BRAKE SYSTEM

F BRAKES

SECTION
BRAKE SYSTEM
BR B

E
CONTENTS
PRECAUTIONS .......................................................... 3 INSTALLATION ................................................... 13 BR
Precautions for Models with SRS Air Bag and Pre- Disassembly and Assembly .................................... 14
Tensioner Seat Belt .................................................. 3 DISASSEMBLY ................................................... 14
Precautions for Brake System .................................. 3 INSPECTION AFTER REMOVAL ....................... 14 G
PREPARATION ........................................................... 4 ASSEMBLY ......................................................... 15
Special Service Tools ............................................... 4 BRAKE BOOSTER ................................................... 16
Commercial Service Tools ........................................ 4 On-Vehicle Inspection and Service ......................... 16
H
NOISE, VIBRATION AND HARSHNESS (NVH) FUNCTION INSPECTION ................................... 16
TROUBLESHOOTING ................................................ 5 AIRTIGHTNESS INSPECTION ........................... 16
NVH Troubleshooting Chart ..................................... 5 Removal and Installation ........................................ 16
BRAKE PEDAL .......................................................... 6 REMOVAL ........................................................... 16 I
On-Vehicle Inspection and Adjustment .................... 6 INSPECTION AFTER REMOVAL ....................... 17
Components ............................................................. 7 INSTALLATION ................................................... 17
Removal and Installation .......................................... 7 VACUUM LINES ....................................................... 18 J
REMOVAL ............................................................. 7 Removal and Installation ........................................ 18
INSPECTION AFTER REMOVAL ......................... 8 Inspection ............................................................... 18
INSTALLATION ..................................................... 8 VISUAL INSPECTION ......................................... 18
K
BRAKE FLUID ............................................................ 9 CHECK VALVE INSPECTION ............................. 18
Checking Brake Fluid Level ..................................... 9 FRONT DISC BRAKE ............................................... 19
Checking Brake Line ................................................ 9 Component ............................................................. 19
Changing Brake Fluid ............................................... 9 Inspection ............................................................... 19 L
Brake Burnishing Procedure .................................. 10 PAD THICKNESS ................................................ 19
Bleeding Brake System .......................................... 10 Pad Replacement ................................................... 20
BRAKE PIPING AND HOSE .....................................11 REMOVAL ........................................................... 20 M
Hydraulic Piping ......................................................11 INSTALLATION ................................................... 20
Removal and Installation of Front Brake Piping and Caliper Removal and Installation ............................ 20
Brake Hose .............................................................11 REMOVAL ........................................................... 20
REMOVAL ............................................................11 INSTALLATION ................................................... 21
INSTALLATION ....................................................11 Caliper Disassembly and Assembly ....................... 21
Removal and Installation of Rear Brake Piping and DISASSEMBLY ................................................... 21
Brake Hose ............................................................ 12 INSPECTION AFTER DISASSEMBLY ................ 22
REMOVAL ........................................................... 12 DISC ROTOR INSPECTION ............................... 22
INSTALLATION ................................................... 12 ASSEMBLY ......................................................... 23
Inspection ............................................................... 12 BRAKE BURNISHING PROCEDURE ................. 23
BRAKE MASTER CYLINDER .................................. 13 REAR DISC BRAKE ................................................. 24
Components ........................................................... 13 Component ............................................................. 24
Removal and Installation ........................................ 13 Inspection ............................................................... 24
REMOVAL ........................................................... 13 PAD WEAR INSPECTION ................................... 24
Pad Replacement ................................................... 25
REMOVAL ........................................................... 25

BR-1
 INSTALLATION .................................................... 25 SERVICE DATA AND SPECIFICATIONS (SDS) ......30
Caliper Removal and Installation ............................ 26 General Specifications ............................................30
REMOVAL ........................................................... 26 Brake Pedal ............................................................30
INSTALLATION .................................................... 26 Check Valve ............................................................30
Caliper Disassembly and Assembly ....................... 26 Brake Booster .........................................................30
DISASSEMBLY ................................................... 26 Front Disc Brake .....................................................30
INSPECTION AFTER DISASSEMBLY ................ 27 Rear Disc Brake ......................................................31
DISC ROTOR INSPECTION ............................... 27
ASSEMBLY ......................................................... 28

BR-2
 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Models with SRS Air Bag and Pre-Tensioner Seat Belt EFS001CU

WARNING:
● Before removing and installing components and harnesses of SRS air bag and seat belt pre-ten- B
sioner system, turn ignition switch OFF, disconnect battery ground cable, and wait at least 3 min-
utes. (This discharges electricity held in the air bag sensor unit's additional power circuit.)
● Do not use pneumatic or electric tools to remove and install the components. C
● Do not solder SRS air bag and seat belt pre-tensioner system harnesses when making repairs.
Make sure harness is not pinched and there is no contact with other components.
● When checking the SRS air bag and the seat belt pre-tensioner circuit or the components of each D
system, do not use an electric tester such as a circuit tester. (This is to prevent accidental trigger-
ing caused by the weak electric current of a tester.)
● Never insert foreign material (such as a screwdriver) in the air bag module and pre-tensioner seat
E
belt connectors. (The units may be actuated by mistake by static electricity.)
● Seat belt pre-tensioner and SRS air bag harnesses can be distinguished from other harnesses by
their yellow connectors.
BR
● When servicing, refer to “SB Seat Belt” and “SRS Air Bag” for safety.
Precautions for Brake System EFS001CV

