E1– 1

1 BRAKE
1-1 PROVIDE WORK EQUIPMENT
Instruments
Torque wrench

Lubricant, glue / sealant, others

Brake fluid (DOT4)

1-2 BASIC TEST AND ADJUSTMENT

1-2-1 BRAKE PEDAL
(1) CHECKING THE HEIGHT
1. Fold over the carpet near the brake pedal.
2. Measure the height from the left center area of the brake
pedal pressing surface to the top of the bulkhead. SET
B. A.
VALUE:
144.4 mm (vehicles with manual transmission)
148.6 mm (vehicles with automatic transmission;
RHD 148.7 mm (vehicles with automatic
transmission; LHD)

Bulkhead
M 21C 7001E T 16

(2) HEIGHT ADJUSTMENT

1. Remove the dashboard lower cover.
2. Disconnect the connector from the brake light switch.
3. Dismantle the brake light switch, turning it counterclockwise so that the brake pedal has free play.
4. Adjust the pedal height by loosening nut A and turning push rod B.
TIGHTENING TORQUE: 13.9 ± 2.1 Nm {142 ± 21kgf · cm}

5. Clamp the brake light switch by turning the housing clockwise. Check and confirm the protruding area
of the brake light switch pin.
TARGET VALUE: 2 mm or less. (There should be a clearance so that the screw end face of the brake
light switch does not come into contact with the holder pad on the brake pedal side.)
6. Connect the brake light switch connector.
ATTENTION
• After completing the brake pedal height adjustment, check that the brake pedal can be moved freely.
Also check that the brake lights come on.

7. Install the lower dashboard cover.

E1– 2
(3) CHECKING THE PEDAL PLAY
1. After switching off the engine, depress the brake pedal
several times so that no vacuum remains in the brake
booster.
2. Measure the free travel (excessive play between clevis
and clevis pin) by pulling the brake pedal towards the
tester (brake light switch).
TARGET VALUE: 0.5 - 3.0 mm
NOTE
• If the value is outside the target value, measure the
protruding area of the brake light switch and adjust if
necessary.
See page E1-6.

M 21C 7002T 16

(4) CHECKING THE PEDAL TRAVEL

1. Fold over the carpet near the brake pedal.
2. While idling and with the handbrake released, depress
the brake pedal with the prescribed force. Then measure
the height from the left central area of the brake pedal
pressing surface to the top of the bulkhead.
TARGET VALUE: 86 mm or more (force applied to the
pedal 294 N {30kgf})

Bulkhead

M 21C 7003E T 16
 E1– 3
1-2-2 FRONT BRAKE PAD
(1) CHECKING THE PAD THICKNESS
1. Jack up the vehicle.
2. Remove the front wheels.
3. Check the thickness of the brake lining.
PERMISSIBLE LIMIT VALUE: 1 mm
NOTE
• New pads: 10 mm
4. If the thickness of the brake lining is below the limit value,
replace the lining.

L18C 5037T 10

1-2-3 FRONT BRAKE DISC

(1) TESTING THE STRIKING
1. Jack up the vehicle.
2. Remove the front wheels.
3. Secure the front brake disc with four suitable wheel nuts.
ATTENTION
• Make sure that the four wheel nuts are tightened evenly.

4. Make sure that the front wheel bearing does not have
excessive play.
See page D2-2.

5. Measure the runout of the disc end face with a dial

gauge.
PERMISSIBLE LIMIT VALUE:
(Measure the value at a point that is 10 mm from the
outer edge of the disc) C 11C 5014T 10

6. If the runout of the front brake disc exceeds the

permissible limit value, check the axle hub for runout. If
no abnormalities are found here, replace the front brake
disc.
(2) CHECKING THE DISC THICKNESS
1. Measure the thickness of the front brake disc.
PERMISSIBLE LIMIT VALUE: 10 mm
NOTE
• New brake disc: 11 mm
2. If the front brake disc thickness is less than the limit,
replace the front brake disc.

1-2-4 REAR BRAKE SHOE PAD M 21C 7047T 10

(1) CHECKING THE PAD THICKNESS

1. Jack up the vehicle.
2. Remove the rear wheels.
E1– 4
3. Remove the rear brake drums.
Vehicles with two-wheel drive and
ABSSee page E1-45.

Two-wheel drive vehicles without ABS

See page E1-49.

4. Measure the thickness of the brake shoe lining.

PERMISSIBLE LIMIT VALUE: 1 mm
NOTE
• New brake shoe lining: 4 mm M 21C 7065T 10

5. If the thickness of the brake shoe lining is below the

allowable limit or if the brake shoe shows excessive,
uneven wear, replace the brake shoe.
ATTENTION
• When replacing the rear wheel brake shoes, replace the
brake shoe linings on the right and left wheels as a set
so that the brakes work evenly.

1-2-5 REAR BRAKE DRUM

(1) INNER DIAMETER CHECK
1. Jack up the vehicle.
2. Remove the rear wheels.
3. Remove the rear brake drum. Vehicles
with two-wheel drive and ABSSee page
E1-45.

Two-wheel drive vehicles without ABS

See page E1-49.

4. Measure the inside diameter of the rear brake drum.

PERMISSIBLE LIMIT VALUE: 166 mm
NOTE M 21C 7066T 10

• New brake drum: 165 mm

5. If uneven wear is evident, polish / smooth or replace the
rear brake drum.
 E1– 5
2 BRAKE PEDAL
2-1 REMOVAL AND INSTALLATION
2-1-1 WORK EQUIPMENT PROVIDE
Instruments
Torque wrench

Lubricant, glue / sealant, others

Multipurpose grease

2-1-2 WORK BEFORE EXPANSION

1.The Remove the lower dashboard cover. (Right-hand drive vehicles)
2-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

BT: 21.0

B.
B.
j

B. d
b
c

G
a d

H
f
e

M21C7004_1S25

Unit: Nm
k: MP fat
(2) REMOVAL AND INSTALLATION
PROCEDURES 6 f Pedal rubber
1 a securing clip 7 g stop buffer
2 b clevis pin 8 h brake pedal
3 c pedal shaft bolts 9 i bracket, Brake
3 d socket pedal 10 j Stop buffer
5 e brake pedal assembly

2-1-4 WORK AFTER INSTALLATION

1. Check and adjust brake pedal.
See page E1-1.

2. Install the dashboard lower cover. (Right-hand drive vehicles)

E1– 6
3 COUNTER THE STOP LIGHT
3-1 REMOVAL AND INSTALLATION
3-1-1 WORK BEFORE EXPANSION
1. Remove the dashboard lower cover. (Right-hand drive vehicles)
2. Disconnect the connector from the brake light switch.
3-1-2 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

a
b

M21C7078S16

(2) REMOVAL AND INSTALLATION PROCEDURES

ji 1 a brake light switch
2 b Adjustment device, brake light switch bracket

3-1-3 POINTS TO EXPAND

1.The Remove the brake light switch by turning it counterclockwise.
3-1-4 VERIFICATION
1.The Check the continuity between the respective terminals
of the brake light switch connector.
SET VALUE:
Switch position Passage
21
Switched on Available
Not turned on Unavailable

M 21C 7079T 10

3-1-5 POINTS FOR INSTALLATION

1. Bring the edge surface of the threaded part of the brake light switch lightly into contact with the holder
on the brake pedal side.
ATTENTION
• Make sure that the edge surface of the threaded part of the brake light switch does not hit the brake
pedal.

2. Turn the brake light switch housing counterclockwise to lock it into place. Make sure that the
protruding area of the stop light switch bolt is 2 mm or less.
 E1– 7
3-1-6 WORK AFTER INSTALLATION
1. Connect the brake light switch connector.
2. Depress the brake pedal. Make sure the brake light switch is working properly.
3. Check that the brake pedal can move freely.
See page E1-2.

