Nissan Xterra Brake System BR 2000 Owner's Manual

BRAKE SYSTEM

CONTENTS

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

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″...............3

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

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

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

Special Service Tools..................................................4

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

NOISE, VIBRATION AND HARSHNESS (NVH)

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

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

ON-VEHICLE SERVICE ..................................................6

Checking Brake Fluid Level.........................................6

Checking Brake Line ...................................................6

Changing Brake Fluid..................................................6

Brake Burnishing Procedure........................................7

Bleeding Brake System...............................................8

BRAKE HYDRAULIC LINE.............................................9

Hydraulic Circuit...........................................................9

Removal.......................................................................9

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

Installation..................................................................10

BRAKE PEDAL AND BRACKET..................................11

Removal and Installation...........................................11

Inspection...................................................................11

Adjustment.................................................................12

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

Removal.....................................................................13

Disassembly...............................................................13

Inspection...................................................................14

Assembly ...................................................................14

Installation..................................................................15

BRAKE BOOSTER........................................................16

On-vehicle Service.....................................................16

OPERATING CHECK AIRTIGHT CHECK

Removal.....................................................................16

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

OUTPUT ROD LENGTH CHECK

...............................................16

...................................................16

..............................16

SECTION

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

VACUUM PIPING...........................................................18

Removal and Installation...........................................18

Inspection...................................................................18

HOSES AND CONNECTORS CHECK VALVE

FRONT DISC BRAKE ...................................................19

Pad Replacement......................................................19

Removal.....................................................................20

Disassembly...............................................................20

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

CALIPER ROTOR

Assembly ...................................................................22

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

Brake Burnishing Procedure......................................22

REAR DRUM BRAKE ...................................................23

Components...............................................................23

Removal.....................................................................23

Inspection...................................................................24

WHEEL CYLINDER

Wheel Cylinder Overhaul...........................................24

Inspection...................................................................25

.....................................................................25

DRUM

....................................................................25

LINING

Installation..................................................................25

PARKING BRAKE CONTROL......................................27

Components...............................................................27

Removal and Installation...........................................27

Inspection...................................................................27

Adjustment.................................................................28

DESCRIPTION...............................................................29

Purpose......................................................................29

Operation...................................................................29

ABS Hydraulic Circuit................................................29

System Components .................................................30

System Description....................................................30

........................................................18

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

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

...................................18

..................................................24

ABS

IDX

CONTENTS (Cont’d)

WHEEL SENSOR CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT) ABS ACTUATOR AND ELECTRIC UNIT G SENSOR (4WD MODELS)

....................................................30

.....................................................30

....................31

....................................31

Component Parts and Harness Connector

Location .....................................................................32

Schematic..................................................................33

2–WHEEL DRIVE 4–WHEEL DRIVE

....................................................33

....................................................34

Wiring Diagram - ABS - 2WD - .................................35

Wiring Diagram - ABS - 4WD - .................................38

ON BOARD DIAGNOSTIC SYSTEM

DESCRIPTION...............................................................41

Self-diagnosis ............................................................41

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

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

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

........................................42

TROUBLE DIAGNOSIS - INTRODUCTION..................43

How to Perform Trouble Diagnoses for Quick

and Accurate Repair..................................................43

INTRODUCTION

......................................................43

TROUBLE DIAGNOSIS - BASIC INSPECTION...........44

Preliminary Check......................................................44

Ground Circuit Check................................................47

ABS ACTUATOR AND ELECTRIC UNIT GROUND

.....47

TROUBLE DIAGNOSIS - GENERAL

DESCRIPTION...............................................................48

Malfunction Code/Symptom Chart.............................48

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC

ITEMS.............................................................................49

Wheel Sensor or Rotor..............................................49

DIAGNOSTIC PROCEDURE

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

ABS Actuator Solenoid Valve or Solenoid Valve

Relay..........................................................................52

DIAGNOSTIC PROCEDURE

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

Motor Relay or Motor.................................................54

DIAGNOSTIC PROCEDURE

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

Low Voltage...............................................................56

DIAGNOSTIC PROCEDURE

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

G Sensor and Circuit.................................................58

DIAGNOSTIC PROCEDURE

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

Control Unit................................................................60

DIAGNOSTIC PROCEDURE

.....................................60

TROUBLE DIAGNOSES FOR SYMPTOMS.................61

1. ABS Works Frequently ..........................................61

2. Unexpected Pedal Action ......................................61

3. Long Stopping Distance........................................63

4. ABS Does Not Work..............................................63

5. Pedal Vibration and Noise.....................................64

6. Warning Lamp Does Not Come On When

Ignition Switch Is Turned On .....................................64

7. Warning Lamp Stays On When Ignition Switch

Is Turned On..............................................................66

REMOVAL AND INSTALLATION.................................69

Front Wheel Sensor...................................................69

Rear Wheel Sensor...................................................69

4WD MODELS 2WD MODELS

.........................................................69

.........................................................70

Front Sensor Rotor....................................................70

REMOVAL INSTALLATION

...............................................................70

........................................................71

Rear Sensor Rotor (4WD).........................................71

REMOVAL INSTALLATION

...............................................................71

........................................................71

Rear Sensor Rotor (2WD).........................................71

REMOVAL AND INSTALLATION

...............................71

G Sensor....................................................................71

ABS Actuator and Electric Unit..................................72

REMOVAL INSTALLATION

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

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

SERVICE DATA AND SPECIFICATIONS (SDS).........73

General Specifications...............................................73

Disc Brake .................................................................73

Drum Brake................................................................73

Brake Pedal...............................................................73

Parking Brake Control ...............................................74

BR-2

PRECAUTIONS

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

The supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-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 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, a crash zone sensor (4WD models), warning lamp, wiring harness and spiral cable. 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 must 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 unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, refer to

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 (except “SEAT BELT PRE-TENSIONER”) covered with yellow insulation either just before the harness connectors or for the complete harness are related to the SRS.

RS-16

NGBR0001

SBR686C

Precautions for Brake System

I Use brake fluid “DOT 3”. 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.

I To clean master cylinder parts, disc brake caliper parts or

wheel cylinder parts, use clean brake fluid.

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

will ruin rubber parts of hydraulic system.

I Use flare nut wrench when removing and installing brake

tubes. I Always torque brake lines when installing.

WARNING:

I Clean brakes with a vacuum dust collector to minimize

risk of health hazard from powder caused by friction.

NGBR0002

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the followings:

GI-10

I “HOW TO READ WIRING DIAGRAMS” refer to I “POWER SUPPLY ROUTING” for power distribution circuit refer to

When you perform trouble diagnosis, refer to the followings:

I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” refer to I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” refer to

EL-9

GI-34

BR-3

GI-23

NGBR0003

IDX

Special Service Tools

PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

KV40106500 (JS25852-B) Wheel bearing puller

Description

Removing rear wheel sensor rotor

NT724

Commercial Service Tools

Tool name Description 1 Flare nut crowfoot

2 Torque wrench

NT360

Brake fluid pressure gauge

Removing and installing each brake piping

a: 10 mm (0.39 in)

Measuring brake fluid pressure

NGBR0004

NGBR0005

Rear wheel sensor rotor drift

NT151

Installing rear wheel sensor rotor

a: 75 mm (2.95 in) dia. b: 63 mm (2.48 in) dia.

NT509

BR-4

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

NGBR0085

NVH Troubleshooting Chart

NGBR0085S01

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

PD-40

Reference page

Possible cause and SUSPECTED PARTS

Noise ×××× Ч Ч ЧЧЧЧЧЧ

BR-25

BR-19, 25

Linings or pads - damaged

Linings or pads - uneven wear

BR-23

BR-18

Return spring damaged

Shims damaged

—

Rotor or drum imbalance

Rotor or drum damage

—

BR-21, 25

Rotor or drum runout

Rotor or drum deformation

—

Rotor or drum deflection

Rotor or drum rust

BR-21

BR-25

Rotor thickness variation

Drum out of round

PD-4

PD-14

NVH,

PROPELLER SHAFT

AX-3

NVH,

PD-62

DIFFERENTIAL

DRIVE SHAFT

AXLE

SU-3

NVH,

SUSPENSION

TIRES

ROAD WHEEL

ST-5

NVH,

STEERING

Symptom BRAKE

×: Applicable

Shake × × ЧЧЧЧЧЧ

Shimmy, Judder ЧЧЧЧЧЧЧЧ ЧЧЧЧЧ

BR-5

IDX

Checking Brake Fluid Level

ON-VEHICLE SERVICE

SBR451D

SBR389C

SBR419C

Checking Brake Fluid Level

NGBR0006

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. I If the brake warning lamp comes on, check brake fluid level

switch and parking brake switch.

Checking Brake Line

NGBR0007

CAUTION:

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

1. Check brake lines (tubes and hoses) for cracks, deterioration

and other damage. Replace any damaged parts.

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

engine is running.

Changing Brake Fluid

NGBR0008

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-8.

BR-6

ON-VEHICLE SERVICE

Brake Burnishing Procedure

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

pressure such that vehicle stopping time equals to 3 to 5 sec-

onds.

