Page 825 of 3502
BRAKE PEDAL
BR-7
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Removal and InstallationBFS000BH
COMPONENTS
NOTE:
Clevis pin can be installed from both left and right.
REMOVAL
1. Remove instrument driver lower panel. Refer to IP-10,
"INSTRUMENT PANEL ASSEMBLY" .
2. Disconnect stop lamp switch connector, brake switch and/or
ASCD cancel switch connector.
3. Remove stop lamp switch, brake switch and/or ASCD cancel
switch from brake pedal assembly.
4. Remove snap pin and clevis pin from brake booster clevis.
5. Remove pedal bracket mounting nuts and bolt, and remove
brake pedal assembly from vehicle.
1. Clevis pin 2. Clip 3. Stop lamp switch
4. Brake switch (Models with VDC)
ASCD cancel switch (Models with
ASCD)5. Brake pedal pad 6. Brake pedal assembly
7. Snap pin
Refer to GI-10, "
Components" and the followings for the symbols in the figure.
: Apply multi-purpose grease.
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Page 826 of 3502
BR-8
BRAKE PEDAL
INSPECTION AFTER REMOVAL
Check rivets in upper part of brake pedal are not deformed.
Check that joint length “L” of sub-bracket and sliding plate is 5.5
mm (0.217 in) or more.
Check brake pedal for bend, damage, and cracks on the welded
parts.
Replace brake pedal assembly if detected.
Check clevis pin and plastic stopper for damage and deforma-
tion. Replace clevis pin if there are.
INSTALLATION
Install in reverse order of the removal.
When installing brake pedal, tighten nuts and bolt according to
the order shown in the figure.
Check brake pedal for smooth operation. There should be no
binding or sticking when applying or releasing brake pedal.
Adjust brake pedal height after installing brake pedal assembly
to vehicle. Refer to BR-6, "
Inspection and Adjustment" .
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SBR997
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Page 827 of 3502

BRAKE FLUID
BR-9
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BRAKE FLUIDPFP:KN100
Checking Brake Fluid LevelBFS000BI
Make sure that a brake fluid level in reservoir tank is within the
standard (between MAX and MIN lines).
Visually check around reservoir tank for fluid leakage.
If fluid level is excessively low, check brake system for leakage.
Release parking brake pedal and see if brake warning lamp
goes off. If not, check brake system for fluid leakage.
Drain and RefillBFS000BJ
CAUTION:
Refill with new brake fluid “DOT 3 or DOT 4”.
Do not reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of the body, immediately wipe off them and wash it away with water
immediately.
Before working, turn ignition switch OFF and disconnect electrical connector of ABS actuator and
electric unit (control unit) or battery cables.
1. Connect a vinyl tube to bleed valve.
2. Depress brake pedal, loosen bleed valve, and gradually remove
brake fluid.
3. Clean inside of reservoir tank, and refill with new brake fluid.
4. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
brake pedal until it stops. Tighten bleed valve. Release brake
pedal. Repeat this process a few time, them pause to and new
brake fluid to master cylinder. Continue until new brake fluid
flows out.
5. Bleed air. Refer to BR-10, "
Bleeding Brake System" .
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BRA0007D
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Page 828 of 3502

BR-10
BRAKE FLUID
Bleeding Brake SystemBFS000BK
CAUTION:
Carefully monitor brake fluid level in reservoir tank during
bleeding operation.
Refill with new brake fluid “DOT 3 or DOT 4”. Make sure it is
at least half way at all times while bleeding air out of sys-
tem.
Place a container under master cylinder not to spill brake
fluid.
Turn ignition switch to the OFF and disconnect connector
for ABS actuator and electric unit (control unit) or battery
cable from negative terminal before working.
1. Connect a vinyl tube to rear right brake caliper bleed valve.
2. Fully depress brake pedal 4 or 5 times.
3. With brake pedal depressed, loosen bleed valve to bleed air in
brake line, and then tighten it immediately.
4. Repeat steps 2 and 3 until all of the air is out of the brake line.
5. Tighten bleed valve to the specified torque. Refer to front disc
brake: BR-26, "
Components" , rear disc brake: BR-33, "Compo-
nents" .
6. From step 1 to 5 above, with master cylinder reservoir tank filled
at least half way, bleed air from brake hydraulic line bleed valves
in the following order:
Rear right brake→Front left brake→Rear left brake→Front right brake
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Page 829 of 3502

