S ST SYST TTS SYT SS... 3 S, VT RSSS (V) TRUST... 3 V Troubleshooting hart...3 RUT... 4 RUTS... 4 recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR"...4 recaution for rocedure without owl Top over...4 recaution for rake System...4 RRT... 5 RRT... 5 Special Service Tool...5 ommercial Service Tool...5 S ST... 6 FRT S... 6...6 : nspection...6 : rake urnishing rocedure...6 S RTR...6 S RTR : nspection...6 RR S... 8...8 : nspection...8 S RTR...8 S RTR : nspection...8 STR... 9 nspection...9 STR YR...10 nspection...10 TU S...11 FRT...11 FRT : nspection...11 RR...11 RR : nspection...11 -V T...12...12 nspection and djustment...12 FU...14 nspection...14 raining...14 Refilling...14 leeding rake System...15 -V RR...16...16 xploded View...16 Removal and nstallation...16 TU S...17 FRT...17 FRT : xploded View...17 FRT : Removal and nstallation...17 RR...18 RR : xploded View...18 RR : Removal and nstallation...19 STR YR...21 xploded View...21 Removal and nstallation...21 STR...23 xploded View...23 Removal and installation...23-1
VUU S... 25 xploded View... 25 Removal and nstallation... 25 nspection fter Removal... 25 FRT S... 27... 27 : xploded View... 27 : Removal and nstallation... 27 R SSY... 29 R SSY : xploded View... 29 R SSY : Removal and nstallation... 29 RR S... 32... 32 : xploded View... 32 : Removal and nstallation... 32 R SSY... 33 R SSY : xploded View... 33 R SSY : Removal and nstallation... 34 SSSY SSY... 36 STR YR... 36 xploded View... 36 isassembly... 36 ssembly... 37 FRT S... 38 R SSY... 38 R SSY : xploded View... 38 R SSY : isassembly... 38 R SSY : ssembly... 39 R SSY : nspection fter isassembly... 40 RR S... 41 R SSY... 41 R SSY : xploded View... 41 R SSY : isassembly... 41 R SSY : ssembly... 42 R SSY : nspection fter isassembly... 43 SRV T SFTS (SS)... 44 SRV T SFTS (SS)... 44 eneral Specifications... 44 rake edal... 44 heck Valve... 44 rake ooster... 44 Front isc rake... 44 Rear isc rake... 45-2
S, VT RSSS (V) TRUST < SYT SS > SYT SS S, VT RSSS (V) TRUST V Troubleshooting hart F:0000000000992386 Use the chart below to help you find the cause of the symptom. f necessary, repair or replace these parts. Reference page -6, -8-6, -8-6, -8-6, -8-6, -8 RX-2, "V Troubleshooting hart" RSU-2, "V Troubleshooting hart" FX-2 Front axle RX-2 Rear axle WT-28, "V Troubleshooting hart" WT-28, "V Troubleshooting hart" FX-2, "V Troubleshooting hart" ST-3, "V Troubleshooting hart" ossible cause and SUST RTS Symptom : pplicable ads - damaged ads - uneven wear Shims damaged Rotor imbalance Rotor damage Rotor runout Rotor deformation oise Shake x Shimmy, Shudder x Rotor deflection Rotor rust Rotor thickness variation rum out of round W U SUSS X TRS R W RV SFT STR -3
< RUT > RUT RUTS RUTS recaution for Supplemental Restraint System (SRS) "R " and "ST T R-TSR" F:0000000000992387 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 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 SRS 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 rocedure without owl Top over When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. F:0000000000992388 recaution for rake System 3706 F:0000000000992389 lean dust on front brake and rear brake with a vacuum dust collector. o not blow with compressed air. Recommended fluid is brake fluid T 3. 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. Use clean brake fluid, to clean or wash all parts of master cylinder and disc brake caliper, etc. ever use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. Use flare nut torque wrench when installing brake tube. When installing brake tube and hose, be sure to check torque. efore working, turn ignition switch FF and disconnect connectors of S actuator and electric unit (control unit) or battery cable from the negative terminal. 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 -6, " : rake urnishing rocedure". WR: lean brake pads and shoes with a waste cloth, then wipe S686 with a dust collector. -4
< RRT > RRT RRT RRT Special Service Tool F:0000000000992390 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 ommercial Service Tool F0227 F:0000000000992391 Tool name escription 1. Flare nut crowfoot a:10 mm (0.39 in) / 12 mm (0.47 in) 2. Torque wrench nstalling each brake tube and hose T360 ower tool Removing front and rear caliper assembly, tires in punch Tip diameter: 4 mm (0.16in) dia. 0190 Removing and installing reservoir tank pin ZZ0515-5
< S ST > S ST FRT S : nspection FRT S F:0000000000992392 WR heck pad thickness from an inspection hole on cylinder body. heck using a scale if necessary. Standard thickness Repair limit thickness : 11.0 mm (0.433 in) : 2.0 mm (0.079 in) : rake urnishing rocedure 0010 F:0000000000992393 urnish contact surfaces between disc rotors and pads according to following procedure after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. e careful of vehicle speed because the brake does not operate easily until pad 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 VSU heck surface of disc rotor for uneven wear, cracks, and serious damage. Replace if there are. RUUT 1. Fix disc rotor to wheel hub using wheel nuts (2 or more positions). 2. nspect runout using a dial gauge. [easured at 10 mm (0.39 in) inside the disc edge.] Runout limit : 0.035 mm (0.0014 in) (with it attached to the vehicle) F:0000000000992394 T: efore measuring, make sure that wheel bearing axial end play is within the specification. Refer to FX-5, "nspection". 3. When runout exceeds limit value, displace mounting positions of disc rotor by one hole. nd then find a position of the minimum value for runout. 4. Replace or lathe disc rotor if runout is outside the specified value after performing the above operation. TSS 0580-6
