REAR DISC BRAKE
BR-29
< ON-VEHICLE REPAIR >
C
D
E
G
H
I
J
K
L
MA
B
BR
N
O
P
3. Drain brake fluid. Refer to BR-8, "Bleeding Brake System".
4. Remove connecting bolt and torque member bolts using power tool, and remove cylinder body.
5. Remove caliper and disc rotor. If the disc rotor cannot be removed, remove as follows:
Make sure parking brake lever is completely disengaged.
Hold down the disc rotor with the wheel nut and remove the
adjuster hole plug.
Insert a flat-bladed screwdriver through the plug opening and
rotate the star wheel on the adjuster assembly in the direction
shown to loosen and retract the brake shoes.
Prior to removing disc rotor, make alignment mark using a
marker between the hub and disc rotor.
Remove wheel nut and rotor.
INSTALLATION
CAUTION:
Refill with new brake fluid. Refer to MA-19, "
Fluids and Lubricants".
Never reuse drained brake fluid.
1. Install disc rotor.
Align marks made during removal on the hub and disc rotor.
2. Install cylinder body to the vehicle, and tighten torque member bolts to the specification. Refer to BR-27,
"Component".
CAUTION:
Before installing cylinder body to the vehicle, wipe off oil and grease on washer seats on axle
assembly and mounting surface of cylinder body.
3. Install brake hose to cylinder body and tighten connecting bolt to the specification. Refer to BR-27, "
Com-
ponent".
CAUTION:
Do not reuse the copper washer for connecting bolts.
Securely attach brake hose to protrusion on cylinder body.
4. Add new brake fluid and bleed air. Refer to BR-8, "
Bleeding Brake System".
5. Install master cylinder reservoir cap.
6. Adjust the parking brake. Refer to PB-4, "
On-Vehicle Service".
7. Attach the tires to the vehicle. Refer to WT-6, "
Rotation".
CAUTION:
Burnish the brake contact surfaces when refinishing or replacing brake rotors, after replacing pads, or
if a soft pedal occurs at very low mileage. Refer to BR-29, "
Brake Burnishing".
Brake BurnishingINFOID:0000000001724670
Burnish the brake contact surface according to the following procedure after refinishing or replacing rotors,
after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal /foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH).
Adjust brake pedal /foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.
WFIA0018E
BRC-6
< BASIC INSPECTION >[ABS]
DIAGNOSIS AND REPAIR WORKFLOW
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work FlowINFOID:0000000001731351
PRECAUTIONS FOR DIAGNOSIS
If steering angle sensor, steering system parts, suspension system parts, ABS actuator and electric unit (con-
trol unit) or tires have been replaced, or if wheel alignment has been adjusted, be sure to adjust neutral posi-
tion of steering angle sensor before driving. Refer to BRC-90, "
ADJUSTMENT OF STEERING ANGLE
SENSOR NEUTRAL POSITION : Description".
BRC-10
< BASIC INSPECTION >[ABS]
INSPECTION AND ADJUSTMENT
INSPECTION AND ADJUSTMENT
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description
INFOID:0000000001731353
After replacing the ABS actuator and electric unit (control unit), perform the following procedures:
Neutral position adjustment for the steering angle sensor
Calibration of the decel G sensor
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Re-
quirement
INFOID:0000000001731354
1.PERFORM THE NEUTRAL POSITION ADJUSTMENT FOR THE STEERING ANGLE SENSOR
Perform the neutral position adjustment for the steering angle sensor.
>> Refer to BRC-90, "
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Spe-
cial Repair Requirement", GO TO 2
2.PERFORM CALIBRATION OF THE DECEL G SENSOR
Perform calibration of the decel G sensor.
>> Refer to BRC-92, "
CALIBRATION OF DECEL G SENSOR : Special Repair Requirement".
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Description
INFOID:0000000001731355
Refer to the table below to determine if adjustment of steering angle sensor neutral position is required.
×: Required –: Not required
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Re-
pair Requirement
INFOID:0000000001731356
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION
CAUTION:
To adjust neutral position of steering angle sensor, make sure to use CONSULT-III
(Adjustment cannot be done without CONSULT-III)
1.ALIGN THE VEHICLE STATUS
Stop vehicle with front wheels in straight-ahead position.
