BRAKE CAMPAIGN CHECK SHEET

CUSTOMER & VEHICLE DETAILS

Customer Name:
Customer Address:
Customer Telephone No.:
Vehicle Registration No.: Customer’s remarks: No problem Concerned
Model / Chassis No.: Brake pedal feeling & effectiveness
Mileage: Noise & vibration
Date Checked: Ride comfort
Stability
Others:
We performed the following free inspections on your vehicle.

Recommend
for next visit
Quotation
Notes

Attention
INSPECTION ITEMS

Urgent
OK Cost Time
( ) (min)

1 Brake Fluid & Vacuum Hose

2 Brake Master Cylinder & Line
3 ABS Actuator with Control Unit
4 Tire & Wheel
5 Wheel Bearing
6 Brake Pad, Caliper & Disc
7 Brake Shoe, Cylinder & Drum
8 Brake Line & Hose (Under floor)
9 Parking Brake component
10 ABS function (by Consult-II)
Brake Pedal & Parking Brake Lever /
11
Pedal
12 Exterior Light

Definition:
Service Advisor’s Name / Signature: Overall Findings: V Inspected OK
X Replaced
R Repaired
Date: A Adjusted
T Tightened
Dealer’s Name: C Cleaned
L Lubricated
-- Not Applicable
 BRAKE SYSTEM CHECK AND REFRESH CAMPAIGN
CHECKING PROCEDURE
– OVERALL FLOW –

Category Lift Position Work/Check Items

1. Vehicle information Completely Down Vehicle Registration No.

Model / Chassis No.
Mileage

2. Engine room Completely Down Brake Fluid

Vacuum Hose
Brake Master Cylinder & Line
ABS Actuator with Control Unit

3. Around Wheels Half way up Tire & Wheel

Wheel Bearing
Brake Pad / Caliper / Disc
Brake Shoe / Cylinder / Drum

4. Under the vehicle Completely Up Brake Line & Hose

Parking Brake component

5. Inside the vehicle Completely Down ABS system check by Consult-II

Brake Pedal
Parking Brake Lever/ Pedal

6. Outside the vehicle Completely Down Exterior Light

Finish
 BRAKE SYSTEM CHECK AND REFRESH CAMPAIGN CHECKING
PROCEDURE
[
Equipment Lift, Consult-II
Tools Air pressure gauge, Ruler, Micro meter, Depth gauge
Parts ---
Resources ---

Figure Operation Remarks

[Preparation] Warning:

(1) Set the vehicle in a service bay with a lift. When setting the lift
arm, do not allow the
(2) Release the hood lock and the trunk lid lock. arm to come into
contact with the brake
(3) Release the parking brake. * lines, brake cable, fuel
lines or sill spoiler.
(4) Set the lift arms to the lift up points of the body sill.
*Tips:
(These are the same as the pantograph jack points) When setting the lift
(5) Raise the vehicle until the center of the wheel is at arm, adjust the vehicle
position by pushing top
waist height. of the tire back and
forth.
(6) Be sure to set the safety lock of the vehicle lift.

1. Check the brake fluid level, color & Vacuum Hose Findings:

(1) Check the Fluid Level and color in the Brake Fluid Fluid;
Low fluid level,
Reservoir Tank. Change in fluid color
Fluid level: Vacuum Hose;
Damage, Improper
Between the indicated scale lines (MIN and attachment
MAX) on the side wall of the reservoir tank
(2) Check the Brake Booster Vacuum Hose condition Note:
New [Clear] Brake Fluid will
Deterioration found:
decrease due to
Recommend replacing the Hose. Pad/Shoe wear.
However, if no
Pad/Shoe wear is
found, fluid leakage is a
possibility.
Fluid color changed to;
Used [Brown]
Brown: Recommend replacing the Fluid.
Black: Recommend replacing Master Cylinder
Cup, Wheel Cylinder Cup and Caliper
Seal with Repair Kit immediately.

Used [Black]
 Figure Operation Remarks
2. Check Brake Master Cylinder & Line Findings:
Fluid leakage,
(1) Check Brake Fluid leakage at Line connection Damage, Improper
attachment
points and Brake Line condition

3. Check ABS Actuator Findings:

Fluid leakage or
(1) Check ABS Actuator Damage

(2) Check Brake Fluid leakage at Line connection

points and Brake Line condition
Leakage found:
Recommend replacing relevant parts.

[Preparation] Make sure that the

front and rear of the
Raise the vehicle until the center of the wheel is at vehicle is well
balanced.
waist height.

Findings:
4. Check Tire pressure, wear and Wheel condition Tire;
Low pressure, Wear,
(1) Inspect air pressure Crack, Scratch on
sidewall, Foreign
Air pressure: matter attached.
For air pressure for tires of each model, refer to Wheel;
Rim deformation
the Caution Label on body at driver’s side or
And also check spare
Owner’s Manual.
tire air pressure

(2) Visually inspect Tire wear and Wheel condition

Wear indicator and or damage shown:
Recommend to replace the Tire or Wheel

Rim deformation found:

New Wear
Recommend replacing wheel.

(Wear
indicator is
shown)
 Figure Operation Remarks
5. Check Wheel Bearings Findings:
Excessive friction,
(1) Shake Wheel to check for excessive play. Excessive end play,
Noise
(2) Inspect Wheel Bearing for smoothly rotation.
Bearing play or sticky movement found:
Recommend to replace the Bearing

6. Check the front brake (Disk type) Findings:

Excessive wear,
(1) Remove the Tire. Leakage, Roughness,
Cracks or chips
Thickness (2) Check the thickness of the pads.
Pad wear limit:
2.0 mm

(1) Inspect appearance and for Fluid leakage at the

Caliper.
Leakage found:
Recommend replacing Seal Kit.
(2) Inspect the appearance, Run-out and thickness of
the Disc Rotor.
Damage found or out of specification:
Recommend replacing the Disc Rotor.

7. Check the rear brake (Drum type) Caution:

Make sure parking
[For disc brake type] brake lever is
completely released.
(1) Refer to Step 6.
Thickness Findings:
Excessive wear,
Leakage, Roughness,
[For Drum Brake Type] Cracks or chips
(1) Remove the Tire and Drum.
(2) Check the thickness of the Lining.
Lining wear limit:
1.5 mm
(3) Check for fluid leakage at Wheel Cylinder.
Leakage found:
Recommend to replace Cup Kit
(3) Check for damage, Out-round and diameter of the
drum.
Damage or excessive wear found: Recommend
to replace the Drum.
(5) Reinstall the Tire and Drum.
Figure Operation Remarks
[Preparation] Make sure that the
front and rear of the
(1) Lift the vehicle to check under the vehicle vehicle is well
balanced.

Findings:
8. Check Brake Hose & Line
Brake Fluid leakage,
(1) Inspect Hose and Line for Brake Fluid leakage Fluid Line / Hose kink,
rubbing
Fluid leakage and damage found: Recommend
to replace relevant parts.

Findings:
9. Check Parking Brake Cable
Cable kink, rubbing,
(1) Inspect Parking Brake Cable condition breakage and clamp
disconnection
Cable kink or rubbing found:
Recommend to replace the Cable
Clamp disconnected:
Refit the Cable properly.
Warning:
[Preparation]
(1) Complete down the vehicle to check remaining process. Please be carefully,
when lift down to avoid
jamming someone,
tools and parts under
the vehicle.

