Xe ô tô hyundai excel toàn tập hyundai excel - P6

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SYSTEM

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GENERAL 2

BRAKE PEDAL 11

MASTER CYLINDER 15

BRAKE BOOSTER 1 8 BRAKE LINE 25

FRONT DISC BRAKE (SUMITOMO) 27

FRONT DISC BRAKE (TOKICO) 35

REAR DRUM BRAKE 39

PARKING BRAKE 43

Brake booster

Type

Effective dia of power cylinder

Boosting ratio, with brake pedal applied with a

force of 160 N (36 Ibs.)

Vacuum type

180 mm (7.1 in.) 3.0 : 1

Sumitomo Front brakes

Disc O.D 229 mm (9.02 in.)

Pad thickness 10.0 mm (0.39 in.)

Disc thickness 13 mm (0.512 in.)

Cylinder bore 51.1 mm (2.01 in.)

Clearance adjustment Automatic adjustment

Mechanical brake acting on rear wheels Cable

Lever type

3.6 MPa (525 psi) 3.7 : 1

SERVICE STANDARD

Standard value

Brake pedal height

Stop light switch outer case to pedal arm clearance

Brake pedal free play

Brake pedal to floorboard clearance

Booster push rod to master cylinder piston clearance

Parking brake lever stroke adjustment

Limit

182-187 mm (7.2-7.4 in.) 0.5-1.0 mm (0.02-0.04 in.) 10-15 mm (0.4-0.6 in.)

40 mm (1.6 in.) or more 0.40-0.80 mm (0.016-0.031 in.) 5-7 clicks

Master cylinder to piston clearance 0.15 mm (0.006 in.)

Pad thickness 1.0 mm (0.04 in.)

Disc thickness Sumitomo 11.4 mm (0.45 in.)

Tokico 17.0 mm (0.67 in.) Disc runout Sumitomo 0.15 mm (0.006 in.)

Tokico 0.15 mm (0.006 in.) Drum brake lining thickness 1.0 mm (0.04 in.)

Brake drum inner diameter 182 mm (7.2 in.)

Wheel cylinder to piston clearance 0.15 mm (0.006 in.)

TIGHTENING TORQUE

Nm kg.cm Ib.ft Master cylinder

Master cylinder to brake booster

Brake fluid reservoir to master cylinder bolt

Piston stopper

Brake booster to booster mounting holder

Booster mounting holder to pedal support member

Brake booster hose fitting to manifold

Bleeder screw

Brake line flare nuts

Brake hose

Proportioning valve mounting bolt

Disc brake (SUMITOMO)

Caliper inner and outer bridge bolts

Caliper assembly to knuckle

Disc to hub

Disc brake (TOKICO)

Cylinder mounting bolt

Cylinder pin bolt

Caliper assembly to knuckle

LUBRICANTS

Recommended lubricant Quantity Brake fluid DOT 3 or equivalent As required

SPECIAL TOOLS

TROUBLESHOOTING

Symptom

Noise or vibration when

brakes are applied

Vehicle pulls to one side

when brakes are applied

Insufficient braking power

Increased pedal stroke

(Reduced pedal to floorboard

clearance)

Probable cause Backing plate or caliper improperly mounted Loose backing plate or caliper mounting bolts Unevenly worn or cracked brake drum or brake disc Foreign material in brake drum

Seized pad or lining contact surface Excessive caliper to pad assembly clearance Uneven pad contact

Lack of lubrication in sliding parts Loose suspension parts

Difference in left and right tire inflation pressure Inadequate contact of pad or lining

Grease or oil on pad or lining surface Drum eccentricity or uneven wear Incorrect wheel cylinder installation Auto adjuster malfunction

Low or contaminated brake fluid Air in brake system

Brake booster malfunction Inadequate contact of pad or lining Grease or oil on pad surface Auto adjuster malfunction Overheated brake rotor due to dragging of pad

or lining Clogged brake line Proportioning valve malfunction Air in brake system

Brake fluid leaks Auto adjuster malfunction Excessive push rod to master cylinder clearance

