BRAKE BRAKE SYSTEM

BR1

BRAKE SYSTEM
PRECAUTION
1. Necessary care must be taken to replace each part properly as it could affect the brake system performance. This could cause driving hazards. Replace each part with an identical part with the same number. It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precautions in the INTRODUCTION section.

BR

2. 3.

BR2

BRAKE BRAKE SYSTEM

SYSTEM DIAGRAM

BR

A A A A A A Front A A A A A A A A A A A A A A A A Hydraulic Brake Booster

B A

A B

Brake Tube Flexible Hose Brake Tube Way

for use without SST: Union Nut Torque: 15 N*m (155 kgf*cm, 11 ft*lbf) for use with SST: Union Nut Torque: 14 N*m (143 kgf*cm, 10 ft*lbf)

Torque: 31 N*m (316 kgf*cm, 23 ft*lbf)

C133081E01

BRAKE BRAKE SYSTEM

BR3

PROBLEM SYMPTOMS TABLE

HINT: Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in the order suggested. If necessary, replace these applicable parts.
Symptom Suspected area 1. Fluid leakage in brake system 2. Air in brake system Low pedal or spongy pedal 3. Piston seal (Worn or damaged) (Front brake) 4. Piston seal (Worn or damaged) (Rear brake) 5. Hydraulic brake booster (Faulty) 1. Brake pedal free play (Minimum) 2. Parking brake lever travel (Out of adjustment) 3. Parking brake wire (Sticking) 4. Parking brake (Shoe clearance out of adjustment) 5. Pad (Cracked or distorted) (Front brake) Brake drag 6. Pad (Cracked or distorted) (Rear brake) 7. Piston (Stuck) (Front brake) 8. Piston (Stuck) (Rear brake) 9. Piston (Frozen) (Front brake) 10. Piston (Frozen) (Rear brake) 11. Tension or return spring (Faulty) 12. Hydraulic brake booster (Faulty) 1. Piston (Stuck) (Front brake) 2. Piston (Stuck) (Rear brake) 3. Pad (Oily) (Front brake) 4. Pad (Oily) (Rear brake) 5. Piston (Frozen) (Front brake) Brake pull 6. Piston (Frozen) (Rear brake) 7. Front disc (Scored) 8. Rear disc (Scored) 9. Pad (Cracked or distorted) (Front brake) 10. Pad (Cracked or distorted) (Rear brake) 11. Hydraulic brake booster (Faulty) 1. Fluid leakage in brake system 2. Air in brake system 3. Pad (Worn) (Front brake) 4. Pad (Worn) (Rear brake) 5. Pad (Cracked or distorted) (Front brake) 6. Pad (Cracked or distorted) (Rear brake) Firm pedal but braking inefficient 7. Pad (Oily) (Front brake) 8. Pad (Oily) (Rear brake) 9. Pad (Glazed) (Front brake) 10. Pad (Glazed) (Rear brake) 11. Front disc (Scored) 12. Rear disc (Scored) 13. Hydraulic brake booster (Faulty) See page BR-5 BR-43 BR-43 BR-30 BR-10 PB-4 PB-11 PB-20 BR-43 BR-51 BR-43 BR-51 BR-43 BR-51 PB-17 BR-30 BR-43 BR-51 BR-43 BR-51 BR-43 BR-51 BR-44 BR-52 BR-43 BR-51 BR-30 BR-5 BR-43 BR-51 BR-43 BR-51 BR-43 BR-51 BR-43 BR-51 BR-44 BR-52 BR-30

BR

BR4
Symptom

BRAKE BRAKE SYSTEM

Suspected area 1. Pad (Cracked or distorted) (Front brake) 2. Pad (Cracked or distorted) (Rear brake) 3. Installation bolt (Loose) 4. Front disc (Scored) 5. Rear disc (Scored) 6. Pad support plate (Loose) See page BR-43 BR-51 BR-50 BR-44 BR-52 BR-50 BR-50 BR-43 BR-51 BR-43 BR-51 PB-17 BR-42 BR-50 PB-17 BR-30 BR-19 BR-30 BR-30 BR-30

BR
Noise from brakes

7. Sliding pin (Worn) 8. Pad (Dirty) (Front brake) 9. Pad (Dirty) (Rear brake) 10. Pad (Glazed) (Front brake) 11 Pad (Glazed) (Rear brake) 12. Tension or return spring (Faulty) 13. Anti-squeal shim (Damaged) (Front brake) 14. Anti-squeal shim (Damaged) (Rear brake) 15. Shoe hold-down spring (Damaged) Noise from hydraulic brake booster (Abnormal pump motor operation noise) Brake warning light illuminates (Parking brake lever released) Brake warning light illuminates and skid control buzzer sounds ABS warning light illuminates 1. Accumulator bracket clearance (Out of adjustment) 1. Brake fluid level 2. Brake master cylinder power supply system (Faulty) 1. Brake master cylinder power supply system (Faulty) 1. Anti-lock brake system (Faulty) 2. Brake master cylinder power supply system (Faulty)

BRAKE BRAKE FLUID

BR5

BRAKE FLUID
BLEEDING
NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces. Depressing the brake pedal with the reservoir cap removed will cause the fluid to spray. HINT: If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system. When bleeding, maintain the amount of fluid in the reservoir between the Min. and Max. lines. 1. FILL RESERVOIR WITH BRAKE FLUID Fluid: SAE J1703 or FMVSS NO. 116 DOT3 BLEED BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY HINT: If the brake master cylinder is disassembled, the brake line is disconnected from the brake master cylinder or if the reservoir becomes empty, bleed the brake master cylinder. (a) Turn the ignition switch to ON, and wait until the pump motor has stopped (step A). HINT: Pump operating sound can be heard. (b) Turn the ignition switch to OFF, and depress the brake pedal more than 20 times (step B). HINT: When pressure in the accumulator is released, the reaction force becomes lighter and the stroke becomes longer. (c) Repeat steps A and B 5 times (step C). (d) Turn the ignition switch to ON, and check that the pump stops after approximately 8 to 14 seconds. NOTICE: If the pump does not stop, repeat step C again. BLEED BRAKE LINE (a) Turn the ignition switch to ON, and wait until the pump motor has stopped. HINT: Pump operating sound can be heard.

BR

2.

3.

BR6

BRAKE BRAKE FLUID

BR
F052299

(b) Front brake line. (1) Connect the vinyl tube to the brake caliper. (2) Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down (step D). (3) At the point when the fluid stops coming out, tighten the bleeder plug, then release the brake pedal (step E). (4) Repeat steps D and E until all the air in the fluid has been bled out. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) (5) Repeat the above procedures to bleed the other brake line. (c) Rear brake line. (1) Connect the vinyl tube to the brake caliper. (2) Depress the brake pedal, hold it, and then loosen the bleeder plug. HINT: Brake fluid is pumped out automatically. (3) Loosen the bleeder plug and release the air. NOTICE: Keep the brake fluid in the reservoir tank above the MIN line during the above procedures. (4) When the air is completely bled out of the brake fluid through the bleeder plug, tighten the bleeder plug. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) (5) Repeat the above procedures to bleed the other brake line. 4. BLEED MASTER CYLINDER SOLENOID HINT: If the brake master cylinder is disassembled, the brake line is disconnected from the brake master cylinder or if the reservoir becomes empty, bleed the brake master cylinder. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to ON. (c) Select "ACTIVE TEST" mode on the intelligent tester. (d) Connect the vinyl tube to the rear brake caliper. (e) Loosen the bleeder plug. (f) Select "SRMF" to drive the solenoids and bleed air from the rear brake caliper (step F). NOTICE: Do not depress the brake pedal. Keep the brake fluid in the reservoir tank above the MIN line during the above procedures. HINT: Brake fluid is sent through the pump.

F052300

Intelligent Tester

CAN VIM DLC3

H102157E03

BRAKE BRAKE FLUID

BR7

To protect the solenoids, the intelligent tester turns OFF automatically 2 seconds after every solenoid has been turned ON. (g) Repeat step F until all the air in the brake fluid is bled out. (h) When the air is completely bled out of the brake fluid through the bleeder plug, tighten the bleeder plug. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) (i) Repeat the above procedures to bleed the other brake line. (j) Turn the ignition switch to OFF. (k) Turn the ignition switch to ON. (l) Clear DTC (see page BC-45). 5. CHECK FLUID LEVEL IN RESERVOIR (a) Turn the ignition switch to OFF, and depress the brake pedal more than 20 times (until the pedal reaction feels light and pedal stroke becomes longer), and adjust the fluid level to the MAX level. (b) When the ignition switch is turned to ON, brake fluid is sent to the accumulator and the fluid level decreases by approximately 5 mm from the level when the ignition switch is OFF (normal).

BR

BR8

BRAKE BRAKE PEDAL

BRAKE PEDAL
BRAKE

COMPONENTS

BR
INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY

INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY

FRONT DOOR OPENING TRIM WEATHERSTRIP

HOOD LOCK CONTROL LEVER SUB-ASSEMBLY

FOOTREST CLIP COWL SIDE TRIM BOARD CLIP

FRONT FLOOR FOOTREST

FRONT DOOR SCUFF PLATE

C133076E01

BRAKE BRAKE PEDAL

BR9

MASTER CYLINDER PUSH ROD CLEVIS CLIP STOP LIGHT SWITCH MOUNTING ADJUSTER

BRAKE PEDAL RETURN SPRING PUSH ROD PIN BRAKE PEDAL SUPPORT SUB-ASSEMBLY

BR

for Manual Transmission: STOP LIGHT SWITCH CONNECTOR BRAKE PEDAL PAD
14 (145, 10)

STOP LIGHT SWITCH

BRAKE PEDAL BUSH BRAKE PEDAL BRAKE PEDAL SHAFT NO. 2 COLLAR

BRAKE PEDAL

34 (350, 25)

BRAKE PEDAL LINK ASSEMBLY

BRAKE PEDAL BUSH

BRAKE PEDAL LINK PIN E RING BRAKE PEDAL SHAFT COLLAR

BRAKE PEDAL LINK ASSEMBLY

BRAKE PEDAL SHAFT COLLAR BRAKE PEDAL LEVER

34 (350, 25)

BRAKE PEDAL BUSH

BRAKE PEDAL PAD

BRAKE PEDAL BUSH

BRAKE PEDAL BRACKET COLLAR

BRAKE PEDAL SUPPORT REINFORCEMENT

20 (204, 15)

N*m (kgf*cm, ft*lbf) : Specified torque

Non-reusable part

Lithium soap base glycol grease

C133077E01

BR10

BRAKE BRAKE PEDAL

ON-VEHICLE INSPECTION
1. INSPECT AND ADJUST BRAKE PEDAL (a) Inspect the brake pedal height. Pedal height from dash panel: 168.7 to 178.7 mm (6.642 to 7.035 in.) If the pedal height is incorrect, adjust the rod operating adapter length. (b) Adjust the brake pedal height. (1) Disconnect the connector from the stop light switch. (2) Turn the stop light switch counterclockwise, and remove the stop light switch. (3) Remove the hydraulic brake booster (See page BR-28).

BR

Pedal Height

F043109E01

(4) Loosen the clevis lock nut. (5) Adjust the rod operating adapter length by turning the pedal push rod clevis. Rod operating adapter length A: 201.7 to 202.7 mm (7.941 to 7.980 in.) (6) Tighten the clevis lock nut. Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) (7) Install the hydraulic brake booster (See page BR-38).
C133078E01

Adjuster

(8) Insert the stop light switch into the adjuster until it just touches the brake pedal. NOTICE: Do not depress the brake pedal.

Brake Pedal

Stop Light Switch

F049043E01

Shaft

Stop Light Switch 0.5 to 2.6 mm (0.020 to 0.102 in.)

C133112E01

(9) Make a quarter turn clockwise to install the stop light switch. NOTICE: Do not depress the brake pedal. HINT: The turning torque for installing the stop light switch: Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less

BRAKE BRAKE PEDAL

BR11

(10) Check the stop light switch clearance. Stop light switch clearance: 0.5 to 2.6 mm (0.020 to 0.102 in.) (11) Connect the connector to the stop light switch. (c) Inspect the brake pedal free play. (1) Stop the engine and depress the brake pedal several times until there is no vacuum left in the booster. (2) Push in the pedal until the beginning of the resistance is felt. Measure the distance as shown. Pedal free play: 1.0 to 6.0 mm (0.039 to 0.236 in.) If incorrect, troubleshoot the brake system. (d) Inspect the brake pedal reserve distance. (1) Release the parking brake pedal. With the engine running, depress the pedal and measure the pedal reserve distance as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 56 mm (2.20 in.) If incorrect, troubleshoot the brake system.

BR

Pedal Free Play

F048932E01

Pedal Reserve Distance

R000934E10

BR12

BRAKE BRAKE PEDAL

REMOVAL
1. 2. 3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE FRONT DOOR SCUFF PLATE (See page IR15) REMOVE FRONT FLOOR FOOTREST (See page IR-2) REMOVE FOOTREST CLIP (See page IR-2) REMOVE COWL SIDE TRIM BOARD (See page IR-15) SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP (See page IP-10) REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-13) SEPARATE HOOD LOCK CONTROL LEVER SUBASSEMBLY (See page IP-13) REMOVE INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY (See page IP-14)

BR

4. 5. 6. 7. 8. 9.

10. REMOVE STOP LIGHT SWITCH (a) Disconnect the stop light switch connector from the stop light switch. (b) Turn the stop light switch counterclockwise and remove the stop light switch. 11. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS (a) Remove the clip and push rod pin and separate the push rod clevis.

F050561

12. REMOVE BRAKE PEDAL SUPPORT REINFORCEMENT (a) Remove the bolt. (b) Remove the bolt and nut and remove the reinforcement from the brake pedal support.

C133079

BRAKE BRAKE PEDAL

BR13

13. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY (a) Remove the 4 nuts and the brake pedal support.

BR
C133080

14. REMOVE BRAKE PEDAL RETURN SPRING (a) Remove the return spring from the brake pedal support and brake pedal. 15. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER (a) Remove the stop light switch mounting adjuster from the brake pedal support.
F050564

16. REMOVE BRAKE PEDAL (a) Remove the bolt and nut and remove the brake pedal and brake pedal lever from the brake pedal support. (b) Remove the 4 brake pedal bushes from the brake pedal and brake pedal lever. (c) Remove the 2 collars from the brake pedal and brake pedal lever.
F043117E01

17. REMOVE BRAKE PEDAL LEVER (a) Using a screwdriver, remove the 2 E-rings from the brake pedal link. (b) Remove the 2 brake pedal links and the brake pedal lever. (c) Remove the 2 brake pedal shaft collars from the brake pedal and brake pedal lever. 18. REMOVE BRAKE PEDAL PAD (a) Remove the brake pedal pad from the brake pedal.
F043118

BR14

BRAKE BRAKE PEDAL

INSTALLATION
1. 2. INSTALL BRAKE PEDAL PAD (a) Install the brake pedal pad onto the brake pedal. INSTALL BRAKE PEDAL LEVER (a) Apply lithium soap base glycol grease to the 2 brake pedal links and 2 brake pedal shaft collars. (b) Install the 2 brake pedal shaft collars into the brake pedal and brake pedal lever. (c) Install the brake pedal lever with the 2 brake pedal links onto the brake pedal. (d) Install 2 new E-rings onto the brake pedal link. INSTALL BRAKE PEDAL (a) Apply lithium soap base glycol grease to the 2 collars and 4 brake pedal bushes. (b) Install the 2 collars and 4 brake pedal bushes onto the brake pedal and brake pedal lever. (c) Install the brake pedal onto the brake pedal support with the bolt and nut. Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf) 4. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER (a) Install a new stop light switch mounting adjuster onto the pedal support. INSTALL BRAKE PEDAL RETURN SPRING (a) Apply lithium soap base glycol grease to the inner surface of the hole in the brake pedal support and brake pedal. (b) Install the return spring onto the brake pedal support and brake pedal.

BR
3.

5.
F043117E01

F050564

6.

INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY (a) Install the 4 nuts and the brake pedal support. Torque: 14 N*m (145 kgf*cm, 10 ft.*lbf)

C133080

BRAKE BRAKE PEDAL

BR15

7.

