Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Altima 2000-2005 Approved Nissan Altima 2000 br

<< Back | Home

Most service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.

Image preview - the first page of the document

>> Download br documenatation <<

Text preview - extract from the document

BRAKE SYSTEM

BR
GI

SECTION MA

LC
CONTENTS
EC
PRECAUTIONS AND PREPARATION....................... 3 Disassembly.......................................................... 21
Supplemental Restraint System (SRS) ``AIR Inspection -- Caliper ............................................ 21
BAG'' and ``SEAT BELT PRE-TENSIONER''.......... 3 Inspection -- Rotor ............................................... 22 FE
Precautions for Brake System ................................ 3 Assembly............................................................... 22
Commercial Service Tools ...................................... 4 Installation ............................................................. 22
NOISE, VIBRATION AND HARSHNESS (NVH) REAR DRUM BRAKE .............................................. 23
CL
TROUBLESHOOTING ................................................ 5 Removal ................................................................ 23
NVH Troubleshooting Chart.................................... 5 Inspection -- Wheel Cylinder ............................... 25 MT
ON-VEHICLE SERVICE ............................................. 6 Wheel Cylinder Overhaul...................................... 25
Checking Brake Fluid Level.................................... 6 Inspection -- Drum ............................................... 25
Checking Brake Line............................................... 6 Inspection -- Lining .............................................. 25 AT
Changing Brake Fluid ............................................. 6 Installation ............................................................. 26
Brake Burnishing Procedure................................... 6 REAR DISC BRAKE................................................. 28
Bleeding Brake System .......................................... 7 Pad Replacement ................................................. 28 FA
BRAKE HYDRAULIC LINE ........................................ 8 Removal ................................................................ 31
CONTROL VALVE ...................................................... 9 Disassembly.......................................................... 31 RA
Proportioning Valve................................................. 9 Inspection -- Caliper ............................................ 32
BRAKE PEDAL AND BRACKET............................. 11 Inspection -- Rotor ............................................... 33
Removal and Installation ...................................... 11 Assembly............................................................... 33 BR
Inspection.............................................................. 11 Installation ............................................................. 36
Adjustment ............................................................ 11 PARKING BRAKE CONTROL ................................. 37
MASTER CYLINDER................................................ 13 Removal and Installation ...................................... 37 ST
Removal ................................................................ 13 Inspection.............................................................. 37
Disassembly.......................................................... 13 Adjustment ............................................................ 38
RS
Inspection.............................................................. 14 ANTI-LOCK BRAKE SYSTEM................................. 39
Assembly............................................................... 14 Purpose................................................................. 39
Installation ............................................................. 15 Operation .............................................................. 39 BT
BRAKE BOOSTER................................................... 16 ABS Hydraulic Circuit ........................................... 39
On-vehicle Service................................................ 16 System Components............................................. 40
Removal ................................................................ 16 System Description ............................................... 40 HA
Inspection.............................................................. 17 Removal and Installation ...................................... 41
Installation ............................................................. 17 Front Wheel Sensor ......................................... 41
EL
VACUUM HOSE........................................................ 18 Rear Wheel Sensor .......................................... 41
Removal and Installation ...................................... 18 Control Unit....................................................... 42
Inspection.............................................................. 18 Actuator ............................................................ 42 IDX
FRONT DISC BRAKE .............................................. 19 Actuator Relay Assembly ................................. 42
Pad Replacement ................................................. 19
Removal ................................................................ 20
CONTENTS (Cont'd.)
TROUBLE DIAGNOSES .......................................... 43 TROUBLE DIAGNOSES FOR
How to Perform Trouble Diagnoses for Quick SELF-DIAGNOSTIC ITEMS ..................................... 63
and Accurate Repair ............................................. 43 Diagnostic Procedure 1 (ABS actuator
Preliminary Check................................................. 44 solenoid valve) ...................................................... 63
Component Parts and Harness Connector Diagnostic Procedure 2 (Wheel sensor or
Location................................................................. 45 rotor)...................................................................... 65
Schematic ............................................................. 46 Component Inspection...................................... 66
Wiring Diagram -ABS-......................................... 47 Diagnostic Procedure 3 (Motor relay or motor).... 67
ABS Control Unit Terminal Reference Chart ........ 52 Diagnostic Procedure 4 (Solenoid valve relay) .... 70
Self-diagnosis........................................................ 53 Diagnostic Procedure 5 (Low voltage) ................. 73
Function ............................................................ 53 Diagnostic Procedure 6 (Control unit) .................. 74
Self-Diagnosis Procedure ................................. 53 TROUBLE DIAGNOSIS FOR SYMPTOMS ............. 75
How To Read Self-Diagnostic Results Diagnostic Procedure 7(ABS works
(Malfunction codes) .......................................... 54 frequently.) ............................................................ 75
How To Erase Self-Diagnostic Results Diagnostic Procedure 8(Unexpected pedal
(Malfunction codes) .......................................... 54 action) ................................................................... 76
Malfunction Code/Symptom Chart ................... 55 Diagnostic Procedure 9(Long stopping
CONSULT-II .......................................................... 56 distance)................................................................ 76
CONSULT-II application to ABS........................ 56 Diagnostic Procedure 10(ABS does not work)..... 77
CONSULT-II Inspection Procedure....................... 57 Diagnostic Procedure 11(Pedal vibration and
Self-Diagnosis Procedure ................................. 57 noise) .................................................................... 77
Self-Diagnostic Results Mode .......................... 58 Diagnostic Procedure 12 (Warning lamp does
Data Monitor Procedure ................................... 59 not come on when ignition switch is turned
Active Test Procedure....................................... 60 ON.)....................................................................... 78
Data Monitor Mode ........................................... 61 Diagnostic Procedure 13 (Warning lamp stays
Active Test Mode .............................................. 61 on when ignition switch is turned ON.)................. 80
Ground Circuit Check ........................................... 62 SERVICE DATA AND SPECIFICATIONS (SDS) ..... 83
Actuator Motor Ground ..................................... 62 General Specifications .......................................... 83
Control Unit Ground ......................................... 62 Inspection and Adjustment.................................... 83
ABS Relay Unit Ground ................................... 62

