Brakes

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 DRUM BRAKE ....................................... 19 I
SIONER" ................................................................... 7 BRAKE LINING ..........................................................19
Precautions Necessary for Steering Wheel Rota- BRAKE LINING : Inspection and Adjustment ..........19
tion After Battery Disconnection ................................ 7 J
Precaution for Procedure without Cowl Top Cover...... 8 BRAKE DRUM ...........................................................19
Precaution for Brake System .................................... 8 BRAKE DRUM : 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 ..........................................26 P
Draining ................................................................... 13 REAR : Removal and Installation ............................27
Refilling ................................................................... 13 REAR : Inspection ...................................................27
Bleeding Brake System ........................................... 14
BRAKE MASTER CYLINDER .......................... 28
BRAKE MASTER CYLINDER ............................15 Exploded View .........................................................28
Inspection ................................................................ 15 Removal and Installation .........................................28
Disassembly and Assembly .....................................29
BR-1
Inspection ............................................................... 30 FOR EUROPE : Precaution for Brake System ....... 49
BRAKE BOOSTER AND CHECK VALVE ........ 32 EXCEPT FOR EUROPE ............................................ 50
Exploded View ........................................................ 32 EXCEPT FOR EUROPE : Precaution for Supple-
Removal and installation ........................................ 32 mental Restraint System (SRS) "AIR BAG" and
Inspection and Adjustment ..................................... 33 "SEAT BELT PRE-TENSIONER" ........................... 50
EXCEPT FOR EUROPE : Precautions Necessary
VACUUM LINES ................................................ 35 for Steering Wheel Rotation After Battery Discon-
Exploded View ........................................................ 35 nection .................................................................... 50
Removal and Installation ........................................ 35 EXCEPT FOR EUROPE : Precaution for Proce-
Inspection ............................................................... 35 dure without Cowl Top Cover .................................. 51
EXCEPT FOR EUROPE : Precaution for Brake
FRONT DISC BRAKE ........................................ 36 System .................................................................... 51
BRAKE PAD ............................................................. 36
BRAKE PAD : Exploded View ................................ 36
PREPARATION .......................................... 53
BRAKE PAD : Removal and Installation ................. 36 PREPARATION ................................................. 53
BRAKE PAD : Inspection ........................................ 37 Commercial Service Tool ........................................ 53
BRAKE CALIPER ASSEMBLY ................................ 37
SYMPTOM DIAGNOSIS ............................ 54
BRAKE CALIPER ASSEMBLY : Exploded View ... 38
BRAKE CALIPER ASSEMBLY : Removal and In- NOISE, VIBRATION AND HARSHNESS
stallation ................................................................. 38 (NVH) TROUBLESHOOTING ............................ 54
BRAKE CALIPER ASSEMBLY : Disassembly and NVH Troubleshooting Chart .................................... 54
Assembly ................................................................ 39
BRAKE CALIPER ASSEMBLY : Inspection ........... 41 PERIODIC MAINTENANCE ....................... 55
REAR DRUM BRAKE ........................................ 42 BRAKE PEDAL ................................................. 55
Exploded View ........................................................ 42 Inspection and Adjustment ...................................... 55
Removal and Installation ........................................ 42
Disassembly and Assembly .................................... 44 BRAKE FLUID ................................................... 57
Inspection and Adjustment ..................................... 44 Inspection ................................................................ 57
Draining ................................................................... 57
SERVICE DATA AND SPECIFICATIONS Refilling ................................................................... 57
(SDS) ........................................................... 46 Bleeding Brake System ........................................... 58
SERVICE DATA AND SPECIFICATIONS BRAKE MASTER CYLINDER ........................... 59

(SDS) .................................................................. 46 Inspection ................................................................ 59
General Specifications ............................................ 46
Brake Pedal ............................................................ 46
BRAKE BOOSTER ............................................ 60
Brake Booster ......................................................... 46 Inspection ................................................................ 60
Front Disc Brake ..................................................... 46 FRONT DISC BRAKE ....................................... 61
Rear Drum Brake .................................................... 46
TYPE 2 BRAKE PAD .............................................................. 61
BRAKE PAD : Inspection and Adjustment .............. 61
HOW TO USE THIS MANUAL .................... 47
DISC ROTOR ............................................................ 61
HOW TO USE THIS SECTION .......................... 47 DISC ROTOR : Inspection and Adjustment ............ 61
Information .............................................................. 47
REAR DRUM BRAKE ....................................... 63
PRECAUTION ............................................. 48
BRAKE LINING ......................................................... 63
PRECAUTIONS ................................................. 48 BRAKE LINING : Inspection and Adjustment ......... 63
FOR EUROPE ........................................................... 48 BRAKE DRUM .......................................................... 63

FOR EUROPE : Precaution for Supplemental Re- BRAKE DRUM : Inspection and Adjustment ........... 63
straint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" ................................................. 48
REMOVAL AND INSTALLATION .............. 65
FOR EUROPE : Precautions Necessary for Steer- BRAKE PEDAL ................................................. 65
ing Wheel Rotation After Battery Disconnection ..... 48 Exploded View ........................................................ 65
FOR EUROPE : Precaution for Procedure without Removal and Installation ......................................... 65
Cowl Top Cover ...................................................... 49
BR-2
Inspection and Adjustment ...................................... 66 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 93 A
BRAKE PIPING ..................................................67 General Specifications .............................................93
FRONT ....................................................................... 67 Brake Pedal .............................................................93
FRONT : Exploded View ......................................... 67 Brake Booster ..........................................................93 B
FRONT : Hydraulic Piping ....................................... 68 Front Disc Brake ......................................................93
FRONT : Removal and Installation ......................... 69 Rear Drum Brake .....................................................93
FRONT : Inspection ................................................ 70 TYPE 3 C
REAR ......................................................................... 70 HOW TO USE THIS MANUAL .................... 94
REAR : Exploded View ........................................... 71
REAR : Hydraulic Piping ......................................... 71 HOW TO USE THIS SECTION ......................... 94 D
REAR : Removal and Installation ............................ 72 Information ...............................................................94
REAR : Inspection ................................................... 73
PRECAUTION .............................................. 95
E
BRAKE MASTER CYLINDER ............................74
Exploded View ........................................................ 74 PRECAUTIONS ................................................. 95
Removal and Installation ......................................... 74 FOR EUROPE ............................................................95
Disassembly and Assembly .................................... 75 BR
FOR EUROPE : Precaution for Supplemental Re-
Inspection ................................................................ 76 straint System (SRS) "AIR BAG" and "SEAT BELT
BRAKE BOOSTER AND CHECK VALVE .........77 PRE-TENSIONER" ..................................................95
FOR EUROPE : Precautions Necessary for Steer- G
Exploded View ........................................................ 77
ing Wheel Rotation After Battery Disconnection ......95
Removal and installation ......................................... 77
FOR EUROPE : Precaution for Procedure without
Inspection and Adjustment ...................................... 78
Cowl Top Cover .......................................................96 H
VACUUM LINES .................................................81 FOR EUROPE : Precaution for Brake System ........96
HR12DE, HR15DE ..................................................... 81 EXCEPT FOR EUROPE ............................................97

EXCEPT FOR EUROPE : Precaution for Supple- I
HR12DE, HR15DE : Exploded View ....................... 81
HR12DE, HR15DE : Removal and Installation ....... 81 mental Restraint System (SRS) "AIR BAG" and
HR12DE, HR15DE : Inspection .............................. 81 "SEAT BELT PRE-TENSIONER" ............................97
EXCEPT FOR EUROPE : Precautions Necessary J
HR12DDR .................................................................. 82 for Steering Wheel Rotation After Battery Discon-
HR12DDR : Exploded View .................................... 82 nection .....................................................................97
HR12DDR : Removal and Installation ..................... 82 EXCEPT FOR EUROPE : Precaution for Proce- K
HR12DDR : Inspection ............................................ 82 dure without Cowl Top Cover ..................................98
EXCEPT FOR EUROPE : Precaution for Brake
FRONT DISC BRAKE ........................................83 System .....................................................................98
L
BRAKE PAD .............................................................. 83
BRAKE PAD : Exploded View ................................. 83
PREPARATION ......................................... 100
BRAKE PAD : Removal and Installation ................. 83 PREPARATION ............................................... 100
BRAKE PAD : Inspection ........................................ 84 M
Commercial Service Tool ...................................... 100
BRAKE CALIPER ASSEMBLY ................................. 84
SYMPTOM DIAGNOSIS ............................ 101
BRAKE CALIPER ASSEMBLY : Exploded View .... 84 N
BRAKE CALIPER ASSEMBLY : Removal and In- NOISE, VIBRATION AND HARSHNESS
stallation .................................................................. 85 (NVH) TROUBLESHOOTING ......................... 101
BRAKE CALIPER ASSEMBLY : Disassembly and NVH Troubleshooting Chart .................................. 101
Assembly ................................................................. 86 O
BRAKE CALIPER ASSEMBLY : Inspection ............ 88 PERIODIC MAINTENANCE ...................... 102
REAR DRUM BRAKE ........................................89 BRAKE PEDAL ............................................... 102 P
Exploded View ........................................................ 89 Inspection and Adjustment .................................... 102
Removal and Installation ......................................... 89
Disassembly and Assembly .................................... 91 BRAKE FLUID ................................................ 104
Inspection and Adjustment ...................................... 91 Inspection .............................................................. 104
Draining ................................................................. 104
SERVICE DATA AND SPECIFICATIONS Refilling .................................................................. 104
(SDS) ............................................................ 93 Bleeding Brake System ......................................... 105
BR-3
BRAKE MASTER CYLINDER ......................... 106 HR12DE, HR15DE : Removal and Installation ..... 135
Inspection ..............................................................106 HR12DE, HR15DE : Inspection ............................ 135
BRAKE BOOSTER .......................................... 107 HR12DDR ................................................................ 136

Inspection ..............................................................107 HR12DDR : Exploded View .................................. 136
HR12DDR : Removal and Installation ................... 136
FRONT DISC BRAKE ...................................... 108 HR12DDR : Inspection .......................................... 137
BRAKE PAD ............................................................108 K9K .......................................................................... 137
BRAKE PAD : Inspection and Adjustment .............108 K9K : Exploded View ............................................ 137
K9K : Removal and Installation ............................. 137
DISC ROTOR ...........................................................108
K9K : Inspection .................................................... 138
DISC ROTOR : Inspection and Adjustment ...........108
FRONT DISC BRAKE ...................................... 139
REAR DRUM BRAKE ...................................... 110
BRAKE PAD ............................................................ 139
BRAKE LINING ........................................................110
BRAKE PAD : Exploded View ............................... 139
BRAKE LINING : Inspection and Adjustment ........110
BRAKE PAD : Removal and Installation ............... 140
BRAKE DRUM .........................................................110 BRAKE PAD : Inspection ...................................... 142
BRAKE DRUM : Inspection and Adjustment .........110 BRAKE CALIPER ASSEMBLY .............................. 142
REMOVAL AND INSTALLATION .............. 112 BRAKE CALIPER ASSEMBLY : Exploded View . 142
BRAKE CALIPER ASSEMBLY : Removal and In-
BRAKE PEDAL ............................................... 112 stallation ................................................................ 144
Exploded View .......................................................112 BRAKE CALIPER ASSEMBLY : Disassembly and
Removal and Installation .......................................113 Assembly .............................................................. 145
Inspection and Adjustment ....................................114 BRAKE CALIPER ASSEMBLY : Inspection .......... 146
BRAKE PIPING ............................................... 115 REAR DRUM BRAKE ...................................... 148

Exploded View ...................................................... 148
FRONT .....................................................................115 Removal and Installation ....................................... 148
FRONT : Exploded View .......................................115 Disassembly and Assembly .................................. 150
FRONT : Hydraulic Piping .....................................118 Inspection and Adjustment .................................... 150
FRONT : Removal and Installation ........................120
FRONT : Inspection ...............................................120 SERVICE DATA AND SPECIFICATIONS
(SDS) ......................................................... 152
REAR ........................................................................121
REAR : Exploded View ..........................................121 SERVICE DATA AND SPECIFICATIONS
REAR : Hydraulic Piping ........................................122 (SDS) ................................................................ 152
REAR : Removal and Installation ..........................124 General Specifications .......................................... 152
REAR : Inspection .................................................124 Brake Pedal .......................................................... 153
DUAL PROPORTIONING VALVE ................... 125 Brake Booster ....................................................... 153
Front Disc Brake ................................................... 153
Exploded View .......................................................125
Rear Drum Brake .................................................. 153
Removal and Installation .......................................125
Inspection ..............................................................126 TYPE 4
BRAKE MASTER CYLINDER ......................... 127 HOW TO USE THIS MANUAL .................. 155
Exploded View .......................................................127
Removal and Installation .......................................128
HOW TO USE THIS SECTION ......................... 155
Disassembly and Assembly ...................................129 Information ............................................................ 155
Inspection ..............................................................130 PRECAUTION ........................................... 156
BRAKE BOOSTER AND CHECK VALVE ...... 131 PRECAUTIONS ................................................ 156
Exploded View .......................................................131
Precaution for Supplemental Restraint System
Removal and installation .......................................131
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Inspection and Adjustment ....................................133 SIONER" ............................................................... 156
VACUUM LINES .............................................. 135 Precautions Necessary for Steering Wheel Rota-
tion After Battery Disconnection ............................ 156
HR12DE, HR15DE ...................................................135 Precaution for Procedure without Cowl Top Cover. 157
HR12DE, HR15DE : Exploded View .....................135 Precaution for Brake System ................................ 157
BR-4
PREPARATION ......................................... 158 REAR : Exploded View .......................................... 178
REAR : Hydraulic Piping ........................................ 179 A
PREPARATION ................................................ 158 REAR : Removal and Installation .......................... 181
Commercial Service Tool ...................................... 158 REAR : Inspection ................................................. 181
SYMPTOM DIAGNOSIS ............................ 159 DUAL PROPORTIONING VALVE .................. 182 B

