null  null
35A-1
GROUP 35A
SERVICE BRAKES
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .
35A-2
BASIC BRAKE SYSTEM DIAGNOSIS
35A-4
INTRODUCTION TO BASIC BRAKE SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . .
35A-4
BASIC BRAKE SYSTEM DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . . . .
35A-4
SYMPTOM CHART. . . . . . . . . . . . . . . . . . .
35A-4
SYMPTOM PROCEDURES . . . . . . . . . . . .
35A-4
SPECIAL TOOLS. . . . . . . . . . . . . . . .
35A-13
ON-VEHICLE SERVICE. . . . . . . . . . . 35A-13
BRAKE PEDAL CHECK AND ADJUSTMENT 35A-13
BRAKE BOOSTER OPERATING TEST . . .
35A-15
CHECK VALVE OPERATION CHECK . . . .
35A-16
PROPORTIONING VALVE FUNCTION TEST
<VEHICLES WITHOUT ABS> . . . . . . . . . .
35A-16
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . .
35A-17
BRAKE FLUID LEVEL SENSOR CHECK. .
35A-18
FRONT DISC BRAKE PAD CHECK AND
REPLACEMENT . . . . . . . . . . . . . . . . . . . . .
35A-19
DISC BRAKE ROTOR CHECK. . . . . . . . . .
35A-21
BRAKE DISC THICKNESS CHECK . . . . . .
35A-21
BRAKE DISC RUN-OUT CHECK AND
CORRECTION . . . . . . . . . . . . . . . . . . . . . .
35A-22
MASTER CYLINDER FUNCTION CHECK.
35A-24
BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A-24
REMOVAL AND INSTALLATION . . . . . . . .
35A-24
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A-25
MASTER CYLINDER ASSEMBLY AND
BRAKE BOOSTER . . . . . . . . . . . . . . . 35A-26
REMOVAL AND INSTALLATION . . . . . . . .
35A-26
MASTER CYLINDER . . . . . . . . . . . . . . . . .
35A-28
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A-29
FRONT DISC BRAKE ASSEMBLY . . 35A-29
REMOVAL AND INSTALLATION . . . . . . . .
35A-29
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A-30
DISASSEMBLY AND ASSEMBLY . . . . . . .
35A-31
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A-32
REAR DISC BRAKE ASSEMBLY . . . 35A-33
REMOVAL AND INSTALLATION . . . . . . . .
35A-33
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A-34
DISASSEMBLY AND ASSEMBLY . . . . . . .
35A-35
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .
35A-36
SPECIFICATIONS . . . . . . . . . . . . . . . 35A-37
FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .
35A-37
GENERAL SPECIFICATIONS . . . . . . . . . .
35A-38
SERVICE SPECIFICATIONS . . . . . . . . . . .
35A-39
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . .
35A-39
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . .
35A-39
35A-2
SERVICE BRAKES
GENERAL DESCRIPTION
GENERAL DESCRIPTION
Top components such as Brembo™ brakes, EBD and
sports ABS improve braking power and braking stability.
IMPROVED STABILITY
1. Sports ABS (4-wheel anti-lock braking system) is
used to prevent slipping caused by the vehicle
wheels locking up in order to maintain an appropriate braking distance, and also to maintain a
stable vehicle posture and steering performance.
2. Adoption of an electronic brake-force distribution
(EBD) makes it possible to maintain the maximum amount of braking force even when the
vehicle's load is unevenly distributed. <Vehicles
with ABS>
3. Front- and rear-wheel X-type brake line layout is
used.
4. Ventilated discs improve anti-fading performance.
CAUTION
Take care not to contact the parts or tools to the
caliper because the paint of caliper will be
scratched.
FEATURES
.
IMPROVED BRAKING PERFORMANCE
1. A 8+9-inch tandem vacuum booster is utilized to
provide high braking force with a small pedal
depression force.
2. Brembo™ 17-inch 4-pot front ventilated disc
brakes and Brembo™ 16-inch 2-pot rear ventilated disc brakes provide stable braking force and
improved braking feel.
.
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M1351000100622
.
IMPROVED SERVICEABILITY
1. A diagnosis function for the ABS system makes
inspection easier.
2. An outer disc method separated hub and rotor
makes removal and installation easier.
3. The master cylinder reservoir tank cap is colored
white to make identification easier.
4. The ABS-ECU and hydraulic unit are integrated
to make them more compact and lightweight.
35A-3
SERVICE BRAKES
GENERAL DESCRIPTION
CONSTRUCTION DIAGRAM
<VEHICLE WITH ABS>
BRAKE BOOSTER
ASSEMBLY
BRAKE MODULATOR
HYDRAULIC UNIT
(INTEGRATED WITH
THE ABS-ECU)
10064AU
PARKING BRAKE
LEVER ASSEMBLY
BRAKE MASTER
CYLINDER ASSEMBLY
REAR DISC BRAKE
FRONT DISC BRAKE
AC211387AC
<VEHICLE WITHOUT ABS>
BRAKE BOOSTER
ASSEMBLY
PARKING BRAKE
LEVER ASSEMBLY
BRAKE MASTER CYLINDER AND
PROPORTIONING VALVES
REAR DISC BRAKE
FRONT DISC BRAKE
AC309895 AB
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35A-4
SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM DIAGNOSIS
INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS
M1351009700267
Hydraulic brakes are composed of the brake pedal,
master cylinder, brake booster and disc brakes. Malfunctions such as insufficient braking power or the
generation of noise may occur due to wear, damage
or incorrect adjustment of these components.
BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
basic brake system fault.
1. Gather information from the customer.
M1351009800264
2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the symptom
chart.
4. Verify malfunction is eliminated.
SYMPTOM CHART
M1351009900272
SYMPTOMS
INSPECTION
PROCEDURE
REFERENCE
PAGE
Vehicle pulls to one side when brakes are applied
1
P.35A-4
Insufficient braking power
2
P.35A-5
Increased pedal stroke (Reduced pedal-to-floor board clearance)
3
P.35A-6
Brake drag
4
P.35A-7
Scraping or grinding noise when brake are applied
5
P.35A-8
Squealing, groaning or chattering noise when brake are applied
6
P.35A-9
Squealing noise when brakes are not applied
7
P.35A-10
Groaning, clicking or rattling noise when brakes are not applied
8
P.35A-12
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied
DIAGNOSIS
STEP 1. Check for oil, water, etc., on the pad
contact surface of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES : Replace the part. Determine and repair the
source/cause of foreign material. Then go to
Step 5.
NO : Go to Step 2.
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SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
STEP 2. Check disc brake pistons for smooth
operation.
(1) With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum
reserves.
(2) Test each disc brake assembly one at a time.
a. Remove the lower caliper bolt, then remove
caliper from mount.
b. Have an assistant slowly depress the brake
pedal. Confirm piston(s) extend slowly and
smoothly with no jumpiness. Repeat for each
disc brake assembly.
