IMPROVED BRAKING PERFORMANCE
- In addition to the 10-inch through bolt type single brake booster, the small and long stroke-type master cylinder is adopted to provide rigidity, to reduce weight, and to secure the assist force.
- Brembo™ 18-inch 4-pot front ventilated disk brakes and Brembo™ 17-inch 2-pot rear ventilated disk brakes are adopted to provide stable braking force and improved braking feel.
- To the front, two-piece structure brake disk is installed. < GSR: Option, MR: Standard >
IMPROVED STABILITY
- Front- and rear-wheel X-type brake line layout is used.
- The brake pedal retreat suppression mechanism that suppresses the retraction of brake pedal surface upon a frontal collision is adopted.
- To the front brake and rear brake, the brake pads with audible wear indicator are adopted which warn the driver of the wear limit.
- The 10-inch single brake booster with brake assist mechanism, which determines an emergency exists based on the brake pedal depression speed and force and provides the maximum braking force, has been adopted.
Scheme 53
Scheme 54
When the driver suddenly applies the brake, generally there is a tendency that a driver depresses the brake pedal quickly but not strong enough, or depresses the pedal once but reduces the depression force immediately after that. In this case, a sufficient braking force cannot be obtained, resulting in a longer stopping distance.
This brake booster with brake assist mechanism recognizes the status as emergency when the driver depresses the brake pedal quickly; it increases the assist force to the maximum value and maintains the output value of the brake booster to activate ABS.
Even if the driver reduces the depression force immediately after depressing the brake pedal quickly, this brake booster maintains the status where the maximum assist force is being applied until no depression force is applied to the brake pedal.
LUBRICANTS
| Item | Specified lubricant | Quantity | ||
|---|---|---|---|---|
| Brake fluid | DOT3 or DOT4 | As required | ||
| Front disc brake | Piston, caliper body, piston seal | DOT3 or DOT4 | ||
| Guide pin, lock pin, pin boot, bushing, boot ring, piston boot | Repair kit grease (Color: Translucent red), Niglube RX-2 or equivalent | |||
| Rear disc brake | Except RALLIART | Piston, caliper body, piston seal | DOT3 or DOT4 | |
| Guide pin, lock pin, pin boot, bushing | Niglube RM or equivalent | |||
| Piston boot | Repair kit grease (Color: Translucent red), Niglube RX-2 or equivalent | |||
| RALLIART | Piston, caliper body, piston seal | DOT3 or DOT4 | ||
| Guide pin, lock pin, pin boot, bushing | Niglube RM or equivalent | |||
| Piston boot | Repair kit grease (Color: Translucent red), Niglube RX-2 or equivalent | |||
| Shim, brake pad assembly | Repair kit grease | |||
| Rear drum brake | Boots | Repair kit grease (Color: Translucent red), Niglube RX-2 or equivalent | 2 g (0.070 oz) | |
LUBRICANTS
BLEEDING
| CAUTION | Be sure to use the specified brand and type of brake fluid. Avoid mixing with other type of brake fluid. |
Brake fluid: DOT3 or DOT4
BLEEDING OF BRAKE PIPELINE
Perform the bleeding in the order shown in the illustration.
Scheme 55
BRAKE PAD CHECK
| CAUTION | If there is a significant difference in thickness between the brake pads at right and left, check the sliding area and the run-out of the brake disc (Refer to BRAKE DISC CHECK ). |
Scheme 56
Scheme 57
Scheme 58
- Visually check the thickness of brake pad from the inspection hole of the caliper body. Standard value: 10.0 mm (0.39 inch) Limit: 2.0 mm (0.08 inch)
- If the brake pad thickness is less than the limit value, replace the brake pad (Refer to «BRAKE PAD REPLACEMENT < EXCEPT RALLIART >»(ref-592607-S32657817872014011000000) < Except RALLIART > or «BRAKE PAD REPLACEMENT < RALLIART >»(ref-592607-S35520282702014011000000) < RALLIART >).
FRONT
| CAUTION | When replacing, replace both brake pads (right and left) as a set. |
Scheme 59
Scheme 60
- Remove the parts indicated in the illustration, swivel the caliper body upward and retain it with a wire or similar tool.
- Remove the following parts from the caliper body. Shim Brake pad assembly Clip CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
- Clean the piston part, and press the piston into the cylinder using the special tool piston expander (MB990520).
- Assemble the shim, brake pad assembly and clip to the caliper support, and tighten the guide pin to the specified torque.
Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb)
Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.
Scheme 61
Scheme 62
REAR
| CAUTION | When replacing, replace both brake pads (right and left) as a set. |
Scheme 63
Scheme 64
- Remove the parts indicated in the illustration, swivel the caliper body upward and retain it with a wire or similar tool.
