BRAKE SYSTEM

F BRAKES

B
SECTION
BRAKE SYSTEM C

E
CONTENTS
PRECAUTIONS .......................................................... 3 INSTALLATION ................................................... 14 BR
Precautions for Supplemental Restraint System Disassembly and Assembly .................................... 15
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- MODELS WITHOUT ESP (PISTON STOPPER
SIONER” .................................................................. 3 APPLIED.) ........................................................... 15 G
Precautions for Brake System .................................. 3 MODELS WITHOUT ESP (PISTON STOPPER
PREPARATION ........................................................... 4 NOT APPLIED.) .................................................. 17
Special Service Tools ............................................... 4 MODELS WITH ESP ........................................... 19
H
Commercial Service Tools ........................................ 4 BRAKE BOOSTER ................................................... 23
NOISE, VIBRATION AND HARSHNESS (NVH) On-Vehicle Inspection and Service ......................... 23
TROUBLESHOOTING ................................................ 5 FUNCTION INSPECTION ................................... 23
NVH Troubleshooting Chart ..................................... 5 AIRTIGHTNESS INSPECTION ........................... 23 I
BRAKE PEDAL .......................................................... 6 Removal and Installation ........................................ 23
On-Vehicle Inspection and Adjustment .................... 6 REMOVAL ........................................................... 23
Components ............................................................. 7 INSPECTION AFTER REMOVAL ....................... 24 J
Removal and Installation .......................................... 7 INSTALLATION ................................................... 24
REMOVAL ............................................................. 7 VACUUM LINES ....................................................... 25
INSPECTION AFTER REMOVAL ......................... 7 Removal and Installation ........................................ 25
K
INSTALLATION ..................................................... 7 Inspection ............................................................... 26
BRAKE FLUID ............................................................ 8 VISUAL INSPECTION ......................................... 26
Checking Brake Fluid Level ..................................... 8 CHECK VALVE INSPECTION ............................. 26
Checking Brake Line ................................................ 8 FRONT DISC BRAKE ............................................... 27 L
Changing Brake Fluid ............................................... 8 Component ............................................................. 27
Bleeding Brake System ............................................ 9 Inspection ............................................................... 27
BRAKE PIPING AND HOSE .................................... 10 PAD THICKNESS ................................................ 27 M
Hydraulic Piping ..................................................... 10 Pad Replacement ................................................... 28
Removal and Installation of Front Brake Piping and REMOVAL ........................................................... 28
Brake Hose .............................................................11 INSTALLATION ................................................... 28
REMOVAL ............................................................11 Caliper Removal and Installation ............................ 28
INSTALLATION ................................................... 12 REMOVAL ........................................................... 28
Removal and Installation of Rear Brake Piping and INSTALLATION ................................................... 29
Brake Hose ............................................................ 12 Caliper Disassembly and Assembly ....................... 29
REMOVAL ........................................................... 12 DISASSEMBLY ................................................... 29
INSTALLATION ................................................... 12 INSPECTION AFTER DISASSEMBLY ................ 29
Inspection ............................................................... 13 DISC ROTOR INSPECTION ............................... 30
BRAKE MASTER CYLINDER .................................. 14 ASSEMBLY ......................................................... 30
Components ........................................................... 14 BRAKE BURNISHING PROCEDURE ................. 31
Removal and Installation ........................................ 14 REAR DISC BRAKE ................................................. 32
REMOVAL ........................................................... 14 Component ............................................................. 32
Inspection ............................................................... 32
PAD WEAR INSPECTION ................................... 32

BR-1
Pad Replacement ................................................... 33 SERVICE DATA AND SPECIFICATIONS (SDS) ......38
REMOVAL ........................................................... 33 General Specifications ............................................38
INSTALLATION .................................................... 33 Brake Pedal ............................................................38
Caliper Removal and Installation ............................ 34 Check Valve ............................................................38
REMOVAL ........................................................... 34 Brake Booster .........................................................38
INSTALLATION .................................................... 34 Front Disc Brake .....................................................38
Caliper Disassembly and Assembly ....................... 34 Rear Disc Brake ......................................................39
DISASSEMBLY ................................................... 34
INSPECTION AFTER DISASSEMBLY ................ 35
DISC ROTOR INSPECTION ............................... 35
ASSEMBLY ......................................................... 36

BR-2
 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EFS002F9

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
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 and SB section of
this Service Manual. C
WARNING:
● 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 must be per-
formed by an authorized NISSAN/INFINITI dealer. D
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section. E
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors. BR
Precautions for Brake System EFS000BZ

● Clean dust on brake pads, shoes, drums, and back plates with a vacuum dust collector. Do not blow with G
compressed air.
● Recommended fluid is brake fluid “DOT 3” or “DOT 4”.
● Never reuse drained brake fluid. H
● Be careful not to splash brake fluid on painted areas such as the body. If brake fluid is splashed or spilled
on painted areas, wipe it off and flush the area with water immediately.
● Use only clean brake fluid when cleaning master cylinder and disc brake components. I
● Never use mineral oils such as gasoline or kerosene to clean. They will ruin the rubber parts and cause
improper operation.
● Always use a flare nut torque wrench to securely tighten brake J
tube flare nuts.
● Brake system is an important safety part. If a brake fluid leak is
detected, always disassemble the related parts. If damage, K
deformation or excessive wear is detected, replace affected
parts with new ones.
● Before starting operation, be sure to turn the ignition switch OFF L
and disconnect the ABS actuator and control module connector
or battery cables.
● When installing brake piping, be sure to check torque.
SBR820BA M

BR-3
 PREPARATION

PREPARATION PFP:00002

Special Service Tools EFS00217

Tool number
Description
Tool name

GG94310000
Flare nut torque wench Removing and installing brake piping
a: 10 mm (0.39 in)/12 mm (0.47 in)

NT406

Commercial Service Tools EFS00218

Tool name Description

Brake fluid pressure gauge Measuring fluid pressure

S-NT151

BR-4
 Symptom

X: Applicable
Reference page

BRAKE
Possible cause and
SUSPECTED PARTS

Noise
Shake

Shimmy, Judder
NVH Troubleshooting Chart

Pads - damaged BR-27, BR-32

×
Pads - uneven wear BR-27, BR-32 .

