Page 209 of 5883

DUAL PROPORTIONING VALVE
BR-17
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DUAL PROPORTIONING VALVE
Removal and InstallationINFOID:0000000001726771
Removal
1. Disconnect brake lines from dual proportioning valve.
Mark brake lines for installation.
2. Remove dual proportioning valve bolt and dual proportioning valve.
3. Remove two bolts and bracket.
Installation
Installation is in the reverse order of removal.
When installing brake lines to the dual proportioning valve, tighten to specifications. Refer to BR-14,
"Hydraulic Circuit".
InspectionINFOID:0000000001726772
CAUTION:
Carefully monitor brake fluid level at master cylinder.
Use the recommended new brake fluid. Refer to MA-19, "
Fluids and Lubricants".
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on paint areas, wash it away with water immediately.
1. Connect commercially available brake fluid pressure gauge to
air bleeders of front and rear brakes on either LH and RH side.
2. Bleed air from the Tool.
3. Check fluid pressure by depressing brake pedal.
Unit: kPa (kg/cm2, psi)
If output pressure is out of specification, replace dual proportioning valve.
4. Bleed air after disconnecting the Tool. Refer to BR-8, "
Bleeding Brake System". Applied pressure
(Front brake)7,355 (75, 1,067)
Output pressure
(Rear brake)5,099 - 5,492 (52 - 56, 740 - 796)
SBR822BA
SBR823BA
Page 210 of 5883

BR-18
< ON-VEHICLE REPAIR >
BRAKE MASTER CYLINDER
BRAKE MASTER CYLINDER
On-Board InspectionINFOID:0000000001716996
LEAK INSPECTION
Check for leaking in a master cylinder installation surface, a reservoir tank installation surface, and brake
tube connections.
Removal and InstallationINFOID:0000000001716997
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, immediately wipe them with cloth and wash it away with water.
REMOVAL
1. Drain brake fluid. Refer to BR-8, "Drain and Refill" .
2. Remove battery. Refer to PG-6, "
Removal and Installation" .
3. Remove air duct and air cleaner. Refer to EM-27, "
Removal and Installation" (HR16DE), EM-154,
"Removal and Installation" (MR18DE), EM-269, "Removal and Installation" (K9K).
4. Disconnect brake fluid level switch harness connector.
5. Using a flare nut wrench, remove brake tube from master cylinder.
6. Remove master cylinder assembly nuts, and remove master cylinder assembly from vehicle..
INSTALLATION
CAUTION:
Refill using recommended brake fluid. Refer to MA-19, "
Fluids and Lubricants".
Never reuse drained brake fluid.
Check if the rod of primary piston has dust or scratches.
1. Install master cylinder to brake booster assembly, and tighten nuts to the specified torque. Refer to BR-19,
"Removal and Installation".
CAUTION:
Do not damage or strain rod of primary piston.
Apply silicone grease for O-ring, primary piston rod and
to inside of booster.
2. Install brake tube to master cylinder, and temporarily tighten the flare nuts on the brake tube to master cyl-
inder by hand.
3. Install brake tube to brake hose, then tighten flare nut to the specified torque using a flare nut torque
wrench. Refer to BR-14, "
Hydraulic Circuit" .
4. Connect brake fluid level switch harness connector.
5. Refill new brake fluid and bleed air. Refer toBR-8, "
Bleeding Brake System" .
SFIA2614E
Page 211 of 5883

BRAKE BOOSTER
BR-19
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BRAKE BOOSTER
On Board InspectionINFOID:0000000001716999
OPERATING CHECK
With the engine stopped, change the vacuum to the atmospheric pressure by depressing brake pedal several
times at intervals of 5 seconds.
Then with brake pedal fully depressed, start engine and when the
vacuum pressure reaches the standard, make sure that the clear-
ance between brake pedal and floor panel decreases.
AIRTIGHT CHECK
Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change the vacuum to the atmospheric pressure. Make sure that
distance between brake pedal and floor panel gradually increases.
Depress the brake pedal while engine is running, then stop engine
with brake pedal depressed. The pedal stroke should not change
after holding pedal down for 30 seconds.
Removal and InstallationINFOID:0000000001717000
COMPONENTS
NOTE:
WFIA0520E
WFIA0521E
Page 212 of 5883

