Brake System: Section

BRAKES
SECTION
BRAKE SYSTEM
BR B
E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 3 BRAKE PAD ..............................................................15 BR
BRAKE PAD : Inspection and Adjustment ...............15
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 3 DISC ROTOR .............................................................15
G
NVH Troubleshooting Chart ...................................... 3 DISC ROTOR : Inspection and Adjustment .............15
PRECAUTION ............................................... 4 REAR DISC BRAKE ......................................... 17

H
BRAKE PAD ..............................................................17
PRECAUTIONS ................................................... 4
BRAKE PAD : Inspection and Adjustment ...............17
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- DISC ROTOR .............................................................17 I
SIONER" ................................................................... 4 DISC ROTOR : Inspection and Adjustment .............17
Service Procedure Precautions for Models with a
Pop-up Roll Bar ......................................................... 4 REMOVAL AND INSTALLATION ............... 19
J
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ..................................... 4 BRAKE PEDAL ................................................. 19
Precaution for Battery Service .................................. 5 Exploded View .........................................................19
Precaution for Procedure without Cowl Top Cover...... 5 Removal and Installation .........................................19 K
Precaution for Brake System .................................... 5 Inspection and Adjustment ......................................20
PREPARATION ............................................ 7 BRAKE PIPING ................................................. 21

L
PREPARATION ................................................... 7 FRONT .......................................................................21
FRONT : Exploded View .........................................21
Commercial Service Tool .......................................... 7
FRONT : Hydraulic Piping .......................................22 M
PERIODIC MAINTENANCE .......................... 8 FRONT : Removal and Installation ..........................23
FRONT : Inspection .................................................25
BRAKE PEDAL ................................................... 8
Inspection and Adjustment ........................................ 8 REAR .........................................................................25 N
REAR : Exploded View ............................................25
BRAKE FLUID ....................................................11 REAR : Hydraulic Piping ..........................................26
Inspection ................................................................ 11 REAR : Removal and Installation ............................27 O
Draining ................................................................... 11 REAR : Inspection ...................................................28
Refilling ................................................................... 11
Bleeding Brake System ........................................... 12 BRAKE MASTER CYLINDER .......................... 30
Exploded View .........................................................30 P
BRAKE MASTER CYLINDER ............................13 Removal and Installation .........................................30
Inspection ................................................................ 13 Disassembly and Assembly .....................................31
Inspection ................................................................32
BRAKE BOOSTER ............................................14
Inspection ................................................................ 14 BRAKE BOOSTER ........................................... 33
Exploded View .........................................................33
FRONT DISC BRAKE ........................................15
Revision: 2010 March BR-1 2009 G37 Convertible

Removal and installation ........................................ 33 REAR DISC BRAKE .......................................... 51
Inspection and Adjustment ..................................... 34
BRAKE PAD (1 PISTON TYPE) ............................... 51
BRAKE BOOSTER PRESSURE SENSOR ....... 35 BRAKE PAD (1 PISTON TYPE) : Exploded View... 51
Exploded View ........................................................ 35 BRAKE PAD (1 PISTON TYPE) : Removal and In-
Removal and Installation ........................................ 35 stallation .................................................................. 51
Inspection ............................................................... 35 BRAKE PAD (1 PISTON TYPE) : Inspection .......... 52
VACUUM LINES ................................................ 36 BRAKE PAD (2 PISTON TYPE) ............................... 52

Exploded View ........................................................ 36 BRAKE PAD (2 PISTON TYPE) : Exploded View... 53
Removal and Installation ........................................ 36 BRAKE PAD (2 PISTON TYPE) : Removal and In-
Inspection ............................................................... 36 stallation .................................................................. 53
BRAKE PAD (2 PISTON TYPE) : Inspection .......... 55
FRONT DISC BRAKE ........................................ 38
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE)... 55
BRAKE PAD (1 PISTON TYPE) ............................... 38 BRAKE CALIPER ASSEMBLY (1 PISTON TYPE)
BRAKE PAD (1 PISTON TYPE) : Exploded View... 38 : Exploded View ...................................................... 55
BRAKE PAD (1 PISTON TYPE) : Removal and In- BRAKE CALIPER ASSEMBLY (1 PISTON TYPE)
stallation ................................................................. 38 : Removal and Installation ....................................... 56
BRAKE PAD (1 PISTON TYPE) : Inspection ......... 39 BRAKE CALIPER ASSEMBLY (1 PISTON TYPE)
: Disassembly and Assembly .................................. 57
BRAKE PAD (4 PISTON TYPE) ............................... 40
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE)
BRAKE PAD (4 PISTON TYPE) : Exploded View... 40
: Inspection .............................................................. 58
BRAKE PAD (4 PISTON TYPE) : Removal and In-
stallation ................................................................. 40 BRAKE CALIPER ASSEMBLY (2 PISTON TYPE)... 59
BRAKE PAD (4 PISTON TYPE) : Inspection ......... 42 BRAKE CALIPER ASSEMBLY (2 PISTON TYPE)
: Exploded View ...................................................... 59
: Removal and Installation ....................................... 60
: Exploded View ...................................................... 42
: Removal and Installation ...................................... 43
: Inspection .............................................................. 63
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) SERVICE DATA AND SPECIFICATIONS
: Inspection ............................................................. 45
(SDS) .......................................................... 64
SERVICE DATA AND SPECIFICATIONS
: Exploded View ...................................................... 46 (SDS) ................................................................. 64
BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) General Specifications ............................................ 64
: Removal and Installation ...................................... 47 Brake Pedal ............................................................ 64
BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) Brake Booster ......................................................... 65
: Disassembly and Assembly .................................. 48 Front Disc Brake ..................................................... 65
BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) Rear Disc Brake ...................................................... 65
: Inspection ............................................................. 49

Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
SUSPECTED PARTS
Revision: 2010 March

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-42, BR-52, BR-55
×
Rotor imbalance BR-15, BR-17
×
×
Rotor damage BR-15, BR-17
BR-3
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 NHV 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
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
× × DRIVE SHAFT NVH in RAX section
STEERING NVH in ST section

×
×
×
INFOID:0000000004927194
2009 G37 Convertible

I
P
K
E
B
A
N
H
D
C
O
G
M
BR
PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000005156177
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
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 the “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Service Procedure Precautions for Models with a Pop-up Roll Bar INFOID:0000000005153351
WARNING:
• Risk of passenger injury or death may increase if the pop-up roll bar does not deploy during a roll
over collision. In order to reduce the chance of an incident where the pop-up roll bar is inoperative,
all maintenance must be performed by a NISSAN or INFINITI dealer.
• Before removing and installing the pop-up roll bar component parts and harness, always turn the
ignition switch OFF, disconnect the battery negative terminal, and wait for 3 minutes or more. (The
purpose of this operation is to discharge electricity that is accumulated in the auxiliary power supply
circuit in the air bag diagnosis sensor unit.)
• When repairing, removing, and installing a pop-up roll bar, always refer to SRS AIR BAG and SRS
AIR BAG CONTROL warnings in the Service Manual.
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
INFOID:0000000005156178
NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
tion, 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-III 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.

PRECAUTIONS
< PRECAUTION >
OPERATION PROCEDURE
1. Connect both battery cables. A
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the push-button ignition switch to ACC position. B
(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. C
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering D
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III.
E
Precaution for Battery Service INFOID:0000000005156179
Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the BR
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Precaution for Procedure without Cowl Top Cover INFOID:0000000004927197
G
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc. H
PIIB3706J
K
Precaution for Brake System INFOID:0000000004927198
WARNING:
Clean any dust from the front brake and rear brake with a vacuum dust collector. Never blow with com- L
pressed air.
• Only use “DOT 3” brake fluid. Refer to MA-10, "Fluids and Lubricants".
• Never reuse drained brake fluid. M
• 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.
• 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. N
• Always clean with new brake fluid when cleaning the master cylinder, brake caliper and other components.
• Never use mineral oils such as gasoline or light oil to clean. They may damage rubber parts and cause
improper operation. O
• Always loosen the brake tube flare nut with a flare nut wrench.

PRECAUTIONS
< PRECAUTION >
• Tighten the brake tube flare nut to the specified torque with a crow-
foot (A) and torque wrench (B).
• Always confirm the specified tightening torque when installing the
brake pipes.
• Brake system is an important safety part. If a brake fluid leak is
detected, always disassemble the affected part. If a malfunction is
detected, replace part with a new one.
• Turn the ignition switch OFF and disconnect the ABS actuator and
electric unit (control unit) connector or the battery negative terminal
before performing the work.
• Check that no brake fluid leakage is present after replacing the
JPFIA0001ZZ
parts.
• 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 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".
- Rear disc rotor: refer to BR-17, "DISC ROTOR : Inspection and Adjustment".

PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Commercial Service Tool INFOID:0000000004927199
B
Tool name Description

C
D
Power tool Loosening bolts and nuts
E
PBIC0190E
BR
• Air tight
Handy vacuum pump
• Inspection of check valve
G
ZZC1313D
Brake caliper wrench Return the piston I
NNFIA0040ZZ J

BRAKE PEDAL
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE
BRAKE PEDAL
Inspection and Adjustment INFOID:0000000004927200
INSPECTION
Brake Pedal Height
Check the height (H1) between the dash lower panel (1) and the
brake pedal upper surface.
H1 : Refer to BR-64, "Brake Pedal".

