Nissan Maxima Brake System BR 2000 Owner's Manual

EXIT

CONTENTS

PRECAUTIONS ...............................................................4

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″...............4

Precautions for Brake System.....................................4

Wiring Diagrams and Trouble Diagnosis.....................5

PREPARATION ...............................................................6

Commercial Service Tools...........................................6

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING.....................................................7

NVH Troubleshooting Chart.........................................7

ON-VEHICLE SERVICE ..................................................8

Checking Brake Fluid Level.........................................8

Checking Brake Line ...................................................8

Changing Brake Fluid..................................................8

Brake Burnishing Procedure........................................8

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

BRAKE HYDRAULIC LINE...........................................10

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

Removal.....................................................................10

Inspection...................................................................10

Installation..................................................................11

DUAL PROPORTIONING VALVE.................................12

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

BRAKE PEDAL AND BRACKET..................................13

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

Inspection...................................................................13

Adjustment.................................................................13

MASTER CYLINDER (TOKICO)...................................15

Removal.....................................................................15

Disassembly...............................................................16

Inspection...................................................................16

Assembly ...................................................................16

Installation..................................................................17

MASTER CYLINDER (NABCO)....................................18

Removal.....................................................................18

Disassembly...............................................................18

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

Assembly ...................................................................19

Installation..................................................................20

BRAKE SYSTEM

SECTION

BRAKE BOOSTER........................................................21

On-vehicle Service.....................................................21

OPERATING CHECK AIRTIGHT CHECK

Removal.....................................................................21

Inspection...................................................................21

OUTPUT ROD LENGTH CHECK

Installation..................................................................22

VACUUM HOSE.............................................................23

Removal and Installation...........................................23

Inspection...................................................................23

HOSES AND CONNECTORS CHECK VALVE

FRONT DISC BRAKE ...................................................24

Component ................................................................24

Pad Replacement......................................................24

Removal.....................................................................25

Disassembly...............................................................25

Inspection...................................................................26

CALIPER ROTOR

Assembly ...................................................................27

Installation..................................................................27

REAR DISC BRAKE......................................................28

Component ................................................................28

Pad Replacement......................................................28

Removal.....................................................................30

Disassembly...............................................................31

Inspection...................................................................32

CALIPER ROTOR

Assembly ...................................................................33

Installation..................................................................35

PARKING BRAKE CONTROL......................................37

Components...............................................................37

Removal and Installation...........................................37

Inspection...................................................................37

Adjustment.................................................................38

........................................................23

.................................................................26

...................................................................26

.................................................................32

...................................................................32

...............................................21

...................................................21

..............................21

...................................23

IDX

CONTENTS (Cont’d)

EXIT

ABS/TCS

DESCRIPTION...............................................................39

Purpose......................................................................39

ABS (Anti-Lock Brake System) Operation ................39

ABS Hydraulic Circuit................................................39

TCS (Traction Control System) Operation................40

System Components .................................................40

System Description....................................................40

SENSOR CONTROL UNIT ACTUATOR

.................................................................40

......................................................41

.............................................................41

Component Parts and Harness Connector

Location .....................................................................42

Schematic..................................................................43

Wiring Diagram - ABS/TCS -.....................................44

ON BOARD DIAGNOSTIC SYSTEM

DESCRIPTION...............................................................49

Self-diagnosis ............................................................49

FUNCTION SELF-DIAGNOSIS PROCEDURE HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)

..............................................................49

..............................49

........................................50

CONSULT-II...............................................................51

CONSULT-II APPLICATION TO ABS/TCS ECU (ABS CONTROL UNIT) PART NUMBER

.....................................................................51

MODE

..................51

CONSULT-II Inspection Procedure............................52

SELF-DIAGNOSIS PROCEDURE SELF-DIAGNOSTIC RESULTS MODE DATA MONITOR PROCEDURE ACTIVE TEST PROCEDURE DATA MONITOR MODE ACTIVE TEST MODE

