BRAKE SYSTEM SECTION BR CONTENTS BRAKES BR-1 SERVICE INFORMATION BRAKE BOOSTER...21 On-Vehicle Service...21 Removal and Installation...

Transcription

1 RS ST R R SYST TTS SRV FRT... 2 RUTS... 2 recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR"...2 recaution for rake System...2 Wiring iagram and Trouble iagnosis...2 RRT... 3 Special Service Tool...3 ommercial Service Tool...3 S, VRT, RSSS (V) TRUST... 4 V Troubleshooting hart...4 R... 5 nspection and djustment...5 Removal and nstallation...7 R FU...10 hecking rake Fluid evel...10 hanging rake Fluid...10 leeding rake System...10 R S...11 ydraulic ircuit...11 Front rake iping and ose...11 Rear rake iping and ose...12 nspection...13 R STR YR...14 n oard nspection...14 Removal and nstallation...14 isassembly and ssembly...15 R STR...21 n-vehicle Service...21 Removal and nstallation...21 VUU S...23 Removal and nstallation...23 nspection...23 FRT S R...25 omponent...25 n oard nspection...26 Removal and nstallation of rake ad...26 Removal and nstallation of aliper ssembly and isc Rotor...27 isassembly and ssembly of aliper ssembly...28 rake urnishing...30 RR S R...32 omponent...32 n oard nspection...33 Removal and nstallation of rake ad...33 Removal and nstallation of aliper ssembly and isc Rotor...33 isassembly and ssembly of aliper ssembly...34 rake urnishing...37 SRV T SFTS (SS)...38 eneral Specification...38 isc rake...38 rake edal...39 rake ooster...39 R R-1

2 < SRV FRT > SRV FRT RUTS RUTS recaution for Supplemental Restraint System (SRS) "R " and "ST T R-TSR" F: The Supplemental Restraint System such as R and ST T R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. nformation necessary to service the system safely is included in the SR and S section of this Service anual. WR: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized SS/FT dealer. mproper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral able and ir ag odule, see the SR section. o not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. recaution for rake System F: UT: Recommended fluid is brake fluid. Refer to -11, "Fluids and ubricants". ever reuse drained brake fluid. e careful not to splash brake fluid on painted areas; it may cause paint damage. f brake fluid is splashed on painted areas, wash it away with water immediately. To clean or wash all parts of master cylinder and disc brake caliper, use clean brake fluid. ever use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. Use flare nut wrench when removing and installing brake tube. f a brake fluid leak is found, the part must be disassembled without fail. Then it has to be replaced with a new one if a defect exists. Turn the ignition switch FF and remove the connector of the S actuator control unit or the battery terminal before performing the work. lways tighten brake lines to specified torque when installing. urnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to R-30, "rake urnishing" (front disc brakes) or R-37, "rake urnishing" (rear disc brakes). WR: lean brake pads and shoes with a waste cloth, then wipe with a dust collector. Wiring iagram and Trouble iagnosis For wiring diagrams or trouble diagnosis relating to the brake system, refer to R section. SR686 F: R-2

3 < SRV FRT > RRT Special Service Tool RRT F: The actual shapes of ent-oore tools may differ from those of special service tools illustrated here. Tool number (ent-oore o.) Tool name (-46532) rake and clutch pedal height measurement tool escription easuring brake pedal height F0227 ommercial Service Tool F: R Tool name escription 1 Flare nut crowfoot 2 Torque wrench Removing and installing each brake piping a: 10 mm (0.39 in) ower tool S-T360 oosening bolts and nuts R-3

4 S, VRT, RSSS (V) TRUST < SRV FRT > S, VRT, RSSS (V) TRUST V Troubleshooting hart F: Use the chart below to help you find the cause of the symptom. f necessary, repair or replace these parts. Reference page R-25, R-32 R-26, R-33 R-25, R-32 R-28, R-34 R-25, R-32 R-28, R-34 R-28, R-34 R-28, R-34 R-30, R-37 R-28, R-34 FX-4, "V Troubleshooting hart" FX-4, "V Troubleshooting hart", RX-4, "V Troubleshooting hart" FSU-5, "V Troubleshooting hart", RSU-4, "V Troubleshooting hart" WT-4, "V Troubleshooting hart" WT-4, "V Troubleshooting hart" S-5, "V Troubleshooting hart" ossible cause and SUST RTS ads - damaged ads - uneven wear Shims damaged Rotor imbalance Rotor damage Rotor runout Rotor deformation Rotor deflection Rotor rust Rotor thickness variation RV SFT X SUSS TRS R W STR Symptom : pplicable oise Shake Shimmy Shudder R-4

5 < SRV FRT > R nspection and djustment R F: ST 1. f equipped with adjustable pedals, move the brake pedal to the forward most position (closest to the floor). 2. nspect the brake pedal height, play, and switch clearance from the dash lower panel as shown. UT: When equipped with adjustable pedals, the brake pedal must be set in the forward most position (closest to the floor) for checking the brake pedal specifications. Tool number : (-46532) R WF0160 Free height epressed pedal height under a force of 490 (50 kg, 110 lb) with engine running learance between pedal stopper and threaded end of stop lamp switch and S cancel switch 1 or 2 edal play mm ( in) ore than 90.3 mm (3.55 in) mm ( in) 3-11 mm ( in) 3. djust the brake pedal as necessary. Refer to "USTT". USTT 1. oosen the stop lamp switch and S cancel switch by turning 45 counterclockwise. 2. oosen the lock nut on the input rod. UT: ake sure that the screw portion of the end of input rod is located inside the clevis as shown. SR229 R-5

