Page 865 of 2389
6. CONNECT LEVEL WARNING SWITCH CONNECTOR
7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR±7)
8. CHECK FOR FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR±6)
INSTALLATION OF MASTER CYLINDER
(See page BR±9)
1. CLEAN OUT GROOVE ON LOWER INSTALLATION
SURFACE OF MASTER CYLINDER
2. CONFIRM THAT ºUPº MARK ON MASTER CYLINDER
BOOT IS IN CORRECT POSITION
5. CONNECT BRAKE TUBES
Using SST, connect. the brake tubes to the master cylin-
der.
Torque the union nuts.
SST 09751±36011
Torque: 155 kg±cm (11 ft±ib, 15 N ± m)
4. INSTALL MASTER CYLINDER
Set the new gasket and install the master cylinder, clamp
and 3±way union on the brake booster with three nuts.
Torque: 130 kg±cm (9 ft±Ib, 13 N¿ m)
3. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
BEFORE INSTALLING MASTER CYLINDER
(See page BR±16)
± BRAKE SYSTEMMaster CylinderBR±14
Page 866 of 2389
1. REMOVE MASTER¿CYLINDER
(See page BR±9)
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN
5. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS
(a) Remove the four nuts and clevis.
(b) Pull out the brake booster and gasket.
BRAKE BOOSTER
REMOVAL OF BRAKE BOOSTER
± BRAKE SYSTEMBrake BoosterBR±15
Page 867 of 2389
INSTALLATION OF BRAKE BOOSTER
(See page BR±15)
1. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Set the SST on the master cylinder with the gasket,
and then lower the pin until its slightly touches the
piston.
SST 09737±00010
3. CONNECT CLEVIS TO BRAKE PEDAL
Insert the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
4. INSTALL PEDAL RETURN SPRING
5. INSTALL INSTRUMENT LOWER FINISH PANEL(b) Turn the SST upside down and set it on the booster.
SST 49737±00010
(c) Measure the clearance between the booster push
rod and pin head (SST).
Clearance: 0 mm (0 in.)
2. INSTALL BRAKE BOOSTER, GASKET AND CLEVIS
(a) Install the clevis lock nut and clevis to the brake
booster.
(b) Install the brake booster and gasket.
(c) Install and torque the booster mounting nuts.
Torque: 130 kg±cm (9 ft±Ib, 13 N¿ m)
(d) Adjust the booster push rod length until the push rod
lightly touches the pin head.
± BRAKE SYSTEMBrake BoosterBR±16
Page 868 of 2389
6. INSTALL MASTER CYLINDER
(See page BR±14)
7. CONNECT VACUUM HOSE TO BRAKE BOOSTER
8. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR±7)
9. CHECK FOR FLUID LEAKAGE
10. CHECK AND ADJUST BRAKE PEDAL
(See page BR±6)
Check and adjust the brake pedal, then tighten the clevis
lock nut.
Torque: 260 kg±cm (19 ft±fb, 25 N±m)
11. PERFORM OPERATIONAL CHECK
(See page BR±7)
± BRAKE SYSTEMBrake BoosterBR±17
Page 869 of 2389
REPLACEMENT OF BRAKE PADS
HINT: If a squealing noise occurs from the front brakes
while driving, check the pad wear indicator. If there are
traces of the indicator contacting the rotor disc, the brake
pad should be replaced.
FRONT BRAKE
COMPONENTS
± BRAKE SYSTEMFront BrakeBR±18
Page 870 of 2389
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the cylinder inspection
hole and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)
4. REMOVE FOLLOWING PARTS:
(a) Two anti±squeal springs.
(b) Two brake pads
(c) Two or four anti±squeal shims
(d) Two pad wear indicator plates
(e) Four pad support plates 1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the rotor disc
with the hub nuts.
(b) Remove the brake cylinder and suspend it so the hose
is not stretched.
HINT: Do not disconnect the brake hose. 3. REMOVE CYLINDER FROM TORQUE PLATE
(a) Remove two installation bolts from the torque plate.
± BRAKE SYSTEMFront BrakeBR±19
Page 871 of 2389

8. INSTALL NEW PADS
(a) Install new pad wear indicator plate to inner pad.
NINT: Be sure the arrow on the pad wear indicator
plate is pointing i n the direction of the disc rotation.
(b) (Except 2VZ±FE Engine of w/ A.B.S.)
Install the one anti±squeal shim to the each pad.
(c) (For 2VZ±FE Engine of w/ A.B.S.)
Install the two anti±squeal shims to the each pad.
HINT: Apply disc brake grease to both side of the inner
anti±squeal shim of the outside pad.
(d) Install the pads onto each support plate.
NOTICE: Do not allow oil or grease to get on the
rubbing face.
(e) Install the two anti±squeal springs.
9. INSTALL CYLINDER
(a) Draw out a small amount of brake fluid from the reser-
voir.
(b) Press in piston with a hammer handle or an equiva-
lent.
HINT: Always change the pad on one wheel at a time as
there is a possibility of the opposite piston flying out.
(c) Insert the brake cylinder carefully ±so the boot is not
wedged. 5. CHECK ROTOR DISC THICKNESS
(See step 2 on page BR±23)
6. CHECK ROTOR DISC RUNOUT
(See step 3 on page BR±23)
7. INSTALL PAD SUPPORT PLATES
± BRAKE SYSTEMFront BrakeBR±20
Page 872 of 2389
REMOVAL OF CYLINDER
(See page BR±18)
1. DISCONNECT BRAKE LINE
Remove the union bolt and disconnect the brake line. Use
a container to catch the brake fluid.(d) Install and torque two installation bolts.
Torque: 400 kg±cm (29 ft±Ib, 39 N¿m)
10. INSTALL FRONT WHEEL
11. CHECK THAT FLUID LEVEL IS MAX LINE
2. REMOVE CYLINDER FROM TORQUE PLATE
Remove the two installation bolts and cylinder.
3. REMOVE PADS
(See step 4 on page BR±19)
± BRAKE SYSTEMFront BrakeBR±21