Brake System: Section

BRAKES
SECTION
BRAKE SYSTEM
BR B
E
CONTENTS
TYPE 1 BRAKE BOOSTER ........................................... 16 BR
Inspection ................................................................16
HOW TO USE THIS MANUAL ...................... 6
FRONT DISC BRAKE ....................................... 17 G
HOW TO USE THIS SECTION ............................ 6
Information ................................................................ 6 BRAKE PAD ..............................................................17
BRAKE PAD : Inspection and Adjustment ...............17
PRECAUTION ............................................... 7 H
DISC ROTOR .............................................................17
PRECAUTIONS ................................................... 7 DISC ROTOR : Inspection and Adjustment .............17
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
REAR DISC BRAKE ......................................... 19 I
SIONER" ................................................................... 7 BRAKE PAD ..............................................................19
Precautions Necessary for Steering Wheel Rota- BRAKE PAD : Inspection and Adjustment ...............19
tion After Battery Disconnection ................................ 7 J
Precaution for Procedure without Cowl Top Cover...... 8 DISC ROTOR .............................................................19
Precaution for Brake System .................................... 8 DISC ROTOR : Inspection and Adjustment .............19
K
PREPARATION ............................................ 9 REMOVAL AND INSTALLATION ............... 21
PREPARATION ................................................... 9 BRAKE PEDAL ................................................. 21
Commercial Service Tool .......................................... 9 Exploded View .........................................................21 L
Removal and Installation .........................................21
SYMPTOM DIAGNOSIS .............................. 10 Inspection and Adjustment ......................................22
M
NOISE, VIBRATION AND HARSHNESS BRAKE PIPING ................................................. 23
(NVH) TROUBLESHOOTING ............................10
NVH Troubleshooting Chart .................................... 10 FRONT .......................................................................23
FRONT : Exploded View .........................................23 N
PERIODIC MAINTENANCE ......................... 11 FRONT : Hydraulic Piping .......................................24
FRONT : Removal and Installation ..........................24
BRAKE PEDAL ..................................................11 FRONT : Inspection .................................................25
O
Inspection and Adjustment ...................................... 11
REAR .........................................................................25
BRAKE FLUID ....................................................13 REAR : Exploded View ............................................26
Inspection ................................................................ 13 REAR : Hydraulic Piping ..........................................27 P
Draining ................................................................... 13 REAR : Removal and Installation ............................27
Refilling ................................................................... 13 REAR : Inspection ...................................................28
Bleeding Brake System ........................................... 14
BRAKE MASTER CYLINDER .......................... 29
BRAKE MASTER CYLINDER ............................15 Exploded View .........................................................29
Inspection ................................................................ 15 Removal and Installation .........................................29
Disassembly and Assembly .....................................30
Revision: 2012 July BR-1 N17

Inspection ............................................................... 31 Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
BRAKE BOOSTER AND CHECK VALVE ........ 33 SIONER" ................................................................. 56
Exploded View ........................................................ 33 Precautions Necessary for Steering Wheel Rota-
Removal and installation ........................................ 33 tion After Battery Disconnection .............................. 56
Inspection and Adjustment ..................................... 34 Precaution for Procedure without Cowl Top Cover... 57
Precaution for Brake System .................................. 57
VACUUM LINES ................................................ 36
Exploded View ........................................................ 36 PREPARATION .......................................... 58
Removal and Installation ........................................ 36
Inspection ............................................................... 36 PREPARATION ................................................. 58
Commercial Service Tool ........................................ 58
FRONT DISC BRAKE ........................................ 37
SYMPTOM DIAGNOSIS ............................ 59
BRAKE PAD ............................................................. 37
BRAKE PAD : Exploded View ................................ 37 NOISE, VIBRATION AND HARSHNESS
BRAKE PAD : Removal and Installation ................. 37 (NVH) TROUBLESHOOTING ............................ 59
BRAKE PAD : Inspection ........................................ 39 NVH Troubleshooting Chart .................................... 59
BRAKE CALIPER ASSEMBLY ................................ 39
PERIODIC MAINTENANCE ....................... 60
BRAKE CALIPER ASSEMBLY : Exploded View ... 39
BRAKE CALIPER ASSEMBLY : Removal and In- BRAKE PEDAL ................................................. 60
stallation ................................................................. 40 Inspection and Adjustment ...................................... 60
BRAKE CALIPER ASSEMBLY : Disassembly and
Assembly ................................................................ 42 BRAKE FLUID ................................................... 62
BRAKE CALIPER ASSEMBLY : Inspection ........... 44 Inspection ................................................................ 62
Draining ................................................................... 62
REAR DISC BRAKE .......................................... 45 Refilling ................................................................... 62
Bleeding Brake System ........................................... 63
BRAKE PAD ............................................................. 45
BRAKE PAD : Exploded View ................................ 45 BRAKE MASTER CYLINDER ........................... 64
BRAKE PAD : Removal and Installation ................. 45 Inspection ................................................................ 64
BRAKE PAD : Inspection ........................................ 47
BRAKE BOOSTER ............................................ 65
BRAKE CALIPER ASSEMBLY ................................ 48
Inspection ................................................................ 65
BRAKE CALIPER ASSEMBLY : Exploded View ... 48
BRAKE CALIPER ASSEMBLY : Removal and In- FRONT DISC BRAKE ....................................... 66
stallation ................................................................. 49
BRAKE CALIPER ASSEMBLY : Disassembly and BRAKE PAD .............................................................. 66
Assembly ................................................................ 50 BRAKE PAD : Inspection and Adjustment .............. 66
BRAKE CALIPER ASSEMBLY : Inspection ........... 53
DISC ROTOR ............................................................ 66
SERVICE DATA AND SPECIFICATIONS DISC ROTOR : Inspection and Adjustment ............ 66
(SDS) ........................................................... 54 REAR DRUM BRAKE ....................................... 68
SERVICE DATA AND SPECIFICATIONS BRAKE LINING ......................................................... 68
(SDS) .................................................................. 54 BRAKE LINING : Inspection and Adjustment ......... 68
General Specifications ............................................ 54
Brake Pedal ............................................................ 54 BRAKE DRUM .......................................................... 68
Brake Booster ......................................................... 54 BRAKE DRUM : Inspection and Adjustment ........... 68
Front Disc Brake ..................................................... 54
Rear Disc Brake ..................................................... 54
REMOVAL AND INSTALLATION .............. 70
TYPE 2 BRAKE PEDAL ................................................. 70
Exploded View ........................................................ 70
HOW TO USE THIS MANUAL .................... 55 Removal and Installation ......................................... 70
HOW TO USE THIS SECTION .......................... 55 Inspection and Adjustment ...................................... 71
Information .............................................................. 55 BRAKE PIPING ................................................. 72
PRECAUTION ............................................. 56 FRONT ....................................................................... 72
FRONT : Exploded View ......................................... 72
PRECAUTIONS ................................................. 56

FRONT : Hydraulic Piping ....................................... 73 HOW TO USE THIS SECTION ......................... 97
FRONT : Removal and Installation ......................... 73 Information ...............................................................97 A
FRONT : Inspection ................................................ 74
PRECAUTION .............................................. 98
REAR ......................................................................... 74
REAR : Exploded View ........................................... 75 PRECAUTIONS ................................................. 98 B
REAR : Hydraulic Piping ......................................... 75 Precaution for Supplemental Restraint System
REAR : Removal and Installation ............................ 76 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
REAR : Inspection ................................................... 77 SIONER" .................................................................98 C
Precautions Necessary for Steering Wheel Rota-
BRAKE MASTER CYLINDER ............................78 tion After Battery Disconnection ..............................98
Exploded View ........................................................ 78 Precaution for Procedure without Cowl Top Cover....99 D
Removal and Installation ......................................... 78 Precaution for Brake System ...................................99
Disassembly and Assembly .................................... 79
Inspection ................................................................ 80 PREPARATION ......................................... 100
E
BRAKE BOOSTER AND CHECK VALVE .........81 PREPARATION ............................................... 100
Exploded View ........................................................ 81 Commercial Service Tool ...................................... 100
Removal and installation ......................................... 81
Inspection and Adjustment ...................................... 82 SYMPTOM DIAGNOSIS ............................ 101 BR
VACUUM LINES .................................................84 NOISE, VIBRATION AND HARSHNESS
Exploded View ........................................................ 84 (NVH) TROUBLESHOOTING ......................... 101 G
Removal and Installation ......................................... 84 NVH Troubleshooting Chart .................................. 101
Inspection ................................................................ 84
PERIODIC MAINTENANCE ...................... 102
H
FRONT DISC BRAKE ........................................85
BRAKE PEDAL ............................................... 102
BRAKE PAD .............................................................. 85 Inspection and Adjustment .................................... 102
BRAKE PAD : Exploded View ................................. 85 I
BRAKE PAD : Removal and Installation ................. 85 BRAKE FLUID ................................................ 104
BRAKE PAD : Inspection ........................................ 87 Inspection .............................................................. 104
Draining ................................................................. 104
BRAKE CALIPER ASSEMBLY ................................. 87 J
Refilling .................................................................. 104
BRAKE CALIPER ASSEMBLY : Exploded View .... 87 Bleeding Brake System ......................................... 105
BRAKE CALIPER ASSEMBLY : Removal and In-
stallation .................................................................. 88 BRAKE MASTER CYLINDER ........................ 106 K
BRAKE CALIPER ASSEMBLY : Disassembly and Inspection .............................................................. 106
Assembly ................................................................. 89
BRAKE CALIPER ASSEMBLY : Inspection ............ 91 BRAKE BOOSTER ......................................... 107
Inspection .............................................................. 107 L
REAR DRUM BRAKE ........................................92
Exploded View ........................................................ 92 FRONT DISC BRAKE ..................................... 108
Removal and Installation ......................................... 92 M
BRAKE PAD ............................................................ 108
Disassembly and Assembly .................................... 94
BRAKE PAD : Inspection and Adjustment ............. 108
Inspection and Adjustment ...................................... 94
DISC ROTOR ........................................................... 108 N
SERVICE DATA AND SPECIFICATIONS DISC ROTOR : Inspection and Adjustment ........... 108
(SDS) ............................................................ 96
REAR DRUM BRAKE ..................................... 110
SERVICE DATA AND SPECIFICATIONS O
(SDS) ..................................................................96 BRAKE LINING ........................................................ 110
General Specifications ............................................ 96 BRAKE LINING : Inspection and Adjustment ........ 110
Brake Pedal ............................................................. 96 BRAKE DRUM ......................................................... 110 P
Brake Booster ......................................................... 96 BRAKE DRUM : Inspection and Adjustment ......... 110
Front Disc Brake ..................................................... 96
Rear Drum Brake .................................................... 96 REMOVAL AND INSTALLATION ............. 112
TYPE 3
BRAKE PEDAL ............................................... 112
HOW TO USE THIS MANUAL ..................... 97 Exploded View ....................................................... 112
Removal and Installation ....................................... 112

Inspection and Adjustment ....................................113 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................ 140
BRAKE PIPING ............................................... 114 General Specifications .......................................... 140
FRONT .....................................................................114 Brake Pedal .......................................................... 140
FRONT : Exploded View .......................................114 Brake Booster ....................................................... 140
FRONT : Hydraulic Piping .....................................115 Front Disc Brake ................................................... 140
FRONT : Removal and Installation ........................115 Rear Drum Brake .................................................. 140
FRONT : Inspection ...............................................116 TYPE 4
REAR ........................................................................116 HOW TO USE THIS MANUAL .................. 141
REAR : Exploded View ..........................................117
REAR : Hydraulic Piping ........................................117 HOW TO USE THIS SECTION ......................... 141
REAR : Removal and Installation ..........................118 Information ............................................................ 141
REAR : Inspection .................................................119
APPLICATION NOTICE ................................... 142
BRAKE MASTER CYLINDER ......................... 120 Information ............................................................ 142
Exploded View .......................................................120
Removal and Installation .......................................120 PRECAUTION ........................................... 143
Disassembly and Assembly ...................................121 PRECAUTIONS ................................................ 143
Inspection ..............................................................121
Precaution for Supplemental Restraint System
BRAKE BOOSTER AND CHECK VALVE ...... 123 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Exploded View .......................................................123 SIONER" ............................................................... 143
Removal and installation .......................................123 Precautions Necessary for Steering Wheel Rota-
Inspection and Adjustment ....................................124 tion After Battery Disconnection ............................ 143
Precaution for Procedure without Cowl Top Cover. 144
VACUUM LINES .............................................. 126 Precaution for Stop/Start System Service ............. 144
Precaution for Brake System ................................ 144
HR15DE ....................................................................126
HR15DE : Exploded View ......................................126 PREPARATION ......................................... 145
HR15DE : Removal and Installation ......................126
HR15DE : Inspection .............................................127 PREPARATION ................................................ 145
Commercial Service Tool ...................................... 145
K9K ...........................................................................127
K9K : Exploded View .............................................127 SYMPTOM DIAGNOSIS ........................... 146
K9K : Removal and Installation .............................127
K9K : Inspection ....................................................128 NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ........................... 146
FRONT DISC BRAKE ...................................... 129 NVH Troubleshooting Chart .................................. 146
BRAKE PAD ............................................................129 PERIODIC MAINTENANCE ...................... 147
BRAKE PAD : Exploded View ...............................129
BRAKE PAD : Removal and Installation ................129 BRAKE PEDAL ................................................ 147
BRAKE PAD : Inspection .......................................131 Inspection and Adjustment .................................... 147
BRAKE CALIPER ASSEMBLY ...............................131 BRAKE FLUID .................................................. 150

BRAKE CALIPER ASSEMBLY : Exploded View ..131 Inspection .............................................................. 150
BRAKE CALIPER ASSEMBLY : Removal and In- Draining ................................................................. 150
stallation ................................................................132 Refilling ................................................................. 150
BRAKE CALIPER ASSEMBLY : Disassembly and Bleeding Brake System ......................................... 151
Assembly ...............................................................133
BRAKE CALIPER ASSEMBLY : Inspection ..........135 BRAKE MASTER CYLINDER .......................... 152
Inspection .............................................................. 152
REAR DRUM BRAKE ...................................... 136
Exploded View .......................................................136 BRAKE BOOSTER ........................................... 153
Removal and Installation .......................................136 Inspection .............................................................. 153
Disassembly and Assembly ...................................138
Inspection and Adjustment ....................................138
FRONT DISC BRAKE ...................................... 154
BRAKE PAD ............................................................ 154
SERVICE DATA AND SPECIFICATIONS BRAKE PAD : Inspection and Adjustment ............ 154
(SDS) .......................................................... 140

DISC ROTOR ........................................................... 154 BRAKE BOOSTER AND CHECK VALVE ...... 181
DISC ROTOR : Inspection and Adjustment .......... 154 Exploded View ....................................................... 181 A
Removal and installation ....................................... 182
REAR DRUM BRAKE ...................................... 156 Inspection and Adjustment .................................... 183
BRAKE LINING ....................................................... 156 B
VACUUM LINES ............................................. 185
BRAKE LINING : Inspection and Adjustment ........ 156 Exploded View ....................................................... 185
BRAKE DRUM ......................................................... 156 Removal and Installation ....................................... 185
BRAKE DRUM : Inspection and Adjustment ......... 156 Inspection .............................................................. 185 C
REMOVAL AND INSTALLATION ............. 158 FRONT DISC BRAKE ..................................... 187
BRAKE PAD ............................................................ 187 D
BRAKE PEDAL ................................................ 158
BRAKE PAD : Exploded View ............................... 187
Exploded View ...................................................... 158
BRAKE PAD : Removal and Installation ................ 187
BRAKE PAD : Inspection ....................................... 189 E
Inspection and Adjustment .................................... 160
BRAKE CALIPER ASSEMBLY ............................... 189
BRAKE PIPING ................................................ 161
BRAKE CALIPER ASSEMBLY : Exploded View .. 189
BRAKE CALIPER ASSEMBLY : Removal and In- BR
FRONT ..................................................................... 161
FRONT : Exploded View ....................................... 161 stallation ................................................................ 190
FRONT : Hydraulic Piping ..................................... 165 BRAKE CALIPER ASSEMBLY : Disassembly and
FRONT : Removal and Installation ....................... 168 Assembly ............................................................... 191 G
FRONT : Inspection .............................................. 169 BRAKE CALIPER ASSEMBLY : Inspection .......... 193
REAR ....................................................................... 169 REAR DRUM BRAKE ..................................... 195

H
REAR : Exploded View ......................................... 169 Exploded View ....................................................... 195
REAR : Hydraulic Piping ....................................... 171 Removal and Installation ....................................... 195
REAR : Removal and Installation .......................... 174 Disassembly and Assembly ................................... 197
REAR : Inspection ................................................. 174 Inspection and Adjustment .................................... 197 I
DUAL PROPORTIONING VALVE ................... 176 SERVICE DATA AND SPECIFICATIONS

Exploded View ...................................................... 176 (SDS) .......................................................... 199 J
Inspection .............................................................. 177 SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................... 199
BRAKE MASTER CYLINDER .......................... 178 General Specifications ........................................... 199 K
Exploded View ...................................................... 178 Brake Pedal ........................................................... 199
Removal and Installation ....................................... 178 Brake Booster ........................................................ 199
Disassembly and Assembly .................................. 179 Front Disc Brake .................................................... 200 L
Inspection .............................................................. 180 Rear Drum Brake ................................................... 200

HOW TO USE THIS SECTION
< HOW TO USE THIS MANUAL > [TYPE 1]
HOW TO USE THIS MANUAL

Information INFOID:0000000007714732
Check the vehicle type to use the service information in this section.
Service information Destination

TYPE 1 China production models
TYPE 2 India production models (LHD)
TYPE 3 India production models (RHD)
TYPE 4 Thailand production models
Refer to GI-34, "Information About Identification or Model Code" to identify a production plant.

