BRAKE SYSTEM SECTION BR CONTENTS BRAKES BR-1 SYMPTOM DIAGNOSIS... 3 PRECAUTION... 4 ON-VEHICLE REPAIR...20 PREPARATION... 8

Transcription

1 RS ST R R SYST TTS SYT SS... 3 S, VRT RSSS (V) TRUST... 3 V Troubleshooting hart...3 RUT... 4 RUTS... 4 FR US...4 FR US : recaution for Supplemental Restraint System (SRS) "R " and "ST T R-TSR"...4 FR US : recaution ecessary for Steering Wheel Rotation after attery isconnect...4 FR US : recaution for rocedure without owl Top over...5 FR US : recaution for rake System...5 FR X...5 FR X : recaution for Supplemental Restraint System (SRS) "R " and "ST T R-TSR"...5 FR X : recaution ecessary for Steering Wheel Rotation after attery isconnect...6 FR X : recaution for rocedure without owl Top over...7 FR X : recaution for rake System...7 RRT... 8 RRT... 8 ommercial Service Tool...8 -V T... 9 R... 9 nspection and djustment...9 R FU...12 nspection...12 raining...12 Refilling...12 leeding rake System...13 R STR YR...14 nspection...14 R STR...15 nspection...15 FRT S R...16 R...16 R : nspection and djustment...16 S RTR...16 S RTR : nspection and djustment...16 RR S R...18 R...18 R : nspection and djustment...18 S RTR...18 S RTR : nspection and djustment V RR...20 R...20 xploded View...20 Removal and nstallation...20 nspection and djustment...21 R...22 FRT...22 FRT : xploded View...22 FRT : ydraulic iping...23 FRT : Removal and nstallation...23 FRT : nspection...24 RR...24 RR : xploded View...24 R R-1

2 RR : ydraulic iping RR : Removal and nstallation RR : nspection R STR YR xploded View Removal and nstallation isassembly and ssembly nspection R STR xploded View Removal and installation nspection and djustment VUU S xploded View Removal and nstallation nspection FRT S R R R : xploded View R : Removal and nstallation R : nspection R R SSY R R SSY : xploded View R R SSY : Removal and nstallation R R SSY : isassembly and ssembly R R SSY : nspection RR S R R R : xploded View R : Removal and nstallation R : nspection R R SSY R R SSY : xploded View R R SSY : Removal and nstallation R R SSY : isassembly and ssembly R R SSY : nspection SRV T SFTS (SS) SRV T SFTS (SS) eneral Specifications rake edal rake ooster Front isc rake Rear isc rake R-2

3 S, VRT RSSS (V) TRUST < SYT SS > SYT SS S, VRT RSSS (V) TRUST V Troubleshooting hart Use the chart below to find the cause of the symptom. f necessary, repair or replace these parts. F: Reference page R-16, R-18 R-16, R-18 R-36, R-42 R-16, R-18 R-16, R-18 R-16, R-18 R-16, R-18 R-16, R-18 R-16, R-18 R-16, R-18 V in section V in section V in FX, RX, FSU and RSU section V in WT section V in WT section V in FX and/or RX section V in ST section R 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 RR SFT FFRT X SUSS TR R W RV SFT STR Symptom : pplicable R oise Shake Shimmy, udder R-3

4 < RUT > RUT RUTS FR US RUTS FR US : 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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. nformation necessary to service the system safely is included in the SRS R and ST T 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 SRS R. ever 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. RUTS W US WR TS (R R TR) RS When working near the irbag iagnosis Sensor Unit or other irbag System sensors while ignition switch is or engine is running, never use air or electric power tools or strike near the sensor(s) with a hammer. eavy vibration may activate the sensor(s), deploy the airbag(s), possibly cause serious injury. When using air or electric power tools or hammers, always turn FF ignition switch, disconnect the battery, and wait 3 minutes or more before performing any service. FR US : recaution ecessary for Steering Wheel Rotation after attery isconnect F: T: efore removing and installing any control units, first turn the push-button ignition switch to the position, then disconnect both battery cables. fter finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. lways use SUT- to perform self-diagnosis as a part of each function inspection after finishing work. f a T is detected, perform trouble diagnosis according to self-diagnosis results. This vehicle is equipped with a push-button ignition switch and a steering lock unit. f the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. f turning the steering wheel is required with the battery disconnected or discharged, follow the procedure below before starting the repair operation. RT RUR 1. onnect both battery cables. T: Supply power using jumper cables if battery is discharged. 2. Turn the push-button ignition switch to position. (t this time, the steering lock will be released.) 3. isconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. 4. erform the necessary repair operation. R-4