4. Install the dashboard lower cover. (Right-hand drive vehicles)

E1– 8
4 MASTER BRAKE CYLINDER
4-1 REMOVAL AND INSTALLATION
ATTENTION
• Be careful not to get any brake fluid on the paint surface. Immediately wipe off any brake fluid
adhering to the paint surface thoroughly and wash off with water.
• Never reuse used brake fluid.

4-1-1 WORK EQUIPMENT PROVIDE

SST:
shap Part number Part designation
e

09023-00100-000 Line key

09730-87401-000 Measurement accessories, brake booster

Lubricant, glue / sealant, others

Brake fluid (DOT4), silicone grease

4-1-2 WORK BEFORE EXPANSION

(1) RIGHT-HAND DRIVE VEHICLES
1. Jack up the vehicle.
2. Remove the wheels (four wheels).
3. Perform the following work on vehicles with ABS.
(1) With the ignition switch in the OFF (LOCK) position, disconnect the ground cable from the negative (-)
terminal of the battery.
WARNING
¥ Removing the earth cable from the negative (-) terminal of the battery will erase the memory of some
systems. Therefore, if necessary, record the contents of the memory of each system and enter them
again after the maintenance process has ended.
(2) Disconnect the connector from the ABS control unit
by turning the safety catch.

M 21C 7204T 10

4. Disconnect the air filter hose.

See page B3-1.
5. Disconnect the brake fluid level warning switch
connector from the master cylinder's brake fluid
expansion tank.
6. Remove the filler cap from the expansion tank.
7. Drain the brake fluid from the master cylinder expansion
tank.
M 21C 7012T 10
 E1– 9
(2) LEFT-HAND DRIVE VEHICLES
1. Jack up the vehicle.
2. Remove the wheels (four wheels).
3. Perform the following work on vehicles with ABS.
(1) With the ignition switch in the OFF (LOCK) position Disconnect the ground cable from the
negative _ pole of the battery.
WARNING
• When the earth cable is removed from the negative terminal of the battery, the memories of some
systems are erased. Therefore, if necessary, record the contents of the memory of each system and
enter them again after the maintenance process has ended.
(2) Disconnect the connector from the ABS control unit
by turning the safety catch.
4. The battery tensioning screw remove. Remove the clamp
holding down the battery, the battery hood and the
battery.

M 21C 7204T 10

5. Remove the battery tray.

L21C 7704T10

6. Remove the holder of the wiring harness coming from the

relay box.

L21C 7706T 10

7. Remove the relay box from the relay box holder.

8. Remove the relay box holder from the body.
9. Disconnect the brake fluid level warning switch connector
from the master cylinder's brake fluid expansion tank.
10. Remove the filler cap from the expansion tank.
11. Drain the brake fluid from the master cylinder expansion
tank.

L21C 7705T10
E1–10
4-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

b
a

~ c d

a
N

L21C7006S20

Unit: Nm
~: Non-reusable parts
l: silicone grease
(2) REMOVAL AND INSTALLATION PROCEDURES
ji 1 a brake line
i 2 b master cylinder
3 c Gasket, master cylinder
4 d Sealing ring, master cylinder

4-1-4 POINTS TO EXPAND

(1) BRAKE LINE
1.The Disconnect the brake line from the master cylinder. Seal the dismantled brake line with a vent plug
or similar.
NOTE
• For vehicles with ABS, it is recommended to remove the brake line from the front of the vehicle.
 E1–11
4-1-5 POINTS FOR INSTALLATION
O-ring
(1) MASTER BRAKE CYLINDER
1. Use the procedure below to check the brake booster
pushrod clearance.
(1) Insert an O-ring (SST) into the groove on the rod of
the gauge (SST). Then attach an additional piece
(SST) in the same place. Also apply silicone grease Additional piece
to the surface of the additional piece (SST)
beforehand. L11C5075E T10

SST: 09730-87401-000
LUBRICANT: silicone grease
(2) Connect the brake vacuum hose to the brake
booster.
(3) Apply silicone grease to the inner surface of the
sealing lip of the main cylinder piston sealing ring,
which was installed between the main cylinder and
the brake booster.
LUBRICANT: silicone grease
(4) Install the master cylinder piston sealing ring on the
Master cylinder piston
brake booster side.
ATTENTION
• Make sure the master cylinder piston oil seal is installed
in the correct direction.
(5) Install the master cylinder gasket on the master
cylinder.

(6) Position the jig (SST) where the rod of the jig (SST) M 21C 7007E T 10

comes into light contact with the piston of the master

cylinder.
(7) Start the engine and apply a negative pressure of
approximately 66.7 kPa {500 mmHg} to the amplifier.
ATTENTION
• For vehicles with ABS or DVS (Daihatsu Vehicle Stability Master
cylinder
System), connect the negative pole (-) of the battery to gasket
the connector on the separate control unit.

M21C7009ET 10
(8) Reverse the special tool on the amplifier side. Then
check the clearance between the rod of the special
tool and the push rod of the amplifier.
SET VALUE: Gap: 0 mm

M 21C 7010T 10
E1–12
2. If the brake booster pushrod clearance is not within the
standard value, readjust using the following procedure.
(1) Leave the push rod pushed out.

(2) Secure the push rod with pliers or similar. Then M 21C 7015T 10

adjust the length by turning the screw attached to the

upper end of the push rod.
3. Apply silicone grease to the entire boundary surface of
the piston section of the main cylinder. LUBRICANT:
silicone grease

L21C 7016T 10
4. Make sure the master cylinder piston seal is installed
correctly. Then mount the master brake cylinder on the Master cylinder piston

brake booster.

M 21C 7007E T 10

(2) BRAKE LINE

NOTE
• For easier bleeding in the following work steps, we recommend that you top up the brake fluid in the
master cylinder's expansion tank and bleed the master cylinder before connecting the brake line.

1. Using the special tool, connect the brake line to the master brake cylinder.
ATTENTION
• Temporarily tighten the union nut of the front brake line by hand until the conical part of the line is
firmly seated on the connection piece; then tighten to the prescribed torque.

NOTE
• For vehicles with ABS, it is recommended to connect the brake line from the front of the vehicle.
Special tool: 09023-00100-000
 E1–13
4-1-6 WORK AFTER INSTALLATION
(1) RIGHT-HAND DRIVE VEHICLES
1. Install the air filter hose.
See page B3-1.

2. Bleed the brake system.

ATTENTION
• Only after venting is complete, check the brake system to see whether air has been able to get into
the system again.
LUBRICANT: Brake Fluid (DOT4)

3. Tighten the vent plug.

TIGHTENING TORQUE: 8.4 ± 1.4 Nm {85 ± 14kgf · cm}
4. Fill the expansion tank with brake fluid up to the MAX line.
LUBRICANT: Brake Fluid (DOT4)

5. Fit the filler cap on the expansion tank.

6. Connect the connector of the brake fluid level warning switch to the brake fluid expansion tank of the
master cylinder.
7. Carry out the following work on vehicles with ABS.
(1) Connect the connector by turning the safety catch on
the ABS control unit until it clicks into place.
(2) The earth cable at the negative terminal _ of the
battery connect.
ATTENTION
• After connecting the earth cable reset each system at
the negative terminal _ of the battery.
M 21C 7210T 10
8. Fit the wheels.
TIGHTENING TORQUE:
103.0 ± 14.7 Nm {1050 ± 150kgf · cm}
9. Check and confirm that the brake is not dragging.
10. Lower the vehicle.
E1–14
(2) LEFT-HAND DRIVE VEHICLES
1. Install the relay box holder on the body.
2. Install the relay box on the relay box holder.
3. Fit the bracket for the wiring harness coming from the relay box.
4. Install the battery tray.
5. Install the battery hold-down bracket, battery hood, and battery. Install the battery tightening screw.
6. Bleed the brake system.
ATTENTION
• Only after venting is complete, check the brake system to see whether air has been able to get into
the system again.

