BRAKE SYSTEM
F BRAKES
CONTENTS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
BRAKE PEDAL .......................................................... 6
Inspection and Adjustment ....................................... 6
ADJUSTMENT ...................................................... 6
Removal and Installation .......................................... 7
COMPONENTS .................................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 8
INSTALLATION ..................................................... 8
BRAKE FLUID ............................................................ 9
Checking Brake Fluid Level ..................................... 9
Drain and Refill ......................................................... 9
Bleeding Brake System .......................................... 10
BRAKE TUBE AND HOSE ........................................11
Hydraulic Circuit ......................................................11
Removal and Installation of Front Brake Tube and
Hose ....................................................................... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Removal and Installation of Rear Brake Tube and
Hose ....................................................................... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection After Installation .................................... 13
BRAKE MASTER CYLINDER .................................. 14
On-Board Inspection .............................................. 14
LEAK INSPECTION ............................................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
BR-1
SECTION
BRAKE SYSTEM
BR B
E
INSTALLATION ................................................... 14 BR
Disassembly and Assembly .................................... 15
COMPONENTS ................................................... 15
MODELS WITHOUT VDC ................................... 16 G
MODELS WITH VDC .......................................... 18
BRAKE BOOSTER ................................................... 21
On-Board Inspection and Service ........................... 21
H
OPERATION CHECK .......................................... 21
AIR TIGHT CHECK ............................................. 21
Removal and Installation ........................................ 22
COMPONENTS ................................................... 22 I
REMOVAL ........................................................... 22
INSPECTION AFTER REMOVAL ....................... 23
INSTALLATION ................................................... 23 J
VACUUM LINES ....................................................... 24
Components ........................................................... 24
Removal and Installation ........................................ 24
K
Inspection ............................................................... 25
VISUAL INSPECTION ......................................... 25
CHECK VALVE INSPECTION ............................. 25
FRONT DISC BRAKE ............................................... 26 L
On-Board Inspection ............................................... 26
PAD WEAR INSPECTION ................................... 26
Components ........................................................... 26 M
Removal and Installation of Brake Pad .................. 27
REMOVAL ........................................................... 27
INSTALLATION ................................................... 27
Removal and Installation of Brake Caliper Assembly
... 28
REMOVAL ........................................................... 28
INSTALLATION ................................................... 29
Disassembly and Assembly of Brake Caliper
Assembly ................................................................ 29
DISASSEMBLY ................................................... 29
INSPECTION AFTER DISASSEMBLY ................ 30
ASSEMBLY ......................................................... 30
DISC ROTOR INSPECTION ............................... 32
BRAKE BURNISHING PROCEDURE ................. 32
REAR DISC BRAKE ................................................. 33
On-Board Inspection ............................................... 33
 PAD WEAR INSPECTION ................................... 33
Components ........................................................... 33
Removal and Installation of Brake Pad ................... 34
REMOVAL ........................................................... 34
INSTALLATION .................................................... 34
Removal and Installation of Brake Caliper Assembly
... 35
REMOVAL ........................................................... 35
INSTALLATION .................................................... 35
Disassembly and Assembly of Brake Caliper
BR-2
Assembly ................................................................36
DISASSEMBLY ....................................................36
INSPECTION AFTER DISASSEMBLY ................37
ASSEMBLY ..........................................................37
DISC ROTOR INSPECTION ...............................39
BRAKE BURNISHING PROCEDURE .................39
SERVICE DATA AND SPECIFICATIONS (SDS) ......40
General Specifications ............................................40
Brake Pedal ............................................................40
Brake Booster .........................................................40
Check Valve ............................................................40
Front Disc Brake .....................................................40
Rear Disc Brake ......................................................41
 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” BFS000BB

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
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. C
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. D
● 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. E
● 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 harnesses or
harness connectors. BR
Precautions for Brake System BFS000BC

● Clean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air. G
● Recommended fluid is brake fluid “DOT 3 or DOT 4”. Refer to MA-14, "Fluids and Lubricants" .
● Do not reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed H
on painted surfaces of body, immediately wipe it off and them wash it away with water immediately.
● To clean or wash all parts of master cylinder, disc brake caliper, use clean brake fluid.
● Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. I
● Use a flare nut torque wrench when installing brake tube.
● When installing brake tube, be sure to check torque.
J
● Before working, turn ignition switch OFF and disconnect electri-
cal connector of ABS actuator and electric unit (control unit) or
battery cables.
● Burnish the brake contact surfaces after refinishing or replacing K
rotors, after replacing pads, or if a soft pedal occurs at very low
mileage. Refer to BR-32, "BRAKE BURNISHING PROCE-
DURE" (Front disc brake), BR-39, "BRAKE BURNISHING L
PROCEDURE" (Rear disc brake).
SBR820BA
WARNING:
● Clean brake pads and shoes with a waste cloth, then wipe with a dust collector. M

BR-3
 PREPARATION

PREPARATION PFP:00002

Special Service Tools BFS000BD

Tool number
Description
Tool name

GG94310000
Flare nut torque wrench
Installing each brake tube
a:10 mm (0.39 in) / 12 mm (0.47 in)

