Nissan X-Trail BR Brake System 2014 - 2021 Nissan XTrail Service Manual

BRAKES
SECTION
BRAKE SYSTEM
BR B
E
CONTENTS
LHD Bleeding Brake System ...........................................14 BR
PRECAUTION ............................................... 5 BRAKE MASTER CYLINDER .......................... 15

Inspection ................................................................15
G
PRECAUTIONS ................................................... 5
Precaution for Supplemental Restraint System BRAKE BOOSTER ........................................... 16
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Inspection ................................................................16
SIONER" ................................................................... 5 H
FRONT DISC BRAKE ....................................... 17
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ..................................... 5 BRAKE PAD ..............................................................17
Precaution for Procedure without Cowl Top Cover...... 6 BRAKE PAD : Inspection and Adjustment ...............17 I
Precautions for Removing Battery Terminal ............. 6
Precaution for Brake System .................................... 7 DISC ROTOR .............................................................17
DISC ROTOR : Inspection and Adjustment .............17
J
PREPARATION ............................................ 8
REAR DISC BRAKE ......................................... 19
PREPARATION ................................................... 8
Commercial Service Tool .......................................... 8 BRAKE PAD ..............................................................19
K
Lubricant or/and Sealant ........................................... 8 BRAKE PAD : Inspection and Adjustment ...............19
DISC ROTOR .............................................................19

SYSTEM DESCRIPTION .............................. 9
DISC ROTOR : Inspection and Adjustment .............19 L
SYSTEM .............................................................. 9
REMOVAL AND INSTALLATION ............... 21
WARNING/INDICATOR/CHIME LIST ......................... 9
BRAKE PEDAL ................................................. 21 M
WARNING/INDICATOR/CHIME LIST : Warning
Lamp/Indicator Lamp ................................................ 9 Exploded View .........................................................21
Removal and Installation .........................................21
SYMPTOM DIAGNOSIS .............................. 10 Inspection and Adjustment ......................................22 N
NOISE, VIBRATION AND HARSHNESS BRAKE PIPING ................................................. 24

(NVH) TROUBLESHOOTING ............................10 FRONT .......................................................................24 O
NVH Troubleshooting Chart .................................... 10
FRONT : Exploded View .........................................24
PERIODIC MAINTENANCE ......................... 11 FRONT : Hydraulic Piping .......................................25
FRONT : Removal and Installation ..........................25 P
BRAKE PEDAL ..................................................11 FRONT : Inspection .................................................27
Inspection and Adjustment ...................................... 11
REAR .........................................................................27
BRAKE FLUID ....................................................13 REAR : Exploded View ............................................27
Inspection ................................................................ 13 REAR : Hydraulic Piping ..........................................29
Draining ................................................................... 13 REAR : Removal and Installation ............................29
Refilling ................................................................... 13 REAR : Inspection ...................................................31
BR-1 GETt heMANUALS.org

BRAKE MASTER CYLINDER ........................... 32 REAR DISC BRAKE .......................................... 60
Exploded View ........................................................ 32
Removal and Installation ........................................ 32 BRAKE PAD .............................................................. 60
Disassembly and Assembly .................................... 34 BRAKE PAD : Exploded View ................................. 60
Inspection ............................................................... 35 BRAKE PAD : Removal and Installation ................. 60
BRAKE PAD : Inspection and Adjustment .............. 62
BRAKE BOOSTER ............................................ 36
Exploded View ........................................................ 36 BRAKE CALIPER ASSEMBLY ................................ 62
Removal and installation ........................................ 36 BRAKE CALIPER ASSEMBLY : Exploded View ... 62
Inspection and Adjustment ..................................... 38 BRAKE CALIPER ASSEMBLY : Removal and In-
stallation .................................................................. 63
VACUUM LINES ................................................ 40 BRAKE CALIPER ASSEMBLY : Disassembly and
Assembly ................................................................ 65
MR20DD .................................................................... 40 BRAKE CALIPER ASSEMBLY : Inspection and
MR20DD : Exploded View ...................................... 40 Adjustment .............................................................. 66
MR20DD : Removal and Installation ...................... 40
MR20DD : Inspection ............................................. 40 SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 67
QR25DE .................................................................... 40
QR25DE : Exploded View ...................................... 41 SERVICE DATA AND SPECIFICATIONS
QR25DE : Removal and Installation ....................... 41 (SDS) ................................................................. 67
QR25DE : Inspection .............................................. 41 General Specifications ............................................ 67
R9M ........................................................................... 41 Brake Pedal ............................................................ 67
R9M : Exploded View ............................................. 42 Brake Booster ......................................................... 67
R9M : Removal and Installation .............................. 42 Front Disc Brake ..................................................... 67
R9M : Inspection ..................................................... 42 Rear Disc Brake ...................................................... 67
RHD
FRONT DISC BRAKE ........................................ 43
PRECAUTION ............................................ 69
BRAKE PAD (1 PISTON TYPE) ............................... 43
BRAKE PAD (1 PISTON TYPE) : Exploded View... 43 PRECAUTIONS ................................................. 69
BRAKE PAD (1 PISTON TYPE) : Removal and In- Precaution for Supplemental Restraint System
stallation ................................................................. 43 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
BRAKE PAD (1 PISTON TYPE) : Inspection ......... 46 SIONER" ................................................................. 69
Precaution Necessary for Steering Wheel Rota-
BRAKE PAD (2 PISTON TYPE) ............................... 46 tion After Battery Disconnect .................................. 69
BRAKE PAD (2 PISTON TYPE) : Exploded View... 46 Precaution for Procedure without Cowl Top Cover... 70
BRAKE PAD (2 PISTON TYPE) : Removal and In- Precautions for Removing Battery Terminal ........... 70
stallation ................................................................. 47 Precaution for Brake System .................................. 71
BRAKE PAD (2 PISTON TYPE) : Inspection ......... 49
PREPARATION .......................................... 72
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE)... 50
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) PREPARATION ................................................. 72
: Exploded View ...................................................... 50 Commercial Service Tool ........................................ 72
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) Lubricant or/and Sealant ......................................... 72
: Removal and Installation ...................................... 51
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) SYSTEM DESCRIPTION ........................... 73
: Disassembly and Assembly .................................. 52
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) SYSTEM ............................................................ 73
: Inspection ............................................................. 54
WARNING/INDICATOR/CHIME LIST ....................... 73
BRAKE CALIPER ASSEMBLY (2 PISTON TYPE)... 54 WARNING/INDICATOR/CHIME LIST : Warning
BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) Lamp/Indicator Lamp .............................................. 73
: Exploded View ...................................................... 55
BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) SYMPTOM DIAGNOSIS ............................ 74
: Removal and Installation ...................................... 56 NOISE, VIBRATION AND HARSHNESS
BRAKE CALIPER ASSEMBLY (2 PISTON TYPE)
(NVH) TROUBLESHOOTING ............................ 74
: Disassembly and Assembly .................................. 57
NVH Troubleshooting Chart .................................... 74
: Inspection ............................................................. 59 PERIODIC MAINTENANCE ....................... 75

BRAKE PEDAL ..................................................75 VACUUM LINES ............................................. 102
Inspection and Adjustment ...................................... 75 Exploded View ....................................................... 102 A
Removal and Installation ....................................... 102
BRAKE FLUID ....................................................77 Inspection .............................................................. 102
Inspection ................................................................ 77
B
Draining ................................................................... 77 FRONT DISC BRAKE ..................................... 103
Refilling ................................................................... 77
Bleeding Brake System ........................................... 78 BRAKE PAD (1 PISTON TYPE) .............................. 103
BRAKE PAD (1 PISTON TYPE) : Exploded View.. 103 C
BRAKE MASTER CYLINDER ............................79 BRAKE PAD (1 PISTON TYPE) : Removal and In-
Inspection ................................................................ 79 stallation ................................................................ 103
BRAKE PAD (1 PISTON TYPE) : Inspection ........ 106
BRAKE BOOSTER ............................................80 D
Inspection ................................................................ 80 BRAKE PAD (2 PISTON TYPE) .............................. 106
BRAKE PAD (2 PISTON TYPE) : Exploded View.. 106
FRONT DISC BRAKE ........................................81 BRAKE PAD (2 PISTON TYPE) : Removal and In- E
stallation ................................................................ 107
BRAKE PAD .............................................................. 81
BRAKE PAD (2 PISTON TYPE) : Inspection ........ 109
BRAKE PAD : Inspection and Adjustment .............. 81
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE).. 110 BR
DISC ROTOR ............................................................. 81
DISC ROTOR : Inspection and Adjustment ............ 81
: Exploded View ..................................................... 110
REAR DISC BRAKE ..........................................83 BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) G
: Removal and Installation ..................................... 111
BRAKE PAD .............................................................. 83 BRAKE CALIPER ASSEMBLY (1 PISTON TYPE)
BRAKE PAD : Inspection and Adjustment .............. 83 : Disassembly and Assembly ................................. 112 H
DISC ROTOR ............................................................. 83 : Inspection ............................................................ 114
DISC ROTOR : Inspection and Adjustment ............ 83
BRAKE CALIPER ASSEMBLY (2 PISTON TYPE).. 114 I
REMOVAL AND INSTALLATION ............... 85 BRAKE CALIPER ASSEMBLY (2 PISTON TYPE)
: Exploded View ..................................................... 115
BRAKE PEDAL ..................................................85 BRAKE CALIPER ASSEMBLY (2 PISTON TYPE)
Exploded View ........................................................ 85 J
: Removal and Installation ..................................... 116
Removal and Installation ......................................... 85
Inspection and Adjustment ...................................... 86
: Disassembly and Assembly ................................. 117
BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) K
BRAKE PIPING ..................................................88
: Inspection ............................................................ 119
FRONT ....................................................................... 88
FRONT : Exploded View ......................................... 88 REAR DISC BRAKE ....................................... 120 L
FRONT : Hydraulic Piping ....................................... 89
BRAKE PAD ............................................................ 120
FRONT : Removal and Installation ......................... 89
BRAKE PAD : Exploded View ............................... 120
FRONT : Inspection ................................................ 91 M
BRAKE PAD : Removal and Installation ................ 120
REAR ......................................................................... 91 BRAKE PAD : Inspection and Adjustment ............. 122
REAR : Exploded View ........................................... 91
BRAKE CALIPER ASSEMBLY ............................... 122
REAR : Hydraulic Piping ......................................... 92 N
BRAKE CALIPER ASSEMBLY : Exploded View .. 122
REAR : Removal and Installation ............................ 92
BRAKE CALIPER ASSEMBLY : Removal and In-
REAR : Inspection ................................................... 94
stallation ................................................................ 123
BRAKE CALIPER ASSEMBLY : Disassembly and O
BRAKE MASTER CYLINDER ............................95
Exploded View ........................................................ 95 Assembly ............................................................... 125
Removal and Installation ......................................... 95 BRAKE CALIPER ASSEMBLY : Inspection and
Disassembly and Assembly .................................... 97 Adjustment ............................................................. 126 P
Inspection ................................................................ 98
SERVICE DATA AND SPECIFICATIONS
BRAKE BOOSTER ............................................99 (SDS) .......................................................... 127
Exploded View ........................................................ 99
Removal and installation ......................................... 99 SERVICE DATA AND SPECIFICATIONS
Inspection and Adjustment .................................... 100 (SDS) ............................................................... 127
General Specifications ........................................... 127

Brake Pedal ...........................................................127 Front Disc Brake ................................................... 127
Brake Booster ........................................................127 Rear Disc Brake .................................................... 128

PRECAUTIONS
< PRECAUTION > [LHD]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000011022305
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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: D
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 E
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
BR
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. G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: H
• 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 I
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. J
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000011022306
K
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition power source and accessory
power source to the OFF, then disconnect both battery cables. L
• 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 M
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- N
cedure below before starting the repair operation.
OPERATION PROCEDURE
O
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Open driver door. P
3. Turn the ignition switch to the ON position.
(At this time, the steering lock will be released.)
4. Turn the ignition switch to OFF position with driver door open.
5. Wait for 3 minutes or longer with driver door open.
NOTE:
• Do not close driver door because the steering wheel locks when driver door is closed.