LUBRICANT: Brake Fluid (DOT4)

7. Tighten the vent plug.

TIGHTENING TORQUE: 8.4 ± 1.4 Nm {85 ± 14kgf · cm}

8. Fill the expansion tank with brake fluid up to the MAX line.
LUBRICANT: Brake Fluid (DOT4)

9. Fit the filler cap on the expansion tank.

10. Connect the connector of the brake fluid level warning switch to the brake fluid expansion tank of the
master cylinder.
11. The following work on vehicles with ABS
carry out.
(1) Connect the connector by turning the ABS control
pawl until it clicks into place.
(2) Connect the earth cable to the negative terminal _
of the battery.
WARNING
• After connecting the earth cable reset each system at
the negative terminal _ of the battery. M 21C 7210T 10

12. Fit the wheels. TIGHTENING

TORQUE: 103.0 ± 14.7Nm {1050
± 150kgf · cm}
13. Check and confirm that the brake is not dragging.
14. Lower the vehicle.
 E1–15
4-2 DISASSEMBLY AND ASSEMBLY PROCEDURE (ABS VEHICLES)
4-2-1 WORK EQUIPMENT PROVIDE

Lubricant, glue / sealant, others

Brake fluid (DOT4), rubber grease, silicone grease

4-2-2 DISASSEMBLY AND ASSEMBLY PROCEDURES

(1) COMPONENTS

f
d i
~j
a k

~
H
~e ~e
~l

m
L21C7019S25
Unit: Nm
~: Non-reusable parts
k: brake fluid (DOT4)
l: rubber grease
m: silicone grease
(2) DISASSEMBLY AND ASSEMBLY PROCEDURES
1 a pen 9i Guide, master cylinder piston
2 b Closure, container i 10 y Secondary cuff, cylinder
3 c Sieve, master cylinder container 11 k Stop washer, master cylinder piston
4th d Reservoir, master cylinder ji 12 l No. 2 piston, master cylinder
i e Rubber grommet / bushing, container 13 m Housing, master cylinder
5
j i f Circlet
6
j i G pen
7
j i H No. 1 piston, master cylinder
8

4-2-3 POINTS FOR DISASSEMBLY

(1) SEEGERING
1. Remove the remaining brake fluid from inside the master cylinder by pushing the piston several
times.
ATTENTION
• Be careful not to let the oil splash around when you push the piston.
E1–16
2. Loosen the circlip that sits on the piston with the help of
circlip pliers.

L21C 7020T 10

(2) PEN
1. At With the piston pushed in, remove the pin using a pen
magnetic gripper or similar.

L21C 7021E T 10

(3) MASTER CYLINDER PISTON NO. 1

1.The Take the No. 1 master cylinder piston straight out.
ATTENTION
• Make sure the piston is removed straight out to avoid scratching the cylinder bore.

(4) MASTER CYLINDER PISTON NO. 2

1. Lightly tap the edge portion against a piece of wood until
the end of the # 2 master cylinder piston pops out.
2. When the end of the # 2 master cylinder piston comes
out, pull the piston straight out.
ATTENTION
• When dismantling, be careful not to scratch the inside of
the cylinder.
Log
L11C 5080E T 10

4-2-4 VERIFICATION
(1) MASTER CYLINDER
1. Check for scratches on the cylinder bore.
2. Check whether the cylinder bore is deformed or scratched.
4-2-5 ASSEMBLY POINTS
(1) MASTER CYLINDER PISTON NO. 2
1. Apply brake fluid to the entire periphery of the inner cylinder surface of the master cylinder housing.
LUBRICANT: Brake Fluid (DOT4)

2. Apply brake fluid to the entire periphery of the No. 2 master cylinder piston.
LUBRICANT: Brake Fluid (DOT4)
 E1–17
3. Insert the No. 2 master cylinder piston so that the
elongated hole is aligned with the pin mounting hole of
the master cylinder housing.

M 21C 7022T 10

(2) SECONDARY CUFF OF THE CYLINDER

1. Apply rubber grease to the entire periphery of the inner and outer surfaces of the secondary sleeve of
the cylinder.
LUBRICANT: rubber grease

2. Install the cylinder secondary boot on the # 1 master cylinder piston.

ATTENTION
• Make sure that the secondary sleeve of the cylinder is
installed in the correct direction.

M 21C 7099T 10

(3) MASTER CYLINDER PISTON NO. 1

1. Apply brake fluid to the entire periphery of the No. 1 master cylinder piston pan.
LUBRICANT: Brake Fluid (DOT4)

2. Insert the No. 1 master cylinder piston into the master cylinder housing.
(4) PEN
1.With Fasten the pin with the piston pushed in. pen

L21C 7021E T 10

(5) SEEGERING
1. With the piston pushed in, mount the circlip using circlip
pliers.

L21C 7020T 10
E1–18
2. Attach the circlip so that the opening is facing down.

L21C 7022T 10

(6) RUBBER COUPLING

1.On Apply brake fluid to the entire periphery of the inner and outer surfaces of the grommet.
LUBRICANT: Brake Fluid (DOT4)
 E1–19
4-3 DISASSEMBLY AND ASSEMBLY (vehicles without ABS)
4-3-1 WORK EQUIPMENT PROVIDE
Lubricant, glue / sealant, others
Brake fluid (DOT4), rubber grease, silicone grease

4-3-2 DISASSEMBLY AND ASSEMBLY

(1) COMPONENTS

e
i
~j
k
c

a
~
H

~l
~d
~d

f
~
G

L21C7100S25
Unit: Nm
~: Not reusable Parts
k: brake fluid (DOT4)
l: Rubber grease
m: silicone grease
(2) DISASSEMBLY AND ASSEMBLY
1 a pen ji 8h piston No. 1, master cylinder
2 b Closure, container 9 iLeadership, Master cylinder piston
3 c Reservoir, master cylinder i 10 j Secondary cuff, cylinder
i 4 d rubber grommet, 11k stop washer, master cylinder piston
container ji 12 l Piston No. 2, master
ji 5 e circlip cylinder 13 m housing, master
ji 6 f hexagon screw cylinder
7 g seal
E1–20
4-3-3 POINTS FOR DISASSEMBLY
(1) SEEGERING
1. Remove the remaining brake fluid from inside the master cylinder by pushing the piston several
times.
ATTENTION
• Make sure that no oil splashes around when you push the piston.

2. Loosen the circlip that sits on the piston with the help of
circlip pliers.

Slide

M 21C 7020E T 10

(2) hex bolt

With the piston pushed in, loosen the hexagon screw.

Slide
M 21C 7098E T 16

(3) MASTER CYLINDER PISTON NO. 1

Remove the No. 1 master cylinder piston straight out.
ATTENTION
• Make sure the piston is removed straight out to avoid scratching the cylinder bore.

(4) MASTER CYLINDER PISTON NO. 2

1. Lightly tap the edge portion against a piece of wood until
the end of the # 2 master cylinder piston pops out.
2. When the end of the # 2 master cylinder piston comes
out, pull the piston straight out.
ATTENTION
• When dismantling, be careful not to scratch the inside of
the cylinder.
Log
L11C 5080E T 10

4-3-4 VERIFICATION
(1) MASTER CYLINDER
1. Check for scratches on the cylinder bore.
2. Check whether the cylinder bore is deformed or scratched.
 E1–21
4-3-5 ASSEMBLY POINTS
(1) MASTER CYLINDER PISTON NO. 2
1. Apply brake fluid to the entire periphery of the inner cylinder surface of the master cylinder housing.
LUBRICANT: Brake Fluid (DOT4)

2. Apply brake fluid to the entire periphery of the No. 2 master cylinder piston.
LUBRICANT: Brake Fluid (DOT4)

3. Insert the No. 2 master cylinder piston into the master cylinder housing.
(2) SECONDARY CUFF OF THE CYLINDER
1. Apply rubber grease to the entire periphery of the inner and outer surfaces of the secondary sleeve of
the cylinder.
LUBRICANT: rubber grease

2. Install the cylinder secondary boot on the # 1 main

cylinder piston.
ATTENTION
• Make sure that the cylinder dust cover is installed in the
correct direction.