NT406

Commercial Service Tools BFS000BE

Tool name Description

Pin punch Removing and installing reservoir tank

Tip diameter: 4 mm (0.16 in) dia. pin

ZZA0515D

BR-4
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

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

A
NVH Troubleshooting Chart BFS000BF

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

NVH in FAX, RAX and FSU, RSU section

C

BR-26, BR-33

BR-26, BR-33

BR-26, BR-33

BR-32, BR-39

BR-32, BR-39
—

—
Reference page D

NVH in FAX section

NVH in WT section

NVH in WT section

NVH in PS section
E

BR

AXLE AND SUSPENSION

Rotor thickness variation
Pads - uneven wear

Rotor deformation
Pads - damaged

Rotor imbalance
Shims damaged

Rotor deflection
Possible cause and

ROAD WHEEL

DRIVE SHAFT
Rotor damage

suspected parts
Rotor runout

STEERING
Rotor rust
H

TYRES
Noise × × × × × × × I

×
Symptom Brake Shake × × × × ×

×
Shimmy, Judder × × × × × × × × × × ×
×: Applicable
J

BR-5
 BRAKE PEDAL

BRAKE PEDAL PFP:46501

Inspection and Adjustment BFS000BG

Play and clearance inspection between brake pedal and floor panel with pedal depressed.
● Check brake pedal height from dash lower panel (1).
● Adjust height referring to the following specifications.
Brake pedal free height (from dash lower panel 195.8 - 205.8 mm
H1
(1) top surface) (7.71 - 8.10 in)
Depressed brake pedal height
More than 115 mm
H2 [under a force of 490 N (50 kg, 110 lb) with
(4.53 in)
engine running]
Clearance between the threaded end of stop
0.74 - 1.96 mm
C lamp switch, brake switch and/or ASCD cancel
(0.0291 - 0.0772 in)
switch (2) and bracket (3)
3 - 11 mm
A Pedal play
(0.12 - 0.43 in)

SFIA2743J

ADJUSTMENT
1. Loosen stop lamp switch, brake switch and/or ASCD cancel
switch by turning it counterclockwise by 45°.
2. Loosen lock nut “A” on input rod, then rotate input rod to set,
brake pedal to the specified height, and tighten lock nut “A”.
Refer to BR-22, "COMPONENTS" .
CAUTION:
Make sure the threaded end of input rod stays inside clevis.
3. With pedal pulled and held by hand, press stop lamp switch,
brake switch and/or ASCD cancel switch until its threaded end
contacts bracket.
4. With threaded end of stop lamp switch, brake switch and/or
ASCD cancel switch contacting bracket, rotate switch clockwise
by 45° to secure.
CAUTION:
● Make sure that the clearance “C” between bracket and
end of stop lamp switch, brake switch and/or ASCD can-
cel switch is within the standard.
● When locking stop lamp switch and ASCD cancel switch,
pull brake pedal to avoid moving toward the direction
where switches are being pressed.
5. Check the pedal play.
PFIA0824E
CAUTION:
Make sure that stop lamps goes off when pedal is released.
6. Start engine to check brake pedal depressed height.

BR-6
 BRAKE PEDAL

Removal and Installation BFS000BH

COMPONENTS A

BR

PFIA0836E

1. Clevis pin 2. Clip 3. Stop lamp switch K

4. Brake switch (Models with VDC) 5. Brake pedal pad 6. Brake pedal assembly
ASCD cancel switch (Models with
ASCD)
L
7. Snap pin
Refer to GI-10, "Components" and the followings for the symbols in the figure.
: Apply multi-purpose grease.
M
NOTE:
Clevis pin can be installed from both left and right.

REMOVAL
1. Remove instrument driver lower panel. Refer to IP-10,
"INSTRUMENT PANEL ASSEMBLY" .
2. Disconnect stop lamp switch connector, brake switch and/or
ASCD cancel switch connector.
3. Remove stop lamp switch, brake switch and/or ASCD cancel
switch from brake pedal assembly.
4. Remove snap pin and clevis pin from brake booster clevis.
5. Remove pedal bracket mounting nuts and bolt, and remove
brake pedal assembly from vehicle.
SFIA2044E

BR-7
 BRAKE PEDAL

INSPECTION AFTER REMOVAL

● Check rivets in upper part of brake pedal are not deformed.
● Check that joint length “L” of sub-bracket and sliding plate is 5.5
mm (0.217 in) or more.
● Check brake pedal for bend, damage, and cracks on the welded
parts.
● Replace brake pedal assembly if detected.

SFIA2487E

● Check clevis pin and plastic stopper for damage and deforma-
tion. Replace clevis pin if there are.

SBR997

INSTALLATION
Install in reverse order of the removal.
● When installing brake pedal, tighten nuts and bolt according to
the order shown in the figure.
● Check brake pedal for smooth operation. There should be no
binding or sticking when applying or releasing brake pedal.
● Adjust brake pedal height after installing brake pedal assembly
to vehicle. Refer to BR-6, "Inspection and Adjustment" .

SFIA3179E

BR-8
 BRAKE FLUID

BRAKE FLUID PFP:KN100

A
Checking Brake Fluid Level BFS000BI

● Make sure that a brake fluid level in reservoir tank is within the
standard (between MAX and MIN lines). B
● Visually check around reservoir tank for fluid leakage.
● If fluid level is excessively low, check brake system for leakage.
● Release parking brake pedal and see if brake warning lamp C
goes off. If not, check brake system for fluid leakage.

SFIA2632E

E
Drain and Refill BFS000BJ

CAUTION:
● Refill with new brake fluid “DOT 3 or DOT 4”. BR
● Do not reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of the body, immediately wipe off them and wash it away with water G
immediately.
● Before working, turn ignition switch OFF and disconnect electrical connector of ABS actuator and
electric unit (control unit) or battery cables.
H
1. Connect a vinyl tube to bleed valve.
2. Depress brake pedal, loosen bleed valve, and gradually remove
brake fluid. I

BRA0007D

L
3. Clean inside of reservoir tank, and refill with new brake fluid.
4. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
brake pedal until it stops. Tighten bleed valve. Release brake
pedal. Repeat this process a few time, them pause to and new M
brake fluid to master cylinder. Continue until new brake fluid
flows out.
5. Bleed air. Refer to BR-10, "Bleeding Brake System" .

