Product Detail Manual BR

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QUICK REFERENCE INDEX
Table of Contents

BR-1

BRAKE SYSTEM

F BRAKES

CONTENTS

SECTION BR A

PRECAUTIONS .......................................................... 3

Precautions for Supplemental Restraint System

(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-

SIONER” .................................................................. 3

Precautions for Brake System .................................. 3

Wiring Diagrams and Trouble Diagnosis .................. 3

PREPARATION ........................................................... 4

Commercial Service Tools ........................................ 4

NOISE, VIBRATION, AND HARSHNESS (NVH)

TROUBLESHOOTING ................................................ 5

NVH Troubleshooting Chart ..................................... 5

BRAKE PEDAL .......................................................... 6

Inspection and Adjustment ....................................... 6

Removal and Installation .......................................... 7

REMOVAL ............................................................. 7

INSPECTION AFTER REMOVAL ......................... 7

INSTALLATION ..................................................... 8

BRAKE FLUID ............................................................ 9

Changing Brake Fluid ............................................... 9

Bleeding Brake System ............................................ 9

Checking Brake Fluid Level ..................................... 9

BRAKE PIPING AND HOSE .................................... 10

Hydraulic Circuit ..................................................... 10

Front Brake Piping and Hose ................................. 10

REMOVAL ........................................................... 10

INSTALLATION ................................................... 10

Rear Brake Piping and Hose ...................................11

REMOVAL ............................................................11

INSTALLATION ....................................................11

Inspection ............................................................... 12

BRAKE MASTER CYLINDER .................................. 13

Removal and Installation ........................................ 13

REMOVAL ........................................................... 13

INSTALLATION ................................................... 13

Disassembly and Assembly ................................... 14

COMPONENTS .................................................. 14

DISASSEMBLY ................................................... 14

INSPECTION AFTER REMOVAL ....................... 15

ASSEMBLY ......................................................... 15

BRAKE BOOSTER ................................................... 17

On-vehicle Service ................................................. 17

OPERATING CHECK .......................................... 17

AIRTIGHT CHECK .............................................. 17

Removal and Installation ........................................ 17

REMOVAL ........................................................... 17

INSPECTION AFTER REMOVAL ....................... 18

INSTALLATION ................................................... 18

VACUUM LINES ....................................................... 19

Removal and Installation ........................................ 19

Inspection ............................................................... 19

HOSES AND CONNECTORS ............................. 19

CHECK VALVE .................................................... 19

FRONT DISC BRAKE ............................................... 20

Component ............................................................. 20

On-vehicle Service ................................................. 20

INSPECTION ...................................................... 20

PAD REPLACEMENT ......................................... 21

Removal and Installation ........................................ 21

REMOVAL ........................................................... 21

INSTALLATION ................................................... 22

Disassembly and Assembly .................................... 22

DISASSEMBLY ................................................... 22

INSPECTION AFTER DISASSEMBLY ................ 23

ASSEMBLY ......................................................... 24

Brake Burnishing Procedure ................................... 25

REAR DISC BRAKE ................................................. 26

Component ............................................................. 26

On-vehicle Service ................................................. 26

INSPECTION ...................................................... 26

PAD REPLACEMENT ......................................... 27

Removal and Installation ........................................ 28

REMOVAL ........................................................... 28

INSTALLATION ................................................... 28

Disassembly and Assembly .................................... 29

DISASSEMBLY ................................................... 29

INSPECTION AFTER DISASSEMBLY ................ 29

ASSEMBLY ......................................................... 30

Brake Burnishing Procedure ................................... 30

DUAL PROPORTIONING VALVE ............................. 31

Inspection ............................................................... 31

BR-2

SERVICE DATA AND SPECIFICATIONS (SDS) ...... 32

General Specifications ............................................ 32

Disc Brake .............................................................. 32

Brake Pedal ............................................................32

Dual Proportioning Valve ........................................32

Brake Booster .........................................................32

PRECAUTIONS

BR-3

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT

BELT PRE-TENSIONER” EFS001FF

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along

with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain

types of collision. Information necessary to service the system safely is included in the SRS and SB section of

this Service Manual.

WARNING:

●To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death

in the event of a collision which would result in air bag inflation, all maintenance must be per-

formed by an authorized NISSAN/INFINITI dealer.

●Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-

sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air

Bag Module, see the SRS section.

●Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connec-

tors.

Precautions for Brake System EFS001FG

●Recommended fluid is brake fluid “DOT 3”.

●Never reuse drained brake fluid.

●Be careful not to splash brake fluid on painted areas.

●To clean or wash all parts of master cylinder, disc brake cal-

iper and wheel cylinder, use clean brake fluid.

●Never use mineral oils such as gasoline or kerosene. They

will ruin rubber parts of the hydraulic system.