Findings:
10. Check ABS function Malfunction code
(1) Check ABS function by CONSULT-II self diagnosis
Malfunction code found:
Record on the check sheet
 Figure Operation Remarks
Findings:
11. Check Brake Pedal, Booster operation & Parking Brake Excessive Pedal stroke,
Lever/Pedal endplay, Clevis Pin
wear, leakage of air
(1) Check Brake Pedal stroke and play and or brake fluid

Abnormality found: Recommend to replace or

adjust relevant parts
(2) Check Clevis Pin wear.
Clevis
Wear found: Replace or adjust relevant parts
(3) Check Brake Booster operation and airtight in
following manner.
a) Depress the Brake Pedal a few times slowly with
engine stopped. The Pedal should go further down
first time, then it should gradually rise thereafter.
(Please refer to figure at left)
b) After that, depress the Pedal several times to
completely exhaust vacuum. After that depress the
pedal, then start engine. If the pedal goes down
slightly, operation is normal. (Please refer to figure
at left)

c) Check number of notch of Parking Brake

Lever/Pedal.
Excessive number found:
Recommend adjusting Parking Brake Cable.

12. Check the exterior lights Findings:

Burnt out bulbs
Check each exterior light function by turning them on:
(1) Check high/low beams of both headlights.
(2) Check all turn signal lights.
(3) Check the clearance lights.
(4) Check the stop lights (all bulbs on both sides and
the high mount stop light).
(5) Move the gearshift lever to “R”.
(6) Check the reverse lights.
 S/A GUIDE FOR BRAKE SYSTEM CHECK AND REFRESH
BRAKE CHECK UP POINTS

1) Brake Fluid & 3) ABS Actuator 9) Parking Bake

Vacuum Hose component
2) Brake Master 11) Brake pedal &
Cylinder & Line Parking Brake
lever/pedal

12) Exterior Light

10) ABS function (by

CONSULT-II)

8) Brake Line &

Hose (Under floor)
4) Tire & Wheel 6) Brake Pad, 7) Brake Shoe,
5) Wheel Bearing Caliper & Disc Cylinder & Drum
 S/A REFERENCE TABLE FOR BRAKE SYSTEM CHECK AND REFRESH CAMPAIGN
No. ITEM FINDINGS FUNCTION/COMPONENT WHAT HAPPENS IF DAMAGES ARE NEGLECTED
1 Brake Fluid Low fluid level, The brake system provides braking force for the Air may enter the brake fluid line because of leaks and/or
Change in color vehicle when the brake pedal is pressed. When insufficient fluid. The force applied to the brake pedal may
the brake pedal is pressed, the pedal pushes the then not be sufficiently transmitted to the caliper or wheel
piston in the master cylinder. The piston then cylinder. As a result, braking performance becomes worse
pushes brake fluid into the caliper (disc brake and stopping distance will be incresed.
type) or the wheel cylinder (drum brake type). The
caliper or the wheel cylinder brakes the vehicle by
applying the brake pads or the brake linings.
Vacuum Hose Damage, Crack, The brake booster reduces the driver’s pedal The brake pedal may become stiff due to insufficient
Chafing, operating effort by using vacuum assistance from vacuum assistance. The braking performance will then
Deterioration, the engine. The brake booster has a diaphragm become worse even if the same amount of force is applied
Improper that is operated by the vacuum of the engine’s to the brake pedal. As a result, the stopping distance will be
attachment, intake manifold and supports operation of the increased.
Vacuum leak brake master cylinder.
2 Brake Master Damage, Crack, The brake system provides braking force for the Air may enter the brake fluid line because of leaks and/or
Cylinder & Line Chafing, vehicle when the brake pedal is pressed. When insufficient fluid. The force applied to the brake pedal may
Deterioration, the brake pedal is pressed, the pedal pushes the then not be sufficiently transmitted to the caliper or wheel
Improper piston in the master cylinder. The piston then cylinder. As a result, the braking performance becomes
attachment, pushes brake fluid into the caliper (disc brake worse and the stopping distance will be increased.
Vacuum leak type) or the wheel cylinder (drum brake type). The
caliper or the wheel cylinder brakes the vehicle by
applying the brake pads or the brake linings.
3 ABS Actuator Fluid leakage, This component controls the hydraulic circuit and ABS system can not operate correctly.
with Control Unit Inoperation increases, holds or decreases hydraulic pressure
to all or individual wheels. The ABS actuator and
electric unit should not be disassembled.
No. ITEM FINDINGS FUNCTION/COMPONENT WHAT HAPPENS IF DAMAGES ARE NEGLECTED
4 Tire & Wheel Low air pressure, Tires play an important and vital role maintaing Worn out tread or a hardened rubber surface drastically
Worn out, Torn, proper contact between the whole vehicle and the reduces friction between the tire and road surfaces, causing
Foreign matter road surface, while assuring ride comfort. easy slipping when applying brakes, accelerating or turning.
present, Crack, This becomes more evident under in the rain, if tread depth
Deformation is reduced to near the limit. Proper tire pressure is also
critical to assure safety and ride comfort.
5 Wheel Bearing Excessive play, Wheel Bearing holds the wheel at designated If excessive endplay develops, the vehicle's movement
position while keeping its rotating friction at a becomes very unstable and might become dangerous. If
minimum. bearing lubrication is spoilt, the bearing might become
damaged or seized, which is also dangerous.
6 Brake Pad, Excessive wear, The brake pads brake the vehicle by sandwiching Excessive wear of brake pads or brake linings leads to
Caliper & Disc Damage the brake rotors that rotate with the tires. noise of metal-to-metal contact as well as worsened
braking performance.
7 Brake Shoe, Diameter The brake linings brake the vehicle by putting Excessive wear of brake pads or brake linings leads to
Cylinder & Drum expansion, pressure on the brake drums that rotate with the noise of metal-to-metal contact as well as worsened
Excessive wear, tires. braking performance.
Damage
No. ITEM FINDINGS FUNCTION/COMPONENT WHAT HAPPENS IF DAMAGES ARE NEGLECTED
8 Brake Line & Brake Fluid The brake system provides braking force for the Air may enter the brake fluid line because of leaks and/or
Hose (Under leakage, Fluid vehicle when the brake pedal is pressed. When insufficient fluid. The force applied to the brake pedal may
floor) Line/ Hose kink,the brake pedal is pressed, the pedal pushes the then not be sufficiently transmitted to the caliper or wheel
rubbing piston in the master cylinder. The piston then cylinder. As a result, the braking performance becomes
pushes brake fluid into the caliper (disc brake worse and the stopping distance is increased.
type) or the wheel cylinder (drum brake type). The
caliper or the wheel cylinder brakes the vehicle by
applying the brake pads or the brake linings.
9 Parking Bake Poor adjustment The parking brake (PKB) lever or pedal is applied If the PKB lever or pedal is misadjusted, the PKB will not
component to brake the rear tires or to keep the vehicle work properly. As a result, the vehicle may not remain
stationary. stationary and may move on its own on a slope.
10 ABS function Mulfunciton The ABS (Anti-Lock Brake System) consists of If malfunciton occurs, the ABS system does not work
electric and hydraulic components. properly.
It assists in control of braking force to avoind
locking the wheels.
The system is comprised by ABS Actuator,
Electric unit, G-sensor and Wheel-sensor.
11 Brake pedal Improper height, The brake pedal is connected to the brake master If the pedal height and/or the free play become outside
Excessive free cylinder. Height and free play of the brake pedal specification, the brake does not work properly.
play are maintained for appropriate operation.
Parking Brake Poor adjustment The parking brake (PKB) lever or pedal brakes If the PKB lever or pedal is misadjusted, the PKB will not
lever/pedal the rear tires to keep the vehicle stationary. work properly. As a result, the vehicle may not remain
stationary and may move on its own on a slope.
12 Brake Lamp Burnt out bulbs. The Brake Lamp turn on a light when Brake If Bulb burnt out found, the lamp does not turn on.
Pedal depressed.