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P.35A-4 - Evo X Service Manuals

1. 35A 40 INSPECTION 35A 41 BRAKE PAD CHECK 35A 17 E BASIC BRAKE SYSTEM 35A 2 GENERAL INFORMATION GENERAL INFORMATION The brake system has high reliability and durability and provides an exceptional braking performance FEATURES e To the front two piece structure brake disk is installed GSR Option MR Standard IMPROVED BRAKING PERFORMANCE In addition to the 10 inch through bolt type singe IMPROVED STABILITY brake booster the small and long stroke type master cylinder is adopted to provide rigidity to x Ss Wipe A p 7 ae e The brake pedal retreat suppression mechanism ee ss that suppresses the retraction of brake pedal sur brakes and Brembo 17 inch 2 pot rear venti face upon a frontal collision is adopted lated disk brakes adopted to provide stable e To the front brake and rear brake the brake pads braking foree ne improved braking with audible wear indicator are adopted which warn the driver of the wear limit M1351000101119 CONSTRUCTION DIAGRAM Brake pedal Brake booster Reserve tank Hydraulic unit Rear disc brake Master cylinder Front disc brake AC708805AB GENERAL SPECIFICATIONS Specification Type Tandem type I D mm in 23 81 0 94 Type Vacuum type single M1351000200599 Effective dia of power cylinder mm in 252 10 Boosting r
2. M1351006001176 Pre removal Operation Post installation Operation Brake Fluid Draining e Brake Fluid Supplying and Air Bleeding Refer to P 35A 16 e Brake Disk Runout Inspection Correction Refer to P 35A 21 16 3 Nm 12 2 ft lb 16 x3 TAN 12 2 ft lb A 5 m 13 2 Nm in 111 22 in Ib 1 82 5 22 4 ft lb N2 AC706937AB Removal steps Removal steps Continued 1 Brake pipe brake caliper side 7 Clip connection gt gt A lt lt 8 Brake hose brake pipe side 2 Gasket connection 3 Front brake caliper assembly 9 Brake hose lt lt A gt gt 4 Front brake disk 10 Front wheel speed sensor wiring 5 Brake pipe brake hose connection harness clip 6 Brake pipe 11 Brake hose bracket TSB Revision E BASIC BRAKE SYSTEM 35A 34 FRONT DISC BRAKE ASSEMBLY REMOVAL SERVICE POINT A FRONT BRAKE DISK REMOVAL If the front brake disk removal is difficult install bolts M8 x 1 25 mm shown in the figure and tighten them evenly and gradually to remove the front brake disk Bolts M8 x 1 25 mm AC707776AB INSTALLATION SERVICE POINT gt gt A lt lt BRAKE HOSE INSTALLATION 1 Pass the brake hose through the hole in the body side bracket 2 Install the brake hose to the brake caliper 3 Install the brake hose at the two fixing points View A 4 Twist the brake hose toward the lesser torsion between the Correct Bracket br
3. install the pin to the brake caliper assembly ZU AC211990AC DISK BRAKE ROTOR CHECK A CAUTION Disk brakes must be kept within the allowable service values in order to maintain normal brake operation Before turning the brake disk the following condi tions should be checked Inspection item Remark M1351002900710 Scratches rust saturated lining materials and wear e If the vehicle is not driven for a long period of time sections of the disks that are not in contact with the pads will become rusty causing noise and shuddering If grooves and scratches resulting from excessive disk wear are not removed prior to installing a new pad assembly there will be inadequate contact between the disk and the lining pad until the pads conform to the disk Run out Excessive run out of the disks will increase the pedal depression resistance due to piston kick back Change in thickness parallelism If the thickness of the disk changes this will cause pedal pulsation shuddering and surging Inset or warping flatness Overheating and improper handling while servicing will cause warping or distortion BRAKE DISK THICKNESS CHECK 1 Using a micrometer measure disk thickness at eight positions approximately 45 degrees apart and 10 mm 0 4 inch in from the outer edge of the disk Standard value 32 0 mm 1 26 inch Front 22 0 mm 0 87 inch Rear Limit 30 0 mm 1 18 inch Front 20 0 m
4. switch installation section to avoid malfunction of the switch In addition do not use gloves which have grease on them 1 Connect a circuit tester Orange to the stoplight switch connector 2 When no continuity is detected with the plunger pressed from the edge of the outer case by the dimension shown in the figure and when continuity is detected with the plunger released the stoplight switch is in good condition M1351008900398 No continuity Continuity J4 0 5 mm 0 16 0 02 in a AC102416AC BRAKE PEDAL DISTORTION CHECK M1351016300197 1 Place the brake pedal assembly on a level surface as shown in the figure and set the distance from the center of the pin assembly mounting hole to the level surface to 97 mm 3 82 inch Make sure that the dimension A in the figure distance from the pedal pad center part to the level surface is within the standard value Standard value A 240 246 mm 9 4 9 7 lt M T gt 242 248 mm 9 5 9 8 lt TC SST gt Brake pedal assembly oe Flat surface acs07986AB 2 When dimension A is not within the standard value replace the brake pedal assembly Pin assembly Pedal pad center part center hole TSB Revision BASIC BRAKE SYSTEM 35A 27 MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY REMOVAL AND INSTALLATION lt MASTER CYLINDER AND BRAKE BOOSTER gt M135
