BRAKE SYSTEM

F BRAKES

B
SECTION
BRAKE SYSTEM C

E
CONTENTS
PRECAUTIONS .......................................................... 3 BRAKE MASTER CYLINDER .................................. 13 BR
Precautions for Supplemental Restraint System Components ........................................................... 13
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- REMOVAL ........................................................... 13
SIONER” .................................................................. 3 INSTALLATION ................................................... 13 G
Precautions for Brake System .................................. 3 DISASSEMBLY ................................................... 14
PREPARATION ........................................................... 4 INSPECTION ...................................................... 14
Special Service Tools ............................................... 4 ASSEMBLY ......................................................... 14
H
NOISE, VIBRATION, AND HARSHNESS (NVH) BRAKE BOOSTER ................................................... 16
TROUBLESHOOTING ................................................ 5 On-Vehicle Service ................................................. 16
NVH Troubleshooting Chart ..................................... 5 OPERATING CHECK .......................................... 16
BRAKE PEDAL .......................................................... 6 AIRTIGHT CHECK .............................................. 16 I
Inspection and Adjustment ....................................... 6 Removal and Installation ........................................ 16
PLAY AND CLEARANCE BETWEEN THE REMOVAL ........................................................... 16
BRAKE PEDAL AND FLOOR PANEL WITH INSPECTION AFTER REMOVAL ....................... 16 J
PEDAL DEPRESSED. .......................................... 6 INSTALLATION ................................................... 17
ADJUSTMENT ...................................................... 7 FRONT DISC BRAKE ............................................... 18
Removal and Installation .......................................... 7 Components(CLZ31VA Model) ............................... 18
K
COMPONENTS .................................................... 7 Inspection ............................................................... 19
REMOVAL ............................................................. 8 PAD WEAR INSPECTION ................................... 19
INSPECTION AFTER REMOVAL ......................... 8 Pad Replacement ................................................... 19
INSTALLATION ..................................................... 8 REMOVAL ........................................................... 19 L
BRAKE FLUID ............................................................ 9 INSTALLATION ................................................... 20
Checking Brake Fluid Level ..................................... 9 Caliper Removal and Installation ............................ 21
Checking Brake Line ................................................ 9 REMOVAL ........................................................... 21 M
Refilling and Bleeding .............................................. 9 INSTALLATION ................................................... 21
BLEEDING OF PRE-CHARGE PUMP PATH ........ 9 Caliper Disassembly and Assembly ....................... 21
BRAKE PIPING AND HOSE .....................................11 DISASSEMBLY ................................................... 21
Hydraulic Circuit ......................................................11 CALIPER INSPECTION ...................................... 22
Front Brake Piping and Hose ................................. 12 DISC ROTOR INSPECTION ............................... 22
REMOVAL ........................................................... 12 ASSEMBLY ......................................................... 23
INSTALLATION ................................................... 12 Brake Burnishing Procedure ................................... 24
Rear Brake Piping and Hose .................................. 12 Component (AD31VB Model) ................................. 25
REMOVAL ........................................................... 12 Inspection ............................................................... 25
INSTALLATION ................................................... 12 PAD THICKNESS ................................................ 25
Inspection ............................................................... 12 Pad Replacement ................................................... 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
Caliper Removal and Installation ............................ 26
REMOVAL ........................................................... 26

BR-1
 INSTALLATION .................................................... 27 REMOVAL ............................................................32
Caliper Disassembly and Assembly ....................... 27 INSTALLATION ....................................................32
DISASSEMBLY ................................................... 27 Caliper Disassembly and Assembly ........................33
INSPECTION AFTER DISASSEMBLY ................ 27 DISASSEMBLY ....................................................33
DISC ROTOR INSPECTION ............................... 28 INSPECTION AFTER DISASSEMBLY ................33
ASSEMBLY ......................................................... 28 DISC ROTOR INSPECTION ...............................34
BRAKE BURNISHING PROCEDURE ................. 29 ASSEMBLY ..........................................................34
REAR DISC BRAKE ................................................. 30 SERVICE DATA AND SPECIFICATIONS (SDS) ......36
Component(AD14VD,AD11VD) .............................. 30 General Specifications ............................................36
Inspection ............................................................... 31 Brake pedal .............................................................36
PAD THICKNESS ................................................ 31 Check valve ............................................................36
Pad Replacement ................................................... 31 Brake booster ..........................................................36
REMOVAL ........................................................... 31 Front disc brake ......................................................36
INSTALLATION .................................................... 32 Rear disc brake .......................................................37
Caliper Removal and Installation ............................ 32

BR-2
 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EFS000OD

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
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. C
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 per-
formed by an authorized NISSAN/INFINITI dealer. D
● 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. E
● 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 harness connec-
tors. BR
Precautions for Brake System EFS000OE

● Recommended fluid is brake fluid “DOT 3”. G

● 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 H
and wheel cylinder, use clean brake fluid.
● Never use mineral oils such as gasoline or kerosene. They will
ruin rubber parts of the hydraulic system. I
● Use flare nut wrench when removing and installing brake tube.
● Always torque brake lines when installing.
● Before working, turn the ignition switch OFF and disconnect the SBR820BA J
connectors for the VDC/TCS/ABS actuator or the battery termi-
nals.
● Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing pads or K
linings, or if a soft pedal occurs at very low mileage.
Refer to BR-24, "Brake Burnishing Procedure" .
WARNING: L
● Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.

BR-3
 PREPARATION

PREPARATION PFP:00002

Special Service Tools EFS002IQ

Tool number
Description
Tool name

GG94310000
Flare nut torque wench Removing and installing brake piping
a: 10 mm (0.39 in)

NT406

BR-4
 Symptom

X: Applicable
Reference page

BRAKE
Possible cause and
SUSPECTED PARTS

Noise
Shake

Shimmy, Judder
NVH Troubleshooting Chart

Pads - damaged BR-19, BR-31

×
Pads - uneven wear BR-19, BR-31 .

