Page 857 of 2389

CHECKS AND ADJUSTMENTS
CHECK AND ADJUSTMENT OF BRAKE
PEDAL
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet:
177.5 ± 187.5 mm (6.988 ± 7.382 in.)
If incorrect, adjust the pedal height.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) If necessary, remove the instrument lower finish pan-
el and air duct.
(b) Loosen the stop light switch lock nut.
(e) Sufficiently loosen the stop light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push
rod.
(f) Return the stop light switch until it lightly contacts the
pedal stopper.
(g) Tighten the two lock nuts.
(h) Check that the stop lights light when the brake pedal
depressed.
(i) After adjusting the pedal height, check and adjust
the pedal freeplay.
3. CHECK THAT PEDAL FREEPLAY IS CORRECT
(a) Stop the engine and depress the brake pedal sever-
al times until there is no more vacuum left in the
booster.
(b) Push in the pedal until the beginning of resistance
is felt. Measure the distance, as shown.
Pedal freeplay: 3 ±6 mm (0.12 ± 0.24 in.)
HINT: The freeplay to the first resistance is due to the play
between the clevis and pin. And it is 1 3 mm (0.04±
0.12 in.) on the pedal.
4. IF NECESSARY, ADJUST PEDAL FREEPLAY
(a) If incorrect, adjust the pedal freeplay by turning the
pedal push rod.
(b) Start the engine and confirm that pedal freepiay ex-
ists.
(e) After adjusting the pedal freeplay, check the pedal
height.
(d) Install the air duct and instrument lower finish panel.
± BRAKE SYSTEMChecks and AdjustmentsBR±6
Page 858 of 2389

OPERATIONAL TEST OF BRAKE
BOOSTER
HINT: If there is leakage or lack of vacuum, repair before
testing. If available, use a brake booster tester to check the
booster operating condition.
1. OPERATING CHECK
(a) Depress the brake pedal several times with the en-
gine stopped, and check that is no change in the ped-
al reserve distance.
(b) Depress the brake pedal and start the engine. If the
pedal goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after one or two minutes.
Depress the brake pedal several times slowly. If the
pedal goes down furtherest the first time, but gradual-
ly rises after the second or third time, the booster is air
tight.
(b) Depress the brake pedal while the engine is running,
and stop it with the pedal depressed. If there is no
change in pedal reserve travel after holding the pedal
for thirty seconds, the booster is air tight.
BLEEDING OF BRAKE SYSTEM
HINT: If any work is done on the brake system or if air is sus-
pected in the brake lines, bleed the system of air.
NOTICE: Do not let brake fluid remain on a painted surface.
Wash it off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir. If necessary, add
brake fluid. 5. CHECK THAT PEDAL RESERVE DISTANCE IS
CORRECT
Release the parking brake. With engine running, depress
the pedal and measure the pedal reserve distance, as
shown.
Pedal reserve distance from asphalt sheet at 50 kg
(110.2 1b): More than 85 mm, (3.35 in.)
If incorrect, troubleshoot the brake system.
2. BLEED MASTER CYLINDER
HINT: If the master cylinder was disassembled or if the res-
ervoir becomes empty, bleed the air from the master cylin-
der.
(a) Disconnect the brake tubes from the master cylinder.
(b) Depress the brake pedal and hold it.
± BRAKE SYSTEMChecks and AdjustmentsBR±7
Page 859 of 2389