● Clean dust on brake pads, shoes, drums, and back plates with a vacuum dust collector. Do not blow with G
compressed air.
● Recommended fluid is brake fluid “DOT 3”.
● Never reuse drained brake fluid. H
● Be careful not to splash brake fluid on painted areas such as the body. If brake fluid is splashed or spilled
on paint, wipe it off and flush the area with water immediately.
● Use only clean brake fluid when cleaning master cylinder and disc brake components. I
● Never use mineral oils such as gasoline or kerosene to clean. They will ruin the rubber parts and cause
improper operation.
J
● Always use a flare nut torque wrench to securely tighten brake
tube flare nuts.
● The brake system is an important safety part. If a brake fluid
leak is detected, always disassemble the related parts. If dam- K
age, deformation or excessive wear is detected, replace
affected parts with new ones.
● Before staring operation, be sure to turn the ignition switch OFF L
and disconnect the ABS actuator and control module connector
or battery cables.
● When installing brake piping, be sure to check torque. M
SBR820BA

BR-3
 PREPARATION

PREPARATION PFP:00002

Special Service Tools EFS00212

Tool number
Description
Tool name

GG94310000
Flare nut torque wench Removing and installing brake piping
a: 10 mm (0.39 in)

NT406

Commercial Service Tools EFS001NZ

Tool name Description

Brake fluid pressure gauge Measuring fluid pressure

S-NT151

BR-4
 Symptom

X: Applicable
Reference page

BRAKE
Possible cause and
SUSPECTED PARTS

Noise
Shake

Shimmy, Judder
NVH Troubleshooting Chart

Pads - damaged BR-19, BR-24

×
Pads - uneven wear BR-19, BR-24

×
×
Shims damaged BR-19, BR-24

×
×
Rotor imbalance —

Rotor damage —

BR-5
Rotor runout BR-22, BR-28

×
Rotor deformation —

×
Rotor deflection —

×
Rotor rust —

×
Rotor thickness variation BR-22, BR-28

×
Drum out of round —

×
×
PROPELLER SHAFT NVH in PR section
×

DIFFERENTIAL NHV in RFD section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

AXLE AND SUSPENSION NVH in FAX, RAX and FSU, RSU section
×
×
×

TIRES NVH in WT section

×
×
×

×
×
×

ROAD WHEEL NVH in WT section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

× × DRIVE SHAFT NVH in RAX section

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×
×
×

STEERING NVH in PS section

PFP:00003

EFS001CX

L
K
E
B
A

H
D
C

M
BR
 BRAKE PEDAL

BRAKE PEDAL PFP:46501

On-Vehicle Inspection and Adjustment EFS001CY

Adjust clearance between dash panel and brake pedal upper surface
to the following dimensions.

SFIA0348E

M/T model 156 - 166 mm (6.10 - 6.54 in)

H1 Brake pedal height
A/T model 164 - 174 mm (6.46 - 6.85 in)

Pedal height when depressed M/T model 80 mm (3.15 in) or more

H2
[With engine running and at depression force of 490 N (50 kg,110.6 lb)] A/T model 85 mm (3.35 in) or more
C Clearance between stopper rubber and threaded end of the stop Stop lamp switch 0.74 - 1.96 mm (0.0291 - 0.0772 in)
A Pedal play 3 - 11 mm (0.12 - 0.43 in)

1. Loosen stop lamp switch by rotating it counter-clockwise by 45°.

2. Loosen input rod lock nut (A), then rotate input rod, set pedal to
the specified height, and tighten lock nut (A).
CAUTION:
Confirm threaded end of input rod remains inside the cle-
vis.
: 16 - 21 N·m (1.6 - 2.2 kg-m, 12 - 15 ft-lb)

3. Pull pedal by hand and hold it. Press stop lamp switch until its
threaded end contacts the stopper rubber.
4. While holding it against the stopper rubber, turn the switch clock-
wise by 45° and secure it.
CAUTION:
Be sure stopper rubber -to stop lamp switch screw
threaded end gap (C) is within specifications.
5. Check pedal free play.
CAUTION:
Be sure stop lamps go off when pedal is released.
6. Start the engine and check brake pedal depressed height.

