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Group 35A
Anti-Lock Brake System
(ABS)
' 00 Minor Change
Table of Contents

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Pub No. TWME9502-435A

 35A

GROUP 35A ANTI-LOCK BRAKE SYSTEM (ABS)

SPECIFICATIONS .......................................................................... 35A-2

STRUCTURE AND OPERATION ................................................... 35A-2

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Periodic Inspection Procedures ............................................................... 35A-9
• Adjustment of Wheel Speed Sensor Clearance .................................... 35A-10
• Inspection of Wheel Speed Sensor Signal Waveform

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Using Oscilloscope .................................................................................. 35A-11
• Hydraulic Unit Operation Check ............................................................. 35A-12

TROUBLESHOOTING
• Troubleshooting Procedures .................................................................. 35A-14
• Diagnosis Code Indication ...................................................................... 35A-15
• Diagnosis Code Chart ............................................................................. 35A-18
• Actuator Drive Chart................................................................................ 35A-19
• Service Data ............................................................................................. 35A-19

WHEEL SPEED SENSOR AND ROTOR

< FRONT AXLE > ........................................................................................ 35A-20
< REAR AXLE > ........................................................................................... 35A-26

ELECTRIC CIRCUIT AND PART INSTALLATION

LOCATIONS .................................................................................. 35A-34

35A-1
SPECIFICATIONS/STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Brake system Hydraulic booster
Anti-lock brake system ABS (4S/4K)
(number of sensors/number of channels)
Manufacturer NIPPON ABS

STRUCTURE AND OPERATION

Anti-lock Brake System (ABS)

The anti-lock brake system (ABS) prevents tire slippage due to wheel lockup caused by sudden braking and braking on
slippery road surfaces. The ABS provides a driver with vehicle controllability and directional stability in braking.

● Wheel lockup
Rotating tires of a moving vehicle have a tendency to continue traveling in the direction of tire rotation. Because of this

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characteristic, a driver can control the vehicle’s traveling direction by moving the front wheels to a desired direction
using the steering wheel.
In a vehicle not equipped with an anti-lock brake system, when a driver depresses the brake pedal with full force, the
wheels can lock up under certain conditions. Tires in a wheel lockup condition lose the tendency to maintain directional
characteristic, and the vehicle starts sliding in a direction of an externally applied force regardless of the tire direction. In
other words, when wheel lockup occurs, the vehicle loses its directional stability, disallowing the driver to control the
vehicle’s movement.
The following shows how a vehicle without ABS loses its directional stability when different tires lock up on slippery
road surfaces.

● Front wheel lockup (both front tires)

Steering direction

Braking point

07729

The front tires lose directional stability, but the rear tires try to travel in the direction of rotation since they are not
locked up. Because of the front wheel lockup, a steering wheel operation does not change the vehicle’s moving
direction.

35A-2
 35A
● Rear wheel lockup (both rear tires)

Steering direction

Braking point

07730

When the steering wheel is operated with the rear wheels in a lockup condition, the front tires try to change the
vehicle’s direction of travel, but the rear tires slide sideways, causing the vehicle to spin. If wheel lockup occurs in a
vehicle traveling in a straight direction, the force of inertia continues to push the vehicle straight ahead from the back
of the vehicle due to the lack of stopping force in the rear tires, and the vehicle can spin.

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● All wheel lock up (front and rear tires)

Steering direction

Braking point

07731

When wheel lockup occurs in both front and rear tires, all four tires lose directional stability. Therefore, the vehicle
slips in the direction of inertia regardless of the steering direction.
● Wheel lockup on surfaces with split µ factors (road surface with different friction coefficients for
right and left tires)

Non-slippery pavement

Slippery pavement
07732

The tires on a surface with a lower friction coefficient lock up first. The tires in a lockup condition start sliding, thus
failing to provide effective stopping force. Due to this imbalance in the stopping power between the right and left tires,
one side of the vehicle slows down while the other side continues traveling, thus resulting in the loss of directional
stability. When this happens during sudden braking, the vehicle spins.
35A-3
STRUCTURE AND OPERATION
Structure of ABS

9 10 1 2 9

8 8

6
7

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8
8

3 4
9 5 9

Brake fluid line

Electric line P 36000

1 Hydraulic booster 6 Hydraulic unit

2 Brake master cylinder 7 Relay box
3 ABS warning lamp 8 Wheel speed sensor
4 Exhaust brake cut relay 9 Rotor
< Manual transmission > 10 Stop lamp switch
5 ECU

The ABS uses wheel speed sensors 8 and ECU 5 to monitor the rotating speed of each wheel. When the wheel speed
exceeds the preset deceleration speed or slip rate, the ECU detects it as a tendency leading to wheel lockup, and sends
control signals to hydraulic unit 6 and relay box 7. The signals activate the solenoid valves to reduce the brake fluid
pressure in the wheel brakes and ease the braking force to prevent wheel lockup. Then, when the wheel speed increases,
wheel speed sensors 8 send signals to the solenoid valves in hydraulic unit 6 by way of ECU 5 to increase the brake fluid
pressure in the wheel brakes to augment the braking force. This control cycle is repeated to prevent wheel lockup on
slippery pavements and ensure the vehicle’s directional stability during braking. The 4-sensor 4-channel anti-lock brake
system uses four wheel speed sensors 8, which are located at the front and rear wheels, to control each of the four
wheels.

35A-4
 35A
● ABS function

Input signals ECU Output signals

Hydraulic unit

Wheel speed sensor Solenoid valve (for front-axle left wheel)

→ → • Pressure holding valve →
(for front-axle left wheel) • Pressure reducing valve

Wheel speed sensor Solenoid valve (for front-axle right wheel)

→ → • Pressure holding valve →
(for front-axle right wheel) • Pressure reducing valve

Wheel speed sensor Solenoid valve (for rear-axle left wheel)

→ → • Pressure holding valve →
(for rear-axle left wheel) ABS control function (solenoid • Pressure reducing valve
valve regulating function)
Wheel speed sensor Solenoid valve (for rear-axle right wheel)
→ → • Pressure holding valve →
(for rear-axle right wheel) • Pressure reducing valve

Hydraulic
Stop lamp switch → → Motor
pump

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Motor power supply
Relay box

→ Motor relay

Hydraulic pump

Solenoid
power supply
→ Valve relay

Exhaust brake cut relay

→
< Manual transmission >
Malfunction diagnosis function
[fail-safe, self-diagnosis, → ABS warning lamp
MUT-II communication]

←→ MUT-II

35A-5
STRUCTURE AND OPERATION
● ABS control function
To provide optimum stopping power, the ABS controls the
braking force based on the slip rate determined by the
relationship between the wheel speed and the vehicle
speed. When the brake is applied, the resulting force
slows down the wheel rotation, thus reducing the vehicle
speed. However, inertia acts on the vehicle and tries to
maintain the vehicle’s forward movement despite the stop-
ping force applied by the tires. When there is a difference
between the wheel speed and vehicle speed, slipping
occurs. The degree of slippage is expressed by a slip rate.

Vehicle speed – Wheel speed

Slip rate (%) = × 100
Vehicle speed

When the slip rate is 0%, there is no slippage between the

tires and pavement. The slip rate of 100% refers to a
wheel lockup condition.

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Slip rate vs. friction coefficient curves The graph shows the time-based changes in the friction
1.0
coefficient of a rolling tire during the process of wheel
Dry asphalt lockup. When the brake is applied gradually while the tires
are rotating on pavement, the tires begin to slip while in
rotation.
Friction coefficient (µ)

Wet asphalt
When the brake is applied harder, the tires stop rotating
and start to slide on the pavement. This condition is called
wheel lockup.
The friction coefficient is highest when the slip rate is
0.5
within the shaded area on the graph.
Cornering force
In other words, tires provide maximum friction when the
braking force is appropriately controlled to maintain the
Snow-
covered road slip rate in the range indicated by the shaded area on the
Frozen road graph, rather than when the brake is applied at full force.
In a vehicle equipped with ABS, the ECU and hydraulic
0
0 50 100% unit adjust the braking force and maintain it within the
(Tire roll) (Wheel lockup) shaded area on the graph where the friction coefficient is
Slip rate (%) 03049 high, thus preventing tire slippage and ensuring braking
stability.

35A-6
 35A
ABS Operation
● ABS control characteristic curve

Actual vehicle speed

Vehicle speed
and wheel
speed Estimated vehicle speed

Slip rate setting Wheel

speed
+b

Wheel
acceleration/
deceleration
0

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speed
–b

Pressure
decrease

Pressure
Signal (from ECU) hold

Pressure
increase

Brake fluid
pressure

A B C D 07734

The above ABS control characteristic graph shows the time-based changes in vehicle speed, wheel acceleration/
deceleration speed and brake fluid pressure level during braking.
• When the wheel deceleration speed exceeds the speed setting – b at point A, the ECU sends a signal to maintain the
brake fluid pressure at the same level.
At the same time, the ECU estimates the vehicle speed according to a programmed calculation method.
• When the vehicle speed decreases further and the slip rate exceeds the setting at point B, the ECU detects it as a
tendency leading to wheel lockup, and sends a signal to reduce the brake fluid pressure.
• When the wheel speed increases because of the reduced brake fluid pressure and the wheel speed exceeds the
setting – b at point C, the ECU sends a signal to maintain the brake fluid pressure at the same level.
• When the wheel speed increases further and the wheel speed exceeds the setting + b at point D, the ECU determines
that there is no risk of wheel lockup and sends a signal to increase the brake fluid pressure.
By repeating the above control cycle, the ABS prevents wheel lockup and provides maximum friction between the tires
and pavement to ensure high stability during braking.
● ABS and exhaust brake system
On slippery road surfaces, activation of the exhaust brake system can result in wheel lockup. If the exhaust brake
activates during an ABS braking operation, proper braking function cannot be provided by the ABS.
To prevent this, the exhaust brake system is deactivated during ABS operation even when the exhaust brake switch is turned ON.
When the ABS stops providing its function, the exhaust brake system becomes operable if the exhaust brake switch is ON.

35A-7
STRUCTURE AND OPERATION
● ECU
This component calculates the wheel speed
10 9 8 7 6 5 4 3 2 1
and estimates the vehicle speed based on sig-
22 21 20 19 18 17 16 15 14 13 12 11 nals sent from the wheel speed sensors. Based
AK22A on the calculation results, it determines the
degree of wheel lockup tendency, and sends
9 8 7 6 5 4 3 2 1 brake fluid pressure control signals to the sole-
20 19 18 17 16 15 14 13 12 11 10
noid valves of the hydraulic unit to regulate
AK20A < Manual transmission > brake fluid pressure accordingly.
The ECU is equipped with a self-diagnosis
8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 9
function. Should an abnormality occur, the
ECU turns on the warning lamp on the instru-
AK18A < Automatic transmission >
ment panel to indicate the system malfunction
and deactivates the ABS control to set the
brake system in normal condition (without anti-
P 36209
lock brake system control).

AK22A AK20A < Manual transmission > AK18A < Automatic transmission >

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Terminal Connection destination
No.
1 Ground – –
2 Ground – –
3 – – Meter cluster (ABS warning lamp)
Hydraulic unit (motor drive) Meter cluster (ABS warning lamp) Starter switch terminal M
4 (ECU power supply)
Hydraulic unit (motor drive monitor) Starter switch terminal M Wheel speed sensor
5 (ECU power supply) (rear-axle right-wheel input)
– Wheel speed sensor Wheel speed sensor
6 (rear-axle right-wheel input) (rear-axle left-wheel input)
Hydraulic unit (rear-axle right-wheel Wheel speed sensor Wheel speed sensor
7 brake fluid pressure decrease) (rear-axle left-wheel input) (front-axle right-wheel input)
Hydraulic unit (rear-axle left-wheel Wheel speed sensor Wheel speed sensor
8 brake fluid pressure decrease) (front-axle right-wheel input) (front-axle left-wheel input)
Hydraulic unit (front-axle right-wheel Wheel speed sensor –
9 brake fluid pressure decrease) (front-axle left-wheel input)
Hydraulic unit (front-axle left-wheel – MUT-II connector
10 brake fluid pressure decrease)
11 Ground – MUT-II connector
12 Ground MUT-II connector Stop lamp switch
13 – MUT-II connector –
14 Relay box (valve relay drive) Stop lamp switch –
Relay box (valve relay and motor – Wheel speed sensor
15 relay power supply) (rear-axle right-wheel grounding)
Exhaust brake cut relay – Wheel speed sensor
16 < Manual transmission > (rear-axle left-wheel grounding)
Exhaust brake cut relay \Wheel speed sensor Wheel speed sensor
17 < Manual transmission > (rear-axle right-wheel grounding) (front-axle right-wheel grounding)
– Wheel speed sensor Wheel speed sensor
18 (rear-axle left-wheel grounding) (front-axle left-wheel grounding)
Hydraulic unit (rear-axle right-wheel Wheel speed sensor
19 brake pressure hold) (front-axle right-wheel grounding)
Hydraulic unit (rear-axle left-wheel Wheel speed sensor
20 brake pressure hold) (front-axle left-wheel grounding)
Hydraulic unit (front-axle right-wheel
21 brake pressure hold)
Hydraulic unit (front-axle left-wheel
22 brake pressure hold)
35A-8
ON-VEHICLE INSPECTION AND ADJUSTMENT 35A
Periodic Inspection Procedures
(1) Periodic inspection of Anti-lock brake system
• Inspect the vehicle’s Anti-lock brake system following the procedure
below.
• If an abnormality is found in this inspection, further inspect the Anti-
lock brake system using 0 MUT-II (multi-use tester) by referring to
TROUBLESHOOTING section.
Õ P35A-15

• Inspection procedure
1 With the vehicle stationary, press the brake pedal and inspect
the hydraulic unit for fluid leaks.
If fluid leaks from the hydraulic unit, replace the unit. If fluid leaks
from the fluid pipe or connector, tighten the joint.
2 Inspection using brake tester
Check the braking force at each wheel with a brake tester by
following the inspection procedure for ordinary vehicles.
If an abnormality is found, inspect the wheel brake units, service

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brake system and hydraulic unit.
3 Drive the vehicle and check the operation of the Anti-lock brake
system.
• Conduct a test drive at an open area to ensure safety.
• Conduct a test drive without cargo.
Attach white tape A on the sides of tires, so that it is easy to
observe the rotation of the front and rear wheels.
• Turn the starter switch from the OFF position to the ON posi-
tion, and make sure that the warning lamp lights.
Then, check that the warning lamp turns off approxi-
A 23971 mately two seconds after the starter switch is turned on.
• Drive the vehicle at a speed of 20 to 30 km/h {12 to 19 mph},
and apply a sudden brake. Make sure that wheel lockup does
not occur in any of the tires.

35A-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
Adjustment of Wheel Speed Sensor Clearance

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
7 Bolt (Anchor bracket mounting) 135 {100, 13.8} —

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

Adjustment of wheel speed

1 Adjuster MH062080 sensor clearance

14912

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Tighten 0 adjuster to extend wheel speed sensor 1, and adjust clear-
5 ance between the sensor and rotor 2.
A 4 • Remove plug 4 located on the back side of back plate 3.
• Mount 0 adjuster in adjustment hole A, and tighten the adjuster.
• Wheel speed sensor 1 contacts the rotor before 0 adjuster is com-
pletely tightened. Therefore, do not press shaft B, and tighten the
adjuster until resistance is felt.
0 • Be sure to reinstall plug 4 after adjustment.
5: Wheel speed sensor harness

14913

3
1 0
2

36379

35A-10
 35A
Inspection of Wheel Speed Sensor Signal Waveform Using Oscilloscope
Inspect the rotor for dents using an oscilloscope, since the tester cannot
be used for dent detection.
NOTE
Use an oscilloscope with a waveform recording function.

• Lift the wheel to be tested off the ground, and disconnect the connec-
tor at the wheel speed sensor.
• Connect the terminal of the oscilloscope to the terminal of the discon-
nected connector. Rotate the wheel at a constant speed. Check the
waveform shown on the oscilloscope to check for dents on the rotor.

• Rotor dents are often made by the rotor press-fit on the hub end
Normal waveform (no dent on rotor) contacting the axle during installation of the hub and brake drum
assembly on the axle. When installing the hub & brake drum assem-
bly, pay close attention to prevent the rotor from contacting other

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parts.

A: Vmin (Minimum peak)

B: Vmean (Average of maximum peaks)
Vmean – Vmin
= 0.2 (20% or lower)
Vmean
03122 If more than 20%, replace the rotor.
Abnormal waveform (with dents on rotor)

A B

03123

35A-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
Hydraulic Unit Operation Check
Operation check using MUT-II
• Lift the vehicle using a jack and support it with jack stands, or position
the tires on brake tester rollers.
WARNING–
• The brake tester rollers and tires must be dry during inspection.
• To test the front brakes, apply the parking brake. To test the rear
brakes, place wheel chokes at the front tires to secure them in
position.

• Disengage the parking brake, and feel the drag resistance of the
brake on each wheel.
When using a brake tester, record the indicated drag resistance of the
brake.
• Set the starter switch to the OFF position, then connect the MUT-II.
• Set the testing equipment and system on the MUT-II.

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• After making sure that the transmission is in the neutral position, start
the engine.
NOTE
• When the engine is turned on, the ABS switches to the MUT-II
mode and the ABS warning lamp flashes.
• When the ABS function is deactivated due to the ECU’s fail-safe
function, the actuator test cannot be performed with the MUT-II.

35A-12
 35A

 Press
Pedal 
operation 

 Release MUT-II actuator test
 (one of items Nos. 11 through 14)
Operation starting


 Pressure
 increase



Solenoid valve 
position  Pressure 3 sec
 decrease

 3 sec
 Pressure hold


 Lock


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
Braking force

check 
 Drag 6 sec
 resistance
 with no brake
 applied 07755

• If an abnormality is found during the inspection, take appropriate measures described in the following operating condition
evaluation chart.

Operating condition evaluation chart

Item MUT-II Judgment
Operation Cause Remedy
No. indication Normal Malfunction

Clogging in brake Inspect and clean

11 FR ABS MV ON (1) Depress the brake Wheel does not
pedal to lock wheels. line other than HU brake lines.
(2) On the MUT-II, select lock when brake
the wheel to be pedal is de-
Braking Clogging in hydraulic Replace HU
12 FL ABS MV ON tested and forcibly pressed.
force eases line inside HU assembly.
drive the actuator. for 6
(3) Rotate the selected seconds
13 RR ABS MV ON wheel using the from locked Erroneous HU brake Correct tube
tube connection connection.
brake tester or by condition. Braking force
hand, and check the does not ease.
change in braking Faulty HU solenoid Replace HU
14 RL ABS MV ON
power. valve assembly.

HU: Hydraulic unit • After inspection, set the starter switch to OFF before disconnecting the MUT-II.

35A-13
TROUBLESHOOTING
Troubleshooting Procedures
Inspection flow chart
The MUT-II allows efficient inspection of the ABS.
The types of system inspections can be roughly divided according to the malfunction condition and diagnosis code, as
shown below.
• Inspection based on individual malfunction diagnosis codes stored in the ECU
• Inspection based on symptoms not indicated by diagnosis codes
• Correcting non-recurring problems

Position vehicle for inspection.

Read diagnosis code.

Abnormal code output Normal code output
Normal code
output after Test-drive.
clearing ECU

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memory
Normal Generation of malfunction

Locate and inspect cause of malfunc- Check for non-recurring Check cause of problem that does
tion indicated by diagnosis code. problems. ^ Gr 00 not generate diagnosis code.

Test-drive.

• If a diagnosis code was generated during the test drive, locate and check the
cause of the diagnosis code generation.
• If a diagnosis code stored in the ECU before the test drive did not generate,
conduct a non-recurring problem check in addition to the inspection based on the
diagnosis code.

Delete diagnosis code.

Cautions in malfunction diagnosis

• The ABS uses electronic control to regulate the braking system. The following phenomena may occur during normal
ABS operation, but they do not denote a malfunction.

Phenomenon Description
When the engine starts, a slight clunking sound may be generated in the left side of the
System checking sound frame near the cargo bed. This sound is produced by the system conducting an operation
check, and does not denote a malfunction.
• Motor noise from the hydraulic unit (humming sound)
• Noise generated as the brake pedal feel changes (grinding sound)
ABS operating sound
• Noise from the chassis produced by repeated ON and OFF operations of the ABS
(wheels: short squeak, suspension: slight thud)
ABS operation effect On snow-covered surfaces and gravel roads, a vehicle equipped with ABS may require a
(longer stopping longer distance to come to a complete stop. Therefore, when driving on such road surfaces,
distance) reduce the speed sufficiently and drive carefully to minimize the use of brakes.

35A-14
 35A
● Inspection of ABS warning lamp
Check the ABS warning lamp to make sure that the following operation
turns on the lamp.
• Set the starter switch to the ON position, and check that the ABS
warning lamp lights for about 1 second and turns off.
• If the lamp does not light as described above, check diagnosis codes
stored in the ECU.

P 36001
ON
Starter
switch
OFF
Approx. 1 sec

ABS ON
warning
lamp

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OFF
07743

1 Diagnosis code indication

● Without MUT-II
• With the vehicle stationary, ground terminal No. 16 of MUT-II connec-
tor 1, then turn the starter switch to the ON position. The ABS warning
lamp will flash to indicate a diagnosis code.
• The ABS warning lamp starts flashing 3.0 seconds after the starter
switch is turned ON. The flashing pattern of the warning lamp indi-
cates a diagnosis code.
35953

(Example) Indication of diagnosis • A diagnosis code is indicated in the following manner.

code No. 12 • To indicate the tens digit (left digit), the lamp remains ON for 1.5
1 2 seconds, then remains OFF for 0.5 seconds. To indicate the ones
digit (right digit), the lamp remains ON for 0.5 second, then remains
ON OFF for 0.5 second.
• For multiple diagnosis codes, each code is indicated one time, in
OFF sequence. When there is no other diagnosis code to indicate, the
2nd-time lamp repeats the diagnosis code indication from the beginning for 7
3.0s 1.5s 2.0s 0.5s 3.0s indication cycles.
0.5s 0.5s
07746 • When there is no diagnosis code stored in the memory (normal
condition), the ABS warning lamp repeats On/Off in 0.25-second
intervals.
(Example) Indication of “12” and “13”
• When two or more diagnosis codes are stored in the ECU.

1st 1st 2nd 2nd 3rd 3rd

12 13 12 13 12 13

07747

35A-15
TROUBLESHOOTING
● Deletion of diagnosis codes
MUT-II Ground
connector Connect terminal No. 16 of the MUT-II connector to the chassis for
terminal
No. 16 Open
grounding. Turn on the starter switch, and depress the brake pedal within
Starter ON 3 seconds and turn On and Off the stop lamp switch ten times in intervals
switch 3 sec 1 sec 1 sec Data
OFF
or less or less or less deletion of 1 second or less. This erases diagnosis codes from the memory.

Stop ON
lamp
switch OFF
1st 2nd 3rd 10th
time time time time
P 37199
● Completion of diagnosis code check
The diagnosis code check completes when diagnosis codes are erased
from the ECU of terminal No. 16 of the MUT-II connector is discon-
nected.

NOTE
The diagnosis code check also ends when the vehicle moves
from a stationary condition during the diagnosis code check.

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With MUT-II
0 Special tools
Tool name and shape Part No. Application
Inspection of Anti-lock brake system

MUT-II MB991496

19492

MUT-II harness
(for data communication) MK327601

19141

ROM pack
MK344606
(MRT-E6)

19493

35A-16
 35A
Tool name and shape Part No. Application
Inspection of Anti-lock brake system

MUT-II harness
MB991499
(for circuit tester)

20536

Memory card
MB991500
(for MUT-II)

20538

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Connecting the MUT-II
B
• Turn the starter switch to the LOCK position.
• Connect the 2 MUT Communication Harness to the 1 MUT-II, and
insert the 3 ROM Pack.
• Plug connector A into the cigarette lighter socket.
• Fit connector C onto MUT connector B (16 pin) in the relay box.
A NOTE
C Instructions for operation of the MUT-II are given in the separate
2 3
1 MUT-II Reference Manual.
31469

Current diagnosis codes

• Turn the starter switch to the ON position.
• Determine the fault location(s) in accordance with the MUT-II diagno-
sis code(s).

Past diagnosis codes

• Turn the starter switch to the ON position.
• Determine the fault location(s) in accordance with the past MUT-II
diagnosis code(s).

Diagnosis code erasure

• Turn the starter switch to the ON position.
• Using the MUT-II, erase all diagnosis codes stored in the control unit.

35A-17
TROUBLESHOOTING
Diagnosis Code Chart
Diagnosis codes can be read by using the MUT-II or ABS warning lamp.

