Brake Pressure Hold Valve: Service and Repair
Hill HolderREMOVAL
PHV (PRESSURE HOLD VALVE)
1) Drain brake fluid from the master cylinder reservoir tank.
2) Remove the adjusting nut and lock nut.
3) Remove the cable clamp, and disconnect the PHV cable from the PHV.
CAUTION: When disconnecting the PHV cable, protect it carefully so as not to damage the boot and inner cable.
4) Disconnect the brake pipes from the PHV.
CAUTION:
^ Do not let brake fluid come into contact with the painted surface of the vehicle body. Completely wash away with water immediately and wipe off if it was accidental.
^ Use a pipe wrench so that the hex head of the flare nut is not damaged.
5) Separate the PHV from the side frame, along with the support.
CAUTION: When removing the PHV, take great care that no foreign objects enter inside.
PHV CABLE
1) Remove the adjusting nut and lock nut.
2) Remove the cable clamp, and disconnect the PHV cable from the PHV.
CAUTION: When disconnecting the PHV cable, protect it carefully so as not to damage the boot and inner cable.
3) Remove the cable clamp from the clutch pedal bracket.
4) Remove the PHV cable.
INSPECTION
Inspect the following items for the removed parts, and replace those that apply.
1) If the PHV cable boot is damaged or deteriorated, or if the inner cable is damaged or rusted.
2) Check for weak return springs, damage, and rust.
3) Check that the rotation of the ball can be heard when the PHV is tilted and the lever is moved smoothly.
CAUTION: The PHV cannot be disassembled. If it requires replacement, replace the entire PHV assembly.
INSTALLATION
PHV (PRESSURE HOLD VALVE)
1) Attach the PHV to the side frame.
Tightening torque: 18 N-m (1.8 kgf-m, 13.0 ft-lb)
2) Connect the brake pipe to the PHV.
Tightening torque: 15 N-m (1.5 kgf-m, 10.8 ft-lb)
CAUTION: Check that there is no deformation or damage on the brake pipe. If necessary, replace with a new part.
3) Attach the PHV cable to the PHV.
CAUTION:
^ If the cable clamp (and clip) is damaged, replace it with a new part.
^ Do not bend the PHV cable sharply to avoid damage.
4) Connect the PHV cable with a clip.
5) Apply grease to the following points.
^ Return spring hook position
^ Lever cable end portion.
Grease: KOPR-KOTE (Part No. 003603001)
6) Bleed air from the brake system.
7) Adjust the PHV cable.
CAUTION: After replacing with a new PHV cable, operate the clutch pedal approximately 30 times to break it in, then perform adjustment.
PHV CABLE
1) The installation of the PHV cable is performed in the reverse order of removal.
CAUTION:
^ If the cable clamp is damaged, replace it with a new part.
^ Do not bend the PHV cable sharply to avoid damage.
2) Apply grease to the following points.
^ Return spring hook position
^ Lever cable end portion.
Grease: KOPR-KOTE (Part No. 003603001)
3) Adjust the PHV cable.
CAUTION: After replacing with a new PHV cable, operate the clutch pedal approximately 30 times to break it in, then perform adjustment.
ADJUSTMENT
Perform inspection of stop, start performance on a hill with an incline of 3 degrees or more.
1) If the vehicle will not stop: Tighten the adjusting nut of the PHV cable.
2) If the vehicle does not advance properly:
^ Case A - If the hill holder is released after the clutch is connected (engine stalls easily):
^ Loosen the adjusting nut gradually until a smooth start is possible.
^ Case B - If the hill holder is released before the clutch is connected (vehicle moves backward):
^ Tighten the adjusting nut so that the hill holder releases after connecting the clutch pedal. (Case A) then perform the same adjustment as for Case A.
CAUTION: When turning the adjusting nut, always make sure that the PHV cable does not turn.
3) Tighten the lock nut.
Tightening torque: 3.5 N-m (0.36 kgf-m, 2.6 ft-lb)