5 < RUT > RUTS 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from position to position, then to position. (The steering wheel will lock when the push-button ignition switch is turned to position.) 6. erform self-diagnosis check of all control units using SUT-. FR US : recaution for rocedure without owl Top over When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. F: FR US : recaution for rake System 3706 F: R WR: lean any dust from the front brake and rear brake with a vacuum dust collector. ever blow with compressed air. nly use T 3 brake fluid. Refer to -15, "FR RT R : Fluids and ubricants". ever reuse drained brake fluid. ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. lways clean with new brake fluid when cleaning the master cylinder, brake caliper and other components. ever use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and cause improper operation. lways loosen the brake tube flare nut with a flare nut wrench. Tighten the brake tube flare nut to the specified torque with crowfoot () and torque wrench (). lways confirm the specified tightening torque when installing the brake pipes. Turn the ignition switch FF and disconnect the S actuator and electric unit (control unit) connector or the battery negative terminal before performing the work. heck that no brake fluid leakage is present after replacing the parts. urnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. - Front brake pad: refer to R-16, "R : nspection and djustment". - Front disc rotor: refer to R-16, "S RTR : nspection and djustment". - Rear brake pad: refer to R-18, "R : nspection and djustment". - Rear disc rotor: refer to R-18, "S RTR : nspection and djustment". FR X F0001ZZ FR X : 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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. R-5

6 < RUT > RUTS nformation necessary to service the system safely is included in the SRS R and ST T 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 SRS R. ever 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. RUTS W US WR TS (R R TR) RS When working near the irbag iagnosis Sensor Unit or other irbag System sensors while ignition switch is or engine is running, never use air or electric power tools or strike near the sensor(s) with a hammer. eavy vibration may activate the sensor(s), deploy the airbag(s), possibly cause serious injury. When using air or electric power tools or hammers, always turn FF ignition switch, disconnect the battery, and wait 3 minutes or more before performing any service. FR X : recaution ecessary for Steering Wheel Rotation after attery isconnect F: T: efore removing and installing any control units, first turn the push-button ignition switch to the position, then disconnect both battery cables. fter finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. lways use SUT- to perform self-diagnosis as a part of each function inspection after finishing work. f a T is detected, perform trouble diagnosis according to self-diagnosis results. This vehicle is equipped with a push-button ignition switch and a steering lock unit. f the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. f turning the steering wheel is required with the battery disconnected or discharged, follow the procedure below before starting the repair operation. RT RUR 1. onnect both battery cables. T: Supply power using jumper cables if battery is discharged. 2. Turn the push-button ignition switch to position. (t this time, the steering lock will be released.) 3. isconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. 4. erform the necessary repair operation. 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from position to position, then to position. (The steering wheel will lock when the push-button ignition switch is turned to position.) 6. erform self-diagnosis check of all control units using SUT-. R-6

7 < RUT > RUTS FR X : recaution for rocedure without owl Top over When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. F: FR X : recaution for rake System F: WR: lean any dust from the front brake and rear brake with a vacuum dust collector. ever blow with compressed air. nly use T 3 brake fluid. Refer to -16, "FR X : Fluids and ubricants". ever reuse drained brake fluid. ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. lways clean with new brake fluid when cleaning the master cylinder, brake caliper and other components. ever use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and cause improper operation. lways loosen the brake tube flare nut with a flare nut wrench. Tighten the brake tube flare nut to the specified torque with crowfoot () and torque wrench (). lways confirm the specified tightening torque when installing the brake pipes. Turn the ignition switch FF and disconnect the S actuator and electric unit (control unit) connector or the battery negative terminal before performing the work. heck that no brake fluid leakage is present after replacing the parts. urnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at F0001ZZ very low mileage. - Front brake pad: refer to R-16, "R : nspection and djustment". - Front disc rotor: refer to R-16, "S RTR : nspection and djustment". - Rear brake pad: refer to R-18, "R : nspection and djustment". - Rear disc rotor: refer to R-18, "S RTR : nspection and djustment" R R-7

8 < RRT > RRT RRT ommercial Service Tool RRT F: Tool name escription ower tool oosening bolts and nuts 0190 R-8

9 < -V T > R -V T R nspection and djustment ST rake edal eight heck the brake pedal height (1) between the dash lower panel (1) and the brake pedal upper surface. Standard 1 Remove the floor trim. Stop amp Switch and S rake Switch heck the clearance () between stopper rubber (1) and stop lamp switch and S brake switch (2) threaded end. Standard : Refer to R-47, "rake edal". : Refer to R-47, "rake edal". The stop lamp must be turned off when the brake pedal is released. T: ull the brake pedal pad to make the clearance between stopper rubber and stop lamp switch and S brake switch threaded end. rake edal lay ress the brake pedal. heck the brake pedal play (). F: F0065ZZ F0122ZZ R Standard : Refer to R-47, "rake edal". F0121ZZ epressed rake edal eight heck the brake pedal height (2) between the dash lower panel (1) and the brake pedal upper surface when depressing the brake pedal at 490 (50 kg, 110 lb) while turning engine. Standard 2 Remove the floor trim. : Refer to R-47, "rake edal". R-9 F0068ZZ