CAUTION:
Remove the floor trim.
JPFIA0065ZZ
ASCD Brake Switch and Stop Lamp Switch

Check the clearance (C1 and C2) among ASCD brake switch (1)
threaded end, stop lamp switch (2) threaded end and the stopper
rubber (3).
C1 : Refer to BR-64, "Brake Pedal".

C2 : Refer to BR-64, "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
JPFIA0004ZZ
lamp switch threaded end and the stopper rubber. (The stopper rub-
ber hits ASCD brake switch threaded end.)
Brake Pedal Play
Press the brake pedal. Check the brake pedal play (A) (stroke until
fluid pressure occurs).
A : Refer to BR-64, "Brake Pedal".
JPFIA0277ZZ
Brake Pedal Shaky Fitting

Check the brake pedal shaky fitting (B) (the stroke when pulling the
brake pedal pad slightly from the free play).
B : Refer to BR-64, "Brake Pedal".
JPFIA0278ZZ

BRAKE PEDAL
Depressed Brake Pedal Height
Check the height between the dash lower panel (1) and the brake A
pedal upper surface (H2) when depressing the brake pedal at 490 N
(50 kg, 110 lb) while turning engine ON.
B
CAUTION:
Remove the floor trim. C
JPFIA0068ZZ D
ADJUSTMENT
Brake Pedal Height E
1. Disconnect the harness connector from ASCD brake switch and stop lamp switch.
2. Turn the stop lamp switch 45° counterclockwise.
3. Loosen ASCD brake switch lock nut. Turn ASCD brake switch counterclockwise. BR
4. Loosen the input rod lock nut (1). Adjust the brake pedal to the
specification. Tighten the input lock nut to the specification.
Refer to BR-33, "Exploded View". G
CAUTION:
The threaded end of the input rod (2) must project to the
inner side (L) of the clevis (3). H
L : 6 – 8 mm (0.24 – 0.31 in)
I
JPFIA0003ZZ
J
JPFIA0279ZZ
M
ASCD Brake Switch and Stop Lamp Switch

1. Disconnect the harness connector from ASCD brake switch and stop lamp switch. N
3. Loosen ASCD brake switch lock nut. Turn ASCD brake switch counterclockwise.
4. Press the brake pedal pad slightly. Release the brake pedal. O
Turn ASCD brake switch (1) until ASCD brake switch threaded
end hits to the stopper rubber (2) clockwise.
CAUTION:
P
Never press-fit the input rod.
5. Tighten ASCD brake switch lock nut (3) to the specification.
Refer to BR-19, "Exploded View".
CAUTION:
The clearance (C1) between the stopper rubber and the
ASCD brake switch threaded end must be the specified
value. Refer to BR-64, "Brake Pedal". JPFIA0071ZZ

BRAKE PEDAL
6. Press-fit the stop lamp switch (4) until the stop lamp switch hits the stopper rubber 45° clockwise while
pulling the brake pedal pad slightly. (ASCD brake switch threaded end hits the stopper rubber.)
CAUTION:
• The clearance (C2) between the stopper rubber and the stop lamp switch threaded end must be
the specified value. Refer to BR-64, "Brake Pedal".
• The stop lamp must turn off when the brake pedal is released.
Brake Pedal Play
4. Press the brake pedal pad slightly. Release the brake pedal.
CAUTION:
CAUTION:
6. Press-fit the stop lamp switch (4) until the stop lamp switch hits
the stopper rubber 45° clockwise while pulling the brake pedal pad slightly. (ASCD brake switch threaded
end hits the stopper rubber.)
CAUTION:
Brake Pedal Shaky Fitting
4. Press the brake pedal pad slightly. Release the brake pedal.
CAUTION:
CAUTION:
6. Press-fit the stop lamp switch (4) until the stop lamp switch hits
the stopper rubber 45° clockwise while pulling the brake pedal pad slightly. (ASCD brake switch threaded
end hits the stopper rubber.)
CAUTION:

BRAKE FLUID
BRAKE FLUID
A
Inspection INFOID:0000000004927201
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.
E
JPFIA0007ZZ
BRAKE LINE
BR
1. Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged
parts.
2. Check for fluid leakage by fully depressing brake pedal while
G
engine is running.
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts. H
SBR389C
J
Draining INFOID:0000000004927202
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.
• Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) con-
nector or the battery negative terminal before performing work. L
• Cover crowfoot and flare nut wrench with a cloth as not to damage the caliper (front 4 piston type,
rear 2 piston type).
1. Connect a vinyl tube to the bleed valve. M
2. Depress the brake pedal and loosen the bleeder valve to gradu-
ally discharge brake fluid.
N
BRA0007D P
Refilling INFOID:0000000004927203
CAUTION:
nector or the battery negative terminal before performing work.

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.
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 all brake fluid is discharged.
Then close the bleeder valve with the brake pedal depressed.
Repeat the same work on each wheel.
3. Perform the air bleeding. Refer to BR-12, "Bleeding Brake Sys-
tem". PFIA0403J
Bleeding Brake System INFOID:0000000004927204
CAUTION:
nector or the battery negative terminal before performing the work.
• Monitor the fluid level in the reservoir tank while performing the air bleeding
• Always use new brake fluid for refilling. Never reuse the drained brake fluid.
1. Connect a vinyl tube to the bleeder valve of the rear right brake.
2. Fully depress the brake pedal 4 to 5 times.
3. Loosen the bleeder valve and bleed air with the brake pedal depressed, and then quickly tighten the
bleeder valve.
4. Repeat steps 2 and 3 until all of the air is out of the brake line.
5. Tighten the bleeder valve to the specified torque.
• Front disc brake
- 1 Piston type: refer to BR-42, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Exploded View".
• Rear disc brake
6. Perform steps 1 to 5 for the rear right brake → front left brake → rear left brake → and front right brake in
order.
7. Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to BR-
11, "Inspection".
8. 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
• Run the engine for 1 minute to apply vacuum to the brake booster, and stop the engine. Then 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.
• 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 seconds or
more.
NOTE:

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD
BRAKE PAD : Inspection and Adjustment INFOID:0000000004927207
B
INSPECTION
1 Piston Type C
Check brake pad wear thickness from an inspection hole on cylinder
body. Check using a scale if necessary.
Wear thickness : Refer to BR-65, "Front Disc Brake". D
BR
BRA0010D
4 Piston Type
Check brake pad wear thickness from an inspection hole on caliper. G
Check using a scale if necessary.
Wear thickness : Refer to BR-65, "Front Disc Brake". H
PFIA0228J J
ADJUSTMENT
CAUTION:
• Burnish contact surfaces between pads according to the following procedure after refinishing or K
replacing pads, or if a soft pedal occurs at very low mileage.
• Be careful of vehicle speed because the brake does not operate firmly/securely until pads and disc
rotor are securely fitted. L
• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
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. M
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.
N
DISC ROTOR
DISC ROTOR : Inspection and Adjustment INFOID:0000000004927208
O
INSPECTION
Appearance
P
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary.
Runout

FRONT DISC BRAKE
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.
Refer to FAX-6, "Inspection".
3. Inspect the runout with a dial indicator to measure at 10 mm
(0.39 in) inside the disc edge.
Runout : Refer to BR-65, "Front Disc Brake".

4. Find the installation position that has a minimum runout by shift-
ing the disc rotor-to-wheel hub and bearing assembly installation BRA0580D
position by one hole at a time if the runout exceeds the limit

value.
5. Refinish the disc rotor if the runout is outside the limit even after performing the above operation. [When
refinishing, use the Pro-Cut PEM On-Car brake Lathe (Tool No. 38-PFM90.5) or equivalent.]
CAUTION:
• Check in advance that the thickness of the disc rotor is wear thickness + 0.3 mm (0.012 in) or
more.
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor.
Wear thickness : Refer to BR-65, "Front Disc Brake".

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-65, "Front Disc

Brake".
Thickness variation : Refer to BR-65, "Front Disc
Brake".
SBR020B
ADJUSTMENT
CAUTION:
• Burnish contact surfaces between disc rotors and pads according to the following procedure after
refinishing or replacing disc rotor, or if a soft pedal occurs at very low mileage.
• Be careful of vehicle speed because the brake does not operate firmly/securely until pad and disc
rotor are securely fitted.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.