PRECAUTIONS
• The auto acc function is adapted to this vehicle. For this reason, even when the ignition switch is turned
to OFF position, the accessory power source does not turned OFF and continues to be supplied for a
certain amount of time.
6. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
7. Perform the necessary repair operation.
8. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from OFF position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
9. Perform self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover INFOID:0000000011022307
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
Precautions for Removing Battery Terminal INFOID:0000000011062349
• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
SEF289H
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
INSTRUCTION 1
1. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened.
3. Get out of the vehicle and close the driver side door.
4. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
D4D engine : 20 minutes

HRA2DDT : 12 minutes

PRECAUTIONS
K9K engine : 4 minutes
M9R engine : 4 minutes A
R9M engine : 4 minutes
V9X engine : 4 minutes
B
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5. Remove 12V battery terminal. C
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF) D
1. Unlock the door with intelligent key or remote keyless entry.

NOTE:
At this moment, ACC power is supplied. E
2. Open the driver side door.
3. Open the hood.
BR
4. Close the driver side door.
5. Wait at least 3 minutes.
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of G
6. Remove 12V battery terminal.
CAUTION: H
Precaution for Brake System INFOID:0000000010838491
I
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed
with a dust collector. Never splatter the dust with an air blow gun. J
• Brake fluid use refer to MA-6, "General Maintenance".
• Never reuse drained brake fluid.
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it off K
immediately and wash with water if it gets on a painted surface. For brake component parts, never wash
them with water.
• 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 L
item of brake pedal.
• 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 M
improper operation.
• Always loosen the brake tube flare nut with a flare nut wrench.
• Tighten the brake tube flare nut to the specified torque with a flare
N
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
terminal before performing the work. O
• Check that no brake fluid leakage is present after replacing the
parts.
• Burnish the brake contact surfaces after refinishing or replacing
P
rotors, after replacing pads, or if a soft pedal occurs at very low
mileage.
- Front brake pad: Refer to BR-17, "BRAKE PAD : Inspection and
JPFIA0061ZZ
Adjustment".
- Front disc rotor: Refer to BR-17, "DISC ROTOR : Inspection and Adjustment".
- Rear brake pad: Refer to BR-19, "BRAKE PAD : Inspection and Adjustment".
- Rear disc rotor: Refer to BR-19, "DISC ROTOR : Inspection and Adjustment".

PREPARATION
< PREPARATION > [LHD]
PREPARATION
PREPARATION
Commercial Service Tool INFOID:0000000010838492
Tool name Description
• Air tight
Handy vacuum pump
• Inspection of check valve
ZZC1313D
Brake caliper wrench Return the piston
NNFIA0040ZZ
Pick tool Removing piston seal and piston boot
JMJIA0490ZZ
Lubricant or/and Sealant INFOID:0000000010838493
Name Description Note

Multi-purpose grease Clevis pin of brake pedal —
Polyglycol ether based lubricant • Master cylinder assembly —
MOLYKOTE® AS880N or silicone-based • Front brake

Molykote is a registered of Dow Corning
grease Corporation
• Front brake Molykote is a registered of Dow Corning
MOLYKOTE® 7439 or equivalent • Rear brake Corporation
• Front brake
Rubber grease —
• Rear brake

SYSTEM
< SYSTEM DESCRIPTION > [LHD]
SYSTEM DESCRIPTION A
SYSTEM
WARNING/INDICATOR/CHIME LIST
B
WARNING/INDICATOR/CHIME LIST : Warning Lamp/Indicator Lamp INFOID:0000000010838494
C
Name Design Layout/Function
For layout: Refer to MWI-10, "METER SYSTEM : Design".
Brake warning D
lamp For function: Refer to MWI-26, "WARNING LAMPS/INDICATOR LAMPS : Brake Warning
Lamp (Red)".
BR

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [LHD]
SYMPTOM DIAGNOSIS
NVH Troubleshooting Chart INFOID:0000000010838495
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
NVH in FAX, RAX and FSU, RSU section

BR-46,BR-49,BR-62
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
BR-17, BR-19
Reference page
NVH in FAX section

NVH in WT section
NVH in WT section
NVH in ST section
AXLE AND SUSPENSION
Rotor thickness variation
Pads uneven wear
Rotor deformation
Rotor imbalance
Shims damaged
Rotor deflection
Possible cause and
Pads damaged
ROAD WHEEL
DRIVE SHAFT
Rotor damage
SUSPECTED PARTS Rotor runout
STEERING
Rotor rust
TIRE
Noise × × × × × × × ×
×
Symptom BRAKE Shake × × × × ×
×
Shimmy, Judder × × × × × × × × × × ×
×: Applicable

BRAKE PEDAL
< PERIODIC MAINTENANCE > [LHD]
PERIODIC MAINTENANCE A
BRAKE PEDAL
Inspection and Adjustment INFOID:0000000010838496
B
INSPECTION
Brake Pedal Height C
Check the height (H1) between the dash lower panel and the
brake pedal upper surface.
D
H1 : Refer to BR-67, "Brake Pedal".
CAUTION:
Remove the floor carpet. E
BR
JPFIA0065ZZ
Stop Lamp Switch and Brake Pedal Position Switch (with ASCD).
G
Check the clearance (C) among the brake pedal bracket and the
stop lamp switch and brake pedal position switch (with ASCD)
threaded end.
H
C : Refer to BR-67, "Brake Pedal".
CAUTION:
The stop lamp must turn off when the brake pedal is released. I
NOTE:
Pull the brake pedal pad to make the clearance between the stop
lamp switch and brake pedal position switch (with ASCD) threaded J
end and the brake pedal lever. JPFIA0674ZZ
Brake Pedal Play

Press the brake pedal. Check the brake pedal play (A) (stroke until K
fluid pressure occurs).
A : Refer to BR-67, "Brake Pedal". L
JPFIA0277ZZ N
Depressed Brake Pedal Height
Check the height between the dash lower panel and the brake
pedal upper surface (H2) when depressing the brake pedal at 490 N O
(50 kg, 110 lb) while turning engine ON.
H2 : Refer to BR-67, "Brake Pedal". P

CAUTION:
Remove the floor carpet.
JPFIA0068ZZ
ADJUSTMENT
BRAKE PEDAL
Brake Pedal Height
Perform the following procedure when brake pedal height is not within the specified value because brake
pedal height is not adjustable.
1. Check input rod length. Refer to BR-38, "Inspection and Adjustment".
2. Replace brake pedal assembly when input rod length is within specified value.
1. Remove instrument lower panel. Refer to IP-14, "Removal and Installation".
2. Disconnect the harness connector from stop lamp switch and brake pedal position switch (with ASCD).
3. Loosen the stop lamp switch and brake pedal position switch (with ASCD) 45° counterclockwise.
4. Press-fit the stop lamp switch and brake position switch (with
ASCD) until the stop lamp switch and brake pedal position
switch (with ASCD) hits the brake pedal bracket 45° clock-
wise while pulling the brake pedal pad slightly.
CAUTION:
• The clearance (C) between the brake pedal bracket and
stop lamp switch and brake pedal position switch (with
ASCD) threaded end must be the specified value.

• The stop lamp must be turned off when the brake pedal is JPFIA0674ZZ
released.
1. Perform the air bleeding. Refer to BR-14, "Bleeding Brake System".
2. Check the height between the dash lower panel 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:0000000010838497
BRAKE FLUID LEVEL B

• Check that the brake fluid level in the reservoir tank is within the
standard (between 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
JPFIA0007ZZ
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:0000000010838498
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:0000000010838499
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 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. PFIA0403J
3. Perform the air bleeding. Refer to BR-14, "Bleeding Brake Sys-

tem".
Bleeding Brake System INFOID:0000000010838500
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
• Never allow foreign matter (e.r.dust) and oil other than brake fluid to enter the reservoir tank.
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 3 and 4 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-50, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Exploded View".
- 2 piston type: Refer to BR-55, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Exploded View".
• Rear disc brake: Refer to BR-62, "BRAKE CALIPER ASSEMBLY : Exploded View".
6. 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.
7. Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to BR-
13, "Inspection".
8. Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-11,
"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.
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:0000000010838503
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-67, "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:0000000010838504
K
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary. L
• For 2WD, refer to FAX-11, "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.
• For 2WD, refer to FAX-16, "Inspection". N
• For 4WD, refer to FAX-77, "Inspection".
3. Inspect the runout with a dial indicator to measure at 10 mm
(0.39 in) inside the disc edge. O
Runout (with it attached : Refer to BR-67, "Front Disc

to the vehicle) Brake". P
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.
5. Refinish the disc rotor if the runout is outside the limit even after BRA0013D
performing the above operation.
CAUTION:

FRONT DISC BRAKE
• 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.
- For 2WD, refer to FAX-11, "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-67, "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-67, "Rear Disc Brake".

D
BRA0010D
BR
ADJUSTMENT
G
CAUTION:
DISC ROTOR J
K
INSPECTION
Appearance
• For 2WD, refer to RAX-7, "Removal and Installation".
Runout M
• For 2WD, refer to RAX-9, "Inspection". N
• For 4WD, refer to RAX-21, "Inspection".
Runout (with it attached : Refer to BR-67, "Rear Disc

value.
5. Refinish the disc rotor if the runout is outside the limit even after SBR019B
CAUTION:

REAR DISC BRAKE
more.
- For 2WD, refer to RAX-7, "Removal and Installation".

Thickness
wear limit. .
Wear thickness : Refer to BR-67, "Rear Disc

Brake".
SBR020B
ADJUSTMENT
CAUTION:

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

BRAKE PEDAL
Exploded View INFOID:0000000010838507
B
BR
JSFIA2684GB J
Clevis pin Brake pedal assembly Brake pedal pad

Snap pin Clip Stop lamp switch K
Brake pedal position switch (with AS-
CD)
: Apply multi-purpose grease. L
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
M
Removal and Installation INFOID:0000000010838508
REMOVAL N
2. Disconnect the stop lamp switch and the brake pedal position switch (with ASCD) harness connectors.
O
3. Rotate the stop lamp switch and the brake pedal switch (with
ASCD) counterclockwise to remove.
P
JPFIA0815ZZ

BRAKE PEDAL
4. Disconnect the accelerator pedal harness connector.

5. Remove snap pin and clevis pin from clevis of brake
booster .
JPFIA0816ZZ
6. Remove the brake pedal assembly.

CAUTION:
Hold the brake booster and master cylinder assembly so as not to drop out or contact them other
parts.
7. Remove the accelerator pedal from the brake pedal assembly. Refer to ACC-4, "Removal and Installa-
tion".
8. Perform inspection after removal. Refer to BR-22, "Inspection and Adjustment".
INSTALLATION
Note the following, and install in the reverse order of removal.
• Never reuse the clevis pin and snap pin.
• 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.
• Never impact brake pedal such as drop and interference with tools and parts.
• Replace brake pedal when impacting brake pedal.
• Perform adjustment after installation. Refer to BR-22, "Inspection and Adjustment".
INSPECTION AFTER REMOVAL

Check for the following items and replace the brake pedal assembly if necessary.
• Check rivet for deformation, crack, and damage.
• Check the brake pedal for bend, damage, and cracks on the
welded parts.
CAUTION:
Never loose bolt .
JSFIA2250ZZ

BRAKE PEDAL
• Check clevis pin and plastic stopper for damage and deforma-
tion. Replace clevis pin if necessary. A
PFIA0756J
D
ADJUSTMENT AFTER INSTALLATION
• Adjust each item of brake pedal after installing the brake pedal assembly to the vehicle. Refer to BR-11,
• Perform the release position learning of the accelerator pedal. E
- MR20DD: Refer to EC-144, "Work Procedure".
- QR25DE: Refer to EC-553, "Work Procedure".
- R9M: Refer to EC-961, "Work Procedure". BR

BRAKE PIPING
BRAKE PIPING
FRONT
FRONT : Exploded View INFOID:0000000010838510
JSFIA2537GB
Brake tube ABS actuator and electric unit (con- Connector bracket
trol unit)
Connector Brake booster Master cylinder assembly
Brake tube bracket Lock plate Brake hose
Union bolt Copper washer
To rear brake tube
: Indicates that the part is connected at points with same symbol in actual vehicle.
: N·m (kg-m, in-lb)