Q: Do (does) the piston(s) move correctly?
YES : Go to Step 3.
NO : Disassemble and inspect the brake
assembly (Front: refer to P.35A-31, Rear:
refer to P.35A-35). Then go to Step 5.
35A-5
STEP 3. Check brake disc(s) for run out.
Refer to P.35A-22.
Q: Is runout outside of specifications?
YES : Repair or replace the brake disc(s) as
necessary. Then go to Step 5.
NO : Go to Step 4.
STEP 4. Check brake discs for correct thickness.
Refer to P.35A-21.
Q: Is the thickness outside of specifications?
YES : Repair or replace the brake disc(s) as
necessary. Then go to Step 5.
NO : Carry out the brake line bleeding. Then go
to Step 5.
STEP 5. Retest the system.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at Step 1. If a new symptom
appears, refer to the appropriate symptom
chart.
INSPECTION PROCEDURE 2: Insufficient Braking Power
DIAGNOSIS
STEP 3. Check the brake booster function.
Refer to P.35A-15.
STEP 1. Check that the specified brake fluid is
used, its level is correct, and no contamination is
found.
Q: Is there fault?
YES : Refill or replace with the specified brake
fluid DOT 3 or DOT 4. Bleed the brakes if
necessary (Refer to P.35A-17). Then go to
Step 7.
NO : Go to Step 2.
STEP 2. Check for spongy (not firm brakes).
(1) With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum
reserve.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops.
(3) With a measuring stick (ruler, etc.) next to the
brake pedal, depress the pedal firmly and
measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES : Bleed the brakes to remove air in the fluid
(Refer to P.35A-17). Then go to Step 7.
NO : Go to Step 3.
TSB Revision
Q: Is there fault?
YES : Replace the brake booster. Then go to Step
7.
NO : Go to Step 4.
STEP 4. Check for pinched or restricted brake
tube or hose.
Q: Is there a pinched or restricted brake tube or hose?
YES : Replace that complete section of brake tube
or brake hose. Then go to Step 7.
NO : Go to Step 5.
STEP 5. Check for oil, water, etc., on the pad
contact surfaces of all brakes.
Q: Is oil, water, etc., on the pad contact surface?
YES : Replace the part. Determine and repair the
source/cause of foreign material. Recheck
symptom. Then go to Step 7.
NO <Vehicle without ABS> : Go to Step 6.
NO <Vehicle with ABS> : The procedure is
complete.
35A-6
SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
STEP 6. Check the proportioning valve operation.
Refer to P.35A-16.
Q: Is there fault?
YES : Replace the part. Then go to Step 7.
NO : Go to Step 7.
STEP 7. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom
surfaces, refer to the appropriate symptom
chart.
INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance)
DIAGNOSIS
STEP 4. Check the master cylinder function.
Refer to P.35A-24.
STEP 1. Check for spongy (not firm brakes).
(1) With engine not running, depress the brake pedal
rapidly several times to deplete booster vacuum
reserve.
(2) With the brake pedal fully released, depress the
brake pedal slowly until it stops.
(3) With a measuring stick (ruler, etc.) next to the
brake pedal, depress the pedal firmly and
measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES : Bleed the brakes to remove air in the fluid
(Refer to P.35A-17). Then go to Step 7.
NO : Go to Step 2.
STEP 2. Check the pad for wear.
Refer to P.35A-19.
Q: Is the pad thickness outside of specifications?
YES : Replace the part. Then go to Step 7.
NO : Go to Step 3.
STEP 3. Check the vacuum hose and check valve
for damage.
Refer to P.35A-16.
Q: Is there damage?
YES : Replace the part. Then go to Step 7.
NO : Go to Step 4.
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Q: Is there fault?
YES : Repair it. Then go to Step 7.
NO : Go to Step 5.
STEP 5. Check for brake fluid leaks.
Q: Is there leaks?
YES : Check the connection for looseness,
corrosion, etc. Clean and repair as
necessary. If leaking in any tube or hose
section, replace the complete tube or hose.
Then go to Step 7 .
NO : Go to Step 6.
STEP 6. Check the clearance (too much) between
the push rod and primary piston.
Refer to P.35A-26.
Q: Is the clearance outside of specifications?
YES : Adjust the clearance. Then go to Step 7.
NO : Go to Step 7.
STEP 7. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom
surfaces, refer to the symptom chart.
SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
35A-7
INSPECTION PROCEDURE 4: Brake Drag
DIAGNOSIS
PARKING BRAKE
OPERATING LEVER
STEP 1. Check the parking brake operating lever return.
Q: Is there fault?
YES : Repair or replace it. Then go to Step 9.
NO : Go to Step 2.
AC210519 AB
SHOE
SPRINGS
STEP 2. Check the brake shoe springs for breakage.
Q: Are the brake shoe springs broken?
YES : Replace the spring. Then go to Step 9.
NO : Go to Step 3.
AC210519AC
STEP 3. Check the amount of grease at each sliding
section.
Refer to GROUP 36, Parking Brake Lining and Drum P.36-8.
Q: Is there insufficient grease?
YES : Apply grease. Then go to Step 9.
NO : Go to Step 4.
STEP 4. Check the parking brake lever effort.
Refer to GROUP 36, On-vehicle Service −Parking Brake Lever
Stroke Check and Adjustment P.36-4.
Q: Is there fault?
YES : Adjust it. Then go to Step 9.
NO : Go to Step 5.
STEP 5. Check the clearance (too low) between the push
rod and primary piston.
Refer to P.35A-26.
Q: Is there fault?
YES : Adjust the clearance. Then go to Step 9.
NO : Go to Step 6.
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35A-8
SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
STEP 6. Check the master cylinder piston return spring for
damage and return port for clogging.
Refer to P.35A-28.
Q: Is there damage?
YES : Replace the part. Then go to Step 9.
NO : Go to Step 7.
STEP 7. Check port for clogging.
Q: Is the port clogged?
YES : Repair it. Then go to Step 9.
NO : Go to Step 8.
STEP 8. Check disc brake pistons for sticking.
Depress the brake pedal, then release. Confirm each wheel
spins freely.
Q: Are all wheels stuck?
YES : Inspect that brake assembly. Then go to Step 9.
NO : Go to Step 9.
STEP 9. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.
INSPECTION PROCEDURE 5: Scraping or Grinding Noise when Brakes are Applied
DIAGNOSIS
STEP 1. Check the front brakes, then rear brakes, for
metal-to-metal condition.
Q: Is the metal-to-metal contact evident?
YES : Repair or replace the components. Then go to Step 6.
NO : Go to Step 2.
STEP 2. Check for interference between the caliper and
wheel.
Q: Is there interference?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 3.
STEP 3. Check for interference between the dust cover and
brake disc.
Q: Is there interference?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 4.
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SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
35A-9
STEP 4. Check the brake discs for cracks.
Q: Are there cracks?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 5.