6 < SRV FRT > R 3. Turn input rod to adjust the brake pedal to the specified height. When the brake pedal is adjusted to specification, tighten the lock nut to specification. Refer to R-21, "Removal and nstallation". Tool number : (-46532) WF0160 Free height epressed pedal height under a force of 490 (50 kg, 110 lb) with engine running learance between pedal stopper and threaded end of stop lamp switch and S cancel switch 1 or 2 edal play mm ( in) ore than 90.3 mm (3.55 in) mm ( in) 3-11 mm ( in) 4. With the pedal pulled up and held by hand, press the stop lamp switch and the S cancel switch in until the threaded ends contact the rubber stops. 5. With the threaded ends of the stop lamp switch and S cancel switch contacting the rubber stops, turn the switches 45 clockwise to lock them in place. UT: ake sure that the gap ( 1 and 2 ) between the rubber stops and switch ends are within specification. 6. heck the pedal play. UT: ake sure that the stop lamp goes off when the pedal is released. 7. Start the engine and check the height of the brake pedal when depressing it. R-6

7 < SRV FRT > Removal and nstallation R on-adjustable edal F: R WF rake pedal assembly 2. Snap pin 3. S cancel switch 4. Stop lamp switch 5. edal pad 6. levis pin R-7

8 < SRV FRT > R djustable edal WF rake pedal assembly 2. Snap pin 3. S cancel switch 4. Stop lamp switch 5. edal pad 6. levis pin WR: o not damage the brake tube. UT: efore removal and installation the accelerator and brake pedals (adjustable type only) must be in the forward most position (closest to the floor). This is to align the base position of the accelerator and brake pedals (adjustable type only). o not disassemble the brake pedal adjusting mechanism (adjustable type only). void damage from dropping the brake pedal assembly during handling. eep the brake pedal assembly away from water. RV 1. Remove the instrument lower panel. Refer to -12, "nstrument ower anel ". 2. Remove the stop lamp switch and S cancel switch from the brake pedal assembly by turning 45 degrees. 3. f equipped with the adjustable pedal, disconnect the adjustable brake pedal cable from the adjustable pedal electric motor. Unlock (1) then pull (2) the adjustable brake pedal cable to disconnect it from the adjustable pedal electric motor as shown R-8

9 < SRV FRT > R 4. Remove snap pin and clevis pin from the brake booster clevis. 5. Remove nuts and the brake pedal assembly. Support the brake booster and master cylinder at the bulkhead so as not to damage the brake tubes. UT: efore removal and installation, the accelerator and brake pedals must be in the forward most position (closest to the floor). This is to align the base position of the accelerator and brake pedals (adjustable type only) for installation. o not disassemble the brake pedal adjusting mechanism (adjustable type only). void damage from dropping the brake pedal assembly during handling. eep the brake pedal assembly away from water. ST FTR RV heck brake pedal for following items. levis pin deformation rack of any welded portion rake pedal bent or damaged STT nstallation is in the reverse order of removal. heck the brake pedal for smooth operation. There should be no binding or sticking when applying or releasing the brake pedal. f equipped, check the brake pedal adjustable feature for smooth operation. There should be no binding or sticking when adjusting the brake pedal forward or backward. fter installing the brake pedal assembly, adjust as necessary. Refer to R-5, "nspection and djustment". R R-9

10 < SRV FRT > R FU hecking rake Fluid evel R FU F: heck fluid level in the sub tank. t should be between X and lines on the sub tank. Visually check around the reservoir tank and sub tank for leaks. f fluid level is extremely low, check brake system for leaks. Release parking brake lever and see if brake warning lamp goes off. f not, check brake system for leaks. hanging rake Fluid F0204 F: UT: Refill with new brake fluid. Refer to -11, "Fluids and ubricants". lways keep fluid level higher than line on sub tank. ever reuse drained brake fluid. e careful not to splash brake fluid on painted areas; it may cause paint damage. f brake fluid is splashed on painted areas, wash it away with water immediately. 1. onnect a vinyl tube and container to the air bleeder. 2. epressing the brake pedal, drain the brake fluid gradually from the air bleeder of each wheel. 3. Turn the ignition switch to FF. isconnect the S actuator and control unit connector or negative battery terminal. 4. lean the inside of the sub tank, and refill the sub tank with new brake fluid. 5. leed the brake system refilling the system with new fluid. Refer to R-10, "leeding rake System". leeding rake System F: UT: arefully monitor brake fluid level at the sub tank during bleeding operation. Fill the sub tank with new brake fluid. Refer to -11, "Fluids and ubricants". ake sure it is full at all times while bleeding the air out of system. lace a container under the sub tank to avoid spilling brake fluid. o not loosen the line fittings at the S actuator during air bleeding. 1. Turn ignition switch FF and disconnect S actuator and control unit connector or negative battery terminal. 2. onnect a transparent vinyl tube and container to air bleeder valve. 3. Fully depress brake pedal several times. 4. With brake pedal depressed, open air bleeder valve to release air. 5. lose air bleeder valve. 6. Release brake pedal slowly. 7. Tighten air bleeder valve to specification. ir bleeder valve : 8 m (0.8 kg-m, 71 in-lb) 8. Repeat steps 2 through 7 until no more air bubbles come out of air bleeder valve. 9. leed the brake hydraulic system air bleeder valves in the following order: Right rear brake eft front brake eft rear brake Right front brake SR419 R-10