10 < -V T > USTT rake edal eight R 1. Remove instrument lower panel. Refer to -11, "xploded View". 2. isconnect the stop lamp switch and S brake switch harness connector. 3. Turn the stop lamp switch and S brake switch 45 counterclockwise. 4. oosen the input rod lock nut (1). djust the brake pedal height (1) to the specification. Tighten the input rod lock nut to the specification. Refer to R-30, "xploded View". The threaded end of the input rod (2) must project to the inner side () of the clevis (3). F0003ZZ Standard 1 : Refer to R-47, "rake edal". F0279ZZ Stop amp Switch and S rake Switch 1. Remove instrument lower panel. Refer to -11, "xploded View". 2. isconnect the stop lamp switch and S brake switch harness connector. 3. Turn the stop lamp switch and S brake switch 45 counterclockwise. 4. ress-fit stop lamp switch and S brake switch (2) until stop lamp switch and S brake switch hits the stopper rubber (1) 45 clockwise. The clearance () between the stopper rubber and stop lamp switch and S brake switch threaded end must be the specified value. Refer to R-47, "rake edal". The stop lamp must be turned off when the brake pedal is released. F0122ZZ rake edal lay 1. Remove instrument lower panel. Refer to -11, "xploded View". 2. isconnect the stop lamp switch and S brake switch harness connector. 3. Turn the stop lamp switch and S brake switch 45 counterclockwise. R-10

11 < -V T > R 4. ress-fit stop lamp switch and S brake switch (2) until stop lamp switch and S brake switch hits the stopper rubber (1) 45 clockwise. The clearance () between the stopper rubber and stop lamp switch and S brake switch threaded end must be the specified value. Refer to R-47, "rake edal". The stop lamp must be turned off when the brake pedal is released. F0122ZZ R R-11

12 < -V T > R FU nspection R FU F: R FU V heck that the fluid level in the sub tank is within the specified range (X lines). Visually check for any brake fluid leakage around the sub tank, reservoir tank and hose. heck the brake system for any leakage if the fluid level is extremely low (lower than ). heck the brake system for fluid leakage if the warning lamp remains illuminated even after the parking brake is released. R F0295ZZ 1. heck brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. 2. heck for fluid leakage by fully depressing brake pedal while engine is running. f leakage occurs around joints, retighten or, if necessary, replace damaged parts. raining SR389 F: ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. Turn the ignition switch FF and disconnect the S actuator and electric unit (control unit) connector or the battery negative terminal before draining. 1. onnect a vinyl tube to the bleed valve. 2. epress the brake pedal and loosen the bleeder valve to gradually discharge brake fluid. Refilling R0007 F: Turn the ignition switch FF and disconnect the S actuator and electric unit (control unit) connector or the battery negative terminal before refilling. 1. heck that there is no foreign material in the sub tank, and refill with new brake fluid. ever reuse drained brake fluid. R-12

13 < -V T > R FU 2. oosen the bleeder valve, slowly depress the brake pedal to the full stroke, and then release the pedal. Repeat this operation at intervals of 2 or 3 seconds until all brake fluid is discharged. Then close the bleeder valve with the brake pedal depressed. Repeat the same work on each wheel. 3. erform the air bleeding. Refer to R-13, "leeding rake System". leeding rake System F: Turn the ignition switch FF and disconnect the S actuator and electric unit (control unit) connector or the battery negative terminal before performing the work. onitor the fluid level in the sub tank during the air bleeding. lways use new brake fluid for refilling. ever reuse the drained brake fluid. 1. onnect a vinyl tube to the bleeder valve of the rear right brake. 2. Fully depress the brake pedal 4 to 5 times. 3. oosen the bleeder valve and bleed air with the brake pedal depressed, and then quickly tighten the bleeder valve. 4. Repeat steps 2 and 3 until all of the air is out of the brake line. 5. Tighten the bleeder valve to the specified torque. Front disc brake: refer to R-36, "R R SSY : xploded View". Rear disc brake: refer to R-42, "R R SSY : xploded View". 6. erform steps 1 to 5 for the rear right brake front left brake rear left brake and front right brake in order. 7. heck that the fluid level in the sub tank is within the specified range after air bleeding. Refer to R-12, "nspection". R R-13

14 R STR YR < -V T > R STR YR nspection F: FU heck for brake fluid leakage from the master cylinder mounting face, reservoir tank mounting face, sub tank mounting face, brake tube connections and hose connections. R-14

15 < -V T > R STR nspection R STR F: RT epress the brake pedal several times at 5-second intervals with the engine stopped. Start the engine with the brake pedal fully depressed. heck that the clearance between brake pedal and dash lower panel decreases. T: slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. This is a normal phenomenon due to the brake system operation. R TT dle the engine for 1 minute to apply vacuum to the brake booster, and stop the engine. Then depress the brake pedal several times at 5-second intervals until the accumulated vacuum is released to atmospheric pressure. heck that the clearance between brake pedal and dash lower panel gradually increases ( ) each time the brake pedal is depressed during this operation. R0037 R F0043ZZ epress the brake pedal with the engine running. Then stop the engine while holding down the brake pedal. heck that the brake pedal stroke does not change after holding down the brake pedal for 30 seconds or more. T: slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. This is a normal phenomenon due to the brake system operation. F0044ZZ R-15

