Page 913 of 3573
POWER ASSISTED BRAKE SYSTEM 5C – 35
REMOVAL
1. Shift Knob
2. Front Console Assembly
3. Lower Cluster Assembly
4. Instrument Panel Driver Lower Cover Assembly
5. Anti-theft Controller
6. Stoplight switch Connector
7. Return Spring
8. Snap Pin
9. Pin
10. Nut
11. Pin, Fulcrum
12. Brake Pedal
INSTALLATION
12. Brake Pedal
11. Pin, Fulcrum
•Apply grease to the entire circumference of the
fulcrum pin.
10. Nut
Bolt and Nut Torque N·m (kg·m / lb·ft)
33 (3.3 / 24)
9. Pin
•Apply grease to the entire circumference of the
push rod pin.
8. Snap Pin
•Adjust pedal free travel. Refer to “Brake Pedal
Adjustment” previously in this section.
7. Return Spring
6. Stoplight Switch Connector
5. Anti-theft Connector
4. Instrument Panel Driver Lower Cover Assembly
3. Lower Cluster Assembly
2. Front Console Assembly
1. Shift Knob
Page 914 of 3573
5C – 36 POWER ASSISTED BRAKE SYSTEM
STOPLIGHT SWITCH REPLACEMENT
675
423
M/T1
Removal Steps
1. Shift Knob
2. Front Console Assembly
3. Lower Cluster Assembly
4. Instrument Panel Driver Lower Cover
Assembly
5. Stoplight Switch Connector
6. Lock Nut
7. Switch
Installation Steps
7. Switch
6. Lock Nut
5. Stoplight Switch Connector
4. Instrument Panel Driver Lower Cover
Assembly
3. Lower Cluster Assembly
2. Front Console Assembly
1. Shift Knob
REMOVAL
1. Shift Knob
2. Front Console Assembly
3. Lower Cluster Assembly
4. Instrument Panel Driver Lower Cover Assembly
5. Stoplight Switch Connector
6. Lock Nut
7. Switch
This illustration is based on the LHD model.
Page 915 of 3573
POWER ASSISTED BRAKE SYSTEM 5C – 37
INSTALLATION
7. Switch
•Adjust the stoplight switch to the specified
clearance (between switch housing and brake
pedal) by rotating the switch housing.
Clearance mm (in)
0 – 0.2 (0 – 0.008)
NOTE:
While adjusting the installation of the stoplight
switch, make sure that the threaded part of the
stoplight switch does not push the brake pedal.
6. Lock Nut
5. Stoplight Switch Connector
4. Instrument Panel Driver Lower Cover Assembly
3. Lower Cluster Assembly
2. Front Console Assembly
1. Shift Knob(A)
Page 916 of 3573
5C – 38 POWER ASSISTED BRAKE SYSTEM
FLUID RESERVOIR TANK
2
4
13
Removal Steps
1. Electrical connector
2. Retainer
3. Fluid reservoir
4. O-ring
Installation Steps
To install, follow the removal steps in the
reverse order.
REMOVAL
NOTE:
Before removing fluid reservoir, remove brake fluid
from fluid reservoir.
1. Electrical Connector
2. Retainer
3. Fluid Reservoir
•The fluid level sensor is built into the fluid
reservoir. It cannot be removed for servicing.
4. O-ring
INSTALLATION
To install, follow the removal steps in the reverse
order, noting the following points;
4. O-ring
•O-ring must be set onto the fluid reservoir, before
installing fluid reservoir.
Retainer
Fluid reservoir
O-ring
Page 917 of 3573
POWER ASSISTED BRAKE SYSTEM 5C – 39
MASATER CYLINDER ASSEMBLY
6
21
5
3
4a
4b
Removal Steps
1. Electrical connector
2. Brake pipes
3. 2 attaching nuts
4a. P&B valve and bracket
4b. 3-way connector and bracket (Vehicle
with LSPV only)
5. Master cylinder
6. Spacer and 2 gaskets
Installation Steps
To install, follow the removal steps in the
reverse order.
