BRAKE SYSTEM sero SFR CONTENTS BRAKE HYDRAULIC LINE .........-000000+ so. BR 2 BRAKE PEDAL ...... ; - BR 4 MASTER CYLINDER BR: 6 BRAKE BOOSTER -- BR 7 FRONT DISC BRAKE (CL28VA, CL2BVB) — Caliper. - BRO FRONT DISC BRAKE (CL28VA, CL28VB) — Rotor. + BR REAR DISC BRAKE (CL14H, CL14HB) — Caliper - BR12 REAR DISC BRAKE — Rotor . - BR-16 PARKING BRAKE BR-17 SERVICE DATA AND SPECIFICATIONS (S.0S.).. +. BRA SPECIAL SERVICE TOOL . - BR-21BRAKE HYDRAULIC LINE Precautions. © Recommended fluid is brake fluid “DOT 3”. © Do not reuse drained brake fluid. ‘© Be careful not to splash brake fluid on painted areas, Bcoke hose connector 7 Giv-20 / Front brake (CL28VA, CL28VB) (17-20, 12-18) Rear brake (CLISH, CL1GHB) Fars mut Tis 19015-1811. 13) — ‘rake hove connector 17-20 (17-20, 12-14) Pre Front \ “Three-way connector a 5-7 (05 -0.7.; 1) Fare nut 16-18 (15-48, 11-13) Master eylinder: Brake booster rake hose connector “Flare nut Brake hose connector 17-20 Fis. 18015-1811 13) 7-20 (17-20, 12-14) 07-20, 12-14) WARNING: Clean pad and shoe dust using a dust collector after cleaning with waste cloth. Primary line Secondary tine (0): Nem (kgm, fb) sonezi Bleeding Procedure PRECAUTIONS Carefully monitor brake fluid level at master cylinder during bleeding operation. Bleed air according to the following pro- cedure: Left rear caliper © > Right rear caliper © > Right front caliper () + Left front caliper ® Connect a transparent vinyl tube to air bleeder valve of caliper. sonsoe BR-2BRAKE HYDRAULIC LINE Removal and Installation. CAUTION : When removing and installing brake tube, use Tool. \ecoss10000 ont s@n600 Cover openings to prevent entrance of dirt whenever disconnecting hydraulic line, To remove brake hose, first remove flare nut securing brake tube to hose, then withdraw lock spring. Next disconnect the other side. All hoses must be free from excessive bending, twisting and pulling. Whenever installing brake lines, be sure to check for oil leakage by fully depressing brake pedal. Inspection Check brake lines (tubes and hoses) for evidence of cracks, deterioration or other damage. Replace any damaged parts. If leakage occurs around connectors re-tighten or, if necessary, replace damaged parts. BR-3BRAKE PEDAL ‘plnpur rod lock nut (Biera as 22, 12-16) veo 43.22.90) sop amo witch =, cree I Re Pedal bracket CCevis pin. Fulerum bot Bushing Dh: Nm (kom, feb) sonez2 Inspection. Check brake pedal for the following items, servicing as necessary. © Brake pedal bend © Clevis pin deformation * Crack of any welded portion BR-4BRAKE PEDAL Adjustment Check brake pedal free height from melt sheet. Adjust if necessary. nour ot Stop lamp switch 12-18, (12-15,9-11) A ASCO. switch Uf Ox. c, (12-18,9-11) Lock nut : 6-22 il] (16-22, 12-16) Floor earpet ath insulator at Floor pane. em tka-m, flo) FL Nem sence H: Free height M/T 182-192 mm (7.17 - 7.56 in) A/T 184-194 mm (7,24 - 7.64 in) Depressed height M/T 90 mm (3.54 in) or more A/T 90 mm (3.54 in) or more Under force of 490 N (50 kg, 110 Ib) with engine running. Clearance between pedal stopper and threaded end of stop lamp switch. 0.3 - 1.0 mm (0.012 - 0.039 in) C,: Clearance between pedal stopper and threaded end of A.S.C.D. switch. 