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 burnish-

ing procedure.

=NGBR0120

BR-7

IDX

Bleeding Brake System

ON-VEHICLE SERVICE

SBR995

SBR419C

Bleeding Brake System

=NGBR0009

CAUTION:

I Carefully monitor brake fluid level at master cylinder dur-

ing bleeding operation. I If master cylinder is suspected to have air inside, bleed air

from master cylinder first. Refer to “Installation”, “MAS-

TER CYLINDER”, BR-15. 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 Turn ignition switch OFF and disconnect ABS actuator

connectors or battery ground cable. I Bleed air in the following order.

1. Left rear brake

2. Right rear brake

3. Left front brake

4. 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.

6. Repeat steps 1. through 4. until clear brake fluid comes out of

air bleeder valve.

7. Tighten air bleeder valve to specified torque.

:7-9N·m(0.7 - 0.9 kg-m, 61 - 78 in-lb)

BR-8

BRAKE HYDRAULIC LINE

Hydraulic Circuit

NGBR0010

SBR992

ABR676

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 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 with-

draw lock spring.

4. Cover openings to prevent entrance of dirt whenever discon-

necting brake line.

NGBR0011

BR-9

IDX

Inspection

BRAKE HYDRAULIC LINE

SBR686C

Inspection

NGBR0012

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

Installation

NGBR0013

CAUTION:

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

1. Tighten all flare nuts and connecting bolts.

Flare nut:

: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

Connecting bolt:

: 17 - 19 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-8.

BR-10

BRAKE PEDAL AND BRACKET

Removal and Installation

NGBR0016

SBR997

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

ABR824

NGBR0017

BR-11

IDX

Adjustment

BRAKE PEDAL AND BRACKET

SBR278AB

SBR930

Adjustment

NGBR0018

Check brake pedal free height from metal floor.

H: Free height

Refer to SDS (BR-73).

D: Depressed height

Refer to SDS (BR-73). Under force of 490 N (50 kg, 110 lb) with engine run-

ning ,C2: Clearance between pedal stopper and

threaded end of stop lamp switch and ASCD switch

0.3 - 1.0 mm (0.012 - 0.039 in)

A: Pedal free play

1-3mm(0.04 - 0.12 in)

If necessary, adjust brake pedal free height.

1. Loosen lock nut and adjust pedal free height by turning brake

booster input rod. Then tighten lock nut.

Make sure that tip of input rod stays inside.

2. Adjust clearance “C

” and “C2” with stop lamp switch and

ASCD switch respectively. Then tighten lock nuts.

3. Check pedal free play.

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

4. Check brake pedal’s depressed height while engine is running.

If depressed height is below specified value, check brake sys-

tem for leaks, accumulation of air or any damage to compo-

nents (master cylinder, wheel cylinder, etc.). Then make nec-

essary repairs.

BR-12

MASTER CYLINDER

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 In the case of brake fluid leakage from the master cylinder,

disassemble the cylinder. Then check piston cups for

deformation and scratches and replace necessary parts.

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.

NGBR0019

Disassembly

1. Bend claws of stopper cap outward.

ABR873

NGBR0020

SBR938A

IDX

BR-13

Disassembly (Cont’d)

MASTER CYLINDER

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

3. Remove piston assemblies.

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

4. Draw out reservoir tank.

SBR939A

ABR767

Inspection

NGBR0021

Check master cylinder inner wall for pin holes and scratches. Replace if damaged.

Assembly

NGBR0022

1. Insert secondary piston assembly. Then insert primary piston

assembly.

I Pay attention to direction of piston cups in figure at left.

Also, insert pistons squarely to avoid scratches on cylin-

der bore.

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.

SBR940A

BR-14

MASTER CYLINDER

Installation

ABR190

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 mount-

ing 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 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

8. Bleed air. Refer to “Bleeding Brake System”, BR-8.

=NGBR0023

BR-15

IDX

On-vehicle Service

BRAKE BOOSTER

SBR002A

SBR365AA

On-vehicle Service

OPERATING CHECK

NGBR0024

NGBR0024S01

1. Depress brake pedal several times with engine off. After

exhausting vacuum, make sure there is no change in pedal

stroke.

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

slightly, operation is normal.

AIRTIGHT CHECK

NGBR0024S02

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

brake pedal several times slowly. Booster is airtight if pedal

stroke is less each time.

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

NGBR0025

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.

ABR909

ABR908

Inspection

OUTPUT ROD LENGTH CHECK

NGBR0026

NGBR0026S01

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

brake booster with a hand vacuum pump.