16 < -V T > FRT S R R R : nspection and djustment FRT S R F: ST heck brake pad wear thickness from an inspection hole on cylinder body. heck using a scale if necessary. imit Wear thickness : Refer to R-47, "Front isc rake". USTT urnish contact surfaces between pads according to the following procedure after refinishing or replacing pads, or if a soft pedal occurs at very low mileage. e careful of vehicle speed because the brake does not operate firmly/securely until pads and disc rotor are securely fitted. nly perform this procedure under safe road and traffic conditions. Use extreme caution. 1. rive vehicle on straight, flat road. 2. epress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. 3. rive without depressing brake for a few minutes to cool the brake. 4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted. S RTR S RTR : nspection and djustment ST F: ppearance heck surface of disc rotor for uneven wear, cracks, and serious damage. Replace if there are any abnormal conditions. Runout 1. Fix the disc rotor to the wheel hub and bearing assembly with wheel nuts (2 points at least). 2. heck the wheel bearing axial end play before the inspection. Refer to FX-8, "nspection" (2W), FX-35, "nspection" (W). 3. nspect the runout with a dial gauge to measured at 10 mm (0.39 in) inside the disc edge. imit Runout : Refer to R-47, "Front SR019 isc rake". 4. Find the installation position with a minimum runout by shifting the disc rotor-to-wheel hub and bearing assembly installation position by one hole at a time if the runout exceeds the limit value. 5. Replace or refinish the disc rotor if the runout is outside the limit even after performing the above operation. [When refinishing, use the ro-ut n-ar rake athe (Tool o. 38-F90.5) or equivalent.] R0010 R-16

17 < -V T > FRT S R Thickness heck the thickness of the disc rotor using a micrometer. Replace the disc rotor if the thickness is below the wear limit. imit Wear thickness Thickness variation : Refer to R-47, "Front isc rake". : Refer to R-47, "Front isc rake". USTT urnish contact surfaces between pads according to the following procedure after refinishing or replacing pads, or if a soft pedal occurs at very low mileage. e careful of vehicle speed because the brake does not operate firmly/securely until pads and disc rotor are securely fitted. nly perform this procedure under safe road and traffic conditions. Use extreme caution. 1. rive vehicle on straight, flat road. 2. epress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. 3. rive without depressing brake for a few minutes to cool the brake. 4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted. SR020 R R-17

18 < -V T > RR S R R R : nspection and djustment RR S R F: ST heck brake pad wear thickness from an inspection hole on cylinder body. heck using a scale if necessary. imit Wear thickness : Refer to R-47, "Rear isc rake". USTT urnish contact surfaces between pads according to the following procedure after refinishing or replacing pads, or if a soft pedal occurs at very low mileage. e careful of vehicle speed because the brake does not operate firmly/securely until pads and disc rotor are securely fitted. nly perform this procedure under safe road and traffic conditions. Use extreme caution. 1. rive vehicle on straight, flat road. 2. epress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. 3. rive without depressing brake for a few minutes to cool the brake. 4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted. S RTR S RTR : nspection and djustment ST F: ppearance heck surface of disc rotor for uneven wear, cracks, and serious damage. Replace if there are any abnormal conditions. Runout 1. Fix the disc rotor to the wheel hub and bearing assembly with wheel nuts (2 points at least). 2. heck the wheel bearing axial end play before the inspection. Refer to RX-4, "nspection" (2W), RX-11, "nspection" (W). 3. nspect the runout with a dial gauge to measured at 10 mm (0.39 in) inside the disc edge. imit Runout : Refer to R-47, "Rear SR019 isc rake". 4. Find the installation position with a minimum runout by shifting the disc rotor-to-wheel hub and bearing assembly installation position by one hole at a time if the runout exceeds the limit value. 5. Replace or refinish the disc rotor if the runout is outside the limit even after performing the above operation. [When refinishing, use the ro-ut n-ar rake athe (Tool o. 38-F90.5) or equivalent.] R0010 R-18

19 < -V T > RR S R Thickness heck the thickness of the disc rotor using a micrometer. Replace the disc rotor if the thickness is below the wear limit. imit Wear thickness Thickness variation : Refer to R-47, "Rear isc rake". : Refer to R-47, "Rear isc rake". USTT urnish contact surfaces between pads according to the following procedure after refinishing or replacing pads, or if a soft pedal occurs at very low mileage. e careful of vehicle speed because the brake does not operate firmly/securely until pads and disc rotor are securely fitted. nly perform this procedure under safe road and traffic conditions. Use extreme caution. 1. rive vehicle on straight, flat road. 2. epress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. 3. rive without depressing brake for a few minutes to cool the brake. 4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted. SR020 R R-19

20 < -V RR > -V RR R xploded View R F: F levis pin 2. rake pedal assembly 3. rake pedal pad 4. S brake switch 5. Stop lamp switch 6. lip 7. Snap pin : pply multi-purpose grease. Refer to -4, "omponents" for symbols not described on the above. Removal and nstallation F: RV 1. Remove instrument lower panel. Refer to -11, "xploded View". 2. Remove knee protector. Refer to ST-16, "WTUT TR TR : Removal and nstallation" (without electric motor), ST-19, "WT TR TR : Removal and nstallation" (with electric motor). 3. isconnect the stop lamp switch and S brake switch harness connectors. 4. Remove snap pin and clevis pin from clevis of brake booster. 5. Remove the brake pedal assembly. old the brake booster and master cylinder so as not to drop out or contact them to other parts. STT ote the following, and install the reverse order of removal. pply the multi-purpose grease to the clevis pin and the mating faces. (ot necessary if grease has been already applied.) T: The clevis pin may be inserted in either direction. R-20