When you read wiring diagrams:
q Read GI section, ``HOW TO READ WIRING DIAGRAMS''.
q See EL section, ``POWER SUPPLY ROUTING'' for power distribution circuit.
When you perform trouble diagnoses, read GI section, ``HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES'' and ``HOW TO PERFORM EFFICIENT DIAGNO-
SIS FOR AN ELECTRICAL INCIDENT''.

BR-2
PRECAUTIONS AND PREPARATION

Supplemental Restraint System (SRS) ``AIR
BAG'' and ``SEAT BELT PRE-TENSIONER''
The Supplemental Restraint System such as ``AIR BAG'' and ``SEAT BELT PRE-TENSIONER'' used along GI
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS composition which is available to NISSAN MODEL L30 is as follows (The
composition varies according to the destination and optional equipment.): MA
q For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side), EM
seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
q For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side LC
of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this service EC
manual.
WARNING: FE
q To avoid rendering the SRS inoperative, which could increase the risk of personal injury or
death in the event of a collision which would result in air bag inflation, all maintenance should
be performed by an authorized NISSAN dealer. For removal of Spiral cable and Air Bag Module, CL
see the RS section.
q Improper maintenance, including incorrect removal and installation of the SRS, can lead to
personal injury caused by unintentional activation of the system. MT
q Do not use electrical test equipment on any circuit related to the SRS unless instructed to in
this Service Manual. Spiral cable and wiring harnesses (except ``SEAT BELT PRE-TEN-
SIONER'') covered with yellow insulation either just before the harness connectors or for the AT
complete harness are related to the SRS.

BR
Precautions for Brake System
q Use brake fluid DOT 3.
q Never reuse drained brake fluid. ST
q Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately. RS
q To clean master cylinder parts, disc brake caliper parts
or wheel cylinder parts, use clean brake fluid.
q Never use mineral oils such as gasoline or kerosene. BT
They will ruin rubber parts of hydraulic system.
SBR686C
q Use flare nut wrench when removing or installing brake
tubes. HA
q Always torque brake lines when installing.
q Burnish the brake contact surfaces after refinishing or
EL
replacing drums or rotors, after replacing pads or
linings, or if a soft pedal occurs at very low mileage.
Refer to ``Brake Burnishing Procedure,'' ``ON-VEHICLE IDX
SERVICE,'' BR-6.
WARNING:
q Clean brakes with a vacuum dust collector to minimize
the hazard of airborne materials.