STEP 5. Check for bent backing plate(s).
Q: Is (Are) the backing plate(s) bent?
YES : Repair or replace the part. Then go to Step 6.
NO : Go to Step 6.
<REAR>
BACKING PLATE
AC210519 AD
STEP 6. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.
INSPECTION PROCEDURE6: Squealing, Groaning or Chattering Noise when Brakes are Applied
DIAGNOSIS
STEP 1. Check the brake disc and pads for wear
or cutting.
Q: Is there wear or cutting?
YES : Repair or replace the part. Then go to Step
4.
STEP 3. Adjust the brake pedal or brake booster
pushrod.
Refer to P.35A-13 or P.35A-26.
Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
YES : Go to Step 4.
NO : Adjust the brake pedal or the brake booster
pushrod. Then go to Step 4.
NO : Go to Step 2.
STEP 2. Check the calipers for rust.
STEP 4. Recheck symptom.
Q: Is there rust?
YES : Remove the rust. Then go to Step 4.
NO : Go to Step 3.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at Step 1. If a new symptom
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surfaces, refer to the symptom chart.
35A-10
SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
INSPECTION PROCEDURE 7: Squealing Noise when Brakes are not Applied
DIAGNOSIS
STEP 1. Check whether the backing plate is bent or loose
and interfering with the drum.
Q: Is there fault?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 2.
STEP 2. Check whether the drum is damaged due to
interference with the backing plate or shoe.
Q: Is there damage?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 3.
STEP 3. Check the brake drum for wear and the shoe
spring for damage.
Q: Is there wear or damage?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 4.
STEP 4. Check the brake discs for rust.
Q: Are the brake discs rusted?
YES : Remove the rust by using sand paper. If still rusted,
turn the rotors with an on-the-car brake lathe. Then go
to Step 10.
NO : Go to Step 5.
STEP 5. Check the brake pads for correct installation.
Q: Are the pads installed incorrectly?
YES : Repair the pads. Then go to Step 10.
NO : Go to Step 6.
STEP 6. Check the calipers for correct installation.
Q: Are the calipers installed incorrectly?
YES : Repair the calipers. Then go to Step 10.
NO : Go to Step 7.
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SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
35A-11
STEP 7. Check the wheel bearings for end play.
(1) Remove the brake discs.
(2) Place a dial gauge as shown, and measure the end play
while moving the hub in the axial direction.
Limit: 0.05 mm (0.002 inch)
<FRONT>
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 10.
NO : Go to Step 8.
AC102438 AC
<REAR>
AC205869AC
STEP 8. Check whether the brake booster or master
cylinder return is insufficient.
Q: Is the brake booster or master cylinder return
insufficient?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 9.
STEP 9. Adjust the brake pedal or brake booster pushrod.
Refer to P.35A-13 or P.35A-26.
Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
YES : Go to Step 10.
NO : Adjust the brake pedal or the brake booster pushrod.
Then go to Step 10.
STEP 10. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at Step 1. If a new symptom surfaces, refer
to the symptom chart.
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35A-12
SERVICE BRAKES
BASIC BRAKE SYSTEM DIAGNOSIS
INSPECTION PROCEDURE 8: Groaning, Clicking or Rattling Noise when Brakes are not Applied.
DIAGNOSIS
.
STEP 1. Check whether foreign material has entered the
wheel covers.
Q: Is there foreign material?
YES : Remove it. Then go to Step 5.
NO : Go to Step 2.
STEP 2. Check for looseness of the wheel nuts.
Q: Are the wheel nuts loose?
YES : Tighten to 98 ± 10 N⋅ m (73 ± 7 ft-lb). Then go to Step
5.
NO : Go to Step 3.
STEP 3. Check for looseness of the caliper installation
bolt.
Q: Is the caliper installation bolt loose?
YES : Tighten to 108 ± 10 N⋅ m (80 ± 7 ft-lb) for the front
caliper. Tighten to 54 ± 5 N⋅ m (40 ± 4 ft-lb) for the rear
caliper. Then go to Step 5.
NO : Go to Step 4.
STEP 4. Check the wheel bearings for end play.
(1) Remove the brake discs.
(2) Place a dial gauge as shown, and measure the end play
while moving the hub in the axial direction.
Limit: 0.05 mm (0.002 inch)
<FRONT>
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 5.
NO : Go to Step 5.
AC102438 AC
<REAR>
AC205869AC
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35A-13
SERVICE BRAKES
SPECIAL TOOLS
STEP 5. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.
SPECIAL TOOLS
TOOL
A
B
MB990964
M1351000600285
TOOL NUMBER AND
NAME
SUPERSESSION
APPLICATION
MB991568
Push rod adjusting socket
General service
tool
Adjustment of the brake booster
push rod protrusion amount
MB990964
MB990619-01 or
Brake tool set
general service
A: MB990520
tool
Disc brake piston expander
B: MB990619
Installer
• Pushing-in of the disc brake
piston
• Installation of the drum brake
wheel cylinder piston cup
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
M1351000900617
BRAKE PEDAL HEIGHT
1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value (A): 169.1 −172.1 mm (6.7 −6.8 inches)
[From the surface of melting sheet (floorboard) to the
face of pedal pad]
A
AC006215AB
3. If the brake pedal height is not within the standard value,
follow the procedure below.
(1) Disconnect the stoplight switch connector.
(2) Loosen the stoplight switch by turning it approximately.
1/4 turns anticlockwise.
(3) Remove the brake booster. (Refer to P.35A-26.)
NOTE: With the master cylinder and brake pipe connected, remove the brake booster only.
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35A-14
SERVICE BRAKES
ON-VEHICLE SERVICE
CLEVIS
(4) Adjust the brake pedal height by turning the clevis.
NOTE: When the clevis is turned 180 degrees, the pedal
height is changed approximately 2.4 mm (0.09 in).
(5) Install the brake booster. (Refer to P.35A-26.)
(6) Measure the brake pedal height, and ensure that the
measured value is within the specified value. When it is
out of the specified value, repeat Step (3) - (6).
AC006217AB
(7) Insert the stoplight switch until its threaded part touches
the stopper. Then lock the stoplight switch by turning it
approximately 1/4 turn clockwise, and confirm that the
clearance between the switch plunger and the stopper is
as shown.
STOPPER
CAUTION
Check that the stoplight does not illuminate when the
brake pedal is not depressed.
(8) Connect the connector at the stoplight switch.
4. Return the carpet, etc.
STOPPER
0.5 - 1.0 mm
(0.02 - 0.04 in)
AC309282AE
BRAKE PEDAL FREE PLAY
1. With the engine stopped, depress the brake pedal two or
three times, After eliminating the vacuum in the power brake
booster, press the pedal down by hand, and confirm that the
amount of movement before resistance is met (the free play)
is within the standard value.