11 < SRV FRT > R S ydraulic ircuit R S F: R WF ctuator 2. aster ylinder 3. rake ooster Flare nut Union olt Front rake iping and ose F: RV UT: e careful not to splash brake fluid on painted areas; it may cause paint damage. f brake fluid is splashed on painted areas, wash it away with water immediately. ll hoses must be free from excessive bending, twisting and pulling. over the open end of lines and hoses when disconnecting to prevent entrance of dirt. 1. onnect vinyl tube and container to air bleeder valve. 2. rain brake fluid from each air bleeder valve by depressing brake pedal. SR419 R-11

12 < SRV FRT > R S 3. Remove the flare nut connecting the brake tube and hose, then withdraw the lock spring. 4. Remove the connecting bolt and disconnect the brake hose from the caliper assembly. 5. Remove lock springs from the mounting portion of the brake tube and the mounting portion of the strut. WF0087 STT UT: Refill with new brake fluid. Refer to -11, "Fluids and ubricants". ever reuse drained brake fluid. 1. ttach the brake hose to the caliper assembly, then temporarily tighten the connecting bolt by hand. UT: orrectly attach the brake hose to the cylinder body. The copper washers of the connecting bolt have to be replaced with new ones every time the fitting is disconnected. 2. ttach the brake hose to the strut, then secure it with a lock spring. 3. ttach the brake hose to the brake tube and temporarily tighten the flare nut as much as possible by hand, then secure it with a lock spring. 4. Tighten all flare nuts and connecting bolts to specification. Refer to R-11, "ydraulic ircuit". 5. Refill until new brake fluid comes out of each air bleeder valve. 6. leed air from the brake system. Refer to R-10, "leeding rake System". Rear rake iping and ose SR686 F: RV UT: e careful not to splash brake fluid on painted areas; it may cause paint damage. f brake fluid is splashed on painted areas, wash it away with water immediately. ll hoses must be free from excessive bending, twisting and pulling. over the open end of lines and hoses when disconnecting to prevent entrance of dirt. 1. onnect vinyl tube and container to air bleeder valve. 2. rain brake fluid from each air bleeder valve by depressing brake pedal. SR419 R-12

13 < SRV FRT > R S 3. Remove flare nut connecting brake tube and hose, then withdraw lock spring. 4. Remove connecting bolt and disconnect brake hose from caliper assembly. WF0088 STT UT: Refill with new brake fluid. Refer to -11, "Fluids and ubricants". ever reuse drained brake fluid. 1. ttach the brake hose to the brake tube and temporarily tighten the flare nut as much as possible by hand. 2. ttach the brake hose with a lock spring, then tighten the connecting bolt and flare nut using a torque wrench to specification. Refer to R-11, "ydraulic ircuit". 3. Refill until new brake fluid comes out of each air bleeder valve. 4. leed air from the brake system. Refer to R-10, "leeding rake System". R nspection UT: f leakage occurs around hose and tube connections, retighten or, if necessary, replace damaged parts. 1. heck brake lines (tubes and hoses) for leaks, cracks, distortion, deformation, without interfering with other parts or loosening connecting parts, deterioration or other damage. Replace any damaged parts. 2. pply a stepping force of 784 (80 kg-f, 176 lb-f) to the brake pedal with the engine running and keep it for about 5 seconds, then check each part for leaks. SR686 F: SR389 R-13

14 < SRV FRT > R STR YR n oard nspection R STR YR F: ST heck for leaking in the master cylinder installation surface, the reservoir tank installation surface, the reservoir hose connections, and the brake tube connections. Removal and nstallation F: UT: e careful not to splash brake fluid on painted areas, it may cause damage. f brake fluid is splashed on painted areas, wash it away with water immediately. RV 1. Remove the cowl top and cowl top extension. Refer to -18, "Removal and nstallation". 2. rain the brake fluid. Refer to R-10, "hanging rake Fluid". 3. Remove the air cleaner to electric throttle control actuator tube attached to air cleaner case (upper). Refer to -15, "Removal and nstallation". 4. isconnect the harness connector for the brake fluid level switch. 5. isconnect the master cylinder brake tubes and the hose from the reservoir tank to the sub tank using a suitable tool. 6. Remove the master cylinder nuts and remove the master cylinder. STT UT: Refill with new brake fluid. Refer to -11, "Fluids and ubricants". ever reuse drained brake fluid. 1. lace master cylinder onto brake booster and tighten the master cylinder nuts to specification. Refer to R-15, "isassembly and ssembly". 2. onnect the sub tank hose to the master cylinder reservoir tank and fill the sub tank with new brake fluid. 3. lug all ports on master cylinder with your fingers to prevent air suction while releasing brake pedal. 4. ave an assistant depress brake pedal slowly several times until no air comes out of the master cylinder. nstall and tighten brake tube flare nuts to specification. Refer to R-11, "ydraulic ircuit". Refill the brake system fluid and bleed the air from the brake system. Refer to R-10, "leeding rake System". 5. nstallation of the remaining components is in reverse order of removal. R-14

15 < SRV FRT > isassembly and ssembly R STR YR F: R WF Reservoir cap 2. il strainer 3. ose 4. lamp 5. racket 6. Reservoir tank 7. rommet 8. iston stopper 9. ylinder body 10. in 11. Secondary piston assembly 12. rimary piston assembly 13. Stopper cap 14. Sub tank 15. rake fluid level switch 16. -ring 17. late 18. uide 19. Snap ring WTUT V S isassembly 1. ift up the tabs on the stopper cap and remove it from the master cylinder using a suitable tool as shown. The piston inside the master cylinder might pop out when this is done, so hold the stopper cap down at the same time. R0031 R-15