...........................................56

...............................................57

..............................52

.......................53

................................54

....................................55

TROUBLE DIAGNOSIS - INTRODUCTION..................58

How to Perform Trouble Diagnoses for Quick

and Accurate Repair..................................................58

INTRODUCTION

......................................................58

TROUBLE DIAGNOSIS - BASIC INSPECTION...........59

Preliminary Check......................................................59

Ground Circuit Check................................................62

ACTUATOR MOTOR GROUND CONTROL UNIT GROUND ABS SOLENOID VALVE RELAY GROUND

................................62

.......................................62

................62

TROUBLE DIAGNOSIS - GENERAL

DESCRIPTION...............................................................63

Malfunction Code/Symptom Chart.............................63

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC

ITEMS.............................................................................65

Wheel Sensor or Rotor..............................................65

DIAGNOSTIC PROCEDURE

.....................................65

ABS Actuator Solenoid Valve....................................68

DIAGNOSTIC PROCEDURE

.....................................68

Solenoid Valve Relay.................................................72

DIAGNOSTIC PROCEDURE

.....................................72

Motor Relay or Motor.................................................78

DIAGNOSTIC PROCEDURE

.....................................78

Low Voltage...............................................................84

DIAGNOSTIC PROCEDURE

.....................................84

Control Unit................................................................86

DIAGNOSTIC PROCEDURE

.....................................86

TCS

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC

ITEMS.............................................................................87

ENGINE CHECK SIGNAL - Engine System.............87

DIAGNOSTIC PROCEDURE

.....................................87

ENG SPEED SIG - Engine Speed Signal.................87

DIAGNOSTIC PROCEDURE

.....................................87

LAN SIGNAL 1 - LAN Monitoring..............................89

DIAGNOSTIC PROCEDURE

.....................................89

LAN SIGNAL 2 - LAN Communication Start

Procedures Incomplete..............................................91

DIAGNOSTIC PROCEDURE

.....................................91

LAN CIRCUITS 1, LAN CIRCUITS2-LAN

Communication System Failure.................................92

DIAGNOSTIC PROCEDURE

.....................................92

LAN SIGNAL 3 - Continued Reception After LAN

Communication Starts ...............................................93

DIAGNOSTIC PROCEDURE

.....................................93

ABS/TCS

TROUBLE DIAGNOSES FOR SYMPTOMS.................94

1. ABS Works Frequently ..........................................94

2. Unexpected Pedal Action ......................................94

3. Long Stopping Distance........................................95

4. ABS Does Not Work..............................................96

5. Pedal Vibration and Noise.....................................97

6. ABS Warning Lamp Does Not Come On

When Ignition Switch Is Turned On...........................98

7. ABS Warning Lamp Stays On When Ignition

Switch Is Turned On................................................101

TCS

TROUBLE DIAGNOSES FOR SYMPTOMS...............106

8. SLIP Indicator Lamp Does Not Come On

When Ignition Switch Is Turned On.........................106

9. TCS OFF Indicator Lamp Does Not Come On

When Ignition Switch Is Turned On.........................107

10. TCS OFF Switch Is Inoperative ........................109

11. Poor Acceleration...............................................112

BR-2

CONTENTS (Cont’d)

EXIT

ABS/TCS

REMOVAL AND INSTALLATION...............................113

Wheel Sensors ........................................................113

Sensor Rotor............................................................113

REMOVAL INSTALLATION

Control Unit..............................................................114

Actuator....................................................................114

REMOVAL INSTALLATION

.............................................................113

......................................................114

.............................................................114

......................................................114

SERVICE DATA AND SPECIFICATIONS (SDS).......115

General Specifications.............................................115

Disc Brake ...............................................................115

Brake Pedal.............................................................115

Parking Brake..........................................................115

Control Valve ...........................................................115

Brake Booster..........................................................116

ABS Wheel Sensor..................................................116

BR-3

IDX

PRECAUTIONS

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELTPRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL A33 is as follows (The composition varies according to optional equipment.):

I For a frontal collision

The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.

I For a side collision

The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).

Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING:

I 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 should be performed by an authorized NISSAN dealer.

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

sonal injury caused by intentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section.

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

Service Manual. Spiral cable and wiring harnesses covered with yellow insulation or tape either just before the harness connectors or for the complete harness are related to the SRS.

NFBR0001

EXIT

SBR686C

Precautions for Brake System

NFBR0002

I Recommended fluid is brake fluid “DOT 3”. I Never reuse drained brake fluid. I Be careful not to splash brake fluid on painted areas. I To clean or wash all parts of master cylinder, disc brake

caliper and wheel cylinder, use clean brake fluid.

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

will ruin rubber parts of the hydraulic system.

I Use flare nut wrench when removing and installing brake

tube.

I Always torque brake lines when installing. I 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 “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-8

WARNING:

I Clean brake pads and shoes with a waste cloth, then wipe

with a dust collector.

BR-4

PRECAUTIONS

Wiring Diagrams and Trouble Diagnosis

EXIT

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the followings:

I “HOW TO READ WIRING DIAGRAMS” in GI section I “POWER SUPPLY ROUTING” for power distribution circuit in EL section

When you perform trouble diagnosis, refer to the followings:

I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” in GI section I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” in GI section

NFBR0003

BR-5

IDX

Commercial Service Tools

PREPARATION

EXIT

Tool name Description 1 Flare nut crowfoot

2 Torque wrench

NT360

Brake fluid pressure gauge

NT151

Commercial Service Tools

Removing and installing each brake piping

a: 10 mm (0.39 in)

Measuring brake fluid pressure

NFBR0004

BR-6

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

NFBR0005

EXIT

NVH Troubleshooting Chart

NFBR0005S01

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

Reference page

Possible cause and SUSPECTED PARTS

Symptom BRAKE

X: Applicable

BR-24, 28

Pads - damaged

Pads - uneven wear Noise X X X XXXXXX Shake X XXXXXX Shimmy, Judder XXXXXXX XXXXX

—

BR-24, 28

Shims damaged

Rotor imbalance

—

BR-26, 32

Rotor damage

Rotor runout

—

Rotor deformation

Rotor deflection

—

Rotor rust

BR-26, 32

NVH in AX section

Rotor thickness variation

DRIVE SHAFT

NVH in AX section

NVH in SU section

AXLE

SUSPENSION

NVH in SU section

TIRES

NVH in SU section

ROAD WHEEL

NVH in ST section

STEERING

BR-7

IDX

Checking Brake Fluid Level

ON-VEHICLE SERVICE

EXIT

SBR451D

SBR389C

SBR419C

Checking Brake Fluid Level

NFBR0006

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

and Min lines on reservoir tank.

I If fluid level is extremely low, check brake system for leaks. I Release parking brake lever and see if brake warning lamp

goes off. If not, check brake system for leaks.

Checking Brake Line

NFBR0007

CAUTION:

If leakage occurs around joints, retighten or, if necessary, replace damaged parts.

1. Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.

2. Check for oil leakage by fully depressing brake pedal while engine is running.

Changing Brake Fluid

NFBR0008

CAUTION:

I Refill with new brake fluid “DOT 3”. I Always keep fluid level higher than minimum line on res-

ervoir tank.

I Never reuse drained brake fluid. I 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. Clean inside of reservoir tank, and refill with new brake fluid.

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

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

4. Refill until brake fluid comes out of each air bleeder valve. Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to “Bleeding Brake System”, BR-9.

Brake Burnishing Procedure

NFBR0036

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

BR-8

ON-VEHICLE SERVICE

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.

Bleeding Brake System

CAUTION:

I Carefully monitor brake fluid level at master cylinder dur-

ing bleeding operation.

I Fill reservoir with new brake fluid “DOT 3”. Make sure it is

full at all times while bleeding air out of system.

I Place a container under master cylinder to avoid spillage

of brake fluid.

I For models with ABS, turn ignition switch OFF and dis-

connect ABS actuator connectors or battery ground cable.

SBR995

I Bleed air in the following order.

Right rear brake , Left front brake , Left rear brake , Right front brake

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

2. Fully depress brake pedal several times.

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

4. Close air bleeder valve.

5. Release brake pedal slowly.

SBR419C

6. Repeat steps 2. through 5. until clear brake fluid comes out of air bleeder valve.

Brake Burnishing Procedure (Cont’d)

NFBR0009

EXIT

BR-9

IDX

Hydraulic Circuit

BRAKE HYDRAULIC LINE

EXIT

SBR992

Hydraulic Circuit

Removal

NFBR0010

MBR151A

NFBR0011

CAUTION:

I 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.

I All hoses must be free from excessive bending, twisting

and pulling.

1. Connect vinyl tube 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 withdraw lock spring.

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

Inspection

NFBR0012

Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.

BR-10

BRAKE HYDRAULIC LINE

Installation

EXIT

SBR686C

Installation

CAUTION:

I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid.

1. Tighten all flare nuts and connecting bolts.

Specification:

Flare nut

15 - 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)

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

3. Bleed air. Refer to “Bleeding Brake System”, BR-9.

NFBR0013

BR-11

IDX

Inspection

DUAL PROPORTIONING VALVE

EXIT

SBR822BA

SBR823BA

Inspection

NFBR0014

CAUTION:

I Carefully monitor brake fluid level at master cylinder. I Use new brake fluid “DOT 3”. I 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.