Standard value (B): 3 −8 mm (0.12 −0.31 inch)
B
AC006219AB
2. If the brake pedal play is not within the standard value,
check the following, and adjust or replace if necessary:
• Excessive play between the brake pedal and the clevis pin,
or between the clevis pin and the brake booster operating
rod
• Brake pedal height
• Installation position of the stoplight switch, etc.
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SERVICE BRAKES
ON-VEHICLE SERVICE
35A-15
CLEARANCE BETWEEN BRAKE PEDAL AND
FLOORBOARD
1. Turn up the carpet, etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 500 N (112 pounds) of force, and measure
the clearance between the brake pedal and the floorboard.
Standard value (C): 90 mm (3.5 inches) or more [From
the surface of the floorboard to the face of pedal pad]
C
AC006220AB
3. If the clearance is outside the standard value, check for air
trapped in the brake line and thickness of the disc brake
pad. And then bleed the air and replace the disc brake pad
as required.
4. Return the carpet etc. to its original position.
BRAKE BOOSTER OPERATING TEST
GOOD
NO GOOD
M1351001000413
1. For simple checking of the brake booster operation, carry
out the following tests:
(1) Run the engine for one or two minutes, and then stop it. If
the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly. If the pedal height remains
unchanged, the booster is defective. Go to step 2.
AC000870 AB
WHEN ENGINE
IS STOPPED
WHEN ENGINE
IS STARTED
(2) With the engine stopped, step on the brake pedal several
times. Then step on the brake pedal and start the engine.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective. Go to step 3.
AC000871AB
GOOD
NO GOOD
(3) With the engine running, step on the brake pedal and
then stop the engine. Hold the pedal depressed for 30
seconds. If the pedal height does not change, the booster
is in good condition, if the pedal rises, the booster is
defective.
AC000872 AB
TSB Revision
35A-16
SERVICE BRAKES
ON-VEHICLE SERVICE
2. If the above three tests are okay, the booster is OK. If one of
the above three tests is not okay, the check valve, vacuum
hose, or booster is defective. Check the check valve
operation (Refer to P.35A-16), vacuum hose for leaks, high
volume engine vacuum applied to booster. Repair or replace
as necessary. If these are OK, replace the booster and
repeat this test starting at Step 1.
CHECK VALVE OPERATION CHECK
M1351009000514
CAUTION
The check valve should not be removed from the vacuum
hose.
1. Remove the vacuum hose. (Refer to P.35A-26.)
VALVE
CAUTION
If the check valve is defective, replace it as an assembly
together with the vacuum hose.
2. Check the operation of the check valve by using a vacuum
pump.
SPRING
A
B
INTAKE
MANIFOLD
SIDE
(DOES NOT
HOLD)
BOOSTER SIDE
(HOLDS)
AC000873AB
VACUUM PUMP
CONNECTION
CRITERIA
Connection at the brake
booster side (A)
A negative pressure
(vacuum) is created and
held.
Connection at the intake
manifold side (B)
A negative pressure
(vacuum) is not created.
PROPORTIONING VALVE FUNCTION TEST
<VEHICLES WITHOUT ABS>
M1351001100421
PRESSURE GAUGE (A)
OUTPUT PORT
CAUTION
The proportioning valves are installed independently for
the right and left brake lines. Always measure each valve.
1. Connect two pressure gauges to the output port of the
master cylinder and output port of the proportioning valve.
2. Bleed the brake line and the pressure gauges (Refer to
P.35A-17).
OUTPUT PORT
PRESSURE GAUGE (B)
PROPORTIONING
VALVE
AC006221AB
TSB Revision
SERVICE BRAKES
ON-VEHICLE SERVICE
35A-17
3. Depress the brake pedal gradually. Then check that the split
point, where the output fluid pressure begins to drop in
proportion to the output fluid pressure, is at the standard
value.
Standard value: 2.70 − 3.19 MPa (392 − 463 psi)
SPLIT POINT
OUTPUT
PRESSURE
<PRESSURE
GAUGE (B)>
INPUT PRESSURE
<PRESSURE GAUGE (A)>
AC006222 AB
4. Depress the brake pedal more strongly than at the above
step. Then check that the output fluid pressure is at the
standard value when the input fluid pressure is 6.86 MPa
(995 psi).
Standard value: 3.68 − 4.17 MPa (534 − 605 psi)
5. Measure each output fluid pressure at both valves, and
check that the difference between the two is at the limit
value or less.
Limit: 0.5 MPa (73 psi)
6. If the measured pressure exceeds the limit, replace the
proportioning valve.
BLEEDING
M1351001400615
CAUTION
Use only brake fluid DOT 3 or DOT 4. Never mix the specified brake fluid with other fluid as it will affect the braking
performance significantly.
MASTER CYLINDER BLEEDING
The master cylinder has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the
brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.)
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with a
finger.
4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2 − 4 three or four times to fill the inside of the
master cylinder with brake fluid.
AC000876
TSB Revision
35A-18
SERVICE BRAKES
ON-VEHICLE SERVICE
DISC BRAKE BLEEDING
;
AIR BLEEDER SCREWS
CAUTION
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe it off quickly.
Connect a vinyl tube to the outer end of the air bleeder screws
to bleed the circuit of air. Then, connect the vinyl tube to the
inner end and bleed the circuit of air. Except for these, the conventional procedures shall be followed. After the circuit has
been bled of air, tighten both air bleeder screws securely.
AC211983AB
4
1
2
3
BRAKE LINE BLEEDING
CAUTION
Be sure to filter/strain the brake fluid being added to the
master cylinder reservoir tank. Debris may damage the
hydraulic unit.
Start the engine and bleed the air in the sequence shown in the
figure.
AC211984 AB
BRAKE FLUID LEVEL SENSOR CHECK
M1351009100317
The brake fluid level sensor is in good condition if there is no
continuity when the float surface is above "MIN" and if there is
continuity when the float surface is below "MIN".
AC006224AB
TSB Revision
SERVICE BRAKES
ON-VEHICLE SERVICE
FRONT DISC BRAKE PAD CHECK AND
REPLACEMENT
WHEN NEW
WHEN WORN
PAD
WEAR INDICATOR
BRAKE
DISC
AC000879 AB
FRONT
REAR
;
PADS
35A-19
M1351002300600
Required Special Tools:
• MB990520: Piston Expander
NOTE: The brake pads have indicators that contact the brake
disc when the brake pad thickness becomes 2 mm (0.08 inch),
and emit a squealing sound to warn the driver.
CAUTION
• Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if
there is brake fluid on the caliper, wipe it off quickly.
• Whenever a pad must be replaced, replace both LH and
RH wheel pads as a set to prevent the vehicle from pulling to one side when braking.
• If there is a significant difference in the thicknesses of
the pads on the left and right sides, check moving
parts.
1. Check the brake pad thickness through the caliper body
check port.
Standard value:
<Front> 10.0 mm (0.39 inch)
<Rear> 9.0 mm (0.35 inch)
Minimum limit: 2.0 mm (0.08 inch)
PADS
AC211985 AB
2. When the thickness is less than the limit, always replace the
pads at an axle set.