Diagnosis Malfunction location

code MUT-II display Description of malfunction
11 FR-SNSR OPEN Broken wire to front-axle right-wheel speed sensor

Wheel speed
12 FL-SNSR OPEN Broken wire to front-axle left-wheel speed sensor
13 RR-SNSR OPEN Broken wire to rear-axle right-wheel speed sensor

sensor
14 RL-SNSR OPEN Broken wire to rear-axle left-wheel speed sensor
*a 15 ROTA OR SNSR Broken wire
16 ECU VOLTAGE Drop in power supply voltage
21 FR-SNSR SHORT Wheel speed No broken wire to front-axle right-wheel speed sensor
22 FL-SNSR SHORT sensor No broken wire to front-axle left-wheel speed sensor
23 RR-SNSR SHORT No broken wire to rear-axle right-wheel speed sensor
24 RL-SNSR SHORT No broken wire to rear-axle left-wheel speed sensor
*b 35 EXB RLY Exhaust brake cut relay
38 STOP LAMP SW Stop lamp switch
41 FR-EV VALVE Front-axle right-wheel solenoid valve (pressure decrease)

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42 FL-EV VALVE Front-axle left-wheel solenoid valve (pressure decrease)
Hydraulic unit

43 RR-EV VALVE Rear-axle right-wheel solenoid valve (pressure decrease)

44 RL-EV VALVE Rear-axle left-wheel solenoid valve (pressure decrease)
45 FR-AV VALVE Front-axle right-wheel solenoid valve (pressure hold)
46 FL-AV VALVE Front-axle left-wheel solenoid valve (pressure hold)
47 RR-AV VALVE Rear-axle right-wheel solenoid valve (pressure hold)
48 RL-AV VALVE Rear-axle left-wheel solenoid valve (pressure hold)
Relay box

51 VALVE RLY Valve relay

Motor relay or motor
53 MOTOR RLY
Motor monitor line
63 ECU ERR ABS ECU

35A-18
 35A
Actuator Drive Chart

MUT-II display
Item No. Item name
11 FR ABS MV ON
12 FL ABS MV ON
13 RR ABS MV ON
14 RL ABS MV ON

Service Data

MUT-II display Inspection condition Criterion

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11 FR SPEED ■ ■ ■. ■ MPH
12 FL SPEED ■ ■ ■. ■ MPH
Constant-speed driving Same as speedometer indication
13 RR SPEED ■ ■ ■. ■ MPH
14 RL SPEED ■ ■ ■. ■ MPH
15 ECU VOLTAGE ■■. ■V Starter switch ON Same as battery voltage
Brake pedal depressed ON
30 STOP LAMP SW ON/OFF
Brake pedal released OFF

35A-19
WHEEL SPEED SENSOR AND ROTOR < FRONT AXLE >
The following describes the service procedures for wheel speed sensors and rotors only.
Regarding the procedures for servicing other components, refer to ^ Gr 26.

15
Ê 19
Ê14 18
15
*
Ê14

17
6

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5
4
3
2
1

9
13
12
36067

● Disassembly sequence
1 Wheel hub cap 8 Nut 15 Clip
2 Bolt 9 Hub bolt 16 Wheel speed sensor
3 Lock plate 10 Rotor 17 Spring spacer
4 Lock nut 11 Oil seal 18 Bolt
5 Lock washer 12 Wheel hub 19 Bracket
6 Outer bearing 13 Brake drum
7 Hub and brake drum assembly 14 Bolt *: Front brake assembly

● Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION–
• When removing or installing hub and brake drum assembly 7, handle rotor 10 with care to prevent damage.
Also, do not damage oil seal 11 during assembly.
• Keep oil and grease off lining surface of front brake assembly * and the inner surface of brake drum 13.

35A-20
 35A
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
10 Wobbling of rotor 0.1 {0.0039} — Replace
Resistance between terminals 950 to 1450Ω — Replace
16 Wheel speed sensor
Insulation resistance 1MΩ or higher — Replace

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
14 Bolt (Clip mounting) 19 to 27 {14 to 20, 1.9 to 2.8} —
18 Bolt (Bracket mounting) 9.8 to 14.0 {7 to 10, 1.0 to 1.4} —

0 Special tools Unit : mm {in.}

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Location Tool name and shape Part No. Application

11 ABS oil seal installer MH062305 Press-fitting of oil seal

ø102
{4.02}
02968

F
◆ Service procedure

[Removal]
Rotor

Strike the outer edge of rotor 10 evenly with flat-tip screwdriver A to

remove the rotor from the wheel hub.
CAUTION–
12 Be careful not to damage wheel hub 12.

10
A
02972

35A-21
WHEEL SPEED SENSOR AND ROTOR < FRONT AXLE >
[Installation]
B Heat rotor 10 to approximately 150°C {302°F}. Press the rotor evenly
with iron plate B to press-fit the rotor to wheel hub 12. Make sure there is
10
no space between the rotor and wheel hub.

12

02973
[Inspection]
10 • If the amount of wobbling exceeds the standard value, repeat the
assembly procedure from the beginning.
• If the amount of wobbling exceeds the standard value after reassem-
12 bly, replace defective parts.
C : Base

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C

G
02974

Installation of oil seal

11 0
CAUTION–
When hub and brake drum assembly 7 is removed for a service
operation and if rotor 10 is still mounted on the wheel hub, use 0
ABS oil seal installer to press-fit oil seal 11.
10

L
02975

Wheel speed sensor

[Removal]
Hold shaded section A of wheel speed sensor 16 with pliers, and remove
the sensor by twisting it slightly in left and right directions.
CAUTION–
• When holding wheel speed sensor 16 with pliers, do not grip any
section other than shaded area A in the diagram.
17 • When removing wheel speed sensor 16, do not apply force on the
16
A 36190 sensor, such as by hitting with a hammer, prying with a screw-
driver or pulling the harness, since these actions can result in
wire breakage.
• If wheel speed sensor 16 dismounts easily, replace spring spacer
17.

35A-22
 35A
[Inspection]
• Since pole piece section B is magnetized by the magnet inside
wheel speed sensor 16, it attracts metals. Do not allow the pole
piece to collect metallic objects.

16
36325

• Measure the resistance between the terminals of wheel speed

sensor 16.
16
If the measured value deviates from the standard value, replace the
wheel speed sensor.

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36825

• Measure the insulation resistance between body C of wheel speed

sensor 16 and each terminal.
C If the measured values deviate from the standard value, replace the
wheel speed sensor.

16

36826

• To check for broken wires, remove the harness clamp section from
the vehicle. Bend and extend the harness to check if there is any
broken wire in the harness. Also, inspect the connector for proper
contact.
If a defect is found, replace wheel speed sensor 16.

P 31296

35A-23
WHEEL SPEED SENSOR AND ROTOR < FRONT AXLE >
D [Installation]
17 E
• Insert spring spacer 17 into holder section D of the knuckle, and
press until stopper section E contacts the holder.
• Insert wheel speed sensor 16, and press until it contacts rotor 10.
• Rotate hub and brake drum assembly 7 slowly for two or three turns
(2 seconds per turn) to make sure it rotates smoothly.
CAUTION–
When installing wheel speed sensor 16, do not apply force on
16 the sensor, such as by hitting with a hammer, prying with a
D 17
36192 screwdriver or pulling the harness, since these actions can
result in wire breakage.
D
7 17
10

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16
36191

• Secure white tape section F of the harness of wheel speed sensor

15
16 in place using clip 15 on the wheel brake side and clip 15 on the
frame side.
CAUTION–
Be sure to clamp the harness of wheel speed sensor 16 at two
white tape sections F. Make sure the harness does not inter-
16 fere with other parts and there is no twist or slack in the
harness.

15

02979
16 F

36184

35A-24
 35A

MEMO

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35A-25
WHEEL SPEED SENSOR AND ROTOR < REAR AXLE >
The following describes the service procedures for wheel speed sensors and rotors only.
Regarding the procedures for servicing other components, refer to ^ Gr 27.

17
18
17
18
17
18
18 21
2

19

1
11
*

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9
22 8
7
6
4
3
10
12

16
15
5

36118

● Disassembly sequence
1 Bolt 10 Hub and brake drum assembly 19 Sensor holder
2 Rear axle shaft 11 Nut 20 Wheel speed sensor
3 Oil seal 12 Hub bolt 21 Spring spacer
4 Oil seal retainer 13 Rotor 22 Inner bearing
5 Bolt 14 Oil seal 23 Oil seal retainer
6 Lock plate 15 Wheel hub
7 Lock nut 16 Brake drum *: Rear brake assembly
8 Lock washer 17 Bolt
9 Outer bearing 18 Clip

● Assembly sequence
Follow the disassembly sequence in reverse.
• Do not remove oil seal retainer 4 unless it is damaged (scratches, bending, tilting).

CAUTION–
• When removing or installing hub and brake drum assembly 10, handle rotor 13 with care to prevent damage.
Also, do not damage oil seal 14 during assembly.
• Keep oil and grease off lining surface of rear brake assembly * and the inner surface of brake drum 16.

35A-26
 35A
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
13 Wobbling of rotor 0.1 {0.0039} — Replace
Resistance between terminals 950 to 1450Ω — Replace
20 Wheel speed sensor
Insulation resistance 1MΩ or higher — Replace

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

Anti-lock brake system

14 MH062664 Press-fitting of oil seal
oil seal installer ø130
{5.12}
ø144
{5.67}

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03023

I
◆ Service procedure
Rotor
[Removal]
Strike the outer edge of rotor 13 evenly with flat-tip screwdriver A to
remove the rotor from the wheel hub.
CAUTION–
Be careful not to damage wheel hub 15.
15

13 A
02991

[Installation]
Heat rotor 13 to approximately 150°C {302°F}. Press the rotor evenly
B with iron plate B to press-fit the rotor to wheel hub 15. Make sure there is
no space between the rotor and wheel hub.
13

15

02992

13 [Inspection]
• If the amount of wobbling exceeds the standard value, repeat the
assembly procedure from the beginning.
15 • If the amount of wobbling exceeds the standard value after
reassembly, replace defective parts.
C : Base

C
02993

35A-27
WHEEL SPEED SENSOR AND ROTOR < REAR AXLE >

14
0 J
NOTE
Installation of oil seal

When hub and brake drum assembly 10 is removed for a service

13 operation and if rotor 13 is still mounted on the wheel hub, use 0
Anti-lock brake system oil seal installer to press-fit oil seal 14.

10

P
02994

21 Wheel speed sensor

20 [Removal]
• With wheel speed sensor 20 and spring space 21 installed in sensor
19 holder 19, remove the sensor holder from oil seal retainer 23.

23

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35581

• Hold shaded section A of wheel speed sensor 20 with pliers, and

remove the sensor by twisting it slightly in left and right directions.
CAUTION–
• When holding wheel speed sensor 20 with pliers, do not grip any
section other than shaded area A in the diagram.
19 • When removing wheel speed sensor 20, do not apply force on the
21
sensor, such as by hitting with a hammer, prying with a screw-
driver or pulling the harness, since these actions can result in
20 wire breakage.
A 35582 • If wheel speed sensor 20 dismounts easily, replace spring spacer 21.

35A-28
 35A
[Inspection]
• Since pole piece section B is magnetized by the magnet inside
wheel speed sensor 20, it attracts metals. Do not allow the pole
piece to collect metallic objects.

20
36325

• Measure the resistance between the terminals of wheel speed

sensor 20.
20
If the measured value deviates from the standard value, replace the
wheel speed sensor.

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36825

• Measure the insulation resistance between body C of wheel speed

sensor 20 and each terminal.
If the measured values deviate from the standard value, replace the
C
wheel speed sensor.

20

36826

• To check for broken wires, remove the harness clamp section from
the vehicle. Bend and extend the harness to check if there is any
broken wire in the harness. Also, inspect the connector for proper
contact.
If a defect is found, replace wheel speed sensor 20.

P 31296

35A-29
WHEEL SPEED SENSOR AND ROTOR < REAR AXLE >
20 [Installation]
21 19 • Insert wheel speed sensor 20 from the back plate, and press until
spring spacer 21 and stopper section D of the wheel speed sensor
20 19 contacts sensor holder 19.
• With wheel speed sensor 20 and spring spacer 21 installed in
23 sensor holder 19, mount the sensor holder on oil seal retainer 23.

21 CAUTION–
D • When installing wheel speed sensor 20, do not apply force on
the sensor, such as by hitting with a hammer, prying with a
35583 screwdriver or pulling the harness, since these actions can
result in wire breakage.
• Note that wheel speed sensor 20 is different for left and right
wheels.
Location Harness connector color Harness connector shape
Left wheel Gray Male
Right wheel Black Female

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• Rear axle housing section
20
Starting from the wheel brake side, secure the harness of wheel
17, 18 speed sensor 20 in place with clip 18 and bolt 17. Make sure the
17, 18 harness does not interfere with other parts and there is no twist or
17, 18 17, 18
17, 18 slack in the harness.

03005

L • Binding of harness
J J
• Gather the harnesses of left and right wheel speed sensors 20, and
bind with corrugated tube F.
20 K
G • Adjust the position of the corrugated tube F so that white tape
F
30 mm {1.18 in.} 30 mm {1.18 in.} section G is located at clip position H on the rear axle housing.
Then, turn the corrugated tube so that the slit faces down. Wrap
H black tape (electric harness tape) on both ends J of the corrugated
G
tube. The tape should be placed over the tube end and harness.
K: Rear axle housing side
• Wrap tape on the harnesses of wheel speed sensors 20 at sections
03006 L (three locations at equal intervals).

35A-30
 35A
18 • Clamping of harness
M • Secure section M of corrugated tube F to the rear axle housing
using clip 18, and attach section N of the corrugated tube to the
F frame using clip 18.
• Connect the wheel speed sensor connector to the harness connec-
tor on the chassis side, and secure the connectors in place using
the bracket.

03007

18
N

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S
03008

Installation of oil seal retainer

When installing oil seal retainer 23, align mounting bolt center A of
A B A sensor holder 19 with the center line of mounting bolt B of rear brake
assembly *.

C : For left wheel

C D D : For right wheel
E : Front of vehicle
19
NOTE
23 The brake assembly diagram shows a left wheel.

*
P 36172

35A-31
35A-32
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 35A

35A-33
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ELECTRIC CIRCUIT AND PART INSTALLATION LOCATIONS

3 8 1 17 15 16
6

5
2 a

4
b

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c

10 9 11 12

13
7

14 35925

35A-34
 35A

3
8 a b

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7 6 5
9

14 13 15 16 10

c
11
17 d
12

36002

1 Starter switch 7 Stop lamp switch 13 Hydraulic unit

2 Exhaust brake cut relay 8 Meter cluster 14 Relay box
3 Relay box 9 Wheel speed sensor (for front-axle right wheel) 15 Main high-current fuse
4 ECU 10 Wheel speed sensor (for front-axle left wheel) 16 Battery
5 MUT-II connector 11 Wheel speed sensor (for rear-axle left wheel) 17 High-current fuse box
6 Fuse box 12 Wheel speed sensor (for rear-axle right wheel)

35A-35
 cardiagn.com
Group 35
Brake

' 98 Minor Change

Table of Contents

BACK HOME

Pub No. TWME9502-235

 35

GROUP 35 BRAKE
SPECIFICATIONS ........................................................................... 35- 2

STRUCTURE AND OPERATION .................................................... 35- 4

TROUBLESHOOTING ..................................................................... 35- 22

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Replacement of Brake Fluid ..................................................................... 35- 28
• Air Bleeding of Brake System .................................................................. 35- 30
• Inspection and Adjustment of Brake Pedal Free Play ............................ 35- 32

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• Inspection and Adjustment of Clearance between Brake Pedal and
Floor Panel ................................................................................................. 35- 32
• Thickness Inspection and Replacement of Brake Lining ...................... 35- 33
• Inspection of Brake Shoe Clearance ....................................................... 35- 33
• Inspection of Brake Booster (Hydraulic Booster) .................................. 35- 34

BRAKE MASTER CYLINDER ......................................................... 35- 36

BRAKE PEDAL AND BRAKE BOOSTER

(HYDRAULIC BOOSTER) ................................................................ 35- 38

BRAKE BOOSTER (HYDRAULIC BOOSTER) .............................. 35- 40

FRONT WHEEL BRAKE ................................................................. 35- 42

REAR WHEEL BRAKE ................................................................... 35- 50

VACUUM PUMP .............................................................................. 35- 58

EXHAUST BRAKE SYSTEM .......................................................... 35- 60

35-1
SPECIFICATIONS
< Equipment for Service Brake >
Item Specifications
Brake booster Booster Hydraulic type
(Hydraulic Manufacturer NABCO
booster)

Brake master Cylinder Inner diameter mm {in.} ø41.28 {1.63}

cylinder
Piston stroke Front mm {in.} 15.5 {0.61}
Rear mm {in.} 19.0 {0.75}
Manufacturer NABCO
Vacuum pump Type Vane type
Delivery cm3 {cu.in.} 120 {7.32}
Manufacturer MITSUBISHI ELECTRIC

< Wheel Brake >

Item Specifications

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Brake type Front Drum brake (2-leading type)
Rear Drum brake (Dual 2-leading type)
Brake drum inner diameter mm {in.} ø320 {12.6}
Wheel cylinder Front mm {in.} ø34.93 {1.38}
inner diameter Rear mm {in.} ø36.51 {1.44}
Brake lining Front mm {in.} 120×12 {4.72×0.47}
Width×Thickness Rear mm {in.} 140×12 {5.51×0.47}

< Exhaust Brake >

Item Specifications
Control type Combined electric and vacuum
Valve type Butterfly valve

35-2
 MEMO
35

35-3
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STRUCTURE AND OPERATION
Hydraulic booster brake system

13
12 15 1

4
14 3
5 6
2

11

10

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9

A 7
B
8
C
D
26879

1 Brake fluid tank 8 Front wheel cylinder 14 Flow switch

2 Brake master cylinder 9 Brake pedal 15 Motor relay
3 Power steering booster 10 Emergency pump motor
4 Power steering fluid level sensor 11 Brake booster (Hydraulic A: Brake fluid line
5 Power steering oil tank booster) B: Power steering fluid line
6 Power steering oil pump 12 Brake warning lamp C: Electric line
7 Rear wheel cylinder 13 Warning buzzer D: Hose

• The brake system is a hydraulic booster brake type, all-wheel braking type consisting of separate front and rear
systems.
• The servo system is fitted with brake booster (hydraulic booster) 11.
• The hydraulic booster brake type uses the fluid pressure from power steering oil pump 6 to boost brake pedal 9
operating force.
• If fluid pressure stops being generated because of engine stoppage, power steering oil pump 6 failure, or fluid leakage
from the power steering piping, it is detected by flow switch 14. To ensure proper fluid pressure in an emergency, the
emergency pump motor 10 rotates by the action of operating currents from motor relay 15.

35-4
 35
• Emergency pump 10 operates only when brake pedal 9 is depressed.
Operation conditions details are as follows.
Alarms
*1 Emergency
Brake warning Warning Power pump motor
Starter Parking brake
Engine lamp buzzer steering Vehicle condition
switch switch
● ··· Lit ● ··· Sounding fluid ● ··· Running
× ··· Not lit × ··· Silent pressure × ··· Stopped

× × Present × When normal

ON (Pulled) *2 Power steering
● ● Absent ●
piping fluid leakage
Running
× × Present × When normal
OFF (Returned) *2 Power steering
● ● ●
ON piping fluid leakage
● When engine is started
● When engine stalls
ON (Pulled) ● ●
during take-off on a

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slope
OFF (Returned) ● ● Absent ● When engine stalls
When vehicle starts
moving right after
Stopped ON (Pulled) × × ● being parked (when
parking brake force
OFF is insufficient)
When engine is cut
off right before the
OFF (Returned) × × ●
vehicle comes to a
stop
When fluid level in
ON — — ● ● — —
power steering oil
tank is below “MIN”
OFF — — × × — — or above “MAX”

*1 : The emergency pump motor operates when the brake pedal is depressed.
*2 : Fluid pressure is obtained by the action of the brake booster (hydraulic booster) fail-safe system which cuts off the
flow of fluid to the power steering piping. ÕP35-6

35-5
STRUCTURE AND OPERATION
Brake Booster (Hydraulic Booster)

A B

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3

4 E
8 D 5

7
26929

1 Spool valve 8 Flow switch

2 Hydraulic piston
3 Emergency pump A: Brake master cylinder
4 Piston B: Brake pedal
5 Spring C: Servo chamber
6 Reservoir D: Power steering oil pump
(Brake booster built-in) E: Power steering booster
7 Emergency pump motor F: Drain

• Spool valve 1 is an adjusting valve linked to brake pedal B that generates fluid pressure in accordance with the pedal
operating force.
• Hydraulic piston 2 is linked to brake master cylinder A, by storing the fluid supplied via spool valve 1 in servo chamber
C its force is boosted.
35-6
 35
• In case there is fluid leaking from the power steering piping and fluid pressure is lost, piston 4 is depressed by the
action of spring 5 and moves to the left, shutting off the flow of fluid to power steering oil pump D and power steering
booster E. As a result fluid hydraulic circuit is created only inside the brake booster.
• When piston 4 moves to the left, flow switch 8 is turned ON and emergency pump motor 7 starts operating. By the
action of emergency pump 3, fluid pressure is generated within the fluid hydraulic circuit inside the brake booster.

● Spool valve
< Low pressure in servo chamber C > < High pressure in servo chamber C >
C 2 G H C
E
D F
E D

1 J 24423

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At operation
Through the action of brake pedal B spool valve 1 Pressure of fluid coming High pressure fluid flows
moves to the left, narrowing down land G* and → from power steering oil → into servo chamber C via
closing off land H pump D rises fluid groove J
→

Hydraulic piston 2 is pushed to the left Piston of brake master cylinder A is pushed
→ and the brake is operated
* : When the brake is operating, land G is not completely shut, therefore the power steering booster is not affected.

G K H
2
E D F C

A
B

1
J 24424

When released
Through the action of brake pedal B spool Pressure of fluid from
Fluid from servo chamber C
valve 1 moves to the right, opening lands G → power steering oil → flows into reservoir 4 and drain F
and H and closing fluid groove K pump D falls
→

Hydraulic piston 2 moves to its original

position
→ Brake master cylinder A piston is released

35-7
STRUCTURE AND OPERATION
Brake Master Cylinder

1 2
13
12
11

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10 8 6
9 4
7 5 3

26923

1 Brake booster (Hydraulic booster) 8 Secondary piston

2 Hydraulic piston 9 Packing cup
3 Brake master cylinder 10 Secondary piston return spring
4 Primary piston 11 Supply valve
5 Packing cup 12 Supply valve stopper
6 Primary piston return spring 13 Cylinder
7 Retainer

• Brake master cylinder 3 consists of separate and independent front and rear hydraulic systems. Therefore, if by chance
there should be leakage in either the front or the rear hydraulic systems, the safety mechanism ensures that the other
unaffected system can operate the brakes.

35-8
 35
● When brake pedal is depressed
11 12 B A • Depressing the brake pedal makes brake booster (hydrau-
D
lic booster) hydraulic piston 2 push in primary piston 4 and
secondary piston 8, packing cup 5 passes return port A,
generates hydraulic pressure in chamber B, and feeds fluid
to front brake system C.
• Supply valve 11 separates from supply valve stopper 12,
generates hydraulic pressure in chamber D, and feeds fluid
to rear brake system E.

8 5 4 2
E C
26924

● When there is fluid leakage in the front brake system

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7 • Depressing the brake pedal makes hydraulic piston 2 push
in primary piston 4. However, if the brake fluid in the front
brake system leaks, hydraulic pressure is not generated in
the front brake system.
• Depressing the brake pedal further makes primary piston 4
compress primary piston return spring 6 causing retainer 7
to push in secondary piston 8, thus generating hydraulic
pressure only in the rear brake system E.

E 8 5 4 2

26925

● When there is fluid leakage in the rear brake system

13
• Depressing the brake pedal makes hydraulic piston 2 push
in primary piston 4 and secondary piston 8. However, if the
brake fluid in the rear brake system leaks, hydraulic pres-
sure is not generated in the rear brake system.
• Depressing the brake pedal further makes the end of sec-
ondary piston 8 hit against cylinder 13, pushing primary
piston 4 and generating hydraulic pressure only in the front
brake system C.

8 4 2
C
26926

35-9
STRUCTURE AND OPERATION
● When the brake pedal is released
B • When hydraulic piston 2 returns to its original position, as a
result of the repercussive force of primary piston return
spring 6, primary piston 4 begins to return immediately.
However, because of a lack of a pressure difference be-
tween chambers B and F brake fluid delivered from the
brake master cylinder cannot return quickly.
• When primary piston 4 begins to return, hydraulic pressure
in chamber B becomes lower than that in chamber F, the
pressure difference causes packing cup 5 to deform open-
ing up passage G. This causes brake fluid from chamber F
to flow into chamber B.
6 5 G F 4 2

26927

• When primary piston 4 moves further and returns to its

B A

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D original position, the pressure in chambers B and F become
the same, and packing cup 5 closes passage G. The hy-
draulic fluid in the brake pipe returns from chamber B to the
reservoir tank via return port A.
• The same action also takes place in the secondary side.
However, when secondary piston 8 is pushed back, supply
valve 11 hits against supply valve stopper 12 and the sup-
ply valve opens.
• Therefore the hydraulic fluid in the brake pipe returns from
chamber D to the reservoir tank via supply valve 11.

11 8 5 G F 4
12
26928

35-10
 35
Wheel Brake
1 Backing plate
< Front > 2 Brake shoe assembly
1 3 Return spring
2 4 Wheel cylinder assembly

12964

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< Rear >
2

1 3
4

12965

• The front wheel brake is an internal expanding 2-leading brake type.

• The rear wheel brake is an internal expanding dual 2-leading brake type.
• Front and rear wheel cylinder assemblies 4 have shoe clearance automatic adjusting mechanisms to adjust shoe
clearance within a specific range.

