Brake System: Section

BRAKES
BR
A
B
SECTION
BRAKE SYSTEM C
E
CONTENTS
SERVICE INFORMATION ............................ 2 2WD ............................................................................15 BR
2WD : Removal and Installation ..............................15
PRECAUTIONS ................................................... 2 2WD : Inspection .....................................................15
Precaution for Supplemental Restraint System G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- 4WD ............................................................................16
SIONER" ................................................................... 2 4WD : Removal and Installation ..............................17
Precaution for Brake System .................................... 2 4WD : Inspection .....................................................17
H
PREPARATION ................................................... 3 BRAKE BOOSTER ........................................... 19
Commercial Service Tool .......................................... 3 On-vehicle Service ..................................................19
Removal and Installation .........................................19
I
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 4 VACUUM LINES ............................................... 21
NVH Troubleshooting Chart ...................................... 4 Removal and Installation .........................................21
Inspection ................................................................21 J
BRAKE PEDAL AND BRACKET ........................ 5
Removal and Installation ........................................... 5 FRONT DISC BRAKE ....................................... 22
Inspection .................................................................. 5 Component ..............................................................22
K
Adjustment ................................................................ 6 Pad Replacement ....................................................22
Caliper Removal and Installation .............................23
BRAKE FLUID ..................................................... 7 Caliper Disassembly and Assembly ........................24
Checking Brake Fluid Level ...................................... 7 Brake Burnishing Procedure ....................................26 L
Checking Brake Line ................................................. 7
Changing Brake Fluid ................................................ 7 REAR DRUM BRAKE ....................................... 27
Bleeding Brake System ............................................. 7 Component ..............................................................27 M
Inspection ................................................................27
BRAKE PIPING AND HOSE ............................... 9 Removal and Installation .........................................28
Hydraulic Circuit ........................................................ 9 Wheel Cylinder Disassembly an Assembly .............30
Front and Rear Brake Piping and Hose .................. 10 N
Inspection ................................................................ 11 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 31
MASTER CYLINDER .........................................12 General Specification ..............................................31 O
Component .............................................................. 12 Load Sensing Valve .................................................31
Removal and Installation ......................................... 12 Disc Brake ...............................................................31
Disassembly and Assembly .................................... 13 Drum Brake .............................................................31
P
Brake Pedal .............................................................31
LOAD SENSING VALVE ....................................15 Brake Booster ..........................................................32
Revision: April 2013 BR-1 2013 D22 LCV

PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000008945281
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• 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 SRS section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precaution for Brake System INFOID:0000000008945282
WARNING:
Clean any dust from the front brake and rear brake with a vacuum dust collector. Do not blow with
compressed air.
CAUTION:
• Brake fluid use refer to MA-9, "Fluids and Lubricants".
• Do not reuse drained brake fluid.
• Do not spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe
it off immediately and wash with water if it gets on a painted surface.
• Always clean with new brake fluid when cleaning the master cylinder, brake caliper and other com-
ponents.
• Do not use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and
cause improper operation.
• Always loosen the brake tube flare nut with a flare nut wrench.
• Tighten the brake tube flare nut to the specified torque with
crowfoot (A) and torque wrench (B).
• Always confirm the specified tightening torque when install-
ing the brake pipes.
• Turn the ignition switch OFF and disconnect the ABS actuator
and electric unit (control unit) connector or the battery nega-
tive terminal before performing the work.
• Check that no brake fluid leakage is present after replacing
the parts.
• Burnish the brake contact surfaces after refinishing or replac-
ing rotors, after replacing pads, or if a soft pedal occurs at
JPFIA0001ZZ
very low mileage. Refer to BR-26, "Brake Burnishing Proce-
dure".

PREPARATION
PREPARATION
A
Commercial Service Tool INFOID:0000000008945283
B
Tool name Description
1 Flare nut crowfoot Removing and installing each brake piping
2 Torque wrench a: 10 mm (0.4 in)
C
NT360
Brake fluid pressure gauge Measuring brake fluid pressure E
BR
NT151 G
Power tool Loosening nuts, screws and bolts
I
PIIB1407E

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000008945284
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
FFD-6, RFD-6,
BR-22, BR-22
FSU-5, RSU-4
BR-22, BR-22
BR-24, BR-27
\BR-27
BR-27
BR-23
BR-24
FAX-4
FAX-4
WT-4
PR-4
PS-5
Reference page
—
—
—
—
—
Linings or pads - uneven wear
Linings or pads - damaged
Rotor or drum deformation

