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fm 1
0411
04112
04113
04113
04113
04113
04114
04114
04114
04115
04115
04115
04116
04116
04119
041110
041111
041111
041111
041111
041113
041113
041114
041114
End of Toc
04111
0411
1712-1U-01G(04-11).fm 2
A3U041101020W01
Z3U0411W101
.
3
4
Vacuum line
(See 04113 VACUUM HOSE CHECK VALVE
INSPECTION (POWER BRAKE UNIT))
Brake pedal
(See 04113 BRAKE PEDAL INSPECTION)
(See 04115 BRAKE PEDAL REMOVAL/
INSTALLATION)
Brake switch
(See 04115 BRAKE SWITCH INSPECTION)
Master cylinder
(See 04116 MASTER CYLINDER REMOVAL/
INSTALLATION)
(See 041110 MASTER CYLINDER
DISASSEMBLY/ASSEMBLY)
Brake fluid level sensor
(See 04119 FLUID LEVEL SENSOR
INSPECTION)
Power brake unit
(See 041111 POWER BRAKE UNIT
INSPECTION)
(See 041113 POWER BRAKE UNIT REMOVAL/
INSTALLATION)
Dual proportioning valve (without ABS) or brake
pipe joint (with ABS)
(See 041113 DUAL PROPORTIONING VALVE
(WITHOUT ABS) INSPECTION )
(See 041114 DUAL PROPORTIONING VALVE
(WITHOUT ABS) AND BRAKE PIPE JOINT (WITH
ABS) REPLACEMENT )
End Of Sie
04112
10
11
12
13
14
15
1712-1U-01G(04-11).fm 3
A3U041143001W01
Note
The brakes should be bled whenever a brake line is disconnected. If a hydraulic line is disconnected at
the master cylinder, start at the slave cylinder farthest from the brake master cylinder, and move to the
next farthest slave cylinder until all 4 cylinders have been bled. If the disconnection point is anywhere
except the master cylinder, start at the point closest to the disconnection, and move to the next closest
slave cylinder until all 4 cylinders have been bled.
Specified fluid
SAEJ1703 or FMVSS 116 DOT-3
1.
2.
3.
4.
5.
On level ground, jack up the vehicle and support it evenly on safety stands.
Remove the bleeder cap and attach a vinyl tube to the bleeder screw.
Place the other end of the vinyl tube in a clear, fluid filled container.
The first person depresses the brake pedal a few times, and then holds it in the depressed position.
The second person loosens the bleeder screw,
drains out the fluid and closes the screw using the
SST.
6. Repeat Steps 4 and 5 until no air bubbles are
seen. The reservoir should be kept about 3/4 full
during bleeding to prevent air from reentering the
lines.
0411
Tightening torque
5.98.8 Nm {6090 kgfcm, 5378 inlbf}
7. Inspect for correct brake operation.
8. Verify that there is no fluid leakage. Wipe off any
spilled fluid immediately.
9. After bleeding the brakes, add brake fluid to the maximum level.
X3U411WA0
End Of Sie
VACUUM HOSE CHECK VALVE INSPECTION (POWER BRAKE UNIT)
A3U041143980W01
End Of Sie
X3U411WA1
A3U041143300W01
04113
1712-1U-01G(04-11).fm 4
X3U411WA2
X3U411WA3
04114
1712-1U-01G(04-11).fm 5
End Of Sie
0411
X3U411WA5
A3U041143300W02
End Of Sie
X3U411WA6
A3U041166490W01
Y3U411WA8
A3U0411W001
End Of Sie
04115
1712-1U-01G(04-11).fm 6
A3U041143400W01
X3U411WA9
Z5U0411W130
04116
Z5U0411W131
1712-1U-01G(04-11).fm 7
Push rod
Too short
Too long
0411
Z5U0411W132
Z5U0411W133
Z5U0411W134
04117
1712-1U-01G(04-11).fm 8
Z5U0411W135
Z5U0411W136
Z5U0411W134
ZM
1. Place the SST atop the master cylinder. Turn the
adjusting bolt until it touches the bottom of the
push rod hole in the piston.
2. Apply 66.7 kPa {500 mmHg, 19.7 inHg} vacuum
to the power brake unit using a vacuum pump.
X3U411WAA
04118
1712-1U-01G(04-11).fm 9
X3U411WAB
End Of Sie
0411
X3U411WAC
A3U041143540W01
Y3U411WA1
X3U411WAD
End Of Sie
04119
1712-1U-01G(04-11).fm 10
A3U041143400W02
Caution
If the master cylinder body is damaged, replace the unit as an assembly. When securing the
master cylinder in a vise, tighten only the flange of the master cylinder.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
Z3U0411W011
.
1
2
3
4
5
6
7
8
9
10
Cap set
Float
Screw
Reservoir
Joint bushing
Fluid level sensor
Snap ring
Spacer
Piston guide
O-ring
041110
11
12
13
14
15
16
17
Cup
Primary piston stopper
Primary piston
Stop screw and O-ring (without ABS)
(See041111 Stop Screw and O-ring (without
ABS) Assembly Note)
Stop pin and O-ring (with ABS)
(See 041111 Stop Pin and O-ring (with ABS)
Assembly Note)
Secondary piston
Master cylinder body
1712-1U-01G(04-11).fm 11
0411
X3U411WAG
End Of Sie
X3U411WAH
A3U041143800W01
041111
1712-1U-01G(04-11).fm 12
Pedal force
200 N {20 kgf, 44 lbf}
Fluid pressure
650 kPa {7 kgf/cm2, 94 psi} min.
600 kPa {6 kgf/cm2, 87 psi} min.
2. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa {500 mmHg, 19.7 inHg}.
If the fluid pressure is within the specification, the unit is operating.
If the fluid pressure is not as specified, inspect for damage on the check valve or vacuum hose, and fluid
leakage of the hydraulic line. Repair as necessary, and inspect again.
Engine type
ZM
FS
End Of Sie
041112
Pedal force
200 N {20 kgf, 44 lbf}
Fluid pressure
6,500 kPa {66 kgf/cm2, 943 psi} min.
7,200 kPa {73 kgf/cm2, 1,044 psi} min.
1712-1U-01G(04-11).fm 13
A3U041143800W02
Vacuum hose
Snap pin
Clevis pin
Nut
Power brake unit
Gasket
Fork
Nut
0411
End Of Sie
X3U411WAK
A3U041143900W01
X3U411WAL
A3U0411W003
Fluid pressure
Engine type
ZM
FS
A'
2,900 {30, 430}200 {2, 30}
3,400 {35, 500}300 {3, 40}
B
5,900 {60, 850}
5,900 {60, 850}
B'
3,800 {39, 550}300 {3, 40}
4,200 {42.5, 600}400 {4, 60}
End Of Sie
041113
1712-1U-01G(04-11).fm 14
A3U041143900W02
Z3U0411W001
.
1
2
Brake pipe
Bolt
Dual Proportioning Valve (Without ABS) or Brake Pipe Joint (With ABS) Installation Note
1. Install the dual proportioning valve so that the R
mark faces the left side of the vehicle.
End Of Sie
X3U411WAP
A3U041133980W01
041114
1712-1U-01G(04-11).fm 15
Y3U411WA4
041115
0411
1712-1U-01G(04-11).fm 16
End Of Sie
X3U411WAS
041116
1712-1U-01G(04-11).fm 17
A3U041133980W02
0411
Z3U0411W003
.
1
2
3
4
5
Flexible hose
Cap (type A only)
Guide pin
Caliper
M-spring (type A only)
6
7
8
9
Disc pad
(See 041118 Disc Pad Installation Note)
Guide plate
Mounting support
Disc plate
(See 041118 Disc Plate Removal Note)
(See 041118 Disc Plate Installation Note)
041117
1712-1U-01G(04-11).fm 18
X3U411WAU
End Of Sie
X3U411WAV
041118
1712-1U-01G(04-11).fm 19
A3U041133630W01
0411
Z3U0411W004
.
1
2
3
4
5
6
End Of Sie
041119
1712-1U-01G(04-11).fm 20
A3U041133990W01
Dust seal
Piston
(See 041120 Piston Disassembly Note)
Piston seal
(See 041120 Piston Seal Disassembly Note)
Bleeder cap
Bleeder screw
(See 041121 Bleeder Screw Assembly Note)
Caliper body
Boot
Z3U0411W005
X3U411WAY
X3U411WAZ
041120
1712-1U-01G(04-11).fm 21
End Of Sie
0411
X3U411WB0
A3U041126980W01
W6U411WB7
End Of Sie
041121
1712-1U-01G(04-11).fm 22
A3U041126980W02
A3U0411W101
.
1
2
3
4
5
6
7
8
9
10
Shim
Guide plate
Mounting support
Disc plate
(See 041118 Disc Plate Removal Note)
(See 041118 Disc Plate Installation Note)
End Of Sie
W6U411WB9
041122
1712-1U-01G(04-11).fm 23
A3U041126630W01
0411
Z3U0411W009
.
1
2
3
4
5
6
Disc pad
(See 041122 Disc Pad Installation Note)
Shim
Guide plate
End Of Sie
041123
1712-1U-01G(04-11).fm 24
A3U041126990W01
Z3U0411W010
.
1
2
3
4
5
6
7
8
Screw plug
Dust seal
Piston
(See 041124 Piston Disassembly Note)
(See 041125 Piston Assembly Note)
Manual adjustment gear
Snap ring
Adjusting bolt
O-ring
Connecting link
9
10
11
12
13
14
15
16
Piston seal
(See 041120 Piston Seal Disassembly Note)
Spring
Operating lever
Boot
Bleeder screw
Boot
Boot
Caliper body
W6U411WBC
041124
1712-1U-01G(04-11).fm 25
End Of Sie
W6U411WBD
A3U041126250W01
X3U411WB1
X3U411WB2
End Of Sie
X3U411WB3
041125
0411
1712-1U-01G(04-11).fm 26
A3U041126250W02
Y3U411WA6
1
2
3
5
6
7
8
Hub cap
Screw
Brake drum
(See 041127 Brake Drum Removal Note)
(See 041127 Brake Drum Installation Note)
Locknut
(See 03114 Locknut Removal Note)
(See 03117 Locknut Installation Note)
Wheel hub
ABS wheel-speed sensor (if equipped)
Return spring
Lever spring
041126
9
10
11
12
13
14
15
16
17
18
19
1712-1U-01G(04-11).fm 27
X3U411WB5
0411
End Of Sie
WHEEL CYLINDER DISASSEMBLY/ASSEMBLY
A3U041126610W01
Caution
Replace the wheel cylinder component if a problem is found.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
X3U411WB6
1
2
3
4
Boot
Wheel cylinder piston
Piston cup
Wheel cylinder spring
5
6
7
Bleeder cap
Bleeder screw
(See 041121 Bleeder Screw Assembly Note)
Wheel cylinder body
End Of Sie
041127