Unit: kPa (kg/cm2, psi) Applied pressure (Front brake) 7,355 (75, 1,067) Output pressure (Rear brake) 5,100 - 5,492 (52 - 56, 739 - 796)

If output pressure is out of specification, replace dual proportioning valve.

4. Bleed air after disconnecting the Tool. Refer to “Bleeding Brake System”, BR-9.

BR-12

BRAKE PEDAL AND BRACKET

Removal and Installation

EXIT

Removal and Installation

Inspection

Check brake pedal for following items.

I Brake pedal bend I Clevis pin deformation I Crack of any welded portion I Crack or deformation of clevis pin stopper

NFBR0015

SBR525E

NFBR0016

SBR997

SBR526E

Adjustment

Check brake pedal free height from metal panel. Adjust if necessary.

H: Free height

Refer to SDS, BR-115.

: Clearance between pedal stopper and threaded

1,C2

end of stop lamp switch and ASCD switch

0.74 - 1.96 mm (0.0291 - 0.0772 in)

NFBR0017

IDX

BR-13

Adjustment (Cont’d)

BRAKE PEDAL AND BRACKET

1. Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut.

2. Check pedal free play.

Make sure that stop lamps go off when pedal is released.

3. Check brake pedal’s depressed height while engine is running. If lower than specification, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.); then make necessary repairs.

SBR229E

EXIT

BR-14

MASTER CYLINDER (TOKICO)

Removal

EXIT

Removal

NFBR0018

1. Reservoir cap

2. Oil filter

3. Reservoir tank

4. Seal

5. Cylinder body

6. O-ring

7. Piston stopper

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.

1. Connect a vinyl tube to air bleeder valve.

2. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder.

3. Remove brake pipe flare nuts.

4. Remove master cylinder mounting nuts.

8. Secondary piston assembly

9. Primary piston assembly

10. Stopper cap

SBR554E

BR-15

IDX

Disassembly

MASTER CYLINDER (TOKICO)

EXIT

SBR938A

SBR231C

Disassembly

NFBR0019

1. Bend claws of stopper cap outward and remove stopper cap.

2. Remove valve 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

NFBR0020

Check for the following items.

Replace any part if damaged. Master cylinder:

I Pin holes or scratches on inner wall.

Piston:

I Deformation of or scratches on piston cups.

SBR354C

SBR940A

Assembly

NFBR0021

1. Insert secondary piston assembly. Then insert primary piston assembly.

I 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.

BR-16

MASTER CYLINDER (TOKICO)

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

Assembly (Cont’d)

EXIT

SBR222B

SBR704C

Installation

CAUTION:

I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid.

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

2. Torque mounting nuts.

: 12 - 15 N·m (1.2 - 1.5 kg-m,9-11ft-lb)

3. Fill up reservoir tank with new brake fluid.

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

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

8. Bleed air from brake system. Refer to “Bleeding Brake System”, BR-9.

NFBR0022

BR-17

IDX

Removal

MASTER CYLINDER (NABCO)

EXIT

Removal

NFBR0095

1. Reservoir cap

2. Oil filter

3. Float

4. Reservoir tank

5. Seal

6. Cylinder body

7. Spring pin

8. Piston stopper pin

9. Secondary piston assembly

10. Primary piston assembly

11. Stopper cap

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.

1. Connect a vinyl tube to air bleeder valve.

2. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder.

3. Remove brake pipe flare nuts.

4. Remove master cylinder mounting nuts.

Disassembly

1. Bend claws of stopper cap outward and remove stopper cap.

SBR555E

NFBR0096

SBR234E

BR-18

MASTER CYLINDER (NABCO)

2. Drive out spring pin from cylinder body.

3. Draw out reservoir tank and seals.

Disassembly (Cont’d)

EXIT

SBR231E

SBR232E

4. Remove piston stopper pin while piston is pushed into cylinder.

5. Remove piston assemblies.

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

Inspection

Check for the following items.

Replace any part if damaged. Master cylinder:

I Pin holes or scratches on inner wall.

Piston:

I Deformation of or scratches on piston cups.

NFBR0097

SBR233E

SBR232E

Assembly

1. Insert secondary piston assembly. Then insert primary piston assembly.

I Pay attention to alignment of secondary piston slit with

valve stopper mounting hole of cylinder body.

