Brake System: Section

BRAKES
SECTION
BRAKE SYSTEM
BR B
E
CONTENTS
LHD BRAKE PAD ..............................................................15 BR
BRAKE PAD : Inspection and Adjustment ...............15
PRECAUTION ............................................... 4
DISC ROTOR .............................................................15
G
PRECAUTIONS ................................................... 4 DISC ROTOR : Inspection and Adjustment .............15
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- REAR DISC BRAKE ......................................... 17
SIONER" ................................................................... 4 H
BRAKE PAD ..............................................................17
Precautions Necessary for Steering Wheel Rota- BRAKE PAD : Inspection and Adjustment ...............17
tion After Battery Disconnection ................................ 4
Precaution for Procedure without Cowl Top Cover...... 5 DISC ROTOR .............................................................17 I
Precaution for Brake System .................................... 5 DISC ROTOR : Inspection and Adjustment .............17
PREPARATION ............................................ 6 REMOVAL AND INSTALLATION ............... 19

J
PREPARATION ................................................... 6 BRAKE PEDAL ................................................. 19
Commercial Service Tool .......................................... 6 Exploded View .........................................................19
Removal and Installation .........................................20 K
SYMPTOM DIAGNOSIS ............................... 7 Inspection and Adjustment ......................................21
NOISE, VIBRATION AND HARSHNESS BRAKE PIPING ................................................. 23
(NVH) TROUBLESHOOTING ............................. 7 L
NVH Troubleshooting Chart ...................................... 7 FRONT .......................................................................23
FRONT : Exploded View .........................................23
PERIODIC MAINTENANCE .......................... 8 FRONT : Hydraulic Piping .......................................25 M
FRONT : Removal and Installation ..........................25
BRAKE PEDAL ................................................... 8 FRONT : Inspection .................................................26
Inspection and Adjustment ........................................ 8
REAR .........................................................................27 N
BRAKE FLUID ....................................................11 REAR : Exploded View ............................................27
Inspection ................................................................ 11 REAR : Hydraulic Piping ..........................................28
Draining ................................................................... 11 REAR : Removal and Installation ............................28 O
Refilling ................................................................... 11 REAR : Inspection ...................................................30
Bleeding Brake System ........................................... 12
BRAKE MASTER CYLINDER .......................... 31
BRAKE MASTER CYLINDER ............................13 Exploded View .........................................................31 P
Inspection ................................................................ 13 Removal and Installation .........................................31
Disassembly and Assembly .....................................33
BRAKE BOOSTER ............................................14 Inspection ................................................................34
Inspection ................................................................ 14
BRAKE BOOSTER ........................................... 35
FRONT DISC BRAKE ........................................15 Exploded View .........................................................35
Revision: 2011 May BR-1 F15

Removal and installation ........................................ 35 Precaution for Supplemental Restraint System
Inspection and Adjustment ..................................... 36 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................. 60
VACUUM LINES ................................................ 38 Precautions Necessary for Steering Wheel Rota-
tion After Battery Disconnection .............................. 60
MR16DDT .................................................................. 38
Precaution for Procedure without Cowl Top Cover... 61
MR16DDT : Exploded View .................................... 38
Precaution for Brake System .................................. 61
MR16DDT : Removal and Installation .................... 38
MR16DDT : Inspection ........................................... 38 PREPARATION .......................................... 62
HR16DE ..................................................................... 39
PREPARATION ................................................. 62
HR16DE : Exploded View ....................................... 39
Commercial Service Tool ........................................ 62
HR16DE : Removal and Installation ....................... 39
HR16DE : Inspection .............................................. 40 SYMPTOM DIAGNOSIS ............................ 63
FRONT DISC BRAKE ........................................ 41 NOISE, VIBRATION AND HARSHNESS
BRAKE PAD ............................................................. 41 (NVH) TROUBLESHOOTING ............................ 63
BRAKE PAD : Exploded View ................................ 41 NVH Troubleshooting Chart .................................... 63
BRAKE PAD : Removal and Installation ................. 42
BRAKE PAD : Inspection ........................................ 44
PERIODIC MAINTENANCE ....................... 64
BRAKE CALIPER ASSEMBLY ................................ 44 BRAKE PEDAL ................................................. 64

BRAKE CALIPER ASSEMBLY : Exploded View ... 45 Inspection and Adjustment ...................................... 64
BRAKE CALIPER ASSEMBLY : Removal and In- BRAKE FLUID ................................................... 67
stallation ................................................................. 46
Inspection ................................................................ 67
BRAKE CALIPER ASSEMBLY : Disassembly and
Draining ................................................................... 67
Assembly ................................................................ 47
Refilling ................................................................... 67
BRAKE CALIPER ASSEMBLY : Inspection ........... 49
Bleeding Brake System ........................................... 68
REAR DISC BRAKE .......................................... 50 BRAKE MASTER CYLINDER ........................... 69
BRAKE PAD ............................................................. 50 Inspection ................................................................ 69
BRAKE PAD : Exploded View ................................ 50
BRAKE BOOSTER ............................................ 70
BRAKE PAD : Removal and Installation ................. 50
Inspection ................................................................ 70
BRAKE PAD : Inspection ........................................ 52
BRAKE CALIPER ASSEMBLY ................................ 52

FRONT DISC BRAKE ....................................... 71
BRAKE CALIPER ASSEMBLY : Exploded View ... 52 BRAKE PAD .............................................................. 71
BRAKE CALIPER ASSEMBLY : Removal and In- BRAKE PAD : Inspection and Adjustment .............. 71
stallation ................................................................. 53
BRAKE CALIPER ASSEMBLY : Disassembly and DISC ROTOR ............................................................ 71
Assembly ................................................................ 54 DISC ROTOR : Inspection and Adjustment ............ 71
BRAKE CALIPER ASSEMBLY : Inspection ........... 56
REAR DRUM BRAKE ....................................... 73
SERVICE DATA AND SPECIFICATIONS
BRAKE LINING ......................................................... 73
(SDS) ........................................................... 58 BRAKE LINING : Inspection and Adjustment ......... 73
SERVICE DATA AND SPECIFICATIONS BRAKE DRUM .......................................................... 73
(SDS) .................................................................. 58 BRAKE DRUM : Inspection and Adjustment ........... 73
General Specifications ............................................ 58
Brake Pedal ............................................................ 58 REAR DISC BRAKE .......................................... 75
Brake Booster ......................................................... 58
BRAKE PAD .............................................................. 75
Front Disc Brake ..................................................... 59
BRAKE PAD : Inspection and Adjustment .............. 75
Rear Disc Brake ..................................................... 59
RHD DISC ROTOR ............................................................ 75
DISC ROTOR : Inspection and Adjustment ............ 75
PRECAUTION ............................................. 60
REMOVAL AND INSTALLATION .............. 77
PRECAUTIONS ................................................. 60
BRAKE PEDAL ................................................. 77
Exploded View ........................................................ 77

Removal and Installation ......................................... 78 BRAKE PAD : Inspection ....................................... 105
Inspection and Adjustment ...................................... 79 A
BRAKE CALIPER ASSEMBLY ............................... 105
BRAKE PIPING ..................................................80 BRAKE CALIPER ASSEMBLY : Exploded View .. 105
BRAKE CALIPER ASSEMBLY : Removal and In-
FRONT ....................................................................... 80 stallation ................................................................ 106 B
FRONT : Exploded View ......................................... 80 BRAKE CALIPER ASSEMBLY : Disassembly and
FRONT : Hydraulic Piping ....................................... 81 Assembly ............................................................... 107
FRONT : Removal and Installation ......................... 82 BRAKE CALIPER ASSEMBLY : Inspection .......... 109 C
FRONT : Inspection ................................................ 84
REAR DRUM BRAKE ..................................... 111
REAR ......................................................................... 84 Exploded View ....................................................... 111
REAR : Exploded View ........................................... 84 D
Removal and Installation ....................................... 111
REAR : Hydraulic Piping ......................................... 86 Disassembly and Assembly ................................... 113
REAR : Removal and Installation ............................ 87 Inspection and Adjustment .................................... 114
REAR : Inspection ................................................... 91 E
REAR DISC BRAKE ....................................... 115
BRAKE MASTER CYLINDER ............................92
Exploded View ........................................................ 92 BRAKE PAD ............................................................ 115
Removal and Installation ......................................... 92 BRAKE PAD : Exploded View ............................... 115 BR
Disassembly and Assembly .................................... 94 BRAKE PAD : Removal and Installation ................ 115
Inspection ................................................................ 94 BRAKE PAD : Inspection ....................................... 117
G
BRAKE BOOSTER ............................................96 BRAKE CALIPER ASSEMBLY ............................... 117
Exploded View ........................................................ 96 BRAKE CALIPER ASSEMBLY : Exploded View .. 117
Removal and installation ......................................... 96 BRAKE CALIPER ASSEMBLY : Removal and In-
Inspection and Adjustment ...................................... 97 stallation ................................................................ 118 H
BRAKE CALIPER ASSEMBLY : Disassembly and
VACUUM LINES .................................................99 Assembly ............................................................... 119
BRAKE CALIPER ASSEMBLY : Inspection .......... 121 I
MR16DDT .................................................................. 99
MR16DDT : Exploded View .................................... 99 SERVICE DATA AND SPECIFICATIONS
MR16DDT : Removal and Installation ..................... 99
(SDS) .......................................................... 123 J
MR16DDT : Inspection ............................................ 99
HR15DE, HR16DE ................................................... 100

SERVICE DATA AND SPECIFICATIONS
HR15DE, HR16DE : Exploded View ..................... 100 (SDS) ............................................................... 123
General Specifications ........................................... 123 K
HR15DE, HR16DE : Removal and Installation ..... 100
HR15DE, HR16DE : Inspection ............................ 101 Brake Pedal ........................................................... 123
Brake Booster ........................................................ 123
FRONT DISC BRAKE ...................................... 102 Front Disc Brake .................................................... 123 L
Rear Drum Brake ................................................... 124
BRAKE PAD ............................................................ 102 Rear Disc Brake .................................................... 124
BRAKE PAD : Exploded View ............................... 102
BRAKE PAD : Removal and Installation ............... 103 M

PRECAUTIONS
< PRECAUTION > [LHD]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000007434930
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 AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000007429538
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

PRECAUTIONS
< PRECAUTION > [LHD]
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock A
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover INFOID:0000000007429539
B
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to C
windshield.
PIIB3706J
BR
Precaution for Brake System INFOID:0000000007429540
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed G
with a dust collector. Never splatter the dust with an air blow gun.
• Brake fluid use refer to MA-13, "Fluids and Lubricants".
• Never reuse drained brake fluid. H
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it off
immediately and wash with water if it gets on a painted surface. For brake component parts, never wash
them with water.
I
• Always confirm the specified tightening torque when installing the brake pipes.
• After pressing the brake pedal more deeply or harder than normal driving, such as air bleeding, check each
item of brake pedal. Adjust brake pedal if it is outside the standard value.
• Always clean with new brake fluid when cleaning the master cylinder, brake caliper and other components. J
• Never use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and cause
improper operation.
• Always loosen the brake tube flare nut with a flare nut wrench. K
• Tighten the brake tube flare nut to the specified torque with a flare
nut torque wrench (A).
• Turn the ignition switch OFF and disconnect the ABS actuator and
electric unit (control unit) harness connector or the battery negative L
terminal before performing the work.
• Check that no brake fluid leakage is present after replacing the
parts. M
• Burnish the brake contact surfaces after refinishing or replacing
rotors, after replacing pads, or if a soft pedal occurs at very low
mileage.
- Front brake pad: Refer to BR-15, "BRAKE PAD : Inspection and N
JPFIA0061ZZ
Adjustment".
- Front disc rotor: Refer to BR-15, "DISC ROTOR : Inspection and Adjustment".
- Rear brake pad: Refer to BR-17, "BRAKE PAD : Inspection and Adjustment". O
- Rear disc rotor: Refer to BR-17, "DISC ROTOR : Inspection and Adjustment".

PREPARATION
< PREPARATION > [LHD]
PREPARATION
PREPARATION
Commercial Service Tool INFOID:0000000007429541
Tool name Description
Pin punch
Removing and installing reservoir tank
a: 4 mm (0.16 in)
NT410
• Air tight
Handy vacuum pump
• Inspection of check valve
ZZC1313D
Brake caliper wrench Return the piston
NNFIA0040ZZ

Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
Revision: 2011 May

SUSPECTED PARTS
Noise
Shake
< SYMPTOM DIAGNOSIS >
Shimmy, Judder
NVH Troubleshooting Chart
Pads damaged BR-15, BR-17
×
Pads uneven wear BR-15, BR-17
×
SYMPTOM DIAGNOSIS
Shims damaged BR-44, BR-52
×
Rotor imbalance BR-15, BR-17
×
×
Rotor damage BR-15, BR-17
BR-7
Rotor runout BR-15, BR-17
×
Rotor deformation BR-15, BR-17
×
Rotor deflection BR-15, BR-17
×
Rotor rust BR-15, BR-17
×
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
Rotor thickness variation BR-15, BR-17
×
Drum out of round NVH in PB section
×
× PROPELLER SHAFT NVH in DLN section
×
DIFFERENTIAL NVH in DLN section

×
AXLE AND SUSPENSION NVH in FAX, RAX and FSU, RSU section
×
×
×
TIRE NVH in WT section

×
×
×
ROAD WHEEL NVH in WT section

×
×
×
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
× × DRIVE SHAFT NVH in FAX section
STEERING NVH in ST section

×
×
×
[LHD]
INFOID:0000000007429542
F15
I
P
K
E
B
A
N
H
D
C
O
G
M
BR
BRAKE PEDAL
< PERIODIC MAINTENANCE > [LHD]
PERIODIC MAINTENANCE
BRAKE PEDAL
Inspection and Adjustment INFOID:0000000007429543
INSPECTION
Brake Pedal Height
Check the height (H1) between the dash lower panel (1) and the
brake pedal upper surface.
H1 : Refer to BR-58, "Brake Pedal".

CAUTION:
Remove the floor trim.
JPFIA0065ZZ
Stop Lamp Switch

Check the clearance (C) among the brake pedal lever (1) and the
stop lamp switch (2) threaded end.
C : Refer to BR-58, "Brake Pedal".

CAUTION:
The stop lamp must turn off when the brake pedal is released.
NOTE:
Pull the brake pedal pad to make the clearance between the stop
lamp switch threaded end and the brake peal lever.
PFIA0813J
Brake Pedal Position Switch (with ASCD)

brake pedal position switch (2) threaded end.

NOTE:
Pull the brake pedal pad to make the clearance between the brake
pedal position switch threaded end and the brake peal lever.
JPFIA0866ZZ
Brake Pedal Play

Press the brake pedal. Check the brake pedal play (A) (stroke until
fluid pressure occurs).
A : Refer to BR-58, "Brake Pedal".
JPFIA0277ZZ
Depressed Brake Pedal Height

BRAKE PEDAL
Check the height between the dash lower panel (1) and the brake
pedal upper surface (H2) when depressing the brake pedal at 490 N A
(50 kg, 110 lb) while turning engine ON.
H2 : Refer to BR-58, "Brake Pedal". B

CAUTION:
C
JPFIA0068ZZ
D
ADJUSTMENT
Brake Pedal Height
1. Remove instrument lower panel. Refer to IP-13, "Removal and Installation". E
2. Disconnect the stop lamp switch and brake pedal position switch (with ASCD) harness connector.
3. Loosen the stop lamp switch and brake pedal position switch (with ASCD) 45° counterclockwise.
4. Loosen the lock nut (2) of input rod (1). BR
5. Rotate the input rod, adjust the brake pedal to the specified
height (H1).
CAUTION: G
The threaded end of the input rod must project to the inner
side (L) of the clevis (3).
H
I
JPFIA0003ZZ
H1 : Refer to BR-58, "Brake Pedal". J
6. Tighten the lock nut. Refer to BR-35, "Exploded View".

7. Adjust the clearance between the brake pedal lever and the stop K
lamp switch and brake pedal position switch (with ASCD)
threaded end after adjusting the brake pedal height.
L
JPFIA0279ZZ
M
Stop Lamp Switch
1. Remove instrument lower panel. Refer to IP-13, "Removal and Installation".
2. Disconnect the harness connector from stop lamp switch. N
3. Loosen the stop lamp switch 45° counterclockwise.
4. Press-fit the stop lamp switch (2) until the stop lamp switch hits
the brake pedal lever (1) 45° clockwise while pulling the brake O
pedal pad slightly.
CAUTION:
• The clearance (C) between the brake pedal lever and stop P
lamp switch threaded and must be the specified value.

• The stop lamp must be turned off when the brake pedal is
released.
PFIA0813J
Brake Pedal Position Switch (with ASCD)

BRAKE PEDAL
2. Disconnect the harness connector from brake pedal position switch.
3. Loosen the brake pedal position switch 45° counterclockwise.
4. Press-fit the brake pedal position switch (2) until the brake pedal
position switch hits the brake pedal lever (1) 45° clockwise while
pulling the brake pedal pad slightly.
CAUTION:
The clearance (C) between the brake pedal lever and brake
pedal position switch threaded and must be the specified
value.
JPFIA0866ZZ

1. Perform the air bleeding. Refer to BR-12, "Bleeding Brake System".
2. Check the height between the dash lower panel (1) and the
brake pedal upper surface (H2) when depressing the brake
pedal at 490 N (50 kg, 110 lb) while turning engine ON.

CAUTION:
JPFIA0068ZZ

BRAKE FLUID
BRAKE FLUID
A
Inspection INFOID:0000000007429544
BRAKE FLUID LEVEL B

• Check that the fluid level in the reservoir tank is within the specified
range [between MAX line + 7 mm (0.28 in) and MIN line].
• Visually check for any brake fluid leakage around the reservoir C
tank.
• Check the brake system for any leakage if the fluid level is
extremely low (lower than MIN).
• Check the brake system for fluid leakage if the warning lamp D
remains illuminated even after the parking brake is released.
• Check the reservoir tank for the mixing of foreign matter (e.g. dust)
and oils other than brake fluid. E
SFIA2634J
BRAKE LINE
BR
1. Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged
parts.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb)
G
and hold down the pedal for approximately 5 seconds with the
engine running. Check for any fluid leakage.
CAUTION:
Retighten the applicable connection to the specified torque H
and repair any abnormal (damaged, worn or deformed) part
if any brake fluid leakage is present.
I
SBR389C
J
Draining INFOID:0000000007429545
CAUTION: K
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface. For brake component parts,
never wash them with water.
• Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) har- L
ness connector or the battery negative terminal before performing work.
1. Connect a vinyl tube to the bleed valve.
2. Depress the brake pedal and loosen the bleeder valve to gradu- M
ally discharge brake fluid.
BRA0007D
P
Refilling INFOID:0000000007429546
CAUTION:
• Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) har-

BRAKE FLUID
1. Check that there is no foreign material in the reservoir tank, and refill with new brake fluid.
CAUTION:
• Never reuse drained brake fluid.
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank.
2. Loosen the bleeder valve, slowly depress the brake pedal to the full stroke, and then release the pedal.
Repeat this operation at intervals of 2 or 3 seconds until new brake fluid is discharged. Then close the
bleeder valve with the brake pedal depressed. Repeat the same work on each wheel.
Bleeding Brake System INFOID:0000000007429547
CAUTION:
ness connector or the battery negative terminal before performing the work.
• Monitor the fluid level in the reservoir tank while performing the air bleeding
CAUTION:
• Never allow oils other than brake fluid to enter the reservoir tank.
2. Connect a vinyl tube to the bleeder valve of the rear right brake.
3. Fully depress the brake pedal 4 to 5 times.
4. Loosen the bleeder valve and bleed air with the brake pedal depressed, and then quickly tighten the
bleeder valve.
5. Repeat steps 3 and 4 until all of the air is out of the brake line.
6. Tighten the bleeder valve to the specified torque.
• Front disc brake: refer to BR-45, "BRAKE CALIPER ASSEMBLY : Exploded View".
• Rear disc brake: refer to BR-52, "BRAKE CALIPER ASSEMBLY : Exploded View".
7. Perform steps 2 to 6. Occasionally fill with the brake fluid in order to keep it in the reservoir tank at least
half of MAX line. Bleed air in the following order: rear right brake → front left brake → rear left brake →
and front right brake in order.
8. Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to BR-
11, "Inspection".
9. Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-8,
"Inspection and Adjustment".

BRAKE MASTER CYLINDER
A
FLUID LEAK B
Check for brake fluid leakage from the master cylinder mounting face, reservoir tank mounting face and brake
tube connections.
C
BR

BRAKE BOOSTER
BRAKE BOOSTER
OPERATION
Depress the brake pedal several times at 5-second intervals with the engine stopped. Start the engine with the
brake pedal fully depressed. Check that the clearance between brake pedal and dash lower panel decreases.
NOTE:
A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. This is a
normal phenomenon due to the brake system operation.
AIR TIGHT
1. Run the engine at idle for 1 minute to apply vacuum to the brake booster, and stop the engine.
2. Depress the brake pedal several times at 5-second intervals until the accumulated vacuum is released to
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually
increases each time the brake pedal is depressed when performing this operation.
3. Depress the brake pedal with the engine running. Then stop the engine while holding down the brake
pedal. Check that the brake pedal stroke does not change after holding down the brake pedal for 30 sec-
onds or more.

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
BRAKE PAD : Inspection and Adjustment INFOID:0000000007429550
B
INSPECTION
Check brake pad wear thickness from an inspection hole on cylinder
body. Check using a scale if necessary. C
Wear thickness : Refer to BR-59, "Front Disc Brake".

D
BRA0010D
BR
ADJUSTMENT
Burnish contact surfaces between disc rotor and brake pads according to the following procedure after refin-
ishing or replacing brake pads, or if a soft pedal occurs at very low mileage.
G
CAUTION:
• Be careful of vehicle speed because the brake does not operate firmly/securely until pads and disc
rotor are securely fitted.
• Only perform this procedure under safe road and traffic conditions. Use extreme caution. H
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake. I
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.
DISC ROTOR J
DISC ROTOR : Inspection and Adjustment INFOID:0000000007429551
K
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary. L
• MR16DDT: Refer to FAX-10, "Removal and Installation".
• HR16DE: Refer to FAX-40, "Removal and Installation".
Runout M
1. Fix the disc rotor to the wheel hub and bearing assembly with
wheel nuts (2 points at least).
2. Check the wheel bearing axial end play before the inspection. N
• MR16DDT: Refer to FAX-8, "Inspection".
• HR16DE: Refer to FAX-38, "Inspection".
3. Inspect the runout with a dial indicator to measure at 10 mm O
(0.39 in) inside the disc edge.
Runout (with it attached : Refer to BR-59, "Front Disc P

to the vehicle) Brake".
SBR019B
4. Find the installation position that has a minimum runout by shift-

ing the disc rotor-to-wheel hub and bearing assembly installation position by one hole at a time if the
runout exceeds the limit value.
• Refinish the disc rotor if the runout is outside the limit even after performing the above operation.
CAUTION:
• Check in advance that the thickness of the disc rotor is wear thickness + 0.3 mm (0.012 in) or more.

FRONT DISC BRAKE
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor.
- MR16DDT: Refer to FAX-10, "Removal and Installation".
- HR16DE: Refer to FAX-40, "Removal and Installation".

Thickness
Check the thickness of the disc rotor using a micrometer. Replace
the disc rotor if the thickness is below the wear limit.
Wear thickness : Refer to BR-59, "Front Disc

Brake".
SBR020B
ADJUSTMENT
Burnish contact surfaces between disc rotors and brake pads according to the following procedure after refin-
ishing or replacing disc rotor, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate firmly/securely until pad and disc
• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
3. Drive without depressing brake for a few minutes to cool the brake.

REAR DISC BRAKE
REAR DISC BRAKE
A
BRAKE PAD
B
INSPECTION
Wear thickness : Refer to BR-59, "Rear Disc Brake".

D
BRA0010D
BR
ADJUSTMENT
G
CAUTION:
DISC ROTOR J
K
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary. Refer to L
RAX-5, "REAR DISK BRAKE TYPE : Removal and Installation".
Runout
1. Fix the disc rotor to the wheel hub and bearing assembly with M
2. Check the wheel bearing axial end play before the inspection.
Refer to RAX-4, "Inspection". N
3. Inspect the runout with a dial indicator to measure at 10 mm
O
Runout (with it attached : Refer to BR-59, "Rear Disc
4. Find the installation position that has a minimum runout by shift- SBR019B P
ing the disc rotor-to-wheel hub and bearing assembly installation
position by one hole at a time if the runout exceeds the limit value.
CAUTION:
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor. Refer to

REAR DISC BRAKE

Thickness
the disc rotor if the thickness is below the wear limit. Refer to RAX-5,
"REAR DISK BRAKE TYPE : Removal and Installation".
Wear thickness : Refer to BR-59, "Rear Disc

Brake".
SBR020B
ADJUSTMENT
CAUTION:

BRAKE PEDAL
< REMOVAL AND INSTALLATION > [LHD]
REMOVAL AND INSTALLATION A

BRAKE PEDAL
Exploded View INFOID:0000000007429554
B
WITHOUT ASCD
C
BR
J
JSFIA0456GB
1. Clevis pin 2. Brake pedal assembly 3. Brake pedal pad K

4. Stop lamp switch 5. Clip 6. Snap pin
: Apply multi-purpose grease.
L
: N·m (kg-m, ft-lb)
WITH ASCD
M

BRAKE PEDAL
JSFIA0457GB
1. Clevis pin 2. Brake pedal assembly 3. Brake pedal pad

4. Brake pedal position switch 5. Clip 6. Stop lamp switch
7. Snap pin
Removal and Installation INFOID:0000000007429555
REMOVAL
2. Disconnect the stop lamp switch and the brake pedal position switch (with ASCD) harness connectors.
3. Rotate the stop lamp switch and the brake pedal position switch
(1) counter clockwise to remove.
4. Disconnect the accelerator pedal harness connector and har-
ness clip.
JPFIA0815ZZ

BRAKE PEDAL
5. Remove snap pin (1) and clevis pin (2) from clevis (3) of brake
booster. A
JPFIA0816ZZ
D
6. Remove the steering member stay (1).
7. Remove the brake pedal assembly.
CAUTION: E
Hold the brake booster and master cylinder assembly so as
not to drop out or contact them other parts.
8. Remove accelerator pedal from brake pedal assembly. Refer to BR
ACC-4, "Removal and Installation".
9. Perform inspection after removal. Refer to BR-21, "Inspection
and Adjustment". G
JSFIA0458ZZ
INSTALLATION H
Note the following, and install in the reverse order of removal.
• Apply the multi-purpose grease to the clevis pin and the mating faces. (Not necessary if grease has been
already applied)
NOTE: I
The clevis pin may be inserted in either direction.
• Perform adjustment after installation. Refer to BR-21, "Inspection and Adjustment".
J
INSPECTION AFTER REMOVAL

• Check for the following items and replace the brake pedal assembly if necessary. K
- Check the brake pedal upper rivet (made by aluminum) (A) for
deformation.
- Check the brake pedal for bend, damage, and cracks on the L
welded parts.
- Check the lapping length (D) of sub-bracket (B) and slide plate (C).
M
D : 6.5 mm (0.256 in) or more
N
JSFIA0459ZZ
• Check clevis pin and plastic stopper (A) for damage and deforma- O
tion. If any is found, replace clevis pin.
PFIA0756J

BRAKE PEDAL
ADJUSTMENT AFTER INSTALLATION
• Adjust each item of brake pedal after installing the brake pedal assembly to the vehicle. Refer to BR-8,
• Perform the release position learning of the accelerator pedal.
- MR16DDT (without EURO-OBD): Refer to EC-591, "Work Procedure".
- MR16DDT (with EURO-OBD): Refer to EC-929, "Work Procedure".
- HR16DE: Refer to EC-322, "Work Procedure".