- Remove the following parts from the caliper body. Shim Brake pad assembly Clip CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
- Clean the piston part, and press the piston into the cylinder using the special tool piston expander (MB990520).
- Assemble the shim, brake pad assembly and clip to the caliper support, and tighten the guide pin to the specified torque.
Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb)
Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.
Scheme 65
Required Special Tool
- MB990520: Disc Brake Piston Expander
| CAUTION | When replacing, replace both brake pads (right and left) as a set. |
Scheme 66
Scheme 67
- Remove the parts indicated in the illustration, swivel the caliper body upward and retain it with a wire or similar tool.
- Remove the following parts from the caliper body. Shim Brake pad assembly Clip CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
- Clean the piston part, and press the piston into the cylinder using the special tool piston expander (MB990520).
- Assemble the shim, brake pad assembly and clip to the caliper support, and tighten the lock pin to the specified torque.
Tightening torque: 74 ± 10 N.m (55 ± 7 ft-lb)
Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.
Scheme 68
| CAUTION | When replacing, replace both brake pads (right and left) as a set. |
Scheme 69
- Remove the parts indicated in the illustration, swivel the caliper body upward and retain it with a wire or similar tool.
- Remove the following parts from the caliper body. Shim Brake pad assembly Clip CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
- Clean the piston part, and press the piston into the cylinder using the special tool piston expander (MB990520).
- Assemble the shim, brake pad assembly and clip to the caliper support, and tighten the guide pin to the specified torque.
Tightening torque: 44 ± 5 N.m (32 ± 4 ft-lb)
Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.
Scheme 70
| CAUTION | Disc brakes must be kept within the allowable service values in order to maintain normal brake operation. |
Before turning the brake disc, the following conditions should be checked.
| INSPECTION ITEM | REMARK |
|---|---|
| Scratches, rust, saturated lining materials and wear | If the vehicle is not driven for a long period of time, sections of the discs that are not in contact with the pads will become rusty, causing noise and shuddering. If grooves and scratches resulting from excessive disc wear are not removed prior to installing a new pad assembly, there will be inadequate contact between the disc and the lining (pad) until the pads conform to the disc. |
| Run-out | Excessive run-out of the discs will increase the pedal depression resistance due to piston kick-back. |
| Change in thickness (parallelism) | If the thickness of the disc changes, this will cause pedal pulsation, shuddering and surging. |
| Inset or warping (flatness) | Overheating and improper handling while servicing will cause warping or distortion. |
INSPECTION ITEMS
Scheme 71
- Remove contaminants or corrosion from the brake disc surface.
- Use a micrometer to measure the brake disc thickness at minimum eight points which are 10 mm (0.39 inch) inward from its circumference. Standard value: 26.0 mm (1.02 inches) < Front (Except RALLIART) > 24.0 mm (0.94 inch) < Front (RALLIART) > 10.0 mm (0.39 inch) < Rear > Limit: 24.4 mm (0.96 inch) < Front (Except RALLIART) > 22.4 mm (0.88 inch) < Front (RALLIART) > 8.4 mm (0.33 inch) < Rear >
- If the brake disc thickness is worn beyond the limit value at more than one point, replace the brake disc and check its run-out.
Scheme 72
- Remove contaminants or corrosion from the brake disc surface.
- Use a micrometer to measure the brake disc thickness at minimum eight points which are 10 mm (0.39 inch) inward from its circumference. Then record the measurements.
- If the brake disc thickness unevenness (the difference between the maximum and minimum values measured above) is 0.015 mm (0.0006 inch) or less, it is within the standard value.
- If the brake disc thickness unevenness exceeds the standard value, grind it according to the procedure below while it is mounted on the vehicle. NOTE: If it is suspected that the brake disc thickness will become less than the limit value after the grinding, replace the brake disc and check its run-out. Check for wheel bearing looseness in the axial direction (Refer to «WHEEL BEARING END PLAY CHECK»(ref-592614-S09378715322014011000000) < Front >, «WHEEL BEARING END PLAY CHECK»(ref-592676-S08833494702014011000000) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(ref-592611-S02323284972014011000000) < Rear (AWD) >). CAUTION: Insert M12 plain washer and then install the adapter as shown in the illustration before grinding. Failure to use the M12 plain washer will cause the brake disc to be deformed and ground incorrectly. To grind the brake disc, ensure that all the nuts (M12 X 1.5) are tightened evenly and in a diagonal sequence to the specified torque [100 N.m (74 ft-lb)]. Failure to use all the nuts (M12 x 1.5), excessive or uneven tightening torque will cause the brake disc to deform or shudder. Correct the brake disc uneven thickness by grinding it while in place on the vehicle.