< S ST > FRT S heck thickness of the disc rotor using a micrometer. Replace disc rotor if thickness is under the wear limit. Standard thickness Wear limit Thickness variation (easured at 8 positions) : 26.0 mm (1.024 in) : 24.0 mm (0.945 in) : 0.015 mm (0.0006 in) S020-7
< S ST > RR S : nspection RR S F:0000000000992395 WR heck pad thickness from an inspection hole on cylinder body. heck using a scale if necessary. Standard Standard thickness Repair limit thickness : 8.5 mm (0.335 in) : 1.0 mm (0.039 in) S RTR S RTR : nspection 0010 F:0000000000992396 VSU heck surface of disc rotor for uneven wear, cracks, and serious damage. Replace if there are. RUUT 1. Fix disc rotor to wheel hub using wheel nuts (2 or more positions). 2. nspect runout using dial gauge. [easured at 10 mm (0.39 in) inside disc edge.] Runout limit : 0.05 mm (0.002 in) (With it attached to the vehicle) T: efore measuring, make sure that wheel bearing axial end play is within the specification. Refer to FX-5, "nspection". 3. When runout exceeds limit value, displace mounting positions of disc rotor by one hole. nd then find a position of the minimum value for runout. 4. Replace disc rotor if it is outside repair limit after performing the above operation. TSS heck the thickness of the disc rotor using a micrometer. Replace disc rotor if the thickness is under the wear limit. 0697 Standard thickness Wear limit Thickness variation (easured at 8 positions) : 9.0 mm (0.354 in) : 8.0 mm (0.315 in) : 0.015 mm (0.0006 in) SF2284-8
< S ST > STR nspection STR F:0000000000992397 RT With engine stopped, change vacuum to atmospheric pressure by depressing brake pedal several times. Then with brake pedal fully depressed, start engine and when vacuum pressure reaches the standard, make sure that clearance between brake pedal and floor panel decreases. R TT Run engine at idle for approximately 1 minute, and stop it after applying vacuum to booster. epress brake pedal normally to change vacuum to atmospheric pressure. ake sure that distance at intervals of 5 seconds between brake pedal and floor panel gradually increases. epress brake pedal while engine is running, and stop engine with pedal depressed. The pedal stroke should not change after holding pedal down for 30 seconds. 0037 S365-9
< S ST > STR YR nspection STR YR F:0000000000992398 FU heck for leaking in a master cylinder installation surface, a reservoir tank installation surface, and brake tube connections. -10
< S ST > TU S FRT FRT : nspection TU S F:0000000000992399 ST FTR RV rake tubes and hoses are important safety parts. lways disassemble the parts and retighten their fittings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is detected. 1. heck brake lines (tubes and hoses) and connections for fluid leakage, damage, twists, deformation, contacts with other parts, and loose connections. Replace any damage parts. 2. While depressing brake pedal under a force of 785 (80 kg-f, 177 lb-f) with engine running for approximately 5 seconds, then check each part for fluid leakage. RR RR : nspection F:0000000000992400 ST FTR RV rake tubes and hoses are important safety parts. lways disassemble the parts and retighten their fittings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is detected. 1. heck brake lines (tubes and hoses) and connections for fluid leakage, damage, twists, deformation, contacts with other parts, and loose connections. Replace any damage parts. 2. While depressing brake pedal under a force of 785 (80 kg-f, 177 lb-f) with engine running for approximately 5 seconds, then check each part for fluid leakage. -11
< -V T > -V T nspection and djustment F:0000000000992401 ST edal lay and learance lay and clearance inspection between brake pedal and floor panel with pedal depressed. heck brake pedal play. heck brake pedal height from dash lower panel (1) using Tool. Tool number : (-46532) djust height referring to the following specifications. SF2743 1 2 rake pedal height (from dash lower panel top surface) rake pedal depressed height [under a force of 490 (50 kg-f, 110 lb-f) with engine running] USTT VT /T 189.7 203.7 mm (7.47 8.02 in) 180.3 194.3 mm (7.10 7.65 in) 130 mm (5.12 in) or more learance between bracket (3) and threaded end of the stop lamp switch and S switch (2) 0.74 1.96 mm (0.0291 0.0772 in) edal play 3 11 mm (0.12 0.43 in) -12
< -V T > 1. oosen stop lamp switch and S switch by turning it counterclockwise by 45. 2. oosen lock nut () on the input rod to rotate input rod for adjusting brake pedal height to the specified one, and tighten lock nut (). Refer to brake pedal height "nspection and djustment", specified torque -16, "xploded View". ake sure the threaded end of input rod stays inside clevis. 3. With the pedal pulled and held by hand, press stop lamp switch and S switch until its threaded end contacts stopper. 4. With the threaded end of the stop lamp switch and S switch contacting the bracket, rotate the switch clockwise by 45 to secure. ake sure that the clearance () between bracket and end of stop lamp switch and brake switch is within the standard. Refer to "nspection and djustment". 5. heck pedal play. ake sure that stop lamps goes off when pedal is released. 6. Start engine to check brake pedal depression height when depressed. Refer to "nspection and djustment". F0436-13
< -V T > FU nspection FU F:0000000000992402 FU V ake sure that a brake fluid level in reservoir tank is within the standard (between X and lines). Visually check around reservoir tank for fluid leakage. f the level is excessively low, check brake system for leakage. Release parking brake pedal and see if brake warning lamp goes off. f not, check brake system for fluid leakage. SF2484 f leakage occurs around joints, retighten or, if necessary, replace damaged parts. 1. heck brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. 2. heck for oil leakage by fully depressing brake pedal while engine is running. raining S389 F:0000000000992403 R 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. efore working, disconnect connectors of S actuator and electric unit (control unit) or battery cable from the negative terminal. 1. onnect a vinyl tube to bleed valve. 2. epress brake pedal, loosen bleed valve, and gradually remove brake fluid. Refilling 0007 F:0000000000992404 RF Refill with new brake fluid T 3. -14
< -V T > FU ever reuse drained brake fluid. efore working, disconnect connectors of S actuator and electric unit (control unit) or battery cable from the negative terminal. 1. ake sure there is no foreign material in the reservoir tank, and refill with new brake fluid. 2. oosen bleed valve, depress brake pedal slowly to full stroke and then release it. Repeat the procedure every 2 or 3 seconds until the new brake fluid comes out, then close the bleed valve while depressing the pedal. Repeat the same work for each wheel. 3. leed air. Refer to -15, "leeding rake System". leeding rake System F0403 F:0000000000992405 SYST While bleeding, pay attention to master cylinder fluid level. efore working, disconnect connectors of S actuator and electric unit (control unit) or battery cable from the negative terminal. 1. onnect a vinyl tube to rear right brake caliper bleed valve. 2. Fully depress brake pedal 4 or 5 times. 3. With brake pedal depressed, loosen bleed valve to bleed air in brake line, and then tighten it immediately. 4. Repeat steps 2 and 3 until all of the air is out of the brake line. 5. Tighten the bleed valve to the specified torque. Refer to front disc brake: -27, " : xploded View", rear disc brake: -32, " : xploded View". 6. From step 1 to 5, with master cylinder reservoir tank filled at least half way, bleed air from brake hydraulic line bleed valves in the following order: Rear right brake Front left brake Rear left brake Front right brake -15
< -V RR > -V RR xploded View F:0000000000992406 WF0001 1. levis pin 2. Snap pin 3. Stop lamp switch 4. S switch 5. lip 6. rake pedal assembly 7. rake pedal pad : ulti-purpose grease Refer to section for symbol marks except in the above. T: levis pin can be installed from both left and right. Removal and nstallation F:0000000000992407 RV 1. Remove instrument lower cover () and lower knee protector. Refer to -10, "xploded View". 2. Remove steering column assembly. Refer to ST-14, "Removal and nstallation". 3. isconnect stop lamp switch and S switch connector. 4. Remove stop lamp switch and S switch from brake pedal assembly. 5. isconnect brake pedal stroke sensor connector.(with pre-crash seat belt) rake pedal stroke sensor is not detachable. o not detach it. 6. Remove snap pin and clevis pin from clevis of brake booster. 7. Remove brake pedal assembly mounting nuts. ull brake booster toward engine room to the extent that does not deform brake tube. 8. Remove brake booster clevis from input rod. 9. Remove mounting bolt and then remove brake pedal assembly from vehicle. STT nstallation is the reverse order of removal. Tightening torques for brake pedal assembly mounting nuts and bolt are referred to -16, "xploded View". Tightening torque for lock nut is referred to -16, "xploded View". djust brake pedal height after installing brake pedal assembly to vehicle. Refer to -12, "nspection and djustment". o not reuse clevis pin. -16
< -V RR > TU S FRT FRT : xploded View TU S F:0000000000992408. With out S. With S 1. Front disc brake 2. aster cylinder 3. rake booster 4. Rear disc brake 5. S actuator and electric unit (control 6. onnector 7. rake hose unit) 8. rake tube : Flare nut :19.1 (1.9, 14) : Flare nut : 16.2 (1.7, 12) : Union bolt :18.2 (1.9, 13) : onnector mounting bolt : 7.0 (0.7, 62) Refer to section for symbol marks in the figure. FRT : Removal and nstallation WF0002ZZ F:0000000000992409-17