BRAKE PIPING
BRAKE PIPING
A
FRONT
FRONT : Exploded View INFOID:0000000007429557
B
WITHOUT VDC
C
BR
J
JSFIA1086GB
1. Brake tube 2. ABS actuator and electric unit (con- 3. Connector

trol unit) K
4. Connector bracket 5. Master cylinder assembly 6. Brake booster
7. Lock plate 8. Brake hose 9. Union bolt
10. Copper washer L
A. To rear brake tube
: N·m (kg-m, ft-lb) M

: N·m (kg-m, in-lb)
: Always replace after every disassembly.
N
: Indicates that the part is connected at points with same symbol in actual vehicle.
WITH VDC
O

BRAKE PIPING
JSFIA1087GB
1. Brake tube 2. ABS actuator and electric unit (con- 3. Connector

trol unit)
4. Connector bracket 5. Master cylinder assembly 6. Brake booster
10. Copper washer


BRAKE PIPING
FRONT : Hydraulic Piping INFOID:0000000007429558
BR
JPFIA0650ZZ
G
1. ABS actuator and electric unit (con- 2. Front disc brake 3. Master cylinder assembly
trol unit)
4. Brake booster 5. Connector 6. Rear disc brake
A. Brake tube B. Brake hose H
: Flare nut
: Union bolt I
FRONT : Removal and Installation INFOID:0000000007429559
J
REMOVAL
CAUTION:
off immediately and wash with water if it gets on a painted surface. For brake component parts, K
• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied
with, brake fluid may splash. L
1. Remove tires.
2. Drain brake fluid. Refer to BR-11, "Draining".
3. Loosen the flare nut (1) with a flare nut wrench (A) and separate M
the brake tube (2) from the brake hose (3).
CAUTION:
• Never scratch the flare nut and the brake tube. N
• Never bend sharply, twist or strongly pull out the brake
hoses and tubes.
• Cover open end of brake tubes and hoses when discon-
necting to prevent entrance of dirt. O
JPFIA0847ZZ P

BRAKE PIPING
4. Remove the union bolt (1) and copper washers (2), and remove
the brake hose (3) from the brake caliper assembly.
5. Remove the lock plate (4) and remove the brake hose.
JPFIA0819ZZ
INSTALLATION
CAUTION:
with, brake fluid may splash.
1. Assemble the union bolt (1) and the copper washer (2) to the
brake hose.
CAUTION:
Never reuse the copper washer.
2. Align the brake hose pin (A) with the brake caliper assembly
projection (B), and tighten the union bolt (1) to the specified
torque.
JPFIA0820ZZ
3. Install the brake tube (2) to the brake hose (1), temporarily
tighten the flare nut (3) by hand until it does not rotate further,
and fix the brake hose to the bracket (5) with the lock plate (4).
CAUTION:
Check that all brake hoses and brake tubes are not twisted
and bent.
JPFIA0821ZZ
4. Tighten the flare nut to the specified torque with a flare nut
torque wrench (A).
CAUTION:
Never scratch the flare nut and the brake tube.
5. Refill with new brake fluid and perform the air bleeding. Refer to
BR-12, "Bleeding Brake System".
CAUTION:
Never reuse drained brake fluid.
6. Install tires. Refer to WT-7, "Exploded View".
7. Perform inspection after installation. Refer to BR-26, "FRONT :
Inspection". JPFIA0061ZZ
FRONT : Inspection INFOID:0000000007429560
INSPECTION AFTER INSTALLATION

BRAKE PIPING
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer-
ence with other components when steering the steering wheel; no looseness at connections. A
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately
5 seconds with the engine running. Check for any fluid leakage.
CAUTION: B
Retighten the applicable connection to the specified torque and repair any abnormal (damaged,
worn or deformed) part if any brake fluid leakage is present.
REAR C
REAR : Exploded View INFOID:0000000007429561
BR
JSFIA1088GB
1. Brake tube 2. Brake hose A 3. Lock plate

L
4. Brake hose bracket 5. Union bolt 6. Brake hose B
7. Copper washer
A. To connector
M
: N·m (kg-m, in-lb) N

: Indicates that the part is connected at points with same symbol in actual vehicle. O

BRAKE PIPING
REAR : Hydraulic Piping INFOID:0000000007429562
JPFIA0650ZZ
1. ABS actuator and electric unit (con- 2. Front disc brake 3. Master cylinder assembly
trol unit)
4. Brake booster 5. Connector 6. Rear disc brake
A. Brake tube B. Brake hose
: Flare nut
: Union bolt
REAR : Removal and Installation INFOID:0000000007429563
REMOVAL
CAUTION:
1. Remove tires.
3. Loosen the flare nut (1) with a flare nut wrench (A) and separate
the brake tube (2) from the brake hose A (3).
CAUTION:
• Never scratch the flare nut and the brake tube.
hoses and tubes.
necting to prevent entrance of dirt.
4. Remove the lock plate (4) and remove the brake hose A.
JPFIA0848ZZ

BRAKE PIPING
the brake tube (2) from the brake hose B (3). A
CAUTION:
B
hoses and tubes.
6. Remove the lock plate (4) from brake hose bracket (5). C
JSFIA0470ZZ
D
the brake hose B (3) from the brake caliper assembly.
E
BR
G
JSFIA0471ZZ
INSTALLATION H
CAUTION:
never wash them with water. I
1. Assemble the union bolt (1) and the copper washer (2) to the J
brake hose B.
CAUTION:
Never reuse the copper washer. K
2. Align the brake hose B L-pin (A) with the brake caliper assembly
hole (B), and tighten the union bolt (1) to the specified torque.
L
JSFIA0472ZZ M
3. Install the brake tube (2) to the brake hose B (1), temporarily
tighten the flare nut (3) by hand until it does not rotate further, N
and fix the brake hose B to the brake hose bracket (5) with the
lock plate (4).
CAUTION: O
and bent.
JSFIA0473ZZ

BRAKE PIPING
torque wrench (A).
CAUTION:
JPFIA0061ZZ
5. Install the brake tube (2) to the brake hose A (1), temporarily
and fix the brake hose with the lock plate (4).
CAUTION:
and bent.
JPFIA0849ZZ
torque wrench (A).
CAUTION:
CAUTION:
9. Perform inspection after installation. Refer to BR-30, "REAR :
REAR : Inspection INFOID:0000000007429564

1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no looseness
at connections.
CAUTION:

A
BR
I
JSFIA0476GB
1. Reservoir cap 2. Oil strainer 3. Reservoir tank J

4. Cylinder body 5. Pin 6. O-ring
7. Grommet
: Apply polyglycol ether based lubricant. K
: Apply brake fluid.
: N·m (kg-m, ft-lb) L

Removal and Installation INFOID:0000000007429566 M
REMOVAL
CAUTION: N
O
• Never depress the brake pedal while removing the brake tube. If this is not complied with, brake fluid
may splash.
1. Perform inspection before removal. Refer to BR-34, "Inspection".
P
2. Depress the brake pedal several times to release the vacuum pressure from the brake booster.
4. Disconnect the brake fluid level switch harness connector.
5. Remove air duct and air cleaner case.
• MR16DDT: Refer to EM-279, "Removal and Installation".
• HR16DE: Refer to EM-148, "Removal and Installation".

6. Separate the brake tube from master cylinder assembly with a
flare nut wrench (A).
CAUTION:
7. Remove the master cylinder assembly.
CAUTION:
• Never deform or bend the brake tubes.
• Never depress the brake pedal after the master cylinder
assembly is removed.
JPFIA0844ZZ
• The piston (A) of the master cylinder assembly is

exposed. Never damage it when removing the master cyl-
inder.
• The piston may drop off when pulled out strongly. Never
hold the piston. Hold the cylinder body when handling the
master cylinder assembly.
8. Remove the O-ring.
JPFIA0824ZZ
INSTALLATION
them with water.
• Never depress the brake pedal while removing the brake tube. If this is not complied with, brake fluid may
splash.
• Never depress the brake pedal after the master cylinder assembly is removed.
• Apply polyglycol ether based lubricant to the brake booster [see
(A) in the figure] when installing the master cylinder assembly to
the brake booster.
JPFIA0013ZZ
• The piston (A) of the master cylinder assembly is exposed. Never

damage it when handling the master cylinder.
• Check that no dirt and dust are present on the piston before instal-
lation. Clean it with new brake fluid if necessary.
• The piston may drop off when pulled strongly. Never hold the pis-
ton. Hold the cylinder body when handling the master cylinder
assembly.
• Never reuse the O-ring.
JPFIA0824ZZ

• Temporarily tighten the brake tube flare nut to the master cylinder
assembly by hand. Then tighten it to the specified torque with a A
flare nut torque wrench (A). Refer to BR-23, "FRONT : Exploded
View".
• Perform the air bleeding. Refer to BR-12, "Bleeding Brake System"
B
• Perform inspection after installation. Refer to BR-34, "Inspection".
JPFIA0844ZZ
D
Disassembly and Assembly INFOID:0000000007429567
DISASSEMBLY E
CAUTION:
• Never disassemble the cylinder body.
• Remove the reservoir tank only when necessary.
BR
1. Fix the master cylinder assembly to a vise.
CAUTION:
• Always set copper plates or cloth between vise grips when fixing the cylinder body to a vise.
• Never overtighten the vise. G
2. Remove the reservoir tank mounting pin with a pin punch (A) [4
mm (0.157 in)].
3. Remove the reservoir tank and grommet from the cylinder body. H
J
JPFIA0825ZZ
ASSEMBLY
K
CAUTION:
• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and
assembly process.
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank. L
• Never drop the when installing. The parts must not be reused if they are dropped.
1. Apply new brake fluid to the grommet and install it to the cylinder body.
CAUTION: M
Never reuse the grommets.
2. Install the reservoir tank to the cylinder body.
3. Fix the cylinder body to a vise. N
CAUTION:
• Place the reservoir tank with the chamfered pin hole ( )
facing up. O
• Always set copper plates or cloth between vise grips
when fixing the cylinder body to a vise.
• Never overtighten the vise.
P
JPFIA0826ZZ

4. Tilt the reservoir tank so that a mounting pin can be inserted. Insert a mounting pin. Return the reservoir
tank to the horizontal position. Insert another mounting pin into the pin hole on the opposite side in the
same manner after the mounting pin passes through the cylinder body pin hole.
CAUTION:
Never reuse the mounting pin.
INSPECTION BEFORE REMOVAL

Check the brake fluid level switch.
• Without VDC: Refer to BRC-73, "Component Inspection".
• With VDC: Refer to BRC-186, "Component Inspection".
Check the following items and replace if necessary.
• Check the master cylinder for deformation, twist, contact with other parts or looseness of connection.
• Check for fluid leakage from connection. Refer to BR-26, "FRONT : Inspection".
CAUTION:
If the fluid leakage is present, retighten to the specified torque. Replace if necessary.

BRAKE BOOSTER
BRAKE BOOSTER
A
BR
G
JSFIA0478GB
1. Master cylinder assembly 2. Brake booster 3. Lock nut

4. Clevis 5. Gasket 6. Spacer
H

I
Removal and installation INFOID:0000000007429570
REMOVAL
J
1. Perform inspection before removal. Refer to BR-36, "Inspection and Adjustment".
2. Remove cowl top and cowl top extension. Refer to EXT-22, "Removal and Installation".
3. Remove air duct and air cleaner case. K
• MR16DDT: Refer to EM-279, "Removal and Installation".
• HR16DE: Refer to EM-148, "Removal and Installation".
4. Remove brake master cylinder assembly. Refer to BR-31, "Removal and Installation". L
5. Remove vacuum hose from brake booster.
• MR16DDT: Refer to BR-38, "MR16DDT : Removal and Installation".
• HR16DE: Refer to BR-39, "HR16DE : Removal and Installation".
M
6. Remove snap pin (1) and clevis pin (2). Refer to BR-19,
"Exploded View".
7. Remove nuts on brake booster and brake pedal assembly.
N
CAUTION:
Hold the brake booster so as to avoid dropping out.
8. Remove brake booster and spacer.
CAUTION: O
Never deform or bend the brake tubes.
NOTE:
If removing brake booster is difficult, remove clevis from brake P
booster. JPFIA0019ZZ
9. Remove spacer from brake booster.

10. Perform inspection after removal. Refer to BR-36, "Inspection and Adjustment".
INSTALLATION
CAUTION:

BRAKE BOOSTER
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installation, the
dash panel may damage the threads.
• Never deform or bend the brake tubes when installing the brake booster.
• Always use a gasket between the brake booster and the spacer.
• Replace the clevis pin if it is damaged. Refer to BR-21, "Inspection and Adjustment".
• Perform the air bleeding. Refer to BR-12, "Bleeding Brake System".
• Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-8,

Air Tight
CAUTION:
Check the air tight condition when the master cylinder and the brake booster is installed.
1. Check the air tight use a handy vacuum pump.
At vacuum of −66.7 kPa (−500 mmHg, : Vacuum should decrease within 3.3 kPa (24.8 mmHg,
−19.69 inHg, −0.067 bar) 0.98 inHg, 0.033 bar) for 15 seconds.
2. If the air tight condition cannot be maintained, perform the following operation.
a. Check the no dirt and dust are present on the brake booster and brake master cylinder mating faces.
Clean it if necessary.
b. Check the O-ring on the master cylinder. If anything is found, replace the O-ring. Refer to BR-31,
"Removal and Installation".
c. Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster.
Input Rod Length Inspection
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (A).
A : Refer to BR-58, "Brake Booster".

2. Tighten the lock nut to the specified torque.
JPFIA0238ZZ

Operation
NOTE:
Air Tight

BRAKE BOOSTER
pedal. Check that the brake pedal stroke does not change after holding down the brake pedal for 30 sec- A
onds or more.
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-8, "Inspection and B
Adjustment".
BR

VACUUM LINES
VACUUM LINES
MR16DDT
MR16DDT : Exploded View INFOID:0000000007429572
JSFIA0480ZZ
1. Clamp 2. Vacuum hose A 3. Vacuum piping

4. Vacuum hose B
A. To engine side B. Paint mark C. To brake booster
MR16DDT : Removal and Installation INFOID:0000000007429573
REMOVAL
1. Remove air duct and air cleaner case. Refer to EM-279, "Removal and Installation".
2. Remove the vacuum hose and vacuum piping.
3. Perform inspection after removal. Refer to BR-38, "MR16DDT : Inspection".
INSTALLATION
Note the following, install the vacuum hose.
• When installing vacuum hose, insert it until its tip reaches the
back-end of length (A) or further as shown in the figure.
CAUTION:
Never use lubricating oil during assembly.
A : 24 mm (0.95 in) or more

- Face the paint mark of vacuum hose A (engine side) upward to
assemble.
- Face the other paint marks to vehicle front side to assemble.
- For clamp mounting direction (the orientation of pawl), refer to BR-
38, "MR16DDT : Exploded View". JPFIA0023ZZ
MR16DDT : Inspection INFOID:0000000007429574

Appearance
Check for correct assembly, damage and deterioration.
Check Valve Airtightness

VACUUM LINES
• Use a handy vacuum pump (A) to check.
A
When connected to the booster side (B):
Vacuum should decrease within 1.3 kPa (9.8 mmHg,
0.38 inHg, 0.013 bar) for 15 seconds under a vacuum B
of −66.7 kPa (−500 mmHg, −19.70 inHg, −0.667 bar).
When connected to the engine side (C):
Vacuum should not exist. C
• Replace vacuum hose if vacuum hose is malfunctioning.