Rotor or drum imbalance
Rotor thickness variation

Rotor or drum deflection
Return spring damaged
Rotor or drum damage
PROPELLER SHAFT
Rotor or drum runout
Rotor or drum rust
Drum out of round

Possible cause
Shims damaged
DIFFERENTIAL
ROAD WHEEL
DRIVE SHAFT
and SUSPECTED PARTS
SUSPENSION
STEERING
TIRES
AXLE
Noise × × × × × × × × × × × ×
Symptom BRAKE Shake × × × × × × × ×
Shimmy, Judder × × × × × × × × × × × × ×
×: Applicable

BRAKE PEDAL AND BRACKET
A
Removal and Installation INFOID:0000000008945285
BR
J
AWFIA0387GB
1. Fulcrum shaft 2. Pedal bracket 3. Stop lamp switch K

4. Return spring 5. Snap pin 6. Brake pedal
7. Clevis pin
L
Inspection INFOID:0000000008945286
Check brake pedal for following items.

M
• Brake pedal bend
• Clevis pin deformation
• Crack of any welded portion
• Crack or deformation of clevis pin stopper N
P
SBR997

Adjustment INFOID:0000000008945287
Check brake pedal free height from metal panel.
Free height (H) : Refer to BR-31, "Brake

Pedal".
Depressed height (D) : Refer to BR-31, "Brake
Pedal".
Clearance (C) between ped- : Refer to BR-31, "Brake
al stopper and threaded Pedal".
end of stop lamp switch
Pedal free play (A) : Refer to BR-31, "Brake
Pedal".
SBR278AB
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.
NOTE:
Make sure that tip of input rod stays inside.
2. Loosen lock nut and adjust clearance with stop lamp switch
respectively, then tighten lock nuts.
3. Check pedal free play.
NOTE:
Make sure that stop lamp is off when pedal is released.
4. Check brake pedal depressed height while engine is running.
If lower than specification, check for leaks, air in system, or SBR930
damage to components (master cylinder, wheel cylinder, etc.).

Then make necessary repairs.

BRAKE FLUID
BRAKE FLUID
A
Checking Brake Fluid Level INFOID:0000000008945288
• Check fluid level in reservoir tank. It should be between MAX and B

MIN lines on reservoir tank.
• If fluid level is extremely low, check brake system.
• If the brake warning lamp comes on, check brake fluid level switch
and parking brake switch. C
SBR451D E
Checking Brake Line INFOID:0000000008945289
CAUTION: BR
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration G
and other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running. H
I
SBR389C
Changing Brake Fluid INFOID:0000000008945290

J
CAUTION:
• Refill with new brake fluid “DOT 3”.
• Always keep fluid level higher than minimum line on reservoir K
tank.
• Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted L
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. M
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal. SBR419C
N
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 BR-7, "Bleeding Brake System".
O
Bleeding Brake System INFOID:0000000008945291
CAUTION:
P

BRAKE FLUID
• Carefully monitor brake fluid level at master cylinder during
bleeding operation.
• If master cylinder is suspected to have air inside, bleed air
from master cylinder first. Refer to BR-12, "Removal and
Installation".
• Fill reservoir with new brake fluid “DOT 3”. Make sure it is full
at all times while bleeding air out of system.
• Place a container under master cylinder to avoid spillage of
brake fluid.
• Turn ignition switch OFF and disconnect the ABS connector
or battery cable.
SBR995
• Bleed air in the following order.
- Left rear brake
- Right rear brake
- Left front brake
- Right front brake
- ABS Actuator and Electric Unit
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.
7. Tighten air bleeder.
SBR419C
Air bleeder : 7 - 9 N·m (0.7 - 0.9 kg-m, 62 - 80 in-lb)

BRAKE PIPING AND HOSE
A
Hydraulic Circuit INFOID:0000000008945292
W/O ABS B
BR
I
AWFIA0389GB
1. Front brake 2. Five-way connector 3. Three-way connector J

4. Rear brake 5. Load sensing valve (LSV) 6. Master cylinder
7. Brake booster 8. Three-way connector (engine Front
compartment) K
31.4 (3.2, 23) 16.2 (1.7, 12)

W/ABS
AWFIA0390GB
1. Front brake 2. Four-way connector 3. Three-way connector (axle)

4. Rear brake 5. Load sensing valve (LSV) 6. Master cylinder
7. Brake booster 8. Three-way connector (engine compart- 9. ABS actuator and electric unit
ment)
31.4 (3.2, 23) 16.2 (1.7, 12) Front
Front and Rear Brake Piping and Hose INFOID:0000000008945293
REMOVAL
CAUTION:
• Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
• All hoses must be free from excessive bending, twisting and pulling.
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.
SBR992
INSTALLATION
CAUTION:
1. Tighten all flare nuts and connecting bolts.