BRAKE PIPING
FRONT : Hydraulic Piping INFOID:0000000010838511
BR
JSFIA2379ZZ
G
ABS actuator and electric unit (con- Front disc brake Master cylinder assembly
trol unit)
Brake booster Connector Rear disc brake
H
Brake tube Brake hose
: Flare nut
: Union bolt I
FRONT : Removal and Installation INFOID:0000000010838512
J
REMOVAL
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
with, brake fluid may splash. L
1. Remove tires. Refer to WT-61, "Removal and Installation".
2. Drain brake fluid. Refer to BR-13, "Draining".
M
3. Loosen the flare nut with a flare nut wrench (A) and separate
the brake tube from the brake hose .
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- O
necting to prevent entrance of dirt.
P
JPFIA0847ZZ

BRAKE PIPING
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.
JPFIA0819ZZ
INSTALLATION
CAUTION:
with, brake fluid may splash.
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank.
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 with the brake caliper assembly pro-
jection , and tighten the union bolt to the specified torque.
JPFIA0820ZZ
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 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-14, "Bleeding Brake System".
CAUTION:
Never reuse drained brake fluid.
6. Install tires. Refer to WT-61, "Removal and Installation".
7. Perform inspection after installation. Refer to BR-27, "FRONT :
Inspection". JPFIA0061ZZ

BRAKE PIPING
FRONT : Inspection INFOID:0000000010838513
A
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. B
CAUTION:
Clearance with brake hose and each parts being secured more than 10 mm (0.39 in) in unladen
condition*. C
*: Fuel, engine coolant and lubricant are quantity to specified. Spare tire, jack, hand tools and mats
are brought out of vehicle.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately D
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:0000000010838514
MR20DD
G
JSFIA2655GB
O
Brake tube Lock plate Brake hose
Union bolt Copper washer Brake tube bracket
Brake tube bracket Brake tube bracket P
To connector To rear brake hose Floor side
Caliper side


BRAKE PIPING
EXCEPT MR20DD
JSFIA2656GB

Brake tube bracket
To connector To rear brake hose Floor side
Caliper side


BRAKE PIPING
REAR : Hydraulic Piping INFOID:0000000010838515
BR
JSFIA2379ZZ
G
ABS actuator and electric unit (con- Front disc brake Master cylinder assembly
trol unit)
Brake booster Connector Rear disc brake
H
: Flare nut
: Union bolt I
REAR : Removal and Installation INFOID:0000000010838516
J
REMOVAL
CAUTION:
• Wipe off immediately when attaching brake fluid with disc rotor and caliper assembly.
2. Drain brake fluid. Refer to BR-13, "Draining". M
the brake tube from the hose .
CAUTION: N
• Never scratch the flare nut and the brake tube.
hoses and tubes. O
• Cover open end of brake tubes and hoses when discon-
P
JSFIA1064ZZ
4. Disconnect the lock plate , then remove the brake hose.

BRAKE PIPING
CAUTION:
hoses and tubes.
6. Disconnect the lock plate , then remove the brake hose from
the brake hose bracket .
JSFIA2702ZZ

JSFIA0471ZZ
INSTALLATION
CAUTION:
1. Assemble the union bolt and copper washers to the brake
hose.
CAUTION:
2. Align the brake hose L-pin with the brake caliper assembly
hole , and tighten the union bolt to the specified torque.
JSFIA0472ZZ
3. Install the brake hose to the brake tube , temporarily tighten

brake hose to the brake hose bracket with the lock plate .
CAUTION:
and bent.
JSFIA2658ZZ

BRAKE PIPING
torque wrench (A). A
CAUTION:
B
JPFIA0061ZZ
D
5. Install the brake hose to the brake tube and the brake tube
, temporarily tighten the flare nut by hand until it does not
rotate further, and fix the brake hose to brake hose brackets with E
the lock plate .
CAUTION:
Check that all brake hoses and brake tubes are not twisted BR
and bent.
G
JSFIA1065ZZ
6. Tighten the flare nut to the specified torque with a flare nut H
torque wrench (A).
CAUTION:
Never scratch the flare nut and the brake tube. I
CAUTION: J
9. Perform inspection after installation. Refer to BR-31, "REAR : K
REAR : Inspection INFOID:0000000010838517
L
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no looseness
at connections. M
CAUTION:
condition*. N
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately O
CAUTION:
worn or deformed) part if any brake fluid leakage is present. P

JSFIA2562GB
Reservoir cap Oil strainer Reservoir tank

Grommet Cylinder body Screw
O-ring
: Apply polyglycol ether based lubricant.
: Apply brake fluid.

REMOVAL
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 while removing the brake tube. If this is not complied with, brake fluid
may splash.
1. Perform inspection before removal. Refer to BR-35, "Inspection".
3. Remove the battery. Refer to PG-142, "EXCEPT FOR R9M : Removal and Installation".
4. Remove the TCM (as a set with bracket). Refer to TM-415, "Removal and Installation".

5. Remove the air duct assembly, the air duct 1, the air duct 2, the air cleaner cover, the cleaner element, the
air cleaner body, and the mass air flow sensor. A
• For MR20DD, refer to EM-31, "Removal and Installation".
• For QR25DE, refer to EM-175, "Removal and Installation".
• For R9M, refer to EM-308, "Removal and Installation".
B
6. Remove the engine cover.
• For R9M, refer to EM-306, "Removal and Installation".
7. Disconnect the brake fluid level switch harness connector and the harness clip.
C
8. Separate the brake tube from the master cylinder assembly with
a flare nut wrench (A).
CAUTION:
Never scratch the flare nut and the brake tube. D
BR
JSFIA2238ZZ
9. Remove the master cylinder assembly. G

CAUTION:
• Never deform or bend the brake tubes.
• Never depress the brake pedal after the master cylinder assembly is removed.
H
• The piston of the master cylinder assembly is exposed.

Never damage it when removing the master cylinder.
• The piston may drop off when pulled out strongly. Never I
hold the piston. Hold the cylinder body when handling the
master cylinder assembly.
J
JSFIA2382ZZ
L
10. Remove the O-ring.
INSTALLATION
CAUTION: 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. For brake component parts, never
wash them with water.
N
• Never reuse the O-ring.
• Apply polyglycol ether based lubricant to the brake booster [see O
in the figure] when installing the master cylinder assembly to the
brake booster.
P
JPFIA0013ZZ

• The piston 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.
JSFIA2382ZZ
• 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-32, "Exploded View".
• Perform the air bleeding. Refer to BR-14, "Bleeding Brake Sys-
tem".
• Perform inspection after installation. Refer to BR-35, "Inspection".
JSFIA2238ZZ
Disassembly and Assembly INFOID:0000000010838520
DISASSEMBLY
CAUTION:
• Never disassemble the cylinder body.
• Remove the reservoir tank only when necessary.
• Never drop parts to remove. Replace new parts when dropping.
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.
2. Remove the reservoir tank mounting screw.
3. Remove the reservoir tank and grommet from the cylinder body.
ASSEMBLY
CAUTION:
• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and
assembly process.
• Never drop 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 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 screw hole
( ) facing up. A
• Always set copper plates or cloth between vise grips
when fixing the cylinder body to a vise.
• Never overtighten the vise. B
4. Tilt the reservoir tank so that a mounting screw can be fixed.
Assemble with screw.
C
JSFIA2383ZZ
D
INSPECTION BEFORE REMOVAL E

Check the brake fluid level switch. Refer to BRC-159, "Component Inspection".
Check the following items and replace if necessary. BR
• Check the master cylinder for deformation, twist, contact with other parts or looseness of connection.
• Check for fluid leakage from connection. Refer to BR-27, "FRONT : Inspection".
CAUTION:
If the fluid leakage is present, retighten to the specified torque. Replace parts if necessary. G

BRAKE BOOSTER
BRAKE BOOSTER
JSFIA2541GB
Brake booster Check valve Master cylinder assembly

Vacuum sensor Gasket
Removal and installation INFOID:0000000010838523
REMOVAL
CAUTION:
1. Perform inspection before removal. Refer to BR-38, "Inspection and Adjustment".
3. Remove brake master cylinder assembly. Refer to BR-32, "Removal and Installation".
4. Remove vacuum hose from check valve.
• For MR20DD, refer to BR-40, "MR20DD : Removal and Installation".
• For QR25DE, refer to BR-41, "QR25DE : Removal and Installation".
• For R9M, refer to BR-42, "R9M : Removal and Installation".
5. Remove cowl top extension. Refer to EXT-25, "Removal and Installation".
6. Remove brake tube between master cylinder assembly and ABS actuator and electric unit (control unit).
Refer to BR-24, "FRONT : Exploded View".

BRAKE BOOSTER
7. Remove snap pin and clevis pin .
A
JPFIA0019ZZ
D
8. Remove nuts on brake booster and brake pedal assembly.
CAUTION:
Hold the brake booster so as to avoid dropping out. E
9. Remove brake booster.
CAUTION:
Never deform or bend the brake tubes. BR
10. Remove check valve from brake booster.
INSTALLATION G
CAUTION:
off immediately and wash with water if it gets on a painted surface. For brake component parts, never H
• Install check valve and vacuum sensor as shown in figure. I
- Except R9M
A :98°± 5°
B :0°±5°
J
: Vehicle upper side
L
JSFIA2543ZZ
- R9M
M
A : 70°±5°
B : 0°±5°
N
: Vehicle upper side
JSFIA2542ZZ
P
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installation, the
dash panel may damage threads.
• Never deform or bend the brake tubes when installing the brake booster.
• Always use new gasket between the brake booster and the dash panel.
• Replace clevis pin when found damage.
• Never allow foreign matter (e.g.dust) and oil other than brake fluid to enter reservoir tank.
• Perform the air bleeding. Refer to BR-13, "Draining".
BRAKE BOOSTER
CAUTION:
Never reuse brake fluid to drain.
• Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-11,
INSPECTION BEFORE REMOVAL

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-32,
"Removal and Installation".
c. Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster.
Check Valve Inspection
1. Check the check valve to use a handy vacuum pump.
In the case of connecting to brake : Vacuum should decrease within 3.3 kPa (24.8 mmHg,
booster 0.98 inHg, 0.033 bar) for 15 seconds at vacuum of −
66.7 kPa (−500 mmHg, −19.69 inHg, −0.067 bar).
In the case of connecting to vacuum : Vacuum should not exist.
hose
Input Rod Length rod Inspection
1. Check the input length (A).
:Input rod
A : Refer to BR-67, "Brake Booster".

2. Replace the brake booster if the input rod length is not the stan-
dard.
JSFIA2251ZZ

Operation
NOTE:
A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. this is nor-
mal phenomenon due to the brake system operation.
Air Tight

BRAKE BOOSTER
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually A
increases each time.
pedal. Check that the brake pedal stroke does not change after holding down the brake pedal for 30 sec- B
onds or more.
Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to BR-11, "Inspection and C
Adjustment".
BR

VACUUM LINES
VACUUM LINES
MR20DD
MR20DD : Exploded View INFOID:0000000010838525
MR20DD
JSFIA2423ZZ
Vacuum piping Vacuum hose Clamp

To intake manifold Paint mark To brake booster
MR20DD : Removal and Installation INFOID:0000000010838526
REMOVAL
1. Remove the vacuum hose and vacuum piping.
2. Perform inspection after removal. Refer to BR-40, "MR20DD : 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 (built-in check valve) to
upward to assemble.
- Face the paint mark of vacuum piping (intake manifold side) to
upward to assemble.
- Face the other paint marks to vehicle front side to assemble. JPFIA0023ZZ
- For clamp mounting direction (the orientation of pawl), refer to BR-

40, "MR20DD : Exploded View".
MR20DD : Inspection INFOID:0000000010838527

Appearance
Check for correct assembly, damage and deterioration.
QR25DE
VACUUM LINES
QR25DE : Exploded View INFOID:0000000010838528
A
QR25DE
BR
JSFIA2385ZZ G
Vacuum piping Vacuum hose Clamp

To intake manifold Paint mark To brake booster H
QR25DE : Removal and Installation INFOID:0000000010838529
I
REMOVAL
2. Perform inspection after removal. Refer to BR-41, "QR25DE : Inspection". J
INSTALLATION
• When installing vacuum hose, insert it until its tip reaches the K
CAUTION:
Never use lubricating oil during assembly. L

- Face the paint mark of vacuum hose (built-in check valve) to M
upward to assemble.
upward to assemble. N

41, "QR25DE : Exploded View".
O
QR25DE : Inspection INFOID:0000000010838530
INSPECTION AFTER REMOVAL P

Appearance
R9M

VACUUM LINES
R9M : Exploded View INFOID:0000000010838983
R9M
JSFIA2547GB
Vacuum hose Clamp Connector

Vacuum hose bracket
To vacuum pump Paint mark To brake booster
R9M : Removal and Installation INFOID:0000000010838984
REMOVAL
1. Remove engine cover. Refer to EM-306, "Removal and Installation".
3. Perform inspection after removal. Refer to BR-42, "R9M : Inspection".
INSTALLATION
CAUTION:

upward to assemble.
upward to assemble.