×
×
Shims damaged BR-27, BR-32

×
×
Rotor imbalance —

Rotor damage —

BR-5
Rotor runout BR-30, BR-35

×
Rotor deformation —

×
Rotor deflection —

×
Rotor rust —

×
Rotor thickness variation BR-30, BR-36

×
Drum out of round —

×
×
PROPELLER SHAFT NVH in PR section
×

DIFFERENTIAL NVH in RFD section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

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

TYRES NVH in WT section

×
×
×

×
×
×

ROAD WHEEL NVH in WT section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

× × DRIVE SHAFT NVH in RAX section

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×
×
×

STEERING NVH in PS section

PFP:00003

EFS000TK

L
K
E
B
A

H
D
C

M
BR
 BRAKE PEDAL

BRAKE PEDAL PFP:46501

On-Vehicle Inspection and Adjustment EFS000C1

Adjust clearance between dash panel and brake pedal upper surface
to the following dimensions.

SFIA0348E

M/T model 156 - 166 mm (6.14 - 6.54 in)

H1 Brake pedal height
A/T model 164 - 174 mm (6.46 - 6.85 in)
Pedal height when depressed M/T model 80 mm (3.15 in) or more
H2 [With engine running and at a depression force of 490 N (50 kg,110.6
lb)] A/T model 85 mm (3.35 in) or more

C Clearance between stopper rubber and threaded end of stop lamp switch 0.74 - 1.96 mm (0.0291 - 0.0772 in)
A Pedal play 3 - 11 mm (0.12 - 0.43 in)

1. Loosen stop lamp switch by rotating it counter-clockwise by 45°.

2. Loosen input rod lock nut (A), then rotate input rod, set pedal to
the specified height, and tighten lock nut (A).
CAUTION:
Confirm threaded end of input rod remains inside the cle-
vis.
: 16 - 21 N·m (1.6 - 2.2 kg-m, 12 - 15 ft-lb)

3. Pull pedal by hand and hold it. Press stop lamp switch until its
threaded end contacts the stopper rubber.
4. While holding it against the stopper rubber, turn the switch clock-
wise by 45° and secure it.
CAUTION:
Be sure stopper rubber to stop lamp switch screw threaded
end gap (C) is within the specifications.
5. Check pedal free play.
CAUTION:
Be sure stop lamps go off when pedal is released.
6. Start engine and check brake pedal depressed height.

SFIA0160E

BR-6
 BRAKE PEDAL

Components EFS001CI

BR

SFIA1797E

1. Snap pin 2. Stop lamp switch 3. Clip G

4. Clevis pin 5. Brake pedal assembly

Removal and Installation EFS000C2 H

REMOVAL
Be careful not to deform brake tube.
1. Remove instrument lower driver panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" . I
2. Remove steering column assembly from steering member. Refer to PS-10, "STEERING COLUMN" .
3. Remove stop lamp switch from brake pedal assembly.
4. Remove snap pin and clevis pin from brake booster clevis. J
5. Remove brake pedal assembly mounting nuts. Pull brake booster toward engine compartment to the
extent that does not deform brake tube.
6. Remove brake booster clevis from input rod. K
7. Remove the mounting bolts from the bracket, and remove the pedal assembly from the vehicle.
INSPECTION AFTER REMOVAL L
Check brake pedal for the following.
● Bent brake pedal
● Deformed clevis pin M
● Cracks in welded area
● Cracked or deformed clevis pin stopper

SBR997

INSTALLATION
Install in reverse order of removal. Be careful of the following:
● Adjust brake pedal assembly after installing it.

BR-7
 BRAKE FLUID

BRAKE FLUID PFP:KN100

Checking Brake Fluid Level EFS000C5

● Confirm reservoir tank fluid level is within the specifications

(between MAX and MIN lines).
● Visually check around reservoir tank for fluid leaks.
● If fluid level is excessively low, check brake system for leaks.
● If warning lamp remains illuminated after parking lever is
released, check brake system for fluid leakage.

SFIA0066J

Checking Brake Line EFS001C5

CAUTION:
If leakage occurs around joints, retighten or, if necessary, replace damaged parts.
1. Check brake line (tube and hoses) for cracks, deterioration or
other damage. Replace and damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.

SBR389C

Changing Brake Fluid EFS000C3

CAUTION:
● Refill with new brake fluid “DOT 3 or DOT 4”.
● Always keep fluid level higher than minimum line on reservoir tank.
● Never reuse drained brake fluid.
● 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 water immediately.
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve of each wheel while
depressing brake pedal.
3. Turn OFF ignition switch. Remove ABS actuator connector.

BRA0007D

BR-8
 BRAKE FLUID

4. Be sure there is no foreign material in reservoir tank. Refill with

new brake fluid. A
5. Connect a vinyl tube to bleed valve.
6. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
pedal until it stops. Tighten bleed valve. Release brake pedal. B
Repeat this process a few times at 2-3 second intervals until
new brake fluid flows out.
For bleeding procedure. Refer to BR-9, "Bleeding Brake Sys-
C
tem" .