Situation Adjustment of steering angle sensor neutral position
Removing/Installing ABS actuator and electric unit (control unit) —
Replacing ABS actuator and electric unit (control unit)×
Removing/Installing steering angle sensor×
Replacing steering angle sensor×
Removing/Installing steering components×
Replacing steering components×
Removing/Installing suspension components×
Replacing suspension components×
Change tires to new ones—
Tire rotation—
Adjusting wheel alignment×
INSPECTION AND ADJUSTMENT
BRC-11
< BASIC INSPECTION >[ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
N
O
P
>> GO TO 2
2.PERFORM THE NEUTRAL POSITION ADJUSTMENT FOR THE STEERING ANGLE SENSOR
1. On the CONSULT-III screen, touch “WORK SUPPORT” and “ST ANG SEN ADJUSTMENT” in order.
2. Touch “START”.
CAUTION:
Do not touch steering wheel while adjusting steering angle sensor.
3. After approximately 10 seconds, touch “END”.
NOTE:
After approximately 60 seconds, it ends automatically.
4. Turn ignition switch OFF, then turn it ON again.
CAUTION:
Be sure to perform above operation.
>> GO TO 3
3.CHECK DATA MONITOR
1. Run vehicle with front wheels in straight-ahead position, then stop.
2. Select “DATA MONITOR”. Then make sure “STR ANGLE SIG” is within 0±2.5°.
Is the steering angle within the specified range?
YES >> GO TO 4
NO >> Perform the neutral position adjustment for the steering angle sensor again, GO TO 1
4.ERASE THE SELF-DIAGNOSIS MEMORY
Erase the self-diagnosis memory of the ABS actuator and electric unit (control unit) and ECM.
ABS actuator and electric unit (control unit): Refer to BRC-25, "
CONSULT-III Function (ABS)".
ECM, refer to:
-EC-107, "
CONSULT-III Function" (HR16DE with EURO-OBD)
-EC-462, "
CONSULT-III Function" (HR16DE without EURO-OBD)
-EC-772, "
CONSULT-III Function" (MR18DE)
-EC-1104, "
Diagnosis Description" (K9K)
Are the memories erased?
YES >> INSPECTION END
NO >> Check the items indicated by the self-diagnosis.
CALIBRATION OF DECEL G SENSOR
CALIBRATION OF DECEL G SENSOR : DescriptionINFOID:0000000001731357
Refer to the table below to determine if calibration of the decel G sensor is required.
×: Required –: Not required
Situation Calibration of decel G sensor
Removing/Installing ABS actuator and electric unit (control unit) —
Replacing ABS actuator and electric unit (control unit)×
Removing/Installing steering angle sensor×
Replacing steering angle sensor×
Removing/Installing steering components×
Replacing steering components×
Removing/Installing suspension components×
Replacing suspension components×
Change tires to new ones—
Tire rotation—
Adjusting wheel alignment×
BRC-86
< BASIC INSPECTION >[ESP/TCS/ABS]
DIAGNOSIS AND REPAIR WORKFLOW
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work FlowINFOID:0000000001731359
PRECAUTIONS FOR DIAGNOSIS
If steering angle sensor, steering system parts, suspension system parts, ABS actuator and electric unit (con-
trol unit) or tires have been replaced, or if wheel alignment has been adjusted, be sure to adjust neutral posi-
tion of steering angle sensor before driving. Refer to BRC-90, "
ADJUSTMENT OF STEERING ANGLE
SENSOR NEUTRAL POSITION : Description".
BRC-90
< BASIC INSPECTION >[ESP/TCS/ABS]
INSPECTION AND ADJUSTMENT
INSPECTION AND ADJUSTMENT
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description
INFOID:0000000001731361
After replacing the ABS actuator and electric unit (control unit), perform the following procedures:
Neutral position adjustment for the steering angle sensor
Calibration of the decel G sensor
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Re-
quirement
INFOID:0000000001731362
1.PERFORM THE NEUTRAL POSITION ADJUSTMENT FOR THE STEERING ANGLE SENSOR
Perform the neutral position adjustment for the steering angle sensor.
