REAR BRAKE INSTALLATION


  1. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY


    1. A017BNJ

      Install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 bolts.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  2. CONNECT REAR FLEXIBLE HOSE


    1. A017BOU

      Connect the rear flexible hose to the rear disc brake cylinder assembly with a new union bolt and a new gasket.

      Torque:
      33 N*m  { 336 kgf*cm, 24 ft.*lbf }

  3. FILL BRAKE FLUID RESERVOIR


    1. A017E1Q

      Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

      Note

      Make sure that there is sufficient brake fluid in the reservoir.

  4. BLEED BRAKE LINE

    Note


    • Bleed the brake line of the wheel farthest from the master cylinder first.

    • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


    1. A017DDG

      Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed (*3).

    3. A017CQE

      When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (*4).

    4. Repeat (*3) and (*4) until all the air in the fluid is completely bled out.

    5. Tighten the bleeder plug completely.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

    6. Repeat the above procedure for each wheel to bleed the brake line.

  5. BLEED BRAKE ACTUATOR

    Note

    After bleeding the brake system, if the specified height or feel of the brake pedal cannot be obtained, bleed the brake actuator assembly with the intelligent tester by following the procedure below.


    1. Depress the brake pedal more than 20 times with the ignition switch off.

    2. Connect the intelligent tester to the DLC3, and then turn the ignition switch on (IG).

      Note

      Do not start the engine.

    3. Turn the intelligent tester on and select "AIR BLEEDING" on the screen.

      Note


      • Refer to the intelligent tester operator's manual for further details.

      • Bleed the air by following the steps displayed on the intelligent tester.

    4. Bleed the air according to "Step 1: Increase" on the intelligent tester display.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. A017DDG

        Connect a vinyl tube to either one of the bleeder plugs.

      2. Depress the brake pedal several times, and then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*5).

      3. A017CQE

        When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (*6).

      4. Repeat (*5) and (*6) until all the air in the fluid is completely bled out.

      5. Tighten the bleeder plug completely.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      6. Repeat the above procedure for the rest of the wheels to bleed the brake lines.

    5. Bleed the suction line according to "Step 2: Inhalation" on the intelligent tester display.

      Note


      • Bleed the suction line by following the steps displayed on the intelligent tester.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. A017C8D

        Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug.

      2. Operate the brake actuator assembly to bleed the air using the intelligent tester (*7).

        Note


        • During this step, be sure to release the brake pedal.

        • The actuator operation stops automatically in 4 seconds.

      3. A017BW2

        Check that the actuator operation has stopped by referring to the intelligent tester display, and tighten the bleeder plug (*8).

      4. Repeat (*7) and (*8) until all the air in the fluid is completely bled out.

      5. Tighten the bleeder plug completely.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      6. For the rest of the wheels, bleed the air in the same way as stated in the above procedure.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

    6. Bleed the pressure reduction line according to "Step 3: Decrease" on the intelligent tester display.

      Note


      • Bleed the pressure reduction line by following the steps displayed on the intelligent tester.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. A017D3G

        Connect a vinyl tube to either one of the bleeder plugs.

      2. Loosen the bleeder plug (*9).

      3. While keeping the brake pedal fully depressed, operate the brake actuator assembly using the intelligent tester.

        Note


        • The actuator operation stops automatically in 4 seconds. When performing this procedure continuously, an interval of at least 20 seconds is required.

        • After the operation is completed, the brake pedal goes down slightly. This is a normal phenomenon when the solenoid opens.

        • During this procedure, the pedal seems heavy, but completely depress it so that the brake fluid comes out from the bleeder plug.

        • Be sure to keep the brake pedal depressed. Never depress and release the pedal repeatedly.

      4. A017CQE

        Tighten the bleeder plug, and then release the brake pedal (*10).

      5. Repeat steps (*9) to (*10) until all the air in the fluid is completely bled out.

      6. Tighten the bleeder plug completely.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      7. Repeat the above procedures for the rest of the brakes to bleed the brake line.

    7. Bleed the brake lines again according to "Step 4: Increase" on the intelligent tester display.

      Note


      • Bleed the air by following the steps displayed on the intelligent tester.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. A017D3G

        Connect a vinyl tube to either one of the bleeder plugs.

      2. Depress the brake pedal several times, and then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*11).

      3. A017CQE

        When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (*12).

      4. Repeat (*11) and (*12) until all the air in the fluid is completely bled out.

      5. Tighten the bleeder plug completely.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      6. Repeat the above procedures for each brake to bleed the brake lines.

    8. Finish "AIR BLEEDING" on the intelligent tester, and then turn off the tester.

    9. Disconnect the intelligent tester from the DLC3.

    10. Turn the ignition switch off.

  6. INSPECT FLUID LEVEL


    1. A017FVOE01

      Check the fluid level.

      If brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  7. INSPECT FOR BRAKE FLUID LEAK

  8. ADJUST PARKING BRAKE SHOE CLEARANCE AND PARKING BRAKE PEDAL TRAVEL (for LHD)


    1. Remove the driver side knee airbag assembly Click here.

    2. Completely release the parking brake pedal.

    3. A017DLHE01

      Loosen the lock nut and the adjusting nut to completely release the parking brake cable.

    4. Remove the rear wheel.

    5. Temporarily install the hub nuts.

    6. Remove the shoe adjusting hole plug.

    7. A017BNUE01

      Turn the shoe adjuster and expand the shoe until the disc locks.

    8. Turn and contract the shoe adjuster until the disc can rotate smoothly.

      Standard
      Return 8 notches.

    9. Check that there is no brake drag against the shoe.

    10. Install the shoe adjusting hole plug.

    11. Turn the adjusting nut until the parking brake pedal travel is corrected to be within the specified range.

      Parking brake pedal travel
      8 to 10 notches at 300 N (31 kgf, 67 lbf)

    12. Using a wrench or an equivalent tool, hold the adjusting nut and tighten the lock nut.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    13. Operate the parking brake pedal 3 to 4 times, and check the parking brake pedal travel.

    14. Check that there is no brake drag against the shoe.

    15. Remove the hub nuts.

    16. Install the rear wheel.

      Torque:
      103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

    17. Install the driver side knee airbag assembly Click here.

  9. ADJUST PARKING BRAKE SHOE CLEARANCE AND PARKING BRAKE PEDAL TRAVEL (for RHD)


    1. Remove the driver side knee airbag assembly Click here.

    2. Completely release the parking brake pedal.

    3. A017C4KE01

      Loosen the lock nut and adjusting nut to completely release the parking brake cable.

    4. Remove the rear wheel.

    5. Temporarily install the hub nuts.

    6. Remove the shoe adjusting hole plug.

    7. A017BNUE01

      Turn the shoe adjuster and expand the shoe until the disc locks.

    8. Turn and contract the shoe adjuster until the disc can rotate smoothly.

      Standard
      Return 8 notches.

    9. Check that there is no brake drag against the shoe.

    10. Install the shoe adjusting hole plug.

    11. Turn the adjusting nut until the parking brake pedal travel is corrected to be within the specified range.

      Parking brake pedal travel
      8 to 10 notches at 300 N (31 kgf, 67 lbf)

    12. Using a wrench or an equivalent tool, hold the adjusting nut and tighten the lock nut.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    13. Operate the parking brake pedal 3 to 4 times, and check the parking brake pedal travel.

    14. Check that there is no brake drag against the shoe.

    15. Remove the hub nuts.

    16. Install the rear wheel.

      Torque:
      103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

    17. Install the driver side knee airbag assembly Click here.

  10. INSTALL REAR WHEEL

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }