Brake

Brake system / pedal / brake booster device

Brake system
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-2
Function inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-2
Symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-3
Brake line
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-5
Arrangement drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-7
Brake fluid
Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-8
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-8
Air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-8
On-vehicle inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-12

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Brake pedal (AT model)
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-13
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-14
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-17
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-18
Brake pedal (MT model)
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-20
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-20
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-23
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-23
Brake master cylinder ASSY
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-24
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-25
Brake booster ASSY
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-26
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-30
Unit inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-31
Vacuum pump ASSY
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-32
BR
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-35
On-vehicle inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR-35
 BR–2 Brake system / pedal / brake booster device － Brake system

Brake system
Brake system / pedal / brake booster device

Precautions
1. The speed sensor FR and RR are easily affected by magnetism. Use extra caution when working with magnets.
2. Replace each part correctly. Otherwise it may impair the brake system, leading to dangerous driving conditions. Use the
same part or the equivalent for replacement.
3. When servicing the brake system, keep the parts and their surroundings clean.
4. If the vehicle is equipped with a device including a radio, refer to the precautions in "General" section.

Function inspection
1. Brake booster simple check
(1) Function inspection of brake booster air-tightness
(a)Start the engine, let it idle for 1 to 2 minutes, and then stop it.
(b)Depress the brake pedal several times with an ordinary force, and check the height change of the brake pedal.
Criteria: The brake pedal height goes up each time the pedal is depressed (The intervals between the first and sec-
ond time, and the second and third time are 5 seconds or more).
(2) Brake booster operation check
(a)Depress the brake pedal several times in the same force with the engine turned OFF, and check that there is no height
change in the brake pedal.

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(b)With the brake pedal depressed, start the engine and check the height change of the brake pedal.
Criteria: When the engine is started with the brake pedal depressed, the brake pedal travels a little farther.
(3) Function inspection of brake booster load air tightness
(a)With the engine running, press and hold the brake pedal and stop the engine for 30 seconds to check the height
change of the brake pedal.
Criteria: No height change in the pedal
2. Function inspection of brake booster
(1) Preparation for inspection

 

  

BR

BR-01102

Captions in illustration
*1 Pressure gauge *2 Vacuum gauge
*3 Adapter hose *4 Vacuum hose
*5 Pedal force gauge

(2) Function inspection of air tightness

 Brake system / pedal / brake booster device － Brake system
BR–3

(a)Start the engine and then stop the engine at the vacuum pressure of 66.7 kPa {500 mmHg} {19.69 inHg} to check the
vacuum pressure change.
Criteria: Vacuum pressure does not drop for 15 seconds.
(3) Function inspection of load air tightness
(a)Start the engine and depress the brake pedal at a pedal force of 196 N {20 kgf} {44.1l bf}. Then stop the engine at the
vacuum pressure of 66.7 kPa {500 mmHg} to check the vacuum pressure change.
Criteria: Vacuum pressure drops to within 3.3 kPa{25 mmHg} {0.97 inHg} for 15 seconds.
(4) Non-boosting action check
(a)Stop the engine and depress the brake pedal several times to check the fluid pressure in each pedal force under con-
ditions without vacuum pressure.
Standard value
Pedal force [N{kgf, lbf}] Fluid pressure [MPa{kgf/cm2, psi}]
147{15, 33.1} 0.56 {5.7, 8.12}
294 {33, 66.1} 1.64 {16.7, 23.8}

(5) Boosting action check

(a)Start the engine and increase the vacuum pressure up to 66.7 kPa{500 mmHg} in the brake booster, and then check
the fluid pressure in each pedal force.
Standard value

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Pedal force [N{kgf, lbf}] Fluid pressure [MPa{kgf/cm2, psi}]
147{15, 33.1} 105 {1075, 1522.5}
294 {33, 66.1} 112 {1146, 1624.0}

NOTE:
If the brake booster ASSY is faulty, check the check valve. If there is no problem with the check valve, replace the
brake booster ASSY.
(6) Remove the pressure gauge, pedal force gauge, and vacuum gauge.
(7) Install the vacuum hose to the brake booster ASSY.
(8) Air bleeding of brake system (Refer to BR - 8)

Symptom table
Brake system
Reference pages
Symptoms Inspection items
Normal type Brembo type
Brake system (fluid leakage) - -
Brake system (air entry) BR - 8 BR - 8
Pedal sinks/Pedal pressure is soft. Front brake piston seal (wear or breakage) FB - 5 FB - 8
Rear brake piston seal (wear or breakage) RB - 27 RB - 30
Master cylinder (faulty) BR - 24 BR - 24
Brake pedal play (minimum) BR - 19 BR - 19
Parking brake lever stroke (improper adjustment) PB - 2 PB - 2
Parking brake cable ASSY No.1 (sticking) PB - 9 PB - 9
Parking brake cable ASSY No.2 (sticking) PB - 9 PB - 9
Parking brake cable ASSY No.3 (sticking) PB - 9 PB - 9

BR
Parking brake shoe clearance (improper adjustment) PB - 24 PB - 24
Front brake pad (crack or deformation) FB - 5 FB - 8
Brake drag
Rear brake pad (crack or deformation) RB - 27 RB - 30
Front brake piston (sticking) FB - 9 FB - 10
Rear brake piston (sticking) RB - 32 RB - 33
Front brake piston (seizure) FB - 9 FB - 10
Rear brake piston (seizure) RB - 32 RB - 33
Air leakage in booster BR - 2 BR - 2
Master cylinder (faulty) BR - 24 BR - 24
 BR–4 Brake system / pedal / brake booster device － Brake system

Reference pages
Symptoms Inspection items
Normal type Brembo type
Front brake piston (sticking) FB - 9 FB - 10
Rear brake piston (sticking) RB - 32 RB - 33
Front brake pad (oil stain) FB - 5 FB - 8
Rear brake pad (oil stain) RB - 27 RB - 30
Front brake piston (seizure) FB - 9 FB - 10
Brake working on one-side
Rear brake piston (seizure) RB - 32 RB - 33
Front disc (uneven wear) FB - 5 FB - 8
Rear disc (uneven wear) RB - 27 RB - 30
Front brake pad (crack or deformation) FB - 5 FB - 8
Rear brake pad (crack or deformation) RB - 27 RB - 30
Brake system (fluid leakage) - -
Brake system (air entry) BR - 8 BR - 8
Front brake piston (sticking) FB - 9 FB - 10
Rear brake piston (sticking) RB - 32 RB - 33
Front brake pad (crack or deformation) FB - 5 FB - 8
Rear brake pad (crack or deformation) RB - 27 RB - 30
Pedal is hard but the brake does not work
Front brake pad (oil stain) FB - 5 FB - 8
well.