BRA0006D

D
Bleeding Brake System EFS000C4

CAUTION:
● Carefully monitor brake fluid level at master cylinder during bleeding operation. E
● Fill reservoir with new brake fluid “DOT 3” or “DOT 4”. Make sure it is full at all times while bleed-
ing air out of system.
● Place a container under master cylinder to avoid spillage of brake fluid. BR
● While bleeding, pay attention to master cylinder fluid level.
● For models with ABS, turn ignition switch OFF and disconnect ABS actuator connectors or bat-
tery ground cable. G
● Bleed air in the following order.
Right rear brake, left front brake, left rear brake, right front brake
1. Turn OFF ignition switch. Remove ABS actuator connector. H
2. Connect a vinyl tube to bleed valve.
3. Fully depress the brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen air bleeder and bleed air. I
5. Close bleed valve.
6. Slowly release brake pedal.
J
7. Tighten bleed valve to the specified torque.
: 6.9 - 8.8 N·m (0.7 - 0.9 kg-m, 61- 78 in-lb)
K
8. Repeat steps 2 - 7. Occasionally refill master cylinder reservoir tank. Be sure to keep it at least half-full.

BR-9
 BRAKE PIPING AND HOSE

BRAKE PIPING AND HOSE PFP:46210

Hydraulic Piping EFS000C6

RHD MODELS

SFIA1798E

SFIA1799E

BR-10
 BRAKE PIPING AND HOSE

LHD MODELS
A

BR

SFIA2137E

SFIA2138E

Removal and Installation of Front Brake Piping and Brake Hose EFS000C7
M
REMOVAL
CAUTION:
● Do not allow brake fluid to spill or splash on painted surfaces. Brake fluid can seriously damage
paint. If it gets on a painted surface, wipe it off immediately and wash it away with water.
● Do not bend or twist brake hose sharply, or strongly pull it.
● Cover brake fluid line joints to prevent dust and other foreign material.
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve of each wheel while depressing brake pedal.

BR-11
 BRAKE PIPING AND HOSE

3. Using a flare nut wrench, loosen brake tube flare nuts and dis-
connect brake tube from brake hose.
4. Remove union bolts and disconnect caliper assembly from
brake hose.
5. First remove lock spring from brake tube and strut mounting
positions. Then remove brake hose.

SFIA0347E

INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3” or “DOT4”.
● Never reuse drained brake fluid.
1. Connect brake hose to caliper assembly and tighten union bolt to the specified torque.
CAUTION:
● Securely connect brake hose to the protrusion on the cylinder body.

● Do not reuse the copper washer for union bolt.

2. Connect brake hose to strut and fix with lock spring.

3. Connect brake hose to brake tube. Temporarily tighten flare nuts by hand as far as they will go. Secure
them with the lock spring.
4. Using a flare nut torque wrench, tighten to the specified torque.
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

5. Refill brake fluid until new brake fluid comes out of each bleed valve.
6. Afterwards, bleed air.
Removal and Installation of Rear Brake Piping and Brake Hose EFS000C8

REMOVAL
CAUTION:
● Do not allow brake fluid to spill or splash on painted surfaces. Brake fluid can seriously damage
paint. If it gets on a painted surface, wipe it off immediately and wash it away with water.
● Do not bend or twist brake hose sharply, or strongly pull it.
● Cover brake fluid line joints to prevent dust and other foreign material.
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve of each wheel while depressing brake pedal.
3. Using a flare nut wrench, remove brake tube flare nuts and dis-
connect brake tube from brake hose.
4. Remove lock spring.

SFIA0046E

INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3” or “DOT 4”.
● Never reuse drained brake fluid.
1. Connect brake hose to the brake tube. Temporarily tighten flare nut by hand as far as it will go.
2. Fix brake hose by lock plate.

BR-12
 BRAKE PIPING AND HOSE

3. Tighten flare nut by using a flare nut wrench with the specified
torque. A
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

4. Refill brake fluid until new brake fluid comes out of each bleed B
valve.
5. Afterwards, bleed air.
C

SBR820BA

D
Inspection EFS000C9

CAUTION:
If any leaks on joints, retighten it. Replace any damaged parts. E
1. Check hose, tube, and joints for fluid leaks, damage, twist, deformation, contact with other parts, and
loose connections.
2. Run engine. Depress brake pedal and hold it for approximately 5 seconds while checking each part for BR
leaks.

BR-13
 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

Components EFS000CB

SFIA1800E

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

4. Pin 5. Cylinder body 6. Piston stopper (Some models with
ABS does not apply.)
7. Grommet 8. O-ring 9. Secondary piston assembly
10. Primary piston assembly 11. Snap ring 12. Guide assembly
13. Plate 14. Stopper cap 15. Primary piston assembly
16. Secondary piston assembly

Removal and Installation EFS001CG

REMOVAL
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wipe it off immediately and wash it away with water.
1. Drain brake fluid.
2. Remove fluid level sensor harness connector.
3. Using a flare nut wrench, disconnect master cylinder assembly and brake tube.
4. First remove master cylinder assembly mounting nuts. Then remove master cylinder assembly.
INSTALLATION
1. Connect brake tube to master cylinder assembly and temporarily tighten flare nut by hand.
2. Connect master cylinder assembly to brake booster assembly and tighten mounting nuts to the specified
torque.
3. Tighten brake tube flare nuts.
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

4. Connect fluid level sensor harness connector.

BR-14
 BRAKE MASTER CYLINDER

5. Refill with new brake fluid and bleed air from the brake piping.
A
Disassembly and Assembly EFS001CH

MODELS WITHOUT ESP (PISTON STOPPER APPLIED.)

Disassembly
B
CAUTION:
Remove master cylinder reservoir tank only when necessary.
1. Using a slotted flat-bladed screwdriver as shown in the figure,
C
lever up stopper cap tabs and remove stopper cap. While
removing, be sure to hold cap securely to prevent the master
cylinder piston from popping out.
D

BRA0533D

2. Secure cylinder body flange in a vise as shown in the figure. BR

CAUTION:
● Secure cylinder body flange with chamfered pin insert
hole, facing upward. G
● When securing in the vise, use copper plates or cloth to
protect the flange.
H

BRA0588D
I

3. Using a pin punch [tool: diameter Approx. 4 mm (0.16 in)],

remove reservoir tank mounting pins. J
4. Remove master cylinder assembly from the vise.
5. Remove reservoir tank and grommet from the cylinder body.
K

SFIA0342E

M
6. Using a Phillips flat-bladed screwdriver, press and hold piston
pin as shown in the figure. Remove piston stopper from the cyl-
inder body.
7. Carefully pull primary piston assembly straight out to prevent
damage to the cylinder inner wall.
8. Tap flange against a wood block to loosen secondary piston
assembly. Carefully pull secondary piston assembly straight out
to prevent damage to the cylinder inner wall.

