Page 913 of 5121

BRAKE PEDAL
BR-17
< ON-VEHICLE REPAIR >
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ON-VEHICLE REPAIR
BRAKE PEDAL
Exploded ViewINFOID:0000000003811183
Removal and InstallationINFOID:0000000003811184
REMOVAL
1. Remove instrument lower panel LH. Refer to IP-11, "Exploded View".
2. Disconnect the stop lamp switch and ASCD brake switch harness connectors.
3. Remove snap pin and clevis pin from clevis of brake booster.
4. Separate steering column assembly and lower shaft. Refer to ST-13, "
Exploded View".
5. Remove the brake pedal assembly.
CAUTION:
Hold the brake booster and master cylinder so as not to drop out or contact them to other parts.
6. Remove accelerator pedal from brake pedal assembly. Refer to ACC-3, "
Exploded View".
INSTALLATION
Note the following, and install the reverse order of removal.
Apply the multi-purpose grease to the clevis pin and the mating faces. (Not necessary if grease has been
already applied.)
NOTE:
The clevis pin may be inserted in either direction.
1. Clevis pin 2. Brake pedal assembly 3. Brake pedal pad
4. Snap pin 5. Clip 6. ASCD brake switch
7. Stop lamp switch
: Apply multi-purpose grease.
Refer to GI-4, "
Components" for symbols not described on the above.
JPFIA0341GB
Page 914 of 5121
BR-18
< ON-VEHICLE REPAIR >
BRAKE PEDAL
Inspection and Adjustment
INFOID:0000000003811185
INSPECTION AFTER REMOVAL
Check the following items and replace the brake pedal assembly if
necessary.
- Check the brake pedal upper rivet (made by aluminum) (A) for
deformation.
- Check the brake pedal for bend, damage, and cracks on the
welded parts.
- Check the lapping length (X) of sub-bracket (B) and slide plate (C).
Check clevis pin and plastic stopper (A) for damage and deforma-
tion. If any damage is found, replace clevis pin.
ADJUSTMENT AFTER INSTALLATION
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-6, "Inspection
and Adjustment".
Perform the accelerator pedal check after installing the accelerator pedal. Refer to ACC-4, "
Inspection". Standard
X : 5.0 mm (0.197 in) or more
JPFIA0342ZZ
PFIA0756J
Page 915 of 5121
BRAKE PIPING
BR-19
< ON-VEHICLE REPAIR >
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BRAKE PIPING
FRONT
FRONT : Exploded ViewINFOID:0000000003811186
WITHOUT VDC
WITH VDC
1. Brake tube 2. ABS actuator and electric unit (con-
trol unit)3. Connector
4. Connector bracket 5. Master cylinder assembly 6. Brake booster
7. Lock plate 8. Brake hose 9. Union bolt
10. Copper washer
A. To front brake hose B. To rear brake tube
Refer to GI-4, "
Components" for symbols in the figure.
JPFIA0343GB
Page 916 of 5121
BR-20
< ON-VEHICLE REPAIR >
BRAKE PIPING
FRONT : Hydraulic Piping
INFOID:0000000003811187
1. Brake tube 2. ABS actuator and electric unit (con-
trol unit)3. Connector
4. Connector bracket 5. Master cylinder assembly 6. Brake booster
7. Lock plate 8. Brake hose 9. Union bolt
10. Copper washer
A. To front brake hose B. To rear brake tube
Refer to GI-4, "
Components" for symbols in the figure.
JPFIA0344GB
JPFIA0345ZZ
Page 917 of 5121