SFIA0160E

BR-6
 BRAKE PEDAL

Components EFS001CZ

BR

SFIA0044E

1. Snap pin 2. Stop lamp switch 3. Brake pedal assembly G

4. Clevis pin

Removal and Installation EFS001D0

H
REMOVAL
Be careful not to deform brake tube.
I
1. Remove the instrument lower driver panel.
2. Remove stop lamp switch from brake pedal assembly.
3. Remove snap pin and clevis pin from brake booster clevis. J
4. Remove brake pedal assembly mounting nuts. Pull brake booster toward the engine compartment. Be
careful not to deform the brake tube.
5. Remove brake booster clevis from input rod. K
6. Remove steering column assembly from steering member.
7. Push brake pedal assembly toward the right. When removing it,
avoid the steering post bracket stay. L

SFIA0349E

BR-7
 BRAKE PEDAL

INSPECTION AFTER REMOVAL

Check brake pedal for the following.
● Bent brake pedal
● Deformed clevis pin
● Cracks in welded area
● Cracked or deformed clevis pin stopper

SBR997

INSTALLATION
Install in reverse order of removal. Be careful of the following:
● Adjust brake pedal assembly after installing it.

BR-8
 BRAKE FLUID

BRAKE FLUID PFP:KN100

A
Checking Brake Fluid Level EFS001D1

● Confirm reservoir tank fluid level is within specifications

(between MAX and MIN lines). B
● Visually check around reservoir tank for fluid leaks.
● If fluid level is excessively low, check brake system for leaks.
● If warning lamp remains illuminated after parking lever is C
released, check brake system for fluid leakage.

SFIA0066J

E
Checking Brake Line EFS001D2

CAUTION:
If leakage occurs around joints, retighten or, if necessary, replace damaged parts. BR
1. Check brake line (tube and hoses) for cracks, deterioration or
other damage. Replace and damaged parts.
2. Check for oil leakage by fully depressing brake pedal while G
engine is running.

I
SBR389C

Changing Brake Fluid EFS001D3

J
CAUTION:
● Refill with new brake fluid “DOT 3”.
● Always keep fluid level higher than minimum line on reservoir tank.
K
● Never reuse drained brake fluid.
● Be careful not to splash brake fluid on spill or splash on painted areas; it may cause paint damage.
If brake fluid is splashed on painted areas, wash it away water immediately. L
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from the air bleeder of each wheel
while depressing the brake pedal. M
3. Turn OFF ignition switch. Remove ABS actuator connector.

BRA0007D

BR-9
 BRAKE FLUID

4. Be sure there is no foreign material in reservoir tank. Refill with

new brake fluid.
5. Connect a vinyl tube to the air bleeder.
6. Rest foot on brake pedal. Loosen air bleeder. Slowly depress
pedal until it stops. Tighten air bleeder. Release brake pedal.
Repeat this process a few times, then pause to add new brake
fluid to master cylinder. Continue until new brake fluid flows out.
For bleeding procedure. Refer to BR-10, "Bleeding Brake Sys-
tem" .

BRA0006D

Brake Burnishing Procedure EFS001D4

Burnish the brake contact surfaces according to the following procedure after refinishing or replacing drums or
rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.
Bleeding Brake System EFS001D5

CAUTION:
● Carefully monitor brake fluid level at master cylinder during bleeding operation.
● Fill reservoir with new brake fluid “DOT 3”. Make sure it is full at all times while bleeding air out of
system.
● Place a container under master cylinder to avoid spillage of brake fluid.
● While bleeding, pay attention to master cylinder fluid level.
● For models with ABS, turn ignition switch OFF and disconnect ABS actuator connectors or bat-
tery ground cable.
● Bleed air in the following order.
Right rear brake, Left front brake, Left rear brake, Right front brake
1. Turn OFF ignition switch. Remove ABS actuator connector.
2. Connect a vinyl tube to the air bleeder.
3. Fully depress the brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen air bleeder and bleed air.
5. Close air bleeder.
6. Slowly release brake pedal.
7. Tighten air bleeder to the specified torque.
: 6.9 - 8.8 N·m (0.7 - 0.9 kg-m, 61- 78 in-lb)

8. Repeat steps 2 - 7. Occasionally refill master cylinder reservoir tank. Be sure to keep it at least half-full.

BR-10
 BRAKE PIPING AND HOSE

BRAKE PIPING AND HOSE PFP:46210

A
Hydraulic Piping EFS001D6

BR

SFIA0346E
G

Removal and Installation of Front Brake Piping and Brake Hose EFS001D7

REMOVAL H
CAUTION:
● Do not allow brake fluid to spill or splash on painted surfaces. Brake fluid can seriously damage
paint. If it gets on a painted surface, wipe it off immediately and wash with water.
I
● Do not bend or twist the brake hose sharply, or strongly pull it.
● Cover brake fluid line connections to prevent dust and other foreign material from entering.
1. Connect a vinyl tube to the air bleeder. J
2. Drain brake fluid gradually from the air bleeder of each wheel while depressing the brake pedal.
3. Using a flare nut wrench, remove brake tube flare nuts and dis-
connect brake tube from the brake hose. K
4. Remove union bolts and disconnect caliper assembly from the
brake hose.
5. First remove lock spring from brake tube and strut mounting L
positions. Then remove brake hose.

SFIA0347E

INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
1. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
● Securely connect brake hose to the protrusions on the cylinder body.

● Do not reuse the copper washer for union bolts.