M 21C 7099T 10

(3) MASTER CYLINDER PISTON NO. 1

1. Apply brake fluid to the entire periphery of the No. 1 master cylinder piston.
LUBRICANT: Brake Fluid (DOT4)

2. Insert the No. 1 master cylinder piston into the master cylinder housing.
(4) hex bolt
With the piston pushed in, mount the seal and the hexagon
screw.

Slide
M 21C 7098E T 16
E1–22
(5) SEEGERING
1. With the piston pushed in, mount the circlip using circlip
pliers.

Slide

M 21C 7020E T 10

2. Attach the circlip so that the opening is facing down.

L21C 7022T 10

(6) RUBBER COUPLING

Apply brake fluid to the entire periphery of the inner and outer surfaces of the grommet.
LUBRICANT: Brake Fluid (DOT4)
 E1–23
5 BRAKING POWER BOOSTER
5-1 REMOVAL AND INSTALLATION
ATTENTION
• Do not turn the ignition switch ON until bleeding is complete. If this instruction is not observed, air can
get into the control unit, which makes venting unnecessarily difficult.
5-1-1 WORK EQUIPMENT PROVIDE
Instruments
MityVac vacuum pump

Lubricant, glue / sealant, others

Brake fluid (DOT4), multi-purpose grease

5-1-2 WORK BEFORE EXPANSION

1.The Remove master brake cylinder.
See page E1 - 8.

5-1-3 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENTS
RIGHT-HAND DRIVE VEHICLES

d
e ~f

~
c b N
G
~
c
a
N

L21C7703S20

Unit: Nm
~
: Non-reusable parts
k: MP fat
E1–24
LEFT-HAND DRIVE VEHICLES

e ~f

b N
G
~c
~c

a
N

L21C7708S20

Unit: Nm
~: Non-reusable parts
k: MP fat
(2) REMOVAL AND INSTALLATION
PROCEDURES 6 f seal, Brake booster bracket
1 a securing clip 7 g Clevis, skin cylinder piston rod
2 b clevis pin
3 c hose clamp
i 4 d vacuum hose
5 e brake booster

5-1-4 VERIFICATION
(1) CHECK VALVE (VACUUM HOSE)
1. Connect a MityVac to the motor side. Then check whether air can flow from the engine side to the
brake booster side.
And vice versa:
2. Connect a MityVac to the amplifier side. Then check that no air can flow from the motor side to the
amplifier side.

2 1

L21C7032ES10
1: engine side
2: amplifier side
3. Replace the vacuum hose if the above conditions are not met.
 E1–25
(2) BRAKE BOOSTER PUSH ROD
1.The Check and adjust gap in brake booster pushrod.
See page E1 - 8.

5-1-5 POINTS FOR INSTALLATION

(1) VACUUM HOSE
1. Connect the vacuum hose.
WARNING
• Make sure that the vacuum hose is connected in the
correct direction. Make sure the “ENGINE” mark is
installed on the intake manifold side of the engine. If the Engine side
pressure mark is worn, check the air passage and install
so that there is passage from the booster side to the
intake manifold side.
• Also make sure that the “ENGINE” mark is facing up
when viewed from the vehicle. A 11C 5021ET 10
ATTENTION
• Connect the vacuum hose to the amplifier side so that mark

the marking line points upwards when viewed from the Amplifier
side
vehicle.

M 21C 7031E T 10

ATTENTION
• Make sure that the vacuum hose is pushed in as far as it
will go on the connecting piece. In addition, attach the
clamp so that the dimension A shown in the picture is 2.0
to 4.5 mm.

A.

A 11C 5022T 10

2. Connect the vacuum hose to the air conditioning pipe

and to the connection hose for the activated carbon filter.
(Left-hand drive vehicles)

L21C 7707T 10

5-1-6 WORK AFTER INSTALLATION

1.The Install the master brake cylinder.
See page E1 - 8.
E1–26
6 BRAKE FORCE REGULATOR
6-1 REMOVAL AND INSTALLATION (vehicles without ABS)
6-1-1 WORK EQUIPMENT PROVIDE
Special tools:
shap Part number Part designation
e

09023-00100-000 Line key

Tool
Brake pedal pushers

Instruments
Torque wrench

Lubricant, glue / sealant, others

Brake fluid (DOT4)

6-1-2 WORK BEFORE EXPANSION

1. Prevent brake fluid from flowing out. Use the following procedure.
(1) Jack up the vehicle.
(2) Remove the wheels (four wheels).
(3) To bleed, connect a bottle to the bleed plug of the
right and left front brake calliper. Then open the vent
plug.

(4) Depress the brake pedal more than 60 mm. Then M 21C 7201T 10

secure the brake pedal.

TOOL: Brake Pedal Push-button
NOTE
• This process closes the connection to the main cylinder.
This prevents the brake fluid from flowing out of the
hydraulic circuit of the brake.
(5) Close the vent plug on the front wheels on the right
and left. L21C 5004T 10

2. Remove the intake manifold.

Vehicles with engine type EJ
See page B3-5.
 E1–27
6-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS
a

B.
M21C7038S20

Unit: Nm
(2) REMOVAL AND INSTALLATION PROCEDURES
ji 1 a brake line
2 b brake force regulator

6-1-4 POINTS TO EXPAND

(1) BRAKE LINE
1. Disconnect the brake line from the brake force regulator assembly. Seal the separate brake line with a
vent plug or similar.
6-1-5 POINTS FOR INSTALLATION
(1) BRAKE LINE
1.With Using the special tool, connect the brake line to the brake force regulator.
ATTENTION
• Temporarily tighten the union nut of the front brake line by hand until the conical hose area is firmly
seated on the connection; then tighten to the prescribed torque.

SST: 09023-00100-000
E1–28
6-1-6 WORK AFTER INSTALLATION
1. Install the intake manifold.
Vehicles with engine type EJ
See page B3-5.

2. Release the brake pedal lever.

3. Bleed the brake system.
ATTENTION
• Only after venting is complete, check the brake system to see whether air has been able to get into
the system again.

LUBRICANT: Brake Fluid (DOT4)

4. Tighten the vent plug.

TIGHTENING TORQUE: 8.4 ± 1.4 Nm {85 ± 14kgf · cm}

5. Fill the expansion tank with brake fluid up to the MAX line.
LUBRICANT: Brake Fluid (DOT4)

6. Fit the filler cap on the expansion tank.

7. Fit the wheels.
TIGHTENING TORQUE: 103.0 ± 14.7 Nm {1050 ± 150kgf · cm}

8. Lower the vehicle.

 E1–29
6-2 REMOVAL AND INSTALLATION (vehicles with ABS)
6-2-1 WORK EQUIPMENT PROVIDE
Special tools:
shap Part number Part designation
e

09023-00100-000 Line key

Tool
Brake pedal pushers

Instruments
Torque wrench

Lubricant, glue / sealant, others

Brake fluid (DOT4)

6-2-2 WORK BEFORE EXPANSION

1. With the ignition switch in the OFF position (LOCK), disconnect the earth cable from the negative
terminal _ of the battery.
WARNING
• When the earth cable is removed from the negative terminal of the battery, the memories of some
systems are erased. Therefore, if necessary, record the contents of the memory of each system and
enter them again after the maintenance process has ended.
2. Disconnect the ABS control unit connector by turning the
pawl.
3. Prevent brake fluid from flowing out. Use the following
procedure.
(1) Jack up the vehicle.
(2) Remove the wheels (four wheels).

