Page 2601 of 3000

BRAKE – BRAKE BOOSTERBR–23
BR
INSTALLATION
1. INSTALL BRAKE VACUUM CHECK VALVE
ASSEMBLY
(a) Install the brake vacuum check valve assembly and
check valve grommet to the brake booster
assembly.
2. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake
booster with master cylinder.
3. INSTALL BRAKE MASTER CYLINDER ASSEMBLY
(a) Install the brake booster assembly with the 4 nuts.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
(b) Slide the clip and connect the brake master cylinder
reservoir hose to the brake master cylinder union.
(c) Slide the clip and connect the vacuum hose from
the brake vacuum check valve assembly.
4. INSTALL PUSH ROD PIN
(a) Install the push rod pin to the brake booster push
rod.
5. INSTALL BRAKE LINE
(a) Install the front brake tube No. 1, front brake tube
No. 2, front brake tube No. 3 and front brake tube
No. 4.
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)
(b) Install the rear brake tube No. 1and rear brake tube
No. 2.
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)
6. INSTALL BRAKE ACTUATOR ASSEMBLY (w/o VSC)
SST 09023-00101
HINT:
See page BC-184
7. INSTALL ABS & TRACTION ACTUATOR ASSEMBLY
(w/ VSC)
SST 09023-00101
HINT:
See page BC-179.
8. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
9. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
3)
10. BLEED BRAKE MASTER CYLINDER (See page BR-3)
11. BLEED BRAKE LINE (See page BR-4)
12. BLEED BRAKE ACTUATOR (w/ VSC) (See page BR-
4)
13. CHECK FLUID LEVEL IN RESERVOIR (See page BR-
7)
14. CHECK BRAKE FLUID LEAKAGE
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Page 2602 of 3000
BR–24BRAKE – BRAKE BOOSTER
BR
15. INSTALL INSTRUMENT PANEL SAFETY PAD INSERT
SUB-ASSEMBLY NO. 1
(a) Install the instrument panel safety pad insert sub-
assembly No. 1 with the 4 bolts.
16. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-
ASSEMBLY LOWER LH
(a) Install the instrument panel finish panel sub-
assembly lower LH with the 2 bolts.
17. INSTALL COWL SIDE TRIM BOARD LH
(a) Install the cowl trim board plate LH with the nut.
18. INSTALL FRONT DOOR SCUFF PLATE LH
19. INSTALL COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT
20. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
21. INSPECT BRAKE PEDAL HEIGHT (See page BR-9)
22. CHECK BRAKE ACTUATOR WITH INTELLIGENT
TESTER
Type of Brake Actuator See Procedure
With VSCBC-178
Without VSCBC-183
Page 2603 of 3000
BR–8BRAKE – BRAKE PEDAL
BR
BRAKE
BRAKE
BRAKE PEDAL
COMPONENTS
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Page 2604 of 3000

BRAKE – BRAKE PEDALBR–9
BR
ON-VEHICLE INSPECTION
1. INSPECT BRAKE PEDAL HEIGHT
(a) Check the brake pedal height.
Pedal height from dash panel:
150.3 to 160.3 mm (5.917 to 6.311 in.)
NOTICE:
Do not adjust the pedal height. Doing so by
changing the push rod length will structurally
change the pedal ratio.
2. CHECK AND ADJUST STOP LIGHT SWITCH
(a) Disconnect the stop light switch assembly connector
from the stop light switch assembly.
(b) Turn the stop light switch assembly
counterclockwise and remove the stop light switch
assembly.
(c) Insert the stop light switch assembly until the body
hits the cushion.
NOTICE:
When inserting the stop light switch assembly,
support the pedal from behind so that the pedal
is not pushed in.
(d) Make a quarter turn clockwise to install the stop light
switch assembly.
NOTICE:
• When inserting the stop light switch
assembly, support the pedal from behind so
that the pedal is not pushed in.
• The turning torque for installing the stop light
switch assembly.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less
(e) Connect the stop light switch connector to the stop
light switch assembly.
(f) Check the protrusion of the rod.
Protrusion of the rod:
0.5 to 2.5mm (0.020 to 0.098 in.)
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Page 2605 of 3000
BR–10BRAKE – BRAKE PEDAL
BR
3. CHECK PEDAL FREE PLAY
(a) Stop the engine and depress the brake pedal
several times until there is no more vacuum left in
the booster.
(b) Push in the pedal until the beginning of the
resistance is felt. Measure the distance, as shown.
Pedal free play:
1 to 6 mm (0.04 to 0.24 in.)
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake pedal.
With the engine running, depress the pedal and
measure the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490
N (50 kgf, 110 lbf):
More than 52 mm (2.0 in.)
HINT:
If the distance is out of the specification,
troubleshoot the brake system.
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Page 2606 of 3000

BRAKE – BRAKE PEDALBR–13
BR
REASSEMBLY
1. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad to the brake pedal sub-
assembly.
2. INSTALL PUSH ROD PIN
(a) Apply lithium soap base glycol grease to inside
surface of 2 new push rod bushes.
(b) Install the 2 new push rod bushes.
(c) Install the 2 push rod pins with the 2 plate to the
brake pedal.
(d) Using needle-nose pliers, install the 2 new E-rings
to the 2 push rod pins.
NOTICE:
Install the E-ring securely to the grooves of the
push rod pin.
3. INSTALL BRAKE PEDAL BUSH
(a) Apply lithium soap base glycol grease to inside
surface of 4 new brake pedal bushes.
(b) Install the 4 brake pedal bushes to the brake pedal.
4. INSTALL BRAKE PEDAL SHAFT COLLAR
(a) Apply the lithium soap base glycol grease to inside
surface of 2 brake pedal shaft collars.
(b) Install the 2 brake pedal shaft collars to the brake
pedal.
5. INSTALL BRAKE PEDAL
(a) Install the 2 brake pedal shafts, 2 nuts, brake pedal
and brake pedal bracket No. 3 to the brake pedal
support sub-assembly.
6. INSTALL STOP LIGHT SWITCH CUSHION
(a) Install the stop light switch cushion to the brake
pedal sub-assembly.
7. INSTALL STOP LIGHT SWITCH ASSEMBLY
(a) Install the stop light switch mounting adjuster to the
brake pedal support sub-assembly.
(b) Install the stop light switch assembly until the body
hits the cushion.
(c) Make a quarter turn clockwise to install the stop light
switch assembly.
NOTICE:
The turning torque for installing the stop light
switch assembly.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less
HINT:
Due to the inverse screw structure, if the stop light
switch assembly is turned clockwise, the stop light
switch assembly moves in the direction to be pulled
out.
Page 2607 of 3000

BR–14BRAKE – BRAKE PEDAL
BR
INSTALLATION
1. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY
(a) Install the brake pedal support sub-assembly with
the 4 nuts.
Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
(b) Install the clip and clevis pin to the brake pedal
lever.
(c) Using needle-nose pliers, install the tension spring.
(d) Install the 2 bolts to the brake pedal bracket No. 3.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
(e) Install the stop light switch harness clamp to the
brake pedal support sub-assembly.
(f) Connect the stop light switch connector.
2. FULLY TIGHTEN BRAKE PEDAL SHAFT
(a) Fully tighten the 2 brake pedal shafts.
Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)
3. INSTALL INSTRUMENT PANEL SAFETY PAD INSERT
SUB-ASSEMBLY NO. 1
(a) Install the instrument panel safety pad insert sub-
assembly No. 1 with the 4 bolts.
4. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-
ASSEMBLY LOWER LH
(a) Install the instrument panel finish panel sub-
assembly lower LH with the 2 bolts.
5. INSTALL COWL SIDE TRIM BOARD LH
6. INSTALL FRONT DOOR SCUFF PLATE LH
7. INSPECT BRAKE PEDAL HEIGHT (See page BR-9)
8. CHECK PEDAL FREE PLAY (See page BR-10)
9. CHECK PEDAL RESERVE DISTANCE (See page BR-
10)
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Page 2608 of 3000

BR–26BRAKE – FRONT BRAKE
BR
DISASSEMBLY
1. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Using soft jaws on the vise, hold the front disc brake
cylinder mounting LH in the vise through aluminum
plates.
(b) Using a screwdriver and hammer, remove the 2
front disc brake bush dust boots from the front disc
brake cylinder mounting LH.
2. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and
cylinder boot.
3. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rug, between the front disc brake
piston and the disc brake cylinder sub-assembly.
(b) Use compressed air to remove the front disc brake
piston from the disc brake cylinder sub-assembly.
CAUTION:
Do not place your fingers in front of the piston
when using compressed air.
NOTICE:
Do not spatter the brake fluid.
4. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from
the front disc brake cylinder sub-assembly.
NOTICE:
Do not damage the inner cylinder and cylinder
groove.
5. REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a) Remove the front disc brake bleeder plug from the
front disc brake cylinder sub-assembly.
6. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
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