●Use flare nut wrench when removing and installing brake

tube.

●Always tighten brake lines to specified torque when install-

ing.

●Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing

pads or linings, or if a soft pedal occurs at very low mileage.

Refer to BR-30 (Front disc brake) and BR-25 (Rear disc brake) for brake burnishing procedure.

WARNING:

●Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.

Wiring Diagrams and Trouble Diagnosis EFS001FH

When you read wiring diagrams, refer to the following:

●Refer to GI-12, "How to Read Wiring Diagrams" .

●Refer to PG-3, "POWER SUPPLY ROUTING CIRCUIT" for power distribution circuit.

When you perform trouble diagnosis, refer to the following:

●Refer to GI-10, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES" .

●Refer to GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" .

●For trouble diagnoses of models with ABS, refer to BRC-7, "TROUBLE DIAGNOSIS" .

●For trouble diagnoses of models with TCS even if the diagnostic items are related to the ABS system,

refer to BRC-50, "TROUBLE DIAGNOSIS" .

SBR686C

BR-4

PREPARATION

PREPARATION PFP:00002

Commercial Service Tools EFS001FI

Tool name Description

1 Flare nut crowfoot

2 Torque wrench

Removing and installing each brake piping

a: 10 mm (0.39 in)

Brake fluid pressure gauge Measuring brake fluid pressure

Power tool Loosening bolts and nuts

S-NT360

NT151

PBIC0190E

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

BR-5

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart EFS001FJ

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

X: Applicable

Reference page

BR-20, BR-26

BR-23, BR-29

BR-20, BR-26

BR-23, BR-29

BR-25

BR-20, BR-26

FAX-4

FSU-4, RSU-4

WT-2

PS-5

Possible cause and

SUSPECTED PARTS

Pads - damaged

Pads - uneven wear

Shims damaged

Rotor imbalance

Rotor damage

Rotor runout

Rotor deformation

Rotor deflection

Rotor rust

Rotor thickness variation

DRIVE SHAFT

AXLE

SUSPENSION

TIRES

ROAD WHEEL

STEERING

Symptom BRAKE

Noise XXX XXXXXX

Shake X XXXXXX

Shimmy, Judder XXXXXXX XXXXX

BR-6

BRAKE PEDAL

BRAKE PEDAL PFP:46501

Inspection and Adjustment EFS002O0

Inspect the brake pedal free height "H" from dash reinforcement panel. Adjust if necessary.

1. Loosen the stop lamp switch and ASCD switch (if equipped) by

turning 45° counterclockwise.

2. Loosen lock nut on the input rod, then turn input rod to adjust the

pedal to specified height. When finished adjusting, tighten lock

nut.

CAUTION:

Make sure that the screw portion of the end of input rod is

located inside the clevis.

3. With the pedal pulled up and held by hand, press the stop lamp

switch and the ASCD switch (if equipped) in until threaded ends

contact rubber stops.

4. With the threaded ends of the stop lamp switch and ASCD switch (if equipped) contacting the rubber

stops, turn the switches 45° clockwise to lock in place.

CAUTION:

Make sure that the gap (C1 , C2 ) between the rubber stops and switch ends are within specifica-

tion.

5. Check the pedal play.

CAUTION:

Make sure that the stop lamp goes off when the pedal is released.

6. Start the engine and check the height of the brake pedal when depressing it.

Free height "H" Refer to BR-32, "Brake Pedal" .

Clearance between pedal

stopper and threaded end of

stop lamp switch and ASCD

switch "C1, C2"

0.74 - 1.96 mm (0.0291 - 0.0772 in)

Pedal height (with engine

running, brake pedal force

490 N {50 kgf, 110 lbf}) "H2"

M/T vehicle : More than 84 mm (3.31 in)

A/T vehicle : More than 90.3 mm (3.55 in)

Pedal play "A" 3 - 11 mm (0.12 - 0.43 in)

WFIA0022E

Lock nut : 16 - 21 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)

SBR229E

BRAKE PEDAL

BR-7

Removal and Installation EFS001FL

REMOVAL

WARNING:

Do not deform the brake tube.

1. Remove the instrument panel lower cover on driver side. Refer to IP-13, "Driver Lower Instrument Panel" .

2. Remove the stop lamp switch from the pedal assembly.

3. Remove snap pins and clevis pins from the clevis of brake booster.

4. Remove mounting nuts from the pedal assembly, then carefully remove the brake booster from the bulk-

head so as not to deform the brake tube.

5. Remove the clevis of brake booster from the input rod.

6. Remove the steering column assembly from the steering member.

7. Pushing down the pedal assembly to the right, remove it from the vehicle while keeping the steering post

bracket stay out.

INSPECTION AFTER REMOVAL

Check brake pedal for following items.