0.3 - 1.0 mm (0.012 - 0.039 in) A: Pedal free play 1.0 - 3.0 mm (0.039 - 0.118 in) (1) Adjust pedal free height with brake booster input rod. Then tighten lock nut. Be sure that tip of input rod stays inside. |g—seays inside sen920 (2) Adjust clearance “C,"" and C2" with stop lamp switch and A.S.C.D. switch respectively. Then tighten lock nuts. {3) Check pedal free play, Make sure that stop lamp is off when pedal is released. (4) Check brake pedal depressed height with engine running, If depressed height is below the specified value, check brake system for leaks, accumula- tion of air or any damage regarding component parts (master cylinder, wheel cylinder, etc.), and make the necessary repairs. BR-5MASTER CYLINDER Rewror a BD) —rearoe cap _P | Piston cup (Secondary) Spring sat Secondary return spring. SY 1) 8-11 Nem (0.8- 1.1 kom, 6.8 - 8.0 fe-IbI- Proportioning valve (Do not aisassembie} © Apply brake fluid or rubber grease to sliding contact sur- face when assembling master cylinder. © Check parts for wear or damage. Replace if any of above conditions are observed. ‘© Replace piston assembly when disassembled, ‘sene20 BR-6——— Operating Check . BRAKE BOOSTER Depress brake pedal several times with engine off, then check that there is no change in pedal stroke, Depress brake pedal, then start engine. If pedal goes down slightly, operation is normal. Airtight Check. Start engine, then stop it in one or two minutes. Depress brake pedal several times slowly. If pedal goes further down the first time, but gradually rises after second or third time, the booster is airtight. Depress brake pedal while engine is running, then stop it with pedal depressed. If there is no change in pedal stroke after holding pedal for thirty seconds, brake booster is airtight. BR-7 Removal and Installation ——_ o Phr0.22 (1e-22,12- 10 As. 1008-11,58-80) 8-19 (08-1.1,58-8.0) FD: em tag, te) senestBRAKE BOOSTER Inspection: HOSES AND CONNECTORS OUTPUT ROD LENGTH © Check condition of vacuum hoses and | Output rod length does not require adjustment connectors, © Check vacuum hoses and check valve for air tightness. A ® Do not apply any oil or lubricants to vacuum a) hose and check valve. A il seraae CHECK VALVE ‘© When pressure is applied to the brake booster side of check valve and valve does not open, replace check valve with a new one. 9 Manifold side Brake booster side sonees BR-8FRONT DISC BRAKE (CL28VA, CL28VB) — Caliper Pad oraue memba ixing bolt Wy '97173-99.53-72) Pd spring {Upper side \ BS ht [Pnsee -Gvlinder body yrinnee sin Pin bolt a (has, 16-23)” G a } eae | Pad spring! Lower side) SN Boot* BR | Piston ae Retainer boot P.B.C. (Poly Buty! Cuprysil grease oF silicone-based grease point Fubber greste pointe 1 Always replace whan disassembled Coa Pad Replacement CAUTION: 2. Swing cylinder body upward. Then remove pad When cylinder body is swung up, do not depress retainer and inner and outer shims. brake pedal because piston will pop out. X 1. Remove brake hose lock spring and pin bolt. Y dS WS oe oe Be careful not to damage piston boot or get oil on rotor, Always replace shims when replacing pads. BR-9FRONT DISC BRAKE (CL28VA, CL28VB) — Caliper Removal and Installation. Remove torque member fixing bolts and brake hose connector. seneso Disassembly Push out piston with dust seal using compressed air, Inspection. CAUTION: Use brake fluid to clean. Never use mineral oil. CYLINDER BODY * Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. © Minor damage from rust of foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary. PISTON Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed. CAUTION: Piston sliding surface is plated. Do not polish with ‘emery paper even if rust or foreign materials are stuck to sliding surface. PIN, PIN BOLT, RETAINER BOOT, RUBBER BUSHING, RETAINER BUSHING, AND PIN BOOT