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BRAKE SYSTEM SECTION
GI MA EM LC EC
BR
CONTENTS
PRECAUTIONS ...............................................................4 Supplemental Restraint System (SRS) AIR BAG and SEAT BELT PRE-TENSIONER...............4 Precautions for Brake System.....................................4 Precautions When Working On ABS...........................5 Precautions for Brake Control .....................................5 Diagnosis Precaution...................................................6 CAN SYSTEM ...........................................................6 Precaution for Harness Repair ....................................6 CAN SYSTEM ...........................................................6 Wiring Diagrams and Trouble Diagnosis.....................7 PREPARATION ...............................................................8 Commercial Service Tools ...........................................8 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................9 NVH Troubleshooting Chart.........................................9 ON-VEHICLE SERVICE ................................................10 Checking Brake Fluid Level.......................................10 Checking Brake Line .................................................10 Changing Brake Fluid ................................................10 Brake Burnishing Procedure......................................10 Bleeding Brake System .............................................11 BRAKE HYDRAULIC LINE ...........................................12 Hydraulic Circuit.........................................................12 Removal.....................................................................12 Inspection...................................................................12 Installation..................................................................13 BRAKE PEDAL AND BRACKET..................................14 Removal and Installation ...........................................14 Inspection...................................................................14 Adjustment .................................................................14 MASTER CYLINDER.....................................................16 Removal.....................................................................16 Disassembly...............................................................16 Inspection...................................................................17 Assembly ...................................................................17 Installation..................................................................18 BRAKE BOOSTER........................................................19 On-vehicle Service.....................................................19
OPERATING CHECK ...............................................19 AIRTIGHT CHECK ...................................................19
FE CL MT AT AX SU
Removal.....................................................................19 Inspection...................................................................19 OUTPUT ROD LENGTH CHECK ..............................19 Installation..................................................................20 VACUUM HOSE.............................................................21 Removal and Installation ...........................................21 Inspection...................................................................22 HOSES AND CONNECTORS ...................................22 CHECK VALVE ........................................................22 VACUUM PUMP ............................................................23 Removal.....................................................................23 Installation..................................................................24 Inspection...................................................................24 Component ................................................................25 Disassembly...............................................................25 Assembly ...................................................................25 FRONT DISC BRAKE ...................................................27 Component ................................................................27 Pad Replacement ......................................................27 Removal.....................................................................28 Disassembly...............................................................28 Inspection...................................................................28 CALIPER .................................................................28 ROTOR ...................................................................29 Assembly ...................................................................30 Installation..................................................................30 REAR DISC BRAKE (CAM & STRUT TYPE) ..............31 Component ................................................................31 Pad Replacement ......................................................31 Removal.....................................................................33 Disassembly...............................................................33 Inspection...................................................................34 CALIPER .................................................................34 ROTOR ...................................................................35 Assembly ...................................................................35 Installation..................................................................38 REAR DISC BRAKE (BALL & RAMP TYPE) ..............39
ST RS BT HA SC EL IDX
CONTENTS
Component ................................................................39 Pad Replacement ......................................................39 Removal.....................................................................41 Disassembly...............................................................41 Inspection...................................................................41 CALIPER .................................................................41 ROTOR ...................................................................42 Installation..................................................................42 PARKING BRAKE CONTROL ......................................43 Components...............................................................43 Removal and Installation ...........................................43 Inspection...................................................................43 Adjustment .................................................................44 ABS DESCRIPTION ...............................................................45 Purpose......................................................................45 ABS (Anti-Lock Brake System) Operation ................45 ABS Hydraulic Circuit ................................................45 System Components .................................................46 System Description....................................................46 SENSOR .................................................................46 CONTROL UNIT ......................................................46 ABS ACTUATOR AND ELECTRIC UNIT ....................46 Component Parts and Harness Connector Location .....................................................................48 Schematic ..................................................................49 Wiring Diagram - ABS - .............................................50 CAN COMMUNICATION ...............................................53 System Description....................................................53 CAN Communication Unit..........................................53 TYPE 1 ...................................................................54 TYPE 2/TYPE 3 .......................................................56 TYPE 4 ...................................................................58 TYPE 5/TYPE 6 .......................................................60 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................61 Trouble Diagnosis Chart by Symptom.......................61 CHECK ITEMS LIST ................................................61 ABS actuator and electric unit Input/Output Signal Standard .........................................................61 SPECIFICATIONS DEFINED BY CONSULT-II ............61 CONSULT-II Functions ..............................................62 CONSULT-II FUNCTION APPLICATION TABLE ..........62 SELF-DIAGNOSIS ...................................................63 DATA MONITOR......................................................66 ACTIVE TEST ..........................................................67 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........70 ABS Actuator and Electric Unit..................................70 Basic Inspection 1 Brake Fluid Level and Leakage Inspection....................................................70 Basic Inspection 2 Inspection for Loose Power Supply Terminal .........................................................70
(Cont'd)