2. Connect brake hose to the strut and fix with lock spring.
3. Connect brake hose to brake tube. Temporarily tighten flare nuts by hand as far as they will go. Secure
them with the lock spring.
4. Using a flare nut torque wrench, tighten to the specified torque.

BR-11
 BRAKE PIPING AND HOSE

: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

5. Refill brake fluid until new brake fluid comes out of each air bleeder.
6. Afterwards, bleed air.
Removal and Installation of Rear Brake Piping and Brake Hose EFS001D8

REMOVAL
CAUTION:
● Do not allow brake fluid to spill or splash on painted surfaces. Brake fluid can seriously damage
paint. If it gets on a painted surface, wipe it off immediately and wash with water.
● Do not bend or twist the brake hose sharply, or strongly pull it.
● Cover brake fluid line connections to prevent dust and other foreign material from entering.
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from the air bleeder of each wheel while depressing the brake pedal.
3. Using a flare nut wrench, remove brake tube flare nuts and dis-
connect brake tube from the brake hose.
4. Remove lock spring.

SFIA0046E

INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
1. Connect brake hose to the brake tube. Temporarily tighten flare nut by hand as far as it will go.
2. Fix brake hose by lock plate.
3. Tighten flare nut of brake tube by using a flare nut wrench with
specified torque.
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

4. Refill brake fluid until new brake fluid comes out of each air
bleeder.
5. Afterwards, bleed air.

SBR820BA

Inspection EFS001D9

CAUTION:
If any connection leaks, retighten it. Replace any damaged parts.
1. Check hose, tube, and connections for fluid leaks, damage, twist, deformation, contact with other parts,
and loose connections.
2. Run the engine. Depress brake pedal and hold it for approximately 5 seconds while checking each part
for leaks.

BR-12
 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

A
Components EFS001DA

BR

G
SFIA0047E

1. Cap 2. Strainer 3. Reservoir tank

4. Grommet 5. Piston stopper 6. Pin H
7. Secondary piston 8. Primary piston assembly 9. Stopper cap

Removal and Installation EFS001DB

REMOVAL I
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately. J
1. Drain brake fluid.
2. Remove fluid level sensor harness connector.
3. Using a flare nut wrench, disconnect master cylinder assembly and brake tube. K
4. First remove master cylinder assembly mounting nuts. Then remove master cylinder assembly.
INSTALLATION L
1. Connect brake tube to master cylinder assembly and temporarily tighten flare nut by hand.
2. Connect master cylinder assembly to brake booster assembly and tighten mounting nuts to the specified
torque. M
3. Tighten brake tube flare nuts.
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

4. Connect fluid level sensor harness connector.

5. Refill with new brake fluid and bleed air from the brake piping.

BR-13
 BRAKE MASTER CYLINDER

Disassembly and Assembly EFS001DC

DISASSEMBLY
CAUTION:
Remove master cylinder reservoir tank only when necessary.
1. Using flat tip screwdriver as shown in the figure, lever stopper
cap tabs up and remove stopper cap. While removing, be sure
to hold cap securely to prevent the master cylinder piston from
popping out.

BRA0533D

2. Secure cylinder body flange in a vise as shown in the figure.

CAUTION:
● Secure with chamfered pin insert hole on the cylinder
body facing upward.
● When securing in the vise, use copper plates or cloth to
protect the flange.

BRA0588D

3. Using a pin punch [tool: diameter Approx. 4 mm (0.16 in)],

remove reservoir tank mounting pins.
4. Remove master cylinder assembly from the vise.
5. Remove reservoir tank and grommet from the cylinder body.

SFIA0342E

6. Using a Phillips screwdriver, press and hold piston pin as shown

in the figure. Remove piston stopper from the cylinder body.
7. Carefully pull primary piston assembly straight out to prevent
damage to the cylinder inner wall.
8. Tap flange against a wood block to loosen secondary piston
assembly. Carefully pull secondary piston assembly straight out
to prevent damage to the cylinder inner wall.

BRA0590D

INSPECTION AFTER REMOVAL

● Check cylinder inner wall for damage, wear, corrosion, and pinholes. Replace cylinder if damage, wear, or
corrosion is detected.

BR-14
 BRAKE MASTER CYLINDER

ASSEMBLY
CAUTION: A
● Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.
● Be sure there is no foreign material on the cylinder inner wall, piston, and cup seal. Be careful not
to damage parts with a service tool during assembly. B
● Do not drop the parts. Do not use any dropped parts.

1. Apply brake fluid to the inner wall of cylinder body and contact C
surface of the piston assembly. Then insert secondary piston
assembly and primary piston assembly into cylinder body in this
order.
D
CAUTION:
● Do not reuse primary and secondary piston assemblies.

● Always replace the inner kit as an assembly.

E
● Pay attention to orientation of the piston cup. Insert it
straight in order to prevent it from catching on the cylin-
der's inner wall.
SFIA0248E BR

2. Visually check secondary piston slit position through cylinder

body secondary tank boss hole and install piston stopper.
G

BRA0590D

J
3. Hold piston with stopper cap. Press stopper cap in until its tabs
fully engage groove on the cylinder body.
CAUTION:
Do not reuse stopper cap. K
4. Apply brake fluid to grommet before pressing it into cylinder
body.
CAUTION: L
Do not reuse grommet.