●Brake pedal bend

●Clevis pin deformation

●Crack of any welded portion

●Crack or deformation of clevis pin stopper

WFIA0023E

1. ASCD cancel switch 2. Stop lamp switch 3. Clevis pin

SBR997

BR-8

BRAKE PEDAL

INSTALLATION

●Install all parts in the reverse order of removal.

●After installing the brake pedal assembly in the vehicle, be sure to adjust it.

BRAKE FLUID

BR-9

BRAKE FLUID PFP:KN100

Changing Brake Fluid EFS002O1

CAUTION:

●Refill with new brake fluid “DOT 3”.

●Always keep fluid level higher than minimum line on reservoir tank.

●Never reuse drained brake fluid.

●Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is

splashed on painted areas, wash it away with water immediately.

1. Connect a vinyl tube and container to the air bleeder.

2. Depressing the brake pedal, drain the brake fluid gradually from the air bleeder of each wheel.

3. Turn the ignition switch to OFF and disconnect the ABS actuator and control unit connector.

4. Clean inside of reservoir tank, and refill with new brake fluid.

5. Loosen the air bleeder, depress the pedal slowly to the full stroke and then release it. Repeat the proce-

dure every 2 or 3 seconds until the new brake fluid comes out, then close the air bleeder while depressing

the pedal. Refer to BR-9, "Bleeding Brake System" .

Bleeding Brake System EFS001FN

CAUTION:

●Carefully monitor brake fluid level at master cylinder during bleeding operation.

●Fill reservoir with new brake fluid “DOT 3”. Make sure it is full at all times while bleeding air out of

system.

●Place a container under master cylinder to avoid spillage of brake fluid.

●Do not loosen the connecting portion of the actuator during air bleeding.

1. For models with ABS, turn ignition switch OFF and disconnect ABS actuator and control unit connectors

or battery ground cable.

2. Connect a transparent vinyl tube to air bleeder valve.

3. Fully depress brake pedal several times.

4. With brake pedal depressed, open air bleeder valve to release

air.

5. Close air bleeder valve.

6. Release brake pedal slowly.

7. Tighten air bleeder valve.

8. Repeat steps 2. through 7. until clear brake fluid comes out of air

bleeder valve.

9. Bleed air in the following order.

Right rear brake → Left front brake → Left rear brake → Right front brake

Checking Brake Fluid Level EFS001FO

●Check fluid level in reservoir tank. It should be between Max and

Min lines on reservoir tank.

●Visually check around the reservoir tank for leaks.

●If fluid level is extremely low, check brake system for leaks.

●Release parking brake lever and see if brake warning lamp goes

off. If not, check brake system for leaks.

Tightening torque : 7 - 9 N·m (0.7 - 0.9 kg-m,

61 - 78 in-lb)

SBR419C

LFIA0096E

BR-10

BRAKE PIPING AND HOSE

BRAKE PIPING AND HOSE PFP:46210

Hydraulic Circuit EFS001FP

Front Brake Piping and Hose EFS001FQ

REMOVAL

CAUTION:

●Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is

splashed on painted areas, wash it away with water immediately.

●All hoses must be free from excessive bending, twisting and pulling.

●Cover openings to prevent entrance of dirt whenever disconnecting brake line.

1. Connect vinyl tube and container to air bleeder valve.

2. Drain brake fluid from each air bleeder valve by depressing brake pedal.

3. Remove flare nut connecting brake tube and hose, then with-

draw lock spring.

4. Remove the connecting bolt and disconnect the caliper assem-

bly from the brake hose.

5. Remove lock plates from the mounting portion of the brake tube

and the mounting portion of the strut.

INSTALLATION

CAUTION:

●Refill with new brake fluid “DOT 3”.

●Never reuse drained brake fluid.

1. Attach the brake hose to the caliper assembly, then tighten the connecting bolts to the specified torque.

CAUTION:

●Correctly attach the brake hose to the cylinder body.

●The copper washer of the connecting bolt has to be replaced with a new one every time the fit-

ting is disconnected.

2. Attach the brake hose to the strut, then install a lock plate.

3. Attach the brake hose to the brake tube and temporarily tighten the flare nut as much as possible by hand,

then install a lock plate.

WFIA0075E

WFIA0087E

BRAKE PIPING AND HOSE

BR-11

4. Tighten all flare nuts and connecting bolts.

5. Refill until new brake fluid comes out of each air bleeder valve.

6. Bleed air. Refer to BR-9, "Bleeding Brake System" .

Rear Brake Piping and Hose EFS001FR

REMOVAL

CAUTION:

●Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is

splashed on painted areas, wash it away with water immediately.

●All hoses must be free from excessive bending, twisting and pulling.

●Cover openings to prevent entrance of dirt whenever disconnecting brake line.

1. Connect vinyl tube and container to air bleeder valve.

2. Drain brake fluid from each air bleeder valve by depressing brake pedal.

3. Remove flare nut connecting brake tube and hose, then with-

draw lock spring.

4. Remove the lock plate and the connecting bolt, and then remove

it from the vehicle.

INSTALLATION

CAUTION:

●Refill with new brake fluid “DOT 3”.

●Never reuse drained brake fluid.

1. Attach the brake hose to the brake tube and temporarily tighten the flare nut as much as possible by hand.

2. Install the brake hose with a lock plate, then tighten the connecting bolt to the specified torque. Tighten the

flare nut with a torque wrench to specification.

3. Refill until new brake fluid comes out of each air bleeder valve.

4. Bleed air. Refer to BR-9, "Bleeding Brake System" .

Specification

Flare nut : 5 - 18 N·m (1.5 - 1.8 kg-m,

11 - 13 ft-lb)

Connecting bolt : 17 - 20 N·m (1.7 - 2.0 kg-m,

12 - 14 ft-lb)

SBR686C

WFIA0088E

Specification

Flare nut : 5 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

Connecting

bolt : 17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)

SBR686C

BR-12

BRAKE PIPING AND HOSE

Inspection EFS001FS

CAUTION:

If leakage occurs around joints, retighten or, if necessary,

replace damaged parts.

1. Check brake lines (tubes and hoses) for leaks, cracks, distor-

tion, deformation, without interfering with other parts or loosen-

ing connecting parts, deterioration or other damage. Replace

any damaged parts.

2. Apply the stepping force of 784 N (80 kgf, 176 lbf) to the brake

pedal with the engine running and keep it for about 5 seconds,

then check each part for leaks.

SBR389C

BRAKE MASTER CYLINDER

BR-13

BRAKE MASTER CYLINDER PFP:46010

Removal and Installation EFS001FT

CAUTION:

Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is

splashed on painted areas, wash it away with water immediately.

REMOVAL

1. Connect a vinyl tube and container to air bleeder valve.

2. Drain brake fluid from each air bleeder valve by depressing brake pedal to empty fluid from the master cyl-

inder. Remove the harness connector of the liquid level sensor.

3. Remove brake pipe flare nuts.

4. Remove master cylinder mounting nuts.

INSTALLATION

CAUTION:

●Refill with new brake fluid “DOT 3”.

●Never reuse drained brake fluid.

1. Place master cylinder onto brake booster and secure mounting nuts lightly.

2. Tighten the mounting nuts.

3. Fill the reservoir tank with new brake fluid.

4. Plug all ports on master cylinder with fingers to prevent air suc-

tion while releasing brake pedal.

5. Have driver depress brake pedal slowly several times until no air

comes out of master cylinder.

6. Fit brake lines to master cylinder.

7. Tighten flare nuts.

8. Bleed air from brake system. Refer to BR-9, "Bleeding Brake

System" .

Tightening torque : 12 - 15 N·m (1.2 - 1.5 kg-m,

9 - 11 ft-lb)

Tightening torque : 15 - 18 N·m (1.5 - 1.8 kg-m,

11 - 13 ft-lb)

WFIA0026E

BR-14

BRAKE MASTER CYLINDER

Disassembly and Assembly EFS001FU

COMPONENTS

DISASSEMBLY

1. Bend claws of stopper cap outward.

1. Reservoir cap 2. O-ring 3. Reservoir tank

4. Seal 5. Cylinder body 6. O-ring

7. Piston stopper 8. Secondary piston assembly 9. Primary piston assembly

10. Stopper cap

WFIA0037E

SBR938A

BRAKE MASTER CYLINDER

BR-15

2. Remove piston stopper while piston is pushed into cylinder.

3. Remove piston assemblies.

If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet.

4. Draw out reservoir tank.

INSPECTION AFTER REMOVAL

Master Cylinder Inner Wall

●Check the inner wall of the cylinder for damage, abrasion, corrosion and pin holes. If NG, replace the cyl-

inder.

Piston

●Check for deformation of or scratches on piston cups.

ASSEMBLY

1. Insert secondary piston assembly. Then insert primary piston

assembly.

●Pay attention to alignment of secondary piston slit with valve

stopper mounting hole of cylinder body.

2. Install stopper cap.

Before installing stopper cap, ensure that claws are bent inward.

3. Push reservoir tank seals into cylinder body.

4. Push reservoir tank into cylinder body.

SBR231C

SBR354C

SBR940A

BR-16

BRAKE MASTER CYLINDER

5. Install piston stopper while piston is pushed into cylinder.

SBR435B

BRAKE BOOSTER

BR-17

BRAKE BOOSTER PFP:47200

On-vehicle Service EFS001FV

OPERATING CHECK

1. Stop engine and depress brake pedal several times. Check that

pedal stroke does not change.