PFIA0403J

BR-9
 BRAKE FLUID

Bleeding Brake System BFS000BK

CAUTION:
● Carefully monitor brake fluid level in reservoir tank during
bleeding operation.
● Refill with new brake fluid “DOT 3 or DOT 4”. Make sure it is
at least half way at all times while bleeding air out of sys-
tem.
● Place a container under master cylinder not to spill brake
fluid.
● Turn ignition switch to the OFF and disconnect connector
for ABS actuator and electric unit (control unit) or battery
cable from negative terminal before working.
PFIA0403J

1. Connect a vinyl tube to rear right brake caliper bleed valve.

2. Fully depress brake pedal 4 or 5 times.
3. With brake pedal depressed, loosen bleed valve to bleed air in
brake line, and then tighten it immediately.
4. Repeat steps 2 and 3 until all of the air is out of the brake line.
5. Tighten bleed valve to the specified torque. Refer to front disc
brake: BR-26, "Components" , rear disc brake: BR-33, "Compo-
nents" .
6. From step 1 to 5 above, with master cylinder reservoir tank filled
at least half way, bleed air from brake hydraulic line bleed valves BRA0007D
in the following order:
Rear right brake→Front left brake→Rear left brake→Front right brake

BR-10
 BRAKE TUBE AND HOSE

BRAKE TUBE AND HOSE PFP:46210

A
Hydraulic Circuit BFS000FY

BR

G
PFIA0821E

1. Actuator 2. Master cylinder 3. Brake booster

: Flare nut 18.2 N·m (1.9 kg-m, 13 ft-lb) (Models with VDC) H

16.2 N·m (1.7 kg-m, 12 ft-lb) (Models without VDC)

: Union bolt 18.2 N·m (1.9 kg-m, 13 ft-lb) I

: Flare nut 16.2 N·m (1.7 kg-m, 12 ft-lb)

CAUTION: J
● All brake tubes and hoses must be free from excessive bending, twisting and pulling.
● Make sure that there is no interference with other parts when turning steering both clockwise and
counterclockwise. K
● Brake tubes and hoses is an important safety part. If a brake fluid leak is detected, always disas-
semble the parts. Replace applicable part with a new one, if necessary.
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is L
splashed on painted surfaces of body, immediately wipe off them and wash it away with water
immediately.
● Do not bend or twist brake hose sharply, or strongly pull it. M
● When removing components, cover brake line connections so that no dirt, no dust, or other for-
eign matter gets in.
● Refill with new brake fluid “DOT 3 or DOT4”.
● Do not reuse drained brake fluid.

BR-11
 BRAKE TUBE AND HOSE

Removal and Installation of Front Brake Tube and Hose BFS000BM

REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from brake caliper
assembly.
4. Remove lock plate and remove brake hose from vehicle.

SFIA2057E

INSTALLATION
1. Install brake hose by aligning with the protrusion on brake caliper assembly, and tighten union bolt to the
specified torque. Refer to BR-11, "Hydraulic Circuit" .
CAUTION:
Do not reuse copper washer.
2. Install brake hose to brake tube. Temporarily tighten flare nut by hand as much as possible. Secure them
to bracket with lock plate.
3. Using a flare nut torque wrench, tighten flare nut to the specified torque. Refer to BR-11, "Hydraulic Cir-
cuit" .
4. Refill with new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
Removal and Installation of Rear Brake Tube and Hose BFS000BN

REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from brake caliper
assembly.
4. Remove lock plate and remove brake hose from vehicle.

SFIA2048E

INSTALLATION
1. Install the L-shape metal fitting of brake hose to brake caliper
assembly positioning hole, and then tighten union bolt to the
specified torque. Refer to BR-11, "Hydraulic Circuit" .
CAUTION:
Do not reuse copper washer.
2. Install brake hose to brake tube. Temporarily tighten flare nut by
hand as much as possible. Secure them to bracket with lock
plate.
3. Using a flare nut torque wrench, tighten flare nut to the specified
torque. Refer to BR-11, "Hydraulic Circuit" .
SFIA2049E
4. Refill with new brake fluid and bleed air. Refer to BR-10, "Bleed-
ing Brake System" .

BR-12
 BRAKE TUBE AND HOSE

Inspection After Installation BFS000BO

A
CAUTION:
If leakage occurs around brake tube and hose connections, retighten or, if damaged part is detected,
replace the damage part.
1. Check brake hoses, brake tubes, and connections for fluid leakage, damage, twists, deformation, contact B
with other parts, and loose connections.
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately
5 seconds, check for fluid leak each part. C

BR

BR-13
 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

On-Board Inspection BFS000BP

LEAK INSPECTION
● Check for leaking in a master cylinder installation surface, a reservoir tank installation surface, and brake
tube connections.
Removal and Installation BFS000BQ

CAUTION:
Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe it off and them wash it away with water imme-
diately.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Remove brake fluid level switch harness connector.
3. Using a flare nut wrench, remove brake tubes from master cylinder assembly.
4. Remove master cylinder mounting nuts, remove master cylinder assembly from vehicle.
INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3 or DOT 4”.
● Do not reuse drained brake fluid.
1. Install in the reverse order of removal and tighten nuts to the specified torque. Refer to BR-22, "COMPO-
NENTS" .
Models with VDC
● Apply silicon grease in inner kit to O-ring and it's surrounding
areas and to booster side inner wall.
CAUTION:
● Do not damage the sliding surface of primary piston rod
and do not allow foreign materials on it's surface.
● Do not reuse the O-ring.

2. Install brake tube to master cylinder assembly and temporarily

tighten flare nut by hand.
3. Tighten brake tube flare nut to the specified torque using a flare
nut torque wrench. Refer to BR-11, "Hydraulic Circuit" . SFIA1302E
4. Install brake fluid level switch harness connector.
5. Refill with new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .

BR-14
 BRAKE MASTER CYLINDER

Disassembly and Assembly BFS000BR

COMPONENTS A

BR

PFIA0822E

1. Reservoir tank 2. Reservoir cap 3. Oil strainer K

(Models with VDC)
4. Pin 5. Cylinder body 6. Piston stopper
(Models with VDC)
L
7. Grommet 8. Secondary piston assembly 9. Primary piston assembly
10. O-ring 11. Snap ring 12. Guide assembly
13. Plate 14. Stopper cap
M
Refer to GI-10, "Components" and the followings for the symbols in the figure.
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.

: Apply brake fluid.

BR-15
 BRAKE MASTER CYLINDER

MODELS WITHOUT VDC

CAUTION:
Remove reservoir tank only when absolutely necessary.
Disassembly (Piston Assembly)
1. Using a flat-bladed screwdriver as shown in the figure, lift up
tabs on stopper cap and remove it from master cylinder.
NOTE:
Remove stopper cap while holding it because primary piston
assembly in master cylinder may pop out.
2. Carefully pull primary piston assembly straight out to prevent
cylinder inner wall from being damaged.