BRA0590D

Inspection After Disassembly

● Check cylinder inner wall for damage, wear, corrosion, and pinholes. Replace cylinder if damage, wear, or
corrosion is detected.

BR-15
 BRAKE MASTER CYLINDER

Assembly
CAUTION:
● Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.
● Be sure there is no foreign material on the cylinder inner wall, piston, and cup seal. Be careful not
to damage parts with a service tool during assembly.
● Do not drop the parts. Do not use any dropped parts.

1. Apply brake fluid to the inner wall of cylinder body and contact
surface of piston assembly. Then insert secondary piston
assembly and primary piston assembly into the cylinder body in
this order.
CAUTION:
● Do not reuse primary and secondary piston assemblies.
● Always replace primary and secondary piston assemblies
as kit.
● Pay attention to orientation of the piston cup. Insert it
straight in order to prevent the cups from catching between
the cylinder's inner wall and piston. SFIA0248E

2. Visually check secondary piston slit position through cylinder

body secondary tank boss hole and install piston stopper.

BRA0590D

3. Hold piston with stopper cap. Press stopper cap in until its tabs
fully engage groove on the cylinder body.
CAUTION:
Do not reuse stopper cap.
4. Apply brake fluid to grommet before pressing it into cylinder
body.
CAUTION:
Do not reuse grommet.

BRA0535D

5. Secure cylinder body flange in a vise as shown in the figure.

CAUTION:
● Secure cylinder body flange with chamfered pin insert hole
facing upward.
● When securing in the vise, use copper plates or cloth to
protect the flange.
6. Install reservoir tank to cylinder body. Tilt reservoir tank as
shown in the figure to the extent that the mounting pin can be
inserted and insert mounting pin. When mounting pin passes
through pinhole in master cylinder, return reservoir tank to the
upright position. Push mounting pin all the way through the SFIA0343E

opposite pinhole in the reservoir tank.

BR-16
 BRAKE MASTER CYLINDER

CAUTION:
● Do not reuse reservoir tank mounting pin. A
● Do not reuse reservoir tank.
● Be sure to insert pin from the chamfered pinhole on the cylinder body.
B
MODELS WITHOUT ESP (PISTON STOPPER NOT APPLIED.)
CAUTION:
Remove reservoir tank only when absolutely necessary.
C
Disassembly (Piston Assembly)
1. Using a flat-bladed screwdriver as shown in the figure, lift up the
tabs on the stopper cap and remove it from the master cylinder. D
NOTE:
Remove stopper cap while holding it because the piston in mas-
ter cylinder may pop out.
E
2. Carefully pull primary piston assembly straight out to prevent the
cylinder inner wall from being damaged.
BR

BRA0031D

G
3. Tap flange using a soft block, such as wood, and carefully pull
secondary piston assembly straight out to prevent cylinder body
inner wall from being damaged.
H

J
BRA0033D

Inspection After Disassembly (Piston Assembly)

Cylinder body K
● Check inner wall of cylinder for damage, abrasion, corrosion, and pinholes. Replace the cylinder body if
detected.
L
Assembly (Piston Assembly)
CAUTION:
● Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
M
● Make sure there is no foreign matter such as dirt or dust attached to the inner cylinder walls, the
piston, or the cap seal, and use care to avoid damaging parts with the assembly tools.
● Do not drop parts. If a part is dropped, do not use it.
1. Apply fluid to cylinder inner wall body and contact surface of the
piston assembly. Then insert secondary piston assembly and
primary piston assembly into cylinder body in this order.
CAUTION:
● Pay attention to the orientation of the piston cup, and
insert straight to prevent the cup from being caught by
cylinder inner wall.
● Be sure to replace the assembly without disassembling
the new inner kit.
● Do not reuse the primary and secondary piston assem-
blies. SFIA2051E

BR-17
 BRAKE MASTER CYLINDER

2. Holding down the piston with the stopper cap, push the stopper
cap tabs so they are firmly into the cylinder grooves, then attach
the stopper cap.
CAUTION:
Do not reuse the stopper cap.

BRA0035D

Disassembly (Reservoir Tank)

1. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:
● When setting the master cylinder assembly in a vise, be
sure not to over-tighten.
● When securing in a vise use copper plates or cloth to
protect the flange.

BRA0588D

2. Using a pin punch [commercial service tool: diameter approxi-

mately 4 mm (0.16 in)], remove mounting pins on the reservoir
tank.
3. Remove master cylinder assembly from the vise.
4. Remove reservoir tank and grommet from cylinder body.

SFIA0342E

Assembly (Reservoir Tank)

1. Apply brake fluid or rubber lubricant to a grommet, and then install it into cylinder body after installing
grommet to reservoir tank.
CAUTION:
Do not reuse the reservoir tank and grommet.
2. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:
● When setting the master cylinder assembly in a vise, be
sure not to over-tighten.
● When securing in a vise use copper plates or cloth to
protect the flange.

BRA0588D

BR-18
 BRAKE MASTER CYLINDER

3. Tilt reservoir tank as shown in the figure for the mounting pin to
be inserted. Return the reservoir tank to the upright position A
when mounting pin passes through pinhole in the cylinder body.
Push mounting pin to the opposite pinhole of the reservoir tank,
so that it is the same condition as the insertion side.
B
CAUTION:
● Be sure to insert pin from the chamfered pinhole of cylin-
der body.
C
● Do not reuse the mounting pin.