INSTALL BRAKE PEDAL SUPPORT REINFORCEMENT (a) Provisionally install the reinforcement onto the brake pedal support with the bolt and nut. (b) Install the reinforcement with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (c) Fully tighten the bolt and nut. Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf) INSTALL MASTER CYLINDER PUSH ROD CLEVIS (a) Apply lithium soap base glycol grease to the inner surface of the hole in the brake pedal lever. (b) Install the push rod clevis onto the brake pedal lever with the push rod pin and clip.

8.
C133079

BR

F050561

9.
Adjuster

INSTALL STOP LIGHT SWITCH (a) Insert the stop light switch into the adjuster until it just touches the brake pedal. NOTICE: Do not depress the brake pedal.

Brake Pedal

Stop Light Switch

F049043E01

Shaft

Stop Light Switch 0.5 to 2.6 mm (0.020 to 0.102 in.)

C133112E01

(b) Make a quarter turn clockwise to install the stop light switch. NOTICE: Do not depress the brake pedal. HINT: The turning torque for installing the stop light switch: Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less (c) Check the stop light switch clearance. Stop light switch clearance: 0.5 to 2.6 mm (0.020 to 0.102 in.) (d) Connect the connector to the stop light switch. 10. INSPECT AND ADJUST BRAKE PEDAL (See page BR-10) 11. INSTALL INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY (See page IP-29) 12. CONNECT HOOD LOCK CONTROL LEVER SUBASSEMBLY (See page IP-30) 13. INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-30)

BR16

BRAKE BRAKE PEDAL

14. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP (See page IP-33) 15. INSTALL COWL SIDE TRIM BOARD (See page IR-45) 16. INSTALL FOOTREST CLIP (See page IR-2) 17. INSTALL FRONT FLOOR FOOTREST (See page IR-2)

BR

18. INSTALL FRONT DOOR SCUFF PLATE (See page IR45) 19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)

BR16
BRAKE

BRAKE HYDRAULIC BRAKE BOOSTER

HYDRAULIC BRAKE BOOSTER

COMPONENTS

BR
INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY

INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY

FRONT DOOR OPENING TRIM WEATHERSTRIP

HOOD LOCK CONTROL LEVER SUB-ASSEMBLY

FOOTREST CLIP COWL SIDE TRIM BOARD CLIP

FRONT FLOOR FOOTREST

FRONT DOOR SCUFF PLATE

C133076E01

BRAKE HYDRAULIC BRAKE BOOSTER

BR17

BR
PUSH ROD PIN FLUID LEVEL WARNING SWITCH CONNECTOR MASTER CYLINDER PUSH ROD CLEVIS CLIP

14 (145, 10)

GASKET

15 (155, 11)

HYDRAULIC BRAKE BOOSTER

CONNECTOR

* 14 (143, 10)

CONNECTOR

N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part * For use with SST
C133082E01

BR18

BRAKE HYDRAULIC BRAKE BOOSTER

BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY BRAKE ACTUATOR BRACKET

1.7 (17, 15 in.*lbf)

MASTER CYLINDER PUSH ROD CLEVIS ROD OPERATING ADAPTER

BR
7.8 (80, 69 in.*lbf)

PIN

26 (260, 19)

26 (260, 19)

GROMMET

32 (325, 24)

C-RING MASTER CYLINDER BODY

57 (585, 42)

PISTON

MASTER CYLINDER BOOT GASKET

BRAKE BOOSTER ACCUMULATOR ASSEMBLY

7.8 (80, 69 in.*lbf)

MASTER CYLINDER SOLENOID

2.9 (30, 26 in.*lbf)

O-RING BRAKE BOOSTER ACCUMULATOR PIPE

BRAKE ACTUATOR NO. 1 BRACKET

2.9 (30, 26 in.*lbf)

COMPRESSION SPRING

BRAKE BOOSTER PUMP ASSEMBLY COLLAR BUSH

PLUG

15 (155, 11)

* 14 (143, 10) BRAKE ACTUATOR NO. 1 TUBE

15 (155, 11)

7.8 (80, 69 in.*lbf)

PIN BRAKE BOOSTER PUMP BRACKET COLLAR BUSH

7.8 (80, 69 in.*lbf)

* 14 (143, 10)

BRAKE ACTUATOR HOSE N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part * For use with SST

PIN

BUSH

CLIP
7.8 (80, 69 in.*lbf)

Lithium soap base glycol

C133083E01

BRAKE HYDRAULIC BRAKE BOOSTER

BR19

ON-VEHICLE INSPECTION
1. INSPECT BRAKE MASTER CYLINDER FLUID PRESSURE CHANGE (a) Inspect the positive battery voltage. Standard voltage: 11 to 14 V (b) Turn the ignition switch to OFF, and depress the brake pedal more than 20 times. HINT: When pressure in the accumulator is released, the reaction force becomes lighter and the stroke becomes longer. (c) Install a LSPV gauge (SST) and brake pedal effort gauge, and bleed the air. SST 09709-29018 (d) When the booster does not operate: (1) Depress the brake pedal and check the fluid pressure. At 245 N (25 kgf, 55 lbf)
Front brake pressure 3,150kPa (32.1 kgf/cm more
2,

BR

Brake Pedal Effort Gauge SST SST

Rear brake pressure 0 kPa (0 kgf/cm2, 0 psi)

457 psi) or

At 343 N (35 kgf, 77 lbf)

Front brake pressure 4,540 kPa (46.3 kgf/cm more
2,

Rear brake pressure 0 kPa (0 kgf/cm2, 0 psi)

659 psi) or

C133084E01

(e) When the booster operates: (1) Turn the ignition switch to ON, and wait until the pump motor has stopped (step A). HINT: Pump operating sound can be heard. (2) Turn the ignition switch to OFF, and depress the brake pedal more than 20 times (step B). HINT: When the pressure in the accumulator is released, the reaction force becomes lighter and the stroke becomes longer. (3) Repeat steps A and B 5 times (step C). (4) Turn the ignition switch to ON, and check that the pump stops after approximately 8 to 14 seconds. NOTICE: If the pump does not stop, repeat step C again. (5) Depress the brake pedal and check the fluid pressure. At 49 N (5 kgf, 11 lbf)
Front brake pressure 1,120 to 2,320 kPa (11.4 to 23.7 kgf/cm2, 162 to 337 psi) Rear brake pressure 1,220 to 2,420 kPa (12.4 to 24.7kgf/cm2, 177 to 351 psi)

BR20

BRAKE HYDRAULIC BRAKE BOOSTER

At 98 N (10 kgf, 22 lbf)

Front brake pressure 3,840 to 5,040 kPa (39.2 to 51.4 kgf/cm2, 557 to 731 psi) Rear brake pressure 3,990 to 5,190 kPa (40.7 to 52.9 kgf/cm2, 579 to 753 psi)

At 147 N (15 kgf, 33 lbf)

Front brake pressure Rear brake pressure 6,660 to 7,860 kPa (67.9 to 80.1 kgf/cm2, 966 to 1,140 psi)

BR

6,460 to 7,660 kPa (65.9 to 78.1 kgf/cm , 937 to 1,111 psi)

2

At 196 N (20 kgf, 44 lbf)

Front brake pressure 8,720 to 9,920 kPa (88.9 to 101.2 kgf/cm2, 1,265 to 1,439 psi) Rear brake pressure 11,330 to 12,530 kPa (115.5 to 127.8 kgf/cm2, 1,644 to 1,818 psi)

2.

INSPECT BRAKE MASTER CYLINDER OPERATION (a) Inspect the positive battery voltage. Standard voltage: 11 to 14 V (b) Turn the ignition switch to OFF, and depress the brake pedal more than 20 times. HINT: When pressure in the accumulator is released, the reaction force becomes lighter and the stroke becomes longer. (c) Check that the brake pedal becomes easy to depress. If the pedal does not become easy to depress, check and replace the brake line and hydraulic brake booster. (d) Turn the ignition switch to ON and check the pump motor operation noise. If the pump motor does not operate, check and replace the wire harness and pump motor (see page BR-34). (e) Connect the intelligent tester. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to ON. (3) Select "ACTIVE TEST" mode on the intelligent tester. HINT: Refer to the intelligent tester operator manual for further details. To protect the solenoids, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

BRAKE HYDRAULIC BRAKE BOOSTER

BR21

(f)

Check the master cylinder solenoid operation.