21 < -V RR > nspection and djustment R ST FTR RV heck the following items and replace the brake pedal assembly if necessary. - heck the brake pedal upper rivet (made by aluminum) () for deformation. - heck the brake pedal for bend, damage, and cracks on the welded parts. - heck the lapping length (X) of sub-bracket () and slide plate (). Standard X : 5.0 mm (0.197 in) or more heck clevis pin and plastic stopper () for damage and deformation. f any damage is found, replace clevis pin. F: F0300ZZ R USTT FTR STT erform the brake pedal adjustment after installing the brake pedal assembly. Refer to R-9, "nspection and djustment". F0756 R-21

22 < -V RR > R FRT FRT : xploded View R F: F rake tube 2. S actuator and electric unit (control unit) 3. onnector 4. onnector bracket 5. aster cylinder assembly 6. rake booster 7. ock plate 8. rake hose 9. Union bolt 10. opper washer. To front brake hose. To rear brake tube Refer to -4, "omponents" for symbols in the figure. R-22

23 < -V RR > FRT : ydraulic iping R F: R F0456ZZ 1. S actuator and electric unit (control 2. Front disc brake 3. aster cylinder assembly unit) 4. rake booster 5. onnector 6. Rear disc brake. rake tube. rake hose : Flare nut : Union bolt FRT : Removal and nstallation F: RV ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. 1. Remove tires with power tool. 2. rain brake fluid. Refer to R-12, "raining". 3. oosen the flare nut with a flare nut wrench and separate the brake tube from the hose. ever scratch the flare nut and the brake tube. ever bend sharply, twist or strongly pull out the brake hoses and tubes. over open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. 4. Remove the union bolt and copper washers, and remove the brake hose from the brake caliper assembly. 5. Remove the lock plate and remove the brake hose. STT ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. 1. ssemble the union bolt and the copper washers to the brake hose. ever reuse the copper washer. R-23

24 < -V RR > R 2. lign the brake hose pin to the projection () of the brake caliper assembly and tighten the union bolt (1) to the specified torque. 3. nstall the brake tube to the brake hose, temporarily tighten the flare nut by hand until it does not rotate further, and fix the brake hose to the bracket with the lock plate. heck that all brake hoses and tubes are not twisted and bent. 4. Tighten the flare nut to the specified torque with a crowfoot and torque wrench. ever scratch the flare nut and the brake tube. 5. Refill with new brake fluid and perform the air bleeding. Refer to R-13, "leeding rake System". ever reuse drained brake fluid. FRT : nspection F0099ZZ F: ST FTR STT 1. heck the brake hoses and tubes for the following: no scratches; no twist and deformation; no interference with other components when steering the steering wheel; no looseness at connections. 2. epress the brake pedal with a force of 785 (80 kg, 176 lb) and hold down the pedal for approximately 5 seconds with the engine running. heck for any fluid leakage. Retighten the applicable connection to the specified torque and repair any abnormal (damaged, worn or deformed) part if any brake fluid leakage is present. RR RR : xploded View F: F0450 R-24

25 < -V RR > R 1. rake tube 2. ock plate 3. rake hose 4. Union bolt 5. opper washer. To connector. To rear brake hose. To brake tube Refer to -4, "omponents" for symbols in the figure. RR : ydraulic iping F: R F0456ZZ 1. S actuator and electric unit (control 2. Front disc brake 3. aster cylinder assembly unit) 4. rake booster 5. onnector 6. Rear disc brake. rake tube. rake hose : Flare nut : Union bolt RR : Removal and nstallation F: RV ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. 1. Remove tires with power tool. 2. rain brake fluid. Refer to R-12, "raining". 3. oosen the flare nut with a flare nut wrench and separate the brake tube from the hose. ever scratch the flare nut and the brake tube. ever sharply bend, twist or strongly pull the brake hoses and tubes. over the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. 4. Remove the union bolt and copper washers, and remove the brake hose from the brake caliper assembly. 5. Remove the lock plate and remove the brake hose from the vehicle. STT ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. 1. ssemble the union bolt and the copper washers to the brake hose. ever reuse copper washer. R-25

26 < -V RR > R 2. nstall the brake hose -pin by aligning it with the brake caliper assembly positioning hole, and tighten the union bolt (1) to the specified torque. 3. onnect the hose to the brake tube, temporarily tighten the flare nut by hand until it does not rotate further, and fix the brake hose to the bracket with the lock plate. heck that the brake hoses and tubes are not twisted and bent. 4. Tighten the flare nut to the specified torque with a crowfoot and torque wrench. ever scratch the flare nut and the brake tube. 5. Refill with new brake fluid and perform the air bleeding. Refer to R-13, "leeding rake System". ever reuse drained brake fluid. RR : nspection F0012ZZ F: ST FTR STT 1. heck the brake hoses and tubes for the following: no scratches; no twist and deformation; no interference with other components when steering the steering wheel; no looseness at connections. 2. epress the brake pedal with a force of 785 (80 kg, 176 lb) and hold down the pedal for approximately 5 seconds with the engine running. heck for any fluid leakage. Retighten the applicable connection to the specified torque and repair any abnormal (damaged, worn or deformed) part if any brake fluid leakage is present. R-26