2. Depress brake pedal, then start engine. If pedal goes down

slightly, operation is normal.

AIRTIGHT CHECK

●Start engine, and stop it after one or two minutes. Depress brake

pedal several times slowly. The pedal should go further down

the first time, and then it should gradually rise thereafter.

●Depress brake pedal while engine is running, and stop engine

with pedal depressed. The pedal stroke should not change after

holding pedal down for 30 seconds.

Removal and Installation EFS001FW

REMOVAL

CAUTION:

●Be careful not to splash brake fluid on painted areas; it may

cause paint damage. If brake fluid is splashed on painted

areas, wash it away with water immediately.

●Be careful not to deform or bend brake pipes during

removal of booster.

●Replace clevis pin if damaged.

●Refill with new brake fluid “DOT 3”.

●Never reuse drained brake fluid.

●Take care not to damage brake booster mounting bolt

thread when installing. Due to the acute angle of installa-

tion, the threads can be damaged with the dash panel.

1. Remove the vacuum piping from the brake booster.

2. Remove the master cylinder.

3. Remove snap pin and clevis pin from clevis, then remove the input rod from the brake pedal.

4. Remove the mounting nuts from the brake booster and the brake pedal assembly.

5. Remove the booster assembly from the engine compartment.

SBR002A

SBR365AA

SBR232CB

BR-18

BRAKE BOOSTER

INSPECTION AFTER REMOVAL

Output Rod Length Check

1. Apply vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg) to brake

booster with a hand vacuum pump.

2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.

3. Check output rod length.

INSTALLATION

1. Adjust the length of the input rod by loosening the lock nut so

that the dimensions shown match the standard value.

2. Tighten the lock nut temporarily and install the booster assembly

in the vehicle.

3. Connect the brake pedal part to the clevis part of the input rod.

4. Tighten the mounting nut for the pedal assembly to the specified

torque.

5. Install the master cylinder in the booster assembly.

6. Adjust the height and play of the brake pedal.

7. Tighten the lock nut of the input rod to the specified torque.

8. Bleed air. Refer to BR-9, "Bleeding Brake System" .

Specified length : 10.275 - 10.525 mm

(0.4045 - 0.4144 in)

SBR208E

Standard value : 125 mm (4.92 in)

: 13 - 16 N·m (1.3 - 1.6 kg-m,

9 - 12 ft-lb)

: 16 - 21 N·m (1.6 - 2.2 kg-m,

12 - 15 ft-lb)

SBR237EA

VACUUM LINES

BR-19

VACUUM LINES PFP:41920

Removal and Installation EFS001FX

CAUTION:

When installing vacuum hoses, pay attention to the following points.

●Do not apply any oil or lubricants to vacuum hose with

check valve.

●Insert vacuum tube into vacuum hose as shown.

●Install vacuum hose with internal check valve, paying atten-

tion to its direction.

Inspection EFS001FY

HOSES AND CONNECTORS

Check vacuum lines and connections for airtightness, improper attachment, chafing and deterioration.

CHECK VALVE

Check vacuum with a vacuum pump.

SBR225B

Connect to booster side Vacuum should exist

Connect to engine side Vacuum should not exist

SBR844B

BR-20

FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

Component EFS001FZ

WARNING:

Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other

materials.

CAUTION:

●When cylinder body is open, do not depress the brake pedal because the piston will pop out.

●It is not necessary to remove connecting bolt except for disassembly or replacement of caliper

assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.

●Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing

pads.

●Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing

pads or linings or if a soft pedal occurs at very low mileage.

Refer to BR-25, "Brake Burnishing Procedure" .

On-vehicle Service EFS002O8

INSPECTION

Pad Thickness

●Remove a wheel with the vehicle lifted up, and then check the

thickness of the pad from the inspection hole of the cylinder

body. If necessary, check it with a micrometer.

1. Main pin 2. Pin boot 3. Torque member fixing bolt

4. Torque member 5. Shim cover 6. Inner shim

7. Inner pad 8. Pad retainer 9. Outer pad

10. Outer shim 11. Connecting bolt 12. Copper washer

13. Main pin bolt 14. Bleed valve 15. Cylinder body

16. Piston seal 17. Piston 18. Piston boot

19. Pad return spring

WFIA0086E

Standard pad thickness : 11 mm (0.43 in)

Pad wear limit : 2.0 mm (0.079 in)

BRA0010D

FRONT DISC BRAKE

BR-21

PAD REPLACEMENT

Removal

●If shims are rusted or show peeling of the rubber coat, replace them with new shims.

●Whenever the brake pads are replaced, the inner shim, the outer shim and the shim cover have to be

replaced as a set.

