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35A-1
SERVICE BRAKES
CONTENTS 35109000159
BASIC BRAKE SYSTEM ......................................... 35A
ANTI-SKID BRAKING SYSTEM (ABS) <2WD> ...................... 35B
ANTI-SKID BRAKING SYSTEM (ABS) <4WD> ...................... 35C
NOTE
THE GROUPS MARKED BY ARE NOT IN THIS MANUAL
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35A-2 BASIC BRAKE SYSTEM CONTENTS 35109000302 Disc Brake Pad Check and Replacement ..... 10 GENERAL INFORMATION .................. 3 Disc Brake Rotor Check ..................... 12 SERVICE SPECIFICATIONS ................. 4 Brake Lining Thickness Check ............... 14 Brake Drum Inside Diameter Check .......... 14 LUBRICANTS .............................. 5 Brake Lining and Brake Drum Connection SEALANTS ................................ 5 Check...................................... 14 SPECIAL
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35A-3 BASIC BRAKE SYSTEM - General Information GENERAL INFORMATION 35100010182 The brake system offers high dependability and durability along with improved braking performance and brake sensitivity. Items Specifications Master cylinder Type Tandem type (with level sensor) I.D. mm 23.8 Brake booster Type Vacuum type, single Effective dia. of power cylinder mm 230 Boosting ratio 6.0 Proportioning valve Type Dual type Decompression ratio 0.25 Front brakes Type Floating caliper, 1-piston, ventilate
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General Information/ 35A-4 BASIC BRAKE SYSTEM - Service Specifications CONSTRUCTION DIAGRAM Brake booster Mastercylinder Rearbrake Brake pedal Proportioningvalve Frontbrake SERVICE SPECIFICATIONS 35100030201 Items Standard value Limit Brake pedal height mm 162.8 - 165.8 - Brake pedal free play mm 3-8 - Brake pedal to floor board clearance mm 90 or more - Proportioning valve Split point MPa Sedan 2.94± 0.25 - Wagon 3.43± 0.25 - ± Output fluid pressure Sedan 4.66 0.39 (9.81) - (Input fluid pressur
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Service Specifications/Lubricants/ 35A-5 BASIC BRAKE SYSTEM - Sealants/Special Tools Items Standard value Limit Rear disc brake Pad thickness mm 10.0 2.0 Disc thickness mm 10.0 8.4 Disc runout mm - 0.08 Dragforce(tangentialforceofwheelmounting 69 or less - bolts) N Rear drum brake Lining thickness mm 4.4 1.0 Drum inside diameter mm 203 205 LUBRICANTS 35100040082 Items Specified Lubricant Brake fluid DOT3 or DOT4 Brake piston seal Repair kit grease (orange) Slide pin boot and slide pin bush inner
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35A-6 BASIC BRAKE SYSTEM - On-vehicle Service ON-VEHICLE SERVICE 35100090186 BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT Stoplamp Operating switch rod 1. Turn up the carpet, etc under the brake pedal. 2. Measurethebrakepedalheightasillustrated.Ifthebrake Operating rod lock nut pedal height is not within the standard value, follow the procedure below. Standard value: 162.8 - 165.8 mm (1) Disconnect the stop lamp switch connector. (2) Adjustthebrakepedalheightbyturningtheoperating Pedal do
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35A-7 BASIC BRAKE SYSTEM - On-vehicle Service Standard value: 3–8 mm If the free play exceeds the standard value, it is probably due to excessive play between the retaining ring bolt and brake pedal arm. Check for excessive clearance and replace faulty parts as required. CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR BOARD 1. Turn back the carpet etc. under the brake pedal. 2. Start the engine, depress the brake pedal with approximately490Nofforce,andmeasuretheclearance between the brake pedal and the
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35A-8 BASIC BRAKE SYSTEM - On-vehicle Service 2. Withtheenginestopped,steponthebrakepedalseveral When engine is When engine is times. stopped started Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective. 3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good
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35A-9 BASIC BRAKE SYSTEM - On-vehicle Service Pressuregauge PROPORTIONING VALVE FUNCTION TEST 35100110172 1. Connect two pressure gauges, one each to the input sideandoutputsideoftheproportioningvalve,asshown. 2. Bleed the air in the brake line and the pressure gauge. 3. While gradually depressing the brake pedal, make the following measurements and check to be sure that the measured values are within the allowable range. Proportioning valve (1) Output pressure begins to drop relative to input p
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35A-10 BASIC BRAKE SYSTEM - On-vehicle Service BLEEDING 35100140089 Caution Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. Specified brake fluid: DOT3 or DOT4 MASTER CYLINDER BLEEDING The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.) (1) Fill the reserve tank with brake flui