JPFIA0024ZZ
HR16DE D
HR16DE : Exploded View INFOID:0000000007429575
BR
J
JSFIA0479ZZ
1. Clamp 2. Vacuum hose (built-in check valve) 3. Vacuum piping K

4. Vacuum hose
A. To intake manifold B. Paint mark C. Stamp indicating engine direction
D. To brake booster L
HR16DE : Removal and Installation INFOID:0000000007429576
M
REMOVAL
1. Remove air duct and air cleaner case. Refer to EM-148, "Removal and Installation".
2. Remove the vacuum hose and vacuum piping. N
3. Perform inspection after removal. Refer to BR-40, "HR16DE : Inspection".
INSTALLATION O

VACUUM LINES
CAUTION:

- Face the paint mark of vacuum hose (built-in check valve, intake
manifold side) upward to assemble.
- Face the other paint marks to vehicle front side to assemble.
39, "HR16DE : Exploded View". JPFIA0023ZZ
HR16DE : Inspection INFOID:0000000007429577

Appearance

0.38 inHg, 0.013 bar) for 15 seconds under a vacuum
Vacuum should not exist.
• Replace vacuum hose assembly if vacuum hose and check valve
JPFIA0024ZZ
are malfunctioning.

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
BRAKE PAD : Exploded View INFOID:0000000007429581
B
MR16DDT (FOR MEXICO)
C
BR
JSFIA0641GB H
1. Cylinder body 2. Inner shim 3. Inner pad (with pad wear sensor)
4. Pad retainer 5. Torque member 6. Outer pad I
7. Outer shim 8. Outer shim cover
1: Apply MOLYKOTE® AS880N or silicone-based grease.

J
2: Apply MOLYKOTE® 7439 or equivalent.

K
MR16DDT (EXCEPT FOR MEXICO)
JSFIA0483GB
4. Pad retainer 5. Torque member 6. Outer pad
7. Outer shim

FRONT DISC BRAKE

HR16DE
JSFIA0482GB
1. Cylinder body 2. Inner shim cover 3. Inner shim

4. Inner pad (with pad wear sensor) 5. Pad retainer 6. Torque member
7. Outer pad 8. Outer shim
®
2: Apply MOLYKOTE 7439 or equivalent.
BRAKE PAD : Removal and Installation INFOID:0000000007429582
REMOVAL
WARNING:
Since dust covering the front brake has an affect on human body, the dust must be removed with a
dust collector. Never splatter the dust with an air blow gun.
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out.
• If the brake fluid or grease adheres to the disc rotor, quickly wipe it off.
1. Remove tires.
2. Remove lower sliding pin bolt.
JPFIA0832ZZ

FRONT DISC BRAKE
3. Suspend the cylinder body with suitable wire so that the brake
hose will not stretch. A
JPFIA0850ZZ
D
4. Remove the brake pads, shims, shim covers and pad retainers from the torque member.
CAUTION:
• Never deform the pad retainer (2) when removing the pad E
retainer from the torque member (1).
• Never damage the piston boot.
• Never drop the brake pads, shims, and the shim covers.
BR
• Remember each position of the removed brake pads.
5. Perform inspection after removal. Refer to BR-44, "BRAKE PAD
: Inspection".
G
JPFIA0118ZZ H
INSTALLATION
WARNING:
I
CAUTION:
• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis- J
ton may pop out.
1. Install the pad retainers (1) to the torque member (2) if the pad K
retainers has been removed.
CAUTION:
• Securely assemble the pad retainers so that it will not be
L
lifted up from the torque member.
• Never deform the pad retainers.
PFIA0763J N
2. Apply MOLYKOTE® AS880N or silicone-based grease to the

mating faces (A) between the brake pads and the shims, and O
install the shims to the brake pad. [Other than MR16DDT (for
Mexico) outer side]
CAUTION: P
Always replace the shim when replacing the brake pad.
3. Apply MOLYKOTE® 7439 or equivalent to the mating faces (B)
between the brake pads and the pad retainers.
JSFIA0484ZZ

FRONT DISC BRAKE
mating faces (A) between shim and shim cover, and install the
shim and shim cover to the brake pad. [MR16DDT (for Mexico)
outer side]
CAUTION:
Always replace the shim together with the shim cover when
replacing the brake pad.
JSFIA0642ZZ
6. Install the brake pads to the torque member.

CAUTION:
• Both inner and outer pads have a pad return system on
the pad retainer. Install pad return lever (1) securely to pad
retainer (2).
7. Install cylinder body to torque member.
CAUTION:
• When replacing brake pad with new one, check a brake
fluid level in the reservoir tank because brake fluid
returns to master cylinder reservoir tank when pressing
piston in. JPFIA0027ZZ
NOTE:
Use a disc brake piston tool to easily press piston.
8. Install the lower sliding pin bolt and tighten it to the specified
torque.
9. Depress the brake pedal several times to check that no drag feel
is present for the front disc brake. Refer to BR-44, "BRAKE PAD
: Inspection".
JPFIA0832ZZ
BRAKE PAD : Inspection INFOID:0000000007429583

• Replace the shims and the shim covers if rust is excessively attached.
• Eliminate rust on the pad retainers and the torque member. Replace them if rust is excessively attached.
1. Check a drag of rear disc brake. If any drag is found, follow the procedure described below.
2. Remove brake pads. Refer to BR-42, "BRAKE PAD : Removal and Installation".
3. Press the pistons. Refer to BR-42, "BRAKE PAD : Removal and Installation".
4. Install brake pads. Refer to BR-42, "BRAKE PAD : Removal and Installation".
5. Securely depress the brake pedal several times.
6. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body and replace if
necessary. Refer to BR-47, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly"
7. Burnish contact surfaces brake pads and disc rotor after refinishing or replacing brake pads, or if a soft
pedal occurs at very low mileage. Refer to BR-15, "BRAKE PAD : Inspection and Adjustment".
BRAKE CALIPER ASSEMBLY

FRONT DISC BRAKE
BRAKE CALIPER ASSEMBLY : Exploded View INFOID:0000000007429584
A
REMOVAL
BR
JPFIA0834GB G
1. Brake caliper assembly
: N·m (kg-m, ft-lb) H
DISASSEMBLY
I
N
JPFIA0511GB
1. Cap 2. Bleeder valve 3. Cylinder body

4. Piston seal 5. Piston 6. Piston boot O
7. Sliding pin 8. Sliding pin boot 9. Bushing
10. Torque member
P
: Apply rubber grease.


FRONT DISC BRAKE
BRAKE CALIPER ASSEMBLY : Removal and Installation INFOID:0000000007429585
REMOVAL
WARNING:
CAUTION:
out immediately and wash with water if it gets on a protect surface. For brake component parts,
• Never depress the brake pedal while removing the brake hose. If this is not complied with, brake
fluid may splash.
• Never drop removed parts.
1. Remove tires.
2. Fix the disc rotor using wheel nuts.
4. Separate brake hose from caliper assembly. Refer to BR-25, "FRONT : Removal and Installation".
5. Remove torque member mounting bolts, and remove brake cali-
per assembly.
CAUTION:
Never drop brake pad and caliper assembly.
6. When removing disc rotor.
JPFIA0835ZZ
INSTALLATION
WARNING:
CAUTION:
fluid may splash.
1. Install disc rotor.
2. Install the brake caliper assembly to the steering knuckle and
tighten the torque member mounting bolts to the specified
torque.
CAUTION:
Never spill or splash any grease and moisture on the brake
caliper assembly mounting face, threads, mounting bolts
and washers. Wipe out any grease and moisture.
3. Install brake hose. Refer to BR-25, "FRONT : Removal and
Installation".
4. Perform the air bleeding. Refer to BR-12, "Bleeding Brake Sys-
tem". JPFIA0835ZZ
5. Check a drag of front disc brake. If any drag is found, refer to

BR-49, "BRAKE CALIPER ASSEMBLY : Inspection".

FRONT DISC BRAKE
7. Perform inspection after installation. Refer to BR-49, "BRAKE CALIPER ASSEMBLY : Inspection". A
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000007429586
B
DISASSEMBLY
NOTE:
Never remove the torque member, brake pad and pad retainers when disassembling and assembling the cyl-
inder body. C
1. Remove the sliding pin bolt, and remove the cylinder body from the torque member. Refer to BR-42,
"BRAKE PAD : Removal and Installation".
CAUTION: D
Fix the brake pad at suitable tape so that the brake pad will not drop.
2. Remove sliding pins and sliding pin boots from torque member.
3. Remove bushing (1) from sliding pin (2). E
BR
JPFIA0851ZZ
H
4. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots. I
CAUTION:
Never get fingers caught in the pistons.
J
MAA0272D
L
5. Remove piston seal from cylinder body using seal pick tool.
CAUTION:
Be careful not to damage a cylinder inner wall. M
6. Remove bleeder valve and cap.
7. Perform inspection after disassembly. Refer to BR-49, "BRAKE
CALIPER ASSEMBLY : Inspection". N
O
JPFIA0738ZZ
ASSEMBLY
P
1. Install bleeder valve and cap.

FRONT DISC BRAKE
2. Apply rubber grease to piston seals (1), and install them to cylin-
der body.
CAUTION:
Never reuse piston seals.
JPFIA0039ZZ
3. Apply rubber grease to piston boots (1). Cover the piston (2) end
with piston boot, and then install cylinder side lip on piston boot
securely into a groove on cylinder body.
CAUTION:
Never reuse piston boots.
JPFIA0739ZZ
4. Apply new brake fluid to pistons (1). Push piston into cylinder
body by hand and push piston boot (2) piston-side lip into the
piston groove.
CAUTION:
Press the pistons evenly and vary the pressing point to pre-
vent cylinder inner wall from being rubbed.
JPFIA0034ZZ
5. Apply rubber grease to mating faces (A) between sliding pin (1)
and bushing (2), and install bushing to sliding pin.
JPFIA0836ZZ

FRONT DISC BRAKE
and sliding pin boot (2), and install sliding pin and sliding pin A
boot to sliding torque member (3).
7. Install the cylinder body to tighten cylinder body mounting bolts
to the specified torque. Refer to BR-41, "BRAKE PAD : B
Exploded View".
JPFIA0837ZZ
D
BRAKE CALIPER ASSEMBLY : Inspection INFOID:0000000007429587
INSPECTION AFTER DISASSEMBLY E

Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage. BR
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil.
Torque Member G
Check the torque member for rust, wear, cracks or damage.
Pistons
Check the surface of the piston for rust, wear, cracks or damage. H
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper.
Sliding Pin, Sliding Pin Boot and Bushing I
Check the sliding pins, sliding boots and bushing for rust, wear, cracks or damage.
J
1. Check a drag of front disc brake. If any drag is found, follow the procedure described below.
3. Press the pistons. Refer to BR-42, "BRAKE PAD : Removal and Installation". K
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body and replace if L
necessary. Refer to BR-47, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".
7. Burnish contact surface between disc rotor and brake pads after refinishing or replacing disc rotor, or if a
soft pedal occurs at very low mileage. Refer to BR-15, "DISC ROTOR : Inspection and Adjustment". M

REAR DISC BRAKE
REAR DISC BRAKE
BRAKE PAD
JSFIA0490GB
1. Sliding pin bolt 2. Cylinder body 3. Inner shim cover

4. Inner shim 5. Inner pad (with pad wear sensor) 6. Pad retainer
7. Torque member 8. Outer pad 9. Outer shim
10. Outer shim cover
1 Apply rubber grease.
REMOVAL
WARNING:
Since dust covering the rear brake has an affect on human body, the dust must be removed with a
CAUTION:
1. Remove tires.
JSFIA0491ZZ

REAR DISC BRAKE
hose will not stretch. A
JSFIA0492ZZ
D
CAUTION:
• Never deform the pad retainer (2) when removing the pad E
BR
5. Perform inspection after removal. Refer to BR-52, "BRAKE PAD
: Inspection".
G
JPFIA0118ZZ H
INSTALLATION
WARNING:
I
CAUTION:
• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis- J
ton may pop out.
1. Install the pad retainers (1) to the torque member (2) if the pad K
CAUTION:
L
PFIA0763J N

mating faces (A) between the brake pads and the shims, and O
install the shims to the brake pad.
CAUTION:
Always replace the shim together with the shim cover when P
CAUTION:
• When replacing brake pad with new one, check a brake JSFIA0493ZZ

REAR DISC BRAKE
returns to master cylinder reservoir tank when pressing piston in.
NOTE:
torque.
is present for the front disc brake. Refer to BR-52, "BRAKE PAD
: Inspection".
JSFIA0491ZZ

6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body and replace if
pedal occurs at very low mileage. Refer to BR-17, "BRAKE PAD : Inspection and Adjustment".
REMOVAL
JPFIA0677GB

REAR DISC BRAKE
1. Brake caliper assembly A

DISASSEMBLY B
BR
JSFIA0494GB
1. Sliding pin bolt 2. Bushing 3. Cap

H
4. Bleeder valve 5. Cylinder body 6. Piston seal
7. Piston 8. Piston boot 9. Sliding pin boot
I
10. Torque member
: Apply brake fluid. J
: N·m (kg-m, in-lb) K

BRAKE CALIPER ASSEMBLY : Removal and Installation INFOID:0000000007429592 L
REMOVAL
WARNING: M
CAUTION: N
• Never depress the brake pedal while removing the brake hose. If this is not complied with, brake O
fluid may splash.
• If the brake fluid or grease adheres to the disc rotor, quickly wipe it off. P
1. Remove tires.
4. Separate brake hose from caliper assembly. Refer to BR-28, "REAR : Removal and Installation".