M
BRA0535D

5. Secure cylinder body flange in a vise as shown in the figure.

CAUTION:
● Secure with chamfered pin insert hole on the cylinder
body facing upward.
● When securing in the vise, use copper plates or cloth to
protect the flange.
6. Install reservoir tank to the cylinder body. Tilt reservoir tank as
shown in the figure and insert mounting pin. When mounting pin
passes through pinhole in the master cylinder, return reservoir
tank to the upright position. Push mounting pin all the way
through the opposite pinhole in the reservoir tank. SFIA0343E

CAUTION:
● Do not reuse reservoir tank mounting pin.

● Do not reuse reservoir tank.

● Be sure to insert pin from the chamfered pinhole on the cylinder body.

BR-15
 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

On-Vehicle Inspection and Service EFS001DD

FUNCTION INSPECTION
With the engine stopped, discharge stored vacuum by depressing
brake pedal several times at 5 second intervals. With the brake
pedal fully depressed, start the engine. Confirm that clearance
between brake pedal and the floor panel decreases when engine
vacuum stabilizes.

BRA0037D

AIRTIGHTNESS INSPECTION
● Run the engine at idle for approximately 1 minute. Stop it after
applying vacuum to the booster. Depress the brake pedal sev-
eral times with normal force to discharge the stored vacuum.
Confirm that clearance between brake pedal and the floor panel
gradually increases as the brake pedal is depressed.
● Run the engine. Depress and hold the brake pedal then stop the
engine. Keep the brake pedal depressed for 30 seconds or more
and make sure the pedal stroke does not change.

SBR365AA

Removal and Installation EFS001DE

REMOVAL

SFIA0139E

CAUTION:
● Be careful not to deform or bend brake piping while removing and installing the brake booster.
● Replace clevis pin if it is damaged.
● Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, the dash panel may damage the threads.
● Be sure to install the check valve in the correct orientation.
1. Remove vacuum piping from the brake booster.
2. Remove master cylinder.
3. Remove snap pin and clevis pin on passenger compartment clevis. Remove input rod from the brake
pedal.
4. Remove brake booster and brake pedal assembly mounting nuts.
5. Remove booster assembly from the engine compartment.

BR-16
 BRAKE BOOSTER

INSPECTION AFTER REMOVAL

Output Rod Length Inspection A
1. Using a handy vacuum pump, apply a vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to the brake
booster.
2. Check output rod length. B

Reference value at vacuum of -66.7 kPa (-500 mmHg, -

19.69 inHg):
C
10.4 mm (0.409 in)

SBR208E
E

INSTALLATION
1. Loosen lock nut to adjust input rod length so that length B (in the BR
figure) satisfies the specified value.
Length B standard : 125 mm (4.92 in)
2. After adjusting B, temporarily tighten lock nut to install booster G
assembly to vehicle.
3. Connect brake pedal to input rod clevis.
4. Connect brake pedal assembly mounting nuts and tighten to the H
specified torque.
5. Connect master cylinder to the booster assembly.
SGIA0060E
6. Adjust brake pedal height and play. I
7. Tighten input rod lock nut to the specified torque.
8. Bleed air. Refer to BR-10, "Bleeding Brake System" .
J

BR-17
 VACUUM LINES

VACUUM LINES PFP:41920

Removal and Installation EFS001DF

SFIA0556E

1. Vacuum hose 2. Vacuum tube 3. Clip

4. Clamp

CAUTION:
● Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer
to the stamp or label to confirm correct installation. The brake booster will not operate normally if
the hose is installed in the wrong direction.
● Insert the vacuum hose for at least 24 mm (0.94 in).
● Never use lubricating oil during assembly.

SBR225B

Inspection EFS001DG

VISUAL INSPECTION
Check for improper assembly, damage and aging.
CHECK VALVE INSPECTION
Airtightness Inspection
Use a hand-held vacuum pump to check.
When connected to booster side (1):
Vacuum decrease should be within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under
a vacuum of -66.7 kPa (-500 mmHg, -19.69
inHg)
When connected to engine side (2):
No vacuum will be applied
SFIA0210E

BR-18
 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

A
Component EFS001DH

BR

G
SFIA0328E

1. Torque member 2. Slid pin boot 3. Slid pin

4. Outer shim cover 5. Outer shim 6. Outer pad H
7. Pad retainer 8. Inner pad 9. Inner shim
10. Inner shim cover 11. Piston boots 12. Piston
13. Piston seal 14. Cylinder body 15. Copper washer I
16. Air bleeder 17. Brake hose union bolt

WARNING:
● Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or J
other materials.
CAUTION:
● When cylinder body is open, do not depress brake pedal because piston will pop out. K
● Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing
pads.
● If shims are rusted or show peeling of the rubber coat, replace them with new shims. L
● It is not necessary to remove connecting bolt except for disassembly or replacement of caliper
assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.
● Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing M
pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-10, "Brake Burnishing
Procedure" .
Inspection EFS001DI

PAD THICKNESS
Check pad thickness by lifting vehicle, removing the wheel, and
looking through check hole on cylinder body. If necessary, use a
scale.
Standard pad thickness : 11 mm (0.43 in)
Pad wear limit : 2.0 mm (0.079 in)

MAA0439D

BR-19
 FRONT DISC BRAKE

Pad Replacement EFS001DJ

REMOVAL
CAUTION:
When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
1. Remove master cylinder reservoir tank cap.
2. Remove lower sliding pin bolt.