PRECAUTIONS
< PRECAUTION > [TYPE 1]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000007738392
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING: D
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by E
an authorized NISSAN/INFINITI dealer.
• Improper 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 Cable and Air Bag
BR
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors. G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: H
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing I
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service. J
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000007738403
K
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
then disconnect both battery cables. L
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing M
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro- N
cedure below before starting the repair operation.
OPERATION PROCEDURE
O
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position. P
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

PRECAUTIONS
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover INFOID:0000000006965693
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
Precaution for Brake System INFOID:0000000006965256
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed
with a dust collector. Never splatter the dust with an air blow gun.
• Brake fluid use refer to MA-17, "Fluids and Lubricants".
• Never reuse drained brake fluid.
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it off
immediately and wash with water if it gets on a painted surface. For brake component parts, never wash
them with water.
• Always confirm the specified tightening torque when installing the brake pipes.
• If the brake fluid or grease adheres to the disc rotor, quickly wipe it off.
• After pressing the brake pedal more deeply or harder than normal driving, such as air bleeding, check each
item of brake pedal. Adjust brake pedal if it is outside the standard value.
• Always clean with new brake fluid when cleaning the master cylinder, brake caliper and other components.
• Never use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and cause
improper operation.
• Always loosen the brake tube flare nut with a flare nut wrench.
• Tighten the brake tube flare nut to the specified torque with a flare
nut torque wrench [(A), (commercial service tool)].
• Turn the ignition switch OFF and disconnect the ABS actuator and
electric unit (control unit) harness connector or the battery negative
terminal before performing the work.
• Check that no brake fluid leakage is present after replacing the
parts.
• Brake component parts are critical safety parts. If a brake fluid leak
is detected, always disassemble the affected part. If a malfunction
is detected, replace part with a new one.
• Burnish the brake contact surfaces after refinishing or replacing
JPFIA0061ZZ
rotors, after replacing brake pads, or if a soft pedal occurs at very
low mileage.
- Front brake pad: Refer to BR-17, "BRAKE PAD : Inspection and Adjustment".
- Front disc rotor: Refer to BR-17, "DISC ROTOR : Inspection and Adjustment".
- Rear brake pad: Refer to BR-19, "BRAKE PAD : Inspection and Adjustment".
- Rear disc rotor: Refer to BR-19, "DISC ROTOR : Inspection and Adjustment".

PREPARATION
< PREPARATION > [TYPE 1]
PREPARATION A
PREPARATION
Commercial Service Tool INFOID:0000000006965257
B
Tool name Description

C
Flare nut torque wrench D

Installing brake piping
a: 10 mm (0.39 in)
E
NT406
BR
Pin punch
Removing and installing reservoir tank
a: 4 mm (0.16 in)
G
NT410
• Air tight
Handy vacuum pump I
• Inspection of check valve
ZZC1313D J
K
Brake caliper wrench (front) Return the piston
L
NNFIA0040ZZ
Brake caliper wrench (rear) Return the piston

N
JSFIA0929ZZ

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [TYPE 1]
SYMPTOM DIAGNOSIS
NVH Troubleshooting Chart INFOID:0000000006965258
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
NVH in FAX, RAX and FSU, RSU section

BR-17, BR-19
BR-17, BR-19
BR-39, BR-47
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
Reference page
NVH in FAX section

NVH in WT section
NVH in WT section
NVH in ST section
AXLE AND SUSPENSION
Rotor thickness variation
Pads uneven wear
Rotor deformation
Rotor imbalance
Shims damaged
Rotor deflection
Possible cause and
Pads damaged
ROAD WHEEL
DRIVE SHAFT
Rotor damage
SUSPECTED PARTS Rotor runout
STEERING
Rotor rust
TIRE
Noise × × × × × × × ×
×
Symptom BRAKE Shake × × × × ×
×
Shimmy, Judder × × × × × × × × × × ×
×: Applicable

BRAKE PEDAL
< PERIODIC MAINTENANCE > [TYPE 1]
PERIODIC MAINTENANCE A
BRAKE PEDAL
Inspection and Adjustment INFOID:0000000006965259
B
INSPECTION
Brake Pedal Height C
Check the height (H1) between the dash lower panel (1) and the
brake pedal upper surface.
D
H1 : Refer to BR-54, "Brake Pedal".
CAUTION:
Remove the floor trim. E
BR
JPFIA0065ZZ
Stop Lamp Switch

Check the clearance (C) among the brake pedal lever (1) and the G
stop lamp switch (2) threaded end.
C : Refer to BR-54, "Brake Pedal". H

CAUTION:
The stop lamp must turn off when the brake pedal is released.
I
J
PFIA0813J
Brake Pedal Play

Press the brake pedal. Check the brake pedal play (A) (stroke until K
fluid pressure occurs).
A : Refer to BR-54, "Brake Pedal".

L
JPFIA0277ZZ
N
Depressed Brake Pedal Height
Check the height between the dash lower panel (1) and the brake
pedal upper surface (H2) when depressing the brake pedal at 490 N O
(50 kg, 110 lb) while turning engine ON.

P
CAUTION:
Remove the floor trim.
JPFIA0068ZZ
ADJUSTMENT

BRAKE PEDAL
Brake Pedal Height
1. Remove instrument lower panel. Refer to IP-13, "Removal and Installation".
2. Disconnect the stop lamp switch harness connector.
3. Loosen the stop lamp switch 45° counterclockwise.
4. Loosen the lock nut (1) of input rod (2).
5. Rotate the input rod, adjust the brake pedal to the specified
height (H1).
CAUTION:
The threaded end of the input rod must project to the inner
side (L) of the clevis (3).
JPFIA0003ZZ

6. Tighten the lock nut. Refer to BR-33, "Exploded View".
7. Adjust the clearance between the brake pedal lever and the stop
lamp switch threaded end after adjusting the brake pedal height.
JPFIA0279ZZ
Stop Lamp Switch

2. Disconnect the harness connector from stop lamp switch.
4. Press-fit the stop lamp switch (2) until the stop lamp switch hits
the brake pedal lever (1) 45° clockwise while pulling the brake
pedal pad slightly.
CAUTION:
• The clearance (C) between the brake pedal lever and stop
lamp switch threaded and must be the specified value.
C : Refer to BR-54, "Brake Pedal".

• The stop lamp must be turned off when the brake pedal is
released.
PFIA0813J

1. Perform the air bleeding. Refer to BR-14, "Bleeding Brake System".
2. Check the height between the dash lower panel (1) and the
brake pedal upper surface (H2) when depressing the brake
pedal at 490 N (50 kg, 110 lb) while turning engine ON.

CAUTION:
JPFIA0068ZZ

BRAKE FLUID
BRAKE FLUID
A
Inspection INFOID:0000000006968046
BRAKE FLUID LEVEL B

• Check that the fluid level in the reservoir tank is within the specified
range (MAX – MIN lines).
• Visually check for any brake fluid leakage around the reservoir C
tank.
• Check the brake system for any leakage if the fluid level is
extremely low (lower than MIN).
• Check the brake system for fluid leakage if the warning lamp D
remains illuminated even after the parking brake is released.
• Check the reservoir tank for the mixing of foreign matter (e.g. dust)
and oils other than brake fluid. E
JPFIA0007ZZ
BRAKE LINE
BR
1. Check brake line (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
2. Check for brake fluid leakage by fully depressing brake pedal
G
while engine is running.
CAUTION:
Retighten the applicable connection to the specified torque
and repair any abnormal (damaged, worn or deformed) part H
if any brake fluid leakage is present.
I
SBR389C
Draining INFOID:0000000006968047
J
CAUTION:
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
K
• Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) har-
ness connector or the battery negative terminal before performing work.
1. Connect a vinyl tube to the bleed valve.
L
2. Depress the brake pedal and loosen the bleeder valve to gradu-
ally discharge brake fluid.
BRA0007D
O
Refilling INFOID:0000000006968048
CAUTION: P

BRAKE FLUID
1. Check that there is no foreign material in the reservoir tank, and
refill with new brake fluid.
CAUTION:
• Never allow foreign matter (e.g. dust) and oils other than
brake fluid to enter the reservoir tank.
2. Loosen the bleeder valve, slowly depress the brake pedal to the
full stroke, and then release the pedal. Repeat this operation at
intervals of 2 or 3 seconds until new brake fluid is discharged.
Then close the bleeder valve with the brake pedal depressed.
Repeat the same work on each wheel. PFIA0403J
3. Perform the air bleeding. Refer to BR-14, "Bleeding Brake Sys-

tem".
Bleeding Brake System INFOID:0000000006968049
CAUTION:
ness connector or the battery negative terminal before performing the work.
• Monitor the fluid level in the reservoir tank while performing the air bleeding
• Always use new brake fluid for refilling. Never reuse the drained brake fluid.
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank.
1. Connect a vinyl tube to the bleeder valve of the rear right brake.
2. Fully depress the brake pedal 4 to 5 times.
3. Loosen the bleeder valve and bleed air with the brake pedal depressed, and then quickly tighten the
bleeder valve.
4. Repeat steps 2 and 3 until all of the air is out of the brake line.
5. Tighten the bleeder valve to the specified torque.
• Front disc brake: Refer to BR-39, "BRAKE CALIPER ASSEMBLY : Exploded View".
• Rear disc brake: Refer to BR-48, "BRAKE CALIPER ASSEMBLY : Exploded View".
6. Perform steps 1 to 5. Occasionally fill with the brake fluid in order to keep it in the reservoir tank at least
half of MAX line. Bleed air in the following order: rear right brake → front left brake → rear left brake →
and front right brake in order.
7. Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to BR-
13, "Inspection".
8. Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-11,
"Inspection and Adjustment".

BRAKE MASTER CYLINDER
A
FLUID LEAK B
Check for brake fluid leakage from the master cylinder mounting face, reservoir tank mounting face and brake
tube connections.
C
BR

BRAKE BOOSTER
BRAKE BOOSTER
OPERATION
Depress the brake pedal several times at 5-second intervals with the engine stopped. Start the engine with the
brake pedal fully depressed. Check that the clearance between brake pedal and dash lower panel decreases.
NOTE:
A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. This is a
normal phenomenon due to the brake system operation.
AIR TIGHT
1. Run the engine at idle for 1 minute to apply vacuum to the brake booster, and stop the engine.
2. Depress the brake pedal several times at 5-second intervals until the accumulated vacuum is released to
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually
increases each time the brake pedal is depressed when performing this operation.
3. Depress the brake pedal with the engine running. Then stop the engine while holding down the brake
pedal. Check that the brake pedal stroke does not change after holding down the brake pedal for 30 sec-
onds or more.

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
BRAKE PAD : Inspection and Adjustment INFOID:0000000006965266
B
INSPECTION
Check brake pad wear thickness from an inspection hole on cylinder
body. Check using a scale if necessary. C
Wear thickness : Refer to BR-54, "Front Disc Brake".

D
BRA0010D
BR
ADJUSTMENT
Burnish contact surfaces between disc rotor and brake pads according to the following procedure after refin-
ishing or replacing brake pads, or if a soft pedal occurs at very low mileage.
G
CAUTION:
• Be careful of vehicle speed because the brake does not operate firmly/securely until pads and disc
rotor are securely fitted.
• Only perform this procedure under safe road and traffic conditions. Use extreme caution. H
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake. I
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.
DISC ROTOR J
DISC ROTOR : Inspection and Adjustment INFOID:0000000006965267
K
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary. Refer to L
FAX-13, "Removal and Installation".
Runout
1. Fix the disc rotor to the wheel hub and bearing assembly with M
wheel nuts (2 points at least).
2. Check the wheel bearing axial end play before the inspection.
Refer to FAX-11, "Inspection". N
3. Inspect the runout with a dial indicator to measure at 10 mm
(0.39 in) inside the disc edge.
O
Runout (with it attached : Refer to BR-54, "Front Disc
to the vehicle) Brake".
4. Find the installation position that has a minimum runout by shift- BRA0013D P
ing the disc rotor-to-wheel hub and bearing assembly installation
position by one hole at a time if the runout exceeds the limit value.
• Refinish or replace the disc rotor if the runout is outside the limit even after performing the above operation.
CAUTION:
• Check in advance that the thickness of the disc rotor is wear thickness + 0.3 mm (0.012 in) or more.
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor. Refer to FAX-
13, "Removal and Installation".

FRONT DISC BRAKE

Thickness
Check the thickness of the disc rotor using a micrometer. Replace
the disc rotor if the thickness is below the wear limit. Refer to FAX-
Wear thickness : Refer to BR-54, "Front Disc

Brake".
Thickness variation : Refer to BR-54, "Front Disc
(measured at 8 posi- Brake".
tions)
SBR020B
ADJUSTMENT
Burnish contact surfaces between disc rotors and brake pads according to the following procedure after refin-
ishing or replacing disc rotor, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate firmly/securely until pad and disc
• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
3. Drive without depressing brake for a few minutes to cool the brake.

REAR DISC BRAKE
REAR DISC BRAKE
A
BRAKE PAD
B
INSPECTION
body. Check using a scale if necessary. C
Wear thickness : Refer to BR-54, "Rear Disc Brake".

D
BRA0010D
BR
ADJUSTMENT
G
CAUTION:
• Only perform this procedure under safe road and traffic conditions. Use extreme caution. H
3. Drive without depressing brake for a few minutes to cool the brake. I
DISC ROTOR J
K
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary. Refer to L
RAX-9, "Removal and Installation".
Runout
1. Fix the disc rotor to the wheel hub and bearing assembly with M
Refer to RAX-8, "Inspection". N
O
Runout (with it attached : Refer to BR-54, "Rear Disc
4. Find the installation position that has a minimum runout by shift- JPFIA0648ZZ P
CAUTION:
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor. Refer to

REAR DISC BRAKE
Wear thickness : Refer to BR-54, "Rear Disc Brake".

Thickness
the disc rotor if the thickness is below the wear limit. Refer to RAX-9,
"Removal and Installation".
Wear thickness : Refer to BR-54, "Rear Disc

Brake".
Thickness variation : Refer to BR-54, "Rear Disc
(measured at 8 posi- Brake".
tions)
SBR020B
ADJUSTMENT
ishing or replacing disc rotor, or if a soft pedal occurs at very low mileage.
CAUTION:

BRAKE PEDAL
< REMOVAL AND INSTALLATION > [TYPE 1]
REMOVAL AND INSTALLATION A

BRAKE PEDAL
Exploded View INFOID:0000000006965270
B
BR
JPFIA0867GB J
1. Clevis pin 2. Brake pedal assembly 3. Brake pedal pad

4. Stop lamp switch 5. Clip 6. Snap pin
K
: Apply multi-purpose grease.
: N·m (kg-m, ft-lb) L

Removal and Installation INFOID:0000000006965271
REMOVAL M

2. Disconnect the stop lamp switch harness connector. N
3. Rotate the stop lamp switch (1) counter clockwise to remove.
4. Disconnect the accelerator pedal harness connector and har-
ness clip. O
JPFIA0815ZZ

BRAKE PEDAL
5. Remove snap pin (1) and clevis pin (2) from clevis (3) of brake
booster.
6. Remove the brake pedal assembly.
CAUTION:
Hold the brake booster and master cylinder assembly so as
not to drop out or contact them other parts.
7. Remove accelerator pedal from brake pedal assembly. Refer to
ACC-3, "Removal and Installation".
8. Perform inspection after removal. Refer to BR-22, "Inspection
and Adjustment".
JPFIA0816ZZ
INSTALLATION
Note the following, and install in the reverse order of removal.
• Apply the multi-purpose grease to the clevis pin and the mating faces. (Not necessary if grease has been
already applied)
NOTE:
The clevis pin may be inserted in either direction.
• Do not give an impact caused by dropping, interference with a tool, contact between parts or with rack to the
brake pedal.
• Do not use any part that has been subject to an impact.
• Perform adjustment after installation. Refer to BR-22, "Inspection and Adjustment".
INSPECTION AFTER REMOVAL

• Check for the following items and replace the brake pedal assembly if any is found.
- Check the brake pedal upper rivet (made by aluminum) (A) for
damage and deformation.
- Check the brake pedal for bend, damage, and cracks on the
welded parts.
- Check the lapping length (D) of sub-bracket (B) and slide plate (C).
NOTE:
Check the slide plate for damage and deformation.
D : 5.5 mm (0.217) in or more
JPFIA0854ZZ
• Check clevis pin and plastic stopper (A) for damage and deforma-
tion. If any is found, replace clevis pin.
PFIA0756J
ADJUSTMENT AFTER INSTALLATION

• Adjust each item of brake pedal after installing the brake pedal assembly to the vehicle. Refer to BR-11,
• Perform the release position learning of the accelerator pedal. Refer to EC-531, "Work Procedure".