Remedy Correct

Retighten Replace Clean Replace Correct Correct Lubricate Retighten Adjust Correct Replace Replace Correct Correct Replenish or change Bleed the system Correct

Correct Replace Correct Correct

Correct Replace Bleed the system Correct

Correct Adjust

Defective master cylinder check valve or piston return spring

Insufficient push rod to master cylinder clearance Worn brake lining

Grease or oil on lining surface Parking brake cable sticking Auto adjuster malfunction Excessive parking brake lever stroke

Remedy Correct

Adjust Replace Correct Replace Lubricate Replace

Adjust Replace Replace Replace Correct Adjust the parking brake lever stroke or check the parking brake cable routing

SERVICE BRAKE PEDAL INSPECTION AND

AD-JUSTMENT

1 Measure the brake pedal height as illustrated If the brake pedal

height is not within the standard value, adjust as follows.

Pedal height (from upper surface of the panel floor to top of the

brake pedal pad) A

[Standard value] 182-187 mm (7.2-7.4 in.)

(a) Move the stop light switch to a position where it does not

contact the brake pedal arm.

(b) Adjust the brake pedal height by turning the operating rod

with pliers (with the operating rod lock nut loosened), until

the correct clearance is obtained

(c) Adjust the stop light switch until the dimension between the

outer case of the stop light switch and the brake pedal arm

reaches the standard value, and then lock the switch in

place with lock nut.

Dimension B [Standard value]

0.5-1.0 mm (0.02-0.04 in.)

2 While the engine is stopped, apply the brake pedal two or

three times After thus eliminating the vacuum in the power

brake booster, press the pedal down by hand, and confirm that

the amount of movement before resistance is correct.

Brake pedal free play C [Standard value] .

10-15 mm (0.4-0.6 in.)

If the free play is less than the standard value, confirm that the

clearance between the outer case of the stop light switch and

brake pedal is within the standard value.

3 Start the engine, apply the brake pedal with approximately

500 N (110 Ibs.) of force, and measure the clearance between

the brake pedal and the floor board.

Pedal to floorboard clearance D when pedal is depressed [Pedal

depressing force: about 500 N (110 Ibs.)] [Standard value]

40 mm (1.6 in.) or more

If the pedal to floor board clearance is less than the standard

value, correct it according to the troubleshooting chart.

PARKING BRAKE STROKE ADJUSTMENT

1 Pull the brake lever with a force of approx 196 N (44 Ibs.), and count the numbers of clicks.

Parking brake lever stroke [Standard value]

3 Loosen the parking brake switch mounting bolt to adjust the switch so that the indicator light will go out when the brake lever is fully released, and will light with the lever pulled one notch.

4 After the adjustment, check to ensure that the rear brakes do not drag with the parking brake lever released.

BRAKE BOOSTER OPERATING TEST

Test Without a Tester

For simple checking of the brake booster operation, carry out

the following tests:

1 Run the engine for one or two minutes, and then stop it.

Depress the brake pedal several times with normal pressure.

If the pedal depresses fully the first time but gradually becomes

higher when depressed succeeding times, the booster is

operat-ing properly If the pedal height remains unchanged, the

boost-er is defective.

2 With the engine stopped, depress the brake pedal several times

with the same foot pressure to make sure that the pedal height

will not change.

Then depress the brake pedal and start the engine If the pedal

moves downward slightly, the booster is in good condition If

there is no change, the booster is defective.

3 With the engine running, depress the brake pedal and then stop

the engine.

Hold the pedal depressed for 30 seconds If the pedal height

does not change, the booster is in good condition, if the pedal

rises, the booster is defective.

If the above three tests are okay, the booster performance can

be determined as good.

If one of the above three tests is not okay, the check valve,

vacuum hose, or booster will be defective.

PROPORTIONING VALVE FUNCTION TEST

1 Connect two pressure gauges, one each to the input side and

output side of the proportioning valve, as illustrated.