REAR DISC BRAKE
per assembly.
CAUTION:
6. When removing disc rotor. Refer to RAX-4, "Inspection".
JSFIA0495ZZ
INSTALLATION
WARNING:
CAUTION:
fluid may splash.
1. Install disc rotor. Refer to RAX-4, "Inspection".
2. Install the brake caliper assembly to the axle housing and
torque.
CAUTION:
3. Install brake hose. Refer to BR-28, "REAR : Removal and Instal-
lation".
tem". JSFIA0495ZZ
5. Check a drag of rear disc brake. If any drag is found, refer to

7. Perform inspection after installation. Refer to BR-56, "BRAKE CALIPER ASSEMBLY : Inspection".
DISASSEMBLY
NOTE:
inder body.
CAUTION:
2. Remove sliding pin boots from torque member.

REAR DISC BRAKE
3. Remove bushing (1) from sliding pin bolt (2).
A
JSFIA0496ZZ
D
union bolt mounting hole to remove pistons and piston boots.
CAUTION: E
BR
G
MAA0272D
5. Remove piston seal from cylinder body using seal pick tool. H
CAUTION:
Be careful not to damage a cylinder inner wall.
6. Remove bleeder valve and cap. I
CALIPER ASSEMBLY : Inspection".
J
JPFIA0738ZZ K
ASSEMBLY
1. Install bleeder valve and cap. L
der body.
CAUTION:
Never reuse piston seals. M
O
JPFIA0039ZZ

REAR DISC BRAKE
with piston boot, and then install cylinder side lip on piston boot
CAUTION:
JPFIA0739ZZ
piston groove.
CAUTION:
JPFIA0034ZZ
5. Apply rubber grease to mating faces (A) between sliding pin bolt
(1) and bushing (2), and install bushing to sliding pin.
JSFIA0497ZZ
(1) and sliding pin boot (2), and install sliding pin and sliding pin
boot to sliding torque member.
7. Install the cylinder body to tighten sliding pin bolts to the speci-
fied torque. Refer to BR-50, "BRAKE PAD : Exploded View".
JSFIA0498ZZ
INSPECTION AFTER DISASSEMBLY

Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage.
CAUTION:
Torque Member

REAR DISC BRAKE
Pistons
Check the surface of the piston for rust, wear, cracks or damage. A
CAUTION:
Sliding Pin, Sliding Pin Boot and Bushing B
C
3. Press the pistons. Refer to BR-50, "BRAKE PAD : Removal and Installation". D
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body and replace if E
soft pedal occurs at very low mileage. Refer to BR-17, "DISC ROTOR : Inspection and Adjustment". BR

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [LHD]

General Specifications INFOID:0000000007429595
MR16DDT
Unit: mm (in)
Cylinder bore diameter 57.2 (2.252)

For Mexico 126.0 × 46.0 × 11.0 (4.96 × 1.811 × 0.433)
Front brake Pad length × width × thickness Except for
109.0 × 45.8 × 11.0 (4.29 × 1.803 × 0.433)
Mexico
Rotor outer diameter × thickness 296 × 26.0 (11.65 × 1.024)
Rear brake Pad length × width × thickness 83.0 × 31.9 × 8.5 (3.268 × 1.256 × 0.335)
Master cylinder Cylinder bore diameter 23.8 (15/16)
Control valve Valve type Electric brake force distribution
Brake booster Diaphragm diameter 256 (10)
Recommended brake fluid Refer to MA-13, "Fluids and Lubricants".
HR16DE
Unit: mm (in)

Front brake Pad length × width × thickness 109.0 × 45.8 × 11.0 (4.29 × 1.803 × 0.433)
Brake Pedal INFOID:0000000007429596
Unit: mm (in)
Item Standard
Brake pedal height 160.4 – 170.4 (6.31 – 6.71)
Depressed brake pedal height MR16DDT 70.0 (2.756) or more

[Depressing 490 N (50 kg, 110 lb) while turning the engine ON] HR16DE 65.0 (2.559) or more
Clearance between stop lamp switch and brake pedal position switch threaded end and the
0.74 – 1.96 (0.0291 – 0.0772)
brake pedal lever
Brake pedal play 3 – 11 (0.12 – 0.43)
Brake Booster INFOID:0000000007429597
Unit: mm (in)
Item Standard
Input rod length 156.5 – 157.5 (6.16 – 6.20)

< SERVICE DATA AND SPECIFICATIONS (SDS) [LHD]
Front Disc Brake INFOID:0000000007429598
A
MR16DDT
Unit: mm (in)
B
Item Limit
Brake pad Wear thickness 2.0 (0.079)
Wear thickness 24.0 (0.945) C
Disc rotor Thickness variation (measured at 8 positions) 0.008 (0.0003)
Runout (with it attached to the vehicle) 0.035 (0.0014)
D
HR16DE
Unit: mm (in)
Item Limit E
Wear thickness 22.0 (0.866)
Disc rotor Thickness variation (measured at 8 positions) 0.008 (0.0003) BR
Rear Disc Brake INFOID:0000000007429599 G
Unit: mm (in)
Item Limit H
I

PRECAUTIONS
< PRECAUTION > [RHD]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000006906347
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 AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000006906348
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

PRECAUTIONS
< PRECAUTION > [RHD]
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock A
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover INFOID:0000000006906349
B
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to C
windshield.
PIIB3706J
BR
Precaution for Brake System INFOID:0000000006906399
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed G
with a dust collector. Never splatter the dust with an air blow gun.
• Brake fluid use refer to MA-13, "Fluids and Lubricants".
• Never reuse drained brake fluid. H
them with water.
I
• Always confirm the specified tightening torque when installing the brake pipes.
• After pressing the brake pedal more deeply or harder than normal driving, such as air bleeding, check each
item of brake pedal. Adjust brake pedal if it is outside the standard value.
• Always clean with new brake fluid when cleaning the master cylinder, brake caliper and other components. J
• Never use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and cause
improper operation.
• Always loosen the brake tube flare nut with a flare nut wrench. K
• Tighten the brake tube flare nut to the specified torque with a flare
nut torque wrench (A).
• Turn the ignition switch OFF and disconnect the ABS actuator and
electric unit (control unit) harness connector or the battery negative L
terminal before performing the work.
• Check that no brake fluid leakage is present after replacing the
parts. M
• Burnish the brake contact surfaces after refinishing or replacing
rotors, after replacing pads, or if a soft pedal occurs at very low
mileage.
- Front brake pad: Refer to BR-71, "BRAKE PAD : Inspection and N
JPFIA0061ZZ
Adjustment".
- Front disc rotor: Refer to BR-71, "DISC ROTOR : Inspection and Adjustment".
- Rear brake lining: Refer to BR-73, "BRAKE LINING : Inspection and Adjustment". O
- Rear brake drum: Refer to BR-73, "BRAKE DRUM : Inspection and Adjustment".
- Rear brake pad: Refer to BR-75, "BRAKE PAD : Inspection and Adjustment".
- Rear disc rotor: Refer to BR-75, "DISC ROTOR : Inspection and Adjustment".
P

PREPARATION
< PREPARATION > [RHD]
PREPARATION
PREPARATION
Commercial Service Tool INFOID:0000000006905956
Tool name Description
Pin punch
Removing and installing reservoir tank
a: 4 mm (0.16 in)
NT410
• Air tight
Handy vacuum pump
• Inspection of check valve
ZZC1313D
Brake caliper wrench Return the piston
NNFIA0040ZZ

Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
Revision: 2011 May

SUSPECTED PARTS
Noise
Shake
< SYMPTOM DIAGNOSIS >
Shimmy, Judder
NVH Troubleshooting Chart
Pads or lining damaged BR-71, BR-73, BR-75
×
SYMPTOM DIAGNOSIS
Pads or lining uneven wear BR-71, BR-73, BR-75
×
Shims damaged BR-105, BR-117
×
Rotor imbalance BR-71, BR-75
×
×
BR-63
Rotor or drum damage BR-71, BR-73, BR-75
×
Rotor runout BR-71, BR-75
×
Rotor deformation BR-71, BR-75
×
Rotor or drum deflection BR-71, BR-73, BR-75
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
Rotor or drum rust BR-71, BR-73, BR-75
×
×
Rotor thickness variation BR-71, BR-75
×
× Drum out of round NVH in PB section
AXLE AND SUSPENSION NVH in FAX, RAX and FSU, RSU section
×
×
×
TIRE NVH in WT section

×
×
×
ROAD WHEEL NVH in WT section

×
×
×
× × DRIVE SHAFT NVH in FAX section
STEERING NVH in ST section

×
×
×
[RHD]
INFOID:0000000006905957
F15
I
P
K
E
B
A
N
H
D
C
O
G
M
BR
BRAKE PEDAL
< PERIODIC MAINTENANCE > [RHD]
PERIODIC MAINTENANCE
BRAKE PEDAL
INSPECTION
Brake Pedal Height
Check the height (H1) between the dash lower panel (1) and the
brake pedal upper surface.

CAUTION:
JPFIA0065ZZ
Stop Lamp Switch

stop lamp switch (2) threaded end.

CAUTION:
The stop lamp must turn off when the brake pedal is released.
NOTE:
Pull the brake pedal pad to make the clearance between the stop
lamp switch threaded end and the brake peal lever.
PFIA0813J
Brake Switch (with VDC)

brake switch (2) threaded end.

NOTE:
Pull the brake pedal pad to make the clearance between the brake
switch threaded end and the brake peal lever.
JPFIA0866ZZ
Brake Pedal Play

Press the brake pedal. Check the brake pedal play (A) (stroke until
fluid pressure occurs).
A : Refer to BR-123, "Brake Pedal".
JPFIA0277ZZ

BRAKE PEDAL
Check the height between the dash lower panel (1) and the brake
pedal upper surface (H2) when depressing the brake pedal at 490 N A
(50 kg, 110 lb) while turning engine ON.
H2 : Refer to BR-123, "Brake Pedal". B

CAUTION:
C
JPFIA0068ZZ
D
ADJUSTMENT
Brake Pedal Height
1. Remove instrument lower panel. Refer to IP-13, "Removal and Installation". E
2. Disconnect the stop lamp switch and brake switch (with VDC) harness connector.
3. Loosen the stop lamp switch and brake switch (with VDC) 45° counterclockwise.
4. Loosen the lock nut (2) of input rod (1). BR
5. Rotate the input rod, adjust the brake pedal to the specified
height (H1).
CAUTION: G
The threaded end of the input rod must project to the inner
side (L) of the clevis (3).
H
I
JPFIA0003ZZ
H1 : Refer to BR-123, "Brake Pedal". J
6. Tighten the lock nut. Refer to BR-96, "Exploded View".

7. Adjust the clearance between the brake pedal lever and the stop K
lamp switch and brake switch (with VDC) threaded end after
adjusting the brake pedal height.
L
JPFIA0279ZZ
M
Stop Lamp Switch
2. Disconnect the harness connector from stop lamp switch. N
3. Loosen the stop lamp switch 45° counterclockwise.
4. Press-fit the stop lamp switch (2) until the stop lamp switch hits
the brake pedal lever (1) 45° clockwise while pulling the brake O
pedal pad slightly.
CAUTION:
• The clearance (C) between the brake pedal lever and stop P
lamp switch threaded and must be the specified value.

• The stop lamp must be turned off when the brake pedal is
released.
PFIA0813J
Brake Switch (with VDC)

BRAKE PEDAL
2. Disconnect the harness connector from brake switch.
3. Loosen the brake switch 45° counterclockwise.
4. Press-fit the brake switch (2) until the brake switch hits the brake
pedal lever (1) 45° clockwise while pulling the brake pedal pad
slightly.
CAUTION:
The clearance (C) between the brake pedal lever and brake
switch threaded and must be the specified value.
JPFIA0866ZZ

2. Check the height between the dash lower panel (1) and the
brake pedal upper surface (H2) when depressing the brake
pedal at 490 N (50 kg, 110 lb) while turning engine ON.

CAUTION:
JPFIA0068ZZ

BRAKE FLUID
BRAKE FLUID
A
BRAKE FLUID LEVEL B

• Check that the fluid level in the reservoir tank is within the specified
range (MAX – MIN lines).
• Visually check for any brake fluid leakage around the reservoir C
tank.
• Check the brake system for any leakage if the fluid level is
extremely low (lower than MIN).
• Check the brake system for fluid leakage if the warning lamp D
remains illuminated even after the parking brake is released.
• Check the reservoir tank for the mixing of foreign matter (e.g. dust)
and oils other than brake fluid. E
SFIA2634J
BRAKE LINE
BR
1. Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged
parts.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb)
G
and hold down the pedal for approximately 5 seconds with the
engine running. Check for any fluid leakage.
CAUTION:
Retighten the applicable connection to the specified torque H
and repair any abnormal (damaged, worn or deformed) part
if any brake fluid leakage is present.
I
SBR389C
J
Draining INFOID:0000000006907662
CAUTION: K
• Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) har- L
1. Connect a vinyl tube to the bleed valve.
2. Depress the brake pedal and loosen the bleeder valve to gradu- M
ally discharge brake fluid.
BRA0007D
P
Refilling INFOID:0000000006907663
CAUTION:

BRAKE FLUID
CAUTION:
2. Loosen the bleeder valve, slowly depress the brake pedal to the full stroke, and then release the pedal.
Repeat this operation at intervals of 2 or 3 seconds until new brake fluid is discharged. Then close the
bleeder valve with the brake pedal depressed. Repeat the same work on each wheel.
Bleeding Brake System INFOID:0000000006907664
CAUTION:
ness connector or the battery negative terminal before performing the work.
• Monitor the fluid level in the reservoir tank while performing the air bleeding
CAUTION:
• Never allow oils other than brake fluid to enter the reservoir tank.
2. Connect a vinyl tube to the bleeder valve of the rear left brake.
3. Fully depress the brake pedal 4 to 5 times.
4. Loosen the bleeder valve and bleed air with the brake pedal depressed, and then quickly tighten the
bleeder valve.
5. Repeat steps 3 and 4 until all of the air is out of the brake line.
6. Tighten the bleeder valve to the specified torque.
• Front disc brake: refer to BR-105, "BRAKE CALIPER ASSEMBLY : Exploded View".
• Rear drum brake: refer to BR-111, "Exploded View".
• Rear disc brake: refer to BR-117, "BRAKE CALIPER ASSEMBLY : Exploded View".
7. Perform steps 2 to 6. Occasionally fill with the brake fluid in order to keep it in the reservoir tank at least
half of MAX line. Bleed air in the following order: rear left brake → front right brake → rear right brake →
and front left brake in order.
8. Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to BR-
67, "Inspection".
9. Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-64,

A
FLUID LEAK B
Check for brake fluid leakage from the master cylinder mounting face, reservoir tank mounting face and brake
tube connections.
C
BR

BRAKE BOOSTER
BRAKE BOOSTER
OPERATION
NOTE:
AIR TIGHT
onds or more.