×
×
Shims damaged BR-18, BR-30

×
×
Rotor imbalance —

Rotor damage —

BR-5
Rotor runout BR-22, BR-34

×
Rotor deformation —

×
Rotor deflection —

×
Rotor rust —

×
Rotor thickness variation BR-23, BR-34

×
Drum out of round —

×
×
PROPELLER SHAFT NVH in PR section
×

DIFFERENTIAL NHV in RFD section

AXLE AND SUSPENSION NVH in FAX, RAX and FSU, RSU section
×
×
×
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

TIRES NVH in WT section

×
×
×

×
×
×

ROAD WHEEL NVH in WT section

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

× × DRIVE SHAFT NVH in RAX section

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

×
×
×

STEERING NVH in PS section

EFS000OH
PFP:00003

L
K
E
B
A

H
D
C

M
BR
 BRAKE PEDAL

BRAKE PEDAL PFP:46501

Inspection and Adjustment EFS000OI

PLAY AND CLEARANCE BETWEEN THE BRAKE PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED.
1. Check the brake pedal free height from the dash floor panel.
2. Adjust the height referring to the following specifications.

SBR453DA

H Brake pedal height 174 - 184 mm (6.85 - 7.24 in)

D Depressed pedal height (under a force of 90 mm (3.54 in) or more
490 N (50 kg, 110lb) with the engine running)
C1 or Clearance between the stopper rubber and 0.74 - 1.96 mm (0.0291 - 0.0772 in)
C2 the threaded end of the stop lamp switch
and ASCD cancel switch.
A Pedal play 3 - 11 mm (0.12 - 0.43 in)

BR-6
 BRAKE PEDAL

ADJUSTMENT
1. Loosen the stop lamp switch and ASCD cancel switch by rotat- A
ing it counterclockwise by 45°.
2. Loosen the lock nut (A) on the input rod, then rotate the input
rod to set the pedal to the specified height, and tighten the lock B
nut (A).
CAUTION:
Check that the threaded end of the input rod stays inside C
the clevis.
Lock nut (A):
D
: 16 - 21 N·m (1.6 - 2.0 kg-m, 12 - 15 in-lb)
3. With the pedal pulled and held by hand, press the stop lamp
switch and ASCD cancel switch until its threaded end contacts E
the stopper rubber.
4. With the threaded end of the stop lamp switch contacting the
stopper rubber and ASCD cancel switch, rotate the switch clock- BR
wise by 45° to secure.
CAUTION:
Make sure that the clearance (C) between the stopper rub-
ber and threaded end of the stop lamp switch and ASCD G
cancel switch is within the standard.
SFIA0160E
5. Check the pedal play.
H
CAUTION:
Make sure that the stop lamps go off when the pedal is released.
6. Start the engine to check the brake pedal's depressed height.
I
Removal and Installation EFS000OJ

COMPONENTS
J

SFIA0132E

BR-7
 BRAKE PEDAL

REMOVAL
1. Remove the lower driver-side instrument panel.
2. Remove the steering column.
3. Remove the stop lamp switch and ASCD cancel switch from the
pedal assembly.
4. Remove the snap pin and clevis pin from the brake booster cle-
vis.
5. Remove the mounting nuts and bolts from the bracket, and
remove the pedal assembly from the vehicle.

SFIA0159E

INSPECTION AFTER REMOVAL

● Check the brake pedal for bend, damage, and cracks on the
welded parts. Replace the applicable part if a failure is detected.
● Check the clevis pin and resin stopper for damage and deforma-
tion. If a failure is detected, replace the clevis pin.

SBR997

INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
● After installing the brake pedal assembly to the vehicle, adjust the brake pedal.

BR-8
 BRAKE FLUID

BRAKE FLUID PFP:KN100

A
Checking Brake Fluid Level EFS000OK

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

Min lines on reservoir tank. B
● 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. C

SBR451D

E
Checking Brake Line EFS000OL

CAUTION:
If leakage occurs around joints, retighten or, if necessary, replace damaged parts. BR
1. Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged
parts.
2. Check for oil leakage by fully depressing brake pedal while G
engine is running.
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
H
replace damaged parts.
3. Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
I
4. Check for oil leakage by fully depressing brake pedal while
engine is running.
SBR389C J
Refilling and Bleeding EFS000OM

CAUTION:
K
● Refill with new brake fluid “DOT 3”
● Always keep fluid level higher than minimum line on reservoir tank.
● Never reuse drained brake fluid. L
● 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.
BLEEDING OF PRE-CHARGE PUMP PATH M
When Using CONSULT-II
1. Loosen the air bleeder on the top of the master cylinder.
2. Slowly depress the brake pedal fully to the stop.
3. Close the air bleeder with the pedal depressed.
4. Release the pedal.
● Repeat the steps 1 to 4 shown above, until new brake fluid
comes out.
5. Bleed air from the brake line of LH front or RH rear wheel (nor-
mal bleeding).
CAUTION:
Check the fluid level after approx. 1 minute, because it PBIB0196E

takes approximately 1 minute to fill the brake fluid in the

reservoir tank fully.
6. Connect CONSULT-II to data link connector on the vehicle, and turn the ignition switch ON (Do not start
the engine).

BR-9
 BRAKE FLUID

7. Touch “START (NISSAN BASED VHCL)”, “VDC or ABS”, “WORK SUPPORT”, and “BLEEDING” on the
CONSULT-II screen in this order.
8. Depress the brake pedal.
9. Loosen the air bleeder on the LH front or RH rear of the wheel.
10. Touch “START”. (The pre-charge pump operates for 20 consecutive seconds, then stops.)
CAUTION:
● At this time, keep depressing the brake pedal.