(1) Holding the cross spring with one hand, pull the pin out of
the caliper.
AC211986
(2) Remove the pad from the caliper.
(3) To measure brake drag force after new pads have been
installed, use a spring scale to measure the turning
sliding resistance of the hub with the pads removed.
AC211987
TSB Revision
35A-20
SERVICE BRAKES
ON-VEHICLE SERVICE
(4) Clean the piston and, using special tool MB990520, push
the piston into the cylinder.
MB990520
AC211988 AB
FRONT
REAR
(5) Apply repair kit grease to the portions of the pads
indicated on the left. At this time, make sure that the
grease will not be applied to any other surfaces.
(6) Mount the pads to the caliper so that its side with the
wear indicator is on the outside of the vehicle. With the
rear pads, ensure that the arrow on the pad faces in the
same direction as the brake disc turns when the vehicle
moves forward.
AC211989 AB
PINS
CROSS
SPRING
AC211990 AB
(7) Holding the cross spring with one hand, fit pins in the
caliper.
(8) Using a spring scale, measure the turning sliding
resistance of the hub in the forward direction.
(9) Find the brake disc drag force [the difference in
measurements taken in step(3) and in step(8)].
Standard value: 69 N (15 pounds) or less
(10)If that drag force exceeds the standard value,
disassemble the caliper assembly. Then check the piston
for contamination or rust, and confirm if the piston or the
piston seal is deteriorated.
TSB Revision
SERVICE BRAKES
ON-VEHICLE SERVICE
DISC BRAKE ROTOR CHECK
35A-21
M1351002900259
CAUTION
Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.
Before turning the brake disc, the following conditions should be checked.
INSPECTION ITEMS
REMARKS
Scratches, rust, saturated lining materials and wear
• If the vehicle is not driven for a long period of
time, sections of the discs that are not in contact
with the pads will become rusty, causing noise
and shuddering.
• If grooves and scratches resulting from excessive
disc wear are not removed prior to installing a new
pad assembly, there will be inadequate contact
between the disc and the lining (pad) until the
pads conform to the disc.
Run-out
Excessive run-out of the discs will increase the pedal
depression resistance due to piston kick-back.
Change in thickness (parallelism)
If the thickness of the disc changes, this will cause
pedal pulsation, shuddering and surging.
Inset or warping (flatness)
Overheating and improper handling while servicing
will cause warping or distortion.
BRAKE DISC THICKNESS CHECK
M1351002400492
.
ACX00668AB
CAUTION
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe it off quickly.
1. Using a micrometer, measure disc thickness at eight
positions, approximately 45 degrees apart and 10 mm (0.39
inch) from the outer edge of the disc.
Standard value:
<Front> 32.0 mm (1.26 inch)
<Rear> 22.0 mm (0.87 inch)
Minimum limit:
<Front> 29.8 mm (1.17 inch)
<Rear> 20.4 mm (0.80 inch)
NOTE: Thickness variation (at least 8 positions) should not
be more than 0.015 mm (0.0006 inch).
TSB Revision
35A-22
SERVICE BRAKES
ON-VEHICLE SERVICE
•
•
M12 FLAT WASHER
•
2.
M12 FLAT WASHER
CAUTION
After a new brake disc is installed, always grind the
brake disc with on-the-car type brake lathe. If this step
is not carried out, the brake disc run-out exceeds the
specified value, resulting in judder.
When the on-the-car type lathe is used, first install a
M12 flat washer on the stud bolt in the brake disc side
according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disc rotor may be deformed, resulting in inaccurate grinding.
Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N⋅ m (74
ft-lb). When all numbers of wheel nuts are not used, or
the tightening torque is excessive or not equal, the
brake disc rotor or drum may be deformed, resulting in
judder.
If the disc thickness is less than the limits, replace it with a
new one. If thickness variation exceeds the specification,
turn rotor with an on-the-car type brake lathe
("Accuturn-8750" or equivalent).
If the calculated final thickness after turning the rotor is less
than the standard value, replace the disc.
AC006226 AB
BRAKE DISC RUN-OUT CHECK AND
CORRECTION
M1351009400545
CAUTION
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe it off quickly.
1. Remove the brake assembly, and then hold it with wire.
2. Temporarily install the disc with the hub nut.
3. Place a dial gauge approximately 5 mm from the outer
circumference of the brake disc, and measure the run-out of
the disc.
Limit: 0.03 mm (0.0012 inch)
ACX00669AB
TSB Revision
SERVICE BRAKES
ON-VEHICLE SERVICE
35A-23
4. If the brake disc run-out exceeds the limit, correct it as
follows:
(1) Chalk phase marks on the wheel stud and the brake disc,
which run-out is excessive as shown.
CHALK MARKS
AC210711AB
(2) Remove the brake disc. Then place a dial gauge as
shown, and measure the end play by pushing and pulling
the wheel hub.
Limit: 0.05 mm (0.002 inch)
<FRONT>
AC102438 AC
(3) If the end play exceeds the limit, disassemble the hub
and knuckle assembly to check each part.
(4) If the end play does not exceed the limit, dephase the
brake disc and secure it. Then recheck the brake disc
run-out.
CAUTION
• After a new brake disc is installed, always grind the
brake disc with on-the-car type brake lathe. If this step
is not carried out, the brake disc run-out exceeds the
specified value, resulting in judder.
<REAR>
AC205869AC
M12 FLAT WASHER
M12 FLAT WASHER
• When the on-the-car type lathe is used, first install a
M12 flat washer on the stud bolt in the brake disc side
according to the figure, and then install the adapter. If
the adapter is installed with M12 flat washer not seated,
the brake disc rotor may be deformed, resulting in inaccurate grinding.
• Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N⋅ m (74
ft-lb). When all numbers of wheel nuts are not used, or
the tightening torque is excessive or not equal, the
brake disc rotor or drum may be deformed, resulting in
judder.
5. If the run-out cannot be corrected by changing the phase of
the brake disc, replace the brake disc or grind it with the
on-the-car type brake lathe ("Accuturn-8750" or equivalent).
AC006226 AB
TSB Revision
35A-24
SERVICE BRAKES
BRAKE PEDAL
MASTER CYLINDER FUNCTION CHECK
M1351010200200
1. Remove the reservoir cap and diaphragm.
2. While watching the open reservoir from a distance of 50 cm
(20 inches), have an assistant depress the brake pedal.
If there was a stream of brake fluid rising from the reservoir,
proceed to Step 3.
If there was no stream of brake fluid rising from the
reservoir, repair or replace the master cylinder.
3. While watching the open reservoir from a distance of 50 cm
(20 inches), have the assistant release the brake pedal.
If there was a small amount of air bubbles rising through the
brake fluid, master cylinder function is normal.
If there were no bubbles rising through the brake fluid, repair
or replace the master cylinder.