M 21C 7204T 10

(3) To bleed, connect a bottle to the bleed plug of the

right and left front brake calliper. Then open the vent
plug.

M 21C 7201T 10
E1–30
(4) Depress the brake pedal more than 60 mm. Then
secure the brake pedal.
TOOL: Brake Pedal Push-button
NOTE
• This process closes the connection to the master
cylinder. This prevents the brake fluid from flowing out of
the hydraulic circuit of the brake.
(5) Close the vent plug on the front wheels on the right
and left. L21C 5004T 10

4. Remove the intake manifold.

Vehicles with engine type EJ
See page B3-5.

6-2-3 REMOVAL AND INSTALLATION PROCEDURES

(1) COMPONENTS

a b

B.
M21C7084S20
Unit: Nm
(2) REMOVAL AND INSTALLATION PROCEDURES
j i 1 a brake line
2 b pipe connector, 2

6-2-4 POINTS TO EXPAND

(1) BRAKE LINE
1. Disconnect the brake line from the line connector. Seal the separate brake line with a vent plug or
similar.
 E1–31
6-2-5 POINTS FOR INSTALLATION
(1) BRAKE LINE
1. Connect the brake line to the connector using the special tool.
ATTENTION
• Temporarily tighten the union nut of the front brake line by hand until the conical hose area is firmly
seated on the connection; then tighten to the prescribed torque.
SST: 09023-00100-000

6-2-6 WORK AFTER INSTALLATION

1. Install the intake manifold.
Vehicles with engine type EJ
See page B3-5.

2. Release the brake pedal lever.

3. Bleed the brake system.
ATTENTION
• Only after venting is complete, check the brake system to see whether air has been able to get into
the system again.

4. Tighten the vent plug.

TIGHTENING TORQUE: 8.4 ± 1.4 Nm {85 ± 14kgf · cm}

5. Fill the expansion tank with brake fluid up to the MAX line.
LUBRICANT: Brake Fluid (DOT3)

6. Fit the filler cap on the expansion tank.

7. Fit the wheels.
TIGHTENING TORQUE:
103.0 ± 14.7 Nm {1050 ± 150kgf · cm}

8. Lower the vehicle.

9. Connect the connector by turning the connector hinge of
the ABS control unit until it clicks into place.
10. Connect the earth cable to the negative terminal _ of
the battery.
ATTENTION
• After connecting the earth cable reset each system at
the negative terminal _ of the battery.
M 21C 7210T 10
E1–32
7 FRONT DISC BRAKE PAD
7-1 REMOVAL AND INSTALLATION
ATTENTION
• Watch out for that no oil or grease etc. adheres to the sliding surface between the brake pad and the
brake disc.
• Be careful not to get any brake fluid on the paint surface. Immediately and thoroughly wipe off any
brake fluid adhering to the paint surface and wash off with water.

7-1-1 WORK EQUIPMENT PROVIDE

Instruments
Torque wrench

Lubricant, glue / sealant, others

wire

7-1-2 WORK BEFORE EXPANSION

1. Jack up the vehicle.
2. Remove the front wheels.
7-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

a
b

M21C7091S22
Unit: Nm
(2) REMOVAL AND INSTALLATION PROCEDURES
1 a lifting pin (g)
ji 2 b caliper, disc brake RH / LH
i 3 c brake pad no.1
4 d Brake pad No. 2
5 e antique creaking disc
 E1–33
7-1-4 POINTS TO EXPAND
(1) CALIPER RIGHT / LEFT
1. Remove the support bolt (caliper cylinder bolt). Then lift up the brake caliper.
2. Hang the brake calliper on a wire or something similar.
ATTENTION
• Do not pull on the brake line. Also, be careful not to
damage the brake line.

M 21C 7041T 10

7-1-5 POINTS FOR INSTALLATION

(1) DISC BRAKE PAD NO. 1
1. Install the brake pad with a wear indicator facing the inside
of the vehicle. Make sure that the wear indicator is
installed on the top of the vehicle when it is attached.

M 21C 7043T 10

(2) BRAKE CALIPER RIGHT LEFT

1. The liquid level in the expansion tank of the
Check master cylinder.
2. Push the plunger slowly.
3. Make sure that no brake fluid is leaking from the master
cylinder's expansion tank.
4. Remove the wire from which the brake calliper was
previously hung and reattach the brake calliper.
M 21C 7044T 10

7-1-6 WORK AFTER INSTALLATION

1. Depress the brake pedal several times to bleed the system.
2. Check the brake fluid level.
3. Fit the front wheels.
TIGHTENING TORQUE: 103.0 ± 14.7 Nm {1050 ± 150kgf · cm}

4. Check and confirm that the brake is not dragging.

5. Lower the vehicle.
E1–34
8th FRONT CALIPER 8-1
REMOVAL AND INSTALLATION
CAUTION
• Be careful not to get any brake fluid on the paint surface. Immediately and thoroughly wipe off any
brake fluid adhering to the paint surface and wash off with water.
• Never reuse used brake fluid.
• Watch out for that no oil or grease etc. adheres to the sliding surface between the brake pad and the
brake disc.
8-1-1 WORK EQUIPMENT PROVIDE
Tool
Brake pedal pushers

Instruments
Torque wrench

Lubricant, glue / sealant, others

Brake fluid (DOT4)

8-1-2 WORK BEFORE EXPANSION

1. Jack up the vehicle.
2. Remove the front wheels (right and left).
3. Prevent brake fluid from flowing out. Use the following
procedure.
(1) To bleed, connect a bottle to the bleed plug of the
right and left front brake caliper. Then open the vent
plug.

M 21C 7201T 10

(2) Depress the brake pedal more than 60 mm. Then

secure the brake pedal.
TOOL: Brake Pedal Push-button
NOTE
• This process closes the connection to the master
cylinder. This prevents the brake fluid from flowing out of
the hydraulic circuit of the brake.
(3) Close the vent plug on the front wheels on the right
and left. L21C 5004T 10
 E1–35
8-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

T: 112.8-22.5 {1150-229} B.

~b

M21C7092S24
Unit: Nm
~
: Non-reusable parts
(2) REMOVAL AND INSTALLATION PROCEDURES
1 a banjo bolt
2 b seal
3 c brake hose
4 d Caliper, front disc brake
E1–36
8-1-4 WORK AFTER INSTALLATION
1. Release the brake pedal lock.
2. Bleed the brake system.
ATTENTION
• Only after venting is complete, check the brake system to see whether air has been able to get into
the system again.
LUBRICANT: Brake Fluid (DOT4)

3. Tighten the vent plug.

TIGHTENING TORQUE: 8.4 ± 1.4 Nm {85 ± 14kgf · cm}

4. Fill the expansion tank with brake fluid up to the MAX line.
LUBRICANT: Brake Fluid (DOT4)

5. Fit the filler cap on the expansion tank.

6. Fit the front wheels.
TIGHTENING TORQUE: 103.0 ± 14.7 Nm {1050 ± 150kgf · cm}

7. Check and confirm that the brake is not dragging.

8. Lower the vehicle.
8-2 DISASSEMBLY AND ASSEMBLY
WARNING
• Ensure that protective goggles are worn when handling compressed air.
ATTENTION
• Never reuse drained brake fluid.
• Watch out for that no oil or grease etc. adheres to the sliding surface between the brake pad and the
brake disc.
8-2-1 WORK EQUIPMENT PROVIDE
Instruments
Torque wrench

Lubricant, glue / sealant, others

Brake fluid (DOT4), rubber grease
 E1–37
8-2-2 DISASSEMBLY AND ASSEMBLY PROCEDURES
(1) COMPONENTS