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35A-11 BASIC BRAKE SYSTEM - On-vehicle Service 1. Check brake pad thickness through caliper body check port. Standard value: 10 mm Limit: 2.0 mm Caution 1. When the limit is exceeded, replace the pads at both sides, and also the brake pads for the wheels on the opposite side at the same time. 2. If there is a significant difference in the thickness of the pads on the left and right sides, check the sliding condition of the piston and guide pin. 2. Remove the guide pin. Lift caliper assembly and
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35A-12 BASIC BRAKE SYSTEM - On-vehicle Service DISC BRAKE ROTOR CHECK 35100290012 Caution When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation. Before re-finishing or re-processing the brake disc surface, the following conditions should be checked. Inspection items Remarks D Scratches, rust, saturated lining materials If the vehicle is not driven for a certain period, the sections o
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35A-13 BASIC BRAKE SYSTEM - On-vehicle Service RUN-OUT CHECK 35100250010 1. Remove the caliper support; then raise the caliper assembly upward and secure by using wire. 2. Inspect the disc surface for grooves, cracks and rust. Clean the disc thoroughly and remove all rust. 3. Place a dial gauge approximately 5 mm from the outer circumferenceofthebrakedisc,andmeasuretherun-out of the disc. Limit: 0.06 mm or less 0.08 mm or less NOTE Tighten the nuts in order to secure the disc to t
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35A-14 BASIC BRAKE SYSTEM - On-vehicle Service BRAKE LINING THICKNESS CHECK 35100300166 1. Remove the brake drum. 2. Measure the wear of the brake lining at the place worn the most. Standard value: 4.4 mm Limit: 1.0 mm Replace the shoe and lining assembly if brake lining thickness is less than the limit or if it is not worn evenly. Forinformationconcerningtheprocedures forinstallation of the shoe and lining assembly, refer to P.35A-24. Caution 1. Whenever the shoe and lining assembly is replaced
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35A-15 BASIC BRAKE SYSTEM - Brake Pedal BRAKE PEDAL 35100340243 REMOVAL AND INSTALLATION Post-installation Operation Brake Pedal Adjustment (Refer to P.35A-6.) 14 Nm 5 11 12 Nm 13 Nm 29 Nm 2 1 9 8 8 4 10 9 3 7 6 Removal steps 1. Stop lamp switch connector 7. Brake pedal pad 2. Stop lamp switch 8. Brake pedal return spring 3. Snap pin 9. Bushing 4. Pin assembly 10. Pipe 5. Brake pedal shaft bolt 11. Pedal support member 6. Brake pedal
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35A-16 BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER 35100370242 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-10.) D Brake Pedal Adjustment (Refer to P.35A-6.) 6 11 12 3 2 20 - 25 Nm 14 9 15 Nm 1 22 Nm 14 Nm 10 8 10 Nm 1 15 Nm 13 6 6 7 15 Nm 7 4 15 N
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35A-17 BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster Removal steps 1. Brake pipe connection 7. Fitting 2. Brake fluid level sensor connector 8. Snap pin 3. Master cylinder assembly 9. Pin assembly "BAD Push rod protruding length check and 10. Clevis adjustment 11. Vacuum switch connector <4D6> 4. Vacuum hose <4D6> 12. Vacuum switch <4D6> 5. Vacuum pipe <4D6> 13. Brake booster "AA 6. Vacuum hose 14. Sealer (with built-in check valve) INSTALLATION SERVICE POINTS "AA VACUUM HOSE CONNECTION
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35A-18 BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster MASTER CYLINDER 35100420145 DISASSEMBLY AND REASSEMBLY 2 1 9 3 10 5 11 9 7 Master cylinder kit 4 12 8 10 10 11 6 11 12 Brake fluid: DOT3 or DOT4 Disassembly steps 1. Reservoir cap assembly 7. Reservoir tank 2. Reservoir cap 8. Reservoir seal 3. Diaphragm 9. Piston retainer 4. Brake fluid level indicator assembly 10. Primary piston assembly 5. Float 11. Secondary piston assembly 6. Spring pin 12. Master cylinder body
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35A-19 BASIC BRAKE SYSTEM - Disc Brake DISC BRAKE 35100800017 REMOVAL AND INSTALLATION Pre-removal Operation Post-installation Operation Brake Fluid Draining D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-10.) 4 90 - 110 Nm 29 Nm 1 2 3 1 3 29 Nm 4 2 55 - 65 Nm Removal steps 1. Brake hose connection "AA 3. Disc brake assembly 2. Gasket 4. Brake disc INSTALLATION SERVICE POIINT MB990998 "AA DISC BRAKE ASSEMBLY INSTALLATION 1. In order to measure the brake drag torque
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35A-20 BASIC BRAKE SYSTEM - Disc Brake (2) Attach the special tool to the front hub assembly as shownintheillustration,andtightenittothespecified torque. Tightening torque: 196 - 255 Nm (3) Use a spring balance to measure the rotary-sliding resistance of the hub in the forward direction. Use a spring balance to measure the rotary-sliding resistance of the hub in the forward direction. 2. After installing the caliper support to the knuckle, install the pad clips and the pads to the caliper