SFIA0342E

D
MODELS WITH ESP
Disassembly
CAUTION: E
● While working, cover primary piston rod with cloth to prevent it from being damaged.
● Only remove reservoir tank when absolutely necessary.
1. Place the side of cylinder body with chamfering around the pin BR
insertion hole up, and secure the cylinder body flange section
with a vise as shown in the figure.
CAUTION:
G
When securing in a vise, use copper plates or cloth to pro-
tect flange.

BRA0558D I
2. Using a pin punch [commercial service tool: approximately 4
mm (0.16 in) dia.], remove reservoir tank mounting pin.
J
3. Remove master cylinder assembly from the vise.
4. Remove reservoir tank and grommet from cylinder body.
K

BRA0559D

5. Push in the primary piston and remove stopper pin from the cyl- M
inder body secondary-side tank boss hole.

BRA0560D

BR-19
 BRAKE MASTER CYLINDER

6. Remove the snap ring while pushing primary piston in to prevent

piston from popping out.
7. Holding primary piston rod, pull primary piston assembly, plate,
and guide straight out.
8. Remove plate and guide from primary piston.
CAUTION:
When removing plate from primary piston rod, make sure
the inside of plate does not damage rod.

BRA0561D

9. Tap flange using a soft block such as wood, and carefully pull
the secondary piston assembly straight out to prevent cylinder
inner wall from being damaged.

BRA0033D

Inspection After Disassembly

Master cylinder
● Make sure there is no damage, friction, rusting, or pinholes on the cylinder inner wall, and replace if there
are any non-standard conditions.
Assembly
CAUTION:
● Never use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
● Make sure there is no foreign matter such as dirt or dust attached to the inner cylinder walls, pis-
ton, or cap seal, and use care to avoid damaging parts with the assembly tools.
● Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid to the inside surface of cylinder body and the
contact surface of piston assembly, and apply the silicon grease
in the inner kit to primary piston rod.
2. Insert secondary piston and primary piston into cylinder body.
CAUTION:
● Do not reuse the primary and secondary piston assem-
blies.
● Be sure to replace the assembly without disassembling
new inner kit.
● Pay attention to the orientation of piston cup, and insert
PFIA0263E
straight to prevent cup from being caught by cylinder
inner wall.

BR-20
 BRAKE MASTER CYLINDER

3. Visually inspect the secondary piston slit through the piston

stopper mounting hole and then install the piston stopper while A
pushing in the primary piston.

BRA0560D

D
4. Insert plate and guide into cylinder body.
CAUTION:
● Make sure not to damage primary piston rod. E
● Pay attention to the orientation of guide assembly.

● Do not drop O-ring.

● Make sure guide and/or plate are not inserted at an angle. BR

G
SFIA1293E

H
5. Cover primary piston rod with cloth to prevent it getting dam-
aged, and attach snap ring with primary piston pushed in.
CAUTION: I
● Make sure the area around snap ring is snug in the cylin-
der body bore groove.
● Do not reuse snap ring. J

K
BRA0561D

6. Apply brake fluid to grommet and attach reservoir tank to master L

cylinder.
CAUTION:
Do not reuse grommet. M
NOTE:
Attach reservoir tank in the orientation shown in the figure.

BRA0568D

BR-21
 BRAKE MASTER CYLINDER

7. Place the side of cylinder body with chamfering around the pin
insertion hole up, and secure the cylinder body flange section
with a vise.
CAUTION:
When securing in a vise, use copper plates or cloth to pro-
tect flange.

BRA0558D

8. Tilt reservoir tank so that mounting pin can be inserted as shown

in the figure, and insert mounting pin. When mounting pin has
passed the master cylinder pinhole, return reservoir tank to a
level position. Attach mounting pin to the opposite mounting pin
hole of reservoir tank so that it is the same as the insertion side.
CAUTION:
● Be sure to insert pin from the chamfered pinhole of cylin-
der body.
● Do not reuse reservoir tank and mounting pin.

SFIA0702E

BR-22
 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

A
On-Vehicle Inspection and Service EFS000CC

FUNCTION INSPECTION
With engine stopped, discharge stored vacuum by depressing brake B
pedal several times at 5 second intervals. With brake pedal fully
depressed, start the engine. Confirm that clearance between brake
pedal and floor panel decreases when engine vacuum stabilizes.
C

BRA0037D
E
AIRTIGHTNESS INSPECTION
● Run engine at idle for approximately 1 minute. Stop it after
applying vacuum to the booster. Depress brake pedal several BR
times with normal force to discharge the stored vacuum. Con-
firm that clearance between brake pedal and floor panel gradu-
ally increases as the brake pedal is depressed. G
● Run engine. Depress and hold brake pedal then stop engine.
Keep brake pedal depressed for 30 seconds or more and make
sure the pedal stroke does not change.
H

SBR365AA
I
Removal and Installation EFS000CD

REMOVAL
CAUTION: J
● Be careful not to deform or bend brake piping while remov-
ing and installing brake booster.
● Replace clevis pin if it is damaged. K
● Be careful not to damage brake booster stud bolt threads. If
brake booster is tilted or inclined during installation, dash
panel may damage the threads.
L
● Be sure to install check valve in the correct orientation.
1. Remove vacuum piping from the brake booster.
2. Remove master cylinder. SFIA0139E
M
3. Remove snap pin and clevis pin on the clevis of input rod. Remove input rod from the brake pedal.
4. Remove brake booster and brake pedal assembly mounting nuts.
5. Remove booster assembly from the engine compartment.

BR-23
 BRAKE BOOSTER

INSPECTION AFTER REMOVAL

Output rod length inspection
1. Using a handy vacuum pump, apply a vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to the brake
booster.
2. Check output rod length.
3.