TU S < -V RR > RV 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. over the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. 1. rain brake fluid. Refer to -14, "raining". 2. isconnect brake hose from brake tube, using a flare nut wrench. 3. Remove union bolt and remove brake hose from caliper assembly. 4. Remove lock plate and remove brake hose from vehicle. STT ll brake hoses and tubes must be free from excessive bending, twisting and pulling. ake sure that there is no interference with other parts when turning steering both clockwise and counterclockwise. rake tubes and hoses are an important safety part. lways disassemble the parts and retighten their fittings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is detected. 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. Refill with new brake fluid T 3. ever reuse drained brake fluid. 1. ssemble the union bolt and copper washer to the brake hose. o not reuse copper washer. 2. nstall brake hose by aligning with the protrusion on brake caliper assembly, and tighten union bolt to the specified torque. Refer to -17, "FRT : xploded View". 3. onnect brake hose to brake tube, partially tighten flare nut by hand as much as possible, then secure it to the bracket with lock plate. 4. Using a flare nut torque wrench, tighten flare nut to the specified torque. Refer to -17, "FRT : xploded View". 5. Refill brake fluid and bleed air. Refer to -15, "leeding rake System". RR RR : xploded View SF2964 F:0000000000992410-18
< -V RR > TU S WF0002ZZ. With out S. With S 1. Front disc brake 2. aster cylinder 3. rake booster 4. Rear disc brake 5. S actuator and electric unit (control 6. onnector 7. rake hose unit) 8. rake tube : Flare nut :19.1 (1.9, 14) : Flare nut : 16.2 (1.7, 12) : Union bolt :18.2 (1.9, 13) : onnector mounting bolt : 7.0 (0.7, 62) Refer to section for symbol marks in the figure. RR : Removal and nstallation F:0000000000992411 RV 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. over the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. -19
< -V RR > TU S 1. rain brake fluid. Refer to -14, "raining". 2. isconnect brake hose from brake tube, using a flare nut wrench. 3. Remove union bolts, and then remove brake hose from brake caliper assembly. 4. Remove lock plate and then remove brake hose from vehicle. SF2049 STT ll brake hoses and tubes must be free from excessive bending, twisting and pulling. ake sure that there is no interference with other parts when turning steering both clockwise and counterclockwise. rake tubes and hoses are an important safety part. lways disassemble the parts and retighten their fittings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is detected. 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. Refill with new brake fluid T 3. ever reuse drained brake fluid. 1. ssemble the union bolt and copper washer to the brake hose. o not reuse copper washer. 2. ttach -shape metal fitting of the brake hose to brake caliper assembly positioning hole, and then tighten union bolt to the specified torque. Refer to -17, "FRT : xploded View". 3. onnect brake hose to brake tube, partially tighten flare nut by hand as much as possible, then secure it to the bracket with lock plate. 4. Using a flare nut torque wrench, tighten flare nut to the specified torque. Refer to -17, "FRT : xploded View". 5. Refill brake fluid and bleed air. Refer to -15, "leeding rake System". -20
< -V RR > STR YR xploded View STR YR F:0000000000992412 WF0003ZZ 1. Reservoir cap 2. il strainer 3. Reservoir tank 4. rommet 5. in 6. aster cylinder assembly 7. -ring 8. rake fluid level switch connector : (oly utyl uprysil) grease or silicone-based grease : rake fluid Refer to section for symbol marks except in the above. Removal and nstallation F:0000000000992413 RV 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. ever scratch the piston of master cylinder when installing/removing because the piston is exposed. heck if any dust is not on the piston, and wash with brake fluid if needed. old cylinder body when handing master cylinder. ever hold the piston because the piston might be detached if pulled strongly. 1. rain brake fluid. Refer to -14, "raining". 2. isconnect brake fluid level switch harness connector. 3. isconnect master cylinder brake tubes, using a flare nut wrench. 4. Remove master cylinder mounting nuts and remove master cylinder assembly from vehicle. STT 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. ever scratch the piston of master cylinder when installing/removing because the piston is exposed. heck if any dust is not on the piston, and wash with brake fluid if needed. old cylinder body when handing master cylinder. ever hold the piston because the piston might be detached if pulled strongly. Refill with new brake fluid T 3. ever reuse drained brake fluid. -21
< -V RR > STR YR 1. nstallation is in the reverse order of removal. pply silicone grease to brake booster (to position as shown) when installing master cylinder to brake booster. 2. Tighten brake tube flare nut to the specified torque using a flare nut torque wrench. Refer to -17, "FRT : xploded View". 3. Refill with new brake fluid and bleed air. Refer to -15, "leeding rake System". SF2847-22
< -V RR > STR xploded View STR F:0000000000992414 SF2956 1. aster cylinder assembly 2. rake booster 3. ock nut 4. rake pedal 5. asket Refer to section for symbol marks in the figure. Removal and installation F:0000000000992415 RV e careful not to deform or bend brake tube while removing and installing brake booster. 1. Remove cowl top. Refer to XT-17, "Removal and nstallation". 2. isconnect fuel lines. 3. Remove brake master cylinder. Refer to -21, "Removal and nstallation". 4. Remove vacuum hose from brake booster. Refer to -23, "xploded View". 5. Remove snap pin and clevis pin from inside vehicle. 6. Remove nuts on brake booster and brake pedal assembly, then remove brake pedal. 7. Remove brake booster from dash panel in engine room side. SF2044 STT e careful not to deform or bend brake tube while removing and installing brake booster. Replace clevis pin if it is damaged. e careful not to damage brake booster stud bolt threads. f brake booster is tilted during installation, the dash panel may damage the threads. -23