Exploded View ....................................................... 182
NOISE, VIBRATION AND HARSHNESS Removal and Installation ....................................... 182
(NVH) TROUBLESHOOTING .......................... 159 Inspection .............................................................. 183 C
NVH Troubleshooting Chart .................................. 159
BRAKE MASTER CYLINDER ........................ 184
PERIODIC MAINTENANCE ....................... 160 Exploded View ....................................................... 184
D
Removal and Installation ....................................... 184
BRAKE PEDAL ................................................ 160 Disassembly and Assembly ................................... 185
Inspection and Adjustment .................................... 160 Inspection .............................................................. 186
E
BRAKE FLUID .................................................. 162 BRAKE BOOSTER AND CHECK VALVE ...... 187
Inspection .............................................................. 162 Exploded View ....................................................... 187
Draining ................................................................. 162 Removal and installation ....................................... 187
Refilling ................................................................. 162 BR
Inspection and Adjustment .................................... 189
Bleeding Brake System ......................................... 163
VACUUM LINES ............................................. 191
BRAKE MASTER CYLINDER .......................... 164 Exploded View ....................................................... 191 G
Inspection .............................................................. 164 Removal and Installation ....................................... 191
BRAKE BOOSTER .......................................... 165 Inspection .............................................................. 191
Inspection .............................................................. 165 H
FRONT DISC BRAKE ..................................... 193
FRONT DISC BRAKE ...................................... 166 BRAKE PAD ............................................................ 193
BRAKE PAD : Exploded View ............................... 193 I
BRAKE PAD ............................................................ 166
BRAKE PAD : Removal and Installation ................ 194
BRAKE PAD : Inspection and Adjustment ............ 166
BRAKE PAD : Inspection ....................................... 195
DISC ROTOR ........................................................... 166 J
DISC ROTOR : Inspection and Adjustment .......... 166 BRAKE CALIPER ASSEMBLY ............................... 195
BRAKE CALIPER ASSEMBLY : Exploded View .. 195
REAR DRUM BRAKE ...................................... 168 BRAKE CALIPER ASSEMBLY : Removal and In-
stallation ................................................................ 196 K
BRAKE LINING ....................................................... 168 BRAKE CALIPER ASSEMBLY : Disassembly and
BRAKE LINING : Inspection and Adjustment ........ 168 Assembly ............................................................... 197
BRAKE CALIPER ASSEMBLY : Inspection .......... 198 L
BRAKE DRUM ......................................................... 168
BRAKE DRUM : Inspection and Adjustment ......... 168 REAR DRUM BRAKE ..................................... 200
Exploded View ....................................................... 200
REMOVAL AND INSTALLATION ............. 170 Removal and Installation ....................................... 201 M
BRAKE PEDAL ................................................ 170 Disassembly and Assembly ................................... 203
Exploded View ...................................................... 170 Inspection and Adjustment .................................... 204
Removal and Installation ....................................... 171 N
SERVICE DATA AND SPECIFICATIONS
Inspection and Adjustment .................................... 172
(SDS) .......................................................... 205
BRAKE PIPING ................................................ 173
SERVICE DATA AND SPECIFICATIONS O
FRONT ..................................................................... 173 (SDS) ............................................................... 205
FRONT : Exploded View ....................................... 173 General Specifications ........................................... 205
FRONT : Hydraulic Piping ..................................... 175 Brake Pedal ........................................................... 206 P
FRONT : Removal and Installation ....................... 177 Brake Booster ........................................................ 206
FRONT : Inspection .............................................. 177 Front Disc Brake .................................................... 206
Rear Drum Brake ................................................... 206
REAR ....................................................................... 178
BR-5
HOW TO USE THIS SECTION
< HOW TO USE THIS MANUAL > [TYPE 1]
HOW TO USE THIS MANUAL

Information INFOID:0000000006708856
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-26, "Information About Identification or Model Code" to identify a production plant.
BR-6
PRECAUTIONS
< PRECAUTION > [TYPE 1]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000006291193
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:0000000006291194
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.
BR-7
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:0000000006291195
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:0000000006273966
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-29, "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.
• 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).
• Always confirm the specified tightening torque when installing the
brake pipes.
• 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.
• 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
JPFIA0061ZZ
parts.
• Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
- Front brake pad: refer to BR-17, "BRAKE PAD : Inspection and Adjustment".
- Front disc rotor: refer to BR-17, "DISC ROTOR : Inspection and Adjustment".
- Rear brake lining: refer to BR-19, "BRAKE LINING : Inspection and Adjustment".
- Rear brake drum: refer to BR-19, "BRAKE DRUM : Inspection and Adjustment".
BR-8
PREPARATION
< PREPARATION > [TYPE 1]
PREPARATION A
PREPARATION
Commercial Service Tool INFOID:0000000006267388
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 Return the piston
L
NNFIA0040ZZ
BR-9
Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
SUSPECTED PARTS
Noise
Shake
< SYMPTOM DIAGNOSIS >
Shimmy, Judder
NVH Troubleshooting Chart
Pads or lining damaged BR-17, BR-19
×
SYMPTOM DIAGNOSIS
Pads or lining uneven wear BR-17, BR-19
×
Shims damaged BR-37
×
Rotor imbalance BR-17
×
×
BR-10
Rotor or drum damage BR-17, BR-19
×
Rotor runout BR-17
×
Rotor deformation BR-17
×
Rotor or drum deflection BR-17, BR-19
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
Rotor or drum rust BR-17, BR-19
×
×
Rotor thickness variation BR-17
×
Drum out of round BR-19
×
AXLE AND SUSPENSION NVH in FAX, RAX and FSU, RSU section
×
×
×
TIRE NVH in WT section

×
×
×
ROAD WHEEL NVH in WT section

×
×
×
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
× × DRIVE SHAFT NVH in FAX section
STEERING NVH in ST section

×
×
×
[TYPE 1]
INFOID:0000000006267389
BRAKE PEDAL
< PERIODIC MAINTENANCE > [TYPE 1]
PERIODIC MAINTENANCE A
BRAKE PEDAL
Inspection and Adjustment INFOID:0000000006267390
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-46, "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-46, "Brake Pedal". H

CAUTION:
The stop lamp must turn off when the brake pedal is released.
I
J
JPFIA0866ZZ
Brake Pedal Play

Press the brake pedal. Check the brake pedal play (A) (stroke until K
fluid pressure occurs).
A : Refer to BR-46, "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
BR-11
BRAKE PEDAL
Brake Pedal Height
1. Remove instrument lower panel. Refer to IP-15, "Removal and Installation".
2. Disconnect the harness connector from stop lamp switch.
3. Loosen the stop lamp switch 45° counterclockwise.
4. Adjust the brake pedal height with the following procedure.
a. Loosen the input rod lock nut (1).
CAUTION:
The threaded end of the input rod (2) must project to the
inner side (L) of the clevis (3).
JPFIA0003ZZ
b. Rotate the input rod, adjust the brake pedal to the specified
height (H1).

c. Tighten the lock nut. Refer to BR-32, "Exploded View".
5. Check the brake pedal play.
JPFIA0279ZZ
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-46, "Brake Pedal".

• The stop lamp must be turned off when the brake pedal is
released.
JPFIA0866ZZ
BR-12
BRAKE FLUID
BRAKE FLUID
A
Inspection INFOID:0000000006267391
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:0000000006267392
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:0000000006267393
CAUTION: P
BR-13
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:0000000006267394
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-38, "BRAKE CALIPER ASSEMBLY : Exploded View".
• Rear drum brake: refer to BR-42, "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".
BR-14
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
BR-15
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. 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
increases each time the brake pedal is depressed when performing this operation.
2. 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.
BR-16
FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
BRAKE PAD : Inspection and Adjustment INFOID:0000000006267397
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-46, "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:0000000006267398
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-46, "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.
5. Refinish or replace the disc rotor if the runout is outside the limit even after performing the above opera-
tion.
CAUTION:
If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor. Refer to
BR-17
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-
13, "Removal and Installation".
Wear thickness : Refer to BR-46, "Front Disc

Brake".
Thickness variation : Refer to BR-46, "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.
BR-18
REAR DRUM BRAKE
REAR DRUM BRAKE
A
BRAKE LINING
BRAKE LINING : Inspection and Adjustment INFOID:0000000006267399
B
INSPECTION
Brake Lining C
1. Remove plug from back plate. Refer to BR-42, "Exploded View".
2. Check brake lining wear thickness (A) from an inspection hole
on back plate. Check using a scale necessary. D
A : Refer to BR-46, "Rear Drum Brake".

E
BR
J
JPFIA0806ZZ
ADJUSTMENT
Burnish contact surfaces between brake lining and brake drum according to the following procedure after K
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
L
brake drum are securely fitted.
M
4. Repeat steps 1 to 3 until brake lining and brake drum are securely fitted. N
BRAKE DRUM
BRAKE DRUM : Inspection and Adjustment INFOID:0000000006267400
O
INSPECTION
Appearance P
Check surface of brake drum for uneven wear, cracks and serious damage. Replace it if necessary. Refer to
RAX-6, "Removal and Installation".
Brake Drum Inner Diameter
BR-19
REAR DRUM BRAKE
Check inner diameter (B) of the brake drum.
B : Refer to BR-46, "Rear Drum Brake".
JPFIA0113ZZ
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:
• Be careful of vehicle speed because the brake does not operate firmly/securely until brake drum and
brake lining are securely fitted.
4. Repeat steps 1 to 3 until brake drum and brake lining are securely fitted.
BR-20
BRAKE PEDAL
< REMOVAL AND INSTALLATION > [TYPE 1]
REMOVAL AND INSTALLATION A

BRAKE PEDAL
Exploded View INFOID:0000000006267401
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.
Refer to GI-4, "Components" for symbols not described on the above.
L
Removal and Installation INFOID:0000000006267402
REMOVAL
M
2. Disconnect the stop lamp switch harness connectors.
3. Disconnect the accelerator pedal harness connector. N
4. Remove harness from brake pedal assembly.
5. Rotate the stop lamp switch counter clockwise to remove.
6. Remove snap pin and clevis pin from clevis. O
7. Remove the brake pedal assembly.
CAUTION:
Hold the brake booster and master cylinder assembly so as not to drop out or contact them other P
parts.
8. Remove accelerator pedal from brake pedal assembly. Refer to ACC-4, "Removal and Installation".
9. Perform inspection after removal. Refer to BR-22, "Inspection and Adjustment".
INSTALLATION
Note the following, and install in the reverse order of removal.
BR-21
BRAKE PEDAL
• 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 any impact caused by dropping, interference with a tool, contact between parts or with rack to
the brake pedal.
• Do not use an 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 EC4-108, "Work Procedure".
BR-22
BRAKE PIPING
BRAKE PIPING
A
FRONT
FRONT : Exploded View INFOID:0000000006267404
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
: Indicates that the part is connected at points with same symbol in actual vehicle.
Refer to GI-4, "Components" for symbols in the figure.
M
BR-23
BRAKE PIPING
FRONT : Hydraulic Piping INFOID:0000000006267405
JPFIA0869ZZ
1. ABS actuator and electric unit (con- 2. Front disc brake 3. Master cylinder assembly
trol unit)
4. Brake booster 5. Connector 6. Rear drum brake
A. Brake tube B. Brake hose
: Flare nut
: Union bolt
FRONT : Removal and Installation INFOID:0000000006267406
REMOVAL
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
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 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:
Never reuse the copper washer.
BR-24
BRAKE PIPING
2. Align the brake hose L-pin by aligning it with the brake caliper
assembly hole, and tighten the union bolt (1) to the specified A
torque.
3. Install the brake tube to the brake hose, temporarily tighten the
flare nut by hand until it does not rotate further, and fix the brake B
hose to the bracket with the lock plate.
CAUTION:
Check that all brake hoses and brake tubes are not twisted
and bent. C
4. Tighten the flare nut to the specified torque with a flare nut
torque wrench. JPFIA0012ZZ
CAUTION: D
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".
CAUTION: E
Never reuse drained brake fluid.
6. Install tires. Refer to WT-7, "Exploded View".
7. Perform inspection after installation. Refer to BR-25, "FRONT : Inspection". BR
FRONT : Inspection INFOID:0000000006267407
G
INSPECTION AFTER INSTALLATION
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer-
ence with other components when steering the steering wheel; no looseness at connections.
H
CAUTION:
Clearance with brake hose and each parts being secured more than 10 mm (0.39 in) in unladen
condition*.
*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in desig- I
nated positions.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately
5 seconds with the engine running. Check for any fluid leakage. J
CAUTION:
Retighten the applicable connection to the specified torque and repair any abnormal (damaged,
worn or deformed) part if any brake fluid leakage is present. K
REAR
L
BR-25
BRAKE PIPING
REAR : Exploded View INFOID:0000000006267408
JPFIA0857GB
1. Brake tube 2. Lock plate 3. Brake hose

A. To connector
REAR : Hydraulic Piping INFOID:0000000006267409
JPFIA0869ZZ
1. ABS actuator and electric unit (con- 2. Front disc brake 3. Master cylinder
trol unit)
BR-26
BRAKE PIPING
A
: Flare nut
: Union bolt
B
REAR : Removal and Installation INFOID:0000000006267410
REMOVAL
CAUTION: C
1. Remove tires. D
3. Loosen the flare nut with a flare nut wrench and separate the brake tube from the brake hose.
CAUTION: E
• Never sharply bend, twist or strongly pull the brake hoses and tubes.
• Cover the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. BR
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. G
INSTALLATION
CAUTION:
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it H
1. Connect the brake tube to the wheel cylinder, temporarily tighten the flare nut by hand until it does not I
rotate further.
2. Connect 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. J
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.
K
CAUTION:
CAUTION: L
M
6. Perform inspection after installation. Refer to BR-27, "REAR : Inspection".
REAR : Inspection INFOID:0000000006267411
N
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no looseness
at connections. O
CAUTION:
condition*. P
*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in desig-
nated positions.
5 seconds with the engine running. Check for any fluid leakage.
CAUTION:
worn or deformed) part if any brake fluid leakage is present.
BR-27
JSFIA1048GB
1. Reservoir cap 2. Oil strainer 3. Reservoir tank

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

REMOVAL
CAUTION:
• 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-30, "Inspection".
3. Remove battery. Refer to PG-530, "FOR MAINTENANCE FREE BATTERY MODELS : Removal and
Installation".
4. Remove air duct and air cleaner case. Refer to EM-337, "Removal and Installation".
5. Move IPDM E/R not to interfere work. Refer to PCS-72, "Removal and Installation" (with intelligent key),
PCS-137, "Removal and Installation" (without intelligent key).
6. Disconnect the brake fluid level switch harness connector.
BR-28
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. Remove the master cylinder assembly. B
CAUTION:
• Never deform or bend the brake tubes.
• Never depress the brake pedal after the master cylinder assembly is removed.
• The piston of the master cylinder assembly is exposed. Never damage it when removing the C
master cylinder.
• The piston may drop off when pulled out strongly. Never hold the piston. Hold the cylinder body
when handling the master cylinder assembly. D
9. Remove the O-ring.
INSTALLATION
CAUTION: E
Note the following, and install in the reverse order of removal. BR
• 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. G
• The piston of the master cylinder assembly is exposed. Never
damage it when handling the master cylinder and check that no dirt
and dust are present on the piston before installation. Clean it with H
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
I
assembly.
• Temporarily tighten the brake tube flare nut to the master cylinder
JPFIA0013ZZ
assembly by hand. Then tighten it to the specified torque with a J
flare nut torque wrench. Refer to BR-23, "FRONT : Exploded View".
CAUTION:
Never scratch the flare nut and the brake tube. K
• After installation, perform the air bleeding. Refer to BR-14, "Bleeding Brake System"
CAUTION:
Never reuse drained brake fluid. L
• Perform inspection after installation. Refer to BR-30, "Inspection".
Disassembly and Assembly INFOID:0000000006267417
M
DISASSEMBLY
CAUTION:
• Remove the reservoir tank only when necessary. N
• 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: O
• 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 (0.16 in)]. P
3. Remove master cylinder from vise.
4. Remove the reservoir tank and grommet from the cylinder body.
BR-29
5. Raise the stopper cap tab with a suitable tool to remove the
stopper cap from the cylinder body.
6. Remove the primary piston assembly.
CAUTION:
Pull out the primary piston assembly straight, being careful
not to damage the cylinder body inner wall.
7. Remove the secondary piston assembly.
CAUTION:
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
ASSEMBLY
CAUTION:
• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and
assembly process.
• 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
then install to the primary piston assembly and the secondary piston.
CAUTION:
• Never reuse the secondary piston assembly and the primary piston assembly.
• 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
direction, being careful not to damage the cylinder body inner wall.
2. Install the stopper cap.
CAUTION:
• Never reuse the stopper cap.
• Replace the secondary piston assembly, the primary piston assembly and the stopper cap as a
set.
• Press the primary piston assembly with the stopper cap
until the stopper cap tab ( ) gets caught in the cylinder
body groove.
3. Apply new brake fluid to the grommet and install it to the cylinder
body.
CAUTION:
Never reuse the grommets.
4. Install the reservoir tank to the cylinder body.
5. Fix the cylinder body to a vise.
CAUTION:
BRA0535D
• Place the reservoir tank with the chamfered pin hole fac-
ing up.
6. 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.
INSPECTION BEFORE REMOVAL