This illustration is based on the LHD model.
330RW015
Page 918 of 3573

5C – 40 POWER ASSISTED BRAKE SYSTEM
REMOVAL
CAUTION:
When removing master cylinder from vacuum
booster, be sure to get rid of the internal negative
pressure of the vacuum booster (by, for instance,
disconnecting vacuum hose) in advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
While removing master cylinder, further, do not hold
the piston as it can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
1. Electrical Connector
2. Brake Pipes
•After disconnecting the brake pipe, cap or tape
the openings of the brake pipe to prevent the
entry of foreign matter.
3. 2 Attaching Nuts
4a. P & B Valve and Bracket
4b.3-way Connector and Bracket (Vehicle with LSPV
Only)
5. Master Cylinder
6. Spacer and 2 Gaskets
INSTALLATION
6. Spacer and 2 Gaskets
5. Master Cylinder
•When replacing the master cylinder or vacuum
booster or both, always measure the vacuum
booster push rod protrusion and adjust it as
necessary. (Refer to Vacuum Booster Assembly in
this section.)
4a. P & B Valve and Bracket
4b.3-way Connector and Bracket (Vehicle with LSPV
Only)
3. 2 Attaching Nuts
•Tighten the attaching nuts to the specified torque.
Attaching Nut Torque N·m (kg·cm / lb·in)
13 (130 / 113)
2. Brake Pipes
•Tighten the brake pipe to the specified torque.
Brake Pipe Torque N·m (kg·m / lb·ft)
Master Cylinder Side Others
12 (1.2 / 9) 16 (1.6 / 12)
1. Electrical Connector
Page 919 of 3573
POWER ASSISTED BRAKE SYSTEM 5C – 41
VACUUM BOOSTER ASSEMBLY
1
P&B valve
equipped
vehicle
LSPV
equipped
vehicle 2
4 3
3
5
Removal Steps
1. Master cylinder
2. Vacuum hose
3. Yoke clevis
4. Vacuum booster fixing nut
5. Vauum booster
Installation Steps
To install, follow the removal steps in the
reverse order.
This illustration is based on the LHD model.
331RW010
Page 920 of 3573

5C – 42 POWER ASSISTED BRAKE SYSTEM
REMOVAL
•Before removing the vacuum booster assembly,
disconnect and remove brake pipes.
1. Master Cylinder
•Refer to Master Cylinder Assembly in this Section.
CAUTION:
When removing master cylinder from vacuum booster,
be sure to get rid of the internal negative pressure of
the vacuum booster (by, for instance, disconnecting
vacuum hose) in advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
While removing master cylinder, further, do not hold
the piston as it can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
2. Vacuum Hose
3. Yoke Clevis
•Disconnect the yoke clevis from the brake pedal.
4. Vacuum Booster Fixing Nut
5. Vacuum Booster
INSPECTION AND REPAIR
Vacuum Hose
Inspect the check valve (1), which is installed inside
the vacuum hose.
1) Air should pass freely from the vacuum booster
side (3) to the engine side (2).
2) Air should not pass from the engine side (2) to the
vacuum booster side (3). If it does, the check valve
is inoperative and vacuum hose must be replaced.
INSTALLATION
5. Vacuum Booster
Vacuum booster push rod adjustment.
NOTE:
When replacing either master cylinder or vacuum
booster, be sure to measure push rod, and adjust
required.
Push rod gauge: 5-8840-2300-0 (J-39216)
Vacuum pump: 5-8840-0279-0 (J-23738-A)
Push rod support: 5-8840-2305-0 (J-39241)
1) Remove retainer from vacuum booster front shell
using a small screwdriver. Then gently draw plate
and seal assembly out of the shell inside.
ENG
1
2 3
360RX001