Page 1649 of 2103
BASIC BRAKE SYSTEM Service
Booster
side
CHECK VALVE OPERATION CHECK
When checking the check valve, keep the check valve fit
in the vacuum hose.,
1. Remove the vacuum hose.
NOTE
The check valve is press-fitted inside the vacuum h ose.
2.Check the operation of the check valve by using a v acuum
Vacuum pump connection Accept/reject criteria
Connection at the brake A negative pressure
booster side (A)is created and held.
Connection at the intake A (vacuum)
manifold side (B) is not created.
Caution
If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.
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Page 1650 of 2103
BASIC BRAKE SYSTEM
Pressure gauge
v a l v e
S p l i t p o i n t S p l i t p o i n t
o u t p u t
o u t p u tpressurepressure
Input pressure
VALVE
.
1. two pressure gauges, one ‘each to the
side and output side of the proportioning
2. Air bleed the brake line and
3. While gradually depressing: the brake pedal, the
following measurements and’
be sure that
measured values are within, the allowable
.
Output pressure ‘begins to” drop ‘to input
p r e s s u r e ( s p l i t p o i n t ) .
S t a n d a r d v a l u e :
(2) Check that the output at the standard
value when the input fluid pressure increases;
according to the table
Standard value:
ItemsVehicles without Vehicles with
ABS ABS
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Input fluid
pressure 6.07 (925) 6.86 (996)
Output fluid
pressure
3.92-4.41
(462-533)
(3) Output pressure difference between left and rig ht
brake lines
Limit: 0.4 (57 psi)
4.If the measured pressures are not within allowable ranges,
replace the proportioning valve.
Page 1651 of 2103
BASIC BRAKE SYSTEM
BRAKE CHECK 35190919953
The brake fluid
sensor is in good condition if there is
no continuity when the float surface is above
or “A”
and if there is continuity when the float surface i s below “MIN
or “A”.
BLEEDING
Caution
35199149955
Use the specified brake fluid. use mixture of the
specified brake fluid and another fluid.
Specified brake fluid:
CYLINDER BLEEDING
The master cylinder has no so if bleeding is
carried out by the following procedure, bleeding of air from
the brake line will become easier. (1) Fill the reserve tank
fluid.
(2). Keep the brake pedal depressed.
(3) Have another person cover the master cylinder outlet
with a finger.
(4) With the outlet still closed, release the brake pedal.
(5) Repeat steps
three or four times to fill the inside
of the master cylinder with brake fluid.
BRAKE LINE BLEEDING
Start the and bleed air sequence shown
in the figure.
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Page 1652 of 2103
4 SYSTEM Service
Pad
indicator
Brake disc
BRAKE PAD CHECK AND . .
REPLACEMENT
brake ‘pads have wear that contact
disc when ‘the brake pad 2
The wear indicators a to warn
to have the pads replaced h&e
checked.
1.Check. brake pad.
port.
Standard’ 10 mm
,
Limit: 2.0 mm in.)
Caution
When the limit is pads on
both the left and be replaced
as a set.
2. If there is, a significant in the
thicknesses of the pads on the left and right sides,
the sliding condition- of -the
pin guide pin.
2. g u i d e c a l i p e r t h e ”
assembly toward, the inside of the wheel well
from the lock Support it
Caution
Donot wipe off the special guide
pin or allow it to
Page 1653 of 2103
BASIC BRAKE SYSTEM
Front hub assembly
196-255 Nm
145-188
3.
4.
5.
6.
8.
Remove the following parts from caliper support. 1. Pad and wear indicator assembly
2. Pad assembly
3. Clip
4 . O u t e r s h i m ( s t a i n l e s s )
5. Outer shim (coated with rubber)
6. Inner shim (stainless)
7. Inner shim (coated with rubber)
Take out the drive shaft. (Refer to GROUP 26
Drive
Shaft
to GROUP 26 Drive Shaft
Set the special tool to the front hub assembly as s hown
in the illustration.’
Measure hub torque (A) with pads removed to measure
brake drag torque. Torque value will be used later to
calculate brake drag force with the pads installed.
NOTE
Tighten the nuts in order to secure the disc to the hub.
Securely attach the pad clip to the caliper support .
Clean piston and insert into cylinder (caliper) with special
Page 1654 of 2103