16 < SRV FRT > R STR YR 2. lace the side flange of cylinder body with chamfering around the pin insertion hole facing up, and firmly set master cylinder assembly in a vise. UT: When setting the master cylinder assembly with the vise, be sure not to over-tighten. When securing with a vise, use copper plates or cloth to protect the flange. F Remove pin on the reservoir tank, using a suitable tool [commercial service tool: diameter approx. 4 mm (0.16 in)]. 4. Remove master cylinder assembly from the vise. 5. Remove reservoir tank and grommets from cylinder body. F Remove brake fluid level switch from reservoir tank, if necessary. 7. ush in the piston and remove the piston stopper from the cylinder body using a suitable tool. F arefully pull the primary piston assembly straight out to prevent cylinder inner wall from being damaged using a suitable tool. R0561 R-16

17 < SRV FRT > R STR YR 9. Tap flange using a soft block such as wood, and carefully pull the secondary piston assembly straight out to prevent cylinder inner wall from being damaged. nspection fter isassembly aster cylinder heck that there is no damage, friction, rusting, or pinholes on the cylinder inner wall, and replace if there are any non-standard conditions. iston heck cup for damage. Replace the piston if damage is found. ssembly UT: ever use mineral oils such as kerosene, gasoline during the cleaning and assembly process. ake sure there is no foreign matter such as dirt or dust attached to the inner cylinder walls, the piston, or the cap seal, and use care to avoid damaging parts with the assembly tools. o not drop parts. f a part is dropped, do not use it. 1. pply fluid to cylinder inner wall body and contact surface of the piston assembly. Then insert secondary piston assembly and primary piston assembly into cylinder body in this order. UT: o not reuse the primary and secondary piston assemblies. e sure to replace the assembly without disassembling the new inner kit. ay attention to the orientation of the piston cup, and insert straight to prevent the cup from being caught by cylinder inner wall. 2. erform a visual inspection of the secondary piston slit through the tank boss hole on the secondary side of the cylinder body, and install the piston stopper using a suitable tool. R0033 SR089 R F olding down the piston with the stopper cap, push the stopper cap tabs so they are firmly into the cylinder grooves, then attach the stopper cap. UT: o not reuse the stopper cap. 4. pply brake fluid to the grommets and attach to the cylinder body. UT: o not reuse the grommets. R0035 R-17

18 < SRV FRT > R STR YR 5. lace master cylinder assembly is a vise as described in disassembly step nstall the reservoir tank pin so that the pin is evenly seated on both sides of the reservoir, using a suitable tool [commercial service tool: diameter approx. 4 mm (0.16 in)]. UT: o not reuse reservoir tank grommets and pin. F f necessary, install brake fluid level switch. WT V S isassembly 1. lace the side flange of cylinder body with chamfering around the pin insertion hole facing up, and firmly set master cylinder assembly in a vise. UT: When setting the master cylinder assembly with the vise, be sure not to over-tighten. When securing with a vise, use copper plates or cloth to protect the flange. F Remove pin on the reservoir tank, using a suitable tool [commercial service tool: diameter approx. 4 mm (0.16 in)]. 3. Remove master cylinder assembly from the vise. 4. Remove reservoir tank and grommets from cylinder body. F Remove brake fluid level switch from reservoir tank, if necessary. 6. ush in the primary piston and remove the piston stopper from the cylinder body. UT: e careful not to damage the inner wall of the cylinder. R0560 R-18

19 < SRV FRT > R STR YR 7. arefully pull the primary piston assembly straight out to prevent cylinder inner wall from being damaged using a suitable tool. 8. olding the rod of the primary piston, remove the primary piston assembly, the plate and the guide. UT: ull components straight out to prevent cylinder inner wall from being damaged. 9. Remove the plate and guide from the primary piston. UT: e careful not to damage the rod on the inner wall of the plate. nspection fter isassembly aster cylinder heck that there is no damage, friction, rusting, or pinholes on the cylinder inner wall, and replace if there are any non-standard conditions. iston heck cup for damage. Replace the piston if damage is found. ssembly UT: ever use mineral oils such as kerosene, gasoline during the cleaning and assembly process. ake sure there is no foreign matter such as dirt or dust attached to the inner cylinder walls, the piston, or the cap seal, and use care to avoid damaging parts with the assembly tools. o not drop parts. f a part is dropped, do not use it. 1. pply fluid to cylinder inner wall body and contact surface of the piston assembly. Then insert secondary piston assembly and primary piston assembly into cylinder body. UT: ay attention to the orientation of the piston cups. lso, insert pistons squarely to prevent scratching the cylinder inner wall. lways replace the inner kit as an assembly. R0561 R 2. lign the slit in the center of the secondary piston with the axial direction of the piston stopper. Visually check the secondary piston slit from the piston stopper hole and install the piston stopper. WF0129 R0560 R-19

20 < SRV FRT > R STR YR 3. nsert the plates and the guide into the cylinder body as shown. UT: e careful not to damage the primary piston rod. ay attention to the orientation of the guide. WF ress in the primary piston and install a new snap ring. UT: ake sure snap ring is fully inserted in the snap ring groove. o not reuse snap ring. R lace the side flange of cylinder body with chamfering around the pin insertion hole facing up, and firmly set master cylinder assembly in a vise. UT: When setting the master cylinder assembly with the vise, be sure not to over-tighten. When securing with a vise, use copper plates or cloth to protect the flange. F Using a pin punch [commercial service tool: diameter approx. 4 mm (0.16 in)], attach the reservoir tank mounting pin so that the attachment side and the opposite side are identical. UT: o not reuse reservoir tank grommets and pin. 7. f necessary, install brake fluid level switch. F0439 R-20