>> Refer to BRC-90, "
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Spe-
cial Repair Requirement", GO TO 2
2.PERFORM CALIBRATION OF THE DECEL G SENSOR
Perform calibration of the decel G sensor.
>> Refer to BRC-92, "
CALIBRATION OF DECEL G SENSOR : Special Repair Requirement".
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Description
INFOID:0000000001731363
Refer to the table below to determine if adjustment of steering angle sensor neutral position is required.
×: Required –: Not required
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Re-
pair Requirement
INFOID:0000000001731364
ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION
CAUTION:
To adjust neutral position of steering angle sensor, make sure to use CONSULT-III
(Adjustment cannot be done without CONSULT-III)
1.ALIGN THE VEHICLE STATUS
Stop vehicle with front wheels in straight-ahead position.
Situation Adjustment of steering angle sensor neutral position
Removing/Installing ABS actuator and electric unit (control unit) —
Replacing ABS actuator and electric unit (control unit)×
Removing/Installing steering angle sensor×
Replacing steering angle sensor×
Removing/Installing steering components×
Replacing steering components×
Removing/Installing suspension components×
Replacing suspension components×
Change tires to new ones—
Tire rotation—
Adjusting wheel alignment×
INSPECTION AND ADJUSTMENT
BRC-91
< BASIC INSPECTION >[ESP/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
N
O
P
>> GO TO 2
2.PERFORM THE NEUTRAL POSITION ADJUSTMENT FOR THE STEERING ANGLE SENSOR
1. On the CONSULT-III screen, touch “WORK SUPPORT” and “ST ANG SEN ADJUSTMENT” in order.
2. Touch “START”.
CAUTION:
Do not touch steering wheel while adjusting steering angle sensor.
3. After approximately 10 seconds, touch “END”.
NOTE:
After approximately 60 seconds, it ends automatically.
4. Turn ignition switch OFF, then turn it ON again.
CAUTION:
Be sure to perform above operation.
>> GO TO 3
3.CHECK DATA MONITOR
1. Run vehicle with front wheels in straight-ahead position, then stop.
2. Select “DATA MONITOR”. Then make sure “STR ANGLE SIG” is within 0±2.5°.
Is the steering angle within the specified range?
YES >> GO TO 4
NO >> Perform the neutral position adjustment for the steering angle sensor again, GO TO 1
4.ERASE THE SELF-DIAGNOSIS MEMORY
Erase the self-diagnosis memory of the ABS actuator and electric unit (control unit) and ECM.
ABS actuator and electric unit (control unit): Refer to BRC-25, "
CONSULT-III Function (ABS)".
ECM, refer to:
-EC-107, "
CONSULT-III Function" (HR16DE with EURO-OBD)
-EC-462, "
CONSULT-III Function" (HR16DE without EURO-OBD)
-EC-772, "
CONSULT-III Function" (MR18DE)
-EC-1104, "
Diagnosis Description" (K9K)
Are the memories erased?
YES >> INSPECTION END
NO >> Check the items indicated by the self-diagnosis.
CALIBRATION OF DECEL G SENSOR
CALIBRATION OF DECEL G SENSOR : DescriptionINFOID:0000000001731365
Refer to the table below to determine if calibration of the decel G sensor is required.
×: Required –: Not required
Situation Calibration of decel G sensor
Removing/Installing ABS actuator and electric unit (control unit) —
Replacing ABS actuator and electric unit (control unit)×
Removing/Installing steering angle sensor×
Replacing steering angle sensor×
Removing/Installing steering components×
Replacing steering components×
Removing/Installing suspension components×
Replacing suspension components×
Change tires to new ones—
Tire rotation—
Adjusting wheel alignment×
CL-4
< SERVICE INFORMATION >
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting ChartINFOID:0000000001375292
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageCL-5CL-8EM-207EM-302CL-11CL-13
XX-XX, "*****"
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Inspection and adjustment)
CLUTCH LINE (Air in line)
ENGINE MOUNTING (Loose)
CSC (Concentric slave cylinder) (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 12 55555 5667