installation
1. Install the oil outlet pipe assembly
1). Install the assembly on the 2 pipe clamps and 2 front
pipe clamps

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2). Install the oil pipe screw to connect the assembly and
ABS/ESP controller
Tightening torque: 16~18N.m

3). Install oil pipe screw to connect assemblyand master

cylinder
Tightening torque: 16~18N·m

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2. Add brake fluid (please refer to “brake fluid”)
3. Exhaust air from brake system (please refer to “air-
removal of brake system”)
4. Close the engine hood

XX Front brake pipe assembly

(I) Disassembly
1. Open the engine hood
2. Drain the break fluid (please refer to “brake fluid”)
3. Remove the left-front brake oil pipe assembly
1). Remove the screw that connects left-front brake pipe
assembly and brake hose

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2). Loosen the screw to disconnect left-front brake oil

pipe assembly and ABS/ESP controller

3). Unfix the two pipe clamps and two white three-hole
clamps that tighten the left-front brake oil pipe
4). Detach the left-front brake oil pipe assembly

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4. Remove the left-rear and right-rear brake pipe assembly

1). Remove the oil pipe screw that connects left-rear brake
pipe assembly and pipe itself
2). Remove the oil pipe screw that connects right-rear
brake pipe assembly and pipe itself

3). Remove the oil pipe screw that connects left-rear brake
pipe assembly and pipe itself
4). Remove the oil pipe screw that connects right-rear
brake pipe assembly and pipe itself

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5). Unfix the two pipe clamps and teo white three-hole cla
mps that tighten the left-rear and right-rear brake pipe
assembly
6). Detach the left-rear and right-rear brake pipe assembly

(II) Installation

1. Install the left-front brake oil pipe assembly

1). Install the screw that connects left-front brake oil pipe
and brake hose

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Tightening torque: 16~18N·m

2). Install the screw that connects left-front brake oil pipe
and ABS/ESP controller
Tightening torque: 16~18N·m

3). Install the left-front brake oil pipe to the two pipe
clamps and two front clamps that fix the left-front brake
oil pipe assembly

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2. Install the left-rear and right-rear brake pipe assembly

1). Tighten the screw that fixes the left-rear brake pipe
assembly and ABS/ESP controller
Tightening torque: 16~18N·m
2). Tighten the screw that fixes the right-rear brake pipe
assembly and ABS/ESP controller
Tightening torque: 16~18N·m

3). Install the screw that connects the left-rear brake pipe
assembly and the final part of left-rear brake pipe

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Tightening torque 16~18N.m
4). Install the screw that connects the right-rear brake
pipe assembly and the final part of right-rear brake pipe
Tightening torque 16~18N.m

5). Install the left-rear and right-rear brake pipe assembly

on the two pipe clamps and two white triple clamps

3. Add brake fluid, please refer to “brake fluid”

4. Exhaust air from brake system, please refer to “Air-
removal of brake system”
5. Close the engine hood

XXI Rear brake pipe assembly

(I) Disassembly

1. Open the engine hood

2. Drain the brake fluid, please refer to “brake fluid”
3. Remove the rear wheel, please refer to “wheel”
4. Disassemble the final parts of left-rear and right-rear
brake pipe assembly
1). Remove the cover-sheet assembly of rear brake pipe
assembly

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2). Loosen the screw that connects left-rear brake pipe and
the final part of left-rear brake pipe
3). Loosen the screw that connects right-rear brake pipe
and the final part of right-rear brake pipe

4). Loosen the screw that connects final part of left-rear

brake pipe assembly and left-rear brake hose

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5). Loosen the screw that connects final part of right-rear
brake pipe assembly and right-rear brake hose

6). Dismantle the five pipe clamps and the single pipe
clamp that connects final-part of left-rear assembly and
car body
7). Dismantle the five pipe clamps and three single pipe
clamp that connects final-part of right-rear assembly and
car body
8). Take off the final part of left-rear and right-rear brake
pipe assembly

5. Dismantle the assembly of left-rear and right-rear brake pipe

1). Loosen the screw that connects left-rear brake pipe
assembly and left-rear brake hose II
2). Loosen the screw that connects right-rear brake pipe
assembly and right-rear brake hose II

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3). Loosen the screw that connects left-rear brake pipe

assembly and left-rear brake hose
4). Loosen the screw that connects right-rear brake pipe
assembly and right-rear brake hose
5). Take off the left-rear and right-rear brake pipe
assembly

6. Remove the rear brake oil pipe support

1). Loosen the fixed bolt that connects rear brake oil
pipe and car body

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2). Take off the rear brake oil pipe support

(II) Installation

1. Install the final part of left-rear and right-rear brake pipe assembly
1). Tighten the screw that connects left-rear brake pipe
assembly and the final part of left-rear brake pipe
Tightening torque 16~18N.m
2). Tighten the screw that connects right-rear brake pipe
assembly and the final part of right-rear brake pipe
Tightening torque 16~18N.m

3). Install the screw that connects the final part of left-
rear brake pipe assembly and left-rear brake hose
Tightening torque 16~18N.m
4). Install the screw that connects the final part of right-
rear brake pipe assembly and right-rear brake hose
Tightening torque 16~18N.m

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5). Install the five pipe clamps and the single pipe clamp
that connect the final part of left-rear brake pipe
assembly and car body
6). Install the five pipe clamps and three single pipe
clamps that connect the final part of left-rear pipe
assembly and car body
7). Install the cover sheet of the final part of rear brake
pipe

2. Install the assembly of left-rear and right-rear brake

pipe
1). Install the screw that connects left-rear brake pipe
assembly and left-rear brake hose II
Tightening torque 16~18N.m

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2). Install the screw that connects right-rear brake pipe
assembly and right-rear brake hose II
Tightening torque 16~18N.m
3). Install the screw that connects left-rear brake pipe
assembly and left-rear brake hose
Tightening torque 16~18N.m
4). Install the screw that connects right-rear brake pipe
assembly and right-rear brake hose
Tightening torque 16~18N.m

3. Install the rear brake oil pipe support

1). Install the two fixed bolts that connect rear brake oil
tube support and car body
Tightening torque 20~25N.m

4. Add brake fluid, please refer to “brake fluid”

5. Exhaust air from brake system, please refer to
“Air-removal of brake system”
6. Install the rear wheels
7. Close the engine hood

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XXII Rear brake hose assembly

(I) Disassembly
1. Lift the car
2. Drain the brake fluid, please refer to “brake fluid”
3. Dismantle the rear brake hose assembly
1). Remove the screw that connects rear brake hose
assembly and the final part of rear brake pipe

2). Remove the screw that connects left-rear brake hose

assembly and the left-rear brake pipe assembly
3). Take off the rear brake hose assembly

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(II) Installation
1. Install the rear brake hose assembly
1). Install the screw that connects left-rear brake hose
assembly and the final part of left-rear brake pipe
Tightening torque 16~18N.m

2). Install the screw that connects left-rear brake hose

assembly and the left-rear brake pipe assembly
Tightening torque 16~18N.m

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2. Add brake fluid, please refer to “brake fluid”

3. Exhaust air from brake system, please refer to “Air-
removal of brake system”
4. Lift down the car
XXIII Right-front brake oil pipe assembly
(I) Disassembly
1. Open the engine hood
2. Drain the brake fluid, please refer to “brake fluid”
3. Dismantle the right-front oil pipe assembly
1). Loosen the screw that connects right-front brake oil
pipe assembly and right-front brake hose

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2). Loosen the screw that connects right-front brake oil
pipe assembly and ABS/ESP controller
3). Take off the right-front brake oil pipe assembly

(II) Installation

1. Install right-front brake oil pipe assembly

1). Tighten the screw that connects right-front brake oil
pipe and right-front brake hose
Tightening torque 16~18N.m

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2). Tighten the screw that connects right-front brake oil

pipe and ABS/ESP controller
Tightening torque 16~18N.m

2. Add brake fluid, please refer to “brake fluid”

3. Exhaust air from brake system, please refer to “Air-removal of brake system”
4. Close the engine hood

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