BRAKE PIPING
BRAKE PIPING
A
FRONT
FRONT : Exploded View INFOID:0000000006965273
B
BR
JPFIA0868GB
J
1. Brake tube 2. ABS actuator and electric unit (con- 3. Master cylinder assembly
trol unit)
4. Brake booster 5. Connector bracket 6. Connector K
7. Lock plate 8. Brake hose 9. Union bolt
10. Copper washer
A. To rear brake tube L
: N·m (kg-m, ft-lb)

M
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
: Indicates that the part is connected at points with same symbol in actual vehicle. N

BRAKE PIPING
FRONT : Hydraulic Piping INFOID:0000000006965274
JSFIA0639ZZ
1. ABS actuator and electric unit (con- 2. Front disc brake 3. Master cylinder assembly
trol unit)
4. Brake booster 5. Connector 6. Rear disc brake
A. Brake tube B. Brake hose
: Flare nut
: Union bolt
FRONT : Removal and Installation INFOID:0000000006965275
REMOVAL
CAUTION:
off immediately and wash with water if it gets on a painted surface. For brake component parts,
never wash them with water.
• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied
with, brake fluid may splash.
1. Remove tires.
2. Drain brake fluid. Refer to BR-13, "Draining".
3. Loosen the flare nut with a flare nut wrench and separate the brake tube from the brake hose.
CAUTION:
• Never scratch the flare nut and the brake tube.
• Never bend sharply, twist or strongly pull out the brake hoses and tubes.
• Cover open end of brake tubes and hoses when disconnecting to prevent entrance of dirt.
4. Remove the union bolt and copper washers, and remove the brake hose from the brake caliper assembly.
5. Remove the lock plate and remove the brake hose.
INSTALLATION
CAUTION:
1. Assemble the union bolt and the copper washer to the brake hose.
CAUTION:

BRAKE PIPING
Never reuse the copper washer.
2. Align the brake hose L-pin by aligning it with the brake caliper A
assembly hole, and tighten the union bolt (1) to the specified
torque.
3. Install the brake tube to the brake hose, temporarily tighten the B
flare nut by hand until it does not rotate further, and fix the brake
hose to the bracket with the lock plate.
CAUTION:
C
Check that all brake hoses and brake tubes are not twisted
and bent.
4. Tighten the flare nut to the specified torque with a flare nut
torque wrench (commercial service tool). JPFIA0012ZZ
D
CAUTION:
Never scratch the flare nut and the brake tube.
5. Refill with new brake fluid and perform the air bleeding. Refer to BR-14, "Bleeding Brake System". E
CAUTION:
Never reuse drained brake fluid.
6. Install tires. Refer to WT-7, "Exploded View". BR
7. Perform inspection after installation. Refer to BR-25, "FRONT : Inspection".
FRONT : Inspection INFOID:0000000006965276
G
INSPECTION AFTER INSTALLATION
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer- H
ence with other components when steering the steering wheel; no looseness at connections.
CAUTION:
Clearance with brake hose and each parts being secured more than 10 mm (0.39 in) in unladen
I
condition*.
*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in desig-
nated positions.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately J
5 seconds with the engine running. Check for any fluid leakage.
CAUTION:
Retighten the applicable connection to the specified torque and repair any abnormal (damaged, K
worn or deformed) part if any brake fluid leakage is present.
REAR
L

BRAKE PIPING
REAR : Exploded View INFOID:0000000006965277
JSFIA0895GB
1. Brake tube A 2. Brake hose A 3. Lock plate

4. Brake tube B 5. Brake hose bracket 6. Brake hose B
7. Copper washer 8. Union bolt
A. To connector

: Indicates that the part is connected at points with same symbol in actual vehicle.

BRAKE PIPING
REAR : Hydraulic Piping INFOID:0000000006978732
BR
JSFIA0639ZZ
G
trol unit)
4. Brake booster 5. Connector 6. Rear disc brake
A. Brake tube B. Brake hose H
: Flare nut
: Union bolt I
REAR : Removal and Installation INFOID:0000000006965279
J
REMOVAL
CAUTION:
off immediately and wash with water if it gets on a painted surface. For brake component parts, K
with, brake fluid may splash. L
1. Remove tires.
3. Loosen the flare nut with a flare nut wrench and separate the brake tube A from the brake hose A. M
CAUTION:
• Never bend sharply, twist or strongly pull out the brake hoses and tubes. N
4. Remove the lock plate and remove the brake hose A.
5. Loosen the flare nut with a flare nut wrench and separate the brake tube B from the brake hose B. O
CAUTION:
• Cover open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. P
6. Remove the lock plate from brake hose bracket.
7. Remove the union bolt and copper washers, and remove the brake hose B from the brake caliper assem-
bly.
INSTALLATION
CAUTION:

BRAKE PIPING
1. Assemble the union bolt and the copper washer to the brake hose B.
CAUTION:
2. Align the brake hose B L-pin with the brake caliper assembly
hole, and tighten the union bolt to the specified torque.
3. Install the brake tube B to the brake hose B, temporarily tighten
the flare nut by hand until it does not rotate further, and fix the
brake hose B to the brake hose bracket with the lock plate.
CAUTION:
and bent.
torque wrench (commercial service tool).
CAUTION: JPFIA0012ZZ

5. Install the brake tube A to the brake hose A, temporarily tighten the flare nut by hand until it does not
rotate further, and fix the brake hose with the lock plate.
CAUTION:
Check that all brake hoses and brake tubes are not twisted and bent.
6. Tighten the flare nut to the specified torque with a flare nut torque wrench (commercial service tool).
CAUTION:
7. Refill with new brake fluid and perform the air bleeding. Refer to BR-14, "Bleeding Brake System".
CAUTION:
8. Install tires. Refer to WT-7, "Exploded View".
9. Perform inspection after installation. Refer to BR-28, "REAR : Inspection".
REAR : Inspection INFOID:0000000006965280

1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no looseness
at connections.
CAUTION:
condition*.
nated positions.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately
CAUTION:
Retighten the applicable connection to the specified torque and repair any abnormal (damaged,

A
BR
I
JPFIA0886GB
1. Reservoir cap 2. Oil strainer 3. Reservoir tank J

4. Pin 5. Grommet 6. Cylinder body
7. Secondary piston assembly 8. Primary piston assembly 9. Stopper cap
10. O-ring K
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
: Apply brake fluid. L

: Always replace after every disassembly. M
N
REMOVAL
CAUTION:
off immediately and wash with water if it gets on a painted surface. O
• Depress the brake pedal several times to release the vacuum pressure from the brake booster. Then
remove the master cylinder assembly.
1. Perform inspection before removal. Refer to BR-31, "Inspection". P
3. Remove battery. Refer to PG-149, "FOR MAINTENANCE REQUIRED BATTERY MODELS : Removal
and Installation" (maintenance required battery), PG-150, "FOR MAINTENANCE FREE BATTERY MOD-
ELS : Removal and Installation" (maintenance free battery).
4. Remove air duct and air cleaner case. Refer to EM-157, "Removal and Installation".

5. Move IPDM E/R not to interfere work. Refer to PCS-39, "Removal and Installation" (with I-KEY), PCS-73,
"Removal and Installation" (without I-KEY).
6. Disconnect the brake fluid level switch harness connector.
7. Remove the brake tube from between ABS actuator and electric unit (control unit) and master cylinder
assembly with a flare nut wrench.
CAUTION:
8. Separate reservoir hose from reservoir tank. Refer to CL-16, "LHD : Removal and Installation". (M/T)
9. Remove the master cylinder assembly.
CAUTION:
• Never deform or bend the brake tubes.
• Never depress the brake pedal after the master cylinder assembly is removed.
10. Remove the O-ring.
INSTALLATION
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
• Never reuse the O-ring.
• Apply silicone grease to the brake booster [see (A) in the figure]
when installing the master cylinder assembly to the brake booster.
• Temporarily tighten the brake tube flare nut to the master cylinder
assembly by hand. Then tighten it to the specified torque with a
flare nut torque wrench (commercial service tool). Refer to BR-23,
"FRONT : Exploded View".
CAUTION:
• Never allow foreign matter (e.g. dust) and oils other than brake
fluid to enter the reservoir tank.
JPFIA0013ZZ
• After installation, perform the air bleeding. Refer to BR-14, "Bleed-
ing Brake System"
CAUTION:
• Perform inspection after installation. Refer to BR-31, "Inspection".
Disassembly and Assembly INFOID:0000000006982054
DISASSEMBLY
CAUTION:
• Remove the reservoir tank only when necessary.
• Never drop the removed parts. The parts must not be reused if they are dropped.
1. Fix the master cylinder assembly to a vise.
CAUTION:
• Always set copper plates or cloth between vise grips when fixing the cylinder body to a vise.
• Never overtighten the vise.
2. Remove the reservoir tank mounting pin with a pin punch [4 mm (0.157 in)] (commercial service tool).
3. Remove master cylinder from vise.
4. Remove the reservoir tank and grommet from the cylinder body.

5. Raise the stopper cap tab with a suitable tool to remove the
stopper cap from the cylinder body. A
6. Remove the primary piston assembly.
CAUTION:
Pull out the primary piston assembly straight, being careful B
not to damage the cylinder body inner wall.
7. Remove the secondary piston assembly.
CAUTION:
C
Pat the flange on a piece of wood. Pull out the secondary
piston assembly straight, being careful not to damage the
cylinder body inner wall. BRA0031D
D
ASSEMBLY
CAUTION:
• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and
assembly process. E
• Never drop the when installing. The parts must not be reused if they are dropped.
1. Apply new brake fluid to the cylinder body inner wall, primary piston assembly and secondary piston, and BR
then install to the primary piston assembly and the secondary piston.
CAUTION:
• Never reuse the secondary piston assembly and the primary piston assembly. G
• Replace the secondary piston assembly, the primary piston assembly and the stopper cap as a
set.
• Install the secondary piston assembly before installing the primary piston assembly.
• Install the secondary piston assembly and the primary piston assembly straight in the specified H
direction, being careful not to damage the cylinder body inner wall.
2. Install the stopper cap.
CAUTION: I
• Never reuse the stopper cap.
• Replace the secondary piston assembly, the primary piston assembly and the stopper cap as a
set. J
• Press the primary piston assembly with the stopper cap
until the stopper cap tab ( ) gets caught in the cylinder
body groove.
K
3. Apply new brake fluid to the grommet and install it to the cylinder
body.
CAUTION:
Never reuse the grommets. L
4. Install the reservoir tank to the cylinder body.
5. Fix the cylinder body to a vise.
CAUTION: M
BRA0535D
• Place the reservoir tank with the chamfered pin hole fac-
ing up.
• Always set copper plates or cloth between vise grips when fixing the cylinder body to a vise. N
6. Tilt the reservoir tank so that a mounting pin can be inserted. Insert a mounting pin. Return the reservoir O
tank to the horizontal position. Insert another mounting pin into the pin hole on the opposite side in the
same manner after the mounting pin passes through the cylinder body pin hole.
CAUTION:
Never reuse the mounting pin. P
INSPECTION BEFORE REMOVAL

Check the brake fluid level switch. Refer to BRC-84, "Component Inspection".

Check the following items and replace if necessary.
• Check the master cylinder for deformation, twist, contact with other parts or looseness of connection.
• Check for fluid leakage from connection. Refer to BR-25, "FRONT : Inspection".
CAUTION:
If the fluid leakage is present, retighten to the specified torque. Replace if necessary.

BRAKE BOOSTER AND CHECK VALVE
A
BR
G
JPFIA0870GB
1. Master cylinder assembly 2. Check valve 3. Brake booster

4. Lock nut 5. Clevis 6. Gasket
H

I
Removal and installation INFOID:0000000006995569
REMOVAL J
CAUTION:
off immediately and wash with water if it gets on a painted surface. K
2. Perform inspection before removal. Refer to BR-34, "Inspection and Adjustment".
3. Remove battery. Refer to PG-149, "FOR MAINTENANCE REQUIRED BATTERY MODELS : Removal L
4. Remove air duct and air cleaner case. Refer to EM-157, "Removal and Installation". M
6. Remove brake master cylinder assembly. Refer to BR-29, "Removal and Installation". N
7. Remove vacuum hose from check valve. Refer to BR-36, "Removal and Installation".
8. Remove snap pin (1) and clevis pin (2). Refer to BR-21,
"Exploded View". O
9. Remove nuts on brake booster and brake pedal assembly. Refer
to BR-33, "Exploded View".
10. Remove brake booster from dash panel in engine room side. P
CAUTION:
Never deform or bend the brake tubes.
NOTE:
If removing brake booster is difficult, remove clevis from brake
booster.
11. Remove check valve from brake booster. JPFIA0019ZZ
12. Perform inspection after removal. Refer to BR-34, "Inspection and Adjustment".

INSTALLATION
CAUTION:
• Set check valve angle (A) as shown in the figure.
A : 25° – 45°
• Be careful not to damage brake booster stud bolt threads. If brake
booster is tilted during installation, the dash panel may damage the
threads.
• Never deform or bend the brake tubes when installing the brake
booster.
• Always use a new gasket between the brake booster and the dash
panel.
• Replace the clevis pin if it is damaged. Refer to BR-22, "Inspection JPFIA0871ZZ
and Adjustment".
• After installation, perform the air bleeding. Refer to BR-14, "Bleeding Brake System".
CAUTION:
• Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-11,

Air Tight
CAUTION:
Check the air tight condition when the master cylinder and the brake booster is installed.
1. Check the air tight use a handy vacuum pump (commercial service tool).
At vacuum of −66.7 kPa (−500 mmHg, : Vacuum should decrease within 3.3 kPa (24.8 mmHg,
−19.69 inHg, −0.067 bar) 0.98 inHg, 0.033 bar) for 15 seconds.
2. If the air tight condition cannot be maintained, perform the following operation.
a. Check the no dirt and dust are present on the brake booster and brake master cylinder mating faces.
Clean it if necessary.
b. Check the O-ring on the master cylinder. If anything is found, replace the O-ring. Refer to BR-29,
c. Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster.
Check Valve Air Tightness
1. Check the air tight use a handy vacuum pump (commercial ser-
vice tool).
When connected to the : Vacuum should decrease

booster side (B) within 1.3 kPa (9.8 mmHg, 0.38
inHg, 0.013 bar) for 15 sec-
onds under a vacuum of −66.7
kPa (−500 mmHg, −19.69 inHg,
−0.067 bar).
When connected to the :Vacuum should not exist. JPFIA0024ZZ
vacuum hose side (C)
2. If the condition still cannot be maintained, replace the check valve.

Input Rod Length Inspection
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci- A
fied length (A).
A : Refer to BR-54, "Brake Booster". B

2. Tighten the lock nut to the specified torque.
C
JPFIA0238ZZ
D

Operation E
brake pedal fully depressed. Check that the clearance between brake pedal and dash lower pane decreases.
NOTE: BR
Air Tight G
1. Run the engine at idle for 1 minute to apply vacuum to the brake booster, and stop the engine. Then
depress the brake pedal several times at 5-second intervals until the accumulated vacuum is released to
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually H
onds or more. I

Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-11, "Inspection and J
Adjustment".

VACUUM LINES
VACUUM LINES
JSFIA0917ZZ
1. Clamp 2. Vacuum hose 3. Vacuum piping

A. To brake booster B. Paint mark C. To intake manifold
REMOVAL
Remove the vacuum hose and vacuum piping.
INSTALLATION
Note the following, install the vacuum hose.
• When installing vacuum hose, insert it until its tip reaches the
back-end of length (A) or further as shown in the figure.
CAUTION:
Never use lubricating oil during assembly.
A : 24 mm (0.95 in) or more

- Face the paint mark of vacuum hose (intake manifold side) to the
upward to assemble.
- Face the other paint marks of vacuum hose to vehicle front side to
assemble.
- For clamp mounting direction (the orientation of pawl), refer to BR- JPFIA0023ZZ
36, "Exploded View".


Appearance
Check for correct assembly, damage and deterioration.

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
BRAKE PAD : Exploded View INFOID:0000000006998308
B
BR
JSFIA0979GB
H
1. Cylinder body 2. Inner shim cover 3. Inner shim
4. Inner pad (with pad wear sensor) 5. Pad return spring 6. Pad retainer
7. Torque member 8. Outer pad 9. Outer shim
I
10. Outer shim cover
1: Apply MOLYKOTE® AS880N or silicone-based grease.

J
2: Apply MOLYKOTE® 7439 or equivalent.

K
BRAKE PAD : Removal and Installation INFOID:0000000006998309
REMOVAL L
WARNING:
Since dust covering the front brake has an affect on human body, the dust must be removed with a
dust collector. Never splatter the dust with an air blow gun. M
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out.
1. Remove tires. N
2. Remove lower sliding pin bolt.
O
JPFIA0832ZZ

FRONT DISC BRAKE
3. Suspend the cylinder body with suitable wire so that the brake
hose will not stretch.
JPFIA0850ZZ
4. Remove the pad return spring, brake pads, shims, shim covers and pad retainers from the torque mem-
ber.
CAUTION:
• Never deform the pad retainer (2) when removing the pad
retainer from the torque member (1).
• Never deform the pad return spring when removing the
pad return spring from the brake pad.
• Never damage the piston boot.
• Never drop the brake pads, shims, and the shim covers.
• Remember each position of the removed brake pads.
5. Perform inspection after removal. Refer to BR-39, "BRAKE PAD
: Inspection".
JPFIA0118ZZ
INSTALLATION
WARNING:
dust collector. Never splatter the dust with an air blow gun.
CAUTION:
• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis-
ton may pop out.
1. Install the pad retainers to the torque member if the pad retain-
ers has been removed.
CAUTION:
• Securely assemble the pad retainers so that it will not be
lifted up from the torque member.
• Never deform the pad retainers.
PFIA0763J
2. Apply MOLYKOTE® AS880N or silicone-based grease to the

mating faces between the inner shim (A) and the inner shim
cover (B), and install them to the inner pad.
CAUTION:
Always replace the shim together with the shim cover when
replacing the brake pad.
3. Apply MOLYKOTE® AS880N or silicone-based grease to the
mating faces between the outer shim (A) and the outer shim
cover (B), and install them to the outer pad.
CAUTION:
Always replace the shim together with the shim cover when JPFIA0764ZZ
replacing the brake pad.

FRONT DISC BRAKE
4. Apply MOLYKOTE® 7439 or equivalent to the mating faces between the brake pads (C) and the pad
retainers, and install the brake pads to the torque member. A
5. Install the pad return spring to the brake pad.
CAUTION:
• Never deform the pad return spring. B
• Correctly insert the pad return spring in to the pad return spring hole on the brake pad.
6. Install cylinder body to torque member.
CAUTION: C
• When replacing brake 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.
NOTE: D
Use a brake caliper wrench (front) (commercial service tool) to easily press piston.
7. Install the lower sliding pin bolt and tighten it to the specified
torque. E
8. Depress the brake pedal several times to check that no drag feel
is present for the front disc brake. Refer to BR-39, "BRAKE PAD
: Inspection". BR
JPFIA0832ZZ
H
BRAKE PAD : Inspection INFOID:0000000006998310
INSPECTION AFTER REMOVAL I

Replace the shims and the shim covers if rust is excessively attached.
1. Check a drag of front disc brake. If any drag is found, follow the procedure described below. J
2. Remove brake pads. Refer to BR-37, "BRAKE PAD : Removal and Installation".
3. Press the piston. Refer to BR-37, "BRAKE PAD : Removal and Installation".
K
4. Install brake pads. Refer to BR-37, "BRAKE PAD : Removal and Installation".
5. Securely depress the brake pedal several times.
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body and replace if L
necessary. Refer to BR-42, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly"
7. Burnish contact surfaces brake pads and disc rotor after refinishing or replacing brake pads, or if a soft
pedal occurs at very low mileage. Refer to BR-17, "DISC ROTOR : Inspection and Adjustment". M
BRAKE CALIPER ASSEMBLY
BRAKE CALIPER ASSEMBLY : Exploded View INFOID:0000000006998462
N
REMOVAL
O

FRONT DISC BRAKE
JPFIA0510GB
1. Brake caliper assembly
DISASSEMBLY
JPFIA0511GB
1. Cap 2. Bleeder valve 3. Cylinder body

4. Piston seal 5. Piston 6. Piston boot
7. Sliding pin 8. Sliding pin boot 9. Bushing
10. Torque member
: Apply rubber grease.
: Apply brake fluid.