42, "R9M : Exploded View".
R9M : Inspection INFOID:0000000010838985

Appearance

FRONT DISC BRAKE
FRONT DISC BRAKE
A
BRAKE PAD (1 PISTON TYPE)
BRAKE PAD (1 PISTON TYPE) : Exploded View INFOID:0000000010838531
B
BR
JSFIA2246GB
H
Cylinder body Inner shim cover Inner shim
Inner pad (with pad wear sensor) Return spring Pad retainer
Torque member Outer pad Outer shim I
Outer shim cover
1: Apply MOLYKOTE® AS 880N or silicone-based grease.

J
2: Apply MOLYKOTE® 7439 or equivalent.

K
Molykote is a registered trademark of Dow Corning Corporation.
BRAKE PAD (1 PISTON TYPE) : Removal and Installation INFOID:0000000010838532
L
REMOVAL
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed M
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. N
• If the brake fluid or grease adheres to the brake caliper assembly and disc rotor, quickly wipe it off.
1. Remove tires with power tool.
2. Remove lower sliding pin bolt. O
JPFIA0832ZZ

FRONT DISC BRAKE
3. Suspend the cylinder body with suitable wire so that the brake
hose will not stretch.
JPFIA0850ZZ
4. Remove the brake pads, shims, shim covers and pad retainer
(as a set with pad return spring) from the torque member .
CAUTION:
• Remove pad retainer together with pad return springs.
• Never deform the pad return springs and pad retainer
when removing the pad retainer from the torque member.
• Never damage the piston boots.
• Never drop the brake pads, shims and shim covers.
• Remember each position of the removed brake pads.
JPFIA0118ZZ
5. Remove the pad return springs from the pad retainer .
: Disc rotor side
CAUTION:
Never deform the pad return springs when removing the
pad return springs from the pad retainer.
6. Perform inspection after removal. Refer to BR-46, "BRAKE PAD
(1 PISTON TYPE) : Inspection".
JSFIA2329ZZ
INSTALLATION
WARNING:
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out.
1. Install the pad return springs to pad retainer if the pad
return springs has been removed.
: Disc rotor side
CAUTION:
Never deform the pad return springs.
JSFIA2329ZZ

FRONT DISC BRAKE
2. Apply MOLYKOTE® 7439 or equivalent to the match face
between the pad retainers and torque member if the pad A
retainers has been removed.
3. Install the pad retainer (upper side with pad return spring) to B
torque member if the pad retainers has been removed.
CAUTION:
• Securely assemble the pad retainers so that it will not be C
lifted up from the torque member.
• Never deform the pad retainers and pad return springs.
JSFIA1938ZZ
D
4. Apply MOLYKOTE® AS880N or silicone-based grease to the
matching faces between the shim and the shim cover ,
and install the shim and the shim covers to the brake pad . E
CAUTION:
Always replace the shims and shim covers when replacing
the brake pad. BR
G
JSFIA1330ZZ
H
between the brake pad and torque member .
I
K
JSFIA1337ZZ
6. Install the brake pads to the torque member.

L
CAUTION:
Both inner and outer pads have a pad return system.
Securely push the pad return spring into the disc rotor
side of brake pad . M
O
JSFIA2330ZZ
7. Install cylinder body to torque member. P

CAUTION:
• Never damage the piston boot.
• When replacing brake pad with new one, check a brake fluid level in the reservoir tank because
brake fluid returns to reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston.

FRONT DISC BRAKE
8. Install the lower sliding pin bolt and tighten it to the specified
torque.
JPFIA0832ZZ
9. Depress the brake pedal several times to check that no drag feel is present for the front disc brake. Refer
to BR-46, "BRAKE PAD (1 PISTON TYPE) : Inspection".
BRAKE PAD (1 PISTON TYPE) : Inspection INFOID:0000000010838533

• Replace the shims and shim covers if rust is excessively attached.
• Eliminate rust on the pad return spring, pad retainers and the torque member. Replace them if rust is exces-
sively attached.
• Check a drag of front disc brake. If any drag is found, follow the procedure described below.
1. Remove brake pads. Refer to BR-43, "BRAKE PAD (1 PISTON TYPE) : Removal and Installation".
2. Press the pistons. Refer to BR-43, "BRAKE PAD (1 PISTON TYPE) : Removal and Installation".
3. Install brake pads. Refer to BR-43, "BRAKE PAD (1 PISTON TYPE) : Removal and Installation".
4. Depress the brake pedal several times.
5. Check a drag of front disc brake again. If any drag is found, disassemble the cylinder body and replace if
necessary. Refer to BR-52, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Disassembly and Assem-
bly".
• 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-17, "BRAKE PAD : Inspection and Adjustment".
JSFIA2246GB

FRONT DISC BRAKE
Cylinder body Inner shim cover Inner shim A

Torque member Outer pad Outer shim
B
Outer shim cover

2: Apply MOLYKOTE® 7439 or equivalent. C
Molykote is a registered trademark of Dow Corning Corporation. D

E
REMOVAL
WARNING:
with a dust collector. Never splatter the dust with an air blow gun. BR
CAUTION:
• If the brake fluid or grease adheres to the brake caliper assembly and disc rotor, quickly wipe it off. G
2. Remove lower sliding pin bolt.
H
JPFIA0832ZZ
K
L
N
JPFIA0850ZZ
4. Remove the brake pads, shims, shim covers and pad retainer O
CAUTION:
• Remove pad retainer together with pad return springs. P
JPFIA0118ZZ

FRONT DISC BRAKE
: Disc rotor side
CAUTION:
6. Perform inspection after removal. Refer to BR-49, "BRAKE PAD
(2 PISTON TYPE) : Inspection".
JSFIA2329ZZ
INSTALLATION
WARNING:
CAUTION:
: Disc rotor side
CAUTION:
JSFIA2329ZZ

between the pad retainers and torque member if the pad
3. Install the pad retainer (upper side with pad return spring) to
CAUTION:
• Securely assemble the pad retainers so that it will not be
JSFIA1938ZZ

and install the shim and the shim covers to the brake pad .
CAUTION:
the brake pad.
JSFIA1330ZZ

FRONT DISC BRAKE
between the brake pad and torque member . A
JSFIA1337ZZ
D
CAUTION:
Both inner and outer pads have a pad return system. E
side of brake pad .
BR
JSFIA2330ZZ H
7. Install cylinder body to torque member.

CAUTION: I
J
NOTE:
torque. K
JPFIA0832ZZ
N
O
P
sively attached.

FRONT DISC BRAKE
necessary. Refer to BR-57, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Disassembly and Assem-
bly".
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Exploded View INFOID:0000000010838534
REMOVAL
JPFIA0834GB
Brake caliper assembly
DISASSEMBLY
JSFIA2351GB

FRONT DISC BRAKE
Cap Bleeder valve Cylinder body A

Piston seal Piston Piston boot
Sliding pin Sliding pin boot Bushing
B
Torque member
: Apply rubber grease.
: Apply brake fluid. C

: Always replace after every disassembly. D
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Removal and Installation

INFOID:0000000010838535
E
REMOVAL
WARNING: BR
CAUTION:
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it G
off immediately and wash with water if it gets on a painted surface. However avoid washing brake
components with water.
• Never depress the brake pedal while removing the brake pads because the piston may pop out. H
2. Fix the disc rotor using wheel nuts. I
4. Remove union bolt and copper washer, and separate brake hose from brake caliper assembly. Refer to
BR-25, "FRONT : Removal and Installation". J
5. Remove torque member mounting bolts, and remove brake cali-
per assembly.
CAUTION: K
Never drop brake pad and brake caliper assembly.
6. Remove disc rotor.
• 2WD: Refer to FAX-11, "Removal and Installation".
L
M
JPFIA0835ZZ
INSTALLATION
N
WARNING:
CAUTION: O
components with water. P
• Never allow foreign matter (e.g.dust) and oils other than brake fluid to enter the reservoir tank.
1. Install disc rotor.

FRONT DISC BRAKE
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 and copper washers to brake caliper assem-
bly. Refer to BR-25, "FRONT : Removal and Installation".
CAUTION:
Never reuse copper washer. JPFIA0835ZZ
CAUTION:
• Never reuse brake fluid.
• Never spill or splash brake fluid on the surface of disc rotor.
5. Check a drag of front disc brake. If any drag is found, refer to BR-54, "BRAKE CALIPER ASSEMBLY (1
PISTON TYPE) : Inspection".
6. Install tires. Refer to WT-61, "Removal and Installation"
7. Perform inspection after installation. Refer to BR-54, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) :
Inspection".
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Disassembly and Assembly
INFOID:0000000010838536
DISASSEMBLY
NOTE:
Never remove the torque member, brake pad and pad retainers when disassembling and assembling the cyl-
inder body.
1. Remove the sliding pin bolt, and remove the cylinder body from the torque member. Refer to BR-43,
"BRAKE PAD (1 PISTON TYPE) : Removal and Installation".
CAUTION:
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 from sliding pin .
JPFIA0851ZZ
4. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Never get fingers caught in the pistons.
MAA0272D

FRONT DISC BRAKE
5. Remove piston seals from cylinder body using seal pick tool.
CAUTION: A
Be careful not to damage a cylinder inner wall.
6. Remove bleeder valve and cap.
7. Perform inspection after disassembly. Refer to BR-54, "BRAKE B
CALIPER ASSEMBLY (1 PISTON TYPE) : Inspection".
JPFIA0038ZZ
D
ASSEMBLY
1. Install bleeder valve and cap.
2. Apply new brake fluid to piston seals , and install them to cyl- E
inder body.
CAUTION:
Never reuse piston seals.
BR
JPFIA0039ZZ H
3. Apply rubber grease to piston boots . Cover the piston end

with piston boot, and then install cylinder side lip on piston boot
I
securely into a groove on cylinder body.
CAUTION:
Never reuse piston boots.
J
JPFIA0040ZZ
L
4. apply new brake fluid to pistons . Push piston into cylinder
body by hand and push piston boot piston-side lip into the pis-
ton groove.
CAUTION: M
Press the pistons evenly and vary the pressing point to pre-
vent cylinder inner wall from being rubbed.
N
O
JPFIA0034ZZ

FRONT DISC BRAKE
5. Apply rubber grease to mating faces between sliding pin
and bushing , and install bushing to sliding pin.
JPFIA0836ZZ
6. Apply rubber grease to mating faces between sliding pins

and sliding pin boots , and install sliding pins and sliding pin
boots to torque member .
7. Install the cylinder body to tighten sliding pin bolts to the speci-
fied torque.
JPFIA0837ZZ
BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Inspection INFOID:0000000010838537
INSPECTION AFTER DISASSEMBLY

Check the following items and replace if necessary.
Cylinder Body
Check the cylinder inner wall for rust, wear, cracks or damage.
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.
Pistons
Check the surface of the piston for rust, wear, cracks or damage.
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper.
Sliding Pin, Sliding Pin Boot and Bushing
Check the sliding pins, sliding pin boots and bushing for rust, wear, cracks or damage.
5. Check a drag of front disc brake again. When any drag is found, disassemble the cylinder body and
replace if necessary. Refer to BR-52, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Disassembly
and Assembly".
• Burnish contact surfaces brake pads and disc rotor after refinishing or replacing disc rotor, or if a soft pedal

FRONT DISC BRAKE
A
REMOVAL
BR
JPFIA0422GB G

H
DISASSEMBLY
I
N
JSFIA1969GB
Cap Bleeder valve Cylinder body

O
Torque member P


FRONT DISC BRAKE
INFOID:0000000010838605
REMOVAL
WARNING:
CAUTION:
2. Fix the disc rotor using wheel nuts.
BR-25, "FRONT : Removal and Installation".
per assembly.
CAUTION:
JPFIA0835ZZ
INSTALLATION
WARNING:
CAUTION:
torque.
CAUTION:
CAUTION:
CAUTION:

FRONT DISC BRAKE
• Never spill or splash brake fluid on the surface of disc rotor. A
6. Install tires. Refer to WT-61, "Removal and Installation" B
Inspection".
C
INFOID:0000000010838606
DISASSEMBLY D
NOTE:
inder body. E
CAUTION: BR
3. Remove bushing from sliding pin . G
JSFIA0496ZZ J
union bolt mounting hole to remove pistons and piston boots. K
CAUTION:
L
BRB0032D
N
CAUTION:
O
7. Perform inspection after disassembly. Refer to BR-59, "BRAKE
P
SFIA0141E
ASSEMBLY

FRONT DISC BRAKE
2. Apply new brake fluid to piston seals , and install them to cyl-
inder body.
CAUTION:
JPFIA0032ZZ

CAUTION:
JPFIA0033ZZ

ton groove.
CAUTION:
JPFIA0034ZZ

JSFIA0497ZZ

FRONT DISC BRAKE
and sliding pin boots , and install sliding pins and sliding pin A
fied torque. B
JSFIA0498ZZ
D
INSPECTION AFTER DISASSEMBLY E

Cylinder Body
Check the cylinder inner wall for rust, wear, cracks or damage. BR
CAUTION:
Torque Member G
Pistons
Check the surface of the piston for rust, wear, cracks or damage. H
CAUTION:
Sliding Pin, Sliding Pin Boot and Bushing I
• Check a drag of front disc brake. If any drag is found, follow the procedure described below. J
K
5. Check a drag of front disc brake again. When any drag is found, disassemble the cylinder body and L
and Assembly".
M

REAR DISC BRAKE
REAR DISC BRAKE
BRAKE PAD
BRAKE PAD : Exploded View INFOID:0000000010838611
JSFIA2411GB

Inner pad (with pad wear sensor) Torque member Outer pad
Outer shim Outer shim cover
1: Apply rubber grease.

2 : Apply MOLYKOTE® AS 880N or silicone-based grease.

BRAKE PAD : Removal and Installation INFOID:0000000010838612
REMOVAL
WARNING:
CAUTION:
1. Release the parking brake.
2. Must be performed additional service when replacing brake pad. Refer to PB-52, "Work Procedure".
3. Remove tires.

REAR DISC BRAKE
A
JPFIA0832ZZ
D
hose and the electric parking brake harness will not stretch.
E
BR
G
JPFIA0850ZZ
6. Remove the brake pads, shims and shim covers. H

CAUTION:
• Never drop the brake pads, shims and shim covers. I
• Never damage the electric parking brake harness and bracket.
7. Perform inspection after removal. Refer to BR-62, "BRAKE PAD : Inspection and Adjustment". J
INSTALLATION
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed K
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out. L
M
mating faces between the shim and the pad , and the
mating faces between the shim and the shim cover , and N
then install the shim and shim cover to the pad.
CAUTION:
Always replace the shims and shim covers when replacing O
the brake pad.
P
JSFIA1805ZZ

3. Apply rubber grease to the cylinder body mounting bolts, and then install the cylinder body to torque mem-
ber.
CAUTION:

REAR DISC BRAKE
torque.
JPFIA0832ZZ
5. Must be performed additional service when removing and installing/replacing brake pad.
When removing and installing brake pad
1. Perform “BRAKE OPERATION”. Refer to PB-61, "Work Procedure".
2. Perform “BRAKE RELEASE”. Refer to PB-63, "Work Procedure".
When replacing brake pad
• Refer to PB-52, "Work Procedure".
to BR-62, "BRAKE PAD : Inspection and Adjustment".

• Eliminate rust on the pad and the torque member. Replace them if rust is excessively attached.
• Check a drag of rear disc brake. If any drag is found, follow the procedure described below.
1. Remove brake pads. Refer to BR-60, "BRAKE PAD : Removal and Installation".
2. Press the pistons. Refer to BR-60, "BRAKE PAD : Removal and Installation".
3. Install brake pads. Refer to BR-60, "BRAKE PAD : Removal and Installation".
5. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body and replace if
necessary. Refer to BR-65, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".
BRAKE CALIPER ASSEMBLY
BRAKE CALIPER ASSEMBLY : Exploded View INFOID:0000000010838618
REMOVAL

REAR DISC BRAKE
JSFIA2412GB BR
: N·m (kg-m, ft-lb) G
DISASSEMBLY
H
M
JSFIA2413GB

N
Sliding pin Bushing Bushing
Torque member
: Apply rubber grease. O
BRAKE CALIPER ASSEMBLY : Removal and Installation INFOID:0000000010838619
P
REMOVAL
WARNING:
CAUTION:

REAR DISC BRAKE
2. Must be performed additional service when replacing brake calipper. Refer to PB-55, "Work Procedure".
3. Remove tires.
BR-29, "REAR : Removal and Installation".
per assembly.
CAUTION:
• Never drop brake pad and brake caliper assembly.
• Never damage the electric parking brake harness and
bracket.
• 2WD: Refer to RAX-7, "Removal and Installation".
JPFIA0835ZZ
INSTALLATION
WARNING:
CAUTION:
torque.
CAUTION:
bly. Refer to BR-29, "REAR : Removal and Installation".
CAUTION:
5. Refill with new brake fluid and perform the air bleeding. Refer to BR-14, "Bleeding Brake System".
REAR DISC BRAKE
CAUTION:
• Never reuse brake fluid. A
6. Check a drag of rear disc brake. If any drag is found, refer to BR-66, "BRAKE CALIPER ASSEMBLY :
Inspection and Adjustment". B
8. Perform inspection after installation. Refer to BR-66, "BRAKE CALIPER ASSEMBLY : Inspection and
Adjustment". C
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000010838620
DISASSEMBLY D
NOTE:
Never remove the torque member and brake pad when disassembling and assembling the cylinder body.
1. Remove the sliding pin bolt, and remove the cylinder body from the torque member. Refer to BR-60, E
"BRAKE PAD : Removal and Installation".
CAUTION:
Fix the brake pad at suitable tape so that the brake pad will not drop. BR
G
JSFIA0496ZZ
J
5. Perform inspection after disassembly. Refer to BR-66, "BRAKE CALIPER ASSEMBLY : Inspection and
Adjustment". K
ASSEMBLY
1. Install bleeder valve and cap. L

and bushing , and install bushing to sliding pin. M
JPFIA0836ZZ

REAR DISC BRAKE
JPFIA0837ZZ
4. Install the cylinder body to tighten cylinder body mounting bolts to the specified torque. Refer to BR-60,
"BRAKE PAD : Exploded View".
BRAKE CALIPER ASSEMBLY : Inspection and Adjustment INFOID:0000000010838621

Cylinder Body
CAUTION:
Torque Member
5. Check a drag of rear disc brake again. When any drag is found, disassemble the cylinder body and
replace if necessary. Refer to BR-65, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".

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

General Specifications INFOID:0000000010838545
B
Unit: mm (in)
C
Caliper type 1 piston type 2 piston type
Cylinder bore diameter 60.33 (2.3752) 44.45 × 2 (1.7500 × 2)
Front brake 123.6 × 47.5 × 10.5 (4.87 × 1.870 × 133.6 × 48.5 × 10.0 (5.26 × 1.909 × D
Pad length × width × thickness
0.413) 0.39)
Rotor outer diameter × thickness 296 × 26.0 (11.65 × 1.024) 320 × 28.0 (12.60 × 1.102)
Cylinder bore diameter 38.2 (1.504) E
Rear brake Pad length × width × thickness 82.9 × 39.8 × 9.0 (3.263 × 1.567 × 0.354)
Rotor outer diameter × thickness 292 × 16.0 (11.50 × 0.630)
BR
Master cylinder Cylinder bore diameter 23.81 (0.9374)
Control valve Valve type Electric brake force distribution
Brake booster Diaphragm diameter 275 (10.83) G
Recommended brake fluid Refer to MA-23, "Fluids and Lubricants".
Brake Pedal INFOID:0000000010838546

H
Unit: mm (in)
Item Standard
I
Brake pedal height 175.9 – 185.9 (6.93 – 7.32)
Depressed brake pedal height
75.0 (2.95) or more
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON]
J
Clearance between stop lamp switch and brake pedal position switch (with ASCD) threaded
0.20 – 1.96 (0.0079 – 0.0772)
end and the brake pedal lever
Brake pedal play 3 – 11 (0.12 – 0.43)
K
Brake Booster INFOID:0000000010838547
Unit: mm (in) L
Item Standard
Input rod length 158.95 – 160.45 (6.26 –6.32)
M
Front Disc Brake INFOID:0000000010838548
Unit: mm (in) N
Item Limit
Brake caliper type 1 piston type 2 piston type
Brake pad Wear thickness 2.0 (0.079) 2.0 (0.079) O
Wear thickness 24.0 (0.945) 26.0 (1.0236)
Disc rotor Thickness variation (measured at 8 positions) 0.020 (0.0008) 0.020 (0.0008)
P
Runout (with it attached to the vehicle) 0.035 (0.0014) 0.035 (0.0014)
Rear Disc Brake INFOID:0000000010838549
Unit: mm (in)

< SERVICE DATA AND SPECIFICATIONS (SDS) [LHD]
Item Limit
Brake pad Wear thickness 2.0 (0.079)
Wear thickness 14.0 (0.551)
Disc rotor Thickness variation (measured at 8 positions) 0.020 (0.0008)
Runout (with it attached to the vehicle) 0.070 (0.0028)

PRECAUTIONS
< PRECAUTION > [RHD]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000011022310
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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: D
• 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 E
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
BR
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. G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: H
• 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 I
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. J
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000011022309
K
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition power source and accessory
power source to the OFF, then disconnect both battery cables. L
• 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 M
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- N
cedure below before starting the repair operation.
OPERATION PROCEDURE
O
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Open driver door. P
3. Turn the ignition switch to the ON position.
(At this time, the steering lock will be released.)
4. Turn the ignition switch to OFF position with driver door open.
5. Wait for 3 minutes or longer with driver door open.
NOTE:
• Do not close driver door because the steering wheel locks when driver door is closed.

PRECAUTIONS
• The auto acc function is adapted to this vehicle. For this reason, even when the ignition switch is turned
to OFF position, the accessory power source does not turned OFF and continues to be supplied for a
certain amount of time.
6. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
7. Perform the necessary repair operation.
8. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from OFF position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
9. Perform self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover INFOID:0000000011022308
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
Precautions for Removing Battery Terminal INFOID:0000000011062270
• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
SEF289H
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
INSTRUCTION 1
1. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened.
3. Get out of the vehicle and close the driver side door.
4. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
D4D engine : 20 minutes

HRA2DDT : 12 minutes

PRECAUTIONS
K9K engine : 4 minutes
M9R engine : 4 minutes A
R9M engine : 4 minutes
V9X engine : 4 minutes
B
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
5. Remove 12V battery terminal. C
CAUTION:
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF) D
1. Unlock the door with intelligent key or remote keyless entry.

NOTE:
At this moment, ACC power is supplied. E
2. Open the driver side door.
3. Open the hood.
BR
4. Close the driver side door.
5. Wait at least 3 minutes.
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of G
6. Remove 12V battery terminal.
CAUTION: H
Precaution for Brake System INFOID:0000000010838554
I
WARNING:
with a dust collector. Never splatter the dust with an air blow gun. J
• Brake fluid use refer to MA-6, "General Maintenance".
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it off K
immediately and wash with water if it gets on a painted surface. For brake component parts, never wash
them with water.
• 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 L
item of brake pedal.
• 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 M
improper operation.
• Always loosen the brake tube flare nut with a flare nut wrench.
• Tighten the brake tube flare nut to the specified torque with a flare
N
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
terminal before performing the work. O
• Check that no brake fluid leakage is present after replacing the
parts.
• Burnish the brake contact surfaces after refinishing or replacing
P
rotors, after replacing pads, or if a soft pedal occurs at very low
mileage.
- Front brake pad: Refer to BR-81, "BRAKE PAD : Inspection and
JPFIA0061ZZ
Adjustment".
- Front disc rotor: Refer to BR-81, "DISC ROTOR : Inspection and Adjustment".
- Rear brake pad: Refer to BR-83, "BRAKE PAD : Inspection and Adjustment".
- Rear disc rotor: Refer to BR-83, "DISC ROTOR : Inspection and Adjustment".