CHECK AND ADJUSTMENT OF PARKING
BRAKE
1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS
CORRECT
Pull the parking brake lever all the way up, and count the num-
ber of clicks.
Parking brake levertravel at 20 kg (44.1 Ib, 196 N):
5 ± 8 clicks
If incorrect, adjust the parking brake.
2. IF NECESSARY, ADJUST PARKING BRAKE LEVER
TRAVEL
HINT: Before adjusting the parking brake, make sure that the
rear brake shoe clearance has been adjusted.
For shoe clearance adjustment, see steps 8 and 9 on page
BR±32 or step 8 on page 48.
(a) Remove the console box.
(b) Loosen the lock nut and turn the adjusting nut until the
lever travel is correct.
(e) Tighten the lock nut.
Torque: 55 kg±cm (48 in.±Ib, 5.4 N±m)
(d) Install the console box. 3. BEGIN BLEEDING AIR FROM BRAKE OR WHEEL
CYLINDER WITH LONGEST HYDRAULIC LINE
(a) Connect the vinyl tube to the brake or wheel cylinder
bleeder plug, and insert the other end of tube in a
halffull container of brake fluid.
(b) Slowly pump the brake pedal several times.
(c) While having an assistant press on the pedal, loosen
the bleeder plug until fluid starts to runout. Then close
the bleeder plug.
(d) Repeat (b) and (c) until there are no more air bubbles
in the fluid.
(e) Tighten the bleeder plug.
Bleeder plug tightening torque:
85 kg±cm (74 in.±!b, 8.3 N±m)
4. REPEAT PROCEDURE FOR EACH WHEEL(c) Block off the outer holes with your fingers, and re-
lease the brake pedal.
(d) Repeat (b) and (c) three or four times.
± BRAKE SYSTEMChecks and AdjustmentsBR±8
Page 860 of 2389
1. DISCONNECT LEVEL WARNING SWITCH
CONNECTOR
2. TAKE OUT FLUID WITH SYRINGE
NOTICE: Do not let brake fluid remain on a painted surface.
Wash it off immediately.
3. DISCONNECT BRAKE TUBES
Using SST, disconnect brake tubes from the master cylinder.
SST 09751±36011
4. REMOVE MASTER CYLINDER
(a) Remove the three nuts and 3±way union.
(b) Remove the clamp.
(c) Remove the master cylinder from the brake booster
and remove the gasket.
MASTER CYLINDER
REMOVAL OF MASTER CYLINDER
± BRAKE SYSTEMMaster CylinderBR±9
Page 861 of 2389
COMPONENTS
± BRAKE SYSTEMMaster CylinderBR±10
Page 862 of 2389

INSPECTION OF MASTER CYLINDER
COMPONENTS
HINT: Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.
DISASSEMBLY OF MASTER
CYLINDER
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
(b) Remove the cap and strainer from the reservoir.
2. REMOVE TWO GROMMETS
3. PLACE CYLINDER IN VISE
5. REMOVE TWO PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
(b) Remove the No. 1 piston and spring hand, pulling
straight out, not at an angle.
NOTICE: If pulled out at an angle, there is possibility of
damaging the cylinder bore.
(c) Place a rag and two wooden blocks on the work table
and lightly tap the cylinder flange against the blocks
until the piston drops out of the cylinder.
HINT: Make sure the distance (A) from the rag to the top
of the blocks is at least 100 mm (3.94 in.) 4. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and
remove the piston stopper bolt and gasket.
HINT: Tape the screwdriver tip before use.
± BRAKE SYSTEMMaster CylinderBR±11
Page 863 of 2389
2. INSTALL TWO SPRINGS AND PISTONS
CAUTION: Be careful not to damage the rubber lips on
the pistons.
(a) Insert the two springs and pistons straight in, not at
an angle.
NOTICE: If insert at an angle, there is possibility of damag-
ing the cylinder bore.
(b) Push in the piston with a screwdriver and install the
snap ring with snap ring pliers.
HINT: Tape the screwdriver tip before use.
3. INSTALL PISTON STOPPER BOLT
Using a screwdriver, push the piston in all the way and
install the piston stopper bolt over the gasket. Torque the
bolt.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
ASSEMBLY OF MASTER CYLINDER
(See page BR±10)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
RUBBER PARTS INDICATED BY ARROWS
4. INSTALL TWO GROMMETS
± BRAKE SYSTEMMaster CylinderBR±12
Page 864 of 2389
5. INSTALL RESERVOIR
(a) Install the cap and strainer to the reservoir.
(b) Push the reservoir onto the cylinder.
(c) Install the set screw while pushing on the reservoir.
Torque: 17.5 kg±cm (15.2 in.±Ib, 1.7 N±m)
NOTICE: Because the master cylinder and reservoir
tank union is a grommet type, the set screw is de-
signed to not separate the reservoir from the cylinder
and will not tighten down the reservoir. Therefore,
there is a clearance at point A. Do not insert washers
or an equivalent when tightening.
± BRAKE SYSTEMMaster CylinderBR±13