Brake System: Section

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION
A
B
BR
Revision: May 2004 2003 Sentra
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) AIR BAG and SEAT BELT PRE-TEN-
SIONER ............................................................. ..... 3
Precautions for Brake System .................................. 3
Wiring Diagrams and Trouble Diagnosis .................. 3
PREPARATION ........................................................... 4
Commercial Service Tools ........................................ 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ................................ ..... 5
ON-VEHICLE SERVICE ............................................. 6
Checking Brake Fluid Level ..................................... 6
Checking Brake Line ................................................ 6
Changing Brake Fluid ............................................... 6
Brake Burnishing Procedure ............................... ..... 6
Bleeding Brake System ............................................ 7
BRAKE HYDRAULIC LINE ................................... ..... 8
Hydraulic Circuit .................................................. ..... 8
Removal ................................................................... 8
Inspection ............................................................ ..... 9
Installation ................................................................ 9
DUAL PROPORTIONING VALVE ......................... ... 10
Inspection ............................................................ ... 10
BRAKE PEDAL AND BRACKET .......................... ....11
Removal and Installation ..................................... ....11
Inspection ............................................................ ....11
Adjustment ............................................................. 12
BRAKE PEDAL HEIGHT ..................................... 12
STOP LAMP SWITCH AND ASCD CANCEL
SWITCH CLEARANCE .................................... ... 12
MASTER CYLINDER ............................................. ... 13
Removal ................................................................. 13
Disassembly ........................................................... 13
Inspection ............................................................ ... 14
Assembly ................................................................ 14
Installation .............................................................. 15
BRAKE BOOSTER ................................................ ... 16
On-vehicle Service .............................................. ... 16
OPERATING CHECK .......................................... 16
AIRTIGHT CHECK .............................................. 16
Removal ................................................................. 16
Inspection ............................................................... 16
OUTPUT ROD LENGTH CHECK ..................... ... 16
Installation .............................................................. 17
VACUUM HOSE ........................................................ 18
Removal and Installation ........................................ 18
Inspection ............................................................... 18
HOSES AND CONNECTORS .......................... ... 18
CHECK VALVE ................................................. ... 18
FRONT DISC BRAKE ............................................ ... 19
Component .......................................................... ... 19
Pad Replacement ................................................ ... 19
Caliper Removal ..................................................... 20
Caliper Disassembly ............................................... 20
Inspection ............................................................... 21
CALIPER ............................................................. 21
ROTOR ............................................................. ... 21
Caliper Assembly .................................................... 22
Caliper Installation .................................................. 22
REAR DISC BRAKE .............................................. ... 23
Component .......................................................... ... 23
Pad Replacement ................................................ ... 23
Caliper Removal ..................................................... 25
Caliper Disassembly ............................................... 25
Inspection ............................................................... 27
CALIPER ............................................................. 27
ROTOR ............................................................. ... 27
Caliper Assembly .................................................... 28
Caliper Installation .................................................. 30
REAR DRUM BRAKE ............................................ ... 31
Components ........................................................ ... 31
Removal ................................................................. 31
Inspection ............................................................... 33
WHEEL CYLINDER ......................................... ... 33
WHEEL CYLINDER OVERHAUL ..................... ... 33
DRUM ............................................................... ... 33
LINING ................................................................ 33
Installation .............................................................. 34
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 35
BR-2 Revision: May 2004 2003 Sentra
General Specifications ............................................ 35
Disc Brake .............................................................. 35
Drum Brake .......................................................... ...35
Brake Pedal ............................................................35
PRECAUTIONS
BR-3
C
D
E
G
H
I
J
K
L
M
A
B
BR
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) AIR BAG and SEAT
BELT PRE-TENSIONER EFS0022M
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:
G To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
G Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
G Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Brake System EFS0022N
G Recommended fluid is brake fluid DOT 3.
G Never reuse drained brake fluid.
G Be careful not to splash brake fluid on painted areas.
G To clean or wash all parts of master cylinder, disc brake cal-
iper and wheel cylinder, use clean brake fluid.
G Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of the hydraulic system.
G Use flare nut wrench when removing and installing brake
tube.
G Always torque brake lines when installing.
G 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 mile-
age.
Refer to BR-6, "Brake Burnishing Procedure".
WARNING:
G Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.
Wiring Diagrams and Trouble Diagnosis EFS0022O
When you read wiring diagrams, refer to the following:
G GI-13, "How to Read Wiring Diagrams"
G PG-2, "POWER SUPPLY ROUTING"
When you perform trouble diagnosis, refer to the following:
G GI-10, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES"
G GI-26, "How to Perform Efficient Diagnosis for an Electrical Incident"
SBR686C
BR-4
PREPARATION
PREPARATION PFP:00002
Commercial Service Tools EFS0022P
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
Removing and installing brake piping
a: 10 mm (0.39 in)
Brake fluid pressure gauge Measuring brake fluid pressure
S-NT360
NT151
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
BR-5
C
D
E
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A
B
BR
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart EFS0022Q
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
X: Applicable
Reference page
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Possible cause and
SUSPECTED PARTS
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Symptom BRAKE
Noise X X X X X X X X X
Shake X X X X X X X
Shimmy, Judder X X X X X X X X X X X X
BR-6
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE PFP:00000
Checking Brake Fluid Level EFS0022R
G Check fluid level in reservoir tank. It should be between the
"Max" and "Min" lines on reservoir tank.
G If fluid level is extremely low, check brake system for leaks.
G Release parking brake lever and see if brake warning lamp goes
off. If not, check brake system for leaks.
Checking Brake Line EFS0022S
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
Changing Brake Fluid EFS0022T
CAUTION:
G Refill with new brake fluid DOT 3.
G Always keep fluid level higher than minimum line on reservoir tank.
G Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
1. Clean inside of reservoir tank, and refill with new brake fluid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
4. Refill until brake fluid comes out of each air bleeder valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to BR-7, "Bleeding Brake System" .
Brake Burnishing Procedure EFS0022U
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).
SBR451D
SBR389C
SBR419C
ON-VEHICLE SERVICE
BR-7
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BR
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 so that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.
Bleeding Brake System EFS0022V
CAUTION:
G Carefully monitor brake fluid level at master cylinder during
bleeding operation.
G Fill reservoir with new brake fluid DOT 3. Make sure it is
full at all times while bleeding air out of system.
G Place a container under master cylinder to avoid spillage of
brake fluid.
G For models with ABS, turn ignition switch OFF and discon-
nect ABS actuator and electric unit connectors or battery
ground cable.
G 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.
7. Tighten air bleeder valve to specification.
SBR995
Air bleeder valve
Front and rear disc
brake
: 7 - 9 Nm (0.7 - 0.9 kg-m,
61 - 78 in-lb)
SBR419C
BR-8
BRAKE HYDRAULIC LINE
BRAKE HYDRAULIC LINE PFP:46210
Hydraulic Circuit EFS0022W
Removal EFS0022X
CAUTION:
G All hoses must be free from excessive bending, twisting and pulling.
WBR074
BRAKE HYDRAULIC LINE
BR-9
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BR
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.
Inspection EFS0022Y
Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.
Installation EFS0022Z
1. Tighten all flare nuts and connecting bolts.
2. Refill until new brake fluid comes out of each air bleeder valve.
CAUTION:
3. Bleed air from brake system. Refer to BR-7, "Bleeding Brake
System" .
SBR992
Specification
Flare nut : 15 - 18 Nm (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Connect-
ing bolt
: 17 - 20 Nm (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
SBR686C
BR-10
DUAL PROPORTIONING VALVE
DUAL PROPORTIONING VALVE PFP:46400
Inspection EFS00230
CAUTION:
G Carefully monitor brake fluid level at master cylinder.
G Use new brake fluid DOT 3.
splashed on paint areas, wash it away with water immediately.
1. Connect Tool to air bleeders of front and rear brakes on either
LH and RH side.
2. Bleed air from the Tool.
3. Check fluid pressure by depressing brake pedal.
Unit: kPa (kg/cm
2
, psi)
G If output pressure is out of specification, replace dual propor-
tioning valve.
4. Bleed air after disconnecting the Tool. Refer to BR-7, "Bleeding
Brake System" .