SBR433D

3. Hang cylinder body with a wire, and remove pads, pad retainers,
shims and pad return springs.

SBR932C

INSTALLATION
1. Apply brake grease on back of the pad and both sides of the shim. Install inner shim and inner shim cover
to inner pad, outer shim to outer pad.
2. Apply brake grease on the pad retainer pad contact surface. Install pad retainers, pads and pad return
springs to the torque member.
3. Connect cylinder body to the torque member.
CAUTION:
When replacing pads with new ones, press piston in until the pads can be installed. Carefully mon-
itor brake master cylinder reservoir fluid level. Brake fluid will return, raising master cylinder res-
ervoir tank fluid level.
4. Insert lower sliding pin bolt and tighten to the specified torque.
5. Check brakes for drag.
Caliper Removal and Installation EFS001DK

REMOVAL
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from air bleeder while depressing brake pedal.
3. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
4. Remove disc rotor.

SBR979B

BR-20
 FRONT DISC BRAKE

INSTALLATION
CAUTION: A
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
1. Install disc rotor. B
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Before installing caliper assembly, wipe oil and grease on steering knuckle washer seats and cali- C
per assembly mounting surface.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
D
CAUTION:
● Do not reuse the copper washer for union bolts.

● Securely assemble brake hose to protrusions on cylinder body.

E
4. Bleed air. Refer to BR-10, "Bleeding Brake System" .

Caliper Disassembly and Assembly EFS001DL

BR
DISASSEMBLY
WARNING:
Be careful not to pinch your fingers in the piston. G
CAUTION:
Be careful not to damage the cylinder inner wall.
1. Place a wooden block as shown in the figure. Blow air into union H
bolt mounting hole to remove pistons and piston boots.

BRB0032D K
2. Using flat tip screwdriver, remove piston seals.
L

SFIA0141E

BR-21
 FRONT DISC BRAKE

INSPECTION AFTER DISASSEMBLY

Cylinder Body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.
● Check cylinder inner wall for corrosion, wear and damage. If corrosion, wear or damage is detected,
replace the cylinder body.
● Minor flaws caused by corrosion or foreign material can be removed by polishing the surface with fine
sandpaper. Replace the cylinder body, if necessary.
Torque Member
Check for wear, cracks and damage. If wear, cracks or damage is detected, replace the applicable part.
Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear and damage. If corrosion, wear or damage is detected, replace the
applicable part.
Sliding Pin, Pin Bolt, and Pin Boot
Check sliding pin and sliding pin boot for wear, damage and cracks. If corrosion, wear or damage is detected,
replace the applicable part.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of the disc rotor for uneven wear, cracks and serious damage. If uneven wear, cracks or seri-
ous damage is detected, replace it.
Run Out Inspection
1. Using wheel nuts, fix the disc rotor to the wheels hub. (2 or more positions)
2. Using a dial indicator, check run out.
Measurement point:
At a point 10 mm (0.39 in) from the outer
edge of the disc.
Run out limit : 0.04 mm (0.0016 in) or
less
CAUTION:
Before measuring, make sure that the axle end play is 0 mm
(0 in).
BRA0013D
3. If the run out is outside the limit, find the minimum run out point
by shifting the mounting positions of the disc rotor and wheel hub by one hole.
Thickness Inspection
Using a micrometer, check thickness of the disc rotor. If the thick-
ness is outside the standard, replace the disc rotor.
Standard thickness : 28.0 mm (1.102 in)
Wear limit : 26.0 mm (1.024 in)
Maximum uneven wear (measured at 8 positions):
0.02 mm (0.0008 in) or less

SBR020B

BR-22
 FRONT DISC BRAKE

ASSEMBLY
CAUTION: A
When assembling, do not use rubber grease.
1. Apply rubber lubricant to piston seals, and install them to cylin-
der body. B
CAUTION:
Do not reuse piston seals.
C

SFIA0154E
E
2. Apply brake fluid or rubber lubricant to piston boots. Cover pis-
ton end with piston boot. Install cylinder side lip on piston boot
properly into groove on cylinder body. BR
CAUTION:
Do not reuse piston boot.
G

H
SFIA0155E

3. Apply brake fluid to piston. Press piston into cylinder body by I

hand. Assemble piston side lip on piston boot properly into
groove on piston.
CAUTION:
J
Press piston evenly and change pressing point to prevent
cylinder inner wall from being rubbed.