BRAKE PEDAL
REMOVAL AND INSTALLATION
M1351003400310
Post-installation Operation
• Brake Pedal Adjustment (Refer to P.35A-13.)
8
12 ± 2 N·m
107 ± 17 in-lb
3
1
2
5
14 ± 3 N·m
124 ± 26 in-lb
7
4
6
AC211554 AB
1.
2.
3.
4.
REMOVAL STEPS
HARNESS CONNECTOR
STOPLIGHT SWITCH
BRAKE PEDAL CLIP
BRAKE PEDAL STOPPER
TSB Revision
5.
6.
7.
>>A<< 8.
REMOVAL STEPS (Continued)
BRAKE BOOSTER PIN
BRAKE PIN ASSEMBLY
BRAKE PEDAL PAD
BRAKE PEDAL ASSEMBLY
SERVICE BRAKES
BRAKE PEDAL
35A-25
INSTALLATION SERVICE POINT
.
>>A<< BRAKE PEDAL ASSEMBLY INSTALLATION
Tighten the brake booster mounting nuts (A), and then the
brake pedal assembly mounting bolts (B).
NOTE: The brake pedal assembly cannot be positioned correctly if the brake pedal assembly mounting bolts (B) are tightened first, as the their holes are oblong holes.
B
B
A
A
AC006234 AB
INSPECTION
M1351003500328
STOPLIGHT SWITCH CHECK
NO CONTINUITY
CONTINUITY
1. Connect an ohmmeter between the stoplight switch
connector terminals.
2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.
4 mm (0.16 in)
AC006235AB
TSB Revision
35A-26
SERVICE BRAKES
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
REMOVAL AND INSTALLATION
M1351003700623
Pre-removal Operation
• Brake Fluid Draining
• Air Intake Hose and Air Cleaner Removal (Refer to
GROUP 15, Air Cleaner P.15-7.)
• Strut Tower Bar Removal (Refer to GROUP 42, Strut
Tower Bar P.42-12.)
Post-installation Operation
• Brake Pedal Adjustment (Refer to P.35A-13.)
• Air Intake Hose and Air Cleaner Installation (Refer to
GROUP 15, Air Cleaner P.15-7.)
• Strut Tower Bar Removal (Refer to GROUP 42, Strut
Tower Bar P.42-12.)
• Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-17.)
7
4
2
3
11
15 ± 2 N·m
12 ± 1 ft-lb
12
8
1
5
10
6
10 ± 2 N·m
89 ± 17 in-lb
5
9
14 ± 3 N·m
124 ± 26 in-lb
22 ± 3 N·m
16 ± 2 ft-lb
15 ± 2 N·m
12 ± 1 ft-lb
PROPORTIONING VALVES
<VEHICLES WITHOUT ABS>
15
7
13
16 ± 1 N·m
12 ± 1 ft-lb
13
SEALANT: 3M TM AAD PART
NO. 8661, 8663, 8672, 8678,
8679 OR EQUIVALENT
1.
2.
3.
4.
5.
6.
MASTER CYLINDER REMOVAL
STEPS
CLUTCH HOSE CONNECTION
BRAKE FLUID LEVEL INDICATOR
SWITCH CONNECTOR
BRAKE FLUID RESERVOIR CAP
BRAKE FLUID LEVEL INDICATOR
SWITCH
BRAKE TUBE CONNECTION
BRAKE MASTER CYLINDER
ASSEMBLY
TSB Revision
30 ± 5 N·m
22 ± 4 ft-lb
14
5
15 ± 2 N·m
12 ± 1 ft-lb
1.
2.
5.
6.
>>B<<
•
AC309899AB
BRAKE BOOSTER REMOVAL
STEPS
CLUTCH HOSE CONNECTION
BRAKE FLUID LEVEL INDICATOR
SWITCH CONNECTOR
BRAKE TUBE CONNECTION
BRAKE MASTER CYLINDER
ASSEMBLY
PUSH ROD PROTRUSION
AMOUNT CHECK AND
ADJUSTMENT
SERVICE BRAKES
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
>>A<<
BRAKE BOOSTER REMOVAL
STEPS (Continued)
7. BRAKE BOOSTER VACUUM
HOSE (WITH BUILT-IN CHECK
VALVE)
8. BRAKE BOOSTER PIN
9. BRAKE BOOSTER PIN
ASSEMBLY
10. CLEVIS
REMOVE A/C LIQUID PIPE B
•
FROM THE RETAINING CLIP.
(REFER TO GROUP 55,
REFRIGERANT LINE P.55-118.)
11. BRAKE BOOSTER ASSEMBLY
12. BRAKE BOOSTER BODY SEAL
>>A<<
35A-27
FITTING REMOVAL STEPS
BRAKE BOOSTER VACUUM
HOSE (WITH BUILT-IN CHECK
VALVE)
13. BRAKE BOOSTER VACUUM
HOSE FITTING
PROPORTIONING VALVE
REMOVAL STEPS
5. BRAKE TUBE CONNECTION
14. PROPORTIONING VALVE
15. O RING
7.
Required Special Tool:
• MB991568: Push Rod Adjusting Socket
INSTALLATION SERVICE POINTS
.
>>A<< BRAKE BOOSTER VACUUM HOSE CONNECTION
Insert the brake booster vacuum hose to the brake booster
assembly with its paint mark facing upward, and then secure
the hose by using the hose clip.
.
>>B<< PUSH ROD PROTRUSION AMOUNT
CHECK AND ADJUSTMENT
1. Measure dimension (A).
Standard value (A): 8.98 − 9.23 mm (0.354 − 0.363 in)
NOTE: When a negative pressure of 66.7 kPa (19.7 inHg) is
applied to the brake booster, the push rod should protrude
10.27 - 10.53 mm (0.404 − 0.414 in).
A
MEASURING DISTANCE A
BLOCK GAUGE
AC006237AB
TSB Revision
35A-28
SERVICE BRAKES
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER
2. If the protrusion amount is not within the standard value
range, adjust the push rod length by turning the push rod.
Use special tool MB991568 to turn the push rod while
holding the rod spline with angle-nose pliers.
ROD SPLINE
ANGLE-NOSE PLIERS
MB991568
AC006238AB
MASTER CYLINDER
M1351004200416
DISASSEMBLY AND ASSEMBLY
7
1
8
3
4
9
2
N
7
MASTER CYLINDER KIT
10
5
8
N
6
9
3
N
9
10
AC006239 AB
DISASSEMBLY STEPS
1. BRAKE FLUID RESERVOIR CAP
2. BRAKE FLUID RESERVOIR FILTER
<VEHICLE WITH ABS>
3. BRAKE MASTER CYLINDER PIN
TSB Revision
8
BRAKE FLUID: DOT 3 OR DOT 4
DISASSEMBLY STEPS (Continued)
4. BRAKE FLUID RESERVOIR
5. BRAKE MASTER CYLINDER TO
RESERVOIR SEAL
35A-29
SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY
DISASSEMBLY STEPS (Continued)
6. BRAKE MASTER CYLINDER PIN
<VEHICLE WITH ABS>
7. PISTON RETAINER
8. PRIMARY PISTON ASSEMBLY
9. SECONDARY PISTON ASSEMBLY
10. MASTER CYLINDER BODY
INSPECTION
M1351004300208
• Check the inner surface of master cylinder body for rust or
pitting.
