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Service Brakes 35A-1 GROUP 35A SERVICE BRAKES CONTENTS GENERAL DESCRIPTION. 35A-2 BRAKE PEDAL. 35A-24 REMOVAL AND INSTALLATION . 35A-24 BASIC BRAKE SYSTEM DIAGNOSIS 35A-4 INSPECTION. 35A-25 INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS . 35A-4 MASTER CYLINDER ASSEMBLY AND BASIC BRAKE SYSTEM DIAGNOSTIC BRAKE BOOSTER . 35A-26 TROUBLESHOOTING STRATEGY . 35A-4 REMOVAL AND INSTALLATION . 35A-26 SYMPTOM CHART. 35A-4 MASTER CYLINDER . 35A-28 SYMPTOM PROCEDURES . 35A-4 INSPECTION. 35A-29 SPECIAL TOOLS. 35A-13 FRONT DISC BRAKE ASSEMBLY . 35A-29 REMOVAL AND INSTALLATION . 35A-29 ON-VEHICLE SERVICE. 35A-13 INSPECTION. 35A-30 BRAKE PEDAL CHECK AND ADJUSTMENT 35A-13 DISASSEMBLY AND ASSEMBLY . 35A-31 BRAKE BOOSTER OPERATING TEST. 35A-15 INSPECTION. 35A-32 CHECK VALVE OPERATION CHECK . 35A-16 PROPORTIONING VALVE FUNCTION TEST REAR DISC BRAKE ASSEMBLY . 35A-33 <VEHICLES WITHOUT ABS> . 35A-16 REMOVAL AND INSTALLATION . 35A-33 BLEEDING . 35A-17 INSPECTION. 35A-34 BRAKE FLUID LEVEL SENSOR CHECK. 35A-18 DISASSEMBLY AND ASSEMBLY . 35A-35 FRONT DISC BRAKE PAD CHECK AND REPLACEMENT . 35A-19 INSPECTION. 35A-36 DISC BRAKE ROTOR CHECK. 35A-21 SPECIFICATIONS . 35A-37 BRAKE DISC THICKNESS CHECK . 35A-21 BRAKE DISC RUN-OUT CHECK AND FASTENER TIGHTENING CORRECTION . 35A-22 SPECIFICATIONS. 35A-37 MASTER CYLINDER FUNCTION CHECK. 35A-24 GENERAL SPECIFICATIONS . 35A-38 SERVICE SPECIFICATIONS . 35A-39 LUBRICANTS . 35A-39 SEALANT . 35A-39 35A-2 SERVICE BRAKES GENERAL DESCRIPTION GENERAL DESCRIPTION M1351000100622 Top components such as Brembo™ brakes, EBD and IMPROVED STABILITY sports ABS improve braking power and braking sta- 1. Sports ABS (4-wheel anti-lock braking system) is bility. used to prevent slipping caused by the vehicle CAUTION wheels locking up in order to maintain an appro- Take care not to contact the parts or tools to the priate braking distance, and also to maintain a caliper because the paint of caliper will be stable vehicle posture and steering performance. scratched. 2. Adoption of an electronic brake-force distribution (EBD) makes it possible to maintain the maxi- FEATURES mum amount of braking force even when the . vehicle's load is unevenly distributed. <Vehicles IMPROVED BRAKING PERFORMANCE with ABS> 1. A 8+9-inch tandem vacuum booster is utilized to 3. Front- and rear-wheel X-type brake line layout is provide high braking force with a small pedal used. depression force. 4. Ventilated discs improve anti-fading performance. 2. Brembo™ 17-inch 4-pot front ventilated disc brakes and Brembo™ 16-inch 2-pot rear venti- . lated disc brakes provide stable braking force and IMPROVED SERVICEABILITY improved braking feel. 1. A diagnosis function for the ABS system makes inspection easier. 2. An outer disc method separated hub and rotor makes removal and installation easier. 3. The master cylinder reservoir tank cap is colored white to make identification easier. 4. The ABS-ECU and hydraulic unit are integrated to make them more compact and lightweight. TSB Revision SERVICE BRAKES 35A-3 GENERAL DESCRIPTION CONSTRUCTION DIAGRAM <VEHICLE WITH ABS> BRAKE BOOSTER ASSEMBLY BRAKE MODULATOR HYDRAULIC UNIT (INTEGRATED WITH THE ABS-ECU) 10064AU REAR DISC BRAKE PARKING BRAKE BRAKE MASTER LEVER ASSEMBLY CYLINDER ASSEMBLY FRONT DISC BRAKE AC211387AC <VEHICLE WITHOUT ABS> BRAKE BOOSTER ASSEMBLY REAR DISC BRAKE PARKING BRAKE LEVER ASSEMBLY BRAKE MASTER CYLINDER AND PROPORTIONING VALVES FRONT DISC BRAKE AC309895AB TSB Revision 35A-4 SERVICE BRAKES BASIC BRAKE SYSTEM DIAGNOSIS BASIC BRAKE SYSTEM DIAGNOSIS INTRODUCTION TO BASIC BRAKE SYSTEM DIAGNOSIS M1351009700267 Hydraulic brakes are composed of the brake pedal, master cylinder, brake booster and disc 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 M1351009800264 Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the you follow them carefully, you will be sure that you customer exists. have exhausted most of the possible ways to find a 3. Find the malfunction by following the symptom basic brake system fault. chart. 1. Gather information from the customer. 