Basic Inspection 3 ABS Warning Lamp Inspection...................................................................71 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS.............................................................................72 Wheel Sensor System ...............................................72 CAN Communication Lines .......................................73 ABS Warning Lamp Does Not Illuminate. (ABS Warning Lamp Does Not Come on When the Ignition Switch is Turned ON.)...................................73 ABS Warning Lamp Illuminates with Ignition ON, but Does Not Illuminates Off After a Few Seconds. (ABS Warning Lamp has been Illuminated.) ...............................................................74 TROUBLE DIAGNOSES FOR SYMPTOMS .................75 1. ABS Works Frequently ..........................................75 2. Unexpected Pedal Action ......................................75 3. Longer Stopping Distance .....................................76 4. ABS Does Not Work..............................................77 5. Pedal Vibration and Noise.....................................77 REMOVAL AND INSTALLATION .................................79 Wheel Sensors ..........................................................79 ABS Actuator and Electric Unit..................................80 REMOVAL ...............................................................80 INSTALLATION........................................................80 Sensor Rotor..............................................................81 REMOVAL ...............................................................81 INSTALLATION........................................................81 ESP/TCS/ABS ON-VEHICLE SERVICE ................................................82 Adjustment of Steering Angle Sensor Neutral Position ......................................................................82 SYSTEM DESCRIPTION ...............................................84 System Diagram ........................................................84 System Component Parts..........................................85 ESP Function.............................................................85 TCS Function.............................................................86 ABS Function.............................................................86 EBD Function.............................................................86 Fail-safe Function ......................................................87 ESP/TCS SYSTEM ..................................................87 ABS, EBD SYSTEM .................................................87 Hydraulic Circuit Diagram..........................................88 CAN COMMUNICATION ...............................................89 System Description....................................................89 CAN Communication Unit..........................................89 TYPE 1 ...................................................................90 TYPE 2/TYPE 3 .......................................................92 TYPE 4 ...................................................................94 TYPE 5/TYPE 6 .......................................................96 TROUBLE DIAGNOSIS .................................................97
BR-2
CONTENTS
How to Perform Trouble Diagnosis for Quick and Accurate Repair .........................................................97 INTRODUCTION ......................................................97 DIAGNOSIS FLOWCHART .......................................98 ASKING COMPLAINTS ............................................99 EXAMPLE OF DIAGNOSIS SHEET ...........................99 Component Parts Location ......................................100 Schematic ................................................................101 Wiring Diagram - ESP/TCS/ABS - ..........................102 Control Unit Input/Output Signal Standard..............107 REFERENCE VALUE FROM CONSULT-II ................107 CONSULT-II Functions ............................................110
CONSULT-II FUNCTION APPLICATION TABLE (MAIN ITEMS) .......................................................110 CONSULT-II BASIC OPERATION PROCEDURE ...... 111 SELF-DIAGNOSIS .................................................112 DATA MONITOR....................................................115 ACTIVE TEST ........................................................118
(Cont'd)
GI MA EM LC EC FE CL MT AT AX SU
For Fast and Accurate Diagnosis ............................120 PRECAUTIONS FOR DIAGNOSIS ..........................120 Basic Inspection.......................................................122
BASIC INSPECTION 1 BRAKE FLUID LEVEL, LEAKS, AND BRAKE PADS ...................................122 BASIC INSPECTION 2 POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPECTION .........................................................122 BASIC INSPECTION 3 ABS WARNING LAMP, ESP OFF INDICATOR LAMP, SLIP INDICATOR LAMP INSPECTION ...............................................122
Inspection 1 Wheel Sensor System ........................123 Inspection 2 Engine System....................................126 Inspection 3 ESP/TCS/ABS Control Unit System ...127 Inspection 4 Pressure Sensor System ....................127 Inspection 5 Steering Angle Sensor System...........129 Inspection 6 Yaw Rate/Side G sensor System .......130 Inspection 7 Solenoid and ESP Change-over Valve System ...........................................................132 Inspection 8 Actuator Motor, Motor Relay, and Circuit.......................................................................134 Inspection 9 ABS Actuator and Electric Unit (Control Unit) Power Supply and Ground Circuit ....136 Inspection 10 Stop Lamp Switch System................138 Inspection 11 Brake Fluid Level Sensor System ....139
Inspection 12 When ST ANG SEN SIGNAL Appears on Self-diagnostic Results Display ...........140 Inspection 13 CAN Communication System ...........140 Inspection 14 When ESTM VEH SPD SIG Appears on Self-diagnostic Results Display ...........142 Inspection 15 ESP OFF Indicator Lamp Does Not Illuminate...........................................................142 Component Inspection.............................................142 ESP OFF SWITCH .................................................142 Symptom 1 Excessive ABS Function Operation Frequency ................................................................143 Symptom 2 Unexpected Pedal Reaction ................143 Symptom 3 The Braking Distance Is Long .............144 Symptom 4 ABS Function Does Not Operate.........145 Symptom 5 Pedal Vibration or ABS Operation Sound Occurs ..........................................................145 Symptom 6 Vehicle Jerks During ESP/TCS/ABS Control .....................................................................147 WHEEL SENSORS......................................................149 Removal and Installation .........................................149 REMOVAL .............................................................149 INSTALLATION......................................................149 SENSOR ROTOR ........................................................150 Removal and Installation .........................................150 REMOVAL .............................................................150 INSTALLATION......................................................150 ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) ....151 Removal and Installation .........................................151 G SENSOR ..................................................................152 Removal and Installation .........................................152 REMOVAL .............................................................152 INSTALLATION......................................................152 STEERING ANGLE SENSOR .....................................153 Removal and Installation .........................................153 SERVICE DATA AND SPECIFICATIONS (SDS) .......154 General Specifications.............................................154 Disc Brake ...............................................................154 Brake Pedal .............................................................154 Parking Brake ..........................................................154
ST RS BT HA SC EL IDX
BR-3
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
NLBR0081
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 SRS system composition which is available to NISSAN MODEL V10 is as follows (The composition varies according to the destination and optional equipment.): ¼ 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), front seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. ¼ For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), side air bag (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: ¼ 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. ¼ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. ¼ 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 tape either just before the harness connectors or for the complete harness are related to the SRS.
Precautions for Brake System
¼ ¼ ¼ ¼
NLBR0002
SBR686C
Recommended fluid is brake fluid "DOT 3" or "DOT 4". Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas. To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. ¼ Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. ¼ Use flare nut wrench when removing and installing brake tube. ¼ Always torque brake lines when installing. ¼ Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to "Brake Burnishing Procedure", "ON-VEHICLE SERVICE", BR-10. WARNING: ¼ Clean brake pads with a waste cloth, then wipe with a dust collector.
BR-4
PRECAUTIONS
Precautions When Working On ABS
Precautions When Working On ABS
¼ ¼ ¼
NLBR0149
¼ ¼ ¼ ¼
¼
Use recommended tyres in combination with ABS. Please fit tyres or studded tyres, etc. with the same size. If different sizes of tyres, or tyres other than the ones recommended for use with the ABS, are fitted, stopping distance will increase and control and stability could deteriorate. When changing brake pads, please use Nissan genuine parts. When fitting radios etc, do not position the radio itself, antenna, or antenna cables within an area of about 100 mm (3.94 in) of the control unit. When doing any work that requires electro-welding, first remove the control unit. Please take care when taking a power supply for the audio, lamps etc., not to take this from any ABS-related harness. (Please refer to the electrical wiring diagrams for ABS-related harnesses) Before working, turn ignition switch OFF and disconnect electrical connectors of ABS actuator and electric unit (control unit) or battery cables.
GI MA EM LC EC FE CL MT
Precautions for Brake Control
¼ ¼ ¼ ¼
NLBR0157
¼ ¼ ¼ ¼
¼
During ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. Just after starting vehicle after ignition switch ON, brake pedal may vibrate or motor operating noise may be heard from engine room. This is a normal status of operation check. Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. When an error is indicated by ABS or another warning lamp, collect all necessary information from customer (what symptoms are present under what conditions) and check for simple causes before starting diagnostic servicing. Besides electrical system inspection, check brake booster operation, brake fluid level, and fluid leaks. If tire size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts, stopping distance or steering stability may deteriorate. If there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, ABS function may have a malfunction or error. If aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness pinches, open circuits, and improper wiring. If the following components are replaced with non-genuine components or converted, the ESP OFF indicator lamp and SLIP indicator lamp may turn on or the ESP system may not operate properly. Components related to suspension (Shock Absorber, Strut, Spring, Bush, etc.), Tires, wheels (exclude specified size), components related to brake (Pad, Rotor, Caliper, etc.), Components related to engine (Muffler, ECM, etc.), Components related to body reinforcement (Roll bar, Tower bar, etc.). Driving in the condition of breakage or excessive wear of the suspension, tires or components related to the brakes may
AT AX SU
ST RS BT HA SC EL IDX
BR-5
PRECAUTIONS
Precautions for Brake Control (Cont'd)
¼ ¼
¼
cause the ESP OFF indicator lamp and the SLIP indicator lamp to turn on, and the ESP system may not operate properly. When the TCS or ESP is activated by sudden acceleration or sudden turn, some noise may occur. The noise is a result of the normal operation of the TCS and ESP. When driving on roads which have extreme slopes (such as mountainous roads) or high banks (such as sharp carves on a freeway), the ESP may not operate normally, or the ESP warning lamp and the SLIP indicator lamp may turn on. However, this is not a problem if normal operation can be resumed after restarting the engine. Sudden turns (such as spin turns, acceleration turns), drifting, etc. When ESP function is OFF (ESP SW ON) may cause the yaw rate/side G sensor system indicate a malfunction. However this is not a malfunction if normal operation can be resumed after restarting the engine.
Diagnosis Precaution
CAN SYSTEM
¼ ¼ ¼
NLBR0158 NLBR0158S01
Do not apply voltage of 7.0V or higher to terminal to be measured. Maximum open terminal voltage of tester in use shall be 7.0V or lower. Before checking harnesses, turn ignition switch to OFF and disconnect battery negative cable.
Precaution for Harness Repair
CAN SYSTEM
¼
NLBR0159 NLBR0159S01
Area to be repaired shall be soldered, and wrapped with a tape [Be sure that fraying of twisted wire shall be within 110 mm (4.33 in)].
PKIA0306E
¼
Do not make a bypass connection to repaired area. (If it is done, branch part will be removed and characteristics of twisted wire will be lost.)
PKIA0307E
BR-6
PRECAUTIONS
Wiring Diagrams and Trouble Diagnosis
Wiring Diagrams and Trouble Diagnosis
When you read wiring diagrams, refer to the following: ¼ GI-11, "HOW TO READ WIRING DIAGRAMS" ¼ EL-12, "POWER SUPPLY ROUTING" When you perform trouble diagnosis, refer to the following: ¼ GI-32, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS" ¼ GI-21, "HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT"
NLBR0003
GI MA EM LC EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
BR-7
PREPARATION
Commercial Service Tools
Commercial Service Tools
Tool name 1 Flare nut crowfoot 2 Torque wrench Description Removing and installing each brake piping a: 10 mm (0.39 in)/12 mm (0.47 in)
NLBR0004
NT360
Brake fluid pressure gauge
Measuring brake fluid pressure
NT151
BR-8
NLBR0005
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
NVH Troubleshooting Chart
NVH in AX, SU section NVH in AX section NVH in AX section NVH in AX section
NLBR0005S01
Use the table below to help you find the cause of the symptom. If necessary, repair or replace these parts.
NVH in ST section STEERING X X X
GI MA EM LC EC
BR-27, 31
BR-27, 31
BR-27, 31
BR-29, 35
Reference page
BR-29, 35
--
--
--
--
--
ROAD WHEEL
DRIVE SHAFT
Rotor damage
Rotor runout
SUSPECTED PARTS (Possible cause)
AXLE AND SUSPENSION
Rotor thickness variation
Pads - uneven wear
Rotor deformation
Pads - damaged
Rotor imbalance
Shims damaged
Rotor deflection
Rotor rust
FE CL MT AT AX SU
Noise Symptom BRAKE Shake Shimmy, Judder X: Applicable
X
X
X X X X X X X X X
X X
X X X
TIRES X X X
X X X
ST RS BT HA SC EL IDX
BR-9
ON-VEHICLE SERVICE
Checking Brake Fluid Level
Checking Brake Fluid Level
¼ ¼ ¼
NLBR0006
Check fluid level in reservoir tank. It should be between Max and Min lines on reservoir tank. If fluid level is extremely low, check brake system for leaks. Release parking brake lever and see if brake warning lamp goes off. If not, check brake system for leaks.
NBR376
Checking Brake Line
NLBR0007
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.
SBR389C
Changing Brake Fluid
NLBR0008
SBR419C
CAUTION: ¼ Refill with new brake fluid "DOT 3" or "DOT 4". ¼ Always keep fluid level higher than minimum line on reservoir tank. ¼ Never reuse drained brake fluid. ¼ 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 while keeping reservoir level higher than minimum line by adding new brake fluid. 4. Repeat until new 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-11 and "Air Bleeding Procedure", CL-10.
Brake Burnishing Procedure
NLBR0036
Burnish the brake contact surfaces according to the following procedure after refinishing or replacing rotors, after replacing pads, 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-10
ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont'd)
3. 4.
pressure such that vehicle stopping time equals 3 to 5 seconds. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.
GI MA EM LC
Bleeding Brake System
NLBR0009
NBR357
SBR419C
CAUTION: ¼ Carefully monitor brake fluid level at master cylinder during bleeding operation. ¼ Fill reservoir with new brake fluid "DOT 3" or "DOT 4". Make sure it is full at all times while bleeding air out of system. ¼ Place a container under master cylinder to avoid spillage of brake fluid. ¼ For models with ABS, turn ignition switch OFF and disconnect ABS actuator connectors or battery ground cable. ¼ 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. 6. Repeat steps 2. through 5. until clear brake fluid comes out of air bleeder valve.
EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
BR-11
BRAKE HYDRAULIC LINE
Hydraulic Circuit
Hydraulic Circuit
NLBR0010
YBR362
Removal
NLBR0011
CAUTION: ¼ 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. ¼ All hoses must be free from excessive bending, twisting and pulling. ¼ For ball & ramp type rear caliper, care should be taken as not to let air enter the cylinder body. 1. Remove flare nut connecting brake tube and hose, then withdraw lock spring. 2. Cover openings to prevent entrance of air and dirt whenever disconnecting brake line.
Inspection
NLBR0012
Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.
BR-12
BRAKE HYDRAULIC LINE
Installation
Installation
NLBR0013
SBR686C
CAUTION: ¼ Refill with new brake fluid "DOT 3" or "DOT 4". ¼ Never reuse drained brake fluid. 1. Tighten all flare nuts and connecting bolts. Specification: Flare nut 14.8 - 17.6 N·m (1.5 - 1.7 kg-m, 11 - 12 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-11, and ``Air Bleeding Procedure'', CL-10.
GI MA EM LC EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
BR-13
BRAKE PEDAL AND BRACKET
Removal and Installation
Removal and Installation
NLBR0015
YBR360
Inspection
Check brake pedal for following items. ¼ Brake pedal bend ¼ Clevis pin deformation ¼ Crack of any welded portion ¼ Crack or deformation of clevis pin stopper
NLBR0016
SBR997
Adjustment
NLBR0017
Check brake pedal free height from metal panel. Adjust if necessary. H: Free height Refer to SDS, BR-154. C1, C2: Clearance between pedal stopper and threaded end of stop lamp switch and brake switch. 0.75 - 2.00 mm (0.0295 - 0.0787 in) D: Depressed height LHD/RHD (M/T): 60 -70 (2.36 - 2.76 in) Under force of 490 N (50 kg, 110 lb) with engine running. A: Pedal free play at pedal pad 1.0 - 3.0 mm (0.039 - 0.118 in)
YBR361
BR-14
BRAKE PEDAL AND BRACKET
Adjustment (Cont'd)
1. 2. 3.
Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut. Check pedal free play. Make sure that stop lamps go off when pedal is released. 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.
GI MA EM LC EC FE CL MT AT AX SU
SBR229E
ST RS BT HA SC EL IDX
BR-15
MASTER CYLINDER
Removal
Removal
NLBR0117
NBR360
1. 2. 3. 4.
Reservoir cap Filter Reservoir tank Adapter
5. 6. 7. 8.
Elastic pin Seal Washer Circlip
9. 10. 11. 12.
Piston stopper pin Primary piston assembly Secondary piston assembly Cylinder body
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 front caliper air bleeder valve, depressing brake pedal to empty fluid from master cylinder. 3. Remove brake pipe flare nuts. 4. Disconnect hoses from adapter. 5. Remove master cylinder mounting nuts.
Disassembly
1. 2. Drive out elastic pin from cylinder body. Remove adapter, washer and seals.
NLBR0118
NBR361
BR-16
MASTER CYLINDER
Disassembly (Cont'd)
3.
Remove the circlip with suitable pliers while piston is pushed into cylinder.
GI MA EM
NBR353
LC
4. 5. Remove piston stopper pin while piston is pushed into cylinder. Remove piston assemblies. If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet.
EC FE CL
SBR232E
MT
Inspection
Check for the following items. Replace any part if damaged. Master cylinder: ¼ Pin holes or scratches on inner wall. Piston: ¼ Deformation or scratches on piston cups.
NLBR0119
AT AX SU
Assembly
1. ¼
NLBR0120
Insert secondary piston assembly. Then insert primary piston assembly. Pay attention to alignment of secondary piston slit with valve stopper mounting hole of cylinder body.
ST RS BT HA
SBR233E
2.
3. 4.
Install piston stopper pin while piston is pushed into cylinder. Then secure the primary and secondary piston assemblies with new circlip. Insert washer and push reservoir seals and adapter into cylinder body. Install elastic pin.
SC EL IDX
SBR232E
BR-17
MASTER CYLINDER
Installation
Installation
NLBR0121
CAUTION: ¼ Refill with new brake fluid "DOT 3" or "DOT 4". ¼ Never reuse drained brake fluid. 1. Place master cylinder onto brake booster and secure mounting nuts lightly. 2. Torque mounting nuts. : 13 - 15 N·m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
3.
Check hoses for damage. If the hoses show cracks or damage, replace the hose. 4. Insert the dot (coloured) mark hoses to the primary - and secondary inlet ports adapter. Then secure it with clamps. Hose marking
Booster model Primary-inlet port Secondary-inlet port
NBR363
M215T White dot Yellow dot
S255 Blue dot Green dot
NBR364
5. 6.
NBR362
Fill up reservoir tank with new brake fluid. Plug all ports on master cylinder with fingers to prevent air suction while releasing brake pedal. 7. Have driver depress brake pedal slowly several times until no air comes out of master cylinder. 8. Fit brake lines to master cylinder. 9. Tighten flare nuts. : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) 10. Bleed air procedure from brake and clutch system. Refer to "Bleeding Brake System", BR-11 and "Air Bleeding Procedure", CL-10.
BR-18
BRAKE BOOSTER
On-vehicle Service
On-vehicle Service
OPERATING CHECK
1. 2.
NLBR0023 NLBR0023S01
Stop engine and depress brake pedal several times. Check that pedal stroke does not change. Depress brake pedal, then start engine. If pedal goes down slightly, operation is normal.
GI MA EM
SBR002A
LC
AIRTIGHT CHECK
1.
NLBR0023S02
2.
Start engine, and stop it after one or two minutes. Depress brake pedal several times slowly. The pedal should go further down at the first time, and then it should gradually rise thereafter. Depress brake pedal while engine is running, and stop engine with pedal depressed. The pedal stroke should not change after holding pedal down for 30 seconds.
EC FE CL MT
SBR365AA
Removal
NLBR0024
CAUTION: ¼ 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. ¼ Be careful not to deform or bend brake pipes, during booster removal.
AT AX SU
SBR232CB
Inspection
OUTPUT ROD LENGTH CHECK
1. 2. 3.
NLBR0025 NLBR0025S01
ST RS BT HA SC EL IDX
SBR208E
Apply vacuum of -66.7 kPa (-667 mbar, -500 mmHg, -19.69 inHg) to brake booster with a handy vacuum pump. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod. Check output rod length. Specified length: Without ESP 10.275 - 10.525 mm (0.4045 - 0.4144 in) With ESP 4.9 - 5.1 mm (0.193 - 0.201 in)
BR-19
BRAKE BOOSTER
Installation
Installation
NLBR0026
SBR237EA
CAUTION: ¼ Be careful not to deform or bend brake pipes, during booster installation. ¼ Replace clevis pin if damaged. ¼ Refill with new brake fluid "DOT 3" or "DOT 4". ¼ Never reuse drained brake fluid. ¼ Take care not to damage brake booster mounting bolt thread during installation. 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 - 12 ft-lb) 5. Install master cylinder. Refer to "Installation" in "MASTER CYLINDER", BR-18. 6. Bleed air. Refer to "Bleeding Brake System", BR-11 and "Air Bleeding Procedure", CL-10.
BR-20
VACUUM HOSE
Removal and Installation
Removal and Installation
NLBR0027
CAUTION: When installing vacuum hoses, pay attention to the following points. ¼ Do not apply any oil or lubricants to vacuum hose and check valve. ¼ Insert vacuum tube into vacuum hose as shown.
GI MA EM
SBR225B
LC
¼ Install check valve, paying attention to its direction.
EC FE CL
SBR498A
MT AT AX SU
NBR385
ST RS BT HA SC EL IDX
BR-21
VACUUM HOSE
Inspection
Inspection
HOSES AND CONNECTORS
=NLBR0028 NLBR0028S01
Check vacuum lines, connections and check valve for airtightness, improper attachment chafing and deterioration.
CHECK VALVE
Check vacuum with a vacuum pump.
Connect to booster side Connect to engine side Vacuum should exist. Vacuum should not exist.
NLBR0028S02
SBR844B
SBR943A
BR-22
VACUUM PUMP
Removal
Removal
NLBR0123
GI MA EM LC EC FE CL
SBR631E
1. ¼ ¼ ¼ ¼ ¼ 2. 3. ¼ 4. ¼
Remove parts shown below. Air duct, air cleaner case (upper) Engine cover Rocker cover Exhaust manifold cover EGR tube Disconnect vacuum hose from vacuum pump. Remove cylinder head rear cover plate. Use a tool such as seal cutter (SST) to remove. Loosen and remove rear cam sprocket installation bolts. Camshaft should not be attached. Using engine inner resistance, loosen installation bolts.
MT AT AX SU
ST RS BT HA
5. ¼ ¼ ¼ ¼
SBR632E
Remove vacuum pump and cylinder head rear cover assembly. Remove and install vacuum pump, sprocket, drive chain, and chain guide as an assembly. Loosen mounting bolts in the reverse order of the numbers shown in the figure to the left. Remove only bolts that are shown in the figure. (Be especially careful not to remove M6 bolts on the vacuum pump.) Use a tool such as a seal cutter (SST).
SC EL IDX
BR-23
VACUUM PUMP
Installation
Installation
1. 2. a.
NLBR0124
Assemble vacuum pump and cylinder head rear cover assembly, referring to "Component" in the next page. Install vacuum pump and cylinder head rear cover assembly to cylinder head. Apply ThreeBond 1207C (KP510 00150) without breaks to the location shown in the figure to the left.
SBR633E
b. 3. 4. ¼ 5. ¼
Tighten the mounting bolts in the numerical order shown by the figure to the left. Install rear cam sprocket installation bolts. Remove sprocket retaining two M6 bolts. M6 bolts will be used for installation. Tighten rear cam sprocket installation bolts. Camshaft should not be fixed. Using engine inner resistance, tighten installation bolts.
SBR632E
6. ¼
Install cylinder head rear cover plate. Apply ThreeBond 1207C (KP510 00150) without breaks to the location shown by the figure to the left. 7. Install parts in the reverse order of removal. CAUTION: If the engine is started with vacuum pump released (vacuum hose disconnected), it causes increase of blowby gas amount, and engine damage may result. When starting the engine, be sure to close vacuum circuit.
SBR634E
Inspection
¼ ¼ ¼ ¼ ¼
NLBR0125
SBR611E
Remove vacuum hose. Then, connect vacuum gauge with three-way connector. Install three-way connector to the area where vacuum pump negative pressure can be directly measured. (The figure shown an example.) Start the engine, then measure negative pressure. Standard: -86.6 to -101.3 kPa (-866 to -1,013 mbar, -650 to -760 mmHg, -25.59 to -29.92 inHg) If it is not within standard, inspect for suction of air in the middle of route and measure it again. If it is still not within standard value, replace the vacuum pump.
BR-24
VACUUM PUMP
Component
Component
NLBR0126
GI MA EM LC EC FE CL
SBR612E
MT
Disassembly
NLBR0136
Disassemble the components, referring to the "Component", then remove vacuum pump. CAUTION: Do not disassemble vacuum pump. (Do not loosen three M6 bolts.)
AT AX SU
SBR613E
Assembly
NLBR0127
Install all parts to cylinder head rear cover as follows. 1. Install vacuum pump. 2. Install chain guide temporarily. ¼ Adjust the chain guide position by the method explained in step 5.
ST RS BT HA
3. ¼ ¼
¼ 4.
SBR614E
5.
Install rear cam sprocket. Installation direction of sprocket is not specified. Insert 2 thickness gauges [3.0 mm (0.118 in)] between cover and rear cam sprocket (shown in the figure). Insert 2 bolts [M6, thread length: 35 - 40 mm (1.38 - 1.57 in)] into sprocket to retain it to cover. Use thickness gauges [3.0 mm (0.118 in)] for chain alignment between vacuum pump sprocket and cam sprocket. Attach drive chain to rear cam sprocket and vacuum pump sprocket. Tighten chain guide installation bolt while pressing chain guide
SC EL IDX
BR-25
VACUUM PUMP
Assembly (Cont'd)
6. ¼
lightly [approximately 9.8 N (1.0 kg, 2.2 lb)]. Remove thickness gauges (2). Leave sprocket retaining bolts (M6) until installation.
BR-26
FRONT DISC BRAKE
Component
Component
NLBR0030
GI MA EM LC EC FE CL
NBR365
1. 2. 3. 4. 5. 6.
Main pin Pin boot Torque member fixing bolt Torque member Inner shim Inner pad
7. 8. 9. 10. 11. 12.
Pad retainer Outer pad Outer shim Connecting bolt Copper washer Main pin bolt
13. 14. 15. 16. 17.