2. Refill until new brake fluid comes out of each air bleeder valve.
3. Bleed air. Refer to BR-7, "Bleeding Brake System". A
Check brake lines (tubes and hoses) for cracks, deterioration and other damage. Replace any damaged parts. B
BR

MASTER CYLINDER
MASTER CYLINDER
Component INFOID:0000000008945295
AWFIA0391GB
1. Reservoir cap 2. Oil filter (w/ABS) 3. Float

4. Reservoir tank 5. Seal 6. Cylinder body
7. Copper sealing washer 8. Piston stopper (w/ABS) 9. Secondary piston assembly
10. Primary piston assembly 11. Stopper cap 12. Primary piston assembly (w/
ABS)
13. Secondary piston assembly (w/ 14. Brake fluid level switch (if
ABS) equipped)
REMOVAL
CAUTION:
• 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.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
1. Connect a vinyl tube to air bleeder on brakes.
2. Drain brake fluid from each air bleeder, depressing brake pedal to empty fluid from master cylinder.
3. Disconnect the harness connector from the brake fluid level switch (if equipped).
4. Remove flare nuts.
5. Remove master cylinder nuts.
INSTALLATION
CAUTION:

MASTER CYLINDER
1. Place master cylinder onto brake booster and secure master
cylinder nuts lightly. A
2. Tighten master cylinder nuts.
3. Connect brake fluid level switch harness connector (if
equipped). B
4. Fill reservoir tank with new brake fluid.
5. Plug all ports on master cylinder with fingers to prevent air suc-
tion while releasing brake pedal. C
6. Have driver depress brake pedal slowly several times until no air
comes out of master cylinder. ABR190
7. Fit brake lines to master cylinder. D

8. Tighten flare nuts. Refer to BR-9, "Hydraulic Circuit".
9. Bleed air from brake system. Refer to BR-7, "Bleeding Brake System".
E
Disassembly and Assembly INFOID:0000000008945297
DISASSEMBLY BR
1. If necessary, remove brake fluid level switch (if equipped).
2. Bend claws of stopper cap outward.
G
SBR938A
J
3. Remove piston assemblies.
NOTE:
If it is difficult to remove secondary piston assembly, gradually
K
apply compressed air through fluid outlet.
4. Draw out reservoir tank.
L
M
SBR939A
INSPECTION AFTER DISASSEMBLY

N
Master cylinder
Check master cylinder inner wall for pin holes and scratches. Replace if damaged.
Piston O
Check the piston cup for damage. Replace the piston if damage is found.
ASSEMBLY
CAUTION: P
• Do not use mineral oils such as kerosene or gasoline during the cleaning and assembly process.
• Make sure there is no foreign material such as dirt and dust on the inner cylinder wall, piston and
cup seal.
• Be careful not to damage the parts with a service tool when assembling.
• Do not drop parts. Do not use dropped parts.

MASTER CYLINDER
1. Insert secondary piston assembly (C). Then insert primary pis-
ton assembly (D).
CAUTION:
• Pay attention to direction of piston cups in figure. Also,
insert pistons squarely to avoid scratches on cylinder
bore.
• Do not reuse piston assemblies.
• (A): Without ABS
• (B): With ABS
AWFIA0421GB
2. Install stopper cap.

CAUTION:
Do not reuse stopper cap.
NOTE:
Before installing stopper cap, ensure that claws are bent inward.
3. Push reservoir tank seals into cylinder body.
CAUTION:
Do not reuse reservoir tank seals.
4. Push reservoir tank into cylinder body.
5. If necessary, install brake fluid level switch (if equipped).
SBR940A

LOAD SENSING VALVE
LOAD SENSING VALVE
A
2WD
2WD : Removal and Installation INFOID:0000000008945298
B
2WD
BR
AWFIA1002ZZ
J
1. Cover 2. Air bleeder cap 3. Air bleeder
4. Load sensing valve 5. Sensor spring 6. Bracket
K
CAUTION:
• Always use a flare nut wrench to remove brake tube. Be careful not to damage flare nut and brake
tube. Also, use flare nut torque wrench for brake tube installation and tightening to the specified L
torque. Refer to BR-9, "Hydraulic Circuit".
• Do not reuse drained brake fluid. M
NOTE:
ing.
N
REMOVAL
1. Drain brake fluid.
2. Using a suitable tool, remove flare nut on brake tubes from load sensing valve. O
3. Remove bolts to remove load sensing valve.
INSTALLATION
• Installation is in the reverse order of removal. P
• After installation perform the following: bleed air from brake line. Refer to BR-7, "Bleeding Brake System",
and check mounting length “L” of sensor spring. Refer to BR-31, "Load Sensing Valve".
2WD : Inspection INFOID:0000000008945299
INSPECTION