4. Verify malfunction is eliminated. SYMPTOM CHART M1351009900272 SYMPTOMS INSPECTION REFERENCE PROCEDURE PAGE Vehicle pulls to one side when brakes are applied 1 P.35A-4 Insufficient braking power 2 P.35A-5 Increased pedal stroke (Reduced pedal-to-floor board clearance) 3 P.35A-6 Brake drag 4 P.35A-7 Scraping or grinding noise when brake are applied 5 P.35A-8 Squealing, groaning or chattering noise when brake are applied 6 P.35A-9 Squealing noise when brakes are not applied 7 P.35A-10 Groaning, clicking or rattling noise when brakes are not applied 8 P.35A-12 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. Determine and repair the source/cause of foreign material. Then go to Step 5. NO : Go to Step 2. TSB Revision SERVICE BRAKES 35A-5 BASIC BRAKE SYSTEM DIAGNOSIS STEP 2. Check disc brake pistons for smooth STEP 3. Check brake disc(s) for run out. operation. Refer to P.35A-22. (1) With engine not running, depress the brake pedal Q: Is runout outside of specifications? rapidly several times to deplete booster vacuum YES : Repair or replace the brake disc(s) as reserves. necessary. Then go to Step 5. (2) Test each disc brake assembly one at a time. NO : Go to Step 4. a. Remove the lower caliper bolt, then remove caliper from mount. b. Have an assistant slowly depress the brake STEP 4. Check brake discs for correct thickness. pedal. Confirm piston(s) extend slowly and Refer to P.35A-21. smoothly with no jumpiness. Repeat for each Q: Is the thickness outside of specifications? disc brake assembly. YES : Repair or replace the brake disc(s) as Q: Do (does) the piston(s) move correctly? necessary. Then go to Step 5. YES : Go to Step 3. NO : Carry out the brake line bleeding. Then go NO : Disassemble and inspect the brake to Step 5. assembly (Front: refer to P.35A-31, Rear: refer to P.35A-35). 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 3. Check the brake booster function. Refer to P.35A-15. STEP 1. Check that the specified brake fluid is Q: Is there fault? used, its level is correct, and no contamination is YES : Replace the brake booster. Then go to Step found. 7. Q: Is there fault? NO : Go to Step 4. YES : Refill or replace with the specified brake fluid DOT 3 or DOT 4. Bleed the brakes if STEP 4. Check for pinched or restricted brake necessary (Refer to P.35A-17). Then go to tube or hose. Step 7. Q: Is there a pinched or restricted brake tube or hose? NO : Go to Step 2. YES : Replace that complete section of brake tube or brake hose. Then go to Step 7. STEP 2. Check for spongy (not firm brakes). NO : Go to Step 5. (1) With engine not running, depress the brake pedal rapidly several times to deplete booster vacuum STEP 5. Check for oil, water, etc., on the pad reserve. contact surfaces of all brakes. (2) With the brake pedal fully released, depress the brake pedal slowly until it stops. Q: Is oil, water, etc., on the pad contact surface? (3) With a measuring stick (ruler, etc.) next to the YES : Replace the part. Determine and repair the brake pedal, depress the pedal firmly and source/cause of foreign material. Recheck measure the distance the pedal traveled. symptom. Then go to Step 7. NO <Vehicle without ABS> : Go to Step 6. Q: Is the distance greater than 20 mm (0.8 inch)? NO <Vehicle with ABS> : The procedure is YES : Bleed the brakes to remove air in the fluid complete. (Refer to P.35A-17). Then go to Step 7. NO : Go to Step 3. TSB Revision 35A-6 SERVICE BRAKES BASIC BRAKE SYSTEM DIAGNOSIS STEP 6. Check the proportioning valve operation. STEP 7. Recheck symptom. Refer to P.35A-16. Q: Is the symptom eliminated? Q: Is there fault? YES : The procedure is complete. YES : Replace the part. Then go to Step 7. NO : Start over at step 1. If a new symptom NO : Go to Step 7. surfaces, refer to the appropriate symptom chart. INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance) DIAGNOSIS STEP 4. Check the master cylinder function. Refer to P.35A-24. STEP 1. Check for spongy (not firm brakes). Q: Is there fault? (1) With engine not running, depress the brake pedal YES : Repair it. Then go to Step 7. rapidly several times to deplete booster vacuum NO : Go to Step 5. reserve. (2) With the brake pedal fully released, depress the STEP 5. Check for brake fluid leaks. brake pedal slowly until it stops. (3) With a measuring stick (ruler, etc.) next to the Q: Is there leaks? brake pedal, depress the pedal firmly and YES : Check the connection for looseness, measure the distance the pedal traveled. corrosion, etc. Clean and repair as necessary. If leaking in any tube or hose Q: Is the distance greater than 20 mm (0.8 inch)? section, replace the complete tube or hose. YES : Bleed the brakes to remove air in the fluid Then go to Step 7 .
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