BASIC BRAKE SYSTEM On-vehicle Service
Pad assembly
Grease
Grease Al
9. Apply grease to the attaching faces of pad and i nner
shim and to the attaching faces of outer shims.
Apply so as not to spread it out from the edge of shim.’
Specified grease:
Brake grease SAE
Caution
1. Do, not deposit grease or on pad or
brake disc friction surfaces’.
2.The grease should be so it does not
protrude from the
surfaces.
10. Be careful that the piston boot does not catch and
as the caliper assembly and lock’ pin are installed.
11. Check brake drag torque as
(1)Start engine and hold brake pedal
[Pedal depression force: approx. 196 (44 Ibs.)]
(2) Stop engine.
(3) Turn brake disc forward.
times,
(4) Check hub torque (B) with spring scale.
(5) Calculate the drag torque of the [difference
between hub torque (B) and torque (A)]. .
Standard value:
69 (15.4 or less,
12. If the difference between brake drag torque’and hub torque
exceeds the standard value, disassemble piston and clean
the piston. Check for corrosion or seal, and
check the sliding condition of the lock
and guide pin.
13. Reinstall the drive shaft.
-to
S h a f t t o
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Page 1655 of 2103

B R A K E S Y S T E M 7 .
FRONT DISC BRAKE ROTOR CHECK
35100270047
Caution
To maintain safe braking performance, the disc brak e rotors must be kept within allowable service
specifications.
Before re-finishing or re-processing the brake disc surface, the following conditions should be checke d.
Inspection itemsRemarks
Scratches, rust, saturated lining lIf the vehicle is not driven for a the of the
and weardiscs that are not in contact with lining will beco me rusty, causing
noise and shudderin.lIf grooves resultingrom excessive disc wear and scratches arenot removed prior to installing a new pad assembly, there will tarily be inappropriate contact between the disc and the lining (pad).
Run-out or drift
Excessive run-out or drift of the discs will increa se the pedal depression
resistance due to piston knock-back.
Change in thickness (parallelism)
If the thickness of the disc changes, this will cau se pedal pulsation,
shuddering and surging.
Inset or warping (flatness)
Overheating and improper handling while servicing w ill cause inset or
warping.
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Page 1656 of 2103

BASIC BRAKE SYSTEM On-vehicle Service
FRONT DISC RUN-OUT’
Remove the caliper support bolts, then raise the’ c aliper
assembly upward and secure by
2. Inspect the disc surface for grooves, cracks,
Clean the disc thoroughly and all
,
3.Place a dial gauge approximately 5 mm in.) from the
outer circumference of the brake disc, and measure- the.
of the disc
Limit:0.06mm in.)
N O T E
Tighten the nuts in order to secure! the
FRONT BRAKE DISC RUN-OUT CORRECTION
1.If the run-out of the brake disc is equivalent to o r exceeds
the limit specification, change the phase of the di sc and
hub, and then measure the run-out again.
(1) Before removing the brake disc, chalk both side s
of the wheel stud on the side at which run-out is
greatest.
(2) Remove the brake disc, and then place a dial ga uge
as shown in the illustration; then move the hub in
the axial direction and measure the play.
Limit: 0.05 mm
in.)
If the play is equivalent to or exceeds the limit,
disassemble the hub knuckle and check each part.
2.
(3) If the play does not exceed the limit specifica tion,
install the brake disc at a position
away from
the chalk mark, and then check the run-out of the
brake disc once again.
If the run-out cannot be corrected by changing the phase
of the brake disc, replace the brake disc or turn rotor
with an on the car type brake lathe
or
equivalent). Be sure to follow the exact brake lath e
manufacturer instructions. Rotors turned on the veh icle
will often have a lower run-out than a new brake di sc.
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