BRAKE CALIPER ASSEMBLY : Removal and Installation INFOID:0000000006998463
REMOVAL

FRONT DISC BRAKE
WARNING:
Since dust covering the front brake has an affect on human body, the dust must be removed with a A
CAUTION:
B
out immediately and wash with water if it gets on a protect surface.
1. Remove tires.
C
2. Fix the disc rotor using wheel nuts.
CAUTION:
Never spill or splash brake fluid or grease on the disc rotor. D
4. Remove union bolt and copper washer, and disconnect brake hose from caliper assembly. Refer to BR-
24, "FRONT : Removal and Installation".
CAUTION: E
Never depress the brake pedal while removing the brake hose. If this is not complied with, brake
fluid may splash.
5. Remove torque member mounting bolts, and remove brake cali- BR
per assembly.
CAUTION:
Never drop brake pad and caliper assembly.
G
6. Remove disc rotor. Refer to FAX-13, "Removal and Installation".
JPFIA0835ZZ I
INSTALLATION
WARNING: J
CAUTION:
• Never depress the brake pedal while removing the brake hose. If this is not complied with, brake K
fluid may splash.
out immediately and wash with water if it gets on a protect surface. L
1. Install disc rotor. Refer to FAX-13, "Removal and Installation".
M
2. Install the brake caliper assembly to the steering knuckle and
tighten the torque member mounting bolts to the specified
torque.
CAUTION: N
Never spill or splash any grease and moisture on the brake
caliper assembly mounting face, threads, mounting bolts
and washers. Wipe out any grease and moisture. O
3. Install brake hose and copper washers to brake caliper assem-
bly, and tighten union bolts to the specified torque. Refer to BR-
24, "FRONT : Removal and Installation". P
Never reuse copper washer.
CAUTION:
• Never spill or splash brake fluid or grease on the disc rotor.

FRONT DISC BRAKE
5. Check a drag of front disc brake. If any drag is found, refer to BR-44, "BRAKE CALIPER ASSEMBLY :
Inspection".
7. Perform inspection after installation. Refer to BR-44, "BRAKE CALIPER ASSEMBLY : Inspection".
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000006998464
DISASSEMBLY
NOTE:
Never remove the torque member, pad return spring, brake pad and pad retainers when disassembling and
assembling the cylinder body.
1. Remove the sliding pin bolt, and remove the cylinder body from the torque member. Refer to BR-37,
"BRAKE PAD : Removal and Installation".
CAUTION:
Fix the brake pad at suitable tape so that the brake pad will not drop.
2. Remove sliding pins and sliding pin boots from torque member.
3. Remove bushing (1) from sliding pin (2).
JPFIA0851ZZ
4. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.
CAUTION:
Never get fingers caught in the piston.
MAA0272D
5. Remove piston seal from cylinder body using suitable tool.

CAUTION:
Be careful not to damage a cylinder inner wall.
6. Remove bleeder valve and cap.
7. Perform inspection after disassembly. Refer to BR-44, "BRAKE
CALIPER ASSEMBLY : Inspection".
JPFIA0738ZZ
ASSEMBLY
1. Install bleeder valve and cap.

FRONT DISC BRAKE
2. Apply rubber grease to piston seal (1), and install them to cylin-
der body. A
CAUTION:
Never reuse piston seal.
B
JPFIA0039ZZ
D
3. Apply rubber grease to piston boot (1). Cover the piston (2) end
with piston boot, and then install cylinder side lip on piston boot
securely into a groove on cylinder body.
E
CAUTION:
Never reuse piston boot.
BR
G
JPFIA0739ZZ
4. Apply new brake fluid to piston (1). Push piston into cylinder
H
body by hand and push piston boot (2) piston-side lip into the
piston groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre- I
vent cylinder inner wall from being rubbed.
JPFIA0034ZZ
K
5. Apply rubber grease to mating faces (A) between sliding pin (1)
and bushing (2), and install bushing to sliding pin.
L
N
JPFIA0836ZZ
6. Apply rubber grease to mating faces (A) between sliding pins (1) O
and sliding pin boots (2), and install sliding pins and sliding pin
boots to sliding torque member (3).
7. Install the cylinder body to tighten cylinder body mounting bolts P
to the specified torque. Refer to BR-37, "BRAKE PAD :
Exploded View".
JPFIA0837ZZ

FRONT DISC BRAKE
BRAKE CALIPER ASSEMBLY : Inspection INFOID:0000000006998465
INSPECTION AFTER DISASSEMBLY

Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage.
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil.
Torque Member
Check the torque member for rust, wear, cracks or damage.
Piston
Check the surface of the piston for rust, wear, cracks or damage.
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper.
Sliding Pin and Sliding Pin Boot
Check the sliding pins and sliding boots for rust, wear, cracks or damage.
1. Check a drag of front disc brake. If any drag is found, follow the procedure described below.
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body and replace if
necessary. Refer to BR-42, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".
7. Burnish contact surface between disc rotor and brake pads after refinishing or replacing disc rotor, or if a
soft pedal occurs at very low mileage. Refer to BR-17, "DISC ROTOR : Inspection and Adjustment".

REAR DISC BRAKE
REAR DISC BRAKE
A
BRAKE PAD
B
BR
JSFIA0918GB
H
1. Sliding pin bolt 2. Return spring 3. Cylinder body
4. Inner shim 5. Inner pad (with pad wear sensor) 6. Pad retainer
7. Torque member 8. Outer pad 9. Outer shim
I
: Apply MOLYKOTE® 7439 or equivalent.
: N·m (kg-m, ft-lb) J
K
REMOVAL
WARNING:
Since dust covering the rear brake has an affect on human body, the dust must be removed with a
L
CAUTION:
• If the brake fluid or grease adheres to the disc rotor, quickly wipe it off. M
1. Remove tires.
2. Remove return spring.
3. Press toggle lever (1) in the direction shown by Arrow (A) to N
remove rear cable (2) in the direction shown by Arrow (B).
JSFIA0857ZZ

REAR DISC BRAKE
JSFIA0919ZZ
JSFIA0920ZZ
6. Remove the brake pads, shims, shim covers and pad retainers from the torque member.
CAUTION:
• Never drop the brake pads, shims, and the shim covers.
: Inspection".
JPFIA0118ZZ
INSTALLATION
WARNING:
CAUTION:
ton may pop out.
1. Install the pad retainers (1) to the torque member (2) if the pad
retainers has been removed.
CAUTION:
2. Install the shims to the brake pad.
CAUTION:
Always replace the shim when replacing the brake pad.
PFIA0763J

REAR DISC BRAKE
3. Apply MOLYKOTE® 7439 or equivalent to the mating faces (A)
between the brake pads and the pad retainers. A
4. Install the brake pads to the torque member.
JSFIA0978ZZ
D
5. With the brake caliper wrench (rear) [(A), (commercial service
tool)], turn piston clockwise so that dent (B) of piston and center
line (C) of sliding pin form an angle of 90 degrees. E
BR
G
JSFIA0921GB
6. Align protrusion (A) of inner pad (1) with dent (B) of piston to H
install cylinder body to torque member.
CAUTION:
I
• When replacing brake 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. J
NOTE:
Use a brake caliper wrench (rear) (commercial service tool) to
easily press piston. K
JSFIA0922GB
7. Install the lower sliding pin bolt and tighten it to the specified
torque. L
: Inspection".
M
9. Install rear cable of parking brake to toggle lever.
10. Install return spring.
11. Install tires. Refer to WT-7, "Exploded View". N
JSFIA0919ZZ

O

• Replace the shims and the shim covers if rust is excessively attached. P
• Eliminate rust on the pad retainers and the torque member. Replace them if rust is excessively attached.
1. Check a drag of rear disc brake. If any drag is found, follow the procedure described below.

REAR DISC BRAKE
5. Adjust the parking brake lever stroke. Refer to PB-4, "Inspection and Adjustment".
7. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body and replace if
pedal occurs at very low mileage. Refer to BR-19, "BRAKE PAD : Inspection and Adjustment".
REMOVAL
JSFIA0923GB
DISASSEMBLY
JSFIA0924GB

4. Sliding pin 5. Bushing 6. Sliding pin boot

REAR DISC BRAKE
10. Torque member A

B

C

D
REMOVAL
E
WARNING:
CAUTION: BR
out immediately and wash with water if it gets on a protect surface. For brake component parts,
never wash them with water. G
1. Remove tires.
2. Fix the disc rotor using wheel nuts. H
4. Remove return spring.
5. Press toggle lever (1) in the direction shown by Arrow (A) to I
remove rear cable (2) in the direction shown by Arrow (B).
JSFIA0857ZZ
L
6. Separate brake hose from caliper assembly. Refer to BR-27, "REAR : Removal and Installation".
CAUTION: M
fluid may splash.
7. Remove torque member mounting bolts, and remove brake cali-
N
per assembly.
CAUTION:
8. When removing disc rotor. Refer to RAX-9, "Removal and Instal- O
lation".
JSFIA0925ZZ
INSTALLATION
WARNING:

REAR DISC BRAKE
CAUTION:
out immediately and wash with water if it gets on a protect surface. For brake component parts,
• Never depress the brake pedal while removing the brake hose. If this is not complied with, brake
fluid may splash.
1. Install disc rotor. Refer to RAX-9, "Removal and Installation".
2. Install the brake caliper assembly to the axle housing and
torque.
CAUTION:
Never spill or splash any grease and moisture on the brake
and washers. Wipe out any grease and moisture.
3. Install brake hose. Refer to BR-27, "REAR : Removal and Instal-
lation".
4. Install rear cable of parking brake control to toggle lever.
5. Install return spring. JSFIA0925ZZ

7. Check a drag of rear disc brake. If any drag is found, refer to BR-53, "BRAKE CALIPER ASSEMBLY :
Inspection".
DISASSEMBLY
NOTE:
Never remove the torque member, brake pad and pad retainers when disassembling and assembling the cyl-
inder body.
CAUTION:
2. Remove sliding pin boots from torque member.
3. Remove bushing (1) from sliding pin bolt (2).
JSFIA0496ZZ

REAR DISC BRAKE
4. With the brake caliper wrench (rear) [(A), commercial service
tool], turn piston counterclockwise to remove piston from caliper A
assembly.
JSFIA0926ZZ
D
5. Remove piston seal and piston boot from cylinder body using
seal pick tool.
CAUTION:
E
6. Remove sliding pin boots from cylinder body.
7. Remove bleeder valve and cap. BR
G
JPFIA0738ZZ
ASSEMBLY
H
der body.
CAUTION: I
JPFIA0039ZZ
3. Apply rubber grease to piston boot (1). Cover the piston (2) end L
CAUTION: M
O
JPFIA0739ZZ
4. Install piston to cylinder body as per the following steps.

P

REAR DISC BRAKE
a. Apply new brake fluid to piston (1) and piston boot (2).
b. Push piston into cylinder body by manually turning piston clock-
wise.
JPFIA0034ZZ
c. With brake caliper wrench (rear) [(A), commercial service tool],

turn piston clockwise until it becomes locked.
JSFIA0927ZZ
d. Turn piston counterclockwise so that dent (A) of piston and cen-

ter line (B) of sliding pin form an angle of 90 degrees.
e. Push piston boot and piston-side lip into the piston groove.
JSFIA0928GB
5. Apply rubber grease to mating faces (A) between sliding pin bolt
(1) and bushing (2), and install bushing to sliding pin.
JSFIA0497ZZ

REAR DISC BRAKE
6. Apply rubber grease to mating faces (A) between sliding pin bolt
(1) and sliding pin boots (2), and install sliding pin and sliding pin A
boots to sliding torque member.
7. Install the cylinder body to tighten sliding pin bolts to the speci-
fied torque. Refer to BR-45, "BRAKE PAD : Exploded View". B
JSFIA0498ZZ
D
INSPECTION AFTER DISASSEMBLY E

Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage. BR
CAUTION:
Torque Member G
Piston
Check the surface of the piston for rust, wear, cracks or damage. H
CAUTION:
Sliding Pin, Sliding Pin Boot and Bushing I
Check the sliding pins, sliding boots and bushing for rust, wear, cracks or damage.
J
1. Check a drag of rear disc brake. If any drag is found, follow the procedure described below.
3. Press the piston. Refer to BR-45, "BRAKE PAD : Removal and Installation". K
5. Adjust the parking brake lever stroke. Refer to PB-4, "Inspection and Adjustment".
6. Securely depress the brake pedal several times. L
7. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body and replace if
8. Burnish contact surface between disc rotor and brake pads after refinishing or replacing disc rotor, or if a M

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [TYPE 1]

General Specifications INFOID:0000000006965311
Unit: mm (in)
Cylinder bore diameter 53.96 (2.1244)

Front brake Pad length × width × thickness 115.0 × 41.0 × 9.0 (4.53 × 1.614 × 0.354)
Rotor outer diameter × thickness 260 × 22.0 (10.24 × 0.866)
Rear brake Pad length × width × thickness 72.0 × 36.5 × 8.0 (2.835 × 1.437 × 0.315)
Master cylinder Cylinder bore diameter 20.6 (13/16)
Control valve Valve type Electric brake force distribution
Brake booster Diaphragm diameter 256.0 (10)
Recommended brake fluid Refer to MA-17, "Fluids and Lubricants".
Brake Pedal INFOID:0000000006965312
Unit: mm (in)
Item Standard
Brake pedal height 153.0 – 163.0 (6.02 – 6.42)
Clearance among the brake pedal lever and the stop lamp switch threaded end 0.2 – 1.96 (0.008 – 0.0772)
Brake pedal play 2 – 9 (0.08 – 0.35)
Depressed brake pedal height
72 (2.83) or more
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON]
Brake Booster INFOID:0000000006965313
Unit: mm (in)
Item Standard
Input rod length 125 (4.92)
Front Disc Brake INFOID:0000000006965314
Unit: mm (in)
Item Limit
Brake pad Wear thickness 2.0 (0.079)
Wear thickness 20.0 (0.787)
Disc rotor Thickness variation (measured at 8 positions) 0.008 (0.0003)
Runout (with it attached to the vehicle) 0.055 (0.0022)
Rear Disc Brake INFOID:0000000006965315
Unit: mm (in)
Item Limit

HOW TO USE THIS MANUAL A

B
C
TYPE 2 India production models (LHD) D
E
BR

PRECAUTIONS
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
WARNING:
the event of a collision that would result in air bag inflation, all maintenance must be performed by
connectors.
WARNING:
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
battery, and wait at least 3 minutes before performing any service.
INFOID:0000000007928336
CAUTION:
then disconnect both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
OPERATION PROCEDURE
NOTE:
2. Turn the ignition switch to ACC position.

PRECAUTIONS
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock A
B
the lower end of windshield with urethane, etc to prevent damage to C
windshield.
PIIB3706J
BR
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed G
• Never reuse drained brake fluid. H
them with water.
I
item of brake pedal. Adjust brake pedal if it is outside the standard value. J
improper operation. K
• Turn the ignition switch OFF and disconnect the ABS actuator and L
• Check that no brake fluid leakage is present after replacing the M
parts.
is detected, replace part with a new one. N
JPFIA0061ZZ
rotors, after replacing brake pads or brake shoe, or if a soft pedal
occurs at very low mileage. O
- Rear brake lining: Refer to BR-68, "BRAKE LINING : Inspection and Adjustment".
- Rear brake drum: Refer to BR-68, "BRAKE DRUM : Inspection and Adjustment". P

PREPARATION
PREPARATION
PREPARATION
Flare nut torque wrench

a: 10 mm (0.39 in)
NT406
• Air tight
Handy vacuum pump
ZZC1313D
Brake caliper wrench Return the piston
NNFIA0040ZZ

SYMPTOM DIAGNOSIS A
B

C
BR-66, BR-68
BR-66, BR-68
BR-66, BR-68
BR-66, BR-68
BR-66, BR-68
BR-66
BR-66
BR-66
BR-66
BR-66
Reference page
NVH in FAX section

NVH in WT section
NVH in WT section
NVH in ST section
E
Pads or linings uneven wear BR
AXLE AND SUSPENSION

Pads or linings damaged

Rotor or drum deflection
Rotor or drum damage
Rotor or drum rust
Drum out of round

Rotor deformation
H
Rotor imbalance
Possible cause and
ROAD WHEEL
DRIVE SHAFT
SUSPECTED PARTS
Rotor runout
STEERING
I
TIRE
Noise × × × × × × ×
×
J
×
Shimmy, Judder × × × × × × × × × × × ×
×: Applicable K

BRAKE PEDAL
PERIODIC MAINTENANCE
BRAKE PEDAL
INSPECTION
Brake Pedal Height

CAUTION:
JPFIA0065ZZ
Stop Lamp Switch

Check the clearance (C) among the brake pedal lever (1) and the

CAUTION:
PFIA0813J
Brake Pedal Play

Press the brake pedal. Check the brake pedal play (A) (stroke until
JPFIA0277ZZ

pedal upper surface (H2) when depressing the brake pedal at 490 N

CAUTION:
JPFIA0068ZZ
ADJUSTMENT

BRAKE PEDAL
Brake Pedal Height
1. Remove instrument lower panel. Refer to IP-13, "Removal and Installation". A
B
height (H1).
CAUTION: C
D
E
JPFIA0003ZZ
BR
7. Adjust the clearance between the brake pedal lever and the stop G
JPFIA0279ZZ
I
Stop Lamp Switch
2. Disconnect the harness connector from stop lamp switch. J
the brake pedal lever (1) 45° clockwise while pulling the brake K
pedal pad slightly.
CAUTION:
• The clearance (C) between the brake pedal lever and stop L
C : Refer to BR-96, "Brake Pedal". M

released.
PFIA0813J
N
2. Check the height between the dash lower panel (1) and the O
P
CAUTION:
JPFIA0068ZZ

BRAKE FLUID
BRAKE FLUID
BRAKE FLUID LEVEL

• Visually check for any brake fluid leakage around the reservoir
tank.
• Check the brake system for fluid leakage if the warning lamp
and oils other than brake fluid.
JPFIA0007ZZ
BRAKE LINE
CAUTION:
and repair any abnormal (damaged, worn or deformed) part
SBR389C
CAUTION:
BRA0007D
CAUTION:

BRAKE FLUID
refill with new brake fluid. A
CAUTION:
B
intervals of 2 or 3 seconds until new brake fluid is discharged. C
3. Perform the air bleeding. Refer to BR-63, "Bleeding Brake Sys- D

tem".
E
CAUTION:
ness connector or the battery negative terminal before performing the work. BR
• Always use new brake fluid for refilling. Never reuse the drained brake fluid. G
1. Connect a vinyl tube to the bleeder valve of the rear right brake.
H
bleeder valve.
I
• Front disc brake: Refer to BR-87, "BRAKE CALIPER ASSEMBLY : Exploded View".
• Rear disc brake: Refer to BR-92, "Exploded View". J
half of MAX line. Bleed air in the following order: rear right brake → front left brake → rear left brake →
and front right brake in order. K
62, "Inspection".
8. Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-60, L

FLUID LEAK
tube connections.