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Rear brake pad (oil stain) RB - 27 RB - 30
Front brake pad (burn in) FB - 5 FB - 8
Rear brake pad (burn in) RB - 27 RB - 30
Front disc (uneven wear) FB - 5 FB - 8
Rear disc (uneven wear) RB - 27 RB - 30
Air leakage in booster BR - 2 BR - 2
Front brake pad (crack or deformation) FB - 5 FB - 8
Rear brake pad (crack or deformation) RB - 27 RB - 30
Front brake mounting bolt (looseness) FB - 5 FB - 8
Rear brake mounting bolt (looseness) RB - 27 RB - 30
Front disc (scratch) FB - 5 FB - 8
Rear disc (scratch) RB - 27 RB - 30
Front pad support plate (looseness) FB - 9 FB - 10
Noise from brake
Front slide pin (wear) FB - 9 FB - 10
Front brake pad (dirt) FB - 5 FB - 8
Rear brake pad (dirt) RB - 27 RB - 30
Front brake pad (burn in) FB - 5 FB - 8
Rear brake pad (burn in) RB - 27 RB - 30
Front anti squeal shim (breakage) FB - 5 FB - 8
Rear anti squeal shim (breakage) RB - 27 RB - 30

BR
 Brake system / pedal / brake booster device － Brake line
BR–5

Brake line
Brake system / pedal / brake booster device

Precautions
1. This part is critical to safety. If brake fluid leakage is found, be sure to disassemble the parts, and replace the faulty parts with
new ones if any.
2. When removing each component of the brake, protect it with cover to prevent foreign matter such as dirt or dust from enter-
ing the connecting part
3. Do not damage or deform the brake tube during removal/installation of the parts.
4. When installing the grommet to the body, make sure that the brake tube is positioned in the center of the grommet.
5. When installing the brake tube and the flexible hose, make sure that they are not twisted or bent.
6. If the connecting part of the flexible hose does not fit the bracket groove, twist the flexible hose at the minimum angle needed
to insert.
7. Do not reuse the flexible hose mounting clip.
8. Make sure that the flexible hose is free from lubricants such as absorber oil and grease.
9. When installing the brake tube to the resin clamp, make sure to attach the brake tube to the clamp securely without the brake
tube wiggling or snagging.
10. When installing the brake tube and the flexible hose, make sure that they do not interfere with other parts.
11. Do not let brake fluid come into contact with the painted surface of the body. Wipe the surface off quickly and clean it with

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water if contaminated.
12. Disconnection and connection of flexible hose and brake tube
C D (1) Using a spanner, secure the flexible hose. Then using a flare-nut
wrench, disconnect the brake tube without deforming it.
Captions in illustration
*1 Clip
*a When disconnecting
*b When connecting


(2) Connect the flexible hose and the brake tube temporarily.
(3) With a new clip, secure the flexible hose. At this time, attach the
BR-01126 clip completely.
(4) Being careful not to deform the brake tube, tighten the brake tube
securely with a flare-nut wrench.
Standard value:T=15N·m {153kgf·cm} {11.1ft·lbf}
13. Connection of brake tube and way
(1) Connect the way and the brake tube temporarily.

BR
 BR–6 Brake system / pedal / brake booster device － Brake line

(2) Holding the way to prevent the brake tube from deforming, connect
 the brake tube with a flare-nut wrench.
 Standard value:T=15N·m {153kgf·cm} {11.1ft·lbf}

Captions in illustration
*1 Brake tube
*2 Way




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BR-01125

(3) Holding the way to prevent the brake tube from deforming, connect the way to the body with bolts.
Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}

BR
 Brake system / pedal / brake booster device － Brake line
BR–7

Arrangement drawing

Brake master cylinder ASSY

C C

A B B Brake booster ASSY A

B B
A A A A

A A A A
Front side
of the Brake actuator ASSY
vehicle A A

C C

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Brake tube

Flexible hose

Brake tube way

A Flare-nut tightening torque

15 N•m{155 kgf•cm, 11.1 ft•lbf} (Specified tightening torque)

B Flare-nut tightening torque

19 N•m{194 kgf•cm, 14.0 ft•lbf}

C Union bolt tightening torque

26 N•m{265 kgf•cm, 19.2 ft•lbf}

BR-10019

BR
 BR–8 Brake system / pedal / brake booster device － Brake fluid

Brake fluid
Brake system / pedal / brake booster device

Refill
1. Refill of brake fluid
CAUTION:
Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
(1) Remove the reservoir filler cap.
(2) Fill the brake master cylinder reservoir ASSY with brake fluid up to the MAX level.