REAR DISC BRAKE
REAR DISC BRAKE
A
BRAKE PAD
BRAKE PAD : Inspection and Adjustment INFOID:0000000004927209
B
INSPECTION
1 Piston Type C
Check brake pad wear thickness from an inspection hole on cylinder
body. Check using a scale if necessary.
Wear thickness : Refer to BR-65, "Rear Disc Brake". D
BR
BRA0010D
2 Piston Type
Check brake pad wear thickness from an inspection hole on caliper. G
Check using a scale if necessary.
Wear thickness : Refer to BR-65, "Rear Disc Brake". H
PFIA0227J J
ADJUSTMENT
CAUTION:
• Burnish contact surfaces between pads according to the following procedure after refinishing or K
replacing pads, or if a soft pedal occurs at very low mileage.
• Be careful of vehicle speed because the brake does not operate firmly/securely until pads and disc
rotor are securely fitted. L
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops. M
N
DISC ROTOR
DISC ROTOR : Inspection and Adjustment INFOID:0000000004927210
O
INSPECTION
Appearance
P
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary.
Runout

REAR DISC BRAKE
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.
Refer to RAX-6, "Inspection".
3. Inspect the runout with a dial indicator to measure at 10 mm
(0.39 in) inside disc edge.
Runout : Refer to BR-65, "Rear Disc Brake".

4. Find the installation position that has a minimum runout by shift-
ing the disc rotor-to-wheel hub and bearing assembly installation BRA0697D
position by one hole at a time if the runout exceeds the limit

value.
5. Refinish the disc rotor if the runout is outside the limit even after performing the above operation. [When
refinishing, use the Pro-Cut PEM On-Car brake Lathe (Tool No. 38-PFM90.5) or equivalent.]
CAUTION:
• Check in advance that the thickness of the disc rotor is wear thickness + 0.3 mm (0.012 in) or
more.
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor.
Wear thickness : Refer to BR-65, "Rear Disc Brake".

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-65, "Rear Disc

Brake".
Thickness variation : Refer to BR-65, "Rear Disc
Brake".
SFIA2284E
ADJUSTMENT
CAUTION:
• Burnish contact surfaces between disc rotors and pads according to the following procedure after
refinishing or replacing disc rotor, or if a soft pedal occurs at very low mileage.
• Be careful of vehicle speed because the brake does not operate firmly/securely until pad and disc
rotor are securely fitted.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.

BRAKE PEDAL
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
BRAKE PEDAL
Exploded View INFOID:0000000004927211
B
BR
JPFIA0475GB J
1. Brake pedal stroke sensor (with pre- 2. Clevis pin 3. Brake pedal assembly
crash seat belt)
4. Brake pedal pad 5. Clip 6. Snap pin
K
7. Lock nut 8. ASCD brake switch 9. Stop lamp switch
: Apply multi-purpose grease.
L
Refer to GI-4, "Components" for symbols not described on the above.
Removal and Installation INFOID:0000000004927212
M
REMOVAL
1. Remove instrument lower panel LH. Refer to IP-12, "Exploded View".
N
2. Remove knee protector. Refer to ST-15, "WITHOUT ELECTRIC MOTOR : Removal and Installation"
(without electric motor), ST-18, "WITH ELECTRIC MOTOR : Removal and Installation" (with electric
motor).
3. Remove steering column assembly. Refer to ST-15, "WITHOUT ELECTRIC MOTOR : Exploded View" O
(without electric motor), ST-18, "WITH ELECTRIC MOTOR : Exploded View" (with electric motor).
4. Disconnect the stop lamp switch and ASCD brake switch harness connectors.
5. Disconnect the brake pedal stroke sensor harness connector. (With pre-crash seat belt) P
CAUTION:
Never removing brake pedal stroke sensor. (With pre-crash seat belt)
6. Turn the stop lamp switch counterclockwise to remove the stop lamp switch.
7. Loosen the lock nut for the ASCD brake switch and remove the ASCD brake switch.

BRAKE PEDAL
8. Remove snap pin (1) and clevis pin (2) from clevis.
9. Remove the cowl top. Refer to EXT-21, "Exploded View".
10. Remove the instrument panel. Refer to IP-12, "Exploded View".
11. Slide the steering member rearward. Refer to HA-48, "Exploded
View".
12. Remove the brake pedal assembly.
JPFIA0019ZZ
INSTALLATION
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:
The clevis pin may be inserted in either direction.
INSPECTION AFTER REMOVAL

• Check for the following items and replace the brake pedal assembly if necessary.
- Check the brake pedal upper rivet (made by aluminum) (A) for
deformation.
- Check the brake pedal for bend, damage, and cracks on the
welded parts.
- Check the lapping length (X) of sub-bracket (B) and slide plate (C).
Standard
X : 5.0 mm (0.197 in) or more
JPFIA0321ZZ
• Check clevis pin and plastic stopper (A) for damage and deforma-
tion. If any is found, replace clevis pin.
PFIA0756J
ADJUSTMENT AFTER INSTALLATION

Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-8, "Inspection and
Adjustment".

BRAKE PIPING
BRAKE PIPING
A
FRONT
FRONT : Exploded View INFOID:0000000004927214
B
1 PISTON TYPE
C
BR
K
JPFIA0538GB
1. Brake tube 2. Connector 3. Master cylinder L

4. Brake booster 5. ABS actuator and electric unit (con- 6. Lock plate
trol unit)
7. Union bolt 8. Brake hose 9. Copper washer
M
10. Brake hose bracket 11. Brake tube
A. To rear brake tube B. To front brake hose C. To front brake tube
Refer to GI-4, "Components" for symbols in the figure.
N
4 PISTON TYPE

BRAKE PIPING
JPFIA0539GB
1. Brake tube 2. Connector 3. Master cylinder

4. Brake booster 5. ABS actuator and electric unit (con- 6. Lock plate
trol unit)
7. Brake tube 8. Brake hose bracket 9. Brake hose
A. To rear brake tube B. To front brake hose C. To front brake tube
FRONT : Hydraulic Piping INFOID:0000000004927215
1 PISTON TYPE
JPFIA0613ZZ

BRAKE PIPING
1. Front disc brake 2. ABS actuator and electric unit (con- 3. Master cylinder A
trol unit)
4. Brake booster 5. Connector 6. Rear disc brake
A. Brake hose B. Brake tube
B
: Flare nut
: Union bolt
C
4 PISTON TYPE
BR
JPFIA0614ZZ
I
1. Front disc brake 2. ABS actuator and electric unit (con- 3. Master cylinder
trol unit)
4. Brake booster 5. Connector 6. Rear disc brake J
: Flare nut
K
FRONT : Removal and Installation INFOID:0000000004927216
REMOVAL L
1 Piston Type
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it M
1. Remove tires with power tool.
2. Drain brake fluid. Refer to BR-11, "Draining". N
3. Loosen the flare nut with a flare nut wrench and separate the brake tube from the hose, and remove the
brake tube.
CAUTION: O
• Never scratch the flare nut and the brake tube.
• Never bend sharply, twist or strongly pull out the brake hoses and tubes.
• Cover open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. P
4. Remove the union bolt and copper washers, and remove the brake hose from the brake caliper assembly.
5. Remove the brake hose mounting nut.
6. Remove the lock plate and remove the brake hose.
4 Piston Type
CAUTION:

BRAKE PIPING
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
2. Drain brake fluid. Refer to BR-11, "Draining".
3. Loosen the flare nut with a flare nut wrench and separate the brake tube from the brake hose and caliper.
CAUTION:
• Cover flare nut wrench with a cloth as not to damage the caliper.
• Never bend sharply, twist or strongly pull out the brake hoses and tubes.
• Cover open end of brake tubes and hoses when disconnecting to prevent entrance of dirt.
4. Remove the brake tube mounting bolt and remove the brake tube.
5. Remove the brake hose mounting nut.
6. Remove the lock plate and remove the brake hose.
INSTALLATION
1 Piston Type
CAUTION:
1. Assemble the union bolt and the copper washer to the brake hose.
CAUTION:
Never reuse the copper washer.
2. Align the brake hose pin to the projection (A) of the brake caliper
assembly and tighten the union bolt (1) to the specified torque.
3. Install the brake tube to the brake hose, temporarily tighten the
flare nut by hand until it does not rotate further, and fix the brake
hose to the bracket with the lock plate.
CAUTION:
Check that all brake hoses and tubes are not twisted and
bent.
4. Tighten the flare nut to the specified torque with a flare nut crow-
foot and a torque wrench.
CAUTION: JPFIA0099ZZ
Never scratch the flare nut and the brake tube.

5. Tighten the brake hose mounting nuts to the specified torque.
CAUTION:
Never reuse the brake hose mounting nuts.
6. Refill with new brake fluid and perform the air bleeding. Refer to BR-12, "Bleeding Brake System".
CAUTION:
7. Install tires.
4 Piston Type
CAUTION:
1. Install the brake tube to the brake hose, temporarily tighten the flare nut by hand until it does not rotate
further, and fix the brake hose to the bracket with the lock plate.
CAUTION:
Check that all brake hoses and tubes are not twisted and bent.
2. Tighten the brake hose mounting nuts to the specified torque.
CAUTION:
Never reuse the brake hose mounting nuts.
3. Tighten the brake tube mounting bolt to the specified torque.
4. Tighten the flare nut to the specified torque with a flare nut crowfoot and a torque wrench.
CAUTION:
• Cover crowfoot with a cloth as not to damage the caliper.