BR
Reservoir Tank Accumulator Pump and Motor

Brake Pedal Master Cylinder Solenoid

STR

SREC

SREA

SMCF

P
SRLH SRRH SFLH SFRH

SRLR

SRRR

SFLR

SFRR

Rear Left Rear Right

Front Left Front Right

C133110E01

Inspection Order (Step) D E

SOL Selected By Active Test SRCF (SA1) SFRH

SOL To Be Activated SMCF SFRH

BR22
Inspection Order (Step) F G H I J

BRAKE HYDRAULIC BRAKE BOOSTER

SOL Selected By Active Test SFLH SFRR SFLR SRMF (SMCF, SA3) SRMR (SMCR, STR) SRRH SRLH SRRR SRLR SOL To Be Activated SFLH SFRR SFLR SREC STR SRRH SRLH SRRR SRLR

BR

K L M N

(g) Prepare the vehicle. (1) Jack up and support the vehicle. (2) Release the parking brake lever. (3) Shift the shift lever to the "N" position and check the rear wheels by rotating them by hand. (h) Inspect front VSC solenoid (SMCF) operation (step D). HINT: ON: Activate SMCF and check that the brake pedal cannot be depressed (the pedal feels tight). OFF: Deactivate SMCF and check that the brake pedal can be depressed. (1) Select "SRCF (SA1)" on the intelligent tester. (2) Turn the "SRCF (SA1)" on by the intelligent tester, then depress the brake pedal with stable force and check that the pedal cannot be depressed. If the pedal can be depressed, replace the hydraulic brake booster. HINT: To protect the solenoids, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. NOTICE: When operating it continuously, set the interval of more than 20 seconds. (3) Release the brake pedal. (4) When the solenoid is off, depress the brake pedal again and check that the brake pedal can be depressed. If the pedal cannot be depressed, replace the hydraulic brake booster. (i) Inspect front ABS solenoid (SFRH) operation (step E). HINT: ON: Activate SFRH, depress the brake pedal, and then check that the right front wheel rotates. OFF: Deactivate SFRH, depress the brake pedal, and then check that the right front wheel does not rotate.

BRAKE HYDRAULIC BRAKE BOOSTER

BR23

(j)

(1) Select "SFRH" on the intelligent tester. (2) Turn the "SFRH" on by the intelligent tester, then depress the brake pedal with stable force. (3) When the solenoid is on, check the right front wheel by rotating it by hand. If the right front wheel stops, replace the hydraulic brake booster. HINT: To protect the solenoid, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible. NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the solenoid is off, depress the brake pedal again and check that the right front wheel does not rotate by hand. If the right front wheel rotates, replace the hydraulic brake booster. Inspect front ABS solenoid (SFLH) operation (step F). HINT: ON: Activate SFLH, depress the brake pedal, and then check that the left front wheel rotates. OFF: Deactivate SFLH, depress the brake pedal, and then check that the front left wheel does not rotate. (1) Select "SFLH" on the intelligent tester. (2) Turn the "SFLH" on by the intelligent tester, then depress the brake pedal with stable force. (3) When the solenoid is on, check the left front wheel by rotating it by hand. If the left front wheel stops, replace the hydraulic brake booster. HINT: To protect the solenoid, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible. NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the solenoid is off, depress the brake pedal again and check that the left front wheel does not rotate by hand. If the left front wheel rotates, replace the hydraulic brake booster.

BR

BR24

BRAKE HYDRAULIC BRAKE BOOSTER

BR

(k) Inspect front ABS solenoid (SFRR) operation (step G). HINT: ON: Depress the brake pedal, activate SFRR, and then check that the right front wheel rotates. OFF: Deactivate SFRR, depress the brake pedal, and then check that the right front wheel does not rotate. (1) Select "SFRR" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SFRR" on by the intelligent tester. (3) When the solenoid is on, check the right front wheel by rotating it by hand. If the right front wheel stops, replace the hydraulic brake booster. HINT: To protect the solenoids, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible. NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the solenoid is off, depress the brake pedal again and check that the right front wheel does not rotate by hand. If the right front wheel rotates, replace the hydraulic brake booster. (l) Inspect front ABS solenoid (SFLR) operation (step H). HINT: ON: Depress the brake pedal, activate SFLR, and then check that the left front wheel rotates. OFF: Deactivate SFLR, depress the brake pedal, and then check that the left front wheel does not rotate. (1) Select "SFLR" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SFLR" on by the intelligent tester. (3) When the solenoid is on, check the left front wheel by rotating it by hand. If the left front wheel stops, replace the hydraulic brake booster. HINT: To protect the solenoids, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.

BRAKE HYDRAULIC BRAKE BOOSTER

BR25

NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the solenoid is off, depress the brake pedal again and check that the left front wheel does not rotate by hand. If the left front wheel rotates, replace the hydraulic brake booster. (m) Inspect rear VSC solenoid (SREC) operation (step I). HINT: ON: Depress the brake pedal, activate SREC. Release the brake pedal and check that the rear wheels do not rotate. OFF: Deactivate SREC and check that the rear wheels rotate. (1) Select "SRMF (SMCF, SA3)" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SRMF (SMCF, SA3)" on by the intelligent tester. (3) Release the brake pedal when the solenoid is on, and check that the rear wheels do not rotate by hand. If the rear wheels rotate, replace the hydraulic brake booster. HINT: To protect the solenoids, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheels fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheels as slowly as possible. NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the solenoid is off, check the rear wheels by rotating them by hand. If the rear wheels stop, replace the hydraulic brake booster. (n) Inspect rear VSC solenoid (STR) operation (step J). HINT: ON: Activate STR, depress the brake pedal, and then check that the rear wheels rotate. OFF: Deactivate STR, depress the brake pedal, and then check that the rear wheels do not rotate. (1) Select "SRMR (SMCR, STR)" on the intelligent tester. (2) Turn the "SRMR (SMCR, STR) on by the intelligent tester.

BR

BR26

BRAKE HYDRAULIC BRAKE BOOSTER

BR

(3) When the solenoid is on, check that the rear wheels rotate by hand. If the rear wheels do not rotate, replace the hydraulic brake booster. HINT: To protect the solenoids, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheels fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheels as slowly as possible. NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the "SRMR (SMCR, STR)" is off, depress the brake pedal again and check that the rear wheels do not rotate by hand. If the rear wheels rotate, replace the hydraulic brake booster. (o) Inspect rear ABS solenoid (SRRH) operation (step K). HINT: ON: Activate SRRH, depress the brake pedal, and then check that the right rear wheel rotates. OFF: Deactivate SRRH, depress the brake pedal, and then check that the right rear wheel does not rotate. (1) Select "SRRH" on the intelligent tester. (2) Turn the "SRRH" on by the intelligent tester, then depress the brake pedal with stable force. (3) When the solenoid is on, check the right rear wheel by rotating it by hand. If the right rear wheel stops, replace the hydraulic brake booster. HINT: To protect the solenoids, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible. NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the solenoid is off, depress the brake pedal again and check that the right rear wheel does not rotate by hand. If the right rear wheel rotates, replace the hydraulic brake booster.

BRAKE HYDRAULIC BRAKE BOOSTER

BR27

(p) Inspect rear ABS solenoid (SRLH) operation (step L). HINT: ON: Activate SRLH, depress the brake pedal, and then check that the left rear wheel rotates. OFF: Deactivate SRLH, depress the brake pedal, and then check that the left rear wheel does not rotate. (1) Select "SRLH" on the intelligent tester. (2) Turn the "SRLH" on by the intelligent tester, then depress the brake pedal with stable force. (3) When the solenoid is on, check the left rear wheel by rotating it by hand. If the left rear wheel stops, replace the hydraulic brake booster. HINT: To protect the solenoid, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible. NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the solenoid is off, depress the brake pedal again and check that the left rear wheel does not rotate by hand. If the left rear wheel rotates, replace the hydraulic brake booster. (q) Inspect rear ABS solenoid (SRRR) operation (step M). HINT: ON: Depress the brake pedal, activate SRRR, and then check that the right rear wheel rotates. OFF: Deactivate SRRR, depress the brake pedal, and then check that the right rear wheel does not rotate. (1) Select "SRRR" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SRRR" on by the intelligent tester. (3) When the solenoid is on, check the right rear wheel by rotating it by hand. If the right rear wheel stops, replace the hydraulic brake booster. HINT: To protect the solenoids, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.