< -V RR > STR 1. oosen lock nut to adjust input rod length so that length (in the figure) satisfies the specified value. ength "" : 125 mm (4.92 in) 2. fter adjusting "", temporarily tighten lock nut to install booster assembly to vehicle. t this time, make sure that a gasket between booster assembly and dash panel is installed. lways install gasket between brake booster and dash panel. S0060 3. nstall and connect brake pedal with clevis of input rod. 4. nstall brake pedal bracket mounting nuts and tighten them to the specified torque. Refer to -16, "xploded View". 5. nstall vacuum hose into brake booster. Refer to -23, "xploded View". 6. nstall master cylinder to booster assembly. Refer to -21, "Removal and nstallation". 7. djust the brake pedal height and the play of the brake pedal. Refer to -12, "nspection and djustment". 8. Tighten lock nut of input rod to the specified torque. Refer to "TS". 9. onnect fuel lines. 10. nstall cowl top. Refer to XT-17, "Removal and nstallation". 11. Refill new brake fluid and bleed air. Refer to -15, "leeding rake System". -24
< -V RR > VUU S xploded View VUU S F:0000000000992416 WF0421 1. lamp 2. heck valve direction stamp 3. Vacuum hose 4. Vacuum piping. To brake booster Front Removal and nstallation RV Removal STT 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. nsert vacuum hose at least 24 mm (0.94 in). o not use lubricating oil during assembly. F:0000000000992417 nspection fter Removal VSU Visual heck for correct assembly, damage and deterioration. S225 F:0000000000992418-25
< -V RR > heck Valve irtightness Use a handy vacuum pump to check. VUU S When connected to the booster side (1): 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, 19.69 ing). When connected to the engine side (2): Vacuum should not exist. Replace vacuum hose assembly if vacuum hose and check valve are malfunctioning. SF0210-26
< -V RR > FRT S : xploded View FRT S F:0000000000992419 WF0007 1. Union bolt 2. opper washer 3. rake hose 4. ap 5. leed valve 6. Sliding pin bolt 7. iston seal 8. iston 9. iston boot 10. ylinder body 11. Sliding pin 12. Torque member mounting bolt 13. Washer 14. Sliding pin boot 15. ushing 16. Torque member 17. nner multilayered shim 18. nner pad 19. ad retainer 20. ad wear sensor 21. uter pad 22. uter shim 23. uter shim cover 1: olykote -77 grease 2: Rubber grease : rake fluid Refer to section for sysmbol marks except in the above. : Removal and nstallation F:0000000000992420 RV WR: lean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials. While removing cylinder body, do not depress brake pedal because piston will pop out. -27
< -V RR > FRT S t is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. n this case, hang cylinder body with a wire so as not to stretch brake hose. o not damage piston boot. f any shim is subject to serious corrosion, replace it with a new one. lways replace shim and shim cover as a set when replacing brake pads. eep rotor free from brake fluid. urnish the brake pads and disc rotor mutually contacting surfaces, after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to -6, " : rake urnishing rocedure". 1. Remove front tires from vehicle using power tool. 2. Remove lower sliding pin bolt. 3. ang cylinder body with a wire, and remove pads, pad retainers, shims, and shim cover from torque member. When removing the pad retainer from the torque member, lift it in the direction indicated by the arrow as shown so that it does not deform. STT WR: lean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials. While removing cylinder body, do not depress brake pedal because piston will pop out. t is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. n this case, hang cylinder body with a wire so as not to stretch brake hose. o not damage piston boot. f any shim is subject to serious corrosion, replace it with a new one. lways replace shim and shim cover as a set when replacing brake pads. eep rotor free from brake fluid. urnish the brake pads and disc rotor mutually contacting surfaces, after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to -6, " : rake urnishing rocedure". 1. pply olykote -77 grease or equivalent to between shim cover and shim. nstall outer shim, outer shim cover to inner pad, and inner multilayered shim to outer pad. 2. pply olykote -77 grease or equivalent to between pad retainer and pad. nstall pad retainers and pads to torque member. Securely assemble pad retainers so that they are not being lifted up from torque member. oth inner and outer pads have a pad return system on the pad retainer. nstall pad return lever securely to pad wear sensor. S556 S557 3. nstall cylinder body to torque member. n the case of 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 (commercial service tool) to easily press piston. -28