G
d
e
H

i
p
a
b

~
O ~m ~l
c j
f

~l

M21C7054S24

Unit: Nm
~: Non-reusable parts
k: brake fluid (DOT4)
l: Rubber grease

(2) DISASSEMBLY AND ASSEMBLY PROCEDURES

1 a cap, vent plug 9 iAntiquette No. 2
2 b vent plug i 10 j Shoe, brake lining guide
i 3 c lifting pin (g) i 11 k shoe, brake lining guide
i 4 d support 12 lcuff, pen
bolts (l) i 13 m piston protection cap
5 e socket j i 14 n pistons, disc brakes
i 6 f Fastener, caliper ji 15 o piston seal
i 7 g brake pad No. 1, disc brake 16 p brake caliper, disc brake RH / LH
8 h brake pad No. 2, disc brake

8-2-3 POINTS FOR DISASSEMBLY

(1) DISC BRAKE PISTON
1. Drain the remaining brake fluid in the brake calliper from the connection of the brake hose.
E1–38
2. When working on the brake, protect the component with
a cloth or something similar to prevent damage to the
brake calliper. While holding the vent plug, apply
compressed air to the connection of the brake hose to
pull out the piston.
WARNING
• Since the piston may pop out forcefully, extreme care
must be taken so that nobody gets caught with their
fingers.
L18C 5043T 10
ATTENTION
• Be careful not to scratch the inner surface of the cylinder.
(2) PISTON SEAL
1.The Remove the piston seal from the piston with a toothpick or similar.
8-2-4 ASSEMBLY POINTS
Before installation, clean all parts with the same brake fluid that is specified for the vehicle.
LUBRICANT: Brake Fluid (DOT4)

(1) PISTON SEAL

1. Apply rubber grease to the entire periphery of the inner and outer surfaces of the piston seal.
LUBRICANT: rubber grease

2. Insert the piston seal tightly into the groove of the piston so that the piston seal does not twist.
(2) DISC BRAKE PISTON
1. Apply brake fluid to the inside surface of the cylinder.
2. Apply brake fluid to the outer periphery of the piston.
LUBRICANT: Brake Fluid (DOT4)

3. Insert the piston into the cylinder by hand.

ATTENTION
• Make sure the piston is inserted straight. Be careful that the piston is not inserted diagonally or
pushed with force.
(3) PISTON PROTECTIVE CAP
1. Attach the piston protection cap to the groove on the edge of the piston.
2. Fasten the piston protection cap securely in the protection cap groove on the inner surface of the cylinder.
3. Make sure that the piston protection cap is firmly seated
in the protection cap groove. For top
(4) DISC BRAKE PAD GUIDE
1. Attach the guide shoe with a pawl to the underside of the
brake calipers. Vice versa; attach the guide shoe without
a pawl to the top of the brake callipers. For bottom

claw

L11C 5241E T 10
 E1–39
(5) DISC BRAKE PAD NO. 1 Top of Wear indicator
Vehicle
1. Install disc brake pad No. 1 with a wear indicator on the
inside of the vehicle. Make sure that the wear indicator is
installed towards the top of the vehicle.

(6) CALIPER ATTACHMENT M 21C 7055E T 10

1.An Apply rubber grease to the sleeve of the support bolt of the fastening and the inner surface of the
support bolt slide hole.
LUBRICANT: rubber grease

(7) CYLINDER PIVOT

1. Apply rubber grease to the installation groove of the bolt protection cap of the cylinder support bolt
and to the entire periphery of the sliding section.
LUBRICANT: rubber grease

2. Install the cylinder slide bolt (l) to the top of the brake
calipers. Install the cylinder slide bolt (g) on the
underside of the brake calipers.

G
G

L18C 5040T 10
E1– 40
9 FRONT BRAKE DISC 9-1
REMOVAL AND INSTALLATION
ATTENTION
• Watch out for that no oil or grease etc. adheres to the sliding surface between the brake pad and the
brake disc.
9-1-1 WORK EQUIPMENT PROVIDE
Instruments
Torque wrench

Lubricant, glue / sealant, others

wire

9-1-2 WORK BEFORE EXPANSION

1. Jack up the vehicle.
2. Remove the front disk wheels.
9-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS
b
a

M21C7093S24

Unit: Nm
(2) REMOVAL AND INSTALLATION PROCEDURES
1 a lifting pin (g)
ji 2 b caliper, RH / LH
j 3c brake disc, front

9-1-4 POINTS TO EXPAND

(1) BRAKE CALIPER RIGHT LEFT
1. Remove the cylinder support bolt. Then lift up the brake caliper.
 E1– 41
2. Hang the brake calliper on a wire or something similar.
ATTENTION
• Do not pull on the brake line. Also be careful not to
damage the brake line.

M 21C 7052T 10

(2) FRONT BRAKE DISC

1. If the front brake disc cannot be removed because it is
stuck on the hub, screw two suitable screws (M8 X 1.25)
into the screw holes in the front disc, thus loosening the
front disc.

M 21C 7045T 10
9-1-5 POINTS FOR INSTALLATION
(1) CALIPER RIGHT / LEFT
1. Check the fluid level in the master cylinder's expansion
tank.
2. Push the plunger slowly.
3. Make sure that no brake fluid is leaking from the master
cylinder's expansion tank.
4. Remove the wire that hung the brake caliper and install
the brake caliper in its original position. M 21C 7044T 10

9-1-6 WORK AFTER INSTALLATION

1. Depress the brake pedal several times to bleed the system.
2. Check the brake fluid level.
3. Fit the front wheels.
TIGHTENING TORQUE: 103.0 ± 14.7 Nm {1050 ± 150kgf · cm}
4. Check and confirm that the brake is not dragging.
5. Lower the vehicle.
E1– 42
10 FRONT BRAKE DUST CAP
10-1 REMOVAL AND INSTALLATION
10-1-1 WORK EQUIPMENT PROVIDE
SST:
shape Part number Part designation

09506-87302-000 Removal / installation tool, rear pinion bearing

09718-87701-000 Removal / installation tool, dust cap

10-1-2 WORK BEFORE EXPANSION

1. Jack up the vehicle.
2. Remove the front wheels.
3. Remove the front wheel speed sensor.
See page E3-5.

4. Remove the front brake caliper from the steering knuckle without kinking or disconnecting the brake
line. Then hang up the brake caliper of the front brake with a wire or something similar.
ATTENTION
• Do not pull on the brake line. Also be careful not to da mage the brake line. See page E3-34.

5. Remove the front brake disc.

See page E3-40.

6. Remove the front axle hub. Then remove the steering knuckle together with the radial ball bearing
and the dust protection plate.
See page D2-1.
 E1– 43
10-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

~a

M21C7086S20
~
: Non-reusable parts
(2) REMOVAL AND INSTALLATION PROCEDURES
ji 1 a dust cov er, front RH / LH

10-1-4 POINTS TO EXPAND

(1) Front disc brake dust cover (RH / LH)
1. Tap lightly against the outer perimeter to create a space.
Then pry off the dust protection plate of the front disc
brake with a flat screwdriver or similar.

10-1-5 POINTS FOR INSTALLATION S 11K 7082T 10

(1) Front disc brake dust cover (RH / LH)

1. Install the dust cover on the steering knuckle. To do this,
use a hydraulic press together with the special tool.
SSTB
SST: 09506-87302-000
09718-87701-000
SSTA

S 11K 7083T 10
E1–44
10-1-6 WORK AFTER INSTALLATION
1. Install the steering knuckle together with the radial ball bearing and the dust cover of the front disc
brake.
2. Install the front axle hub.
See page D2-1.

3. Install the front brake disc.

See page E1-40.

4. Install the front brake caliper.

See page E1-34.