1. Remove master cylinder reservoir cap.

2. Remove pin bolt, using power tool.

3. Suspend the cylinder body with wire. Then remove pads with

retainers, inner and outer shims and pad return springs.

Installation

1. Attach the inner shim and shim cover to the inner pad and attach the outer shim to the outer pad.

2. Apply grease to the contact surface of pad retainer with the pads, then attach the pad retainer, pads and

pad return spring to the torque member.

3. Install the cylinder body to the torque member.

4. Insert a main pin bolt (on the lower side) and tighten it to specification. Refer to BR-20, "Component" .

5. Check the brakes for drag.

CAUTION:

Burnish the brake contact surfaces after refinishing or replacing brake rotors, after replacing pads, or

if a soft pedal occurs at very low mileage. Refer to BR-25, "Brake Burnishing Procedure" .

Removal and Installation EFS002O9

REMOVAL

1. Connect the vinyl tube and container to the air bleeder.

2. Depress the brake pedal and drain the brake fluid gradually from the air bleeder.

3. Remove torque member fixing bolts using power tool and brake

hose connecting bolt.

4. Remove the brake caliper, using power tool.

5. Remove brake rotor.

SBR976B

SBR932C

SBR979B

BR-22

FRONT DISC BRAKE

INSTALLATION

CAUTION:

●Refill with new brake fluid “DOT 3”.

●Never reuse drained brake fluid.

1. Install brake rotor.

2. Install the brake caliper and tighten main pin bolt to specification. Refer to BR-20, "Component" .

CAUTION:

When installing the caliper assembly in the vehicle, wipe oil from the seating surface of the

knuckle spindle washer and the mounting surface of the caliper assembly.

3. Install brake hose to caliper and tighten connecting bolt to spec-

ification. Refer to BR-20, "Component" .

CAUTION:

●The copper washer of the connecting bolt has to be

replaced every time the fitting is disconnected.

●Correctly attach the brake hose to the projecting portion

of the cylinder body.

4. Bleed air from brake system. Refer to BR-9, "Bleeding Brake

System" .

CAUTION:

Burnish the brake contact surfaces after refinishing or replac-

ing brake rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-25,

"Brake Burnishing Procedure" .

Disassembly and Assembly EFS002OA

DISASSEMBLY

1. Push out piston with piston boot using compressed air.

WARNING:

Do not place your fingers in front of piston.

2. Remove piston seal with a suitable tool.

CAUTION:

Do not scratch or score cylinder wall.

SBR980B

SBR772

WFIA0029E

FRONT DISC BRAKE

BR-23

INSPECTION AFTER DISASSEMBLY

Caliper

CYLINDER BODY

CAUTION:

Use brake fluid to clean. Never use mineral oil.

●Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If

any of the above conditions are observed, replace cylinder body.

●Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine

emery paper. Replace cylinder body if necessary.

TORQUE MEMBER

Check for wear, cracks or other damage. Replace if necessary.

PISTON

CAUTION:

Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are

stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-

ditions are observed.

SLIDE PIN, PIN BOLT AND PIN BOOT

Check for wear, cracks or other damage. Replace if any of the conditions are observed.

Rotor

VISUAL INSPECTION

Check rotor for roughness, cracks or chips.

RUNOUT

1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).

2. Check runout using a dial indicator.

Make sure that wheel bearing axial end play is within the specifi-

cations before measuring runout. Refer to FAX-5, "Front Wheel

Bearing" .

3. Change relative positions of rotor and wheel hub so that runout

is minimized.

4. If the runout is still out of specification, turn rotor with on-car

brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equiva-

lent).

THICKNESS

●Check thickness using a micrometer.

●If thickness variation exceeds the specification, turn rotor with

on-car brake lathe.

Maximum runout : 0.07 mm (0.0028 in)

SBR019B

Thickness variation

(At least 8 positions) : Maximum 0.015 mm

(0.0006 in)

Rotor thickness

repair limit : 22.0 mm (0.866 in)

SBR020B

BR-24

FRONT DISC BRAKE

ASSEMBLY

1. Apply rubber grease to new piston seal and insert seal into

groove on cylinder body.

2. With piston boot fitted to piston, insert piston boot into groove on

cylinder body and install piston.

3. Make sure piston boot is properly installed.

SBR574

WFIA0030E

WFIA0031E

WFIA0032E

FRONT DISC BRAKE

BR-25

Brake Burnishing Procedure EFS001G4

Burnish the brake contact surfaces according to the following procedure after refinishing or replacing brake

rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.

CAUTION:

Only perform this procedure under safe road and traffic conditions. Use extreme caution.

1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).

2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH).

Adjust brake pedal/foot pressure so that vehicle stopping time equals 3 to 5 seconds.

3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.

