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BRAKES

                                                                                                                                                                      A




                                                                                                     SECTION
                                                                                                              BRAKE SYSTEM
                                                                                                                                BR                                    B



                                                                                                                                                                      C


                                                                                                                                                                      D


                                                                                                                                                                      E
                                                                   CONTENTS
                      REGULAR GRADE                                                 BRAKE PAD .............................................................14
                                                                                                                                                       .              BR
                                                                                     BRAKE PAD : Inspection and Adjustment ..............14            .
SYMPTOM DIAGNOSIS .............................. 3
                                            .
                                                                                    DISC ROTOR ............................................................14
                                                                                                                                                       .
                                                                                                                                                                      G
NOISE, VIBRATION AND HARSHNESS                                                       DISC ROTOR : Inspection and Adjustment ............14             .
(NVH) TROUBLESHOOTING ............................ 3
                                             .
  NVH Troubleshooting Chart ..................................... 3
                                                           .
                                                                                    REAR DRUM BRAKE ....................................... 16
                                                                                                                                                                      H
                                                                                    BRAKE LINING .........................................................16
                                                                                                                                                      .
PRECAUTION .............................................. 4
                                                     .                               BRAKE LINING : Inspection ...................................16  .
PRECAUTIONS .................................................. 4
                                                         .                          BRAKE DRUM ..........................................................16
                                                                                                                                                     .                 I
  Precaution for Supplemental Restraint System                                       BRAKE DRUM : Inspection ....................................16  .
  (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
  SIONER" .................................................................. 4
                                                                      .             REMOVAL AND INSTALLATION .............. 17
                                                                                                                        .
  Precaution Necessary for Steering Wheel Rota-                                                                                                                       J
  tion after Battery Disconnect .................................... 4.             BRAKE PEDAL ................................................. 17
  Precaution for Procedure without Cowl Top Cover 5                   ......          Exploded View ........................................................17
                                                                                                                                                        .
  Precaution for Brake System ................................... 5   .               Removal and Installation ........................................18
                                                                                                                                                        .             K
                                                                                      Inspection and Adjustment .....................................18 .
PREPARATION ........................................... 6
                                                   .
                                                                                    BRAKE PIPING ................................................. 20
PREPARATION .................................................. 6
                                                         .                                                                                                            L
  Commercial Service Tool ......................................... 6
                                                             .                      FRONT ......................................................................20
                                                                                                                                                            .
                                                                                     FRONT : Exploded View ........................................20       .
PERIODIC MAINTENANCE ......................... 7
                                          .                                          FRONT : Hydraulic Piping ......................................21      .         M
                                                                                     FRONT : Removal and Installation .........................21           .
BRAKE PEDAL .................................................. 7
                                                         .                           FRONT : Inspection ................................................22  .
  Inspection and Adjustment ....................................... 7
                                                             .
                                                                                    REAR ........................................................................22
                                                                                                                                                             .        N
BRAKE FLUID ...................................................10
                                                           .                         REAR : Exploded View ...........................................22      .
  Inspection ............................................................... 10
                                                                          .          REAR : Hydraulic Piping .........................................23     .
  Draining .................................................................. 10
                                                                          .          REAR : Removal and Installation ...........................23           .        O
  Refilling .................................................................. 10
                                                                          .          REAR : Inspection ..................................................24  .
  Bleeding Brake System .......................................... 11     .
                                                                                    BRAKE MASTER CYLINDER .......................... 25
BRAKE MASTER CYLINDER ...........................12
                                             .                                        Exploded View ........................................................25
                                                                                                                                                            .         P
  Inspection ............................................................... 12
                                                                        .             Removal and Installation ........................................25   .
                                                                                      Disassembly and Assembly ....................................26       .
BRAKE BOOSTER ...........................................13
                                                     .                                Inspection ...............................................................27
                                                                                                                                                            .
  Inspection ............................................................... 13
                                                                        .
                                                                                    BRAKE BOOSTER ........................................... 28
FRONT DISC BRAKE .......................................14
                                                    .                                 Exploded View ........................................................28
                                                                                                                                                        .



Revision: 2009 March                                                          BR-1                                                                    2009 Z12
  Removal and installation ....................................... 28
                                                               .                    Disassembly and Assembly ................................... 41
                                                                                                                                                .
  Inspection and Adjustment .................................... 29
                                                               .                    Inspection and Adjustment ..................................... 41
                                                                                                                                                .