PREPARATION
< PREPARATION > [RHD]
PREPARATION
PREPARATION
Commercial Service Tool INFOID:0000000010838555
Tool name Description
• Air tight
Handy vacuum pump
• Inspection of check valve
ZZC1313D
Brake caliper wrench Return the piston
NNFIA0040ZZ
Pick tool Removing piston seal and piston boot
JMJIA0490ZZ
Lubricant or/and Sealant INFOID:0000000010838556
Name Description Note

Multi-purpose grease Clevis pin of brake pedal —
Polyglycol ether based lubricant • Master cylinder assembly —
MOLYKOTE® AS880N or silicone-based • Front brake

Molykote is a registered of Dow Corning
grease Corporation
• Front brake Molykote is a registered of Dow Corning
MOLYKOTE® 7439 or equivalent • Rear brake Corporation
• Front brake
Rubber grease —
• Rear brake

SYSTEM
< SYSTEM DESCRIPTION > [RHD]
SYSTEM DESCRIPTION A
SYSTEM
WARNING/INDICATOR/CHIME LIST
B
WARNING/INDICATOR/CHIME LIST : Warning Lamp/Indicator Lamp INFOID:0000000010838557
C
Name Design Layout/Function
For layout: Refer to MWI-10, "METER SYSTEM : Design".
Brake warning D
lamp For function: Refer to MWI-26, "WARNING LAMPS/INDICATOR LAMPS : Brake Warning
Lamp (Red)".
BR

Symptom
×: Applicable
Reference page
Possible cause and
BRAKE
SUSPECTED PARTS
Noise
Shake
< SYMPTOM DIAGNOSIS >
Shimmy, Judder
NVH Troubleshooting Chart
×
Pads damaged BR-81, BR-83
SYMPTOM DIAGNOSIS
×
Pads uneven wear BR-81, BR-83
×
Shims damaged BR-103, BR-107, BR-120
×
×
Rotor imbalance BR-81, BR-83
BR-74
×
Rotor damage BR-81, BR-83
×
Rotor runout BR-81, BR-83
×
Rotor deformation BR-81, BR-83
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
×
Rotor deflection BR-81, BR-83
×
× Rotor rust BR-81, BR-83
×
Rotor thickness variation BR-81, BR-83
×
×
×
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:0000000010838558
GETt heMANUALS.org
BRAKE PEDAL
< PERIODIC MAINTENANCE > [RHD]
PERIODIC MAINTENANCE A
BRAKE PEDAL
B
INSPECTION
Brake Pedal Height C
Check the height (H1) between the dash lower panel and the
brake pedal upper surface.
D
CAUTION:
Remove the floor carpet. E
BR
JPFIA0065ZZ
G
Check the clearance (C) among the brake pedal bracket and the
stop lamp switch and brake pedal position switch (with ASCD)
threaded end.
H
CAUTION:
The stop lamp must turn off when the brake pedal is released. I
NOTE:
Pull the brake pedal pad to make the clearance between the stop
lamp switch and brake pedal position switch (with ASCD) threaded J
end and the brake pedal lever. JPFIA0674ZZ
Brake Pedal Play

Press the brake pedal. Check the brake pedal play (A) (stroke until K
fluid pressure occurs).
A : Refer to BR-127, "Brake Pedal". L
JPFIA0277ZZ N
Check the height between the dash lower panel and the brake
pedal upper surface (H2) when depressing the brake pedal at 490 N O
(50 kg, 110 lb) while turning engine ON.
H2 : Refer to BR-127, "Brake Pedal". P

CAUTION:
JPFIA0068ZZ
ADJUSTMENT
BRAKE PEDAL
Brake Pedal Height
Perform the following procedure when brake pedal height is not within the specified value because brake
pedal height is not adjustable.
1. Check input rod length. Refer to BR-99, "Removal and installation".
2. Replace brake pedal assembly when input rod length is within specified value.
2. Disconnect the harness connector from stop lamp switch and brake pedal position switch (with ASCD).
3. Loosen the stop lamp switch and brake pedal position switch (with ASCD) 45° counterclockwise.
4. Press-fit the stop lamp switch and brake position switch (with
ASCD) until the stop lamp switch and brake pedal position
switch (with ASCD) hits the brake pedal bracket 45° clock-
wise while pulling the brake pedal pad slightly.
CAUTION:
• The clearance (C) between the brake pedal bracket and
stop lamp switch and brake pedal position switch (with
ASCD) threaded end must be the specified value.

• The stop lamp must be turned off when the brake pedal is JPFIA0674ZZ
released.
1. Perform the air bleeding. Refer to BR-78, "Bleeding Brake System".
2. Check the height between the dash lower panel 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 brake fluid level in the reservoir tank is within the
standard (between 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
JPFIA0007ZZ
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:0000000010838561
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:0000000010838562
CAUTION:

BRAKE FLUID
1. Check that there is no foreign material in the reservoir tank, and
refill with new brake fluid.
CAUTION:
• 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. PFIA0403J
3. Perform the air bleeding. Refer to BR-78, "Bleeding Brake Sys-

tem".
Bleeding Brake System INFOID:0000000010838563
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
• Never allow foreign matter (e.r.dust) and oil other than brake fluid to enter the reservoir tank.
1. Connect a vinyl tube to the bleeder valve of the rear left 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 3 and 4 until all of the air is out of the brake line.
5. In case of rear brake caliper with electric parking brake system, operate parking brake 5 times to bleed the
air.
6. Tighten the bleeder valve to the specified torque.
• Front disc brake (1 piston type) : Refer to BR-110, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) :
Exploded View".
• Front disc brake (2 piston type) : Refer to BR-115, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) :
Exploded View".
• Rear disc brake: Refer to BR-122, "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-
77, "Inspection".
9. Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to BR-75,

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
AIR TIGHT
increases each time the brake pedal is depressed when performing this operation.
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
Runout M
• For 2WD, refer to FAX-16, "Inspection". N
• For 4WD, refer to FAX-77, "Inspection".
Runout (with it attached : Refer to BR-127, "Front Disc

value.
CAUTION:

FRONT DISC BRAKE
more.

Thickness
wear limit.
Wear thickness : Refer to BR-127, "Front Disc

Brake".
SBR020B
ADJUSTMENT
CAUTION:

REAR DISC BRAKE
REAR DISC BRAKE
A
BRAKE PAD
B
INSPECTION

D
BRA0010D
BR
ADJUSTMENT
G
CAUTION:
DISC ROTOR J
K
INSPECTION
Appearance
Runout M
• For 2WD, refer to RAX-9, "Inspection". N
• For 4WD, refer to RAX-21, "Inspection".
Runout (with it attached : Refer to BR-128, "Rear Disc

value.
CAUTION:

REAR DISC BRAKE
more.

Thickness
wear limit. .
Wear thickness : Refer to BR-128, "Rear Disc

Brake".
SBR020B
ADJUSTMENT
CAUTION:

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

BRAKE PEDAL
B
BR
JSFIA2685GB J
Clevis pin Brake pedal assembly Brake pedal pad

Snap pin Clip Stop lamp switch K
Brake pedal position switch (with AS-
CD)
: Apply multi-purpose grease. L
M
REMOVAL N
2. Disconnect the stop lamp switch and the brake pedal position switch (with ASCD) harness connectors.
O
3. Rotate the stop lamp switch and the brake pedal switch (with
ASCD) counterclockwise to remove.
P
JPFIA0815ZZ

BRAKE PEDAL
4. Disconnect the accelerator pedal harness connector.

5. Remove snap pin and clevis pin from clevis of brake
booster .
JPFIA0816ZZ
6. Remove the brake pedal assembly.

CAUTION:
Hold the brake booster and master cylinder assembly so as not to drop out or contact them other
parts.
7. Remove the accelerator pedal from the brake pedal assembly. Refer to ACC-4, "Removal and Installa-
tion".
INSTALLATION
• Never reuse the clevis pin and snap pin.
• 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.
• Never impact brake pedal such as drop and interference with tools and parts.
• Replace brake pedal when impacting brake pedal.
• Perform adjustment after installation. Refer to BR-86, "Inspection and Adjustment".

Check for the following items and replace the brake pedal assembly if necessary.
• Check rivet for deformation, crack, and damage.
• Check the brake pedal for bend, damage, and cracks on the
welded parts.
CAUTION:
Never loose bolt .
JSFIA2250ZZ

BRAKE PEDAL
• Check clevis pin and plastic stopper for damage and deforma-
tion. Replace clevis pin if necessary. A
PFIA0756J
D
• Adjust each item of brake pedal after installing the brake pedal assembly to the vehicle. Refer to BR-75,
• Perform the release position learning of the accelerator pedal.Refer to EC-961, "Work Procedure". E
BR

BRAKE PIPING
BRAKE PIPING
FRONT
FRONT : Exploded View INFOID:0000000010838573
JSFIA2704GB
Brake booster Master cylinder assembly Brake tube

ABS actuator and electric unit (con- Connector bracket Connector
trol unit)
Brake tube bracket Lock plate Brake hose
Union bolt Copper washer
To rear brake tube
, , : Indicates that the part is connected at points with same symbol in actual vehicle.


BRAKE PIPING
FRONT : Hydraulic Piping INFOID:0000000010838574
BR
JSFIA2427ZZ
G
Brake booster Master cylinder assembly Front disc brake
ABS actuator and electric unit (con- Connector Rear disc brake
trol unit)
H
: Flare nut
: Union bolt I
FRONT : Removal and Installation INFOID:0000000010838575
J
REMOVAL
CAUTION:
M
the brake tube from the brake hose .
CAUTION:
• Never scratch the flare nut and the brake tube. N
hoses and tubes.
• Cover open end of brake tubes and hoses when discon- O
P
JPFIA0847ZZ

BRAKE PIPING
5. Remove the lock plate and remove the brake hose.
JPFIA0819ZZ
INSTALLATION
CAUTION:
1. Assemble the union bolt and the copper washer to the
brake hose.
CAUTION:
2. Align the brake hose pin with the brake caliper assembly pro-
jection , and tighten the union bolt to the specified torque.
JPFIA0820ZZ
3. Install the brake tube to the brake hose , temporarily tighten

brake hose to the bracket with the lock plate .
CAUTION:
and bent.
JPFIA0821ZZ
torque wrench (A).
CAUTION:
BR-77, "Refilling".
CAUTION:
7. Perform inspection after installation. Refer to BR-91, "FRONT :

BRAKE PIPING
FRONT : Inspection INFOID:0000000010838576
A
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. B
CAUTION:
condition*. C
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately D
CAUTION:
E
REAR
BR
REAR : Exploded View INFOID:0000000010838577
N
JSFIA2656GB

O
Brake tube bracket
To connector To rear brake hose Floor side P
Caliper side


BRAKE PIPING
REAR : Hydraulic Piping INFOID:0000000010838578
JSFIA2427ZZ
Brake booster Master cylinder assembly Front disc brake

ABS actuator and electric unit (con- Connector Rear disc brake
trol unit)
: Flare nut
: Union bolt
REAR : Removal and Installation INFOID:0000000010838579
REMOVAL
CAUTION:
CAUTION:
hoses and tubes.
JSFIA1064ZZ
4. Disconnect the lock plate , then remove the brake hose.

BRAKE PIPING
the brake tube from the hose . A
CAUTION:
• Never bend sharply, twist or strongly pull out the brake B
hoses and tubes.
C
6. Disconnect the lock plate , then remove the brake hose from
the brake hose bracket .
JSFIA2702ZZ
D
E
BR
G
JSFIA0471ZZ
INSTALLATION H
CAUTION:
never wash them with water. I
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank. J
1. Assemble the union bolt and copper washers to the brake
hose. K
CAUTION:
2. Align the brake hose L-pin with the brake caliper assembly L
hole , and tighten the union bolt to the specified torque.
JSFIA0472ZZ
N
3. Install the brake hose to the brake tube , temporarily tighten
brake hose to the brake hose bracket with the lock plate . O
CAUTION:
and bent.
P
JSFIA2658ZZ

BRAKE PIPING
torque wrench (A).
CAUTION:
JPFIA0061ZZ
5. Install the brake hose to the brake tube and the brake tube
, temporarily tighten the flare nut by hand until it does not
rotate further, and fix the brake hose to brake hose brackets with
the lock plate .
CAUTION:
and bent.
JSFIA1065ZZ
torque wrench (A).
CAUTION:
CAUTION:
9. Perform inspection after installation. Refer to BR-94, "REAR :
REAR : Inspection INFOID:0000000010838580

1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no looseness
at connections.
CAUTION:
condition*.
2. Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately
CAUTION:

A
BR
I
JSFIA2563GB
Reservoir cap Oil strainer Reservoir tank J

Grommet Cylinder body Screw
O-ring
K
: Apply polyglycol ether based lubricant.