2. Install piston stopper pin while piston is pushed into cylinder.

3. Push reservoir tank seals and reservoir tank into cylinder body.

4. Install spring pin.

NFBR0098

BR-19

IDX

Assembly (Cont’d)

MASTER CYLINDER (NABCO)

5. Install stopper cap.

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

SBR235E

EXIT

SBR236E

Installation

NFBR0099

CAUTION:

I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid.

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

2. Torque mounting nuts.

: 12 - 15 N·m (1.2 - 1.5 kg-m,9-11ft-lb)

3. Fill up reservoir tank with new brake fluid.

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

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

8. Bleed air from brake system.

BR-20

BRAKE BOOSTER

On-vehicle Service

EXIT

SBR002A

SBR365AA

On-vehicle Service

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

1. 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.

2. 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

CAUTION:

I 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.

I Be careful not to deform or bend brake pipes, during

removal of booster.

NFBR0023

NFBR0023S01

NFBR0023S02

NFBR0024

SBR232CB

SBR208E

Inspection

OUTPUT ROD LENGTH CHECK

1. Apply vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg) to brake booster with a handy vacuum pump.

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

3. Check output rod length.

Specified length:

10.275 - 10.525 mm (0.4045 - 0.4144 in)

NFBR0025

NFBR0025S01

IDX

BR-21

Installation

BRAKE BOOSTER

EXIT

SBR237EB

Installation

NFBR0026

CAUTION:

I Be careful not to deform or bend brake pipes, during

installation of booster.

I Replace clevis pin if damaged. I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid. I Take care not to damage brake booster mounting bolt

thread when installing. Due to the acute angle of installation, the threads can be damaged with the dash panel.

1. Before fitting booster, temporarily adjust clevis to dimension shown.

2. Fit booster, then secure mounting nuts (brake pedal bracket to master cylinder) lightly.

3. Connect brake pedal and booster input rod with clevis pin.

4. Secure mounting nuts.

Specification:

13 - 16 N·m (1.3 - 1.6 kg-m,9-12ft-lb)

5. Install master cylinder. Refer to “Installation” in “MASTER CYLINDER”, BR-17.

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

BR-22

VACUUM HOSE

Removal and Installation

EXIT

SBR225B

Removal and Installation

CAUTION:

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

I Do not apply any oil or lubricants to vacuum hose and

check valve.

I Insert vacuum tube into vacuum hose as shown. I Install check valve, paying attention to its direction.

Inspection

HOSES AND CONNECTORS

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

CHECK VALVE

Check vacuum with a vacuum pump.

NFBR0027

NFBR0028

NFBR0028S01

NFBR0028S02

SBR844B

Connect to booster side Vacuum should exist. Connect to engine side Vacuum should not exist.

BR-23

IDX

Component

FRONT DISC BRAKE

EXIT

1. Main pin

2. Pin boot

3. Torque member fixing bolt

4. Torque member

5. Shim cover

6. Inner shim

7. Inner pad

Component

8. Pad retainer

9. Outer pad

10. Outer shim

11. Shim cover

12. Connecting bolt

13. Copper washer

NFBR0030

SBR527EA

14. Main pin bolt

15. Bleed valve

16. Cylinder body

17. Piston seal

18. Piston

19. Piston boot

Pad Replacement

NFBR0029

WARNING:

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

CAUTION:

I When cylinder body is open, do not depress brake pedal

because piston will pop out.

I Be careful not to damage piston boot or get oil on rotor.

Always replace shims when replacing pads.

I If shims are rusted or show peeling of the rubber coat,

replace them with new shims.

I 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.

I 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 “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-8.

BR-24

SBR976B

FRONT DISC BRAKE

Pad Replacement (Cont’d)

1. Remove master cylinder reservoir cap.

2. Remove pin bolt.

3. Open cylinder body upward. Then remove pad with retainers, inner and outer shims.

Standard pad thickness:

11 mm (0.43 in)

Pad wear limit:

2.0 mm (0.079 in)

Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

EXIT

SBR932C

SBR979B

SBR772

Removal

WARNING:

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

Remove torque member fixing bolts and connecting bolt.

It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.

Disassembly

WARNING:

Do not place your fingers in front of piston.

CAUTION:

Do not scratch or score cylinder wall.

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

2. Remove piston seal with a suitable tool.

CAUTION:

When removing the pad retainer from the torque member, lift it up and out in the direction of the arrows in the figure.