BRA0031D

3. Tap flange using a soft block, such as wood, and carefully pull
secondary piston assembly straight out to prevent cylinder body
inner wall from being damaged.

BRA0033D

Inspection After Disassembly (Piston Assembly)

Cylinder body
● Check a inner wall of cylinder for damage, abrasions, corrosion, and pinholes. Replace cylinder body if
detected.
Assembly (Piston Assembly)
CAUTION:
● Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
● Make sure there is no foreign matter such as dirt or dust attached to inner cylinder walls, piston,
or cap seal, and use care to avoid damaging parts with the assembly tools.
● Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid to cylinder inner wall, piston cups and contact
surfaces between piston assemblies. Then insert secondary pis-
ton assembly and primary piston assembly into cylinder body in
this order.
CAUTION:
● Do not reuse primary and secondary piston assemblies.

● Be sure to replace piston assemblies without disassem-

bling new inner kit.
● Pay attention to the orientation of piston cup, and insert
straight to prevent cup seal from being caught by cylin-
der inner wall. SFIA2051E

BR-16
 BRAKE MASTER CYLINDER

2. Holding down piston with stopper cap, push stopper cap tabs so
they are firmly into cylinder grooves, then install stopper cap. A
CAUTION:
Do not reuse stopper cap.
B

BRA0035D

D
Disassembly (Reservoir Tank)
1. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
E
CAUTION:
● When setting master cylinder assembly with vise, be sure
not to over-tighten.
● When setting with vise use copper plates or cloth to pro-
BR
tect the flange.

PFIA0505J

2. Using a pin punch [commercial service tool: diameter approxi- H

mately 4 mm (0.16 in)], remove mounting pins on reservoir tank.
3. Remove master cylinder assembly from vise.
4. Remove reservoir tank and grommet from cylinder body. I

SFIA2052E
K

Assembly (Reservoir Tank)

1. Apply brake fluid to grommet, and then install it into cylinder body after installing grommet to reservoir L
tank.
CAUTION:
Do not reuse reservoir tank and grommet.
M
2. Secure master cylinder assembly into vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:
● When setting master cylinder assembly in vise, be sure
not to over-tighten.
● When setting in vise use copper plates or cloth to protect
the flange.

PFIA0505J

BR-17
 BRAKE MASTER CYLINDER

3. Using a pin punch, [commercial service tool: diameter approxi-

mately 4 mm (0.16 in)] insert reservoir tank mounting pin into the
pin hole so that the attachment side and the opposite side are
identical.
CAUTION:
● Be sure to insert pin from the chamfered pinhole of cylin-
der body.
● Do not reuse mounting pin.

SFIA2052E

MODELS WITH VDC

Disassembly
CAUTION:
● Cover primary piston rod using cloths during disassembly to prevent damage to it.
1. Secure master cylinder assembly into vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:
● When setting master cylinder assembly in vise, be sure
not to overtighten.
● When setting with vise use copper plates or cloth to pro-
tect the flange.

PFIA0505J

2. Using a pin punch [commercial service tool: diameter approxi-

mately 4 mm (0.16 in)], remove mounting pin on reservoir tank.
3. Remove master cylinder assembly from vise.
4. Remove reservoir tank and grommet from cylinder body.

SFIA2052E

5. Push in primary piston assembly, and then remove piston stop-

per pin from cylinder body secondary-side tank boss hole.
CAUTION:
Be careful not to damage an inner wall of cylinder body.

BRA0560D

BR-18
 BRAKE MASTER CYLINDER

6. Remove snap ring while pressing in primary piston assembly

into prevent piston from popping out. A
7. Hold primary piston rod, and then pull primary piston assembly,
plate, and guide assembly straight out.
8. Remove plate and guide assembly from primary piston assem- B
bly.
CAUTION:
When removing plate from primary piston rod, make sure C
inside of plate dose not damage rod.
BRA0561D

D
9. Tap flange using a soft block, such as wood, and carefully pull
secondary piston assembly straight out to prevent a cylinder
body inner wall from being damaged.
E

BR

G
BRA0033D

Inspection After Disassembly

H
Cylinder body
● Check a inner wall of cylinder for damage, abrasions, corrosion, and pinholes. Replace cylinder body if
detected.
I
Assembly
CAUTION:
● Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process. J
● Make sure there is no foreign matter such as dirt or dust attached to inner cylinder wall, piston, or
piston cup seal, and use care to avoid damaging parts with assembly tools.
● Do not drop parts. If a part is dropped, do not use it. K
1. Apply brake fluid to cylinder inner wall, piston cup seal and con-
tact surfaces between piston assembly. Then insert secondary
piston assembly and primary piston assembly into cylinder body
L
in this order.
CAUTION:
● Do not reuse primary and secondary piston assemblies.
M
● Be sure to replace piston assemblies without disassem-
bling new inner kit.
● Pay attention to the orientation of piston cup, and insert
straight to prevent piston cup seal from being caught by
cylinder inner wall. PFIA0263E

2. Visually inspect secondary piston assembly slit through piston

stopper mounting hole and then install piston stopper while
pushing in primary piston assembly.

BRA0560D

BR-19
 BRAKE MASTER CYLINDER

3. Insert plate and guide assembly into cylinder body as shown.

CAUTION:
● Make sure not to damage primary piston rod.

● Pay attention to the orientation of guide assembly.

● Do not drop O-ring.

● Make sure guide assembly and plate are not inserted at

angle.

SFIA2054E

4. Cover primary piston assembly rod with cloths to prevent dam-

age to it, and then install snap ring when pressing in primary pis-
ton assembly.
CAUTION:
● Make sure that snap ring is securely engaged in cylinder
body inner diameter groove.
● Do not reuse snap ring.

BRA0561D

5. Apply brake fluid to a grommet, and then install it into cylinder body after installing grommet to reservoir
tank.
CAUTION:
Do not reuse reservoir tank and grommet.
6. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:
● When setting master cylinder assembly with vise, be sure
not to over-tighten.
● When setting in a vise use copper plates or cloth to pro-
tect the flange.