BR

BR28

BRAKE HYDRAULIC BRAKE BOOSTER

BR

NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the solenoid is off, depress the brake pedal again and check that the right rear wheel does not rotate by hand. If the right rear wheel rotates, replace the hydraulic brake booster. (r) Inspect rear ABS solenoid (SRLR) operation (step N). HINT: ON: Depress the brake pedal, activate SRLR, and then check that the left rear wheel rotates. OFF: Deactivate SRLR, depress the brake pedal, and then check that the left rear wheel does not rotate. (1) Select "SRLR" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SRLR" on by the intelligent tester. (3) When the solenoid is on, check the left rear wheel by rotating it by hand. If the left rear wheel stops, replace the hydraulic brake booster. HINT: To protect the solenoids, intelligent tester turns off automatically 2 seconds after every solenoid has been turned on. When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible. NOTICE: When operating it continuously, set the interval of more than 20 seconds. (4) When the solenoid is off, depress the brake pedal again and check that the left rear wheel does not rotate by hand. If the left rear wheel rotates, replace the hydraulic brake booster. (s) Lower the vehicle. (t) Disconnect the intelligent tester.

BRAKE HYDRAULIC BRAKE BOOSTER

BR29

REMOVAL
NOTICE: Before starting the work, make sure that the ignition switch is OFF and depress the brake pedal more than 20 times. As high pressure is applied to the brake actuator No. 1 tube, never deform it. Do not turn the ignition switch to ON until the work is completed. HINT: When the pressure in the accumulator is released, the reaction force becomes lighter and the stroke becomes longer. 1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL DRAIN BRAKE FLUID NOTICE: Immediately wash off any brake fluid that comes into contact with a painted surface. REMOVE FRONT DOOR SCUFF PLATE (See page IR15) REMOVE FRONT FLOOR FOOTREST (See page IR-2) REMOVE FOOTREST CLIP (See page IR-2) REMOVE COWL SIDE TRIM BOARD (See page IR-15) SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP (See page IP-10) REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-13) SEPARATE HOOD LOCK CONTROL LEVER SUBASSEMBLY (See page IP-13)

BR

3. 4. 5. 6. 7. 8. 9.

10. REMOVE INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY (See page IP-14) 11. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS (See page BR-12)

BR30

BRAKE HYDRAULIC BRAKE BOOSTER

12. REMOVE HYDRAULIC BRAKE BOOSTER (a) Disconnect the 3 connectors from the hydraulic brake booster.

BR

F051438E01

(b) Using SST, disconnect the 4 brake tubes from the hydraulic brake booster. SST 09023-00101

C133113

To Right Rear Wheel To Right Front Wheel To Left Front Wheel To Left Rear Wheel
C133114E01

(c) Use tags or labels to identify the place to reconnect each line.

(d) Remove the 4 nuts and pull out the hydraulic brake booster. (e) Remove the gasket from the hydraulic brake booster.

F050571

BRAKE HYDRAULIC BRAKE BOOSTER

BR31

DISASSEMBLY
1. REMOVE BRAKE ACTUATOR NO. 1 BRACKET (a) Using a 5 mm hexagon wrench, remove the bolt and brake actuator bracket.

BR
F051421

(b) Using a screwdriver, remove the fluid level warning switch connector.

F051180

2.

REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (a) Using a pin punch and hammer, remove the pin from the master cylinder reservoir.

F051177

(b) Remove the screw and pull out the master cylinder reservoir.

F051178E01

(c) Remove the 3 grommets from the master cylinder reservoir.

F051181E01

BR32

BRAKE HYDRAULIC BRAKE BOOSTER

3.

REMOVE BRAKE ACTUATOR HOSE (a) Using needle-nose pliers, slide the 2 clips and remove the brake actuator hose.

BR
F051182E01

4.

REMOVE BRAKE ACTUATOR NO. 1 TUBE (a) Using SST, remove the brake actuator tube. SST 09023-00101

F051518

5.

REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY (a) Using a screwdriver, remove the 2 plugs.

F051519E02

(b) Remove the 2 screws and pull the wire harness.

Red Cable Black Cable

F051520E02

(c) Using a screwdriver, remove the clip.

F051521

BRAKE HYDRAULIC BRAKE BOOSTER

BR33

(d) Remove the brake booster with accumulator pump assembly. (e) Remove the 2 bushes and 2 collars from the brake booster with accumulator pump assembly.

BR
F051188

(f)

Using a 4 mm hexagon wrench, remove the 2 pins.

F051415E01

6.

REMOVE BRAKE ACTUATOR BRACKET (a) Using a 5 mm hexagon wrench, remove the bolt and brake actuator bracket.

F051423

7.

REMOVE BRAKE BOOSTER PUMP BRACKET (a) Using a 5 mm hexagon wrench, remove the 2 bolts and the brake booster pump bracket. (b) Remove the bush from the brake booster pump bracket.

F051189E01

8.

REMOVE MASTER CYLINDER SOLENOID (a) Remove the 6 bolts and the master cylinder solenoid.

F051195E01

BR34

BRAKE HYDRAULIC BRAKE BOOSTER

(b) Remove the gasket.

BR
F051196

9.

REMOVE MASTER CYLINDER PUSH ROD CLEVIS (a) Loosen the lock nut on the rod operating adapter, and then remove the push rod clevis and lock nut.

F051191E01

(b) Loosen the lock nut on the brake master cylinder side, and then remove the rod operating adapter and lock nut. 10. REMOVE MASTER CYLINDER BOOT

F051192E01

C-ring

Pin
F051417E01

11. REMOVE PISTON (a) When pressing in the piston with a screwdriver, use a pin or the equivalent to push the C-ring from the hole in the master cylinder body. Then remove the C-ring with another screwdriver. (b) Remove the piston by pulling it straight out, not at an angle. NOTICE: If the piston is pulled out at an angle, there is a possibility that the cylinder bore could be damaged. 12. REMOVE BRAKE BOOSTER ACCUMULATOR ASSEMBLY (a) Place the brake booster with accumulator pump assembly in a vise lined with a cloth. (b) Remove the brake booster accumulator. (c) Remove the brake booster accumulator pipe, compression spring and O-ring.

F051527

BRAKE HYDRAULIC BRAKE BOOSTER

BR35

INSPECTION
1. INSPECT BRAKE BOOSTER PUMP ASSEMBLY (a) Connect the positive (+) lead from the battery to the red cable of the pump, and the negative (-) lead to the black cable. (b) Check the brake booster pump operation. OK: Operation sound is heard.

Black Cable Red Cable

F051528E02

BR

REASSEMBLY
1. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY (a) Place the brake booster pump in a vise lined with a cloth. (b) Install the brake booster accumulator pipe, compression spring and a new O-ring. NOTICE: Ensure that no foreign matter enters the pump. (c) Install the brake booster accumulator onto the brake booster pump. Torque: 57 N*m (585 kgf*cm, 42 ft.*lbf) INSTALL PISTON (a) Apply lithium soap base glycol grease to a new piston. (b) Install the piston into the master cylinder body. (c) Using 2 screwdrivers, install a new C-ring while pressing the piston. NOTICE: Do not damage the rubber lips on the piston when reassembling. 3. INSTALL MASTER CYLINDER BOOT

F051527

2.

F051194

4.

INSTALL MASTER CYLINDER PUSH ROD CLEVIS (a) Install the master cylinder side lock nut and rod operating adapter. Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)

F051192E01

BR36

BRAKE HYDRAULIC BRAKE BOOSTER

(b) Install the lock nut and push rod clevis. Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)

BR
F051191E01

5.

INSTALL MASTER CYLINDER SOLENOID (a) Place a new gasket onto the master cylinder solenoid.

F051196

(b) Install the master cylinder solenoid with 6 new bolts. Torque: 32 N*m (325 kgf*cm, 24 ft.*lbf) NOTICE: Do not let water, dust, or other foreign matter adhere to the surface or fitting surfaces of the master cylinder solenoid, master cylinder body and gasket.