Reference value at vacuum of –66.7 kPa (–500 mmHg,

–19.69 inHg):
Without ESP models : 10.4 mm (0.409 in)
With ESP models : -6.2 mm (-0.244 in)

SBR208E

INSTALLATION
1. Loosen lock nut to adjust input rod length so that length “B” (in
the figure) satisfies the specified value.
Length “B” standard : 125 mm (4.92 in)
2. After adjusting “B”, temporarily tighten lock nut to install booster
assembly to vehicle.
3. Connect brake pedal to input rod clevis.
4. Connect brake pedal assembly mounting nuts and tighten to the
specified torque.
5. Connect master cylinder to booster assembly.
SGIA0060E
6. Adjust brake pedal height and play.
7. Tighten input rod lock nut to the specified torque.
8. Bleed air. Refer to BR-9, "Bleeding Brake System" .

BR-24
 VACUUM LINES

VACUUM LINES PFP:41920

A
Removal and Installation EFS000CE

RHD MODELS
B

BR

SFIA2093E

1. Vacuum hose 2. Vacuum tube 3. Clip

H
4. Clamp

LHD MODELS I

SFIA2094E

1. Vacuum hose 2. Clip 3. Clamp

CAUTION:
● Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer
to the stamp or label to confirm correct installation. Brake booster will not operate normally if
hose is installed in the wrong direction.

BR-25
 VACUUM LINES

● Insert the vacuum hose at least 24 mm (0.94 in).

● Never use lubricating oil during assembly.

SBR225B

Inspection EFS000CF

VISUAL INSPECTION
Check for improper assembly, damage and aging.
CHECK VALVE INSPECTION
Airtightness Inspection
Use a hand-held vacuum pump to check.
When connected to booster side (1):
Vacuum decrease should be within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under
a vacuum of –66.7 kPa (–500 mmHg, –19.69
inHg)
When connected to engine side (2):
No vacuum will be applied
SFIA0210E

BR-26
 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

A
Component EFS000CG

BR

G
SFIA2142E

1. Torque member 2. Slid pin boot 3. Slid pin

4. Outer shim cover 5. Outer shim 6. Outer pad H
7. Pad retainer 8. Inner pad 9. Inner shim
10. Inner shim cover 11. Piston boots 12. Piston
13. piston seal 14. Cylinder body 15. Slid pin bolt I
16. Copper washer 17. Bleed valve 18. Brake hose union bolt

WARNING:
● Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or J
other materials.
CAUTION:
● When cylinder body is open, do not depress brake pedal because piston will pop out. K
● Be careful not to damage piston boot or spill brake fluid oil on rotor. Always replace shims when
replacing pads.
● If shims are rusted or show peeling of the rubber coat, replace them with new shims. L
● It is not necessary to remove torque member mounting bolt and brake hose union bolt except for
disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so
as not to stretch brake hose. M
● Burnish the brake pad contact surfaces after refinishing or replacing drums or rotors, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-31, "BRAKE BUR-
NISHING PROCEDURE" .
Inspection EFS000CH

PAD THICKNESS
Check pad thickness by lifting vehicle, removing the wheel, and
looking through check hole on cylinder body. If necessary, use a
scale.
Standard pad thickness : 11 mm (0.43 in)
Pad wear limit : 2.0 mm (0.079 in)

MAA0439D

BR-27
 FRONT DISC BRAKE

Pad Replacement EFS000CI

REMOVAL
CAUTION:
When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
1. Remove master cylinder reservoir tank cap.
2. Remove lower sliding pin bolt.

SBR433D

3. Hang cylinder body with a wire, and remove pads, pad retainers,
shims and pad return springs.

SBR932C

INSTALLATION
1. Apply brake grease on back of the pad and both sides of the shim. Install inner shim and inner shim cover
to inner pad, outer shim to outer pad.
2. Apply brake grease on a pad sliding part of pad retainer. Install pad retainers, pads and pad return springs
to torque member.
3. Connect cylinder body to torque member.
CAUTION:
When replacing pads with new ones, press piston in until the pads can be installed. Carefully mon-
itor brake master cylinder reservoir fluid level. Brake fluid will return, raising master cylinder res-
ervoir tank fluid level.
4. Insert lower sliding pin bolt and tighten to the specified torque.
5. Check brakes for drag.
Caliper Removal and Installation EFS000CJ

REMOVAL
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve while depressing brake pedal.
3. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
4. Remove disc rotor.

SBR979B

BR-28
 FRONT DISC BRAKE

INSTALLATION
CAUTION: A
● Refill with new brake fluid “DOT 3” or “DOT 4”.
● Never reuse drained brake fluid.
1. Install disc rotor. B
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Before installing caliper assembly, wipe brake fluid and grease on steering knuckle washer seats C
and caliper assembly mounting surface.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
D
CAUTION:
● Do not reuse copper washer for union bolts.

● Securely assemble brake hose to protrusions on cylinder body.

E
4. Bleed air. Refer to BR-9, "Bleeding Brake System" .

Caliper Disassembly and Assembly EFS000CK

BR
DISASSEMBLY
WARNING:
Be careful not to pinch your fingers in the piston. G
CAUTION:
Be careful not to damage the cylinder inner wall.
1. Place a wooden block as shown in the figure. Blow air into union H
bolt mounting hole to remove pistons and piston boots.