Bleed valve Cylinder body Piston seal Piston Piston boot
MT AT AX SU
Pad Replacement
NLBR0029
WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ¼ When cylinder body is open, do not depress brake pedal because piston will pop out. ¼ Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads. ¼ If shims are rusted or show peeling of the rubber coat, replace them with new shims. ¼ 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. ¼ Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to "Brake Burnishing Procedure", "ON-VEHICLE SERVICE", BR-10.
ST RS BT HA SC EL IDX
BR-27
FRONT DISC BRAKE
Pad Replacement (Cont'd)
1. 2. 3.
SBR976B
Remove master cylinder reservoir cap. Remove pin bolt. 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.
SBR932C
Removal
NLBR0031
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.
SBR979B
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.
NLBR0032
SBR772
Inspection
CALIPER Cylinder Body
¼ ¼
NLBR0033 NLBR0033S01 NLBR0033S0101
Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.
BR-28
FRONT DISC BRAKE
Inspection (Cont'd)
CAUTION: Use brake fluid to clean. Never use mineral oil.
Piston
GI
NLBR0033S0102
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.
MA EM LC EC
Slide Pin, Pin Bolt and Pin Boot
NLBR0033S0103
Check for wear, cracks or other damage. Replace if any of the above conditions are observed.
ROTOR Rubbing Surface
Check rotor for roughness, cracks or chips.
NLBR0033S02 NLBR0033S0201
FE CL MT
Runout
1. 2.
NLBR0033S0202
3.
SBR219C
a. b. c. d. 4.
Secure rotor to wheel hub with at least two nuts (M12 x 1.25). 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: 0.08 mm (0.0031 in) If the runout is out of specification, find minimum runout position as follows: Remove nuts and rotor from wheel hub. Shift the rotor one hole and secure rotor to wheel hub with nuts. Measure runout. Repeat steps a. to c. so that minimum runout position can be found. If the runout is still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or equivalent).
AT AX SU
ST RS BT HA
Thickness
NLBR0033S0203
SC EL IDX
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)
BR-29
FRONT DISC BRAKE
Assembly
Assembly
1. 2. 3.
NLBR0034
Insert piston seal into groove on cylinder body. With piston boot fitted to piston, insert piston boot into groove on cylinder body and install piston. Properly secure piston boot.
SBR574
Installation
CAUTION: ¼ Refill with new brake fluid "DOT 3" or "DOT 4". ¼ 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-11.
NLBR0035
SBR980B
BR-30
REAR DISC BRAKE (CAM & STRUT TYPE)
Component
Component
NLBR0038
GI MA EM LC EC FE CL MT AT AX SU
NBR366
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Cable guide Cylinder Toggle lever Pin Pin boot Torque member Inner shim Inner pad Outer pad Outer shim
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Strut O-ring Push rod Key plate Retaining washer Spring Spring cover Snap ring B Piston seal Snap ring A
21. 22. 23. 24. 25. 26. 27. 28. 29.
Washer Wave washer Washer Bearing Adjuster Cup Piston Piston boot Sleeve
ST RS BT HA
Pad Replacement
NLBR0037
SC EL IDX
WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ¼ When cylinder body is open, do not depress brake pedal because piston will pop out. ¼ Be careful not to damage piston boot or get oil on rotor. Always replace shims in replacing pads. ¼ If shims are rusted or show peeling of rubber coat, replace them with new shims.
BR-31
REAR DISC BRAKE (CAM & STRUT TYPE)
Pad Replacement (Cont'd)
¼
¼
It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to "Brake Burnishing Procedure", "ON-VEHICLE SERVICE", BR-10.
1. 2. 3. 4. 5.
SBR764E
Remove master cylinder reservoir cap. Remove brake cable mounting bolt and lock spring. Release parking brake control lever, then disconnect cable from the caliper. Remove upper pin bolt. Open cylinder body downward. Then remove pads inner and outer shims. Standard pad thickness: 9.3 mm (0.366 in) Pad wear limit: 2.0 mm (0.079 in)
SBR916C
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.
SBR641
7.
Adjust the piston to the right angle as shown in the figure.
NBR374
BR-32
REAR DISC BRAKE (CAM & STRUT TYPE)
Pad Replacement (Cont'd)
8. 9.
As shown in the figure, align the piston's concave to the pad's convex, then install the cylinder body to the torque member. Install brake cable, brake cable mounting bolt, lock spring and master cylinder reservoir cap.
GI MA EM
NBR375
LC
Removal
NLBR0039
NBR167
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.
EC FE CL MT AT AX SU
Disassembly
1.
NLBR0040
Remove piston by turning it counterclockwise with long nose pliers or suitable tool.
ST RS BT HA
SBR646
2.
Pry off snap ring A from piston with suitable pliers and remove adjusting nut.
SC EL IDX
SBR889
BR-33
REAR DISC BRAKE (CAM & STRUT TYPE)
Disassembly (Cont'd)
3. a. b.
Disassemble cylinder body. Pry off snap ring B with suitable pliers, then remove spring cover, spring and seat. Remove washer, key plate, push rod, O-ring and strut.
SBR088B
c.
Remove piston seal. Be careful not to damage cylinder body.
SBR656
4.
Remove return spring, toggle lever and cable guide.
SBR767E
Inspection
CALIPER
CAUTION: Use brake fluid to clean cylinder. Never use mineral oil.
NLBR0041 NLBR0041S01
Cylinder Body
¼ ¼
NLBR0041S0101
Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body. Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.
NLBR0041S0102
Torque Member Piston
Check for wear, cracks or other damage. Replace if necessary.
NLBR0041S0103
CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign matter is 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.
BR-34
REAR DISC BRAKE (CAM & STRUT TYPE)
Inspection (Cont'd)
Pin and Pin Boot
Check for wear, cracks or other damage. Replace if any of the above conditions are observed.
NLBR0041S0104
GI MA EM LC
ROTOR Rubbing Surface
Check rotor for roughness, cracks or chips.
NLBR0041S02 NLBR0041S0201
EC FE CL MT AT AX SU
Runout
NLBR0041S0202
SBR219C
1. Secure rotor to wheel hub with two nuts (M12 x 1.25). 2. Check runout using a dial indicator. Make sure that axial end play is within the specifications before measuring. Refer to AX section ("REAR WHEEL BEARING", "On-vehicle Service"). 3. Change relative positions of rotor and wheel hub so that runout is minimized. Maximum runout: 0.07 mm (0.0028 in)
Thickness
Rotor repair limit: Standard thickness 10 mm (0.39 in) Minimum thickness 9 mm (0.35 in) Thickness variation (At least 8 portions) Maximum 0.02 mm (0.0008 in)
NLBR0041S0203
ST RS BT HA
Assembly
1.