4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

BR-26

REAR DISC BRAKE

REAR DISC BRAKE PFP:44000

Component EFS001G5

WARNING:

Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other

materials.

CAUTION:

●When cylinder body is open, do not depress brake pedal because piston will pop out.

●Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing

pads.

●It is not necessary to remove connecting bolt except for disassembly or replacement of caliper

assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.

●Burnish the brake contact surfaces after refinishing or replacing brake rotors, after replacing pads

or linings, or if a soft pedal occurs at very low mileage.

Refer to BR-30, "Brake Burnishing Procedure" .

On-vehicle Service EFS002O5

INSPECTION

Pad Thickness

●Remove a wheel with the vehicle lifted up, and then check the

thickness of the pad from the inspection hole of the cylinder

body. If necessary, check it with a scale.

1. Main pin bolt 2. Pin boot 3. Torque member fixing bolt

4. Torque member 5. Shim cover 6. Inner shim

7. Inner pad 8. Pad retainer 9. Outer pad

10. Outer pad 11. Connecting bolt 12. Copper washer

13. Bleed valve 14. Cylinder body 15. Piston seal

16. Piston 17. Piston boot 18. Retainer

WFIA0089E

Standard pad thickness : 8 mm (0.31 in)

Pad wear limit : 1.5 mm (0.059 in)

BRA0010D

REAR DISC BRAKE

BR-27

PAD REPLACEMENT

Removal

●If shims are rusted or show peeling of the rubber coat, replace them with new shims.

●Whenever the brake pads are replaced, the inner shim, the outer shim and the shim cover have to be

replaced as a set.

1. Remove master cylinder reservoir cap.

2. Remove lower pin bolt, using power tool.

3. Open cylinder body upward and secure with wire. Then remove

pad retainers, and inner and outer shims.

Installation

1. Apply grease to the inner and outer shim, and then attach them to the pads.

2. Attach the pad retainer to the torque member, and then attach it to the pad.

3. When installing new pads, push piston back into cylinder body.

●Carefully monitor brake fluid level because brake fluid will return to the reservoir when pushing back

piston.

4. Close cylinder body down into the torque member.

5. Insert a main pin bolt and tighten it to specified torque. Refer to BR-26, "Component" .

6. Check the brake for drag.

CAUTION:

Burnish the brake contact surfaces refinishing or replacing brake rotors, after replacing pads, or if a

soft pedal occurs at very low mileage. Refer to BR-30, "Brake Burnishing Procedure" .

SBR090C

SBR042C

BR-28

REAR DISC BRAKE

Removal and Installation EFS002O6

REMOVAL

WARNING:

Clean brakes with a vacuum dust collector to minimize the hazard of airborne particles or other mate-

rials.

1. Connect the vinyl tube and container to the air bleeder.

2. Depress the brake pedal and drain the brake fluid gradually from the air bleeder.

3. Remove torque member fixing bolts using power tool and brake

hose connecting bolt.

4. Remove caliper and brake rotor. If the brake rotor cannot be removed, remove as follows:

●Make sure parking brake lever is completely disengaged.

●Hold down the brake rotor with the wheel nut and remove the brake rotor plug.

●Insert a flat-bladed screwdriver through the plug opening and

rotate the star wheel on the adjuster assembly in the direction

shown to loosen and retract the brake shoes.

●Remove wheel nuts and rotor.

INSTALLATION

CAUTION:

●Refill with new brake fluid “DOT 3”.

●Never reuse drained brake fluid.

1. Install brake rotor.

2. Install caliper assembly and tighten main pin bolt to specification. Refer to BR-26, "Component" .

3. Install brake hose to caliper and tighten connecting bolt to spec-

ification. Refer to BR-26, "Component" .

CAUTION:

●The copper washers for the connecting bolt have to be

replaced every time the fitting is disconnected.

4. Bleed air from brake system. Refer to BR-9, "Bleeding Brake

System" .

5. Adjust the parking brake. Refer to PB-3, "Adjustment" .

CAUTION:

Burnish the brake contact surfaces refinishing or replacing

brake rotors, after replacing pads, or if a soft pedal occurs at

very low mileage. Refer to BR-30, "Brake Burnishing Procedure" .

WFIA0078E

WFIA0018E

SBR093C

REAR DISC BRAKE

BR-29

Disassembly and Assembly EFS002O7

DISASSEMBLY

1. Remove piston boot retainer with a flat-bladed screwdriver.

2. Push out piston and piston boot with compressed air.

WARNING:

Do not place your finger in front of piston.

3. Remove piston seal with a suitable tool.

CAUTION:

Do not scratch or score cylinder wall.

INSPECTION AFTER DISASSEMBLY

Caliper

CYLINDER BODY

CAUTION:

Use brake fluid to clean. Never use mineral oil.

●Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If

any of the above conditions are observed, replace cylinder body.

●Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine

emery paper. Replace cylinder body if necessary.

TORQUE MEMBER

Check for wear, cracks or other damage. Replace if necessary.

PISTON

CAUTION:

Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are

stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-

ditions are observed.

SLIDE PIN, PIN BOLT AND PIN BOOT

Check for wear, cracks or other damage. Replace if any of the conditions are observed.

Rotor

VISUAL INSPECTION

Check rotor for roughness, cracks or chips.

SBR028A

SBR772

BR-30

REAR DISC BRAKE

RUNOUT

1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).

2. Check runout using a dial indicator.

Make sure that wheel bearing axial end play is within the specifi-

cations before measuring runout. Refer to RAX-5, "Rear Wheel

Bearing" .

3. Change relative positions of rotor and wheel hub so that runout

is minimized.

THICKNESS

Check thickness using a micrometer.

ASSEMBLY

1. Insert piston seal into groove on cylinder body.

2. With piston boot fitted to piston, insert piston boot into groove on

cylinder body and install piston.

3. Secure piston boot with retainer.

Brake Burnishing Procedure EFS001GA

Burnish the brake contact surfaces according to the following procedure after refinishing or replacing brake

rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.

CAUTION:

Only perform this procedure under safe road and traffic conditions. Use extreme caution.

1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).

2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH).

Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.

3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.

4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

Maximum runout : 0.07 mm (0.0028 in)

SBR019B

Rotor repair limit

Standard thickness : 9 mm (0.35 in)

Minimum thickness : 8 mm (0.31 in)

Thickness variation (At

least 8 positions) : Maximum 0.015 mm

(0.0006 in)

SBR020B

SBR044C

DUAL PROPORTIONING VALVE

BR-31

DUAL PROPORTIONING VALVE PFP:46400

Inspection EFS001GB

CAUTION:

●Carefully monitor brake fluid level at master cylinder.

●Use new brake fluid “DOT 3”.

●Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is

splashed on paint areas, wash it away with water immediately.

1. Connect Tool to air bleeders of front and rear brakes on either

LH and RH side.

2. Bleed air from the Tool.

3. Check fluid pressure by depressing brake pedal.

If output pressure is out of specification, replace dual proportion-

ing valve.

4. Bleed air after disconnecting the Tool. Refer to BR-9, "Bleeding

Brake System" .

SBR822BA

Applied pressure

(Front brake) : 7,355 kPa (75 kg/cm2, 1,067 psi)

Output pressure

(Rear brake) : 5,100 - 5,492 kPa (52 - 56 kg/cm2,

739 - 796 psi)

SBR823BA

BR-32

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications EFS001GC

Unit: mm (in)

Disc Brake EFS001GD

Unit: mm (in)

Brake Pedal EFS001GE

Unit: mm (in)

*: Measured from surface of dash reinforcement panel to surface of pedal pad

Dual Proportioning Valve EFS001GF

Unit: kPa (kg/cm2 , psi)

Brake Booster EFS001GG

Unit: mm (in)

Front brake

Brake model CLZ25VD disc brake

Cylinder bore diameter 57.2 (2.252)

Pad

Length × width × thickness 125.6 × 46 × 11 (4.94 × 1.81 × 0.43)

Rotor outer diameter × thickness 296 × 26 (11.65 × 1.02)

Rear brake

Brake model AD9V disc brake

Cylinder bore diameter 34.9 (1.3740)

Pad

Length × width × thickness 89.1 × 39.5 × 10 (3.508 × 1.555 × 0.31)

Rotor outer diameter × thickness 292 × 9 (11.50 × 0.35)

Master cylinder Cylinder bore diameter 23.81 (15/16)

Control valve Screw in type 30 × 0.4 (1.18 × 0.02)

Brake booster

Booster model M215T

Diaphragm diameter Primary 230 (9.06)

Secondary 205 (8.07)

Recommended brake fluid DOT 3

Brake model CLZ25VD AD9V

Pad wear limit Minimum thickness 2.0 (0.079) 1.5 (0.059)

Rotor repair limit Maximum runout 0.07 (0.0028) 0.07 (0.0028)

Minimum thickness 22.0 (0.866) 8 (0.31)

Free height “H”* M/T 164.1 - 174.1 (6.46 - 6.85)

A/T 173.1 - 183.1 (6.81 - 7.21)

Clearance “C” between pedal stopper and threaded end of stop lamp switch or ASCD switch 0.74 - 1.96 (0.0291 - 0.0772)

Applied pressure (front) 7,355 (75, 1,067)

Output pressure (rear) 5,100 - 5,492 (52 - 56, 739 - 796)

Output rod length 10.275 - 10.525 (0.4045 - 0.4144)

Clevis length 130 (5.12)

Product Detail Manual BR

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