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
B
INSPECTION

D
BRA0010D
BR
ADJUSTMENT
G
CAUTION:
DISC ROTOR J
K
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary. L
• HR15DE, HR16DE: Refer to FAX-40, "Removal and Installation".
Runout M
1. Fix the disc rotor to the wheel hub and bearing assembly with
2. Check the wheel bearing axial end play before the inspection. N
• MR16DDT: Refer to FAX-8, "Inspection".
• HR15DE, HR16DE: Refer to FAX-38, "Inspection".
3. Inspect the runout with a dial indicator to measure at 10 mm O
Runout (with it attached : Refer to BR-123, "Front Disc P

SBR019B
4. Find the installation position that has a minimum runout by shift-

ing the disc rotor-to-wheel hub and bearing assembly installation position by one hole at a time if the
runout exceeds the limit value.
CAUTION:

FRONT DISC BRAKE
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor.
- MR16DDT: Refer to FAX-10, "Removal and Installation".
- HR15DE, HR16DE: Refer to FAX-40, "Removal and Installation".

Thickness
Check the thickness of the disc rotor using a micrometer. Replace the disc rotor if the thickness is below the
wear limit.
• HR15DE, HR16DE: Refer to FAX-40, "Removal and Installation".
Wear thickness : Refer to BR-123, "Front Disc

Brake".
SBR020B
ADJUSTMENT
CAUTION:

REAR DRUM BRAKE
REAR DRUM BRAKE
A
BRAKE LINING
BRAKE LINING : Inspection and Adjustment INFOID:0000000006907695
B
INSPECTION
Brake Lining C
1. Remove plug from back plate. Refer to BR-111, "Exploded View".
2. Check brake lining wear thickness (A) from an inspection hole
on back plate. Check using a scale necessary. D
A : Refer to BR-124, "Rear Drum Brake".

E
BR
J
JPFIA0806ZZ
ADJUSTMENT
Burnish contact surfaces between brake lining and brake drum according to the following procedure after K
refinishing or replacing brake lining, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate firmly/securely until brake lining and
L
brake drum are securely fitted.
M
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted. N
BRAKE DRUM
BRAKE DRUM : Inspection and Adjustment INFOID:0000000006907696
O
INSPECTION
Appearance P
Check surface of brake drum for uneven wear, cracks and serious damage. Replace it if necessary. Refer to
BR-111, "Removal and Installation".
Brake Drum Inner Diameter

REAR DRUM BRAKE
Check inner diameter (B) of the brake drum.
B : Refer to BR-124, "Rear Drum Brake".
JPFIA0113ZZ
ADJUSTMENT
Burnish contact surfaces between brake drum and brake lining according to the following procedure after
refinishing or replacing brake drum, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate firmly/securely until brake drum and
brake lining are securely fitted.

REAR DISC BRAKE
REAR DISC BRAKE
A
BRAKE PAD
B
INSPECTION

D
BRA0010D
BR
ADJUSTMENT
G
CAUTION:
DISC ROTOR J
K
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary. Refer to L
Runout
1. Fix the disc rotor to the wheel hub and bearing assembly with M
2. Check the wheel bearing axial end play before the inspection.
Refer to RAX-4, "Inspection". N
3. Inspect the runout with a dial indicator to measure at 10 mm
O
Runout (with it attached : Refer to BR-124, "Rear Disc
4. Find the installation position that has a minimum runout by shift- SBR019B P
ing the disc rotor-to-wheel hub and bearing assembly installation
position by one hole at a time if the runout exceeds the limit value.
CAUTION:
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor. Refer to

REAR DISC BRAKE

Thickness
the disc rotor if the thickness is below the wear limit. Refer to RAX-5,
"REAR DISK BRAKE TYPE : Removal and Installation".
Wear thickness : Refer to BR-124, "Rear Disc

Brake".
SBR020B
ADJUSTMENT
CAUTION:

BRAKE PEDAL
< REMOVAL AND INSTALLATION > [RHD]
REMOVAL AND INSTALLATION A

BRAKE PEDAL
B
WITHOUT VDC
C
BR
J
JPFIA0814GB
1. Clevis pin 2. Brake pedal assembly 3. Brake pedal pad K

4. Stop lamp switch 5. Clip 6. Snap pin

L
WITH VDC
M

BRAKE PEDAL
JSFIA0499GB
1. Clevis pin 2. Brake pedal assembly 3. Brake pedal pad

4. Brake switch 5. Clip 6. Stop lamp switch
7. Snap pin
REMOVAL
2. Disconnect the stop lamp switch and the brake switch (with VDC) harness connectors.
3. Rotate the stop lamp switch and the brake switch (with VDC) (1)
counter clockwise to remove.
4. Disconnect the accelerator pedal harness connector and har-
ness clip.
JPFIA0815ZZ

BRAKE PEDAL
5. Remove snap pin (1) and clevis pin (2) from clevis (3) of brake
booster. A
6. Remove the brake pedal assembly.
CAUTION:
Hold the brake booster and master cylinder assembly so as B
not to drop out or contact them other parts.
7. Remove accelerator pedal from brake pedal assembly. Refer to
ACC-4, "Removal and Installation".
C
and Adjustment".
JPFIA0816ZZ
D
INSTALLATION
• Apply the multi-purpose grease to the clevis pin and the mating faces. (Not necessary if grease has been
already applied) E
NOTE:
The clevis pin may be inserted in either direction.
• Perform adjustment after installation. Refer to BR-79, "Inspection and Adjustment". BR
INSPECTION AFTER REMOVAL G

• Check for the following items and replace the brake pedal assembly if necessary.
- Check the brake pedal upper rivet (made by aluminum) (A) and pin
(B) for deformation. H
- Check the brake pedal for bend, damage, and cracks on the
welded parts.
- Check the lapping length (E) of sub-bracket (C) and slide plate (D).
I
E : 5.5 mm (0.217 in) or more
J
JPFIA0817ZZ
K
• Check clevis pin and plastic stopper (A) for damage and deforma-
tion. If any is found, replace clevis pin.
L
N
PFIA0756J

O
• Adjust each item of brake pedal after installing the brake pedal assembly to the vehicle. Refer to BR-64,
• Perform the release position learning of the accelerator pedal.
- MR16DDT (without EURO-OBD): Refer to EC-591, "Work Procedure". P
- MR16DDT (with EURO-OBD): Refer to EC-929, "Work Procedure".

BRAKE PIPING
BRAKE PIPING
FRONT
FRONT : Exploded View INFOID:0000000006905972
WITHOUT VDC
JSFIA0500GB
1. Brake booster 2. Master cylinder assembly 3. Brake tube

4. Connector bracket 5. Connector 6. ABS actuator and electric unit (con-
trol unit)
10. Copper washer

WITH VDC

BRAKE PIPING
BR
H
JSFIA0787GB
1. Brake booster 2. Master cylinder assembly 3. Brake tube

4. Connector bracket 5. Connector 6. ABS actuator and electric unit (con- I
trol unit)
10. Copper washer J
: N·m (kg-m, ft-lb) K

: Always replace after every disassembly. L
FRONT : Hydraulic Piping INFOID:0000000006905973

M
WITHOUT VDC
N

BRAKE PIPING
JSFIA0788ZZ
1. Brake booster 2. Master cylinder assembly 3. Front disc brake

4. ABS actuator and electric unit (con- 5. Connector 6. Rear drum brake
trol unit)
: Flare nut
: Union bolt
WITH VDC
JPFIA0657ZZ

4. ABS actuator and electric unit (con- 5. Connector 6. Rear disc brake
trol unit)
: Flare nut
: Union bolt
FRONT : Removal and Installation INFOID:0000000006905974
REMOVAL

BRAKE PIPING
CAUTION:
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it A
B
1. Remove tires.
C
CAUTION:
• Never scratch the flare nut and the brake tube. D
hoses and tubes.
• Cover open end of brake tubes and hoses when discon- E
BR
JPFIA0847ZZ
4. Remove the union bolt (1) and copper washers (2), and remove G
the brake hose (3) from the brake caliper assembly.
H
JPFIA0819ZZ J
INSTALLATION
CAUTION:
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it K
• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied L
brake hose.
M
CAUTION:
2. Align the brake hose pin (A) with the brake caliper assembly
projection (B), and tighten the union bolt (1) to the specified N
torque.
JPFIA0820ZZ

BRAKE PIPING
3. Install the brake tube (2) to the brake hose (1), temporarily
and fix the brake hose to the bracket (5) with the lock plate (4).
CAUTION:
and bent.
JPFIA0821ZZ
torque wrench (A).
CAUTION:
CAUTION:
7. Perform inspection after installation. Refer to BR-84, "FRONT :
FRONT : Inspection INFOID:0000000006905975

1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer-
ence with other components when steering the steering wheel; no looseness at connections.
CAUTION:
REAR
REAR : Exploded View INFOID:0000000006905976
WITHOUT VDC

BRAKE PIPING
BR
H
JPFIA0822GB
1. Brake tube 2. Brake hose 3. Lock plate

A. To connector B. To right rear brake C. To left rear brake I

J
: Indicates that the part is connected at points with same symbol in actual vehicle. K
WITH VDC
L

BRAKE PIPING
JSFIA0465GB
1. Brake tube 2. Brake hose A 3. Lock plate

4. Brake hose bracket 5. Union bolt 6. Brake hose B
7. Copper washer
A. To connector

REAR : Hydraulic Piping INFOID:0000000006905977
WITHOUT VDC

BRAKE PIPING
JSFIA0788ZZ BR

4. ABS actuator and electric unit (con- 5. Connector 6. Rear drum brake
G
trol unit)
: Flare nut H
: Union bolt
WITH VDC
I
N
JPFIA0657ZZ
1. Brake booster 2. Master cylinder assembly 3. Front disc brake O

4. ABS actuator and electric unit (con- 5. Connector 6. Rear disc brake
trol unit)
A. Brake tube B. Brake hose P
: Flare nut
: Union bolt
REAR : Removal and Installation INFOID:0000000006905978
REMOVAL

BRAKE PIPING
WITHOUT VDC
CAUTION:
1. Remove tires.
CAUTION:
hoses and tubes.
JPFIA0848ZZ
WITH VDC
CAUTION:
1. Remove tires.
the brake tube (2) from the brake hose A (3).
CAUTION:
hoses and tubes.
4. Remove the lock plate (4) and remove the brake hose A.
JPFIA0848ZZ
the brake tube (2) from the brake hose B (3).
CAUTION:
hoses and tubes.
6. Remove the lock plate (4) from brake hose bracket (5).
JSFIA0470ZZ

BRAKE PIPING
the brake hose B (3) from the brake caliper assembly. A
JSFIA0471ZZ
D
INSTALLATION
WITHOUT VDC
CAUTION: E
• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied BR
tighten the flare nut (3) by hand until it does not rotate further, G
CAUTION:
Check that all brake hoses and brake tubes are not twisted H
and bent.
JPFIA0849ZZ
J
torque wrench (A).
CAUTION: K
BR-68, "Bleeding Brake System". L
CAUTION:
4. Install tires. Refer to WT-7, "Exploded View". M
WITH VDC N
CAUTION:
off immediately and wash with water if it gets on a painted surface. For brake component parts, O
P

BRAKE PIPING
brake hose B.
CAUTION:
2. Align the brake hose B L-pin (A) with the brake caliper assembly
hole (B), and tighten the union bolt (1) to the specified torque.
JSFIA0472ZZ
3. Install the brake tube (2) to the brake hose B (1), temporarily
and fix the brake hose B to the brake hose bracket (5) with the
lock plate (4).
CAUTION:
and bent.
JSFIA0473ZZ
torque wrench (A).
CAUTION:
JPFIA0061ZZ
CAUTION:
and bent.
JPFIA0849ZZ

BRAKE PIPING
torque wrench (A). A
CAUTION:
7. Refill with new brake fluid and perform the air bleeding. Refer to B
CAUTION:
C
D
REAR : Inspection INFOID:0000000006905979
INSPECTION AFTER INSTALLATION E

1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no looseness
at connections.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately BR
CAUTION:
Retighten the applicable connection to the specified torque and repair any abnormal (damaged, G

JPFIA0823GB
1. Reservoir cap 2. Oil strainer 3. Reservoir tank

4. Cylinder body 5. Pin 6. O-ring
7. Grommet
: Apply polyglycol ether lubricant

REMOVAL
CAUTION:
• Never depress the brake pedal while removing the brake tube. If this is not complied with, brake fluid
may splash.
1. Perform inspection before removal. Refer to BR-94, "Inspection".
2. Depress the brake pedal several times to release the vacuum pressure from the brake booster.
4. Disconnect the brake fluid level switch harness connector.
5. Separate the brake tube from master cylinder assembly with a
flare nut wrench (A).
CAUTION:
6. Remove the master cylinder assembly.
CAUTION:
• Never depress the brake pedal after the master cylinder
assembly is removed.
JPFIA0844ZZ

• The piston (A) of the master cylinder assembly is A

exposed. Never damage it when removing the master cyl-
inder.
• The piston may drop off when pulled out strongly. Never
hold the piston. Hold the cylinder body when handling the B
master cylinder assembly.
7. Remove the O-ring.
C
JPFIA0824ZZ
D
INSTALLATION
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it off E
them with water.
• Never depress the brake pedal while removing the brake tube. If this is not complied with, brake fluid may
BR
splash.
• Never depress the brake pedal after the master cylinder assembly is removed.
• Apply polyglycol ether based lubricant to the brake booster [see
(A) in the figure] when installing the master cylinder assembly to G
the brake booster.
JPFIA0013ZZ
J
• The piston (A) of the master cylinder assembly is exposed. Never
damage it when handling the master cylinder.
• Check that no dirt and dust are present on the piston before instal- K
lation. Clean it with new brake fluid if necessary.
• The piston may drop off when pulled strongly. Never hold the pis-
ton. Hold the cylinder body when handling the master cylinder L
assembly.
• Never reuse the O-ring.
M
JPFIA0824ZZ
N
• Temporarily tighten the brake tube flare nut to the master cylinder
assembly by hand. Then tighten it to the specified torque with a
flare nut torque wrench (A). Refer to BR-80, "FRONT : Exploded
View". O
• Perform the air bleeding. Refer to BR-68, "Bleeding Brake System"
• Perform inspection after installation. Refer to BR-94, "Inspection".
P
JPFIA0844ZZ

DISASSEMBLY
CAUTION:
• Never disassemble the cylinder body.
• Remove the reservoir tank only when necessary.
1. Fix the master cylinder assembly to a vise.
CAUTION:
• Always set copper plates or cloth between vise grips when fixing the cylinder body to a vise.
2. Remove the reservoir tank mounting pin with a pin punch (A) [4
mm (0.157 in)].
3. Remove the reservoir tank and grommet from the cylinder body.
JPFIA0825ZZ
ASSEMBLY
CAUTION:
• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and
assembly process.
• Never drop the when installing. The parts must not be reused if they are dropped.
1. Apply new brake fluid to the grommet and install it to the cylinder body.
CAUTION:
Never reuse the grommets.
2. Install the reservoir tank to the cylinder body.
3. Fix the cylinder body to a vise.
CAUTION:
• Place the reservoir tank with the chamfered pin hole ( )
facing up.
• Always set copper plates or cloth between vise grips
when fixing the cylinder body to a vise.
JPFIA0826ZZ
4. Tilt the reservoir tank so that a mounting pin can be inserted. Insert a mounting pin. Return the reservoir
tank to the horizontal position. Insert another mounting pin into the pin hole on the opposite side in the
same manner after the mounting pin passes through the cylinder body pin hole.
CAUTION:
Never reuse the mounting pin.