● While the pre-charge pump operates for 20 consecutive seconds, pay attention to the level of
the fluid in the reservoir tank, and refill the tank in order to always keep it at least half-full.
11. Touch “END”.
12. Tighten the air bleeder.
13. Release the brake pedal.
14. Disconnect the data link connector.
15. Carry out the steps 1 to 4 shown above.
16. Bleed the brake line of four wheels (normal bleeding).
When Not Using CONSULT-II
1. Loosen the air bleeder on the top of the master cylinder.
2. Slowly depress the brake pedal fully to the stop.
3. Close the air bleeder with the pedal depressed.
4. Release the pedal.
● Repeat the steps 1 to 4 shown above, until new brake fluid
comes out.
5. Bleed air from the brake path of the LH front or RH rear wheel
(normal bleeding).
CAUTION:
Check the fluid level after approx. 1 minute, because it SBR647E

takes approximately 1 minute to fill the brake fluid in the

reservoir tank fully.
6. After turning the ignition switch ON, turn it OFF. Short-circuit the vehicle-side DDL2 data link connector
terminal No. 9 on to body ground.
7. Turn the ignition switch ON with the brake pedal depressed, and wait for at least 10 seconds. (Keep the
brake pedal depressed during this time.)
8. Within approximately 40 seconds after turning the ignition switch ON, repeat releasing and short-circuiting
the vehicle-side DDL2 data link connector terminal No. 9 for 10 times to short-circuit to body ground.
(grounded to body ground)
9. Release the air bleeder on the front LH or rear RH wheel.
10. 2 or 3 seconds later, repeat turning the VDC OFF switch ON to OFF for 10 times, after that turn it OFF.
11. 5 seconds later, the pre-charge pump operates for 20 seconds consecutively, then stops.
12. Tighten the air bleeder.
13. Release the brake pedal.
14. Disconnect the DDL2 data link connector terminal No. 9 from body ground.
15. Carry out the steps 1 to 4 shown above.
16. Bleed the brake line of four wheels (normal bleeding).

BR-10
 BRAKE PIPING AND HOSE

BRAKE PIPING AND HOSE PFP:46210

A
Hydraulic Circuit EFS000ON

LHD model
B

BR

SFIA0169E

RHD model H

SFIA0259E

CAUTION:
● When installing, check for twist and fracture.
● Make sure that there is no interference with other parts when turning the steering clockwise or
counterclockwise.
● The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble
the parts. Replace the applicable part with a new one.

BR-11
 BRAKE PIPING AND HOSE

Front Brake Piping and Hose EFS000OO

REMOVAL
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from the air bleeder of each wheel
while depressing the brake pedal.
3. Cover the brake line connection to prevent foreign material such
as dust or dirt from entering into the connection.
4. Using a flare nut wrench, remove the brake tube from the brake
hose. Remove the union bolt, and remove the brake hose from
the caliper assembly.
5. Remove the lock plate.
6. Remove the mounting nuts, and remove the brake hose from SFIA0170E
the vehicle.
INSTALLATION
1. Install the brake hose by aligning with the protrusion on the caliper assembly, and tighten the union bolts
to the specified torque.
CAUTION:
● Do not reuse the copper washer.

2. Install the brake hose to the brake tube on the vehicle, and temporarily tighten the flare nut by hand until it
stops to install the bracket. Fix it with the lock plate, and tighten it to the specified torque.
3. Install the brake hose to the vehicle, and tighten the mounting nuts to the specified torque.
4. After the work, bleed air.
Rear Brake Piping and Hose EFS000OP

REMOVAL
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from the air bleeder of each wheel
while depressing the brake pedal.
3. Cover the brake line connection to prevent foreign material such
as dust or dirt from entering into the connection.
4. Using a flare nut wrench, remove the brake tube from the brake
hose.
5. Remove the union bolts, and then remove the brake hose from
the caliper assembly.
6. Remove the brake hose mounting bolts, and remove the brake PFIA0006E
hose from the vehicle.
INSTALLATION
1. Install the brake hose by aligning with the protrusion on the caliper assembly, and tighten the union bolts
to the specified torque.
CAUTION:
● Do not reuse the copper washer.

● Refill with new brake fluid “DDT3”.

● Never reuse drained brake fluid.

2. Fix the brake hose to the vehicle. Temporarily tighten the flare nut by hand until it stops, and tighten it to
the specified torque.
3. After the work, bleed air.
Inspection EFS000OQ

CAUTION:
If leak is detected at the connections, retighten it or replace the damaged part if necessary.
1. Check the hose, tube, and connections for fluid leaks, damage, twist, deformation, contact with other
parts, and loose connections.
2. While depressing the pedal under the force of 785 N (80 kg, 177 lb) with the engine running for approxi-
mately 5 seconds, check for fluid leak from each part.

BR-12
 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

A
Components EFS000OR

BR

G
SFIA0138E

1. Reservoir cap 2. Oil filter 3. Reservoir tank

4. Seal 5. Cylinder body 6. O-ring H
7. Valve stopper 8. Secondary piston assembly 9. Primary piston assembly
10. Bleed valve 11. Bleed cap

REMOVAL I
CAUTION:
● Be careful not 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. J
● In the case of brake fluid leakage from the master cylinder, disassembly the cylinder. Then check
piston cups for deformation or scratches and replace if necessary.
1. Drain brake fluid. K
2. Remove the harness connectors for the fluid level sensor and pressure sensor.
3. Using a flare nut wrench, remove the brake tube from the master cylinder.
L
4. For models with VDC, remove the suction hose from the reservoir tank.
5. Remove the mounting nuts, and remove the master cylinder assembly from the vehicle.
INSTALLATION M
CAUTION:
● Refill with new brake fluid “DOT3”.
● Never reuse drained brake fluid.
1. Temporarily tighten the flare nuts on the brake tube to master cylinder by hand.
2. Install the master cylinder to the brake booster assembly, and tighten the mounting nuts to the specified
torque.
3. Using a flare nut torque wrench, tighten the flare nut on the brake tube to the specified torque.
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 12 ft-lb)

4. Install the suction hose to the reservoir tank.

5. Refill the new brake fluid and bleed air. Refer to BR-9, "Refilling and Bleeding" .

BR-13
 BRAKE MASTER CYLINDER

DISASSEMBLY
1. Remove the valve stopper from the cylinder body. Using a Phil-
lips screwdriver as shown on the left, remove the piston stopper
with the piston pressed in.