• Check the primary and secondary pistons for rust, scoring,
wear or damage.
• Check the diaphragm for cracks and wear.
FRONT DISC BRAKE ASSEMBLY
REMOVAL AND INSTALLATION
M1351006000634
CAUTION
Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
And if there is brake fluid on the caliper, wipe it off quickly.
Pre-removal Operation
• Brake Fluid Draining
Post-installation Operation
• Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-17.)
108 ± 10 N·m
80 ± 7 ft-lb
4
30 ± 5 N·m
22 ± 4 ft-lb
1
N
2
3
AC211991 AB
REMOVAL STEPS
1. BRAKE HOSE CONNECTION
2. GASKET
TSB Revision
REMOVAL STEPS (Continued)
>>A<< 3. DISC BRAKE ASSEMBLY
4. BRAKE DISC
35A-30
SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY
INSTALLATION SERVICE POINT
.
>>A<< DISC BRAKE ASSEMBLY INSTALLATION
1. Find the drag force of the disc brake (Refer to P.35A-19).
Standard value: 69 N (15 pound) or less
2. If that drag force exceeds the standard value, disassemble
the caliper assembly. Then check the piston for
contamination or rust, and confirm if the piston or the piston
seal is deteriorated.
INSPECTION
BRAKE DISC CHECK
Disc wear (Refer to P.35A-21.)
Disc run-out (Refer to P.35A-22.)
TSB Revision
M1351006100404
35A-31
SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY
DISASSEMBLY AND ASSEMBLY
M1351006200564
CAUTION
Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
And if there is brake fluid on the caliper, wipe it off quickly.
5
6
6
N
7 9N
8
10
4
3
14 ± 2 N·m
124 ± 18 in-lb
5
1
GREASE: REPAIR KIT GREASE
2
AC211994 AB
6
7 9
8
6
10
5
9
5
7
7
1
9
2
BRAKE CALIPER KIT
SEAL AND BOOT REPAIR KIT
SHIM SET
3
4
2
1
3
1
2
4
PAD SET
CLIP SET
TSB Revision
35A-32
SERVICE BRAKES
FRONT DISC BRAKE ASSEMBLY
DISASSEMBLY STEPS
1. PIN
2. PAD ANTI-SQUEAK SPRING
3. PAD AND WEAR INDICATOR
ASSEMBLY
4. PAD ASSEMBLY
5. SHIM
<<A>>
<<A>>
<<B>>
6.
7.
8.
9.
10.
DISASSEMBLY STEPS (Continued)
CALIPER BLEEDER
PISTON BOOT
PISTON
PISTON SEAL
CALIPER BODY
DISASSEMBLY SERVICE POINTS
CAUTION
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe it off quickly.
When disassembling the disc brakes, disassemble both sides
(left and right) as a set.
.
<<A>> PISTON BOOT/PISTON REMOVAL
CAUTION
Do not remove one piston completely before trying to
remove the other piston, because it will become impossible to remove other pistons.
Remove the pistons by pumping in air slowly from the brake
hose connection. Be sure to use a wood block and adjust the
height of the four pistons so that the pistons protrude evenly.
WOOD BLOCK
AC212148AB
.
<<B>> PISTON SEAL REMOVAL
CAUTION
To prevent damage to inner cylinder, do not use a
flat-tipped screwdriver or other tool.
1. Remove the piston seal with finger tip.
2. Clean the piston surface and inner cylinder with alcohol or
brake fluid DOT 3 or DOT 4.
INSPECTION
•
•
•
•
.
TSB Revision
M1351006300516
Check the cylinder for wear, damage or rust.
Check the piston surface for wear, damage or rust.
Check the caliper body for wear.
Check the pad for damage or adhesion of grease, check the
backing metal for damage.
35A-33
SERVICE BRAKES
REAR DISC BRAKE ASSEMBLY
PAD WEAR CHECK
WARNING
• Always replace both brake pads on each wheel as
a set (both front wheels or both rear wheels). Failure to do so will result in uneven braking, which
may cause unreliable brake operation.
• If there is significant difference in the thickness of
the pads on the left and right sides, check the
moving parts.
Measure thickness at the thinnest, most worn area of the pad.
Replace the pad assembly if pad thickness is less than the limit
value.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
ACX00690
REAR DISC BRAKE ASSEMBLY
REMOVAL AND INSTALLATION
M1351007000488
CAUTION
Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
And if there is brake fluid on the caliper, wipe it off quickly.
Pre-removal Operation
• Brake Fluid Draining
Post-installation Operation
• Brake Fluid Filling and Air Bleeding (Refer to P.35A-17.)
54 ± 5 N·m
40 ± 4 ft-lb
1
15 ± 2 N·m
12 ± 1 ft-lb
2N
3
4
AC402735 AB
REMOVAL STEPS
1. BRAKE HOSE CONNECTION
2. GASKET
TSB Revision
REMOVAL STEPS (Continued)
>>A<< 3. DISC BRAKE ASSEMBLY
4. BRAKE DISC
35A-34
SERVICE BRAKES
REAR DISC BRAKE ASSEMBLY
INSTALLATION SERVICE POINT
.
>>A<< DISC BRAKE ASSEMBLY INSTALLATION
1. Find the drag force of the disc brake (Refer to P.35A-19).
Standard value: 69 N (15 pound) or less
2. If that drag force exceeds the standard value, disassemble
the caliper assembly. Then check the piston for
contamination or rust, and confirm if the piston or the piston
seal is deteriorated.
INSPECTION
BRAKE DISC CHECK
Disc wear: Refer to P.35A-21.
Disc run-out: Refer to P.35A-22.
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M1351007100377
35A-35
SERVICE BRAKES
REAR DISC BRAKE ASSEMBLY
DISASSEMBLY AND ASSEMBLY
M1351007200352
CAUTION
Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
And if there is brake fluid on the caliper, wipe it off quickly.
14 ± 2 N·m
124 ± 18 in-lb
6
5
4
2
3
5
6
1
10
N
7
N
9
GREASE: REPAIR KIT GREASE
8
10
6
8
9
AC211995 AB
2
9
7
6
7
5
1
7
BRAKE CALIPER KIT
5
9
SEAL AND BOOT REPAIR KIT
SHIM SET
3
1
4
4
3
2
1
2
PAD SET
CLIP SET
1.
2.
3.
4.
5.
DISASSEMBLY STEPS
PIN
PAD ANTI-SQUEAK SPRING
PAD AND WEAR INDICATOR
ASSEMBLY
PAD ASSEMBLY
SHIM
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<<A>>
<<A>>
<<B>>
6.