LOAD SENSING VALVE
1. With the vehicle in unladen condition, a person should sit in driver's seat at the rear. Then he/she should
get out of car gently. (This is to stabilize suspension deflection.)
NOTE:
“Unladen condition”: with full coolant, lubricant, 6 to 8 litters of fuel, spare tire, jack, and hand tools loaded.
2. Press load sensing valve against stopper bolt. Check if center-to-center length “L” between adjusting ref-
erence hole and reference pin is as specified below.
Length “L” : Refer to BR-31, "Load Sensing Valve".

• If measurement is outside the standard, perform following;
loosen bolt of sensor spring bracket. By moving sensor spring
bracket, adjust so that the length “L” comes into specified
range.
3. Connect brake fluid pressure tester (special service tool) to
bleed valves of front caliper and rear wheel cylinder.
4. Bleed air from brake fluid pressure tester (special service tool).
5. With brake pedal depressed, check brake fluid pressure at front
caliper and rear wheel cylinder. The respective measurements
should be as specified in the table below.
SFIA0245E
6. Under condition of step 2 above, adjust rear shaft weight with

weights to obtain 163.4 mm (6.43 in) as length “L”. Then, check
brake fluid pressure as described in step 5 above. If measure-
ments are outside the standards, replace load sensing valve
main body.
BRA0515D
Standard
Front caliper brake fluid Rear wheel cylinder brake fluid pressure kPa (bar, kg/cm2, psi)
pressure 2WD
kPa (bar, kg/cm2, psi) unladen loaded
3236 - 4217 (32.36 - 42.17, 33 - 43, 3923 − 5884 (39.2 - 58.8, 40 - 60,
4,904 (49.0, 50, 711)
469 - 611) 569 - 853)
4119 - 5100 (41.1 - 57.0, 42 - 52, 597 6375 - 8336 (64.0 - 83.4, 65 - 85, 924
9,807 (98.1, 100, 1422)
- 739) - 1209
7. After inspection, remove brake fluid pressure tester (special service tool) and bleed air. Refer to BR-7,
"Bleeding Brake System".
4WD

LOAD SENSING VALVE
4WD : Removal and Installation INFOID:0000000008945300
A
4WD
BR
AWFIA1003ZZ
I
1. Air bleeder 2. Load sensing valve 3. Air bleeder cap
4. Cover 5. Bracket 6. Sensor spring
7. Bracket J
CAUTION:
• Always use a flare nut wrench to remove brake tube. Be careful not to damage flare nut and brake K
tube. Also, use flare nut torque wrench for brake tube installation and tightening to the specified
torque. Refer to BR-9, "Hydraulic Circuit".
• Refill with new brake fluid “DOT 3”. L
NOTE:
ing. M
REMOVAL
1. Drain brake fluid. N
2. Using a suitable tool, remove flare nut on brake tubes from load sensing valve.
3. Remove bolts to remove load sensing valve.
INSTALLATION O
• Installation is in the reverse order of removal.
• After installation perform the following: bleed air from brake line. Refer to BR-7, "Bleeding Brake System",
and check mounting length “L” of sensor spring. Refer to BR-31, "Load Sensing Valve". P
4WD : Inspection INFOID:0000000008945301
INSPECTION
1. With the vehicle in unladen condition, a person should sit in driver's seat at the rear. Then he/she should
get out of car gently. (This is to stabilize suspension deflection.)
NOTE:

LOAD SENSING VALVE
“Unladen condition”: with full coolant, lubricant, 6 to 8 litters of fuel, spare tire, jack, and hand tools loaded.
2. Press load sensing valve against stopper bolt. Check if center-to-center length “L” between adjusting ref-
erence hole and reference pin is as specified below.
Length “L” : Refer to BR-31, "Load Sensing Valve".

• If measurement is outside the standard, perform following;
loosen bolt of sensor spring bracket. By moving sensor spring
bracket, adjust so that the length “L” comes into specified
range.
3. Connect brake fluid pressure tester (special service tool) to
bleed valves of front caliper and rear wheel cylinder.
4. Bleed air from brake fluid pressure tester (special service tool).
5. With brake pedal depressed, check brake fluid pressure at front
caliper and rear wheel cylinder. The respective measurements
should be as specified in the table below.
SFIA0245E
6. Under condition of step 2 above, adjust rear shaft weight with

weights to obtain 163.4 mm (6.43 in) as length “L”. Then, check
brake fluid pressure as described in step 5 above. If measure-
ments are outside the standards, replace load sensing valve
main body.
BRA0515D
Standard
Rear wheel cylinder brake fluid pressure kPa (bar, kg/cm2, psi)
Front caliper brake fluid pressure
4WD
kPa (bar, kg/cm2, psi)
unladen loaded
1765 - 2746 (18.0 - 27.5, 18 - 28, 3923 - 5884 (39.2 - 58.8, 40 -
4,904 (49.0, 50, 711)
256 - 398) 60, 569 - 853)
2648 - 3629 (26.5 - 36.3, 27 - 37, 6865 - 8924 68.7 - 89.2, 71 - 91,
9,807 (98.1, 100, 1422)
384 - 526) 995 - 1294)
7. After inspection, remove brake fluid pressure tester (special service tool) and bleed air. Refer to BR-7,
"Bleeding Brake System".

BRAKE BOOSTER
BRAKE BOOSTER
A
On-vehicle Service INFOID:0000000008945302
OPERATING CHECK B
• Depress brake pedal several times with engine off. After exhaust-
ing vacuum, make sure there is no change in pedal stroke.
C
E
SBR002A
• Depress brake pedal, then start engine. If pedal goes down BR

slightly, operation is normal.
SBR365AA
I
AIRTIGHT CHECK
• Start engine, and stop it after one or two minutes. Depress brake pedal several times slowly. Booster is air-
tight if pedal stroke is less each time. J
• 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.
K
REMOVAL
L
CAUTION:
• Be careful not to deform or bend brake pipes during removal of booster. M
INSPECTION AFTER REMOVAL
1. Apply vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg) to brake N
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. O
Output rod length : Refer to BR-32, "Brake Booster".

P
ABR875
INSTALLATION
CAUTION:
• Be careful not to deform or bend brake pipes during installation of booster.

BRAKE BOOSTER
• Replace clevis pin if damaged.
• 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.
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
(A) : 160 mm (6.30 in)

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 brake booster nuts.
Brake booster nuts : 14.2 N·m (1.4 kg-m, 10 ft-lb) SBR116BE
5. Install master cylinder. Refer to BR-12, "Removal and Installation".

6. Adjust brake pedal height and free play. Refer to BR-6, "Adjustment".
7. Secure lock nut for clevis.
Lock nut : 19 N·m (1.9 kg-m, 14 ft-lb)

8. Bleed air. Refer to BR-7, "Bleeding Brake System".
SBR930

VACUUM LINES
VACUUM LINES
A
D
AWFIA0404GB
1. Check valve A. To engine B. To brake booster

E
CAUTION:
When installing vacuum hoses, pay attention to the following points.
BR
• Do not apply any oil or lubricants to vacuum hose with check valve.
• Insert vacuum tube into vacuum hose as shown.
• Install vacuum hose with internal check valve, paying atten-
tion to its direction. G
I
SBR225B
Inspection INFOID:0000000008945305 J
VISUAL INSPECTION
Check vacuum lines and connections for airtightness, improper attachment, chafing and deterioration. K
CHECK VALVE INSPECTION
Check vacuum with a vacuum pump.
L
Connect to booster side Vacuum should exist.
Connect to engine side Vacuum should not exist.
M
SBR844B

FRONT DISC BRAKE
FRONT DISC BRAKE
AWFIA0406GB
1. Main pin 2. Pin boot 3. Torque member bolt

4. Torque member 5. Shim cover (if equipped) 6. Inner shim
7. Inner pad 8. Pad retainer 9. Outer pad
10. Outer shim 11. Connecting bolt 12. Copper sealing washer
13. Main pin bolt 14. Bleed valve 15. Cylinder body
16. Piston seal 17. Piston 18. Piston boot
A. Apply to sliding portion B. Bake fluid R. Rubber grease
Pad Replacement INFOID:0000000008945309
WARNING:
Clean brakes with a vacuum dust collector to minimize the hazard of airborne particles or other mate-
rials.
CAUTION:
• When cylinder body is open, do not depress brake pedal, or piston will pop out.
• Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads.
• If shims are rusted or show peeling of the rubber coat, replace them with new shims.
• 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 drums or rotors, after replacing
pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-26, "Brake Burnishing Pro-
cedure".
1. Remove wheel and tire using power tool. Refer to WT-6, "Adjustment".
2. Remove reservoir cap.
3. Partially drain brake fluid.

FRONT DISC BRAKE
4. Remove lower main pin bolt.
A
SBR081A
D
5. Rotate cylinder body upward. Remove pad retainers, inner and
outer shims and shim cover (if equipped).
E
Standard pad thickness : 10 mm (0.4 in)
Pad wear limit : 2 mm (0.08 in)
CAUTION: BR
Carefully monitor brake fluid level because brake fluid will
return to reservoir tank when pushing back pistons.
G
SBR010B
K
Caliper Removal and Installation INFOID:0000000008945310
L
REMOVAL
WARNING:
Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other
M
materials.
CAUTION:
Suspend caliper assembly with wire so as not to stretch brake hose.
NOTE: N
ing.
1. Remove wheel and tire using power tool. Refer to WT-6, "Adjustment". O
2. Remove reservoir cap.

FRONT DISC BRAKE
3. Remove torque member bolts and connecting bolt.
NOTE:
It is not necessary to remove connecting bolt except for disas-
sembly or replacement of caliper assembly. In this case, sus-
pend caliper assembly with wire so as not to stretch brake hose.
4. Remove brake hose and caliper assembly.
SBR083A
INSTALLATION
CAUTION:
1. Install caliper assembly and brake hose. Align protrusion on
brake hose with slot on caliper assembly.
CAUTION:
Do not reuse copper sealing washers.
2. Bleed air. Refer to BR-7, "Bleeding Brake System".
3. Install reservoir cap.
4. Install wheel and tire. Refer to WT-6, "Adjustment".
SBR084A
Caliper Disassembly and Assembly INFOID:0000000008945311
DISASSEMBLY
WARNING:
Do not place your fingers in front of piston.
CAUTION:
• Do not scratch or score cylinder wall.
• Front disc brake uses plastic pistons. Handle them carefully.
1. Push out piston and dust covers with compressed air. Use a
wooden block so that both pistons come out evenly.
2. Remove piston seal with a suitable tool.
SBR085A
INSPECTION AFTER DISASSEMBLY

Cylinder Body
• 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.
• 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. Do not use mineral oil.
Piston
CAUTION:

FRONT DISC BRAKE
Piston sliding surface is plated. Do not polish with emery paper
even if rust or foreign objects are stuck to sliding surface. A
SBR177C
D
Main Pin, Main Pin Bolt and Pin Boot
Check for wear, cracks, rust and other damage. Replace if any of the above conditions are observed.
DISC ROTOR INSPECTION E
Runout
1. Check rotor runout using a dial indicator.
Make sure that wheel bearing axial end play is within the speci- BR
fications before measuring. Refer to FAX-5, "Front Wheel Bear-
ing".
G
Maximum rotor runout : Refer to BR-31, "Disc
Brake".
2. If the rotor runout is out of specification, find minimum rotor H
runout position as follows:
a. Remove nuts and rotor from wheel hub.
SBR089A
b. Shift the rotor one hole and secure rotor to wheel hub with nuts. I
c. Measure runout.
d. Repeat steps a. to c. so that minimum rotor runout position can be found.
3. If the rotor runout is still out of specification, turn rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO J
700 and 705” or equivalent).
Thickness
K
Rotor repair limit (mini- : Refer to BR-31, "Disc
mum thickness Brake".
L
Rotor thickness varia- : Refer to BR-31, "Disc
tion (At least 8 positions) Brake".
If thickness variation exceeds the specification, turn rotor with on-car M
brake lathe.
N
SBR090A
ASSEMBLY
1. Insert piston seal into groove on cylinder body. O

FRONT DISC BRAKE
2. With piston boot fitted to piston, insert piston boot into groove on
cylinder body and install piston.
CAUTION:
Lubricate with new brake fluid before installing pistons into
cylinder body.
SBR178C
3. Properly secure piston boot.

CAUTION:
Secure dust seal properly.
SBR179CA
Brake Burnishing Procedure INFOID:0000000008945312
Burnish the brake contact surfaces according to the following procedure after refinishing or replacing drums or
rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

REAR DRUM BRAKE
REAR DRUM BRAKE
A
BR
I
AWFIA0407GB
1. Shoe hold pin 2. Plug 3. Shoe hold pin J

4. Back plate 5. Air bleeder cap 6. Air bleeder
7. Cylinder body 8. Piston cup 9. Piston
10. Dust cover 11. Spring 12. Wheel cylinder K
13. Pin 14. Adjusting lever 15. Toggle lever
16. Washer 17. Retainer clip 18. Retainer spring
19. Spring seat 20. Shoe hold spring 21. Retainer L
22. Shoe (leading side) 23. Adjuster 24. Shoe (trailing side)
Brake grease Front B. Brake fluid
R. Rubber grease M
N
WHEEL CYLINDER
• Check wheel cylinder for leakage.
• Check for wear, damage and loose conditions. O
Replace if any such condition exists.
ABR370

REAR DRUM BRAKE
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. Remove wheel and tire using power tool. Refer to WT-6, "Adjustment".
2. Release parking brake lever fully, then remove drum.
If drum is hard to remove, the following procedures should be
carried out.
a. Remove plug. Then shorten adjuster to make clearance
between brake shoe and drum.
SBR280B
b. Install two bolts as shown. Tighten the two bolts gradually.
SBR093A
3. After removing shoe hold pin by rotating retainer, remove lead-

ing shoe then remove trailing shoe. Remove spring by rotating
shoes.
CAUTION:
• Be careful not to damage wheel cylinder piston boots.
• Be careful not to damage parking brake cable when sepa-
rating it.
4. Remove adjuster.
5. Disconnect parking brake cable from toggle lever.
CAUTION:
Be careful not to damage parking brake cable when sepa- ABR369
rating it.
6. Remove retainer clip with a suitable tool. Then separate toggle
lever and brake shoe (trailing side).
ABR408
INSPECTION AFTER REMOVAL

REAR DRUM BRAKE
Drum
A
Maximum inner diame- : Refer to BR-31, "Drum
ter (Repair limit) Brake".
• Contact surface should be fine finished with No. 120 to 150 emery B
paper.
• Using a drum lathe, lathe brake drum if it shows scoring, partial
wear or stepped wear. C
• After brake drum has been completely reconditioned or replaced,
check drum and shoes for proper contact pattern.
SBR095A
D
Lining
Check lining thickness.
E
Standard lining : Refer to BR-31, "Drum
thickness Brake".
BR
Lining wear limit (A) : Refer to BR-31, "Drum
Brake".
SBR021A
H
INSTALLATION
NOTE:
• Always perform shoe clearance adjustment. I
• Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing pads or lin-
ings, or if a soft pedal occurs at very low mileage. Refer to BR-26, "Brake Burnishing Procedure".
1. Fit toggle lever to brake shoe (trailing side) with retainer clip.
J
SBR092B
M
2. Shorten adjuster by rotating it.
• Pay attention to direction of adjuster.
N
Wheel Screw Depression
Left LH thread Yes
O
Right RH thread No
3. Connect parking brake cable to toggle lever.
4. Installation is in the reverse order of removal. P
CAUTION:
SBR217B

REAR DRUM BRAKE
Be careful not to damage wheel cylinder piston boots.
WFIA0085E
5. Adjust shoe-to-drum clearance.

6. Install brake drum.
7. When installing new wheel cylinder or overhauling wheel cylin-
der, bleed air. Refer to BR-7, "Bleeding Brake System".
8. Adjust parking brake. Refer to PB-4, "Adjustment".
9. Install the wheel and tire. Refer to WT-6, "Adjustment".
ABR917
Wheel Cylinder Disassembly an Assembly INFOID:0000000008945316
• Check all internal parts for wear, rust and damage. Replace if nec-
essary.
• Pay attention not to scratch cylinder when installing pistons.
WFIA0084E

SERVICE DATA AND SPECIFICATIONS (SDS)
A
General Specification INFOID:0000000008945317
Unit: mm (in) B
Brake model CL28VD
Cylinder bore diameter × number of pistons 42.8 (1.685) x 2
Front brake Pad 146.6 x 48.5 x 10 C
Length × width × thickness (5.77 x 1.909 x 0.39)
Rotor outer diameter × thickness 260 x 26 (10.2 x 1.02)
D
Brake model LT26
Cylinder bore diameter 22.22 (7/8)
Rear brake
Lining length × width × thickness 249.6 x 40 x 5.5 (9.83 x 1.57 x 0.217) E
Drum inner diameter 260.0 (10.23)
Master cylinder Bore diameter 25.40 (1)
Booster model M195T BR
Brake booster Pri: 205 (8.07)
Diaphragm diameter
Sec: 180 (7.09)
G
Recommended brake fluid DOT 3
Load Sensing Valve INFOID:0000000008945318
H
LOAD SENSING VALVE
Load Sensing Valve spring length spring lenght "L" (center to center) 163.4 mm (6.43 in) I
Disc Brake INFOID:0000000008945319
Unit: mm (in) J
Brake model CL28VD
Wear limit minimum thickness 2.0 (0.079)
Pad K
Standard pad thickness 10 (0.39)
Rotor repair limit Minimum thickness 24.0 (0.945)
Rotor runout Maximum 0.07 (0.0028) L
Rotor thickness variation Maximum 0.02 (0.0008)
Drum Brake INFOID:0000000008945320 M
Unit: mm (in)
Brake model LT26 N

Minimum thickness 1.5 (0.059)
Lining wear limit
Standard thickness 5.5 (0.217)
Maximum inner diameter 261.5 (10.30) O
Drum repair limit
Out-of-round limit 0.03 (0.0012)
Brake Pedal INFOID:0000000008945321 P
Unit: mm (in)
Transmission M/T
Free height * 191 - 201 (7.52 - 7.91)
Depressed height
105 (4.13)
[under force of 490 N (50 kg, 110 lb) with engine running]

Clearance between pedal stopper and threaded end of stop lamp switch 0.3 - 1.0 (0.012 - 0.039)
Pedal free play At pedal pad 1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of metal floor to pedal pad
Brake Booster INFOID:0000000008945322
Unit: mm (in)
Output rod length 10.275 - 10.525 (0.4045 - 0.4144)

Brake System: Section

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Brake System: Section

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BRAKES

Revision: April 2013 BR-1 2013 D22 LCV

Revision: April 2013 BR-2 2013 D22 LCV

Brake fluid pressure gauge Measuring brake fluid pressure E

Revision: April 2013 BR-3 2013 D22 LCV

Rotor or drum deformation

Rotor thickness variation

Rotor or drum damage

Rotor or drum rust

Drum out of round

Revision: April 2013 BR-4 2013 D22 LCV

1. Fulcrum shaft 2. Pedal bracket 3. Stop lamp switch K

Check brake pedal for following items.

Revision: April 2013 BR-5 2013 D22 LCV

Check brake pedal free height from metal panel.

Free height (H) : Refer to BR-31, "Brake

If necessary, adjust brake pedal free height.

damage to components (master cylinder, wheel cylinder, etc.).

Revision: April 2013 BR-6 2013 D22 LCV

• Check fluid level in reservoir tank. It should be between MAX and B

Changing Brake Fluid INFOID:0000000008945290

Revision: April 2013 BR-7 2013 D22 LCV

Air bleeder : 7 - 9 N·m (0.7 - 0.9 kg-m, 62 - 80 in-lb)

Revision: April 2013 BR-8 2013 D22 LCV

1. Front brake 2. Five-way connector 3. Three-way connector J

Revision: April 2013 BR-9 2013 D22 LCV

1. Front brake 2. Four-way connector 3. Three-way connector (axle)

31.4 (3.2, 23) 16.2 (1.7, 12) Front

Front and Rear Brake Piping and Hose INFOID:0000000008945293

Revision: April 2013 BR-10 2013 D22 LCV

Revision: April 2013 BR-11 2013 D22 LCV

1. Reservoir cap 2. Oil filter (w/ABS) 3. Float

Removal and Installation INFOID:0000000008945296

Revision: April 2013 BR-12 2013 D22 LCV

7. Fit brake lines to master cylinder. D

INSPECTION AFTER DISASSEMBLY

Revision: April 2013 BR-13 2013 D22 LCV

2. Install stopper cap.

Revision: April 2013 BR-14 2013 D22 LCV

Revision: April 2013 BR-15 2013 D22 LCV

Length “L” : Refer to BR-31, "Load Sensing Valve".

6. Under condition of step 2 above, adjust rear shaft weight with

Revision: April 2013 BR-16 2013 D22 LCV

4WD : Inspection INFOID:0000000008945301

Revision: April 2013 BR-17 2013 D22 LCV

Length “L” : Refer to BR-31, "Load Sensing Valve".

6. Under condition of step 2 above, adjust rear shaft weight with

Revision: April 2013 BR-18 2013 D22 LCV

• Depress brake pedal, then start engine. If pedal goes down BR

Output rod length : Refer to BR-32, "Brake Booster".

Revision: April 2013 BR-19 2013 D22 LCV

(A) : 160 mm (6.30 in)

Brake booster nuts : 14.2 N·m (1.4 kg-m, 10 ft-lb) SBR116BE

5. Install master cylinder. Refer to BR-12, "Removal and Installation".

Lock nut : 19 N·m (1.9 kg-m, 14 ft-lb)

Revision: April 2013 BR-20 2013 D22 LCV

1. Check valve A. To engine B. To brake booster

Revision: April 2013 BR-21 2013 D22 LCV

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

Pad Replacement INFOID:0000000008945309

Revision: April 2013 BR-22 2013 D22 LCV

Revision: April 2013 BR-23 2013 D22 LCV

Caliper Disassembly and Assembly INFOID:0000000008945311