Check the brake fluid level switch. Refer to BRC-101, "Component Inspection".
BR-30
Check the following items and replace if necessary.
• Check the master cylinder for deformation, twist, contact with other parts or looseness of connection. A
• 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.
B
BR
BR-31
BRAKE BOOSTER AND CHECK VALVE
JPFIA0870GB
1. Master cylinder assembly 2. Check valve 3. Brake booster

4. Lock nut 5. Clevis 6. Gasket
Removal and installation INFOID:0000000006267420
REMOVAL
CAUTION:
2. Perform inspection before removal. Refer to BR-33, "Inspection and Adjustment".
3. Remove battery. Refer to PG-530, "FOR MAINTENANCE FREE BATTERY MODELS : Removal and
Installation".
4. Remove air duct and air cleaner case. Refer to EM-337, "Removal and Installation".
6. Remove brake master cylinder assembly. Refer to BR-28, "Removal and Installation".
7. Remove vacuum hose from check valve. Refer to BR-35, "Removal and Installation".
8. Remove snap pin (1) and clevis pin (2). Refer to BR-21,
"Exploded View".
9. Remove nuts on brake booster and brake pedal assembly.
10. Remove brake booster from dash panel in engine room side.
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-33, "Inspection
and Adjustment".
INSTALLATION
BR-32
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it A
• Set check valve angle (A) as shown in the figure.
B
A : 25° – 45°
• Be careful not to damage brake booster stud bolt threads. If brake C
booster is tilted during installation, the dash panel may damage the
threads.
• Never deform or bend the brake tubes when installing the brake
booster. D
• 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
E
and Adjustment".
• After installation, perform the air bleeding. Refer to BR-14, "Bleeding Brake System".
CAUTION: BR
• Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-11,
"Inspection and Adjustment". G
INSPECTION BEFORE REMOVAL H
Air Tight
CAUTION: I
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.
J
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. K
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-28, L
"Removal and Installation".
c. Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster.
INSPECTION AFTER REMOVAL M
Check Valve Air Tightness

1. Check the air tight use a handy vacuum pump. N
When connected to the : Vacuum should decrease within 1.3 kPa (9.8 mmHg, 0.38 inHg,
booster side 0.013 bar) for 15 seconds under a vacuum of −66.7 kPa (−500 O
mmHg, −19.69 inHg, −0.067 bar).
When connected to the :Vacuum should not exist.
vacuum hose side P
2. If the condition still cannot be maintained, replace the check valve.
Input Rod Length Inspection
BR-33
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (A).
A : Refer to BR-46, "Brake Booster".

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

Operation
brake pedal fully depressed. Check that the clearance between brake pedal and dash lower pane decreases.
NOTE:
Air Tight
onds or more.
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-11, "Inspection and
Adjustment".
BR-34
VACUUM LINES
VACUUM LINES
A
BR
I
JPFIA0872ZZ
1. Clamp 2. Vacuum hose 3. Vacuum piping J

A. To brake booster B. Paint mark C. To intake manifold

K
REMOVAL
Remove the vacuum hose and vacuum piping.
L
INSTALLATION
Note the following, install the vacuum hose.
• When installing vacuum hose, insert it until its tip reaches the M
back-end of length (A) or further as shown in the figure.
CAUTION:
Never use lubricating oil during assembly.
N
A : 24 mm (0.95 in) or more
- Face the paint mark of vacuum hose (intake manifold side) to the
upward to assemble. O
- Face the other paint marks of vacuum hose to vehicle front side to
assemble.
JPFIA0023ZZ
P

Appearance
Check for correct assembly, damage and deterioration.
BR-35
FRONT DISC BRAKE
FRONT DISC BRAKE
BRAKE PAD
BRAKE PAD : Exploded View INFOID:0000000006267425
JPFIA0859GB
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
10. Outer shim cover
1: Apply MOLYKOTE® AS880N or silicone-based grease.
2: Apply MOLYKOTE® 7439 or equivalent.
BRAKE PAD : Removal and Installation INFOID:0000000006267426
REMOVAL
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.
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out.
1. Remove tires.
2. Remove lower sliding pin bolt.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the pad
return spring, brake pads, shims, shim covers and pad retainers from the torque member.
CAUTION:
• Never deform the pad return spring when removing the pad return spring from the brake pad.
• Never deform the pad retainer when removing the pad retainer from the torque member.
• Never damage the piston boot.
• Never drop the brake pads, shims, and the shim covers.
• Remember each position of the removed brake pads.
4. Perform inspection after removal. Refer to BR-37, "BRAKE PAD : Inspection".
INSTALLATION
WARNING:
BR-36
FRONT DISC BRAKE
dust collector. Never splatter the dust with an air blow gun. A
CAUTION:
• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis-
ton may pop out.
B
1. Install the pad retainers to the torque member if the pad retainers has been removed.
CAUTION:
• Securely assemble the pad retainers so that it will not be lifted up from the torque member. C
• Never deform the pad retainers.
2. Apply MOLYKOTE® AS880N or silicone-based grease to the
mating faces between the inner shim (A) and the inner shim D
cover (B), and install them to the inner pad.
CAUTION:
Always replace the shim together with the shim cover when E
replacing the brake pad.
mating faces between the outer shim (A) and the outer shim BR
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. G
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. H
5. Install the pad return spring to the brake pad.
CAUTION:
• Never deform the pad return spring.
• Correctly insert the pad return spring in to the pad return spring hole on the brake pad. I
6. Install cylinder body to torque member.
CAUTION:
• Never damage the piston boot. J
• 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: K
Use a disc brake piston tool to easily press piston.
7. Install the lower sliding pin bolt and tighten it to the specified torque.
8. Depress the brake pedal several times to check that no drag feel is present for the front disc brake. Refer L
to BR-37, "BRAKE PAD : Inspection".
BRAKE PAD : Inspection INFOID:0000000006267427
M

Replace the shims and the shim covers if rust is excessively attached. N

1. Check a drag of front disc brake. If any drag is found, follow the procedure described below. O
2. Remove brake pads. Refer to BR-36, "BRAKE PAD : Removal and Installation".
3. Press the pistons. Refer to BR-36, "BRAKE PAD : Removal and Installation".
4. Install brake pads. Refer to BR-36, "BRAKE PAD : Removal and Installation". P
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
necessary. Refer to BR-39, "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, "BRAKE PAD : Inspection and Adjustment".
BRAKE CALIPER ASSEMBLY
BR-37
FRONT DISC BRAKE
BRAKE CALIPER ASSEMBLY : Exploded View INFOID:0000000006267428
REMOVAL
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.

BRAKE CALIPER ASSEMBLY : Removal and Installation INFOID:0000000006267429
REMOVAL
BR-38
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. Brake fluid may splash while removing the brake hose.
5. Remove torque member mounting bolts, and remove brake caliper assembly.
CAUTION: BR
Never drop brake pad and caliper assembly.
6. Remove disc rotor. Refer to FAX-13, "Removal and Installation".
INSTALLATION G
WARNING:
dust collector. Never splatter the dust with an air blow gun. H
CAUTION:
• Never depress the brake pedal. Brake fluid may splash while removing the brake hose.
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it I
J
1. Install disc rotor. Refer to FAX-13, "Removal and Installation".
2. Install the brake caliper assembly to the steering knuckle and tighten the torque member mounting bolts to
the specified torque.
CAUTION: K
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.
3. Install brake hose and copper washers to brake caliper assembly, and tighten union bolts to the specified L
torque. Refer to BR-24, "FRONT : Removal and Installation".
CAUTION:
Never reuse copper washer. M
CAUTION:
• Never reuse drained brake fluid. N
• Never spill or splash brake fluid or grease on the disc rotor.
5. Check a drag of front disc brake. If any drag is found, refer to BR-41, "BRAKE CALIPER ASSEMBLY :
Inspection".
O
7. Perform inspection after installation. Refer to BR-41, "BRAKE CALIPER ASSEMBLY : Inspection".
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000006267430 P
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-36,
"BRAKE PAD : Removal and Installation".
BR-39
FRONT DISC BRAKE
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 from sliding pin.
4. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Never get fingers caught in the pistons.
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-41, "BRAKE
CALIPER ASSEMBLY : Inspection".
JPFIA0738ZZ
ASSEMBLY
1. Install bleeder valve and cap.
2. Apply rubber grease to piston seals (1), and install them to cylin-
der body.
CAUTION:
Never reuse piston seals.
JPFIA0039ZZ
3. Apply rubber grease to piston boots (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.
CAUTION:
Never reuse piston boots.
JPFIA0739ZZ
BR-40
FRONT DISC BRAKE
4. Apply new brake fluid to pistons (1). Push piston into cylinder
body by hand and push piston boot (2) piston-side lip into the A
piston groove.
CAUTION:
Press the pistons evenly and vary the pressing point to pre-
B
vent cylinder inner wall from being rubbed.
5. Apply rubber grease to bushing, and install bushing to sliding
pin.
C
6. Apply rubber grease to sliding pins and sliding boots, and install
sliding pins and sliding pin boots to torque member.
7. Install the cylinder body to tighten cylinder body mounting bolts JPFIA0034ZZ
to the specified torque. Refer to BR-36, "BRAKE PAD : D

Exploded View".
BRAKE CALIPER ASSEMBLY : Inspection INFOID:0000000006267431
E
INSPECTION AFTER DISASSEMBLY

BR
Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage.
CAUTION: G
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. H
Pistons
Check the surface of the piston for rust, wear, cracks or damage.
CAUTION: I
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. J
1. Check a drag of front disc brake. If any drag is found, follow the procedure described below.
K
4. Install brake pads. Refer to BR-36, "BRAKE PAD : Removal and Installation". L
necessary. Refer to BR-39, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly". M
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".
N
BR-41
REAR DRUM BRAKE
REAR DRUM BRAKE
JSFIA0635GB
1. Shoe hold pin 2. Back plate 3. Plug

4. Brake shoe 5. Spring 6. Upper spring
7. Adjuster 8. Return spring 9. Brake drum
10. Boot 11. Piston cover 12. Piston
13. Piston cup 14. Spring 15. Wheel cylinder
16. Bleeder valve 17. Cap
1: Apply polyglycol ether based lubricant.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
: Apply brake fluid

REMOVAL
WARNING:
Since dust covering the rear brake has an affect on human body, the dust must be removed with a
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-13, "Draining".
3. Release parking brake lever, and then remove brake drum. Refer to RAX-6, "Removal and Installation".
BR-42
REAR DRUM BRAKE
4. While pushing and rotating the spring (1), pull out shoe hold pin,
and remove brake shoe assembly (brake shoe, each spring, and A
adjuster).
CAUTION:
Never damage the boot of the wheel cylinder.
B
5. Remove the parking brake cable from operating lever.
CAUTION:
Never bend sharply the parking brake lever.
C
JSFIA0636ZZ
D
6. Disassemble the brake shoe assembly (brake shoe, each
spring, and adjuster).
7. Remove the wheel cylinder with the following procedure. E
a. Separate the brake tube from the wheel cylinder.
b. Remove the wheel cylinder from back plate.
BR
and Adjustment".
G
JPFIA0903ZZ
INSTALLATION H
WARNING:
I
CAUTION:
• Never depress the brake pedal while removing the brake drum.
• Never spill or splash brake fluid on the brake drum. J
Note the following, and install in the reverse of removal.
• Check the difference between left and right wheel of adjuster.
: Vehicle front K
Adjuster Direction
Left side Left screw L
Right side Right screw
• Shorten adjuster by rotating it.
M
• Apply PBC (Poly Butyl Cuprysil) silicone-based grease to the mat-
ing faces between the adjuster and brake shoe.
ing faces between the back plate and brake shoe. JPFIA0904ZZ
N
• Never damage the wheel cylinder.
• Check the component parts of drum brake assembly are installed
properly.
O
• 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
cylinder. Refer to BR-14, "Bleeding Brake System". P
• Never allow foreign matter (e.g. dust) and oils other than brake
fluid to enter the reservoir tank.
• Adjust the brake shoe clearance (parking brake lever stroke) after
install and air bleeding. Refer to PB-2, "Inspection and Adjust-
ment".
JSFIA0637ZZ
BR-43
REAR DRUM BRAKE
DISASSEMBLY
1. Remove the boot from wheel cylinder. Refer to BR-42, "Exploded View".
2. Remove the piston cover, 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-44, "Inspection and Adjustment".
ASSEMBLY
1. Apply polyglycol ether based lubricant to the piston cup (1) and
boot (2).
2. Install piston cover, piston cup and boot to piston (3).
CAUTION:
• Never mistake the direction.
• Never reuse piston cup and boot.
• When replacing the piston or the piston cover, replace the
piston and the piston cover as a set.
3. Apply new brake fluid to piston and wheel cylinder inner wall,
and install spring, piston cover, piston to wheel cylinder.
CAUTION: JPFIA0915ZZ
Never damage the wheel cylinder inner wall.