L
M
REMOVAL
N
CAUTION:
never wash them with water. O
• 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 while removing the brake tube. If this is not complied with, brake fluid P
may splash.
1. Perform inspection before removal. Refer to BR-98, "Inspection".
3. Disconnect the brake fluid level switch harness connector.

4. Separate the brake tube from the master cylinder assembly with
a flare nut wrench (A).
CAUTION:
JSFIA2238ZZ
5. Remove the master cylinder assembly.

CAUTION:
• The piston of the master cylinder assembly is exposed.

Never damage it when removing the master cylinder.
• The piston may drop off when pulled out strongly. Never
hold the piston. Hold the cylinder body when handling the
master cylinder assembly.
JSFIA2239ZZ
6. Remove the O-ring.

INSTALLATION
CAUTION:
• Never reuse the O-ring.
• Apply polyglycol ether based lubricant to the brake booster [see
in the figure] when installing the master cylinder assembly to the
brake booster.
JPFIA0013ZZ

• The piston of the master cylinder assembly is exposed. Never
damage it when handling the master cylinder. A
• 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-
B
ton. Hold the cylinder body when handling the master cylinder
assembly.
C
JSFIA2239ZZ
D
• 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-95, "Exploded View". E
• Perform the air bleeding. Refer to BR-78, "Bleeding Brake System"
• Perform inspection after installation. Refer to BR-98, "Inspection".
BR
G
JSFIA2238ZZ
Disassembly and Assembly INFOID:0000000010838583

H
DISASSEMBLY
CAUTION: I
• Never disassemble the cylinder body.
• Remove the reservoir tank only when necessary.
• Never drop parts to remove. Replace new parts when dropping.
J
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. K
2. Remove the reservoir tank mounting screw.
3. Remove the reservoir tank and grommet from the cylinder body.
L
ASSEMBLY
CAUTION:
• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and
assembly process. M
• Never drop 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. N
CAUTION:
Never reuse grommets.
2. Install the reservoir tank to the cylinder body. O
3. Fix the cylinder body to a vise.
CAUTION:
P

• Place the reservoir tank with the chamfered screw hole
( ) facing up.
• Always set copper plates or cloth between vise grips
when fixing the cylinder body to a vise.
• Never overtighten the vise.
4. Tilt the reservoir tank so that a mounting screw can be fixed.
Assemble with screw.
JPFIA0826ZZ

Check the brake fluid level switch. Refer to BRC-159, "Component Inspection".
• Check the master cylinder for deformation, twist, contact with other parts or looseness of connection.
• Check for fluid leakage from connection. Refer to BR-91, "FRONT : Inspection".
CAUTION:
If the fluid leakage is present, retighten to the specified torque. Replace parts if necessary.

BRAKE BOOSTER
BRAKE BOOSTER
A
BR
I
JSFIA2240GB
Master cylinder assembly Check valve Vacuum sensor J

Brake booster Gasket
: N·m (kg-m, ft-lb) K

Removal and installation INFOID:0000000010838586
L
REMOVAL
CAUTION:
off immediately and wash with water if it gets on a painted surface. For brake component parts, never M
1. Perform inspection before removal. Refer to BR-100, "Inspection and Adjustment".
2. Drain brake fluid. Refer to BR-77, "Draining". N
3. Disconnect vacuum sensor harness connector.
4. Remove brake master cylinder assembly. Refer to BR-95, "Removal and Installation".
O
5. Remove vacuum hose from check valve. Refer to BR-102, "Removal and Installation".
6. Remove cowl top extension. Refer to EXT-25, "Removal and Installation".
7. Remove brake tube between master cylinder assembly and ABS actuator and electric unit (control unit). P
Refer to BR-88, "FRONT : Exploded View".

BRAKE BOOSTER
8. Remove snap pin and clevis pin .
JPFIA0019ZZ
9. Remove nuts on brake booster and brake pedal assembly.

CAUTION:
Hold the brake booster so as to avoid dropping out.
10. Remove brake booster.
CAUTION:
Never deform or bend the brake tubes.
11. Remove check valve from brake booster.
12. Remove vacuum sensor from brake booster.
INSTALLATION
CAUTION:
• Install check valve and vacuum sensor as shown in figure.
A :±15°
:Vehicle upper side
JSFIA2245ZZ
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installation, the
dash panel may damage threads.
• Never deform or bend the brake tubes when installing the brake booster.
• Always use new gasket between the brake booster and the dash panel.
• Replace clevis pin when found damage.
• Never allow foreign matter (e.g.dust) and oil other than brake fluid to enter reservoir tank.
• Perform the air bleeding. Refer to BR-78, "Bleeding Brake System".
CAUTION:
Never reuse brake fluid to drain.
• Check each item of brake pedal.

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.

BRAKE BOOSTER
At vacuum of −66.7 kPa (−500 mmHg, : Vacuum should decrease within 3.3 kPa (24.8 mmHg, A
−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.
B
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-95,
"Removal and Installation". C
c. Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster.
INSPECTION AFTER REMOVAL D
Check Valve Inspection
1. Check the check valve to use a handy vacuum pump.
E
In the case of connecting to brake : Vacuum should decrease within 3.3 kPa (24.8 mmHg,
booster 0.98 inHg, 0.033 bar) for 15 seconds at vacuum of −
66.7 kPa (−500 mmHg, −19.69 inHg, −0.067 bar). BR
In the case of connecting to vacuum : Vacuum should not exist.
hose
G
Input Rod Length rod Inspection
1. Check the input length (A).
H
:Input rod
A : Refer to BR-127, "Brake Booster". I

2. Replace the brake booster if the input rod length is not the stan-
dard.
J
JPFIA0238ZZ
INSPECTION AFTER INSTALLATION K
Operation
Depress the brake pedal several times at 5-second intervals with the engine stopped. Start the engine with the L
NOTE:
A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. this is nor-
mal phenomenon due to the brake system operation. M
Air Tight
1. Run the engine at idle for 1 minute to apply vacuum to the brake booster, and stop the engine. N
increases each time.
O
onds or more.
P
Perform the brake pedal adjustment after installing the brake assembly. Refer to BR-75, "Inspection and
Adjustment".

VACUUM LINES
VACUUM LINES
JSFIA2546GB
Vacuum piping Clamp Vacuum hose

Connector Vacuum hose bracket
To vacuum pump Paint mark To brake booster
REMOVAL
1. Remove engine cover. Refer to EM-306, "Removal and Installation".
3. Perform inspection after removal. Refer to BR-102, "Inspection".
INSTALLATION
CAUTION:

upward to assemble.
upward to assemble.

102, "Exploded View".

Appearance

FRONT DISC BRAKE
FRONT DISC BRAKE
A
B
BR
JSFIA2246GB
H
Torque member Outer pad Outer shim I
Outer shim cover

J
2: Apply MOLYKOTE® 7439 or equivalent.

K
L
REMOVAL
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed M
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out. N
2. Remove lower sliding pin bolt. O
JPFIA0832ZZ

FRONT DISC BRAKE
JPFIA0850ZZ
4. Remove the brake pads, shims, shim covers and pad retainer
CAUTION:
• Remove pad retainer together with pad return springs.
JPFIA0118ZZ
: Disc rotor side
CAUTION:
6. Perform inspection after removal. Refer to BR-106, "BRAKE
PAD (1 PISTON TYPE) : Inspection".
JSFIA2329ZZ
INSTALLATION
WARNING:
CAUTION:
: Disc rotor side
CAUTION:
JSFIA2329ZZ

FRONT DISC BRAKE
between the pad retainers and torque member if the pad A
3. Install the pad retainer (upper side with pad return spring) to B
CAUTION:
• Securely assemble the pad retainers so that it will not be C
JSFIA1938ZZ
D
and install the shim and the shim covers to the brake pad . E
CAUTION:
the brake pad. BR
G
JSFIA1330ZZ
H
between the brake pad and torque member .
I
K
JSFIA1337ZZ

L
CAUTION:
Both inner and outer pads have a pad return system.
side of brake pad . M
O
JSFIA2330ZZ
7. Install cylinder body to torque member. P

CAUTION:
NOTE:

FRONT DISC BRAKE
torque.
JPFIA0832ZZ

sively attached.
necessary. Refer to BR-112, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Disassembly and
Assembly".
JSFIA2246GB

FRONT DISC BRAKE
Cylinder body Inner shim cover Inner shim A

Torque member Outer pad Outer shim
B
Outer shim cover

2: Apply MOLYKOTE® 7439 or equivalent. C
Molykote is a registered trademark of Dow Corning Corporation. D

E
REMOVAL
WARNING:
with a dust collector. Never splatter the dust with an air blow gun. BR
CAUTION:
• If the brake fluid or grease adheres to the brake caliper assembly and disc rotor, quickly wipe it off. G
H
JPFIA0832ZZ
K
L
N
JPFIA0850ZZ
4. Remove the brake pads, shims, shim covers and pad retainer O
CAUTION:
• Remove pad retainer together with pad return springs. P
JPFIA0118ZZ

FRONT DISC BRAKE
: Disc rotor side
CAUTION:
6. Perform inspection after removal. Refer to BR-109, "BRAKE
PAD (2 PISTON TYPE) : Inspection".
JSFIA2329ZZ
INSTALLATION
WARNING:
CAUTION:
: Disc rotor side
CAUTION:
JSFIA2329ZZ

between the pad retainers and torque member if the pad
3. Install the pad retainer (upper side with pad return spring) to
CAUTION:
• Securely assemble the pad retainers so that it will not be
JSFIA1938ZZ

and install the shim and the shim covers to the brake pad .
CAUTION:
the brake pad.
JSFIA1330ZZ

FRONT DISC BRAKE
between the brake pad and torque member . A
JSFIA1337ZZ
D
CAUTION:
Both inner and outer pads have a pad return system. E
side of brake pad .
BR
JSFIA2330ZZ H
7. Install cylinder body to torque member.

CAUTION: I
J
NOTE:
torque. K
JPFIA0832ZZ
N
O
P
sively attached.

FRONT DISC BRAKE
necessary. Refer to BR-117, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Disassembly and
Assembly".
REMOVAL
JPFIA0834GB
DISASSEMBLY
JSFIA2351GB

FRONT DISC BRAKE
Cap Bleeder valve Cylinder body A

B
Torque member
: Apply brake fluid. C

: Always replace after every disassembly. D

INFOID:0000000010838601
E
REMOVAL
WARNING: BR
CAUTION:
• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it G
• Never depress the brake pedal while removing the brake pads because the piston may pop out. H
2. Fix the disc rotor using wheel nuts. I
BR-89, "FRONT : Removal and Installation". J
per assembly.
CAUTION: K
L
M
JPFIA0835ZZ
INSTALLATION
N
WARNING:
CAUTION: O
components with water. P

FRONT DISC BRAKE
torque.
CAUTION:
CAUTION:
CAUTION:
7. Perform inspection after installation. Refer to BR-106, "BRAKE PAD (1 PISTON TYPE) : Inspection".
INFOID:0000000010838602
DISASSEMBLY
NOTE:
inder body.
CAUTION:
JPFIA0851ZZ
union bolt mounting hole to remove pistons and piston boots.
CAUTION:
MAA0272D

FRONT DISC BRAKE
CAUTION: A
7. Perform inspection after disassembly. Refer to BR-114, "BRAKE B
JPFIA0038ZZ
D
ASSEMBLY
2. Apply new brake fluid to piston seals , and install them to cyl- E
inder body.
CAUTION:
BR
JPFIA0039ZZ H

I
CAUTION:
J
JPFIA0040ZZ
L
ton groove.
CAUTION: M
N
O
JPFIA0034ZZ

FRONT DISC BRAKE
JPFIA0836ZZ

fied torque.
JPFIA0837ZZ

Cylinder Body
CAUTION:
Torque Member
Pistons
Check the surface of the piston for rust, wear, cracks or damage.
CAUTION:
5. Check a drag of front disc brake again. When any drag is found, disassemble the cylinder body and
and Assembly".