Replacement
1. Replacement of brake fluid
CAUTION:
• Do not let brake fluid come into contact with the painted surface of the
vehicle. If spilled, wash it off with water and wipe clean quickly.
• Do not reuse drained brake fluid. When refilling, always use new brake
fluid.
• To prevent deterioration of brake fluid performance, do not mix different
grades of brake fluid (even if they are same brand).
• Do not allow dirt or dust to enter the brake master cylinder reservoir
ASSY.
NOTE:

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• During work, refill brake fluid frequently to prevent the brake master
cylinder reservoir ASSY from becoming empty, which prevents air
entry.
• When operating the brake pedal, depress it slowly to full stroke.
• Work in pairs to work safely and easily.
• The necessary amount of brake fluid is approx. 500 mL (16.9 US fl
oz, 17.6 Imp fl oz) for the entire brake system.
(1) Lift up the vehicle.
(2) Remove the wheels (front and rear, both sides).
(3) Drain brake fluid from the brake master cylinder reservoir ASSY.
(4) Refill the brake master cylinder reservoir ASSY with the recom-
mended brake fluid, and then perform the same procedure as the
brake line air bleeding on each brake caliper. (Refer to BR - 8)
Recommended brake fluid: FMVSS No. 116 DOT3 or DOT4
NOTE:
Repeat depressing the brake pedal to full stroke slowly until the
new brake fluid flows out of the transparent plastic tube. (For the
new brake fluid from the brake master cylinder SUB-ASSY to flow
out of the bleeder screw, the pedal operation is required twenty
times or more for each brake caliper.)
2. Brake fluid level check (Refer to BR - 12)

Air bleeding
1. Precautions for handling·procedures

BR CAUTION:
• Do not let brake fluid come into contact with the painted surface of the vehicle. If spilled, wash it off with water and wipe clean
quickly.
• Do not reuse drained brake fluid. When refilling, always use new brake fluid.
• To prevent deterioration of brake fluid performance, do not mix different grades of brake fluid (even if they are same brand).
• Do not allow dirt or dust to enter the brake master cylinder SUB-ASSY.
• Work in pairs to work safely and easily.
• During work, refill brake fluid frequently to over the MIN level to prevent the brake master cylinder reservoir ASSY from becom-
ing empty, which prevents air entry.
NOTE:
For procedures of air bleeding in each part, refer to the following.
 Brake system / pedal / brake booster device － Brake fluid
BR–9

• Brake master cylinder SUB-ASSY: Refer to BR - 9.

• Brake line: Refer to BR - 10.
• Brake actuator ASSY: Refer to BR - 11.
• Caliper body ASSY: Refer to BR - 12.
2. Air bleeding of master cylinder
NOTE:
• When the brake master cylinder SUB-ASSY has been replaced, or the brake master cylinder reservoir ASSY is empty,
bleed air from the brake master cylinder ASSY.
• When air bleeding of the brake master cylinder SUB-ASSY is not necessary, omit the following procedure and bleed air
from the brake line. (Refer to BR - 10)

(1) While pushing the brake tube against the brake master cylinder
E SUB-ASSY, press it until the tip of the flare-nut comes into contact
with the back surface of the brake tube flare, and then tighten it.
D CAUTION:
Be careful not to damage the inner wall of the brake tube flare.
Standard value:T=19 N·m {194 kgf·cm} {14 ft-lb}

*a Flare-nut
*b Brake pipe

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BR-01492

(2) Fill the brake master cylinder reservoir ASSY of the brake master cylinder SUB-ASSY with brake fluid.
NOTE:
• Fill the brake fluid up to the MAX level.
• During work, refill brake fluid frequently to over the MIN level to prevent the brake master cylinder reservoir ASSY
from becoming empty, which prevents air entry.
(3) Install a transparent plastic tube to the bleeder screw of the right front caliper body ASSY, and install the other end of the
tube to a recovery container.
(4) Loosen the bleeder screw, and then slowly depress the brake pedal and hold it.
(5) Tighten the bleeder screw, and then release the brake pedal quickly.
(6) Repeat the steps (4) to (5) until no air bubbles are seen in the brake fluid in the plastic tube.
NOTE:
• Repeat the steps six or seven times to get rid of air bubbles.
• For the brembo type, perform in the order of inner →outer.
(7) Install a transparent plastic tube to the bleeder screw of the left front caliper body ASSY, and install the other end of the
tube to a brake fluid recovery container.
(8) Repeat the steps (4) to (5) until no air bubbles are seen in the brake fluid in the plastic tube.
NOTE:
• Repeat the steps seven or eight times to get rid of air bubbles.
• For the brembo type, perform in the order of inner →outer.
• By performing steps up to here, air in the front brake piping passage and the front caliper is bled.
Then perform the following procedure to bleed air which entered the rear brake piping passage and the rear caliper
from the brake actuator ASSY.
(9) Install a transparent plastic tube to the bleeder screw of the left rear caliper body ASSY, and install the other end of the
tube to a brake fluid recovery container. BR
(10) Loosen the bleeder screw and repeat depressing the brake pedal to full stroke slowly. Then tighten the bleeder screw
repeatedly until no air bubbles are seen in the brake fluid in the plastic tube.
NOTE:
• For the brembo type, perform in the order of inner →outer.
• By repeating the steps fifteen times or more, the air which entered the rear brake piping passage from the brake actu-
ator ASSY reaches to the bleeder screw of the left rear caliper body ASSY, and then is drained.
(11) Install a transparent plastic tube to the bleeder screw of the right rear caliper body ASSY, and install the other end of the
tube to a brake fluid recovery container.
(12) Perform the step (10).
 BR–10 Brake system / pedal / brake booster device － Brake fluid

NOTE:
• For the brembo type, perform in the order of inner →outer.
• By repeating the steps ten times or more, the air which entered the rear brake piping passage from the brake actuator
ASSY reaches to the bleeder screw of the right rear caliper body ASSY, and then is drained.
• By performing steps up to here, air which entered the rear brake piping passage and the rear caliper body ASSY from
the brake actuator ASSY is bled.
Finally, perform the following procedure to bleed air which may remain in brake fluid stagnation areas.
(13) Install a transparent plastic tube to the bleeder screw of the right front caliper body ASSY, and install the other end of the
tube to a brake fluid recovery container.
(14) Repeat depressing the brake pedal hard and quickly five or six times, and then hold the pedal depressed.
(15) Loosen the bleeder screw to drain brake fluid. When the brake pedal reaches the full stroke position, tighten the bleeder
screw quickly, and then release the brake pedal.
(16) Repeat the steps (14) to (15) until no air bubbles are seen in the transparent plastic tube.
NOTE:
Repeat the steps four or five times.
(17) Repeat the steps (14) to (16) on each caliper body ASSY.
NOTE:
• Perform air bleeding in order of the front RH→front LH→rear LH→rear RH.
• For the brembo type, perform air bleeding in inner →outer in the order of front RH →front LH →rear LH →rear RH.
(18) Tighten each bleeder screw to the specified torque.