Check the brake fluid level switch.
• Without VDC: Refer to BRC-73, "Component Inspection".
• With VDC: Refer to BRC-186, "Component Inspection".

Check the following items and replace if necessary. A
• Check the master cylinder for deformation, twist, contact with other parts or looseness of connection.
• Check for fluid leakage from connection. Refer to BR-84, "FRONT : Inspection".
CAUTION: B
If the fluid leakage is present, retighten to the specified torque. Replace if necessary.
BR

BRAKE BOOSTER
BRAKE BOOSTER
JPFIA0829GB
1. Master cylinder assembly 2. Brake booster 3. Lock nut

4. Clevis 5. Gasket
Removal and installation INFOID:0000000006912735
REMOVAL
1. Perform inspection before removal. Refer to BR-97, "Inspection and Adjustment".
2. Remove cowl top and cowl top extension. Refer to EXT-22, "Removal and Installation".
3. Remove brake master cylinder assembly. Refer to BR-92, "Removal and Installation".
4. Remove vacuum hose from brake booster.
• MR16DDT: Refer to BR-99, "MR16DDT : Removal and Installation".
• HR16DE, HR15DE: Refer to BR-100, "HR15DE, HR16DE : Removal and Installation".
5. Remove low-pressure flexible hose.
• MR16DDT: Refer to HA-87, "LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation".
• HR16DE, HR15DE: Refer to HA-34, "LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation".
6. Remove snap pin (1) and clevis pin (2). Refer to BR-77,
"Exploded View".
7. Remove nuts on brake booster and brake pedal assembly.
CAUTION:
Hold the brake booster so as to avoid dropping out.
8. Remove brake booster.
CAUTION:
Never deform or bend the brake tubes.
NOTE:
If removing brake booster is difficult, remove clevis from brake
booster. JPFIA0019ZZ
9. Remove vacuum pipe from brake booster.

10. Perform inspection after removal. Refer to BR-97, "Inspection and Adjustment".
INSTALLATION
CAUTION:

BRAKE BOOSTER
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface. A
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installation, the
dash panel may damage the threads.
B
• Never deform or bend the brake tubes when installing the brake booster.
• Always use a gasket between the brake booster and the dash panel.
• Replace the clevis pin if it is damaged. Refer to BR-79, "Inspection and Adjustment".
• Perform the air bleeding. Refer to BR-68, "Bleeding Brake System". C
• Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-79,
D

E
Air Tight
CAUTION:
Check the air tight condition when the master cylinder and the brake booster is installed.
BR
1. Check the air tight use a handy vacuum pump.
At vacuum of −66.7 kPa (−500 mmHg, Vacuum should decrease within 3.3 kPa (24.8 mmHg,
G
−19.69 inHg, −0.067 bar) 0.98 inHg, 0.033 bar) for 15 seconds.
2. If the air tight condition cannot be maintained, perform the following operation.
a. Check the no dirt and dust are present on the brake booster and brake master cylinder mating faces. H
Clean it if necessary.
b. Check the O-ring on the master cylinder. If anything is found, replace the O-ring. Refer to BR-92,
"Removal and Installation". I
c. Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster.
J
Input Rod Length Inspection
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (A). K
A : Refer to BR-123, "Brake Booster".

2. Tighten the lock nut to the specified torque. L
JPFIA0238ZZ
INSPECTION AFTER INSTALLATION N
Operation
O
NOTE:
normal phenomenon due to the brake system operation. P
Air Tight

BRAKE BOOSTER
onds or more.
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-79, "Inspection and
Adjustment".

VACUUM LINES
VACUUM LINES
A
MR16DDT
MR16DDT : Exploded View INFOID:0000000006912738
B
BR
JSFIA0510ZZ
H
1. Clamp 2. Vacuum hose
A. To engine side B. Paint mark C. To brake booster
MR16DDT : Removal and Installation INFOID:0000000006912739

I
REMOVAL
J
2. Perform inspection after removal. Refer to BR-99, "MR16DDT : Inspection".
INSTALLATION K
back-end of length (A) or further as shown in the figure. L
CAUTION:
A : 24 mm (0.95 in) or more M
- Face the paint mark of vacuum hose (engine side) upward to

assemble.
- Face the paint mark of vacuum hose (brake booster side) to the N
vehicle front side to assemble.
- For clamp mounting direction (the orientation of pawl), refer to BR- JPFIA0023ZZ
99, "MR16DDT : Exploded View". O

MR16DDT : Inspection INFOID:0000000006912740
INSPECTION AFTER REMOVAL P
Appearance

VACUUM LINES

JPFIA0024ZZ
are malfunctioning.
HR15DE, HR16DE
HR15DE, HR16DE : Exploded View INFOID:0000000006912741
JPFIA0830ZZ
1. Clamp 2. Vacuum hose (built-in check valve)

A. To intake manifold B. Paint mark C. Stamp indicating engine direction
D. To brake booster
HR15DE, HR16DE : Removal and Installation INFOID:0000000006912742
REMOVAL
2. Perform inspection after removal. Refer to BR-101, "HR15DE, HR16DE : Inspection".
INSTALLATION
CAUTION:

- Face the paint marks upward to assemble.
100, "HR15DE, HR16DE : Exploded View".
JPFIA0023ZZ

VACUUM LINES
HR15DE, HR16DE : Inspection INFOID:0000000006912743
A
Appearance
B
• Use a handy vacuum pump (A) to check. C

Vacuum should decrease within 1.3 kPa (9.8 mmHg, D
When connected to the engine side (C): E
are malfunctioning. JPFIA0024ZZ BR

FRONT DISC BRAKE
FRONT DISC BRAKE
BRAKE PAD
MR16DDT
JSFIA0641GB
4. Pad retainer 5. Torque member 6. Outer pad
7. Outer shim 8. Outer shim cover

HR15DE, HR16DE
JPFIA0831GB
1. Cylinder body 2. Inner shim cover 3. Inner shim

4. Inner pad (with pad wear sensor) 5. Pad retainer 6. Torque member
7. Outer pad 8. Outer shim 9. Outer shim cover

FRONT DISC BRAKE

A

B
REMOVAL C
WARNING:
dust collector. Never splatter the dust with an air blow gun. D
CAUTION:
E
1. Remove tires.
BR
JPFIA0832ZZ
I
hose will not stretch.
J
L
JPFIA0850ZZ
4. Remove the brake pads, shims, shim covers and pad retainers from the torque member. M
CAUTION:
• Never deform the pad retainer (2) when removing the pad
• Never damage the piston boot. N
5. Perform inspection after removal. Refer to BR-105, "BRAKE O
PAD : Inspection".
JPFIA0118ZZ
INSTALLATION
WARNING:
CAUTION:

FRONT DISC BRAKE
• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis-
ton may pop out.
1. Install the pad retainers (1) to the torque member (2) if the pad
CAUTION:
PFIA0763J

mating faces (A) between the brake pads and the shims, and
install the shims to the brake pad. (MR16DDT inner side)
CAUTION:
Always replace the shim when replacing the brake pad.
JSFIA0484ZZ

mating faces (A) between the outer shim cover and the outer
shim, and install the outer shim and outer shim cover to the
outer pad. (Other than MR16DDT inner side)
CAUTION:
between the outer pad and the pad retainers.
JSFIA0642ZZ

CAUTION:
• Both inner and outer pads have a pad return system on
the pad retainer. Install pad return lever (1) securely to pad
retainer (2).
CAUTION:
• When replacing brake pad with new one, check a brake
returns to master cylinder reservoir tank when pressing
piston in. JPFIA0027ZZ
NOTE:

FRONT DISC BRAKE
torque. A
is present for the front disc brake. Refer to BR-105, "BRAKE
PAD : Inspection". B
JPFIA0832ZZ
D
INSPECTION AFTER REMOVAL E

INSPECTION AFTER INSTALLATION BR
3. Press the pistons. Refer to BR-103, "BRAKE PAD : Removal and Installation". G
H
pedal occurs at very low mileage. Refer to BR-71, "BRAKE PAD : Inspection and Adjustment". I

J
REMOVAL
K
P
JPFIA0834GB
DISASSEMBLY

FRONT DISC BRAKE
JPFIA0511GB
1. Cap 2. Bleeder valve 3. Cylinder body

4. Piston seal 5. Piston 6. Piston boot
7. Sliding pin 8. Sliding pin boot 9. Bushing
10. Torque member

REMOVAL
WARNING:
CAUTION:
fluid may splash.
1. Remove tires.
4. Separate brake hose from caliper assembly. Refer to BR-82, "FRONT : Removal and Installation".

FRONT DISC BRAKE
per assembly. A
CAUTION:
6. When removing disc rotor. B
• HR15DE, HR16DE: Refer to FAX-40, "Removal and Installa-
tion".
C
JPFIA0835ZZ
D
INSTALLATION
WARNING:
E
CAUTION:
out immediately and wash with water if it gets on a protect surface. For brake component parts, BR
fluid may splash.
G
1. Install disc rotor.
• HR15DE, HR16DE: Refer to FAX-40, "Removal and Installation". H
2. Install the brake caliper assembly to the steering knuckle and
torque. I
CAUTION:
caliper assembly mounting face, threads, mounting bolts J
3. Install brake hose. Refer to BR-82, "FRONT : Removal and
Installation". K
tem". JPFIA0835ZZ
5. Check a drag of front disc brake. If any drag is found, refer to L

7. Perform inspection after installation. Refer to BR-109, "BRAKE CALIPER ASSEMBLY : Inspection". M
DISASSEMBLY N
NOTE:
inder body. O
CAUTION: P
2. Remove sliding pins and sliding pin boots from torque member.

FRONT DISC BRAKE
3. Remove bushing (1) from sliding pin (2).
JPFIA0851ZZ
CAUTION:
MAA0272D
CAUTION:
JPFIA0738ZZ
ASSEMBLY
der body.
CAUTION:
JPFIA0039ZZ

FRONT DISC BRAKE
with piston boot, and then install cylinder side lip on piston boot A
CAUTION:
B
JPFIA0739ZZ
D
piston groove.
E
CAUTION:
BR
G
JPFIA0034ZZ
5. Apply rubber grease to mating faces (A) between sliding pin (1) H
and bushing (2), and install bushing to sliding pin.
JPFIA0836ZZ K
and sliding pin boot (2), and install sliding pin and sliding pin L
boot to sliding torque member (3).
7. Install the cylinder body to tighten cylinder body mounting bolts
to the specified torque. Refer to BR-102, "BRAKE PAD : M
Exploded View".
JPFIA0837ZZ
O
INSPECTION AFTER DISASSEMBLY P

Cylinder Body
CAUTION:
Torque Member

FRONT DISC BRAKE
Pistons
Check the surface of the piston for rust, wear, cracks or damage.
CAUTION:
Sliding Pin, Sliding Pin Boot and Bushing
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body and replace if
soft pedal occurs at very low mileage. Refer to BR-71, "DISC ROTOR : Inspection and Adjustment".

REAR DRUM BRAKE
REAR DRUM BRAKE
A
BR
I
JPFIA0838GB
1. Back plate 2. Shoe hold pin 3. Plug J

4. Retainer ring 5. Operating lever 6. Brake shoe
7. Adjuster 8. Adjuster spring 9. Return spring (upper side)
10. Return spring (lower side) 11. Adjuster lever 12. Spring K
13. Retainer 14. Boot 15. Piston
16. Piston cup 17. Spring 18. Wheel cylinder
19. Bleed valve 20. Cap L
1: Apply polyglycol ether based lubricant.

2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease. M
: Apply brake fluid
: N·m (kg-m, ft-lb) N

O
REMOVAL P
WARNING:
CAUTION:
Never drop the removed parts.
1. Remove tires.

REAR DRUM BRAKE
2. Drain brake fluid when removing or disassembling wheel cylinder. Refer to BR-67, "Draining".
3. Remove plug from back plate.
4. Remove drum.
5. Remove return spring (1) of the upper side.
6. Remover adjuster lever.
7. Expand brake shoe to remove adjuster.
CAUTION:
• Never damage wheel cylinder boot.
• Expand leading shoe (front of vehicle) and trailing shoe
(rear of vehicle) evenly.
JPFIA0861ZZ
8. Press and rotate retainer (1) to remove retainer.

NOTE:
Never rotate the shoe hole pin.
9. Remove spring and shoe hole pin.
10. Remove adjuster spring and return spring (lower side) to
remove leading shoe (front of vehicle).
JPFIA0852ZZ
11. With spring (1) of parking brake rear cable compressed, discon-
nect rear cable from clamp (A) of operating lever (2) to remove
trailing shoe (rear of vehicle).
CAUTION:
Never bend parking rear cable.
JPFIA0840ZZ
12. Remove retainer ring (1) by expanding its joint to pull out operat-
ing lever (2) from pin (A) of brake shoe.
13. To remove wheel cylinder, follow the steps below:
a. Disconnect brake tube from wheel cylinder. Refer to BR-84,
"REAR : Exploded View".
b. Remove wheel cylinder from back plate.
and Adjustment".
JPFIA0842ZZ
INSTALLATION
WARNING:
CAUTION:
• Never depress the brake pedal while removing the brake drum.
• Never drop the removed parts.