BRAKE BOOSTER
BRAKE BOOSTER
A
OPERATION B
NOTE: C
AIR TIGHT D
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually E
pedal. Check that the brake pedal stroke does not change after holding down the brake pedal for 30 sec- BR
onds or more.

FRONT DISC BRAKE
FRONT DISC BRAKE
BRAKE PAD
INSPECTION
body. Check using a scale if necessary.
BRA0010D
ADJUSTMENT
CAUTION:
DISC ROTOR
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary. Refer to
Runout
1. Fix the disc rotor to the wheel hub and bearing assembly with
Refer to FAX-40, "Inspection".

4. Find the installation position that has a minimum runout by shift- BRA0013D

CAUTION:

FRONT DISC BRAKE
Wear thickness : Refer to BR-96, "Front Disc Brake". A

Thickness
the disc rotor if the thickness is below the wear limit. Refer to FAX- B
Wear thickness : Refer to BR-96, "Front Disc C

Brake".
(measured at 8 posi- Brake". D
tions)
SBR020B
E
ADJUSTMENT
ishing or replacing disc rotor, or if a soft pedal occurs at very low mileage. BR
CAUTION:
• Only perform this procedure under safe road and traffic conditions. Use extreme caution. G
H
I

REAR DRUM BRAKE
REAR DRUM BRAKE
BRAKE LINING
BRAKE LINING : Inspection and Adjustment INFOID:0000000007928363
INSPECTION
Brake Lining
1. Remove plug from back plate. Refer to BR-92, "Exploded View".
2. Check brake lining wear thickness (A) from an inspection hole
on back plate. Check using a scale necessary.
A : Refer to BR-96, "Rear Drum Brake".
JSFIA1039ZZ
ADJUSTMENT
Burnish contact surfaces between brake lining and brake drum according to the following procedure after
refinishing or replacing brake lining, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate firmly/securely until brake lining and
brake drum are securely fitted.
4. Repeat steps 1 to 3 until brake lining and brake drum are securely fitted.
BRAKE DRUM
BRAKE DRUM : Inspection and Adjustment INFOID:0000000007928364
INSPECTION
Appearance
Check surface of brake drum for uneven wear, cracks and serious damage. Replace it if necessary. Refer to
Brake Drum Inner Diameter

REAR DRUM BRAKE
Check inner diameter (B) of the brake drum.
A
B : Refer to BR-96, "Rear Drum Brake".
JPFIA0113ZZ
D
ADJUSTMENT
Burnish contact surfaces between brake drum and brake lining according to the following procedure after
refinishing or replacing brake drum, or if a soft pedal occurs at very low mileage.
CAUTION: E
• Be careful of vehicle speed because the brake does not operate firmly/securely until brake drum and
brake lining are securely fitted.
• Only perform this procedure under safe road and traffic conditions. Use extreme caution. BR
3. Drive without depressing brake for a few minutes to cool the brake. G
4. Repeat steps 1 to 3 until brake drum and brake lining are securely fitted.

BRAKE PEDAL
REMOVAL AND INSTALLATION

BRAKE PEDAL
JSFIA1176GB

REMOVAL
ness clip.
JPFIA0815ZZ

BRAKE PEDAL
booster. A
CAUTION:
Hold the brake booster and master cylinder assembly so as B
C
and Adjustment".
JPFIA0816ZZ
D
INSTALLATION
already applied) E
NOTE:
• Do not give an impact caused by dropping, interference with a tool, contact between parts or with rack to the BR
brake pedal.
G
INSPECTION AFTER REMOVAL H

• Check the brake pedal for bend, damage, and cracks on the welded parts, and replace the brake pedal
assembly if any is found.
I
PFIA0756J
L
"Inspection and Adjustment". M
• Perform the release position learning of the accelerator pedal. Refer to EC-1122, "Work Procedure".

BRAKE PIPING
BRAKE PIPING
FRONT
JPFIA0868GB
1. Brake tube 2. ABS actuator and electric unit (con- 3. Master cylinder assembly
trol unit)
4. Brake booster 5. Connector bracket 6. Connector
10. Copper washer
A. To rear brake tube


BRAKE PIPING
BR
JPFIA0869ZZ
G
trol unit)
4. Brake booster 5. Connector 6. Rear drum brake
: Flare nut
: Union bolt I
J
REMOVAL
CAUTION:
1. Remove tires.
3. Loosen the flare nut with a flare nut wrench and separate the brake tube from the brake hose. M
CAUTION:
5. Remove the lock plate and remove the brake hose. O
INSTALLATION
CAUTION:
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it P
CAUTION:

BRAKE PIPING
2. Align the brake hose L-pin by aligning it with the brake caliper
torque.
3. Install the brake tube to the brake hose, temporarily tighten the
CAUTION:
and bent.
CAUTION:
CAUTION:

1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer-
CAUTION:
condition*.
nated positions.
CAUTION:
REAR

BRAKE PIPING
BR
JSFIA1157GB
I
1. Brake tube 2. Lock plate 3. Brake hose
A. To connector
J

K

L
JPFIA0869ZZ

BRAKE PIPING
trol unit)
4. Brake booster 5. Connector 6. Rear drum brake
: Flare nut
: Union bolt
REMOVAL
CAUTION:
1. Remove tires.
CAUTION:
• Never bend sharply, twist or strongly pull the brake hoses and tubes.
4. Remove the lock plate and remove the brake hose from the vehicle.
5. Loosen the flare nut with a flare nut wrench and separate the brake tube from the wheel cylinder, and
remove the brake tube.
CAUTION:
INSTALLATION
CAUTION:
1. Install the brake tube to the wheel cylinder, temporarily tighten the flare nut by hand until it does not rotate
further.
2. Install the brake hose to the brake tube, temporarily tighten the flare nut by hand until it does not rotate
further, and fix the brake hose to the bracket with the lock plate.
CAUTION:
Check that the brake hoses and tubes are not twisted and bent.
3. Tighten the flare nut to the specified torque with a flare nut flare nut torque wrench (commercial service
tool).
CAUTION:
CAUTION:

BRAKE PIPING
A
at connections. B
CAUTION:
condition*. C
nated positions.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately D
CAUTION:
E
BR

JSFIA1027GB
1. Reservoir cap 2. Oil strainer 3. Reservoir tank

4. Grommet 5. Cylinder body 6. O-ring

REMOVAL
CAUTION:
1. Perform inspection before removal. Refer to BR-80, "Inspection".
3. Remove battery. Refer to PG-149, "FOR MAINTENANCE REQUIRED BATTERY MODELS : Removal
4. Remove air duct and air cleaner case. Refer to EM-284, "Removal and Installation".

7. Remove the brake tube from between ABS actuator and electric unit (control unit) and master cylinder
assembly with a flare nut wrench. A
CAUTION:
8. Separate reservoir hose from reservoir tank. Refer to CL-16, "LHD : Removal and Installation". (M/T) B
CAUTION:
C
INSTALLATION D
CAUTION:
off immediately and wash with water if it gets on a painted surface. E
• Apply silicone grease to the brake booster [see (A) in the figure] BR
• The piston of the master cylinder assembly is exposed. Never
damage it when handling the master cylinder and check that no dirt G
and dust are present on the piston before installation. Clean it with
new brake fluid if necessary.
• The piston may drop off when pulled strongly. Never hold the pis-
ton. Hold the cylinder body when handling the master cylinder H
assembly.
• Temporarily tighten the brake tube flare nut to the master cylinder I
JPFIA0013ZZ
flare nut torque wrench (commercial service tool). Refer to BR-72, "FRONT : Exploded View".
CAUTION:
Never scratch the flare nut and the brake tube. J
CAUTION: K
Disassembly and Assembly INFOID:0000000007928383 L
DISASSEMBLY
CAUTION: M
• Never disassemble the cylinder body.
• Never drop the removed parts. The parts must not be reused if they are dropped. N
Remove the reservoir tank and grommet from the cylinder body.
ASSEMBLY
CAUTION: O
assembly process.
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank. P
1. Apply new brake fluid to the grommet and install it to the cylinder body.
CAUTION:
Never reuse the grommets.


CAUTION:

A
BR
G
JSFIA1028GB

H

I
REMOVAL J
CAUTION:
off immediately and wash with water if it gets on a painted surface. K
3. Remove battery. Refer to PG-149, "FOR MAINTENANCE REQUIRED BATTERY MODELS : Removal L
4. Remove air duct and air cleaner case. Refer to EM-284, "Removal and Installation". M
6. Remove brake master cylinder assembly. Refer to BR-78, "Removal and Installation". N
"Exploded View". O
10. Remove brake booster from dash panel in engine room side. P
CAUTION:
NOTE:
booster.

INSTALLATION
CAUTION:
A : 45°
threads.
booster.
panel.
• Replace the clevis pin if it is damaged. Refer to BR-71, "Inspection JPFIA0871ZZ
and Adjustment".
CAUTION:

Air Tight
CAUTION:
vice tool).

kPa (−500 mmHg, −19.69 inHg,
−0.067 bar).

1. Loosen the lock nut (1) and adjust the input rod (2) to the speci- A
fied length (A).
A : Refer to BR-96, "Brake Booster". B

C
JPFIA0238ZZ
D

Operation E
NOTE: BR
Air Tight G
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually H
onds or more. I

Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-60, "Inspection and J
Adjustment".

VACUUM LINES
VACUUM LINES
JPFIA0872ZZ
1. Clamp 2. Vacuum hose 3. Vacuum piping

REMOVAL
Remove the vacuum hose and vacuum piping.
INSTALLATION
CAUTION:

- Face the paint mark of vacuum hose (intake manifold side) to the
upward to assemble.
- Face the other paint marks of vacuum hose to vehicle front side to
assemble.


Appearance

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
B
BR
JPFIA0878GB
H
1. Cylinder body 2. Inner pad (with pad wear sensor) 3. Pad retainer
4. Torque member 5. Outer pad (with double faced adhe-
sive tape)
I
BRAKE PAD : Removal and Installation INFOID:0000000007928447 J
REMOVAL
WARNING: K
CAUTION: L
1. Remove tires. M
P
JPFIA0832ZZ

FRONT DISC BRAKE
JPFIA0850ZZ
4. Remove the brake pads from the torque member.

CAUTION:
• When removing the outer pad, never deform or cut the double-faced tape bonding the outer pad
and the cylinder pawl.
• If the double-faced tape is deformed or cut, replace brake pad.
• Keep the double-faced tape placed on the outer pad side.
• Never touch the double-faced tape to keep its stickiness.
• Never drop the brake pads.
: Inspection".
JPFIA0118ZZ
INSTALLATION
WARNING:
CAUTION:
ton may pop out.
CAUTION:
2. Install the pad return springs to the brake pad.
CAUTION:
Never touch the double-faced tape to keep its stickiness.
3. Remove the protector paper of the double-faced tape when
replacing the new brake pad. PFIA0763J
CAUTION:
CAUTION:
• Clean the pawl of the cylinder body.
• Never deform or cut the double-faced tape.

FRONT DISC BRAKE
brake fluid returns to master cylinder reservoir tank when pressing piston in. A
NOTE:
Use a brake caliper wrench (commercial service tool) to easily press piston.
5. Install the lower sliding pin bolt and tighten it to the specified B
torque.
6. Press the outer pad in the cylinder body pawl direction.
CAUTION:
C
Securely place the double-faced tape.
: Inspection". D
JPFIA0832ZZ E
INSPECTION AFTER INSTALLATION BR

G
5. Securely depress the brake pedal several times. H
7. Burnish contact surfaces brake pads and disc rotor after refinishing or replacing brake pads, or if a soft I
J
REMOVAL K
JPFIA0879GB

FRONT DISC BRAKE
DISASSEMBLY
JPFIA0880GB

7. Sliding pin 8. Sliding pin boot 9. Torque member

REMOVAL
WARNING:
CAUTION:
1. Remove tires.
CAUTION:
Never spill or splash brake fluid or grease on the disc rotor.
CAUTION:
fluid may splash.

FRONT DISC BRAKE
per assembly. A
CAUTION:
6. Remove disc rotor. Refer to FAX-42, "Removal and Installation". B
JPFIA0835ZZ
D
INSTALLATION
WARNING:
E
CAUTION:
fluid may splash. BR
G
2. Install the brake caliper assembly to the steering knuckle and H
torque.
CAUTION:
Never spill or splash any grease and moisture on the brake I
3. Install brake hose and copper washers to brake caliper assem- J
K
CAUTION:
• Never reuse drained brake fluid. L
Inspection". M
N
DISASSEMBLY O
NOTE:
inder body.
P
CAUTION:

FRONT DISC BRAKE
CAUTION:
MAA0272D

CAUTION:
JPFIA0738ZZ
ASSEMBLY
der body.
CAUTION:
JPFIA0039ZZ
CAUTION:
JPFIA0739ZZ

FRONT DISC BRAKE
body by hand and push piston boot (2) piston-side lip into the A
piston groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre-
B
JPFIA0034ZZ
D
5. Apply rubber grease to mating faces (A) between sliding pins (1)
E
6. Install the cylinder body to tighten cylinder body mounting bolts
Exploded View".
BR
G
JPFIA0837ZZ

H
I
Cylinder Body
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil. J
Torque Member
K
Piston
CAUTION: L
Check the sliding pins and sliding boots for rust, wear, cracks or damage. M
2. Remove brake pads. Refer to BR-85, "BRAKE PAD : Removal and Installation". N
O
P

REAR DRUM BRAKE
REAR DRUM BRAKE
JPFIA0881GB
1. Shoe hold pin 2. Back plate 3. Plug

4. Brake shoe 5. Spring 6. Retainer
7. Upper Spring 8. Adjuster 9. Adjuster spring
10. Return spring (lower side) 11. Brake drum 12. Boot
13. Piston 14. Piston cup 15. Spring
16. Wheel cylinder 17. Bleeder valve 18. Cap
1: Apply polyglycol ether based lubricant.

2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.

REMOVAL
WARNING:
CAUTION:
• Never depress the brake pedal while removing the brake drum because the piston may pop out.
• Never drop the removed parts.
• Never spill or splash brake fluid on the brake drum.
1. Remove tires.
2. Perform drain the brake fluid when remove or disassemble the wheel cylinder. Refer to BR-62, "Draining".

REAR DRUM BRAKE
3. Release parking brake lever, and then remove brake drum. Refer to RAX-19, "Removal and Installation".
4. While pushing and rotating the spring (1), pull out shoe hold pin, A
and remove brake shoe assembly (brake shoe, each spring, and
adjuster).
CAUTION: B
Never damage the boot of the wheel cylinder.
5. Remove the parking brake cable from operating lever.
CAUTION:
C
Never bend sharply the parking brake lever.
JPFIA0852ZZ
D
6. Disassemble the brake shoe assembly (brake shoe, each

spring, and adjuster). E
7. Remove the wheel cylinder with the following procedure.
a. Separate the brake tube from the wheel cylinder.
BR
b. Remove the wheel cylinder from back plate.
and Adjustment".
G
JPFIA0882ZZ
H
INSTALLATION
WARNING:
Since dust covering the rear brake has an affect on human body, the dust must be removed with a I
CAUTION:
• Never depress the brake pedal while removing the brake drum.
• Never drop the removed parts. J
Note the following, and install in the reverse of removal.
• Check the difference between left and right wheel of adjuster. K
: Vehicle front
Adjuster Direction L
Left side Left screw
Right side Right screw
M
• Shorten adjuster by rotating it.
• Apply PBC (Poly Butyl Cuprysil) silicone-based grease to the mat-
ing faces between the adjuster and brake shoe.
• Apply PBC (Poly Butyl Cuprysil) silicone-based grease to the mat- N
ing faces between the back plate and brake shoe. JPFIA0883ZZ
• Never damage the wheel cylinder.