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(a)Normal type
Standard value:T=8 N·m {82 kgf·cm} {5.9 ft-lb}
(b)Brembo type
Standard value:T=20 N·m {203 kgf·cm} {14.8 ft-lb}
(19) Install the cap bleeder to each bleeder screw.
CAUTION:
Remaining brake fluid inside and outside of the bleeder screw may cause misleading of damage to the painted surface and fluid
leakage. Therefore, make sure to wipe off the brake fluid well after tightening.
3. Air bleeding of brake line

(1) When the brake master cylinder SUB-ASSY has been replaced, or
the brake master cylinder reservoir ASSY is empty, bleed air from
the brake master cylinder SUB-ASSY before bleeding air from the
brake line. (Refer to BR - 9)

BR
(2) Fill the brake master cylinder reservoir ASSY of the brake master cylinder SUB-ASSY with brake fluid.
NOTE:
During work, refill brake fluid frequently to prevent the brake master cylinder reservoir ASSY from becoming empty,
which prevents air entry.
(3) Install one end of a transparent plastic tube to the bleeder screw, and then install the other end of the tube to a brake fluid
recovery container.
(4) Loosen the bleeder screw and depress the brake pedal to full stroke. Repeat it until no air bubbles are seen in the brake
fluid in the transparent plastic tube.
 Brake system / pedal / brake booster device － Brake fluid
BR–11

NOTE:
Repeat the depressing operation fifteen times or more for the front caliper body ASSY and twenty times or more for the
rear caliper body ASSY to get rid of air bubbles.
(5) Repeat the steps (2) to (4) on each caliper body ASSY.
NOTE:
• Perform air bleeding in order of the front RH→front LH→rear LH→rear RH.
• For the brembo type, perform air bleeding in inner →outer in the order of front RH →front LH →rear LH →rear RH.
(6) Tighten the loosened bleeder screw and repeat depressing the brake pedal hard and quickly five or six times, and then
hold the pedal depressed.
(7) Loosen the bleeder screw and drain the brake fluid. When the brake pedal reaches the full stroke position, tighten the
bleeder screw quickly, and then release the brake pedal.
(8) Repeat the steps (6) to (7) until no air bubbles are seen in the transparent plastic tube.
(9) Repeat the steps (6) to (8) on each brake caliper.
NOTE:
• Perform air bleeding in order of the front RH→front LH→rear LH→rear RH.
• For the brembo type, perform air bleeding in inner →outer in the order of front RH →front LH →rear LH →rear RH.
(10) Perform function inspection of both systems ABS and VSC.
CAUTION:
• If the entry of air into the pressure control part in the brake actuator ASSY may occur, perform the steps (11) to (16).
• In the regular air bleeding, do not activate the function inspection of the brake actuator ASSY (The function inspection may

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cause air in the regular air bleeding passage to move into the pressure control part).
NOTE:
• The regular air bleeding cannot bleed air which entered the pressure control part in the brake actuator ASSY.
• If the entry of air into the pressure control part in the brake actuator ASSY may occur (such as the case when the
VSC or ABS was accidentally activated while air existed in the regular air bleeding passage), perform function
inspection of both systems ABS and VSC.
(11) Perform the ABS function inspection. (Refer to BC - 4)
CAUTION:
Always perform the ABS function inspection first.
(12) Perform the air bleeding (3) to (4) on the bleeder screw of each caliper body ASSY.
NOTE:
• Perform air bleeding in order of the front RH→front LH→rear LH→rear RH.
• For the brembo type, perform air bleeding in inner →outer in the order of front RH →front LH →rear LH →rear RH.
• The necessary number of the full stroke depressing operation is approx. six times.
(13) Perform the VSC function inspection. (Refer to BC - 4)
(14) Perform the air bleeding (3) to (4) on the bleeder screw of each caliper body ASSY.
(15) Repeat the steps (11) to (14) three times.
(16) If the air is not bled completely in step (15), repeat the steps (11) to (14) until all the air is bled.
(17) Fill the brake master cylinder reservoir ASSY with brake fluid up to the MAX level.
(18) Tighten each bleeder screw to the specified torque.
(a)Normal type
Standard value:T=8 N·m {82 kgf·cm} {5.9 ft-lb}
(b)Brembo type
Standard value:T=20 N·m {203 kgf·cm} {14.8 ft-lb}
(19) Install the cap bleeder to each bleeder screw.
CAUTION:
Remaining brake fluid inside and outside of the bleeder screw may cause misleading of damage to the painted surface and fluid
BR
leakage. Therefore, make sure to wipe off the brake fluid well after tightening.
(20) Check the flare-nut part or the entire brake system for brake fluid leakage.
(21) Perform the road test to confirm the brake works correctly.
4. Air bleeding of brake actuator
(1) Bleed air from the brake line. (Refer to BR - 10)
NOTE:
If the entry of air into the pressure control part in the brake actuator ASSY may occur, perform function inspection of both
systems ABS and VSC. (Refer to the steps for the brake line (10) to (16).)
 BR–12 Brake system / pedal / brake booster device － Brake fluid

5. Air bleeding of caliper body ASSY

(1) Bleed air from the brake line. (Refer to BR - 10)
6. Brake fluid leak check
7. Brake fluid level check (Refer to BR - 12)

On-vehicle inspection
1. Precautions for handling·procedures
CAUTION:
• Do not let brake fluid come into contact with the painted surface of the vehicle. If spilled, wash it off with water and wipe clean
quickly.
• Do not reuse drained brake fluid. When refilling, always use new brake fluid.
• To prevent deterioration of brake fluid performance, do not mix different grades of brake fluid (even if they are same brand).
• Do not allow dirt or dust to enter the reservoir tank.
• If a syringe, etc. is used for adjusting the fluid level, make sure that it has not been used for mineral oil, water, or deteriorated
brake fluid. It causes deterioration of sealing parts and brake fluid, and fluid leakage and poor brake performance.
2. Brake fluid level check
Captions in illustration
*a MAX level
*b MIN level
C
(1) Check the fluid for discoloration.