SBR574 L
BRAKE BURNISHING PROCEDURE
Burnish the brake contact surfaces according to the following procedure after refinishing or replacing drums or
rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. M
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH).
Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

BR-23
 REAR DISC BRAKE

REAR DISC BRAKE PFP:44000

Component EFS001DM

SFIA0330E

1. Pad retainer 2. Outer shim cover 3. Outer shim

4. Outer pad 5. Pad retainer 6. Inner pad
7. Inner shim 8. Inner shim cover 9. Sliding pin boot
10. Sliding pin 11. Sliding pin bolt 12. Cylinder body
13. Copper washer 14. Brake hose 15. Union bolt
16. Copper washer 17. Air bleeder 18. Piston seal
19. Piston 20. Piston boot 21. Retaining ring
22. Torque member

WARNING:
● Clean dust on brake caliper and pad with a vacuum dust collector. Do not blow with compressed
air.
CAUTION:
● Never depress brake pedal while removing cylinder body because the piston will pop out.
● Do not remove brake hose and torque member mounting bolts unless disassembling or replacing
caliper assembly. Hang the cylinder body with a wire so that the brake hose is not under tension.
● Be careful not to damage the piston boot. Do not allow brake fluid to get on the rotor.
● When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
Inspection EFS001DN

PAD WEAR INSPECTION

Check pad thickness by lifting vehicle, removing the wheel, and
looking through check hole on cylinder body. If necessary, use a
scale.
standard thickness : 8.5 mm (0.335 in)
pad wear limit : 2.0 mm (0.079 in)

BRA0010D

BR-24
 REAR DISC BRAKE

Pad Replacement EFS001DO

REMOVAL A
CAUTION:
When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
1. Remove master cylinder reservoir tank cap. B
2. Remove lower sliding pin bolt.

E
BRB0302D

3. Hang cylinder body with a wire, and remove pads, pad retainers, BR
and shims.

SBR042C

INSTALLATION M
1. Apply brake grease on back of the pad and both sides of the shim. Install inner shim and inner shim cover
to inner pad, outer shim to outer pad.
2. Install pad retainers to torque member and install pads.
3. Connect cylinder body to the torque member.
CAUTION:
When replacing pads with new ones, press piston in until the pads can be installed. Carefully mon-
itor brake master cylinder reservoir fluid level. Brake fluid will return, raising master cylinder res-
ervoir tank fluid level.
4. Insert lower sliding pin bolt and tighten to the specified torque.
5. Check brakes for drag.

BR-25
 REAR DISC BRAKE

Caliper Removal and Installation EFS001DP

REMOVAL
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from air bleeder while depressing brake pedal.
3. Remove brake hose connected to caliper assembly and union bolts. Remove brake hose from caliper
assembly.
4. Remove torque member mounting bolts, and remove caliper
assembly.
5. Remove disc rotor.

SFIA0143E

INSTALLATION
CAUTION:
● Refill with new brake fluid “ DOT 3”.
● Never reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Wipe oil and grease on axle assembly washer seats and caliper assembly mounting surface.
Install caliper assembly.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
● Do not reuse the copper washer for union bolts.

● Securely assemble brake hose to protrusions on cylinder body.

4. Bleed air. Refer to BR-10, "Bleeding Brake System" .

Caliper Disassembly and Assembly EFS001DQ

DISASSEMBLY
WARNING:
Be careful not to pinch your fingers in the piston.
CAUTION:
Be careful not to damage the cylinder inner wall.
1. Remove caliper assembly from vehicle.
2. Remove sliding pin from cylinder body. Then remove pads, shims, shim covers, and pad retainers from
caliper assembly.
3. Remove sliding pin boots from torque member.
4. Using flat tip screwdriver (as shown in the figure), remove retain-
ing ring.

SBR028A

BR-26
 REAR DISC BRAKE

5. Place a wooden block as shown in the figure. Blow air into union
bolt mounting hole to remove pistons and piston boots. A

BRD0041D

D
6. Using flat tip screwdriver, remove piston seals.

BR

G
SFIA0340E

INSPECTION AFTER DISASSEMBLY

H
Cylinder Body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.
I
● Check cylinder inner wall for corrosion, wear and damage. If corrosion, wear or damage is detected,
replace the cylinder body.
● Minor flaws caused by corrosion or foreign material can be removed by polishing the surface with fine
sandpaper. Replace the cylinder body, if necessary. J

Torque Member
Check for wear, cracks and damage. If wear, cracks or damage is detected, replace the applicable part. K
Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper. L
Check piston surface for corrosion, wear and damage. If corrosion, wear or damage is detected, replace the
applicable part.
Sliding Pin, Pin Bolt and Pin Boot M
Check sliding pin and sliding pin boot for wear, damage and cracks. If corrosion, wear or damage is detected,
replace the applicable part.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of the disc rotor for uneven wear, cracks and serious damage. If uneven wear, cracks or seri-
ous damage is detected, replace it.

