BR-6
< ON-VEHICLE MAINTENANCE >
BRAKE PEDAL
ON-VEHICLE MAINTENANCE
BRAKE PEDAL
Inspection and AdjustmentINFOID:0000000003811172
INSPECTION
Brake Pedal Height
Check the brake pedal height (H1) between the dash lower panel (1)
and the brake pedal upper surface.
CAUTION:
Remove the floor trim.
Stop Lamp Switch and ASCD Brake Switch
Check the clearance (C) between stopper rubber (1) and stop lamp
switch and ASCD brake switch (2) threaded end.
CAUTION:
The stop lamp must be turned off when the brake pedal is
released.
NOTE:
Pull the brake pedal pad to make the clearance between stopper
rubber and stop lamp switch and ASCD brake switch threaded end.
Brake Pedal Play
Press the brake pedal. Check the brake pedal play (A).
Depressed Brake Pedal Height
Check the brake pedal height (H2) between the dash lower panel (1)
and the brake pedal upper surface when depressing the brake pedal
at 490 N (50 kg, 110 lb) while turning engine ON.
CAUTION:
Remove the floor trim.Standard
H
1: Refer to BR-45, "Brake
Pedal".
JPFIA0065ZZ
Standard
C : Refer to BR-45, "
Brake
Pedal".
JPFIA0122ZZ
Standard
A : Refer to BR-45, "
Brake
Pedal".
JPFIA0121ZZ
Standard
H
2: Refer to BR-45, "Brake
Pedal".
JPFIA0068ZZ
BRAKE PEDAL
BR-7
< ON-VEHICLE MAINTENANCE >
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ADJUSTMENT
Brake Pedal Height
1. Remove instrument lower panel LH. Refer to IP-11, "Exploded View".
2. Disconnect the stop lamp switch and ASCD brake switch harness connector.
3. Turn the stop lamp switch and ASCD brake switch 45° counterclockwise.
4. Loosen the input rod lock nut (1). Adjust the brake pedal height
(H
1) to the specification. Tighten the input rod lock nut to the
specification. Refer to BR-28, "
Exploded View".
CAUTION:
The threaded end of the input rod (2) must project to the
inner side (L) of the clevis (3).
Stop Lamp Switch and ASCD Brake Switch
1. Remove instrument lower panel LH. Refer to IP-11, "Exploded View".
2. Disconnect the stop lamp switch and ASCD brake switch harness connector.
3. Turn the stop lamp switch and ASCD brake switch 45° counterclockwise.
4. Press-fit stop lamp switch and ASCD brake switch (2) until stop
lamp switch and ASCD brake switch hits the stopper rubber (1)
45° clockwise.
CAUTION:
The clearance (C) between the stopper rubber and stop
lamp switch and ASCD brake switch threaded end must
be the specified value. Refer to BR-45, "
Brake Pedal".
The stop lamp must be turned off when the brake pedal is
released.
Brake Pedal Play
1. Remove instrument lower panel LH. Refer to IP-11, "Exploded View".
2. Disconnect the stop lamp switch and ASCD brake switch harness connector.
3. Turn the stop lamp switch and ASCD brake switch 45° counterclockwise.
JPFIA0003ZZ
Standard
H
1: Refer to BR-45, "Brake
Pedal".
JPFIA0279ZZ
JPFIA0122ZZ
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-45
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationsINFOID:0000000003811218
Unit: mm (in)
Brake PedalINFOID:0000000003811219
Unit: mm (in)
Brake BoosterINFOID:0000000003811220
Unit: mm (in)
Front Disc BrakeINFOID:0000000003811221
Unit: mm (in)
Rear Disc BrakeINFOID:0000000003811222
Unit: mm (in)
Front brakeCylinder bore diameter 57.2 (2.252)
Pad length × width × thickness 126.0 × 46.0 × 11.0 (4.96 × 1.811 × 0.433)
Rotor outer diameter × thickness 296 × 26.0 (11.65 × 1.024)
Rear brake Cylinder bore diameter 34.93 (1.3752)
Pad length × width × thickness 83.0 × 31.9 × 8.5 (3.268 × 1.256 × 0.335)
Rotor outer diameter × thickness 292 × 9.0 (11.50 × 0.354)
Master cylinder Cylinder bore diameter 23.8 (15/16)
Control valve Valve type Electric brake force distribution
Brake booster Diaphragm diameter 278 (10.94)
Recommended brake fluid DOT 3 or DOT 4
Item Standard
Brake pedal height 191.7 – 201.7 (7.55 – 7.94)
Clearance between stopper rubber and stop lamp switch and ASCD brake switch threaded end 0.74 – 1.96 (0.0291 – 0.0772)
Brake pedal play3.0 – 11.0 (0.118 – 0.433)
Depressed brake pedal height
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON]103 (4.06) or more
Item Standard
Output rod length 30.4 – 30.6 (11.97 – 12.05)
Input rod length126.5 (4.98)
Item Limit
Brake pad Wear thickness 2.0 (0.079)
Disc rotorWear thickness 24.0 (0.945)
Runout (with it attached to the vehicle) 0.040 (0.0016) or less
Item Limit
Brake pad Wear thickness 2.0 (0.079)
Disc rotorWear thickness 8.0 (0.315)
Runout (with it attached to the vehicle) 0.050 (0.0020) or less
HOOD
DLK-193
< ON-VEHICLE REPAIR >[WITH INTELLIGENT KEY SYSTEM]
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Front grille: Refer to EXT-18, "Removal and Installation".