35-11
STRUCTURE AND OPERATION
● Wheel cylinder assembly
1 Piston cup
< Front >
2 Backup ring
3 4 3 Boot
1 2
4 Seal
5 Screw
6 Piston
7 Cylinder body
8 Anchor piece < Rear >
9 Piston < Rear >

6 5
7
12966
< Rear >

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9 2 1 1 2 5

8
4

3 7 6 3
12967

Even if the brake lining has worn to the extent that the brake shoe clearance is higher than the specified value, the brake
shoe clearance automatic adjusting mechanism automatically adjusts the brake shoe clearance to maintain the appropri-
ate brake shoe clearance when the vehicle is braked when moving forward.

● Operation of automatic shoe clearance adjusting mechanism (one-way clutch)

30° : When piston 6 appears, the double helical gear slides

out easily.
6 30° 45° 45° : When turning piston 6, the double helical gear receives
and maintains the rotational force.
A A : Clutch
B : Guide

7
12968

35-12
 35
● When braking starts
B 6
• When hydraulic braking pressure acts on the wheel cylinder, it pushes
piston 6 forward.
• Idler C of extended piston 6 is engaged with the diagonal gears cut in
guide B of the cylinder body, so the idler advances while turning, in
accordance with the travel of the piston.

C 10659

• The rotation of idler C slides out the double helical gear of clutch A.
C A 6

C A

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10660

● When depressing brake pedal

C A 6 When the brake shoe clearance conforms to the specified value
• The amount of travel of idler C is proportional to the amount of travel of
C A piston 6. The amount of travel is not enough to make the double
helical gear of clutch A climb over the opposite double helical gear
when the brake shoe clearance is within the specified value.

10661

When the brake shoe clearance is higher than the specified value
• When the brake shoe clearance is higher than the specified value, the
C A 6
amount of travel of idler C increases enough to make the double
helical gear of clutch A climb over the opposite double helical gear.
C A

10662

35-13
STRUCTURE AND OPERATION
● When releasing brake pedal
C A 6 D • As the brake fluid pressure decreases and piston 6 returns, idler C
also returns, turning in the opposite direction along guide B of the
cylinder body.
C A
• When the brake shoe clearance is within the specified value, piston 6
returns to its original position without turning, because the double
helical gear of clutch A has not climbed over the opposite double
helical gear.
• When the brake shoe clearance is higher than the specified value,
5 10663 piston 6 returns while turning by one gear tooth, since the double
helical gear of clutch A has climbed over the opposite gear. This
lowers the brake shoe clearance to the specified value, because
screw 5 of the piston is fixed by brake shoe D and does not turn.

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35-14
 35
Vacuum Pump
1 Rotor
2 Check valve
3 Vane
A 4 Housing
2
5 Oil filler hole

1 A : Inlet
B : Outlet

3
4

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B

01100

• The vacuum pump is installed on the rear part of alternator and is rotated by the V-belt.
• Check valve 2 is fitted to prevent the atmospheric pressure and the lubricating oil from flowing in reverse from the
vacuum pump when the engine is stopped.

● Operation
< Suction stroke > A
• Inside cylindrical housing 4, rotor 1 equipped with three vanes
(movable blades) 3 rotates, pressing the vanes against the inside
4
surface of the housing by centrifugal force.
• Since rotor 1 is eccentric with respect to housing 4, as the rotor
3
rotates, the atmospheric pressure of the exhaust brake unit is
1 drawn in from inlet A and discharges from outlet B by the gradual
compression of the air. This repetition of the suction, compression
< Compression stroke > and exhaust strokes generates a vacuum, realizing a near-vacuum
in the exhaust brake unit.
• The engine oil that lubricates and cools the inside of housing 4 is
returned, along with air pressure, through outlet B to the oil pan.

< Exhaust stroke >

B 04213

35-15
STRUCTURE AND OPERATION
Exhaust Brake System

11
1

12
2

3 13

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10
4
8
14

7 6 5

27412

1 Fuse box 8 Diode

2 Clutch switch 9 Meter cluster
3 Accelerator switch 10 Exhaust brake indicator lamp
4 Exhaust brake switch 11 Vacuum pump
5 Relay box 12 3-way magnetic valve
6 Exhaust brake cut relay 13 Exhaust brake unit
7 Transmission neutral switch 14 Butterfly valve

• Excitation of the coil of 3-way magnetic valve 12 closes the atmospheric valve and opens the vacuum valve. This
makes the vacuum pump 11 act on exhaust brake unit 13 which closes butterfly valve 14, activating the exhaust brake.
• If the exhaust brake is activated while the vehicle is stationary, the coolant temperature can rise excessively,
overheating the engine. To avoid this, when the transmission is in neutral, transmission neutral switch 7 turns ON,
cutting the exhaust brake system.

35-16
 35
● When exhaust brake system is activated
When exhaust brake switch 4 is turned on, the current
flows as illustrated to activate the exhaust brake.
11
1

12
2

3 13
9
10
4
8

14
7 65

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27413

Fuse 1→Clutch switch 2→Accelerator switch 3→Exhaust brake switch 4→Exhaust brake cut relay 6→3-way magnetic
valve 12→Ground

→Exhaust brake indicator lamp 10 (ON)→Ground

● When the exhaust brake system is released

When the accelerator pedal or clutch pedal is de-
pressed while the exhaust brake is working, all switches
11 3, 2 turn off, shutting off the current, releasing the
1
exhaust brake.

12
2

3
13
9
10
4
8

14
7 65

27414

● When clutch pedal is depressed

Fuse 1→Clutch switch 2 (OFF)→Since no current flows, the circuit turns off and the exhaust brake is released.
● When accelerator pedal is depressed
Fuse 1→Clutch switch 2→Accelerator switch 3 (OFF)→Since there is no grounding, current does not flow, so the exhaust
brake is released.
35-17
STRUCTURE AND OPERATION
● Releasing exhaust brake system by placing transmission in neutral
Fuse 1→Exhaust brake cut relay 6 excitation→Transmission neutral switch 7→Ground
Fuse 1→Clutch switch 2→Accelerator switch 3→Exhaust brake switch 4→Exhaust brake cut relay 6 (OFF)→Beyond this,
current does not flow so the exhaust brake is released.

● Working principle of exhaust brake

14 When butterfly valve 14 of exhaust brake unit 13, in exhaust pipe A, is

closed, the pressure in the exhaust pipe rises. The pressure rises further
13 in the exhaust stroke, generating a force that pushes back piston B, the
A exhaust braking force.

12473

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● Exhaust brake unit
1 Connector
1 2 Spring
3 Push rod
4 Butterfly valve
5 Diaphragm
5 2

26930

35-18
 35
Brake Warning and Brake booster (Hydraulic Booster) Fail-Safe System

3 1 Fuse box
2 4 2 High current fuse box
5 3 Warning buzzer
1 4 Meter cluster
5 Brake warning lamp
6 Brake fluid level switch
15 6 7 Brake booster (Hydraulic booster)
8 Emergency pump motor
9 Motor relay
10 Flow switch
8 11 Stop lamp switch
7 12 Power steering fluid level sensor
^ Gr 37
9 13 Parking brake switch
14 14 Diode
10 15 Joint connector

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A: To stop lamp

11

13

12
A 27578

● Power steering fluid level warning circuit

3 • Since the fluid pressure of the power steering
2 4 fluid is also used for brake booster (hydraulic
5 booster) 7, the power steering fluid level warn-
1 ing circuit is connected to warning buzzer 3 and
brake warning lamp 5.
• When the power steering fluid level drops be-
15 6 low the “MIN” level or rises above the “MAX”
level of the power steering oil tank, power steer-
ing fluid level sensor 12 is turned ON, and the
flow of current at such time is as follows.
8 7 Fuse 1 → Warning buzzer 3
→

Brake warning lamp 5 Joint connector 15

9
→

14 Diode 14
10
→

→ Joint connector 15

→

Power steering fluid

11
level sensor 12
→

13 Ground

12 As a result warning buzzer 3 sounds and warn-

A 27579 ing lamp 5 lights to warn the driver.
35-19
STRUCTURE AND OPERATION
● Brake booster (hydraulic booster) fail-safe system
• If there is a fluid leakage in the power steering
3
system piping and hydraulic pressure is lost,
2 4
the brake booster (hydraulic booster) fail-safe
5
1 system will act in the following manner.
Flow switch 10 is turned ON and the flow of
current is as follows.
6
15 Fuse 1 → Warning buzzer 3

→
→
Brake warning lamp 5 Diode 14

→
→
8
7 Joint connector 15 → Flow switch 10

→
→
Diode 14 Ground
9
14 As a result warning buzzer 3 sounds and brake
10 warning lamp 5 lights.
Depressing the brake pedal when flow switch

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10 is ON, will cause the current to flow as
11 follows.
Fuse 1 → Stop lamp switch 11

→
13
High current Diode 14

→
A 12 27580
fuse 2
(Contact) → Motor relay 9
(coil)

→
Emergency
pump motor 8 ← Flow switch 10

→
→

Ground Ground

As a result emergency pump motor 8 starts

operating, maintaining the hydraulic pressure
during an emergency.

35-20
 35
● Brake fluid warning circuit
• When the brake fluid in the fluid tank drops
3
4 below the specified level, brake fluid level
2
5 switch 6 in the fluid tank turns on, brake warn-
1 ing lamp 5 lights.

15 6

8
7

9
14
10

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11

13

12 27581
A

● Brake fluid level switch

1 Fluid tank
2 Float
3 Brake fluid level switch
*1 : For brakes
1
*2 : For clutch

• Brake fluid level switch 3, installed on fluid tank 1, monitors

2 the brake fluid level in the fluid tank. If the brake fluid level
3 drops below the specified level, float 2 moves and lights up
the warning lamp within the meter cluster to alert the driver.

*1 *2 27437

A • If the brake fluid level in fluid tank 1 drops and float 2 drops lower than
level L, magnetic force B that passes through the contact point
B
C (ferromagnetic body A), increases generating north and south poles at
the ends of the contact points. Therefore, the contact points pull each
other and overcome the repercussive force of the springs of the
contact points, forming an electric circuit.
C : Permanent magnet
D : Glass
2
D 01668

35-21
TROUBLESHOOTING
● Wheel Brake

One-sided braking Noise and judder

Symptoms
when brakes are
applied

Noise generated when wheels are rotating, with

Braking shoe return slow after releasing brake

Braking force difference between left and right

Noise and judder when brakes are applied

Continuous noise generated while braking

Brake pedal stroke reduced
Braking force insufficient
Braking force unstable

Lock points difference

One-sided braking

vehicle jacked up

(at low speed)

pedal

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Possible causes
Tires Air pressures uneven, etc. ^ Gr 31 ●
Left and right tire sizes different ^ Gr 31 ●
Axle Wheel hub bearing adjusted incorrectly
● ●
^ Gr 26, 27
Left and right wheelbase difference excessive
●
^ Gr 26, 27
Wheel alignment incorrect ^ Gr 26 ●
Kingpin bushing worn ^ Gr 26
Wheel Backing plate ledge surface rough ● ●
brakes Backing plate ledge surface not smooth
Backing plate deformed, mounted incorrectly ●
Oil or water on brake lining surfaces ● ●
Brake lining changed in quality or wrong material
●
used
Brake lining unevenly worn or surface roughened ●
Brake lining fading (surface change in material) ●
Brake lining worn out completely ●
Abrasive on brake lining
Brake lining worn
Brake lining contact incorrect ● ● ●
Brake lining ground radius irregular ●
Wheel cylinder malfunctioning ● ● ● ●
Wheel cylinder piston cup faulty
Shoe return spring fatigued or broken ● ●
Brake drum worn unevenly ●
Brake drum warped ●
Brake drum worn ●
Brake drum surface roughened ●
Brake drum roughness excessive ●
Brake drum glassy

35-22
 35
Symptoms One-sided braking Noise and judder
when brakes are
applied

Noise generated when wheels are rotating, with

Braking shoe return slow after releasing brake

Braking force difference between left and right

Noise and judder when brakes are applied

Continuous noise generated while braking

Brake pedal stroke reduced
Braking force insufficient
Braking force unstable

Lock points difference

One-sided braking

vehicle jacked up

(at low speed)

pedal
Possible causes

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Wheel Brake drum cracked ●
brakes Brake drum clogged by foreign particles
Brake drum deformed or eccentric ●
Brake shoe deformed or damaged ●
Brake shoe twisted or tilted
Moving parts greased insufficiently ●
Brake pedal Brake pedal stroke faulty (52 mm {2.05 in.} or more
●
at 490 N {110 lbf, 50 kgf} foot pressure)
Brake pedal adjusted incorrectly, looseness
●
excessive
Brake booster (Hydraulic booster) operating rod
pushing up
Brake fluid Brake fluid insufficient ●
system Brake fluid leaking ●
Air lock in system ●
Vapor lock ●
Brake fluid return insufficient because brake pipe
tightened excessively
Power Degree of power steering fluid line pressure reduced
●
steering fluid
system
Brake Brake booster (Hydraulic booster) defective ● ●
booster
(Hydraulic
booster)
Brake Piston cup faulty ●
master Return port clogged
cylinder

35-23
TROUBLESHOOTING

Symptoms Brake drums Brakes

overheating squeaking

Squeaking in new vehicle or after brake lining

Remarks

Brake pedal return faulty

One wheel overheating
All wheels overheating

Brakes squeaking

Action too severe

Brake juddering
replacement

Brake drags
Possible causes

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Tires Air pressures uneven, etc. ^ Gr 31
Left and right tire sizes different ^ Gr 31
Axle Wheel hub bearing adjusted incorrectly ● ● ● ^ Gr26, 27
Left and right wheelbase difference excessive ^ Gr26, 27
Wheel alignment incorrect ^ Gr26
Kingpin bushing worn ● ^ Gr26
Wheel Backing plate ledge surface rough ●
brakes Backing plate ledge surface not smooth ●
Backing plate deformed, mounted incorrectly ●
Oil or water on brake lining surfaces
Brake lining changed in quality or wrong
material used
Brake lining unevenly worn or surface
roughened
Brake lining fading (surface change in
●
material)
Brake lining worn out completely
Abrasive on brake lining ●
Brake lining worn ●
Brake lining contact incorrect ●
Brake lining ground radius irregular
Wheel cylinder malfunctioning ● ●
Wheel cylinder piston cup faulty ● ●
Shoe return spring fatigued or broken ● ●
Brake drum worn unevenly
Brake drum warped
Brake drum worn
Brake drum surface roughened
Brake drum roughness excessive
Brake drum glassy ●

35-24
 35
Symptoms Brake drums Brakes
overheating squeaking

Squeaking in new vehicle or after brake lining

Remarks

Brake pedal return faulty

One wheel overheating
All wheels overheating

Brakes squeaking

Action too severe

Brake juddering
replacement

Brake drags
Possible causes

cardiagn.com
Wheel Brake drum cracked
brakes Brake drum clogged by foreign particle
Brake drum deformed or eccentric ●
Brake shoe deformed or damaged ●
Brake shoe twisted or tilted ●
Moving parts greased insufficiently
Brake pedal Brake pedal stroke faulty (52 mm {2.05 in.} or more
at 490 N {110 lbf, 50 kgf} foot pressure)
Brake pedal adjusted, looseness excessive
Brake pedal return faulty ●
Brake pedal free play inadequate ●
Linkage rusted or deformed ●
Return spring fatigued or broken ●
Brake booster (Hydraulic booster) operating rod ●
pushing up
Brake fluid Brake fluid insufficient
system Brake fluid leaking
Air lock in system
Vapor lock
Brake fluid return insufficient because brake pipe
●
tightened excessively
Power Degree of power steering fluid line pressure reduced
steering fluid
system
Brake Brake booster (Hydraulic booster) defective ● ●
booster
(Hydraulic
booster)
Brake Piston cup faulty ● ●
master Return port clogged
cylinder ● ●

35-25
TROUBLESHOOTING
● Exhaust Brake

Symptoms

Exhaust brake does not release

Exhaust brake does not work
Remarks

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Possible causes
Vacuum Degree of vacuum insufficient ●
system Pipe crushed ●
3-way Does not work
magnetic ● ● ^ Gr 54
valve
Exhaust Valve assembly does not work ● ●
brake Valve assembly shaft stuck ● ●
unit
Vacuum chamber does not work ●
Electric Electric system faulty
● ● ^ Gr 54
system

35-26
 MEMO
35

35-27
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ON-VEHICLE INSPECTION AND ADJUSTMENT
Replacement of Brake Fluid

- Fluid
Location Points of application Specified fluid Quantity
3 Fluid tank Brake fluid As required
(SAE J1703f or FMVSS No.116 DOT3)

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

1200 {47.2}
1 Vinyl hose MH033102 Air bleeding

ø7 {0.28}
00328

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WARNING–
• The clutch fluid system and the brake fluid system use the fluid
tank in common.
• You must use new brake fluid (SAE J17031 or FMVSS No. 116
DOT 3). Do not add different quality fluid or mineral oil (gas oil,
engine oil, gear oil, automatic transmission fluid, etc.) to the
clutch system, because this will cause the rubber parts of the
clutch system and brake system to swell, resulting in faulty
clutch operation, as well as ineffective braking and brake drag-
ging.
• Do not allow foreign particles or water to become mixed into the
brake fluid when refilling, because this will result in ineffective
clutch and brake operations.
• If you use a mug for adding brake fluid, keep it solely for that
purpose.

CAUTION–
• Be careful not to splash brake fluid on related parts as this could
damage the paintwork.
• Be sure to wipe off brake fluid immediately if you splash it on the
paintwork.

NOTE
Supply and maintain the brake fluid level to the “MAX” level of
the fluid tank.

35-28
 35
• Start engine and let it idle until brake fluid replacement is completed.

• Attach one end of 0 vinyl hose to air bleeder 1 and place the other
< Front > end in container A.
1

04865

< Rear >

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0

04866

• Loosen air bleeder 1 and depress brake pedal 2 to drain brake fluid
2 completely.
1

12548

• Maintain a supply of new brake fluid up to the “MAX” level of fluid tank
3, depress the brake pedal repeatedly until the old brake fluid of the
brake system is replaced with new fluid.

“MAX”
“MIN” • Bleed air from the brake system.
Õ P35-30

3
11775

35-29
ON-VEHICLE INSPECTION AND ADJUSTMENT
Air Bleeding of Brake System

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Air bleeder 7.8 to 12 {5.8 to 8.5, 0.8 to 1.2} —

- Fluid
Location Points of application Specified fluid Quantity
— Fluid tank Brake fluid As required
(SAE J1703f or FMVSS No.116 DOT3)

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

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1200 {47.2}

1 Vinyl hose MH033102 Air bleeding

ø7 {0.28}
00328

WARNING–
• The clutch fluid system and the brake fluid system use the fluid
tank in common.
• You must use new brake fluid (SAE J1703f or FMVSS No. 116
DOT 3). Do not add different quality fluid or mineral oil (gas oil,
engine oil, gear oil, automatic transmission fluid, etc.) to the
clutch system, because this will cause the rubber parts of the
clutch system and brake system to swell, resulting in faulty
clutch operation, as well as ineffective braking and brake drag-
ging.
• Do not allow foreign particles or water to become mixed into the
brake fluid when refilling, because this will result in ineffective
clutch and brake operations.
• If you use a mug for adding brake fluid, keep it solely for that
purpose.

35-30
 35
CAUTION–
• Be careful not to splash brake fluid on related parts as this could
damage the paintwork.
• Be sure to wipe off brake fluid immediately if you splash it on the
paintwork.

NOTE
• Supply and maintain brake fluid to the “MAX” level of the fluid
tank.
• Make sure you maintain brake fluid at the “MAX” level of the fluid
tank since the brake fluid level drops during air bleeding.

• Start engine and let it idle until brake fluid replacement is completed.
• Attach one end of 0 vinyl hose to air bleeder 1 of the wheel brake.
1
Place free end in container A filled with brake fluid.

• Carry out air bleeding in the following sequence:

0
Front brake system Rear brake system

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A
Right-hand side wheel brake Right-hand side wheel brake
↓ ↓
04867
Left-hand side wheel brake Left-hand side wheel brake

• Depress brake pedal 2 slowly a few times, and with the brake pedal
2 depressed, loosen air bleeder 1 to drain brake fluid containing air.
1 • Tighten air bleeder 1, and release brake pedal 2.
• Repeat this service procedure until air is no longer present in the fluid
being drained.
• Tighten air bleeder 1 at specified torque as soon as brake fluid flowing
out is free of air bubbles.

• Adjust brake shoe clearance when you have finished air bleeding.
12548 Õ P35-30
• Check that brake fluid comes up to level “MAX” of fluid tank. If it does
not, refill with new brake fluid.
• Depress brake pedal 2 a few times and check for any leakage of brake
fluid, then test the brakes.

35-31
ON-VEHICLE INSPECTION AND ADJUSTMENT
Inspection and Adjustment of Brake Pedal Free Play

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
— Free play of brake pedal 10 to 15 {0.39 to 0.59} — Adjust

[Inspection]
Check if brake pedal free play A confirms to the standard value. If the
measured value deviates from the standard value, adjust the position of
the brake pedal.

[Adjustment]
Õ P35-39

06539

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Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
— Clearance between brake pedal and floor panel 52 {2.05} or more — Adjust
(with pedal depressed at 490 N {110 lbf, 50 kgf})

[Inspection]
Depress the brake pedal using 490 N {110 lbf, 50 kgf} when the engine is
idling to check if clearance A between the brake pedal and the floor
panel conforms to the standard value. If the measured value deviates
from the standard value, adjust the position of the brake pedal.

[Adjustment]
A Õ P35-39

06540

35-32
 35
Thickness Inspection and Replacement of Brake Lining

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
2 Thickness of brake lining — 5.5 {0.22} Replace
(Side shoulder
means wear
limit)

[Inspection]

A
NOTE
Be sure to inspect at two points for each wheel per side.
2
• Remove check hole plug 1 from the backing plate.
• Inspect through check hole A whether brake lining 2 is worn to the
2 point of side shoulder B of the brake lining (the limit).
1
• If the measured value is lower than the limit, replace brake lining 2 on

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B
the same axle as a unit.
06541 • After inspection, be sure to reinstall check hole plug 1.

[Replacement]
Õ P35-42, 50

Inspection of Brake Shoe Clearance

NOTE
A When the vehicle is jacked up and the wheel is being turned,
1
B make sure that there is no dragging.

• Remove the check hole plug from the backing plate.

A : Check hole
• Try to insert a 1 mm {0.039 in.} feeler gauge B between brake drum 1
and brake lining 2. Check that the clearance is too small to let the
feeler gauge enter.
2 00320 If feeler gauge A enters the clearance, disassemble the wheel cylinder
and inspect.
Õ P35-48, 56

35-33
ON-VEHICLE INSPECTION AND ADJUSTMENT
Inspection of Brake Booster (Hydraulic Booster)
(1) Inspection of electric equipment
Perform inspection in accordance with the flow-chart below. Make sure the power steering fluid level sensor is working
properly and power steering oil tank fluid level is normal. Make sure the parking brake is working properly and the
wheels are choked during inspection.

Starter switch ON (engine stopped) ←

←
←

BRAKE Brake warning lamp is lit and warning buzzer is sounding

NO
YES

←
←

Check the motor relay operation sound by depressing the brake pedal Replace the flow
switch Õ P35-40
YES NO

←
Replace the motor relay
Õ P35-40

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←

Check the emergency pump motor operation sound by depressing the brake pedal
NO
YES
←

←
Normal Replace the brake booster (hydraulic booster)
(Emergency pump motor faulty) Õ P35-40

35-34
 35
1 (2) Performance inspection
• Mount foot pressure meter A on the brake pedal, remove the front
wheel brake air bleeder and after installing oil pressure gauge B,
bleed the air from the pressure gauge.
A • Carry out a performance evaluation test on the power steering
system and make sure hydraulic pressure in the power steering
fluid system is at a normal level. ^ Gr 37
• If the above proves normal, check to make sure the hydraulic
pressure of the front wheel brakes in response to foot pressure on
the brake pedal is in conformity with the performance characteris-
27234
tics chart.
B If faulty, replace brake booster (hydraulic booster) 1.
Õ Gr 35-38

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27582

Performance characteristics chart

20 {200}
Front wheel brake hydraulic pressure MPa {kgf/cm2}

0°F}
ture 60°c {14
a
temper
17 {170}
teering fluid
s
Power
15 {150}

9.8 {100}

4.9 {50}

0 {0}
98 195 295 390 490 590 685 785
{10} {20} {30} {40} {50} {60} {70} {80}
Depression force on pedal N{kgf}
27583

35-35
BRAKE MASTER CYLINDER

6
-
1
5
2

7 A

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Ê3
26873

● Disassembly sequence
1 Retaining ring 5 Clamp A : Brake booster support
2 Primary piston assembly 6 Connector * : Brake pedal and brake
3 Set bolt 7 Cylinder body booster (hydraulic
4 Secondary piston assembly booster) Õ P35-38

WARNING–
Be sure not to damage the inner surface of cylinder body 7, since it will cause air to get mixed in or will result
in brake fluid leakage during the removal and installation of primary piston assembly 2 and secondary piston
assembly 4.