BRAKE PIPING
5. Refill with new brake fluid and perform the air bleeding. Refer to BR-12, "Bleeding Brake System". A
CAUTION:
6. Install tires. B
FRONT : Inspection INFOID:0000000004927217
C
INSPECTION AFTER INSTALLATION
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.
D
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:
Retighten the applicable connection to the specified torque and repair any abnormal (damaged, E
worn or deformed) part if any brake fluid leakage is present.
REAR
BR
REAR : Exploded View INFOID:0000000004927218
1 PISTON TYPE G
JPFIA0536GB
O
1. Brake tube 2. Brake hose 3. Lock plate
4. Union bolt 5. Copper washer
A. To connector B. To rear brake hose C. To rear brake tube P
2 PISTON TYPE

BRAKE PIPING
JPFIA0537GB
1. Brake tube 2. Brake hose 3. Lock plate

4. Brake hose bracket
A. To connector B. To rear brake hose C. To rear brake tube
REAR : Hydraulic Piping INFOID:0000000005156188
1 PISTON TYPE
JPFIA0613ZZ
1. Front disc brake 2. ABS actuator and electric unit (con- 3. Master cylinder
trol unit)

BRAKE PIPING
: Flare nut
A
: Union bolt
2 PISTON TYPE
B
BR
G
JPFIA0614ZZ
1. Front disc brake 2. ABS actuator and electric unit (con- 3. Master cylinder H
trol unit)
I
: Flare nut
REAR : Removal and Installation INFOID:0000000004927220

J
REMOVAL
1 Piston Type K
CAUTION:
off immediately and wash with water if it gets on a painted surface. L
3. Loosen the flare nut with a flare nut wrench and separate the brake tube from the brake hose. M
CAUTION:
• Never sharply bend, twist or strongly pull the brake hoses and tubes.
• Cover the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt. N
4. Remove the union bolt and copper washers, and remove the brake hose from the brake caliper assembly.
5. Remove the lock plate and remove the brake hose from the vehicle.
O
2 Piston Type
CAUTION:
P
3. Loosen the flare nut with a flare nut wrench and separate the brake tube from the brake hose and caliper,
and remove the brake tube.
CAUTION:

BRAKE PIPING
• Never sharply bend, twist or strongly pull the brake hoses and tubes.
• Cover the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt.
4. Remove the brake hose mounting bolt.
5. Remove the lock plate and remove the brake hose from the vehicle.
INSTALLATION
1 Piston Type
CAUTION:
1. Assemble the union bolt and the copper washer to the brake hose.
CAUTION:
Never reuse copper washer.
2. Install the brake hose L-pin by aligning it with the brake caliper
assembly positioning hole, and tighten the union bolt (1) to the
specified torque.
3. Connect the hose to the brake tube, temporarily tighten the flare
nut by hand until it does not rotate further, and fix the brake hose
to the bracket with the lock plate.
CAUTION:
Check that the brake hoses and tubes are not twisted and
bent.
4. Tighten the flare nut to the specified torque with a flare nut crow-
foot and torque wrench. JPFIA0012ZZ
CAUTION:
CAUTION:
6. Install tires.
2 Piston Type
CAUTION:
1. Connect the hose to the brake tube, temporarily tighten the flare nut by hand until it does not rotate fur-
ther, and fix the brake hose to the bracket with the lock plate.
CAUTION:
Check that the brake hoses and tubes are not twisted and bent.
2. Tighten the brake hose mounting bolt to the specified torque.
3. Tighten the flare nut to the specified torque with a flare nut crowfoot and torque wrench.
CAUTION:
CAUTION:
5. Install tires.
REAR : Inspection INFOID:0000000004927221

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.
2. Depress the brake pedal with a force of 785 N (80kg, 176 lb) and hold down the pedal for approximately 5
seconds with the engine running. Check for any fluid leakage.

BRAKE PIPING
CAUTION:
Retighten the applicable connection to the specified torque and repair any abnormal (damaged, A
worn or deformed) part if any brake fluid leakage is present.
BR

JPFIA0525GB
1. Reservoir cap 2. Oil strainer 3. Reservoir tank

4. Brake fluid level switch connector 5. Cylinder body 6. Pin
7. O-ring 8. Grommet
: Apply silicone grease.
: Apply brake fluid.

REMOVAL
CAUTION:
1. Remove the brake master cylinder cover and hoodledge cover LH. Refer to EXT-21, "Exploded View".
3. Disconnect the brake fluid level switch harness connector.
4. Remove the brake tube from between ABS actuator and electric unit (control unit) and master cylinder
assembly with a flare nut wrench.
CAUTION:
5. Remove the master cylinder assembly.
CAUTION:
• Depress the brake pedal several times to release the vacuum pressure from the brake booster.
Then remove the master cylinder assembly.
• Never depress the brake pedal after the master cylinder assembly is removed.

• The piston of the master cylinder assembly is exposed. Never damage it when removing the
master cylinder. A
• The piston may drop off when pulled out strongly. Never hold the piston. Hold the cylinder body
when handling the master cylinder assembly.
INSTALLATION B
CAUTION:
off immediately and wash with water if it gets on a painted surface. C
• Never depress the brake pedal after the master cylinder assembly is removed.
• Apply silicone grease to the brake booster [see (A) in the figure]
when installing the master cylinder assembly to the brake booster. D
• The piston of the master cylinder assembly is exposed. Never
damage it when handling the master cylinder and check that no dirt
and dust are present on the piston before installation. Clean it with E
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. BR
• Never reuse the O-ring.
• Temporarily tighten the brake tube flare nut to the master cylinder
JPFIA0013ZZ
assembly by hand. Then tighten it to the specified torque with a G
flare nut crowfoot and torque wrench. Refer to BR-21, "FRONT : Exploded View".
CAUTION:
H
• After installation, perform the air bleeding. Refer to BR-12, "Bleeding Brake System"
CAUTION:
I
Disassembly and Assembly INFOID:0000000004927224
DISASSEMBLY J
CAUTION:
• Never disassemble the cylinder body.
• Remove the reservoir tank only when necessary.
K
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. L
2. Remove the reservoir tank mounting pin with a pin punch [4 mm
(0.157 in).
3. Remove the reservoir tank and grommet from the cylinder body. M
CAUTION:
Never drop the removed parts. The parts must not be
reused if they are dropped. N
O
JPFIA0015ZZ
ASSEMBLY
P
1. Apply new brake fluid to the grommet and install it to the cylinder body.
CAUTION:
• Never use mineral oil such as gasoline or light oil.
• Never reuse the grommets.
2. Install the reservoir tank to the cylinder body.
CAUTION:
Never drop the parts when installing. The parts must not be reused if they are dropped.

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. Never overtighten
the vise.
JPFIA0016ZZ
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.
JPFIA0015ZZ

Fluid Leak
Check for brake fluid leakage from the cylinder body-to-brake booster mounting face, reservoir tank mounting
face and brake tube connections.

BRAKE BOOSTER
BRAKE BOOSTER
A
BR
G
JPFIA0241GB
1. Master cylinder assembly 2. Brake booster 3. Lock nut

4. Gasket 5. Clevis
H
Removal and installation INFOID:0000000004927227 I
REMOVAL
1. Remove brake master cylinder cover and hoodledge cover LH. Refer to EXT-21, "Exploded View". J
2. Remove brake booster pressure sensor mounting bracket. Hang brake booster pressure sensor mounting
bracket not to interfere with work.
3. Remove brake master cylinder assembly. Refer to BR-30, "Exploded View". K
4. Remove vacuum hose from brake booster. Refer to BR-36, "Exploded View".
5. Remove brake booster pressure sensor and vacuum hose. Refer to BR-35, "Exploded View".
L
6. Remove snap pin and clevis pin. Refer to BR-19, "Exploded View".
7. Remove nuts on brake booster and brake pedal assembly. Refer to BR-19, "Exploded View".
CAUTION:
Hold the brake booster so as to avoid dropping out. M
8. Remove brake booster from dash panel in engine room side.
CAUTION:
Never deform or bend the brake tubes. N
NOTE:
If removing brake booster is difficult, remove clevis from brake booster.
INSTALLATION O
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installation, the
dash panel may damage the threads. P
• Never deform or bend the brake tubes when installing the brake booster.
• Always use a new gasket between the brake booster and the dash panel.
• Replace the clevis pin if it is damaged. Refer to BR-20, "Inspection and Adjustment".
• Install the brake pedal assembly and brake booster mounting nuts, and tighten it to the specified torque.
• After installation, perform the air bleeding. Refer to BR-12, "Bleeding Brake System".
CAUTION:

BRAKE BOOSTER
INSPECTION BEFORE REMOVAL

Air Tight
CAUTION:
Check the air tight condition when the master cylinder and the brake booster is installed.
1. With a handy vacuum pump, apply vacuum pressure of −66.7 kPa (−500 mmHg, −19.70 inHg) to the
brake booster.
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 O-ring on the master cylinder. If anything is found, replace the O-ring.
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-65, "Brake Booster".

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

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 pane decreases.
NOTE:
Air Tight
• Run the engine for 1 minute to apply vacuum to the brake booster, and stop the engine. Then 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.
• 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 seconds or
more.
NOTE:
ADJUSTMENT AFTER INSTALLATION
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-8, "Inspection and
Adjustment".