INSTALLATION
Install in the reverse order of removal.
CAUTION:
After installing, perform hood fitting adjustment. Refer to DLK-193, "
HOOD ASSEMBLY : Adjust-
ment".
After installing, perform front washer nozzle and tube inspection and adjustment. Refer to WW-102,
"Inspection and Adjustment".
HOOD ASSEMBLY : AdjustmentINFOID:0000000003813385
Check the clearance and the surface height between hood and each part visually and by touching. (Fitting
standard dimension in the table below should be satisfied.
If the clearance and the surface height are out of specification, adjust them according to the procedures
shown below.
Unit: mm (in)
1. Remove hood lock and adjust the height by rotating hood bumper rubber (side, lower) until hood becomes
1 to1.5 mm (0.039 to 0.059 in) lower than fender.
2. Temporarily tighten hood lock assembly, and position by engaging it with hood striker. Check hood lock
and striker for looseness and adjust the clearance and evenness with striker to satisfy the specification.
3. Adjust A and B shown in the figure to the following value with hood's own weight by dropping it from
approximately 200 mm (7.874 in) height or by pressing hood lightly [approximately 29 N (3.0 kg, 6.5 lb)].
4. After adjustment, tighten lock bolts to the specified torque.
HOOD HINGE
Portion StandardDifference
(RH/LH, MAX)
Hood – Front bumper
fasciaA – A D Clearance3.7 – 8.3
(0.146 – 0.315)2.0
(0.079)
Hood – Front combina-
tion lampB – B E Clearance2.4 – 6.8
(0.094 – 0.268)2.5
(0.098)
Hood – Front fender C – CF Clearance3.1 – 6.1
(0.122 – 0.240)2.0
(0.079)
G Surface height−1.5 – 1.5
(−0.059 – 0.059)—
1. Hood striker 2. Primary latch 3. Secondary striker
4. Secondary latch
A : 20.0 mm (0.787 in)
B : 6.8 mm (0.268 in)
JMKIA2399ZZ
FRONT DOOR
DLK-203
< ON-VEHICLE REPAIR >[WITH INTELLIGENT KEY SYSTEM]
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Check door hinge rotating part for poor lubrication. If necessary, apply body grease.
After installation, perform the fitting adjustment. Refer to DLK-203, "
DOOR ASSEMBLY : Adjust-
ment".
After installation, apply touch-up paint (the body color) onto the head of door hinge mounting nuts.
DOOR ASSEMBLY : AdjustmentINFOID:0000000003813396
Check the clearance and surface height between front door and each part by visually and touching.
If the clearance and the surface height are out of specification, adjust them according to the procedures
shown below.
Unit: mm (in)
1. Remove front fender. Refer to DLK-199, "Removal and Installation".
2. Loosen door hinge mounting nuts on door side.
3. Adjust the surface height of front door according to the fitting standard dimension.
4. Temporarily tighten door hinge mounting nuts on door side.
5. Loosen door hinge mounting bolts on body side.
6. Raise front door at rear end to adjust clearance of the front door according to the fitting standard dimen-
sion.
7. After adjustment tighten bolts and nuts to the specified torque.
8. Install front fender. Refer to DLK-199, "
Removal and Installation".
DOOR STRIKER ADJUSTMENT
Adjust door striker so that it becomes parallel with door lock insertion direction.
DOOR STRIKER
DOOR STRIKER : Exploded ViewINFOID:0000000003819380
Portion Clearance Surface height
Front fender – Front door A – A 2.6 – 4.6 (0.102 – 0.181)−1.0 – 1.0 (−0.039 – 0.039)
Front door – Rear door B – B 3.6 – 5.6 (0.142 – 0.220)−1.0 – 1.0 (−0.039 – 0.039)
JMKIA2384ZZ
REAR DOOR
DLK-209
< ON-VEHICLE REPAIR >[WITH INTELLIGENT KEY SYSTEM]
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Check door hinge rotating part for poor lubrication. If necessary, apply body grease.
After installation, perform the fitting adjustment. Refer to DLK-209, "
DOOR ASSEMBLY : Adjust-
ment".
After installation, apply touch-up paint (the body color) onto the head of door hinge mounting nuts.
DOOR ASSEMBLY : AdjustmentINFOID:0000000003813405
Check the clearance and surface height between rear door and each part by visually and touching.
If the clearance and surface height are out of specification, adjust them according to the procedures shown
below.
Unit: mm (in)
1. Remove center pillar lower garnish. Refer to INT-39, "Removal and Installation".
2. Loosen door hinge mounting nuts on door side.
3. Adjust the surface height of rear door according to the fitting standard dimension.
4. Temporarily tighten door hinge mounting nuts on door side.
5. Loosen door hinge mounting nuts and bolts on body side.
6. Raise rear door at rear end to adjust clearance of the rear door according to the fitting standard dimen-
sion.
7. After adjustment, tighten bolts and nuts to the specified torque.
8. Install center pillar lower garnish. Refer to INT-39, "
Removal and Installation".
DOOR STRIKER ADJUSTMENT
Adjust door striker so that it becomes parallel with door lock insertion direction.
DOOR STRIKER
DOOR STRIKER : Exploded ViewINFOID:0000000003819605
Portion Clearance Surface height
Front door – Rear door B – B 3.6 – 5.6 (0.142 – 0.220) -1.0 – 1.0 (-0.039 – 0.039)
Rear door – Body side outer C – C 2.6 – 4.6 (0.102 – 0.181) -1.0 – 1.0 (-0.039 – 0.039)
JMKIA2385ZZ
TRUNK LID
DLK-215
< ON-VEHICLE REPAIR >[WITH INTELLIGENT KEY SYSTEM]
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TRUNK LID ASSEMBLY : AdjustmentINFOID:0000000003813414
Check the clearance and surface height between trunk lid and each part by visually and touching.
If the clearance and surface height are out of specification, adjust them according to the procedures shown
below.
Unit: mm (in)
1. Loosen trunk lid hinge mounting bolts (trunk lid side).
2. Remove trunk rear finisher. Refer to INT-57, "
Removal and Installation".
3. Loosen trunk lid striker mounting bolts.
4. Lift up trunk lid approximately 100 – 150 mm (3.937 – 5.906 in) height then close it lightly and check that it
is engaged firmly with trunk lid closed.
5. Check the clearance and surface height.
6. Finally tighten trunk lid hinge and trunk lid striker.
7. Install trunk rear finisher. Refer to INT-57, "
Removal and Installation".
TRUNK LID STRIKER ADJUSTMENT
Adjust trunk lid striker so that it becomes parallel with trunk lid lock insertion direction.
TRUNK LID STRIKER
Portion StandardDifference
(RH/LH, MAX)
Trunk lid – Body side outer A – AD Clearance2.5 – 4.5
(0.098 – 0.177)1.0 (0.039)
ESurface
height−1.5 – 0.5
(−0.059 – 0.020)1.4 (0.055)
Trunk lid – Rear combina-
tion lampB – BF Clearance2.9 – 6.5
(0.114 – 0.256)2.0 (0.079)
GSurface
height−2.3 – 1.3
(−0.091 – 0.051)2.0 (0.079)
Trunk lid – Rear bumper fas-
ciaC – C H Clearance5.0 – 9.0
(0.197 – 0.354)—
P0031, P0032, P0051, P0052 A/F SENSOR 1 HEATER
EC-141
< COMPONENT DIAGNOSIS >[VQ25DE, VQ35DE]
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Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair or replace ground connection.
2.CHECK AIR FUEL RATIO (A/F) SENSOR 1 POWER SUPPLY CIRCUIT
1. Disconnect air fuel ratio (A/F) sensor 1 harness connector.
2. Turn ignition switch ON.
3. Check the voltage between A/F sensor 1 harness connector and ground.
Is the inspection result normal?
YES >> GO TO 4.
NO >> GO TO 3.
3.DETECT MALFUNCTIONING PART
Check the following.
IPDM E/R harness connector F12
15A fuse (No. 46)
Harness for open or short between A/F sensor 1 and fuse
>> Repair or replace harness or connectors.
4.CHECK A/F SENSOR 1 HEATER OUTPUT SIGNAL CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between A/F sensor 1 harness connector and ECM harness connector.
4. Also check harness for short to ground and short to power.
Is the inspection result normal?
YES >> GO TO 5.
NO >> Repair open circuit, short to ground or short to power in harness or connectors.
5.CHECK A/F SENSOR 1 HEATER
Refer to EC-142, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 7.
NO >> GO TO 6.
6.REPLACE AIR FUEL RATIO (A/F) SENSOR 1
Replace malfunctioning air fuel ratio (A/F) sensor 1.
CAUTION:
• Discard any A/F sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; use a new one.
Before installing new A/F sensor, clean exhaust system threads using Oxygen Sensor Thread
Cleaner and approved anti-seize lubricant.
>> INSPECTION END
DTCA/F sensor 1
Ground Voltage
Bank Connector Terminal
P0031, P0032 1 F27 4
Ground Battery voltage
P0051, P0052 2 F64 4
DTCA/F sensor 1 ECM
Continuity
Bank Connector Terminal Connector Terminal
P0031, P0032 1 F27 3
F74
Existed
P0051, P0052 2 F64 3 8