● Assembly sequence
Follow the disassembly sequence in reverse.

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy

(Basic diameter in [ ])
2 Primary piston assembly spring load 100 to 115 N 93 N Replace
(Installed length 35.1{1.38}) {22 to 26 lbf, 10.2 to 11.7 kgf} {21 lbf, 9.5 kgf}
2, 4, 7 Clearance between primary and secondary [41.28] 0.02 to 0.10 0.2 {0.0079} Replace
piston assemblies and cylinder body {[1.63] 0.00079 to 0.0039}
4 Secondary piston assembly spring load 71 to 86 N 67 N Replace
(Installed length 34.1{1.34}) {16 to 19 lbf, 7.2 to 8.8 kgf} {15 lbf, 6.8 kgf}

35-36
 35
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
3 Set bolt 6.86 to 8.82 {5.1 to 6.5, 0.7 to 0.9} —

- Lubricant
Location Points of application Specified lubricant Quantity
1 Periphery of retaining ring Rubber grease As required

4
◆ Service procedure

[Removal]
Secondary piston assembly

A • Using rod A, push in secondary piston assembly 4, then loosen set

bolt 3.
4

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3 26875

• Feed compressed air via discharge port B that leads to the rear wheel
brake to extract secondary piston assembly 4.
WARNING–
You must apply compressed air gradually when you remove
secondary piston assembly 4. If you applied compressed air
strongly at one time, the secondary piston assembly would be
violently ejected.

B
26876

[Installation]
A Using rod A, push in secondary piston assembly 4, then tighten set bolt 3
at specified torque.
4

3 26875

35-37
BRAKE PEDAL AND BRAKE BOOSTER (HYDRAULIC BOOSTER)

5Ê
2
Ê 13 Ê
8 1
9

-6 4
3

Ê
1

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11
10 26872

● Disassembly sequence
1 Pipe ^ Gr 37 6 Bolt 12 Stop lamp switch
2 Nut 7 Spring ^ Gr 54
3 Clevis pin 8 Collar 13 Support assembly
4 Brake booster (Hydraulic booster) 9 Bushing
Õ P35-40 10 Pedal pad
5 Nut 11 Brake pedal

WARNING–
Power steering fluid is a mineral fluid. Make sure it does not get mixed with brake fluid (vegetable fluid) during
disassembly, because it causes the rubber parts of the brake equipment to expand resulting in brake dragging
or malfunction.

NOTE
Do not disassemble brake booster (hydraulic booster) 4 because it is a non-disassemble type.

● Assembly sequence
Follow the disassembly sequence in reverse.

● Adjustment after assembly Õ P35-39

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy

(Basic diameter in [ ])
8, 9 Clearance between collar and bushing [16] 0.02 to 0.26 0.5 {0.020} Replace
{0.00079 to 0.010}
11 Brake pedal Height from pedal pad center to 264 {10.4} — Adjust
instrument panel underside
Full stroke 163 {6.42} — Adjust
11, 12 Clearance between brake pedal stopper and tip of 0 to 0.1 {0 to 0.0039} — Adjust
stop lamp switch thread area

35-38
 35
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
1 Pipe (Brake booster connecting) 66.69±12.75 {49±9.4, 6.8±1.3} —
2 Nut (Brake booster mounting) 8.8 to 14 {6.5 to 10, 0.9 to 1.4} —
5 Nut (Brake pedal mounting) 34.3 to 53.9 {25 to 40, 3.5 to 5.5} —

- Lubricant
Location Points of application Specified lubricant Quantity
6 Friction surface of bolt bushing Chassis grease [NLGI No.1 (Ca soap)] As required

◆ Service procedure
● Adjustment after assembly
• Adjustment of brake pedal installation height
4 By turning operating rod C of brake booster (hydraulic booster) 4,
A

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adjust height B from the center of pedal pad 10 to the underside of
C D instrument panel A to the standard value, then secure in place
using nut D.
WARNING–
Make sure, when brake pedal 11 is depressed fully, that
operating rod C of brake booster (hydraulic booster) 4 func-
tions as the stopper and the pedal does not come to a stop
B
by hitting against the floor panel, since this will reduce
10 11 brake effectiveness.

• Inspection of brake pedal full stroke

Make sure that full stroke E when brake pedal 11 is depressed fully
E conforms to the standard value.
If there is any fault, adjust the installation height of the brake pedal.

H
26874 • Inspection of play towards brake pedal Õ Gr 35-32

Adjustment of stop lamp switch

Turn stop lamp switch 12 to adjust clearance A between the top of the
thread area of the stop lamp switch and the stopper of brake pedal 11
to the standard value, and fasten with lock nut B.

11
WARNING–
Make sure, when brake pedal 11 is released, that stop lamp
A
B switch 12 does not stop the pedal, since this will cause the
12 brake to drag.
05819

35-39
BRAKE BOOSTER (HYDRAULIC BOOSTER)
● Disassembly sequence
1 Motor relay
2 Flow switch
3 Brake booster (Hydraulic booster)
1
*: Emergency pump motor

2 ● Assembly sequence
3
Ê Follow the disassembly sequence in reverse.

*
26877

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Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
2 Flow switch 24.5 to 34.3 {18 to 25, 2.5 to 3.5} —

35-40
 MEMO
35

35-41
cardiagn.com
FRONT WHEEL BRAKE
Front Wheel Brake Assembly

2
3Ê

1
Ê

18 21
Ê4
Ê19
-
5 17
Ê
15
Ê
14
Ê

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-

9
- 8
- 7
13 Ù

Ù 11
12561

● Disassembly sequence
1 Bolt 9 Washer 17 Adjusting hole plug
2 Joint assembly 10 Brake shoe assembly 18 Check hole plug
3 Pipe assembly 11 Rivet 19 Nut
4 Bolt 12 Brake lining 20 Holder pin
5 Pipe assembly 13 Brake shoe 21 Backing plate
6 Return spring 14 Bolt
7 Split pin 15 Bolt Ù : Non-reusable parts
8 Holder pin nut 16 Wheel cylinder assembly Õ P35-48
* : Brake drum ^ Gr 26
WARNING–
Do not leave grease or oil on the surface of brake lining 12 or inner surface of brake drum * because this
reduces braking performance.

CAUTION–
Do not turn or remove holder pin 20 unless it is necessary, or the squareness of brake shoe assembly 10 can
be influenced causing brake drag.

● Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit : Brake lining kit
● Initial adjustment of brake shoe clearance after installation
Õ P35-43
35-42
 35
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
6 Return spring load (Installed length 192 {7.56}) 325 N {73 lbf, 33 kgf} Clearance Replace
between
coils or
coil and cover
12 Brake lining thickness 12.0 {0.47} 5.0 {0.20} Replace
(Side shoulder brake lining
means wear
limit)
* Brake drum Inner diameter 320 {12.5} *321 {12.64} 322 {12.68} Replace
Cylindrical accuracy 0.05 {0.0020} 0.2 {0.0079} Correct
or replace
* : Indicates correction limit.

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

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Location Parts to be tightened Tightening torque Remarks
1 Bolt (Joint assembly mounting) 9.8±1.0 {7.2±1.4, 1.0±0.2} —
3, 5 Flair nut (Pipe assembly mounting) 14±2.0 {10±1.4, 1.4±0.2} —
4 Bolt (Pipe clamp mounting) 4.9±1.0 {3.6±0.7, 0.5±0.1} —
14 Bolt (Wheel cylinder assembly mounting) 78±16 {58±12, 8.0±1.6} —
15 Bolt (Wheel cylinder assembly mounting) 44±8.8 {33±6.5, 4.5±0.9} —
19 Nut (Holder pin mounting) 29±5.9 {22±4.3, 3,0±0.6} —

- Lubricant
Location Points of application Specified lubricant Quantity
9, 10, 16 Contact areas between washer and brake shoe assembly; and Wheel bearing grease [NLGI No.2 (Li soap)] As required
between brake shoe assembly and wheel cylinder assembly

◆ Service procedure
● Initial adjustment of brake shoe clearance after installation
• Jack up the front wheels, and make sure that there is no play in the
B hub bearings.
C
• Insert screwdriver B into adjusting hole A and turn adjuster C in the
direction of the arrow marked on backing plate 21 until the wheel
drags slightly when turned by hand.
A
NOTE
• Be sure to adjust the clearance at two points for each wheel per
side.
00318 • The arrow mark on backing plate 21 is near adjusting hole A.

35-43
FRONT WHEEL BRAKE
• After depressing the brake pedal several times, release it and make
sure that the wheel drags lightly when turned by hand. If the wheel
turns without stress, repeat the above steps. Slacken off adjuster B,
in the reverse direction to the arrow mark, by eight or nine notches.
NOTE
Be sure to adjust the clearance at two points for each wheel per
side.
• Make sure that the wheel does not drag when turned by hand.
If the wheel drags, repeat the above steps.
• Insert feeler gauge D between brake drum * and brake lining 12
C
* through check hole C, and make sure that a little resistance is felt
D when the feeler gauge is pulled out or pushed in.

NOTE
Be sure to adjust the clearance at two points for each wheel per
side.

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12 00320

10
6 Return Spring
[Removal]
6 16 To remove return spring 6, place screwdriver B on the hook of the return
spring, then pry and remove the return spring making use of wheel
cylinder assembly 16 adjuster A as a fulcrum.
A
B

12583

[Installation]
10 • Install the shorter hook end of return spring 6 in brake shoe assembly
6 10 at the side opposite to adjuster A of wheel cylinder assembly 16.
16 • Insert a small Phillips screwdriver C into the hook of return spring 6,
insert the tip of the screwdriver into return spring installation hole D of
A the brake shoe assembly to pry on the return spring.

D C

F
12584

Brake shoe assembly

12 [Inspection]
If thickness A of brake lining 12 is lower than the limit replace the brake
lining on the same axle as a unit.

12501

35-44
 35
[Installation]
20 10 • Install brake shoe assembly 10.
21
• Insert washer 9 with the side stamped “NUT ” facing outside, screw
7 down holder pin nut 8 until washer hits stepped area B of holder pin 20
B gently, then slacken off the nut within the 0 to 60° limit until the nut is
aligned with the first split pin hole.
• Insert split pin 7, and bend it securely.
20
8

H
9 00572

Brake lining
[Removal]

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12806

[Installation]
• Clean the mounting surfaces of brake lining 12 and brake shoe 13 with
cleaning fluid and dry them.
13
• Insert rivets 11 from brake lining 12 side, and caulk the rivets at the
specified load so that there is no clearance between brake shoe 13
and the brake lining.

12 Caulking load for rivets : 17 to 19 kN {3750 to 4190 lbf, 1700 to

11 1900 kgf}
00573 • Make sure that you inspect contact with the inner surface of brake
drum * after you replace brake linings 12. If contact is incorrect,
correct with the brake assembled.
WARNING–
Do not leave lubricant on the surface of brake lining 12 because
this reduces braking performance.

CAUTION–
Make sure that the type of brake linings 12 you fit are suitable for
the intended use of the vehicle. Make sure that you fit identical
size and color coated linings on the left and right sides of one

L
shaft.

16 “A” or “B” Installation of wheel cylinder assembly

Identification mark Installation position

RA Front of front axle right wheel
RB Rear of front axle right wheel
LA Front of front axle left wheel
LB Rear of front axle left wheel

“R ”or “L” 12585

35-45
FRONT WHEEL BRAKE
P Adjustment of holder pin
• Install the front wheel brake assembly on the front axle. ^ Gr 26

12580

• Turn adjuster A to adjust the outer diameter to approximately

10 B
ø319±0.5 mm {12.6±0.020 in.}.
21
• Then, move brake shoe assembly 10 to adjust clearance B evenly.
A Approximately
ø319±0.5 mm
{12.6±0.020 in.}

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10 B 11413

• Install hub and drum assembly C on the front wheel brake assembly.
C 21
D ^ Gr 26
At this time, the hub and drum assembly cannot be inserted in the
specified position if squareness D is 90° or more, so loosen nut 19 and
turn holder pin 20 to adjust the squareness to as close to 90° as
possible.
• Bleed the brake system. Õ P35-30
10
20 19 11414

★ • Turn adjuster A to widen brake shoe assembly 10 until 0.2 mm

21 {0.0079 in.} feeler gauge E cannot be pulled out easily.
C
★ • Loosen nut 19 and turn holder pin 20 to the right or left so that feeler
E gauge E can be pushed in or pulled out easily.
• Repeat the above steps (marked ★) until feeler gauge E cannot be
pushed in or pulled out easily.
• Depress the brake pedal a few times lightly to equalize clearance B
20
(adjusted in the previous section).
10
• Repeat the above steps (marked ★) until feeler gauge E cannot be
19 pushed in or pulled out easily.

11415

35-46
 35
21 • If feeler gauge E cannot be pushed in or pulled out easily it is because
C
it is making contact over the full width of brake shoe assembly 10.
E • Turn holder pin 20 so that when you pull out feeler gauge E, in the
above condition, and reinsert the feeler gauge, pushing in or pulling
out the feeler gauge at the rear is difficult.
• After adjustment, tighten nut 19 at specified torque.

10

19 20 11416

* Correction of brake drum

If the cylindrical accuracy of brake drum * is higher than the limit, or
there are seams, correct by machining to the correction limit. Machining
of the brake drum should be done with the wheel hub attached as an
integral part.

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35-47
FRONT WHEEL BRAKE
Wheel Cylinder Assembly
● Disassembly sequence
1- 1 Screw
- 2 Seal
2
3 Piston
- 4 Piston cup
3
5 Backup ring
6 Boot
7 Air bleeder (only at the rear)
8 Body

Ù : Non-reusable parts
5
Ù
● Assembly sequence
6-Ù Follow the disassembly sequence in re-
verse.

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Repair kit : Wheel cylinder kit
8
- 7Ê 03398

Service standards Unit : mm {in.}

Standard value
Location Maintenance item (Basic diameter in [ ]) Limit Remedy

3, 8 Clearance between piston and body [34.93] 0.03 to 0.09 0.2 {0.0079} Replace
{[1.38] 0.0012 to 0.0035} piston

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
7 Air bleeder 9.8±2.0 {7.2±1.4, 1.0±0.2} —

- Lubricant
Location Points of application Specified lubricant Quantity
1, 2, 3, Thread area of screw, outer periphery of seal, outer periphery Rubber grease As required
6, 8 of piston, mounting groove and thread area of boot, and inner
surface of body

35-48
 35
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application

50 {1.97}

4 Piston cup guide MC895722 Installation of piston cup

ø39 {1.54}

13697

3 5 4 0
4
◆ Service procedure
Installation of piston cup

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13698

35-49
REAR WHEEL BRAKE
Rear Wheel Brake Assembly

1Ê 16Ê

15 18

Ê2
13
11 14
Ê -
13

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-

10 6 5
- 4
Ù

Ù8
12562

● Disassembly sequence
1 Bolt 8 Rivet 14 Adjusting hole plug
2 Pipe assembly 9 Brake lining 15 Check hole plug
3 Return spring 10 Brake shoe 16 Nut
4 Split pin 11 Bolt 17 Holder pin
5 Holder pin nut 12 Wheel cylinder assembly 18 Backing plate
6 Washer Õ P35-56
13 Wheel cylinder cover Ù : Non-reusable parts
7 Brake shoe assembly
* : Brake drum ^ Gr 27

WARNING–
Do not leave grease or oil on the surface of brake lining 9 or inner surface of brake drum * because this
reduces braking performance.

CAUTION–
Do not turn or remove holder pin 17 unless it is necessary, or the squareness of brake shoe assembly can be
influenced causing brake drag.

● Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit : Brake lining kit
● Initial adjustment of brake shoe clearance after installation
Õ P35-51
35-50
 35
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
3 Return spring load (Installed length 217 {8.54}) 390 N {88 lbf, 40 kgf} Clearance Replace
between
coils or
coil and cover
9 Brake lining thickness 12.0 {0.47} 5.0 {0.20} Replace
(Side shoulder lining
means wear
limit)
* Brake drum Inner diameter 320 {12.5} *321 {12.64} 322 {12.68} Replace
Cylindrical accuracy 0.05 {0.0020} 0.2 {0.0079} Correct
or replace
* : Indicates correction limit.

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks

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1 Bolt (Pipe clamp mounting) 4.9±1.0 {3.6±0.7, 0.5±0.1} —
2 Flair nut (Pipe assembly mounting) 14±2.0 {10±1.4, 1.4±0.2} —
11 Bolt (Wheel cylinder assembly mounting) 78±16 {58±12, 8.0±1.6} —
16 Nut (Holder pin mounting) 29±5.9 {22±4.3, 3,0±0.6} —

- Lubricant
Location Points of application Specified lubricant Quantity
6, 7, 12 Contact areas between washer and brake shoe assembly; and Wheel bearing grease [NLGI No.2 (Li soap)] As required
between brake shoe assembly and wheel cylinder assembly

◆ Service procedure
● Initial adjustment of brake shoe clearance after installation
• Jack up the front wheels, and make sure that there is no play in the
hub bearings.
B • Insert screwdriver B into adjusting hole A and turn adjuster C in the
direction of the arrow marked on the back plate until the wheel drags
slightly when turned by hand.
C
NOTE
A • Be sure to adjust the clearance at two points for each wheel per
side.
• The arrow mark on backing plate 18 is near adjusting hole A.
00319

35-51
REAR WHEEL BRAKE
• After depressing the brake pedal several times, release it and make
sure that the wheel drags lightly when turned by hand. If the wheel
turns without stress, repeat the above steps. Slacken off adjuster B,
in the reverse direction to the arrow mark, by eight or nine notches.
NOTE
Be sure to adjust the clearance at two points for each wheel per
side.
• Make sure that the wheel does not drag when turned by hand.
If the wheel drags, repeat the above steps.
• Insert feeler gauge D between brake drum * and lining 9 through
C
* check hole C, and make sure that a little resistance is felt when the
D feeler gauge is pulled out or pushed in.

NOTE
Be sure to adjust the clearance at two points for each wheel per
side.

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9

3
00320

3 Return Spring
7 [Removal]
To remove return spring 3, place screwdriver B on the hook of the return
12
spring, then pry and remove the return spring making use of wheel
cylinder assembly 12 adjuster A as a fulcrum.

A
12586

[Installation]
3 • Refer to the illustration on the caution plate fitted to brake shoe
7
assembly 7 or marking C, and connect shorter hook end of return
12
spring 3 to the brake shoe assembly at the side opposite the adjuster
of wheel cylinder assembly 12.
C A
• Insert a small Phillips screwdriver D into the hook of return spring 3,
insert the tip of the screwdriver into return spring installation hole E of
brake shoe assembly 7 to pry on the return spring.
D
E

7
12587

Brake shoe assembly

9 [Inspection]
If thickness A of brake lining 9 is lower than the limit replace the brake
lining on the same axle as a unit.

12501

35-52
 35
[Installation]
17 • Install brake shoe assembly 7.
7
18 • Insert washer 6 with the side stamped “NUT ” facing outside, screw
4 down holder pin nut 5 until washer hits stepped area B of holder pin 17
B gently, then slacken off the nut within the 0 to 60° limit until the nut is
aligned with the first split pin hole.
• Insert split pin 4, and bend it securely.
17
5
6 00572

9 Brake lining
[Removal]

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12806

[Installation]
• Clean the mounting surfaces of brake lining 9 and brake shoe 10 with
cleaning fluid and dry them.
10
• Insert rivets 8 from brake lining 9 side, and caulk the rivets at the
specified load so that there is no clearance between brake shoe 10
and the brake lining.

9 Caulking load for rivets : 17 to 19 kN {3750 to 4190 lbf, 1700 to

8
1900 kgf}
00573
• Make sure that you inspect contact with the inner surface of brake
drum * after you replace brake linings 9. If contact is incorrect, correct
with the brake assembled.
WARNING–
Do not leave lubricant on the surface of brake lining 9 because
this reduces braking performance.

CAUTION–
Make sure that the type of brake linings 9 you fit are suitable for
the intended use of the vehicle. Make sure that you fit identical
size and color coated linings on the left and right sides of one
shaft.

35-53
REAR WHEEL BRAKE

12
H A:
Installation of wheel cylinder assembly
Identification mark

Identification mark Installation position

R Right wheel forward
L Left wheel forward
A No mark Left and right wheel rearward

12589 • Install anchor piece C so its recession is at the deeper side of the
C brake shoe at the outside.
B : Front of the vehicle
13 12
B

12 13

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M
12590

Adjustment of holder pin

• Install the rear wheel brake assembly on the rear axle. ^ Gr 27

12581

• Turn adjuster A to adjust the outer diameter to approximately

7 B
ø319±0.5 mm {12.6±0.020 in.}.
18
• Then, move brake shoe assembly 7 to adjust clearance B evenly.
A Approximately
ø319±0.5 mm
{12.6±0.020 in.}

7 B 11413

• Install hub and drum assembly C on the rear wheel brake assembly.
C 18
D ^ Gr 27
At this time, the hub and drum assembly cannot be inserted in the
specified position if squareness D is 90° or more, so loosen nut 16 and
turn holder pin 17 to adjust the squareness to as close to 90° as
possible.
• Bleed the brake system. Õ P35-30
7
17 16 11414

35-54
 35
18 ★ • Turn adjuster A to widen brake shoe assembly 7 until 0.2 mm
C {0.0079 in.} feeler gauge E cannot be pulled out easily.
E ★ • Loosen nut 16 and turn holder pin 17 to the right or left so that feeler
gauge E can be pushed in or pulled out easily.
• Repeat the above steps (marked ★) until feeler gauge E cannot be
pushed in or pulled out easily.
17 • Depress the brake pedal a few times lightly to equalize clearance B
7 (adjusted in the previous section).
• Repeat the above steps (marked ★) until feeler gauge E cannot be
16 pushed in or pulled out easily.

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11952

18 • If feeler gauge E cannot be pushed in or pulled out easily it is because

C it is making contact over the full width of brake shoe assembly 7.
E • Turn holder pin 17 so that when you pull out feeler gauge E, in the
above condition, and reinsert the feeler gauge, pushing in or pulling
out the feeler gauge at the rear is difficult.
• After adjustment, tighten nut 16 at specified torque.

16 17 11416

* Correction of brake drum

If the cylindrical accuracy of brake drum * is higher than the limit, or
there are seams, correct by machining to the correction limit. Machining
of the brake drum should be done with the wheel hub attached as an
integral part.

35-55
REAR WHEEL BRAKE
Wheel Cylinder Assembly

1
-
13 2
-
3 Ù
-
5
Ù
6-Ù

11
- 12
9 Ù Ù Ê

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10
-7 -
03399

● Disassembly sequence
1 Screw 7 Anchor piece 12 Air bleeder
2 Seal 8 Piston cup (Only identification marks L, R)
3 Piston 9 Backup ring 13 Body
4 Piston cup 10 Piston
5 Backup ring 11 Boot Ù : Non-reusable parts
6 Boot

● Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit : Wheel cylinder kit

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy

(Basic diameter in [ ])
3, 10, 13 Clearance between piston and body [36.51] 0.03 to 0.09 0.2 {0.0079} Replace
{[1.44] 0.0012 to 0.0035} piston

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
12 Air bleeder 9.8±2.0 {7.2±1.4, 1.0±0.2} —

- Lubricant
Location Points of application Specified lubricant Quantity
1, 2, 3, Thread area of screw, outer periphery of seal, outer periphery Rubber grease As required
6, 10, 11 of piston, mounting groove and thread area of boot, and inner
surface of body
7 Bottom surface of anchor piece Wheel bearing grease [NLGI No.2 (Li soap)]As required

35-56
 35
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application

50 {1.97}

4, 8 Piston cup guide MC895722 Installation of piston cup

ø39 {1.54}

13697

3 5 4 0
4
◆ Service procedure
Installation of piston cup

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13698

10 9 8 0
8 Installation of piston cup

13699

35-57
VACUUM PUMP
● Disassembly sequence
1 Vacuum housing
2 O-ring
3 Vane
4 Rotor
5 Plate
6 O-ring

Ù : Non-reusable parts

● Assembly sequence
Follow the disassembly sequence in re-
verse.