PFIA0505J

7. Using a pin punch, [commercial service tool: diameter approxi-

mately 4 mm (0.16 in)] insert reservoir tank mounting pin into the
pin hole so that the attachment side and the opposite side are
identical.
CAUTION:
● Be sure to insert pin from the chamfered pinhole of cylin-
der body.
● Do not reuse mounting pin.

SFIA2052E

BR-20
 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

A
On-Board Inspection and Service BFS000BS

OPERATION CHECK
With engine stopped, change the vacuum to the atmospheric pres- B
sure by depressing brake pedal several times. Then with brake
pedal fully depressed, start engine and when the vacuum pressure
reaches the standard, make sure that clearance between brake
pedal and floor panel decreases. C
CAUTION:
Depressing pedal interval is approximately 5 seconds.
D

BRA0037D
E
AIR TIGHT CHECK
● Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to BR
change the vacuum to the atmospheric pressure. Make sure
distance between brake pedal and floor panel gradually
increases. G
● Depress brake pedal while engine is running, and stop engine
with brake pedal is depressed. Brake pedal stroke should not
change after holding brake pedal down for 30 seconds.
H
CAUTION:
Depressing brake pedal interval is approximately at intervals 5
seconds. SBR365AA
I

BR-21
 BRAKE BOOSTER

Removal and Installation BFS000BT

COMPONENTS

SFIA2633E

1. Reservoir tank 2. Master cylinder 3. Brake booster

4. Gasket 5. Lock nut

CAUTION:
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe it off and them wash it away with water
immediately.
● Be careful not to deform or bend brake tube while removing and installing brake booster.
● Replace clevis pin if it is damaged.
● Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, dash panel may damage the threads.
● Install check valve in the correct direction.
REMOVAL
1. Remove vacuum hose from brake booster. Refer to BR-24, "VACUUM LINES" .
2. Remove brake master cylinder. Refer to BR-14, "Removal and Installation" .
3. Remove snap pin and clevis pin from brake pedal.
4. Remove nuts on brake booster and brake pedal assembly.
5. Remove brake booster from dash panel in engine room side.

SFIA2044E

BR-22
 BRAKE BOOSTER

INSPECTION AFTER REMOVAL

Output Rod Length Inspection A
1. Using a handy vacuum pump, apply a vacuum of −66.7 kPa (−
500 mmHg, −19.69 inHg) to brake booster.
2. Check output rod length. B

Standard dimension when applying vacuum of −66.7

kPa (−500 mmHg, −19.69 inHg) (Reference value)
C
Models without VDC : 10.4 mm (0.409 in)
Models with VDC : −6.2 mm (−0.244 in)
D
SBR208E

INSTALLATION E
1. Loosen lock nut to adjust input rod length so that the length “B”
(shown in the figure) satisfies the specified value.
Length “B” : 125 mm (4.92 in) BR
2. Temporarily tighten lock nut after adjusting the length “B” to the
specified value, and then install brake booster on dash panel.
CAUTION: G
Always install gasket between brake booster and dash-
board panel.
3. Install brake booster and brake pedal assembly nuts and bolt, H
and then tighten to the specified torque. Refer to BR-7, SGIA0060E

"Removal and Installation" .

4. Connect brake pedal with clevis of input rod. I
5. Install brake master cylinder. Refer to BR-14, "Removal and Installation" .
6. Install vacuum hose. Refer to BR-24, "VACUUM LINES" .
7. Adjust brake pedal free height and the play of brake pedal. Refer to BR-6, "Inspection and Adjustment" . J
8. Tighten input rod lock nut to the specified torque. Refer to BR-22, "COMPONENTS" .
9. Refill with new brake fluid and bleed air. Refer to BR-11, "Hydraulic Circuit" .
K

BR-23
 VACUUM LINES

VACUUM LINES PFP:41920

Components BFS000BU

PFIA0823E

1. Clamp 2. Vacuum hose 3. Hose clamp

4. Vacuum tube 5. Vacuum hose (Build in check valve) 6. Engine side indicator stamp
A: To intake manifold
B: To brake booster

Removal and Installation BFS000BV

CAUTION:
● Because vacuum hose contains a check valve, it must be installed in the correct direction. Refer to
the stamp or label to confirm correct installation. Brake booster will not operate normally if hose is
installed in the wrong direction.

● Insert vacuum hose at least 24 mm (0.94 in).

● Do not use lubricating oil during assembly.

SBR225B

BR-24
 VACUUM LINES

Inspection BFS000BW

VISUAL INSPECTION A
Check for improper assembly, damage and deterioration.
CHECK VALVE INSPECTION B
Airtightness Inspection
Use a handy vacuum pump to check.
When connected to booster side (1): C
Vacuum decrease should decrease within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under a vac-
uum of −66.7 kPa (−500 mmHg, −19.69 inHg). D
When connected to engine side (2):
No vacuum will be applied.
E
● Replace vacuum hose assembly if vacuum hose and check
valve are malfunctioning. SFIA1306E

BR

BR-25
 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

On-Board Inspection BFS000BX

PAD WEAR INSPECTION

● Check pad thickness from the inspection hole on cylinder body.
Check use a scale for inspection necessary.
Standard thickness : 11.0 mm (0.433 in)
Repair limit thickness : 2.0 mm (0.079 in)

BRA0010D

Components BFS000BY

PFIA0837E

1. Union bolt 2. Brake hose 3. Copper washer

4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Inner shim cover 12. Inner shim
13. Pad wear sensor 14. Inner pad 15. Pad retainer
(Only for inner pad RH)
16. Outer pad 17. Outer shim 18. Sliding pin
19. Sliding pin boot 20. Bushing 21. Torque member
22. Torque member mounting bolt
Refer to GI-10, "Components" and the followings for the symbols in the figure.
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
3: Apply polyglycol ether based lubricant.

: Apply brake fluid.

WARNING:
Clean dust on caliper and brake pads with a vacuum dust collector to minimize the hazard of airborne
particles or other materials.
CAUTION:
● While removing cylinder body, never depress brake pedal because piston will pop out.