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(2) Check that the brake fluid level is between MIN and MAX.
(3) When the brake fluid level is close to MIN, check that there is no
D leakage from the brake tube or the flexible hose, and then confirm
that the brake fluid level was lowered because of the worn brake
BR-01128 pad.
(4) If the inspection reveals that the fluid is discolored significantly or
inadequate for the specified amount, refill or change the brake fluid
with new one.

BR
 Brake system / pedal / brake booster device － Brake pedal (AT model)
BR–13

Brake pedal (AT model)

Brake system / pedal / brake booster device

Exploded view

Instrument side panel LH

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Instrument panel under cover
SUB-ASSY No.1
x2

BR-10131

BR
 BR–14 Brake system / pedal / brake booster device － Brake pedal (AT model)

18 (184, 13.3)

Stop light switch ASSY

x4

Stop light switch

mounting adjuster

18 (184, 13.3) x2
Brake pedal support ASSY Brake pedal
return spring

Brake pedal bushings

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30 (306, 22.1)

Normal model
Brake pedal
shaft collar
Brake pedal pad
Clip

Brake pedal
Sports model

Push rod clevis pin

Brake pedal pad

N*m {kgf*cm,ft*lbf} : Tightening torque NIGTIGHT LTS No.2 grease or equivalent

BR
Non-reusable part

BR-11031

Removal
1. Removal of instrument side panel LH (Refer to IT - 24)
2. Removal of instrument panel under cover SUB-ASSY No.1 (Refer to ME - 68)
3. Removal of stop light switch ASSY (Refer to LE - 78)
 Brake system / pedal / brake booster device － Brake pedal (AT model)
BR–15

4. Removal of stop light switch mounting adjuster

(1) Release 2 claws and remove the stop light switch mounting
adjuster.

BR-01146

5. Removal of push rod pin

(1) Remove the clips and the push rod pin.

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BR-01147

6. Removal of brake pedal support ASSY.

(1) Remove 2 bolts.

BR-01148

(2) Remove 4 nuts and then the brake pedal support ASSY.

Disassembly BR
1. Removal of brake pedal stopper.
(1) Remove the brake pedal stopper from the brake pedal.
 BR–16 Brake system / pedal / brake booster device － Brake pedal (AT model)

2. Removal of brake pedal

(1) Remove the bolt and nut from the brake pedal support ASSY.
NOTE:
Hold the bolt and rotate the nut.
(2) Remove the brake pedal return spring.
(3) Remove the brake pedal shaft collar.
(4) Remove 2 brake pedal shaft bushings.

Assembly
1. Installation of brake pedal bushings
(1) Install the brake pedal bushings to the brake pedal.
*1
Captions in illustration
*1 Brake pedal bushings
*2 Brake pedal

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*2

2. Installation of brake pedal

(1) Apply NIGTIGHT LTS No.2 grease or equivalent to the sides of
brake pedal shaft collar and the brake pedal return spring.
Captions in illustration

NIGTIGHT LTS No.2 grease or equivalent

(2) Install the brake pedal return spring and the brake pedal shaft col-
lar to the brake pedal.
BR-01150

BR
 Brake system / pedal / brake booster device － Brake pedal (AT model)
BR–17

(3) Install the brake pedal to the brake pedal support ASSY.
Captions in illustration
*1 Brake pedal
*2 Brake pedal support ASSY

*2

*1

(4) Install the brake pedal to the brake pedal support ASSY with bolt
and nut.
NOTE:

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Secure the bolt and tighten the nut.
Standard value:T=30N·m {306kgf·cm} {22.1ft·lbf}

3. Installation of brake pedal stopper

(1) Install the brake pedal stopper to the brake pedal.

Installation
1. Installation of brake pedal support ASSY
(1) Temporarily install the brake pedal support ASSY with 2 bolts and 4 nuts.
(2) Tighten 4 nuts.
Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}
(3) Tighten 2 bolts.
Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}
2. Installation of push rod pin
(1) Apply NIGTIGHT LTS No.2 grease or equivalent to the periphery
of a push rod pin.
Captions in illustration

NIGTIGHT LTS No.2 grease or equivalent

(2) Insert a new push rod pin from the left side of the vehicle, and con-
BR
nect the push rod clevis to the brake pedal ASSY with a new clip.
BR-01189
 BR–18 Brake system / pedal / brake booster device － Brake pedal (AT model)

3. Installation of stop light switch mounting adjuster

(1) Engage 2 claws, and install the stop light switch mounting adjuster.

BR-01146

4. Brake pedal height check ·adjustment (Refer to BR - 18)

5. Brake pedal free play check (Refer to BR - 19)
6. Brake pedal clearance check (Refer to BR - 19)
7. Installation of stop light switch ASSY (Refer to LE - 79)
8. Installation of instrument panel under cover SUB-ASSY No.1 (Refer to ME - 69)
9. Installation of instrument side panel LH (Refer to IT - 29)

Adjustment

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1. Brake pedal height check/adjustment
(1) Brake pedal height check
Captions in illustration
*1 Clevis lock nut
*2 Floor mat
*a Pedal height

Standard value (from the center of pedal pad to the upper surface of the
 floor mat)
M/T model 145mm {5.709in}
A/T model 150mm {5.906in}

 (2) Brake pedal height adjustment

(a)Remove the instrument panel under cover SUB-ASSY No.1.
(b)Disconnect the connector from the stop light switch.
C
(c)Remove the stop light switch ASSY.
BR-01139 (d)Loosen the clevis lock nut and rotate the push rod clevis to
adjust the pedal height.
Standard value (from the center of pedal pad to the upper surface of the
floor mat)
M/T model 145mm {5.709in}
A/T model 150mm {5.906in}

(e)Tighten the clevis lock nut.