BRB0032D K

2. Using flat-bladed screwdriver, remove piston seals.

L

SFIA0141E

INSPECTION AFTER DISASSEMBLY

Cylinder Body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.
● Check cylinder inner wall for corrosion, wear and damage. If corrosion, wear or damage is detected,
replace the cylinder body.
● Minor flaws caused by corrosion or foreign material can be removed by polishing the surface with fine
sandpaper. Replace the cylinder body, if necessary.
Torque Member
Check for wear, cracks and damage. If wear, cracks or damage is detected, replace the applicable part.
BR-29
 FRONT DISC BRAKE

Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear and damage. If corrosion, wear or damage is detected, replace the
applicable part.
Sliding Pin, Pin Bolt, and Pin Boot
Check sliding pin and sliding pin boot for wear, damage and cracks. If corrosion, wear or damage is detected,
replace the applicable part.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks and serious damage. If uneven wear, cracks or serious
damage is detected, replace it.
Run Out Inspection
1. Using wheel nuts, fix disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check run out.
Measurement point:
At a point of 10 mm (0.39 in) from the outer edge of
the disc.
Run out limit : 0.04 mm (0.0016 in) or less
NOTE:
Make sure that wheel bearing axial endplay is with in the specifi-
cations before measuring runout. Refer to FAX-7, "On-Vehicle
Inspection" .
BRA0013D
3. If the run out is outside the limit, find the minimum run out point
by shifting the mounting positions of disc rotor and wheel hub by one hole.
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If the thickness is
outside the standard, replace the disc rotor.
Standard thickness : 28.0 mm (1.102 in)
Wear limit : 26.0 mm (1.024 in)
Maximum uneven wear (measured at 8 positions):
0.02 mm (0.0008 in) or less

SBR020B

ASSEMBLY
CAUTION:
When assembling, do not use rubber grease.
1. Apply rubber lubricant to piston seals, and install them to cylin-
der body.
CAUTION:
Do not reuse piston seals.

SFIA0154E

BR-30
 FRONT DISC BRAKE

2. Apply brake fluid or rubber lubricant to piston boots. Cover pis-

ton end with piston boot. Install cylinder side boot lip properly A
into groove on cylinder body.
CAUTION:
Do not reuse piston boot. B

SFIA0155E

D
3. Apply brake fluid to piston. Press piston into cylinder body by
hand. Assemble piston side boot lip properly into groove on pis-
ton. E
CAUTION:
Press piston evenly and change pressing point to prevent
cylinder inner wall from being rubbed. BR

G
SBR574

BRAKE BURNISHING PROCEDURE H

Burnish the brake pad contact surfaces according to the following procedure after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION: I
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring vehicle to a complete stop from 50 km/h (31 MPH).
J
Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.
K

BR-31
 REAR DISC BRAKE

REAR DISC BRAKE PFP:44000

Component EFS0017X

SFIA2143E

1. Pad retainer 2. Outer shim cover 3. Outer shim

4. Outer pad 5. Pad retainer 6. Inner pad
7. Inner shim 8. Inner shim cover 9. Sliding pin boot
10. Sliding pin 11. Sliding pin bolt 12. Cylinder body
13. Copper washer 14. Brake hose 15. Union bolt
16. Copper washer 17. Bleed valve 18. Piston seal
19. Piston 20. Piston boot 21. Retaining ring
22. Torque member

WARNING:
● Clean dust on brake caliper and pad with a vacuum dust collector. Do not blow with compressed
air.
CAUTION:
● Never depress brake pedal while removing cylinder body because piston will pop out.
● Do not remove brake hose and torque member mounting bolts unless disassembling or replacing
caliper assembly. Hang the cylinder body with a wire so that the brake hose is not under tension.
● Be careful not to damage piston boot. Do not allow brake fluid to get the rotor.
● When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
Inspection EFS0017Y

PAD WEAR INSPECTION

Check pad thickness by lifting vehicle, removing tyre and wheel, and
looking through check hole on cylinder body. If necessary, use a
scale.
standard thickness : 8.5 mm (0.335 in)
pad wear limit : 2.0 mm (0.079 in)

BRA0010D

BR-32
 REAR DISC BRAKE

Pad Replacement EFS0017Z

REMOVAL A
CAUTION:
When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
1. Remove master cylinder reservoir tank cap. B
2. Remove lower sliding pin bolt.

E
BRB0302D

BR
3. Hang cylinder body with a wire, and remove pads, pad retainers,
and shims.

SBR042C

INSTALLATION M
1. Apply brake grease on back of the pad and both sides of the shim. Install inner shim and inner shim cover
to inner pad, outer shim to outer pad.
2. Install pad retainers to torque member and install pads.
3. Connect cylinder body to torque member.
CAUTION:
When replacing pads with new ones, press piston in until the pads can be installed. Carefully mon-
itor brake master cylinder reservoir fluid level. Brake fluid will return, raising master cylinder res-
ervoir tank fluid level.
4. Insert lower sliding pin bolt and tighten to the specified torque.
5. Check brakes for drag.

BR-33
 REAR DISC BRAKE

Caliper Removal and Installation EFS00180

REMOVAL
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve while depressing
brake pedal.
3. Remove union bolt and remove brake hose from caliper assem-
bly.
4. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
5. Remove disc rotor.

SFIA0143E

INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3 or DOT 4”.
● Never reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Wipe brake fluid and grease on axle assembly washer seats and caliper assembly mounting sur-
face. Install caliper assembly.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
● Do not reuse the copper washer for union bolts.

● Securely assemble brake hose to protrusions on cylinder body.

4. Bleed air. Refer to BR-9, "Bleeding Brake System" .

Caliper Disassembly and Assembly EFS00181

DISASSEMBLY
WARNING:
Be careful not to pinch your fingers in the piston.
CAUTION:
Be careful not to damage the cylinder inner wall.

1. Remove caliper assembly from vehicle.

2. Remove sliding pin from cylinder body. Then remove pads, shims, shim covers, and pad retainers from
caliper assembly.
3. Remove sliding pin boots from torque member.
4. Using flat-bladed screwdriver (as shown in the figure), remove
retaining ring.

SBR028A

BR-34
 REAR DISC BRAKE

5. Place a wooden block as shown in the figure. Blow air into union
bolt mounting hole to remove pistons and piston boots. A

BRD0041D

D
6. Using flat-bladed screwdriver, remove piston seals.