4. Install the boot to wheel cylinder. Refer to BR-42, "Exploded View".
5. Perform inspection after assembly. Refer to BR-44, "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.
CAUTION:
When replacing the piston or the piston cover, replace the piston and the piston cover as a set.
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-42, "Removal and Installation".
4. Push the piston.
CAUTION:
Push both side of the piston simultaneously.
5. Install the brake shoe. Refer to BR-42, "Removal and Installation".
BR-44
REAR DRUM BRAKE
6. Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-2, "Inspection and Adjustment".
7. Check a drag of rear drum brake again. If any drag is found, disassemble the wheel cylinder and replace A
if necessary. Refer to BR-44, "Disassembly and Assembly".
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-19, "BRAKE LINING : Inspection B
and Adjustment" (brake lining), BR-19, "BRAKE DRUM : Inspection and Adjustment" (brake drum).
Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-2, "Inspection and Adjustment". C
BR
BR-45
SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [TYPE 1]

General Specifications INFOID:0000000006267436
Unit: mm (in)
Cylinder bore diameter 51.1 (2.012)

Front brake Pad length × width × thickness 115.0 × 41.0 × 9.0 (4.53 × 1.614 × 0.354)
Rotor outer diameter × thickness 238 × 22.0 (9.37 × 0.866)
Cylinder bore diameter 17.46 (11/16)
Rear brake Lining length × width × thickness 172.3 × 26.0 × 4.8 (6.78 × 1.024 × 0.189)
Drum inner diameter 180.0 (7.09)
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-29, "Fluids and Lubricants"
Brake Pedal INFOID:0000000006267437
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:0000000006267438
Unit: mm (in)
Item Standard
Input rod length 125 (4.92)
Front Disc Brake INFOID:0000000006267439
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 Drum Brake INFOID:0000000006267440
Unit: mm (in)
Item Limit
Brake lining Wear thickness 1.5 (0.059)
Brake drum Wear inner diameter 181.0 (7.13)
BR-46
HOW TO USE THIS MANUAL A

B
C
TYPE 2 India production models (LHD) D
E
BR
BR-47
PRECAUTIONS
PRECAUTION
PRECAUTIONS
FOR EUROPE
FOR EUROPE : Precaution for Supplemental Restraint System (SRS) "AIR BAG" and
"SEAT BELT PRE-TENSIONER" INFOID:0000000006882427
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
The vehicle may be equipped with a passenger air bag deactivation switch. Because no rear seat exists where
a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a
rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the
instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is
enabled and could inflate for certain types of collision. When the switch is turned to the OFF position, the pas-
senger air bag is disabled and will not inflate. A passenger air bag OFF indicator on the instrument panel lights
up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected
by the passenger air bag deactivation switch.
WARNING:
the event of a collision that would result in air bag inflation, all maintenance must be performed by
Module, see the “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
• The vehicle may be equipped with a passenger air bag deactivation switch which can be operated by
the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and
will not inflate. When the passenger air bag is switched ON, the passenger air bag is enabled and
could inflate for certain types of collision. After SRS maintenance or repair, make sure the passenger
air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for ser-
vice.
WARNING:
ignition ON or engine running, DO NOT 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 serious injury.
battery, and wait at least 3 minutes before performing any service.
FOR EUROPE : Precautions Necessary for Steering Wheel Rotation After Battery Dis-
connection INFOID:0000000006037605
CAUTION:
then disconnect both battery cables.
BR-48
PRECAUTIONS
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results. A
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
B
OPERATION PROCEDURE
1. Connect both battery cables. C
NOTE:
2. Turn the ignition switch to ACC position. D
nected and the steering wheel can be turned. E
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock BR
FOR EUROPE : Precaution for Procedure without Cowl Top Cover INFOID:0000000006037608 G
the lower end of windshield with urethane, etc to prevent damage to H
windshield.
PIIB3706J
FOR EUROPE : Precaution for Brake System INFOID:0000000005986565

K
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed L
• Never reuse drained brake fluid. M
• After pressing the brake pedal more deeply or harder than normal driving, such as air bleeding, check each N
• Never use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and cause O
improper operation.
P
BR-49
PRECAUTIONS
brake pipes.
JPFIA0061ZZ
parts.
EXCEPT FOR EUROPE
EXCEPT FOR EUROPE : Precaution for Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER" INFOID:0000000007405697
WARNING:
connectors.
WARNING:
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
EXCEPT FOR EUROPE : Precautions Necessary for Steering Wheel Rotation After
Battery Disconnection INFOID:0000000007405698
CAUTION:
BR-50
PRECAUTIONS
cannot be turned. A
OPERATION PROCEDURE B
NOTE:
Supply power using jumper cables if battery is discharged. C
2. Turn the ignition switch to ACC position.
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon- D
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn E
6. Perform self-diagnosis check of all control units using CONSULT. BR
EXCEPT FOR EUROPE : Precaution for Procedure without Cowl Top Cover
INFOID:0000000007405699
G
windshield.
H
J
PIIB3706J
EXCEPT FOR EUROPE : Precaution for Brake System INFOID:0000000007405695
K
WARNING:
with a dust collector. Never splatter the dust with an air blow gun. L
immediately and wash with water if it gets on a painted surface. M
item of brake pedal. Adjust brake pedal if it is outside the standard value. N
improper operation.
O
BR-51
PRECAUTIONS
brake pipes.
JPFIA0061ZZ
parts.
BR-52
PREPARATION
PREPARATION A
PREPARATION
B

C
Flare nut torque wrench D

a: 10 mm (0.39 in)
E
NT406
BR
• Air tight
Handy vacuum pump
G
ZZC1313D
Brake caliper wrench Return the piston I
NNFIA0040ZZ J
BR-53
Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
SUSPECTED PARTS
Noise
Shake
Shimmy, Judder
×
SYMPTOM DIAGNOSIS
×
×
×
BR-54
Rotor runout BR-61
×
×
×
×
× Rotor thickness variation BR-61
×
Drum out of round BR-63
×
×
×
×

×
×
×

×
×
×

×
×
×
[TYPE 2]
INFOID:0000000005986561
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 Switch (With ASCD)

Check the clearance (C) among the brake pedal lever (1) and the G
stop lamp switch and/or brake switch (with ASCD) (2) threaded end.
C : Refer to BR-93, "Brake Pedal". H

CAUTION:
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
BR-55
BRAKE PEDAL
Brake Pedal Height
1. Remove instrument lower pane. Refer to IP-15, "Removal and Installation".
2. Disconnect the harness connector from stop lamp switch and/or brake switch (with ASCD).
3. Loosen the stop lamp switch and/or brake switch (with ASCD) 45° counterclockwise.
CAUTION:
The threaded end of the input rod (2) must project to the
JPFIA0003ZZ
b. Rotate the input rod, adjust the brake pedal to the specified
height (H1).

5. Check the brake pedal play.
JPFIA0279ZZ

4. Press-fit the stop lamp switch and/or brake switch (with ASCD)
(2) until the stop lamp switch and/or brake switch (with ASCD)
hits the brake pedal lever (1) 45° clockwise while pulling the
brake pedal pad slightly.
CAUTION:
lamp switch and/or brake switch (with ASCD) threaded
and must be the specified value.

• The stop lamp must be turned off when the brake pedal is PFIA0813J
released.
BR-56
BRAKE FLUID
BRAKE FLUID
A
BRAKE FLUID LEVEL B

• Visually check for any brake fluid leakage around the reservoir C
tank.
• Check the brake system for fluid leakage if the warning lamp D
and oils other than brake fluid. E
JPFIA0007ZZ
BRAKE LINE
BR
G
CAUTION:
and repair any abnormal (damaged, worn or deformed) part H
I
SBR389C
J
CAUTION:
K
L
BRA0007D
O
CAUTION: P
BR-57
BRAKE FLUID
refill with new brake fluid.
CAUTION:
intervals of 2 or 3 seconds until new brake fluid is discharged.
3. Perform the air bleeding. Refer to BR-58, "Bleeding Brake Sys-

tem".
CAUTION:
ness connector or the battery negative terminal before performing the work.
1. Connect a vinyl tube to the bleeder valve of the rear right brake.
bleeder valve.
• Front disc brake: refer to BR-84, "BRAKE CALIPER ASSEMBLY : Exploded View".
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.
57, "Inspection".
BR-58
A
FLUID LEAK B
tube connections.
C
BR
BR-59
BRAKE BOOSTER
BRAKE BOOSTER
OPERATION
NOTE:
AIR TIGHT
onds or more.
BR-60
FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
B
INSPECTION
body. Check using a scale if necessary. C

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
Runout
1. Fix the disc rotor to the wheel hub and bearing assembly with M
Refer to FAX-44, "Inspection". N
O
4. Find the installation position that has a minimum runout by shift- BRA0013D P
tion.
CAUTION:
BR-61
FRONT DISC BRAKE

Thickness
Wear thickness : Refer to BR-93, "Front Disc

Brake".
(measured at 8 posi- Brake".
tions)
SBR020B
ADJUSTMENT
ishing or replacing disc rotor, or if a soft pedal occurs at very low mileage.
CAUTION:
BR-62
REAR DRUM BRAKE
REAR DRUM BRAKE
A
BRAKE LINING
B
INSPECTION
Brake Lining C
on back plate. Check using a scale necessary. D

E
BR
J
JPFIA0806ZZ
ADJUSTMENT
Burnish contact surfaces between brake lining and brake drum according to the following procedure after K
CAUTION:
L
M
4. Repeat steps 1 to 3 until brake lining and brake drum are securely fitted. N
BRAKE DRUM
O
INSPECTION
Appearance P
BR-63
REAR DRUM BRAKE
JPFIA0113ZZ
ADJUSTMENT
CAUTION:
BR-64
BRAKE PEDAL
REMOVAL AND INSTALLATION A

BRAKE PEDAL
B
BR
JSFIA0626GB J

4. Brake switch (with ASCD) 5. Stop lamp switch 6. Clip
K
7. Snap pin
Refer to GI-4, "Components" for symbols not described on the above. L
REMOVAL M

2. Disconnect the stop lamp switch and/or brake switch (with ASCD) harness connectors. N
3. Disconnect the accelerator pedal harness connector.
5. Rotate the stop lamp switch and/or brake switch (with ASCD) counter clockwise to remove. O
6. Remove snap pin and clevis pin from clevis.
CAUTION: P
Hold the brake booster and master cylinder assembly so as not to drop out or contact them other
parts.
INSTALLATION
BR-65
BRAKE PEDAL
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.
• Do not use any part that has been subject to an impact.

welded parts.
NOTE:
D : 5.5 mm (0.217) in or more
JPFIA0854ZZ
PFIA0756J

• Perform the release position learning of the accelerator pedal. Refer to EC3-171, "Work Procedure"
[HR12DE (L-jetronic)], EC3-594, "Work Procedure" [HR12DE (D-jetronic)], EC4-392, "Work Procedure"
(HR15DE), EC3-982, "Work Procedure" (HR12DDR).
BR-66
BRAKE PIPING
BRAKE PIPING
A
FRONT
B
WITHOUT ESP
C
BR
J
JPFIA0868GB
trol unit) K
4. Brake booster 5. Connector bracket 6. Connector
10. Copper washer L
A. To rear brake tube
M
WITH ESP
N
BR-67
BRAKE PIPING
JSFIA1026GB
trol unit)
4. Brake booster 5. Connector bracket 6. Connector
10. Copper washer
WITHOUT ESP
JPFIA0869ZZ
BR-68
BRAKE PIPING
1. ABS actuator and electric unit (con- 2. Front disc brake 3. Master cylinder assembly A
trol unit)
B
: Flare nut
: Union bolt
C
WITH ESP
BR
JSFIA0629ZZ
I
trol unit)
4. Brake booster 5. Connector 6. Rear drum brake J
: Flare nut
K
: Union bolt

L
REMOVAL
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it M
1. Remove tires.
2. Drain brake fluid. Refer to BR-57, "Draining". N
CAUTION:
• Never scratch the flare nut and the brake tube. O
4. Remove the union bolt and copper washers, and remove the brake hose from the brake caliper assembly. P
INSTALLATION
CAUTION:
BR-69
BRAKE PIPING
CAUTION:
assembly hole, and tighten the union bolt (1) to the specified
torque.
flare nut by hand until it does not rotate further, and fix the brake
CAUTION:
and bent.
CAUTION:
CAUTION:
7. Perform inspection after installation. Refer to BR-70, "FRONT : Inspection".

CAUTION:
condition*.
nated positions.
CAUTION:
REAR
BR-70
BRAKE PIPING
BR
JPFIA0857GB
I
A. To connector
: Indicates that the part is connected at points with same symbol in actual vehicle. J
REAR : Hydraulic Piping INFOID:0000000005986586 K
WITHOUT ESP
L
JPFIA0869ZZ
BR-71
BRAKE PIPING
trol unit)
: Flare nut
: Union bolt
WITH ESP
JSFIA0629ZZ
trol unit)
: Flare nut
: Union bolt
REMOVAL
CAUTION:
1. Remove tires.
CAUTION:
• Cover the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt.
remove the brake tube.
INSTALLATION
CAUTION:
BR-72
BRAKE PIPING
1. Connect the brake tube to the wheel cylinder, temporarily tighten the flare nut by hand until it does not
rotate further. A
further, and fix the brake hose to the bracket with the lock plate.
CAUTION: B
CAUTION:
C
CAUTION:
Never reuse drained brake fluid. D
E
INSPECTION AFTER INSTALLATION BR

at connections.
CAUTION: G
condition*.
*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in desig- H
nated positions.
I
CAUTION:
J
BR-73
JSFIA1027GB

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

REMOVAL
CAUTION:
3. Remove battery. Refer to PG-529, "FOR MAINTENANCE REQUIRED BATTERY MODELS : Removal
and Installation" (maintenance required battery model), PG-530, "FOR MAINTENANCE FREE BATTERY
MODELS : Removal and Installation" (maintenance free battery models).
4. Remove air duct and air cleaner case. Refer to EM-33, "TYPE 1 : Removal and Installation" [HR12DE (L-
jetronic)], EM-34, "TYPE 2 : Removal and Installation" [HR12DE (D-jetronic)], EM-337, "Removal and
Installation" (HR15DE), EM-199, "Removal and Installation" (HR12DDR).
BR-74
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. Remove the master cylinder assembly. B
CAUTION:
• The piston of the master cylinder assembly is exposed. Never damage it when removing the C
master cylinder.
when handling the master cylinder assembly. D
INSTALLATION
CAUTION: E
Note the following, and install in the reverse order of removal. BR
when installing the master cylinder assembly to the brake booster. G
and dust are present on the piston before installation. Clean it with H
I
assembly.
JPFIA0013ZZ
assembly by hand. Then tighten it to the specified torque with a J
CAUTION:
Never scratch the flare nut and the brake tube. K
CAUTION:
Never reuse drained brake fluid. L
M
DISASSEMBLY
CAUTION:
• Never disassemble the cylinder body. N
• Remove the reservoir tank only when necessary.
Remove the reservoir tank and grommet from the cylinder body. O
ASSEMBLY
CAUTION:
• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and P
assembly process.
1. Apply new brake fluid to the grommet and install it to the cylinder body.
CAUTION:
BR-75

Check the brake fluid level switch. Refer to BRC-101, "Component Inspection" (Without ESP), BRC-232,
"Component Inspection" (With ESP).
• Check the master cylinder for deformation, twist, contact with other parts or looseness of connection.
CAUTION:
BR-76
A
HR12DE, HR15DE B
BR
JSFIA1028GB
H
I
HR12DDR
JSFIA1029GB O
1. Master cylinder assembly 2. Check valve 3. Vacuum sensor

4. Brake booster 5. Lock nut 6. Clevis
P
7. Gasket
REMOVAL
CAUTION:
BR-77
• Never remove vacuum sensor from brake booster. Replace vacuum sensor and brake booster as a
set. (HR12DDR)
3. Remove battery. Refer to PG-529, "FOR MAINTENANCE REQUIRED BATTERY MODELS : Removal
and Installation" (maintenance required battery model), PG-530, "FOR MAINTENANCE FREE BATTERY
MODELS : Removal and Installation" (maintenance free battery models).
4. Remove air duct and air cleaner case. Refer to EM-33, "TYPE 1 : Removal and Installation" [HR12DE (L-
jetronic)], EM-34, "TYPE 2 : Removal and Installation" [HR12DE (D-jetronic)], EM-337, "Removal and
Installation" (HR15DE), EM-199, "Removal and Installation" (HR12DDR).
7. Remove vacuum hose from check valve. Refer to BR-81, "HR12DE, HR15DE : Removal and Installation"
(HR12DE, HR15DE), BR-82, "HR12DDR : Removal and Installation" (HR12DDR).
"Exploded View".
CAUTION:
NOTE:
booster.
JPFIA0019ZZ
and Adjustment".
INSTALLATION
CAUTION:
A : 45°
• Be careful not to damage brake booster stud bolt threads. If brake
threads.
booster.
panel.
• Replace the clevis pin if it is damaged. Refer to BR-66, "Inspection JPFIA0871ZZ
and Adjustment".
CAUTION:
BR-78
Air Tight
CAUTION: A
B
2. If the air tight condition cannot be maintained, perform the following operation. C
b. Check the O-ring on the master cylinder. If anything is found, replace the O-ring. Refer to BR-74, D
E
1. Check the air tight use a handy vacuum pump. BR
booster side 0.013 bar) for 15 seconds under a vacuum of −66.7 kPa (−500 G
mmHg, −19.69 inHg, −0.067 bar).
vacuum hose side H