21 < SRV FRT > R STR n-vehicle Service R STR F: RT With the engine stopped, change the vacuum to the atmospheric pressure by depressing the brake pedal several times. Then with brake pedal fully depressed, start the engine and when the vacuum pressure reaches the standard, check that the clearance between the brake pedal and floor panel decreases. UT: epressing pedal interval is approximately 5 seconds. RTT Run the engine at idle for approximately 1 minute, and stop it after applying vacuum to the booster. epress the brake pedal normally to change the vacuum to the atmospheric pressure. heck that distance between the brake pedal and floor panel gradually increases. epress the brake pedal while the engine is running, then stop the engine with the pedal depressed. The pedal stroke should not change after holding pedal down for 30 seconds. UT: epressing pedal interval is approximately 5 seconds. Removal and nstallation R0037 SR365 F: R WF0143 R-21

22 < SRV FRT > R STR 1. aster cylinder 2. Reservoir tank 3. rake booster 4. asket 5. ock nut RV UT: e careful not to deform or bend brake piping while removing and installing the brake booster. Replace clevis pin if it is damaged. e careful not to damage brake booster stud bolt threads. f brake booster is tilted or inclined during installation, the dash panel may damage the threads. ttach the check valve in the correct orientation. 1. Remove the cowl top and cowl top extension. Refer to -18, "Removal and nstallation". 2. Remove the brake master cylinder. Refer to R-14, "Removal and nstallation". 3. Remove vacuum hose from the brake booster. Refer to R-23, "Removal and nstallation". 4. Remove instrument lower panel. Refer to -12, "nstrument ower anel ". 5. Remove the brake pedal attachment snap pin and clevis pin from inside the vehicle. 6. Remove the nuts on the brake booster and brake pedal assembly. 7. Remove brake booster assembly from the engine compartment side. ST FTR RV utput Rod ength nspection pply specified vacuum to the brake booster. Then check output rod length, using a suitable tool. Standard dimension at vacuum of ( 66.7 ka) [( 500 mmg), ( ing)] : mm ( in) STT 1. oosen the lock nut to adjust the input rod length so that the dimension shown satisfies the specified value. SR208 Standard value : 110 mm (4.33 in) 2. fter adjusting, temporarily tighten the lock nut to install the booster assembly to the vehicle. t this time, make sure to install a gasket between the booster assembly and the vehicle. 3. onnect the brake pedal with the clevis of the input rod while installing brake pedal assembly onto brake booster studs. 4. nstall nuts to secure brake pedal assembly to brake booster WF0159 and tighten to specification. 5. nstall the brake piping from the brake master cylinder to S actuator. Refer to R-11, "ydraulic ircuit". 6. nstall the brake master cylinder to the brake booster. Refer to R-14, "Removal and nstallation". 7. djust the height and play of the brake pedal. 8. Tighten the lock nut of the input rod to the specification. 9. djust brake pedal. Refer to R-5, "nspection and djustment". 10. Refill new brake fluid and bleed air. Refer to R-10, "leeding rake System". R-22

23 < SRV FRT > VUU S Removal and nstallation VUU S F: R WF lamp 2. Vacuum hose 3. heck valve inclusion position stamp 4. Vacuum piping rake booster UT: ecause vacuum hose contains a check valve, it must be installed in the correct orientation. Refer to the stamp or label to confirm correct installation. The brake booster will not operate normally if the hose is installed in the wrong direction. nsert the vacuum hose for at least 24 mm (0.94 in). ever use lubricating oil during assembly. nspection VSU ST heck for improper assembly, damage and deteriorate. VV ST irtightness nspection SR225 F: R-23

24 < SRV FRT > Use a suitable tool to check. VUU S When connected to booster side (1): Vacuum decrease should be within 1.3 ka (10 mmg, 0.39 ing) for 15 seconds under a vacuum of ( 66.7 ka) [( 500 mmg), ( ing)] When connected to engine side (2): o vacuum will be applied WF0158 R-24

25 < SRV FRT > FRT S R omponent FRT S R F: R WF Union bolt 2. opper washers 3. rake hose 4. nner shim cover 5. Sliding pin 6. ap 7. ir bleeder 8. ylinder body 9. Sliding pin boot 10. iston seal 11. iston 12. iston boot 13. Torque member 14. uter shim cover 15. nner shim 16. nner pad 17. ad retainer 18. ad retainer 19. uter pad 20. uter shim 21. ock washer 22. Torque member bolts Front WR: lean dust on caliper and brake pad with a vacuum dust collector. o not blow with compressed air. UT: While the brake pad and cylinder body are separated, the piston may suddenly jump out, so do not depress the brake pedal. t is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of the cylinder body. n this case, hang cylinder body with a wire so that brake hose is not under tension. o not damage piston boot. f any shim is subject to serious corrosion, replace it with a new one. lways replace shims and shim covers as a set when replacing brake pads. eep the rotor clean of brake fluid. urnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to R-30, "rake urnishing". R-25

26 < SRV FRT > n oard nspection FRT S R F: WR ST nspect the thickness of the pad through the cylinder body inspection hole. Use a scale for inspection if necessary. Standard pad thickness ad wear limit : 10 mm (0.394 in) : 2.0 mm (0.079 in) Removal and nstallation of rake ad 0439 F: RV WR: lean brake pads with a vacuum dust collector to minimize a hazard of airborne particles or other materials. UT: While removing pad assemblies, do not depress brake pedal because piston will pop out. e careful not to damage piston boot or get oil on disc rotor. lways replace shims when replacing pads. f shims are rusted or show peeling of rubber coat, replace them with new shims. t is not necessary to remove torque member mounting bolt except for disassembly or replacement of cylinder body. n this case, suspend cylinder body with wire so as not to stretch brake hose. arefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston. urnish the brake pads (or linings) and disc rotor mutually contacting surfaces after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at a very low mileage. Refer to R-30, "rake urnishing". 1. Remove wheel and tire using power tool. 2. Remove lower sliding pin. SR ang the cylinder body with a wire and remove the pad and shim assemblies, then pad retainers from the torque member. UT: o not damage piston boot. When removing pad retainer from torque member, lift pad retainer in the direction of arrow as shown so as not to deform it. eep rotor clean and free from brake fluid. STT R-26 SR556