< -V RR > FRT S 4. nstall lower sliding pin bolt, and tighten it to the specified torque. Refer to -27, " : xploded View". 5. heck front disc brake for drag. 6. nstall front tires. R SSY R SSY : xploded View F:0000000000992421 WF0007 1. Union bolt 2. opper washer 3. rake hose 4. ap 5. leed valve 6. Sliding pin bolt 7. iston seal 8. iston 9. iston boot 10. ylinder body 11. Sliding pin 12. Torque member mounting bolt 13. Washer 14. Sliding pin boot 15. ushing 16. Torque member 17. nner multilayered shim 18. nner pad 19. ad retainer 20. ad wear sensor 21. uter pad 22. uter shim 23. uter shim cover 1: olykote -77 grease 2: Rubber grease : rake fluid Refer to section for sysmbol marks except in the above. R SSY : Removal and nstallation F:0000000000992422 RV WR: lean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials. -29
< -V RR > FRT S While removing cylinder body, do not depress brake pedal because piston will pop out. o not damage piston boot. eep rotor free from brake fluid. 1. Remove front tires using power tool. 2. Fasten disc rotor using wheel nut. 3. rain brake fluid. Refer to -14, "raining". 4. Remove union bolt, and then disconnect brake hose from caliper assembly. 5. Remove torque member mounting bolts, and remove brake caliper assembly. o not drop brake pad. SF2437 6. Remove disc rotor. ut matching marks on wheel hub assembly and disc rotor, if it is necessary to remove disc rotor. S2608 STT WR: lean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials. While removing cylinder body, do not depress brake pedal because piston will pop out. o not damage piston boot. eep rotor free from brake fluid. Refill with new brake fluid T 3. ever reuse drained brake fluid. 1. nstall disc rotor. ut alignment marks on disc rotor and wheel hub at the time of removal when reusing disc rotor. 2. nstall brake caliper assembly to vehicle, and tighten torque member mounting bolts to the specified torque. Refer to -29, " R SSY : xploded View". o not allow oil or any moisture on all contact surfaces between steering knuckle and caliper assembly, bolts, and washer. -30
< -V RR > FRT S 3. nstall brake hose to brake caliper assembly, and tighten union bolts to the specified torque. Refer to -17, "FRT : Removal and nstallation". 4. Refill with new brake fluid and bleed air. Refer to -15, "leeding rake System". 5. heck front disc brake for drag. 6. nstall front tires. SF2431-31
< -V RR > RR S : xploded View RR S F:0000000000992423 WF0006 1. Union bolt 2. rake hose 3. opper washer 4. ap 5. leed valve 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 multilayered shim 18. Sliding pin boot 19. ushing 20. Torque member mounting bolt 21. Washer 22. Torque member 23. ad wear sensor 24. nner pad (R) 1: (oly utyl uprysil) grease or silicone-based grease 2: Rubber grease : rake fluid Refer to section for symbol marks except in the above. : Removal and nstallation F:0000000000992424 RV WR: lean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials. While removing cylinder body, do not depress brake pedal because piston will pop out. t is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. n this case, hang cylinder body with a wire so as not to stretch brake hose. o not damage piston boot. f any shim is subject to serious corrosion, replace it with a new one. lways replace shim and shim covers as a set when replacing brake pads. -32
RR S < -V RR > eep rotor free from brake fluid. urnish the brake pads and disc rotor mutually contacting surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to -6, " : rake urnishing rocedure". 1. Remove rear tires using power tool. 2. Remove upper sliding pin bolt. 3. Remove pads, pad retainers, shims, and shim cover from torque member. eform pad retainer when removing pad retainer from torque member. STT WR: lean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials. While removing cylinder body, do not depress brake pedal because piston will pop out. t is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. n this case, hang cylinder body with a wire so as not to stretch brake hose. o not damage piston boot. f any shim is subject to serious corrosion, replace it with a new one. lways replace shim and shim covers as a set when replacing brake pads. eep rotor free from brake fluid. urnish the brake pads and disc rotor mutually contacting surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to -6, " : rake urnishing rocedure". 1. pply olykote -77 grease or equivalent to between shim cover and shim. nstall inner shim, inner shim cover to inner pad, and outer multilayered shim to outer pad. 2. pply olykote -77 grease or equivalent to between pad retainer and pad. nstall pad retainers and pads to torque member. 3. ress in piston until pads can be installed, and then install cylinder body to torque member. n the case of 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 (commercial service tool) to easily F0273 press piston. 4. nstall upper sliding pin bolt and tighten to the specified torque. Refer to -32, " : xploded View". 5. heck rear disc brake for drag. 6. nstall rear tires. R SSY R SSY : xploded View F:0000000000992425-33
< -V RR > RR S WF0006 1. Union bolt 2. rake hose 3. opper washer 4. ap 5. leed valve 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 multilayered shim 18. Sliding pin boot 19. ushing 20. Torque member mounting bolt 21. Washer 22. Torque member 23. ad wear sensor 24. nner pad (R) 1: (oly utyl uprysil) grease or silicone-based grease 2: Rubber grease : rake fluid Refer to section for symbol marks except in the above. R SSY : Removal and nstallation F:0000000000992426 RV WR: lean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials. While removing cylinder body, do not depress brake pedal because piston will pop out. o not damage piston boot. eep rotor free from brake fluid. 1. Remove rear tires using power tool. 2. Fasten disc rotor using wheel nut. 3. rain brake fluid. Refer to -14, "raining". -34