Standard value:T=19N·m {194kgf·cm} {14.0ft·lbf}
(f) Install the stop light switch.
BR (g)Connect the connector to the stop light switch.
(h)Make sure that the stop light does not illuminate with the brake
pedal released.
 Brake system / pedal / brake booster device － Brake pedal (AT model)
BR–19

2. Brake pedal free play check

(1) After stopping the engine, strongly depress the pedal several times
*b to release the vacuum pressure in the brake booster.
(2) Check the brake pedal for free play.
*e
Captions in illustration
*d *c *a Pedal free play
*a
*b Stop light switch
*c Mat
*d Toe board
*e Brake booster operating rod
BR-01130
When pushing the brake pedal with the force less than 10 N {1 kgf,
2.2 lbf}.
Standard value: 0.5 to 2.7mm {0.020 to 0.106in}
(3) If the free play is 1 mm {0.039 in} or less, check the protrusion
allowance of the stop light switch ASSY shaft. (Refer to LE - 79)
3. Brake pedal clearance check
CAUTION:
Start the engine and make the vacuum pressure in the brake booster 66.7 kPa{500 mmHg} {19.69 inHg}. Then, check the brake
pedal clearance.

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(1) Check the brake pedal clearance.
Captions in illustration
*1 Floor mat
*a Brake pedal clearance

Standard value
Standard for checking Standard value
Pedal force of 490 N{50 kgf} {110.2 lbf}, from
55 mm {2.165 in} or more
upper surface of the floor mat
C


BR
 BR–20 Brake system / pedal / brake booster device － Brake pedal (MT model)

Brake pedal (MT model)

Brake system / pedal / brake booster device

Exploded view

Brake pedal support SUB-ASSY

Stop light switch mounting adjuster

Stop light switch ASSY

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Clutch master cylinder bracket

Brake pedal bushings

18 (184, 13.3)

Brake pedal return spring

Normal model
Brake pedal

Brake pedal pad

Sports model

BR
N*m {kgf*cm,ft*lbf} : Tightening torque

Brake pedal pad

NIGTIGHT LTS No.2 grease or equivalent

BR-11032

Removal
1. Removal of instrument side panel LH (Refer to IT - 24)
 Brake system / pedal / brake booster device － Brake pedal (MT model)
BR–21

2. Removal of instrument panel under cover SUB-ASSY No.1 (Refer to ME - 68)

3. Removal of clutch pedal support SUB-ASSY (Refer to CL - 7)
4. Removal of stop light switch ASSY (Refer to LE - 78)
5. Removal of stop light switch mounting adjuster
(1) Release 2 claws and remove the stop light switch mounting
adjuster.

Disassembly
1. Removal of clutch pedal SUB-ASSY (Refer to CL - 9)
2. Removal of brake pedal

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(1) Remove the bolt.

(2) Remove the clutch master cylinder bracket and brake pedal from
the brake pedal support SUB-ASSY.
Captions in illustration
*1 Clutch master cylinder bracket
*2 Brake pedal
*3 Brake pedal support ASSY
*1

*3

*2

BR
3. Removal of brake pedal return spring
(1) Remove the brake pedal return spring from the clutch master cylinder bracket.
 BR–22 Brake system / pedal / brake booster device － Brake pedal (MT model)

4. Removal of brake pedal bushings

*1 (1) Remove the brake pedal bushings from the brake pedal.
Captions in illustration
*1 Brake pedal bushing
*2 Brake pedal

*2

Assembly
1. Installation of brake pedal bushings

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*1 (1) Install the brake pedal bushings to the brake pedal.
Captions in illustration
*1 Brake pedal bushings
*2 Brake pedal

*2

2. Installation of brake pedal

(1) Apply NIGTIGHT LTS No.2 grease or equivalent to the brake pedal
return spring and clutch master cylinder bracket.
Captions in illustration
*1 *1 Brake pedal return spring
*2 Clutch master cylinder bracket

*2 NIGTIGHT LTS No.2 grease or equivalent

BR
 Brake system / pedal / brake booster device － Brake pedal (MT model)
BR–23

(2) Install the clutch master cylinder bracket and brake pedal to the
brake pedal support SUB-ASSY.
Captions in illustration
*1 Clutch master cylinder bracket
*2 Brake pedal
*3 Brake pedal support SUB-ASSY
*1

*3

*2

(3) Install the bolt.

Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}

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3. Installation of clutch pedal SUB-ASSY (Refer to CL - 10)

Installation
1. Installation of clutch pedal support SUB-ASSY (Refer to CL - 11)
2. Installation of stop light switch mounting adjuster
(1) Engage 2 clamps, and install the stop light switch mounting adjuster.
3. Brake pedal height check ·adjustment (Refer to BR - 18)
4. Brake pedal free play check (Refer to BR - 19)
5. Brake pedal clearance check (Refer to BR - 19)
6. Installation of stop light switch ASSY (Refer to LE - 79)
7. Installation of instrument panel under cover SUB-ASSY No.1 (Refer to ME - 69)
8. Installation of instrument side panel LH (Refer to IT - 29)

Adjustment
1. Brake pedal height check ·adjustment (Refer to BR - 18)
2. Brake pedal free play check (Refer to BR - 19)
3. Brake pedal clearance check (Refer to BR - 19) BR
 BR–24 Brake system / pedal / brake booster device － Brake master cylinder ASSY

Brake master cylinder ASSY

Brake system / pedal / brake booster device

Exploded view

Seal SUB-ASSY
19 {194,14.0}

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Brake tube

13 {133,9.6}
x2

Brake tube
Brake master cylinder SUB-ASSY

19 {194,14.0}

N*m {kgf*cm,ft*lbf} : Tightening torque

Non-reusable parts

BR-10395

Removal
1. Removal of front tire LH
BR 2. Draining of brake fluid
CAUTION:
Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
3. Removal of front upper suspension-to-cowl brace SUB-ASSY LH (Refer to FP - 4)
4. Removal of brake master cylinder SUB-ASSY
(1) Operate the brake pedal more than several times and release the vacuum pressure from the brake booster.
(2) Disconnect the brake fluid level warning switch connector from the reservoir.
 Brake system / pedal / brake booster device － Brake master cylinder ASSY
BR–25

(3) Using a flare-nut wrench, disconnect 2 brake tubes from the mas-
ter cylinder SUB-ASSY.