5. Install the front wheel speed sensor.

See page E3-5.

6. Install the front wheels.

TIGHTENING TORQUE: 103.0 + -14.7 Nm {1050 + -150kgf cm}

7. Lower the vehicle.

8. Check and correct the front axle track.
See page C1 - 1.
 E1– 45
11 REAR BRAKE DRUM
11-1 REMOVAL AND INSTALLATION (vehicles with ABS)
ATTENTION
• Be careful not to get any brake fluid on the paint surface. Immediately wipe off any brake fluid
adhering to the paint surface thoroughly and wash off with water.
• Make sure that no oil or grease etc. stick to the sliding surface between the brake pad and t he brake
drum.
11-1-1 WORK EQUIPMENT PROVIDE
Special tools:
shap Part number Part designation
e

09023-00100-000 Line key

Tool
Long Torx wrench T55, brake pedal lever

Instruments
Torque wrench

Lubricant, glue / sealant, others

Brake fluid (DOT4), brake grease

11-1-2 WORK BEFORE EXPANSION

1. Jack up the vehicle.
2. Remove the rear wheels (right and left).
3. Prevent brake fluid from flowing out. Use the following
procedure.
(1) To bleed, connect a bottle to the bleed plug of the
rear wheel cylinder on the right and left side. Then
open the vent plug.

M 21C 7201T 10

(2) Depress the brake pedal more than 60 mm. Then

secure the brake pedal.
TOOL: Brake Pedal Push-button
NOTE
• This process closes the connection to the main cylinder.
This prevents the brake fluid from flowing out of the
hydraulic circuit of the brake.
(3) Close the vent plug on the rear wheels on the right
and left. L21C 5004T 10
E1–46
11-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

a
r B.
q

c n
O

~
k m e d

j H

B.
l
G

e
i d

L21C7060S25

Unit: Nm
~
: Non-reusable parts
m: brake grease
(2) REMOVAL AND INSTALLATION PROCEDURES
j i a Brake line 10 j Strut, parking brake brake shoe
1
j i b Brake drum 11 k Tension spring
2
j i c Rear hub & bearings 12th l Brake cable, handbrake, No. 2 / No. 3
3
4th d Hold-down spring, brake shoe 13 m Circlip, E
5 e Pin, hold-down spring brake shoe 14th n Parking lever, handbrake RH / LH
6th f Tension spring 15th O Brake shoe, rear brake No. 3
7th G Tension spring 16 p Wheel brake cylinder, rear
8th H Tension spring 17th q Brake anchor plate, rear, RH / LH
9 i Brake shoe, rear brake, No. 3 18th r Stopper, inspection opening

11-1-4 POINTS TO EXPAND

(1) BRAKE LINE
1. Disconnect the brake line from the rear wheel brake cylinder. The separate brake line with a Close
vent plug or similar.
 E1– 47
(2) BRAKE DRUM
1. If the brake drum cannot be removed because it is stuck
on the hub, screw two suitable screws (M8 X 1.25) into
the screw holes of the brake drum and thus loosen the
brake drum.

M 21C 7063T 10

(3) REAR HUB AND BEARING ASSEMBLY

1. Loosen the rear axle hub / bearing fastening screw. To do this, use a long torx ®-Use the T55 key.
TOOL: Long TORX® key T55
2. Slowly pull the rear axle hub / bearing off the rear swing arm. Disconnect the connector from the
wheel speed sensor.

11-1-5 VERIFICATION
(1) Contact between brake lining and brake drum
1. Apply chalk to the inside surface of the brake drum. Let the
brake shoe slide along the inner surface of the drum with
light pressure. If the contact is poor, grind the brake lining
to correct it.
TARGET VALUE: No recognizable bad contact.
ATTENTION
• After completing the exam, wipe off the chalk. L21C 7064T 10

(2) WHEEL BRAKE CYLINDER, REAR

1.The Check the rear wheel brake cylinder for corrosion and damage.
(3) BRAKE ANCHOR PLATE, REAR
1.The Check rear brake anchor plate for wear and damage.
11-1-6 POINTS FOR INSTALLATION
(1) REAR HUB AND BEARING ASSEMBLY
1. Connect the wheel speed sensor connector to the rear hub / bearing. Then mount the rear axle hub /
bearing on the swing arm.
2. With a long torx ®-Fasten the T55 rear axle hub / bearing and the rear brake carrier.
TOOL: Long TORX key T55

(2) HAND BRAKE LOCKING LEVER (RH / LH)

1. Attach the brake lever to the handbrake cable by turning
the brake lever while compressing the spring of the
handbrake cable using the pawl on the locking lever.

L21C 7075T 10
E1–48
(3) BRAKE DRUM
1. Using a flat head screwdriver, turn the automatic jack from
the brake shoe adjustment hole of the brake anchor
plate, which will disengage the automatic jack from the
mesh. Completely press the primary and secondary shoe
sides together and install the brake drum.

L21C 7070T 10

(4) BRAKE LINE

1.With Using the special tool, connect the brake line to the brake cylinder of the rear wheel.
ATTENTION
• Temporarily tighten the union nut of the front brake line by hand until the conical line section is firmly
seated on the connection piece; then tighten to the prescribed torque.

SST: 09023-00100-000

11-1-7 WORK AFTER INSTALLATION

1. Release the brake pedal lever.
2. Bleed the brake system.
ATTENTION
• After venting is complete, check the brake system to see whether air has penetrated again.

LUBRICANT: Brake Fluid (DOT4)

3. Tighten the vent plug.

TIGHTENING TORQUE: 8.4 ± 1.4 Nm {85 ± 14kgf · cm}

4. Fill the expansion tank with brake fluid up to the MAX line.
LUBRICANT: Brake Fluid (DOT4)

5. Fit the filler cap on the expansion tank.

6. Depress the brake pedal several times, which activates the brake shoe clearance adjustment
mechanism. This means that the brake shoe play is optimally adjusted.
7. Check and adjust the travel of the handbrake.
See page E2-1.

8. Install the rear wheels.

TIGHTENING TORQUE: 103.0 ± 14.7 Nm {1050 ± 150kgf · cm}

9. Check and confirm that the brake is not dragging.

10. Lower the vehicle.
 E1– 49
11-2 REMOVAL AND INSTALLATION (vehicles without ABS)
ATTENTION
• Be careful not to get any brake fluid on the paint surface. Immediately wipe off any brake fluid
adhering to the paint surface thoroughly and wash off with water.
• Make sure that no oil or grease etc. stick to the sliding surface between the brake pad and the brake
drum.

11-2-1 WORK EQUIPMENT PROVIDE

Special tools:
shape Part number Part designation

09023-00100-000 Line key

09510-87301-000 Puller, front axle hub + drum

(Separation of hub + axle shaft)

Tool
Brake pedal pushers

Instruments
Torque wrench

Lubricant, glue / sealant, others

Brake fluid (DOT4), brake grease, Three Bond 1212, multi -purpose grease

11-2-2 WORK BEFORE EXPANSION

1. Jack up the vehicle.
2. Remove the rear wheels (right and left).
3. Prevent brake fluid from flowing out. Use the following
procedure.
(1) To bleed, connect a bottle to the bleed plug of the
rear wheel cylinder on the right and left side. Then
open the vent plug.
M 21C 7201T 10