BRA0323D

2. Carefully pull the primary piston assembly straight out to prevent

the inner wall of the cylinder from being damaged.
3. Tap the flange using a soft block such as wood, and carefully
pull the secondary piston assembly straight out to prevent the
inner wall of the cylinder from being damaged.
4. Remove the reservoir tank.
CAUTION:
Remove the reservoir tank only when necessary.

BRA0033D

INSPECTION
● Check the inner wall of the cylinder for damage, wear, corrosion, and pin holes. Replace the cylinder if a
malfunction is detected.

ASSEMBLY
CAUTION:
● Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.
● Make sure that there is no foreign material such as dirt and dust on the inner wall of the cylinder,
piston, and cup seal. Be careful not to damage the parts with a service tool when assembling.
● Do not drop the parts. Do not use any dropped parts.
1. Apply brake fluid to the inner wall of cylinder body and contact
surface of the piston assembly. Then insert secondary piston
assembly and primary piston assembly into cylinder body in this
order.
CAUTION:
● Do not reuse the primary and secondary piston assem-
blies.
● Always replace the inner kit as an assembly.

● Pay attention to the orientation of the piston cup, and

insert straight to prevent the cup from being caught by
the inner wall of the cylinder. SBR089C

2. Align the slit in the center of the piston with the axial direction of
the valve stopper to assemble. Visually check the secondary
piston slit from the valve stopper mounting hole, and install the
valve stopper.
CAUTION:
Always replace the piston pin O-ring with new one in the
repair kit.
3. Apply brake fluid to a grommet, and press it into the master cyl-
inder to install.

BRA0323D

BR-14
 BRAKE MASTER CYLINDER

CAUTION:
Do not reuse the grommet. A
4. Press a new reservoir tank in the cylinder body.

BR

BR-15
 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

On-Vehicle Service EFS000OS

OPERATING CHECK
With the engine stopped, change the vacuum to the atmospheric
pressure by depressing the brake pedal several times. Then with
brake pedal fully depressed, start the engine and when the vacuum
pressure reaches the standard, check that the clearance between
the brake pedal and floor panel decreases.
CAUTION:
Depressing pedal interval is approximately 5 seconds.

BRA0037D

AIRTIGHT CHECK
● Run the engine at idle for approximately 1 minute, and stop it
after applying vacuum to the booster. Depress the brake pedal
normally to change the vacuum to the atmospheric pressure.
Check that distance between the brake pedal and floor panel
gradually increases.
CAUTION:
Depressing pedal interval is approximately 5 seconds.

SBR365AA

Removal and Installation EFS000OT

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.
● Be careful not to deform or bend brake pipes, during
removal of booster.
1. Remove the vacuum hose from the brake booster.
2. Remove the master cylinder.
3. Remove the snap pin and clevis pin on the clevis in the passen-
ger compartment, and remove the input rod from the brake
pedal. SFIA0139E
4. Remove the mounting nuts on the pedal bracket.
5. Remove the booster assembly from the engine compartment.
INSPECTION AFTER REMOVAL
Output Rod Length Inspection
1. Using a handy vacuum pump, apply a vacuum of –66.7 kPa (–
500 mmHg,19.69 inHg) to the brake booster.
2. Check output rod length.
Standard dimension when vacuum :–2 mm (–0.08 in)
–66.7 kPa (–500 mmHg, –19.69
inHg)

SBR208E

BR-16
 BRAKE BOOSTER

INSTALLATION
1. Loosen the lock nut to adjust the input rod length so that the A
length B (in the figure on the left) satisfies the specified value.
Length B : 125 mm (4.92 in)
B
2. After adjusting″ B″, temporarily tighten the lock nut to install the
booster assembly to the vehicle. At this time, make sure to
install a gasket between the booster assembly and the vehicle.
C
3. Connect the brake pedal with the clevis of the input rod.
4. Install the pedal bracket mounting nuts and tighten them to the
specified torque.
SGIA0060E
D
5. Install the master cylinder to the booster assembly.
6. Adjust the height and play of the brake pedal.
7. Tighten the lock nut of the input rod to the specified torque. E
8. Bleed air.

BR

BR-17
 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

Components(CLZ31VA Model) EFS000OU

PFIA0063E

1. Main pin 2. Pin boot 3. Washer

4. Torque member 5. Inner shim cover 6. inner shim
7. Inner pad 8. Pad retainer 9. Outer pad
10. Outer shim 11. Outer shim cover 12. Connecting bolt
13. Copper washer 14. Bleed valve 15. Cylinder body
16. Piston seal 17. Piston 18. Piston boot

CAUTION:
● Clean dust on the caliper and brake pad with a vacuum dust collector. Do not blow with com-
pressed air.
● While removing the cylinder body, never depress the brake pedal because the piston will pop out.
● It is not necessary to remove the mounting bolts on the torque member and brake hose except for
disassembly or replacement of the caliper assembly. In this case, hang the cylinder body with a
wire so that the brake hose is not under tension.
● Do not damage the piston boot.
● Always replace the shims and shim covers as a set when replacing the brake pads.
● Keep brake fluid clean of the rotor.

BR-18
 FRONT DISC BRAKE

Inspection EFS000OV

PAD WEAR INSPECTION A

● Remove the wheel with the vehicle lifted to check the pad thick-
ness from the check hole on the cylinder body. If necessary, use
a scale to check. B
Standard thickness : 10.0 mm (0.394 in)
Repair limit thickness : 2.0 mm (0.079 in)
C

D
MAA0439D

Pad Replacement EFS000OW

E
REMOVAL
WARNING:
Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other
BR
materials.
CAUTION:
● When cylinder body is open, do not depress brake pedal because the piston will pop out.
G
● Be careful not to damage piston boot or get oil on rotor always replace shims in replacing pads.
● It shims are rusted or show peeling of rubber coat, replace them with new shims.
● it is not necessary to remove connecting bolt except for disassembly or replacement of caliper H
assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.
● Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back
piston.
I
● Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing
pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-24, "Brake Burnishing
Procedure" .
J
1. Remove master cylinder reservoir cap.
2. Remove the lower sliding pin bolt.
K

SBR433D

BR-19
 FRONT DISC BRAKE

3. Hang the cylinder body with a wire, and remove the pads, pad
retainers, shims from the torque member.

SBR040C

CAUTION:
● When removing the pad retainer from the torque member,
lift the pad retainer in the direction shown by the arrow
(shown in the figure) so as not to deform it.
● Do not damage the piston boot.

● Keep brake fluid clean of the rotor.

SBR556E

INSTALLATION
1. Apply brake grease to the back of the pad and both sides of the
shim, install the inner shim to the inner pad, and the outer shim
and outer shim cover to the outer pad.
2. Apply disc brake grease to the pad contact surface on the pad
retainer, and install the pad retainers and pads to the torque
member.
CAUTION:
The CLZ31VA inner pad and outer pad have the pad-return
mechanism on the upper side of the pad retainer. When
installing the CLZ31VA pad to the torque member, be sure
to install the pad return lever to the pad wear sensor SBR557E

securely.
3. Install the cylinder body to the torque member.
CAUTION:
When replacing the pads with new ones, press in the piston until the pads can be installed. In this
case, carefully monitor the brake fluid level in the reservoir tank because the brake fluid will return
to the reservoir tank of the master cylinder.

BR-20
 FRONT DISC BRAKE

4. Install the lower sliding pin bolt, and tighten it to the specified
torque. A
5. Check the brake for drag.

SBR433D

D
Caliper Removal and Installation EFS000OX

REMOVAL
1. Connect a vinyl tube to the air bleeder.
E
2. Drain brake fluid gradually from the air bleeder while depressing
the brake pedal.
3. Remove the union bolts, and then remove the brake hose from
BR
the caliper assembly.
4. Remove the mounting bolts from the torque member, and
remove the caliper assembly from the vehicle.
G
5. Remove the disc rotor.

SFIA0140E
H
INSTALLATION
1. Install the disc rotor.
2. Install the caliper assembly to the vehicle, and tighten the mounting bolts to the specified torque. I
CAUTION:
Before installing the torque member to the vehicle, wipe oil and grease on the washer seats on the
knuckle spindle and mounting surface of the torque member. J
3. Install the brake hose by aligning with the protrusions on the caliper assembly, and tighten the union bolts
to the specified torque.
CAUTION: K
● Do not reuse the copper washer for union bolts.

● Assemble the brake hose securely to the protrusions on caliper assembly.

4. After installing the caliper assembly, refill with new brake fluid and bleed air. L
Caliper Disassembly and Assembly EFS000OY

DISASSEMBLY
1. Remove the caliper assembly from the vehicle. M
2. Remove the sliding pin bolts from the cylinder body, and remove
the pad, shim, shim cover and pad retainer from the torque
member.
CAUTION:
When removing the pad retainer from the torque member,
lift the pad retainer in the direction shown by the arrow
(shown in the figure) so as not to deform it.

SBR556E

BR-21
 FRONT DISC BRAKE

3. Remove the sliding pins and sliding pin boots from the torque
member.
4. Place a wooden block as shown at the left, and blow air from the
union bolt mounting hole to remove the pistons and piston
boots.

BRB0032D

5. Using a slotted screwdriver, remove the piston seals from the

cylinder body.
CAUTION:
Be careful not to damage the inner wall of the cylinder.

SFIA0141E

CALIPER INSPECTION
Cylinder Body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.
● Check the inner wall of the cylinder for corrosion, wear, and damage. If a failure is detected, replace the
cylinder body.
● Minor flaws caused by corrosion or a foreign material can be removed by polishing the surface with a fine
sandpaper. Replace the cylinder body, if necessary.
Torque Member
Check for wear, cracks, and damage. If a malfunction is detected, replace the applicable part.
Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check the piston surface for corrosion, wear, and damage. If a malfunction is detected, replace the applicable
part.
Sliding Pin, Pin Bolt, and Pin Boot
Check the sliding pin and sliding pin boot for wear, damage, and cracks. If a malfunction is detected, replace
the applicable part.
DISC ROTOR INSPECTION
Visual Inspection
Check the surface of the disc rotor for uneven wear, cracks, and serious damage. If a malfunction is detected,
replace the applicable part.
Runout Inspection
1. Using wheel nuts, fix the disc rotor to the wheels hub. (2 or more positions)

BR-22
 FRONT DISC BRAKE

2. Using a dial indicator, check the runout.

Measurement point: A
At a point 10 mm (0.394 in) from the outer edge of
the disc.
B
Maximum runout : 0.07 mm (0.0028 in) or less
CAUTION:
Before measuring, make sure that the axle endplay is 0 mm. C
3. If the runout is outside the limit, find the minimum runout point by
shifting the mounting positions of the disc rotor and wheel hub
SBR019B
by one hole. D
Thickness Inspection
1. Using a micrometer, check the thickness of the disc rotor. If the
thickness is outside the standard, replace the disc rotor. E
Standard thickness : 28.0 mm (1.10 in)
Wear limit : 26.0 mm (1.02 in)
BR
Maximum uneven wear (measured at 8 positions):
0.015 mm (0,0006 in) or less
2. If the runout is still out of specification, turn rotor with on-car G
brake lathe(“MAD, DL-8700”, “AMMCO 700 and 705”or equiva-
lent). SBR020B

H
ASSEMBLY
1. Apply rubber grease to the piston seals, and install them to the
cylinder body.
I
CAUTION:
Do not reuse the piston seals.

SFIA0154E

2. Apply brake fluid to the piston boots. Cover the piston end with L
the piston boot, and install the cylinder-side lip on the piston
boot properly into the groove on the cylinder body.
CAUTION: M
Do not reuse the piston boot.

SFIA0155E

BR-23
 FRONT DISC BRAKE

3. Apply brake fluid to the piston, and press the piston into the cyl-
inder body by hand to assemble the piston-side lip on the piston
boot properly into the groove on the piston.
CAUTION:
Press the piston evenly and change the pressing point to
prevent the inner wall of the cylinder from being rubbed.
4. Install the sliding pins and sliding pin boots to the torque mem-
ber.