• Check the component parts of drum brake assembly are installed O
properly.
• Check the brake shoe sliding surface and brake drum inner sur-
face for grease. Wipe it out any adheres to the surfaces.
• Perform the air bleeding when removed or disassembled the wheel P
cylinder. Refer to BR-63, "Bleeding Brake System".
• Adjust the brake shoe clearance (parking brake lever stroke) after
install and air bleeding. Refer to PB-10, "Inspection and Adjust-
ment".
JPFIA0884ZZ

REAR DRUM BRAKE
DISASSEMBLY
1. Remove the boot from wheel cylinder. Refer to BR-92, "Exploded View".
2. Remove the piston, piston cup and spring from wheel cylinder.
CAUTION:
Pull the piston out from the wheel cylinder to prevent the wheel cylinder inner wall from being
damaged.
3. Remove piston cup from piston.
4. Perform inspection after disassembly. Refer to BR-94, "Inspection and Adjustment".
ASSEMBLY
1. Apply polyglycol ether based lubricant to the piston cup (1) and
boot (2).
2. Install piston cup and boot to piston (3).
CAUTION:
• Never mistake the direction.
• Never reuse piston cup and boot.
3. Apply new brake fluid to piston and wheel cylinder inner wall,
and install spring and piston to wheel cylinder.
CAUTION:
Never damage the wheel cylinder inner wall.
4. Install the boot to wheel cylinder. Refer to BR-92, "Exploded JPFIA0885ZZ
View".
5. Perform inspection after assembly. Refer to BR-94, "Inspection and Adjustment".

• Check the brake lining for excessive wear, damage, and peeling.
• Check the brake shoe sliding surface for excessive wear and damage.
• Check each spring for settling, excessive wear, damage, and rust.
• Check the adjuster for smoothness, and check it for excessive wear, damage, and rust.
• Check the back plate for damage, cracks, and deformation.
• Check the wheel cylinder for cracks, damage, and leakage of brake fluid.
• Visually check the brake drum for excessive wear, cracks, and damage with a pair of vernier calipers.
• Check the drum brake component parts for excessive wear, damage, and rust.
• Check the wheel cylinder inner wall for excessive wear, cracks, and damage.
• Check the piston for excessive wear and damage.
INSPECTION AFTER ASSEMBLY
Check that the piston moves smoothly.
1. Check that the component parts of drum brake assembly are installed properly.
2. Rotate the brake drum and check that there is no drag. Perform the following procedure if necessary.
3. Remove the brake shoe. Refer to BR-92, "Removal and Installation".
4. Push the piston.
CAUTION:
Push both side of the piston simultaneously.
5. Install the brake shoe. Refer to BR-92, "Removal and Installation".
6. Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-10, "Inspection and Adjust-
ment".

REAR DRUM BRAKE
7. Check a drag of rear drum brake again. If any drag is found, disassemble the wheel cylinder and replace
if necessary. Refer to BR-94, "Disassembly and Assembly". A
8. Burnish contact surface between brake lining and brake drum after refinishing or replacing brake lining or
brake drum, or if a soft pedal occurs at very low mileage. Refer to BR-68, "BRAKE LINING : Inspection
and Adjustment" (brake lining), BR-68, "BRAKE DRUM : Inspection and Adjustment" (brake drum). B
Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-10, "Inspection and Adjustment".
C
BR


Unit: mm (in)
Cylinder bore diameter 19.0 (3/4)
Leading 158.7 × 36.5 × 4.7 (6.25 × 1.437 × 0.185)
Rear brake Lining length × width × thickness
Trailing 194.0 × 36.5 × 4.7 (7.64 × 1.437 × 0.185)
Drum inner diameter 203.2 (8.00)
Unit: mm (in)
Item Standard
Brake pedal play 2 – 9 (0.08 – 0.35)
80 (3.15) or more
Unit: mm (in)
Item Standard
Unit: mm (in)
Item Limit
Rear Drum Brake INFOID:0000000007928465
Unit: mm (in)
Item Limit
Brake lining Wear thickness 1.5 (0.059)
Brake drum Wear inner diameter 204.2 (8.04)


B
C
E
BR

PRECAUTIONS
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
WARNING:
the event of a collision that would result in air bag inflation, all maintenance must be performed by
connectors.
WARNING:
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
battery, and wait at least 3 minutes before performing any service.
INFOID:0000000007848905
CAUTION:
then disconnect both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
OPERATION PROCEDURE
NOTE:
2. Turn the ignition switch to ACC position.

PRECAUTIONS
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock A
B
the lower end of windshield with urethane, etc to prevent damage to C
windshield.
PIIB3706J
BR
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed G
• Never reuse drained brake fluid. H
them with water.
I
item of brake pedal. Adjust brake pedal if it is outside the standard value. J
improper operation. K
• Turn the ignition switch OFF and disconnect the ABS actuator and L
• Check that no brake fluid leakage is present after replacing the M
parts.
is detected, replace part with a new one. N
JPFIA0061ZZ
rotors, after replacing brake pads or brake shoe, or if a soft pedal
occurs at very low mileage. O
- Rear brake drum: Refer to BR-110, "BRAKE DRUM : Inspection and Adjustment". P

PREPARATION
PREPARATION
PREPARATION
Flare nut torque wrench

a: 10 mm (0.39 in)
NT406
• Air tight
Handy vacuum pump
ZZC1313D
NNFIA0040ZZ

SYMPTOM DIAGNOSIS A
B

C
BR-108, BR-110
BR-108, BR-110
BR-108, BR-110
BR-108, BR-110
BR-108, BR-110
D
BR-108
BR-108
BR-108
BR-108
BR-110
Reference page
NVH in FAX section

NVH in WT section
NVH in WT section
NVH in ST section
E
Pads or linings uneven wear BR
AXLE AND SUSPENSION

Pads or linings damaged

Rotor or drum deflection
Rotor or drum damage
Rotor or drum rust
Drum out of round

Rotor deformation
H
Rotor imbalance
Possible cause and
ROAD WHEEL
DRIVE SHAFT
SUSPECTED PARTS
Rotor runout
STEERING
I
TIRE
Noise × × × × × × ×
×
J
×
Shimmy, Judder × × × × × × × × × × × ×
×: Applicable K

BRAKE PEDAL
PERIODIC MAINTENANCE
BRAKE PEDAL
INSPECTION
Brake Pedal Height

CAUTION:
JPFIA0065ZZ
Stop Lamp Switch

Check the clearance (C) among the brake pedal lever (1) and the

CAUTION:
PFIA0813J
Brake Pedal Play

Press the brake pedal. Check the brake pedal play (A) (stroke until
JPFIA0277ZZ

pedal upper surface (H2) when depressing the brake pedal at 490 N

CAUTION:
JPFIA0068ZZ
ADJUSTMENT

BRAKE PEDAL
Brake Pedal Height
1. Remove instrument lower panel. Refer to IP-13, "Removal and Installation". A
B
height (H1).
CAUTION: C
D
E
JPFIA0003ZZ
BR
7. Adjust the clearance between the brake pedal lever and the stop G
JPFIA0279ZZ
I
Stop Lamp Switch
2. Disconnect the harness connector from stop lamp switch. J
the brake pedal lever (1) 45° clockwise while pulling the brake K
pedal pad slightly.
CAUTION:
• The clearance (C) between the brake pedal lever and stop L
C : Refer to BR-140, "Brake Pedal". M

released.
PFIA0813J
N
2. Check the height between the dash lower panel (1) and the O
P
CAUTION:
JPFIA0068ZZ

BRAKE FLUID
BRAKE FLUID
BRAKE FLUID LEVEL

tank.
JPFIA0007ZZ
BRAKE LINE
CAUTION:
SBR389C
CAUTION:
BRA0007D
CAUTION:

BRAKE FLUID
CAUTION:
B

tem".
E
CAUTION:
ness connector or the battery negative terminal before performing the work. BR
• Always use new brake fluid for refilling. Never reuse the drained brake fluid. G
1. Connect a vinyl tube to the bleeder valve of the rear left brake.
H
bleeder valve.
I
• Front disc brake: refer to BR-131, "BRAKE CALIPER ASSEMBLY : Exploded View".
• Rear drum brake: refer to BR-136, "Exploded View". J
half of MAX line. Bleed air in the following order: rear left brake → front right brake → rear right brake →
and front left brake in order. K
104, "Inspection".
8. Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-102, L

FLUID LEAK
tube connections.

BRAKE BOOSTER
BRAKE BOOSTER
A
OPERATION B
NOTE: C
AIR TIGHT D
onds or more.

FRONT DISC BRAKE
FRONT DISC BRAKE
BRAKE PAD
INSPECTION
BRA0010D
ADJUSTMENT
CAUTION:
DISC ROTOR
INSPECTION
Appearance
Runout


CAUTION:

FRONT DISC BRAKE

Thickness

Brake".
tions)
SBR020B
E
ADJUSTMENT
CAUTION:
H
I

REAR DRUM BRAKE
REAR DRUM BRAKE
BRAKE LINING
INSPECTION
Brake Lining
JSFIA1039ZZ
ADJUSTMENT
CAUTION:
BRAKE DRUM
INSPECTION
Appearance

REAR DRUM BRAKE
A
JPFIA0113ZZ
D
ADJUSTMENT
CAUTION: E

BRAKE PEDAL

BRAKE PEDAL
JPFIA0873GB

REMOVAL
2. Disconnect the stop lamp switch harness connectors.
ness clip.
JPFIA0815ZZ

BRAKE PEDAL
booster. A
CAUTION:
Hold the brake booster and master cylinder assembly so as B
C
and Adjustment".
JPFIA0816ZZ
D
INSTALLATION
already applied) E
NOTE:
• Do not give an impact caused by dropping, interference with a tool, contact between parts or with rack to the BR
brake pedal.
G
INSPECTION AFTER REMOVAL H

• Check the brake pedal for bend, damage, and cracks on the welded parts, and replace the brake pedal
assembly if any is found.
I
PFIA0756J
L
"Inspection and Adjustment". M
• Perform the release position learning of the accelerator pedal. Refer to EC-1122, "Work Procedure"
(HR15DE).
N

BRAKE PIPING
BRAKE PIPING
FRONT
JPFIA0855GB
1. Brake booster 2. Master cylinder assembly 3. Brake tube

4. ABS actuator and electric unit (con- 5. Connector bracket 6. Connector
trol unit)
10. Copper washer


BRAKE PIPING
BR
JSFIA1061ZZ
G
1. Brake booster 2. Master cylinder assembly 3. Front disc brake
4. ABS actuator and electric unit (con- 5. Connector 6. Rear drum brake
trol unit)
: Flare nut
: Union bolt I
J
REMOVAL
CAUTION:
1. Remove tires.
3. Loosen the flare nut with a flare nut wrench and separate the brake tube from the brake hose. M
CAUTION:
5. Remove the lock plate and remove the brake hose. O
INSTALLATION
CAUTION:
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it P
CAUTION:

BRAKE PIPING
torque.
CAUTION:
and bent.
CAUTION:
CAUTION:

CAUTION:
condition*.
nated positions.
CAUTION:
REAR

BRAKE PIPING
BR
JSFIA1157GB
I
A. To connector
J

K

L
JSFIA1061ZZ

BRAKE PIPING

trol unit)
: Flare nut
: Union bolt
REMOVAL
CAUTION:
1. Remove tires.
CAUTION:
CAUTION:
INSTALLATION
CAUTION:
further.
CAUTION:
tool).
CAUTION:
CAUTION:

BRAKE PIPING
A
at connections. B
CAUTION:
condition*. C
nated positions.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately D
CAUTION:
E
BR

JSFIA0764GB

4. Grommet 5. Cylinder body 6. O-ring

REMOVAL
CAUTION:
4. Separate the brake tube from master cylinder assembly with a flare nut wrench.
CAUTION:
5. Separate reservoir hose from reservoir tank. Refer to CL-18, "RHD : Removal and Installation".
CAUTION:

• Never depress the brake pedal after the master cylinder assembly is removed. A
• The piston of the master cylinder assembly is exposed. Never damage it when removing the
master cylinder.
• The piston may drop off when pulled out strongly. Never hold the piston. Hold the cylinder body
B
when handling the master cylinder assembly.
INSTALLATION C
CAUTION:
D
• Apply silicone grease to the brake booster [see (A) in the figure] E
• The piston of the master cylinder assembly is exposed. Never
damage it when handling the master cylinder and check that no dirt BR
• The piston may drop off when pulled strongly. Never hold the pis-
ton. Hold the cylinder body when handling the master cylinder G
assembly.
• Temporarily tighten the brake tube flare nut to the master cylinder H
JPFIA0013ZZ
CAUTION:
Never scratch the flare nut and the brake tube. I
• After installation, perform the air bleeding. Refer to BR-105, "Bleeding Brake System"
CAUTION: J
Disassembly and Assembly INFOID:0000000007848625 K
DISASSEMBLY
CAUTION: L
• Never drop the removed parts. The parts must not be reused if they are dropped. M
Remove the reservoir tank and grommet from the cylinder body.
ASSEMBLY
CAUTION: N
assembly process.
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank. O
CAUTION:
Never reuse the grommets. P


CAUTION:

A
BR
G
JSFIA0765GB

H

I

J
REMOVAL
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it K
2. Perform inspection before removal. Refer to BR-124, "Inspection and Adjustment". L
3. Remove air duct and air cleaner case. Refer to EM-284, "Removal and Installation" (HR15DE), EM-404,
"Removal and Installation" (K9K).
4. Remove intake manifold. Refer to EM-286, "Removal and Installation" (HR15DE). M
5. Remove brake master cylinder assembly. Refer to BR-120, "Removal and Installation".
6. Remove vacuum hose from check valve. Refer to BR-126, "HR15DE : Removal and Installation"
(HR15DE), BR-127, "K9K : Removal and Installation" (K9K). N
7. Remove tire (front RH side). Refer to WT-7, "Exploded View".
8. Remove brake tube. Refer to BR-114, "FRONT : Exploded View".
• Without ABS O
- Between master cylinder assembly and dual proportioning valve.
- Between brake hose (front RH side) and dual proportioning valve.
• Without ABS P
- Between master cylinder assembly and ABS actuator and electric unit (control unit).
- Between brake hose (front RH side) and ABS actuator and electric unit (control unit).
9. Move high-pressure pipe and low-pressure flexible hose not to interfere work. Refer to HA-35, "HIGH-
PRESSURE PIPE : Removal and Installation" (high-pressure pipe), HA-35, "LOW-PRESSURE FLEXIBLE
HOSE : Removal and Installation" (low-pressure flexible hose).

"Exploded View".
12. Remove brake booster from dash panel in engine room side.
CAUTION:
NOTE:
booster.
INSTALLATION
CAUTION:
A : 45°
threads.
booster.
panel.
• Replace the clevis pin if it is damaged. Refer to BR-113, "Inspec- JPFIA0916ZZ
tion and Adjustment".

CAUTION:

Air Tight
CAUTION:

vice tool). A

booster side (B) within 1.3 kPa (9.8 mmHg, 0.38 B
kPa (−500 mmHg, −19.69 inHg, C
−0.067 bar).
vacuum hose side (C) D
E
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (A).
BR
A : Refer to BR-140, "Brake Booster".
G
H
JPFIA0238ZZ

I
Operation
NOTE: J
Air Tight K
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually L
pedal. Check that the brake pedal stroke does not change after holding down the brake pedal for 30 sec- M
onds or more.
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-102, "Inspection N
and Adjustment".

VACUUM LINES
VACUUM LINES
HR15DE
HR15DE : Exploded View INFOID:0000000007848648
JPFIA0865ZZ
1. Clamp 2. Vacuum hose

HR15DE : Removal and Installation INFOID:0000000007848649
REMOVAL
1. Remove the vacuum hose.
2. Perform inspection after removal. Refer to BR-127, "HR15DE : Inspection".
INSTALLATION
CAUTION:

- Face the paint marks of vacuum hose (brake booster side) to vehi-
cle front side to assemble.
- Face the paint marks of vacuum hose (intake manifold side) to the
upward to assemble.
126, "HR15DE : Exploded View".

VACUUM LINES
HR15DE : Inspection INFOID:0000000007848650
A
Appearance
B
K9K
K9K : Exploded View INFOID:0000000007848901
C
BR
K
JSFIA1170GB
1. Clamp 2. Vacuum hose A 3. Vacuum piping

4. Vacuum hose B 5. Bracket 6. Connector L
A. To brake booster B. Paint mark C. To vacuum pump

M
K9K : Removal and Installation INFOID:0000000007848902
REMOVAL N
1. Remove the vacuum hose and vacuum piping.
2. Perform inspection after removal. Refer to BR-128, "K9K : Inspection".
O
INSTALLATION
Note the following, install the vacuum hose and vacuum piping.
P

VACUUM LINES
CAUTION:

- Face the paint mark of vacuum hose B (connector side) to the
upward to assemble.
- Face the other paint marks to vehicle front side to assemble.
- For clamp mounting direction (the orientation of pawl), refer to BR-
127, "K9K : Exploded View". JPFIA0023ZZ
K9K : Inspection INFOID:0000000007848903

Appearance

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
B
BR
JPFIA0878GB
H
1. Cylinder body 2. Inner pad (with pad wear sensor) 3. Pad retainer
4. Torque member 5. Outer pad (with double faced adhe-
sive tape)
I
BRAKE PAD : Removal and Installation INFOID:0000000007848658 J
REMOVAL
WARNING: K
CAUTION: L
1. Remove tires. M
P
JPFIA0832ZZ

FRONT DISC BRAKE
JPFIA0850ZZ
4. Remove the brake pads from the torque member.

CAUTION:
• When removing the outer pad, never deform or cut the double-faced tape bonding the outer pad
and the cylinder pawl.
• Keep the double-faced tape placed on the outer pad side.
• Never touch the double-faced tape to keep its stickiness.
• Never drop the brake pads.
5. Perform inspection after removal. Refer to BR-131, "BRAKE
PAD : Inspection".
JPFIA0118ZZ
INSTALLATION
WARNING:
CAUTION:
ton may pop out.
CAUTION:
CAUTION:
3. Remove the protector paper of the double-faced tape when
replacing the new brake pad. PFIA0763J
CAUTION:
CAUTION:
• Clean the pawl of the cylinder body.
• Never deform or cut the double-faced tape.