1
2
4 3 Ù
Ù

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5
8 00359

Service standards
Location Maintenance item Standard value Limit Remedy
— Ultimate vacuum 93.3 kPa — —
(When alternator number of revolutions is 1500 rpm) {27.6 in.Hg, 700 mmHg} or more

35-58
 MEMO
35

35-59
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EXHAUST BRAKE SYSTEM
Exhaust Brake Unit

Ê
-

14

11
10 2

Ù9 6

1Ê

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5Ê

8 4
7
3

16Ê
25 17

18
23 19 Ê

20
22
24

21
26931

● Disassembly sequence
1 Bolt 10 Retainer 19 Lock nut
2 Cover 11 Bearing 20 Bolt
3 Pin 12 Vacuum chamber assembly 21 Valve assembly
4 Clevis pin 13 Connector 22 Seal ring (Small)
5 Nut 14 Vacuum chamber Õ P35-64 23 Seal ring (Large)
6 Collar 15 Valve and bracket assembly 24 Bushing
7 Clevis 16 Nut 25 Bracket assembly
8 Lock nut 17 Lever
9 Dust protector 18 Adjusting bolt Ù : Non-reusable parts

35-60
 35
● Assembly sequence
12 : 14→13 15 : 21→24→23→22
→20→19→18→17→16
25
15→ 9
→5→8→7→4→3→2→1
12→11→10→6

● Adjustment after assembly

Õ P35-62

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
12 Airtightness in vacuum chamber 63 kPa — Replace
(Airtightness 15 seconds after applying negative {18.7 in.Hg, 475 mmHg} or more
pressure 67 kPa {19.7 in.Hg, 500 mmHg})

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— Clearance between valve assembly butterfly valve 0.4 to 0.6 {0.016 to 0.023} — Adjust
and body when butterfly valve is fully closed
(Degree of negative pressure in power chamber
87 to 93 kPa {25.6 to 27.6 in.Hg, 650 to 700 mmHg})

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (Cover mounting) 4.9 to 6.9 {3.6 to 5.0, 0.5 to 0.7} —
5, 16 Nut (Vacuum chamber and lever mounting) 9.8 to 16 {7.3 to 11.5, 1.0 to 1.6} —
13 Connector 9.8 {7.3, 1} or more —
19 Lock nut (Adjusting bolt mounting) 4.9 to 6.9 {3.6 to 5.0, 0.5 to 0.7} —

- Sealant
Location Points of application Specified sealant Quantity
13 Thread area of connector THREEBOND 1211 As required

35-61
EXHAUST BRAKE SYSTEM
◆ Service procedure
B ● Adjustment after assembly
Adjustment of valve when fully-closed
• While applying negative pressure B of 87 to 93 kPa {25.6 to 27.5
12 in.Hg, 650 to 700 mmHg} to vacuum chamber assembly 12, adjust
by turning adjusting bolt 18 so that clearance D and E between the
butterfly valve and body C conforms to the standard value.
18
• After adjustment, tighten lock nut 19 at specified torque.
• Average value of clearance D, E = (D + E)/2.
• Fully-opened adjustment of butterfly valve A is done while valve and
19
15 bracket assembly 15 is installed.

C C
D

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A 26932

H Vacuum chamber assembly

[Installation]
• Adjust valve and bracket assembly 15. Õ P35-63
• Adjust the hole of clevis 7 to position as illustrated.
12
• Fix clevis 7 using lock nut 8.
11 • Push up and align clevis 7 with the hole of lever 17 and install using
8 clevis pin 4.
10

9
7
26933

8
7
17

15
18 4 00781

35-62
 35
B [Inspection]
A Apply negative pressure A of 67 kPa {19.6 in.Hg, 500 mmHg} or more
to vacuum chamber assembly 12. Check to ensure that the value of
negative pressure gauge B 15 seconds after indicating 67 kPa {19.6
in.Hg, 500 mmHg} conforms to the standard value.

12

I
00583

Installation of connector
13

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12

K
11464

A Adjustment of valve and bracket assembly butterfly valve

when fully-opened
• Adjust by turning adjusting bolt 18 so that lever 17 and the head of the
adjusting bolt meet horizontally (butterfly valve A is fully opened at
such time).
A • After adjustment, tighten lock nut 19 at specified torque.

15 19 18 17
00782

35-63
EXHAUST BRAKE SYSTEM
Vacuum Chamber
● Disassembly sequence
1
1 Dust cover
2 Rear shell
11 3 Nut
4 Diaphragm retainer
5 Diaphragm
10 6 Diaphragm plate
7 O-ring
8 Piston washer
9 9 Push rod
10 Spring
8 11 Front shell
7Ù
6 Ù : Non-reusable parts

5 ● Assembly sequence

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Follow the disassembly sequence in reverse.
4
3Ê
● Inspection after assembly
Õ P35-65
00784

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
3 Nut (Push rod mounting) 44 to 59 {32.6 to 43.3, 4.5 to 6} —

0 Special tools
Location Tool name and shape Part No. Application
2 Plate *910-22060 Removal and installation of rear shell
Lever *910-22100
11 Socket *910-22110 Fixing of front shell
* : JIDOSHA KIKI part No.

35-64
 35
◆ Service procedure
● Inspection after assembly
• Inspect the airtightness of the vacuum chamber assembly.
Õ P35-63
• If the measured value is higher than the limit, replace the vacuum

2
chamber assembly.

C Rear shell
2
3 [Removal]
• Fix 1 socket in a vice.
• Fix nut A of front shell 11 using 1 socket.
B
• Assemble 2 plate and 3 lever and install on rear shell 2. Turn
11 2 3 lever in direction B.
A
1 [Installation]
Set up as described above and turn 3 lever in direction C.
00785
• After making sure the flange area of diaphragm 5 is fully inserted

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inside front shell 11, turn rear shell 2.

35-65
EXHAUST BRAKE SYSTEM
Exhaust Brake System Electric Equipment
1 Meter cluster
1 2 3 ^ Gr 54
2 Exhaust brake switch
^ Gr 37, ^ Gr 54
3 Fuse box
^ Gr 54
4 Diode
5 Exhaust brake cut relay
^ Gr 54
6 Accelerator switch
^ Gr 13, ^ Gr 54
7 7 Clutch switch
5 4 ^ Gr 21, ^ Gr 54
8 3-way magnetic valve
^ Gr 54
9 Transmission neutral switch
^ Gr 22, ^ Gr 54

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8

9
26970

6
◆ Service procedure
Adjustment of accelerator switch
• While the engine is idling, turn exhaust brake switch 2 ON, depress
the accelerator gradually, and check the engine revolution when the
exhaust indicator lamp within the meter cluster goes off.
A • Adjust on the basis of the following chart using accelerator switch 6.
6
Engine revolution Adjusting direction of
accelerator switch 6
800 rpm or less
11470
950 rpm or more

• After adjustment, tighten nut A to fix accelerator switch 6.

35-66
 cardiagn.com
Group 35
Brake
Table of Contents
BACK
HOME

Pub No. TWME9502-35

 35

GROUP 35 BRAKE
SPECIFICATIONS .................................................................................. 2

STRUCTURE AND OPERATION ........................................................... 4

TROUBLESHOOTING .......................................................................... 26

INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE

• Replacement of Brake Fluid ............................................................................ 30
• Air Bleeding of Brake System ......................................................................... 32
• Inspection and Adjustment of Clearance between Brake Pedal and

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Floor Panel ........................................................................................................ 34
• Thickness Inspection and Replacement of Brake Lining ............................. 35
• Inspection of Brake Shoe Clearance .............................................................. 35
• Inspection and Maintenance of Air Dryer ....................................................... 36

HANDLING OF CONNECTORS ........................................................... 37

BRAKE PEDAL .................................................................................... 38

DUAL BRAKE VALVE .......................................................................... 42

BRAKE BOOSTER (AIRMASTER) ...................................................... 49

FRONT WHEEL BRAKE ...................................................................... 56

REAR WHEEL BRAKE ........................................................................ 64

AIR COMPRESSOR ............................................................................. 72

AIR DRYER ........................................................................................... 80

AIR PRESSURE GOVERNOR ............................................................. 84

FLUID TANK ......................................................................................... 86

CHECK VALVE ..................................................................................... 87

SAFETY VALVE .................................................................................... 87

SUPPLY VALVE .................................................................................... 88

EXHAUST BRAKE SYSTEM ............................................................... 90

35-1
SPECIFICATIONS
< Equipment for Service Brake >
Item Specifications
Brake booster Power cylinder inner diameter×Stroke mm {in.} ø114.3×79 {4.50×3.11}
(Airmaster) Hydraulic cylinder inner diameter×Stroke mm {in.} ø23.8×76 {0.94×2.99}
2 2
Operating starting pressure kPa {lbf/in , kgf/cm } 18±9.8 {2.6±1.4, 0.18±0.1}
Residual pressure kPa {lbf/in2, kgf/cm2} 78 to 125 {11 to 18, 0.8 to 1.3}
Manufacturer JIDOSHA KIKI
Air compressor Type Air-cooled, single cylinder
Cylinder diameter×Stroke mm {in.} ø70×40 {2.76×1.57}
3
Cylinder capacity cm {cu.in.} 154 {9.40}
Manufacturer SANWA SEIKI
Air dryer Type DR-41
Heater capacity V-W 12-50
Thermostat operating ON 4±4 {39±7.2}
temperature °C {°F}
OFF 20 {68} or less

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Purge chamber capacity L {qts} 0.9 {0.95}
Required time for recycling desiccant Sec 30
Manufacturer NABCO
Air tank Capacity L {qts} 8+9+8 {8.45+9.50+8.45}

< Wheel Brake >

Item Specifications
Brake type Front Drum brake (2-leading type)
Rear Drum brake (Dual 2-leading type)
Brake drum inner diameter mm {in.} ø320 {12.6}
Wheel cylinder Front mm {in.} ø34.93 {1.38}
inner diameter Rear mm {in.} ø36.51 {1.44}
Brake lining Front mm {in.} 120×12 {4.72×0.47}
Width×Thickness Rear mm {in.} 140×12 {5.51×0.47}

< Exhaust Brake >

Item Specifications
Control type Combined electric and air
Valve type Butterfly valve

35-2
 MEMO
35

35-3
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35-4
1 11

5 8
Brake System

2 2
7
2

4
E 3
D 6
E E E
9 10
D D D F G
21 23
G G G
F F F

23
22 13
12
STRUCTURE AND OPERATION

21
14
20 19

15
16

17

18

A
B
C

12544

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 35
1 Front wheel cylinder 17 Power cylinder
2 Check valve 18 Master cylinder
3 Air tank 19 Air horn
4 Safety valve 20 Air pressure gauge
5 Air dryer 21 Low air pressure switch
6 Air pressure governor 22 Dual brake valve
7 Supply valve 23 Stop lamp switch
8 Fluid tank
9 Airmaster (Front) A: Fluid line
10 Airmaster (Rear) B: Air line
11 Rear wheel cylinder C: Hose
12 3-way magnetic valve D: Red identification tape
13 Exhaust brake unit E: Blue identification tape
14 Intake silencer < Manual transmission > F: White identification tape
15 Air compressor G: Yellow identification tape
16 Air cleaner

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• The brake system is an air over hydraulic, all-wheel braking type consisting of separate front and rear systems.
• The servo system is fitted with airmasters 9, 10.
• An exhaust brake system, of the exhaust pipe opening and closing valve type, is fitted as a sub-brake system.

35-5
STRUCTURE AND OPERATION
Dual Brake Valve

2 3 4 5 6 7

15
14 13 12 11 10 9 8
12545

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1 Brake pedal 9 Secondary inlet valve
2 Plate assembly 10 Relay piston spring
3 Primary inlet valve 11 Sleeve inner spring
4 Primary inlet valve spring 12 Sleeve outer spring
5 Body 13 Primary piston spring
6 Relay piston 14 Primary piston
7 Cover 15 Plunger
8 Secondary inlet valve spring

The dual brake valve controls the braking force of the vehicle by feeding pressurized air to the airmaster in accordance
with the brake pedal depression angle of brake pedal 1.

● When depressing brake pedal (braking pressure is generated)

• The repercussive forces of primary inlet valve spring 4 and secondary
12 14 inlet valve spring 8 seat primary inlet valve 3 at primary side A, and
secondary inlet valve 9 at secondary side B, on their respective seats.
E
13 This shuts off air C from the air tank to maintain airtightness.
3 • The repercussive force of primary piston spring 13 raises primary
D
11 4 A piston 14 to its upper position. Exhaust valve seat D opens and
chamber E is open to atmosphere G via chamber F.
C
K L • Since the repercussive forces of sleeve inner spring 11 and sleeve
6 outer spring 12 is stronger than the repercussive force of relay piston
H 5 spring 10, relay piston 6 is raised to its upper position and exhaust
J 10 B valve seat H is opened. This opens chamber J to atmosphere G via
chamber F.
C F
Chamber E at the primary side and chamber K at the upper part of
relay piston 6 at the secondary side are connected via passage port L
9 8 of body 5.
G 01641

35-6
 35
● When depressing brake pedal (before braking pressure is generated)

M • Depressing the brake pedal (illustrated as pedal action M), forces

15 14 down primary piston 14 via plunger 15.
• Forcing down primary piston 14 changes the balance between the
repercussive forces of inner spring 11 and outer spring 12, and the
D repercussive force of relay piston spring 10, forcing down relay piston
12 6. This seats the relay piston on secondary inlet valve 9 and closes
11 exhaust valve seat H.
C
10 • This closes the secondary side exhaust passage; however, primary
side exhaust valve seat D remains open. No braking pressure is
H generated at either primary or secondary sides.
9 6

G 01642

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● When depressing brake pedal (braking pressure is generated)

Primary side
M 14 • As the brake pedal is depressed further (illustrated as brake pedal
action M), primary piston 14 is forced down until it is seated on primary
N E inlet valve 3, closing exhaust valve seat D.
D • Primary inlet valve 3 is forced down, compressing primary valve
3 spring 4, and supply valve seat N of body 5 separates from the
P primary inlet valve. The air in chamber P flows into chamber E and is
C R fed to rear brake system R via discharge port Q as braking pressure.
Q

5 4

01643

Secondary side
M
• The air at the primary side flows into chamber K via passage port L of
body 5.
E • The air fed into chamber K acts on the upper part of relay piston 6 to
L force down the relay piston and compress secondary valve spring 8,
P forcing down secondary inlet valve 9.
• This separates supply valve seat T and secondary inlet valve 9 of
5
K cover 7.
J
• The air in supply port chamber S flows into chamber J and is fed to
T
6 front brake system U via discharge port Q as braking pressure.
Q
C U
S
8 9
7 H
01644

35-7
STRUCTURE AND OPERATION
● Stabilization of braking pressure
When the brake pedal remains depressed at the specified depression angle, the braking air pressure stabilizes at the
pressure corresponding to the brake pedal depression angle.

M Primary side
• The braking air pressure fed under the bottom of primary piston 14
14
raises the primary piston and primary inlet valve 3 together in tandem.
5
• Primary inlet valve 3 makes contact with supply valve seat N of body
N
5, then the supply of air C from the air tank ceases and the increases
in the braking air pressure stops. This stabilizes braking pressure R
for the rear brake system.
C R

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01645

Secondary side
M
• As the braking pressure (pressure in chamber J) for the front brake
system balances the pressures in chambers E and K, the force raising
relay piston 6 disappears, and the relay piston rises in tandem with
E secondary inlet valve 9.
• Secondary inlet valve 9 makes contact with supply valve seat T of
cover 7, then the supply of air from supply port chamber S to chamber
J ceases. This stabilizes brake pressure U for the front system.
6
K
J 9
T
C U
S

7 01646

● Release of brake pressure

Primary side
M 15 When the brake pedal is released (illustrated as brake pedal action M),
primary piston spring 13 and air pressure R at discharge port Q (pres-
14 E
sure in chamber E) raise plunger 15 and primary piston 14. Then,
13 D exhaust valve seat D at the lower end of the primary piston separates
from primary inlet valve 3. The air pressure of the rear brake system
3 Q flows through chamber E to be discharged from exhaust passage cham-
R ber F into atmosphere G.

K
J

F G 01647

35-8
 35
M Secondary side
• As the air pressure in the rear brake system drops, the air pressure in
D
chamber K is discharged via passage port L of body 5, and chambers
E
E, F into atmosphere G.
• This changes the air pressure balance between chambers K and J.
The air pressure in chamber J raises relay piston 6, and exhaust valve
5 seat H at the lower end of the relay piston separates from secondary
R
6 inlet valve 9. Air pressure U in the front brake system is discharged
L from exhaust passage chamber F into atmosphere G.
H
K
J

9 U

F G 01648

● When abnormality occurs

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Operation when the air pipe of the front brake system fails
M
• The primary side operates the same as normal, generating braking
pressure in rear brake system R.
• At the secondary side, even if the primary side generates air pressure
in chamber K, braking pressure is not generated in front brake system
U, since no air pressure is generated in supply port S.

C R
K

S U

01649

Operation when the air pipe of the rear brake system fails
M
• In the rear brake system, air pressure is not generated up to supply
14
port P. Therefore, even if the brake pedal is depressed (causing
primary piston 14 to force down primary inlet valve 3), braking pres-
sure is not generated.
3 • If the brake pedal is depressed further (illustrated as brake pedal
action M), primary piston 14 makes contact with relay piston 6 and
P
they force down secondary inlet valve 9.
J • This action separates supply valve seat T of cover 7 from secondary
6
inlet valve 9. The air pressure flows into chamber J from chamber S
7 T
and is fed to front brake system U via discharge port Q as braking
C U pressure.
Q

S 9 H
01650

35-9
STRUCTURE AND OPERATION
Brake Booster (Airmaster)
1 Push rod
2 Return spring
A 4 B 3 Retainer assembly
2 3
1 4 Spring
5 5 Connector
6 6 Residual valve
7 Hydraulic piston
7 8 Body assembly
9 Steel ball
10 Return spring
11 Yoke
12 Stroke switch
9 13 Rod
14 Cylinder shell
8
15 Cup packing
16 Piston plate

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15 14 13 11 10
16 A : Power cylinder area
B : Hydraulic piston area
C : Power piston stroke detection switch
C 12 area
04952

● Power cylinder area

2 • Operation of the dual brake valve feeds compressed air D into cham-
ber E, activating piston plate 16. This opens chamber F to the atmos-
phere, generating a pressure difference between chambers E and F.
1 When this force becomes greater than the repercussive force of return
D spring 2, the piston plate moves to the right.
• Piston plate 16 is fitted with push rod 1 that transmits the force of the
compressed air received at the piston plate to hydraulic piston area B.
E

16 F 01652

35-10
 35
● Hydraulic piston area

When functioning
• The movement of the piston plate compresses return spring 2, which
moves push rod 1, then hydraulic piston 7 to the right. This movement
4 separates yoke 11 from retainer assembly 3, and seats steel ball 9 at
6
the end of the hydraulic piston. This closes the passage between
G brake fluid tank chamber G and wheel cylinder chamber H. The
hydraulic piston moves to the right and pressurizes the brake fluid in
chamber H, transmitting power to the wheel cylinder.
• In residual valve 6, negative pressure from chamber G increases as
3 the volume expands in line with the movement of the hydraulic piston.
2 7
This opens the residual valve, allowing it to suck brake fluid from the
H fluid tank.

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G 9
1 11
04968

When released
• Releasing the brake pedal frees the compressed air at the rear side of
the piston plate into the atmosphere. Hydraulic piston 7 is returned to
4 its original position by the combined repercussive forces of return
6 spring 2 of push rod 1, and the brake fluid pressure of chamber H yoke
11 hits retainer assembly 3, connecting chamber G and chamber H.
G • Brake fluid flows through chamber G to compress spring 4 of residual
valve 6. The brake fluid passes around the residual valve and returns
to the fluid tank.
• Residual valve 6 closes when the repercussive forces of spring 4 and
3
2 the brake fluid pressure balance.
7
H

9
1 11
04969

● Power piston stroke detecting switch area

12 • When brake fluid has been lost due to damage to the brake pipe, the
13 stroke of the power piston increases, and piston plate 16 hits the end
16
of rod 13, and the rod is moved to the right.
• Because of this, stroke switch 12 leaves the recessed area of the rod
13, and turns the stroke switch ON. This turns on a warning lamp
within the meter cluster to alert the driver.

01655
35-11
STRUCTURE AND OPERATION
Wheel Brake
1 Backing plate
< Front > 2 Brake shoe assembly
1 3 Return spring
2 4 Wheel cylinder assembly

12964

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< Rear >
2

1 3
4

12965

• The front wheel brake is an internal expanding 2-leading brake type.

• The rear wheel brake is an internal expanding dual 2-leading brake type.
• Front and rear wheel cylinder assemblies 4 have shoe clearance automatic adjusting mechanisms to adjust shoe
clearance within a specific range.

35-12
 35
● Wheel cylinder assembly
1 Piston cup
< Front >
2 Backup ring
3 4 3 Boot
1 2
4 Seal
5 Screw
6 Piston
7 Cylinder body
8 Anchor piece < Rear >
9 Piston < Rear >

6 5
7
12966
< Rear >

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9 2 1 1 2 5

8
4

3 7 6 3
12967

Even if the brake lining has worn to the extent that the brake shoe clearance is higher than the specified value, the brake
shoe clearance automatic adjusting mechanism automatically adjusts the brake shoe clearance to maintain the appropri-
ate brake shoe clearance when the vehicle is braked when moving forwards.

● Operation of automatic shoe clearance adjusting mechanism (one-way clutch)

30° : When piston 6 appears, the double helical gear slides

out easily.
6 30° 45° 45° : When turning piston 6, the double helical gear receives
and maintains the rotational force.
A A : Clutch
B : Guide

7
12968

35-13
STRUCTURE AND OPERATION
● When braking starts
B 6
• When hydraulic braking pressure acts on the wheel cylinder, it pushes
piston 6 forward.
• Idler C of extended piston 6 is engaged with the diagonal gears cut in
guide B of the cylinder body, so the idler advances while turning, in
accordance with the travel of the piston.

C 10659

• The rotation of idler C slides out the double helical gear of clutch A.
C A 6

C A

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10660

● When depressing brake pedal

C A 6 When the brake shoe clearance conforms to the specified value
• The amount of travel of idler C is proportional to the amount of travel of
C A piston 6. The amount of travel is not enough to make the double
helical gear of clutch A climb over the opposite double helical gear
when the brake shoe clearance is within the specified value.

10661

When the brake shoe clearance is higher than the specified value
• When the brake shoe clearance is higher than the specified value, the
C A 6
amount of travel of idler C increases enough to make the double
helical gear of clutch A climb over the opposite double helical gear.
C A

10662

35-14
 35
● When releasing brake pedal
C A 6 D • As the brake fluid pressure decreases and piston 6 returns, idler C
also returns, turning in the opposite direction along guide B of the
cylinder body.
C A
• When the brake shoe clearance is within the specified value, piston 6
returns to its original position without turning, because the double
helical gear of clutch A has not climbed over the opposite double
helical gear.
• When the brake shoe clearance is higher than the specified value,
5 10663 piston 6 returns while turning by one gear tooth, since the double
helical gear of clutch A has climbed over the opposite gear. This
lowers the brake shoe clearance to the specified value, because
screw 5 of the piston is fixed by brake shoe D and does not turn.

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35-15
STRUCTURE AND OPERATION
Air Compressor
1 Cylinder head
2 2 Unloader valve
3 Unloader valve spring
3 4 Suction valve spring
5 Suction valve
1 6 Delivery valve
7 Delivery valve spring
14 8 Crankcase
4 56 7
13 9 Drive gear
8
10 Crankshaft
12 9 11 Bearing holder
12 Connecting rod
13 Cylinder liner
14 Piston

The air compressor is driven by the engagement of

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drive gear 9 with the engine timing gear.
11
10
12546

● During suction
• When drive gear 16 is driven, crankshaft 10 engaged with the drive
A gear turns to force down piston 14.
• The negative pressure generated at this time opens suction valve 5,
5 sucking air A into cylinder liner 13.
14

13

01631

● During pressurized delivery

• As piston 14 rises and enters into the compression stroke, suction
valve spring 4 closes suction valve 5.
5
• The pressure of the compressed air overcomes the repercussive force
7 of delivery valve spring 7 and opens delivery valve 6 to compress and
4
deliver air B to the air tank.

B 14

6
01632

● When unloader valve operates

C 2 • When the air pressure in the air tank becomes higher than the speci-
3 fied value, the air pressure governor feeds compressed air C to
unloader valve 2. This forces down the unloader valve and holds
A
suction valve 5 open at the same time. Therefore, air A is not com-
5 pressed and the air compressor idles.
• When the air pressure in the air tank drops below the specified value,
the air pressure governor discharges compressed air from the upper
part of unloader valve 2. So, unloader spring 3 returns the unloader
valve to its original position.
01633

35-16
 35
Air Dryer
1 Purge chamber
2
2 Check valve
3 Case
4 Desiccant
5 Oil filter
6 Valve
1 3 7 Body

4 The air dryer removes moisture and oil in the air compressed
by the air compressor and protects the brake assembly.

6
7

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01634

2 Dehumidification
• The pressurized air from the air compressor enters delivery side A of
the air dryer. Once in body 7, moisture and oil are separated from the
1 air and collected in the bottom. Then, the air passes through oil filter 5,
4 where small oil droplets and dust are removed. Next, the air is deliv-
ered into case 3, where moisture is removed by desiccant 4.
• As the air travels from the bottom to the top of case 3, it comes into
contact with more dried desiccant. This removes residual moisture
5
3 from the air, drying the air as it reaches the top of the case. The air
passes through check valve 2 and purge chamber 1, and is delivered
to the air tank through exhaust side B.
B A

7 01635

Regeneration of desiccant
C
• When the supply of air from the air compressor stops, pressure D from
the air pressure governor opens valve 6 of the control port of the air
1 dryer. The pressure in case 3 cleans oil filter 5, releasing the con-
4
densed water and oil into the atmosphere.
3 • After being quickly decompressed, the dry air in purge chamber 1
passes through hole C, where the air expands under the reduced
pressure, becoming super dry air. This air flows back through case 3
5
and collects the moisture in desiccant 4, releasing this moisture into
the atmosphere, thereby recycling the desiccant.
B

01636

35-17
STRUCTURE AND OPERATION
Air Pressure Governor
1 Adjusting screw
2 2 Cover
3 Spring
4 Body
3
5 Piston
1 6 Exhaust stem
7 Valve
4
The air pressure governor keeps the air pressure in the air
tank at the specified pressure, by operating the air compressor
5 with or without load in accordance with the air pressure in the
air tank.
6

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12236

● High specified-pressure
• Pressurized air A from the air tank acts constantly on piston 5. As the
pressure in the air tank rises to overcome the repercussive force of
spring 3, the piston rises and valve 7 closes.
3 • As air pressure A from the air tank rises further to become higher than
the high specified-pressure, piston 5 rises further. Therefore, exhaust
stem 6 opens inlet valve C and the air pressure in the air tank flows
from unloader port B to the unloader valve of the air compressor via
the inlet valve. Then the air compressor enters unloaded operation.
Pressure also reaches the air dryer to recycle the desiccant.
6
B
C

7
A 5
12237

● Low specified-pressure
When pressurized air A from the air tank gradually drops below the
specified-pressure, spring 3 forces down piston 5. This closes inlet valve
C and opens exhaust valve seat D so pressurized air B, up to the
3
unloader valve of the air compressor, is discharged through the opening
E of cover 2 via exhaust stem 6 as exhausted air E, operating the air
compressor at load. The pressurized air up to the air dryer is also
discharged into the atmosphere.
B 5

6
A

6
C

D 12238
35-18
 MEMO
35

35-19
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STRUCTURE AND OPERATION
Exhaust Brake System

1 10

11

3 12 13

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8
9
4

A A

7 6 5

15040

1 Fuse box 9 Exhaust brake indicator lamp

2 Clutch switch 10 Air tank
3 Accelerator switch 11 3-way magnetic valve
4 Exhaust brake switch 12 Intake silencer actuator
5 Relay box 13 Exhaust brake unit
6 Exhaust brake cut relay
7 Transmission neutral switch A : Butterfly valve
8 Meter cluster

• Excitation of 3-way magnetic valve 11 causes the air pressure in air tank 10 to act on intake silencer actuator 12 and
exhaust brake unit 13 to close butterfly valve A, activating the exhaust brake.
• If the exhaust brake is activated while the vehicle is stationary, the coolant temperature can rise excessively,
overheating the engine. To avoid this, when the transmission is in neutral, transmission neutral switch 7 turns ON,
cutting the exhaust brake system.