VACUUM LINES ............................................... 31
                                                         .                        SERVICE DATA AND SPECIFICATIONS
  Exploded View ....................................................... 31
                                                                        .         (SDS) .......................................................... 43
  Removal and Installation ....................................... 31   .
  Inspection .............................................................. 31
                                                                        .         SERVICE DATA AND SPECIFICATIONS
                                                                                  (SDS) ................................................................ 43
                                                                                                                                                     .
FRONT DISC BRAKE ....................................... 33
                                                     .                              General Specifications ........................................... 43
                                                                                                                                                        .
BRAKE PAD ............................................................ 33
                                                                   .                Brake Pedal ........................................................... 43
                                                                                                                                                        .
 BRAKE PAD : Exploded View ............................... 33      .                Brake Booster ........................................................ 43
                                                                                                                                                        .
 BRAKE PAD : Removal and Installation ................ 33          .                Front Disc Brake .................................................... 43
                                                                                                                                                        .
 BRAKE PAD : Inspection ....................................... 34 .                Rear Drum Brake ................................................... 43
                                                                                                                                                        .
                                                                                                                      Krom
BRAKE CALIPER ASSEMBLY ............................... 34                .
 BRAKE CALIPER ASSEMBLY : Exploded View ... 34                                    SPEC CHANGE INFORMATION ............... 44
 BRAKE CALIPER ASSEMBLY : Removal and In-
 stallation ................................................................ 35
                                                                         .        DRILLED ALUMINUM PEDAL ......................... 44
                                                                                                                               .
 BRAKE CALIPER ASSEMBLY : Disassembly and                                           Drilled Aluminum Pedal .......................................... 44
                                                                                                                                                  .
 Assembly ............................................................... 36
                                                                         .
 BRAKE CALIPER ASSEMBLY : Inspection .......... 38                       .
                                                                                  REMOVAL AND INSTALLATION .............. 45

REAR DRUM BRAKE ....................................... 39
                                                    .                             DRILLED ALUMINUM PEDAL ......................... 45
                                                                                                                               .
                                                                                    Removal and Installation of Drilled Aluminum Ped-
  Exploded View ....................................................... 39
                                                                    .
                                                                                    al ............................................................................ 45
                                                                                                                                                                .
  Removal and Installation ....................................... 39
                                                                    .




Revision: 2009 March                                                         BR-2                                                                       2009 Z12
           NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >                                                                                                                                                                                                                                                                                   [REGULAR GRADE]

SYMPTOM DIAGNOSIS                                                                                                                                                                                                                                                                                                                                                                                                                   A
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart                                                                                                                                                                                                                                                                                                                                           INFOID:0000000005015019
                                                                                                                                                                                                                                                                                                                                                                                                                                    B
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
                                                                                                                                                                                                                                                                                                                                                                                                                                    C


                                                                                                                                                                                                                                                                                                                                                                                                                                    D




                                                     BR-14, BR-16

                                                                              BR-14, BR-16




                                                                                                                                              BR-14, BR-16




                                                                                                                                                                                                        BR-14, BR-16

                                                                                                                                                                                                                                   BR-14, BR-16
                                                                                                           BR-34

                                                                                                                            BR-14



                                                                                                                                                                     BR-14

                                                                                                                                                                                    BR-14




                                                                                                                                                                                                                                                        BR-14

                                                                                                                                                                                                                                                                                    BR-16
 Reference page




                                                                                                                                                                                                                                                                                                                                                                                           NVH in FAX section
                                                                                                                                                                                                                                                                                                                                                NVH in WT section

                                                                                                                                                                                                                                                                                                                                                                      NVH in WT section



                                                                                                                                                                                                                                                                                                                                                                                                                NVH in ST section
                                                                                                                                                                                                                                                                                                                                                                                                                                    E



                                                                                                                                                                                                                                                                                                                                                                                                                                    BR
                                                                              Pads or lining uneven wear




                                                                                                                                                                                                                                                                                                                                                                                                                                    G




                                                                                                                                                                                                                                                                                                         AXLE AND SUSPENSION
                                                                                                                                                                                                                                                        Rotor thickness variation
                                                                                                                                                                                                        Rotor or drum deflection
                                                     Pads or lining damaged




                                                                                                                                              Rotor or drum damage




                                                                                                                                                                                                                                   Rotor or drum rust



                                                                                                                                                                                                                                                                                    Drum out of round
                                                                                                                                                                                    Rotor deformation
                                                                                                                            Rotor imbalance
                                                                                                           Shims damaged




 Possible cause and                                                                                                                                                                                                                                                                                                                                                                                                                 H




                                                                                                                                                                                                                                                                                                                                                                      ROAD WHEEL

                                                                                                                                                                                                                                                                                                                                                                                           DRIVE SHAFT
 SUSPECTED PARTS
                                                                                                                                                                     Rotor runout




                                                                                                                                                                                                                                                                                                                                                                                                                STEERING
                                                                                                                                                                                                                                                                                                                                                                                                                                     I




                                                                                                                                                                                                                                                                                                                                                TIRE
                            Noise                             



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