NLBR0042
SC EL IDX
Insert cam with depression facing towards open end of cylinder.
NBR367
BR-35
REAR DISC BRAKE (CAM & STRUT TYPE)
Assembly (Cont'd)
2.
Generously apply rubber grease to strut and push rod to make insertion easy.
SBR248B
3.
Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.
SBR893
4.
Install rod, push rod and key plate.
SBR754E
5.
Install seat, spring, spring cover and snap ring B with suitable press and drift.
SBR869CB
SBR879-B
BR-36
REAR DISC BRAKE (CAM & STRUT TYPE)
Assembly (Cont'd)
6.
Install cup in the specified direction.
GI MA EM
SBR892
LC
7. Install adjuster, bearing, washers and snap ring A with a suitable tool.
EC FE CL
SBR755E
MT
8. 9. Insert piston seal into groove on cylinder body. With piston boot fitted to piston, insert piston boot into groove on cylinder body and fit piston by turning it clockwise with long nose pliers, or suitable tool.
AT AX SU
SBR646
10. Fit toggle lever, return spring and cable guide.
ST RS BT HA
SBR767E
11. Adjust the piston to the right angle as shown in the figure.
SC EL IDX
NBR374
BR-37
REAR DISC BRAKE (CAM & STRUT TYPE)
Installation
Installation
NLBR0043
NBR375
CAUTION: ¼ Refill with new brake fluid "DOT 3" or "DOT 4". ¼ Never reuse drained brake fluid. 1. Install caliper assembly. ¼ As shown in the figure, align the piston's concave to the pad's convex, then install the cylinder body to the torque member. 2. Install brake hose to caliper securely. 3. Install all parts and secure all bolts. 4. Bleed air. Refer to "Bleeding Brake System", BR-11 and "Air Bleeding Procedure", CL-10.
BR-38
REAR DISC BRAKE (BALL & RAMP TYPE)
Component
Component
NLBR0150
GI MA EM LC EC FE CL
NBR422
1. 2. 3.
Cylinder body Pin Pin boot
4. 5. 6.
Torque member Inner shim Inner pad
7. 8.
Outer pad Outer shim
MT AT AX SU
NOTE: The cylinder body cannot be disassembled.
Pad Replacement
NLBR0151
WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: ¼ When cylinder body is open, do not depress brake pedal because piston will pop out. ¼ Be careful not to damage piston boot or get oil on rotor. Always replace shims in replacing pads. ¼ If shims are rusted or show peeling of rubber coat, replace them with new shims. ¼ It is not necessary to remove connecting bolt except for replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. ¼ Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to "Brake Burnishing Procedure", "ON-VEHICLE SERVICE", BR-10.
ST RS BT HA SC EL IDX
BR-39
REAR DISC BRAKE (BALL & RAMP TYPE)
Pad Replacement (Cont'd)
1. 2. 3. 4.
Remove Remove Release from the Remove
master cylinder reservoir cap. brake cable lock spring. parking brake control lever, then disconnect cable caliper. upper pin bolt.
NBR423
5.
Open cylinder body downward. Then remove pads inner and outer shims. Standard pad thickness: 9.3 mm (0.366 in) Pad wear limit: 2.0 mm (0.079 in)
NBR426
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.
SBR641
7.
Adjust the piston to the right angle as shown in the figure.
NBR374
8. 9.
As shown in the figure, align the piston's concave to the pad's convex, then install the cylinder body to the torque member. Install brake cable, brake cable mounting bolt, lock spring and master cylinder reservoir cap.
NBR375
BR-40
REAR DISC BRAKE (BALL & RAMP TYPE)
Removal
Removal
NLBR0152
NBR427
WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. 1. Remove brake cable lock spring. 2. Release parking brake control lever, then disconnect cable from the caliper. 3. Remove torque member fixing bolts and connecting bolt. 4. Remove brake hose connecting bolt. 5. Plug off the brake hose and cylinder body to prevent air entering the system. CAUTION: Care should be taken as not to let: ¼ Air enter the cylinder body and brake hose. ¼ Brake fluid spill from the cylinder body and brake hose.
GI MA EM LC EC FE CL MT
Disassembly
Remove pin bolts and pins. NOTE: Cylinder body cannot be disassembled.
NLBR0153
AT AX SU
Inspection
CALIPER
NLBR0154 NLBR0154S01
ST RS BT HA SC EL IDX
CAUTION: Do not drain any brake fluid from cylinder body. Cylinder body can not be disassembled.
Cylinder Body
NLBR0154S0101
Check cylinder body for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.
Torque Member Pin and Pin Boot
Check for wear, cracks or other damage. Replace if any of the above conditions are observed.
NLBR0154S0102
Check for wear, cracks or other damage. Replace if necessary.
NLBR0154S0104
BR-41
REAR DISC BRAKE (BALL & RAMP TYPE)
Inspection (Cont'd)
ROTOR Rubbing Surface
Check rotor for roughness, cracks or chips.
NLBR0154S02 NLBR0154S0201
Runout
NLBR0154S0202
SBR219C
1. Secure rotor to wheel hub with two nuts (M12 x 1.25). 2. Check runout using a dial indicator. Make sure that axial end play is within the specifications before measuring. Refer to AX section ("REAR WHEEL BEARING", "On-vehicle Service"). 3. Change relative positions of rotor and wheel hub so that runout is minimized. Maximum runout: 0.07 mm (0.0028 in)
Thickness
Rotor repair limit: Standard thickness 10 mm (0.39 in) Minimum thickness 9 mm (0.35 in) Thickness variation (At least 8 portions) Maximum 0.02 mm (0.0008 in)
NLBR0154S0203
Installation
NLBR0156
NBR374
CAUTION: ¼ Refill with new brake fluid "DOT 3" or "DOT 4". ¼ Never reuse drained brake fluid. ¼ Do not drain (factory) filled brake fluid from (new) caliper assemblies. 1. Install caliper assembly. ¼ As shown in the figure, align the piston's concave to the pad's convex, then install the cylinder body to the torque member. 2. Remove the plug from the cylinder body and brake hose. CAUTION: Care should be taken as not to let: ¼ Air enter the cylinder body and brake hose. ¼ Brake fluid spill from the cylinder body and brake hose. 3. Install brake hose to caliper securely. 4. Install all parts and secure all bolts. 5. Bleed air. Refer to "Bleeding Brake System", BR-11 and "Air Bleeding Procedure", CL-10.
NBR375
BR-42
PARKING BRAKE CONTROL
Components
Components
NLBR0044
GI MA EM LC EC FE CL
NBR368
MT
Removal and Installation
1. 2. 3. 4. 5.
NLBR0045
To remove parking brake cable, first remove center console. Disconnect warning lamp switch connector. Remove adjusting nut. Remove bolts and nuts securing parking brake cable. Remove parking brake device.
AT AX SU
SBR897D
6.
Remove lock plate and disconnect cable.
ST RS BT HA
SBR025D
Inspection
1. 2. 3. 4.
NLBR0046
SC EL IDX
Check control lever for wear or other damage. Replace if necessary. Check wires for discontinuity or deterioration. Replace if necessary. Check warning lamp and switch. Replace if necessary. Check parts at each connecting portion and, if found deformed or damaged, replace.
BR-43
PARKING BRAKE CONTROL
Adjustment
Adjustment
NLBR0047
Before or after adjustment, pay attention to the following points. ¼ For rear disc brake be sure that toggle lever returns to stopper when parking brake lever is released. ¼ There is no drag when parking brake lever is released. ¼ Vehicle is unladen.
SBR768E
1. a. b.
Adjust clearance between pad and rotor as follows: Release parking brake lever and loosen adjusting nut. Depress brake pedal fully at least 10 times with engine running.
2.
Pull control lever 10 times or more to make a lever stroke of 195 mm (7.68 in). At 5 - 6 notches, adjust the parking brake cable by turning the adjusting nut.
SBR756E
3.
Pull control lever with specified amount of force. Check lever stroke and ensure smooth operation. Number of notches 5-6
SBR033A
4. ¼ ¼
Bend warning lamp switch plate to ensure: Warning lamp comes on when lever is lifted "A" notches. Warning lamp goes out when lever is fully released. Number of "A" notches: 1
BR-44
DESCRIPTION Purpose
ABS
Purpose
NLBR0082
The ABS consists of electronic and hydraulic components. It allows to control the braking force so that locking of the wheels can be avoided. The ABS: 1) Ensures proper tracking performance through steering wheel operation. 2) Enables obstacles to be avoided through steering wheel operation. 3) Ensures vehicle stability by preventing flat spins.
GI MA EM
ABS (Anti-Lock Brake System) Operation
¼ ¼
NLBR0083
¼
When the vehicle speed is less than 10 km/h (6 MPH) this system does not work. The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning lamp for 1 second after turning the ignition switch ON. The system performs another test the first time the vehicle reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs a self-test. This is a normal part of the self-test feature. If a malfunction is found during this check, the ABS warning lamp will come on. During ABS operation, a mechanical noise may be heard. This is a normal condition.
LC EC FE CL MT AT AX SU
ABS Hydraulic Circuit
NLBR0084
ST RS BT HA
SBR757E
1. 2. 3.
Inlet solenoid valve Outlet solenoid valve Reservoir
4. 5.
Pump Motor
6. 7.
Bypass check valve Damper
SC EL IDX
BR-45
DESCRIPTION
System Components
ABS
System Components
NLBR0086
NBR369
System Description
SENSOR
NLBR0087 NLBR0087S01
The sensor unit consists of a gear-shaped sensor rotor and a sensor element. The element contains a bar magnet around which a coil is wound. The sensor is installed on the back side of the brake rotor. Sine-wave current is generated by the sensor as the wheel rotates. The frequency and voltage increase(s) as the rotating speed increases.
SBR124B
CONTROL UNIT
NLBR0087S02
The control unit computes the wheel rotating speed by the signal current sent from the sensor. Then it supplies a DC current to the actuator solenoid valve. It also controls ON-OFF operation of the valve relay and motor relay. If any electrical malfunction should be detected in the system, the control unit causes the warning lamp to light up. In this condition, the ABS will be deactivated by the control unit, and the vehicle's brake system reverts to normal operation.
SBR759E
ABS ACTUATOR AND ELECTRIC UNIT
The ABS actuator and electric unit contains: ¼ An electric motor and pump ¼ Two relays ¼ Eight solenoid valves, each inlet and outlet for -- LH front -- RH front -- LH rear -- RH rear ¼ ABS control unit
YBR327
NLBR0087S03
BR-46
DESCRIPTION
ABS
System Description (Cont'd)
This components controls the hydraulic circuit and increases, holds or decreases hydraulic pressure to all or individual wheels. The ABS actuator and electric unit can not be disassemble and will be service as an assembly.
GI MA EM
ABS Actuator Operation
Inlet solenoid valve Normal brake operation Pressure hold Pressure decrease Pressure increase OFF (Open) ON (Closed) Outlet solenoid valve OFF (Closed) OFF (Closed)
NLBR0087S0301
Master cylinder brake fluid pressure is directly transmitted to caliper via the inlet solenoid valve. Hydraulic circuit is shut off to hold the caliper brake fluid pressure. Caliper brake fluid is sent to reservoir via the outlet solenoid valve. Then it is pushed up to the master cylinder by pump. Master cylinder brake fluid pressure is transmitted to caliper.
LC EC FE CL MT AT AX SU
ABS operation
ON (Closed)
ON (Open)
OFF (Open)
OFF (Closed)
ST RS BT HA SC EL IDX
BR-47
DESCRIPTION
Component Parts and Harness Connector Location
ABS
Component Parts and Harness Connector Location
NLBR0088
YBR366
BR-48
DESCRIPTION Schematic
ABS
Schematic
NLBR0089
GI MA EM LC EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
YBR327A
BR-49
DESCRIPTION
Wiring Diagram -- ABS --
ABS
Wiring Diagram -- ABS --
NLBR0090
YBR328A
BR-50
DESCRIPTION
ABS
Wiring Diagram -- ABS -- (Cont'd)
GI MA EM LC EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
YBR329A
BR-51
DESCRIPTION
Wiring Diagram -- ABS -- (Cont'd)
ABS
YBR330A
BR-52
CAN COMMUNICATION System Description
ABS
System Description
NLBR0226
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multipl