BRAKE BOOSTER PRESSURE SENSOR
BRAKE BOOSTER PRESSURE SENSOR
A
BR
G
JPFIA0240GB
1. Brake booster 2. Vacuum hose 3. Clamp

4. Brake booster pressure sensor
H
A. Paint mark
I
REMOVAL J
1. Remove master cylinder cover.
2. Remove brake booster pressure sensor.
K
3. Remove vacuum hose.
INSTALLATION
Note the following, install in the reverse order of removal. L
• When installing vacuum hose, insert it until its tip reaches the
back-end of length (A) or further as shown in the figure.
Standard M
A : 25 mm (0.98 in) or more
• Face the marking side vehicle front when assembling. (Brake N
booster side)
CAUTION:
Never use lubricating oil during assembly.
• Face the marking side connector when assembling. (Brake O
JPFIA0023ZZ
booster pressure sensor side)
CAUTION:
Never use lubricating oil during assembly. P

• Check for correct assembly, damage and deterioration.
• Check for brake booster pressure sensor. Refer to EC-357, "Component Inspection".

VACUUM LINES
VACUUM LINES
JPFIA0412ZZ
1. Clamp 2. Vacuum hose 3. Vacuum piping

4. Vacuum hose (built in check valve) 5. Grommet
A. To brake booster B. Paint mark C. Stamp indicating grommet installa-
tion position
D. Stamp indicating engine direction E. To intake manifold
REMOVAL
1. Remove the engine cover. Refer to EM-25, "Exploded View".
2. Remove the cowl top cover. Refer to EXT-21, "Exploded View".
3. Remove the vacuum hose and tube.
INSTALLATION
Note the following, install in the reverse order of removal.
• Because vacuum hose contains a check valve, it must be installed in the correct position. Refer to the stamp
to confirm correct installation. Brake booster will not operate normally if the hose is installed in the wrong
direction.
• When installing vacuum hose, insert it until its tip reaches the
back-end of length (A) or further as shown in the figure.
Standard
A : 24 mm (0.95 in) or more
• Face the marking side up when assembling.
CAUTION:
Never use lubricating oil during assembly.
JPFIA0023ZZ

Appearance

VACUUM LINES
Check for correct assembly, damage and deterioration.
Check Valve Airtightness A
• Use a handy vacuum pump (A) to check.
When connected to the booster side (B): B

Vacuum should decrease within 1.3 kPa (9.8 mm-
Hg, 0.38 inHg) for 15 seconds under a vacuum of −
66.7 kPa (−500 mmHg, −19.69 inHg). C
When connected to the engine side (C):
Vacuum should not exist.
D
• Replace vacuum hose assembly if vacuum hose and check valve
JPFIA0024ZZ
are malfunctioning.
E
BR

FRONT DISC BRAKE
FRONT DISC BRAKE
BRAKE PAD (1 PISTON TYPE)
BRAKE PAD (1 PISTON TYPE) : Exploded View INFOID:0000000004928421
JPFIA0364GB
1. Cylinder body 2. Protector 3. Bushing

4. Location pin 5. Inner pad (with pad wear sensor) 6. Pad retainer
7. Pad return spring 8. Torque member 9. Outer pad
: Apply bentonite noise damping brake grease.
BRAKE PAD (1 PISTON TYPE) : Removal and Installation INFOID:0000000004928422
REMOVAL
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out.
• Never spill or splash brake fluid on the disc rotor.
2. Remove the protector and location pin.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the pad
return springs and brake pads from the torque member.
CAUTION:
• Never deform the pad return spring when removing the pad return spring.
• Never deform the pad retainers when removing the pad retainers from the torque member.
• Never damage the piston boot.
• Never remove the shims from the brake pads.
• Never drop the brake pads.
• Remember each position of the removed brake pads.
INSTALLATION
WARNING:
compressed air.
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. A
1. Apply bentonite noise damping brake grease to the pad retainers before it to installing the torque member
if the pad retainers has been removed. B
CAUTION:
• Securely assemble the pad retainers so that it will not be lifted up from the torque member.
• Never deform the pad retainers.
C
2. Install the brake pads to the torque member.
CAUTION:
The brake pads is directional. Never mistake the direction.
(See the figure) D
: Direction of disc rotor rotation (Forward direction)

E
BR
JPFIA0029ZZ
3. Install the pad return spring (1) to the brake pad (2).
CAUTION: G
Correctly insert the pad return spring into the pad return
spring hole on the brake pad.
4. Install cylinder body to torque member. H
CAUTION:
• When of replacing brake pad with new one, check a brake I
fluid level in the reservoir tank because brake fluid
returns to master cylinder reservoir tank when pressing
piston in. JPFIA0028ZZ
NOTE: J
Use a disc brake piston tool to easily press piston.
5. Install the location pin and tighten it to the specified torque.
6. Install the protector. K
7. Depress the brake pedal several times to check that no drag feel is present for the front disc brake. Refer
to BR-39, "BRAKE PAD (1 PISTON TYPE) : Inspection".
8. Install tires. L
BRAKE PAD (1 PISTON TYPE) : Inspection INFOID:0000000004928423
M
Eliminate rust on the pad retainers and the torque member. Replace them if rust is excessively attached.
INSPECTION AFTER INSTALLATION N
1. Check a drag of front disc brake. If any drag is found, follow the procedure described below.
2. Remove brake pads.
O
3. Press the piston.
CAUTION:
• When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake P
fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
4. Install brake pads.
5. Depress the brake pedal several times.

FRONT DISC BRAKE
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body. Refer to BR-
44, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : 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".
JPFIA0384ZZ
1. Clip 2. Pad pin 3. Inner shim

4. Inner pad (with pad wear sensor)* 5. Cross spring 6. Caliper
7. Outer pad 8. Outer shim
*: Some vehicles has pad wear sensor only for one side.
: Apply copper based brake grease.
REMOVAL
WARNING:
compressed air.
CAUTION:
• Never spill or splash brake fluid on the disc rotor and caliper.
2. Remove clips (1) from pad pins.
JPFIA0213ZZ

FRONT DISC BRAKE
3. Remove pad pins while holding down cross spring, then remove
cross spring from caliper. A
JPFIA0214ZZ
D
4. Using pliers, remove brake pads and shims from caliper.
CAUTION:
E
• Never drop the brake pads, shims.
BR
G
JPFIA0215ZZ
INSTALLATION
H
WARNING:
compressed air.
CAUTION: I
1. Apply copper based brake grease to the mating faces between the brake pads and shims, and install J
shims to the brake pad.
CAUTION:
Always replace the shims together when replacing the brake pad.
K
2. Apply copper based brake grease to the mating faces between the brake pads and caliper.
3. Install brake pads to caliper.
CAUTION:
L
• In the case of replacing a 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.
NOTE: M
4. Install upper pad pin from the inner side, then install firmly to the outer side through the hole in the top of
brake pad. N
5. Place the top of cross spring (1) over the upper pad pin (2),
press in the cross spring, install lower pad pin from the inner
side to the outer side, and secure cross spring. O
6. Install clips to the pad pins.
CAUTION:
If clip is not fully attached, pad pin or brake pad could fall
out while vehicle is in motion. P
7. Depress the brake pedal several times to check that no drag feel
is present for the front disc brake. Refer to BR-42, "BRAKE PAD
(4 PISTON TYPE) : Inspection".
8. Install tires. JPFIA0216ZZ

FRONT DISC BRAKE

Replace the shims if rust is excessively attached.
3. Press the pistons.
CAUTION:
• When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake
NOTE:
6. Check a drag of front disc brake again. If any drag is found, disassemble the caliper. Refer to BR-48,
"BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) : 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 (1 PISTON TYPE) : Exploded View INFOID:0000000004928424
REMOVAL
JPFIA0476GB
1. Brake caliper assembly

DISASSEMBLY

FRONT DISC BRAKE
JPFIA0366GB BR
1. Bleeder valve 2. Cap 3. Cylinder body

4. Sliding pin 5. Sliding pin boot 6. Piston seal
G
7. Piston 8. Piston boot 9. Torque member
: Apply rubber grease.

H
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Removal and Installation I

INFOID:0000000004928425
REMOVAL J
WARNING:
compressed air. K
CAUTION:
Never depress the brake pedal. Brake fluid may splash while removing the brake hose.
1. Remove tires with power tool. L
2. Fix the disc rotor using wheel nuts.
CAUTION: M
Never spill or splash brake fluid on the disc rotor.
4. Remove union bolt and copper washer, and disconnect brake hose from caliper assembly. Refer to BR-
21, "FRONT : Exploded View".
N
5. Remove torque member mounting bolts, and remove brake caliper assembly.
CAUTION:
Never drop brake pads and caliper assembly.
6. Remove disc rotor. O
CAUTION:
• Put matching marks on the wheel hub and bearing assembly and the disc rotor before removing
the disc rotor. P
• Never drop disc rotor.
INSTALLATION
WARNING:
compressed air.
CAUTION:

FRONT DISC BRAKE
1. Install disc rotor.
CAUTION:
Align the matching marks that have been made during removal when reusing the disc rotor.
2. Install the brake caliper assembly to the vehicle 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 and copper washers to brake caliper assembly, and tighten union bolts to the specified
torque. Refer to BR-21, "FRONT : Exploded View".
CAUTION:
• Never reuse drained brake fluid.
5. Check a drag of front disc brake. If any drag is found, refer to BR-45, "BRAKE CALIPER ASSEMBLY (1
PISTON TYPE) : Inspection".
6. Install tires.
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Disassembly and Assembly
INFOID:0000000004928426
DISASSEMBLY
NOTE:
Never remove the torque member and pad retainers when disassembling and assembling the cylinder body.
1. Remove the protector, location pin and the sliding pin bolt, and remove the cylinder body from the torque
member. Refer to BR-38, "BRAKE PAD (1 PISTON TYPE) : Exploded View".
CAUTION:
Never drop brake pads, return springs and pad retainers from torque member.
2. Remove pad return springs and brake pads. Refer to BR-38, "BRAKE PAD (1 PISTON TYPE) : Exploded
View".
3. Remove sliding pin and sliding pin boot from torque member.
4. Remove bushing from cylinder body.
5. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.
CAUTION:
Never get fingers caught in the piston.
MAA0272D
6. Remove piston seal from cylinder body using suitable tool.

CAUTION:
Be careful not to damage a cylinder inner wall.
7. Remove bleeder valve and cap.
JPFIA0038ZZ
ASSEMBLY

FRONT DISC BRAKE
1. Install bleeder valve and cap.
2. Apply brake fluid to piston seal (1), and install them to cylinder A
body.
CAUTION:
Never reuse piston seal. B
JPFIA0039ZZ
D
3. Apply rubber grease to piston boot (1). Cover the piston (2) end
with piston boot, and then install cylinder side lip on piston boot E
securely into a groove on cylinder body.
CAUTION:
Never reuse piston boot.
BR
JPFIA0040ZZ
H
4. Apply brake fluid to piston (1). Push piston into cylinder body by
hand and push piston boot (2) piston-side lip into the piston
groove.
CAUTION: I
Press the piston evenly and vary the pressing point to pre-
vent cylinder inner wall from being rubbed.
5. Apply rubber grease to bushing, and install bushing to sliding J
pin.
6. Apply rubber grease to sliding pin and sliding pin boot, and
install sliding pin and sliding pin boots to torque member. K
7. Install pad return springs and brake pads. Refer to BR-38, JPFIA0034ZZ
"BRAKE PAD (1 PISTON TYPE) : Exploded View".

8. Install the cylinder body to the torque member and tighten the location pin and sliding pin bolt to the spec- L
ified torque. Refer to BR-38, "BRAKE PAD (1 PISTON TYPE) : Exploded View".
9. Install the protector.
M
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Inspection INFOID:0000000004928427
INSPECTION AFTER DISASSEMBLY

N
Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage. Replace the cylinder if any abnormal
condition is detected. O
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil.
Torque Member P
• Check the torque member for wear, cracks or damage. Replace the torque member if any abnormal condi-
tion is detected.
• Eliminate rust on the torque member. Replace them if rust is excessively attached.
Piston
Check the surface of the piston for rust, wear, cracks or damage. Replace the piston if any abnormal condition
is detected.
CAUTION:

FRONT DISC BRAKE
A piston sliding surface is plated. Never polish with sandpaper.
Location Pin, Protector and Bushing
Check the location pin, protector and bushing for rust, wear, cracks or damage. Replace the parts if any abnor-
mal condition is detected.
Sliding Pin and Sliding Pin Boot
Check the sliding pin and sliding boots for rust, wear, cracks or damage. Replace the parts if any abnormal
condition is detected.
2. Remove brake pads. Refer to BR-38, "BRAKE PAD (1 PISTON TYPE) : Exploded View".
CAUTION:
NOTE:
4. Install brake pads. Refer to BR-38, "BRAKE PAD (1 PISTON TYPE) : Exploded View"
6. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body. Refer to BR-
7. Burnish contact surfaces 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".
REMOVAL
JPFIA0474GB
1. Caliper
DISASSEMBLY

FRONT DISC BRAKE
JPFIA0386GB BR
1. Piston 2. Piston seal 3. Piston boot

4. Retaining ring 5. Bleeder Valve 6. Cap
G
7. Cap 8. Caliper
: Apply rubber grease.

H
BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) : Removal and Installation I

INFOID:0000000004927246
REMOVAL J
WARNING:
compressed air. K
CAUTION:
Never depress the brake pedal. Brake fluid may splash while removing the brake hose and brake tube.
1. Remove tires with power tool. L
CAUTION: M
Never spill or splash brake fluid on the disc rotor and caliper.
4. Loosen the flare nut with a flare nut wrench and separate the brake tube from caliper. Refer to BR-21,
"FRONT : Exploded View".
CAUTION: N
• Never bend sharply, twist or strongly pull out the brake tube. O
• Cover open end of brake tube when disconnecting to prevent entrance of dirt.
5. Remove caliper mounting bolts, and remove caliper.
CAUTION: P
Never drop brake pad and caliper.
6. Remove disc rotor.
CAUTION:
the disc rotor.
INSTALLATION

FRONT DISC BRAKE
WARNING:
compressed air.
CAUTION:
1. Install disc rotor.
CAUTION:
2. Install the brake caliper to the vehicle and tighten the caliper mounting bolts to the specified torque.
CAUTION:
Never spill or splash any grease and moisture on the caliper mounting face, threads, mounting
bolts and washers. Wipe out any grease and moisture.
3. Tighten the flare nut to the specified torque with a flare nut crowfoot and a torque wrench. Refer to BR-21,
"FRONT : Exploded View".
CAUTION:
CAUTION:
5. Check a drag of front disc brake. If any drag is found, refer to BR-49, "BRAKE CALIPER ASSEMBLY (4
6. Install tires.
INFOID:0000000004927247
DISASSEMBLY
CAUTION:
Never drop brake pads, shims, pad pins and clips.
2. Remove caliper assembly. Refer to BR-46, "BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) : Exploded
View".
brake tube mounting hole to remove pistons and piston boots
and retaining rings.
CAUTION:
Never get fingers caught in the pistons.
BRB0261D
4. Remove piston seal (1) from caliper using suitable tool (A).
CAUTION:
Be careful not to damage a caliper inner wall.
JPFIA0217ZZ

FRONT DISC BRAKE
ASSEMBLY
1. Apply brake fluid to piston seals (1), and install them to caliper. A
CAUTION:
Never reuse piston seals.
B
D
JPFIA0218ZZ
2. Apply rubber grease to piston boots (1). Cover the piston (2) end
with piston boots, and then install caliper side lip on piston boot E
securely into a groove on caliper.
CAUTION:
Never reuse piston boots.
BR
3. Apply brake fluid to piston. Push piston into caliper by hand and
push piston boot piston-side lip into the piston groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre- G
vent caliper inner wall from being rubbed.
4. Secure piston boot with retaining ring.
CAUTION: H
• Make sure that boot is securely engaged in the groove on
caliper.
• Never reuse retaining ring. I
5. Install the caliper to tighten the caliper mounting bolts to the
specified torque.
6. Install brake pads. Refer to BR-40, "BRAKE PAD (4 PISTON J
TYPE) : Exploded View".
CAUTION:
Never drop brake pads, shims, pad pins and clips.
K
PFIA0905J
L
Caliper
M
Check the inner wall of the caliper for rust, wear, cracks or damage. Replace the caliper if any abnormal con-
dition is detected.
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil. N
Pistons
is detected. O
CAUTION:
INSPECTION AFTER INSTALLATION P
CAUTION:

FRONT DISC BRAKE
NOTE:
4. Install brake pads. Refer to BR-40, "BRAKE PAD (4 PISTON TYPE) : Exploded View".
6. Check a drag of front disc brake again. If any drag is found, disassemble the caliper. Refer to BR-48,
"BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) : Disassembly and Assembly".
7. Burnish contact surface between disc rotor and brake pads after refinishing or replacing disc rotor, or if a

REAR DISC BRAKE
REAR DISC BRAKE
A
B
BR
JPFIA0367GB
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
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease. J

K
REMOVAL
WARNING: L
compressed air.
CAUTION:
M
ton may pop out.
1. Remove tires with power tool. N
2. Remove the upper sliding pin bolt.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Remove the brake
pads, shims, shim cover and pad retainers from the torque member. O
CAUTION:
• Never deform the pad retainers if removing the pad retainers.
• Never damage the piston boot. P
• Never drop the brake pad, shims, and the shim cover.
INSTALLATION
WARNING:
compressed air.

