IMPROVEMENT OF BRAKING PERFORMANCE
- In addition to the 10-inch single brake booster, the small and long stroke-type master cylinder is used to achieve the downsizing and secure the assist force.
- The installation of 16-inch ventilated disc brake on the front axle and 16-inch solid disc brake on the rear axle achieves the secure braking force and direct braking feeling.
IMPROVEMENT IN SAFETY
- The 4-wheel anti-lock brake system (4ABS) has been installed to prevent slippage resulting from the wheel lock and assure stable vehicle posture and driveability.
- Electronic control braking force distribution system (EBD) has been adopted to assure the maximum braking force independently of the passenger' position in the vehicle.
- X-type piping of brake lines have been adopted for the front and rear wheels.
- Audible wear indicator has been adopted to the front and rear brake pads to 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.
SERVICE QUALITY IMPROVEMENTS
- Diagnostic function has been adopted to ABS for easier inspection.
- Brake fluid reservoir, master cylinder, and brake booster have been integrated for downsizing and better serviceability.
Scheme 30
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 disk 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 disk brake | 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, AS880N or equivalent | ||
LUBRICANT SPECIFICATIONS
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 31
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 runout of the brake disk (Refer to BRAKE DISC RUN-OUT CHECK AND CORRECTION ). |
Scheme 32
Scheme 33
- 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»(ref-593035-S35147691162014011300000) ).
< FRONT >
| CAUTION | When replacing, replace both brake pads (right and left) as a set. |
Scheme 34
Scheme 35
Scheme 36
- 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 disk 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 disk, making sure that the wear indicator is located on the top.
Scheme 37
< REAR >
| CAUTION | When replacing, replace both brake pads (right and left) as a set. |
Scheme 38
Scheme 39
- 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 disk 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 disk, making sure that the wear indicator is located on the bottom.
Scheme 40
Scheme 41
BRAKE DISC CHECK
| 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 CHART
Scheme 42
- 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 inch) < Front > 10.0 mm (0.39 inch) < Rear > Limit: 24.4 mm (0.96 inch) < Front > 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 43
- 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-593009-S28584894502014011300000) < Front >, «WHEEL BEARING END PLAY CHECK»(ref-592983-S23655325442014011300000) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(ref-593030-S34282252312014011300000) < 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 (M12x1.5), excessive or uneven tightening torque will cause the brake disc to deform or judder. Correct the brake disc uneven thickness by grinding it while in place on the vehicle.
Scheme 44
- Check for wheel bearing looseness in the axial direction (Refer to «WHEEL BEARING END PLAY CHECK»(ref-593009-S28584894502014011300000) < Front >, «WHEEL BEARING END PLAY CHECK»(ref-592983-S23655325442014011300000) < Rear (FWD) > or «WHEEL BEARING END PLAY CHECK»(ref-593030-S34282252312014011300000) < Rear (AWD) >).
- If the end play is within the limit value, secure the brake disc by tightening the nut (M12x1.5) evenly to the specified torque [100 N.m (74 ft-lb)]. If the end play still exceeds the limit value, replace the wheel bearing. Then secure the brake disc by tightening the nut (M12x1.5) 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, re-phase 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 (M12x1.5), excessive or uneven tightening torque will cause the brake disc to deform or judder.
- If the brake disc run-out exceeds the limit value after re-phasing, 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 re-phase 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 45
- Remove the brake pad, shim and clip (Refer to «BRAKE PAD REPLACEMENT»(ref-593035-S35147691162014011300000) ).
- 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»(ref-593035-S35147691162014011300000) ).
- 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 disk 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 disk brake drag force (difference between measured values of item 2 and item 6). Standard value: 68 N (15.3 pounds) or less
- 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»(ref-593035-S09377232612014011300000) < Front > or «DISASSEMBLY AND ASSEMBLY»(ref-593035-S01086148252014011300000) < Rear >).
STOPLIGHT SWITCH CHECK
| 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) |
TERMINALS REFERENCE
Scheme 46
Scheme 47
- 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 inch). Make sure that the dimension A in the illustration (distance from the pedal pad surface to the level surface) is within the standard value. Standard value (A): 250 - 254 mm (9.8 - 10.0 inch)
- When dimension A is not within the standard value, replace the brake pedal assembly.
- Disc wear (Refer to «BRAKE DISC CHECK»(ref-593035-S15730234822014011300000) ).
- Disc run-out (Refer to «BRAKE DISC RUN-OUT CHECK AND CORRECTION»(ref-593035-S13412580652014011300000) ).
Scheme 48
Scheme 49
BRAKE PAD WEAR CHECK
| WARNING | Always replace both brake pads on each wheel as a set (both front wheels or both rear wheels). Failure to do so will result in uneven braking, which may cause unreliable brake operation. If there is significant difference in the thickness of the pads on the left and right sides, check the moving parts. |
Measure thickness at the thinnest, most worn area of the pad. Replace the pad assembly if pad thickness is less than the limit value.
Standard value: 10.0 mm (0.39 inch)
Limit: 2.0 mm (0.08 inch)
Scheme 50
Scheme 51
- Disc wear (Refer to «BRAKE DISC CHECK»(ref-593035-S15730234822014011300000) ).
- Disc run-out (Refer to «BRAKE DISC RUN-OUT CHECK AND CORRECTION»(ref-593035-S13412580652014011300000) ).
Scheme 52
Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disk, making sure that the wear indicator is located on the bottom.