Input Rod Length Inspection I
fied length (A).
J
K
L
JPFIA0238ZZ

M
Operation
brake pedal fully depressed. Check that the clearance between brake pedal and dash lower pane decreases. N
NOTE:
O
Air Tight
P
onds or more.
BR-79
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-55, "Inspection and
Adjustment".
BR-80
VACUUM LINES
VACUUM LINES
A
HR12DE, HR15DE
HR12DE, HR15DE : Exploded View INFOID:0000000005986596
B
BR
JPFIA0872ZZ
J
1. Clamp 2. Vacuum hose 3. Vacuum piping
K
HR12DE, HR15DE : Removal and Installation INFOID:0000000005986597
REMOVAL L
INSTALLATION
Note the following, install the vacuum hose and vacuum piping. M
• When installing vacuum hose, insert it until its tip reaches the
CAUTION: N

O
- Face the paint marks of vacuum hose (intake manifold side) to
upward to assemble.
- Face the other paint marks of vacuum hose and vacuum piping to
the vehicle front side to assemble. P
JPFIA0023ZZ
HR12DE, HR15DE : Inspection INFOID:0000000005986598

Appearance
BR-81
VACUUM LINES
HR12DDR
HR12DDR : Exploded View INFOID:0000000007251803
JSFIA1030GB
1. Clamp 2. Vacuum hose A 3. Vacuum piping A

4. Vacuum hose B 5 Vacuum piping B 6. Vacuum hose C
HR12DDR : Removal and Installation INFOID:0000000007251804
REMOVAL
INSTALLATION
Note the following, install the vacuum hose and vacuum piping.
CAUTION:

- Face the paint marks of vacuum hose A (vacuum piping A side)
and vacuum piping A (vacuum hose A side) to vehicle right side to
assemble.
- Face the paint marks of vacuum hose C (vacuum piping B side)
and vacuum piping B (vacuum hose C side) to vehicle left side to JPFIA0023ZZ
assemble.
- Face the paint marks of vacuum hose B (vacuum piping B side) and vacuum piping B (vacuum hose B side)
to upward to assemble.
- Face the other paint marks of vacuum hose and vacuum piping to the vehicle front side to assemble.
HR12DDR : Inspection INFOID:0000000007251805

Appearance
BR-82
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
J
REMOVAL
WARNING:
Since dust covering the front brake has an affect on human body, the dust must be removed with a K
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out. L
1. Remove tires.
2. Remove lower sliding pin bolt. M
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the
brake pad and pad retainers from the torque member.
CAUTION: N
• 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. O
• Never touch the double-faced tape to keep its stickiness.
• Never damage the piston boot. P
• Never drop the brake pads.
INSTALLATION
WARNING:
CAUTION:
BR-83
FRONT DISC BRAKE
ton may pop out.
CAUTION:
• Securely assemble the pad retainers so that it will not be lifted up from the torque member.
2. Install the brake pads to the torque member.
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.
CAUTION:
CAUTION:
• Clean the pawl of the cylinder body.
• Never deform or cut the double-faced tape
NOTE:
6. Press the outer pad in the cylinder body pawl direction.
CAUTION:
Securely place the double-faced tape.
7. Depress the brake pedal several times to check that no drag feel is present for the front disc brake. Refer

4. Install brake pads. Refer to BR-83, "BRAKE PAD : Removal and Installation".
REMOVAL
BR-84
FRONT DISC BRAKE
JPFIA0879GB BR

G
DISASSEMBLY
JPFIA0880GB M

4. Piston seal 5. Piston 6. Piston boot N
7. Sliding pin 8. Sliding pin boot 9. Torque member
O
BRAKE CALIPER ASSEMBLY : Removal and Installation INFOID:0000000005986603 P
REMOVAL
WARNING:
CAUTION:
BR-85
FRONT DISC BRAKE
1. Remove tires.
CAUTION:
Never spill or splash brake fluid or grease on the disc rotor.
CAUTION:
CAUTION:
INSTALLATION
WARNING:
CAUTION:
CAUTION:
3. Install brake hose and copper washers to brake caliper assembly, and tighten union bolts to the specified
CAUTION:
Never reuse copper washer.
CAUTION:
Inspection".
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000005986604
DISASSEMBLY
NOTE:
Never remove the torque member, brake pad and pad retainers when disassembling and assembling the cyl-
inder body.
CAUTION:
BR-86
FRONT DISC BRAKE
union bolt mounting hole to remove pistons and piston boots. A
CAUTION:
B
MAA0272D
D
CAUTION:
E
CALIPER ASSEMBLY : Inspection". BR
G
JPFIA0738ZZ
ASSEMBLY
H
der body.
CAUTION: I
JPFIA0039ZZ
3. Apply rubber grease to piston boots (1). Cover the piston (2) end L
CAUTION: M
O
JPFIA0739ZZ
BR-87
FRONT DISC BRAKE
body by hand and push piston boot (2) piston-side lip into the
piston groove.
CAUTION:
6. Install the cylinder body to tighten cylinder body mounting bolts
to the specified torque. Refer to BR-83, "BRAKE PAD :
Exploded View". JPFIA0034ZZ

Cylinder Body
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.
Pistons
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper.
Check the sliding pins and sliding boots for rust, wear, cracks or damage.
necessary. Refer to BR-86, "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
BR-88
REAR DRUM BRAKE
REAR DRUM BRAKE
A
BR
I
JPFIA0881GB
1. Shoe hold pin 2. Back plate 3. Plug J

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 K
13. Piston 14. Piston cup 15. Spring
16. Wheel cylinder 17. Bleeder valve 18. Cap
1: Apply polyglycol ether based lubricant. L
: Apply brake fluid M


N
REMOVAL
WARNING: O
CAUTION:
• Never depress the brake pedal while removing the brake drum because the piston may pop out. P
1. Remove tires.
2. Perform drain the brake fluid when remove or disassemble the wheel cylinder. Refer to BR-57, "Draining".
BR-89
REAR DRUM BRAKE
and remove brake shoe assembly (brake shoe, each spring, and
adjuster).
CAUTION:
CAUTION:
JPFIA0852ZZ

7. Remove the wheel cylinder with the following procedure.
and Adjustment".
JPFIA0882ZZ
INSTALLATION
WARNING:
CAUTION:
: Vehicle front
Adjuster Direction
Left side Left screw

properly.
cylinder. Refer to BR-58, "Bleeding Brake System".
ment".
JPFIA0884ZZ
BR-90
REAR DRUM BRAKE
A
DISASSEMBLY
B
2. Remove the piston, piston cup and spring from wheel cylinder.
CAUTION:
damaged. C
3. Perform inspection after disassembly. Refer to BR-91, "Inspection and Adjustment"
ASSEMBLY
D
boot (2), and install them to piston (3).
CAUTION:
E
and install spring, piston to wheel cylinder. BR
CAUTION:
3. Install the boot to wheel cylinder. Refer to BR-89, "Exploded G
View". JPFIA0885ZZ
4. Perform inspection after assembly. Refer to BR-91, "Inspection

and Adjustment". H
INSPECTION AFTER REMOVAL I

• Check the brake shoe sliding surface for excessive wear and damage. J
• Check the back plate for damage, cracks, and deformation. K
L
• Check the piston for excessive wear and damage. M

Check that the piston moves smoothly. N
2. Rotate the brake drum and check that there is no drag. Perform the following procedure if necessary. O
4. Push the piston.
CAUTION: P
7. Check a drag of rear drum brake again. If any drag is found, disassemble the wheel cylinder and replace
BR-91
REAR DRUM BRAKE
brake drum, or if a soft pedal occurs at very low mileage. Refer to BR-63, "BRAKE LINING : Inspection
Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-2, "Inspection and Adjustment".
BR-92
SERVICE DATA AND SPECIFICATIONS (SDS) A

B
Unit: mm (in)
C
Cylinder bore diameter 19.0 (3/4) D
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)
E
Control valve Valve type Electric brake force distribution BR
HR12DE
231 (9)
Brake booster Diaphragm diameter HR15DE
HR12DDR 257 (10) G
Brake Pedal INFOID:0000000005986611 H
Unit: mm (in)
Item Standard I
J
Brake pedal play 2 – 9 (0.08 – 0.35)
80 (3.15) or more
K
Unit: mm (in)
L
Item Standard
M
Unit: mm (in)
Item Limit
N

O
P
Unit: mm (in)
Item Limit
BR-93
HOW TO USE THIS MANUAL


BR-94
PRECAUTIONS
PRECAUTION A
PRECAUTIONS
FOR EUROPE
B
FOR EUROPE : Precaution for Supplemental Restraint System (SRS) "AIR BAG" and
"SEAT BELT PRE-TENSIONER" INFOID:0000000006882431
C
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and D
The vehicle may be equipped with a passenger air bag deactivation switch. Because no rear seat exists where
a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a E
rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the
instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is
enabled and could inflate for certain types of collision. When the switch is turned to the OFF position, the pas- BR
senger air bag is disabled and will not inflate. A passenger air bag OFF indicator on the instrument panel lights
up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected
by the passenger air bag deactivation switch.
G
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in H
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal I
Module, see the “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har- J
ness connectors.
• The vehicle may be equipped with a passenger air bag deactivation switch which can be operated by
the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and K
will not inflate. When the passenger air bag is switched ON, the passenger air bag is enabled and
could inflate for certain types of collision. After SRS maintenance or repair, make sure the passenger
air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for ser-
vice. L

WARNING: M
ignition ON or engine running, DO NOT 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 N
causing serious injury.
battery, and wait at least 3 minutes before performing any service. O
FOR EUROPE : Precautions Necessary for Steering Wheel Rotation After Battery Dis-
connection INFOID:0000000006882432
P
CAUTION:
BR-95
PRECAUTIONS
cannot be turned.
OPERATION PROCEDURE
NOTE:
FOR EUROPE : Precaution for Procedure without Cowl Top Cover INFOID:0000000006882435
windshield.
PIIB3706J
FOR EUROPE : Precaution for Brake System INFOID:0000000006713754
WARNING:
improper operation.
BR-96
PRECAUTIONS
nut torque wrench (A). A
brake pipes.
B
electric unit (control unit) harness connector [with ESP and without C
ESP (with ABS)] or the battery negative terminal before performing
the work.
JPFIA0061ZZ
• Check that no brake fluid leakage is present after replacing the D
parts.
- Front brake pad: refer to BR-108, "BRAKE PAD : Inspection and Adjustment". E
- Rear brake drum: refer to BR-110, "BRAKE DRUM : Inspection and Adjustment". BR
EXCEPT FOR EUROPE
EXCEPT FOR EUROPE : Precaution for Supplemental Restraint System (SRS) "AIR
G
BAG" and "SEAT BELT PRE-TENSIONER" INFOID:0000000006882430
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain H
WARNING: I
the event of a collision that would result in air bag inflation, all maintenance must be performed by J
Module, see “SRS AIR BAG”. K
connectors. L
WARNING:
Always observe the following items for preventing accidental activation. M
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing N
serious injury.
O
EXCEPT FOR EUROPE : Precautions Necessary for Steering Wheel Rotation After
Battery Disconnection INFOID:0000000006882433
P
CAUTION:
BR-97
PRECAUTIONS
cannot be turned.
OPERATION PROCEDURE
NOTE:
EXCEPT FOR EUROPE : Precaution for Procedure without Cowl Top Cover
INFOID:0000000006882434
windshield.
PIIB3706J
EXCEPT FOR EUROPE : Precaution for Brake System INFOID:0000000006882429
WARNING:
improper operation.
BR-98
PRECAUTIONS
nut torque wrench (A). A
brake pipes.
B
electric unit (control unit) harness connector [with ESP and without C
ESP (with ABS)] or the battery negative terminal before performing
the work.
JPFIA0061ZZ
• Check that no brake fluid leakage is present after replacing the D
parts.
- Front brake pad: refer to BR-108, "BRAKE PAD : Inspection and Adjustment". E
- Rear brake drum: refer to BR-110, "BRAKE DRUM : Inspection and Adjustment". BR
BR-99
PREPARATION
PREPARATION
PREPARATION
Flare nut torque wrench

a: 10 mm (0.39 in)
NT406
Brake pressure gauge Check brake fluid pressure
S-NT151
Pin punch
a: 4 mm (0.16 in)
NT410
• Air tight
Handy vacuum pump
ZZC1313D
NNFIA0040ZZ
BR-100
Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
SUSPECTED PARTS
Noise
Shake
Shimmy, Judder
×
SYMPTOM DIAGNOSIS
×
Shims damaged BR-142
×
×
×
BR-101
×
Rotor runout BR-108
×
×
×
×
×
×
× Drum out of round BR-110
×
×
×

×
×
×

×
×
×

×
×
×
[TYPE 3]
INFOID:0000000006713756
P
K
E
B
A
N
H
D
C
O
G
M
BR
BRAKE PEDAL
PERIODIC MAINTENANCE
BRAKE PEDAL
INSPECTION
Brake Pedal Height

CAUTION:
JPFIA0065ZZ

Check the clearance (C) among the brake pedal lever (1) and the
stop lamp switch and/or brake switch (with ASCD) (2) threaded end.

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
BR-102
BRAKE PEDAL
Brake Pedal Height
1. Remove instrument lower pane. Refer to IP-15, "Removal and Installation". A
B
CAUTION:
The threaded end of the input rod (2) must project to the C
JPFIA0003ZZ
b. Rotate the input rod, adjust the brake pedal to the specified BR
height (H1).
H1 : Refer to BR-153, "Brake Pedal". G

5. Check the brake pedal play. H
I
JPFIA0279ZZ

1. Remove instrument lower panel. Refer to IP-15, "Removal and Installation". J
4. Press-fit the stop lamp switch and/or brake switch (with ASCD) K
(2) until the stop lamp switch and/or brake switch (with ASCD)
hits the brake pedal lever (1) 45° clockwise while pulling the
brake pedal pad slightly. L
CAUTION:
lamp switch and/or brake switch (with ASCD) threaded
and must be the specified value. M

N
• The stop lamp must be turned off when the brake pedal is PFIA0813J
released.
BR-103
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:
ness connector [with ESP and without ESP (with ABS)] or the battery negative terminal before per-
forming work.
BRA0007D
CAUTION:
ness connector [with ESP and without ESP (with ABS)] or the battery negative terminal before per-
forming work.
BR-104
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-105, "Bleeding Brake Sys- D

tem".
E
CAUTION:
ness connector [with ESP and without ESP (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
1. Connect a vinyl tube to the bleeder valve of the rear left brake. H
bleeder valve. I
• Front disc brake: refer to BR-142, "BRAKE CALIPER ASSEMBLY : Exploded View". J
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.
104, "Inspection". L
M
BR-105
FLUID LEAK
tube connections.
BR-106
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
BR
onds or more.
BR-107
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-44, "Inspection".

