Page 1665 of 2103
BASIC BRAKE SYSTEM Master Cylinder arid Brake
m m
Marking
Prima
piston Push rod
Straight scale
- -
INSTALLATION SERVICE POINTS
HOSE CONNECTION
(1) Install the vacuum hose to the brake
nipple
shown in the figure. Secure the hose with the hose clip.
Caution
1. The check valve and the pipe part of
booster must not contact each other.
2. Connect so that the marking faces upwards.
(2) Install the other end of the vacuum hose fully onto its
port on the engine. Secure the hose using the hose clip.
CLEARANCE ADJUSTMENT BETWEEN BRAKE
BOOSTER PUSH ROD AND PRIMARY PISTON
Adjust the clearance (A) between the brake booster push
rod and
piston as follows:
Calculate clearance A from the
and measurements.
Standard value: mm in.)
NOTE
When brake booster negative pressure 67 (9.7 psi) is applied,
clearance value will become mm in.)
Straight scale
Page 1666 of 2103
BASIC BRAKE SYSTEM Master Brake Booster
If the clearance is not within the standard
turn
the
screw to achieve desired length.
‘ I
.
,
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Page 1667 of 2103
BASIC BRAKE SYSTEM Master and ‘Brake
MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
Disassembly steps
1.Reservoir bracket2.Reservoir hoses3. Reservoir cap assembly4.Diaphragm5.Reservoir cap6. Brake fluid level sensor
7.Float8.Reservoir9.Pin10.Retainer
Master cylinder kit
Brake fluid:
or
11.Connector12.Grommet13. Piston stopper ring14. Primary piston assembly15. Secondary piston assembly16. Master cylinder body
CautionDo not disassemble the and secondaryassemblies.
DISASSEMBLY SERVICE POINT
(A, PISTON STOPPER RING DISASSEMBLY
Remove thepiston stopper ring, while depressing the piston.
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Page 1668 of 2103
BASIC BRAKE SYSTEM Master Cvlinder and’
INSPECTION
Check the inner
or pitting.
Check the primary and secondary pistons for rust, s coring,
wear, damage or wear.
Check the diaphragm for cracks and wear.
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Page 1669 of 2103
BASIC SYSTEM Front
FRONT DISC BRAKE
REMOVAL AND ,
I1I Operation
l Brake Fluid DrainingPost-installation Operationl Brake Fluid Supplying
lBrake Line Bleeding (Refer to
I
88Nm6 5
Removal steps
1. Brake hose connection
2.Gasket assembly
INSTALLATION SERVICE
FRONT BRAKE ASSEMBLY INSTALLATION
Install the front brake assembly and measure the disc brake
drag torque. (Refer to
INSPECTION
Check the brake disc for damage.
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Page 1670 of 2103
BASIC BRAKE SYSTEM Front Disc Brake
DISASSEMBLY AND REASSEMBLY
74 Nm542
74 Nm
54
4
5 7
Brake caliper kitPad repair kit
Seal and boots repair kit
Caliper assembly disassembly Pad assembly disassembl
y steps
steps 1. Guide pin 1. Guide pin 2. Lock pin 2. Lock pin 3. Bushing3.Bushing4. Caliper support (pad, clip, shim)
4. Caliper support (pad, clip, shim) 11. Pad and wear indicator assembly
5.Boot12. Pad assembly6.Boot ring
13. Outer shim (stainless)7.Piston boot14. Outer shim (coated with rubber)
8.Piston15. Inner shim (stainless)9.Piston seal16. Inner shim (coatedwith rubber)
10.Caliper body 17.
Clip
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Page 1671 of 2103
BASIC BRAKE SYSTEM Front Disc
LUBRICATION POINTS
CautionThe piston seal inside the seal andboot kit is coated with specialgrease. Do not wipe this grease off.
Brake fluid: or
Grease:Repair kit grease
Inner shi
Grease: grease SAE
Grease: Repair kit grease
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Page 1672 of 2103
BASIC BRAKE SYSTEM Front
Lock pin
DISASSEMBLY SERVICE
When disassembling the disc brakes, disassemble both sides
(left and right) as a set.
PISTON BOOT/PISTON
Protect caliper body with cloth. Blow compressed air through
brake hose to remove piston boot and
Caution
Blow air gently.
SEAL REMOVAL
(1) Remove piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
( 2 ) C l e a n p i s t o n s u r f a c e a n d , i n n e r c y l i n d e r w i t h trichloro-ethylene, alcohol, or specified brake flu id.
Specified brake fluid:
REASSEMBLY SERVICE POINTS
PIN
INSTALLATION
(1) Grease parts as illustrated with specified grea se.
Specified grease: Repair kit grease (orange)
(2) Install the guide pin and lock pin as illustrat ed
eath
head mark of the auide
and the pin matches
the indication
or located the caliper
body.
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