7.
8.
9.
10.
DISASSEMBLY STEPS (Continued)
CALIPER BLEEDER
PISTON BOOT
PISTON
PISTON SEAL
CALIPER BODY
35A-36
SERVICE BRAKES
REAR DISC BRAKE ASSEMBLY
DISASSEMBLY SERVICE POINTS
CAUTION
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if there
is brake fluid on the caliper, wipe it off quickly.
When disassembling the disc brakes, disassemble both sides
(left and right) as a set.
.
<<A>> PISTON BOOT/PISTON REMOVAL
Remove the pistons by pumping in air slowly from the brake
hose connection. Be sure to use a wood block and adjust the
height of the two pistons while so that the pistons protrude
evenly.
WOODEN PLATE
AC212149AB
.
<<B>> PISTON SEAL REMOVAL
CAUTION
To prevent damage to inner cylinder, do not use a
flat-tipped screwdriver or other tool.
1. Remove the piston seal with finger tip.
2. Clean the piston surface and inner cylinder with alcohol or
brake fluid DOT 3 or DOT 4.
INSPECTION
•
•
•
•
.
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M1351007300207
Check the cylinder for wear, damage or rust.
Check the piston surface for wear, damage or rust.
Check the caliper body for wear.
Check the pad for damage or adhesion of grease, check the
backing metal for damage.
35A-37
SERVICE BRAKES
SPECIFICATIONS
PAD WEAR CHECK
WARNING
• Always replace both brake pads on each wheel as
a set (both front wheels or both rear wheels). Failure to do so will result in uneven braking, which
may cause unreliable brake operation.
• If there is significant difference in the thickness of
the pads on the left and right sides, check the
moving parts.
Measure thickness at the thinnest, most worn area of the pad.
Replace the pad assembly if pad thickness is less than the limit
value.
Standard value: 9.0 mm (0.35 inch)
Minimum limit: 2.0 mm (0.08 inch)
ACX00690
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ITEMS
M1351009600497
SPECIFICATIONS
Brake line
15 ± 2 N⋅ m (12 ± 1 ft-lb)
Brake tube flare nut
Brake pedal
Brake pedal assembly bolt
12 ± 2 N⋅ m (107 ± 17 in-lb)
Brake pedal assembly nut
14 ± 3 N⋅ m (124 ± 26 in-lb)
Front disc brake
Brake hose connector bolt
30 ± 5 N⋅ m (22 ± 4 ft-lb)
Caliper bleeder
14 ± 2 N⋅ m (124 ± 18 in-lb)
Front brake assembly mounting bolt
108 ± 10 N⋅ m (80 ± 7 ft-lb)
Master cylinder assembly and brake booster
Brake booster mounting nut
14 ± 3 N⋅ m (124 ± 26 in-lb)
Fitting
16 ± 1 N⋅ m (12 ± 1 ft-lb)
Master cylinder mounting nut
10 ± 2 N⋅ m (89 ± 17 in-lb)
Operating rod jam nut
22 ± 3 N⋅ m (16 ± 2 ft-lb)
Proportioning valve <Vehicles without ABS>
30 ± 5 N⋅ m (22 ± 4 ft-lb)
Rear disc brake
Brake hose connector bolt
15 ± 2 N⋅ m (12 ± 1 ft-lb)
Caliper bleeder
14 ± 2 N⋅ m (124 ± 18 in-lb)
Rear brake assembly mounting bolt
54 ± 5 N⋅ m (40 ± 4 ft-lb)
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35A-38
SERVICE BRAKES
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM
M1351000200447
SPECIFICATION
Master
cylinder
Type
Tandem type
I.D. mm (in)
26.9 (1.06)
Brake
booster
Type
Vacuum type, tandem
Effective dia. of power
cylinder mm (in)
205 + 230 (8 + 9)
Boosting ratio
4.5 <Brake pedal depressing force: 230 N (51.7 lb)>
Rear wheel hydraulic control method
Proportioning valve <Vehicles without ABS>, Electronic
brake-force distribution (EBD) <Vehicles with ABS>
Front brakes Type
4-opposed piston, ventilated disc
Rear brakes
Disc effective dia. ×
thickness mm (in)
263 × 32 (10.4 × 1.3)
Wheel cylinder I.D. mm (in)
40.0 (1.58) × 2, 46.0 (1.81) × 2
Pad thickness mm (in)
10.0 (0.39)
Clearance adjustment
Automatic
Type
2-opposed piston, ventilated disc
Disc effective dia. ×
thickness mm (in)
252 × 22 (9.9 × 0.9)
Wheel cylinder I.D. mm (in)
40.0 (1.58) × 2
Pad thickness mm (in)
9.0 (0.35)
Clearance adjustment
Automatic
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35A-39
SERVICE BRAKES
SPECIFICATIONS
SERVICE SPECIFICATIONS
M1351000300541
ITEM
STANDARD VALUE
LIMIT
Brake pedal height mm (in)
169.1 − 172.1 (6.7 − 6.8)
−
Brake pedal free play mm (in)
3 − 8 (0.12 − 0.31)
−
Brake pedal to floorboard clearance mm (in)
90 (3.5) or more
−
Proportioning valve
Split point
2.70 − 3.19 (392 − 463)
output fluid pressure MPa When input fluid pressure 3.68 − 4.17 (534 − 605)
(psi) <Vehicles without
is 6.86 MPa (995 psi).
ABS>
−
Proportioning valve output fluid pressure difference
between left and right MPa (psi) <Vehicles without
ABS>
−
0.5 (73)
Front disc brake pad thickness mm (in)
10.0 (0.39)
Minimum 2.0 (0.08)
Front disc brake disc thickness mm (in)
32.0 (1.26)
Minimum 29.8 (1.17)
Front disc brake disc run-out mm (in)
−
0.03 (0.0012)
Front disc brake drag force N (lb)
69 (15) or less
−
Rear disc brake pad thickness mm (in)
9.0 (0.35)
Minimum 2.0 (0.08)
Rear disc brake disc thickness mm (in)
22.0 (0.87)
Minimum 20.4 (0.80)
Rear disc brake disc run-out mm (in)
−
0.03 (0.0012)
Rear disc brake drag force N (lb)
69 (15) or less
−
Front wheel bearing axial play mm (in)
−
0.05 (0.002)
Rear wheel bearing axial play mm (in)
−
0.05 (0.002)
Brake booster push rod protruding amount mm (in)
8.98 − 9.23
(0.354 − 0.363)
−
−
LUBRICANTS
M1351000400333
ITEM
SPECIFIED LUBRICANT
Brake fluid
DOT3 or DOT4
Pad assembly
Repair kit grease
SEALANT
M1351000500288
ITEM
SPECIFIED SEALANT
Fitting
3MTM AAD Part No. 8661, 8663, 8672, 8678, 8679 or Semi-drying sealant
equivalent
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REMARK
NOTES
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