2. Add preload of 19.6 N (2.0 kg, 4.4 lb) to output rod length.

3. Check output rod length.

Specified length:

10.275 - 10.525 mm (0.4045 - 0.4144 in)

BR-16

BRAKE BOOSTER

Installation

SBR116BE

Installation

CAUTION:

I Be careful not to deform or bend brake pipes during instal-

lation 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 narrow angle of

installation, the threads can be damaged by the dash

panel.

A: 138.5 mm (5.45 in)

1. Before fitting booster, temporarily adjust clevis to dimension

shown.

2. Fit booster, then secure mounting nuts (brake pedal bracket to

brake booster) 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-15.

6. Adjust brake pedal height and free play. Refer to “Adjustment”

in “BRAKE PEDAL AND BRACKET”, BR-12.

7. Secure lock nut for clevis.

: 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)

8. Bleed air. Refer to “Bleeding Brake System”, BR-8.

=NGBR0027

BR-17

IDX

Removal and Installation

VACUUM PIPING

SBR225B

SBR498A

Removal and Installation

NGBR0029

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

NGBR0030

NGBR0030S01

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

SBR943A

CHECK VALVE

Check vacuum with a vacuum pump.

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

BR-18

NGBR0030S02

FRONT DISC BRAKE

Pad Replacement

WARNING:

Clean brakes 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,

or 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 Carefully monitor brake fluid level because brake fluid will

return to reservoir when pushing back piston.

1. Remove master cylinder reservoir cap.

2. Remove lower pin bolt.

NGBR0032

SBR081A

3. Open cylinder body upward. Then remove pad retainers, and

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.

SBR010B

IDX

BR-19

Pad Replacement (Cont’d)

FRONT DISC BRAKE

ABR918

SBR083A

Removal

NGBR0033

WARNING:

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

CAUTION:

Suspend caliper assembly with wire so as not to stretch brake hose.

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

NGBR0034

WARNING:

Do not place your fingers in front of piston.

CAUTION:

Do not scratch or score cylinder wall.

1. Push out piston with dust seal with compressed air.

2. Remove piston seal with a suitable tool.

SBR085A

BR-20

FRONT DISC BRAKE

Inspection

SBR089A

Inspection

CALIPER Cylinder Body

I Check inside surface of cylinder for score, rust, wear, damage

and presence of foreign objects. If any of the above conditions

are observed, replace cylinder body. I Minor damage from rust or foreign objects 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

CAUTION:

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

Check pistons for uneven surface, chips or cracks. Replace if any of these conditions are observed.

Slide Pin, Pin Bolt and Pin Boot

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

ROTOR Runout

1. Check runout using a dial indicator.

Make sure that wheel bearing axial end play is within the

AX-4

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

Maximum runout:

0.07 mm (0.0028 in)

2. If the runout is out of specification, machine rotor with on-car

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

equivalent).

“Front Wheel

NGBR0035

NGBR0035S01

NGBR0035S0101

NGBR0035S0102

NGBR0035S0103

NGBR0035S02

NGBR0035S0201

SBR090A

Thickness

Thickness variation (At least 8 positions):

Maximum 0.02 mm (0.0008 in)

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

Rotor repair limit:

26.0 mm (1.024 in)

NGBR0035S0202

BR-21

IDX

Assembly

FRONT DISC BRAKE

SBR178C

SBR179CA

Assembly

NGBR0036

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

CAUTION:

I Secure dust seal property. I Lubricate with new brake fluid before installing plastic pis-

tons into cylinder body.

Installation

NGBR0037

CAUTION:

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

1. Install caliper assembly.

2. Install brake hose to caliper securely.

3. Install all parts and secure all bolts.

4. Bleed air. Refer to “Bleeding Brake System”, BR-8.

SBR084A

Brake Burnishing Procedure

NGBR0088

When experiencing soft brake pedal feel at very low mileage, or after replacing the rotor, burnish the brake pad contact surfaces according to the following procedures.

CAUTION:

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

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

MPH).

2. Use medium brake pedal/foot effort to bring the vehicle to a

complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot

pressure such that vehicle stopping time equals 3 to 5 sec-

onds.

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 burnish-

ing procedure.

BR-22

REAR DRUM BRAKE

Components

NGBR0038

ABR768

Removal

WARNING:

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

CAUTION:

Make sure parking brake lever is released completely.

1. Release parking brake lever fully, then remove drum.

I If drum is hard to remove, the following procedures

should be carried out. a. Remove plug. Shorten adjuster to make clearance

between brake shoe and drum as shown

NGBR0039

SBR264CA

IDX

BR-23

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