BR-26
 FRONT DISC BRAKE

● It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch A
brake hose.
● Do not damage piston boot.
● If any shim is subject to serious corrosion, replace it with a new one. B
● Always replace shim and inner shim cover as a set when replacing brake pads.
● Keep rotor clean from brake fluid.
● Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft C
pedal occurs at very low mileage. Refer toBR-32, "BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake Pad BFS000BZ
D
REMOVAL
1. Remove tyres from vehicle.
2. Remove lower sliding pin bolt. E
3. Suspend cylinder body with wire, and remove pads, pad retain-
ers, shims, and shim cover from torque member.
CAUTION: BR
When removing pad retainers from torque member, lift pad
retainers in the direction by the arrow (shown in the figure)
so as not to damage it.
G

H
SBR556E

INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based I
grease to the both sides of inner shim and outer shim, install
inner shim and inner shim cover to inner pad and outer shim to
outer pad. J
CAUTION:
Securely install shim cover according to shim mounting
direction.
K

PFIA0267E
L

2. Install pad retainers and pads to torque member.

CAUTION: M
Securely assemble pad retainers so that they are not being
lifted up from torque member.
3. Press in piston until pads can be installed, and then install cylin-
der body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool) to easily
press piston in.
CAUTION: PFIA0273E
When replacing pads with new ones, press in piston until
pads can be installed. In this case, carefully monitor brake fluid level in reservoir tank because
brake fluid will return to master cylinder reservoir tank.
4. Install lower sliding pin bolt, and tighten it to the specified torque. Refer to BR-26, "Components" .
5. Secure disc rotor with wheel nut. Depress brake pedal a few times until it gets a responsive touch.
6. Check front disc brake for drag.
7. Install tyres to vehicle.

BR-27
 FRONT DISC BRAKE

Removal and Installation of Brake Caliper Assembly BFS000C0

REMOVAL
1. Remove tyres from vehicle.
2. Secure disc rotor using wheel nut.
CAUTION:
● Do not drop brake pad.

3. Drain brake fluid. Refer to BR-9, "Drain and Refill" .

4. Remove union bolt and then disconnect brake hose from caliper
assembly.

SFIA2057E

5. Remove torque member bolts, and remove brake caliper

assembly.

SFIA1410J

6. Remove disc rotor.

CAUTION:
Put matching marks on wheel hub assembly and disc rotor,
if it necessary to remove disc rotor.

SDIA2608E

BR-28
 FRONT DISC BRAKE

INSTALLATION
CAUTION: A
● Refill with new brake fluid “DOT 3 or DOT 4”.
● Do not reuse drained brake fluid.
1. Install disc rotor. B
CAUTION:
Align the matching marks of disc rotor and wheel hub,
which were marked at the time of removal when reusing C
disc rotor.
2. Install brake caliper assembly to vehicle, and tighten torque
member mounting bolts to the specified torque. Refer to BR-26, D
"Components" .
CAUTION:
Before installing torque member to vehicle, wipe oil and E
grease on washer seats on steering knuckle and mounting SDIA2608E

surface of torque member.

3. Install brake hose to brake caliper assembly, and tighten union bolts to the specified torque. Refer to BR- BR
26, "Components" .
CAUTION:
● Do not reuse copper washers for union bolts. G
● Connect brake hose aligning with caliper assembly mounting protrusion.

4. Refill with new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
5. Check front disc brake for drag. H
6. Install tyres to vehicle.
Disassembly and Assembly of Brake Caliper Assembly BFS000C1 I
NOTE:
Do not remove torque member, pads, shims, inner shim cover, and pad retainers when disassembling and
assembling cylinder body. J
DISASSEMBLY
1. Remove caliper assembly from Vehicle. Refer to BR-28, "Removal and Installation of Brake Caliper
Assembly" . K
2. Remove sliding pin bolts, from cylinder body, and remove pads
shims shim cover and pad retainers from torque member.
CAUTION: L
● When removing pad retainers from torque member, lift
pad retainer in the direction by the arrow (shown in the
figure) so as not to damage it. M
● Do not drop pads, shims, inner shim cover and pad
retainers from torque member.

SBR556E

3. Remove sliding pins and sliding pin boots from torque member.

BR-29
 FRONT DISC BRAKE

4. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Do not get fingers caught in pistons.

MAA0272D

5. Using a flat-bladed screwdriver, remove piston seal from cylin-

der body.
CAUTION:
Be careful not to damage a cylinder inner wall.

SFIA0999E

INSPECTION AFTER DISASSEMBLY

Cylinder Body
CAUTION:
Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
● Check inner wall of cylinder for corrosion, wear, and damage. If a malfunction is detected, replace cylinder
body.
● Minor flaws caused by corrosion or a foreign material can be removed by polishing a surface of inner wall
with a fine sandpaper. Replace cylinder body, if necessary.
Torque Member
Check for wear, cracks, and damage. If a malfunction is detected, replace torque member.
Piston
CAUTION:
Piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear, and damage. If a malfunction is detected, replace applicable part.
Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check sliding pins and sliding pin boots for wear, damage, and cracks. If a malfunction is detected, replace
applicable part.
ASSEMBLY
1. Apply polyglycol ether based lubricant to piston seal, and install
them to cylinder body.
CAUTION:
Do not reuse piston seal.

SFIA2278E

BR-30
 FRONT DISC BRAKE

2. Apply rubber grease to piston boot. Cover piston end with piston
boot, and install cylinder side lip on piston boot properly into a A
groove on cylinder body.
CAUTION:
Do not reuse piston boot. B

SFIA2498E

D
3. Apply brake fluid to piston, and press piston into cylinder body
by hand to assemble piston side lip on piston boot properly into
groove on piston. E
CAUTION:
Press piston evenly and vary the pressing point to prevent
cylinder inner wall from being rubbed. BR

G
SFIA2279E

4. Install sliding pins and sliding pin boots to torque member. H

5. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based

grease to the both side of inner shim and outer shim, install I
inner shim and inner shim cover to inner pad and outer shim to
outer pad.
CAUTION: J
Securely install inner shim cover according to shim mount-
ing direction.
K

PFIA0267E
L

6. Install pad retainer, inner pad assembly and outer pad assembly
to torque member.
M
CAUTION:
● Securely assemble pad retainers so that it is not being
lifted up from torque member.

PFIA0273E

7. Press in piston until pads can be installed, and then install cylinder body to torque member.
NOTE:
Use a disc brake piston tool (commercial service tool) to easily press piston in.
8. Tighten sliding pin bolts to the specified torque.BR-26, "Components"

BR-31
 FRONT DISC BRAKE

DISC ROTOR INSPECTION

Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any of them is detected, replace
applicable part.
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check runout.
: At a point 10.0 mm (0.394 in)
Measurement point
from outer edge of disc.
Runout limit : 0.040 mm (0.0016 in) or less
CAUTION:
Before measuring, make sure that axle end play within the
specification before measuring runout. FAX-5, "WHEEL
BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting the mounting positions of disc rotor and wheel hub by SBR019B

one hole.
4. If runout is still out of specification, turn rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and
705” or equivalent).
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is out-
side the specification, replace disc rotor.
Standard thickness : 24.0 mm (0.945 in)
Wear limit : 22.0 mm (0.866 in)
Maximum uneven wear : 0.010 mm (0.0004 in)
(measured at 8 positions) or less

SBR020B

BRAKE BURNISHING PROCEDURE

Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
● Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are
securely fitted.
● Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.

BR-32
 REAR DISC BRAKE

REAR DISC BRAKE PFP:44000

A
On-Board Inspection BFS000C2

PAD WEAR INSPECTION

● Check pad thickness from the inspection hole on cylinder body. B
Use a scale for inspection.
Standard thickness : 8.5 mm (0.335 in)
Repair limit thickness : 2.0 mm (0.079 in) C

BRA0010D
E
Components BFS000C3

BR

PFIA0810E

1. Brake hose 2. Union bolt 3. Copper washer

4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Retaining ring 12. Inner shim cover
13. Inner shim 14. Inner pad 15. Pad retainer
16. Outer pad 17. Outer shim 18. Outer shim cover
19. Sliding pin boot 20. Bushing 21. Torque member mounting bolt
22. Washer 23. Torque member 24. Pad wear sensor
25. Inner pad (RH)

BR-33
 REAR DISC BRAKE

Refer to GI-10, "Components" and the followings for the symbols in the figure.
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
3: Apply polyglycol ether based lubricant.

: Apply brake fluid.

WARNING:
Clean dust on caliper and brake pads with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.
CAUTION:
● While removing cylinder body, do never depress brake pedal because piston will pop out.
● It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, hang cylinder body with wire so as not to stretch
brake hose.
● Do not damage piston boot.
● If any shim is subject to serious corrosion, replace it with a new one.
● Always replace shims and shim covers as a set when replacing brake pads.
● Keep rotor clean from brake fluid.
● Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or if a soft
pedal occurs at very low mileage. Refer to BR-39, "BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake Pad BFS000C4

REMOVAL
1. Remove tyres from vehicle.
2. Remove upper sliding pin bolt.
3. Suspend cylinder body with wire, and remove pads, pad retainers and shims, and shim covers from
torque member.
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease to the bosh side of inner shim and outer
shin, install inner shim, inner shim cover to inner pad, and outer shim, outer shim cover to outer pad.
2. Install pad retainers and pads to torque member.
3. Press in piston until pads can be installed, and then install cylin-
der body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool) to easily
press piston in.
CAUTION:
When replacing pads with new ones, press in piston until
pads can be installed. In this case, carefully monitor brake
fluid level in reservoir tank because brake fluid will return to
master cylinder reservoir tank. PFIA0273E

4. Install upper sliding pin bolt and tighten to the specified torque. Refer to BR-33, "Components" .
5. Secure disc rotor with wheel nut. Depress brake pedal a few times until it gets a responsive touch.
6. Check rear disc brake for drag.
7. Install tyres to vehicle.

BR-34
 REAR DISC BRAKE

Removal and Installation of Brake Caliper Assembly BFS000C5

REMOVAL A
1. Remove tyres from vehicle.
2. Secure disc rotor using wheel nut to wheel hub.
CAUTION: B
● Do not drop brake pad.

● Put matching marks on both disc rotor and wheel hub

before removing disc rotor, if it is necessary to remove C
disc rotor.

SDIA2638E
E
3. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
4. Remove union bolt and then disconnect brake hose from caliper
assembly. BR
5. Remove torque member bolts, and remove brake caliper
assembly.
6. Remove disc rotor. G

PFIA0413E

I
INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3 or DOT 4”.
J
● Do not reuse drained brake fluid.
1. Install disc rotor.
CAUTION: K
Align the matching marks of disc rotor and wheel hub,
which were marked at the time of removal when reusing
disc rotor.
L
2. Install brake caliper assembly to vehicle, and tighten torque
member mounting bolts to the specified torque. refer to BR-33,
"Components" .
CAUTION: M
Before installing torque member to vehicle, oil and grease
on washer seats on setting knuckle and torque member. SDIA2638E

3. Install L-shaped pin of brake hose to caliper assembly as shown

in the figure, and then tighten union bolt to the specified torque.
Refer to BR-33, "Components" .
CAUTION:
● Do not reuse copper washer for union bolt.

● Securely install brake hose to protrusion on caliper

assembly.
4. Refill with new brake fluid and bleed air. Refer to BR-10, "Bleed-
ing Brake System" .
5. Check rear disc brake for drag. SFIA2049E
6. Install tyres to vehicle.

BR-35
 REAR DISC BRAKE

Disassembly and Assembly of Brake Caliper Assembly BFS000C6

NOTE:
Do not remove torque member, pads, shims, shim covers, and pad retainers when disassembling and assem-
bling cylinder body.
DISASSEMBLY
1. Remove caliper assembly from vehicle. Refer to BR-35, "Removal and Installation of Brake Caliper
Assembly" .
2. Using a flat-bladed screwdriver remove retaining ring from cylin-
der body as shown in the figure.

SBR028A

3. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.
CAUTION:
Do not get you fingers caught in piston.