35-20
 35
● When exhaust brake system is activated
When exhaust brake switch 4 is turned on, the current
flows as illustrated to activate the exhaust brake.

1 10
11
2

3 12 13

8
4 9

15 14
7 6 5

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15041

Fuse 1→Clutch switch 2→Accelerator switch 3→Exhaust brake switch 4→Exhaust brake cut relay 6→3-way magnetic
valve 11→Ground

→Exhaust brake indicator lamp 9 (ON)→Ground

● When the exhaust brake system is released

When the accelerator pedal or clutch pedal is de-
pressed while the exhaust brake is working, all switches
3, 2 turn off, shutting off the current, releasing the
1 10
exhaust brake.
11

3 12 13

8
9
4
15 14

7 6 5

15042

● When clutch pedal is depressed

Fuse 1→Clutch switch 2 (OFF)→Since no current flows, the circuit turns off and the exhaust brake is released.
● When accelerator pedal is depressed
Fuse 1→Clutch switch 2→Accelerator switch 3 (OFF)→Since there is no grounding, current does not flow, so the exhaust
brake is released.
35-21
STRUCTURE AND OPERATION
● Releasing exhaust brake system by placing transmission in neutral
Fuse 1→Exhaust brake cut relay 6 excitation→Transmission neutral switch 7→Ground
Fuse 1→Clutch switch 2→Accelerator switch 3→Exhaust brake switch 4→Exhaust brake cut relay 6 (OFF)→Beyond this,
current does not flow so the exhaust brake is released.

● Working principle of exhaust brake

A When butterfly valve A of exhaust brake unit 13, in exhaust pipe B, is

closed, the pressure in the exhaust pipe rises. The pressure rises further
13 in the exhaust stroke, generating a force that pushes back piston C, the
B exhaust braking force.

12473

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35-22
 35
● Exhaust brake unit

1 1 Connector
2 Packing
3 Shaft assembly
6 2 4 Butterfly valve
5 Spring
6 Plate
5

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01587

● Intake silencer
1 Actuator assembly
2 2 Intake pipe
3
3 Butterfly valve

12547

35-23
STRUCTURE AND OPERATION
Brake Warning System
1 Fuse and relay box
1 2 2 Meter cluster
3 Brake fluid warning lamp
3 4 4 Air warning lamp
5 Warning buzzer
6 Low air pressure switch
7 Brake fluid level switch (installed on
fluid tank)
8 Stroke switch (installed on airmaster)

The brake warning system consists of two

circuits: the air pressure warning circuit and
the brake fluid warning circuit. The first detects
decrease of air pressure in the air tank, the
second detects decrease in brake fluid in the
fluid tank and brake fluid leakage in the brake

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5 6 6 7 8 8 fluid system. Both circuits light warning lamps
and at the same time sound a buzzer to alert
14358 the driver.

● Air pressure warning circuit

1 2 When the air pressure in the air tank drops below the specified
value, low air pressure switch 6 turns on to light air warning
4 lamp 4 and sound warning buzzer 5.

5 6 6 14359

● Brake fluid warning circuit

1 2 • When the brake fluid in the fluid tank drops below the
specified level, brake fluid level switch 7 in the fluid tank
3 turns on, brake fluid warning lamp 3 lights and warning
buzzer 5 sounds. At this time, current flows as follows:
• If brake fluid leaks from the brake fluid system, stroke
switch 8 of the airmaster turns on, brake fluid warning lamp
3 lights and warning buzzer 5 sounds.

5 7 8 8 14360

35-24
 35
● Brake fluid level switch
1 Fluid tank
2 Float
3 Brake fluid level switch

• Brake fluid level switch 3, installed on fluid tank 1, monitors

1
the brake fluid level in the fluid tank. If the brake fluid level
drops below the specified level, float 2 moves and lights up
3 the warning lamp within the meter cluster to alert the driver.
2

01667

A • If the brake fluid level in fluid tank 1 drops and float 2 drops lower than
level L, magnetic force B that passes through the contact point
B

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C (ferromagnetic body A), increases generating north and south poles at
the ends of the contact points. Therefore, the contact points pull each
other and overcome the repercussive force of the springs of the
contact points, forming an electric circuit.
C : Permanent magnet
D : Glass
2
D 01668

35-25
TROUBLESHOOTING
● Wheel Brake

Symptoms Wheel brake Brake

does not work drum
effectively over-
heating

No air leakage but brake works ineffectively

Brake shoe self-return poor after releasing

Air leakage when brake pedal depressed
Air leakage when brake pedal released

Noise when brake pedal depressed

Wheel brake works suddenly

brake pedal (Wheel drags)

Brake warning lamp lights

One-sided braking
Air pressure low

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Possible causes
Wheel cylinder malfunctioning ● ● ●
Brake lining surface contaminated with oil ●
Brake lining surface hardened ● ●
Brake fluid leaking because wheel cylinder cup worn ●
Brake lining worn ●
Brake lining worn exposing rivet head ●
Brake drum interior worn unevenly ●
Brake shoe and brake lining close contact faulty ●
Wheel brake Brake drum installation loose ● ●
Brake lining materials unequal ●
Brake lining contact faulty ●
Brake drum runout ●
Backing plate warped ●
Brake shoe clearance insufficient ● ● ●
Brake shoe return spring deteriorated or fractured ● ●
Wheel cylinder piston return faulty ● ●
Brake fluid return faulty because brake pipe or joints
●
clogged

35-26
 35
Symptoms Wheel brake Brake
does not work drum
effectively over-
heating

No air leakage but brake works ineffectively

Brake shoe self-return poor after releasing

Air leakage when brake pedal depressed
Air leakage when brake pedal released

Noise when brake pedal depressed

Wheel brake works suddenly

brake pedal (Wheel drags)

Brake warning lamp lights

One-sided braking
Air pressure low

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Possible causes
O-ring damaged ●
Primary and secondary valve airtightness faulty ● ●
Dual brake valve
Primary and secondary valve return faulty or exhaust
●
port clogged with foreign particles
Power cylinder lubrication faulty or rubber packing
●
damaged
Hydraulic piston valve seal close contact faulty ●
Hydraulic piston cup packing damaged, wrong
Airmaster ● ●
combination, or foreign particles adhering to it
Exhaust port clogged with foreign particles ●
Push rod bent ●
Power cylinder rubber packing lubricated incorrectly ●
Connector loose ● ●
Air leakage ●
Brake air system
Air pressure governor adjusted incorrectly ●
Air compressor malfunctioning ●
Brake fluid leaking or insufficient ● ●
Brake fluid system
Air mixed in brake fluid system ● ●
Tire Left and right air pressure different ^ Gr 31 ●
Suspension Leaf spring U-bolt loose ^ Gr 33, 34 ●

35-27
TROUBLESHOOTING

Symptoms

Air pressure in air reservoir drops extraordinarily

Drainage not drawn off from exhaust port

Engine oil coming out exhaust port

Drainage from air tank drain cock

Air leakage from exhaust port

Remarks

Air dryer interior frozen

Possible causes

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Desiccant deteriorated ●
Heater not working and air dryer frozen ●
Valve malfunctioning because of foreign particles
●
adhering to it
No warming because heater wiring broken ●
Heater malfunctioning because thermostat faulty ●
Temperature extremely low because of snow and ice
●
Air Dryer sticking to air dryer body
Heater malfunctioning because wiring to thermostat
●
disconnected
Valve seat close contact faulty because of clogging by
●
foreign particles
Dry air returning from air tank because air tank check valve
●
malfunctioning during air compressor unloading cycle
Air compressor oiling-up ●

35-28
 35
● Exhaust Brake

Symptoms

Intake silencer cannot be released

Exhaust brake cannot be released
Intake silencer does not work
Exhaust brake does not work
Remarks

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Possible causes
Valve assembly malfunctioning ● ●
Valve assembly shaft stuck ● ●
Exhaust brake unit
Control cylinder malfunctioning ●
Butterfly valve adjusted incorrectly ●
Intake silencer Malfunctioning ● ●
3-way magnetic valve Malfunctioning ● ● ● ^ Gr 54
Air pressure abnormal ● ●
Brake air system
Air pipes crushed ● ●
Electric system Malfunctioning ● ● ● ● ^ Gr 54

35-29
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
Replacement of Brake Fluid

- Fluid
Location Points of application Kinds Quantity
— Fluid tank Brake fluid As required
(SAE J1703f or FMVSS No.116 DOT3)

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

1200 {47.2}
1 Vinyl hose MH033102 Air bleeding

ø7 {0.28}
00328

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WARNING–
• You must use new brake fluid (SAE J1703f or FMVSS No. 116
DOT3).
• Do not add different quality fluid or mineral oil (gas oil, engine oil,
gear oil, automatic transmission fluid, etc.) to the brake system,
because this will cause the rubber parts of the brake system to
swell, resulting in brake dragging or ineffective braking.
• Do not allow foreign particles or water to get mixed in with the
brake fluid when you add it.
• If you use a mug for adding brake fluid, keep it solely for that
purpose to prevent contamination from different quality fluids or
mineral oil.

CAUTION–
• Be careful not to splash brake fluid on related parts as this could
damage the paintwork.
• Be sure to wipe off brake fluid immediately if you splash it on the
paintwork.

NOTE
Supply and maintain brake fluid to the “H” level of the fluid tank.

35-30
 35
• Start engine and let it idle until brake fluid replacement is completed.

• Attach one end of 0 vinyl hose to air bleeder 1 and place the other
< Front > end in container A.
1

04865

< Rear >

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0

04866

• Loosen air bleeder 1 and depress brake pedal 2 to drain brake fluid
2 completely.
1

12548

• Maintain a supply of new brake fluid up to the “H” level of fluid tank 3,
depress the brake pedal repeatedly until the old brake fluid of the
brake system is replaced with new fluid.

3
04852

35-31
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• If diaphragm 5 is not in its normal posture when the brake fluid is
4 supplied, correct it to its normal posture, and install cap 4. If brake fluid
leaks from the cap area after you have supplied brake fluid, check
whether the diaphragm is assembled as illustrated.

6 : Slide ring
B
7 : Ring cover
C B : Correct condition of diaphragm when brake fluid is being sup-
plied
C : Condition when diaphragm is extended when brake fluid has
decreased

6
7
5
< General < Section at
section > protrusion > 01679
• Air bleeding of brake system. Õ P35-32

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Air Bleeding of Brake System

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
— Air bleeder (Airmaster) 6.9 to 12.7 {5.1 to 9.4, 0.7 to 1.3} —
— Air bleeder (Wheel brake) 7.8 to 12 {5.8 to 8.5, 0.8 to 1.2} —

- Fluid
Location Points of application Kinds Quantity
— Fluid tank Brake fluid As required
(SAE J1703f or FMVSS No.116 DOT3)

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

1200 {47.2}

2 Vinyl hose MH033102 Air bleeding

ø7 {0.28}
00328

35-32
 35
WARNING–
• You must use new brake fluid (SAE J1703f or FMVSS No. 116
DOT3).
• Do not add different quality fluid or mineral oil (gas oil, engine oil,
gear oil, automatic transmission fluid, etc.) to the brake system,
because this will cause the rubber parts of the brake system to
swell, resulting in brake dragging or ineffective braking.
• Do not allow foreign particles or water to get mixed in with the
brake fluid when you add it.
• If you use a mug for adding brake fluid, keep it solely for that
purpose to prevent contamination from different quality fluids or
mineral oil.

CAUTION–
• Be careful not to splash brake fluid on related parts as this could
damage the paintwork.
• Be sure to wipe off brake fluid immediately if you splash it on the
paintwork.

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NOTE
• Supply and maintain brake fluid to the “H” level of the fluid tank.
• Make sure you maintain brake fluid at the “H” level of the fluid
tank since the brake fluid level drops during air bleeding.

• Start engine and let it idle until brake fluid replacement is completed.
• Attach one end of 0 vinyl hose to front or rear airmaster 1. Then,
attach one end of another vinyl hose to air bleeder 2 of the wheel
0 brake. Finally, place both free ends in container A filled with brake
A fluid.

• Carry out air bleeding in the following sequence:

1
2 Front brake system Rear brake system

Airmaster for front Airmaster for rear

04903
↓ ↓
2 Right-hand side wheel brake Right-hand side wheel brake
↓ ↓
Left-hand side wheel brake Left-hand side wheel brake
0

04867

• Depress brake pedal 3 slowly a few times, and with the brake pedal
3 depressed, loosen air bleeder 2 to drain brake fluid containing air.
2

12548
35-33
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
• Tighten air bleeder 2, and release brake pedal 3.
• Repeat this service procedure until air is no longer present in the fluid
being drained.
• Tighten air bleeder 2 at specified torque as soon as brake fluid flowing
out is free of air bubbles.

• Adjust brake shoe clearance when you have finished air bleeding.
Õ P35-32
• Check that brake fluid comes up to level “H” of fluid tank. If it does not,
refill with new brake fluid.
• Depress brake pedal 3 a few times and check for any leakage of brake
fluid, then test the brakes.
• When you test the brakes, if the brake warning lamp within the meter
cluster lights, it means that air has not been bled completely. Redo air
bleeding.

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Inspection and Adjustment of Clearance between Brake Pedal and Floor Panel

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
— Clearance between brake pedal and floor panel 45 {1.8} or more — Adjust
(with pedal depressed at 490 N {110 lbf, 50 kgf})

[Inspection]
Depress the brake pedal using 490 N {110 lbf, 50 kgf} when the engine is
idling to check if clearance A between the brake pedal and the floor
panel conforms to the standard value. If the measured value deviates
from the standard value, adjust the height of the brake pedal.

[Adjustment]
Õ P35-38
A
06540

35-34
 35
Thickness Inspection and Replacement of Brake Lining

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
2 Thickness of brake lining — 5.5 {0.22} Replace
(Side shoulder
means wear
limit)

[Inspection]

A
NOTE
Be sure to inspect at two points for each wheel per side.
2
• Remove check hole plug 1 from the backing plate.
• Inspect through check hole A whether brake lining 2 is worn to the
2 point of side shoulder B of the brake lining (the limit).
1
• If the measured value is lower than the limit, replace brake lining 2 on

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B
the same axle as a unit.
06541 • After inspection, be sure to reinstall check hole plug 1.

[Replacement]
Õ P35-56, 64

Inspection of Brake Shoe Clearance

NOTE
A When the vehicle is jacked up and the wheel is being turned,
1
B make sure that there is no dragging.

• Remove the check hole plug from the backing plate.

A : Check hole
• Try to insert a 1 mm {0.039 in.} feeler gauge B between brake drum 1
and brake lining 2. Check that the clearance is too small to let the
feeler gauge enter.
2 00320 If feeler gauge A enters the clearance, disassemble the wheel cylinder
and inspect.
Õ P35-62, 70

35-35
INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
Inspection and Maintenance of Air Dryer
Carry out inspection and maintenance according to the following interval
or vehicle milage.
(1) Every three months or 10000 km {6000 miles}
• To check that the air dryer operates correctly, open the drain cock
of the air tank and see if any drainage comes out.
• If a little drainage comes out, check if desiccant 1 is discolored. If
more than one fifth of the desiccant has changed color from white to
1
brown, renew desiccant.

NOTE
In an operational environment where the decrease of the ambi-
ent temperature in the air tank is higher than 16°C {29°F}, a
12549 little moisture might collect.

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• Pour desiccant 1 into container 2, tap around the container lightly to
1 2 settle the desiccant.

12550

• Carefully inspect the drainage from the exhaust port of the air dryer
body. Inspect the air compressor and take appropriate action for
abnormal oil consumption.
Õ P35-72

(2) Every year or every 60000 km {36000 miles}

Disassemble the air dryer body. Replace the oil filter, filter and all the
rubber parts together with a repair kit.
Õ P35-80

35-36
HANDLING OF CONNECTORS 35
- Sealant
Location Points of application Kinds Quantity
— Taper thread of connector THREEBOND 1110B As required

• If the connectors for the brake air system are to be reused after
A removal, thoroughly remove residual sealant, oil, moisture, etc.
• Apply sealant to the threads of the connector taper except for one or
two turns from the end, then tighten.
• When positioning, adjust in the tightening direction.
B A : Taper thread
B : Parallel thread (Do not apply sealant here)
C : Apply sealant here

C 01692

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35-37
BRAKE PEDAL

8 5

1 3

1 Ê
Ê 10
Ê
4 12 Ê

21

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6 2
14
11 15
-
20
15
19 1
13

17
18
16

12551

● Removal sequence
1 Nylon tube 8 Low air pressure switch ^ Gr 54 15 Bushing
2 Vinyl tube 9 Connector 16 Stopper
3 Clevis pin 10 Dual brake valve Õ P35-42 17 Pedal pad
4 Nut 11 Bolt 18 Brake pedal
5 Valve support bracket 12 Nut 19 Pedal stopper bolt
6 Stop lamp switch ^ Gr 54 13 Return spring 20 Lock nut
7 Connector 14 Collar 21 Support assembly

● Installation sequence
Follow the removal sequence in reverse.

35-38
 35
Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy

(Basic diameter in [ ])
14, 15 Clearance between collar and bushing [16] 0.02 to 0.26 0.05 {0.0020} Replace
{[0.63] 0.00079 to 0.010}
18 Installation height of brake pedal 305 {12.0} — Adjust
Stroke of brake pedal 54 {2.13} — Adjust

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
4 Nut (Dual brake valve mounting) 19 to 28 {14 to 21, 1.9 to 2.9} —
7 Connector 29.4 to 39.2 {22 to 29, 3.0 to 4.0} —
9 Connector 29.4 to 117.6 {22 to 87, 3.0 to 12} —
12 Nut (Brake pedal mounting) 34.3 to 53.9 {25 to 40, 3.5 to 5.5} —

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- Lubricant
Location Points of application Kinds Quantity
11 Friction surfaces of bolt and bushing Chassis grease [NLGI No.1 (Ca soap)] As required

◆ Service procedure
● Adjustment after assembly

(1) Adjustment of brake pedal installation height

• Adjust the installation distance of pedal stopper bolt 19 to 17 mm
C B {0.67 in.}.
• Turn operating rod B to adjust brake pedal installation height A to
the standard value. After adjustment, fix using lock nut C.

20
(2) Inspection of brake pedal stroke
A
• Make sure that brake pedal stroke D is the standard value when
19 brake pedal 18 is depressed fully.
18 • If any fault is found, adjust the brake pedal installation height.

WARNING–
Make sure that brake pedal 18 is stopped by operating rod B,
D because if the brake pedal makes contact with the floor panel
19 when depressed fully, braking force is reduced.
18
17 mm {0.67 in.}
12552

35-39
BRAKE PEDAL
79 Installation of connector
For connectors 7, 9, determine the direction within one turn of exceeding
29 N·m {22 lbf.ft, 3 kgf·m}.

9
9
7

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7 12553

35-40
 MEMO
35

35-41
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DUAL BRAKE VALVE

37
36 10
35 11
34 Ê 23
Ù - 33 - 39 - Ù
24
Ù - 32 25 - 6Ê 49
31 26
Ù - 21 7 48
30
47
20
46
Ù - 17 Ù - 27
45
Ù- 44 - Ù
29 43 - Ù
42
Ê 16 9

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41
15 38
14 40
13
Ê8
Ê 12

12554

● Work before disassembly

Õ P35-45
● Disassembly sequence
1 Clevis 18 O-ring 35 Valve spring
2 Nut 19 Relay piston 36 Washer
3 Push rod 20 Relay piston spring 37 Inlet valve
4 Boot 21 O-ring 38 Body
5 Plunger 22 Bushing 39 O-ring
6 Bolt 23 Self-locking bolt 40 Retaining ring
7 Plate 24 Spring seat 41 Valve seat
8 Bolt 25 Outer spring 42 Washer
9 Plug 26 Inner spring 43 O-ring
10 Retaining ring 27 O-ring 44 O-ring
11 Spring 28 Primary piston 45 Valve retainer
12 Screw 29 Spring 46 Valve spring
13 Outer spring 30 Retaining ring 47 Valve retainer
14 Inner spring 31 Valve retainer 48 Inlet valve
15 Washer 32 O-ring 49 Cover
16 Sleeve 33 O-ring
17 O-ring 34 Washer Ù : Non-reusable parts

35-42
 35
● Assembly sequence
< Primary side >
37→36→35→34→33→32→31
→30→29
38 28→27
22→21

→26→25→24→23→20
19→18→17
→11→10→9
16→15→14→13→12
→8→7→6→5→4

→
3→2→1
< Secondary side >
48→47→46→45→44→43→42
→41→40→39
49

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Repair kit : Dual brake valve kit
● Inspection of function after assembly
Õ P35-45

35-43
DUAL BRAKE VALVE
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
5 Outer diameter of plunger 19.9 {0.783} 19.8 {0.780} Replace
7 Inner diameter of bushing 20 {0.787} 20.08 {0.791} Replace
plate
11 Spring load (Installed length 12.6 {0.496}) — 215 N {49 lbf, Replace
22 kgf}
20 Relay piston spring load (Installed length 12.8 {0.504}) — 47 N {11 lbf, Replace
48 kgf}
25 Outer spring load (Installed length 26.5 {1.04}) — 214 N {48 lbf, Replace
21.8 kgf}
26 Inner spring load (Installed length 19.1 {0.75}) — 60 N {13 lbf, Replace
6.1 kgf}
29 Spring load (Installed length 17 {0.67}) — 97 N {22 lbf, Replace
9.9 kgf}
35 Valve spring load (Installed length 14.3 {0.56}) — 37 N {8.4 lbf, Replace
38 kgf}

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46 Valve spring load (Installed length 12.8 {0.51}) — 47 N {11 lbf, Replace
4.8 kgf}
— Input air pressure 1.5 {0.059} — — —
Play

685 kPa {100 lbf/in2,

Output air pressure
Push rod stroke

7 kgf/cm2} 1.5 +0.6 29 kPa — Replace

–0.4
Pressure stroke

{0.059+0.024
–0.016} {43 lbf/in2, 0.3 kgf/cm2} or less springs
6 {0.24} 310 kPa —
{45 lbf/in2, 3.18 kgf/cm2}
7 {0.28} 685 kPa —
{100 lbf/in2, 7 kgf/cm2}

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
6 Bolt (Plate mounting) 12 to 19 {8.7 to 14, 1.2 to 1.9) —
8 Bolt (Primary and secondary side assembling) 4.9 to 7.8 {3.6 to 5.8, 0.5 to 0.8) —
12 Screw 4.9 to 7.8 {3.6 to 5.8, 0.5 to 0.8) —
16 Sleeve 1.0 to 2.9 {0.7 to 2.2, 0.1 to 0.3} —
23 Self-locking bolt 12 to 19 {8.7 to 14, 1.2 to 1.9} —

- Lubricant
Location Points of application Kinds Quantity
4, 5 Pack between boot and plunger Multipurpose grease [NLGI No.2 (Li soap)] 1 cm3
{0.061 cu. in.}
5 Friction surfaces of plunger and other parts Multipurpose grease [NLGI No.2 (Li soap)] As required
— O-ring and its friction surface, metal friction surface, and Multipurpose grease [NLGI No.2 (Li soap)] As required
O-ring groove

35-44
 35
0 Special tools
Location Tool name and shape Part No. Application
21 Insert tool *910-24461 Installation of O-ring
32 Retainer *910-24590 Holding of primary piston
* : JIDOSHA KIKI Part No.