< -V RR > RR S 4. Remove union bolt and then disconnect brake hose from caliper assembly. 5. Remove torque member mounting, bolts, and remove brake caliper assembly. o not drop brake pad. 6. Remove disc rotor. ut matching marks on wheel hub assembly and disc rotor, if it necessary to remove disc rotor. SF2972 S2638 STT WR: lean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials. While removing cylinder body, do not depress brake pedal because piston will pop out. o not damage piston boot. eep rotor free from brake fluid. Refill with new brake fluid T 3. ever reuse drained brake fluid. 1. nstall disc rotor. lignment marks of disc rotor and wheel hub put at the time of removal when reusing disc rotor. 2. nstall brake caliper assembly vehicle, and tighten torque member mounting bolts to the specified torque. efore installing caliper assembly, wipe off oil and moisture on all mounting surfaces of rear axle and caliper assembly and threads, bolts and washers. 3. nstall -shaped pin of brake hose and then tighten union bolt to the specified torque. Refer to -19, "RR : Removal and nstallation". 4. Refill with new brake fluid and bleed air. Refer to -15, "leeding rake System". 5. heck rear disc brake for drag. 6. nstall rear tires. SF2049-35
STR YR < SSSY SSY > SSSY SSY STR YR xploded View F:0000000000992427 WF0003ZZ 1. Reservoir cap 2. il strainer 3. Reservoir tank 4. rommet 5. in 6. aster cylinder assembly 7. -ring 8. rake fluid level switch connector : (oly utyl uprysil) grease or silicone-based grease : rake fluid Refer to section for symbol marks except in the above. isassembly SSSY While working, cover primary piston rod with cloth to prevent it from being damaged. 1. Secure flange of cylinder body in vise as shown. Using copper plate or cloth to cover flange for securing vise. When securing master cylinder assembly in a vise, be sure not to over tighten. F:0000000000992428 0558-36
< SSSY SSY > STR YR 2. Using a pin-punch [commercial service tool: diameter approx. 4 mm (0.16 in)], remove pin from reservoir tank. 3. Remove master cylinder assembly from vise. 4. Remove reservoir tank and grommet from cylinder body. ssembly ssembly is in the reverse order of disassembly. 0559 F:0000000000992429-37
FRT S < SSSY SSY > FRT S R SSY R SSY : xploded View F:0000000000992430 WF0007 1. Union bolt 2. opper washer 3. rake hose 4. ap 5. leed valve 6. Sliding pin bolt 7. iston seal 8. iston 9. iston boot 10. ylinder body 11. Sliding pin 12. Torque member mounting bolt 13. Washer 14. Sliding pin boot 15. ushing 16. Torque member 17. nner multilayered shim 18. nner pad 19. ad retainer 20. ad wear sensor 21. uter pad 22. uter shim 23. uter shim cover 1: olykote -77 grease 2: Rubber grease : rake fluid Refer to section for sysmbol marks except in the above. R SSY : isassembly F:0000000000992431 SSSY T: o not remove torque member, pads, shims, shim covers, and pad retainers when disassembling and assembling cylinder body assembly. 1. Remove sliding pin bolt, and then remove cylinder body from torque member. o not drop pads, shims, shim cover and pad retainers from torque member. -38
< SSSY SSY > FRT S 2. Remove sliding pins and sliding pin boots from torque member. 3. lace a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove piston and piston boot. o not get fingers caught in the pistons. 0041 4. Remove piston seal from cylinder body using a flat-bladed screwdriver. e careful not to damage a cylinder inner wall. R SSY : ssembly SSY ever use issan Rubber rease (R00 00010, R00 00010 01) during assembly. 1. pply rubber lubricant to piston seal, and install into cylinder body. o not reuse piston seal. SF2277 F:0000000000992432 2. pply rubber lubricant to piston boot. over the piston end with piston boot, and then install cylinder side lip on piston boot securely into a groove on cylinder body. o not reuse piston boot. SF2278 SF2498-39
FRT S < SSSY SSY > 3. pply brake fluid to piston. ush piston into cylinder body by hand and push piston boot piston-side lip into the piston groove. ress the piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed. 4. nstall sliding pins and sliding pin boots to torque member. SF2279 5. nstall torque member to steering knuckle, and tighten mounting bolts to the specified torque. Refer to - 29, " R SSY : xploded View". o not allow oil or any moisture on all contact surfaces between steering knuckle and brake caliper assembly. 6. ress in piston until pads can be installed, and then install cylinder body to torque member. 7. Tighten sliding pin bolts to the specified torque. Refer to -29, " R SSY : xploded View". R SSY : nspection fter isassembly ST FTR SSSY F:0000000000992433 ylinder ody heck the inner wall of cylinder for corrosion, wear, and damage. f a malfunction is detected, replace cylinder body. lean cylinder body using new brake fluid. ever use mineral oils such as gasoline or kerosene. Torque ember heck torque member for wear, cracks, and damage. Replace if necessary. iston heck the piston surface for corrosion, wear, and damage. f a malfunction is detected, replace applicable part. piston sliding surface is plated. o not polish with sandpaper. Sliding in, Sliding in olt, and Sliding in oot heck sliding pin, sliding pin bolt, and sliding pin boot for wear, damage, and cracks. Replace if there are. -40