REAR DISC BRAKE
CAUTION:
ton may pop out.
1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease to the pad retainers before installing it to
the torque member if the pad retainers has been removed.
CAUTION:
• Securely assemble the pad retainers so that it will not be lifted up from the torque member.
• Never deform the pad retainers.
2. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease to the mating faces between the brake
pads and shims, and install shims and shim cover to brake pads.
CAUTION:
Always replace the shims together with the shim cover when replacing the brake pad.
3. Install cylinder body and brake pads to torque member.
CAUTION:
• When of replacing a pads 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.
NOTE:
4. Install the upper sliding pin bolt and tighten it to the specified torque.
5. Depress the brake pedal several times to check that no drag feel is present for the rear disc brake. Refer
to BR-52, "BRAKE PAD (1 PISTON TYPE) : Inspection".
6. Install tires.

Replace the shims and the shim cover if rust is excessively attached.
1. Check a drag of rear disc brake. If any drag is found, follow the procedure described below.
CAUTION:
NOTE:
6. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body. Refer to BR-
7. Burnish contact surfaces after refinishing or replacing pads, or if a soft pedal occurs at very low mileage.
Refer to BR-17, "BRAKE PAD : Inspection and Adjustment".

REAR DISC BRAKE
BR
JPFIA0462ZZ
G
1. Clip 2. Pad pin 3. Inner shim cover
4. Inner shim 5. Inner pad (with pad wear sensor)* 6. Cross spring
7. Caliper 8. Outer pad 9. Outer shim
H
10. Outer shim cover
: Apply copper based brake grease. I

J
REMOVAL
WARNING: K
compressed air.
CAUTION:
• Never depress the brake pedal while removing the brake pads or the caliper because the piston may L
pop out.
1. Remove tires with power tool. M
2. Remove clips from pad pins.
P
JPFIA0220ZZ

REAR DISC BRAKE
3. Remove pad pins while holding down cross spring, then remove
cross spring from caliper.
JPFIA0221ZZ
4. Using pliers, remove brake pads, shims and shim covers from
caliper.
CAUTION:
• Never drop the brake pad, shims, and the shim cover.
JPFIA0222ZZ
INSTALLATION
WARNING:
compressed air.
CAUTION:
1. Apply copper based brake grease to the mating faces between the brake pads, shims and shim cover,
and install shims and shim cover to the brake pad.
CAUTION:
Always replace the shims together when replacing the brake pad.
2. Apply copper based brake grease to the mating faces between the brake pads and caliper.
3. Apply copper based brake grease to the mating faces between the brake pads and pad pins.
4. Apply copper based brake grease to the mating faces between the brake pads and cross spring.
5. Install brake pads to caliper.
CAUTION:
• In the case of replacing a 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.
NOTE:
6. Install upper pad pin from the inner side, then install firmly to the outer side through the hole in the top of
brake pad.
7. Place the top of cross spring over the upper pad pin, press in the
cross spring, install lower pad pin from the inner side to the outer
side, and secure cross spring.
8. Install clips to the pad pins.
CAUTION:
If clip is not fully attached, pad pin or brake pad could fall
out while vehicle is in motion.
9. Depress the brake pedal several times to check that no drag feel
is present for the rear disc brake. Refer to BR-55, "BRAKE PAD
(2 PISTON TYPE) : Inspection".
10. Install tires. JPFIA0223ZZ

REAR DISC BRAKE
A
Replace the shims and shim covers if rust is excessively attached.
B
2. Remove brake pads. C
CAUTION:
• Never damage the piston boot. D
NOTE:
Use a disc brake piston tool to easily press piston. E
BR
6. Check a drag of rear disc brake again. If any drag is found, disassemble the caliper. Refer to BR-61,
7. Burnish contact surface between brake pads and disc rotor after refinishing or replacing brake pads, or if
a soft pedal occurs at very low mileage. Refer to BR-17, "BRAKE PAD : Inspection and Adjustment". G
H
REMOVAL
I
N
JPFIA0615GB
1. Brake caliper assembly O

DISASSEMBLY
P

REAR DISC BRAKE
JPFIA0368GB
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
2: Apply polyglycol ether based lubricant.

BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Removal and Installation

INFOID:0000000004928432
REMOVAL
WARNING:
compressed air.
CAUTION:
CAUTION:
4. Remove union bolt and copper washers, and disconnect brake hose from caliper assembly. Refer to BR-
25, "REAR : Exploded View"
5. Remove torque member mounting bolts, and remove brake caliper assembly.
CAUTION:
Never drop brake pads and caliper assembly.
CAUTION:
the disc rotor.
INSTALLATION
WARNING:

REAR DISC BRAKE
compressed air. A
CAUTION:
1. Install disc rotor. B
CAUTION:
2. Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the
C
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. D
3. Install brake hose and copper washers to brake caliper assembly, and tighten union bolts to the specified
torque. Refer to BR-25, "REAR : Exploded View".
4. Refill with new brake fluid and perform the air bleeding. Refer to BR-12, "Bleeding Brake System". E
CAUTION:
• Never spill or splash brake fluid on the disc rotor. BR
5. Check a drag of rear disc brake. If any drag is found, refer to BR-58, "BRAKE CALIPER ASSEMBLY (1
6. Install tires. G
INFOID:0000000004928433
H
DISASSEMBLY
NOTE:
Never remove the torque member and pad retainers when disassembling and assembling the cylinder body. I
1. Remove the sliding pin bolts and remove the cylinder body from the torque member.
2. Remove brake pads, shims and shim cover. Refer to BR-51, "BRAKE PAD (1 PISTON TYPE) : Exploded
View". J
3. Remove sliding pin boots from torque member.
4. Remove bushing form sliding pin bolt.
5. Place a wooden block as shown in the figure, and blow air from K
union bolt mounting hole to remove piston and piston boot.
CAUTION:
Never get fingers caught in the piston. L
BRD0041D
N
6. Remove piston seal from cylinder body using suitable tool.

CAUTION: O
Be careful not to damage a cylinder inner wall.
7. Remove bleeder valve and cap.
P
JPFIA0038ZZ
ASSEMBLY

REAR DISC BRAKE
1. Install bleeder valve and cap.
2. Apply polyglycol ether based lubricant to piston seal (1), and
install them to cylinder body.
CAUTION:
Never reuse piston seal.
JPFIA0039ZZ
3. Apply rubber grease to piston boot (1). Cover the piston (2) end
with the piston boot, and then install cylinder side lip on the pis-
ton boot securely into the groove on cylinder body.
CAUTION:
Never reuse piston boot.
JPFIA0040ZZ
4. Apply brake fluid to piston (1). Push piston into cylinder body by
hand and push piston boot (2) piston side lip into the piston
groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre-
vent cylinder inner wall from being rubbed.
5. Apply rubber grease to bushing, and install bushing to sliding pin
bolt.
6. Apply rubber grease to sliding pin boots, and install sliding pin
boot to torque member.
7. Install brake pads, shims and shim cover. Refer to BR-51, JPFIA0041ZZ
"BRAKE PAD (1 PISTON TYPE) : Exploded View".

8. Apply rubber grease to sliding pin bolts, and install the cylinder body to the torque member and tighten the
sliding pin bolts to the specified torque.

Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage. Replace the cylinder if any abnormal
condition is detected.
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil.
Torque Member
Check the torque member for rust, wear, cracks or damage. Replace the member if any abnormal condition is
detected.
Piston
Check the piston for rust, wear, cracks or damage. Replace the piston if any abnormal condition is detected.
CAUTION:
Sliding Pin Bolt and Sliding Pin Boot

REAR DISC BRAKE
Check the sliding pin bolts and sliding pin boots for rust, wear, cracks or damage. Replace the parts if any
abnormal condition is detected. A
B
CAUTION:
C
NOTE: D
5. Depress the brake pedal several times. E
6. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body. Refer to BR-
7. Burnish contact surfaces after refinishing or replacing pads, or if a soft pedal occurs at very low mileage. BR
Refer to BR-17, "DISC ROTOR : Inspection and Adjustment".
G
REMOVAL H
JPFIA0623GB
N
1. Caliper assembly
DISASSEMBLY O

REAR DISC BRAKE
JPFIA0390GB
1. Piston 2. Piston seal 3. Piston boot

4. Retaining ring 5. Cap 6. Bleeder valve
7. Cap 8. Caliper

BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal and Installation

INFOID:0000000004927260
REMOVAL
WARNING:
compressed air.
CAUTION:
CAUTION:
4. Loosen the flare nut with a flare nut wrench and separate the brake tube from caliper. Refer to BR-25,
"REAR : Exploded View".
CAUTION:
• Never bend sharply, twist or strongly pull out the brake tube.
• Cover open end of brake tube when disconnecting to prevent entrance of dirt.
5. Remove brake hose mounting bolt.