(4) Remove 2 nuts, and disconnect the brake master cylinder SUB-
ASSY.
CAUTION:
• The piston comes off from the brake master cylinder SUB-ASSY
easily. Therefore, do not hold or pull out the piston. If the piston
comes off the brake master cylinder SUB-ASSY, do not reuse it but
replace the brake master cylinder SUB-ASSY with new one,
because the brake master cylinder SUB-ASSY may malfunction
• Do not give a shock to the piston of the brake master cylinder

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SUB-ASSY, fix it with a vise, or scratch it.
• Remove the brake master cylinder SUB-ASSY after operating the
brake pedal several times and releasing the vacuum pressure from
the brake booster.
• Do not tilt the brake master cylinder SUB-ASSY's piston side
below a horizontal position.
• Be careful not to allow foreign matter to stick to the piston of the
brake master cylinder SUB-ASSY. If a foreign matter sticks to the
piston, remove the foreign matter with a cloth and apply rubber
grease all around the outer surface of the piston (sliding part).
• Do not use undesignated oil.
5. Removal of seal SUB-ASSY
(1) Remove the seal sub ASSY.

Installation
1. Installation of seal SUB-ASSY
(1) Install a new seal SUB-ASSY.
2. Installation of brake master cylinder SUB-ASSY
(1) Install the brake master cylinder SUB-ASSY with 2 nuts.
Standard value:T=13N·m {133kgf·cm} {9.6ft·lbf}
(2) Using a union nut wrench 12, connect 2 brake tubes to the brake master cylinder SUB-ASSY.
Standard value:T=19N·m {194kgf·cm} {14.0ft·lbf}
(3) Connect the brake fluid level warning switch connector.
3. Brake fluid refill (Refer to BR - 8)
4. Air bleeding of brake master cylinder SUB-ASSY (Refer to BR - 9)
5. Air bleeding of brake system (Refer to BR - 10) BR
6. Brake fluid leak check
7. Brake fluid level check (Refer to BR - 12)
8. Installation of front upper suspension-to-cowl brace SUB-ASSY RH (Refer to FP - 5)
9. Installation of front tire LH
Standard value:T=120N·m {1224kgf·cm} {88.5ft·lbf}
 BR–26 Brake system / pedal / brake booster device － Brake booster ASSY

Brake booster ASSY

Brake system / pedal / brake booster device

Exploded view

Instrument side panel LH

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Instrument panel under cover
SUB-ASSY No.1
x2

BR-10131

BR
 Brake system / pedal / brake booster device － Brake booster ASSY
BR–27

19 (194, 14.0)

Brake tube front No. 1

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Brake tube front No. 2

19 (194, 14.0)

N•m {kgf•cm, ft•lbf} : Tightening torque

BR-01121

BR
 BR–28 Brake system / pedal / brake booster device － Brake booster ASSY

Vacuum hose

Clip
Push rod clevis

19 {194,14.0}
Lock nut

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x4

18 {184,13.3}

Push rod clevis pin

Brake booster gasket

Brake booster ASSY

N*m {kgf*cm,ft*lbf} : Tightening torque

Non-reusable part

NIGTIGHT LTS No.2 grease or equivalent

BR-11033

BR Removal
1. Removal of instrument side panel LH (Refer to IT - 24)
2. Removal of instrument panel under cover SUB-ASSY No.1
3. Removal of transmission control computer ASSY (Refer to AT - 323)
4. Removal of brake master cylinder SUB-ASSY (Refer to BR - 24)
5. Disconnection of vacuum hose
(1) Slide the clip and disconnect the vacuum hose from the brake booster ASSY.
 Brake system / pedal / brake booster device － Brake booster ASSY
BR–29

6. Removal of the brake tube front No. 1

(1) Using a flare-nut wrench, disconnect the brake tube front No. 1
from the brake actuator.

(2) Release 2 clips and remove the brake tube front No. 1.

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7. Removal of the brake tube front No. 2

(1) Using a flare-nut wrench, disconnect the brake tube front No. 2
from the brake actuator.

(2) Release 2 clips and remove the brake tube front No. 2.
8. Removal of brake booster ASSY
(1) Remove 4 nuts.

BR
 BR–30 Brake system / pedal / brake booster device － Brake booster ASSY

(2) Remove the push rod clevis.

(3) Remove the brake booster ASSY.

Installation
1. Installation of brake booster ASSY
(1) Temporarily attach the push rod clevis with a lock nut.

(2) Measure the length between the vacuum booster assembly

# mounting surface and clevis pin hole.
Standard value (A): 155.2 mm {6.11 in}
NOTE:

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If it is not within the specification, loosen the lock nut, rotate the
vacuum booster operating rod to perform adjustment.

(3) Tighten the lock nut securely.