BR-3
PRECAUTIONS AND PREPARATION

Commercial Service Tools
Tool name Description
1 Flare nut crowfoot Removing and installing brake lines
2 Torque wrench

NT360 a: 10 mm (0.39 in)
Brake fluid pressure Measuring brake fluid pressure
gauge

NT151

BR-4
Symptom

X: Applicable
Reference page

(Possible cause)

Noise
Shake
SUSPECTED PARTS

Shimmy, Judder
X
Linings or pads - Damaged BR-33, 25, 28

X
Linings or pads - Uneven wear BR-19, 25, 28

X
Return springs damaged BR-23

BR-5
X Shims damaged BR-19, 28

X
X
Rotor or drum imbalance --
X
Rotor or drum runout BR-22, 25, 33
X

Rotor or drum deformation BR-22, 25, 33
X

Rotor or drum rust BR-22, 25, 33
X

Rotor thickness variation BR-22, 33
NVH Troubleshooting Chart

Drum out of round BR-25
X
X

DRIVESHAFT NVH in FA Section
X
X
X

AXLE AND SUSPENSION NVH in FA, RA Section
X
X
X

TIRES NVH in FA Section
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

X
X
X

ROAD WHEEL NVH in FA Section
X
X
X

STEERING NVH in ST Section
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
GI

EL
FE

ST
FA

BT
CL
LC

RS
EC

HA
MT

BR
EM
MA

IDX
ON-VEHICLE SERVICE

Checking Brake Fluid Level
q Check fluid level in reservoir tank. It should be between
Max. and Min. lines on reservoir tank.
q If fluid level is extremely low, check brake system for leaks.
q If the brake warning lamp comes on, check brake fluid level
switch and parking brake switch.

ABR536

Checking Brake Line
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deteriora-
tion or other damage. Replace any damaged parts.
2. Check for fluid leakage by fully depressing brake pedal
while engine is running.

ABR159

Changing Brake Fluid
CAUTION:
q Refill with new brake fluid DOT 3.
q Always keep fluid level higher than minimum line on
reservoir tank.
q Never reuse drained brake fluid.
q Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
ABR160
1. Clean inside of reservoir tank, and refill with new brake fluid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
4. Refill until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to ``Bleeding Brake System'', BR-7.
Brake Burnishing Procedure
q Burnish the brake contact surfaces according to the follow-
ing procedure after refinishing or replacing drums or rotors,
after replacing pads or linings, or if a soft pedal occurs at
very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic
conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/
foot pressure such that vehicle stopping time equals 3 to 5
seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.

BR-6
ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont'd)
4. Repeat steps 1 to 3, 10 times or more to complete the bur-
nishing procedure.
GI

LC
Bleeding Brake System
CAUTION:
q Carefully monitor brake fluid level at master cylinder EC
during bleeding operation.
q If master cylinder is suspected to have air inside, bleed
air from master cylinder first. Refer to ``Installation'', FE
``MASTER CYLINDER'', BR-15.
q Fill reservoir with new brake fluid DOT 3. Make sure it
is full at all times while bleeding air out of system. CL
q Place a container under master cylinder to avoid spill-
ABR554
age of brake fluid.
q For models with ABS, turn ignition switch OFF and dis- MT
connect ABS actuator connector or battery cable.
AT

BR
q Bleed air in the following order:
Right rear brake Left front brake Left rear brake Right
front brake ST
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to RS
release air.
4. Close air bleeder valve.
5. Release brake pedal slowly. BT
6. Repeat steps 2 through 5 until clear brake fluid comes out
ABR160 of air bleeder valve.
7. Tighten air bleeder valve. HA
: 7 - 9 N m (0.7 - 0.9 kg-m, 61 - 78 in-lb)

IDX

BR-7
BRAKE HYDRAULIC LINE

ABR557

REMOVAL
CAUTION:
q Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
q All hoses must be free from excessive bending, twist-
ing and pulling.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
ABR160
3. Remove flare nut securing brake tube to hose, then with-
draw lock spring.
4. Cover openings to prevent entrance of dirt when discon-
necting hydraulic line.