F051195E01

6.

INSTALL BRAKE BOOSTER PUMP BRACKET (a) Using a 5 mm hexagon wrench, install the brake booster pump bracket with the 2 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) (b) Install the bush onto the brake booster pump bracket.

F051189E01

7.

INSTALL BRAKE ACTUATOR BRACKET (a) Using a 5 mm hexagon wrench, install the brake actuator bracket with the bolt. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)

F051423

BRAKE HYDRAULIC BRAKE BOOSTER

BR37

8.

INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY (a) Using a 4 mm hexagon wrench, install the 2 pins. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) (b) Install the 2 collars and 2 bushes onto the brake booster with accumulator pump assembly.

BR
F051415E01

(c) Install the brake booster with accumulator pump assembly.

F051188

(d) Install a new clip.

F051199

(e) Install the wire harnesses with the 2 screws. Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf)

Red Cable Black Cable

F051520E02

(f)

Install 2 new plugs.

F051519E02

BR38

BRAKE HYDRAULIC BRAKE BOOSTER

9.

SST

BR

Fulcrum Length

F051184E02

INSTALL BRAKE ACTUATOR NO. 1 TUBE (a) Using SST, install the brake actuator tube. SST 09023-00101 Torque: for use without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) for use with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective when SST is parallel to the torque wrench.

10. INSTALL BRAKE ACTUATOR HOSE (a) Using needle-nose pliers, install the brake actuator hose with the 2 clips. 11. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (a) Apply lithium soap base glycol grease to 3 new grommets.
F051182E01

(b) Install the 3 grommets onto the master cylinder body. NOTICE: The grommets are different sizes. Install the grommets in their correct positions.

F051416

(c) Install the master cylinder reservoir with the screw. Torque: 1.7 N*m (17 kgf*cm, 15 in.*lbf)

F051178E01

BRAKE HYDRAULIC BRAKE BOOSTER

BR39

(d) Using a pin punch and hammer, install a new pin onto the master cylinder reservoir. 12. INSTALL BRAKE ACTUATOR NO. 1 BRACKET (a) Install the fluid level warning switch connector.

BR
F051177

(b) Using a 5 mm hexagon wrench, install the brake actuator bracket with the bolt. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)

F051421

BR40

BRAKE HYDRAULIC BRAKE BOOSTER

INSTALLATION
1. INSTALL HYDRAULIC BRAKE BOOSTER (a) Install a new gasket onto the hydraulic brake booster. (b) Install the hydraulic brake booster with the 4 nuts. Torque: 14 N*m (145 kgf*cm, 10 ft.*lbf)

BR

F050571

To Right Rear Wheel To Right Front Wheel To Left Front Wheel To Left Rear Wheel
C133114E01

(c) Using SST, connect the 4 brake tubes to the correct positions on the hydraulic brake booster, as shown in the illustration. SST 09023-00101 Torque: for use without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) for use with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective when SST is parallel to the torque wrench. (d) Connect the 3 connectors. 2. 3. INSTALL MASTER CYLINDER PUSH ROD CLEVIS (See page BR-14) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) FILL RESERVOIR WITH BRAKE FLUID (See page BR5) BLEED BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY (See page BR-5) BLEED BRAKE LINE (See page BR-5) BLEED MASTER CYLINDER SOLENOID (See page BR-6) CHECK FLUID LEVEL IN RESERVOIR (See page BR7) CHECK FOR BRAKE FLUID LEAKAGE

4. 5. 6. 7. 8. 9.
F051439E01

10. INSPECT AND ADJUST BRAKE PEDAL (See page BR-10) 11. INSTALL INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY (See page IP-29)

BRAKE HYDRAULIC BRAKE BOOSTER

BR41

12. CONNECT HOOD LOCK CONTROL LEVER SUBASSEMBLY (See page IP-30) 13. INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See page IP-30) 14. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP (See page IP-33) 15. INSTALL COWL SIDE TRIM BOARD (See page IR-45) 16. INSTALL FOOTREST CLIP (See page IR-2) 17. INSTALL FRONT FLOOR FOOTREST (See page IR-2) 18. INSTALL FRONT DOOR SCUFF PLATE (See page IR45) 19. INSPECT BRAKE MASTER CYLINDER OPERATION (See page BR-20)

BR

DISPOSAL
1. DISPOSE OF BRAKE BOOSTER ACCUMULATOR ASSEMBLY (a) Place the brake booster accumulator in a vise and cover it with a cloth. (b) Slowly cut a hole in area A on the brake booster accumulator as shown in the illustration. And discharge the gas and liquid inside. NOTICE: As gas may spray out, cover the brake booster accumulator with a cloth when performing the operation. Work slowly and do not cut the hole too quickly or suddenly. Wear protective glasses during the operation. (c) When the outer body of the brake booster accumulator is cut, gas and liquid discharge. HINT: The gas is colorless, odorless and nonpoisonous nitrogen gas. The liquid is brake fluid.

A
F051529E01

BRAKE FRONT BRAKE

BR41

FRONT BRAKE
BRAKE

COMPONENTS
FRONT DISC BRAKE ANTI RATTLE SPRING

PIN HOLD CLIP

FRONT NO. 2 ANTI SQUEAL SHIM

BR

FRONT NO. 1 ANTI SQUEAL SHIM

FRONT DISC BRAKE ANTI RATTLE WITH HOLE PIN

FRONT DISC BRAKE PAD

FRONT DISC BRAKE BLEEDER PLUG CAP

15 (155, 11) * 14 (143, 10) 11 (110, 8)

FRONT DISC BRAKE BLEEDER PLUG

123 (1,254, 91)

FRONT DISC DISC BRAKE CYLINDER ASSEMBLY

PISTON SEAL FRONT DISC BRAKE PISTON CYLINDER BOOT SET RING N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part * For use with SST Lithium soap base glycol grease Disc brake grease
C133115E01

BR42

BRAKE FRONT BRAKE

REMOVAL
1. 2. REMOVE FRONT WHEEL DRAIN BRAKE FLUID NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces. REMOVE FRONT DISC BRAKE ANTI RATTLE WITH HOLE PIN (a) Remove the 2 pin hold clips, then remove the 2 hole pins from the disc brake cylinder. (b) Remove the anti rattle spring from the disc brake pad. REMOVE FRONT DISC BRAKE PAD (a) Remove the 2 disc brake pads with anti squeal shims from the disc brake cylinder. REMOVE FRONT ANTI SQUEAL SHIM KIT (a) Remove the No. 1 and No. 2 anti squeal shims from each of the disc brake pads. REMOVE DISC BRAKE CYLINDER ASSEMBLY (a) Using SST, separate the brake tube from the disc brake cylinder. SST 09023-00101 HINT: Use a container to collect the brake fluid as it drains out.

BR

3.

4.
F043185

5.

6.

SST

F050777E01

(b) Remove the 2 bolts and disc brake cylinder. 7. REMOVE FRONT DISC (a) Place matchmarks on the disc and the axle hub and remove the disc.

F050211

DISASSEMBLY
1. REMOVE CYLINDER BOOT (a) Using a screwdriver, remove the 4 set rings and 4 cylinder boots from the disc brake cylinder.

F043024

BRAKE FRONT BRAKE

BR43

2.
170 mm (6.69 in.) 50 mm (1.97 in.)

REMOVE FRONT DISC BRAKE PISTON (a) Prepare a wooden plate to hold the pistons.

30 mm (1.18 in.)
F042676E02

BR
(b) Place the plate between the pistons and insert a pad into one side. (c) Apply compressed air to remove the pistons one side at a time from the disc brake cylinder. CAUTION: Do not place your fingers in front of the piston when applying compressed air. NOTICE: Do not spatter the brake fluid.
F042677

3.

REMOVE PISTON SEAL (a) Using a screwdriver, remove the 4 piston seals from the cylinder. NOTICE: Do not damage the inner surface or piston seal groove of the cylinder. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP REMOVE FRONT DISC BRAKE BLEEDER PLUG

4. 5.
F042678

BR44

BRAKE FRONT BRAKE

INSPECTION
1. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust and scoring. If necessary, replace the disc brake cylinder and piston. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 in.) Minimum thickness: 1.0 mm (0.039 in.) If the pad lining thickness is equal to or less than the minimum thickness, replace the disc brake pad kit.