5. the calipers for correct installation Q Are the calipers installed incorrectly YES Repair the calipers Then go to Step 9 NO Go to Step 7 STEP 7 Check the wheel bearings for end play Refer to GROUP 26 On vehicle Service Wheel bearing end play check P 26 7 Front or GROUP 27 On vehicle Service Wheel bearing end play check P 27 33 Rear Q Does the measured end play exceed the limit YES Replace the faulty hub assembly Then go to Step 9 NO Goto Step 8 TSB Revision BASIC BRAKE SYSTEM 35A 1 1 BASIC BRAKE SYSTEM DIAGNOSIS STEP 8 Adjust the brake pedal Refer to P 35A 12 Q Is the brake pedal adjusted correctly YES Go to Step 9 NO Adjust the brake pedal Then go to Step 9 STEP 9 Recheck symptom Q Is the symptom eliminated YES The procedure is complete NO Start over at step 1 If a new symptom surfaces refer to the symptom chart INSPECTION PROCEDURE 8 Groaning Clicking or Rattling Noise when Brakes are not Applied DIAGNOSIS STEP 1 Check whether foreign material has entered the wheel covers Q Is there any foreign material YES Remove it Then go to Step 5 NO Goto Step 2 STEP 2 Check for looseness of the wheel nuts Q Are the wheel nuts loose YES Tighten to 98 10 N m 73 7 ft lb Then go to Step 5 NO Goto Step 3 STEP 3 Check for looseness of the caliper installation bolt Is the caliper installation bolt loose YES Tighten
6. to outside the vehicle TSB Revision BASIC BRAKE SYSTEM REAR DISC BRAKE ASSEMBLY 35A 41 LUBRICATION POINTS d Wood block AC212149AC Grease Repair kit grease Molykote AS880N Grease Repair kit grease Molykote 7439 or equivalent or equivalent AC710741AB DISASSEMBLY SERVICE POINTS lt lt A gt gt PISTON BOOT PISTON REMOVAL A CAUTION Do not remove one piston separately before trying to remove the other piston because it will become impossi ble to remove other pistons Remove the pistons by pumping in air slowly from the brake hose connection Be sure to use a wood block and adjust the height of the two pistons while so that the pistons protrude evenly lt lt B gt gt PISTON SEAL REMOVAL N CAUTION To prevent damage to inner cylinder do not use a flat tipped screwdriver or other tool 1 Remove the piston seal with finger tip 2 Clean the piston surface and cylinder inner face with alcohol or specified brake fluid Brake fluid DOT3 or DOT4 INSPECTION Check the cylinder for wear damage or rust Check the piston surface for wear damage or rust Check the caliper body for wear Check the pad for damage or adhesion of grease check the backing metal for damage M1351007300412 TSB Revision BASIC BRAKE SYSTEM 35A 42 REAR DISC BRAKE ASSEMBLY PAD WEAR CHECK WARNING e Always replace bo
7. 1003701499 Pre removal operation Brake Fluid Draining Strut Tower Bar Removal Refer to GROUP 42 Strut tower bar P 42A 15 Wiring Joint Removal Refer to GROUP 544A Battery P 54A 10 Solenoid Valve Assembly Removal Refer to GROUP 54A Battery P 54A 10 Post installation operation Solenoid Valve Assembly Installation Refer to GROUP 54 Battery P 54A 10 e Wiring Joint Installation Refer to GROUP 544A Battery P 54A 10 e Strut Tower Bar Installation Refer to GROUP 42 Strut tower bar 42 15 e Brake Fluid Refilling and Air Bleeding Refer to P 35A 16 TSB Revision 35A 28 BASIC BRAKE SYSTEM MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY 14 3N m 124 26 in Ib 2 uli d 16 3N m 25 13 2 N m AC709313AB 16 3N m 12 2 ft lb 5 0 1 0 44 9 in Ib 36 17 in Ib Master cylinder removal steps Master cylinder removal steps 1 Brake fluid level switch connector 3 Brake fluid reservoir filter connection 4 Brake pipe connection 2 Reservoir cap TSB Revision gt gt B lt lt gt gt B lt lt gt gt A lt lt BASIC BRAKE SYSTEM MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY Master cylinder removal steps Master cylinder assembly air bleeding Only at installation Reservoir hose connection lt M T gt Battery harness clip connection Self locking nut Reservoir assembly and mast
8. 35A 1 GROUP 35A BASIC BRAKE SYSTEM CONTENTS GENERAL INFORMATION 35A 2 BRAKE PAD REPLACEMENT 35A 18 DISK BRAKE ROTOR CHECK 35A 21 GENERAL SPECIFICATIONS 35A 2 BRAKE DRAG FORCE CHECK 35A 24 SERVICE SPECIFICATIONS 35A 3 BRAKEPEDAL 35A 25 REMOVAL AND INSTALLATION 35A 25 LUBRICANTS 35A 4 INSPECTION 35A 26 STOPLIGHT SWITCH CHECK 35A 26 BASIC BRAKE SYSTEM DIAGNOSIS 35A 4 BRAKE PEDAL DISTORTION CHECK 35 26 INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS 35A 4 MASTER CYLINDER ASSEMBLY AND BASIC BRAKE SYSTEM DIAGNOSTIC BRAKE BOOSTER ASSEMBLY 35A 27 TROUBLESHOOTING STRATEGY 35A 4 REMOVAL AND INSTALLATION 35A 27 SYMPTOM 35A 4 SYMPTOM PROCEDURES 35A 5 FRONT DISC BRAKE ASSEMBLY 35A 33 REMOVAL AND INSTALLATION 35A 33 SPECIAL TOOLS 35A 12 INSPECTION 35A 34 DISASSEMBLY AND ASSEMBLY 35A 35 SERVICE sengatan 35A412 INSPECTION 35A 36 BRAKE PEDAL CHECK AND ADJUSTMENT 35A 12 BEAR DISC BRAKE ASSEMBLY 35A 38 BRAKE BOOSTER OPERATION CHECK 35A 15 CHEER VALVE GOPEDATIONCHECK MEAE REMOVAL AND INSTALLATION 35A 38 dea d INSPECTION 35A 39 ms s DISASSEMBLY AND ASSEMBLY
9. CHART M1351009900410 SYMPTOM INSPECTION REFERENCE PROCEDURE PAGE Vehicle pulls to one side when brakes are applied P 35A 5 Insufficient braking power P 35A 5 Increased pedal stroke Reduced pedal to floor board clearance P 35A 6 Brake drag P 35A 7 Scraping or grinding noise when brake are applied P 35A 8 Squealing groaning or chattering noise when brake are applied P 35A 9 Squealing noise when brakes are not applied P 35A 10 Groaning clicking or rattling noise when brakes are not applied P 35A 11 TSB Revision BASIC BRAKE SYSTEM 35A 5 BASIC BRAKE SYSTEM DIAGNOSIS SYMPTOM PROCEDURES INSPECTION PROCEDURE 1 Vehicle Pulls to One Side when Brakes are Applied DIAGNOSIS STEP 1 Check for oil water etc on the pad contact surface of all brakes Q Is oil water etc on the pad contact surface YES Replace the part and determine the source cause of foreign material Then go to Step 5 NO Go to Step 2 STEP 2 Check disk brake pistons for smooth operation 1 With engine not running depress the brake pedal rapidly several times to deplete booster vacuum reserves 2 Test each disk brake assembly one at a time a Remove the lower caliper bolt then remove caliper from mount b Have an assistant slowly depress the brake pedal Confirm piston s extend slowly and smoothly with no jumpiness Repeat for each disk brake assembly Q Do does the