INSPECTION
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.

INSTALLATION
CAUTION:
q Refill with new brake fluid DOT 3.
q Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Flare nut:
: 15 - 18 N m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Connecting bolt:
: 17 - 20 N m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
2. Refill until new brake fluid comes out of each air bleeder
valve.
3. Bleed air. Refer to ``Bleeding Brake System'', BR-7.
SBR686C

BR-8
CONTROL VALVE

Proportioning Valve
INSPECTION
CAUTION: GI
q Carefully monitor brake fluid level at master cylinder.
q Use new brake fluid DOT 3.
q Be careful not to splash brake fluid on painted areas; it MA
may cause paint damage. If brake fluid is splashed on
paint areas, wash it away with water immediately.
q Depress pedal slowly when raising front brake pressure. EM
SBR822BA
q Check rear brake pressure two seconds after front
brake pressure reaches specified value.
LC
q For models with ABS, disconnect harness connectors
from ABS actuator relay box before checking.
1. Connect Tool to air bleeders of front and rear brakes on EC
either LH or RH side.
2. Bleed air from the Tool.
3. Check rear brake pressure by depressing brake pedal FE
(increasing front brake pressure).
Unit: kPa (kg/cm2, psi)
CL
Applied model Except SE model SE model
ABR184 Applied pressure (Front
6,375 (65, 924) 7,355 (75, 1,067)
brake) D1 MT
Output pressure (Rear 3,432 - 3,825 4,413 - 4,806
brake) D2 (35 - 39, 498 - 555) (45 - 49, 640 - 697)
AT
If output pressure is out of specification, replace dual pro-
portioning valve (separated type) or master cylinder assem- FA
bly (built-in type).
4. Bleed air after disconnecting the Tool. Refer to ``Bleeding
Brake System'', BR-7. RA
SBR705AA
BR

IDX

BR-9
CONTROL VALVE
Proportioning Valve (Cont'd)
REMOVAL (Separated type)
CAUTION:
q Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
q All hoses must be free from excessive bending, twist-
ing and pulling.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
SBR850B
3. Loosen flare nut.
4. Remove proportioning valve mounting bolt, then remove
flare nut.
INSTALLATION (Separated type)
CAUTION:
q Refill with new brake fluid DOT 3.
q Never reuse drained brake fluid.
1. Temporarily fit flare nut to proportioning valve.
2. Tighten proportioning valve mounting bolt, then tighten flare
nut.
Flare nut:
: 15 - 18 N m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
3. Refill until new brake fluid comes out of each air bleeder
valve.
4. Bleed air. Refer to ``Bleeding Brake System'', BR-7.
REMOVAL AND INSTALLATION (Built-in type)
q Always replace proportioning valve and master cylin-
der as an assembly.
q Refer to ``MASTER CYLINDER'', BR-13.

BR-10
BRAKE PEDAL AND BRACKET

Removal and Installation

CL
ABR538

MT
Inspection
Check brake pedal for following items:
q Brake pedal bend. AT
q Clevis pin deformation.
q Crack in any welded portion.
q Crack or deformation of clevis pin stopper. FA

RA
SBR997
BR
Adjustment
Check brake pedal free height from dash reinforcement panel.
H: Free height ST
Refer to SDS, BR-83.
D: Depressed height
Refer to SDS, BR-83. RS
Under force of 490 N (50 kg, 110 lb)
with engine running
C1, C2: Clearance between pedal stopper and BT
threaded end of stop lamp switch and ASCD
brake switch (or A/T shift lock switch)
0.3 - 1.0 mm (0.012 - 0.039 in) HA
A: Pedal free play
1.0 - 3.0 mm (0.039 - 0.118 in)
EL

IDX

WBR007

BR-11
BRAKE PEDAL AND BRACKET
Adjustment (Cont'd)
If necessary, adjust brake pedal free height.
1. Loosen lock nut and adjust pedal free height by turning
brake booster input rod. Tighten lock nut.
q Make sure that tip of input rod stays inside of clevis.