BR

Ruler

2.

F042679E01

3.

Micrometer

INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) If the disc thickness is less than the minimum, replace the front disc. INSPECT DISC RUNOUT (a) Check the bearing play in the axial direction and check for the axle hub runout (See page AH-1). (b) Provisionally fasten the front disc together with the hub nuts. Torque: 112 N*m (1,137 kgf*cm, 82 ft.*lbf) (c) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the front disc. Maximum disc runout: 0.05 mm (0.0020 in.) If the runout exceeds the maximum value, change the installation positions of the disc and axle to make the minimum runout. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the front disc.

4.
F042680E01

Dial Indicator
F043106E01

BRAKE FRONT BRAKE

BR45

REASSEMBLY
1. 2. 3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP INSTALL PISTON SEAL (a) Apply lithium soap base glycol grease to 4 new piston seals. (b) Install the 4 piston seals onto the disc brake cylinder. NOTICE: Securely install the piston seal into the groove of the disc brake cylinder. INSTALL FRONT DISC BRAKE PISTON (a) Apply lithium soap base glycol grease to the 4 disc brake pistons and 4 new cylinder boots. (b) Install the 4 cylinder boots to the 4 disc brake pistons. (c) Install the 4 disc brake pistons onto the disc brake cylinder. NOTICE: Do not forcibly install the piston into the disc brake cylinder. INSTALL CYLINDER BOOT (a) Install the 4 cylinder boots onto the disc brake cylinder. NOTICE: Securely install the cylinder boot into the grooves of the disc brake cylinder and piston. (b) Using a screwdriver, install 4 new set rings. NOTICE: Do not damage the boot.

BR

4.

Lithium Soap Base Glycol Grease

C111385E01

5.

C111386

BR46

BRAKE FRONT BRAKE

INSTALLATION
1. INSTALL FRONT DISC (a) Align the matchmarks of the disc and axle hub and install the disc. HINT: When replacing the disc, select the position that gives the minimum disc runout. INSTALL DISC BRAKE CYLINDER ASSEMBLY (a) Install the disc brake cylinder with the 2 bolts. Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf)

BR

2.

F050211

SST

F050777E01

(b) Using SST, install the brake tube onto the disc brake cylinder. SST 09023-00101 Torque: for use without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) for use with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective when SST is parallel to the torque wrench. 3. INSTALL FRONT ANTI SQUEAL SHIM KIT NOTICE: If necessary, replace the anti squeal shim when replacing the brake pad. (a) Apply disc brake grease to both sides of each No. 1 shim. (b) Install the No. 1 and No. 2 anti squeal shims onto each brake pad. 4. INSTALL FRONT DISC BRAKE PAD (a) Install the 2 disc brake pads with anti squeal shims onto the disc brake cylinder. NOTICE: There should be no oil or grease on the friction surfaces of the disc brake pads or the front disc.

No. 2 Shim

No. 1 Shim

Disc brake grease

C133116E01

BRAKE FRONT BRAKE

BR47

5.
Pin Hold Clip

F043185E03

INSTALL FRONT DISC BRAKE ANTI RATTLE WITH HOLE PIN (a) Install the anti rattle spring and 2 hole pins onto the disc brake cylinder. HINT: The anti rattle spring is installed onto the lower hole pin. (b) Install the 2 new pin hold clips onto the hole pin. NOTICE: Install the pin hold clip with its handle oriented in the center of the vehicle. FILL RESERVOIR WITH BRAKE FLUID (See page BR5) BLEED BRAKE LINE (See page BR-5) CHECK FLUID LEVEL IN RESERVOIR (See page BR7) CHECK FOR BRAKE FLUID LEAKAGE

BR

6. 7. 8. 9.

10. INSTALL FRONT WHEEL Torque: 112 N*m (1,137 kgf*cm, 82 ft.*lbf)

BRAKE FRONT BRAKE FLEXIBLE HOSE

BR47

FRONT BRAKE FLEXIBLE HOSE

BRAKE

COMPONENTS

BR
CLIP
15 (155, 11)

* 14 (143, 10)

FRONT FLEXIBLE HOSE

CLIP

15 (155, 11)

* 14 (143, 10)

N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part * For use with SST
C133086E01

BR48

BRAKE FRONT BRAKE FLEXIBLE HOSE

REMOVAL
1. 2. REMOVE FRONT WHEEL DRAIN BRAKE FLUID NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces. REMOVE FRONT FLEXIBLE HOSE (a) Using SST, separate the brake tubes. SST 09023-00101 HINT: Use a container to collect the brake fluid as it drains out. (b) Remove the 2 clips and flexible hose.

BR
SST

3.

C133087E01

INSTALLATION
SST

1.

C133087E01

INSTALL FRONT FLEXIBLE HOSE (a) Install the flexible hose with 2 new clips. (b) Using SST, install the 2 brake tubes onto the flexible hose. SST 09023-00101 Torque: for use without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) for use with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective when SST is parallel to the torque wrench. FILL RESERVOIR WITH BRAKE FLUID (See page BR5) BLEED BRAKE LINE (See page BR-5) CHECK FLUID LEVEL IN RESERVOIR (See page BR7) CHECK FOR BRAKE FLUID LEAKAGE INSTALL FRONT WHEEL Torque: 112 N*m (1,137 kgf*cm, 82 ft.*lbf)

2. 3. 4. 5. 6.

BRAKE REAR BRAKE

BR49

REAR BRAKE
BRAKE

COMPONENTS
11 (110, 8)

REAR DISC BRAKE BLEEDER PLUG

88 (897, 65)

BR
REAR DISC BRAKE BLEEDER PLUG CAP

REAR DISC BRAKE CYLINDER SLIDE PIN

REAR FLEXIBLE HOSE

31 (316, 23)

REAR DISC BRAKE CYLINDER ASSEMBLY REAR DISC BRAKE PISTON

REAR FLEXIBLE HOSE UNION BOLT

PISTON SEAL GASKET REAR DISC BRAKE PAD SUPPORT PLATE CYLINDER BOOT

REAR DISC BRAKE PAD REAR DISC BRAKE ANTI SQUEAL SHIM REAR DISC BRAKE ANTI SQUEAL SHIM

105 (1,071, 78)

WASHER

REAR DISC BRAKE PAD WEAR INDICATOR PLATE

REAR DISC BRAKE REAR DISC BUSH DUST BOOT BRAKE PAD SUPPORT PLATE

REAR DISC BRAKE CYLINDER HOLE PLUG

REAR DISC BRAKE CYLINDER SLIDE BUSH

105 (1,071, 78)

REAR DISC BRAKE CYLINDER MOUNTING WASHER

REAR DISC

N*m (kgf*cm, ft*lbf) : Specified torque

Non-reusable part

Lithium soap base glycol grease

C133091E01

BR50

BRAKE REAR BRAKE

REMOVAL
1. 2. REMOVE REAR WHEEL DRAIN BRAKE FLUID NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces. SEPARATE REAR FLEXIBLE HOSE (a) Remove the union bolt and gasket and separate the flexible hose from the disc brake cylinder. HINT: Use a container to collect the brake fluid as it drains out.

BR

3.

F043125

4.

REMOVE REAR DISC BRAKE CYLINDER ASSEMBLY (a) Remove the 2 slide pins and remove the disc brake cylinder from the disc brake cylinder mounting. REMOVE REAR DISC BRAKE PAD (a) Remove the 2 disc brake pads with anti squeal shim from the disc brake cylinder mounting. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM (a) Remove the 2 anti squeal shims from each brake pad. REMOVE REAR DISC BRAKE PAD WEAR INDICATOR PLATE (a) Remove the indicator plate from the inner side of the brake pad. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE (a) Remove the 4 pad support plates from the disc brake cylinder mounting. REMOVE REAR DISC BRAKE CYLINDER MOUNTING (a) Remove the 2 bolts and disc brake cylinder mounting.

5.

6.
F043124

7.

8.

9.

10. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH (a) Remove the slide bush from the disc brake cylinder mounting.
F043126

11. REMOVE REAR DISC BRAKE BUSH DUST BOOT (a) Remove the dust boot from the disc brake cylinder mounting. 12. REMOVE REAR DISC BRAKE CYLINDER HOLE PLUG (a) Remove the hole plug from the disc brake cylinder mounting.