10. E SYSTEM FRONT DISC BRAKE ASSEMBLY or equivalent Wood block Grease Repair kit grease Molykote AS880N AC604930 AB Grease Repair kit grease Molykote 7439 or equivalent AC707832AB DISASSEMBLY SERVICE POINTS lt lt A gt gt PISTON BOOT PISTON REMOVAL A CAUTION Do not remove one piston completely before trying to remove the other piston because it will become impossi ble to remove other pistons Remove the pistons by pumping in air slowly from the brake hose connection Be sure to use a wood block and adjust the height of the four pistons so that the pistons protrude evenly lt lt B gt gt PISTON SEAL REMOVAL CAUTION To prevent damage to inner cylinder do not use a flat tipped screwdriver or other tool 1 Remove the piston seal with finger tip 2 Clean the piston surface and cylinder inner face with alcohol or specified brake fluid Brake fluid DOT3 or DOT4 INSPECTION Check the cylinder for wear damage or rust Check the piston surface for wear damage or rust Check the caliper body for wear Check the pad for damage or adhesion of grease check the backing metal for damage M1351006300680 TSB Revision AC709429 BASIC BRAKE SYSTEM FRONT DISC BRAKE ASSEMBLY 35 37 BRAKE PAD WEAR CHECK WARNING e Always replace both brake pads on each wheel as a set both front wheels or both rear wheels Fail u
11. LOOR PANEL CLEARANCE CHECK AND ADJUSTMENT 1 Turn up the floor carpet or other similar material under the brake pedal 2 Using a needle or similar tools measure the dimension E shown in the figure from the dash panel pad surface to the dash panel 3 Start the engine and depress the brake pedal with approximately 500 N Then measure the dimension F shown in the figure from the center of pedal pad surface to the dash panel pad surface 4 Check that the sum of the dimensions E and F measured in Steps 2 and 3 clearance between the brake pedal and the floor panel is within the standard value Standard value E F 85 mm 3 35 inch 5 If the clearance between the brake pedal and the floor panel is not within the standard value check for the air intrusion in brake line and the thickness of disk brake pad Make corrections or replace components as necessary 6 Recover the floor carpet or other similar material under the brake pedal AC706067AB TSB Revision BASIC BRAKE SYSTEM 35A 1 5 ON VEHICLE SERVICE BRAKE BOOSTER OPERATION CHECK M1351001000822 INSPECTION WITHOUT USING TESTER 1 Carry out the simplified brake booster operation check in the following procedure 1 Run the engine for 1 to 2 minutes and then stop Depress the brake pedal with normal depression force The result is judged as Good when the pedal stroke is great at the first depression and becomes smaller as you repeat d
12. STEM 35A 31 MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY INSTALLATION SERVICE POINTS gt gt A lt lt VACUUM HOSE INSTALLATION j Vacuum hose eT D V D View View Lio gt L ri Paint maik T Paint mark D MM d Hoss hose ene picem Align the mark as shown in the figure to assemble the vacuum amp lt N 72 AC709408 AB TSB Revision 35A 32 BASIC BRAKE SYSTEM MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY gt gt B lt lt MASTER CYLINDER ASSEMBLY AIR BLEEDING When removed the master cylinder assembly bleed the master cylinder in the following procedure to make bleeding of the brake pipeline easier When no brake fluid is in the master inder 1 2 3 Outlet AC709402AB Fill the brake fluid reservoir with the brake fluid Depress and hold the brake pedal Another operator closes the master cylinder outlets with his fingers In this condition release the brake pedal Repeat Steps 2 to 4 for 3 or 4 times to fill the master cylinder with the brake fluid TSB Revision BASIC BRAKE SYSTEM FRONT DISC BRAKE ASSEMBLY 35 33 FRONT DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION A CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched And if there is brake fluid on the caliper wipe it off quickly
13. Wear indicator 9 Vehicle out side AC710737 AB TSB Revision BASIC BRAKE SYSTEM 35A 1 9 ON VEHICLE SERVICE 3 Remove the following parts from the brake caliper assembly 1 Shim 2 Brake pad assembly CAUTION Keep grease or other soiling off the pad and brake disk friction surfaces 4 Clean the piston then press the piston into the cylinder using the piston expander Special tool MB990520 MB990520 Ss Caliper body AC706163AB Piston TSB Revision AC710738AB Grease Repair kit grease Molykote AS880N or equivalent AC710739AB Grease Repair kit grease Molykote 7439 or equivalent BASIC BRAKE SYSTEM ON VEHICLE SERVICE 5 Apply grease to the pad as shown in the figure Grease Between pad and shim Repair kit grease Molykote AS880N or equivalent Shoulder section Repair kit grease Molykote 7439 or equivalent 6 Install the shim to the brake pad assembly Then install the brake pad assembly to the brake caliper assembly so that the direction of shim arrow points to the same direction as the brake disk rotation direction of when the vehicle travels forward NOTE Install the brake pad assembly with wear indicator to outside the vehicle 7 Install the cross spring to the brake caliper assembly TSB Revision BASIC BRAKE SYSTEM ON VEHICLE SERVICE 35A 21 8 While pressing the cross spring by hand