SBR930

2. Loosen lock nut and adjust clearance ``C1'' and ``C2'' with
stop lamp switch and ASCD brake switch (or A/T shift lock
switch) respectively. Then tighten lock nuts.
3. Check pedal free play.
q Make sure that stop lamps go off when pedal is
released.
4. Check brake pedal depressed height while engine is run-
ning. If lower than specification, check for leaks, air in
system, or damage to components (master cylinder, wheel
cylinder, etc.). Then make necessary repairs.

BR-12
MASTER CYLINDER

Removal
CAUTION:
q Be careful not to splash brake fluid on painted areas; it GI
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
q In the case of brake fluid leakage from the master MA
cylinder, disassemble the cylinder. Then check piston
cups for deformation or scratches and replace neces-
sary parts. EM
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing
brake pedal to empty fluid from master cylinder. LC
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
EC
Disassembly
FE

ABR564 ST

HA
1. Bend claws of stopper cap outward.

IDX

SBR938A

BR-13
MASTER CYLINDER
Disassembly (Cont'd)
2. Remove valve stopper while piston is pushed into cylinder
(Models with ABS only).
3. Remove piston assemblies.
q If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
4. Draw out reservoir tank.

Inspection
Check master cylinder inner wall for pin holes or scratches.
ABR539 Replace if damaged.

Assembly
1. Insert secondary piston assembly. Then insert primary pis-
ton assembly.
q Pay attention to direction of piston cups in figure. Also,
insert pistons squarely to avoid scratches on cylinder
bore.
q Pay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body (For mod-
els with ABS only).
SBR012A

ABR296

2. Install stopper cap.
q Before installing stopper cap, ensure that claws are
bent inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.

SBR940A

5. Install valve stopper while piston is pushed into cylinder.
(Models with ABS only)

SBR435B

BR-14
MASTER CYLINDER

Installation
CAUTION:
q Refill with new brake fluid DOT 3. GI
q Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure
mounting nuts slightly. MA
2. Tighten mounting nuts.
: 12 - 15 N m (1.2 - 1.5 kg-m, 9 - 11 ft-lb)
3. Fill up reservoir tank with new brake fluid. EM
ABR190
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until LC
no air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts. EC
: 15 - 18 N m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air. Refer to ``Bleeding Brake System'', BR-7.
FE

IDX

BR-15
BRAKE BOOSTER

On-vehicle Service
OPERATING CHECK
q Depress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
q Depress brake pedal, then start engine. If pedal goes down
slightly, booster operation is normal.

SBR002A

AIRTIGHT CHECK
q Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. Booster is airtight if pedal
stroke is less each time.
q Depress brake pedal while engine is running, and stop
engine with pedal depressed. The pedal stroke should not
change after holding pedal down 30 seconds.

ABR162

Removal

ABR540

CAUTION:
q Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.

BR-16
BRAKE BOOSTER
Removal (Cont'd)
q Be careful not to deform or bend brake pipes during
removal of booster.
q It is necessary to remove ABS actuator and actuator
bracket first because space around booster is limited. GI

LC
Inspection
OUTPUT ROD LENGTH CHECK
EC
1. Apply vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to
brake booster with a hand vacuum pump.
2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod. FE
3. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in) CL
ABR706
MT
Installation
CAUTION:
q Be careful not to deform or bend brake pipes during AT
installation of booster.
q Replace clevis pin if damaged.
q Refill with new brake fluid DOT 3. FA
q Never reuse drained brake fluid.
q Take care not to damage brake booster mounting bolt
RA
thread when installing. Due to the narrow angle of
SBR116B
installation, the threads can be damaged by the dash
panel. BR
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket ST
to brake booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts. RS
: 13 - 16 N m (1.3 - 1.6 kg-m, 9 - 12 ft-lb)
5. Install master cylinder. Refer to BR-15.
6. Adjust brake pedal height and free play. Refer to ``Adjust- BT
ment'' in ``BRAKE PEDAL AND BRACKET'', BR-11.
7. Secure lock nut for clevis.
: 16 - 22 N m (1.6 - 2.2 kg-m, 12 - 16 ft-lb) HA
8. Bleed air. Refer to ``Bleeding Brake System'', BR-7.
EL

IDX

BR-17
VACUUM HOSE

Removal and Installation
CAUTION:
When installing vacuum hoses, pay attention to the follow-
ing points:
q Do not apply any oil or lubricants to vacuum hose and
check valve.
q Insert vacuum tube into vacuum hose as shown.

