REMOVAL AND INSTALLATION
Pre-removal and Post-installation operation
Knee Air Bag Module Removal and Installation (Refer to KNEE AIR BAG MODULE ).
Scheme 62
INSTALLATION SERVICE POINT
>>A<< SNAP PIN INSTALLATION
- Install the snap pin as shown in the figure.
Scheme 63
| Pre-removal operation Brake fluid draining Air Cleaner Cover Removal (Refer to AIR CLEANER ). | Post-installation operation Air Cleaner Cover Installation (Refer to AIR CLEANER ). Brake fluid refilling and air bleeding (Refer to BLEEDING ). |
MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER PRE-REMOVAL AND POST-INSTALLATION OPERATION
Scheme 64
INSTALLATION SERVICE POINTS
>>A<< SNAP PIN INSTALLATION
- Install the snap pin as shown in the figure.
Scheme 65
- Install the check valve to the brake booster as shown in the figure.
- Align the mark as shown in the figure to assemble the vacuum hose.
Scheme 66
| Pre-removal operation Brake fluid draining | Post-installation operation Brake fluid refilling and air bleeding (Refer to BLEEDING ). |
FRONT DISC BRAKE ASSEMBLY PRE-REMOVAL AND POST-INSTALLATION OPERATION
Scheme 67
>>A<< BRAKE HOSE INSTALLATION
- Pass the brake hose through the hole in the body-side bracket.
- Install the brake hose to the brake caliper.
- Install the brake hose at the two fixing points.
- Twist the brake hose toward the lesser torsion between the brake hose and body-side bracket as shown in the figure, and fix it to the body-side bracket with a clip.
Scheme 68
>>B<< BRAKE CALIPER ASSEMBLY INSTALLATION
Measure the brake drag force in the following procedure
Scheme 69
- Using a spring scale, measure the hub sliding torque in the forward direction. CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
- Clean the piston, and press the piston into the cylinder using the piston expander (Special tool: MB990520).
- Assemble the pad clip and pad to the caliper support, and tighten the guide pin to the specified torque. Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb)
- Start the engine, and depress the brake pedal forcibly two or three times. Then, stop the engine.
- Turn the brake disc 10 times in the forward direction.
- Using a spring scale, measure the hub sliding torque in the forward direction.
- Obtain the disc brake drag force (difference between measured values of item 1 and item 6). Standard value: 68 N (15.3 pounds) or less
- If the brake drag force exceeds the standard value, disassemble the piston to check for fouling/rust on the piston sliding section and piston/seal deterioration, and confirm whether the slide pin slides properly.
Scheme 70
Scheme 71
< > PISTON BOOT/PISTON REMOVAL
| CAUTION | Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly. |
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
<< B>> PISTON SEAL REMOVAL
| CAUTION | Do not use a flat-tipped screwdriver to remove the piston seal. This may damage the inner side of the cylinder. |
Scheme 72
Scheme 73
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid. Brake fluid: DOT3 or DOT4
Scheme 74
Scheme 75
| CAUTION | Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly. |
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
<< B>> PISTON SEAL REMOVAL
| CAUTION | Do not use a flat-tipped screwdriver to remove the piston seal. This may damage the inner side of the cylinder. |
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid. Brake fluid: DOT3 or DOT4
Pre-removal operation
Brake fluid draining
Post-installation operation
Brake fluid refilling and air bleeding (Refer to BLEEDING ).
Scheme 76
>>A<< REAR BRAKE CALIPER ASSEMBLY INSTALLATION
Measure the brake drag force in the following procedure
Scheme 77
- Using a spring scale, measure the hub sliding torque in the forward direction. CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
- Clean the piston, and press the piston into the cylinder using the piston expander (Special tool: MB990520).
- Install the caliper support to the backing plate assembly, and assemble the pad clip and pad to the caliper support.
- Lower the caliper assembly with care not to catch the piston boot, and tighten the lock pin to the specified torque. Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb)
- Start the engine, and depress the brake pedal forcibly two or three times. Then, stop the engine.
- Turn the brake disc 10 times in the forward direction.
- Using a spring scale, measure the hub sliding torque in the forward direction.
- Obtain the disc brake drag force (difference between measured values of item 1 and item 7). Standard value: 68 N (15.3 pounds) or less
- If the brake drag force exceeds the standard value, disassemble the piston to check for fouling/rust on the piston sliding section and piston/seal deterioration, and confirm whether the slide pin slides properly.
Scheme 78
Scheme 79
< > PISTON/PISTON BOOT REMOVAL
| CAUTION | Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly. |
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
<< B>> PISTON SEAL REMOVAL
| CAUTION | Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder. |
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid. Brake fluid: DOT3 or DOT4
Scheme 80
Scheme 81
| CAUTION | Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly. |
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
<< B>> PISTON SEAL REMOVAL
| CAUTION | Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder. |
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid. Brake fluid: DOT3 or DOT4
| CAUTION | Do not disassemble the rear wheel hub assembly. The magnetic encoder collects metallic particles easily, because it is magnetised. Make sure that the magnetic encoder should not collect metallic particles. Check that there is not any trouble prior to reassembling it. When the rear wheel hub assembly is removed/installed, make sure that the magnetic encoder (integrated with inner oil seal) does not contact with surrounding parts to avoid damage. When removing and installing the rear wheel speed sensor, make sure that its pole piece at the end does not contact with surrounding parts to avoid damage. The part indicated with * is the bolt with friction coefficient stabilizer. In removal, replace it with a new one. |
| Pre-removal Operation Brake Fluid Draining | Post-installation Operation Brake Fluid Filling and Air Bleeding (Refer to BLEEDING ). Parking Brake Lever Stroke Adjustment (Refer to PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT ). |
REAR DRUM BRAKE PRE-REMOVAL AND POST-INSTALLATION OPERATION
Scheme 82
< > RETAINER REMOVAL
Use a flat-tipped screwdriver or a similar tool to open up the retainer joint. Then remove the retainer.
Scheme 83
>>A<< RETAINER INSTALLATION
Use pliers or a similar tool to close the retainer end onto the pin.
Scheme 84
Scheme 85
>>A<< PISTON CUP/PISTON INSTALLATION
- Use alcohol or brake fluid DOT3 or DOT4 to clean the wheel cylinder and the piston. CAUTION: In order to keep the piston cup from becoming twisted or slanted, slide the piston cup down special tool installer (MB990619) slowly and carefully, without stopping.
- Apply brake fluid DOT3 or DOT4 to the piston cups and special tool installer (MB990619).
- Set the piston cup on special tool with the lip of the cup facing up. Fit the cup onto special tool, and then slide it down the outside of special tool into the piston groove.