Installation
Install the disc rotor.
Install the caliper body and support to housing.
Tightening torque
80 Nm (8.2 kgf-m, 59 ft-lb)
Install the wheel.
Install in the reverse order of removal.
Adjust the parking brake.
Removal
Set the vehicle on a lift.
Loosen the wheel nuts.
Lift-up the vehicle, and then remove the wheels.
Pull down and release the parking brake.
Remove the two mounting bolts, and then remove the disc brake assembly.
Scheme 22
Suspend the disc brake assembly so that hose is not stretched.
Remove the disc rotor.
Note. If the disc rotor is difficult to remove try following two methods in order.
Turn the adjusting screw using a flat tip screwdriver until brake shoe gets away enough from the disc rotor.
Scheme 23
- Adjusting screw
- Cover
- Flat tip screwdriver
- Back plate
If the disc rotor seizes up within hub, drive the disc rotor out by installing an 8-mm bolt in holes B on rotor.
Scheme 24
Install in the reverse order of removal.
Adjust the parking brake.
| IMPORTANT | Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled. |
Thoroughly drain brake fluid from reservoir tank.
Disconnect the fluid level indicator harness connector.
Remove the brake pipes from master cylinder.
Remove the master cylinder mounting nuts, and take out master cylinder from brake booster.
To install the master cylinder to body, reverse the sequence of removal procedure.
Tightening torque
Master cylinder mounting nut
14 Nm (1.4 kgf-m, 10.1 ft -lb)
Piping flare nut
15 Nm (1.5 kgf-m, 10.8 ft -lb)
| IMPORTANT | Be sure to use recommended brake fluid. |
Bleed air from the brake system.
Remove or disconnect the following parts at engine compartment.
Disconnect the connector for brake fluid level indicator.
Remove the brake pipes from master cylinder.
Remove the master cylinder installing nuts.
Disconnect the vacuum hose from brake booster.
Remove the following parts from pedal bracket.
Snap pin and clevis pin
Four brake booster installing nuts
Scheme 25
- Nuts
- Clevis pin
- Snap pin
- Operating rod
Remove the brake booster while shunning brake pipes.
Note. Be careful not to drop the brake booster. The brake booster should be discarded if it has been dropped. Use special care when handling the operating rod. If excessive force is applied to the operating rod, sufficient to cause a change in the angle in excess of +/-3°, it may result in damage to the power piston cylinder. Use care when placing the brake booster on floor. Do not change the push rod length. If it has been changed, reset the projected length "L" to standard length.
Standard L
10.05 mm (0.40 in)
Scheme 26
| IMPORTANT | If external force is applied from above when the brake booster is placed in this position, the resin portion as indicated by "P", may be damaged. |
Scheme 27
- Force
Adjust the operating rod of brake booster.
Standard L
144.6 mm (5.69 in)
If it is not within specified value, adjust it by adjusting the brake booster operating rod.
Scheme 28
Mount the brake booster in position.
Connect the operating rod to brake pedal with clevis pin and snap pin.
Scheme 29
- Nuts
- Clevis pin
- Snap pin
- Operating rod
Connect the vacuum hose to brake booster.
Scheme 30
Mount the master cylinder onto brake booster.
Connect the brake pipes to master cylinder.
Connect the electric connector for brake fluid level indicator.
Measure the clearance between threaded end of stop light switch and stopper. If it is not within specified value, adjust it by adjusting the position of stop light switch.
If it is not within specified value, adjust it by adjusting the position of stop light switch.
| IMPORTANT | Be careful not to rotate the stop light switch. |
Stop light switch clearance A
0.3 mm (0.012 in)
Scheme 31
Apply grease to operating rod connecting pin to prevent it from wearing.
Bleed air from the brake system.
Tightening torque (Air bleeder screw)
8 Nm (0.8 kgf-m, 5.8 ft-lb)
Conduct road tests to ensure brakes do not drag.
Replacement
| IMPORTANT | To always maintain the brake fluid characteristics, replace the brake fluid according to maintenance schedule or earlier than that when used in severe condition. The FMVSS No. 116, fresh DOT3 or DOT4 brake fluid must be used. Cover the bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled. Avoid mixing different brands of brake fluid to prevent degrading the quality of fluid. Be careful not to allow dirt or dust to get into the reservoir tank. |
Note. During replacement, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. The brake pedal operating must be very slow. For convenience and safety, two people should do the work. The amount of brake fluid required is approx. 500 milliliters (16.9 US fl oz, 17.6 Imp fl oz) for total brake system.
Either lift-up the vehicle and place a rigid rack under it, or lift-up vehicle.
Remove both front and rear wheels.
Draw out the brake fluid from master cylinder with syringe.
Refill the reservoir tank with recommended brake fluid.
Recommended brake fluid
FMVSS No. 116, fresh DOT3 or DOT4 brake fluid
Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid.
Scheme 32
Scheme 33
- Air bleeder screw
| IMPORTANT | Brake fluid replacement sequence; (A) Front right ? (B) Rear left ? (C) Front left ? (D) Rear right |
Scheme 34
- Master cylinder
- Hydraulic unit
- Two-way connector
Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed.
Loosen the bleeder screw approx. 1/4 turn until a small amount of brake fluid drains into container, and then quickly tighten the screw.
Release the brake pedal slowly. Repeat steps 6) through 8) until new fluid flows through vinyl tube.
Note. Add brake fluid as necessary during replacement, in order to prevent the tank from running short of brake fluid.
After completing the replacement, hold brake pedal depressed and tighten screw and install bleeder cap.
Tightening torque (Bleeder screw)
8 Nm (0.8 kgf-m, 5.8 ft-lb)
Replace brake fluid of each wheel cylinder using the same procedures as described in steps 6) through 8) above.
Depress the brake pedal with a force of approx. 294 N (30 kg, 66 lb) and hold it there for approx. 20 seconds. At this time check for mix in air and pedal height change. Visually inspect the bleeder screws and brake pipe joints to make sure that there is no fluid leakage.
Install the wheels, and drive the vehicle for a short distance between 2 to 3 km (1 to 2 miles) to make sure that brakes are operating properly.
Note. Airbag system wiring harness is routed near the center brake pipe.
| IMPORTANT | All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage the airbag system wiring harness when servicing the center brake pipe. When removing the brake pipe, make sure that it is not bent. |
Note. Airbag system wiring harness is routed near the center brake pipe.
| IMPORTANT | All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage the airbag system wiring harness when servicing the center brake pipe. When installing the brake pipe, make sure that it is not bent. After installing the brake pipe and hose, bleed the air. After installing the brake hose, make sure that it does not touch the tire or suspension assembly, etc. |
Brake pipe tightening torque
15 Nm (1.5 kgf-m, 10.8 ft -lb)
Install in the reverse order of removal.
| IMPORTANT | If the cable clamp is damaged, replace it with a new one. Never fail to cover the outer cable end with boot. Be careful not to kink the accelerator cable. Always use new clevis pins. |
Adjust the clutch pedal
Inspect the brake pedal after installation
Disconnect the ground cable from battery.
Disconnect the stop light switch connector.
Loosen nuts, and unscrew stop light switch to remove.
Scheme 35
- Stop light switch
Screw the stop light switch onto a bracket and secure it temporarily with a nut.
Adjust the stop light switch position, and then tighten the nut.
Tightening torque
8 Nm (0.8 kgf-m, 5.8 ft-lb)