Check for wear, cracks or other damage, Replace if any of the above conditions are observed. eres Assembly. © With dust seal fitted to piston, insert dust seal into groove on cylinder body and install piston. Properly secure dust seal. Pay attention to piston seal direction. Boot Piston seal Clinger body sansr — BR-10FRONT DISC BRAKE (CL28VA, CL28VB) — Rotor Inspection RUBBING SURFACE Check rotor for roughness, cracks or chips. RUNOUT Make sure axle shaft has no axial end play. Then check runout with a dial indicator. sonissa Rotor repair limi Maximum runout {Total indicator reading at center of rotor pad contact surface) 0.07 mm (0.0028 in) THICKNESS Rotor repair limi Minimum thickness 20.0 mm (0.787 in) BR-11REAR DISC BRAKE (CL14H, CL14HB) — Caliper BR-12REAR DISC BRAKE (CL14H, CL14HB) — Caliper Pad Replacement CAUTION: When cylinder body is swung up, do not depress brake pedal because piston will pop out. 1. Disconnect parking brake cable, then remove pin bolts. 3. When installing pads, retract piston into cylin- der body by turning it clockwise. Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads. sence Removal and Installation. Disconnect parking brake cable and brake hose, then remove caliper assembly. BR-13nut. Pry off ring from piston and remove adjusting REAR DISC BRAKE (CL14H, CL14HB) — Caliper Disassembly Remove piston by turning it counterclockwise with suitable long nose pliers. (2) Pry off ring B, then remove key plate, push rod and rod, senees seRi64a, (3) Remove piston seal. Be careful not to damage cylinder body. 3. Disassembly cylinder body. (1) Pry off ring A with suitable pliers, then remove spring cover, spring and seat. sontaaa sences s@R6ss BR-14REAR DISC BRAKE (CL14H, CL14HB) — Caliper Inspection CAUTION: Use brake fluid to clean. Never use mineral oil. CYLINDER BODY © Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. © Minor damage from rust of foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary. TORQUE MEMBER Check for wear, cracks or other damage. Replace if necessary. PISTON Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any wear or damage is found. CAUTION: Piston sliding surface is plated. Do not polish with ‘emery paper even if rust or foreign matter is stuck. to sliding surface. PIN AND PIN BOOT Check for wear, cracks or other damage. Replace if any of the above conditions are observed. Assembly © Install cup securely in the sp ‘® Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder. ‘spree © Install ring B with suitable tool. Key plate = Push rod reef] ‘© Install seat, spring, spring cover and ring A with suitable press and drift. Ring A— Si 8 ser Spring cover BR-15REAR DISC BRAKE — Rotor Inspection RUBBING SURFACE Check rotor for roughness, cracks or chips. Repair or replace if necessary. RUNOUT Make sure that axial end play is within the specifi cations before measuring. Refer to section RA, ‘Then check runout with a dial indicator. Rotor repair limit: Maximum runout (Total indicator reading at center of rotor pad contact surface) 0.07 mm (0.0028 in} THICKNESS spni624 Rotor repair limit: Minimum thickness 9.0 mm (0.354 in) BR-16PARKING BRAKE aor cable sably (LH 7 Rear eabie assembly (R.H.1 Cone Aisa 08- DI): Nem tka, teab) Removal If necessary, separate front cable from parking | 1 brake lever by breaking pin. Front cable, clevis pin and cotter pin are available | 2: as service parts. 3. 4. soneas (AP) 3.1-43 00.32-0.48,23-321 pa Memon ssa-aa Control lever new / "que mnsane ~ Inspection Check control lever for wear or other damage. Replace if necessary. Check wires for discontinuity or deterioration. Replace if necessary. Check warning lamp and switch. Replace if necessary. Check parts at each connecting portion and, if found deformed or damaged, replace. BR-17PARKING BRAKE Adjustment STROKE © Pull lever with specified amount of force. Check lever stroke and ensure smooth operation. bs Pulling force: 4 196" KO A beta. cams ee Number of notehes S10 seRege © Adjust lever stroke, WARNING LAMP SWITCH Bend parking brake warning lamp switch plate so that brake warning light comes on when ratchet at parking brake lever is pulled one notch and goes out when fully released. BR-18SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications. Engine VG30e lveaoer Grade Gu, tem SF Gut Front broke Brake model cL2ava cizeve baa Inner 43 11 x 12655 (1,69 x 0.43 x 4.98) Width thickness x Fength mm in) | Oat 43 x 11 x 1290 (1,69 «0.49 x 5.08) Rotor outer diameter Inspection and Adjustment BRAKE PEDAL Pedal ratio 38 wit 182 192(7.17-7.56) Free height sven tod |e 14-194 (7.24-7.64) Depressed height (Under force of 490 N (50 kg, 110 Ib) with engine running] ‘mm fin) 90 {2.54 or more Clearance between pedal stopper and none | geo iwee | 274 9070 Ciruta on of op amp ech are == "| 08. 1010012-009) Ceti ner ase 60.6 (2.386) arene brane pan sonar and Fer broke mt Brake model eres GD Pedal free play. mm (in) | 1.0- 3,0 (0.039 - 0.118) mea eee width x thickness « 40 x 8.0 x 75 (1.57 x 0.315 x 2.95) teem Rotor outer vied 258 (10.16) 290 (11.42) PARKING BRAKE Saipan Te Som eer vee diameter mm {in} 42.8 (1.638) Number of notches when warning lamp 1 onorevinge seh comes mm tind) 23.81 (18/16) force of 196 N (20 kg, 44 IbI) cad tae! wor Primary 208 (8.07) Secondary 201 (7.91) Diapnragm aiameter ‘mm (inh Control valve CHECK VALVE Maximum vacuum leakage [15 seconds after 66.7 KPe (500 mmHg, not cece {15 cond a 60.2 13 110,0301 wa ir ite) Sprit pone age Fearon sen | aa2s0,son — | SS Reducing ratio 04 BRAKE BOOSTER (15 seconds after engin is stopped) kPa (mmHg, nH) 3.3 (25, 0.98) BR-19SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment ____ Tightening Torque. (Cont'd) teem Nm Kem Fe DISC BRAKE Brake pedal Front brake Rear brake Pedel bracket tobody 2-11 08-1. 88-80 Pedal bracket to pedal 30-40 31-81 22-30 Brake mode! | cuzeva | cu2eve | cura | cuiaHe Soplempenieniock W825 ett Pad wear tim | ut Minimum Brake booster thickness 21008) 21008) Srakeboorte tobody 8-11 —08-1.1 58-80 mn ti Input rodiockrut 16-22 46-22 12-16 Brakeboorterto = «B-11OB-1.1 58-80 Rotor repair init | maser evindor asin “Threewoy connector ae 9.07 (0.0028) 07 fo.o028) Theesnay connector 15-18 18-18 11-13 ron to brake tube Minima Threemay conmector 5-7 05-07 36-81 thickets 2000 0.787) 9.0 (0.84) enounting bolt rom i Brakehote connector —«17-20-4.7-20 12-14 Brake tube flrenut 15184-11813 Wheel cylinder airbleeder 7-9 07-09 51-65 Front die broke Bal plate 31-43 032-044 23-32 Torque member ting 72-97 73-99 63-72 voit Torquemember! 22-31 -22-32 16-23 evlinder body (Pin bol) Dieevotortowhee! hub 59-69 60-70 49-81 Rear dis brake ‘atl pate 21-43 092.044 23-32 Torque member fixing 98-52 39-53 78-38, wot Torquememberto 22-31. 222.32 16-23 cylinder body [Pin bolt) Parking brake Canter over type Contre! lever tobody 16-21 1.6-2.1 12.15. Adjusterlock nut 31-42 092-044 23-32 Front cable clamp to 8-11 OB-1.1 58-80 body BR-20SPECIAL SERVICE TOOL oo! number (Kent Moore No) | Tostname ‘6694310000 Flare nut torque wrench (- ) BR-21