SBR574

5. Install the torque member to the knuckle spindle and tighten the
mounting bolts to the specified torque.
CAUTION:
Before installing the torque member to the vehicle, wipe oil
and grease on the washer seats on the knuckle spindle and
mounting surface of the torque member.
6. Install the pad retainers to the torque member.
7. After assembling the shims and shim covers to the pad, install it
to the torque member.
CAUTION: SBR557E
The inner pad and outer pad have the pad-return mecha-
nism on the upper side of the pad retainer. When installing the pad, be sure to install the pad return
lever to the pad wear sensor securely shown to the left.
8. Install the cylinder body, and tighten the sliding pin bolt to the specified torque.
9. Install the brake hose to the cylinder body and tighten the union bolts to the specified torque.
CAUTION:
● Assemble the brake hose securely to the protrusions on the cylinder body.

● Do not reuse the copper washer for union bolts.

10. After installing the caliper assembly, refill with new brake fluid and bleed air.
Brake Burnishing Procedure EFS000OZ

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.

BR-24
 FRONT DISC BRAKE

Component (AD31VB Model) EFS001P4

BR

SFIA0328E

1. Torque member 2. Slid pin boot 3. Slid pin G

4. Outer shim cover 5. Outer shim 6. Outer pad
7. Pad retainer 8. Inner pad 9. Inner shim
10. Inner shim cover 11. Piston boots 12. Piston
H
13. 2 piston seal 14. Cylinder body 15. Copper washer
16. Air bleeder 17. Brake hose union bolt
I
WARNING:
● Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or
other materials.
J
CAUTION:
● When cylinder body is open, do not depress brake pedal because piston will pop out.
● Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing
K
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 L
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-24, "Brake Burnishing
Procedure" . M

Inspection EFS001P5

PAD THICKNESS
Check pad thickness by lifting vehicle, removing the wheel, and
looking through check hole on cylinder body. If necessary, use a
scale.
Standard pad thickness : 11 mm (0.43 in)
Pad wear limit : 2.0 mm (0.079 in)

MAA0439D

BR-25
 FRONT DISC BRAKE

Pad Replacement EFS001P6

REMOVAL
CAUTION:
When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
1. Remove master cylinder reservoir tank cap.
2. Remove lower sliding pin bolt.

SBR433D

3. Hang cylinder body with a wire, and remove pads, pad retainers,
shims and pad return springs.

SBR932C

INSTALLATION
1. Apply brake grease on back of the pad and both sides of the shim. Install inner shim and inner shim cover
to inner pad, outer shim to outer pad.
2. Apply brake grease on the pad retainer pad contact surface. Install pad retainers, pads and pad return
springs to the torque member.
3. Connect cylinder body to the torque member.
CAUTION:
When replacing pads with new ones, press piston in until the pads can be installed. Carefully mon-
itor brake master cylinder reservoir fluid level. Brake fluid will return, raising master cylinder res-
ervoir tank fluid level.
4. Insert lower sliding pin bolt and tighten to the specified torque.
5. Check brakes for drag.
Caliper Removal and Installation EFS001P7

REMOVAL
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from air bleeder while depressing brake pedal.
3. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
4. Remove disc rotor.

SBR979B

BR-26
 FRONT DISC BRAKE

INSTALLATION
CAUTION: A
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
1. Install disc rotor. B
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Before installing caliper assembly, wipe oil and grease on the trailing arm washer seats and cali- C
per assembly mounting surface.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
D
CAUTION:
● Do not reuse the copper washer for union bolts.

● Securely assemble brake hose to protrusions on cylinder body.

E
4. Bleed air. Refer toBR-9, "Refilling and Bleeding" .

Caliper Disassembly and Assembly EFS001P8

BR
DISASSEMBLY
WARNING:
Be careful not to pinch your fingers in the piston. G
CAUTION:
Be careful not to damage the cylinder inner wall.
1. Place a wooden block as shown in the figure. Blow air into union H
bolt mounting hole to remove pistons and piston boots.

BRB0032D K

2. Using a slotted screwdriver, remove piston seals.

L

SFIA0141E

INSPECTION AFTER DISASSEMBLY

Cylinder Body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.
● Check cylinder inner wall for corrosion, wear and damage. If corrosion, wear or damage is detected,
replace the cylinder body.
● Minor flaws caused by corrosion or foreign material can be removed by polishing the surface with fine
sandpaper. Replace the cylinder body, if necessary.
Torque Member
Check for wear, cracks and damage. If wear, cracks or damage is detected, replace the applicable part.
BR-27
 FRONT DISC BRAKE

Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear and damage. If corrosion, wear or damage is detected, replace the
applicable part.
Sliding Pin, Pin Bolt, and Pin Boot
Check sliding pin and sliding pin boot for wear, damage and cracks. If corrosion, wear or damage is detected,
replace the applicable part.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of the disc rotor for uneven wear, cracks and serious damage. If uneven wear, cracks or seri-
ous damage is detected, replace it.
Run Out Inspection
1. Using wheel nuts, fix the disc rotor to the wheels hub. (2 or more positions)
2. Using a dial indicator, check run out.
Measurement point:
At a point 10 mm (0.39 in) from the outer edge of
the disc.
Run out limit:
0.04 mm (0.0016 in) or less
CAUTION:
Before measuring, make sure that the axle endplay is 0 mm
(0 in). BRA0013D
3. If the run out is outside the limit, find the minimum run out point
by shifting the mounting positions of the disc rotor and wheel hub by one hole.
Thickness Inspection
Using a micrometer, check thickness of the disc rotor. If the thick-
ness is outside the standard, replace the disc rotor.
Standard thickness : 28.0 mm (1.102 in)
Wear limit : 26.0 mm (1.024 in)
Maximum uneven wear (measured at 8 positions):
0.02 mm (0.0008 in) or less

SBR020B

ASSEMBLY
CAUTION:
When assembling, do not use rubber grease.
1. Apply rubber lubricant to piston seals, and install them to cylin-
der body.
CAUTION:
Do not reuse piston seals.