14. ake disk 8 Brake hose TSB Revision BASIC BRAKE SYSTEM REAR DISC BRAKE ASSEMBLY 35 39 REMOVAL SERVICE POINT lt lt A gt gt FRONT BRAKE DISK REMOVAL If the rear brake disk removal is difficult install bolts M8 x 1 25 mm shown in the figure and tighten them evenly and gradually to remove the rear brake disk Bolts M8 x 1 25 mm AC707776AB INSPECTION M1351007 100399 BRAKE DISC CHECK e Disc wear Refer to P 35A 21 e Disc run out Refer to P 35A 21 TSB Revision BASIC BRAKE SYSTEM 35A 40 REAR DISC BRAKE ASSEMBLY DISASSEMBLY AND ASSEMBLY M1351007200868 N CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched And if there is brake fluid on the caliper wipe it off quickly 2 19 x 1 N m 14 1 ft lb AC710740AB lt Right side gt lt Left side gt ER n L 6 i lt Right side gt WR 4 0 0 eq Gq As 0 0 V V ic 6 6 3 Shim kit Clip set yf Right side Left side 5 5 Ord 2p 1 3 Repair kit grease Brake caliper kit Seal and boot kit Pad set Disassembly steps Disassembly steps Continued 1 Bleeder cap lt lt A gt gt 7 Piston boot 2 Bleeder lt lt A gt gt 8 Piston 3 Pin lt lt B gt gt 9 Piston seal 4 Cross spring 10 Caliper body 5 Brake pad assembly NOTE Install the brake pad assembly with wear 6 Shim indicator
15. ake hose and body side bracket as shown in the figure and fix it to the body side bracket with a clip Brake hose AC507195AB INSPECTION M1351006100460 BRAKE DISC CHECK e Disc wear Refer to P 35A 21 Disc run out Refer to P 35A 21 TSB Revision BASIC BRAKE SYSTEM FRONT DISC BRAKE ASSEMBLY DISASSEMBLY AND ASSEMBLY CAUTION 35A 35 M1351006201341 Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched And if there is brake fluid on the caliper wipe it off quickly lt lt A gt gt lt Right side gt fof 3 lt Left side gt S Tu ak QS lt gt 3 Clip set lt Right side gt lt Left side gt 0 n 0 0 3 6 6 AC707016AB Shim kit lt Right side gt Left side S 9 5 N 2 fA A a 0 09 0 Ug A a 0 m 9 Repair kit grease Brake caliper kit Seal and boot kit Pad set Disassembly steps Disassembly steps Continued 1 Bleeder cap lt lt A gt gt 8 Piston 2 Bleeder lt lt B gt gt 9 Piston seal 3 Pin 10 Caliper body 4 Cross spring NOTE Install the brake pad assembly with wear 5 Brake pad assembly indicator to outside the vehicle 6 Shim 7 Piston boot TSB Revision 35A 36 LUBRICATION POINTS 0 LA X f BASIC BRAK
16. atio 5 5 Pedal depression force 663 N 149 Ib TSB Revision BASIC BRAKE SYSTEM SERVICE SPECIFICATIONS 35A 3 Item Specification Front brakes Disk brake nomenclature Brembo 4 opposed piston ventilated disk V8 Z4046 Disk effective dia x thickness mm in 294 x 32 11 6 x 1 3 Cylinder I D mm in 40 0 1 58 x 2 46 0 1 81 x 2 Brake pad thickness mm in 9 85 0 39 Clearance adjustment Automatic adjustment Rear brakes Disk brake nomenclature Brembo 2 opposed piston ventilated disk V7 X40 Disk effective dia x thickness mm in 278 x 22 10 9 x 0 9 Cylinder 1 0 mm in 40 0 1 58 x 2 Brake pad thickness mm in 9 0 0 35 Clearance adjustment Automatic adjustment Brake fluid DOT3 or DOT4 SERVICE SPECIFICATIONS Item Standard value Brake pedal height mm in 219 8 227 8 8 7 9 0 Dimension from the brake booster stud bolt end to the clevis 74 2 91 hole center mm in Brake pedal free play mm in 3 8 0 12 0 31 Pedal to floor clearance when brake pedal is depressed mm 85 3 35 or more Pedal depression force approx 500 Front disk brake Pad thickness mm in 9 85 0 39 2 0 0 08 Brake disk thickness mm in 32 0 1 26 30 0 1 18 Brake disk runout mm in _ 0 06 0 0024 Brake drag force N Ib 68 15 3 or less E Rear disk brake Pad thickness mm in 9 0 0 35 2 0 0 08 Brake d
17. ed values of Step 2 and Step 6 Standard value 68 N 15 3 pounds or less lt Front gt 68 N 15 3 pounds or less lt Rear gt If the brake drag force exceeds the standard value disassemble the brake caliper assembly and check the fouling rust on the piston sliding section piston seal deterioration and the sliding status of guide pin and lock pin Refer to P 35A 35 lt Front gt or P 35A 40 lt Rear gt TSB Revision BASIC BRAKE SYSTEM S BRAKE PEDAL 35A 25 BRAKE PEDAL REMOVAL AND INSTALLATION CAUTION Do not apply grease or lubricant to the switch and the switch installation section to avoid malfunction of the switch In addition do not use gloves which have grease on them M1351003401131 Pre removal operation Post installation operation Instrument Panel Cover Lower Removal Refer to GROUP Instrument Panel Cover Lower Installation Refer to GROUP 52A Instrument Lower Panel P 52A 8 MR 52A Instrument Lower Panel P 52A 8 MR 15 x 3 Nm 11 2 ft lb 14 3 N m 1 124 26 in Ib e AC709280AB Removal steps Removal steps Continued 1 Stoplight switch connector 5 Snap pin connection 6 Pin assembly 2 Stoplight switch 7 Pedal pad 3 Pedal clip 8 Brake pedal assembly 4 Pedal stopper TSB Revision BASIC BRAKE SYSTEM 35A 26 BRAKE PEDAL INSPECTION STOPLIGHT SWITCH CHECK N CAUTION Do not apply grease or lubricant to the switch and the
18. en go to Step 4 NO Goto Step 3 STEP 3 Adjust the brake pedal Refer to P 35A 12 Q Is the brake pedal adjusted correctly YES Go to Step 4 NO Adjust the brake pedal Then go to Step 4 STEP 4 Recheck symptom Q Is the symptom eliminated YES The procedure is complete NO Start over at step 1 Ifa new symptom surfaces refer to the symptom chart TSB Revision BASIC BRAKE SYSTEM 35A 1 0 BASIC BRAKE SYSTEM DIAGNOSIS INSPECTION PROCEDURE 7 Squealing Noise when Brakes are not Applied DIAGNOSIS STEP 1 Check whether the backing plate is bent or loose and interfering with the drum Q Is there a fault YES Replace the part Then go to Step 9 NO Go to Step 2 STEP 2 Check whether the drum is damaged due to interference with the backing plate or shoe Is there any damage YES Replace the part Then go to Step 9 NO Goto Step 3 STEP 3 Check the brake drum for wear and the shoe spring for damage Is there any wear or damage YES Replace the part Then go to Step 9 NO Go to Step 4 STEP 4 Check the brake disks for rust Q Are the brake disks rusted YES Remove the rust by using sand paper If still rusted turn the rotors with an on the car brake lathe Then go to Step 9 NO Goto Step 5 STEP 5 Check the brake pads for correct installation Q Are the pads installed incorrectly YES Repair the pads Then go to Step 9 NO Goto Step 6 STEP 6 Check
19. ep 2 AC709382AB STEP 2 Check the shoe to anchor springs and adjusting wheel spring for breakage Q Are the shoe to anchor springs and adjusting wheel spring broken YES Replace the spring Then go to Step 7 NO Goto Step 3 Shoe to anchor springs gsm Adjusting wheel spring mA STEP 3 Check the amount of grease at each sliding section Refer to GROUP 36 Parking Brake Lining and Drum P 36 17 Q Is the grease amount low YES Apply grease Then go to Step 7 NO Goto Step 4 STEP 4 Check the parking brake pull amount Refer to GROUP 36 On vehicle Service Parking Brake lever Stroke Check and Adjustment P 36 11 Q Is there a fault YES Adjust it Then go to Step 7 NO Goto Step 5 STEP 5 Check port for clogging Q Is the port clogged YES Repair it Then go to Step 7 NO Go to Step 6 TSB Revision 35A 8 BASIC BRAKE SYSTEM BASIC BRAKE SYSTEM DIAGNOSIS STEP 6 Check disk brake pistons for sticking Depress the brake pedal then release Confirm each wheel spins freely Q Does any wheel stick YES Inspect that brake assembly Then go to Step 7 NO Go to Step 7 STEP 7 Recheck symptom Q Is the symptom eliminated YES The procedure is complete NO Start over at step 1 If anew symptom surfaces refer to the symptom chart INSPECTION PROCEDURE 5 Scraping or Grinding Noise when Brakes are Applied DIAGNOSIS STEP 1 Check the front brak
20. epressing the pedal If the pedal stroke does not change the result is judged as No Good AC000870AC When engine When engine 2 With the engine stopped depress the brake pedal is stopped is started several times Keep the brake pedal depressed and start the engine At this time when the pedal moves down slightly the result is judged as Good The result is judged as No Good if the pedal does not move down AC000871 AC Y 3 With the engine running depress the brake pedal Stop Good No good dde Arai og the engine in this condition The result is judged as Good when the pedal height does not change for approximately 30 seconds The result is judged as No Good if the pedal moves up NN 2 The brake booster is judged as normal when the results of all the above checks are Good When one or more of the above check results are No Good then the check valve vacuum hose or brake booster 0008 2 is suspected faulty TSB Revision 35A 16 Valve Spring Booster side AC508114 AB 4m Front of vehicle 4 1 AC607428AE Bleeder screws AC211983AC BASIC BRAKE SYSTEM ON VEHICLE SERVICE CHECK VALVE OPERATION CHECK 1 Remove the check valve Refer to P 35A 27 A CAUTION Replace the check valve when it is faulty 2 Using a vacuum pump check operatio
21. er cylinder assembly Torx bolt Reservoir assembly O ring Master cylinder assembly Brake booster removal steps Air cleaner assembly Refer to GROUP 15 Cleaner 15 10 Cowl top panel Refer to GROUP 42A Loose panel P 42A 192 Brake fluid level switch connector connection Brake pipe connection Master cylinder assembly air bleeding Only at installation Reservoir hose connection lt M T gt Battery harness clip connection Self locking nut Reservoir assembly and master cylinder assembly Vacuum hose connection Hose clip Check valve Dash panel heat protector Dash panel drain hose Chassis FR harness connection Brake pipe connection Clip Clip Clip Snap pin Pin assembly Brake booster mounting nut Brake booster assembly Seal and spacer assembly TSB Revision 35A 29 35A 30 BASIC BRAKE SYSTEM MASTER CYLINDER ASSEMBLY AND BRAKE BOOSTER ASSEMBLY lt VACUUM HOSE AND VACUUM PIPE gt 1 11 1N m gt 98 4 in Ib 2 44 p c 4 9 Ow YS dca hin RI 98 4 in Ib 5 7 E 24 3 N m 18 2 ft lb AC709314AB Removal steps Removal steps Continued gt gt A lt lt 1 Vacuum hose 5 Emission vacuum hose connection 2 Hose clip e Fuel injector return pipe Refer to gt gt A lt lt 3 Vacuum hose GROUP 13A Injector P 13A 914 4 Hose clip 6 Vacuum pipe assembly Engine Upper Cover Refer to GROUP 16 Ignition coil P 16 39 TSB Revision BASIC BRAKE SY
22. es then rear brakes for metal to metal condition 15 any metal to metal contact evident YES Repair or replace the components Then go to Step 6 NO Goto Step 2 STEP 2 Check for interference between the caliper and wheel Q Is there any interference YES Repair or replace the part Then go to Step 6 NO Goto Step 3 STEP 3 Check for interference between the dust cover and brake disk 1 there any interference YES Repair or replace the part Then go to Step 6 NO Go to Step 4 STEP 4 Check the brake drums or disks for cracks Q Are there cracks YES Repair or replace the part Then go to Step 6 NO Goto Step 5 TSB Revision BASIC BRAKE SYSTEM 35A 9 BASIC BRAKE SYSTEM DIAGNOSIS STEP 5 Check for bent backing plate s AC709382AD Q Is Are the backing plate s bent YES Repair or replace the part Then go to Step 6 NO Goto Step 6 STEP 6 Recheck symptom Q 15 the symptom eliminated YES The procedure is complete NO Start over at step 1 If anew symptom surfaces refer to the symptom chart INSPECTION PROCEDURE 6 Squealing Groaning or Chattering Noise when Brakes are Applied DIAGNOSIS STEP 1 Check the brake disk and pads for wear or cutting Q Is there wear or cutting YES Repair or replace the part Then go to Step 4 NO Go to Step 2 STEP 2 Check the calipers for rust Q Is there any rust YES Remove the rust Th
23. hen hold it with wire Temporarily install the disk with the hub nut Place a dial gauge approximately 5 mm 0 2 inch from the outer circumference of the brake disk and measure the run out of the disk Limit 0 06 mm 0 0024 inch Front 0 08 mm 0 0032 inch Rear When the brake disk runout exceeds the limit value correct the brake disk runout according to the following procedure TSB Revision BASIC BRAKE SYSTEM ON VEHICLE SERVICE 35A 23 1 Before removing the brake disk make marks using a chalk to the stud bolt on the side with the greater runout and to both sides of the stud bolt 2 Check the wheel bearing axial looseness Refer to GROUP 26 On vehicle Service Wheel Bearing End Play Check P 26 7 Front or GROUP 27 On vehicle Service Wheel Bearing End Play Check P 27 33 lt Rear gt 3 When the looseness is within the limit value install the brake disk after changing the phase between the hub and the brake disk then check the runout of the brake disk again A CAUTION e After a new brake disk is installed always grind the brake disk with on the car type brake lathe If this step is not carried out the brake disk run out exceeds the specified value resulting in judder e When the on the car type lathe is used first install M12 flat washer on the stud bolt in the brake disk side according to the figure and then install the adapter If the adapter is installed with M12 flat wa
24. is a significant difference in the thicknesses of the pads on the left and right sides check moving parts Refer to P 35A 21 1 Visually check the thickness of brake pad from the inspection hole of the caliper body Standard value 9 85 mm 0 39 inch lt Front gt 9 0 mm 0 35 inch lt Rear gt Limit 2 0 mm 0 08 inch lt Front gt 2 0 mm 0 08 inch lt Rear gt 2 When the thickness is lower than the limit value replace both brake pads right and left as a set Refer to P 35A 18 M1351017300048 lt Rear gt TSB Revision 35A 18 Cross spring AC211986AB lt Front disc brake gt lt Right side gt BASIC BRAKE SYSTEM ON VEHICLE SERVICE BRAKE PAD REPLACEMENT M1351017400056 CAUTION e Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched And if there is brake fluid on the caliper wipe it off quickly e Whenever a pad must be replaced replace both LH and RH wheel pads as a set to prevent the vehicle from pull ing to one side when braking 1 While pressing the cross spring by hand remove the pin from the brake caliper assembly 2 Remove the cross spring from the brake caliper assembly lt Left side gt m ibn indicator Vehicle out K 6 Df 7 d Rear disc brake Vehicle out sf Wear indicator d 1 Wear indicator nl EV 0
25. isk thickness mm in 22 0 0 87 20 0 0 79 Brake disk runout mm in 0 08 0 0032 Brake drag force N Ib 68 15 3 or less Brake pedal distortion mm 240 246 9 4 9 7 TC SST 242 248 9 5 9 8 M1351000301403 TSB Revision BASIC BRAKE SYSTEM 35A 4 LUBRICANTS LUBRICANTS Item Specified lubricant Quantity Brake fluid DOT3 or DOT4 Adequate Brake pad assembly between pad and Repair kit grease Molykote AS880N or equivalent shim Brake pad assembly shoulder section Repair kit grease Molykote 7439 or equivalent M1351000401002 BASIC BRAKE SYSTEM DIAGNOSIS INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS Hydraulic brakes are composed of the brake pedal master cylinder brake booster and disk brakes Mal functions such as insufficient braking power or the generation of noise may occur due to wear damage or incorrect adjustment of these components BASIC BRAKE SYSTEM DIAGNOSTIC TROUBLESHOOTING STRATEGY Use these steps to plan your diagnostic strategy If 2 Verify that the condition described by the M1351009700405 you follow them carefully you will be sure that you customer exists have exhausted most of the possible ways to finda Find the malfunction by following the symptom basic brake system fault chart 1 Gather information from the customer 4 Verify malfunction is eliminated SYMPTOM
26. m 0 79 inch Rear NOTE Thickness variation at least 8 positions should not be more than 0 015 mm 0 0006 inch ACX00668 AB TSB Revision 35A 22 AC006226 AE BASIC BRAKE SYSTEM ON VEHICLE SERVICE CAUTION After a new brake disk is installed always grind the brake disk with on the car type brake lathe If this step is not carried out the brake disk run out exceeds the specified value resulting in judder When the on the car type lathe is used first install M12 flat washer on the stud bolt in the brake disk side according to the figure and then install the adapter If the adapter is installed with M12 flat washer not seated the brake disk rotor may be deformed resulting in inac curate grinding Grind the brake disk with all wheel nuts diagonally and equally tightened to the specified torque 100 N m 74 ft Ib When all numbers of wheel nuts are not used or the tightening torque is excessive or not equal the brake disk rotor or drum may be deformed resulting in judder If the disk thickness is less than the limits replace it with a new one If thickness variation exceeds the specification turn rotor with an on the car type brake lathe MAD DL 8700PF or equivalent If the calculated final thickness after turning the rotor is less than the standard value replace the disk FRONT BRAKE DISK RUN OUT CHECK AND CORRECTION Remove the brake assembly and t
27. n of the check valve M1351009000815 Vacuum pump Normal condition connection When connected to the Vacuum is generated booster side 1 and maintained When connected to the No vacuum is generated engine side 2 BLEEDING A CAUTION Be sure to use the specified brand and type of brake fluid Avoid mixing with other type of brake fluid Brake fluid DOT3 or DOTA BLEEDING OF BRAKE PIPELINE Perform the bleeding in the order shown in the figure M1351001401027 DISK BRAKE BLEEDING A CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched And if there is brake fluid on the caliper wipe it off quickly Connect a vinyl tube to the outer end of the air bleeder screws to bleed the circuit of air Then connect the vinyl tube to the inner end and bleed the circuit of air Except for these the con ventional procedures shall be followed After the circuit has been bled of air tighten both air bleeder screws securely TSB Revision BASIC BRAKE SYSTEM 3 ON VEHICLE SERVICE 35A 17 BRAKE FLUID LEVEL SWITCH CHECK M1351009100801 The brake fluid level switch is normal when the following condi tions are met When the brake fluid level is above MIN conti nuity is detected and when the level is below MIN no continuity is detected AC707397AB BRAKE PAD CHECK N CAUTION If there