27 < -V RR > R STR YR xploded View R STR YR F: R F Sub tank cap 2. Sub tank 3. Sub tank bracket 4. lamp 5. ose 6. lamp 7. Reservoir tank 8. rommet 9. ylinder body 10. in 11. -ring : pply (oly utyl uprysil) grease or silicone-based grease. : pply brake fluid. Refer to -4, "omponents" for symbols not described on the above. Removal and nstallation R-27 F: RV ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. 1. rain brake fluid. Refer to R-12, "raining". 2. Separate the brake fluid level switch harness connector. 3. Remove sub tank and hose. 4. Remove cowl top cover. Refer to XT-20, "xploded View". 5. Remove front wiper drive assembly. Refer to WW-130, "xploded View". 6. Remove extension cowl top. Refer to XT-20, "xploded View". 7. Remove air duct assembly and air cleaner case. Refer to -27, "xploded View". 8. Separate the brake tubes from the master cylinder assembly with a flare nut wrench. ever scratch the flare nut and the brake tube. 9. Remove the master cylinder assembly.

28 R STR YR < -V RR > epress the brake pedal several times to release the vacuum pressure from the brake booster. Then remove the master cylinder assembly. ever depress the brake pedal after the master cylinder assembly is removed. The piston of the master cylinder assembly is exposed. ever damage it when removing the master cylinder. The piston may drop off when pulled out strongly. ever hold the piston. old the cylinder body when handling the master cylinder assembly. STT ever spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. ote the following, and install the reverse order of removal. ever depress the brake pedal after the master cylinder assembly is removed. pply (oly utyl uprysil) silicone-based grease to the brake booster [see () in the figure] when installing the master cylinder assembly to the brake booster. The piston of the master cylinder assembly is exposed. ever damage it when handling the master cylinder and check that no dirt and dust are present on the piston before installation. lean it with new brake fluid if necessary. The piston may drop off when pulled strongly. ever hold the piston. old the cylinder body when handling the master cylinder assembly. Temporarily tighten the brake tube flare nut to the master cylinder F0013ZZ assembly by hand. Then tighten it to the specified torque with a crowfoot and torque wrench. Refer to R-22, "FRT : xploded View". ever scratch the flare nut and the brake tube. fter installation, perform the air bleeding. Refer to R-13, "leeding rake System". ever reuse drained brake fluid. isassembly and ssembly F: SSSY ever disassemble the cylinder body. Remove the reservoir tank if necessary. 1. Fix the master cylinder assembly to a vise. lways set copper plates or cloth between vise when fixing the cylinder body to a vise. ever overtighten the vise. 2. Remove the reservoir tank mounting pin with a pin punch. 3. Remove the reservoir tank and grommet from the cylinder body. ever drop the removed parts. The parts must not be reused if they are dropped. SSY 1. pply new brake fluid to the grommet and install it to the cylinder body. ever use mineral oil such as gasoline or light oil. ever reuse the grommets. R-28 F0303ZZ

29 < -V RR > R STR YR 2. nstall the reservoir tank to the cylinder body. ever drop the parts when installing. The parts must not be reused if they are dropped. ever reuse reservoir tank. 3. Fix the cylinder body to a vise. lace the reservoir tank with the chamfered pin hole ( ) facing up. lways set copper plates or cloth between vise when fixing the cylinder body to a vise. ever overtighten the vise. F0304ZZ 4. Tilt the reservoir tank so that a mounting pin can be inserted. nsert a mounting pin. Return the reservoir tank to the horizontal position. nsert another mounting pin into the pin hole on the opposite side in the same manner after the mounting pin passes through the cylinder body pin hole. ever reuse the mounting pin. R nspection F0303ZZ F: ST FTR STT Fluid eak heck for brake fluid leakage from the cylinder body-to-brake booster mounting face, reservoir tank mounting face, brake tube connections and hose connections. R-29

30 < -V RR > R STR xploded View R STR F: F aster cylinder assembly 2. rake booster 3. ock nut 4. levis 5. asket Refer to -4, "omponents" for symbols in the figure. Removal and installation F: RV 1. Remove brake master cylinder assembly. Refer to R-27, "xploded View". epress the brake pedal several times to release the vacuum pressure from the brake booster. Then remove the master cylinder assembly. ever depress the brake pedal after the master cylinder assembly is removed. The piston of the master cylinder assembly is exposed. ever damage it when removing the master cylinder. The piston may drop off when pulled out strongly. ever hold the piston. old the cylinder body when handling the master cylinder assembly. 2. Remove vacuum hose from brake booster. Refer to R-33, "xploded View". 3. Remove snap pin (1) and clevis pin (2) from inside vehicle. 4. Remove nuts on brake booster and brake pedal assembly. old the brake booster so as to avoid dropping out. 5. Remove brake booster from dash panel in engine room side. ever deform or bend the brake tubes. F0019ZZ STT ote the following, and installation is the reverse order of removal. e careful not to damage brake booster stud bolt threads. f brake booster is tilted during installation, the dash panel may damage the threads. ever deform or bend the brake tubes when installing the brake booster. lways use a new gasket between the brake booster. R-30

31 < -V RR > R STR Replace the clevis pin if it is damaged. Refer to R-21, "nspection and djustment". fter installation, perform the air bleeding. Refer to R-13, "leeding rake System". ever reuse drained brake fluid. nspection and djustment F: ST FTR RV ir Tight heck the air tight condition when the master cylinder and the brake booster is installed. 1. With a handy vacuum pump, apply vacuum pressure of 66.7 ka ( 500 mmg, ing) to the brake booster. 2. f the air tight condition cannot be maintained, perform the following operation. a. heck -ring on the master cylinder. f anything is found, replace the -ring. b. heck the air tight condition again. f the condition still cannot be maintained, replace the brake booster. nput Rod ength nspection 1. oosen the lock nut (1) and adjust the input rod (2) to the specified length (). Standard : Refer to R-47, "rake ooster". 2. Tighten the lock nut to the specified torque. R F0020ZZ ST FTR STT peration epress the brake pedal several times at 5-second intervals with the engine stopped. Start the engine with the brake pedal fully depressed. heck that the clearance between brake pedal and dash lower pane decreases. T: slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. This is a normal phenomenon due to the brake system operation. ir Tight dle the engine for 1 minute to apply vacuum to the brake booster, and stop the engine. Then depress the brake pedal several times at 5-second intervals until the accumulated vacuum is released to atmospheric pressure. heck that the clearance between brake pedal and dash lower panel gradually increases ( ) each time the brake pedal is depressed during this operation. R0037 F0043ZZ R-31

32 < -V RR > R STR epress the brake pedal with the engine running. Then stop the engine while holding down the brake pedal. heck that the brake pedal stroke does not change after holding down the brake pedal for 30 seconds or more. T: slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. This is a normal phenomenon due to the brake system operation. F0044ZZ USTT FTR STT erform the brake pedal adjustment after installing the brake pedal assembly. Refer to R-9, "nspection and djustment". R-32

33 < -V RR > VUU S xploded View VUU S F: R F0306ZZ 1. lamp 2. Vacuum hose (built in check valve) 3. Vacuum tube 4. Vacuum hose. To intake manifold. aint mark. Stamp indicating engine direction. To brake booster Removal and nstallation RV Remove the vacuum hose and tube. F: STT ote the following, install the vacuum hose and tube. ecause vacuum hose contains a check valve, it must be installed in the correct position. Refer to the stamp to confirm correct installation. rake booster will not operate normally if the hose is installed in the wrong direction. When installing vacuum hose, insert it until its tip reaches the back-end of length () or further as shown in the figure. Standard - Face the marking side up when assembling of vacuum hose. (rake booster and intake manifold side) - Face the marking side vehicle front when assembling of vacuum hose. (Vacuum tube side) ever use lubricating oil during assembly. nspection : 24 mm (0.95 in) or more F0023ZZ F: ST FTR RV ppearance heck for correct assembly, damage and deterioration. heck Valve irtightness R-33

34 < -V RR > Use a handy vacuum pump () to check. VUU S When connected to the brake booster side () : Vacuum should decrease within 1.3 ka (10 mm- g, 0.39 ing) for 15 seconds under a vacuum of 66.7 ka ( 500 mmg, ing). When connected to the engine side (): : Vacuum should not exist. Replace vacuum hose assembly if vacuum hose and check valve are malfunctioning. F0024ZZ R-34

35 < -V RR > FRT S R R R : xploded View FRT S R F: R 1. ylinder body 2. nner shim 3. nner pad (only R side with pad wear sensor) 4. ad retainer 5. Torque member 6. uter pad 7. uter shim 8. uter shim cover 1: pply (oly utyl uprysil) grease or silicone-based grease. 2: pply copper based brake grease. Refer to -4, "omponents" for symbols not described on the above. R : Removal and nstallation RV R-35 F: WR: lean any dust from the brake caliper and brake pads with a vacuum dust collector. ever blow with compressed air. ever depress the brake pedal while removing the brake pads because the piston may pop out. ever spill or splash brake fluid on the disc rotor. 1. Remove tires with power tool. 2. Remove lower sliding pin bolt. 3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the brake pads, shims and shim cover from the torque member. ever reuse the pad retainers when removed the pad retainers from the torque member. ever damage the piston boot. ever drop the brake pads, shims, and the shim cover. STT WR: lean any dust from the brake caliper and brake pads with a vacuum dust collector. ever blow with compressed air. ever depress the brake pedal while removing the brake pads or the cylinder body because the piston may pop out. F0495