SFIA0154E

BR-28
 FRONT DISC BRAKE

2. Apply brake fluid or rubber lubricant to piston boots. Cover pis-

ton end with piston boot. Install cylinder side lip on piston boot A
properly into groove on cylinder body.
CAUTION:
Do not reuse piston boot. B

SFIA0155E

D
3. Apply brake fluid to piston. Press piston into cylinder body by
hand. Assemble piston side lip on piston boot properly into
groove on piston. E
CAUTION:
Press piston evenly and change pressing point to prevent
cylinder inner wall from being rubbed. BR

G
SBR574

BRAKE BURNISHING PROCEDURE H

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: I
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).
J
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.
K

BR-29
 REAR DISC BRAKE

REAR DISC BRAKE PFP:44000

Component(AD14VD,AD11VD) EFS000P0

PFIA0005E

1. Union bolt 2. Copper washer 3. Brake hose

4. Copper washer 5. Sliding pin bolt 6. Air bleeder
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Retaining ring 12. Inner shim cover
13. Inner shim 14. Inner brake pad 15. Pad retainer
16. Outer brake pad 17. Outer shim 18. Outer shim cover
19. Sliding pin 20. Sliding pin boot 21. Torque member mounting bolts
22. Decrement shim 23. Torque member 24. Cap

CAUTION:
● Clean dust on the caliper and brake pad with a vacuum dust collector. Do not blow with com-
pressed air.
● While removing the cylinder body, never depress the brake pedal because the piston will pop out.
● It is not necessary to remove the mounting bolts on the torque member and brake hose except for
disassembly or replacement of the caliper assembly. In this case, hang the cylinder body with a
wire so that the brake hose is not under tension.
● Do not damage the piston boot.
● Always replace the shims and shim covers as a set when replacing the brake pads.
● Keep brake fluid clean of the rotor.

BR-30
 REAR DISC BRAKE

Inspection EFS000P1

PAD THICKNESS A
● Remove the wheel with the vehicle lifted to check the pad thick-
ness from the check hole on the cylinder body. If necessary, use
a scale to check. B
Rear brake pad
Standard thickness : 9.8 mm (0.386 in)
C
Repair limit thickness : 2.0 mm (0.079 in)

D
MAA0439D

Pad Replacement EFS000P2

E
REMOVAL
WARNING:
Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other
BR
materials.
CAUTION:
● While cylinder body is open, do not depress brake pedal, otherwise piston will pop out.
G
● 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 rubber coat, replace them with new shims.
H
● 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.
● Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back
piston. I
● Burnish the brake contact surfaces after refinishing or replacing drums or rotor, after replacing
pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-24, "Brake Burnishing
Procedure" . J
1. Remove master cylinder reservoir cap.
2. Remove the lower sliding pin bolt.
K

SBR090C

BR-31
 REAR DISC BRAKE

3. Hang the cylinder body with a wire, and remove the pads, pad
retainers, shims from the torque member.
CAUTION:
● Do not damage the piston boot.
● Keep brake fluid clean of the rotor.

SBR042C

INSTALLATION
1. Apply disc brake grease to the back of the pad and both sides of the shim, and install the inner shim and
shim cover to the inner pad, and outer shim and outer shim cover to the pad.
2. Apply disc brake grease to the pad contact surface on the pad retainer, and install the pad retainers and
pads to the torque member.
3. Install the cylinder body to the torque member.
CAUTION:
When replacing the pads with new ones, press in the piston until the pads can be installed. In this
case, carefully monitor the brake fluid level in the reservoir tank because the brake fluid will return
to the reservoir tank of the master cylinder.
4. Insert the lower sliding pin bolt to tighten to the specified torque.
5. Check the brake for drag.
Caliper Removal and Installation EFS000P3

REMOVAL
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from the air bleeder while depressing
the brake pedal.
3. Remove the union bolts, and then remove the brake hose from
the caliper assembly.
4. Remove the mounting bolts from the torque member, and
remove the caliper assembly from the vehicle.
5. Remove the disc rotor.

SFIA0143E

INSTALLATION
1. Install the disc rotor.
2. Install the caliper assembly to the vehicle, and tighten the mounting bolts to the specified torque.
CAUTION:
Before installing the caliper assembly to the vehicle, wipe oil and grease on the washer seats on
the axle assembly and mounting surface of the caliper assembly.
3. Install the brake hose to the caliper assembly and tighten the union bolts to the specified torque.

BR-32
 REAR DISC BRAKE

CAUTION:
● Do not reuse the copper washer for union bolts. A
● Assemble the brake hose securely to the protrusion on caliper assembly.

4. After installing the caliper assembly, refill with new brake fluid and bleed air.
B
Caliper Disassembly and Assembly EFS000P4

DISASSEMBLY
1. Remove the caliper assembly from the vehicle.
C
2. Remove the sliding pins. Then remove the pads, shims, and
shim covers from the caliper assembly, and remove the pad
retainers from the cylinder body.
D
3. Remove the sliding pin boot from the torque member.
4. Using a flat-bladed screwdriver as shown in the figure, remove
the retaining ring from the cylinder body.
E

SBR028A
BR

5. Place a wooden block as shown in the figure, and blow air from
the union bolt mounting hole to remove the pistons and piston
boots. G

BRD0041D

J
6. Using a flat-bladed screwdriver, remove the piston seals from
the cylinder body.
CAUTION: K
Be careful not to damage the inner wall of the cylinder.

M
SFIA0141E

INSPECTION AFTER DISASSEMBLY

Cylinder body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.
● Check the inner wall of the cylinder for corrosion, wear, and damage. If a failure is detected, replace the
cylinder body.
● Minor flaws caused by corrosion or foreign material can be removed by polishing the surface with a fine
sandpaper. Replace the cylinder body, if necessary.
Torque member
Check for wear, cracks, and damage. If a malfunction is detected, replace the applicable part.