BRD0041D

4. Using a flat-bladed screwdriver remove piston seal from cylinder

body.
CAUTION:
Be careful not to damage a cylinder inner wall.

SFIA2277E

BR-36
 REAR DISC BRAKE

INSPECTION AFTER DISASSEMBLY

Cylinder Body A
CAUTION:
Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
● Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the above con- B
ditions 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. C
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace torque member.
D
Piston
CAUTION:
● Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials E
are stuck to sliding surface.
● Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the
above condition are observed. BR
Sliding Pin Bolts and Sliding Pin Boots
Check sliding pin bolts and sliding pin boots, for wear, damage and cracks. If damage or deformation is
present, replace the applicable part. G
ASSEMBLY
1. Apply polyglycol ether based lubricant to piston seal, and install
them to cylinder body. H
CAUTION:
Do not reuse piston seal.
I

SFIA2278E
K
2. Apply rubber grease to piston boot. Cover piston end with piston
boot, and install cylinder side lip on piston boot properly into the
groove on cylinder body. L
CAUTION:
Do not reuse piston boot.
M

SFIA2498E

3. Apply brake fluid to piston, and press piston into cylinder body
by hand to assemble piston side lip on piston boot properly into
groove on piston.
CAUTION:
Press piston evenly and vary the pressing point to prevent
cylinder inner wall from being rubbed.

SFIA2279E

BR-37
 REAR DISC BRAKE

4. Fix piston boot with retaining ring.

CAUTION:
● Make sure boot is firmly in cylinder body groove on.

● Do not reuse retainer ring.

SFIA2280E

5. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based

grease to between shim and shim cover. Install inner shim, inner
shim cover to inner pad, and outer shim, outer shim cover to
outer pad.
6. Install pad retainers and, inner pad assembly and outer pad
assembly to torque member.
CAUTION:
Securely assemble pad retainer so that it is not being lifted
up from torque member.
7. Install sliding pin boot to torque member.
PFIA0273E
8. Press in piston until pads can be installed, and then install cylin-
der body to torque member. Use a disc brake piston tool (commercial service tool) to easily press piston
in.
9. Install cylinder body to torque member, and then tighten sliding pin bolt to the specified torque. Refer to
BR-33, "Components" .

BR-38
 REAR DISC BRAKE

DISC ROTOR INSPECTION

Visual Inspection A
Check surfaces of disc rotor for uneven wear, cracks, and serious damage. If a malfunction is detected,
replace applicable part.
B
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check runout. C
: At a point 10 mm (0.394 in)
Measurement point
from outer edge of disc.
Runout limit : 0.050 mm (0.0020 in) or less D
CAUTION:
Before measuring, make sure that axle end play is within
the specification before measuring runout. Refer to RAX-3, E
"WHEEL BEARING INSPECTION" .
3. If runout is outside the limit, find minimum runout point by shift-
ing mounting positions of disc rotor and wheel hub by one hole. BRA0013D
BR
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is out-
side the specification, replace disc rotor. G
Standard thickness : 9.0 mm (0.354 in)
Wear limit : 8.0 mm (0.315 in) H
Maximum uneven wear : 0.015 mm (0.0006 in) or
(measured at 8 positions) less
I

SBR020B
J
BRAKE BURNISHING PROCEDURE
Burnish brake pad or lining contact surfaces of rotor according to following procedure after refinishing or
replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. K
CAUTION:
● Be careful of vehicle speed because brake does not operate easily until pad and disc rotor are
securely fitted. L
● Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until vehicle stops. M
3. Drive without depressing brake for a few minutes to cool brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.

BR-39
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications BFS000C7

Unit: mm (in)
Cylinder bore diameter 57.2 (2.252)
Front brake Pad length × width × thickness 125.6 × 46.0 × 11.0 (4.94 × 1.81 × 0.433)
Rotor outer diameter × thickness 296 × 24 (11.65 × 0.945)
Cylinder bore diameter 34.93 (1.375)
Rear brake Pad length × width × thickness 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335)
Rotor outer diameter × thickness 292 × 9 (11.50 × 0.354)
Master cylinder Cylinder bore diameter 23.8 (0.94)
Control valve Valve model Electric brake force distribution
Brake booster Booster model M215T
Primary 228.5 (9.0)
Diaphragm diameter
Secondary 203 (8.0)
Recommended brake fluid DOT 3 or DOT 4

Brake Pedal BFS000C8

Unit: mm (in)
Brake pedal height (from dash lower panel top surface) 195.8 - 205.8 (7.71 - 8.10)
Depressed brake pedal height
More than 115 (4.53)
[under a force of 490 N (50 kg, 110 lb) with engine running]
Clearance between threaded end of stop lamp switch, brake
0.74 - 1.96 (0.0291 - 0.0772)
switch and/or ASCD cancel switch and bracket
Pedal play 3 - 11 (0.12 - 0.43)

Brake Booster BFS000C9

Vacuum type
Input rod installation standard dimension 125 mm (4.92 in)

Check Valve BFS000CA

Vacuum leakage
Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
[at vacuum of –66.7 kPa (–500 mmHg, –19.69 inHg)]

Front Disc Brake BFS000CB

Unit: mm (in)
Standard thickness 11.0 (0.433)
Brake pad
Repair limit thickness 2.0 (0.079)
Standard thickness 24.0 (0.945)
Wear limit 22.0 (0.866)
Disc rotor
Maximum uneven wear (measured at 8 positions) 0.010 (0.0004) or less
Runout limit (with it attached to vehicle) 0.040 (0.0016) or less

BR-40
 SERVICE DATA AND SPECIFICATIONS (SDS)

Rear Disc Brake BFS000CC

Unit: mm (in) A
Standard thickness 8.5 (0.335)
Brake pad
Repair limit thickness 2.0 (0.079)
B
Standard thickness 9.0 (0.354)
Wear limit 8.0 (0.315)
Disc rotor
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006) or less C
Runout limit (with it attached to vehicle) 0.050 (0.0020) or less

BR

BR-41
SERVICE DATA AND SPECIFICATIONS (SDS)

BR-42