27 < SRV FRT > FRT S R 1. pply (oly utyl uprysil) or equivalent, refer to -11, to the pad back plate and inner shim sides. nstall inner shims and outer shim covers to inner and outer pads. 2. nstall pad retainers and pad assemblies to the torque member. SR ush the piston in so that the pad is firmly attached, and install the cylinder body to the torque member. T: Using a disc brake piston tool (commercial service tool), makes it easier to push in the piston. UT: y pushing in the piston, the brake fluid returns to the master cylinder reservoir tank and sub tank. Watch the level of the fluid in the sub tank. When installing pad retainer, make sure it firmly seated to the toque member. 4. nstall the sliding pin and tighten to specification. Refer to R-25, "omponent". 5. heck brake for drag. 6. nstall wheel and tire. Refer to WT-6, "onventional Tire and Wheel". UT: urnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to R-30, "rake urnishing". Removal and nstallation of aliper ssembly and isc Rotor RV 1. Remove wheel and tire using power tool. 2. rain brake fluid. Refer to R-10, "hanging rake Fluid". 3. Remove union bolt and torque member bolts using power tool, then remove cylinder body. F: R SF Remove disc rotor. UT: ut matching marks on both disc rotor and wheel hub when removing disc rotor. STT UT: Refill with new brake fluid. Refer to -11, "Fluids and ubricants". ever reuse drained brake fluid. 1. nstall disc rotor. UT: lign matching marks made during removal when reusing disc rotor. R-27

28 < SRV FRT > FRT S R 2. nstall cylinder body to the vehicle, and tighten torque member bolts to specification. Refer to R-25, "omponent". UT: efore installing the cylinder body to the vehicle, wipe any oil off the knuckle spindle washers and cylinder body attachment surfaces. 3. nstall brake hose to the cylinder body, and tighten union bolt to the specification. Refer to R-25, "omponent". UT: o not reuse the copper washer for union bolts. ttach the brake hose to the protrusion on the cylinder body attachment part. SF Refill new brake fluid and bleed air. Refer to R-10, "leeding rake System". 5. nstall wheel and tire. Refer to WT-6, "onventional Tire and Wheel". UT: urnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to R-30, "rake urnishing". isassembly and ssembly of aliper ssembly F: T: o not remove torque member, pads, shims, shim covers or pad retainers, when disassembling or assembling cylinder body. SSSY 1. Remove caliper assembly. Refer to R-27, "Removal and nstallation of aliper ssembly and isc Rotor". 2. Remove cylinder body from torque member, then sliding pin boots from torque member. 3. lace a wooden block as shown, and blow air from union bolt mounting hole to remove pistons and piston boots. WR: o not get your fingers caught in the piston. R Remove the piston seal from the cylinder body using a suitable tool. UT: e careful not to damage cylinder inner wall. ST FTR SSSY ylinder ody UT: Use new brake fluid to clean. ever use mineral oils such as gasoline or kerosene. heck for corrosion, wear, or damage to the cylinder inner wall, and replace the caliper if there are any non-standard conditions. R-28 SF0141

29 < SRV FRT > FRT S R inor flaws caused by corrosion or a foreign material can be removed by polishing the surface with a fine sandpaper. Replace the cylinder body, if necessary. Torque ember heck for wear, cracks, and damage. f damage or deformation is present, replace the affected part. iston UT: Since the piston surface is plated, do not repair using sandpaper. heck piston surface for corrosion, wear, and damage. f any non-standard condition is detected, replace applicable part. Sliding ins, Sliding in olts, and Sliding in oots heck sliding pins, sliding pin bolts, and sliding pin boot for wear, damage, and cracks. f damage or deformation is present, replace the affected part. S RTR ST Visual nspection heck surface of the disc rotor for uneven wear, cracks, and serious damage. f any non-standard condition is detected, replace applicable part. Runout nspection 1. Using wheel nuts, secure disc rotor to the wheel hub in 2 or more positions. 2. nspect runout using a dial gauge. R easurement point aximum runout (with it attached to the vehicle) UT: efore measuring, make sure the axle end play is 0 mm (0 in). Refer to FX-5, "n-vehicle nspection and Service". 3. f runout is outside the limit, find the minimum runout point by shifting mounting positions of the disc rotor and wheel hub by one hole. Thickness nspection Using a micrometer, check thickness of the disc rotor. f thickness does not meet specification, replace disc rotor. Standard thickness inimum thickness aximum thickness variation (measured at 8 positions) : t a point 10 mm (0.39 in) from outer edge of the disc : 0.04 mm ( in) or less : 28 mm (1.10 in) : 26 mm (1.02 in) : mm ( in) or less SR019 SR020 SSY UT: o not use enuine SS Rubber rease (R or R ) when assembling. R-29

30 < SRV FRT > FRT S R 1. pply rubber grease to the piston seals and install them into cylinder body. UT: o not reuse the piston seals. SF pply brake fluid or rubber grease to the piston boot, place it on the piston, and firmly insert the piston boot cylinder-side lip into the cylinder body groove. UT: o not reuse the piston boot. 3. pply brake fluid or rubber grease to the piston, insert into the cylinder body by hand and firmly attach the piston boot pistonside lip into the piston groove. UT: ress the piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed. SF0155 F nstall sliding pins and sliding pin boots to torque member. 5. pply (oly utyl uprysil) or equivalent, refer to -11, to the pad back plate and inner shim sides. nstall inner shims and outer shim covers to inner and outer pads. 6. ttach the pad retainer to the torque member. UT: When attaching the pad retainer, attach it firmly so that it does not float up higher than the torque member, as shown. SR fter assembling the shims and the shim covers to the pad, install it to the torque member. 8. nstall cylinder body and tighten sliding pin to the specification. Refer to R-25, "omponent". rake urnishing R-30 F: urnish the brake contact surface according to the following procedure after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. UT: nly perform this procedure under safe road and traffic conditions. Use extreme caution.