BR-20
< ON-VEHICLE REPAIR >
BRAKE BOOSTER
LHD shown RHD similar.
REMOVAL
CAUTION:
Be careful not to splash brake fluid on painted areas such as body. It may cause paint damage. If
brake fluid is splashed on painted surfaces of body, wipe them with cloth immediately and then wash
it away with water.
Be careful not to deform or bend brake tubes while removing 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.
1. Remove vacuum hose from brake booster.
2. Remove master cylinder assembly. Refer to BR-18, "
Removal and Installation" .
3. Remove snap pin and clevis pin on the clevis of the brake
booster, and remove input rod from brake pedal.
4. Remove brake pedal nuts on pedal bracket.
5. Remove between spacer and dash panel nut from dash panel.
6. Remove brake booster and spacer from vehicle.
7. Remove spacer from brake booster.
INSTALLATION
1. Reservoir tank 2. Master cylinder 3. Brake booster
4. Clevis 5. Spacer 6. Gasket
⇐:Up
SFIA3095E
SFIA2044E
Page 213 of 5883

BRAKE BOOSTER
BR-21
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1. Loosen lock nut to adjust input rod length so that the length B
satisfies the specified value.
2. Install spacer to brake booster and tighten spacer nut (brake
booster side) to the specified torque.
3. After adjusting length “B”, temporarily tighten lock nut to install
brake booster assembly to dash panel. At this time, make sure
to install a gasket between brake booster and vehicle.
CAUTION:
Be sure to install the gasket between brake booster and
vehicle.
4. Connect brake pedal to clevis of input rod with the clevis pin and snap pin.
5. Install brake pedal bracket nuts and tighten them to the specified torque.
6. Adjust the height and play of brake pedal. Refer to BR-6, "
Inspection and Adjustment" .
7. Tighten lock nut of input rod to the specified torque. Refer to "COMPONENTS" .
8. Install vacuum hose into brake booster. Refer to BR-22, "
Removal and Installation" .
9. Bleed air from brake system. Refer to BR-8, "
Bleeding Brake System" . Length “B” : 154 - 161 mm (6.06 - 6.34 in)
SGIA0060E
Page 214 of 5883
BR-22
< ON-VEHICLE REPAIR >
VACUUM LINES
VACUUM LINES
ComponentINFOID:0000000001717001
NOTE:
LHD shown RHD similar.
Removal and InstallationINFOID:0000000001717002
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.
Insert vacuum hose at least 24 mm (0.94 in).
Never use lubricating oil during assembly.
InspectionINFOID:0000000001717003
VISUAL INSPECTION
Check for improper assembly, damage and aging.
CHECK VALVE INSPECTION
Airtightness Inspection
1. Clamp 2. Engine side indicator stamp (built-in
check valve)3. Vacuum hose
4. Clip 5. Clip position stamp 6. Vacuum tube
7. To brake booster A. To intake manifold B. To brake booster
WFIA0541E
SBR225B
Page 215 of 5883
VACUUM LINES
BR-23
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Use a handy vacuum pump to check.
Replace vacuum hose with the check valve as a set if damage or
deformation is present at the vacuum hose.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 216 of 5883

BR-24
< ON-VEHICLE REPAIR >
FRONT DISC BRAKE
FRONT DISC BRAKE
ComponentINFOID:0000000001717005
CAUTION:
Clean dust on caliper and brake pad with a vacuum dust collector. Do not blow with compressed air.
While removing brake pad or cylinder body, do not depress brake pedal because piston will pop out.
It is not necessary to remove torque member mounting bolts and brake hose except for disassembly
or replacement of caliper assembly. In this case, hang cylinder body with a wire so that brake hose is
not under tension.
Do not damage piston boot.
If any shim is subject to serious corrosion, replace it with a new one.
Keep rotor free from brake fluid.
When replacing brake pad, replace shim with a new one.
Removal and Installation of Brake PadINFOID:0000000001717006
REMOVAL
1. Remove tires from vehicle.
1. Union bolt 2. Brake hose 3. Copper washer
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Inner shim cover 12. Inner shim
13. Inner pad 14. Pad wear sensor 15. Pad retainer
16. Outer pad 17. Outer shim 18. Outer shim cover
19. Sliding pin 20. Sliding pin boot 21. Bushing
22. Torque member mounting bolt 23. Torque member : Front
: Brake fluid 1: M-77 grease 2: Rubber grease
3: Polyglycol ether based lubricant 4: M7439 grease
Refer to GI section GI-3
for symbol marks unless shown.
WFIA0535E