BR-27
 REAR DISC BRAKE

Run Out Inspection

1. Using wheel nuts, fix the disc rotor to the wheels hub. (2 or more positions)
2. Using a dial indicator, check run out.
Measurement point:
At a point 10 mm (0.39 in) from the outer
edge of the disc.
Run out limit:
0.07 mm (0.0028 in) or less
CAUTION:
Before measuring, make sure that the axle end play is 0 mm
(0 in). BRA0013D

3. If the run out is outside the limit, find the minimum run out point
by shifting the mounting positions of the disc rotor and wheel hub by one hole.
Thickness Inspection
Using a micrometer, check thickness of the disc rotor. If the thick-
ness is outside the standard, replace the disc rotor.
Standard thickness : 16.0 mm (0.630 in)
Wear limit : 14.0 mm (0.551 in)
Maximum uneven wear (measured at 8 positions):
0.02 mm (0.0008 in) or less

SBR020B

ASSEMBLY
CAUTION:
When assembling, do not use rubber grease.
1. Apply rubber lubricant to piston seals, and install them to cylin-
der body.
CAUTION:
Do not reuse piston seals.

SFIA0156E

2. Apply brake fluid to piston boots. Cover piston end with piston
boot. Install cylinder side lip on piston boot properly into groove
on cylinder body.
CAUTION:
Do not reuse piston boot.
3. Press piston into cylinder body by hand. Assemble piston side
lip on piston boot properly into groove on the piston.
CAUTION:
Press piston evenly and change pressing point to prevent
cylinder inner wall from being rubbed.
SFIA0157E

BR-28
 REAR DISC BRAKE

4. Fix piston boot with retaining ring.

CAUTION: A
● Be sure boot is securely engaged in groove on cylinder
body.
● Do not reuse retaining ring. B
5. Connect sliding pins and sliding pin boots to torque member.
6. Connect torque member to axle assembly and tighten mounting
bolts to specified torque. C
CAUTION:
Wipe oil and grease on axle assembly washer seats and SFIA0158E
torque member mounting surface. Install torque member to D
axle assembly.
7. Connect pads, pad retainers, shims, and shim covers to torque member and assemble cylinder body.
8. Tighten sliding pin bolts to the specified torque. E
9. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
Do not reuse union bolt copper washer. BR
10. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake
System"
G

BR-29
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications EFS001DR

Unit: mm (in)
Brake model AD31VD
Cylinder bore diameter 44.4 × 2 (1.748 × 0.08)
Front brake Pad 132.0 × 52.5 × 11.0
Length x width x thickness (5.20 × 2.067 × 0.433)
Rotor outer diameter x thickness 280 × 28 (11.02 × 1.10)
Brake model ADV9VA
Cylinder bore diameter 34.9 (1.374)
Rear brake Pad 83.0 × 33.0 × 8.5
Length x width x thickness (3.268 × 1.299 × 0.335)
Rotor outer diameter x thickness 292 × 16 (11.50 × 0.63)
Master cylinder Cylinder bore diameter 25.4 (1)
Control valve Valve model Electronic control type
Booster model C215T
Brake booster Diaphragm diameter Primary 230 (9.06)
Secondary 205 (8.07)
Recommended brake fluid DOT 3

Brake Pedal EFS001DS

Free play (at pedal top surface) 3 - 11 mm (0.12 - 0.43 in)

Looseness at clevis pin 1 - 3 mm (0.04 - 0.12 in)
M/T model 156 - 166 mm (6.14 - 6.54 in)
Brake pedal height (from dash panel top surface)
A/T model 164 - 174 mm (6.46 - 6.85 in)

Depressed pedal height under force of 490 N (50 kg, 110.6 lb) M/T model 80 mm (3.15 in) or more
(from dash panel top surface) A/T model 85 mm (3.35 in) or more
0.74 - 1.96 mm (0.0291 -
Clearance between threaded end of stop lamp switch and pedal stopper
0.0772 in)

Check Valve EFS001DT

Vacuum leakage [at vacuum of 66.7 kPa (-500 mmHg, -19.69 Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 sec-
inHg)] onds

Brake Booster EFS001DU

Vacuum type
Vacuum leakage [at vacuum of -66.7 kPa (-500 mmHg, -19.69 Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 sec-
inHg)] onds
Input rod installation standard dimension 125 mm (4.92 in)

Front Disc Brake EFS001DV

Brake type AD31VD

Standard thickness (new) 11 mm (0.43 in)
Brake pad
Repair limit thickness 2.0 mm (0.07 in)
Standard thickness (new) 28 mm (1.10 in)
Disc rotor Repair limit thickness 26 mm (1.02 in)
Runout limit 0.04 mm (0.0016 in)

BR-30
 SERVICE DATA AND SPECIFICATIONS (SDS)

Rear Disc Brake EFS001DW

A
Brake type AD9VA
Standard thickness (new) 8.5 mm (0.335 in)
Brake pad
Repair limit thickness 2.0 mm (0.079 in) B
Standard thickness (new) 16 mm (0.63 in)
Disc rotor Repair limit thickness 14 mm (0.55 in)
C
Runout limit 0.07 mm (0.0028 in)

BR

BR-31
SERVICE DATA AND SPECIFICATIONS (SDS)

BR-32