28. piston s move correctly YES Go to Step 3 NO Disassemble and inspect the brake assembly Front refer to P 35A 35 Rear refer to P 35A 40 Then go to Step 5 STEP 3 Check brake disk s for runout Refer to P 35A 21 Q Is runout outside of specifications YES Repair or replace the brake disk s as necessary Then go to Step 5 NO to Step 4 STEP 4 Check brake disks for correct thickness Refer to P 35A 21 Q Is the thickness outside of specifications YES Repair or replace the brake disk s as necessary Then go to Step 5 NO Perform the brake line bleeding Then go to Step 5 STEP 5 Retest the system Q Is the symptom eliminated YES The procedure is complete NO Start over at Step 1 If a new symptom appears refer to the appropriate symptom chart INSPECTION PROCEDURE 2 Insufficient Braking Power DIAGNOSIS STEP 1 Check that the specified brake fluid is used its level is correct and no contamination is found Q Is there a fault YES Refill or replace with the specified brake fluid DOT 3 or DOT 4 Bleed the brakes if necessary Refer to P 35A 16 Then go to Step 6 NO to Step 2 STEP 2 Check for spongy not firm brakes 1 With engine not running depress the brake pedal rapidly several times to deplete the booster vacuum reserve 2 With the brake pedal fully released depress the brake pedal slowly until it stops 3 With a measuring device ruler etc ne
29. re to do so will result in uneven braking which may cause unreliable brake operation If there is significant difference the thickness of the pads on the left and right sides check the moving parts Measure thickness at the thinnest most worn area of the pad Replace the pad assembly if pad thickness is less than the limit value Standard value 9 85 mm 0 39 inch Limit 2 0 mm 0 08 inch TSB Revision E BASIC BRAKE SYSTEM 35A 38 REAR DISC BRAKE ASSEMBLY REAR DISC BRAKE ASSEMBLY REMOVAL AND INSTALLATION A CAUTION Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched And if there is brake fluid on the caliper wipe it off quickly M1351007000790 Pre removal Operation Post installation Operation Brake Fluid Draining e Brake Fluid Supplying and Air Bleeding Refer to 16 Brake Disk Runout Inspection Correction Refer to P 35A 21 Lining Running in Refer to GROUP 36 Parking Brake Lining Seating Procedure P 36 12 11 2 Nm 98 17 in Ib 16 x 3 N m 6 4 und 1 30 5 22 3 ft lb nine 59 7 ft Ib 6 AC707657AB Removal steps Removal steps Continued 1 Brake hose brake caliper side 5 Adjusting hole plug connection 6 Clip 2 Gasket 7 Brake hose brake pipe side 3 Rear brake caliper assembly connection lt lt A gt gt 4 Rear br
30. rve 2 With the brake pedal fully released depress the brake pedal slowly until it stops 3 With a measuring device ruler etc next to the brake pedal depress the pedal firmly and measure the distance the pedal traveled Q Is the distance greater than 20 mm 0 8 inch YES Bleed the brakes to remove air in the fluid Refer to P 35A 16 Then go to Step 5 NO Go to Step 2 STEP 2 Check the pad for wear Refer to P 35A 17 Q Is the pad thickness outside of specifications YES Replace the part Then go to Step 5 NO Goto Step 3 STEP 3 Check the vacuum hose and check valve for damage Refer to P 35A 16 Q Is there a damage YES Replace the part Then go to Step 5 NO Go to Step 4 STEP 4 Check for brake fluid leaks Q Is there a leak YES Check the connection for looseness corrosion etc Clean and repair as necessary If leaking in any tube or hose section replace the complete tube or hose Then go to Step 5 NO Goto Step 5 STEP 5 Recheck symptom Q Is the symptom eliminated YES The procedure is complete NO Start over at step 1 If a new symptom surfaces refer to the symptom chart TSB Revision BASIC BRAKE SYSTEM BASIC BRAKE SYSTEM DIAGNOSIS 35A INSPECTION PROCEDURE 4 Brake Drag DIAGNOSIS STEP 1 Check the parking brake operating lever return Q Is the operation faulty Parking brake YES Repair it Then go to Step 7 operating lever NO Go to St
31. sher not seated the brake disk rotor may be deformed resulting in inac curate grinding Grind the brake disk with all wheel nuts diagonally and equally tightened to the specified torque 100 N m 74 ft Ib When all numbers of wheel nuts are not used or the tightening torque is excessive or not equal the brake disk rotor or drum may be deformed resulting in judder 5 f the run out cannot be corrected by changing the phase of the brake disk replace the brake disk or grind it with the lat wasner on the car type brake lathe MAD DL 8700PF or equivalent AY Chalk marks TPN AC201323 AD AC006226 AE TSB Revision 35A 24 BASIC BRAKE SYSTEM ON VEHICLE SERVICE BRAKE DRAG FORCE CHECK amp m Front of vehicle AC707502AB M1351017200052 Remove the brake pad shim and clip Refer to P 35A 18 Using a spring scale and with the brake pad shim and clip removed measure the hub sliding torque in the forward direction Install the brake pad shim and clip Refer to P 35A 18 Start the engine and depress the brake pedal forcibly two or three times Then stop the engine Rotate the brake disk 10 times in the forward direction Using a spring scale and with the brake pad shim and clip installed measure the hub sliding torque in the forward direction Obtain the disk brake drag force difference between measur
32. th brake pads on each wheel as a set both front wheels or both rear wheels Fail ure to do so will result in uneven braking which may cause unreliable brake operation If there is significant difference the thickness of the pads on the left and right sides check the moving parts Measure thickness at the thinnest most worn area of the pad Replace the pad assembly if pad thickness is less than the limit value Standard value 9 0 mm 0 35 inch Limit 2 0 mm 0 08 inch AC709430 TSB Revision
33. the dash panel pad surface to the dash panel 4 Measure the dimension B in the figure distance from the pedal pad surface to the dash panel pad surface Dash 5 Make sure that the total of the dimensions A and B inet measured in Steps 2 and 3 brake pedal height is within the standard value Nu Standard value A B 219 8 227 8 mm 8 7 9 0 inch ash panel pad AC505506 AJ 6 When the brake pedal height is not within the standard value inspect the brake pedal in the following procedure 1 Remove the brake pedal assembly Refer to P 35A 25 TSB Revision BASIC BRAKE SYSTEM E ON VEHICLE SERVICE 35A 13 2 Check the removed brake pedal assembly for distortion and replace it when deformed Refer to P 35A 26 3 Install the brake pedal assembly Refer to P 35A 25 4 Measure the brake pedal height again and make sure that it is within the standard value A B When the measured value is not within the standard value measure the dimension C in the figure distance from the stud bolt end to the clevis hole center and make sure it is within the standard value C Standard value C 74 mm 2 91 inch 5 When the measured value is not within the standard value C replace the brake booster Refer to P 35A 27 AC508163AB 7 After checking the brake pedal height install the stoplight Stoplight switch switch in the following procedure Z 1 Scre
34. to 135 15 N m 100 11 ft lb for the front caliper Tighten to 80 10 N m 59 7 ft lb for the rear caliper Then go to Step 5 NO Go to Step 4 STEP 4 Check the wheel bearings for end play Refer to GROUP 26 On vehicle Service Wheel bearing end play check P 26 7 Front or GROUP 27 On vehicle Service Wheel bearing end play check P 27 33 Rear Q Does the measured end play exceed the limit YES Replace the faulty hub assembly Then go to Step 5 NO Goto Step 5 TSB Revision _ BASIC BRAKE SYSTEM 35A 12 SPECIAL TOOLS STEP 5 Recheck symptom Q 15 the symptom eliminated YES The procedure is complete NO Start over at step 1 If anew symptom surfaces refer to the symptom chart SPECIAL TOOLS Number Name Use MB992146 Booster test Inspection using a simplified tester adapter M1352000601526 MB992146 MB990964 Brake tool set Disk brake piston pushing back A MB990520 A Piston expander MB990964 ON VEHICLE SERVICE BRAKE PEDAL CHECK AND ADJUSTMENT M1351003500737 N CAUTION Do not apply grease or lubricant to the switch and the switch installation section to avoid malfunction of the switch In addition do not use gloves which have grease on them BRAKE PEDAL HEIGHT CHECK 1 Turn up the floor carpet under the brake pedal 2 Remove the stoplight switch Refer to P 35A 25 3 Use a needle or similar tool to measure the dimension A in the figure distance from
35. w in the stoplight switch until its thread contacts the Pedal stopper gt gt Pedal stopper X pedal stopper then turn the switch approximately one eighth of a clockwise turn to fix it While doing this pull and hold the brake pedal by hand 2 Check that the clearance between the stoplight switch and the pedal stopper is as shown in the figure 3 Connect the stoplight switch connector NOTE Make sure that the stoplight is not illuminated when the brake pedal is not depressed 8 Check the shift lock mechanism lt TC SST gt Refer to GROUP 22C On vehicle Service Shift Lock Mechanism Check P 22C 332 9 Recover the floor carpet under the brake pedal 0 5 to 1 5 mm 0 02 to 0 06 in AC309282 AG TSB Revision _ BASIC BRAKE SYSTEM 35A 14 ON VEHICLE SERVICE BRAKE PEDAL PLAY CHECK AND ADJUSTMENT 1 With the engine stopped depress the brake pedal 2 or 3 times to release the vacuum in the brake booster Then press the brake pedal with your finger and check if the pedal stroke until the pedal becomes heavy play is within the standard value Standard value B 3 8 mm 0 12 0 31 inch 2 When the brake pedal play is not within the standard value check the brake pedal to clevis pin looseness clevis pin to booster operating rod looseness brake pedal height AC505506 AF and stoplight switch position and adjust or replace as necessary BRAKE PEDAL TO F
36. xt to the brake pedal depress the pedal firmly and measure the distance the pedal traveled Q Is the distance greater than 20 mm 0 8 inch YES Bleed the brakes to remove air in the fluid Refer to P 35A 16 Then go to Step 6 NO Goto Step 3 TSB Revision 35A 6 BASIC BRAKE SYSTEM BASIC BRAKE SYSTEM DIAGNOSIS STEP 3 Check the brake booster function Refer to P 35A 15 Q Is there a fault YES Replace the brake booster Then go to Step 6 NO to Step 4 STEP 4 Check for pinched or restricted brake tube or hose Q Is there a pinched or restricted brake tube or hose YES Replace that complete section of brake tube or brake hose Then go to Step 6 NO Goto Step 5 STEP 5 Check for oil water etc on the pad contact surfaces of all brakes Q Is oil water etc on the pad contact surface YES Replace the part and determine the source cause of foreign material Recheck symptom Then go to Step 6 NO The procedure is complete Then go to Step 6 STEP 6 Recheck symptom Q Is the symptom eliminated YES The procedure is complete NO Start over at step 1 If a new symptom surfaces refer to the appropriate symptom chart INSPECTION PROCEDURE 3 Increased Pedal Stroke Reduced Pedal to Floor Board Clearance DIAGNOSIS STEP 1 Check for spongy not firm brakes 1 With engine not running depress the brake pedal rapidly several times to deplete booster vacuum rese

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