Page 905 of 3573
POWER ASSISTED BRAKE SYSTEM 5C – 27
BRAKE PIPE REPLACEMENT
1
12
Removal Steps
1. Brake pipe
2. Plastic clip
Installation Steps
To install, follow the removal steps in the
reverse order.
REMOVAL
Preparation:
1) Raise the vehicle and support it with suitable
safety stands.
2) Remove wheel and tire assembly as necessary.
3) Clean dirt, grease, and other foreign material off
the pipe fittings at both ends.
1. Brake Pipe
2. Plastic Clip
1 Vehice with LSPV
Page 906 of 3573

5C – 28 POWER ASSISTED BRAKE SYSTEM
P & B (PROPORTIONING AND BYPASS) VALVE
Master cylinder
(Primary) Master cylinder
(Secondary)
Rear brakeFront brake
INSTALLATION
To install, follow the removal steps in the reverse
order, noting the following points. After installing the
brake pipes, bleed brakes as described in this section.
1. Tighten the brake pipes to the specified torque.
Brake Pipe Torque N·m(kg·m/lb·ft)
Master Cylinder Side Others
12 (1.2/9) 16 (1.6/12)
The P & B valve contains two sections, each serving a
different function.
The proportioning section of the P & B valve
proportions outlet pressure to the rear brakes after a
predetermined rear input pressure has been reached.
This is done to prevent rear wheel lock-up on the
vehicles with light rear wheel loads.
The valve has a By-bass feature which assures full
system pressure to the rear brakes in the event of a
font brake mulfunction, also full front pressure is
retained in the event of rear brake mulfunction.
The P & B valve is not repairable and must be
replaced as a complete assembly.
Page 907 of 3573
POWER ASSISTED BRAKE SYSTEM 5C – 29
P & B VALVE REPLACEMENT
1
3
1yy
2
Removal Steps
1. Hydraulic pipes
2. Bolt
3. P & B valve
Installation Steps
To install, follow the removal steps in the
reverse order.
REMOVAL
•P & B valve is not repairable and must be
replaced as a complete assembly.
•Care must be taken to prevent brake fluid from
contacting any painted surface.
1. Hydraulic Pipes
•Plug the pipes to prevent the loss of fluid or the
entrance of dirt.
2. Bolt
3. P & B Valve
INSTALLATION
3. P & B Valve
2. Bolt
Bolt Torque N·m(kg·cm/lb·in)
13 (130/113)
1. Hydraulic Pipes
Hydraulic Pipe Torque N·m(kg·m/lb·ft)
16 (1.6/12)
After installing the brake pipes, bleed brakes as
described in Bleeding Brake Hydrauric System this
section.
Page 908 of 3573
5C – 30 POWER ASSISTED BRAKE SYSTEM
LOAD SENSING PROPORTIONING VALVE (LSPV)
(FOR EUROPE AND SOUTH AFRICA)
to rear wheel cylinder
from front master cylinder
from rear master cylinder
Structure and Operation
The following is an explanation of the structure and
operation of the linkage type load sensing device.
This device controls the fluid pressure to the rear
brakes in accordance with changes in rear axle load
(vertical displacements of the rear axle springs).
•Structure
This device consists of a load sensing lever and a
valve.
The valve is mounted through a bracket to the
frame. One end of the load sensing lever is fixed
to the valve at the frame and the other end to the
rear axle housing through a spring.
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POWER ASSISTED BRAKE SYSTEM 5C – 31
•Operation
1) Outline
When the L.S.P.V. (Load Sensing Proportioning
Valve) detects a change in load weight, the load
sensing lever moves. Its reaction force is
transmitted to the bottom of the load sensing
valve to secure an optimum rear wheel cylinder
fluid pressure break point in proportion to the
actual load weight.
Besides, if the front brake system should fail, the
devices is designed to prevent the master cylinder
fluid pressure from decreasing and to apply it
directly to the rear wheel cylinder to obtain a
sufficient braking performance.
From rear
master cylinder
2) Operation
(1) When the fluid pressure is under the break point.
The fluid pressure of the rear master cylinder
passes through a clearance between the valve
seal and the piston and acts on the rear wheel
cylinder. At this moment, a downward force is
applied to the piston. However, the compression
spring force and reaction force of the load sensing
lever keep the piston in the upper position by
pushing upwards. (See the left figure.)To rear
wheel cylinder
(2) When the fluid pressure is equal to the break
point.
As the rear wheel cylinder pressure increases, it
surpasses the compression spring force and
reaction force of the load sensing lever, causing
the pistion to move downwards, so that the
pistion butts against the valve seal to shut off the
fluid line between the master cylinder and rear
wheel cylinder. (See the left figure.)
(3) When the fluid pressure is over the break point.
When the fluid pressure increases further, the
piston moves upwards. The moment the piston
comes apart from the valve seal, fluid pressure is
applied to the rear wheel cylinder and the piston
moves downwards so that the fluid line is shut off
again. This process goes on repeatedly to control
the fluid pressure to the rear wheel cylinder.
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Page 910 of 3573