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

tion.
CAUTION:
BR-108
FRONT DISC BRAKE
Wear thickness : Refer to BR-153, "Front Disc Brake". A
Thickness
B
Wear thickness : Refer to BR-153, "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
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. H
I
BR-109
REAR DRUM BRAKE
REAR DRUM BRAKE
BRAKE LINING
INSPECTION
Brake Lining
on back plate. Check using a scale necessary.
JPFIA0806ZZ
ADJUSTMENT
Burnish contact surfaces between brake lining and brake drum according to the following procedure after
CAUTION:
4. Repeat steps 1 to 3 until brake lining and brake drum are securely fitted.
BRAKE DRUM
INSPECTION
Appearance
BR-110
REAR DRUM BRAKE
A
JPFIA0113ZZ
D
ADJUSTMENT
CAUTION: E
• 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
BR-111
BRAKE PEDAL
REMOVAL AND INSTALLATION

BRAKE PEDAL
FOR INDIA AND SOUTH AFRICA
JPFIA0873GB

EXCEPT FOR INDIA AND SOUTH AFRICA
BR-112
BRAKE PEDAL
BR
H
JSFIA0631GB

4. Stop lamp switch 5. Brake switch 6. Clip I
7. Snap pin
Refer to GI-4, "Components" for symbols not described on the above. J
K
REMOVAL
2. Disconnect the stop lamp switch harness connectors. L
3. Disconnect the accelerator pedal harness connector.
M
7. Remove the brake pedal assembly. N
CAUTION:
parts.
O
INSTALLATION P
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.
BR-113
BRAKE PEDAL
• Do not use any part that has been subject to an impact.

welded parts.
NOTE:
D : 5.5 mm (0.217 in)
JPFIA0854ZZ
PFIA0756J

[HR12DE (J-jetronic)], EC3-594, "Work Procedure" [HR12DE (D-jetronic)], EC3-982, "Work Procedure"
(HR12DDR), EC4-392, "Work Procedure" (HR15DE).
BR-114
BRAKE PIPING
BRAKE PIPING
A
FRONT
B
WITH OUT ABS
C
BR
J
JPFIA0890GB
1. Brake booster 2. Master cylinder assembly 3. Brake tube

K
4. Dual proportioning valve 5. Lock plate 6. Brake hose
7. Union bolt 8. Copper washer
L
WITHOUT ESP (WITH ABS) M
BR-115
BRAKE PIPING
JPFIA0855GB

4. ABS actuator and electric unit (con- 5. Connector bracket 6. Connector
trol unit)
10. Copper washer
WITH ESP
BR-116
BRAKE PIPING
HR12DE
A
BR
H
JSFIA0771GB

4. ABS actuator and electric unit (con- 5. Connector bracket 6. Connector I
trol unit)
10. Copper washer J
Refer to GI-4, "Components" for symbols in the figure. K
BR-117
BRAKE PIPING
HR12DDR
JSFIA1031GB

trol unit)
10. Copper washer
WITHOUT ABS
JPFIA0757ZZ
BR-118
BRAKE PIPING
1. Brake booster 2. Master cylinder assembly 3. Front disc brake A

4. Dual proportioning valve 5. Rear drum brake
: Flare nut B
: Union bolt
WITHOUT ESP (WITH ABS) C
BR
JSFIA1061ZZ
I
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)
A. Brake tube B. Brake hose J
: Flare nut
: Union bolt K
WITH ESP
L
JSFIA0772ZZ

trol unit)
BR-119
BRAKE PIPING
: Flare nut
: Union bolt
REMOVAL
CAUTION:
1. Remove tires.
CAUTION:
INSTALLATION
CAUTION:
CAUTION:
assembly hole, and tighten the union bolt (1) to the specified
torque.
CAUTION:
and bent.
CAUTION:
CAUTION:
7. Perform inspection after installation. Refer to BR-120, "FRONT : Inspection".

CAUTION:
condition*.
BR-120
BRAKE PIPING
nated positions. A
CAUTION: B
REAR C
D
WITHOUT ABS
BR
JPFIA0758GB L

A. To dual proportioning valve
M
WITH ESP AND WITHOUT ESP (WITH ABS) N
BR-121
BRAKE PIPING
JPFIA0857GB

A. To connector
WITHOUT ABS
JPFIA0757ZZ

BR-122
BRAKE PIPING
: Flare nut
A
: Union bolt
WITHOUT ESP (WITH ABS)

B
BR
G
JSFIA1061ZZ
1. Brake booster 2. Master cylinder assembly 3. Front disc brake H

trol unit)
I
: Flare nut
: Union bolt
J
WITH ESP
JSFIA0772ZZ
P
trol unit)
: Flare nut
: Union bolt
BR-123
BRAKE PIPING
REMOVAL
CAUTION:
1. Remove tires.
CAUTION:
INSTALLATION
CAUTION:
rotate further.
CAUTION:
CAUTION:
CAUTION:

at connections.
CAUTION:
condition*.
nated positions.
CAUTION:
BR-124
DUAL PROPORTIONING VALVE
A
BR
G
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
H
D. To front LH brake caliper E. To master cylinder secondary side F. To rear RH wheel cylinder
I
REMOVAL J
1. Remove the air duct and air cleaner case. Refer to EM-34, "TYPE 2 : Removal and Installation".
K
3. Loosen the brake tube flare nuts, and then remove brake tubes from dual proportioning valve. Refer to
BR-115, "FRONT : Exploded View" (front), BR-121, "REAR : Exploded View" (rear).
CAUTION:
Never scratch the flare nut and the brake tube. L
4. Remove the dual proportioning valve from bracket.
CAUTION:
Never apply excessive impact to dual proportioning valve, such as dropping it. M
5. Remove the bracket from vehicle.
INSTALLATION
Note the following, and install in the reverse order of removal. N
• Install the brake tube with flare nut torque wrench. Refer to BR-115, "FRONT : Exploded View" (front), BR-
121, "REAR : Exploded View" (rear).
CAUTION: O
• Never apply excessive impact to dual proportioning valve, such as dropping it.
• After work is completed, bleed air from brake tube. Refer to BR-105, "Bleeding Brake System".
P
BR-125
1. Connect brake fluid pressure gauge to bleeders valve of front

and rear brake on either LH and RH side.
SBR822BA
2. Bleed air from brake fluid pressure gauge.

3. Check brake fluid pressure by depressing the brake pedal.
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
• If output pressure (rear brake) is out of specification, replace
dual proportioning valve.
SBR823BA
4. Bleed air after disconnecting the brake fluid pressure gauge.
Refer to BR-105, "Bleeding Brake System".
BR-126
A
HR12DE, HR15DE AND K9K B
BR
JSFIA0764GB
J
4. Grommet 5. Cylinder body 6. O-ring
K

HR12DDR
M
BR-127
JPFIA0875GB

7. O-ring

REMOVAL
CAUTION:
4. Remove the brake tube from between dual proportioning valve (without ABS) or ABS actuator and electric
unit (control unit) [with ESP and without ESP (with ABS)] and master cylinder assembly with a flare nut
wrench.
CAUTION:
5. Remove the master cylinder assembly.
CAUTION:
• The piston of the master cylinder assembly is exposed. Never damage it when removing the
master cylinder.
BR-128
when handling the master cylinder assembly. A
INSTALLATION
CAUTION: B
Note the following, and install in the reverse order of removal. C
D
when installing the master cylinder assembly to the brake booster.
and dust are present on the piston before installation. Clean it with E
ton. Hold the cylinder body when handling the master cylinder BR
assembly.
JPFIA0013ZZ
assembly by hand. Then tighten it to the specified torque with a G
CAUTION:
Never scratch the flare nut and the brake tube. H
CAUTION:
Never reuse drained brake fluid. I
J
DISASSEMBLY
HR12DE, HR15DE and K9K K
CAUTION:
• Never disassemble the cylinder body.
• Remove the reservoir tank only when necessary. L
Remove the reservoir tank and grommet from the cylinder body.
HR12DDR M
CAUTION:
• Never disassemble the cylinder body.
• Never drop the removed parts. The parts must not be reused if they are dropped. N
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. O
2. Remove the reservoir tank mounting pin with a pin punch [4 mm (0.16 in)].
3. Remove master cylinder from vise. P
4. Remove the reservoir tank and grommet from the cylinder body.
ASSEMBLY
HR12DE, HR15DE and K9K
CAUTION:
assembly process.
BR-129
CAUTION:
HR12DDR
CAUTION:
assembly process.
CAUTION:
CAUTION:
• Place the reservoir tank with the chamfered pin hole facing up.
CAUTION:

Check the brake fluid level switch. Refer to BRC-19, "Component Inspection".
CAUTION:
BR-130
A
HR12DE, HR15DE AND K9K B
BR
JSFIA0765GB
H
I
HR12DDR
JSFIA1032GB O

P
7. Gasket
REMOVAL
CAUTION:
BR-131
set. (HR12DDR)
4. Remove vacuum hose from check valve. Refer to BR-135, "HR12DE, HR15DE : Removal and Installa-
tion" (HR12DE, HR15DE), BR-136, "HR12DDR : Removal and Installation" (HR12DDR).
5. Remove intake manifold. Refer to EM-38, "TYPE 1 : Removal and Installation" [HR12DE (L-jetronic)], EM-
40, "TYPE 2 : Removal and Installation" [HR12DE (D-jetronic)], EM-340, "Removal and Installation"
(HR15DE).
6. Remove air duct and air cleaner case. Refer to EM-199, "Removal and Installation" (HR12DDR).
7. Remove supercharger. Refer to EM-209, "Removal and Installation" (HR12DDR).
8. Remove low-pressure flexible hose. Refer to HA-37, "LOW-PRESSURE FLEXIBLE HOSE : Removal and
Installation".
9. Separate brake tube from dual proportioning valve and front RH brake hose (dual proportioning valve side
only). (Without ABS)
10. Separate brake tube from ABS actuator and electric unit (control unit) and front RH brake hose [ABS actu-
ator and electric unit (control unit) side only]. [with ESP and without ESP (with ABS)]
"Exploded View".
CAUTION:
NOTE:
booster.
JPFIA0019ZZ
and Adjustment".
INSTALLATION
CAUTION:
• Set check valve angle (A) as shown in the figure. (HR12DE,
HR15DE AND K9K)
A : 45°
JPFIA0916ZZ
BR-132
• Set check valve angle (A) as shown in the figure. (HR12DDR)
A
A : 90°
booster is tilted during installation, the dash panel may damage the B
threads.
booster. C
panel.
• Replace the clevis pin if it is damaged. Refer to BR-114, "Inspec- JSFIA1033ZZ
tion and Adjustment". D

CAUTION: E
BR
INSPECTION BEFORE REMOVAL G

Air Tight
CAUTION:
Check the air tight condition when the master cylinder and the brake booster is installed. H
At vacuum of −66.7 kPa (−500 mmHg, : Vacuum should decrease within 3.3 kPa (24.8 mmHg, I
2. If the air tight condition cannot be maintained, perform the following operation.
J
b. Check the O-ring on the master cylinder. If anything is found, replace the O-ring. Refer to BR-128,
K
INSPECTION AFTER REMOVAL L
M
booster side 0.013 bar) for 15 seconds under a vacuum of −66.7 kPa (−500
N
mmHg, −19.69 inHg, −0.067 bar).
vacuum hose side
O
P
BR-133
fied length (A).

JPFIA0238ZZ

Operation
brake pedal fully depressed. Check that the clearance between brake pedal and dash lower pane decreases.
NOTE:
Air Tight
onds or more.
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-102, "Inspection
and Adjustment".
BR-134
VACUUM LINES
VACUUM LINES
A
HR12DE, HR15DE
HR12DE, HR15DE : Exploded View INFOID:0000000006713789
B
BR
JPFIA0865ZZ
J
1. Clamp 2. Vacuum hose
K
HR12DE, HR15DE : Removal and Installation INFOID:0000000006713790
REMOVAL L
Remove the vacuum hose.
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
JPFIA0023ZZ
HR12DE, HR15DE : Inspection INFOID:0000000006713791

Appearance
BR-135
VACUUM LINES
HR12DDR
HR12DDR : Exploded View INFOID:0000000007251806
JSFIA1034GB
1. Clamp 2. Vacuum hose A 3. Vacuum piping

4. Vacuum hose B
HR12DDR : Removal and Installation INFOID:0000000007251807
REMOVAL
Remove the vacuum hose.
INSTALLATION
CAUTION:

- Face the paint marks of vacuum hose A (brake booster side) and
vacuum hose B (intake manifold side) to vehicle front side to
assemble.
- Face the paint marks of vacuum hose B (vacuum piping side) and
vacuum piping (vacuum hose B side) to vehicle front left to assem- JPFIA0023ZZ
ble.
- Face the paint marks of vacuum hose A (vacuum piping side) and vacuum piping (vacuum hose A side) to
the upward to assemble.
BR-136
VACUUM LINES
HR12DDR : Inspection INFOID:0000000007251808
A
Appearance
B
K9K
K9K : Exploded View INFOID:0000000006748313
C
BR
K
JSFIA0773GB
1. Clamp 2. Vacuum hose A 3. Vacuum piping

4. Vacuum hose B 5. Connector L
A. To brake booster B. Paint mark C. To vacuum pump
K9K : Removal and Installation INFOID:0000000006748314 M
REMOVAL
Remove the vacuum hose. N
INSTALLATION
• When installing vacuum hose, insert it until its tip reaches the O
CAUTION:
P
- 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.
JPFIA0023ZZ
BR-137
VACUUM LINES
K9K : Inspection INFOID:0000000006748315

Appearance
BR-138
FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
B
FOR GASOLINE ENGINE (WITHOUT ABS)
C
BR
JPFIA0859GB H

4. Inner pad (with pad wear sensor) 5. Pad return spring 6. Pad retainer I
1: Apply MOLYKOTE® AS880N or silicone-based grease. J
K
FOR GASOLINE ENGINE (WITH ABS) AND DIESEL ENGINE
JPFIA0878GB
1. Cylinder body 2. Inner pad (with pad wear sensor) 3. Pad retainer
BR-139
FRONT DISC BRAKE
4. Torque member 5. Outer pad (with double-faced adhe-
sive tape)
REMOVAL
For Gasoline Engine (Without ABS)
WARNING:
CAUTION:
1. Remove tires.
return spring, brake pads, shims, shim covers and pad retainers from the torque member.
CAUTION:
• Never drop the brake pads, shims, and the shim covers.
For Gasoline Engine (With ABS) and Diesel Engine
WARNING:
CAUTION:
1. Remove tires.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the
brake pad and pad retainers 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.
INSTALLATION
WARNING:
CAUTION:
ton may pop out.
BR-140
FRONT DISC BRAKE
CAUTION: A
2. Apply MOLYKOTE® AS880N or silicone-based grease to the B
mating faces between the inner shim (A) and the inner shim
cover (B), and install them to the inner pad.
CAUTION:
C
Always replace the shim together with the shim cover when
3. Apply MOLYKOTE® AS880N or silicone-based grease to the D
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 E
retainers, and install the brake pads to the torque member. BR
CAUTION:
• Never deform the pad return spring. G
• Correctly insert the pad return spring in to the pad return spring hole on the brake pad.
CAUTION: H
NOTE: I
8. Depress the brake pedal several times to check that no drag feel is present for the front disc brake. Refer J
K
WARNING:
Since dust covering the front brake has an affect on human body, the dust must be removed with a L
CAUTION:
ton may pop out. M
CAUTION: N
2. Install the brake pads to the torque member. O
CAUTION:
3. Remove the protector paper of the double-faced tape when replacing the new brake pad.
P
CAUTION:
CAUTION:
• Clean the pawl of the cylinder body.
• Never deform or cut the double-faced tape
BR-141
FRONT DISC BRAKE
NOTE:
6. Press the outer pad in the cylinder body pawl direction.
CAUTION:
Securely place the double-faced tape.