BR-33
 REAR DISC BRAKE

Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check the piston surface for corrosion, wear, and damage. If a malfunction is detected, replace the applicable
part.
Sliding pin, pin bolt, and pin boot
Check the sliding pin and sliding pin boot for wear, damage, and cracks. If a malfunction is detected, replace
the applicable part.
DISC ROTOR INSPECTION
Visual inspection
Check the surface of the disc rotor for uneven wear, cracks, and serious damage. If a malfunction is detected,
replace the applicable part.
Runout inspection
1. Using wheel nuts, fix the disc rotor to the wheels hub. (2 or more positions)
2. Using a dial indicator, check the runout.
Measurement point:
At a point 10 mm (0.39 in) from the outer
edge of the disc.
Maximum runout:
0.10 mm (0.0039 in) or less
CAUTION:
Before measuring, make sure that the axle endplay is 0 mm.
3. If the runout is outside the limit, find the minimum runout point by BRA0013D
shifting the mounting positions of the disc rotor and wheel hub
by one hole.
Thickness inspection
Using a micrometer, check the thickness of the disc rotor. If the thick-
ness is outside the standard, replace the disc rotor.
Standard thickness : 16.0 mm (0.63 in)
Wear limit : 14.0 mm (0.55 in)
Maximum uneven wear (measured at 8 positions):
0.015 mm (0.0006 in) or less

SBR020B

ASSEMBLY
1. Apply brake grease to the piston seals, and install them to the
cylinder body.
CAUTION:
Do not reuse the piston seals.

SFIA0156E

BR-34
 REAR DISC BRAKE

2. Apply brake fluid to piston boots. Cover the piston end with the
piston boot, and install the cylinder-side lip on the piston boots A
properly into the groove on the cylinder body.
CAUTION:
Do not reuse the piston boot. B
3. Press the piston into the cylinder body by hand to assemble the
piston-side lip on the piston boot properly into the groove on the
piston.
C
CAUTION:
Press the piston evenly and change the pressing point to
prevent the inner wall of the cylinder from being rubbed. SFIA0157E

D
4. Fix the piston boot with the retaining ring.
CAUTION: E
● Make sure that the boot is securely engaged in the
groove on the cylinder body.
● Do not reuse the retaining ring.
BR
5. Install the sliding pins and sliding pin boots to the torque mem-
ber.
6. Install the torque member to the axle assembly, and tighten the
mounting bolts to the specified torque. G
CAUTION: SFIA0158E
Before installing the torque member to the axle assembly, wipe
oil and grease on the washer seats on the axle assembly and mounting surface of the torque member. H
7. Install the pad retainers to the torque member.
8. After assembling the shims and shim covers to the pads, assemble it to the torque member.
I
9. Install the cylinder body, and tighten the sliding pin bolts to the specified torque.
10. Install the brake hose to the cylinder body and tighten the union bolts to the specified torque.
CAUTION: J
● Assemble the brake hose securely to the protrusions on the cylinder body.
● Do not reuse the copper washer on the union bolt.
11. After installing the caliper assembly, refill the new brake fluid and bleed air. K

BR-35
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications EFS000P5

Unit: mm (in)
Applied model Except MIDDLE EAST For MIDDLE EAST
Brake model CLZ31VA AD31VB
Cylinder bore diameter 45.0 (1.77) × 2 44.4 (1.748) × 2
Front brake Pad 127.0 × 56.0 × 10.0 132.0 × 52.5 × 11.0
Length × width × thickness (5.00 × 2.20 × 0.374) (5.20 × 2.067 × 0.433)
Rotor outer diameter × thickness 290 (11.42) 280 × 28 (11.02 × 1.10)
Brake model AD14VD
Cylinder bore diameter 43.86 (1.727)
Rear brake Pad 97.4 × 33.9 × 9.8
Length × width × thickness (3.835 × 1.335 × 0.39)
Rotor outer diameter × thickness 292 × 16 (11.50 × 0.63)
Master cylinder Cylinder bore diameter 25.4 (1)
Control valve Valve model Electric brake force distribution
Booster model M215T
Brake booster Primary 230 (9.06)
Diaphragm diameter
Secondary 205 (8.07)
Recommended brake fluid DOT 3

Brake pedal EFS000P6

Free play (at pedal top surface) 3 - 11 mm (0.12 - 0.43 in)

Brake pedal height (from dash panel top surface) 174 - 184 mm (6.85 - 7.24 in)
Depressed pedal height under force of 490 N (50 kg, 110 lb)
90 mm (3.54 in) or more
(from dash panel top surface)
Clearance between the stopper rubber and the threaded end
0.74 - 1.96 mm (0.0291 - 0.0772 in)
of the stop lamp switch/ASCD cancel switch

Check valve EFS000P7

Vacuum leakage
Vacuum for 15 seconds
(at vacuum of –66.7 kPa(–500 mmHg, –19.69 inHg)

Brake booster EFS000P8

Vacuum type
Vacuum leakage
Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 seconds
(at vacuum of –66.7 kPa (–500 mmHg, –19.69 inHg))
Input rod installation standard dimension 125 mm (4.92 in)

Front disc brake EFS000P9

Brake model CLZ31VA AD31VB

Standard thickness (new) 10 mm (0.394 in) 11 mm (0.43 in)
Brake pad
Repair limit thickness 2.0 mm (0.079 in)
Standard thickness (new) 28.0 mm (1.10 in)
Disc rotor Repair limit thickness 26.0 mm (1.02 in)
Maximum runout 0.07 mm (0.0028 in) or less 0.04 mm (0.0016 in) or less

BR-36
 SERVICE DATA AND SPECIFICATIONS (SDS)

Rear disc brake EFS000PA

A
Brake model AD14VD
Standard thickness (new) 9.8 mm (0.386 in)
Brake pad
Repair limit thickness 2.0 mm (0.079 in) B
Standard thickness (new) 16.0 mm (0.63 in)
Disc rotor Repair limit thickness 14.0 mm (0.55 in)
C
Maximum runout 0.10 mm (0.0039 in) or less

BR

BR-37
SERVICE DATA AND SPECIFICATIONS (SDS)

BR-38