FRONT DISC BRAKE
NOTE:
torque.
6. Press the outer pad in the cylinder body pawl direction.
CAUTION:
C
Securely place the double-faced tape.
is present for the front disc brake. Refer to BR-131, "BRAKE
PAD : Inspection". D
JPFIA0832ZZ E
INSPECTION AFTER INSTALLATION BR

G
5. Securely depress the brake pedal several times. H
7. Burnish contact surfaces brake pads and disc rotor after refinishing or replacing brake pads, or if a soft I
J
REMOVAL K
JPFIA0879GB

FRONT DISC BRAKE
DISASSEMBLY
JPFIA0880GB

7. Sliding pin 8. Sliding pin boot 9. Torque member

REMOVAL
WARNING:
CAUTION:
1. Remove tires.
CAUTION:
CAUTION:
fluid may splash.

FRONT DISC BRAKE
per assembly. A
CAUTION:
JPFIA0835ZZ
D
INSTALLATION
WARNING:
E
CAUTION:
G
torque.
CAUTION:
K
CAUTION:
Inspection". M
N
DISASSEMBLY O
NOTE:
inder body.
P
CAUTION:

FRONT DISC BRAKE
CAUTION:
MAA0272D

CAUTION:
JPFIA0738ZZ
ASSEMBLY
der body.
CAUTION:
JPFIA0039ZZ
CAUTION:
JPFIA0739ZZ

FRONT DISC BRAKE
body by hand and push piston boot (2) piston-side lip into the A
piston groove.
CAUTION:
B
JPFIA0034ZZ
D
E
Exploded View".
BR
G
JPFIA0837ZZ

H
I
Cylinder Body
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil. J
Torque Member
K
Piston
CAUTION: L
Check the sliding pins and sliding boots for rust, wear, cracks or damage. M
2. Remove brake pads. Refer to BR-129, "BRAKE PAD : Removal and Installation". N
O
P

REAR DRUM BRAKE
REAR DRUM BRAKE
JPFIA0881GB
1. Shoe hold pin 2. Back plate 3. Plug

4. Brake shoe 5. Spring 6. Retainer
7. Upper Spring 8. Adjuster 9. Adjuster spring
10. Return spring (lower side) 11. Brake drum 12. Boot
13. Piston 14. Piston cup 15. Spring
16. Wheel cylinder 17. Bleeder valve 18. Cap


REMOVAL
WARNING:
CAUTION:
1. Remove tires.

REAR DRUM BRAKE
2. Perform drain the brake fluid when remove or disassemble the wheel cylinder. Refer to BR-104, "Drain-
ing". A
4. While pushing and rotating the spring (1), pull out shoe hold pin,
and remove brake shoe assembly (brake shoe, each spring, and B
adjuster).
CAUTION:
C
CAUTION:
D
JPFIA0852ZZ
E
spring, and adjuster).
7. Remove the wheel cylinder with the following procedure. BR
G
and Adjustment".
H
JPFIA0882ZZ
INSTALLATION I
WARNING:
dust collector. Never splatter the dust with an air blow gun. J
CAUTION:
• Never spill or splash brake fluid on the brake drum. K
• Check the difference between left and right wheel of adjuster.
: Vehicle front L
Adjuster Direction
Left side Left screw M
Right side Right screw
N
O

REAR DRUM BRAKE
• Check the component parts of drum brake assembly are installed
properly.
• Perform the air bleeding when removed or disassembled the wheel
• Adjust the brake shoe clearance (parking brake lever stroke) after
ment".
JPFIA0884ZZ
DISASSEMBLY
CAUTION:
damaged.
ASSEMBLY
1. Apply polyglycol ether based lubricant to the piston cup (1) and
boot (2).
CAUTION:
3. Apply new brake fluid to piston and wheel cylinder inner wall,
CAUTION:
View".
5. Perform inspection after assembly. Refer to BR-138, "Inspection and Adjustment".

• Check the brake shoe sliding surface for excessive wear and damage.
• Check the wheel cylinder for cracks, damage, and leakage of brake fluid.
REAR DRUM BRAKE
2. Rotate the brake drum and check that there is no drag. Perform the following procedure if necessary. A
4. Push the piston.
CAUTION: B
6. Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-15, "Inspection and Adjust- C
ment".
if necessary. Refer to BR-138, "Disassembly and Assembly". D
and Adjustment" (brake lining), BR-110, "BRAKE DRUM : Inspection and Adjustment" (brake drum). E
BR


Unit: mm (in)
Leading 158.7 × 36.5 × 4.7 (6.25 × 1.437 × 0.185)
Trailing 194.0 × 36.5 × 4.7 (7.64 × 1.437 × 0.185)
Unit: mm (in)
Item Standard
Brake pedal play 2 – 9 (0.08 – 0.35)
80 (3.15) or more
Unit: mm (in)
Item Standard
Unit: mm (in)
Item Limit
Unit: mm (in)
Item Limit


B
C
E
BR

APPLICATION NOTICE
APPLICATION NOTICE
In this manual, “Idling Stop System” is referred to as “Stop / Start System”.

PRECAUTIONS
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
WARNING: D
the event of a collision that would result in air bag inflation, all maintenance must be performed by E
BR
connectors. G
WARNING: H
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing I
serious injury.
battery, and wait at least 3 minutes before performing any service. J
INFOID:0000000007738406
K
CAUTION:
then disconnect both battery cables. L
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing M
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro- N
OPERATION PROCEDURE
O
NOTE:
2. Turn the ignition switch to ACC position. P

PRECAUTIONS
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
Precaution for Stop/Start System Service INFOID:0000000007738446
CAUTION:
When performing an inspection and its related work with the engine at idle, always open the hood and
release the stop/start system.
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed
them with water.
item of brake pedal. Adjust brake pedal if it is outside the standard value.
improper operation.
• Turn the ignition switch OFF and disconnect the ABS actuator and
electric unit (control unit) harness connector [with VDC and without
VDC (with ABS)] or the battery negative terminal before performing
the work.
• Check that no brake fluid leakage is present after replacing the
parts.
is detected, replace part with a new one.
JPFIA0061ZZ
rotors, after replacing brake pads or brake shoe, or if a soft pedal occurs at very low mileage.
- Rear brake drum: Refer to BR-156, "BRAKE DRUM : Inspection and Adjustment".

PREPARATION
PREPARATION A
PREPARATION
B

C
Flare nut torque wrench D

a: 10 mm (0.39 in), 12mm (0.47 in)
E
NT406
BR
Brake fluid pressure gauge Check brake fluid pressure
S-NT151
Pin punch
Removing and installing reservoir tank I
a: 4 mm (0.16 in)
NT410 J
K
• Air tight
Handy vacuum pump
L
ZZC1313D

N
NNFIA0040ZZ

Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
Revision: 2012 July

SUSPECTED PARTS
Noise
Shake
< SYMPTOM DIAGNOSIS >
Shimmy, Judder
NVH Troubleshooting Chart
Pads or linings damaged BR-154, BR-156
×
SYMPTOM DIAGNOSIS
Pads or linings uneven wear BR-154, BR-156
×
Shims damaged BR-189
×
Rotor imbalance BR-154
×
×
BR-146
Rotor or drum damage BR-154, BR-156
×
Rotor runout BR-154
×
Rotor deformation BR-154
×
Rotor or drum deflection BR-154, BR-156
×
Rotor or drum rust BR-154, BR-156
×
× Rotor thickness variation BR-154
×
Drum out of round BR-156
×
AXLE AND SUSPENSION NVH in FAX, RAX and FSU, RSU section
×
×
×
TIRE NVH in WT section

×
×
×
ROAD WHEEL NVH in WT section

×
×
×
× × DRIVE SHAFT NVH in FAX section
STEERING NVH in ST section

×
×
×
[TYPE 4]
INFOID:0000000007654227
N17
BRAKE PEDAL
PERIODIC MAINTENANCE A
BRAKE PEDAL
B
INSPECTION
Brake Pedal Height C
D
CAUTION:
Remove the floor trim. E
BR
JPFIA0065ZZ
Stop Lamp Switch and/or Brake Pedal Position Switch

Check the clearance (C) among the brake pedal lever (1) and the G
stop lamp switch and/or brake pedal position switch (2) threaded
end.
H
CAUTION:
The stop lamp must turn off when the brake pedal is released. I
J
PFIA0813J
Brake Pedal Play

Press the brake pedal. Check the brake pedal play (A) (stroke until K

L
JPFIA0277ZZ
N
pedal upper surface (H2) when depressing the brake pedal at 490 N O

P
CAUTION:
JPFIA0068ZZ
ADJUSTMENT

BRAKE PEDAL
Brake Pedal Height
2. Disconnect the stop lamp switch and/or brake pedal position switch harness connector.
3. Loosen the stop lamp switch and/or brake pedal position switch 45° counterclockwise.
height (H1).
CAUTION:
JPFIA0003ZZ

7. Adjust the clearance between the brake pedal lever and the stop
lamp switch and/or brake pedal position switch threaded end
after adjusting the brake pedal height.
JPFIA0279ZZ
Stop Lamp Switch and/or Brake Pedal Position Switch

2. Disconnect the harness connector from stop lamp switch and/or brake pedal position switch.
3. Loosen the stop lamp switch and/or brake pedal position switch 45° counterclockwise.
4. Press-fit the stop lamp switch and/or brake pedal position switch
(2) until the stop lamp switch and/or brake pedal position switch
hits the brake pedal lever (1) 45° clockwise while pulling the
brake pedal pad slightly.
CAUTION:
• The clearance (C) between the brake pedal lever and stop
lamp switch and/or brake pedal position switch threaded
and must be the specified value.

• The stop lamp must be turned off when the brake pedal is PFIA0813J
released.

BRAKE PEDAL
2. Check the height between the dash lower panel (1) and the
brake pedal upper surface (H2) when depressing the brake A
H2 : Refer to BR-199, "Brake Pedal". B

CAUTION:
C
JPFIA0068ZZ
BR

BRAKE FLUID
BRAKE FLUID
BRAKE FLUID LEVEL

tank.
JPFIA0007ZZ
BRAKE LINE
CAUTION:
SBR389C
CAUTION:
ness connector [with VDC and without VDC (with ABS)] or the battery negative terminal before per-
forming work.
BRA0007D
CAUTION:
ness connector [with VDC and without (with ABS)] or the battery negative terminal before perform-
ing work.

BRAKE FLUID
CAUTION:
B

tem".
E
CAUTION:
ness connector [with VDC and without VDC (with ABS)] or the battery negative terminal before per- BR
forming the work.
off immediately and wash with water if it gets on a painted surface. G
• Always use new brake fluid for refilling. Never reuse the drained brake fluid.
1. Connect a vinyl tube to the bleeder valve of the rear left brake. H
bleeder valve. I
• Front disc brake: refer to BR-189, "BRAKE CALIPER ASSEMBLY : Exploded View". J
• Rear drum brake: refer to BR-195, "Exploded View".
half of MAX line. Bleed air in the following order: rear left brake → front right brake → rear right brake → K
and front left brake in order.
150, "Inspection". L
8. Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-147,
M

FLUID LEAK
tube connections.

BRAKE BOOSTER
BRAKE BOOSTER
A
OPERATION B
NOTE: C
AIR TIGHT D
onds or more.

FRONT DISC BRAKE
FRONT DISC BRAKE
BRAKE PAD
INSPECTION
BRA0010D
ADJUSTMENT
CAUTION:
DISC ROTOR
INSPECTION
Appearance
Runout


CAUTION:

FRONT DISC BRAKE

Thickness

Brake".
tions)
SBR020B
E
ADJUSTMENT
CAUTION:
H
I

REAR DRUM BRAKE
REAR DRUM BRAKE
BRAKE LINING
INSPECTION
Brake Lining
JSFIA1039ZZ
ADJUSTMENT
CAUTION:
BRAKE DRUM
INSPECTION
Appearance

REAR DRUM BRAKE
A
JPFIA0113ZZ
D
ADJUSTMENT
CAUTION: E

BRAKE PEDAL

BRAKE PEDAL
EXCEPT FOR AUSTRALIA, HONG KONG
JSFIA1115GB

7. Brake pedal position switch (with stop
/ start system)
FOR AUSTRALIA, HONG KONG

BRAKE PEDAL
BR
H
JPFIA0853GB

4. Stop lamp switch 5. Clip 6. Snap pin I
K
REMOVAL
2. Disconnect the stop lamp switch and/or brake pedal position switch harness connectors. L
3. Rotate the stop lamp switch and/or brake pedal position switch
(1) counter clockwise to remove.
4. Disconnect the accelerator pedal harness connector and har- M
ness clip.
O
JPFIA0815ZZ

BRAKE PEDAL
booster.
CAUTION:
Hold the brake booster and master cylinder assembly so as
and Adjustment".
JPFIA0816ZZ
INSTALLATION
already applied)
NOTE:
• Do not give an impact caused by dropping, interference with a tool, contact between parts or with rack to the
brake pedal.

• Check for the following items and replace the brake pedal assem-
bly if any is found.
- Check the brake pedal upper rivet (made by aluminum) (A) for
damage and deformation.
- Check the brake pedal for bend, damage, and cracks on the
welded parts.
- Check the lapping length (D) of sub-bracket (B) and slide plate (C).
NOTE:
Check the slide plate for damage and deformation.
D : 5.5 mm (0.217 in) or more JPFIA0854ZZ
PFIA0756J

• Perform the release position learning of the accelerator pedal.
- HR12DE: Refer to EC-157, "Work Procedure".
- HR15DE for Australia: Refer to EC-841, "Work Procedure".
- HR15DE except for Australia: Refer to EC-1122, "Work Procedure".

BRAKE PIPING
BRAKE PIPING
A
FRONT
B
WITHOUT ABS
C
BR
J
JPFIA0890GB

K
4. Dual proportioning valve 5. Lock plate 6. Brake hose
7. Union bolt 8. Copper washer
L
: Always replace after every disassembly. M
WITHOUT VDC (WITH ABS)

N

BRAKE PIPING
Without Stop / Start System
JPFIA0855GB

trol unit)
10. Copper washer


BRAKE PIPING
With Stop / Start System
A
BR
H
JSFIA1205GB

4. ABS actuator and electric unit (con- 5. Pressure sensor bracket 6. Pressure sensor I
trol unit)
7. Connector 8. Connector bracket 9. Lock plate
10. Brake hose 11. Union bolt 12. Copper washer J
: N·m (kg-m, ft-lb) K

: Always replace after every disassembly. L
WITH VDC
M

BRAKE PIPING
JSFIA0771GB

trol unit)
10. Copper washer


BRAKE PIPING
A
BR
H
JSFIA1206GB

4. ABS actuator and electric unit (con- 5. Pressure sensor bracket 6. Pressure sensor I
trol unit)
7. Connector 8. Connector bracket 9. Lock plate
10. Brake hose 11. Union bolt 12. Copper washer J
: N·m (kg-m, ft-lb) K

: Always replace after every disassembly. L

M
WITHOUT ABS
N

BRAKE PIPING
JPFIA0757ZZ

4. Dual proportioning valve 5. Rear drum brake
: Flare nut
: Union bolt

JSFIA1061ZZ

trol unit)
: Flare nut
: Union bolt

BRAKE PIPING
A
JSFIA1246ZZ BR

4. Pressure sensor 5. ABS actuator and electric unit (con- 6. Connector
trol unit)
G
7. Rear drum brake
H
: Flare nut
: Union bolt
I
WITH VDC
J
JSFIA0772ZZ
O
trol unit) P
: Flare nut
: Union bolt

BRAKE PIPING
JSFIA1247ZZ

trol unit)
7. Rear drum brake
: Flare nut
: Union bolt
REMOVAL
CAUTION:
1. Remove tires.
CAUTION:
5. Remove the lock plate and remove the brake hose.
INSTALLATION
CAUTION:
CAUTION:

BRAKE PIPING
assembly hole, and tighten the union bolt (1) to the specified A
torque.
flare nut by hand until it does not rotate further, and fix the brake B
CAUTION:
and bent. C
CAUTION: D
CAUTION: E
7. Perform inspection after installation. Refer to BR-169, "FRONT : Inspection". BR
G
H
CAUTION:
condition*.
*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in desig- I
nated positions.
5 seconds with the engine running. Check for any fluid leakage. J
CAUTION:
worn or deformed) part if any brake fluid leakage is present. K
REAR
L
WITHOUT ABS
M

BRAKE PIPING
JSFIA1177GB

A. To dual proportioning valve

WITH VDC AND WITHOUT VDC (WITH ABS)

BRAKE PIPING
BR
H
JSFIA1157GB

A. To connector I

J
K
WITHOUT ABS L
JPFIA0757ZZ

BRAKE PIPING

4. Dual proportioning valve 5. Rear drum brake
: Flare nut
: Union bolt

JSFIA1061ZZ

trol unit)
: Flare nut
: Union bolt
JSFIA1246ZZ

trol unit)

BRAKE PIPING
7. Rear drum brake
A. Brake tube B. Brake hose A
: Flare nut
: Union bolt B
WITH VDC
Without Stop / Start System C
BR
H
JSFIA0772ZZ

4. ABS actuator and electric unit (con- 5. Connector 6. Rear drum brake I
trol unit)
: Flare nut J
: Union bolt
With Stop / Start System K
P
JSFIA1247ZZ

trol unit)
7. Rear drum brake

BRAKE PIPING
: Flare nut
: Union bolt
REMOVAL
CAUTION:
1. Remove tires.
CAUTION:
CAUTION:
INSTALLATION
CAUTION:
further.
CAUTION:
tool).
CAUTION:
CAUTION:

at connections.
CAUTION:

BRAKE PIPING
condition*. A
nated positions.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately B
CAUTION:
C
BR

DUAL PROPORTIONING VALVE
JPFIA0759GB
1. Dual proportioning valve 2 Clip 3. Bracket

A. To rear LH wheel cylinder B. To master cylinder primary side C. To front RH brake caliper
D. To front LH brake caliper E. To master cylinder secondary side F. To rear RH wheel cylinder
REMOVAL
1. Remove the air duct and air cleaner case. Refer to EM-29, "Removal and Installation" (HR12DE), EM-
284, "Removal and Installation" (HR15DE).
3. Loosen the brake tube flare nuts, and then remove brake tubes from dual proportioning valve. Refer to
BR-161, "FRONT : Exploded View" (front), BR-169, "REAR : Exploded View" (rear).
CAUTION:
4. Remove the dual proportioning valve from bracket.
CAUTION:
Never apply excessive impact to dual proportioning valve, such as dropping it.
5. Remove the bracket from vehicle.
INSTALLATION
• Install the brake tube with flare nut torque wrench (commercial service tool). Refer to BR-161, "FRONT :
Exploded View" (front), BR-169, "REAR : Exploded View" (rear).
CAUTION:
• Never apply excessive impact to dual proportioning valve, such as dropping it.
• After work is completed, bleed air from brake tube. Refer to BR-151, "Bleeding Brake System".

