Page 2785 of 4179
BRAKE MASTER CYLINDER
BR-21
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BR
3. Visually inspect the secondary piston slit through the piston
stopper mounting hole and then install the piston stopper while
pushing in the primary piston.
4. Insert plate and guide into cylinder body.
CAUTION:
Make sure not to damage primary piston rod.
Pay attention to the orientation of guide assembly.
Do not drop O-ring.
Make sure guide and/or plate are not inserted at an angle.
5. Cover primary piston rod with cloth to prevent it getting dam-
aged, and attach snap ring with primary piston pushed in.
CAUTION:
Make sure the area around snap ring is snug in the cylin-
der body bore groove.
Do not reuse snap ring.
6. Apply brake fluid to grommet and attach reservoir tank to master
cylinder.
CAUTION:
Do not reuse grommet.
NOTE:
Attach reservoir tank in the orientation shown in the figure.
BRA0560D
SFIA1293E
BRA0561D
BRA0568D
Page 2786 of 4179
BR-22
BRAKE MASTER CYLINDER
7. Place the side of cylinder body with chamfering around the pin
insertion hole up, and secure the cylinder body flange section
with a vise.
CAUTION:
When securing in a vise, use copper plates or cloth to pro-
tect flange.
8. Tilt reservoir tank so that mounting pin can be inserted as shown
in the figure, and insert mounting pin. When mounting pin has
passed the master cylinder pinhole, return reservoir tank to a
level position. Attach mounting pin to the opposite mounting pin
hole of reservoir tank so that it is the same as the insertion side.
CAUTION:
Be sure to insert pin from the chamfered pinhole of cylin-
der body.
Do not reuse reservoir tank and mounting pin.
BRA0558D
SFIA0702E
Page 2787 of 4179

BRAKE BOOSTER
BR-23
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BRAKE BOOSTERPFP:47200
On-Vehicle Inspection and ServiceEFS000CC
FUNCTION INSPECTION
With engine stopped, discharge stored vacuum by depressing brake
pedal several times at 5 second intervals. With brake pedal fully
depressed, start the engine. Confirm that clearance between brake
pedal and floor panel decreases when engine vacuum stabilizes.
AIRTIGHTNESS INSPECTION
Run engine at idle for approximately 1 minute. Stop it after
applying vacuum to the booster. Depress brake pedal several
times with normal force to discharge the stored vacuum. Con-
firm that clearance between brake pedal and floor panel gradu-
ally increases as the brake pedal is depressed.
Run engine. Depress and hold brake pedal then stop engine.
Keep brake pedal depressed for 30 seconds or more and make
sure the pedal stroke does not change.
Removal and InstallationEFS000CD
REMOVAL
CAUTION:
Be careful not to deform or bend brake piping while remov-
ing and installing brake booster.
Replace clevis pin if it is damaged.
Be careful not to damage brake booster stud bolt threads. If
brake booster is tilted or inclined during installation, dash
panel may damage the threads.
Be sure to install check valve in the correct orientation.
1. Remove vacuum piping from the brake booster.
2. Remove master cylinder.
3. Remove snap pin and clevis pin on the clevis of input rod. Remove input rod from the brake pedal.
4. Remove brake booster and brake pedal assembly mounting nuts.
5. Remove booster assembly from the engine compartment.
BRA0037D
SBR365AA
SFIA0139E
Page 2788 of 4179
BR-24
BRAKE BOOSTER
INSPECTION AFTER REMOVAL
Output rod length inspection
1. Using a handy vacuum pump, apply a vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to the brake
booster.
2. Check output rod length.
3.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that length “B” (in
the figure) satisfies the specified value.
2. After adjusting “B”, temporarily tighten lock nut to install booster
assembly to vehicle.
3. Connect brake pedal to input rod clevis.
4. Connect brake pedal assembly mounting nuts and tighten to the
specified torque.
5. Connect master cylinder to booster assembly.
6. Adjust brake pedal height and play.
7. Tighten input rod lock nut to the specified torque.
8. Bleed air. Refer to BR-9, "
Bleeding Brake System" . Reference value at vacuum of –66.7 kPa (–500 mmHg,
–19.69 inHg):
Without ESP models : 10.4 mm (0.409 in)
With ESP models : -6.2 mm (-0.244 in)
SBR208E
Length “B” standard : 125 mm (4.92 in)
SGIA0060E
Page 2789 of 4179
VACUUM LINES
BR-25
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VACUUM LINESPFP:41920
Removal and InstallationEFS000CE
RHD MODELS
LHD MODELS
CAUTION:
Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer
to the stamp or label to confirm correct installation. Brake booster will not operate normally if
hose is installed in the wrong direction.
SFIA2093E
1. Vacuum hose 2. Vacuum tube 3. Clip
4. Clamp
SFIA2094E
1. Vacuum hose 2. Clip 3. Clamp
Page 2790 of 4179
BR-26
VACUUM LINES
Insert the vacuum hose at least 24 mm (0.94 in).
Never use lubricating oil during assembly.
InspectionEFS000CF
VISUAL INSPECTION
Check for improper assembly, damage and aging.
CHECK VALVE INSPECTION
Airtightness Inspection
Use a hand-held vacuum pump to check.
SBR225B
When connected to booster side (1):
Vacuum decrease should be within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under
a vacuum of –66.7 kPa (–500 mmHg, –19.69
inHg)
When connected to engine side (2):
No vacuum will be applied
SFIA0210E
Page 2791 of 4179