REAR DISC BRAKE
6. Remove caliper mounting bolts, and remove caliper.
CAUTION: A
Never drop brake pad and caliper.
CAUTION: B
• Put matching marks on the wheel hub and bearing assem-
bly and the disc rotor before removing the disc rotor.
C
JPFIA0224ZZ
D
INSTALLATION
WARNING:
E
compressed air.
CAUTION:
1. Install disc rotor. BR
CAUTION:
2. Install the brake caliper to the vehicle and tighten the caliper mounting bolts to the specified torque. G
CAUTION:
Never spill or splash any grease and moisture on the caliper mounting face, threads, mounting
bolts and washers. Wipe out any grease and moisture. H
3. Install the brake hose mounting bolt to the specified torque.
4. Tighten the flare nut to the specified torque with a flare nut crowfoot and a torque wrench. Refer to BR-25,
"REAR : Exploded View". I
CAUTION:
J
CAUTION:
• Never spill or splash brake fluid on the disc rotor. K
6. Check a drag of rear disc brake. If any drag is found, refer to BR-63, "BRAKE CALIPER ASSEMBLY (2
7. Install tires. L

INFOID:0000000004927261
M
DISASSEMBLY
N
CAUTION:
Never drop brake pad, shims, shim covers, pad pins and clips.
2. Remove caliper assembly. Refer to BR-59, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Exploded
View". O

REAR DISC BRAKE
brake tube mounting hole to remove pistons and piston boots
and retaining rings.
CAUTION:
Never get fingers caught in the pistons.
JPFIA0225ZZ
4. Remove piston seal (1) from caliper using suitable tool.

CAUTION:
Be careful not to damage a caliper inner wall.
JPFIA0226ZZ
ASSEMBLY
1. Apply brake fluid to piston seals (1), and install them to caliper.
CAUTION:
Never reuse piston seals.
PFIA0872E

REAR DISC BRAKE
2. Apply rubber grease to piston boots (1). Cover the piston (2) end
with piston boots, and then install caliper side lip on piston boot A
securely into a groove on caliper.
CAUTION:
Never reuse piston boots.
B
3. Apply brake fluid to piston. Push piston into caliper by hand and
push piston boot piston-side lip into the piston groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre- C
vent caliper inner wall from being rubbed.
4. Secure piston boot with retaining ring.
CAUTION: D
• Make sure that boot is securely engaged in the groove on
caliper.
• Never reuse retaining ring. E
5. Install the caliper to tighten the caliper mounting bolts to the
specified torque. Refer to BR-59, "BRAKE CALIPER ASSEM-
BLY (2 PISTON TYPE) : Exploded View".
BR
6. Install brake pads. Refer to BR-53, "BRAKE PAD (2 PISTON
TYPE) : Exploded View".
CAUTION:
Never drop brake pads, shims, pad pins and clips. G
PFIA0906J
H
Caliper
I
Check the inner wall of the caliper for rust, wear, cracks or damage. Replace the caliper if any abnormal con-
dition is detected.
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil. J
Pistons
is detected. K
CAUTION:
INSPECTION AFTER INSTALLATION L
M
CAUTION:
• When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake N
NOTE:
Use a disc brake piston tool to easily press piston. O
6. Check a drag of rear disc brake again. If any drag is found, disassemble the caliper. Refer to BR-61, P
7. Burnish contact surface between disc rotor and brake pads after refinishing or replacing disc rotor, or if a

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications INFOID:0000000004927263
FRONT 1 PISTON, REAR 1 PISTON TYPE

Unit: mm (in)
Cylinder bore diameter 57.15 (2.250)

Front brake Pad length × width × thickness 116.1 × 51.7 × 10.3 (4.57 × 2.035 × 0.406)
Rotor outer diameter × thickness 330 × 32.0 (12.99 × 1.260)
Cylinder bore diameter 38.1 (1.500)
Rear brake Pad length × width × thickness 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335)
Master cylinder Cylinder bore diameter 23.81 (15/16)
Control valve Valve type Electric brake force distribution
Primary: 230 (9.06)
Brake booster Diaphragm diameter
Secondary: 205 (8.07)
Recommended brake fluid DOT 3
FRONT 4 PISTON, REAR 2 PISTON TYPE

Unit: mm (in)
Caliper bore diameter 41.3 (1.626) × 2 + 44.45 (1.750) × 2

Front brake Pad length × width × thickness 123.2 × 55.0 × 11.0 (4.85 × 2.165 × 0.433)
Caliper bore diameter 41.3 (1.626) × 2
Rear brake Pad length × width × thickness 95.8 × 41.5 × 9.5 (3.772 × 1.634 × 0.374)
Master cylinder Cylinder bore diameter 25.4 (1)
Control valve Valve type Electric brake force distribution
Primary: 230 (9.06)
Brake booster Diaphragm diameter
Secondary: 205 (8.07)
Recommended brake fluid DOT 3
Brake Pedal INFOID:0000000004927264
Unit: mm (in)
Item Standard
Brake pedal height 171.5 – 181.5 (6.75 – 7.15)
Clearance between ASCD brake switch threaded end and the stopper rubber 0 – 0.6 (0 – 0.024)
Clearance between the stop lamp switch threaded end and the stopper rubber 0.74 – 1.96 (0.0291 – 0.0772)
Brake pedal play 2.0 – 8.0 (0.079 – 0.315)
Brake pedal shaky fitting 0 – 1.4 (0 – 0.055)
Depressed brake pedal height
124.0 (4.88) or more
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON]

< SERVICE DATA AND SPECIFICATIONS (SDS)
Brake Booster INFOID:0000000004927265
A
Unit: mm (in)
Item Standard
Input rod length 127.5 – 128.5 (5.02 – 5.06)
B
Front Disc Brake INFOID:0000000004927266
C
1 PISTON TYPE
Unit: mm (in)
Item Limit D
Brake pad Wear thickness 2.0 (0.079)
Wear thickness 30.0 (1.181)
E
Disc rotor Thickness variation (measured at 8 positions) 0.015 (0.0006)
Runout (with it attached to the vehicle) 0.035 (0.0014)
4 PISTON TYPE BR
Unit: mm (in)
Item Limit
G
Disc rotor Thickness variation (measured at 8 positions) 0.015 (0.0006) H
Rear Disc Brake INFOID:0000000004927267

I
1 PISTON TYPE
Unit: mm (in)
J
Item Limit
Wear thickness 15.0 (0.591) K
L
2 PISTON TYPE
Unit: mm (in)
Item Limit M
N

Brake System: Section

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Brake System: Section

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BRAKES

PRECAUTION ............................................... 4 REAR DISC BRAKE ......................................... 17

PREPARATION ............................................ 7 BRAKE PIPING ................................................. 21

Revision: 2010 March BR-1 2009 G37 Convertible

VACUUM LINES ................................................ 36 BRAKE PAD (2 PISTON TYPE) ............................... 52

Revision: 2010 March BR-2 2009 G37 Convertible

Possible cause and

Revision: 2010 March

Pads - damaged BR-15, BR-17

Shims damaged BR-42, BR-52, BR-55

Rotor thickness variation BR-15, BR-17

DIFFERENTIAL NHV in DLN section

TIRE NVH in WT section

ROAD WHEEL NVH in WT section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

× × DRIVE SHAFT NVH in RAX section

STEERING NVH in ST section

2009 G37 Convertible

Revision: 2010 March BR-4 2009 G37 Convertible

Revision: 2010 March BR-5 2009 G37 Convertible

Revision: 2010 March BR-6 2009 G37 Convertible

Tool name Description

Brake caliper wrench Return the piston I

Revision: 2010 March BR-7 2009 G37 Convertible

H1 : Refer to BR-64, "Brake Pedal".

ASCD Brake Switch and Stop Lamp Switch

C1 : Refer to BR-64, "Brake Pedal".

A : Refer to BR-64, "Brake Pedal".

Brake Pedal Shaky Fitting

B : Refer to BR-64, "Brake Pedal".

Revision: 2010 March BR-8 2009 G37 Convertible

ASCD Brake Switch and Stop Lamp Switch

Revision: 2010 March BR-9 2009 G37 Convertible

Revision: 2010 March BR-10 2009 G37 Convertible

BRAKE FLUID LEVEL B

Revision: 2010 March BR-11 2009 G37 Convertible

Bleeding Brake System INFOID:0000000004927204

Revision: 2010 March BR-12 2009 G37 Convertible

Revision: 2010 March BR-13 2009 G37 Convertible

Revision: 2010 March BR-14 2009 G37 Convertible

Wear thickness : Refer to BR-65, "Front Disc Brake". D

Wear thickness : Refer to BR-65, "Front Disc Brake". H

Revision: 2010 March BR-15 2009 G37 Convertible

Runout : Refer to BR-65, "Front Disc Brake".

position by one hole at a time if the runout exceeds the limit

Wear thickness : Refer to BR-65, "Front Disc Brake".

Wear thickness : Refer to BR-65, "Front Disc

Revision: 2010 March BR-16 2009 G37 Convertible

Wear thickness : Refer to BR-65, "Rear Disc Brake". D

Wear thickness : Refer to BR-65, "Rear Disc Brake". H

Revision: 2010 March BR-17 2009 G37 Convertible

Runout : Refer to BR-65, "Rear Disc Brake".

position by one hole at a time if the runout exceeds the limit

Wear thickness : Refer to BR-65, "Rear Disc Brake".

Wear thickness : Refer to BR-65, "Rear Disc

Revision: 2010 March BR-18 2009 G37 Convertible

Removal and Installation INFOID:0000000004927212

Revision: 2010 March BR-19 2009 G37 Convertible