BRAKE TUBE AND HOSE
BR-11
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BRAKE TUBE AND HOSEPFP:46210
Hydraulic CircuitBFS000FY
CAUTION:
All brake tubes and hoses must be free from excessive bending, twisting and pulling.
Make sure that there is no interference with other parts when turning steering both clockwise and
counterclockwise.
Brake tubes and hoses is an important safety part. If a brake fluid leak is detected, always disas-
semble the parts. Replace applicable part with a new one, if necessary.
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe off them and wash it away with water
immediately.
Do not bend or twist brake hose sharply, or strongly pull it.
When removing components, cover brake line connections so that no dirt, no dust, or other for-
eign matter gets in.
Refill with new brake fluid “DOT 3 or DOT4”.
Do not reuse drained brake fluid.
1. Actuator 2. Master cylinder 3. Brake booster
: Flare nut 18.2 N·m (1.9 kg-m, 13 ft-lb) (Models with VDC)
16.2 N·m (1.7 kg-m, 12 ft-lb) (Models without VDC)
: Union bolt 18.2 N·m (1.9 kg-m, 13 ft-lb)
: Flare nut 16.2 N·m (1.7 kg-m, 12 ft-lb)
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Page 830 of 3502

BR-12
BRAKE TUBE AND HOSE
Removal and Installation of Front Brake Tube and HoseBFS000BM
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from brake caliper
assembly.
4. Remove lock plate and remove brake hose from vehicle.
INSTALLATION
1. Install brake hose by aligning with the protrusion on brake caliper assembly, and tighten union bolt to the
specified torque. Refer to BR-11, "
Hydraulic Circuit" .
CAUTION:
Do not reuse copper washer.
2. Install brake hose to brake tube. Temporarily tighten flare nut by hand as much as possible. Secure them
to bracket with lock plate.
3. Using a flare nut torque wrench, tighten flare nut to the specified torque. Refer to BR-11, "
Hydraulic Cir-
cuit" .
4. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
Removal and Installation of Rear Brake Tube and HoseBFS000BN
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from brake caliper
assembly.
4. Remove lock plate and remove brake hose from vehicle.
INSTALLATION
1. Install the L-shape metal fitting of brake hose to brake caliper
assembly positioning hole, and then tighten union bolt to the
specified torque. Refer to BR-11, "
Hydraulic Circuit" .
CAUTION:
Do not reuse copper washer.
2. Install brake hose to brake tube. Temporarily tighten flare nut by
hand as much as possible. Secure them to bracket with lock
plate.
3. Using a flare nut torque wrench, tighten flare nut to the specified
torque. Refer to BR-11, "
Hydraulic Circuit" .
4. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleed-
ing Brake System" .
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BRAKE TUBE AND HOSE
BR-13
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Inspection After InstallationBFS000BO
CAUTION:
If leakage occurs around brake tube and hose connections, retighten or, if damaged part is detected,
replace the damage part.
1. Check brake hoses, brake tubes, and connections for fluid leakage, damage, twists, deformation, contact
with other parts, and loose connections.
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately
5 seconds, check for fluid leak each part.
Page 832 of 3502

BR-14
BRAKE MASTER CYLINDER
BRAKE MASTER CYLINDERPFP:46010
On-Board InspectionBFS000BP
LEAK INSPECTION
Check for leaking in a master cylinder installation surface, a reservoir tank installation surface, and brake
tube connections.
Removal and InstallationBFS000BQ
CAUTION:
Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe it off and them wash it away with water imme-
diately.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Remove brake fluid level switch harness connector.
3. Using a flare nut wrench, remove brake tubes from master cylinder assembly.
4. Remove master cylinder mounting nuts, remove master cylinder assembly from vehicle.
INSTALLATION
CAUTION:
Refill with new brake fluid “DOT 3 or DOT 4”.
Do not reuse drained brake fluid.
1. Install in the reverse order of removal and tighten nuts to the specified torque. Refer to BR-22, "
COMPO-
NENTS" .
Models with VDC
Apply silicon grease in inner kit to O-ring and it's surrounding
areas and to booster side inner wall.
CAUTION:
Do not damage the sliding surface of primary piston rod
and do not allow foreign materials on it's surface.
Do not reuse the O-ring.
2. Install brake tube to master cylinder assembly and temporarily
tighten flare nut by hand.
3. Tighten brake tube flare nut to the specified torque using a flare
nut torque wrench. Refer to BR-11, "
Hydraulic Circuit" .
4. Install brake fluid level switch harness connector.
5. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
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