FRONT DISC BRAKE
A
REMOVAL
BR
JPFIA0422GB G

H
DISASSEMBLY
I
N
JSFIA1969GB

O
Torque member P


FRONT DISC BRAKE
INFOID:0000000010838973
REMOVAL
WARNING:
CAUTION:
BR-89, "FRONT : Removal and Installation".
per assembly.
CAUTION:
JPFIA0835ZZ
INSTALLATION
WARNING:
CAUTION:
torque.
CAUTION:
CAUTION:
CAUTION:

FRONT DISC BRAKE
• Never spill or splash brake fluid on the surface of disc rotor. A
6. Install tires. Refer to WT-61, "Removal and Installation" B
Inspection".
C
INFOID:0000000010838974
DISASSEMBLY D
NOTE:
inder body. E
CAUTION: BR
3. Remove bushing from sliding pin . G
JSFIA0496ZZ J
union bolt mounting hole to remove pistons and piston boots. K
CAUTION:
L
BRB0032D
N
CAUTION:
O
7. Perform inspection after disassembly. Refer to BR-119, "BRAKE
P
SFIA0141E
ASSEMBLY

FRONT DISC BRAKE
2. Apply new brake fluid to piston seals , and install them to cyl-
inder body.
CAUTION:
JPFIA0032ZZ

CAUTION:
JPFIA0033ZZ

ton groove.
CAUTION:
JPFIA0034ZZ

JSFIA0497ZZ

FRONT DISC BRAKE
and sliding pin boots , and install sliding pins and sliding pin A
fied torque. B
JSFIA0498ZZ
D
INSPECTION AFTER DISASSEMBLY E

Cylinder Body
Check the cylinder inner wall for rust, wear, cracks or damage. BR
CAUTION:
Torque Member G
Pistons
Check the surface of the piston for rust, wear, cracks or damage. H
CAUTION:
Sliding Pin, Sliding Pin Boot and Bushing I
• Check a drag of front disc brake. If any drag is found, follow the procedure described below. J
K
5. Check a drag of front disc brake again. When any drag is found, disassemble the cylinder body and L
and Assembly".
M

REAR DISC BRAKE
REAR DISC BRAKE
BRAKE PAD
BRAKE PAD : Exploded View INFOID:0000000010838976
JSFIA2411GB

Inner pad (with pad wear sensor) Torque member Outer pad
Outer shim Outer shim cover
1: Apply rubber grease.

2 : Apply MOLYKOTE® AS 880N or silicone-based grease.

BRAKE PAD : Removal and Installation INFOID:0000000010838977
REMOVAL
WARNING:
CAUTION:
2. Must be performed additional service when replacing brake pad. Refer to PB-52, "Work Procedure".
3. Remove tires.

REAR DISC BRAKE
A
JPFIA0832ZZ
D
hose and the electric parking brake harness will not stretch.
E
BR
G
JPFIA0850ZZ
6. Remove the brake pads, shims and shim covers. H

CAUTION:
• Never drop the brake pads, shims and shim covers. I
• Never damage the electric parking brake harness and bracket.
7. Perform inspection after removal. Refer to BR-122, "BRAKE PAD : Inspection and Adjustment". J
INSTALLATION
WARNING:
Since dust covering the front and rear brakes has an affect on human body, the dust must be removed K
CAUTION:
• Never depress the brake pedal while removing the brake pads because the piston may pop out. L
M
mating faces between the shim and the pad , and the
mating faces between the shim and the shim cover , and N
then install the shim and shim cover to the pad.
CAUTION:
Always replace the shims and shim covers when replacing O
the brake pad.
P
JSFIA1805ZZ

3. Apply rubber grease to the cylinder body mounting bolts, and then install the cylinder body to torque mem-
ber.
CAUTION:

REAR DISC BRAKE
torque.
JPFIA0832ZZ
to BR-122, "BRAKE PAD : Inspection and Adjustment".

• Eliminate rust on the pad and the torque member. Replace them if rust is excessively attached.
5. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body and replace if
necessary. Refer to BR-125, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".
BRAKE CALIPER ASSEMBLY
BRAKE CALIPER ASSEMBLY : Exploded View INFOID:0000000010838979
REMOVAL

REAR DISC BRAKE
JSFIA2412GB BR
: N·m (kg-m, ft-lb) G
DISASSEMBLY
H
M
JSFIA2413GB

N
Sliding pin Bushing Bushing
Torque member
: Apply rubber grease. O
BRAKE CALIPER ASSEMBLY : Removal and Installation INFOID:0000000010838980
P
REMOVAL
WARNING:
CAUTION:

REAR DISC BRAKE
2. Must be performed additional service when replacing brake calipper. Refer to PB-55, "Work Procedure".
3. Remove tires.
BR-92, "REAR : Removal and Installation".
per assembly.
CAUTION:
• Never drop brake pad and brake caliper assembly.
• Never damage the electric parking brake harness and
bracket.
JPFIA0835ZZ
INSTALLATION
WARNING:
CAUTION:
torque.
CAUTION:
bly. Refer to BR-92, "REAR : Removal and Installation".
CAUTION:
5. Refill with new brake fluid and perform the air bleeding. Refer to BR-78, "Bleeding Brake System".
REAR DISC BRAKE
CAUTION:
• Never reuse brake fluid. A
6. Check a drag of rear disc brake. If any drag is found, refer to BR-126, "BRAKE CALIPER ASSEMBLY :
Inspection and Adjustment". B
8. Perform inspection after installation. Refer to BR-126, "BRAKE CALIPER ASSEMBLY : Inspection and
Adjustment". C
BRAKE CALIPER ASSEMBLY : Disassembly and Assembly INFOID:0000000010838981
DISASSEMBLY D
NOTE:
Never remove the torque member and brake pad when disassembling and assembling the cylinder body.
1. Remove the sliding pin bolt, and remove the cylinder body from the torque member. Refer to BR-120, E
"BRAKE PAD : Removal and Installation".
CAUTION:
Fix the brake pad at suitable tape so that the brake pad will not drop. BR
G
JSFIA0496ZZ
J
5. Perform inspection after disassembly. Refer to BR-126, "BRAKE CALIPER ASSEMBLY : Inspection and
Adjustment". K
ASSEMBLY
1. Install bleeder valve and cap. L

and bushing , and install bushing to sliding pin. M
JPFIA0836ZZ

REAR DISC BRAKE
JPFIA0837ZZ
4. Install the cylinder body to tighten cylinder body mounting bolts to the specified torque. Refer to BR-120,
"BRAKE PAD : Exploded View".
BRAKE CALIPER ASSEMBLY : Inspection and Adjustment INFOID:0000000010838982

Cylinder Body
CAUTION:
Torque Member
5. Check a drag of rear disc brake again. When any drag is found, disassemble the cylinder body and
replace if necessary. Refer to BR-125, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".

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

General Specifications INFOID:0000000010930899
B
Unit: mm (in)
C
Caliper type 1 piston type 2 piston type
Cylinder bore diameter 60.33 (2.3752) 44.45 × 2 (1.7500 × 2)
Front brake 123.6 × 47.5 × 10.5 (4.87 × 1.870 × 133.6 × 48.5 × 10.0 (5.26 × 1.909 × D
Pad length × width × thickness
0.413) 0.39)
Rotor outer diameter × thickness 296 × 26.0 (11.65 × 1.024) 320 × 28.0 (12.60 × 1.102)
Cylinder bore diameter 38.2 (1.504) E
Rear brake Pad length × width × thickness 82.9 × 39.8 × 9.0 (3.263 × 1.567 × 0.354)
Rotor outer diameter × thickness 292 × 16.0 (11.50 × 0.630)
BR
Master cylinder Cylinder bore diameter 23.81 (0.9374)
Control valve Valve type Electric brake force distribution
Brake booster Diaphragm diameter 250 (0.9374) G
Recommended brake fluid Refer to MA-23, "Fluids and Lubricants".
Brake Pedal INFOID:0000000010838623

H
Unit: mm (in)
Item Standard
I
Brake pedal height 175.0 – 185.0 (6.89 – 7.28)
Depressed brake pedal height
85.0 (3.35) or more
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON]
J
Clearance between stop lamp switch and brake pedal position switch (with ASCD) threaded
0.20 – 1.96 (0.0079 – 0.0772)
end and the brake pedal lever
Brake pedal play 3 – 11 (0.12 – 0.43)
K
Brake Booster INFOID:0000000010838624
Unit: mm (in) L
Item Standard
Input rod length 124.25 – 125.75 (4.89 – 4.95)
M
Front Disc Brake INFOID:0000000010930900
Unit: mm (in) N
Item Limit
Brake caliper type 1 piston type 2 piston type
Brake pad Wear thickness 2.0 (0.079) 2.0 (0.079) O
Wear thickness 24.0 (0.945) 26.0 (1.0236)
Disc rotor Thickness variation (measured at 8 positions) 0.020 (0.0008) 0.020 (0.0008)
P
Runout (with it attached to the vehicle) 0.035 (0.0014) 0.035 (0.0014)

< SERVICE DATA AND SPECIFICATIONS (SDS) [RHD]
Rear Disc Brake INFOID:0000000010930901
Unit: mm (in)
Item Limit
Brake pad Wear thickness 2.0 (0.079)
Wear thickness 14.0 (0.551)
Disc rotor Thickness variation (measured at 8 positions) 0.020 (0.0008)
Runout (with it attached to the vehicle) 0.070 (0.0028)

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BRAKES

PRECAUTION ............................................... 5 BRAKE MASTER CYLINDER .......................... 15

DISC ROTOR .............................................................19

NOISE, VIBRATION AND HARSHNESS BRAKE PIPING ................................................. 24

BR-1 GETt heMANUALS.org

BR-2 GETt heMANUALS.org

BR-3 GETt heMANUALS.org

BR-4 GETt heMANUALS.org

BR-5 GETt heMANUALS.org

Precautions for Removing Battery Terminal INFOID:0000000011062349

D4D engine : 20 minutes

BR-6 GETt heMANUALS.org

1. Unlock the door with intelligent key or remote keyless entry.

BR-7 GETt heMANUALS.org

Tool name Description

Brake caliper wrench Return the piston

Pick tool Removing piston seal and piston boot

Lubricant or/and Sealant INFOID:0000000010838493

Name Description Note

MOLYKOTE® AS880N or silicone-based • Front brake

BR-8 GETt heMANUALS.org

BR-9 GETt heMANUALS.org

NVH in FAX, RAX and FSU, RSU section

NVH in FAX section

SUSPECTED PARTS Rotor runout

BR-10 GETt heMANUALS.org

Brake Pedal Play

A : Refer to BR-67, "Brake Pedal". L

H2 : Refer to BR-67, "Brake Pedal". P

C : Refer to BR-67, "Brake Pedal".

H2 : Refer to BR-67, "Brake Pedal".

BR-12 GETt heMANUALS.org

BRAKE FLUID LEVEL B

BR-13 GETt heMANUALS.org

3. Perform the air bleeding. Refer to BR-14, "Bleeding Brake Sys-

BR-14 GETt heMANUALS.org

BR-15 GETt heMANUALS.org

BR-16 GETt heMANUALS.org

Wear thickness : Refer to BR-67, "Front Disc Brake".

Runout (with it attached : Refer to BR-67, "Front Disc

BR-17 GETt heMANUALS.org

Wear thickness : Refer to BR-67, "Front Disc Brake".

Wear thickness : Refer to BR-67, "Front Disc

BR-18 GETt heMANUALS.org

Wear thickness : Refer to BR-67, "Rear Disc Brake".

Runout (with it attached : Refer to BR-67, "Rear Disc

BR-19 GETt heMANUALS.org

Wear thickness : Refer to BR-67, "Rear Disc Brake".

Wear thickness : Refer to BR-67, "Rear Disc

BR-20 GETt heMANUALS.org

REMOVAL AND INSTALLATION A

Clevis pin Brake pedal assembly Brake pedal pad

BR-21 GETt heMANUALS.org

4. Disconnect the accelerator pedal harness connector.

6. Remove the brake pedal assembly.

INSPECTION AFTER REMOVAL

BR-22 GETt heMANUALS.org

BR-23 GETt heMANUALS.org

: N·m (kg-m, ft-lb)