(2) Depress the brake pedal more than 60 mm. Then

secure the brake pedal.
TOOL: Brake Pedal Push-button
NOTE
• This process closes the connection to the main cylinder.
This prevents the brake fluid from flowing out of the
hydraulic circuit of the brake.
(3) Close the vent plug on the rear wheels on the right
and left. L21C 5004T 10
E1–50
11-2-3 REMOVAL AND INSTALLATION PROCEDURES
(1) COMPONENTS

a
B. t

q
u s r

~p
n H G

N m k

j
e
d
i ~c
b
O
H
l
G

M21C7059S25

Unit: Nm
~
: Non-reusable parts
m: brake grease

(2) REMOVAL AND INSTALLATION PROCEDURES

ji 1 a Brake line 12 l Brake shoe, rear brake No. 3
th
2 b Grease cap, rear wheel 13 m Strut, parking brake brake shoe
i 3 c Sapwood 14 n Tension spring
th
i 4t d Castle nut 15 O Brake cable, handbrake, No. 2 / No. 3
h th
5 e Washer 16 p Circlip, E
ji 6t f Drum, rear brake 17 q Parking lever, handbrake RH / LH
h th
7t G Hold-down spring No. 1, brake shoe 18 r Brake shoe, rear brake No. 3
h th
8t H Pin, hold-down spring, brake shoe 19 s Wheel brake cylinder, rear
h th
9 i Tension spring i 20 t Brake anchor plate, rear, RH / LH
th
10 j Tension spring 21 u Stopper, inspection opening
11 k Tension spring

11-2-4 POINTS TO EXPAND

(1) BRAKE LINE
1.The Disconnect the brake line from the rear wheel brake cylinder assembly. Seal the separate brake
line with a vent plug or similar.
 E1– 51
(2) BRAKE DRUM
1. Remove the brake drum with the special tool. SST
SST: 09510-87301-000

C 11C 5017T 10

11-2-5 VERIFICATION
(1) Contact between brake lining and brake drum
1. Apply chalk to the inside surface of the brake drum. Let the
brake shoe slide along the inner surface of the drum with
light pressure. If the contact is poor, grind the brake lining
to correct it.
TARGET VALUE: No recognizable bad contact.
ATTENTION
• After completing the exam, wipe off the chalk. M 21C 7069T 10

(2) REAR WHEEL BRAKE CYLINDER

1.The Check the rear wheel brake cylinder for corrosion and damage.
(3) BRAKE ANCHOR PLATE, REAR
1.The Check rear brake anchor plate for wear and damage.
11-2-6 POINTS FOR INSTALLATION
(1) BRAKE ANCHOR PLATE, REAR
1. Clean the contact surface between the rear brake anchor plate and the rear axle stub.
ATTENTION
• To do this, use thinner and a synthetic resin spatula so that the contact surface is not damaged or
scratched.

2. Apply adhesive to the contact surface between the rear axle stub and the anchor plate.
ATTENTION scope of application
• Install the anchor plate immediately after applying the
adhesive.
ADHESIVE: Three Bond 1212

M 21C 7076E T 10
E1–52
(2) HAND BRAKE LOCKING LEVER (RH / LH)
1. Attach the brake lever to the handbrake cable by turning
the brake lever while compressing the spring of the
handbrake cable using the pawl on the locking lever.

(3) BRAKE DRUM M 21C 7075T 10

1. Using a flat head screwdriver, rotate the auto pawl from the brake shoe adjustment hole on the brake
anchor plate, which will disengage the auto lever from the mesh. Completely squeeze the primary
and secondary shoe sides and install the brake drum.
ATTENTION
• Make sure that no grease adheres to the inside of the
brake drum.

M 21C 7070T 10

(4) CROWN NUT

1. Make sure that no oil, grease or the like adheres to the threaded part of the rear axle shaft and to
both sides of the washer.
ATTENTION
• If oil, grease or similar stick to the component, it must be degreased.

2. Tighten the castle nut to the correct tightening torque. Then continue to tighten until the hole position
is aligned
(5) SPLINT
1. Attach a new split pin as shown in the picture on the right.
ATTENTION
• Split the split pin vertically and bend it until it touches the
shaft.

(6) Rear wheel grease cap L11K 5216T 10

1. Pour 15 cc MP grease into the grease cap of the rear wheel. Then attach the grease cap to the brake
drum.
LUBRICANT: MP - grease
 E1– 53
(7) BRAKE LINE
1. Using the special tool, connect the brake line to the rear wheel brake cylinder assembly.
ATTENTION
• Temporarily tighten the union nut of the front brake line by hand until the conical area is firmly seated
on the connection piece; then tighten to the prescribed torque. SST: 09023-00100-000

11-2-7 WORK AFTER INSTALLATION

1. Release the brake pedal lever.
2. Bleed the brake system.
ATTENTION
• After venting is complete, check the brake system to see whether air has penetrated again.

LUBRICANT: Brake Fluid (DOT4)

3. Tighten the vent plug.

TIGHTENING TORQUE: 8.4 ± 1.4 Nm {85 ± -14kgf · cm}

4. Fill the expansion tank with brake fluid up to the MAX line.
LUBRICANT: Brake Fluid (DOT4)

5. Fit the filler cap on the expansion tank.

6. Depress the brake pedal several times, which activates the brake shoe clearance adjustment
mechanism. This means that the brake shoe play is optimally adjusted.
7. Check and adjust the travel of the handbrake.
See page E2-1.

8. Install the rear wheels.

TIGHTENING TORQUE: 103.0 ± 14.7 Nm {1050 ± 150kgf · cm}

9. Check and confirm that the brake is not dragging.

10. Lower the vehicle.
E1-54
12 REAR BRAKE CYLINDER
12-1 DISASSEMBLY AND ASSEMBLY
ATTENTION
• Never reuse used brake fluid.

12-1-1 WORK EQUIPMENT PROVIDE

Instruments
Torque wrench

Lubricant, glue / sealant, others

Brake fluid (DOT4), rubber grease

12-1-2OPERATION BEFORE DISMANTLING

1. Remove the rear wheel brake cylinder. Vehicles
with two-wheel drive and ABS
See page E1-45.

Two-wheel drive vehicles without ABS

See page E1-49.

2. Drain the remaining brake fluid in the brake cylinder of the wheel from the connection point of the
brake line.
12-1-3 DISASSEMBLY AND ASSEMBLY PROCEDURES
(1) COMPONENTS

e
f

~
a
c

~
b

~
b
c

~
M21C7088S20
a
Unit: Nm
~
: Not reusable Parts
k: brake fluid (DOT4)
l: R ub b e r g re as e
 E1-55
(2) DISASSEMBLY AND ASSEMBLY PROCEDURES
1 a Sleeve, wheel brake cylinder 6th f Vent plug
i b Cup seal, cylinder i 7 G Housing, wheel brake cylinder, rear (2WD)
2
i c Pistons, wheel brake cylinders Housing, wheel brake cylinder, rear, No. 2 (4WD)
3
4th d Compression spring
5 e Cap, vent plug

12-1-4 VERIFICATION
(1) WHEEL BRAKE CYLINDER PISTON
1.On Check wear and damage.
(2) REAR BRAKE CYLINDER HOUSING
1.The Check the inner surface of the cylinder for wear and damage.
12-1-5 ASSEMBLY POINTS
(1) REAR BRAKE CYLINDER HOUSING
1.On Apply brake fluid to the entire periphery of the cylinder inner surface of the cylinder housing.
LUBRICANT: Brake Fluid (DOT4)
(2) WHEEL CYLINDER PISTON
1.On Apply rubber grease to the entire periphery of the wheel cylinder piston.
LUBRICANT: rubber grease

(3) POT CUFF OF THE CYLINDER

1. Apply rubber grease to the entire periphery of the inner and outer surface of the cup collar of the
cylinder.
LUBRICANT: rubber grease

2. Attach the cylinder cup seal to the piston.

ATTENTION
• Make sure that the cylinder cup seal is installed in the
correct direction.

M 21C 7090T 10

12-1-6 WORK AFTER ASSEMBLY

1.The Mount the wheel brake cylinder of the rear
wheel. Vehicles with two-wheel drive and ABS
See page E1-45.

Two-wheel drive vehicles without ABS

See page E1-49.