For 1990-2009 cars

Step | Action | Value(s) | Yes | No
--- | --- | --- | --- | ---
1 | Did you perform the Hydraulic Brake Diagnostic System Check? | -- | Go to Step 2 | Go to Hydraulic Brake Diagnostic System Check
2 | Inspect the hydraulic brake system for leaks. Are there any leaks? | -- | Go to Step 3 | Go to Step 5
3 |

1. Tighten the brake hose or pipe fittings. Refer to Fastener Tightening Specifications .
2. Start the engine.
3. Press the brake pedal several times.
4. Turn OFF the engine.
5. Inspect the hydraulic brake system for leaks.

Does the leak still exist?

--

Go to Step 4

Go to Hydraulic Brake Diagnostic System Check

4 | Replace the brake hose or pipe as necessary. Refer to the following procedures:

• | Front Brake Hose Replacement

• | Rear Brake Hose Replacement

• | ISO Flares Replacement

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

--

5 | Inspect the disc brake pads and brake shoe linings for the following conditions:

• | Excessive wear

• | Uneven wear

• | Abuse

• | Glazing

• | Contaminated lining material

• | Incorrect lining material

Refer to Brake Pad Inspection in Disc Brakes or Brake Pad Inspection in Drum Brakes.

Did you find a condition?

--

Go to Step 6

Go to Step 7

6 | Replace the brake linings. Refer to the following procedures:

• | Front Disc Brake Pads Replacement in Disc Brakes

• | Rear Disc Brake Pads Replacement in Disc Brakes

• | Brake Shoe Replacement in Drum Brakes

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

--

7 | Inspect the following brake caliper assembly components for corrosion:

• | The mounting bolts

• | The guide pins

• | The steering knuckle

• | The brake caliper and mounting bracket

• | The brake pad shims

• | The brake caliper pistons

Are any of the above components corroded or sticking?

--

Go to Step 8

Go to Step 9

8 | Replace the corroded components. Refer to the following procedures:

• | Front Brake Caliper Overhaul in Disc Brakes

• | Rear Brake Caliper Overhaul in Disc Brakes

• | Front Brake Caliper Replacement in Disc Brakes

• | Rear Brake Caliper Replacement in Disc Brakes

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

--

9 | Inspect the brake assembly for loose, missing or broken components. Refer to Brake Pad Inspection in Disc Brakes or Brake Shoe Inspection in Drum Brakes. Are there loose, missing or broken brake assembly components? | -- | Go to Step 10 | Go to Step 11
10 | Tighten or replace the components as necessary. Refer to the following procedures:

• | Front Disc Brake Pads Replacement in Disc Brakes

• | Rear Disc Brake Pads Replacement in Disc Brakes

• | Brake Shoe Replacement in Drum Brakes

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

--

11 |

1. Inspect the wheel cylinders for leakage.
2. Inspect the wheel cylinders for binding.

Are the wheel cylinders leaking or binding?

--

Go to Step 12

Go to Step 13

12 | Overhaul or replace the wheel cylinder. Refer to Wheel Cylinder Overhaul or Wheel Cylinder Replacement . Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check | --
13 |

1. Inspect the brake pedal assembly for bent or misaligned components.
2. Inspect the brake pedal for interference (binding) between the pedal and the booster input rod.

Is the brake pedal binding?

--

Go to Step 14

Go to Step 15

14 |

1. Disassemble and realign or replace components as necessary.
2. Replace the brake pedal. Refer to Brake Pedal Replacement .

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

--

15 | Inspect the brake pedal for interference with other components. Inspect the brake pedal area for the following conditions:

• | Loose or misaligned trim panels

• | Loose components, wiring harnesses or aftermarket devices

Are there any loose or interfering components?

--

Go to Step 16

Go to Step 17

16 | Realign or reposition components as necessary. Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check | --
17 |

• | Inspect for collapsed, dented, or bent brake pipes.

• | Inspect the brake hoses for sharp kinks.

Did you find a condition?

--

Go to Step 18

Go to Step 19

18 | Reroute or replace the brake hoses or pipes as necessary. Refer to the following procedures:

• | Front Brake Hose Replacement

• | Rear Brake Hose Replacement

• | ISO Flares Replacement

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

--

19 |

1. Remove the master cylinder reservoir cover.
2. Rapidly apply the brake pedal 3 cm (1 in), observing the brake fluid in the reservoir.

Does the fluid surface in the forward reservoir show movement, or spouting?

--

Go to Step 20

Go to Step 21

20 |

1. Install the master cylinder reservoir cover.
2. Loosen the master cylinder mounting nuts 13 mm (0.5 in).
3. Separate the master cylinder from the vacuum brake booster.
4. Apply the brake pedal 3 cm (1 in).

Does the booster output rod move?

--

Go to Step 23

Go to Step 22

21 | Replace the master cylinder. Refer to Master Cylinder Replacement . Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check | --
22 | Replace the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement . Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check | --
23 |

1. Remove the master cylinder reservoir cover.
2. Inspect the brake fluid for contamination.

Is the brake fluid contaminated?

--

Go to Step 24

Go to Step 25

24 |

1. Replace all of the rubber brake system components. Refer to the following procedures:

• | Master Cylinder Replacement

• | Front Brake Hose Replacement

• | Rear Brake Hose Replacement

• | Front Brake Caliper Replacement in Disc Brakes

• | Wheel Cylinder Overhaul in Drum Brakes

• | Rear Brake Caliper Replacement in Disc Brakes

• | Brake Pressure Modulator Valve Assembly Replacement in Antilock Brakes

• | Proportioning Valve Replacement

2. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

--

25 | Inspect the master cylinder outlet ports for restricted passages. Refer to Hydraulic Brake System Bleeding . Are the outlet ports restricted? | -- | Go to Step 26 | Go to Step 27
26 |

1. Replace the master cylinder. Refer to Master Cylinder Replacement .
2. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

--

27 | Inspect the brake pipes and the brake hoses for restricted passages. Refer to Hydraulic Brake System Flushing . Inspect for the following conditions:

• | Low fluid or no fluid output

• | Spurting of fluid while pressing the brake pedal

• | Particles suspended in the fluid

Did you find a condition?

--

Go to Step 28

Go to Step 29

28 |

1. Determine the area of the restriction. This will involve the disassembly of individual brake lines and checking for low fluid output.
2. Flush the individual brake line or the brake hose.
3. If the restriction cannot be removed, replace the brake hose or the brake pipe as necessary. Refer to the following procedures:

• | Front Brake Hose Replacement

• | Rear Brake Hose Replacement

• | ISO Flares Replacement

4. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

--

29 | Verify proper brake system operation. Does the original condition still exist? | -- | Go to Step 1 | System OK