Replace the shims and the shim covers if rust is excessively attached. (Without ABS)
REMOVAL
JPFIA0510GB

BR-142
FRONT DISC BRAKE
JPFIA0879GB BR

G
DISASSEMBLY
For Gasoline engine (Without ABS)
H
M
JPFIA0511GB
1. Cap 2. Bleeder valve 3. Cylinder body N

10. Torque member O
: Apply brake fluid. P

BR-143
FRONT DISC BRAKE
JPFIA0880GB

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

REMOVAL
WARNING:
CAUTION:
1. Remove tires.
CAUTION:
CAUTION:
CAUTION:
INSTALLATION
WARNING:
CAUTION:
BR-144
FRONT DISC BRAKE
out immediately and wash with water if it gets on a protect surface. A
1. Install disc rotor. Refer to FAX-46, "Removal and Installation". B
CAUTION:
C
3. Install brake hose and copper washers to brake caliper assembly, and tighten union bolts to the specified
torque. Refer to BR-120, "FRONT : Removal and Installation". D
CAUTION:
Never reuse copper washer.
4. Refill with new brake fluid and perform the air bleeding. Refer to BR-105, "Bleeding Brake System". E
CAUTION:
• Never spill or splash brake fluid or grease on the disc rotor. BR
Inspection".
6. Install tires. Refer to WT-7, "Exploded View". G
H
DISASSEMBLY
NOTE:
Never remove the torque member, pad return spring [for gasoline engine (without ABS)], brake pad and pad I
retainers when disassembling and assembling the cylinder body.
"BRAKE PAD : Removal and Installation". J
CAUTION:
2. Remove sliding pins and sliding pin boots from torque member. K
3. Remove bushing from sliding pin. [For gasoline engine (without ABS)]
union bolt mounting hole to remove pistons and piston boots. L
CAUTION:
M
MAA0272D
BR-145
FRONT DISC BRAKE
CAUTION:
JPFIA0738ZZ
ASSEMBLY
der body.
CAUTION:
JPFIA0039ZZ
CAUTION:
JPFIA0739ZZ
piston groove.
CAUTION:
pin. [For gasoline engine (without ABS)]

Exploded View".

Cylinder Body
BR-146
FRONT DISC BRAKE
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil. A
Torque Member
B
Pistons
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper. C
D
2. Remove brake pads. Refer to BR-140, "BRAKE PAD : Removal and Installation". E
5. Securely depress the brake pedal several times. BR
7. Burnish contact surface between disc rotor and brake pads after refinishing or replacing disc rotor, or if a G
BR-147
REAR DRUM BRAKE
REAR DRUM BRAKE
JPFIA0881GB

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
: Apply brake fluid

REMOVAL
WARNING:
CAUTION:
1. Remove tires.
2. Perform drain the brake fluid when remove or disassemble the wheel cylinder. Refer to BR-104, "Drain-
ing".
BR-148
REAR DRUM BRAKE
and remove brake shoe assembly (brake shoe, each spring, and A
adjuster).
CAUTION:
B
CAUTION:
C
JPFIA0852ZZ
D
7. Remove the wheel cylinder with the following procedure. E
BR
and Adjustment".
G
JPFIA0882ZZ
INSTALLATION H
WARNING:
I
CAUTION:
• Never spill or splash brake fluid on the brake drum. J
: Vehicle front K
Adjuster Direction
Left side Left screw L
M
N
properly.
O
cylinder. Refer to BR-105, "Bleeding Brake System". P
ment".
JPFIA0884ZZ
BR-149
REAR DRUM BRAKE
DISASSEMBLY
2. Remove the piston, piston cup and spring from wheel cylinder.
CAUTION:
damaged.
ASSEMBLY
boot (2), and install them to piston (3).
CAUTION:
and install spring, piston to wheel cylinder.
CAUTION:
3. Install the boot to wheel cylinder. Refer to BR-148, "Exploded
View". JPFIA0885ZZ
4. Perform inspection after assembly. Refer to BR-150, "Inspection

and Adjustment".

4. Push the piston.
CAUTION:
BR-150
REAR DRUM BRAKE
brake drum, or if a soft pedal occurs at very low mileage. Refer to BR-110, "BRAKE LINING : Inspection A
Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-2, "Inspection and Adjustment". B
BR
BR-151


Unit: mm (in)

Control valve Valve type Dual proportioning valve
Brake booster Diaphragm diameter 231 (9)
FOR GASOLINE ENGINE (WITH ABS)

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)
HR12DE 231 (9)
Brake booster Diaphragm diameter Primary: 230 (9)
HR12DDR
Secondary: 205 (8)
FOR DIESEL ENGINE (WITHOUT ABS)

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)
Control valve Valve type Dual proportioning valve
BR-152
FOR DIESEL ENGINE (WITH ABS)
Unit: mm (in) A
B
Leading 158.7 × 36.5 × 4.7 (6.25 × 1.437 × 0.185) C
Trailing 194.0 × 36.5 × 4.7 (7.64 × 1.437 × 0.185)
Master cylinder Cylinder bore diameter 22.2 (7/8) D
E

BR
Unit: mm (in)
Item Standard
G
Brake pedal play 2 – 9 (0.08 – 0.35) H
80 (3.15) or more
I
Unit: mm (in)
J
Item Standard

K
Unit: mm (in)
Item Limit L
M
N

O
Unit: mm (in)
Item Limit
P
FOR GASOLINE ENGINE (WITH ABS) AND DIESEL ENGINE
BR-153
Unit: mm (in)
Item Limit
BR-154
HOW TO USE THIS MANUAL A

B
• In this manual, “Idling Stop System” is referred to as “Stop / Start System”.
• Check the vehicle type to use the service information in this section.
C
D
TYPE 4 Thailand production models E
BR
BR-155
PRECAUTIONS
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000006291196
WARNING:
connectors.
WARNING:
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000006291197
CAUTION:
cannot be turned.
OPERATION PROCEDURE
NOTE:
BR-156
PRECAUTIONS
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock A
Precaution for Procedure without Cowl Top Cover INFOID:0000000006291198
B
the lower end of windshield with urethane, etc to prevent damage to C
windshield.
PIIB3706J
BR
Precaution for Brake System INFOID:0000000006274627
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
I
• Never use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and cause J
improper operation.
• Tighten the brake tube flare nut to the specified torque with a flare K
brake pipes.
• Brake component parts are critical safety parts. If a brake fluid leak L
• Turn the ignition switch OFF and disconnect the ABS actuator and M
electric unit (control unit) harness connector [with VDC and without
VDC (with ABS)] or the battery negative terminal before performing
the work.
JPFIA0061ZZ
N
parts.
occurs at very low mileage. O
- Rear brake drum: refer to BR-168, "BRAKE DRUM : Inspection and Adjustment". P
BR-157
PREPARATION
PREPARATION
PREPARATION
Flare nut torque wrench

a: 10 mm (0.39 in)
NT406
Brake pressure gauge Check brake fluid pressure
S-NT151
Pin punch
a: 4 mm (0.16 in)
NT410
• Air tight
Handy vacuum pump
ZZC1313D
NNFIA0040ZZ
BR-158
Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
SUSPECTED PARTS
Noise
Shake
Shimmy, Judder
×
SYMPTOM DIAGNOSIS
×
Shims damaged BR-195
×
×
×
BR-159
×
Rotor runout BR-166
×
×
×
×
×
×
× Drum out of round BR-168
×
×
×

×
×
×

×
×
×

×
×
×
[TYPE 4]
INFOID:0000000006274629
P
K
E
B
A
N
H
D
C
O
G
M
BR
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
stop lamp switch (2) threaded end.

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
BR-160
BRAKE PEDAL
Brake Pedal Height
1. Remove instrument lower panel. Refer to IP-15, "Removal and Installation". A
B
CAUTION:
The threaded end of the input rod (2) must project to the C
JPFIA0003ZZ
b. Rotate the input rod, adjust the brake pedal to the specified BR
height (H1).
H1 : Refer to BR-206, "Brake Pedal". G

5. Check the brake pedal play. H
I
JPFIA0279ZZ
Stop Lamp Switch

1. Remove instrument lower panel. Refer to IP-15, "Removal and Installation". J
4. Press-fit the stop lamp switch (2) until the stop lamp switch hits K
the brake pedal lever (1) 45° clockwise while pulling the brake
pedal pad slightly.
CAUTION: L
lamp switch threaded and must be the specified value.
C : Refer to BR-206, "Brake Pedal". M
• The stop lamp must be turned off when the brake pedal is
released.
PFIA0813J
N
BR-161
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:
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 VDC (with ABS)] or the battery negative terminal before per-
forming work.
BR-162
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-163, "Bleeding Brake Sys- D

tem".
E
CAUTION:
ness connector [with VDC and without VDC (with ABS)] or the battery negative terminal before per- BR
forming the work.
1. Connect a vinyl tube to the bleeder valve of the rear left brake. H
bleeder valve. I
• Front disc brake: refer to BR-195, "BRAKE CALIPER ASSEMBLY : Exploded View". J
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.
162, "Inspection". L
M
BR-163
FLUID LEAK
tube connections.
BR-164
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
BR
onds or more.
BR-165
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-88, "Inspection".

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

tion.
CAUTION:
BR-166
FRONT DISC BRAKE
Wear thickness : Refer to BR-206, "Front Disc Brake". A
Thickness
B
Wear thickness : Refer to BR-206, "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
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. H
I
BR-167
REAR DRUM BRAKE
REAR DRUM BRAKE
BRAKE LINING
INSPECTION
Brake Lining
on back plate. Check using a scale necessary.
JPFIA0806ZZ
ADJUSTMENT
Burnish contact surfaces between brake lining and brake drum according to the following procedure after
CAUTION:
4. Repeat steps 1 to 3 until brake lining and brake drum are securely fitted.
BRAKE DRUM
INSPECTION
Appearance
BR-168
REAR DRUM BRAKE
A
JPFIA0113ZZ
D
ADJUSTMENT
CAUTION: E
• 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
BR-169
BRAKE PEDAL
REMOVAL AND INSTALLATION

BRAKE PEDAL
EXCEPT FOR AUSTRALIA, NEW ZEALAND, HONG KONG
JPFIA0873GB

FOR AUSTRALIA, NEW ZEALAND AND HONG KONG
BR-170
BRAKE PEDAL
BR
H
JPFIA0853GB

4. Stop lamp switch 5. Clip 6. Snap pin I
J
REMOVAL K
2. Disconnect the stop lamp switch harness connectors.
3. Disconnect the accelerator pedal harness connector. L
M
CAUTION:
N
parts.
O
INSTALLATION
Note the following, and install in the reverse order of removal. P
already applied)
NOTE:
• Do not give any impact caused by dropping, interference with a tool, contact between parts or with rack to
the brake pedal.
• Do not use an part that has been subject to an impact.
• Perform inspection after installation. Refer to BR-172, "Inspection and Adjustment".
BR-171
BRAKE PEDAL

welded parts.
NOTE:
D : 5.5 mm (0.217 in) or more
JPFIA0854ZZ
PFIA0756J

[HR12DE (L-jetronic)], EC3-594, "Work Procedure" [HR12DE (D-jetronic)], EC4-108, "Work Procedure"
(HR15DE).
BR-172
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
WITHOUT VDC (WITH ABS) M
BR-173
BRAKE PIPING
JPFIA0855GB

trol unit)
10. Copper washer
WITH VDC
BR-174
BRAKE PIPING
BR
H
JSFIA0771GB

4. ABS actuator and electric unit (con- 5. Connector bracket 6. Connector I
trol unit)
10. Copper washer J
Refer to GI-4, "Components" for symbols in the figure. K
L
WITHOUT ABS
JPFIA0757ZZ
BR-175
BRAKE PIPING

: Flare nut
: Union bolt
WITHOUT VDC (WITH ABS)
JSFIA1061ZZ

trol unit)
: Flare nut
: Union bolt
WITH VDC
JSFIA0772ZZ

trol unit)
BR-176
BRAKE PIPING
A
: Flare nut
: Union bolt
B
REMOVAL
CAUTION: C
1. Remove tires. D
CAUTION: E
• Cover open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. BR
INSTALLATION G
CAUTION:
off immediately and wash with water if it gets on a painted surface. H
CAUTION: I
assembly hole, and tighten the union bolt (1) to the specified J
torque.
K
CAUTION:
and bent. L
CAUTION: M
CAUTION: N
7. Perform inspection after installation. Refer to BR-177, "FRONT : Inspection". O
INSPECTION AFTER INSTALLATION P

CAUTION:
condition*.
BR-177
BRAKE PIPING
nated positions.
CAUTION:
REAR
WITHOUT ABS
JPFIA0758GB

A. To dual proportioning valve
WITH VDC AND WITHOUT VDC (WITH ABS)
BR-178
BRAKE PIPING
BR
H
JPFIA0857GB

A. To connector I
J
WITHOUT ABS K
JPFIA0757ZZ

BR-179
BRAKE PIPING
: Flare nut
: Union bolt
WITHOUT VDC (WITH ABS)
JSFIA1061ZZ

trol unit)
: Flare nut
: Union bolt
WITH VDC
JSFIA0772ZZ

trol unit)
: Flare nut
: Union bolt
BR-180
BRAKE PIPING
A
REMOVAL
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it B
1. Remove tires.
2. Drain brake fluid. Refer to BR-162, "Draining". C
CAUTION:
• Never scratch the flare nut and the brake tube. D
4. Remove the lock plate and remove the brake hose from the vehicle. E
INSTALLATION BR
CAUTION:
rotate further. H
CAUTION:
Check that the brake hoses and tubes are not twisted and bent. I
CAUTION:
Never scratch the flare nut and the brake tube. J
CAUTION:
Never reuse drained brake fluid. K
L
INSPECTION AFTER INSTALLATION M

at connections.
CAUTION:
N
condition*.
nated positions. O
CAUTION: P
BR-181
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-33, "TYPE 1 : Removal and Installation" [HR12DE
(L-jettonic)], EM-34, "TYPE 2 : Removal and Installation" [HR12DE (D-jettonic)], EM-337, "Removal and
Installation" (HR15DE).
3. Loosen the brake tube flare nuts, and then remove brake tubes from dual proportioning valve. Refer to
BR-173, "FRONT : Exploded View" (front), BR-178, "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. Refer to BR-173, "FRONT : Exploded View" (front), BR-
178, "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-163, "Bleeding Brake System".
BR-182
A
1. Connect brake fluid pressure gauge 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. E

3. Check brake fluid pressure by depressing the brake pedal.
Applied pressure (front : 4.90 MPa (49.0 bar, 50.0 BR

Output pressure (rear : 3.07 MPa (30.7 bar, 31.3
G
• If output pressure (rear brake) is out of specification, replace
dual proportioning valve. H
SBR823BA
4. Bleed air after disconnecting the brake fluid pressure gauge.
Refer to BR-163, "Bleeding Brake System".
I
BR-183
JPFIA0875GB