5C – 32 POWER ASSISTED BRAKE SYSTEM
(4) When the front brake system fails.
When there is a failure in the front brake system,
the fluid pressure from the front master cylinder
decreases. As a result, the balance between the
front and rear brake side fluid pressures is lost at
the control valve sleeve so that the control valve
sleeve moves upwards.
The control valve sleeve strikes against the piston,
thereby pushing the piston upwards.
Accordingly, the fluid pressure of the rear master
cylinder is not decreased and is applied directly to
the rear wheel cylinder to secure a sufficient
braking performance of the rear brakes. (See the
left figure.)
Valve Maintenance
In the case of fluid leak or other abnormalities, faulty
valve should be replaced.
Note:
The load sensing proportioning valve is not
repairable and must be replaced as a complete
assembly.
ADJUSTMENT PROCEDURE OF LSPV
1. Adjust the rear axle weight by loading the
laggage compartmemt as necessary.
Rear Axle Weight N (kg / lb)
10,300 (1,050 / 2,315)
Note:
The rear axle weight should be adjusted to the
specified value with a man seated in the driver seat.
Rear master cylinder
fluid Pressure
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Page 911 of 3573

POWER ASSISTED BRAKE SYSTEM 5C – 33
2. Check the rear wheel cylinder fluid pressure.
Install the pressure gauge on bleeder screws on
the front and rear brakes.
a. Depress the brake pedal slowly until the front
wheel cylinder fluid pressure reaches 7845 kPa
(80 kg/cm
2/ 114 psi)
Note:
•The brake pedal should be depressed
gradually until specified pressure is reached
without pumping or adjusting foot pressure.
•If the front wheel cylinder fluid pressure rises
abobe 7845 kPa (80 kg/cm
2/ 114 psi), release
the pedal fully, then depress the pedal again.
b. Hold the front wheel cylinder fluid pressure at
7845 kPa (80 kg/cm
2/ 114 psi) for 2 seconds,
check the rear wheel cylinder fluid pressure.
Rear wheel cylinder
fluid pressure kPa (kg/cm
2/ psi)
6374±539 (65±5.5 / 924±78)
c. If the rear wheel cylinder fluid pressure is not
within the specified range, adjust the fluid
pressure.
3. Adjust the rear wheel cylinder fluid pressure.
The fluid pressure can be adjusted by the bolt
projection (1) or bolt projection (2).
a. If the fluid pressure is lower than specified
range, increase the dimention (1) or (2).
b. If the fluid pressure is higher than the specified
range, decrease the dimention (1) or (2).
Reference:
Dimention (1): The fluid pressure can be
adjusted about 196 kPa (2
kg/cm
2/ 28 psi) by one turning
of the nut.
Dimention (2): The fluid pressure can be
adjusted about 98 kPa (1 kg/cm
2
/ 14 psi) by sliding the bolt
position (per 1 mm / 0.039 in).
4. Check the rear wheel cylinder fluid pressure.
If the rear wheel cylinder fluid pressure is not
within the specified range, try the adjustment
again.
5. Bleed the brake hydraulic line and check the fluid
leak.
2
1
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Page 912 of 3573
5C – 34 POWER ASSISTED BRAKE SYSTEM
BRAKE PEDAL REPLACEMENT
10
9
5
124
2 7 86
11
3
1
M/T
Removal Steps
1. Shift knob
2. Front console assembly
3. Lower cluster assembly
4. Instrument panel driver lower cover
assembly
5. Anti-theft controller
6. Stoplight switch connector
7. Return spring
8. Snap pin
9. Pin
10. Nut
11. Pin, fulcrum
12. Brake pedal
Installation Steps
12. Brake pedal
11. Pin, fulcrum
10. Nut
9. Pin
8. Snap pin
7. Return spring
6. Stoplight switch connector
5. Anti-theft controller
4. Instrument panel driver lower cover
assembly
3. Lower cluster assembly
2. Front console assembly
1. Shift knob
This illustration is based on the LHD model.