2 With the brakes applied, measure the input pressure and the

output pressure If the measured pressures are within the

per-missible ranges shown, the proportioning valve is good.

3 If the measured pressures are not within the permissible

ranges, replace the proportioning valve as an assembly.

4 Reconnect the brake tubes in their original positions and bleed

the system.

NOTE:

This figure indicates only when the pressure of the master

cylinder is rising.

BRAKE BLEEDING

The brake hydraulic system should be bled whenever the brake tube, brake hose, master cylinder or wheel cylinder has been removed or whenever the brake pedal feels spongy when depressed.

Bleed the brake system in the sequence shown in the illustration.

Recommended brake fluid

DOT 3 or equivalent.

CAUTION

(a) Use the specified brake fluid Avoid using a mixture of the specified brake fluids.

(b) If brake fluid is exposed to the air, it will absorb moisture;

As water is absorbed from the atmosphere, the boiling point of the brake fluid will be lowered and the braking performance will be seriously impaired For this reason, use a hermetically sealed 1 liter (1.06 U.S.qts., 0.88 Imp.qts.)

or 0.5 liter (0.52 U.S.qts., 0.44 Imp.qts.) brake fluid container.

(c) Firmly close the cap of the brake fluid container after use.

BRAKE PEDAL

BRAKE PEDAL

COMPONENTS

TORQUE: Nm (kg.cm, lb.ft)

BRAKE PEDAL

REMOVAL

1 Remove the coupling bolt of the steering shaft and universal joint and remove the steering shaft and column as an assembly NOTE

When only the bushing is to be replaced, the steering shaft need not be removed.

2 Remove the brake pedal return spring, clutch cable and cover.

3 Separate the operating rod and brake pedal from each other.

4 Remove the stopper and the washer.

5 Remove the pedal support (left) and draw out the pedal toward the left.

BRAKE PEDAL

INSPECTION

TORQUE: Nm (kg.cm, lb.ft)

1 Check the bushing for wear.

2 Check the stop light switch operation.

3 Check the brake pedal for bend or twisting.

4 Check the brake pedal return spring for damage.

BRAKE PEDAL

CAUTION

Be sure to install the split pin on the operating rod clevis pin.

2 Apply chassis grease to the sliding surface of the brake pedal and operating rod clevis pin.

3 Adjust the brake pedal height and free play.

4 Adjust the clutch pedal stroke and free play.

5 Install the steering shaft.

MASTER CYLINDER

MASTER CYLINDER

COMPONENTS

REMOVAL

1 Disconnect the harness connector of the fluid level sensor.

2 Detach the brake tubes from the master cylinder.

3 Remove the master cylinder from the brake booster.

DISASSEMBLY

1 Remove the reservoir.

2 Remove the piston stopper bolt, while depressing the piston.

MASTER CYLINDER

3 Remove the piston stopper ring.

4 Remove the primary and secondary pistons from the master cylinder body.

CAUTION

Do not disassemble the primary and secondary pistons.

INSPECTION

1 Check inner surface of master cylinder body for rust or scoring.

2 Check primary and secondary pistons for rust, scoring, wear, damage or deterioration.

3 Check primary and secondary piston springs for deterioration.

4 Check clearance between master cylinder inner diameter and piston outer diameter as described below.

Clearance between Master Cylinder Inner Diameter and Piston Outer Diameter.

1 Measure three positions of the master cylinder inner diameter (bottom middle and top) by using a cylinder bore gauge.

Master cylinder to piston clearance [Limit]

0.15 mm (0.006 in.)

2 If the clearance between these inner diameters and the piston outer diameter exceeds the limit, replace the master cylinder and the piston assembly as a set.

REASSEMBLY

1 Apply the specified brake fluid to the inner surface of the master cylinder body and to the entire periphery of the secondary and primary pistons.