Standard value:T=19N·m {194kgf·cm} {14.0ft·lbf}
(4) Install the brake booster ASSY with 4 nuts.
Standard value:T=18N·m {184kgf·cm} {13.3ft·lbf}
2. Installation of brake tube front No. 2
(1) Engage 2 clips, and install the brake tube front No. 2.
(2) Using a flare-nut wrench, connect the brake tube front No. 2 to the brake actuator.
Standard value:T=19N·m {194kgf·cm} {14.0ft·lbf}
CAUTION:
• Do not bend or damage the brake tubes.
• When installing the brake tube, make sure that they are not twisted or bent.
• Do not let foreign matter including dirt and dust enter the brake tube.
3. Installation of brake tube front No. 1
(1) Engage 2 clips, and install the brake tube front No. 1.
(2) Using a flare-nut wrench, connect the brake tube front No. 1 to the brake actuator.
CAUTION:
• Do not bend or damage the brake tubes.
• When installing the brake tube, make sure that they are not twisted or bent.
• Do not let foreign matter including dirt and dust enter the brake tube.
BR 4. Installation of vacuum hose
(1) Attach the vacuum hose with the clamp.
5. Installation of push rod pin (Refer to BR - 17)
6. Installation of transmission control ASSY (Refer to AT - 323)
7. Installation of instrument panel under cover SUB-ASSY No.1 (Refer to ME - 69)
8. Installation of instrument side panel LH (Refer to IT - 29)
9. Brake fluid refill (Refer to BR - 8)
10. Air bleeding of brake master cylinder SUB-ASSY (Refer to BR - 9)
11. Air bleeding of brake system (Refer to BR - 10)
 Brake system / pedal / brake booster device － Brake booster ASSY
BR–31

12. Brake fluid leak check

13. Brake fluid level check (Refer to BR - 12)
14. Brake pedal height check ·adjustment (Refer to BR - 18)
15. Brake pedal free play check (Refer to BR - 19)
16. Brake pedal clearance check (Refer to BR - 19)

Unit inspection
1. Brake vacuum check valve ASSY check
(1) Slide 2 clamps to remove the vacuum hose ASSY.

(2) Using vacuum gauge, check that there is a ventilation from the
C D brake booster ASSY to the engine side. Also, check that there is
no ventilation from the engine side to the brake booster ASSY
side.
Captions in illustration
*a Booster side
*b Engine side

NOTE:
If it is faulty, replace the vacuum hose ASSY.

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(3) Face the engine stamp to the engine side as shown in the figure,
and then install it to the engine side.
Captions in illustration
*1 Paint
*a Engine side
C
*b Booster side

D

BR-01109

(4) Face the paint to the front side of the vehicle and install it to the brake booster side.
NOTE:
If the paint is worn off, check the ventilation and connect them so that there is a ventilation from the brake booster side to
the engine side.
(5) Install the vacuum hose with 2 clamps.

BR
 BR–32 Brake system / pedal / brake booster device － Vacuum pump ASSY

Vacuum pump ASSY

Brake system / pedal / brake booster device

Exploded view

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Union to connector
tube hose

16 {163.11.8}
x3 O-ring

Vacuum pump ASSY

N•m {kgf•cm, ft•lbf} : Tightening torque

Non-reusable parts
BR
BR-01140
 Brake system / pedal / brake booster device － Vacuum pump ASSY
BR–33

Removal
1. Disconnection of the union to connector tube hose
(1) Change the front hood stay position from A to B, and fully open the
front hood.

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(2) Slide the clamp and disconnect the union to connector tube hose
from the vacuum pump ASSY.

2. Removal of front upper suspension-to-cowl brace SUB-ASSY RH (Refer to FP - 4)

BR
 BR–34 Brake system / pedal / brake booster device － Vacuum pump ASSY

3. Removal of vacuum pump ASSY

(1) Remove 3 bolts.
(2) Using a flat tip screwdriver or an equivalent to the position shown
in the figure, pry the vacuum pump ASSY to remove it.

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BR-01151

(3) Remove the O-ring.

(4) Remove the liquid gasket from the vacuum pump ASSY and the
engine unit.

BR
 Brake system / pedal / brake booster device － Vacuum pump ASSY
BR–35

Installation
1. Installation of vacuum pump ASSY (transmission A/T)
(1) As shown in the figure, apply the seal gasket 1217G to the cam
carrier RH.
$ Captions in illustration
*a Liquid gasket diameter: 2.0-4.0 mm
*b Within 1.0 mm
*c Groove end

CAUTION:
• Clean and degrease the installation surface.
$ • Install within 5 min. after applying liquid gasket.
(2) Install a new O-ring.

$$

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E
ME-20115

(3) Align the groove on the vacuum pump ASSY and the claw on the
intake camshaft RH.
D
C Captions in illustration
*a Groove on the vacuum pump ASSY
*b Claw of the intake camshaft (RH)

CAUTION:
Be careful not to let the O-ring catch.
(4) Install the vacuum pump ASSY with 3 bolts.
Standard value:T=16N·m {163kgf·cm} {11.8ft·lbf}

2. Installation of union to connector tube hose

(1) Install the union to connector tube hose with a clamp.
3. Installation of front upper suspension-to-cowl brace SUB-ASSY RH (Refer to FP - 5)

On-vehicle inspection
1. Function inspection of vacuum pump ASSY
(1) Slide the clip and disconnect the union to connector tube hose
from the vacuum pump ASSY.
(2) Connect the vacuum gauge hose to the vacuum pump ASSY.
(3) Use the vacuum gauge in the portable brake tester.
(4) Plug the hose on the other side of the vacuum gauge with the hose BR
plug No.2.
(5) Start the engine and warm up for 2 minutes or more.
 BR–36 Brake system / pedal / brake booster device － Vacuum pump ASSY

(6) Check the vacuum pressure of the vacuum pump ASSY when the

engine is running at idle speed.
NOTE:
Read the value after 25 seconds have passed from starting the
measurement.
Captions in illustration
*1 Vacuum gauge

Limit: 93 kPa {698 mmHg, 13.5 psi}

(7) If the value is below the limit, replace the vacuum pump ASSY.
(Refer to BR - 33)
NOTE:
After replacing the vacuum pump ASSY, perform function inspec-
tion of the vacuum pump ASSY.
(8) Remove the vacuum gauge.
(9) Connect the union to connector tube hose to the vacuum pump
ASSY with a clip.

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BR