Scheme 73
- Check for wheel bearing looseness in the axial direction (Refer to «WHEEL BEARING END PLAY CHECK»(ref-592614-S09378715322014011000000) < Front >, «WHEEL BEARING END PLAY CHECK»(ref-592676-S08833494702014011000000) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(ref-592611-S02323284972014011000000) < Rear (AWD) >).
- If the axial play is within the limit value, secure the brake disc by tightening the nut (M12 x 1.5) evenly to the specified torque [100 N.m (74 ft-lb)]. If the axial play still exceeds the limit value, replace the wheel bearing. Then secure the brake disc by tightening the nut (M12 x 1.5) evenly to the specified torque [100 N.m (74 ft-lb)].
- Place a dial gauge ca. 5 mm (0.2 inch) inward from the circumference of the brake disc to measure its run-out. Limit: 0.06 mm (0.0024 inch) < Front > 0.08 mm (0.0032 inch) < Rear >
- If the brake disc run-out exceeds the limit value, reface the brake disc to the hub so that the minimum brake disc run-out is obtained. CAUTION: Insert M12 plain washer and then install the adapter as shown in the illustration before grinding. Failure to use the M12 plain washer will cause the brake disc to be deformed and ground incorrectly. To grind the brake disc, ensure that all the nuts (M12 X 1.5) are tightened evenly and in a diagonal sequence to the specified torque [100 N.m (74 ft-lb)]. Failure to use all the nuts (M12 x 1.5), excessive or uneven tightening torque will cause the brake disc to deform or shudder.
- If the brake disc run-out exceeds the limit value after refacing, grind the disc while in place on the vehicle so that the brake disc run-out is within the limit value.
Note. If it is suspected that the brake disc thickness will be below the limit value, replace the brake disc. Then reface the brake disc so that the minimum brake disc run-out is obtained, or grind the disc while in place on the vehicle so that its run-out is below the limit value.
Scheme 74
- Remove the brake pad, shim and clip (Refer to «BRAKE PAD REPLACEMENT < EXCEPT RALLIART >»(ref-592607-S32657817872014011000000) < Except RALLIART > or «BRAKE PAD REPLACEMENT < RALLIART >»(ref-592607-S35520282702014011000000) < RALLIART >).
- Using a spring scale, measure the hub sliding torque in the forward direction with the brake pad, shim and clip removed.
- Install the brake pad, shim and clip (Refer to «BRAKE PAD REPLACEMENT < EXCEPT RALLIART >»(ref-592607-S32657817872014011000000) < Except RALLIART > or «BRAKE PAD REPLACEMENT < RALLIART >»(ref-592607-S35520282702014011000000) < RALLIART >).
- Start the engine, and depress the brake pedal lightly two or three times. Then stop the engine. [Depressing force: approximately 50 - 100 N (11.2 - 22.5 pound)]
- Turn the brake disc 10 times in the forward direction.
- Using a spring scale, measure the hub sliding torque in the forward direction with the brake pad, shim and clip installed.
- Obtain the disc brake drag force (difference between measured values of item 2 and item 6). Standard value: 68 N (15.3 pounds) or less < Front (Except RALLIART) > 85 N (19.1 pounds) or less < Front (RALLIART) > 68 N (15.3 pounds) or less < Rear >
- If the brake drag force exceeds the standard value, disassemble the brake caliper assembly to check for fouling/rust on the piston sliding section and piston seal deterioration, and confirm whether the guide pin and lock pin slide properly (Refer to «DISASSEMBLY AND ASSEMBLY < 15-INCH FRONT DISC BRAKE >»(ref-592607-S30322453422014011000000) < 15-inch front disc brake >, «DISASSEMBLY AND ASSEMBLY < 16-INCH FRONT DISC BRAKE (EXCEPT RALLIART) >»(ref-592607-S34549363552014011000000) < 16-inch front disc brake (Except RALLIART) >, «DISASSEMBLY AND ASSEMBLY < 16-INCH FRONT DISC BRAKE (RALLIART) >»(ref-592607-S41101902642014011000000) < 16-inch front disc brake (RALLIART) >, «DISASSEMBLY AND ASSEMBLY < 14-INCH REAR DISC BRAKE >»(ref-592607-S02543231052014011000000) < 14-inch rear disc brake >, «DISASSEMBLY AND ASSEMBLY < 16-INCH REAR DISC BRAKE (EXCEPT RALLIART) >»(ref-592607-S23106915722014011000000) < 16-inch rear disc brake (Except RALLIART) > or «DISASSEMBLY AND ASSEMBLY < RALLIART >»(ref-592607-S05665472052014011000000) < 16-inch rear disc brake (RALLIART) >).