7. O-ring

REMOVAL
CAUTION:
4. Remove the brake tube from between dual proportioning valve (without ABS) or ABS actuator and electric
unit (control unit) [with VDC and without VDC (with ABS)] and master cylinder assembly with a flare nut
wrench.
CAUTION:
5. Remove the master cylinder assembly.
CAUTION:
BR-184
• The piston of the master cylinder assembly is exposed. Never damage it when removing the A
master cylinder.
when handling the master cylinder assembly.
B
INSTALLATION
CAUTION: C
D
when installing the master cylinder assembly to the brake booster. E
and dust are present on the piston before installation. Clean it with BR
assembly. G
JPFIA0013ZZ
assembly by hand. Then tighten it to the specified torque with a H
CAUTION:
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank. I
CAUTION:
Never reuse drained brake fluid. J
K
DISASSEMBLY
CAUTION:
• Never disassemble the cylinder body. L
1. Fix the master cylinder assembly to a vise. M
CAUTION:
N
2. Remove the reservoir tank mounting pin with a pin punch [4 mm (0.16 in)].
3. Remove master cylinder from vise.
4. Remove the reservoir tank and grommet from the cylinder body. O
ASSEMBLY
CAUTION:
• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and P
assembly process.
CAUTION:
BR-185
CAUTION:
• Place the reservoir tank with the chamfered pin hole facing up.
CAUTION:

Check the brake fluid level switch. Refer to BRC-19, "Component Inspection" (without ABS), BRC-101, "Com-
ponent Inspection" [without VDC/ESP (with ABS)], BRC-232, "Component Inspection" [with VDC (ESP)].
CAUTION:
BR-186
A
WITHOUT STOP / START SYSTEM B
BR
JPFIA0874GB
H
I
WITH STOP / START SYSTEM
JPFIA0858GB O

P
7. Gasket
REMOVAL
CAUTION:
BR-187
set. (With stop / start system)
3. Disconnect vacuum sensor harness connector. (With stop / start system)
5. Remove vacuum hose from check valve. Refer to BR-191, "Removal and Installation".
6. Remove intake manifold. Refer to EM-38, "TYPE 1 : Removal and Installation" [HR12DE (L-jettonic)], EM-
40, "TYPE 2 : Removal and Installation" [HR12DE (D-jettonic)], EM-340, "Removal and Installation"
(HR15DE).
7. Remove low-pressure flexible hose. Refer to HA-37, "LOW-PRESSURE FLEXIBLE HOSE : Removal and
Installation".
8. Separate brake tube from dual proportioning valve and front RH brake hose (dual proportioning valve side
only). (Without ABS)
9. Separate brake tube from ABS actuator and electric unit (control unit) and front RH brake hose [ABS actu-
ator and electric unit (control unit) side only]. [with VDC and without VDC (with ABS)]
"Exploded View".
CAUTION:
NOTE:
booster.
JPFIA0019ZZ
and Adjustment".
INSTALLATION
CAUTION:
A : 45°
threads.
booster.
panel.
• Replace the clevis pin if it is damaged. Refer to BR-172, "Inspec- JPFIA0916ZZ
tion and Adjustment".

CAUTION:
BR-188
A
Air Tight
B
CAUTION:
C
D
2. If the air tight condition cannot be maintained, perform the following operation.
Clean it if necessary. E
b. Check the O-ring on the master cylinder. If anything is found, replace the O-ring. Refer to BR-187,
"Removal and installation".
c. Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster. BR
G
When connected to the : Vacuum should decrease within 1.3 kPa (9.8 mmHg, 0.38 inHg, H
booster side 0.013 bar) for 15 seconds under a vacuum of −66.7 kPa (−500
mmHg, −19.69 inHg, −0.067 bar).
When connected to the :Vacuum should not exist. I
vacuum hose side
J
fied length (A).
K

2. Tighten the lock nut to the specified torque. L
JPFIA0238ZZ
INSPECTION AFTER INSTALLATION N

Operation
brake pedal fully depressed. Check that the clearance between brake pedal and dash lower pane decreases. O
NOTE:
normal phenomenon due to the brake system operation. P
Air Tight
BR-189
onds or more.
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-160, "Inspection
and Adjustment".
BR-190
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-191, "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
P
upward to assemble.
JPFIA0023ZZ

Appearance
BR-191
VACUUM LINES
BR-192
FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
B
EXCEPT FOR AUSTRALIA AND NEW ZEALAND
C
BR
JPFIA0859GB H

4. Inner pad (with pad wear sensor) 5. Pad return spring 6. Pad retainer I
1: Apply MOLYKOTE® AS880N or silicone-based grease. J
K
FOR AUSTRALIA AND NEW ZEALAND
JSFIA0634GB
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
BR-193
FRONT DISC BRAKE
: Apply MOLYKOTE® 7439 or equivalent.

REMOVAL
WARNING:
CAUTION:
1. Remove tires.
return spring, brake pads, shims, shim covers (except for Australia and New Zealand) and pad retainers
from the torque member.
CAUTION:
• Never drop the brake pads, shims, and the shim covers (except for Australia and New Zealand).
INSTALLATION
WARNING:
Since dust covering the front brakes has an affect on human body, the dust must be removed with a
CAUTION:
ton may pop out.
CAUTION:
mating faces between the inner shim (A) and the inner shim cov-
ers (B), and install them to the inner pad. (except for Australia
and New Zealand)
CAUTION:
Always replace the shim together with the shim covers
(except for Australia and New Zealand) when replacing the
brake pad.
mating faces between the outer shim (A) and the outer shim
cover (B), and install them to the outer pad. (except for Australia JPFIA0764ZZ
and New Zealand)

CAUTION:
Always replace the shim together with the shim covers (except for Australia and New Zealand)
when replacing the brake pad.
retainers, and Install the brake pads to the torque member.
CAUTION:
• Never deform the pad return spring.
BR-194
FRONT DISC BRAKE
• Correctly insert the pad return spring in to the pad return spring hole on the brake pad.
6. Install cylinder body to torque member. A
CAUTION:
• When replacing brake pad with new one, check a brake fluid level in the reservoir tank because B
NOTE:
C
D
E
Replace the shims and the shim covers (except for Australia and New Zealand) if rust is excessively attached.
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
JPFIA0510GB

DISASSEMBLY
BR-195
FRONT DISC BRAKE
JPFIA0511GB

10. Torque member

REMOVAL
WARNING:
CAUTION:
1. Remove tires.
CAUTION:
CAUTION:
CAUTION:
INSTALLATION
WARNING:
CAUTION:
BR-196
FRONT DISC BRAKE
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it A
B
C
CAUTION:
3. Install brake hose and copper washers to brake caliper assembly, and tighten union bolts to the specified D
CAUTION:
Never reuse copper washer. E
CAUTION:
• Never reuse drained brake fluid. BR
Inspection".
G
H
DISASSEMBLY
NOTE: I
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-194, J
CAUTION:
Fix the brake pad at suitable tape so that the brake pad will not drop. K
3. Remove bushing from sliding pin.
4. Place a wooden block as shown in the figure, and blow air from L
union bolt mounting hole to remove pistons and piston boots.
CAUTION:
M
MAA0272D O
BR-197
FRONT DISC BRAKE
CAUTION:
JPFIA0738ZZ
ASSEMBLY
der body.
CAUTION:
JPFIA0039ZZ
CAUTION:
JPFIA0739ZZ
piston groove.
CAUTION:
pin.

Exploded View".

Cylinder Body
BR-198
FRONT DISC BRAKE
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil. A
Torque Member
B
Pistons
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper. C
D
2. Remove brake pads. Refer to BR-194, "BRAKE PAD : Removal and Installation". E
5. Securely depress the brake pedal several times. BR
7. Burnish contact surface between disc rotor and brake pads after refinishing or replacing disc rotor, or if a G
BR-199
REAR DRUM BRAKE
REAR DRUM BRAKE
JPFIA0901GB

4. Brake shoe 5. Spring 6. Upper spring
10. Boot 11. Piston cover 12. Piston
13. Piston cup 14. Spring 15. Wheel cylinder
16. Bleeder valve 17. Cap
: Apply brake fluid

BR-200
REAR DRUM BRAKE
BR
H
JSFIA0766GB

4. Brake shoe 5. Spring 6. Upper spring I
10. Boot 11. Piston 12. Piston cup
13. Spring 14. Wheel cylinder 15. Bleeder valve J
16. Cap
K
: Apply brake fluid

M
REMOVAL
WARNING:
Since dust covering the rear brake has an affect on human body, the dust must be removed with a N
CAUTION:
• Never drop the removed parts. O
1. Remove tires.
P
2. Perform drain the brake fluid when remove or disassemble the wheel cylinder. Refer to BR-162, "Drain-
ing".
BR-201
REAR DRUM BRAKE
adjuster). (Except for Australia and New Zealand)
CAUTION:
JPFIA0902ZZ
adjuster). (For Australia and New Zealand)
CAUTION:
CAUTION:
JSFIA0636ZZ

8. Remove the wheel cylinder with the following procedure.
and Adjustment".
JPFIA0903ZZ
INSTALLATION
WARNING:
CAUTION:
: Vehicle front
JPFIA0904ZZ
BR-202
REAR DRUM BRAKE
Except for Australia and New Zealand
Adjuster Direction A
Left side Left screw
B
For Australia and New Zealand
Adjuster Direction
Left side Left screw C
Right side Left screw
• Shorten adjuster by rotating it. D
• Apply PBC (Poly Butyl Cuprysil) silicone-based grease to the mating faces between the adjuster and brake
shoe.
• Apply PBC (Poly Butyl Cuprysil) silicone-based grease to the mating faces between the back plate and
brake shoe. E
properly. (Except for Australia and New Zealand) BR
JPFIA0905ZZ
I
properly. (For Australia and New Zealand)
• Check the brake shoe sliding surface and brake drum inner sur- J
cylinder. Refer to BR-163, "Bleeding Brake System".
• Never allow foreign matter (e.g. dust) and oils other than brake K
install and air bleeding. Refer to PB-2, "Inspection and Adjust- L
ment".
JSFIA0637ZZ

M
DISASSEMBLY
1. Remove the boot from wheel cylinder. Refer to BR-200, "Exploded View". N
2. Remove the piston cover (except for Australia and New Zealand), piston, piston cup and spring from
wheel cylinder.
CAUTION:
O
damaged.
3. Remove piston cup from piston.
P
ASSEMBLY
BR-203
REAR DRUM BRAKE
boot (2).
2. Install piston cover (except for Australia and New Zealand), pis-
ton cup and boot to piston (3).
CAUTION:
• When replacing the piston or the piston cover, replace the
piston and the piston cover as a set. (Except for Australia
and New Zealand)
3. Apply new brake fluid to piston and wheel cylinder inner wall, JPFIA0915ZZ
and install spring, piston cover (except for Australia and New
Zealand), piston to wheel cylinder.
CAUTION:
4. Install the boot to wheel cylinder. Refer to BR-200, "Exploded View".
5. Perform inspection after assembly. Refer to BR-204, "Inspection and Adjustment".

CAUTION:
When replacing the piston or the piston cover, replace the piston and the piston cover as a set.
(Except for Australia and New Zealand).
4. Push the piston.
CAUTION:
brake drum, or if a soft pedal occurs at very low mileage. Refer to BR-168, "BRAKE LINING : Inspection
Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-2, "Inspection and Adjustment".
BR-204
SERVICE DATA AND SPECIFICATIONS (SDS) A

B
EXCEPT FOR AUSTRALIA AND NEW ZEALAND (WITHOUT ABS)

Unit: mm (in) C
Rotor outer diameter × thickness 238 × 22.0 (9.37 × 0.866) D
E
Control valve Valve type Dual proportioning valve BR
G
EXCEPT FOR AUSTRALIA AND NEW ZEALAND [WITHOUT VDC (WITH ABS)]
Unit: mm (in)
Cylinder bore diameter 51.1 (2.012) H

I
Drum inner diameter 180.0 (7.09) J
K
FOR AUSTRALIA AND NEW ZEALAND L

Unit: mm (in)

M
Cylinder bore diameter 19.05 (3/4) N
Leading 162.8 × 37.0 × 4.8 (6.41 × 1.457 × 0.189)
Trailing 180.5 × 37.0 × 4.8 (7.11 × 1.457 × 0.189)
O
Control valve Valve type Electric brake force distribution P
BR-205
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

Unit: mm (in)
Item Limit
BR-206

Brakes

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Brakes

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BRAKES

SERVICE DATA AND SPECIFICATIONS BRAKE MASTER CYLINDER ........................... 59

FOR EUROPE ........................................................... 48 BRAKE DRUM .......................................................... 63

HR12DE, HR15DE ..................................................... 81 EXCEPT FOR EUROPE ............................................97

BRAKE BOOSTER .......................................... 107 HR12DDR ................................................................ 136

BRAKE PIPING ............................................... 115 REAR DRUM BRAKE ...................................... 148

SYMPTOM DIAGNOSIS ............................ 159 DUAL PROPORTIONING VALVE .................. 182 B

HOW TO USE THIS MANUAL

Service information Destination

Precaution for Brake System INFOID:0000000006273966

Tool name Description

Flare nut torque wrench D

Possible cause and

Pads or lining damaged BR-17, BR-19

Pads or lining uneven wear BR-17, BR-19

Rotor or drum rust BR-17, BR-19

TIRE NVH in WT section

ROAD WHEEL NVH in WT section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

× × DRIVE SHAFT NVH in FAX section

STEERING NVH in ST section

Stop Lamp Switch

C : Refer to BR-46, "Brake Pedal". H

Brake Pedal Play

A : Refer to BR-46, "Brake Pedal".

H2 : Refer to BR-46, "Brake Pedal".

H1 : Refer to BR-46, "Brake Pedal".

Stop Lamp Switch

C : Refer to BR-46, "Brake Pedal".

BRAKE FLUID LEVEL B

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

Wear thickness : Refer to BR-46, "Front Disc Brake".

Wear thickness : Refer to BR-46, "Front Disc Brake".

Wear thickness : Refer to BR-46, "Front Disc

A : Refer to BR-46, "Rear Drum Brake".

B : Refer to BR-46, "Rear Drum Brake".

REMOVAL AND INSTALLATION A

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

INSPECTION AFTER REMOVAL

D : 5.5 mm (0.217 in) or more

ADJUSTMENT AFTER INSTALLATION

FRONT : Removal and Installation INFOID:0000000006267406

1. Brake tube 2. Lock plate 3. Brake hose

REAR : Hydraulic Piping INFOID:0000000006267409

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

: Apply brake fluid.

Removal and Installation INFOID:0000000006267416

INSPECTION BEFORE REMOVAL

1. Master cylinder assembly 2. Check valve 3. Brake booster

Removal and installation INFOID:0000000006267420

INSPECTION BEFORE REMOVAL H

Check Valve Air Tightness

A : Refer to BR-46, "Brake Booster".

INSPECTION AFTER INSTALLATION

1. Clamp 2. Vacuum hose 3. Vacuum piping J

Removal and Installation INFOID:0000000006267423

INSPECTION AFTER REMOVAL

1. Cylinder body 2. Inner shim cover 3. Inner shim

BRAKE PAD : Removal and Installation INFOID:0000000006267426