31 FRT S R < SRV FRT > 1. rive the vehicle on a straight smooth road at 50 km/h (31 ). 2. Use medium brake pedal /foot effort to bring the vehicle to a complete stop from 50 km/h (31 ). djust brake pedal /foot pressure such that vehicle stopping time equals 3 to 5 seconds. 3. To cool the brake system, drive the vehicle at 50 km/h (31 ) for 1 minute without stopping. 4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure. R R-31

32 < SRV FRT > RR S R omponent RR S R F: WF Union bolt 2. rake hose 3. opper washer 4. ap 5. ir bleeder 6. Sliding pin bolt 7. ylinder body 8. iston seal 9. iston 10. iston boot 11. Retaining ring 12. nner shim cover 13. nner shim 14. nner pad 15. ad retainer 16. uter pad 17. uter shim 18. Sliding pin boot 19. Torque member bolts 20. Sliding pin 21. Torque member Front WR: lean dust on caliper and brake pad with a vacuum dust collector. o not blow with compressed air. UT: While removing cylinder body, never depress the brake pedal because the piston will pop out. t is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of the cylinder body. n this case, hang cylinder body with a wire so that brake hose is not under tension. o not damage piston boot. f any shim is subject to serious corrosion, replace it with a new one. lways replace shims and shim covers as a set when replacing brake pads. eep the rotor clean of brake fluid. urnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to R-37, "rake urnishing". R-32

33 < SRV FRT > n oard nspection RR S R WR ST nspect the thickness of the pad through the cylinder body inspection hole. Use a scale for inspection if necessary. F: Standard pad thickness ad wear limit : 8.5 mm (0.335 in) : 2.0 mm (0.079 in) Removal and nstallation of rake ad R0010 F: RV 1. Remove wheel and tires assemblies using power tool. 2. Remove bottom sliding pin bolt. 3. ang cylinder body with a wire then remove pads, pad retainers, and shims from torque member. STT 1. pply (oly utyl uprysil) grease or silicone-based grease to the rear of the pad and to both sides of the shim, and attach the inner shim and shim cover to the inner pad, and the outer shim to the outer pad. 2. ttach the pad retainer and pad to the torque member. 3. ush the piston in so that the pad is firmly attached and attach the cylinder body to the torque member. T: Using a disc brake piston tool (commercial service tool), makes it easier to push in the piston. UT: y pushing in the piston, the brake fluid returns to the master cylinder reservoir tank and the sub tank. Watch the brake fluid level in the sub tank. When attaching the pad retainer, attach it firmly so that it does not float up higher than the torque member, as shown. 4. nstall the sliding pin bolt and tighten to specification. Refer to R-32, "omponent". 5. heck the brake for any drag. 6. nstall the wheel and tire assemblies. Refer to WT-6, "onventional Tire and Wheel". UT: urnish the brake contact surfaces when refinishing or SR556 replacing brake rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to R-37, "rake urnishing". Removal and nstallation of aliper ssembly and isc Rotor RV F: R R-33

34 < SRV FRT > RR S R 1. Remove the wheel and tire assemblies using power tool. 2. rain brake fluid. Refer to R-10, "leeding rake System". 3. Remove union bolt and torque member bolts using power tool, and remove cylinder body. 4. Remove caliper and disc rotor. f the disc rotor cannot be removed, remove as follows: ake sure parking brake lever is completely disengaged. old down the disc rotor with the wheel nut and remove the adjuster hole plug. nsert a flat-bladed screwdriver through the plug opening and rotate the adjuster in the direction shown to loosen and retract the brake shoes. rior to removing disc rotor, make alignment mark using a marker between the hub and disc rotor. Remove wheel nut and rotor. F0413 STT UT: Refill with new brake fluid. Refer to -11, "Fluids and ubricants". ever reuse drained brake fluid. 1. nstall the disc rotor. lign the marks made during removal on the hub and disc rotor. 2. nstall the cylinder body, and tighten the torque member bolts to specification. Refer to R-32, "omponent". UT: efore installing cylinder body to the vehicle, wipe off oil and grease on washer seats on axle assembly and mounting surface of cylinder body. 3. nstall brake hose to cylinder body and tighten union bolt to specification. Refer to R-32, "omponent". UT: o not reuse the copper washer for the union bolts. Securely attach the brake hose to the protrusion on the cylinder body. 4. dd new brake fluid and bleed the air. Refer to R-10, "leeding rake System". 5. djust the parking brake. Refer to -4, "n-vehicle Service". 6. nstall the wheel and tire assemblies. Refer to -27, "Tire Rotation". UT: urnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to R-37, "rake urnishing". isassembly and ssembly of aliper ssembly SSSY WF0018 F: Remove the sliding pin bolt, and then remove the pad, shim, shim cover, and pad retainer from the torque member and cylinder. 2. Remove the sliding pin and the sliding pin boot from the torque member. R-34