◆ Service procedure
● Work before disassembly
A: Alignment mark
A

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A
12555

● Inspection of function after assembly

Check if the output air pressure, corresponding to the stroke of push rod
3, conforms to the standard value. This inspection of function is carried
B
out by installing a gauge on the brake pedal. Õ P35-38
3 • Install pressure gauge B capable of measuring 980 kPa {140 lbf/in2,
10 kgf/cm2} or more on primary output side port A.
• Install depression gauge C on the brake pedal.
• Apply air pressure of 685 kPa {100 lbf/in2, 7 kgf/cm2} to primary input
side port D and inspect the parts for air leakage.
D • If an air leakage is found, take the following countermeasures:
• Tighten connectors further.
A • Disassemble the dual brake valve and inspect the O-ring assem-
blies of all parts.
C
• Then, adjust the installation height of the brake pedal.
• After adjustment, read pressure gauge B and make sure that the
primary output pressure, corresponding to the stroke of push rod 3,
conforms to the standard value as shown in the input/output charac-
teristic curve diagram overleaf.
• If the primary output air pressure is lower than the standard
12556 value, replace the following springs:
• Spring 11
• Outer spring 25
• Inner spring 26

35-45
DUAL BRAKE VALVE
Input/Output Characteristic Curve Diagram

C
D

12557

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685 {100, 7}
kPa {lbf/in2, kgf/cm2}

Push rod thrust

590 {85, 6}
Output pressure

N {lbf, kgf}
490 {71, 5}
310 {45, 3.18}
390 {57, 4} 1570 {350,160}

295 {43, 3} 1170 {265, 120}

195 {28, 2} 785 {175, 80}

29 {4.3, 0.3} or less
98 {14, 1} 390 {88,40}

0
1 +0.6 3 5 6 7 8
1.5 –0.4 4
{0.039} +0.024 {0.12} {0.16} {0.20} {0.24} {0.28} {0.31}
{0.059 –0.016 }
Push rod stroke mm {in.}

Output pressure [primary pressure when air pressure

is 685 kPa {100 lbf/in2, 7 kgf/cm2}]

Push rod thrust

12558

A: Play 1.5 mm {0.059 in.}

+0.6 +0.024
B: Pressure stroke 1.5 –0.4mm {0.059 in.}
–0.016
C: Pressure stroke 6 mm {0.24 in.}
D: Pressure stroke 7 mm {0.28 in.}

35-46
 35
3 2 1 13 to Installation of clevis, nut and push rod

79 mm {3.11 in.}

12559

A
4
45 Packing grease between boot and plunger
A : Grease
5

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5

12560

0
N Installation of O-ring

18

19

01702

B
O Removal of relay piston
• Grip a (14 mm {0.55 in.}) socket wrench A in a vise.
19 • Insert the head of self-locking bolt 23 into socket wrench A to tighten
body 38.
23
A 12 WARNING–
A You must be careful when you loosen screw 12, because the
spring in body 38 can forcibly eject relay piston 19. To avoid this
38 hazard, press down on the relay piston with your hand when you
01703 carry out the above work.

• Loosen screw 12 gradually to remove relay piston 19.

B : Phillips screwdriver

35-47
DUAL BRAKE VALVE

A
38 22
R
A:
Installation of bushing
Indent

11489

28 0 X Removal and installation of primary piston

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38

01704

35-48
BRAKE BOOSTER (AIRMASTER) 35

5
4

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*

3
04875

● Disassembly sequence
1 Air pipe 5 Airmaster Õ P35-50
2 Connector
3 Brake pipe * : Airmaster and air tank bracket
4 Brake hose

● Assembly sequence
Follow the disassembly sequence in reverse.

NOTE
Check for air and liquid leakage after installation. Also, carry out air bleeding of brake system. Õ P35-32

35-49
BRAKE BOOSTER (AIRMASTER)
Airmaster Assembly

Ê
1Ê

5 Ù
2
7 -
6 -
8 1
Ê

1
Ê
Ê 3
15 -
4
14 Ù

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13
12
Ê
11 10

9Ê

22
24
Ù - 25
-
Ù 33
-
30
28
27
26
31

36

Ê
23
19
Ù

-
35 - Ù
04876

35-50
 35
● Disassembly sequence
1 Nut 20 Cup packing
2 Bracket 21 Piston plate
3 Cylinder shell 22 Return spring
4 O-ring 23 Straight pin
5 Retaining ring 24 Retaining ring
6 O-ring 25 Washer
7 Connector 26 Retaining ring
8 Residual valve 27 Spring
9 Stroke switch ^ Gr 54 28 Steel ball
10 Shim 29 Cup packing
11 Retainer 30 Backup ring
12 Return spring 31 Straight pin
13 Retaining ring 32 Hydraulic piston
14 Rod 33 O-ring
15 Air bleeder 34 Retainer assembly
16 Exhaust cover 35 Push rod
17 Body assembly 36 Body

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18 Nut
19 O-ring Ù : Non-reusable parts

● Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit : Airmaster kit

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy

(Basic diameter in [ ])
3, 21 Clearance between cylinder shell and piston plate [114.3] 0.5 to 1.4 1.8 {0.071} Replace
{[4.50] 0.20 to 0.055} piston plate
22 Return spring load (Installed length 120 {4.72}) 78±7.8 N {18±1.8 lbf, 8±0.8 kgf} 69 N Replace
{15 lbf, 7 kgf}
32, 36 Clearance between body and hydraulic piston [23.8] 0.04 to 0.11 0.15 {0.0059} Replace
{[0.94] 0.0016 to 0.0043} hydraulic
piston
35 Bend of push rod 0.05 {0.0020} or less 0.15 {0.0059} Replace

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Nut (Body and cylinder shell mounting) 11 to 15 {8.0 to 12, 1.1 to 1.6} —
9 Stroke switch 24.6 to 34.3 {18 to 25, 2.5 to 3.5} —
11 Retainer 7.9 to 19 {5.8 to 14, 0.8 to 2} —
15 Air bleeder 6.9 to 12.7 {5.1 to 9.4, 0.7 to 1.3} —
16 Exhaust cover 7.9 to 19 {5.8 to 14, 0.8 to 2} —
18 Nut (Piston plate and push rod mounting) 20 to 29 {14 to 22, 2 to 3} —

35-51
BRAKE BOOSTER (AIRMASTER)
- Lubricant and fluid
Location Points of application Kinds Quantity
3 Cylinder shell bore Multipurpose grease [NLGI No.2 (Li soap)] 10 g
{0.35 oz}
6 O-ring Brake fluid As required
(SAE J1703f or FMVSS No.116 DOT3)
8 Residual valve Brake fluid As required
(SAE J1703f or FMVSS No.116 DOT3)
20 Surface of cup packing and friction surface of push rod Multipurpose grease [NLGI No.2 (Li soap)] 5 g {0.18 oz}
29 Interior surface of cup packing Multipurpose grease [NLGI No.2 (Li soap)] As required
33 O-ring Brake fluid As required
(SAE J1703f or FMVSS No.116 DOT3)
34 Fill oil seal groove of inside of retainer Silicon grease As required
35 Push rod friction surface against retainer Silicon grease As required

0 Special tools

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Location Tool name and shape Part No. Application
16 L-spanner *910-23370 Removal and installation of exhaust cover
17 Stand *910-00450 Working bench
21 Holder *910-24831 Removal and installation of piston plate
29 Cup insert guide *910-23289 Installation of cup packing
* : JIDOSHA KIKI Part No.

L
◆ Service procedure
Removal and installation of exhaust cover

0
A: Removal
B B: Installation

16 01707

17
M Installation of body assembly

01708

35-52
 35
35
N Installation of nut
After tightening nut 18 at specified torque, caulk the nut and push rod 35
thread area.
A A : Center punch
18

P
01709

Installation of cup packing

21 A A: Grease

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20
01710

B
0
Q A:
Removal and installation of piston plate
Removal
A B: Installation
21

18
NOTE
After installation, tighten nut 18 at specified torque.

01711

0 A 29
Y A:
Installation of cup packing
Grease

29

30

32 01713

35-53
BRAKE BOOSTER (AIRMASTER)

B
A 32
\ Hydraulic piston
[Removal]
A : Spring
B : Needle
31
35

01714

[Installation]
31 Align holes of hydraulic piston 32 and push rod 35, and insert straight pin
32 31.
A A : Spring

NOTE
35

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After inserting straight pin 31, make sure that the hydraulic piston
spring is hanging over the straight pin and working as a stopper.

01715

A
^ Removal and installation of retainer

CAUTION–
Do not remove or install retainer 34 from the side of thread area
A, or the inside of the retainer might be damaged.

35

34 01712

35-54
 MEMO
35

35-55
cardiagn.com
FRONT WHEEL BRAKE
Front Wheel Brake Assembly

2
3Ê

1
Ê

18 21
Ê4
Ê19
-
5 17
Ê
15
Ê
14
Ê

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-

9
- 8
- 7
13 Ù

Ù 11
12561

● Disassembly sequence
1 Bolt 9 Washer 17 Adjusting hole plug
2 Joint assembly 10 Brake shoe assembly 18 Check hole plug
3 Pipe assembly 11 Rivet 19 Nut
4 Bolt 12 Brake lining 20 Holder pin
5 Pipe assembly 13 Brake shoe 21 Backing plate
6 Return spring 14 Bolt
7 Split pin 15 Bolt Ù : Non-reusable parts
8 Holder pin nut 16 Wheel cylinder assembly Õ P35-62
* : Brake drum ^ Gr 26
WARNING–
Do not leave grease or oil on the surface of brake lining 12 or inner surface of brake drum * because this
reduces braking performance.

CAUTION–
Do not turn or remove holder pin 20 unless it is necessary, or the squareness of brake shoe assembly 10 can
be influenced causing brake drag.

● Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit : Brake lining kit
● Initial adjustment of brake shoe clearance after installation
Õ P35-57
35-56
 35
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
6 Return spring load (Installed length 192 {7.56}) 325 N {73 lbf, 33 kgf} Clearance Replace
between
coils or
coil and cover
12 Brake lining thickness 12.0 {0.47} 5.0 {0.20} Replace
(Side shoulder brake lining
means wear
limit)
* Brake drum Inner diameter 320 {12.5} *321 {12.64} 322 {12.68} Replace
Cylindrical accuracy 0.05 {0.0020} 0.2 {0.0079} Correct
or replace
* : Indicates correction limit.

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

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Location Parts to be tightened Tightening torque Remarks
1 Bolt (Joint assembly mounting) 9.8±1.0 {7.2±1.4, 1.0±0.2} —
3, 5 Flair nut (Pipe assembly mounting) 14±2.0 {10±1.4, 1.4±0.2} —
4 Bolt (Pipe clamp mounting) 4.9±1.0 {3.6±0.7, 0.5±0.1} —
14 Bolt (Wheel cylinder assembly mounting) 78±16 {58±12, 8.0±1.6} —
15 Bolt (Wheel cylinder assembly mounting) 44±8.8 {33±6.5, 4.5±0.9} —
19 Nut (Holder pin mounting) 29±5.9 {22±4.3, 3,0±0.6} —

- Lubricant
Location Points of application Kinds Quantity
9, 10, 16 Contact areas between washer and brake shoe assembly; and Wheel bearing grease [NLGI No.2 (Li soap)] As required
between brake shoe assembly and wheel cylinder assembly

◆ Service procedure
● Initial adjustment of brake shoe clearance after installation
• Jack up the front wheels, and make sure that there is no play in the
B hub bearings.
C
• Insert screwdriver B into adjusting hole A and turn adjuster C in the
direction of the arrow marked on backing plate 21 until the wheel
drags slightly when turned by hand.
A
NOTE
• Be sure to adjust the clearance at two points for each wheel per
side.
00318 • The arrow mark on backing plate 21 is near adjusting hole A.

35-57
FRONT WHEEL BRAKE
• After depressing the brake pedal several times, release it and make
sure that the wheel drags lightly when turned by hand. If the wheel
turns without stress, repeat the above steps. Slacken off adjuster B,
in the reverse direction to the arrow mark, by eight or nine notches.
NOTE
Be sure to adjust the clearance at two points for each wheel per
side.
• Make sure that the wheel does not drag when turned by hand.
If the wheel drags, repeat the above steps.
• Insert feeler gauge D between brake drum * and brake lining 12
C
* through check hole C, and make sure that a little resistance is felt
D when the feeler gauge is pulled out or pushed in.

NOTE
Be sure to adjust the clearance at two points for each wheel per
side.

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12 00320

10
6 Return Spring
[Removal]
6 16 To remove return spring 6, place screwdriver B on the hook of the return
spring, then pry and remove the return spring making use of wheel
cylinder assembly 16 adjuster A as a fulcrum.
A
B

12583

[Installation]
10 • Install the shorter hook end of return spring 6 in brake shoe assembly
6 10 at the side opposite to adjuster A of wheel cylinder assembly 16.
16 • Insert a small Phillips screwdriver C into the hook of return spring 6,
insert the tip of the screwdriver into return spring installation hole D of
A the brake shoe assembly to pry on the return spring.

D C

F
12584

Brake shoe assembly

12 [Inspection]
If thickness A of brake lining 12 is lower than the limit replace the brake
lining on the same axle as a unit.

12501

35-58
 35
[Installation]
20 10 • Install brake shoe assembly 10.
21
• Insert washer 9 with the side stamped “NUT ” facing outside, screw
7 down holder pin nut 8 until washer hits stepped area B of holder pin 20
B gently, then slacken off the nut within the 0 to 60° limit until the nut is
aligned with the first split pin hole.
• Insert split pin 7, and bend it securely.
20
8

H
9 00572

Brake lining
[Removal]

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12806

[Installation]
• Clean the mounting surfaces of brake lining 12 and brake shoe 13 with
cleaning fluid and dry them.
13
• Insert rivets 11 from brake lining 12 side, and caulk the rivets at the
specified load so that there is no clearance between brake shoe 13
and the brake lining.

12 Caulking load for rivets : 17 to 19 kN {3750 to 4190 lbf, 1700 to

11 1900 kgf}
00573 • Make sure that you inspect contact with the inner surface of brake
drum * after you replace brake linings 12. If contact is incorrect,
correct with the brake assembled.
WARNING–
Do not leave lubricant on the surface of brake lining 12 because
this reduces braking performance.

CAUTION–
Make sure that the type of brake linings 12 you fit are suitable for
the intended use of the vehicle. Make sure that you fit identical
size and color coated linings on the left and right sides of one

L
shaft.

16 “A” or “B” Installation of wheel cylinder assembly

Identification mark Installation position

RA Front of front axle right wheel
RB Rear of front axle right wheel
LA Front of front axle left wheel
LB Rear of front axle left wheel

“R ”or “L” 12585

35-59
FRONT WHEEL BRAKE
P Adjustment of holder pin
• Install the front wheel brake assembly on the front axle. ^ Gr 26

12580

• Turn adjuster A to adjust the outer diameter to approximately

10 B
ø319±0.5 mm {12.6±0.020 in.}.
21
• Then, move brake shoe assembly 10 to adjust clearance B evenly.
A Approximately
ø319±0.5 mm
{12.6±0.020 in.}

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10 B 11413

• Install hub and drum assembly C on the front wheel brake assembly.
C 21
D ^ Gr 26
At this time, the hub and drum assembly cannot be inserted in the
specified position if squareness D is 90° or more, so loosen nut 19 and
turn holder pin 20 to adjust the squareness to as close to 90° as
possible.
• Bleed the brake system. Õ P35-32
10
20 19 11414

★ • Turn adjuster A to widen brake shoe assembly 10 until 0.2 mm

21 {0.0079 in.} feeler gauge E cannot be pulled out easily.
C
★ • Loosen nut 19 and turn holder pin 20 to the right or left so that feeler
E gauge E can be pushed in or pulled out easily.
• Repeat the above steps (marked ★) until feeler gauge E cannot be
pushed in or pulled out easily.
• Depress the brake pedal a few times lightly to equalize clearance B
20
(adjusted in the previous section).
10
• Repeat the above steps (marked ★) until feeler gauge E cannot be
19 pushed in or pulled out easily.

11415

35-60
 35
21 • If feeler gauge E cannot be pushed in or pulled out easily it is because
C
it is making contact over the full width of brake shoe assembly 10.
E • Turn holder pin 20 so that when you pull out feeler gauge E, in the
above condition, and reinsert the feeler gauge, pushing in or pulling
out the feeler gauge at the rear is difficult.
• After adjustment, tighten nut 19 at specified torque.

10

19 20 11416

* Correction of brake drum

If the cylindrical accuracy of brake drum * is higher than the limit, or
there are seams, correct by machining to the correction limit. Machining
of the brake drum should be done with the wheel hub attached as an
integral part.

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35-61
FRONT WHEEL BRAKE
Wheel Cylinder Assembly
● Disassembly sequence
1- 1 Screw
- 2 Seal
2
3 Piston
- 4 Piston cup
3
5 Backup ring
6 Boot
7 Air bleeder (only at the rear)
8 Body

Ù : Non-reusable parts
5
Ù
● Assembly sequence
6-Ù Follow the disassembly sequence in re-
verse.

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Repair kit : Wheel cylinder kit
8
- 7Ê 03398

Service standards Unit : mm {in.}

Standard value
Location Maintenance item (Basic diameter in [ ]) Limit Remedy

3, 8 Clearance between piston and body [34.93] 0.03 to 0.09 0.2 {0.0079} Replace
{[1.38] 0.0012 to 0.0035} piston

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
7 Air bleeder 9.8±2.0 {7.2±1.4, 1.0±0.2} —

- Lubricant
Location Points of application Kinds Quantity
1, 2, 3, Thread area of screw, outer periphery of seal, outer periphery Rubber grease As required
6, 8 of piston, mounting groove and thread area of boot, and inner
surface of body

35-62
 35
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application

50 {1.97}

4 Piston cup guide MC895722 Installation of piston cup

ø39 {1.54}

13697

3 5 4 0
4
◆ Service procedure
Installation of piston cup

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13698

35-63
REAR WHEEL BRAKE
Rear Wheel Brake Assembly

1Ê 16 Ê

15 18

2
13
11 14
Ê -
13

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-

10 6 5
- 4
Ù

Ù8
12562

● Disassembly sequence
1 Bolt 8 Rivet 14 Adjusting hole plug
2 Pipe assembly 9 Brake lining 15 Check hole plug
3 Return spring 10 Brake shoe 16 Nut
4 Split pin 11 Bolt 17 Holder pin
5 Holder pin nut 12 Wheel cylinder assembly 18 Backing plate
6 Washer Õ P35-70
13 Wheel cylinder cover Ù : Non-reusable parts
7 Brake shoe assembly
* : Brake drum ^ Gr 27

WARNING–
Do not leave grease or oil on the surface of brake lining 9 or inner surface of brake drum * because this
reduces braking performance.

CAUTION–
Do not turn or remove holder pin 17 unless it is necessary, or the squareness of brake shoe assembly can be
influenced causing brake drag.

● Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit : Brake lining kit
● Initial adjustment of brake shoe clearance after installation
Õ P35-65
35-64
 35
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
3 Return spring load (Installed length 217 {8.54}) 390 N {88 lbf, 40 kgf} Clearance Replace
between
coils or
coil and cover
9 Brake lining thickness 12.0 {0.47} 5.0 {0.20} Replace
(Side shoulder lining
means wear
limit)
* Brake drum Inner diameter 320 {12.5} *321 {12.64} 322 {12.68} Replace
Cylindrical accuracy 0.05 {0.0020} 0.2 {0.0079} Correct
or replace
* : Indicates correction limit.

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks

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1 Bolt (Pipe clamp mounting) 4.9±1.0 {3.6±0.7, 0.5±0.1} —
2 Flair nut (Pipe assembly mounting) 14±2.0 {10±1.4, 1.4±0.2} —
11 Bolt (Wheel cylinder assembly mounting) 78±16 {58±12, 8.0±1.6} —
16 Nut (Holder pin mounting) 29±5.9 {22±4.3, 3,0±0.6} —

- Lubricant
Location Points of application Kinds Quantity
6, 7, 12 Contact areas between washer and brake shoe assembly; and Wheel bearing grease [NLGI No.2 (Li soap)] As required
between brake shoe assembly and wheel cylinder assembly

◆ Service procedure
● Initial adjustment of brake shoe clearance after installation
• Jack up the front wheels, and make sure that there is no play in the
hub bearings.
B • Insert screwdriver B into adjusting hole A and turn adjuster C in the
direction of the arrow marked on the back plate until the wheel drags
slightly when turned by hand.
C
NOTE
A • Be sure to adjust the clearance at two points for each wheel per
side.
• The arrow mark on backing plate 18 is near adjusting hole A.
00319

35-65
REAR WHEEL BRAKE
• After depressing the brake pedal several times, release it and make
sure that the wheel drags lightly when turned by hand. If the wheel
turns without stress, repeat the above steps. Slacken off adjuster B,
in the reverse direction to the arrow mark, by eight or nine notches.
NOTE
Be sure to adjust the clearance at two points for each wheel per
side.
• Make sure that the wheel does not drag when turned by hand.
If the wheel drags, repeat the above steps.
• Insert feeler gauge D between brake drum * and lining 9 through
C
* check hole C, and make sure that a little resistance is felt when the
D feeler gauge is pulled out or pushed in.

NOTE
Be sure to adjust the clearance at two points for each wheel per
side.

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9

3
00320

3 Return Spring
7 [Removal]
To remove return spring 3, place screwdriver B on the hook of the return
12
spring, then pry and remove the return spring making use of wheel
cylinder assembly 12 adjuster A as a fulcrum.

A
12586

[Installation]
3 • Refer to the illustration on the caution plate fitted to brake shoe
7
assembly 7 or marking C, and connect shorter hook end of return
12
spring 3 to the brake shoe assembly at the side opposite the adjuster
of wheel cylinder assembly 12.
C A
• Insert a small Phillips screwdriver D into the hook of return spring 3,
insert the tip of the screwdriver into return spring installation hole E of
brake shoe assembly 7 to pry on the return spring.
D
E

7
12587

Brake shoe assembly

9 [Inspection]
If thickness A of brake lining 9 is lower than the limit replace the brake
lining on the same axle as a unit.

12501

35-66
 35
[Installation]
17 • Install brake shoe assembly 7.
7
18 • Insert washer 6 with the side stamped “NUT ” facing outside, screw
4 down holder pin nut 5 until washer hits stepped area B of holder pin 17
B gently, then slacken off the nut within the 0 to 60° limit until the nut is
aligned with the first split pin hole.
• Insert split pin 4, and bend it securely.
17
5
6 00572

9 Brake lining
[Removal]

cardiagn.com
12806

[Installation]
• Clean the mounting surfaces of brake lining 9 and brake shoe 10 with
cleaning fluid and dry them.
10
• Insert rivets 8 from brake lining 9 side, and caulk the rivets at the
specified load so that there is no clearance between brake shoe 10
and the brake lining.

9 Caulking load for rivets : 17 to 19 kN {3750 to 4190 lbf, 1700 to

8
1900 kgf}
00573
• Make sure that you inspect contact with the inner surface of brake
drum * after you replace brake linings 9. If contact is incorrect, correct
with the brake assembled.
WARNING–
Do not leave lubricant on the surface of brake lining 9 because
this reduces braking performance.

CAUTION–
Make sure that the type of brake linings 9 you fit are suitable for
the intended use of the vehicle. Make sure that you fit identical
size and color coated linings on the left and right sides of one
shaft.

35-67
REAR WHEEL BRAKE

12
H A:
Installation of wheel cylinder assembly
Identification mark

Identification mark Installation position

R Right wheel forward
L Left wheel forward
A No mark Left and right wheel rearward

12589 • Install anchor piece C so its recession is at the deeper side of the
C brake shoe at the outside.
B : Front of the vehicle
13 12
B

12 13

cardiagn.com
M
12590

Adjustment of holder pin

• Install the rear wheel brake assembly on the rear axle. ^ Gr 27

12581

• Turn adjuster A to adjust the outer diameter to approximately

7 B
ø319±0.5 mm {12.6±0.020 in.}.
18
• Then, move brake shoe assembly 7 to adjust clearance B evenly.
A Approximately
ø319±0.5 mm
{12.6±0.020 in.}

7 B 11413

• Install hub and drum assembly C on the rear wheel brake assembly.
C 18
D ^ Gr 27
At this time, the hub and drum assembly cannot be inserted in the
specified position if squareness D is 90° or more, so loosen nut 16 and
turn holder pin 17 to adjust the squareness to as close to 90° as
possible.
• Bleed the brake system. Õ P35-32
7
17 16 11414

35-68
 35
18 ★ • Turn adjuster A to widen brake shoe assembly 7 until 0.2 mm
C {0.0079 in.} feeler gauge E cannot be pulled out easily.
E ★ • Loosen nut 16 and turn holder pin 17 to the right or left so that feeler
gauge E can be pushed in or pulled out easily.
• Repeat the above steps (marked ★) until feeler gauge E cannot be
pushed in or pulled out easily.
17 • Depress the brake pedal a few times lightly to equalize clearance B
7 (adjusted in the previous section).
• Repeat the above steps (marked ★) until feeler gauge E cannot be
16 pushed in or pulled out easily.