< SSSY SSY > RR S R SSY RR S R SSY : xploded View F:0000000000992434 1. Union bolt 2. rake hose 3. opper washer 4. ap 5. leed valve 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 multilayered shim 18. Sliding pin boot 19. ushing 20. Torque member mounting bolt 21. Washer 22. Torque member 23. ad wear sensor 24. nner pad (R) 1: (oly utyl uprysil) grease or silicone-based grease 2: Rubber grease : rake fluid Refer to section for symbol marks except in the above. R SSY : isassembly WF0006 F:0000000000992435 SSSY T: o not remove torque member, pads, shims, shim covers, and pad retainers when disassembling and assembling cylinder body assembly. 1. Remove sliding pin bolt, and then remove cylinder body from torque member. o not drop pads, shims, shim cover and pad retainers from torque member. 2. Remove sliding pin boot from torque member. -41
< SSSY SSY > RR S 3. Remove retaining ring from cylinder body using a flat-bladed screwdriver as shown. S028 4. lace a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove piston and piston boot. o not get fingers caught in the piston. 0041 5. Remove piston seal from cylinder body using a flat-bladed screwdriver. e careful not to damage a cylinder inner wall. SF2277 R SSY : ssembly F:0000000000992436 SSY ever use issan Rubber rease (R00 00010, R00 00010 01) during assembly. 1. pply rubber lubricant to piston seal, and install them to cylinder body. o not reuse piston seal. SF2278-42
< SSSY SSY > RR S 2. pply rubber lubricant to piston boot. over the piston end with the piston boot, and then install cylinder side lip on the piston boot securely into the groove on cylinder body. o not reuse piston boot. 3. pply brake fluid to piston. ush piston into cylinder body by hand and push piston boot piston side lip into the piston groove. ress the piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed. SF2498 SF2279 4. Secure piston boot with retaining ring. ake sure that boot is securely engaged in the groove on cylinder body. o not reuse retainer ring. 5. nstall sliding pin boot to torque member. 6. nstall the cylinder body to torque member, and then tighten sliding pin bolt to the specified torque. Refer to -33, " R SSY : xploded View". R SSY : nspection fter isassembly ST FTR SSSY SF2280 F:0000000000992437 ylinder ody heck the inner wall of cylinder for corrosion, wear, and damage. f a malfunction is detected, replace cylinder body. lean cylinder body using new brake fluid. ever use mineral oils such as gasoline or kerosene. Torque ember heck torque member for wear, cracks, and damage. Replace as necessary. iston heck the piston surface for corrosion, wear, and damage. f a malfunction is detected, replace applicable part. piston sliding surface is plated. o not polish with sandpaper. Sliding in olt, Sliding in oot heck sliding pin bolt and sliding pin boot for wear, damage, and cracks. Replace as necessary. -43
SRV T SFTS (SS) < SRV T SFTS (SS) SRV T SFTS (SS) SRV T SFTS (SS) eneral Specifications F:0000000000992438 Unit: mm (in) rake model (tbd) Front brake ylinder bore diameter 57.2 (2.25) ad length width thickness 132 50 11 (5.20 1.969 0.433) Rotor outer diameter thickness 296 26 (11.65 1.024) rake model (tbd) Rear brake ylinder bore diameter 34.93 (1.375) ad length width thickness 83.0 31.9 8.5 (3.268 1.256 0.335) Rotor outer diameter thickness 292 9 (11.50 0.35) aster cylinder ylinder bore diameter 25.4 (1) ontrol valve Valve model lectric brake force distribution rake booster ooster model (tbd) iaphragm diameter 280 (11) Recommended brake fluid T 3 rake edal F:0000000000992439 rake pedal height (from dash lower panel top surface) VT /T 189.7-203.7 mm (7.47-8.02 in) 180.3-194.3 mm (7.10-7.65 in) epressed pedal height [under a force of 490 (50 kg-f, 110 lb-f) with engine running] learance between stopper rubber and threaded end of the stop lamp switch and brake switch 90 mm (3.54 in) or more 0.74-1.96 mm (0.0291-0.0772 in) edal play heck Valve 3-11 mm (0.12-0.43 in) F:0000000000992440 Vacuum leakage [at vacuum of 66.7 ka ( 500 mmg, 19.69 ing)] rake ooster Within 1.3 ka (10 mmg, 0.39 ing) of vacuum for 15 seconds F:0000000000992441 Vacuum type nput rod installation standard dimension Front isc rake 125 mm (4.92 in) F:0000000000992442 rake model (tbd) rake pad isc rotor Standard thickness (new) Repair limit thickness Standard thickness (new) Repair limit thickness Thickness variation (measured at 8 positions) aximum runout (with it attached to the vehicle) 11.0 mm (0.433 in) 2.0 mm (0.079 in) 26.0 mm (1.024 in) 24.0 mm (0.945 in) 0.015 mm (0.0006 in) 0.035 mm (0.0014 in) -44
SRV T SFTS (SS) < SRV T SFTS (SS) Rear isc rake F:0000000000992443 rake model rake pad Standard thickness (new) Repair limit thickness (tbd) 8.5 mm (0.335 in) 1.0 mm (0.039 in) isc rotor Standard thickness (new) Repair limit thickness Thickness variation (measured at 8 positions) 9.0 mm (0.354in) 8.0 mm (0.315 in) 0.015 mm (0.0006 in) aximum runout (with it attached to the vehicle) 0.05 mm (0.002 in) -45