35 < SRV FRT > RR S R 3. Remove the retaining ring from the cylinder body using a screwdriver or suitable tool, as shown. 4. lace a wooden block as shown, and blow air from union bolt mounting hole to remove pistons and piston boots. WR: o not place your finger in front of piston. SR028 R R Remove piston seals from cylinder body using a screwdriver or suitable tool, as shown. UT: e careful not to damage cylinder inner wall. R ST F0269 ylinder ody UT: Use new brake fluid to clean. ever use mineral oils such as gasoline or kerosene. heck inner wall of cylinder for corrosion, wear, and damage. f any non-standard condition is detected, replace cylinder body. inor flaws caused by corrosion or a foreign material can be removed by polishing the surface with a fine sandpaper. Replace the cylinder body, if necessary. Torque ember heck for wear, cracks, and damage. f damage or deformation is present, replace the affected part. iston UT: Since the piston surface is plated, do not repair using sandpaper. heck piston surface for corrosion, wear, and damage. f any non-standard condition is detected, replace applicable part. Sliding in olts and Sliding in oots heck that there is no wear, damage, or cracks in the sliding pin bolts and sliding pin boots, and if there are, replace them. SSY UT: o not use enuine SS Rubber rease (R or R ) when assembling. R-35

36 < SRV FRT > RR S R 1. pply a rubber grease to the piston seal and attach to cylinder body. UT: o not reuse the piston seals. SF pply brake fluid or rubber grease to the piston boot, place it on the piston, and firmly insert the piston boot cylinder-side lip into the cylinder body groove. UT: o not reuse the piston boot. 3. pply a brake fluid or rubber grease to the piston, insert into the cylinder body by hand and firmly attach the piston boot pistonside lip into the piston boot. UT: ress the piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed. F Fix piston boot with retaining ring. UT: ake sure the boot is firmly in the cylinder body groove. o not reuse the retaining ring. SF ttach the sliding pin and sliding pin boot to the torque member. 6. pply (oly utyl uprysil) grease or silicone-based grease, or equivalent, refer to -11 to the rear of the pad and to both sides of the shim, and attach the inner shim and shim cover to the inner pad, and the outer shim and outer shim cover to the outer pad. 7. ttach the pad retainer and pad to the torque member. UT: When attaching the pad retainer, attach it firmly so that it does not float up higher than the torque member, as shown. 8. fter assembling shims and shim covers to pad, install it to the torque member. 9. nstall cylinder body. Tighten sliding pin bolts to specification. Refer to R-32, "omponent". S RTR ST Visual nspection heck surface of the disc rotor for uneven wear, cracks, and serious damage. f any non-standard condition is detected, replace applicable part. Runout nspection 1. Using wheel nuts, secure disc rotor to the wheel hub. (2 or more positions) R-36 SR556

37 < SRV FRT > 2. nspect runout using a dial gauge. easurement position Runout limit (with it attached to the vehicle) RR S R : t a point 10 mm (0.39 in) from outer edge of the disc. : 0.05 mm ( in) or less UT: efore measuring, make sure the axle end play is 0 mm (0 in). Refer to RX-5, "n-vehicle nspection and Service". 3. f runout is outside the limit, find the minimum runout point by shifting mounting positions of the disc rotor and wheel hub by one hole. Thickness nspection Using a micrometer, check thickness of the disc rotor. f thickness is not within specification, replace disc rotor. SR019 Standard thickness inimum thickness aximum thickness variation (measured at 8 positions) : 16.0 mm (0.630 in) : 14.0 mm (0.551 in) : mm ( in) or less R SR020 rake urnishing F: UT: nly perform this procedure under safe road and traffic conditions. Use extreme caution. T: urnish the brake contact surface according to the following procedure after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. 1. rive the vehicle on a straight smooth road at 50 km/h (31 ). 2. Use medium brake pedal /foot effort to bring the vehicle to a complete stop from 50 km/h (31 ). djust brake pedal /foot pressure such that vehicle stopping time equals 3 to 5 seconds. 3. To cool the brake system, drive the vehicle at 50 km/h (31 ) for 1 minute without stopping. 4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure. R-37

38 SRV T SFTS (SS) < SRV FRT > SRV T SFTS (SS) eneral Specification F: Front brake isc rake rake model 35V disc brake ylinder bore diameter (1.87) ad ength width thickness ( ) Rotor outer diameter thickness ( ) rake model 14V disc brake ylinder bore diameter (1.69) Rear brake ad ength width thickness ( ) Rotor outer diameter thickness ( ) aster cylinder ylinder bore diameter 25.4 (1.00) rake booster Recommended brake fluid ooster model iaphragm diameter 245T rimary 252 (9.92) Secondary 230 (9.06) Unit: mm (in) enuine SS Super eavy uty rake Fluid or equivalent, T 3 (US FVSS o. 116) F: rake model 35V (Front) 14V (Rear) ad wear limit inimum thickness 2.0 (0.079) 2.0 (0.079) Rotor repair limit aximum runout 0.04 (0.0016) 0.05 (0.0020) inimum thickness 26.0 (1.02) 14.0 (0.55) aximum thickness variation (measured at 8 positions) (0.0006) or less Unit: mm (in) R-38

39 < SRV FRT > rake edal SRV T SFTS (SS) F: Unit: mm (in) R WF0160 Free height * ( ) epressed pedal height [under a force of 490 (50 kg, 110 lb) with engine running] * more than 90.3 (3.55) learance 1 or 2 between pedal stopper and threaded end of stop lamp switch or S switch ( ) edal play 3-11 ( ) *: easured from surface of dash reinforcement panel to surface of pedal pad rake ooster F: utput rod length ( ) levis length 110 (4.33) Unit: mm (in) R-39