NFBR0031

NFBR0032

SBR556E

IDX

BR-25

Inspection

FRONT DISC BRAKE

EXIT

Inspection

CALIPER Cylinder Body

NFBR0033

NFBR0033S01

NFBR0033S0101

I 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.

I Minor damage from rust or foreign materials may be eliminated

by polishing surface with a fine emery paper. Replace cylinder body if necessary.

CAUTION:

Use brake fluid to clean. Never use mineral oil.

Piston

NFBR0033S0102

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 conditions are observed.

Slide Pin, Pin Bolt and Pin Boot

NFBR0033S0103

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

ROTOR Rubbing Surface

NFBR0033S02

NFBR0033S0201

Check rotor for roughness, cracks or chips.

SBR219C

Runout

NFBR0033S0202

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 specifications before measuring. Refer to AX section (“Front Wheel Bearing”, “ON-VEHICLE SERVICE”).

Maximum runout:

0.07 mm (0.0028 in)

3. If the runout is out of specification, find minimum runout position as follows:

a. Remove nuts and rotor from wheel hub. b. Shift the rotor one hole and secure rotor to wheel hub with

nuts.

c. Measure runout. d. Repeat steps a. to c. so that minimum runout position can be

found.

4. If the runout is still out of specification, turn rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equivalent).

BR-26

FRONT DISC BRAKE

Inspection (Cont’d)

EXIT

SBR574

Thickness

Thickness variation (At least 8 positions):

Maximum 0.01 mm (0.0004 in)

If thickness variation exceeds the specification, turn rotor with oncar brake lathe.

Rotor repair limit:

24.0 mm (0.945 in)

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. Properly secure piston boot.

Installation

CAUTION:

I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid.

1. Install brake hose to caliper securely.

2. Install all parts and secure all bolts.

3. Bleed air. Refer to “Bleeding Brake System”, BR-9.

NFBR0033S0203

NFBR0034

NFBR0035

SBR980B

SBR557E

CAUTION:

The upper pad retainer is built so the pad returns to its original position. Be careful to install the pad-return lever securely to the pad wear sensor, as shown in the left figure.

IDX

BR-27

Component

REAR DISC BRAKE

EXIT

Component

NFBR0038

1. Nut

2. Washer

3. Return spring

4. Parking brake lever

5. Cam boot

6. Cam

7. Brake hose

8. Connecting bolt

9. Copper washer

10. Bleed screw

11. Pin bolt

12. Cable mounting bracket

13. Cylinder

14. Strut

15. O-ring

16. Push rod

17. Key plate

18. Ring C

19. Seat

20. Spring

21. Spring cover

22. Ring B

23. Piston seal

24. Ring A

25. Spacer

26. Wave washer

27. Spacer

28. Ball bearing

29. Adjust nut

30. Cup

31. Piston

32. Dust seal

33. Inner shim

34. Inner pad

35. Outer pad

36. Outer shim

37. Pin

38. Pin boot

39. Pad retainer

40. Torque member

41. Torque member fixing bolt

Pad Replacement

WARNING:

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

CAUTION:

I When cylinder body is open, do not depress brake pedal

because piston will pop out.

I Be careful not to damage piston boot or get oil on rotor.

Always replace shims in replacing pads.

I If shims are rusted or show peeling of rubber coat, replace

them with new shims.

SBR558E

NFBR0037

BR-28

SBR938C

REAR DISC BRAKE

Pad Replacement (Cont’d)

I 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.

I 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 “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-8.

1. Remove master cylinder reservoir cap.

2. Remove brake cable mounting bolt and lock spring.

3. Release parking brake control lever, then disconnect cable from the caliper.

4. Remove upper pin bolt.

5. Open cylinder body downward. Then remove pad retainers, and inner and outer shims.

Standard pad thickness:

10 mm (0.39 in)

Pad wear limit:

1.5 mm (0.059 in)

EXIT

SBR916C

SBR641

6. When installing new pads, push piston into cylinder body by gently turning piston clockwise, as shown.

Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

SBR868C

IDX

BR-29

Pad Replacement (Cont’d)

SBR306E

REAR DISC BRAKE

7. Adjust the piston to the right angle as shown in the figure.

8. As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member.

EXIT

SBR307E

SBR939C

Removal

NFBR0039

WARNING:

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

1. Remove brake cable mounting bolt and lock spring.

2. Release parking brake control lever, then disconnect cable from the caliper.

3. Remove torque member fixing bolts and connecting bolt.

It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.

BR-30

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