A
1. Connect brake fluid pressure gauge (commercial service tool) to
bleeders valve of front and rear brake on either LH and RH side.
B
D
SBR822BA
2. Bleed air from brake fluid pressure gauge (commercial service E

tool).
3. Check brake fluid pressure by depressing the brake pedal.
BR
Applied pressure (front : 4.90 MPa (49.0 bar, 50.0
brake) kg/cm2, 711 psi)
Output pressure (rear : 3.07 MPa (30.7 bar, 31.3 G
brake) kg/cm2, 445 psi)
• If output pressure (rear brake) is out of specification, replace H
SBR823BA
dual proportioning valve.
4. Bleed air after disconnecting the brake fluid pressure gauge (commercial service tool). Refer to BR-151,
"Bleeding Brake System". I

JPFIA0875GB

4. Pin 5. Grommet 6. Cylinder body
7. O-ring

REMOVAL
CAUTION:
4. Separate the brake tube from master cylinder assembly with a flare nut wrench.
CAUTION:
5. Separate reservoir hose from reservoir tank. Refer to CL-18, "RHD : Removal and Installation". (M/T)

CAUTION:
• Never deform or bend the brake tubes. A
• The piston of the master cylinder assembly is exposed. Never damage it when removing the
master cylinder.
B
• The piston may drop off when pulled out strongly. Never hold the piston. Hold the cylinder body
when handling the master cylinder assembly.
C
INSTALLATION
CAUTION:
D
• Never depress the brake pedal after the master cylinder assembly is removed. E
• Apply silicone grease to the brake booster [see (A) in the figure]
• The piston of the master cylinder assembly is exposed. Never BR
damage it when handling the master cylinder and check that no dirt
• The piston may drop off when pulled strongly. Never hold the pis- G
ton. Hold the cylinder body when handling the master cylinder
assembly.
• Never deform or bend the brake tubes. H
• Temporarily tighten the brake tube flare nut to the master cylinder
JPFIA0013ZZ
CAUTION: I
• After installation, perform the air bleeding. Refer to BR-151, "Bleeding Brake System" J
CAUTION:
K
DISASSEMBLY L
CAUTION:
• Remove the reservoir tank only when necessary. M
• Never drop the removed parts. The parts must not be reused if they are dropped.
1. Fix the master cylinder assembly to a vise.
CAUTION:
• Always set copper plates or cloth between vise grips when fixing the cylinder body to a vise. N
2. Remove the reservoir tank mounting pin with a pin punch [4 mm (0.157 in)] (commercial service tool).
3. Remove master cylinder from vise. O
4. Remove the reservoir tank and grommet from the cylinder body.
ASSEMBLY P
CAUTION:
assembly process.
CAUTION:

Never reuse the grommets.
3. Fix the cylinder body to a vise.
CAUTION:
• Place the reservoir tank with the chamfered pin hole facing up.
• Always set copper plates or cloth between vise grips when fixing the cylinder body to a vise.
4. Tilt the reservoir tank so that a mounting pin can be inserted. Insert a mounting pin. Return the reservoir
tank to the horizontal position. Insert another mounting pin into the pin hole on the opposite side in the
same manner after the mounting pin passes through the cylinder body pin hole.
CAUTION:
Never reuse the mounting pin.

Check the brake fluid level switch. Refer to BRC-13, "Component Inspection" (without ABS), BRC-84, "Com-
ponent Inspection" [without VDC (with ABS)], BRC-198, "Component Inspection" (with VDC).
CAUTION:

A
WITHOUT STOP / START SYSTEM B
BR
JPFIA0874GB
H
I
J
WITH STOP / START SYSTEM
JPFIA0858GB
P
1. Master cylinder assembly 2. Check valve 3. Vacuum sensor
4. Brake booster 5. Lock nut 6. Clevis
7. Gasket


REMOVAL
CAUTION:
• Never remove vacuum sensor from brake booster. Replace vacuum sensor and brake booster as a
set. (With stop / start system)
3. Remove air duct and air cleaner case. Refer to EM-29, "Removal and Installation" (HR12DE), EM-284,
"Removal and Installation" (HR15DE).
4. Remove intake manifold. Refer to EM-33, "Removal and Installation" (HR12DE), EM-286, "Removal and
Installation" (HR15DE).
5. Disconnect vacuum sensor harness connector. (With stop / start system)
6. Remove brake master cylinder assembly. Refer to BR-178, "Removal and Installation".
8. Remove tire (front RH side). Refer to WT-7, "Exploded View".
9. Remove brake tube. Refer to BR-161, "FRONT : Exploded View".
• Without ABS
- Between master cylinder assembly and dual proportioning valve.
- Between brake hose (front RH side) and dual proportioning valve.
• With VDC and without VDC (with ABS)
- Between master cylinder assembly and ABS actuator and electric unit (control unit).
- Between brake hose (front RH side) and ABS actuator and electric unit (control unit).
10. Move high-pressure pipe and low-pressure flexible hose not to interfere work. Refer to HA-35, "HIGH-
PRESSURE PIPE : Removal and Installation" (high-pressure pipe), HA-35, "LOW-PRESSURE FLEXIBLE
HOSE : Removal and Installation" (low-pressure flexible hose).
"Exploded View".
13. Remove brake booster from dash panel in engine room side.
CAUTION:
NOTE:
booster.
INSTALLATION
CAUTION:
A : 45°
threads.
booster.
panel.
JPFIA0916ZZ

• Replace the clevis pin if it is damaged. Refer to BR-160, "Inspection and Adjustment".
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank. A
CAUTION:
B
C

Air Tight D
CAUTION:
1. Check the air tight use a handy vacuum pump (commercial service tool). E
−19.69 inHg, −0.067 bar) 0.98 inHg, 0.033 bar) for 15 seconds. BR
Clean it if necessary. G
H
Check Valve Air Tightness I
vice tool).
J
inHg, 0.013 bar) for 15 sec- K
kPa (−500 mmHg, −19.69 inHg,
−0.067 bar). L
M
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci- N
fied length (A).
A : Refer to BR-199, "Brake Booster". O

JPFIA0238ZZ

Operation

NOTE:
Air Tight
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually
onds or more.
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-147, "Inspection
and Adjustment".

VACUUM LINES
VACUUM LINES
A
BR
I
JPFIA0865ZZ
1. Clamp 2. Vacuum hose J


K
REMOVAL
1. Remove the vacuum hose. L
2. Perform inspection after removal. Refer to BR-185, "Inspection".
INSTALLATION
Note the following, install the vacuum hose. M
CAUTION: N

O
- Face the paint marks of vacuum hose (brake booster side) to vehi-
cle front side to assemble.
- Face the paint marks of vacuum hose (intake manifold side) to the
upward to assemble. P


VACUUM LINES
Appearance

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
B
BR
JSFIA1120GB
H
1. Cylinder body 2. Inner shim 3. Inner pad (with pad wear sensor)
4. Pad return spring 5. Pad retainer 6. Torque member
7. Outer pad 8. Outer shim
I
: Apply MOLYKOTE® 7439 or equivalent.
K
REMOVAL
WARNING:
L
CAUTION:
• If the brake fluid or grease adheres to the disc rotor, quickly wipe it off. M
1. Remove tires.
N
JPFIA0832ZZ

FRONT DISC BRAKE
JPFIA0850ZZ
4. Remove the pad return springs, brake pads, shims and pad retainers from the torque member.
CAUTION:
• Never deform the pad return springs when removing the
pad return spring from the brake pad.
• Never drop the brake pads and shims.
5. Perform inspection after removal. Refer to BR-189, "BRAKE
PAD : Inspection".
JPFIA0118ZZ
INSTALLATION
WARNING:
CAUTION:
ton may pop out.
CAUTION:
2. Install the shims to brake pads.
PFIA0763J
3. Apply MOLYKOTE® 7439 or equivalent to the mating faces (A)

between the brake pads and the pad retainers, and install the
brake pads to the torque member.
CAUTION:
• Never deform the pad return spring.
• Correctly insert the pad return spring in to the pad return
spring hole on the brake pad.
CAUTION:
• Never damage the piston boot. JSFIA1117ZZ

FRONT DISC BRAKE
NOTE:
torque.
is present for the front disc brake. Refer to BR-189, "BRAKE
C
PAD : Inspection".
D
JPFIA0832ZZ E
INSPECTION AFTER REMOVAL BR

Replace the shims if rust is excessively attached.
INSPECTION AFTER INSTALLATION G
3. Press the piston. Refer to BR-187, "BRAKE PAD : Removal and Installation". H
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body and replace if I
pedal occurs at very low mileage. Refer to BR-154, "BRAKE PAD : Inspection and Adjustment". J
BRAKE CALIPER ASSEMBLY : Exploded View INFOID:0000000007654294 K
REMOVAL
L
JPFIA0510GB

FRONT DISC BRAKE
DISASSEMBLY
JPFIA0511GB

7. Sliding pin 8. Sliding pin boot 9. Bushing
10. Torque member

REMOVAL
WARNING:
CAUTION:
1. Remove tires.
CAUTION:
CAUTION:
fluid may splash.

FRONT DISC BRAKE
per assembly. A
CAUTION:
JPFIA0835ZZ
D
INSTALLATION
WARNING:
E
CAUTION:
G
torque.
CAUTION:
K
CAUTION:
Inspection". M
N
DISASSEMBLY O
NOTE:
Never remove the torque member, pad return spring, brake pad and pad retainers when disassembling and
assembling the cylinder body.
P
CAUTION:

FRONT DISC BRAKE
3. Remove bushing (1) from sliding pin (2).
JPFIA0851ZZ
CAUTION:
MAA0272D

CAUTION:
JPFIA0738ZZ
ASSEMBLY
der body.
CAUTION:
JPFIA0039ZZ

FRONT DISC BRAKE
with piston boot, and then install cylinder side lip on piston boot A
CAUTION:
B
JPFIA0739ZZ
D
body by hand and push piston boot (2) piston-side lip into the
piston groove.
E
CAUTION:
BR
G
JPFIA0034ZZ
5. Apply rubber grease to mating faces (A) between sliding pin (1)
H
and bushing (2), and install bushing to sliding pin.
JPFIA0836ZZ
K
boots to sliding torque member (3). L
Exploded View". M
N
JPFIA0837ZZ
BRAKE CALIPER ASSEMBLY : Inspection INFOID:0000000007654297 O

Check the following items and replace if necessary. P
Cylinder Body
CAUTION:
Torque Member

FRONT DISC BRAKE
Piston
CAUTION:
Check the sliding pins and sliding boots for rust, wear, cracks or damage.

REAR DRUM BRAKE
REAR DRUM BRAKE
A
BR
I
JSFIA1114GB
1. Shoe hold pin 2. Back plate 3. Plug J

4. Brake shoe 5. Spring 6. Upper spring
7. Adjuster 8. Return spring 9. Brake drum
10. Boot 11. Piston 12. Piston cup K
13. Spring 14. Wheel cylinder 15. Bleeder valve
16. Cap
L

M

: Always replace after every disassembly. N
O
REMOVAL
WARNING:
Since dust covering the rear brake has an affect on human body, the dust must be removed with a P
CAUTION:
1. Remove tires.

REAR DRUM BRAKE
2. Perform drain the brake fluid when remove or disassemble the wheel cylinder. Refer to BR-150, "Drain-
ing".
4. While pushing and rotating the spring (1), pull out shoe hold pin,
and remove brake shoe assembly (brake shoe, each spring, and
adjuster).
CAUTION:
CAUTION:
JSFIA0636ZZ

spring, and adjuster).
7. Remove the wheel cylinder with the following procedure.
and Adjustment".
JSFIA1056ZZ
INSTALLATION
WARNING:
CAUTION:
• Check the difference between left and right wheel of adjuster.
: Vehicle front
Adjuster Direction
Left side Left screw
Right side Left screw

REAR DRUM BRAKE
• Check the component parts of drum brake assembly are installed
properly. A
• Perform the air bleeding when removed or disassembled the wheel
B
• Adjust the brake shoe clearance (parking brake lever stroke) after C
ment".
JSFIA0637ZZ
D
DISASSEMBLY E
CAUTION: BR
damaged.
G
ASSEMBLY
1. Apply polyglycol ether based lubricant to the piston cup (1) and H
boot (2).
CAUTION: I
3. Apply new brake fluid to piston and wheel cylinder inner wall, J
CAUTION:
K
View".
5. Perform inspection after assembly. Refer to BR-197, "Inspection and Adjustment". L
INSPECTION AFTER REMOVAL M

• Check the brake shoe sliding surface for excessive wear and damage. N
• Check the wheel cylinder for cracks, damage, and leakage of brake fluid. O
INSPECTION AFTER DISASSEMBLY P
REAR DRUM BRAKE
2. Rotate the brake drum and check that there is no drag. Perform the following procedure if necessary.
4. Push the piston.
CAUTION:
6. Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-20, "Inspection and Adjust-
ment".
if necessary. Refer to BR-197, "Disassembly and Assembly".
and Adjustment" (brake lining), BR-156, "BRAKE DRUM : Inspection and Adjustment" (brake drum).

SERVICE DATA AND SPECIFICATIONS (SDS) A

B
WITHOUT ABS
Unit: mm (in) C
Rotor outer diameter × thickness 260 × 22.0 (10.24 × 0.866) D
Leading 162.8 × 37.0 × 4.8 (6.41 × 1.457 × 0.189)
Rear brake Lining length × width × thickness E
Trailing 180.5 × 37.0 × 4.8 (7.11 × 1.457 × 0.189)
Master cylinder Cylinder bore diameter 20.6 (13/16) BR
Control valve Valve type Dual proportioning valve
G
WITH VDC AND WITHOUT VDC (WITH ABS)

Unit: mm (in) H
I
Leading 162.8 × 37.0 × 4.8 (6.41 × 1.457 × 0.189) J
Trailing 180.5 × 37.0 × 4.8 (7.11 × 1.457 × 0.189)
Master cylinder Cylinder bore diameter 20.6 (13/16) K
L

M
Unit: mm (in)
Item Standard
N
Clearance among the brake pedal lever and the stop lamp switch and/or brake pedal posi-
0.2 – 1.96 (0.008 – 0.0772)
tion switch threaded end
O
Brake pedal play 2 – 9 (0.08 – 0.35)
80 (3.15) or more
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON] P
Unit: mm (in)
Item Standard

Unit: mm (in)
Item Limit
Unit: mm (in)
Item Limit

Brake System: Section

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Brake System: Section

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BRAKES

Revision: 2012 July BR-1 N17

Revision: 2012 July BR-2 N17

Revision: 2012 July BR-3 N17

BRAKE CALIPER ASSEMBLY ...............................131 BRAKE FLUID .................................................. 150

Revision: 2012 July BR-4 N17

REAR ....................................................................... 169 REAR DRUM BRAKE ..................................... 195

DUAL PROPORTIONING VALVE ................... 176 SERVICE DATA AND SPECIFICATIONS

Revision: 2012 July BR-5 N17

HOW TO USE THIS MANUAL

Service information Destination

Revision: 2012 July BR-6 N17

Revision: 2012 July BR-7 N17

Precaution for Brake System INFOID:0000000006965256

Revision: 2012 July BR-8 N17

Tool name Description

Flare nut torque wrench D

Brake caliper wrench (rear) Return the piston

Revision: 2012 July BR-9 N17

NVH in FAX, RAX and FSU, RSU section

NVH in FAX section

SUSPECTED PARTS Rotor runout

Revision: 2012 July BR-10 N17

Stop Lamp Switch

C : Refer to BR-54, "Brake Pedal". H

Brake Pedal Play

A : Refer to BR-54, "Brake Pedal".

H2 : Refer to BR-54, "Brake Pedal".

Revision: 2012 July BR-11 N17

H1 : Refer to BR-54, "Brake Pedal".

Stop Lamp Switch

C : Refer to BR-54, "Brake Pedal".

Depressed Brake Pedal Height

H2 : Refer to BR-54, "Brake Pedal".

Revision: 2012 July BR-12 N17

BRAKE FLUID LEVEL B

Revision: 2012 July BR-13 N17

3. Perform the air bleeding. Refer to BR-14, "Bleeding Brake Sys-

Revision: 2012 July BR-14 N17

Revision: 2012 July BR-15 N17

Revision: 2012 July BR-16 N17

Wear thickness : Refer to BR-54, "Front Disc Brake".

Revision: 2012 July BR-17 N17

Wear thickness : Refer to BR-54, "Front Disc Brake".

Wear thickness : Refer to BR-54, "Front Disc

Revision: 2012 July BR-18 N17

Wear thickness : Refer to BR-54, "Rear Disc Brake".

Revision: 2012 July BR-19 N17

Wear thickness : Refer to BR-54, "Rear Disc Brake".

Wear thickness : Refer to BR-54, "Rear Disc

Revision: 2012 July BR-20 N17

REMOVAL AND INSTALLATION A

1. Clevis pin 2. Brake pedal assembly 3. Brake pedal pad

: N·m (kg-m, ft-lb) L

1. Remove instrument lower panel. Refer to IP-13, "Removal and Installation".

Revision: 2012 July BR-21 N17

INSPECTION AFTER REMOVAL

D : 5.5 mm (0.217) in or more

ADJUSTMENT AFTER INSTALLATION

Revision: 2012 July BR-22 N17

: N·m (kg-m, ft-lb)

Revision: 2012 July BR-23 N17

FRONT : Removal and Installation INFOID:0000000006965275