Applied model All QG18DE
QR25DE without
ABS
QR25DE with ABS
Applied pressure
(Front brake)
7,355 (75, 1,067) 6,374 (65, 924) 6,374 (65, 924)
Output pressure
(Rear brake)
5,099 - 5,492
(52 - 56,
740 - 796)
3,775 - 4,168
(38 - 42,
548 - 604)
4,119 - 4,511
(42 - 46,
597 - 654)
SBR822BA
SBR823BA
BRAKE PEDAL AND BRACKET
BR-11
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A
B
BR
BRAKE PEDAL AND BRACKET PFP:46501
Removal and Installation EFS00231
Inspection EFS00232
G Check brake pedal for following items:
Brake pedal bend
Clevis pin deformation
Crack of any welded portion
Crack or deformation of clevis pin stopper
WBR022
SBR997
BR-12
BRAKE PEDAL AND BRACKET
Adjustment EFS00233
BRAKE PEDAL HEIGHT
G Check brake pedal free height from metal panel and adjust if
necessary.
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
2. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3. Check brake pedal's depressed height while engine is running. If
lower than specification, check brake system for leaks, accumu-
lation of air or any damage to components (master cylinder,
wheel cylinder, etc.); then make necessary repairs.
STOP LAMP SWITCH AND ASCD CANCEL SWITCH CLEARANCE
1. Twist and pull to remove switch.
2. Pull up on brake pedal pad and hold.
3. Insert switch into retainer until switch plunger is completely depressed.
4. Turn the switch until it locks into place in the brake pedal bracket.
NOTE:
When turning the switch to lock into place, the switch backs off the stopper to the correct clearance automati-
cally.
5. Release the brake pedal pad.
H : Free height
Refer to BR-35, "Brake Pedal" .
D : Depressed height
90 mm (3.54 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)
WBR075
SBR229E
MASTER CYLINDER
BR-13
C
D
E
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A
B
BR
MASTER CYLINDER PFP:46010
Removal EFS00234
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder.
3. Remove brake line flare nuts from master cylinder.
4. Remove master cylinder mounting nuts.
Disassembly EFS00235
1. Bend claws of stopper cap outward and remove stopper cap.
WFIA0073E
1. Reservoir cap 2. Oil filter 3. Float
4. Reservoir tank 5. Seal 6. Cylinder body
7. Spring pin (with ABS) 8. Piston stopper pin (with ABS) 9. Secondary piston assembly
10. Primary piston assembly 11. Stopper cap 12. Proportioning valve (without ABS)
SBR234E
BR-14
MASTER CYLINDER
2. Drive out spring pin from cylinder body (with ABS).
3. Draw out reservoir tank and seals.
4. Remove piston stopper pin while piston is pushed into cylinder
(with ABS).
5. Remove piston assemblies.
G If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
Inspection EFS00236
Check for the following items.
Replace any part if damaged.
Master cylinder:
G Pin holes or scratches on inner wall.
Piston:
G Deformation of or scratches on piston cups.
Assembly EFS00237
1. Insert secondary piston assembly. Then insert primary piston
assembly.
G Pay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body (with ABS).
SBR231E
SBR232E
WBR068
SBR221BA
MASTER CYLINDER
BR-15
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BR
2. Install piston stopper pin while piston is pushed into cylinder
(with ABS).
3. Push reservoir tank seals and reservoir tank into cylinder body.
4. Install spring pin (with ABS).
5. Install stopper cap.
G Before installing stopper cap, ensure that claws are bent
inward.
Installation EFS00238
1. Place master cylinder onto brake booster and secure mounting
nuts lightly.
2. Tighten master cylinder mounting nuts.
3. Fill reservoir tank with new brake fluid DOT 3.
CAUTION:
4. Plug all ports on master cylinder with fingers to prevent air suc-
tion while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
8. Bleed air from brake system. Refer to BR-7, "Bleeding Brake System" .
SBR232E
SBR235E
Master cylinder : 12 - 15 Nm (1.2 - 1.5 kg-m,
9 - 11 ft-lb)
Flare nuts : 15 - 18 Nm (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
SBR236E
BR-16
BRAKE BOOSTER
BRAKE BOOSTER PFP:47200
On-vehicle Service EFS00239
OPERATING CHECK
1. Stop engine and depress brake pedal several times. Check that
pedal stroke does not change.
2. Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
1. Start engine, and stop it after one or two minutes. Depress brake
pedal several times slowly. The pedal should go further down
the first time, and then it should gradually rise thereafter.
2. Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change after
holding pedal down for 30 seconds.
Removal EFS0023A
CAUTION:
G 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.
G Be careful not to deform or bend brake lines, during
removal of booster.
Inspection EFS0023B
OUTPUT ROD LENGTH CHECK
1. Apply vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) to brake
booster with a hand vacuum pump.
2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.
3. Check output rod length.
SBR002A
SBR365AA
SBR232CB
Specified length : 10.275 - 10.525 mm
(0.4045 - 0.4144 in)
SBR208E
BRAKE BOOSTER
BR-17
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Installation EFS0023C
CAUTION:
G Be careful not to deform or bend brake lines, during installation of booster.
G Replace clevis pin if damaged.
G Take care not to damage brake booster mounting bolt thread when installing. Due to the acute
angle of installation, the threads can be damaged with the dash panel.
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to
master cylinder) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Install and tighten brake booster mounting nuts to specification.
5. Install master cylinder. Refer to BR-15, "Installation" .
6. Connect brake booster vacuum hose.
7. Adjust brake pedal height. Refer to BR-12, "BRAKE PEDAL
HEIGHT" .
8. Bleed air from brake system. Refer to BR-7, "Bleeding Brake System" .
Brake booster : 13 - 16 Nm (1.3 - 1.6 kg-m, 9 - 12 ft-lb)
WFIA0042E
BR-18
VACUUM HOSE
VACUUM HOSE PFP:41920
Removal and Installation EFS0023D
CAUTION:
When installing vacuum hoses, pay attention to the following points:
G Do not apply any oil or lubricants to vacuum hose with
check valve.
G Insert vacuum tube into vacuum hose as shown.
G Install vacuum hose with the internal check valve oriented
in the correct direction. The arrow on the hose should point
to the engine connection.
Inspection EFS0023E
HOSES AND CONNECTORS
Check vacuum lines and connections for airtightness, improper attachment, chafing and deterioration.
CHECK VALVE
Check vacuum with a vacuum pump.
SBR225B
Connect to booster side Vacuum should exist
Connect to engine side Vacuum should not exist
SBR844B
FRONT DISC BRAKE
BR-19
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BR
FRONT DISC BRAKE PFP:41000
Component EFS0023F
Pad Replacement EFS0023G
WARNING:
Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other
materials.
CAUTION:
G When cylinder body is open, do not depress brake pedal because piston will pop out.
G Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing
pads.
G If shims are rusted or show peeling of the rubber coat, replace them with new shims.
G 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.
G 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-6, "Brake Burnishing Procedure" .
1. Remove master cylinder reservoir cap.
2. Remove wheel and tire. Refer to MA-31, "Tire Rotation" .
ABR556
1. Main pin 2. Pin boot 3. Torque member fixing bolt
4. Torque member 5. Shim cover 6. Inner shim
7. Inner pad 8. Pad retainer 9. Outer pad
10. Outer shim 11. Connecting bolt 12. Copper washer
13. Main pin bolt 14. Air bleeder valve 15. Cylinder body
16. Piston seal 17. Piston 18. Piston boot
BR-20
FRONT DISC BRAKE
3. Remove pin bolt.
4. Open cylinder body upward. Then remove pad with retainers,
inner and outer shims.
NOTE:
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
Caliper Removal EFS0023H
2. Remove torque member fixing bolts and brake hose connecting
bolt.
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne particles or other materials.
G It is not necessary to remove brake hose connecting bolt
except for disassembly or replacement of caliper assem-
bly. In this case, suspend caliper assembly with wire so
as not to stretch brake hose.
Caliper Disassembly EFS0023I
1. Push out piston with piston boot with compressed air.
WARNING:
Do not place your fingers in front of piston.
2. Remove piston seal with a suitable tool.
CAUTION:
Do not scratch or score cylinder wall.
SBR976B
Standard pad thickness
(CL25VA, CL25VB)
: 11 mm (0.43 in)
Pad wear limit
(CL25VA, CL25VB)
: 2.0 mm (0.079 in)
SBR932C
SBR979B
SBR772
FRONT DISC BRAKE
BR-21
C
D
E
G
H
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A
B
BR
3. Remove the pad retainer.
CAUTION:
When removing the pad retainer from the torque member,
lift it up and out in the direction of the arrows in the figure.
Inspection EFS0023J
CALIPER
Cylinder Body
CAUTION:
Use brake fluid to clean. Never use mineral oil.
G 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.
G Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery
paper. Replace cylinder body if necessary.
Piston
CAUTION:
Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are
stuck to sliding surface.
G Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above
conditions are observed.
Slide Pin, Pin Bolt and Pin Boot
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.
Runout
1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
CAUTION:
Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to FAX-5, "Front
Wheel Bearing"
3. If the runout is out of specification, find minimum runout mount-
ing position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can be found.
4. If the runout is still out of specification, turn rotor with on-car brake lathe (MAD, DL-8700, AMMCO 700
and 705 or equivalent).
Thickness
SBR556E
Maximum runout : 0.07 mm (0.0028 in)
SBR219C
Thickness variation
(At least 8 positions)
:Maximum 0.01 mm (0.0004 in)
BR-22
FRONT DISC BRAKE
G If rotor thickness variation exceeds the specification, turn rotor with on-car brake lathe.
Caliper Assembly EFS0023K
1. Insert piston seal into groove in cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove on
cylinder body and install piston.
3. Properly secure piston boot.
Caliper Installation EFS0023L
CAUTION:
1. Install brake hose to caliper securely.
2. Install all parts and tighten all bolts. Refer to BR-19, "Compo-
nent" .
System" .
Rotor thickness
repair limit
: 20.0 mm (0.787 in)
SBR574
SBR980B
REAR DISC BRAKE
BR-23
C
D
E
G
H
I
J
K
L
M
A
B
BR
REAR DISC BRAKE PFP:44000
Component EFS0023M
Pad Replacement EFS0023N
WARNING:
materials.
CAUTION:
G When cylinder body is open, do not depress brake pedal because piston will pop out.
G Be careful not to damage piston boot or get oil on rotor. Always replace shims in replacing pads.
G If shims are rusted or show peeling of rubber coat, replace them with new shims.
G 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.
WBR076
1. Nut 2. Washer 3. Return spring
4. Toggle lever 5. Cam 6. Cam boot
7. Brake hose 8. Connecting bolt 9. Copper washers
10. Air bleeder valve 11. Pin bolt 12. Cable guide
13. Cylinder body 14. Strut 15. O-ring
16. Push rod 17. Key plate 18. Ring C
19. Seat 20. Spring 21. Spring cover
22. Ring B 23. Piston seal 24. Ring A
25. Spacer 26. Wave washer 27. Spacer
28. Ball bearing 29. Adjuster 30. Cup
31. Piston 32. Dust seal 33. Inner shim
34. Inner pad 35. Outer pad 36. Outer shim
37. Pin 38. Pin boot 39. Pad retainer
40. Torque member 41. Torque member fixing bolt
BR-24
REAR DISC BRAKE
G 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-6, "Brake Burnishing Procedure" .
1. Remove master cylinder reservoir cap.
3. Remove brake cable mounting bolt and lock spring.
4. Release parking brake control lever, then disconnect cable from the caliper.
5. Remove upper pin bolt.
6. Open cylinder body downward and secure with wire as shown.
Then remove pad retainers, and inner and outer shims.
7. When installing new pads, push piston into cylinder body by
gently turning piston clockwise, as shown.
NOTE:
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
SBR938C
Standard pad thickness : 10 mm (0.39 in)
Pad wear limit : 2.0 mm (0.079 in)
SBR916C
SBR641
SBR868C
REAR DISC BRAKE
BR-25
C
D
E
G
H
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J
K
L
M
A
B
BR
8. Adjust the piston to the right angle as shown.
9. Align the piston's concave to the pad's convex, then install the
cylinder body to the torque member as shown.
Caliper Removal EFS0023O
WARNING:
materials.
2. Remove brake cable mounting bolt and lock spring.
3. Release parking brake control lever, then disconnect cable from
the caliper.
4. Remove torque member fixing bolts and brake hose connecting
bolt.
NOTE:
It is not necessary to remove brake hose 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.
5. Remove caliper assembly.
Caliper Disassembly EFS0023P
1. Remove piston by turning it counterclockwise with suitable com-
mercial service tool or long nose pliers.
SBR306E
SBR307E
SBR939C
SBR868C
BR-26
REAR DISC BRAKE
2. Pry off ring A from piston with suitable pliers and remove cup,
adjuster, bearing, spacers, and wave washer.
3. Disassemble cylinder body.
a. Pry off ring B with suitable pliers, then remove spring cover,
spring and seat.
b. Pry off ring C, then remove key plate, push rod and rod.
c. Remove piston seal with a suitable tool.