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11952

18 • If feeler gauge E cannot be pushed in or pulled out easily it is because

C it is making contact over the full width of brake shoe assembly 7.
E • Turn holder pin 17 so that when you pull out feeler gauge E, in the
above condition, and reinsert the feeler gauge, pushing in or pulling
out the feeler gauge at the rear is difficult.
• After adjustment, tighten nut 16 at specified torque.

16 17 11416

* Correction of brake drum

If the cylindrical accuracy of brake drum * is higher than the limit, or
there are seams, correct by machining to the correction limit. Machining
of the brake drum should be done with the wheel hub attached as an
integral part.

35-69
REAR WHEEL BRAKE
Wheel Cylinder Assembly

1
-
13 2
-
3 Ù
-
5
Ù
6-Ù

11
- 12
9 Ù Ù Ê

cardiagn.com
10
-7 -
03399

● Disassembly sequence
1 Screw 7 Anchor piece 12 Air bleeder
2 Seal 8 Piston cup (Only identification marks L, R)
3 Piston 9 Backup ring 13 Body
4 Piston cup 10 Piston
5 Backup ring 11 Boot Ù : Non-reusable parts
6 Boot

● Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit : Wheel cylinder kit

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy

(Basic diameter in [ ])
3, 10, 13 Clearance between piston and body [36.51] 0.03 to 0.09 0.2 {0.0079} Replace
{[1.44] 0.0012 to 0.0035} piston

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
12 Air bleeder 9.8±2.0 {7.2±1.4, 1.0±0.2} —

- Lubricant
Location Points of application Kinds Quantity
1, 2, 3, Thread area of screw, outer periphery of seal, outer periphery Rubber grease As required
6, 10, 11 of piston, mounting groove and thread area of boot, and inner
surface of body
7 Bottom surface of anchor piece Wheel bearing grease [NLGI No.2 (Li soap)] As required

35-70
 35
0 Special tools Unit : mm {in.}
Location Tool name and shape Part No. Application

50 {1.97}

4, 8 Piston cup guide MC895722 Installation of piston cup

ø39 {1.54}

13697

3 5 4 0
4
◆ Service procedure
Installation of piston cup

cardiagn.com
13698

10 9 8 0
8 Installation of piston cup

13699

35-71
AIR COMPRESSOR
● Removal sequence
1 Unloader pipe
5Ê 2 Connector
6
1 3 Eye bolt
Ê 2
4 4 Air outlet pipe
3 5 Eye bolt
6 Air inlet pipe
7 Eye bolt
8 Oil pipe
9 O-ring
10 Air compressor assembly Õ P35-74

*1 : Injection pump assembly ^ Gr 13

*2 : Timing gear case
Ù : Non-reusable parts

● Installation sequence

cardiagn.com
Follow the removal sequence in reverse.

*1
*2 9 8 7 Ê
Ù

12563

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
3 Eye bolt 98 {72, 10} —
5 Eye bolt 98 {72, 10} —
7 Eye bolt 21 {15, 2.1} —

F
◆ Service procedure
Installation of air compressor assembly
• Position No.1 cylinder of the engine at top dead center in the compres-
sion cycle. ^ Gr 11
• Align marking line A with notch B, then install air compressor assem-
B
A bly 10 on timing gear case *2.

12564

35-72
 MEMO
35

35-73
cardiagn.com
AIR COMPRESSOR
Air Compressor Assembly

Ê 11
Ù 12
Ù - 13
14
15

27

Ù 26 20 Ù 10

25 19

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9Ê
18

24 17
37 Ù
23 -
Ê 35
Ù 22 36 7
- 8
35

Ê 28 Ê 38 Ê
- Ù 29
39

30
41

Ù 29
5Ê
6Ù
47 44
45
46

45
42

4
1
Ê Ù

12565

35-74
 35
● Disassembly sequence
1 Nut 18 Suction valve 35 Retaining ring
2 Lock washer 19 Suction valve seat 36 Piston pin
3 Drive gear 20 Packing 37 Piston
4 Collar 21 Delivery valve seat 38 Nut
5 Bolt 22 Packing 39 Lock washer
6 O-ring 23 Delivery valve 40 Connecting rod
7 Oil seal 24 Delivery valve spring 41 Bearing
8 Bearing holder 25 Delivery valve holder 42 Bolt
9 Bolt 26 Packing 43 Connecting rod cap
10 Cylinder head assembly 27 Cylinder head 44 Sleeve
11 Connector 28 Bolt 45 Bearing
12 Packing 29 O-ring 46 Crankshaft
13 O-ring 30 Cylinder liner 47 Crankcase
14 Unloader valve 31 1st compression ring
15 Unloader valve spring 32 2nd compression ring Ù : Non-reusable parts
16 Suction valve holder 33 3rd compression ring
17 Suction valve spring 34 Oil ring

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● Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit : Piston ring kit

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy

(Basic diameter in [ ])
17 Suction valve spring load (Installed length 7 {0.28}) 1.3 N {0.3 lbf, 0.13 kgf} 0.98 N {0.2 lbf, Replace
0.1 kgf}
24 Delivery valve spring load (Installed length 11.5 {0.45}) 2.9 N {0.7 lbf, 0.3 kgf} 1.5 N {0.3 lbf, Replace
0.15 kgf}
30, 37 Clearance between piston and Top [70] {0.22 to 0.28 0.32 {0.013} Replace
cylinder liner {[2.76] 0.0087 to 0.011} cylinder
Skirt [70] {0.13 to 0.18 0.22 {0.0087} liner
{[2.76] 0.0051 to 0.0071}
31 to 34 Clearance of piston ring gap Compression — 0.8 {0.031} Replace
(Measure at interior of cylinder liner) ring piston ring
Oil ring — 0.8 {0.031} kit

31 to 34, Clearance between piston ring and Compression — 0.07 {0.0028} Replace
37 piston ring groove ring piston ring
Oil ring — 0.07 {0.0028} kit

36, 37 Clearance between piston pin and [6] {[0.63]} 0.08 {0.0031} Replace
piston piston pin
36, 40 Clearance between piston pin and [6] {[0.63]} 0.07 {0.0028} Replace
connecting rod small end connecting
rod
40, 43, 46 End play of connecting rod — 0.5 {0.020} Replace
41, 46 Clearance between crankshaft and connecting rod [34] {[1.34]} 0.1 {0.0039} Replace
bearing
46, 47 End play of crankshaft — 1.0 {0.0039} Replace

35-75
AIR COMPRESSOR
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
1 Nut (Drive gear mounting) 166.7 to 210.8 {120 to 155, 17.0 to 21.5} —
5 Bolt (Bearing holder mounting) 13.7 to 17.7 {10 to 13, 1.4 to 1.8} —
9 Bolt (Cylinder head assembly mounting) 24.5 to 29.4 {18 to 22, 2.5 to 3.0} —
11 Connector 29.4 to 34.3 {22 to 25, 3.0 to 3.5} —
16 Suction valve holder 117.7 to 127.5 {87 to 94, 12 to 13} —
21 Delivery valve seat 117.7 to 127.5 {87 to 94, 12 to 13} —
28 Bolt (Cylinder liner mounting) 24.5 to 29.4 {18 to 22, 2.5 to 3.0} —
38 Nut (Connecting rod mounting) 22.6 to 25.5 {17 to 19, 2.3 to 2.6} —

- Lubricant and sealant

Location Points of application Kinds Quantity
7 Oil seal lip Engine oil As required

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13 O-ring Silicon grease As required
16 Thread area of suction valve holder THREEBOND 1360 As required
21 Thread area of delivery valve seat THREEBOND 1360 As required

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

16 Suction valve tool MH061984 Removal and installation of suction valve

holder

13 {0.51}
01730

21 Delivery valve tool MH061595 Removal and installation of delivery valve

seat

14 {0.55}
01731

31 to 34 Piston ring tool MH060014 Removal and installation of piston ring

(Compression ring and oil ring)

01732

35-76
 35

23
◆ Service procedure
Installation of lock washer and drive gear

46
4 3 2
1 12566

After installation, bend lock washer 2 to nut 1 side.

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1

12567

L Removal and installation of suction valve holder

16
01735

0
Q Removal and installation of delivery valve seat

21

01737

35-77
AIR COMPRESSOR
[^ to Piston ring (Compression ring and oil ring)
[Removal and installation]

31 to 34

0
01738

[Installation position]

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A 37 A : Stamped area
31 B : 1st compression ring split 31
C : 2nd compression ring split 32
32,33 D : 3rd compression ring split 33

34

C
120° 120°

D B
01739

41
38
deg Installation of connecting rod, bearing and
connecting rod cap
A
B 41 39 A : Lug
C B : Notch
A C : Alignment marks
B
C
40 43 C
13457

35-78
 MEMO
35

35-79
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AIR DRYER

2 3Ê

4
Ê1

6-Ù

Ù - 17
7

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10

11
Ù - 18
12
20
Ù - 19
13 Ê
34

14

15 - Ù

16
Ù - 29
- 30

31

Ù - 32

33
23 Ê
26

28

Ê 27
25 22
Ê 21
24
13564

35-80
 35
● Disassembly sequence
1 Bolt 13 Screw 25 Exhaust cover
2 Purge chamber 14 Oil filter 26 Retaining ring
3 Screw 15 O-ring 27 Bolt
4 Check valve 16 Case 28 Valve assembly
5 Case cover 17 O-ring 29 O-ring
6 O-ring 18 O-ring 30 Piston
7 Set spring 19 O-ring 31 Valve spring
8 Filter plate 20 Gasket 32 O-ring
9 Filter 21 Screw 33 Valve body
10 Desiccant 22 Thermostat assembly ^ Gr 54 34 Body
11 Filter 23 Heater ^ Gr 54
12 Filter plate 24 Stopper ring Ù : Non-reusable parts

CAUTION–
Clean disassembled parts thoroughly, except for rubber parts and desiccant 10, with clean wash oil, wipe off
foreign particles and dry.

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● Assembly sequence
Follow the disassembly sequence in reverse.
Repair kit : Air dryer kit

CAUTION–
Make sure you install filters 9, 11, with their soft layer sides toward desiccant 10.

● Inspection after installation

Õ P35-82

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (Purge chamber and body mounting) 8.8 to 14 {6.5 to 10, 0.9 to 1.4} —
3 Screw (Case cover and case mounting) 0.8 to 1.0 {0.6 to 0.7, 0.08 to 0.1} —
13 Screw (Oil filter mounting) 0.8 to 1.0 {0.6 to 0.7, 0.08 to 0.1} —
21 Screw (Thermostat assembly mounting) 0.8 to 1.0 {0.6 to 0.7, 0.08 to 0.1} —
23 Heater 20 to 29 {14 to 22, 2 to 3} —
27 Bolt (Valve assembly mounting) 3.9 to 6.9 {2.9 to 5.1, 0.4 to 0.7} —

- Lubricant
Location Points of application Kinds Quantity
6, 15, Friction surfaces of O-ring and piston Multipurpose grease [NLGI No. 2 (Li soap)] As required
17 to 19,
29, 30,
32

35-81
AIR DRYER
◆ Service procedure
● Inspection after installation
• Start the engine.
• Make sure that air is exhausted from the port of exhaust cover 25
when the air pressure reaches the specified level and the air compres-
sor is switched to idling.
NOTE
If high air pressure is exhausted first and approximately three
seconds later, you cannot hear an exhausting sound, do not
worry, it is normal.

• Make sure that there is no air leakage from any piping connection.

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35-82
 MEMO
35

35-83
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AIR PRESSURE GOVERNOR
● Disassembly sequence
1 1 Cover
2 Nut
2 3 Plate
4 Seat
3 5 Retaining ring
4 6 Adjusting screw assembly
7 Lock nut
Ê7 5 8 Upper spring seat
8 9 Spring
10 Lower spring seat
9 11 Spring guide
12 Adjusting screw
13 Exhaust stem
10 13 14 Exhaust stem spring
- 11 15 O-ring
10 14 16 O-ring
15 - Ù 17 Piston

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- 12 16 - Ù 18 Valve spring
19 Valve
17 - 20 Filter
21 Body
16 - Ù
19 Ù : Non-reusable parts
18 -
● Assembly sequence
21 - Follow the disassembly sequence in re-
verse.

20 Repair kit : Air pressure governor kit

12239
● Inspection of function after assembly
Õ P35-85

Service standards
Location Maintenance item Standard value Limit Remedy
— Specified High specified pressure 805 +29
–20 kPa — Adjust
+0.3
pressure {115+4.3 2 2
–2.8 lbf/in , 8.2 –0.2 kgf/cm }
Low specified pressure 685±20 kPa
{100±2.8 lbf/in2, 7.0±0.2 kgf/cm2}

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
7 Lock nut 3.9 to 6.9 {2.9 to 5.1, 0.4 to 0.7} —

35-84
 35
- Lubricant
Location Points of application Kinds Quantity
11 Surface of spring guide Multipurpose grease [NLGI No. 2 (Li soap)] As required
12 Surface of adjusting screw, except for thread area Multipurpose grease [NLGI No. 2 (Li soap)] As required
15, 16 Entire O-ring Multipurpose grease [NLGI No. 2 (Li soap)] As required
17 Outer periphery of piston and O-ring groove Multipurpose grease [NLGI No. 2 (Li soap)] As required
21 Interior of body Multipurpose grease [NLGI No. 2 (Li soap)] As required

◆ Service procedure
● Inspection of function after assembly
• Increase air pressure A gradually and read the value on air pressure
12
gauge C when air is discharged from B. Adjust by turning adjusting
screw 12 so that the reading conforms to the standard value (high
D
B C specified-pressure).
E
D : Turning clockwise decreases the pressure

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E : Turning counterclockwise increases the pressure
• Lower air pressure A to 685 kPa {100 lbf/in2, 7 kgf/cm2} or less, then
raise the air pressure gradually. Read air pressure gauge C when it
stops and check that the value conforms to the standard value (high
A specified-pressure). If the value deviates from the standard value,
01755
readjust.

• Lower air pressure A gradually. When the discharge of air from B

ceases, read air pressure gauge C to check that the valve conforms to
the standard value (high specified-pressure). If the value deviates
from the standard value, replace the air pressure governor assembly.

• After adjusting, tighten lock nut 7 to prevent adjusting screw 12 being

turned accidentally.

12
7

6
13408

Preliminary adjustment of adjusting screw assembly

It is recommended that you adjust the distance from the upper level of
upper spring seat 8 to the lower level of adjusting screw 12 to 47.6 mm
8 {1.87 in.} by turning the adjusting screw, because this makes adjustment
47.6 mm to the specified value easier.
{1.87 in.}

12
01758

35-85
FLUID TANK
● Disassembly sequence
1 Brake fluid level switch ^ Gr 54
2 2 Cap
3 Slide ring
4 Diaphragm
5 Ring cover
6 Stopper ring
7 Float stopper
8 Float
9 Screw
10 Fluid tank bracket
11 Tank

6 ● Assembly sequence
7 Follow the disassembly sequence in reverse.
8

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11

9
10

01759

3
A 35
◆ Service procedure
to Installation of slide ring, diaphragm and ring cover
Be sure to install claw A of slide ring 3 to ring cover 5 securely. Install
diaphragm 4 in the direction as illustrated.

4 01760

35-86
CHECK VALVE/SAFETY VALVE 35
CHECK VALVE
CAUTION–
Do not disassemble this check valve because it is a unit con-
struction.

11493

Service standards
Location Maintenance item Standard value Limit Remedy
— Pressure difference between inlet and outlet 29 kPa {4.3 lbf/in2, 0.3 kgf/cm2} or less — Replace

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SAFETY VALVE

11494

Service standards
Location Maintenance item Standard value Limit Remedy
— Release pressure of safety valve 950±20 kPa — Replace
{135±2.8 lbf/in2, 9.7±0.2 kgf/cm2}

35-87
SUPPLY VALVE
● Disassembly sequence
1 1 Adjusting bolt
2 Lock nut
2 3 Claw washer
3Ù 4 Cap
5 Spring retainer
6 Spring
7 Piston
4
8 O-ring
9 Valve body
5
Ù : Non-reusable parts

6 CAUTION–
Make sure that adjusting bolt 1 is not turned except for
adjustment.
7

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● Assembly sequence
Follow the disassembly sequence in reverse.
8Ù

● Inspection after assembly

Õ P35-88
9

03441

Service standards
Location Maintenance item Standard value Limit Remedy
2 2
— Specified Valve opening pressure 345±29 kPa {50±4.3 lbf/in , 3.5±0.3 kgf/cm } — Adjust
pressure Valve closing pressure 2 2
315±20 kPa {46±2.8 lbf/in , 3.2±0.2 kgf/cm } — or replace

◆ Service procedure
● Inspection after assembly
Adjust by turning adjusting bolt 1 after loosening lock nut 2. After adjust-
ing, tighten the lock nut without turning the adjusting bolt, and bend claw
washer 3 to secure the lock nut.
• Adjust adjusting bolt 1 so that air is discharged from the outlet port
(arrow mark B in the illustration), when valve opening pressure is
A applied to the inlet port (arrow mark A in the illustration).
• After adjusting valve opening pressure, adjust adjusting bolt 1 so that
air is not discharged from the outlet port (arrow mark B in the illustra-
1
tion) when valve closing pressure is applied to the inlet port (arrow
mark A in the illustration).
B : Arrow showing the air flow direction
B
12538

35-88
 MEMO
35

35-89
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EXHAUST BRAKE SYSTEM
Exhaust Brake Unit

31 -
32
-
36
33

35 23
34 24 Ê
25
27
26 Ê Ù
28
30 29
-
-
- Ê 21

Ê1

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37

Ê2 38
3 8
9
67
5
14 4Ê
15
10 Ê

Ê 12 Ê
13

Ê 12568

● Disassembly sequence
1 Nut 15 Bushing 29 Plate
2 Bolt 16 Valve assembly 30 Wear ring
3 Arm 17 Adjusting bolt 31 Shaft assembly
4 Screw 18 Lock nut 32 Spring
5 Cover 19 Adjusting bolt 33 Dust seal
6 Plain washer 20 Lock nut 34 Retaining ring
7 Wave washer 21 Connector 35 Filter
8 Pin 22 Control cylinder 36 Cylinder
9 Link 23 Bolt 37 Cover
10 Nut 24 Cover 38 Plate
11 Lever 25 O-ring
12 Bolt 26 Retainer Ù : Non-reusable parts
13 Seal ring (Large) 27 Nut
14 Seal ring (Small) 28 Packing

● Assembly sequence
Follow the disassembly sequence in reverse.

35-90
 35
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
16 Clearance between butterfly valve and body; when 0.4 to 0.6 {0.016 to 0.024} — Adjust
butterfly valve of valve assembly is working (when
air pressure 685±49 kPa {100±7.1 lbf/in2,
7±0.5 kgf/cm2} is applied to control cylinder)
22 Airtightness of control cylinder (air leakage from No leakage — Replace
various parts when subjected to air pressure of
980 kPa {140 lbf/in2, 10 kgf/cm2})
32 Spring load (Installed length 109 {4.29}) 72 N {16 lbf, 7.3 kgf} 61 N {14 lbf, Replace
6.2 kgf}

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Nut (Arm, plate, and control cylinder mounting) 21 to 25 {15 to 19, 2.1 to 2.6} —

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2 Bolt (Arm and valve assembly mounting) 9.8 to 16 {7.2 to 12, 1.0 to 1.6} —
4 Screw (Cover and plate mounting) 4.9 to 6.9 {3.6 to 5.1, 0.5 to 0.7} —
10 Nut (Valve assembly and spindle mounting) 9.8 to 16 {7.2 to 12, 1.0 to 1.6} —
12 Bolt (Valve assembly body mounting) 9.8 to 16 {7.2 to 12, 1.0 to 1.6} —
18, 20 Lock nut 4.9 to 6.9 {3.6 to 5.1, 0.5 to 0.7} —
21 Connector 4.9 {3.6, 0.5} or more —
23 Bolt (Cover mounting) 9.8 to 16 {7.2 to 12, 1.0 to 1.6} —
27 Nut (Plate mounting) 9.8 to 16 {7.2 to 12, 1.0 to 1.6} —

- Lubricant and sealant

Location Points of application Kinds Quantity
21 Thread area of connector THREEBOND No.1211 As required
28 Packing surface Multipurpose grease [NLGI No. 2 (Li soap)] As required
29, 31 Mating surfaces of plate and shaft assembly SANNOW KOGYO CO., HERMETIC GA As required
31 ø12 mm {0.47 in.} area of shaft assembly Multipurpose grease [NLGI No. 2 (Li soap)] As required
36 Inside of cylinder Multipurpose grease [NLGI No. 2 (Li soap)] 2 cm3
{0.12 cu. in.}

35-91
EXHAUST BRAKE SYSTEM
Inspection and Adjustment of Exhaust Brake System
[Inspection]
Turn the exhaust brake switch ON, depress the accelerator pedal gradu-
ally, and make sure that when the engine revolution reaches 800 to
950 rpm the exhaust brake operation indicator lamp within the meter
cluster goes out. If any fault is found, adjust accelerator switch 1.

1
◆ Service procedure
Adjustment of accelerator switch
• Turn the exhaust brake switch ON while the engine is idling, depress
the accelerator pedal gradually, and check the engine revolution when
the exhaust brake operation indicator lamp within the meter cluster
A goes out.
1 • Turn accelerator switch 1 to adjust the engine revolution, referring to
the following table:

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Confirmed engine revolution Adjusting direction of
accelerator switch 1
11470
800 rpm or less
950 rpm or more

• After adjustment, tighten nut A to fix accelerator switch 1.

GL N to Adjustment of fully opened position of butterfly

valve of valve assembly
Turn adjusting bolt 17 so that its head is level with lever 11 (at this time,
A 16 butterfly valve A of valve assembly 16 is fully open). Then, tighten lock
17 nut 18 at specified torque.

18

11 01776

A LOPR Adjustment of fully closed position of butterfly

valve of valve assembly
C
22 • Supply air pressure A of 685±49 kPa {100±7.1 lbf/in2, 7±0.5 kgf/cm2}
E to control cylinder 22, and turn adjusting bolt 19 (bolt for adjustment of
fully closed position) so that the mean value of clearances D and E
D B between butterfly valve B and body C conforms to the standard value.
• Calculate the mean value of clearances D and E by (D+E)/2.
16 • Tighten lock nut 20 at specified torque.
19

20
01777

35-92
 35
A R Inspection of airtightness of control cylinder
Check that there is no air leakage when pressure A of 980 kPa {140 lbf/
in2, 10 kgf/cm2} is applied to control cylinder 22. Replace any control
cylinder that leaks.

22

01778

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35-93
EXHAUST BRAKE SYSTEM
Intake Silencer

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Ê

6- 7
5
2
Ê

1Ê-

12569

● Disassembly sequence
1 Nut 4 Actuator assembly 6 Thrust washer
2 Bolt 5 Spacer 7 Air inlet pipe
3 Connector

● Assembly sequence
Follow the disassembly sequence in reverse.
● Adjustment after assembly
Õ P35-95

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
— Clearance between top of butterfly valve and center 1.5 {0.059} — Adjust
of air inlet pipe
Clearance of butterfly valve (when Upper and lower 1 {0.039} or more — Adjust
fully closed) and air inlet pipe clearances
Mean value of 3.5 to 4.0 {0.14 to 0.16} — Adjust
upper and lower
clearances

35-94
 35
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}
Location Parts to be tightened Tightening torque Remarks
1 Nut (Valve shaft mounting) 8 {5.9, 0.8} —
2 Bolt (Actuator assembly mounting) 15 {11, 1.5} —
3 Connector 10 {7.2, 1.0} —

- Lubricant and sealant

Location Points of application Kinds Quantity
1 Thread area of nut LOCTITE 271 As required
6 Both surfaces of thrust washer Molybdenum disulfide grease As required

◆ Service procedure

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● Adjustment after assembly
4 2
7 (1) Butterfly valve full-open adjustment
• Loosen bolt 2 so that actuator assembly 4 can move slightly.
A • Move actuator assembly 4 to adjust clearance A to the standard
B value.
• After adjustment, tighten bolt 2 at specified torque.
B : Center of air inlet pipe 7
C
C : Butterfly valve
12570

(2) Butterfly valve full-close adjustment

F G H 4
• Move butterfly valve C so that stopper F makes contact with adjust-
ing screw G.
D • Turn adjusting screw G to adjust clearances D (upper) and E
(lower) to their respective standard values, and check that the
C mean value of upper and lower clearances D, E conforms to the
standard value.
E • Calculate the mean value of the upper and lower clearances by
(D+E)/2.
12571 • After adjustment, fix adjusting screw G using lock nut H.

35-95
EXHAUST BRAKE SYSTEM
Exhaust Brake System Electric Equipment
1 Exhaust brake switch
1 ^ Gr 37
^ Gr 54
2 Clutch switch
^ Gr 21
^ Gr 54
3 Accelerator switch
^ Gr 13
^ Gr 54
4 Exhaust brake cut relay
^ Gr 54
2 3 4 5 3-way magnetic valve
^ Gr 54
6 Transmission neutral switch
< Automatic transmission > ^ Gr 22, ^ Gr 23
^ Gr 54

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5

6
6

12572

35-96