36 < -V RR > FRT S R ever spill or splash brake fluid on the disc rotor. 1. nstall the pad retainer to the torque member if the pad retainers has been removed. ever reuse the pad retainers. Securely assemble the pad retainers so that it will not be lifted up from the torque member. ever deform the pad retainers. liminate double-faced adhesive tape on torque member. Remove adhesive's protective liner on pad retainers. 2. pply (oly utyl uprysil) grease or silicone-based grease to the mating faces between the brake pads and pad retainers. 3. pply copper based brake grease to the mating faces between the brake pads, shims and shim covers, and install them to the brake pad. lways replace the shims together with the shim covers when replacing the brake pad. 4. nstall the cylinder body and brake pads to the torque member. ever damage the piston boot. When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake fluid returns to master cylinder reservoir tank when pressing piston in. T: Use a disc brake piston tool to easily press piston. 5. nstall the lower sliding pin bolt and tighten it to the specified torque. 6. epress the brake pedal several times to check that no drag feel is present for the front disc brake. Refer to R-36, "R : nspection". R : nspection ST FTR RV Replace the shims and the shim cover if rust is excessively attached. ST FTR STT F: heck a drag of front disc brake. f any drag is found, follow the procedure described below. 2. Remove brake pads. 3. ress the piston. ever damage the piston boot. When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake fluid returns to master cylinder reservoir tank when pressing piston in. T: Use a disc brake piston tool to easily press piston. 4. nstall brake pads. 5. epress the brake pedal several times. 6. heck a drag of front disc brake again. f any drag is found, disassemble the cylinder body. Refer to R- 38, "R R SSY : isassembly and ssembly". 7. urnish contact surfaces after refinishing or replacing pads, or if a soft pedal occurs at very low mileage. Refer to R-16, "R : nspection and djustment". R R SSY R R SSY : xploded View F: RV R-36

37 < -V RR > FRT S R F0308 R 1. rake caliper assembly Refer to -4, "omponents" for symbols not described on the above. SSSY F ap 2. leeder valve 3. ylinder body 4. iston seal 5. iston 6. iston boot 7. Sliding pin 8. Sliding pin boot 9. ushing 10. Torque member 1: pply rubber grease. 2: pply polyglycol ether based lubricant. : pply brake fluid. Refer to -4, "omponents" for symbols not described on the above. R R SSY : Removal and nstallation F: RV WR: R-37

38 < -V RR > FRT S R lean any dust from the brake caliper and brake pads with a vacuum dust collector. ever blow with compressed air. ever depress the brake pedal. rake fluid may splash while removing the brake hose. 1. Remove tires with power tool. 2. Fix the disc rotor using wheel nuts. 3. rain brake fluid. Refer to R-12, "raining". ever spill or splash brake fluid on the disc rotor. 4. Remove union bolt and copper washers, and then disconnect brake hose from caliper assembly. Refer to R-22, "FRT : xploded View". 5. Remove torque member mounting bolts, and remove brake caliper assembly. ever drop brake pads and caliper assembly. 6. Remove disc rotor. ut matching marks on the wheel hub and bearing assembly and the disc rotor before removing the disc rotor. ever drop disc rotor. STT WR: lean any dust from the brake caliper and brake pads with a vacuum dust collector. ever blow with compressed air. ever depress the brake pedal. rake fluid may splash while removing the brake hose. 1. nstall disc rotor. lign the matching marks put during removal when reusing the disc rotor. 2. nstall the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the specified torque. ever spill or splash any grease and moisture on the brake caliper assembly mounting face, threads, mounting bolts and washers. Wipe out any grease and moisture. 3. nstall brake hose and copper washers to brake caliper assembly, and tighten union bolts to the specified torque. Refer to R-22, "FRT : xploded View". ever reuse copper washer. 4. Refill with new brake fluid and perform the air bleeding. Refer to R-13, "leeding rake System". ever reuse drained brake fluid. ever spill or splash brake fluid on the disc rotor. 5. heck a drag of front disc brake. f any drag is found, refer to R-40, "R R SSY : nspection". R R SSY : isassembly and ssembly F: SSSY T: ever remove the torque member and pad retainers when disassembling and assembling the cylinder body. 1. Remove the sliding pin bolts, and remove the cylinder body from the torque member. ever drop brake pads, shims, shim covers and pad retainers from torque member. 2. Remove brake pads, shims and shim cover. Refer to R-35, "R : xploded View". 3. Remove sliding pins and sliding pin boots from torque member. 4. Remove bushing from sliding pin. R-38

39 < -V RR > FRT S R 5. lace a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove piston and piston boot. ever get fingers caught in the piston. 6. Remove piston seal from cylinder body using suitable tool. e careful not to damage a cylinder inner wall. 7. Remove bleeder valve and cap R SSY 1. nstall bleeder valve and cap. 2. pply polyglycol ether based lubricant to piston seal (1), and install to cylinder body. ever reuse piston seal. F0038ZZ 3. pply rubber grease to piston boot (1). over the piston (2) end with piston boot, and then install cylinder side lip on piston boot securely into a groove on cylinder body. ever reuse piston boot. F0039ZZ F0040ZZ R-39