FRONT DISC BRAKE
BR-27
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FRONT DISC BRAKEPFP:41000
ComponentEFS000CG
WARNING:
Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or
other materials.
CAUTION:
When cylinder body is open, do not depress brake pedal because piston will pop out.
Be careful not to damage piston boot or spill brake fluid oil on rotor. Always replace shims when
replacing pads.
If shims are rusted or show peeling of the rubber coat, replace them with new shims.
It is not necessary to remove torque member mounting bolt and brake hose union bolt except for
disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so
as not to stretch brake hose.
Burnish the brake pad contact surfaces after refinishing or replacing drums or rotors, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-31, "
BRAKE BUR-
NISHING PROCEDURE" .
InspectionEFS000CH
PAD THICKNESS
Check pad thickness by lifting vehicle, removing the wheel, and
looking through check hole on cylinder body. If necessary, use a
scale.
1. Torque member 2. Slid pin boot 3. Slid pin
4. Outer shim cover 5. Outer shim 6. Outer pad
7. Pad retainer 8. Inner pad 9. Inner shim
10. Inner shim cover 11. Piston boots 12. Piston
13. piston seal 14. Cylinder body 15. Slid pin bolt
16. Copper washer 17. Bleed valve 18. Brake hose union bolt
SFIA2142E
Standard pad thickness : 11 mm (0.43 in)
Pad wear limit : 2.0 mm (0.079 in)
MAA0439D
Page 2792 of 4179

BR-28
FRONT DISC BRAKE
Pad ReplacementEFS000CI
REMOVAL
CAUTION:
When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
1. Remove master cylinder reservoir tank cap.
2. Remove lower sliding pin bolt.
3. Hang cylinder body with a wire, and remove pads, pad retainers,
shims and pad return springs.
INSTALLATION
1. Apply brake grease on back of the pad and both sides of the shim. Install inner shim and inner shim cover
to inner pad, outer shim to outer pad.
2. Apply brake grease on a pad sliding part of pad retainer. Install pad retainers, pads and pad return springs
to torque member.
3. Connect cylinder body to torque member.
CAUTION:
When replacing pads with new ones, press piston in until the pads can be installed. Carefully mon-
itor brake master cylinder reservoir fluid level. Brake fluid will return, raising master cylinder res-
ervoir tank fluid level.
4. Insert lower sliding pin bolt and tighten to the specified torque.
5. Check brakes for drag.
Caliper Removal and InstallationEFS000CJ
REMOVAL
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve while depressing brake pedal.
3. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
4. Remove disc rotor.
SBR433D
SBR932C
SBR979B