Recommended brake fluid

DOT 3 or equivalent

MASTER CYLINDER

INSTALLATION

1 Check master cylinder push rod adjustment.

2 Bleed the brake system.

MASTER CYLINDER PUSH ROD ADJUSTMENT

1 Measure the clearance between the brake booster push rod and

the primary piston.

Booster push rod to master cylinder piston clearance

A (A=B-C-D) [Standard value]

0.4-0.8 mm (0.016-0.031 in.)

NOTE

If the clearance is not within the standard value range, adjust

the push rod length by turning the screw of the push rod.

CAUTION

Insufficient clearance may cause brake drag.

2 Make sure that the brake pedal free play is within the standard

BRAKE BOOSTER

BRAKE BOOSTER

COMPONENTS

TQRQUE : Nm (kg.cm, Ib.ft)

CHECK VALVE OPERATING TEST

Remove the booster hose from the check

Start the engine.

Plug the check valve hole with a finger.

BRAKE BOOSTER

BRAKE BOOSTER OPERATING TEST

Test Using Simple Testers

Test the following two items If either or both of them show

unsatisfactory results, a malfunction of the check valve,

vacuum hose and/or brake booster is suspected.

Prior to the test, connect a vacuum gauge, pressure gauges and

foot force gauge as shown in the illustration Bleed the system.

Test 1 - Boosting function test

Start the engine

Maintain a vacuum of approx 65 kPa (9.4 psi, 0.7 kg/cm 2 ) by controlling the throttle opening control.

Measure the fluid pressure by depressing the brake pedal

at two levels of force.

Foot force Fluid pressure

100 22 2.5 to 3.4 355 to 500 25 to 34

290 66 5.4 to 6.9 780 to 1,000 54 to 69

Good

Test 2 - Non boosting function test

Engine is not started

Measure the fluid pressure by depressing the brake pedal

at two levels of force.

Foot force Fluid pressure

100 22 0.3 or more 43 or more 3 or more

290 66 2.5 or more 355 or more 2.5 or more

Good

BRAKE BOOSTER

REMOVAL

1 Remove the master cylinder.

2 Remove the vacuum hose.

3 Remove the operating rod from the brake pedal.

4 Loosen the booster mounting nuts to remove the booster assembly.

3 Pay attention to the direction of the check valve when installing.

4 Apply sealant to the fitting before tightening.

5 Tighten the vacuum hose securely to prevent air leaks from the connections.

6 Couple the operating rod with the brake pedal and adjust the pedal.

7 Bleed the system.

During disassembling, do not allow the dust, dirt, water and

other impurities into the brake booster.

DISASSEMBLY

1 Mount the Special Tool on the front shell and hold it in a vice.

2 Put mating marks on the front and rear shells.

3 Remove the two steel pipes as shown in the illustration and

connect them to the Special Tool (09591-21100) with suitable

bolts.

4 Using a 9 mm (0.35 in.) drill, make two holes in the steel pipes as

shown.

5 Connect the Special Tool to the rear shell.

6 Turn the Special Tool counterclockwise to remove the rear

shell.

BRAKE BOOSTER

7 The brake booster can be disassembled into the following subassemblies.

(1) Front shell assembly

(2) Diaphragm plate assembly

(3) Rear shell and seal assembly

(3) Valve body seal

9 Disassemble the diaphragm plate assembly.

(a) Pull off the diaphragm from the diaphragm plate.

(b) Remove the silencer retainer from the diaphragm plate with

a screwdriver.

BRAKE BOOSTER

(c) Remove the valve plunger stop key.

(d) Remove the valve rod and plunger assembly slowly.

(e) Push out the reaction disc.

10 Disassemble the front shell.

(a) Remove the retainer from the front shell.

(b) Pull off the plate, seal and push rod assembly.

INSPECTION

Reassembly

1 Coat the following parts with silicone grease.

(1) Rod seal lip

(2) Push rod perimeter

(3) Rod body perimeter

(4) Reaction disc (all surfaces)

(5) Bearing, valve body seal lip

(6) Diaphragm plate inside and outside

(7) Diaphragm to shell contacting surfaces