REAR DRUM BRAKE
• Never spill or splash brake fluid on the brake drum.
Note the following, and install in the reverse of removal. A
• When installing retainer ring, crimp retainer ring joint until perfectly
connected.
CAUTION:
B
Never reuse retainer ring.
• If the adjuster is disassembled, check the mounting location (right
and left) to assemble.
C
Location Thread cutting direction
Left Left-hand screw
D
Right Right-hand screw JPFIA0843ZZ
• Apply NISSAN brake grease special to the part listed below, refer-
ring to BR-111, "Exploded View". E
- -Contact surface of back plate and brake shoe,
- -Adjuster screw,
- -Contact surface of adjuster and brake shoe.
• Assemble rear drum brake with the adjuster tightened. BR
• Never damage wheel cylinder.
• Check that the component parts of the drum brake assembly are
properly installed. G
• Check that the sliding surface of brake lining and the inner surface
of drum are free from adherents, such as grease. Wipe out adher-
ents, if necessary.
• After wheel cylinder is removed or disassembled, bleed the H
brakes. Refer to BR-68, "Bleeding Brake System".
• After installation or bleeding, adjust the clearance (parking brake
lever stroke) of brake shoe. Refer to BR-114, "Inspection and I
Adjustment".
JPFIA0839ZZ
J
DISASSEMBLY
K
1. Remove the boot from wheel cylinder. Refer to BR-111, "Exploded View".
2. Remove the piston cover, piston, piston cup, and spring from wheel cylinder.
CAUTION: L
Pull out the piston from the wheel cylinder to prevent damage to the wheel cylinder inner wall.
3. Remove piston cup from piston.
4. Perform inspection after disassembly. Refer to BR-114, "Inspection and Adjustment". M
ASSEMBLY
1. Apply polyglycol ether based lubricant to the piston cup (1) and
boot (2). N
2. Install piston cover, piston cup and boot to piston (3).
CAUTION:
• Install in the correct direction. O
• Never reuse piston cup and boot.
• When replacing the piston or the piston cover, replace the
piston and the piston cover as a set.
P
3. Apply new brake fluid to piston and wheel cylinder inner wall,
and install spring, piston cover, piston to wheel cylinder.
CAUTION: JPFIA0234ZZ
Never damage the wheel cylinder inner wall.

4. Install the boot to wheel cylinder. Refer to BR-111, "Exploded View".
5. Perform inspection after assembly. Refer to BR-114, "Inspection and Adjustment".

REAR DRUM BRAKE

• Check the brake lining for excessive wear, damage, and peeling.
• Check the brake shoe sliding surface for excessive wear and damage.
• Check each spring for settling, excessive wear, damage, and rust.
• Check that the adjuster moves smoothly and check for excessive wear, damage, and rust.
• Check the back plate for damage, cracks, and deformation.
• Check the wheel cylinder for cracks, damage, and leakage of brake fluid.
• Visually check the brake drum for excessive wear, cracks, and damage with a pair of vernier calipers.
• Check the drum brake component parts for excessive wear, damage, and rust.
INSPECTION AFTER DISASSEMBLY
• Check the wheel cylinder inner wall for excessive wear, cracks, and damage.
• Check the piston for excessive wear and damage.
CAUTION:
When replacing the piston or the piston cover, replace the piston and the piston cover as a set.
INSPECTION AFTER ASSEMBLY
Check that the piston moves smoothly.
1. Check that the component parts of drum brake assembly are installed properly.
2. Rotate the brake drum and check that there is no drag. Perform the following procedure if necessary.
3. Remove the brake shoe. Refer to BR-111, "Removal and Installation".
4. Push the piston.
CAUTION:
Push both side of the piston simultaneously.
5. Install the brake shoe. Refer to BR-111, "Removal and Installation".
6. Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-10, "Inspection and Adjust-
ment".
7. Recheck rear drum brake for drag. If any drag is found, disassemble the wheel cylinder and replace if nec-
essary. Refer to BR-113, "Disassembly and Assembly".
8. Burnish contact surface between brake lining and brake drum after refinishing or replacing brake lining or
brake drum, or if a soft pedal occurs at very low mileage. Refer to BR-73, "BRAKE LINING : Inspection
and Adjustment" (brake lining), BR-73, "BRAKE DRUM : Inspection and Adjustment" (brake drum).
Adjust the brake shoe clearance (parking brake lever stroke). Refer to PB-10, "Inspection and Adjustment".

REAR DISC BRAKE
REAR DISC BRAKE
A
BRAKE PAD
B
BR
JSFIA0490GB
H
1. Sliding pin bolt 2. Cylinder body 3. Inner shim cover
4. Inner shim 5. Inner pad (with pad wear sensor) 6. Pad retainer
7. Torque member 8. Outer pad 9. Outer shim
I
10. Outer shim cover
1 Apply rubber grease.

J

K
REMOVAL L
WARNING:
dust collector. Never splatter the dust with an air blow gun. M
CAUTION:
1. Remove tires. N
O
JSFIA0491ZZ

REAR DISC BRAKE
hose will not stretch.
JSFIA0492ZZ
CAUTION:
• Never deform the pad retainer (2) when removing the pad
5. Perform inspection after removal. Refer to BR-117, "BRAKE
PAD : Inspection".
JPFIA0118ZZ
INSTALLATION
WARNING:
CAUTION:
• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis-
ton may pop out.
1. Install the pad retainers (1) to the torque member (2) if the pad
CAUTION:
PFIA0763J

mating faces (A) between the brake pads and the shims, and
install the shims to the brake pad.
CAUTION:
CAUTION:
• When replacing brake pad with new one, check a brake JSFIA0493ZZ

REAR DISC BRAKE
returns to master cylinder reservoir tank when pressing piston in.
NOTE: A
torque. B
is present for the rear disc brake. Refer to BR-117, "BRAKE PAD
: Inspection".
C
JSFIA0491ZZ
E

BR
INSPECTION AFTER INSTALLATION G
3. Press the pistons. Refer to BR-115, "BRAKE PAD : Removal and Installation". H
6. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body and replace if I
pedal occurs at very low mileage. Refer to BR-75, "BRAKE PAD : Inspection and Adjustment". J
BRAKE CALIPER ASSEMBLY : Exploded View INFOID:0000000006906000 K
REMOVAL
L
JPFIA0677GB

REAR DISC BRAKE
DISASSEMBLY
JSFIA0494GB
1. Sliding pin bolt 2. Bushing 3. Cap

4. Bleeder valve 5. Cylinder body 6. Piston seal
7. Piston 8. Piston boot 9. Sliding pin boot
10. Torque member

REMOVAL
WARNING:
CAUTION:
fluid may splash.
1. Remove tires.
4. Separate brake hose from caliper assembly. Refer to BR-87, "REAR : Removal and Installation".

REAR DISC BRAKE
per assembly. A
CAUTION:
6. When removing disc rotor. Refer to RAX-5, "REAR DISK B
BRAKE TYPE : Removal and Installation".
JSFIA0495ZZ
D
INSTALLATION
WARNING:
E
CAUTION:
out immediately and wash with water if it gets on a protect surface. For brake component parts, BR
fluid may splash.
G
1. Install disc rotor. Refer to RAX-5, "REAR DISK BRAKE TYPE : Removal and Installation".
2. Install the brake caliper assembly to the axle housing and H
torque.
CAUTION:
Never spill or splash any grease and moisture on the brake I
3. Install brake hose. Refer to BR-87, "REAR : Removal and Instal- J
lation".
tem". JSFIA0495ZZ
K
5. Check a drag of rear disc brake. If any drag is found, refer to
6. Install tires. Refer to WT-7, "Exploded View". L
7. Perform inspection after installation. Refer to BR-121, "BRAKE CALIPER ASSEMBLY : Inspection".
M
DISASSEMBLY
NOTE:
Never remove the torque member, brake pad and pad retainers when disassembling and assembling the cyl- N
inder body.
"BRAKE PAD : Removal and Installation". O
CAUTION:
2. Remove sliding pin boots from torque member. P

REAR DISC BRAKE
3. Remove bushing (1) from sliding pin bolt (2).
JSFIA0496ZZ
CAUTION:
MAA0272D
CAUTION:
JPFIA0738ZZ
ASSEMBLY
der body.
CAUTION:
JPFIA0039ZZ

REAR DISC BRAKE
with piston boot, and then install cylinder side lip on piston boot A
CAUTION:
B
JPFIA0739ZZ
D
piston groove.
E
CAUTION:
BR
G
JPFIA0034ZZ
5. Apply rubber grease to mating faces (A) between sliding pin bolt H
(1) and bushing (2), and install bushing to sliding pin.
JSFIA0497ZZ K
(1) and sliding pin boot (2), and install sliding pin and sliding pin L
boot to sliding torque member.
7. Install the cylinder body to tighten sliding pin bolts to the speci-
fied torque. Refer to BR-115, "BRAKE PAD : Exploded View". M
JSFIA0498ZZ
O
INSPECTION AFTER DISASSEMBLY P

Cylinder Body
CAUTION:
Torque Member

REAR DISC BRAKE
Pistons
Check the surface of the piston for rust, wear, cracks or damage.
CAUTION:
Sliding Pin, Sliding Pin Boot and Bushing
soft pedal occurs at very low mileage. Refer to BR-75, "DISC ROTOR : Inspection and Adjustment".

< SERVICE DATA AND SPECIFICATIONS (SDS) [RHD]
SERVICE DATA AND SPECIFICATIONS (SDS) A

General Specifications INFOID:0000000006906004
B
HR16DE, HR15DE
Unit: mm (in) C
Rotor outer diameter × thickness 280 × 24.0 (11.02 × 0.945) D
Rear brake Lining length × width × thickness 218.7 × 35.0 × 4.0 (8.61 × 1.378 × 0.157)
E
Drum inner diameter 228.6 (9.00)
Control valve Valve type Electric brake force distribution BR
G
MR16DDT
Unit: mm (in)
Cylinder bore diameter 57.2 (2.252) H

I
Rotor outer diameter × thickness 292 × 9.0 (11.50 × 0.354) J
K
Brake Pedal INFOID:0000000006906005

L
Unit: mm (in)
Item Standard M
Brake pedal height 158.9 – 168.9 (6.26 – 6.65)
Depressed brake pedal height
80.0 (3.15) or more N
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON]
Clearance between stop lamp switch and brake switch threaded end and the brake pedal lever 0.74 – 1.96 (0.0291 – 0.0772)
Brake pedal play 3 – 11 (0.12 – 0.43) O
Brake Booster INFOID:0000000006906006
Unit: mm (in) P
Item Standard
Input rod length 125.5 – 126.5 (4.94 – 4.98)
Front Disc Brake INFOID:0000000006906007
HR16DE, HR15DE

< SERVICE DATA AND SPECIFICATIONS (SDS) [RHD]
Unit: mm (in)
Item Limit
MR16DDT
Unit: mm (in)
Item Limit
Rear Drum Brake INFOID:0000000006913590
Unit: mm (in)
Item Limit
Brake lining Wear thickness 1.5 (0.059)
Brake drum Wear inner diameter 230.0 (9.06)
Rear Disc Brake INFOID:0000000006906008
Unit: mm (in)
Item Limit

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Brake System: Section

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BRAKES

PREPARATION ............................................ 6 REMOVAL AND INSTALLATION ............... 19

Revision: 2011 May BR-1 F15

BRAKE CALIPER ASSEMBLY ................................ 44 BRAKE PEDAL ................................................. 64

BRAKE CALIPER ASSEMBLY ................................ 52

Revision: 2011 May BR-2 F15

HR15DE, HR16DE ................................................... 100

Revision: 2011 May BR-3 F15

Revision: 2011 May BR-4 F15

Revision: 2011 May BR-5 F15

Tool name Description

Brake caliper wrench Return the piston

Revision: 2011 May BR-6 F15

Possible cause and

Revision: 2011 May

Pads damaged BR-15, BR-17

Shims damaged BR-44, BR-52

Rotor thickness variation BR-15, BR-17

DIFFERENTIAL NVH in DLN section

TIRE NVH in WT section

ROAD WHEEL NVH in WT section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

× × DRIVE SHAFT NVH in FAX section

STEERING NVH in ST section

H1 : Refer to BR-58, "Brake Pedal".

Stop Lamp Switch

C : Refer to BR-58, "Brake Pedal".

Brake Pedal Position Switch (with ASCD)

C : Refer to BR-58, "Brake Pedal".

Brake Pedal Play

A : Refer to BR-58, "Brake Pedal".

Depressed Brake Pedal Height

Revision: 2011 May BR-8 F15

H2 : Refer to BR-58, "Brake Pedal". B

H1 : Refer to BR-58, "Brake Pedal". J

6. Tighten the lock nut. Refer to BR-35, "Exploded View".

C : Refer to BR-58, "Brake Pedal".

Brake Pedal Position Switch (with ASCD)

Revision: 2011 May BR-9 F15

C : Refer to BR-58, "Brake Pedal".

Depressed Brake Pedal Height

H2 : Refer to BR-58, "Brake Pedal".

Revision: 2011 May BR-10 F15

BRAKE FLUID LEVEL B

Revision: 2011 May BR-11 F15

Revision: 2011 May BR-12 F15

Revision: 2011 May BR-13 F15

Revision: 2011 May BR-14 F15

Wear thickness : Refer to BR-59, "Front Disc Brake".

Runout (with it attached : Refer to BR-59, "Front Disc P

4. Find the installation position that has a minimum runout by shift-

Revision: 2011 May BR-15 F15

Wear thickness : Refer to BR-59, "Front Disc Brake".

Wear thickness : Refer to BR-59, "Front Disc

Revision: 2011 May BR-16 F15

Wear thickness : Refer to BR-59, "Rear Disc Brake".

Revision: 2011 May BR-17 F15

Wear thickness : Refer to BR-59, "Rear Disc Brake".

Wear thickness : Refer to BR-59, "Rear Disc