BRAKE REAR BRAKE

BR51

13. REMOVE REAR DISC (a) Place matchmarks on the disc and axle hub and remove the disc.

DISASSEMBLY
1. REMOVE CYLINDER BOOT (a) Using a screwdriver, remove the cylinder boot from the disc brake cylinder.

BR
F043127

2.

F043128

REMOVE REAR DISC BRAKE PISTON (a) Place a shop rag or piece of cloth between the piston and disc brake cylinder. (b) Apply compressed air to remove the piston from the disc brake cylinder. CAUTION: Do not place your fingers in front of the piston when applying compressed air. NOTICE: Do not spatter the brake fluid. REMOVE PISTON SEAL (a) Using a screwdriver, remove the piston seal from the disc brake cylinder. NOTICE: Do not damage the inner surface or piston seal groove of the cylinder. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP REMOVE REAR DISC BRAKE BLEEDER PLUG

3.

4. 5.
F043129

BR52

BRAKE REAR BRAKE

INSPECTION
1. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust and scoring. If necessary, replace the disc brake cylinder and piston. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) If the pad lining thickness is equal to or less than the minimum thickness, replace the disc brake pad kit. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE (a) Make sure that the support plates have sufficient rebound, that there is no deformation, cracks or wear, and that all rust and dirt are removed. If necessary, replace the disc brake pad support plate. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 18.0 mm (0.709 in.) Minimum thickness: 16.0 mm (0.630 in.) If the disc thickness is less than the minimum, replace the rear disc. INSPECT DISC RUNOUT (a) Check the bearing play in the axial direction and check for the axle hub runout (See page AH-2). (b) Provisionally fasten the rear disc together with the hub nuts. Torque: 112 N*m (1,137 kgf*cm, 82 ft.*lbf) (c) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the rear disc. Maximum disc runout: 0.20 mm (0.0079 in.) If the runout exceeds the maximum value, change the installation positions of the disc and axle to make the minimum runout. If the runout exceeds the maximum even when the installation positions are changed, grind the disc. If the disc thickness is less than the minimum, replace the rear disc.

BR

2.
Ruler

3.
F043130E01

4.

Micrometer

5.
F043131E01

Dial Indicator

F043187E01

BRAKE REAR BRAKE

BR53

REASSEMBLY
1. 2. 3. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG INSTALL REAR DISC BRAKE BLEEDER PLUG CAP INSTALL PISTON SEAL (a) Apply lithium soap base glycol grease to a new piston seal. (b) Install the piston seal onto the disc brake cylinder. NOTICE: Securely install the piston seal into the groove of the disc brake cylinder. INSTALL REAR DISC BRAKE PISTON (a) Apply lithium soap base glycol grease to the piston. (b) Install the piston into the disc brake cylinder. NOTICE: Do not forcibly install the piston into the disc brake cylinder. INSTALL CYLINDER BOOT (a) Apply lithium soap base glycol grease to a new cylinder boot. (b) Install the cylinder boot onto the disc brake cylinder. NOTICE: Securely install the cylinder boot into the grooves of the disc brake cylinder and piston.

BR

4.

5.

BR54

BRAKE REAR BRAKE

INSTALLATION
1. INSTALL REAR DISC (a) Align the matchmarks of the disc and axle hub and install the disc. NOTICE: When replacing the disc, select the position that gives the minimum disc runout. INSTALL REAR DISC BRAKE CYLINDER HOLE PLUG (a) Install a new hole plug onto the disc brake cylinder mounting. INSTALL REAR DISC BRAKE BUSH DUST BOOT (a) Apply lithium soap base glycol grease to a new dust boot. (b) Install the dust boot onto the disc brake cylinder mounting. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH (a) Apply lithium soap base glycol grease to a new slide bush. (b) Install the slide bush onto the disc brake cylinder mounting. INSTALL REAR DISC BRAKE CYLINDER MOUNTING (a) Install the disc brake cylinder mounting with the 2 bolts and 2 washers. Torque: 105 N*m (1,071 kgf*cm, 78 ft.*lbf) INSTALL REAR DISC BRAKE PAD SUPPORT PLATE (a) Install the 4 pad support plates onto the disc brake cylinder mounting. INSTALL REAR DISC BRAKE PAD WEAR INDICATOR PLATE (a) Install the indicator plate onto the inner side brake pad. HINT: Install the indicator plate facing downward. INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM NOTICE: If necessary, replace the anti squeal shim when replacing the brake pad. (a) Install the 2 anti squeal shims onto the brake pads. INSTALL REAR DISC BRAKE PAD (a) Install the 2 disc brake pads with anti squeal shims onto the disc brake cylinder mounting. NOTICE: There should be no oil or grease on the friction surfaces of the disc brake pads or the rear disc.

BR

2.

3.

4.

5.

6.

7.
F043126

8.

9.

10. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY (a) Apply lithium soap base glycol grease to the 2 slide pins.

BRAKE REAR BRAKE

BR55

(b) Install the disc brake cylinder onto the disc brake cylinder mounting with the 2 slide pins. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf)

BR
F043124

11. INSTALL REAR FLEXIBLE HOSE (a) Install the flexible hose with the union bolt and a new gasket. Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 12. FILL RESERVOIR WITH BRAKE FLUID (See page BR5) 13. BLEED BRAKE LINE (See page BR-5)
F043125

14. CHECK FLUID LEVEL IN RESERVOIR (See page BR7) 15. CHECK FOR BRAKE FLUID LEAKAGE 16. INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 82 ft.*lbf)

BRAKE REAR BRAKE FLEXIBLE HOSE

BR55

REAR BRAKE FLEXIBLE HOSE

BRAKE

COMPONENTS

BR

15 (155, 11)

* 14 (143, 10)

CLIP

REAR BRAKE TUBE FLEXIBLE HOSE

CLIP
15 (155, 11)

* 14 (143, 10) CLIP

15 (155, 11)

* 14 (143, 10) REAR FLEXIBLE HOSE

31 (316, 23)

REAR FLEXIBLE HOSE UNION BOLT GASKET

N*m (kgf*cm, ft*lbf) : Specified torque Non-reusable part * For use with SST
C133088E01

BR56

BRAKE REAR BRAKE FLEXIBLE HOSE

REMOVAL
1. 2. REMOVE REAR WHEEL DRAIN BRAKE FLUID NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces. REMOVE REAR FLEXIBLE HOSE (a) Remove the union bolt and gasket and separate the flexible hose from the disc brake cylinder. HINT: Use a container to collect the brake fluid as it drains out. (b) Using SST, separate the brake tube. SST 09023-00101 HINT: Use a container to collect the brake fluid as it drains out. (c) Remove the clip and flexible hose. REMOVE REAR BRAKE TUBE FLEXIBLE HOSE (a) Using SST, separate the brake tubes. SST 09023-00101 HINT: Use a container to collect the brake fluid as it drains out. (b) Remove the 2 clips and flexible hose.

BR

SST

3.

C133089E01

4.
SST

C133090E01

SST

INSTALLATION
1. INSTALL REAR FLEXIBLE HOSE (a) Install the flexible hose with a new clip. (b) Using SST, install the brake tube onto the flexible hose. SST 09023-00101 Torque: for use without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) for use with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective when SST is parallel to the torque wrench. (c) Install the flexible hose onto the disc brake cylinder with the union bolt and a new gasket. Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf)

C133089E01

BRAKE REAR BRAKE FLEXIBLE HOSE

BR57

2.
SST

C133090E01

INSTALL REAR BRAKE TUBE FLEXIBLE HOSE (a) Install the flexible hose with 2 new clips. (b) Using SST, install the 2 brake tubes onto the flexible hose. SST 09023-00101 Torque: for use without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) for use with SST 14 N*m (143 kgf*cm, 10 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective when SST is parallel to the torque wrench. FILL RESERVOIR WITH BRAKE FLUID (See page BR5) BLEED BRAKE LINE (See page BR-5) CHECK FLUID LEVEL IN RESERVOIR (See page BR7) CHECK FOR BRAKE FLUID LEAKAGE INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 82 ft.*lbf)

BR

3. 4. 5. 6. 7.