BRAKE PIPINGBR-21
< ON-VEHICLE REPAIR >
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FRONT : Removal and InstallationINFOID:0000000003811188
REMOVAL
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
1. Remove tires.
2. Drain brake fluid. Refer to BR-9, "
Draining".
3. Loosen the flare nut with a flare nut wrenc h and separate the brake tube from the hose.
CAUTION:
Never scratch the flare nut and the brake tube.
Never bend sharply, twist or strong ly pull out the brake hoses and tubes.
Cover open end of brake tub es and hoses when disconnecting to prevent entrance of dirt.
4. Remove the union bolt and copper washers, and remove the brake hose from the brake caliper assembly.
5. Remove the lock plate and remove the brake hose.
INSTALLATION
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
1. Assemble the union bolt and the copper washers to the brake hose. CAUTION:
Never reuse the copper washer.
2. Align the brake hose pin to the projection (A) of the brake caliper assembly and tighten the union bolt (1) to the specified torque.
3. Install the brake tube to the brake hose, temporarily tighten the flare nut by hand until it does not rotate further, and fix the brake
hose to the bracket with the lock plate.
CAUTION:
Check that all brake hoses and tubes are not twisted and
bent.
4. Tighten the flare nut to the specified torque with a crowfoot and torque wrench.
CAUTION:
Never scratch the flare nut and the brake tube.
5. Refill with new brake fluid and perform the air bleeding. Refer to BR-10, "
Bleeding Brake System".
CAUTION:
Never reuse drained brake fluid.
FRONT : InspectionINFOID:0000000003811189
INSPECTION AFTER INSTALLATION
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer-
ence with other components when steering the steering wheel; no looseness at connections.
2. Depress the brake pedal with a force of 785N (80 kg, 177 lb) and hold down the pedal for approximately 5
seconds with the engine running. Check for any fluid leakage.
CAUTION:
Retighten the applicable connect ion to the specified torque and repair any abnormal (damaged,
worn or deformed) part if any brake fluid leakage is present.
1. ABS actuator and electric unit (con-
trol unit) 2. Front disc brake 3. Master cylinder assembly
4. Brake booster 5. Connector 6. Rear disc brake
A. Brake tube B. Brake hose : Flare nut
: Union bolt
JPFIA0099ZZ
Page 918 of 5121
BR-22
< ON-VEHICLE REPAIR >
BRAKE PIPING
REAR
REAR : Exploded ViewINFOID:0000000003811190
REAR : Hydraulic PipingINFOID:0000000003811191
1. Brake tube 2. Lock plate 3. Brake hose
4. Union bolt 5. Copper washer
A. To connector B. To rear brake hose C. To brake tube
Refer to GI-4, "
Components" for symbols in the figure.
JPFIA0346GB
JPFIA0345ZZ
Page 919 of 5121

BRAKE PIPINGBR-23
< ON-VEHICLE REPAIR >
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REAR : Removal and InstallationINFOID:0000000003811192
REMOVAL
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
1. Remove tires.
2. Drain brake fluid. Refer to BR-9, "
Draining".
3. Loosen the flare nut with a flare nut wrenc h and separate the brake tube from the hose.
CAUTION:
Never scratch the flare nut and the brake tube.
Never sharply bend, twist or strongly pull the brake hoses and tubes.
Cover the open end of brake tubes and hoses wh en disconnecting to prevent entrance of dirt.
4. Remove the union bolt and copper washers, and remove the brake hose from the brake caliper assembly.
5. Remove the lock plate and remove the brake hose from the vehicle.
INSTALLATION
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
1. Assemble the union bolt and the copper washers to the brake hose. CAUTION:
Never reuse copper washer.
2. Install the brake hose L-pin by aligning it with the brake caliper assembly positioning hole, and tighten the union bolt (1) to the
specified torque.
3. Connect the hose to the brake tube, temporarily tighten the flare nut by hand until it does not rotate further, and fix the brake hose
to the bracket with the lock plate.
CAUTION:
Check that the brake hoses and tubes are not twisted and
bent.
4. Tighten the flare nut to the specified torque with a crowfoot and torque wrench.
CAUTION:
Never scratch the flare nut and the brake tube.
5. Refill with new brake fluid and perform the air bleeding. Refer to BR-10, "
Bleeding Brake System".
CAUTION:
Never reuse drained brake fluid.
REAR : InspectionINFOID:0000000003811193
INSPECTION AFTER INSTALLATION
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer-
ence with other components when steering the steering wheel; no looseness at connections.
2. Depress the brake pedal with a force of 785N (80
kg, 177 lb) and hold down the pedal for approximately 5
seconds with the engine running. Check for any fluid leakage.
CAUTION:
1. ABS actuator and electric unit (con- trol unit) 2. Front disc brake 3. Master cylinder assembly
4. Brake booster 5. Connector 6. Rear disc brake
A. Brake tube B. Brake hose : Flare nut
: Union bolt
JPFIA0012ZZ
Page 920 of 5121
BR-24
< ON-VEHICLE REPAIR >
BRAKE PIPING
Retighten the applicable connection to the specified torque and repair any abnormal (damaged,
worn or deformed) part if any brake fluid leakage is present.