BRAKE LINING THICKNESS CHECK - VEHICLES WITH REAR DRUM BRAKE
| CAUTION | Whenever the shoe and lining assembly is replaced, replace both RH and LH assemblies as a set to prevent the car from pulling to one side when braking. If there is a significant difference in the thickness of the shoe and lining assemblies on the left and right sides, check the sliding condition of the piston. |
Scheme 75
- Remove the brake drum.
- Measure the thickness of the brake lining at the area with the most wear. Standard value: 4.0 (0.16 inch) Limit: 1.0 mm (0.04 inch)
- Replace the shoe and lining assembly if the brake lining thickness is less than the limit or if it is not worn evenly. For installation procedures for the shoe and lining assembly, refer to «REAR DRUM BRAKE»(ref-592607-S19020634172014011000000) .
Scheme 76
- Remove the brake drum.
- Measure the inside diameter of the brake drum at two or more locations. Standard value: 203 mm (8.0 inches) Limit: 205 mm (8.1 inches)
- Replace the brake drums, shoe and lining assembly when wear exceeds the limit value or is badly imbalanced.
BRAKE LINING AND BRAKE DRUM CONTACT CHECK - VEHICLES WITH REAR DRUM BRAKE
- Remove the brake drum.
- Remove the shoe and lining assembly (Refer to «REAR DRUM BRAKE»(ref-592607-S19020634172014011000000) ).
- Chalk the inner surface of the brake drum and rub with the shoe and lining assembly.
- Replace the shoe and lining assembly or brake drums if there are any irregular contact areas.
Note. Clean off chalk after check.
Scheme 77
Scheme 78
Scheme 79
- Remove the brake drum.
- Operate the parking brake lever. Observe adjuster lever movement for ratcheting action of the auto adjuster. Repair or replace the lever(s) as required.
- Remove the shoe-to-lever spring.
- Remove the adjuster. NOTE: It may be necessary to rotate the adjuster wheel bottom to top to release tension.
- Inspect the adjuster wheel for wear, i.e., flat spots, worn teeth, etc. Replace if faulty.
- Check both ends of the adjuster for smooth rotation. Replace if faulty.
- Apply Multi-purpose grease or equivalent as shown in the illustration.
- To install adjuster, assemble the adjuster so it is at its minimum length and insert between shoe and lining assemblies.
- Install adjuster lever and shoe-to-lever spring.
- Rotate the adjuster wheel top to bottom until the drum has a slight drag when the drum is installed.
VEHICLES WITHOUT CRUISE CONTROL SYSTEM
| CAUTION | Do not apply grease or lubricant to the switch and the switch installation section to avoid malfunction of the switch. In addition, do not use gloves which have grease on them. |
Check for continuity between the terminals of the switch.
| Check condition | Terminal connector of tester | Normal condition |
|---|---|---|
| At free position | 1 - 2 | Continuity exists (2 ohms or less) |
| Press the plunger from the edge of the outer case by the dimension shown in the illustration. | 1 - 2 | No continuity |
STOPLIGHT SWITCH CONDITIONS
Scheme 80
VEHICLES WITH CRUISE CONTROL SYSTEM
| CAUTION | Do not apply grease or lubricant to the switch and the switch installation section to avoid malfunction of the switch. In addition, do not use gloves which have grease on them. |
Check for continuity between the terminals of the switch.
| Check condition | Terminal connector of tester | Normal condition |
|---|---|---|
| At free position | 1 - 2 (for stoplight switch) | Continuity exists (2 ohms or less) |
| 3 - 4 (for cruise control) | No continuity | |
| Press the plunger from the edge of the outer case by the dimension shown in the illustration. | 1 - 2 (for stoplight switch) | No continuity |
| 3 - 4 (for cruise control) | Continuity exists (2 ohms or less) |
STOPLIGHT SWITCH CONDITIONS
Scheme 81
Scheme 82
- Place the brake pedal assembly on a level surface as shown in the illustration, and set the distance from the center of the pin assembly mounting hole to the level surface to 97 mm (3. 82 inches). Make sure that the dimension A in the illustration (distance from the pedal pad center part to the level surface) is within the standard value. Standard value (A): 237 - 245 mm (9.3 - 9.6 inches) < M/T > 240 - 248 mm (9.4 - 9.8 inches) < CVT, TC-SST >
- When dimension A is not within the standard value, replace the brake pedal assembly.
