BRAKE SYSTEM
F BRAKES
CONTENTS
MODIFICATION NOTICE ............................................ 2
Major Modification Item ............................................ 2
BRAKE PEDAL .......................................................... 3
On-Vehicle Service ................................................... 3
INSPECTION ........................................................ 3
ADJUSTMENT ...................................................... 3
Components ............................................................. 4
Removal and Installation .......................................... 4
INSPECTION AFTER REMOVAL ......................... 4
BRAKE FLUID ............................................................ 5
Bleeding Brake System ............................................ 5
BRAKE TUBE AND HOSE ......................................... 6
Hydraulic Circuit ....................................................... 6
BRAKE MASTER CYLINDER .................................... 7
Components ............................................................. 7
BRAKE BOOSTER ..................................................... 9
Revision: 2006 January BR-1
SECTION
BRAKE SYSTEM
BR B
E
Components ............................................................. 9 BR
Removal and Installation ........................................ 10
VACUUM LINES ....................................................... 11
Components ........................................................... 11 G
FRONT DISC BRAKE ............................................... 12
Components ........................................................... 12
REAR DRUM BRAKE ............................................... 13
H
Components ........................................................... 13
Removal and Installation of Drum Brake Assembly... 14
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 15
General Specifications ............................................ 15 I
Brake Pedal ............................................................ 15
Check Valve ............................................................ 15
Brake Booster ......................................................... 15 J
Front Disc Brake ..................................................... 15
Rear Drum Brake .................................................... 15
K
C11
 MODIFICATION NOTICE

MODIFICATION NOTICE PFP:00000

Major Modification Item GFS000MI

● Brake master cylinder has been changed for RHD models.

● Brake booster has been changed for RHD models.
● Vacuum line has been changed for RHD models.

Revision: 2006 January BR-2 C11

 BRAKE PEDAL

BRAKE PEDAL PFP:46501

A
On-Vehicle Service GFS000MD

INSPECTION
Check the following. If it is out of specification, adjust it. B
Dimension Item Specification
172.4 – 182.4 mm (6.79 –
Brake pedal free height A/T models C
7.18 in)
H1 (from dash panel (1) top
surface) 162.3 – 172.3 mm (6.39 –
M/T models
6.78 in)
Brake pedal depressed A/T models 98 mm (3.86 in) or more D
height [under a force of
H2
490 N (50 kg, 110 lb) M/T models 90 mm (3.54 in) or more
with the engine running]
E
Clearance between the threaded end
0.74 – 1.96 mm (0.0291 –
C of stop lamp switch (2) and brake pedal
0.0772 in)
lever (3)
BR
A Pedal play 3 – 11 mm (0.12 – 0.43 in)

H
SFIA3056J

ADJUSTMENT
I
1. Loosen stop lamp switch by rotating it counterclockwise by 45°.
2. Loosen lock nut on input rod, then rotate input rod to set pedal to
the specified height, and tighten lock nut.
J
CAUTION:
Make sure that the threaded end of input rod stays inside
clevis.
K

SBR229E

M
3. With the pedal pulled and held by hand, press stop lamp switch
(2) until its threaded end contacts brake pedal lever (1).
4. With the threaded end of stop lamp switch (2) contacting brake
pedal lever (1), rotate the switch clockwise by 45° to secure.
CAUTION:
Make sure that the clearance “C” is within the standard.
Refer to BR-3, "INSPECTION" .
5. Check the pedal play.
CAUTION:
Make sure that stop lamps go off when brake pedal is PFIA0813J
released.
6. Start engine to check brake pedal depressed height.

Revision: 2006 January BR-3 C11

 BRAKE PEDAL

Components GFS000BR

SFIA3065E

1. Snap pin 2. Stop lamp switch 3. Clip

4. Brake pedal assembly 5. Clevis 6. Brake pedal pad
Refer to GI-11, "Components" and the followings for the symbols in the figure.
: Apply multi-purpose grease.

Removal and Installation GFS000MJ

INSPECTION AFTER REMOVAL

● Make sure the rivets (A) in the upper part of brake pedal are not
deformed.
● Make sure that joint length “X” of sub-bracket (B) and sliding
plate (C).
Joint length “X”
LHD models : 6.9 mm (0.272 in) or more
RHD models : 5.3 mm (0.209 in) or more

PFIA0755J

Revision: 2006 January BR-4 C11

 BRAKE FLUID

BRAKE FLUID PFP:KN100

A
Bleeding Brake System GFS000MF

CAUTION:
While bleeding, pay attention to reserver tank fluid level. B
1. Turn ignition switch OFF.
2. LHD models: Connect a vinyl tube to rear right bleed valve.
RHD models: Connect a vinyl tube to rear left bleed valve. C
3. Fully depress brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately.
5. Repeat steps 3, 4 until no more air comes out. D
6. Tighten bleed valve to specified torque. Refer to BR-12, "Components" (front disc brake), BR-13, "Com-
ponents" (rear drum brake).
7. LHD models: E
● In steps 2 to 6 below, with master cylinder reservoir tank filled at least half way, bleed air from front left,
rear left, and front right, bleed valve, in that order.
RHD models: BR
● In steps 2 to 6 below, with master cylinder reservoir tank filled at least half way, bleed air from front
right, rear right, and front left, bleed valve, in that order.
G

Revision: 2006 January BR-5 C11

 BRAKE TUBE AND HOSE

BRAKE TUBE AND HOSE PFP:46300

Hydraulic Circuit GFS0002K

WITHOUT ABS

PFIA0707E

1. Front disc brake 2. Brake master cylinder 3. Brake booster

4. Rear drum brake 5. Connector 6. Proportioning valve
7. Brake tube 8. Brake hose
: Union bolt : Connector mounting bolt : Flare nut
: Proportioning valve
Refer to GI-11, "Components" , for the symbols in the figure.

WITH ABS

PFIA0724E

1. Front disc brake 2. Brake master cylinder 3. Brake booster

4. Rear drum brake 5. Connector 6. ABS actuator and electric unit (con-
trol unit)
7. Brake tube 8. Brake hose
: Union bolt : Connector mounting bolt : Flare nut
Refer to GI-11, "Components" , for the symbols in the figure.

Revision: 2006 January BR-6 C11

 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

A
Components GFS000BS

LHD MODELS
B

BR

SFIA3094E

1. Reservoir cap 2. Oil filter 3. Reservoir tank

H
4. Grommet 5. Piston stopper 6. Cylinder body
7. Pin 8. Brake fluid level switch connector 9. O-ring
10. Secondary piston assembly 11. Primary piston assembly 12. Plate
I
13. Guide assembly 14. Snap-ring
Refer to GI-11, "Components" and the followings for the symbols in the figure.
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease. J
: Apply brake fluid.

RHD MODELS K

PFIA0731J

1. Reservoir cap 2. Oil filter 3. Reservoir tank

4. Brake fluid level switch connector 5. Grommet 6. Piston stopper
7. Pin 8. Cylinder body 9. Secondary piston assembly
10. Primary piston assembly 11. Stopper cap

Revision: 2006 January BR-7 C11

 BRAKE MASTER CYLINDER

Refer to GI-11, "Components" and the followings for the symbols in the figure.
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.

: Apply brake fluid.

Revision: 2006 January BR-8 C11

 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

A
Components GFS000BT

LHD MODELS
B

BR

K
SFIA3095E

1. Reservoir tank 2. Master cylinder 3. Brake booster

4. Clevis 5. Spacer 6. Gasket
L
Refer to GI-11, "Components" , for the symbols in the figure.

Revision: 2006 January BR-9 C11

 BRAKE BOOSTER

RHD MODELS

SFIA2638J

1. Reservoir tank 2. Master cylinder 3. Gasket

4. Brake booster
Refer to GI-11, "Components" , for the symbols in the figure.

Removal and Installation GFS000MG

● When installing, loosen lock nut to adjust input rod length so that
length “B” satisfies the specified value.

SGIA0060E

Revision: 2006 January BR-10 C11

 VACUUM LINES

VACUUM LINES PFP:41920

A
Components GFS0002T

LHD MODELS
B

BR

SFIA3069E

1. To intake manifold 2. Clamp 3. Engine side indicator stamp

H
4. Vacuum hose (Built-in check valve) 5. Clip 6. Clip position stamp
7. Vacuum tube 8. To brake booster

RHD MODELS I

PFIA0732J

1. Clamp 2. Engine side indicator stamp 3. Vacuum hose (Built-in check valve)
A: To brake booster
B: To intake manifold

Revision: 2006 January BR-11 C11

 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

Components GFS0002X

PFIA0715E

1. Brake hose 2. Union bolt 3. Copper washer

4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Sliding pin boot 9. Bushing
10. Piston seal 11. Piston 12. Piston boot
13. Torque member 14. Torque member mounting bolt 15. Inner shim
16. Inner pad 17. Pad retainer 18. Pad return spring
19. Outer pad 20. Outer shim
Refer to GI-11, "Components" and the followings for the symbols in the figure.
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
3: Apply polyglycol ether based lubricant.

: Apply brake fluid.

Revision: 2006 January BR-12 C11

 REAR DRUM BRAKE

REAR DRUM BRAKE PFP:43206

A
Components GFS00032

BR

PFIA0717E

1. Back plate 2. Shoe hold pin 3. Plug J

4. Parking brake rear cable 5. Retainer ring 6. Operating lever
7. Adjuster lever 8. Spring 9. Retainer
10. Return spring (lower side) 11. Return spring (upper side) 12. Adjuster spring K
13. Adjuster 14. Brake shoe 15. Brake drum
16. Wheel cylinder 17. Spring 18. Piston seal
19. Piston 20. Boot 21. Bleed valve L
22. Cap
Refer to GI-11, "Components" and the followings for the symbols in the figure.
1: Apply rubber grease. M
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.

: Apply brake fluid.

Revision: 2006 January BR-13 C11

 REAR DRUM BRAKE

Removal and Installation of Drum Brake Assembly GFS000MH

● If removing brake drum is difficult, then remove as follows.

– Press up adjuster lever with a wire or equivalent from plug hole
(plug hole at the side of wheel cylinder) on the back plate as
shown in the figure. Turn frame of adjuster assembly with a flat
bladed screw driver in the direction that narrows frame to narrow
enlarged brake shoe.

SFIA3080E

● When disassembled adjuster, confirm the difference between

left and right wheel for assemble.
: Front
Adjuster position A B C
Left side Yellow Green Gray
Right side Green Yellow Gray

PFIA0781J

Revision: 2006 January BR-14 C11

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
General Specifications GFS00036

Cylinder bore diameter 53.97 mm (2.125 in)

Front brake Pad length × width × thickness 121.4 mm × 44.0 mm × 9.0 mm (4.780 in × 1.732 in × 0.354 in) B
Rotor outer diameter × thickness 260 mm × 22.0 mm (10.24 in × 0.866 in)
Without ABS: 17.46 mm (0.687 in)
Cylinder bore diameter C
With ABS: 15.87 mm (0.625 in)
Rear brake
Lining length × width × thickness 194.1 mm × 30.0 mm × 4.0 mm (7.642 in × 1.181 in × 0.157 in)
Drum outer diameter 203 mm (7.992 in) D
Master cylinder Cylinder bore diameter 22.22 mm (0.875 in)
Control valve Valve model Electric brake force distribution
Brake booster Diaphragm diameter 255 mm (10.04 in) E
Recommended brake fluid DOT 3

Brake Pedal GFS00037 BR

A/T models 172.4 – 182.4 mm (6.79 – 7.18 in)
Brake pedal free height (from dash panel top surface)
M/T models 162.3 – 172.3 mm (6.39 – 6.78 in)
G
Brake pedal depressed height A/T models 98 mm (3.86 in) or more
[under a force of 490 N (50 kg, 110 lb) with the engine running] M/T models 90 mm (3.54 in) or more
Clearance between the threaded end of stop lamp switch and brake pedal lever 0.74 – 1.96 mm (0.0291 – 0.0772 in) H
Pedal play 3 – 11 mm (0.12 – 0.43 in)

Check Valve GFS00038 I

Vacuum leakage
Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
[at vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg]
J
Brake Booster GFS00039

Vacuum type
Vacuum leakage K
Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 seconds
[at vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg)]
Input rod installation standard dimension 159 mm (6.26 in)
L
Front Disc Brake GFS0003A

Standard thickness 9.0 mm (0.354 in)

Brake pad
Repair limit thickness 1.5 mm (0.059 in) M
Standard thickness 22.0 mm (0.866 in)
Disc rotor Repair limit thickness 20.0 mm (0.787 in)
Runout limit 0.07 mm (0.0028 in)

Rear Drum Brake GFS0003B

Standard thickness 4.0 mm (0.157 in)

Brake lining
Repair limit thickness 1.5 mm (0.059 in)
Standard inner diameter 203 mm (7.992 in)
Drum
Repair limit inner diameter 204.5 mm (8.051 in)

Revision: 2006 January BR-15 C11

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: 2006 January BR-16 C11