BR

G
SFIA0340E

INSPECTION AFTER DISASSEMBLY H

Cylinder Body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene. I
● Check cylinder inner wall for corrosion, wear and damage. If corrosion, wear or damage is detected,
replace the cylinder body.
● Minor flaws caused by corrosion or foreign material can be removed by polishing the surface with fine J
sandpaper. Replace the cylinder body, if necessary.
Torque Member
Check for wear, cracks and damage. If wear, cracks or damage is detected, replace the applicable part. K
Piston
CAUTION: L
The piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear and damage. If corrosion, wear or damage is detected, replace the
applicable part.
M
Sliding Pin, Pin Bolt and Pin Boot
Check sliding pin and sliding pin boot for wear, damage and cracks. If corrosion, wear or damage is detected,
replace the applicable part.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of the disc rotor for uneven wear, cracks and serious damage. If uneven wear, cracks or seri-
ous damage is detected, replace it.
Run Out Inspection
1. Using wheel nuts, fix the disc rotor to wheels hub. (2 or more positions)

BR-35
 REAR DISC BRAKE

2. Using a dial indicator, check run out.

Measurement point:
At a point of 10 mm (0.39 in) from the outer
edge of the disc.
Run out limit:
0.07 mm (0.0028 in) or less
NOTE:
Make sure that wheel bearing axial endplay is with in the specifi-
cation before measuring runout. Refer to FAX-7, "On-Vehicle BRA0013D
Inspection" .
3. If the run out is outside the limit, find the minimum run out point by shifting the mounting positions of disc
rotor and wheel hub by one hole.
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If the thickness is
outside the standard, replace disc rotor.
Standard thickness : 16.0 mm (0.630 in)
Wear limit : 14.0 mm (0.551 in)
Maximum uneven wear (measured at 8 positions):
0.02 mm (0.0008 in) or less

SBR020B

ASSEMBLY
CAUTION:
When assembling, do not use rubber grease.
1. Apply rubber lubricant to piston seals, and install them to the cyl-
inder body.
CAUTION:
Do not reuse piston seals.

SFIA0156E

2. Apply brake fluid to piston boots. Cover piston end with piston
boot. Install cylinder side boot lip properly into groove on cylin-
der body.
CAUTION:
Do not reuse piston boot.
3. Press piston into cylinder body by hand. Assemble piston side
boot lip properly into groove on the piston.
CAUTION:
Press piston evenly and change pressing point to prevent
the cylinder inner wall from being rubbed.
SFIA0157E

BR-36
 REAR DISC BRAKE

4. Fix piston boot with retaining ring.

CAUTION: A
● Be sure boot is securely engaged in groove on cylinder
body.
● Do not reuse retaining ring. B
5. Install sliding pins and sliding pin boots to torque member.
6. Install torque member to axle assembly and tighten mounting
bolts to the specified torque. C
CAUTION:
Wipe brake fluid and grease on axle assembly washer seats SFIA0158E
and torque member mounting surface. Install torque member to D
axle assembly.
7. Install pads, pad retainers, shims, and shim covers to torque member and assemble cylinder body.
8. Tighten sliding pin bolts to the specified torque. E
9. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
Do not reuse union bolt copper washer. BR
10. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-9, "Bleeding Brake
System"
G

BR-37
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications EFS000CQ

Unit: mm (in)
Brake model AD31VD
Front brake Cylinder bore diameter 44.4 × 2 (1.748 × 0.08)
Pad 132.0 × 52.5 × 11.0
Length x width x thickness (5.20 × 2.067 × 0.433)
Rotor outer diameter x thickness 280 × 28 (11.02 × 1.10)
Brake model AD9VA
Rear brake Cylinder bore diameter 34.9 (1.374)
Pad 83.0 × 33.0 × 8.5
Length x width x thickness (3.268 × 1.299 × 0.335)
Rotor outer diameter x thickness 292 × 16 (11.50 × 0.63)
Master cylinder Cylinder bore diameter 25.4 (1)
Control valve Valve model Electronic control type
Booster model C215T
Brake booster Diaphragm diameter Primary 230 (9.06)
Secondary 205 (8.07)
Recommended brake fluid DOT 3 or DOT 4

Brake Pedal EFS000CR

Pedal play 3 - 11 mm (0.12 - 0.43 in)

Looseness at clevis pin 1 - 3 mm (0.04 - 0.12 in)
M/T model 156 - 166 mm (6.14 - 6.54 in)
Brake pedal height (from dash panel top surface)
A/T model 164 - 174 mm (6.46 - 6.85 in)

Depressed pedal height under a force of 490 N (50 kg,110.6 lb) M/T model 80 mm (3.15 in) or more
(from dash panel top surface) A/T model 85 mm (3.35 in) or more
Clearance between threaded end of stop lamp switch and pedal stopper 0.74 - 1.96 mm (0.0291 - 0.0772 in)

Check Valve EFS000CS

Vacuum leakage [at vacuum of 66.7 kPa (-500 mmHg, -19.69

Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
inHg)]

Brake Booster EFS000CT

Vacuum type
Vacuum leakage [at vacuum of -66.7 kPa (-500 mmHg, -19.69
Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 seconds
inHg)]
Input rod installation standard dimension 125 mm (4.92 in)

Front Disc Brake EFS000CU

Brake type AD31VD

Standard thickness (new) 11 mm (0.43 in)
Brake pad
Repair limit thickness 2.0 mm (0.079 in)
Standard thickness (new) 28.0 mm (1.102 in)
Disc rotor Repair limit thickness 26.0 mm (1.024 in)
Runout limit 0.04 mm (0.0016 in)

BR-38
 SERVICE DATA AND SPECIFICATIONS (SDS)

Rear Disc Brake EFS000CV

A
Brake type AD9VA
Standard thickness (new) 8.5 mm (0.335 in)
Brake pad
Repair limit thickness 2.0 mm (0.079 in) B
Standard thickness (new) 16.0 mm (0.63 in)
Disc rotor Repair limit thickness 14.0 mm (0.55 in)
C
Runout limit 0.07 mm (0.0028 in)

BR

BR-39
SERVICE DATA AND SPECIFICATIONS (SDS)

BR-40