CAUTION:
Be careful not to damage cylinder body.
4. Remove return spring, toggle lever and cable guide.
SBR646
SBR889
SBR088B
SBR656
SBR877
REAR DISC BRAKE
BR-27
C
D
E
G
H
I
J
K
L
M
A
B
BR
Inspection EFS0023Q
CALIPER
CAUTION:
Use brake fluid to clean cylinder. Never use mineral oil.
Cylinder Body
G 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.
G Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery
paper.
Replace cylinder body if necessary.
Torque Member
Check for wear, cracks or other damage. Replace if necessary.
Piston
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.
Pin and Pin Boot
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.
Runout
1. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
CAUTION:
Make sure that axial end play is within the specifications
before measuring. Refer to RAX-5, "Rear Wheel Bearing" .
3. Change relative positions of rotor and wheel hub so that runout
is minimized.
Thickness
Maximum runout : 0.07 mm (0.0028 in)
SBR219C
Rotor repair limit
Standard thickness : 9 mm (0.35 in)
Minimum thickness : 8 mm (0.31 in)
Maximum thickness variation
(At least 8 portions)
: 0.02 mm (0.0008 in)
BR-28
REAR DISC BRAKE
Caliper Assembly EFS0023R
1. Insert cam with depression facing toward open end of cylinder.
2. Generously apply rubber grease to strut and push rod to make
insertion easy.
3. Fit push rod into square hole in key plate. Also match convex
portion of key plate with concave portion of cylinder.
4. Install ring C with a suitable tool.
SBR247B
SBR248B
SBR893
WFIA0077E
REAR DISC BRAKE
BR-29
C
D
E
G
H
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A
B
BR
5. Install seat, spring, spring cover and ring B with snap ring pliers
and a suitable press and drift.
6. Install cup in the specified direction.
7. Install cup, adjuster, bearing, spacers, washer and ring A with a
suitable tool.
8. Insert piston seal into groove on cylinder body.
9. 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.
SBR869C
SBR879
SBR892
SBR100B
SBR646
BR-30
REAR DISC BRAKE
10. Fit toggle lever, return spring and cable guide.
11. Adjust the piston to the right angle as shown.
Caliper Installation EFS0023S
1. Install caliper assembly.
G 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 tighten all bolts. Refer to BR-23, "Compo-
nent" .
System" .
CAUTION:
SBR868C
SBR027D
SBR306E
SBR307E
REAR DRUM BRAKE
BR-31
C
D
E
G
H
I
J
K
L
M
A
B
BR
REAR DRUM BRAKE PFP:43206
Components EFS0023T
Removal EFS0023U
WARNING:
Clean brake lining with a vacuum dust collector to minimize the hazard of airborne materials or other
materials.
CAUTION:
Make sure parking brake lever is completely released.
LBR139
1. Air bleeder valve 2. Cylinder body 3. Wheel cylinder
4. Shoe 5. Shoe hold-down spring 6. Brake drum
7. Return spring 8. Return spring 9. Shoe
10. Adjuster spring 11. Adjuster 12. Shoe hold-down pin
13. Adjuster plug 14. Back plate 15. Retainer
16. Adjusting lever 17. Washer 18. Toggle lever
19. Dust cover 20. Piston 21. Piston cap
22. Spring
BR-32
REAR DRUM BRAKE
2. Release parking brake lever fully, then remove drum.
G If drum is hard to remove, remove adjuster plug. Shorten
adjuster as shown to make clearance between brake shoe
and drum. Install two bolts as shown. Tighten the two bolts
gradually.
3. After removing retainer, remove spring by rotating shoes.
NOTE:
Be careful not to damage parking brake cable when sepa-
rating it.
4. Remove adjuster.
5. Disconnect parking brake cable from toggle lever.
6. Remove retainer ring with a suitable tool. Then separate toggle
lever and adjusting lever from the brake shoe.
LBR027
LBR030
ABR015
ABR016
REAR DRUM BRAKE
BR-33
C
D
E
G
H
I
J
K
L
M
A
B
BR
Inspection EFS0023V
WHEEL CYLINDER
G Check wheel cylinder for leakage.
G Check for wear, damage and loose conditions.
Replace if any such condition exists.
WHEEL CYLINDER OVERHAUL
G Check all internal parts for wear, rust and damage. Replace if
necessary.
G Be careful not to scratch cylinder when installing pistons.
DRUM
G Contact surface should be fine finished with No. 120 to 150
emery paper.
G Using a drum lathe, resurface brake drum if it shows score, par-
tial wear or stepped wear.
G After brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.
LINING
Check lining thickness.
SBR330C
LBR028
Maximum inner
diameter
: 204.5 mm (8.05 in)
Out-of-roundness : 0.03 mm (0.0012 in) or less
LBR031
Standard lining
thickness
: 4.5 mm (0.177 in)
Lining wear limit : 1.5 mm (0.059 in)
WBR186
BR-34
REAR DRUM BRAKE
Installation EFS0023W
G Always perform shoe clearance adjustment. Refer to PB-3, "Adjustment" .
G Burnish the brake contact surfaces after refinishing or replacing drums, after replacing linings, or
if a soft pedal occurs at very low mileage. Refer to BR-6, "Brake Burnishing Procedure" .
1. Fit toggle lever and adjusting lever to brake shoe with retainer ring.
2. Apply brake grease to the contact areas shown.
3. Shorten adjuster by rotating it.
G Pay attention to direction of adjuster.
4. Connect parking brake cable to toggle lever.
5. Install all parts.
Be careful not to damage wheel cylinder piston boots.
6. Check that all parts are installed properly.
Pay attention to direction of adjuster assembly.
7. Install brake drum.
8. When installing new wheel cylinder or overhauling wheel cylin-
der, bleed air from brake system. Refer to BR-7, "Bleeding
Brake System" .
9. Adjust parking brake. Refer to PB-3, "Adjustment" .
10. Install wheel and tire. Refer to MA-31, "Tire Rotation" .
LBR029
Wheel Screw
Left Left-hand thread
Right Right-hand thread
LBR026
LBR032
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-35
C
D
E
G
H
I
J
K
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M
A
B
BR
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
General Specifications EFS0023X
Unit: mm (in)
Disc Brake EFS0023Y
Unit: mm (in)
Drum Brake EFS0023Z
Unit: mm (in)
Brake Pedal EFS00240
Unit: mm (in)
*: Measured from surface of dash reinforcement panel.
Applied Model QG18DE QR25DE
Front brake
Brake model CL25VA CL25VB
Cylinder bore diameter 57.2 (2.252)
Pad length width thickness 125.6 46.0 11.0 (4.94 1.811 0.433)
Rotor outer diameter thickness 257 22 (10.12 0.87) 280 22 (11.02 0.87)
Rear brake
Brake model LT20G CL9HC
Cylinder bore diameter/caliper bore diameter
15.87 (5/8) type a
17.45 (11/16) type b
33.96 (1 11/32)
Lining length width thickness
219.4 35 4.5
(8.64 1.38 0.177)
89.1 39.5 10
(3.508 1.555 0.39)
Drum inner diameter/Disc diameter thickness 203.2 (8) 258 9 (10.16 0.35)
Master cylinder Cylinder bore diameter 23.81 (15/16)
Control valve
Valve model Dual proportioning valve
Split point [kPa (kg/cm
2
, psi)] reducing ratio
1,961 (20,284) 0.2 2,942 (30,427) 0.2
Brake booster
Booster model M215T
Diaphragm diameter
Primary: 230 (9.06)
Secondary: 205 (8.07)
Brake fluid Recommended brake fluid DOT 3
Brake model CL25VA/CL25VB (Front) CL9HC (Rear)
Pad wear limit
Minimum thickness
2.0 (0.079) 2.0 (0.079)
Rotor repair limit
Minimum thickness
20 (0.79) 8.0 (0.31)
Brake model LT20G
Lining wear limit Minimum thickness 1.5 (0.059)
Drum repair limit
Maximum inner diameter 204.5 (8.05)
Maximum out-of round 0.03 (0.0012)
Free height H*
M/T 156 - 166 (6.14 - 6.54)
A/T 164.9 - 174.9 (6.49 - 6.89)
Depressed height "D"
[under force of 490 N (50 kg, 110 lb) with engine running]
90 (3.54)
Pedal free play "A" 1.0 - 3.0 (0.039 - 0.118)
BR-36
SERVICE DATA AND SPECIFICATIONS (SDS)

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