SBR225B

q Install check valve or vacuum line with internal check
valve, paying attention to its direction arrow.

WBR082

Inspection
HOSES AND CONNECTORS
Check vacuum lines, connections and check valve for
airtightness, improper attachment, chafing or deterioration.

CHECK VALVE
Check vacuum with a vacuum pump.

Connect to booster
Vacuum should exist.
side
Connect to engine
Vacuum should not exist.
side

WBR083

BR-18
FRONT DISC BRAKE

Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize GI
the hazard of airborne particles or other materials.
CAUTION:
q When cylinder body is open, do not depress brake MA
pedal or piston will pop out.
q Be careful not to damage piston boot or get oil on rotor.
q Always replace shims when replacing pads. EM
q If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
q It is only necessary to remove connecting bolt if disas- LC
sembling or replacing caliper assembly. Otherwise,
suspend cylinder body with wire so as not to stretch
brake hose. EC
q Burnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or
FE
linings, or if a soft pedal occurs at very low mileage.
Refer to ``Brake Burnishing Procedure,'' BR-6.
CL

MT
1. Remove master cylinder reservoir cap.
2. Remove lower pin bolt.
AT

RA
ABR544
BR
3. Open cylinder body upward. Then remove pad retainers
and inner and outer shims.
Standard pad thickness: ST
11.0 mm (0.433 in)
Pad wear limit:
2.0 mm (0.079 in) RS
q Carefully monitor brake fluid level because brake fluid
will return to reservoir when pushing back piston.
BT

IDX

ABR543

BR-19
FRONT DISC BRAKE

ABR556

1 Main pin 7 Inner pad 13 Main pin bolt
2 Pin boot 8 Pad retainer 14 Bleed valve
3 Torque member fixing bolt 9 Outer pad 15 Cylinder body
4 Torque member 10 Outer shim 16 Piston seal
5 Shim cover 11 Connecting bolt 17 Piston
6 Inner shim 12 Copper washer 18 Piston boot

Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
Suspend caliper assembly with wire so as not to stretch
brake hose.

Remove torque member fixing bolts and connecting bolt.
It is only necessary to remove connecting bolt if disassem-
bling or replacing caliper assembly. Otherwise, suspend
caliper assembly with wire so as not to stretch brake hose.

SBR979B

BR-20
FRONT DISC BRAKE

Disassembly
WARNING:
Do not place your fingers in front of piston. GI
CAUTION:
Do not scratch or score cylinder wall.
1. Push out piston and dust seal with compressed air. MA
2. Remove piston seal with a suitable tool.
EM
SBR772

LC
Inspection -- Caliper
CYLINDER BODY
EC
q Check inside surface of cylinder for scores, rust, wear, dam-
age or presence of foreign objects. If any of these condi-
tions are observed, replace cylinder body. FE
q Minor damage from rust or foreign objects may be elimi-
nated by polishing surface with a fine emery paper. Replace
cylinder body if necessary. CL
CAUTION:
Use brake fluid to clean. Never use mineral oil.
MT
PISTON
Check piston for scores, rust, wear, damage or presence of for-
eign objects. Replace if any of these conditions are observed. AT
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign objects are stuck to sliding FA
surface.
SLIDE PIN, PIN BOLT AND PIN BOOT RA
Check for wear, cracks, rust or other damage. Replace if any of
these conditions are observed.
BR

IDX

BR-21
FRONT DISC BRAKE

Inspection -- Rotor
RUNOUT
1. Secure rotor to wheel hub with at least two nuts (M12

◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo