BRAKE SYSTEM

F BRAKES

SECTION
BRAKE SYSTEM
BR B

E
CONTENTS
PRECAUTIONS .......................................................... 3 INSTALLATION ................................................... 15 BR
Precautions for Supplemental Restraint System Inspection ............................................................... 16
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- INSPECTION ...................................................... 16
SIONER” .................................................................. 3 BRAKE MASTER CYLINDER .................................. 17 G
Precautions for Brake System .................................. 3 On-Board Inspection ............................................... 17
PREPARATION ........................................................... 4 LEAK INSPECTION ............................................ 17
Special Service Tools ............................................... 4 Removal and Installation ........................................ 17
H
Commercial Service Tools ........................................ 4 REMOVAL ........................................................... 17
NOISE, VIBRATION AND HARSHNESS (NVH) INSTALLATION ................................................... 17
TROUBLESHOOTING ................................................ 5 Components ........................................................... 17
NVH Troubleshooting Chart ..................................... 5 Disassembly and Assembly .................................... 18 I
BRAKE PEDAL .......................................................... 6 DISASSEMBLY ................................................... 18
Inspection and Adjustment ....................................... 6 ASSEMBLY ......................................................... 18
ADJUSTMENT ...................................................... 7 BRAKE BOOSTER ................................................... 19 J
Removal and Installation .......................................... 8 On-Vehicle Service ................................................. 19
COMPONENTS .................................................... 8 OPERATING CHECK .......................................... 19
REMOVAL ............................................................. 8 AIRTIGHT CHECK .............................................. 19
K
INSPECTION AFTER REMOVAL ......................... 9 Removal and Installation ........................................ 20
INSTALLATION ..................................................... 9 COMPONENTS ................................................... 20
BRAKE FLUID .......................................................... 10 REMOVAL ........................................................... 20
On-board Inspection ............................................... 10 INSPECTION AFTER REMOVAL ....................... 20 L
CHECKING BRAKE FLUID LEVEL .................... 10 INSTALLATION ................................................... 21
Drain and Refill ....................................................... 10 VACUUM LINES ....................................................... 22
Bleeding Brake System ...........................................11 Component ............................................................. 22 M
LHD MODEL ........................................................11 Removal and Installation ........................................ 23
RHD MODEL ........................................................11 Inspection ............................................................... 23
BRAKE TUBE AND HOSE ....................................... 12 VISUAL INSPECTION ......................................... 23
Hydraulic Circuit ..................................................... 12 CHECK VALVE INSPECTION ............................. 23
Removal and Installation of Front Brake Tube and FRONT DISC BRAKE ............................................... 24
Brake Hose ............................................................ 13 On-Board Inspection ............................................... 24
REMOVAL ........................................................... 13 PAD WEAR INSPECTION ................................... 24
INSTALLATION ................................................... 13 Components ........................................................... 24
Removal and Installation of Rear Brake Tube and Removal and Installation of Brake Pad .................. 25
Brake Hose ............................................................ 13 REMOVAL ........................................................... 25
REMOVAL ........................................................... 13 INSTALLATION ................................................... 25
INSTALLATION ................................................... 13 RemovalandInstallationofBrakeCaliperAssembly
Inspection after Installation .................................... 14 ... 26
LOAD SENSING VALVE .......................................... 15 REMOVAL ........................................................... 26
Removal and Installation ........................................ 15 INSTALLATION ................................................... 26
REMOVAL ........................................................... 15 Disassembly and Assembly of Brake Caliper

BR-1
 Assembly ................................................................ 26 REMOVAL ............................................................34
DISASSEMBLY ................................................... 26 INSTALLATION ....................................................34
INSPECTION AFTER DISASSEMBLY ................ 27 Disassembly and Assembly of Wheel Cylinder .......34
ASSEMBLY ......................................................... 28 DISASSEMBLY ....................................................34
DISC ROTOR INSPECTION ............................... 28 INSPECTION AFTER DISASSEMBLY ................34
BRAKE BURNISHING PROCEDURE ................. 29 ASSEMBLY ..........................................................34
REAR DRUM BRAKE ............................................... 30 SERVICE DATA AND SPECIFICATIONS (SDS) ......35
Components ........................................................... 30 General Specifications ............................................35
Removal and Installation of Drum Brake Assembly... 31 Brake Pedal ............................................................35
REMOVAL ........................................................... 31 Brake Booster .........................................................35
INSPECTION AFTER REMOVAL ........................ 32 Check Valve ............................................................35
INSTALLATION .................................................... 33 Front Disc Brake .....................................................35
Removal and Installation of Wheel Cylinder ........... 34 Rear Disc Brake ......................................................36

BR-2
 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EFS006DL

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 EFS005SD

● Clean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air. G
● Recommended fluid is brake fluid “DOT 3” or “DOT 4”.
● 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 H
on painted areas, wash it away with water immediately.
● To clean or wash all parts of master cylinder, disc brake caliper, wheel cylinder, use new brake fluid.
● Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. I
● Use a flare nut wrench when removing flare nuts, and use a flare
nut torque wrench when tighten flare nuts.
● Always tighten brake lines to the specified torque when install- J
ing.
● Before working, turn ignition switch OFF and disconnect electri-
cal connector of ABS actuator and electric unit (control unit) or K
the battery cables.
● Burnish the new brake surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal L
occurs at very low mileage.
Refer to BR-29, "BRAKE BURNISHING PROCEDURE" . SBR820BA

WARNING: M
Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.

BR-3
 PREPARATION

PREPARATION PFP:00002

Special Service Tools EFS005SE

Tool number
Description
Tool name

GG94310000
Flare nut torque wrench Installing brake tube and hose
a:10 mm (0.39 in)

NT406

KV991V0010
Brake fluid pressure measurement
Brake fluid pressure tester

ZZA0752D

Commercial Service Tools EFS005TE

Tool name Description

PBIC0190E
Power tool Removing front caliper assembly, tyres

PBIC0191E

BR-4
 Symptom

×: Applicable
suspected parts
Reference page

Brake
Possible cause and

Noise
Shake
Shimmy, Judder
NVH Troubleshooting Chart

Pads/Lining damaged BR-24, BR-32

×
×
Pads/Lining - uneven wear BR-24, BR-32

×
Shims damaged BR-24

×
×
Rotor imbalance BR-28

Rotor/Drum damage BR-28, BR-32

BR-5
Rotor runout/Drum inner diameter BR-28, BR-32

×
Rotor/Drum deformation BR-28, BR-32

×
Rotor deflection BR-28

×
Rotor rust —

×
Rotor thickness variation BR-29

×
×
Drum out of round BR-32

×
×
PROPELLER SHAFT NVH in PR section
×
DIFFERENTIAL NVH in FFD, 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 FAX and 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

EFS005SF

L
K
E
B
A

H
D
C

M
BR
 BRAKE PEDAL

BRAKE PEDAL PFP:46501

Inspection and Adjustment EFS005SG

Play and clearance inspection between brake pedal and floor panel with pedal depressed.
● Check brake pedal play.
● Check brake pedal height from dash lower panel (1).
● Adjust height referring to the following specifications.

SFIA2743J

182.1 − 192.1 mm
A/T
LHD (7.17 − 7.56 in)
model 174.7 − 184.7 mm
M/T
Brake pedal height (6.88 − 7.27 in)
H1
(From dash lower panel top surface) 171.2 − 181.2 mm
A/T
RHD (6.74 − 7.13 in)
model 164.1 − 174.1 mm
M/T
(6.46 − 6.85 in)
Brake pedal depressed height LHD model 120 mm (4.72 in) or more
H2 [Under a force of 490 N (50 kg, 110 lb) with engine
running] RHD model 110 mm (4.33 in) or more

Clearance between bracket (3) and threaded end of the stop lamp 0.74 − 1.96 mm
C
switch (2) (0.0291 − 0.0772 in)
3 − 11 mm
A Pedal play
(0.12 − 0.43 in)

BR-6
 BRAKE PEDAL

ADJUSTMENT
1. Loosen the stop lamp switch and by turning it counterclockwise A
by 45°.
2. Loosen lock nut (A) on the input rod, then turn input rod to adjust
the pedal to specified height, and tighten lock nut (A). B
CAUTION:
Make sure the threaded end of the input rod stays inside the
clevis. C
Lock nut (A) :18.7 N·m (1.9 kg-m, 14 ft-lb)
3. With the pedal pulled and held by hand, press the stop lamp D
switch and until its threaded end contacts the stopper.
4. With the threaded end of the stop lamp switch and contacting
the stopper, turn the switch clockwise by 45° to secure.
E
CAUTION:
Make sure that the clearance (C) between the bracket and
threaded end of the stop lamp switch and are within the
standard. BR
5. Check the pedal play.
CAUTION:
Make sure that the stop lamp goes off when the pedal is G
released.
PFIA0436E
6. Start the engine to check the brake pedal depressed height.
Refer to BR-6, "Inspection and Adjustment" . H

BR-7
 BRAKE PEDAL

Removal and Installation EFS005SH

COMPONENTS

SFIA3191E

1. Brake pedal assembly 2. Clip 3. Stop lamp switch

4. Snap pin 5. Brake pedal pad 6. Clevis pin
: Multi-purpose grease
Refer to GI section for symbol marks except in the above.

REMOVAL
1. Remove lower instrument panel LH. Refer to IP-13, "LOWER INSTRUMENT PANEL LH" .
2. Remove stop lamp switch and from brake pedal assembly.
3. Remove snap pin and clevis pin from input rod clevis.
4. Remove mounting nuts from pedal bracket, and remove brake
pedal assembly from vehicle.

PFIA0435E

BR-8
 BRAKE PEDAL

INSPECTION AFTER REMOVAL

● Check brake pedal upper rivet for deformation. A
● Make sure that the lapping length of sub-bracket and slide plate
is at least 4 mm (0.16 in).
● Check brake pedal for bend, damage, and cracks on the welded B
parts.
● Replace brake pedal assembly if any non-standard condition is
detected. C

SFIA2866E
D

● Check clevis pin and plastic stopper for damage and deforma-
tion. Replace clevis pin if there are. E

BR

SBR997

H
INSTALLATION
Installation is in the reverse order of the removal. Tightening torques for brake pedal assembly mounting nut
and bolt are referred to BR-8, "COMPONENTS" . Tightening torque for lock nut (A) is referred to Refer to BR-
7, "ADJUSTMENT" . I
● After installing the brake pedal assembly to the vehicle, adjust the brake pedal. Refer to BR-6, "Inspection
and Adjustment" .
J

BR-9
 BRAKE FLUID

BRAKE FLUID PFP:KN100

On-board Inspection EFS005SI

CHECKING BRAKE FLUID LEVEL

● Make sure the fluid level in the tank is within the standard
(between MAX and MIN lines).
● Visually check around the reservoir tank for fluid leakage.
● If fluid level is excessively low, check brake system for fluid leak-
age.
● Release parking brake lever and see if brake warning lamp goes
off. If not, check brake system for fluid leakage.

LFIA0225E

Drain and Refill EFS005SJ

CAUTION:
● Refill with new brake fluid “DOT 3” or “DOT 4”.
● 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, immediately wipe off them and wash it away with water.
● Before working, disconnect connector of ABS actuator and electric unit (control unit) or the bat-
tery cables.
1. Connect a vinyl tube to bleed valve.
2. Depress the brake pedal, loosen the bleed valve, and gradually
remove the brake fluid.

BRA0007D

3. Clean inside of reservoir tank, and refill with new brake fluid.
4. Loosen bleed valve, depress brake pedal slowly to full stroke
and then release it. Repeat the procedure every 2 or 3 seconds
until the new brake fluid comes out, then close the bleed valve
while depressing the pedal. Repeat the same work for each
wheel.

5. Bleed air. Refer to BR-11, "Bleeding Brake System" .

BRA0006D

BR-10
 BRAKE FLUID

Bleeding Brake System EFS005SK

A
CAUTION:
● While bleeding, pay attention to master cylinder fluid level.
● Before working, disconnect electrical connector of ABS actuator and electric unit (control unit) or
the battery cable from the negative terminal. B

LHD MODEL
1. Connect a vinyl tube to the rear right bleed valve. C
2. Fully depress brake pedal 4 to 5 times.
3. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately.
4. Repeat steps 3, 4 until no more air comes out. D
5. Tighten bleed valve to specified torque. Refer to BR-24, "Components" (front disc brake), BR-30, "Com-
ponents" (rear drum brake).
6. From the steps 1 to 5 above, with master cylinder reservoir tank filled at least half way, bleed air from the E
front left, rear left, and front right brake, in that order.
RHD MODEL
1. Connect a vinyl tube to the rear left bleed valve. BR
2. Fully depress brake pedal 4 to 5 times.
3. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately.
G
4. Repeat steps 3, 4 until no more air comes out.
5. Tighten bleed valve to specified torque. Refer to BR-24, "Components" (front disc brake), BR-30, "Com-
ponents" (rear drum brake).
H
6. From the steps 1 to 5 above, with master cylinder reservoir tank filled at least half way, bleed air from the
front right, rear right, and front left brake, in that order.
I

BR-11
 BRAKE TUBE AND HOSE

BRAKE TUBE AND HOSE PFP:46300

Hydraulic Circuit EFS005SL

LHD MODEL

SFIA3192E

1. Front disc brake 2. Master cylinder 3. Brake booster

4. Connector 5. ABS actuator and electric unit (con- 6. Rear drum brake
trol unit)
7. Load sensing valve :Brake tube :Brake hose
: Flare nut : Connector mounting bolt : Union bolt
: 16.2 N·m (1.7 kg-m, 12.0 ft-lb) : 7.0 N·m (0.71 kg-m, 62.0 in-lb) : 18.2 N·m (1.9 kg-m, 13.0 ft-lb)

RHD MODEL

SFIA3193E

1. Front disc brake 2. Master cylinder 3. Brake booster

4. Connector 5. ABS actuator and electric unit (con- 6. Rear drum brake
trol unit)
7. Load sensing valve :Brake tube :Brake hose
: Flare nut : Connector mounting bolt : Union bolt
: 16.2 N·m (1.7 kg-m, 12.0 ft-lb) : 7.0 N·m (0.71 kg-m, 62.0 in-lb) : 18.2 N·m (1.9 kg-m, 13.0 ft-lb)

BR-12
 BRAKE TUBE AND HOSE

CAUTION:
● All brake tubes and hoses must be free from excessive bending, twisting and pulling. A
● Make sure that there is no interference with other parts when turning steering both clockwise and
counterclockwise.
● Brake tube and hose is an important safety part. Always disassemble the parts and retighten their B
fittings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is
detected.
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is C
splashed on painted surfaces of body, immediately wipe off them and wash it away with water.
● Do not bend or twist brake hose sharply, or strongly pull it.
● Cover the open end of brake tube and hoses when disconnecting to prevent entrance of dirt. D
● Refill with new brake fluid “DOT 3” or “DOT 4”.
● Never reuse drained brake fluid.
E
Removal and Installation of Front Brake Tube and Brake Hose EFS005SM

REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
BR
2. Using a flare nut wrench, disconnect brake tube from brake hose.
3. Remove union bolt and remove brake hose from caliper assembly.
4. Remove lock plate and remove brake hose from vehicle. G
INSTALLATION
1. Assemble the union bolt and copper washers to the brake hose.
2. Insert brake hose by aligning with the protrusion on caliper H
assembly, and tighten union bolt to the specified torque. Refer to
BR-12, "Hydraulic Circuit" .
3. Connect brake hose to the brake tube, partially tighten the flare I
nut as much as possible by hand, then secure it to the bracket
with lock plate.
4. Using flare nut torque wrench, tighten flare nut to the specified J
torque. Refer to BR-12, "Hydraulic Circuit" .
5. Refill brake fluid and bleed air. Refer to BR-11, "Bleeding Brake
System" . K
SFIA2290E

Removal and Installation of Rear Brake Tube and Brake Hose EFS005SN

REMOVAL L
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Using a flare nut wrench, disconnect brake tube from brake hose, wheel cylinder and load sensing valve.
3. Remove lock plate and remove brake tube from vehicle. M
INSTALLATION
1. Insert brake tube, then secure it to bracket with lock plate.
2. Install brake tube to brake hose, wheel cylinder and load sensing valve, then tighten the flare nut to the
specified torque using a flare nut torque wrench. Refer to BR-12, "Hydraulic Circuit" .
3. Refill brake fluid and bleed air. Refer to BR-11, "Bleeding Brake System" .

BR-13
 BRAKE TUBE AND HOSE

Inspection after Installation EFS005SO

CAUTION:
Brake tubes and hoses are important safety parts. Always disassemble the parts and retighten their fit-
tings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is
detected.
1. Check hydraulic brake lines (tubes and hoses) and connections for fluid leakage, damage, twists, defor-
mations, contacts with other parts, and loose connections. Replace any damage parts.
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running at idle speed for
approximately 5 seconds, check each part for fluid leakage.

BR-14
 LOAD SENSING VALVE

LOAD SENSING VALVE PFP:46400

A
Removal and Installation EFS006A7

BR

SFIA3190E

1. Torsion member 2. Load sensing valve bracket 3. Load sensing valve J

4. Stopper 5. Sensor spring 6. Rear axle tube
Refer to GI section for symbol marks in the figure.
K
CAUTION:
● Always use a flare nut wrench to remove brake tube. Be careful not to damage flare nut and brake
tube. Also, use flare nut torque wrench for brake tube installation and tightening to the specified
torque. Refer to BR-12, "Hydraulic Circuit" . L
● Refill with new brake fluid “DOT 3” or “DOT 4”.
● Never reuse drained brake fluid.
M
REMOVAL
1. Drain brake fluid.
2. Cover brake line connections/openings to protect them from foreign material such as dust or dirt.
3. Using a flare nut wrench, remove flare nut on brake tube from load sensing valve.
4. Remove mounting bolts to remove load sensing valve.
INSTALLATION
● Carefully performing the following, install in the reverse order of removal.
● After installing load sensing valve to vehicle, perform the following: bleed air from brake line. Refer to BR-
11, "Bleeding Brake System" , and check mounting length “L” of sensor spring.

BR-15
 LOAD SENSING VALVE

Inspection EFS006A8

INSPECTION
1. With the vehicle in unladen condition, a person should sit in driver's seat at the rear. Then he/she should
get out of car gently. (This is to stabilize suspension deflection.)
NOTE:
“Unladen condition”: with full coolant, lubricant, 6 to 8 litters of fuel, spare tyre, jack, and hand tools
loaded.
2. Press load sensing valve against stopper bolt. Check if center-to-center length “L” between adjusting ref-
erence hole and reference pin is as specified below.
Length “L” : 143.9 − 146.9 mm (5.67 − 5.78 in)
● If measurement is outside the standard, perform following;
loosen mounting bolt of sensor spring bracket. By moving
sensor spring bracket, adjust so that the length “L” comes into
specified range.
3. Connect brake fluid pressure tester (special service tool) to
bleed valves of front caliper and rear wheel cylinder.
4. Bleed air from brake fluid pressure tester (special service tool).
5. With brake pedal depressed, check brake fluid pressure at front
caliper and rear wheel cylinder. The respective measurements
should be as specified in the table below.
SFIA0245E

6. Under condition of step 2 above, adjust rear shaft weight with

weights to obtain 143.9 − 146.9 mm (5.67 − 5.78 in) as length
“L”. Then, check brake fluid pressure as described in step 5
above. If measurements are outside the standards, replace load
sensing valve main body.

BRA0515D

Standard

Rear wheel cylinder brake fluid pressure MPa (kg/cm2 )

Front caliper brake fluid pressure
2WD 4WD
MPa (kg/cm2 )
unladen loaded unladen loaded
3.2 − 4.2 3.9 − 5.9 1.8 − 2.7 3.9 − 5.9
4.9 (50)
(33 − 43) (40 − 60) (18 − 28) (40 − 60)
4.1 − 5.1 6.3 − 8.3 2.6 − 3.6 7.0 − 8.9
9.8 (100)
(42 − 52) (65 − 85) (27 − 37) (71 − 91)
7. After inspection, remove brake fluid pressure tester (special service tool) and bleed air. Refer to BR-11,
"Bleeding Brake System" .

BR-16
 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

A
On-Board Inspection EFS005SP

LEAK INSPECTION
● Check for fluid leakage from master cylinder attachment portion such as reservoir tank and brake tube B
connections.
Removal and Installation EFS005SQ

CAUTION: C
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas immediately wipe off then and wash it away with water.
D
REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Using flare nut wrench, disconnect brake tube from master cylinder assembly.
E
3. Remove master cylinder assembly mounting nuts and master cylinder assembly.
INSTALLATION
● Installation is in the reverse order of the removal. BR
● Refill brake fluid and bleed air. Refer to BR-11, "Bleeding Brake System" .
CAUTION:
● Refill with new brake fluid “DOT 3” or “DOT 4”. G
● Never reuse drained brake fluid.
Components EFS005SR
H

SFIA3101E

1. Reservoir cap 2. Brake fluid level switch 3. Grommet

4. Master cylinder assembly 5. Reservoir tank 6. Screw
7. Screw : Brake fluid
Refer to GI section for symbol marks except in the above.

BR-17
 BRAKE MASTER CYLINDER

Disassembly and Assembly EFS005SS

DISASSEMBLY
CAUTION:
● Master cylinder assembly cannot be disassembled.
● Remove reservoir tank only when absolutely necessary.
Pull reservoir tank off master cylinder sub-assembly, then remove grommets from master cylinder sub-assem-
bly body.
ASSEMBLY
CAUTION:
● Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
● Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid to the grommet and attach to the cylinder body.
2. Install reservoir tank onto the cylinder body.

BR-18
 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

A
On-Vehicle Service EFS005ST

OPERATING CHECK
With engine stopped, change vacuum to atmospheric pressure by B
depressing brake pedal several times. Then with brake pedal fully
depressed, start engine and when vacuum pressure reaches the
standard, make sure that clearance between brake pedal and floor
panel decreases. C

BRA0037D
E
AIRTIGHT CHECK
● Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to BR
change vacuum to atmospheric pressure. Make sure that dis-
tance at intervals of 5 seconds between brake pedal and floor
panel gradually increases. G
● Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change after
holding pedal down for 30 seconds.
H

SBR365AA
I

BR-19
 BRAKE BOOSTER

Removal and Installation EFS005SU

COMPONENTS

SFIA3194E

1. Reservoir tank 2. Master cylinder 3. Gasket

4. Brake pedal 5. Lock nut 6. Brake booster
7. Spacer
Refer to GI section for symbol marks in the figure.

REMOVAL
CAUTION:
● Be careful not to deform or bend brake tube while removing and installing the brake booster.
● Replace clevis pin if it is damaged.
● Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, the dash panel may damage the threads.
1. Remove ABS actuator and electric unit (control unit). Refer to BRC-40, "Removal and Installation" .
2. Remove brake tube from brake master cylinder.
3. Remove brake master cylinder. Refer to BR-17, "Removal and Installation" .
4. Remove vacuum hose from brake booster. Refer to BR-23, "Removal and Installation" .
5. Remove brake pedal attachment snap pin and clevis pin from inside vehicle.
6. Remove nuts on brake booster and brake pedal assembly.
7. Remove brake booster assembly from dash panel.
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.
Standard dimension at a vacuum of –66.7 kPa
(–500 mmHg, –19.69 inHg)
: –15.6 mm - 15.9 mm (–0.614 - 0.626 in)

SBR208E

BR-20
 BRAKE BOOSTER

INSTALLATION
1. Loosen the lock nut to adjust the input rod length so that the A
length B (in the figure) satisfies the specified value.
Length “B” : 145 - 152 mm (5.71- 5.98 in)
B
2. After adjusting “B”, temporarily tighten the lock nut to install the
booster assembly to the vehicle. At this time, securely install a
gasket and spacer block between the booster assembly and the
dash panel. C
3. Connect brake pedal with the clevis of the input rod.
4. Install brake booster mounting nuts and tighten them to the
D
specified torque.Refer to BR-20, "COMPONENTS" . SGIA0060E

5. Install brake tube from brake master cylinder to ABS actuator and electric unit (control unit). Refer to BR-
12, "Hydraulic Circuit" .
E
6. Connect vacuum hose to brake booster.
7. Install master cylinder to brake booster assembly. Refer to BR-17, "Removal and Installation" .
8. Adjust the height and play of brake pedal.Refer to BR-6, "Inspection and Adjustment" . BR
9. Tighten lock nut of input rod to the specified torque. Refer to BR-7, "ADJUSTMENT" .
10. Refill new brake fluid and bleed air. Refer to BR-11, "Bleeding Brake System" .
G

BR-21
 VACUUM LINES

VACUUM LINES PFP:41920

Component EFS005SV

LHD MODEL

SFIA3009E

1. Clamp 2. Vacuum hose 3. Vacuum tube

4. Vacuum hose 5. Clip 6. Connector
7. Vacuum hose 8. For brake booster 9. For vacuum pump
Refer to GI section for symbol marks in the figure.

RHD MODEL

SFIA3010E

BR-22
 VACUUM LINES

1. Clamp 2. Vacuum hose 3. Vacuum tube

4. Vacuum hose 5. For vacuum pump 6. For brake booster
A
Refer to GI section for symbol marks in the figure.

Removal and Installation EFS005SW B

CAUTION:
● Because vacuum hose contains a check valve, it must be
installed in the correct position. Refer to the stamp to con- C
firm correct installation. Brake booster will not operate nor-
mally if the hose is installed in the wrong direction.
● Insert vacuum hose at least 24 mm (0.94 in). D
● Do not use lubricating oil during assembly.

SBR225B

BR
Inspection EFS005SX

VISUAL INSPECTION
Check for correct assembly, damage and deterioration. G
CHECK VALVE INSPECTION
Airtightness Inspection
Check vacuum with a handy vacuum pump. H
When connected to the booster side (1):
Vacuum should decrease within 1.3 kPa (10 I
mmHg, 0.39 inHg) for 15 seconds under a vacuum
of −66.7 kPa (−500 mmHg, −19.69 inHg).
When connected to the engine side (2): J
Vacuum should not exist.
● Replace vacuum hose assembly if vacuum hose and check
valve are malfunctioning. SFIA0210E
K

BR-23
 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

On-Board Inspection EFS005SY

PAD WEAR INSPECTION

● Check pad thickness from a inspection hole on cylinder body.
Check using a scale if necessary.
Standard thickness : 11.0 mm (0.43 in)
Repair limit thickness : 2.0 mm (0.08 in)

MAA0439D

Components EFS005SZ

SFIA3168E

1. Union bolt 2. Copper washer 3. Brake hose

4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Sliding pin 12. Sliding pin boot
13. Bushing 14. Torque member mounting bolt 15. Torque member
16. Inner shim 17. Inner pad 18. Pad wear sensor (RH side)
19. Pad retainer 20. Outer pad 21. Outer shim
1: Rubber grease 2: PBC (Poly Butyl Cuprysil) grease 3: Polyglycol ether based lubricant
or silicone-based grease

BR-24
 FRONT DISC BRAKE

: Brake fluid
A
Refer to GI section for symbol marks except in the above.

WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air- borne B
particles or other materials.
CAUTION:
● While removing cylinder body, do not depress brake pedal because piston will pop out. C
● It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch
brake hose.
D
● Do not damage piston boot.
● If any shim is subject to serious corrosion, replace it with a new one.
● Always replace shim as a set when replacing brake pad. E
● Keep rotor out of brake fluid.
Removal and Installation of Brake Pad EFS005T0

REMOVAL BR
1. Remove tyre from vehicle.
2. Remove lower sliding pin bolt.
G
3. Hang cylinder body with a wire. Remove pad assembly and pad retainer from torque member.
CAUTION:
When removing the pad retainer from the torque member, lift it in the direction indicated by the
H
arrow in the figure so that it does not deform.
INSTALLATION
1. Install inner shim to inner pad, and outer shim to outer pad. I
2. Install pad retainers and pad assembly to torque member.
3. Press in piston until pads can be installed, and then install cylin-
der body to torque member. J
CAUTION:
● When installing pad retainer, attach it firmly so that it
does not flat up higher than torque member, as shown in K
the figure.
● In the case of replacing pad with new one, check a brake
fluid level in the reservoir tank because brake fluid
L
returns to master cylinder reservoir tank when pressing
piston in. PFIA0273E

4. Install lower sliding pin bolt and tighten to the specified torque. Refer to BR-24, "Components" .
M
5. Check front disc brake for drag.
6. Install tyre to vehicle.

BR-25
 FRONT DISC BRAKE

Removal and Installation of Brake Caliper Assembly EFS005T1

REMOVAL
1. Remove tyre from vehicle.
2. Fasten disc rotor using wheel nut.
CAUTION:
Align the matching marks of disc rotor and wheel hub, which were marked at the time of removal
when reusing disc rotor.
3. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
4. Remove union bolt and then disconnect brake hose from caliper
assembly.
5. Remove torque member mounting bolt, and remove brake cali-
per assembly.

SFIA0140E

INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT 3” or “DOT 4”.
● Never reuse drained brake fluid.
1. Install brake caliper assembly to vehicle, and tighten torque member mounting bolts to the specified
torque. Refer to BR-24, "Components" .
CAUTION:
Before installing caliper assembly, wipe off oil and moisture on all mounting surfaces of steering
knuckle and caliper assembly and threads, bolts.
2. Install brake hose and then tighten union bolt to the specified torque. Refer to BR-12, "Hydraulic Circuit" .
3. Refill with new brake fluid and bleed air. Refer to BR-11, "Bleeding Brake System" .
4. Check front disc brake for drag.
5. Install tyre to vehicle.
Disassembly and Assembly of Brake Caliper Assembly EFS005T2

DISASSEMBLY
NOTE:
Do not remove torque member, pads, shims, and pad retainers when disassembly and assembly cylinder
body assembly.
1. Remove sliding pin bolts. And then remove the pad assembly and pad retainers from torque member, if
necessary.
CAUTION:
When removing the pad retainer from the torque member, lift it in the direction indicated by the
arrow in the figure so that it does not deform.

2. Remove sliding pins and sliding pin boots from torque member.

BR-26
 FRONT DISC BRAKE

3. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots. A
CAUTION:
Do not get fingers caught in the piston.
B

BRB0032D

D
4. Using a flat-bladed screwdriver, remove piston seal from cylin-
der body.
CAUTION: E
Be careful not to damage cylinder inner wall.

BR

G
SFIA0141E

INSPECTION AFTER DISASSEMBLY H

Cylinder Body
Check inner wall of cylinder for corrosion, wear, and damage. If a malfunction is detected, replace cylinder
body. I
CAUTION:
Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
Torque Member J
Check torque member for wear, cracks, and damage. If a malfunction is detected, replace applicable part.
Piston
K
Check piston surface for corrosion, wear, and damage. If a malfunction is detected, replace applicable part.
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper. L
Sliding Pin, Sliding Pin Bolt and Sliding Pin Boot
Check sliding pin, sliding pin bolt and sliding pin boot for wear, damage, and cracks. If a malfunction is
detected, replace applicable part. M

BR-27
 FRONT DISC BRAKE

ASSEMBLY
CAUTION:
When assembling, use only rubber lubricant specified below.
1. Apply polyglycol ether based lubricant to the piston seal, and
install them to the cylinder body.

SFIA2920E

2. Apply brake fluid to piston and apply rubber grease to piston

boot. Cover the piston end with the piston boot, and then install
cylinder side lip of the piston boot securely into the groove on
cylinder body.
3. Insert piston into cylinder body by hand and insert piston boot
piston-side lip into the piston groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre-
vent cylinder inner wall from being rubbed.

SFIA2279E

4. Install sliding pin and sliding pin boot to torque member.

5. If pad assemblies are removed, install pad assemblies to torque member. Refer to BR-25, "Removal and
Installation of Brake Pad" .

6. Install cylinder body to torque member, and then tighten sliding pin bolt to the specified torque. Refer to
BR-24, "Components" .
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any of them is detected, replace
applicable part.
Runout Inspection
1. Using wheel nuts, secure disc rotor to wheel hub. (2 or more positions)
2. Check runout using a dial indicator.
[measured at 10 mm (0.39 in) inside the disc edge]
Runout limit : 0.05 mm (0.002 in)
(with it attached to the vehicle)
CAUTION:
Make sure that wheel bearing axial end play is within the
specifications before measuring runout. Refer to FAX-5,
"WHEEL BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting mounting positions of disc rotor and wheel hub by one
hole. BRA0013D

4. If runout is still out of the specification, refinish the disc rotor with
on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equivalent). Or replace the disc rotor.

BR-28
 FRONT DISC BRAKE

Thickness Inspection
Using a micrometer, check thickness of the disc rotor. If thickness is A
outside the standard, replace disc rotor.
Standard thickness : 28.0 mm (1.102 in)
B
Repair limit : 26.0 mm (1.024 in)
Thickness variation : 0.005 mm (0.0002 in)
(measured at 8 positions)
C

SBR020B
D

BRAKE BURNISHING PROCEDURE

Burnish the new braking surface according to the following procedure after refinishing or replacing rotors, after E
replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
BR
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.
G
3. To cool brake system, drive the 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.
H

BR-29
 REAR DRUM BRAKE

REAR DRUM BRAKE PFP:43206

Components EFS006AF

SFIA3199E

1. Plug 2. Shoe hold pin 3. Back plate

4. Boot 5. Piston 6. Piston cup
7. Cap 8. Bleed valve 9. Wheel cylinder
10. Spring 11. Pin 12. Adjuster lever
13. Toggle lever 14. Adjuster 15. Conical washer
16. Shoe (trailing side) 17. Shoe (leading side) 18. Retainer ring
19. Retainer 20. Adjuster spring 21. Return spring (lower side)
22. Return spring (upper side) 23. Drum : Brake fluid

1: PBC (Poly Butyl Cuprysil) grease 2: Rubber grease 3: Polyglycol ether based lubricant
or silicone-based grease
Refer to GI section for seasonal marks except in the above.

WARNING:
Clean dust on drum and back plate with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.
CAUTION:
Make sure parking brake lever is released completely.

BR-30
 REAR DRUM BRAKE

Removal and Installation of Drum Brake Assembly EFS006AG

REMOVAL A
1. Remove tyre from the vehicle.
2. With the parking brake lever released, remove the brake drum. If it is difficult to remove brake drum,
remove as follows: B
a. Press up adjuster lever with a wire or equivalent from plug hole
(plug hole at the side of wheel cylinder) on the back plate as
shown in the figure. Turn frame of adjuster assembly with a flat C
bladed screw driver in the direction that narrows frame to narrow
enlarged brake shoe.
D

E
SFIA3080E

3. While pushing and rotating the retainer, pull out shoe hold pin, BR
and remove shoe assembly.
CAUTION:
Do not damage the wheel cylinder boot. G

SFIA3200E I

4. Remove the parking brake rear cable from the operating lever.
CAUTION: J
Do not bend the parking brake cable.
5. Disassemble the shoe assembly (shoe, springs, adjuster,
adjuster lever). K

SFIA3201E

6. Remove retainer ring with a tool to separate operating lever from

brake shoe.
A: Retainer ring
B: Contact point
C: Operating lever
D: Pin

SFIA3075E

BR-31
 REAR DRUM BRAKE

INSPECTION AFTER REMOVAL

Lining Thickness Inspection
Check lining thickness.
Standard thickness (A) : 5.5 mm (0.22 in)
Repair limit thickness (A) : 1.5 mm (0.06 in)

SBR021A

Drum Inner Diameter Inspection

Check inner diameter of brake drum.
Measurement area: lining contact surface (center)
Standard inner diameter : 295 mm (11.61 in) dia.
Repair limit inner diameter : 296.5 mm (11.67 in) dia.

SBR022A

Wheel Cylinder Leakage Inspection

● Check wheel cylinder for brake fluid leakage.
● Check for wear, damage, and looseness. If any non-standard
condition is found, replace it.

SFIA0657J

Other Inspections
Check the following:
● Inside of the drum for excessive wear, damage, and cracks.
● Lining for excessive wear, damage, and peeling.
● Shoe sliding surface for excessive wear and damage.
● Return spring for sagging.
Replace with new part if the above part is malfunction.
● Check back plate for damage, cracks, and deformation. If malfunction is detected, repair or replace it.

BR-32
 REAR DRUM BRAKE

INSTALLATION
1. When removing operating lever, install following procedure. A
a. Install operating lever to brake shoe.
b. Install retainer ring to operating lever, and crimp them until their
contact points are met. B

A: Retainer ring
B: Contact point C
C: Operating lever
D: Pin
SFIA3075E
D

2. Apply rubber grease to brake shoes sliding surfaces (the

shaded areas) and other parts on the back plate as indicated by E
arrows in the figure.

BR

BRE0220D

H
3. Apply rubber grease to screw and confirm the difference
between right and left wheel for assembling when disassem-
bled.
I
Right rear Thread cutting : Right-hand screw
wheel direction
Left rear Thread cutting : Left-hand screw J
wheel direction

K
SFIA3076E

4. Assemble the shoe, adjuster, adjuster lever and springs to the

shoe assembly. L

SFIA3202E

5. Connect the parking brake rear cable to the operating lever.

6. Install the shoe assembly. After assembly, be sure that each part is installed properly.
CAUTION:
Do not damage the wheel cylinder piston boot.
7. Install the brake drum.
8. Depress brake pedal for several time (approximately 2, 3 time).
9. Adjust clearance of brake shoe. Refer to PB-2, "ADJUSTMENT" .
10. Install tyres to the vehicle.

BR-33
 REAR DRUM BRAKE

Removal and Installation of Wheel Cylinder EFS006AH

REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Remove rear brake shoe assembly.
3. Remove brake tube from the wheel cylinder.
4. Remove bolts on the wheel cylinder, and then remove wheel cylinder from the back plate.
INSTALLATION
● Installation is the reverse order of removal. Tighten bolts to the specified torque. Refer to BR-30, "Compo-
nents" .
● Refill with new brake fluid and bleed air. Refer to BR-11, "Bleeding Brake System" .
Disassembly and Assembly of Wheel Cylinder EFS006AI

DISASSEMBLY
1. Remove boots at the right and left of the wheel cylinder, and pull
out the pistons from cylinder.
2. Remove piston from piston cup.

SFIA3077E

INSPECTION AFTER DISASSEMBLY

Check the pistons, piston cups, and inner wall of the cylinder for wear, corrosion, and damage. If malfunction
is detected, replace it.
ASSEMBLY
CAUTION:
● Do not use Nissan rubber grease (KRE0000010, KRE000001001) during assembly.
● When inserting the piston, be careful not to scratch the cylinder.
1. Apply brake fluid to the piston sliding surface on the wheel cylinder.
2. Apply polyglycol ether based lubricant to the piston cups and
piston boots and assemble as shown in the figure.

SFIA3078E

BR-34
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
General Specifications EFS005T8

Unit: mm (in)
Front brake Brake model CLZ33VB
B
Cylinder bore diameter 46.4 (1.83) × 2
Pad length × width × thickness 140 × 47.8 × 11 (5.51 × 1.88 × 0.43)
Rotor outer diameter × thickness 296 × 28 (11.65 × 1.10) C
Rear brake Brake model LT30
Cylinder bore diameter 38.1 (1.50)
D
Lining Length × width × thickness 295 × 55 × 5.5 (11.61 × 2.17 × 0.22)
Drum inner diameter 295 (11.61)
Master cylinder Cylinder bore diameter 25.4 (1.0) E
Control valve Valve model Electric brake force distribution
Brake booster Booster model C215T
BR
Primary 228.5 (9.0)
Diaphragm diameter
Secondary 203 (8.0)
Recommended brake fluid DOT 3 or DOT 4 G
Brake Pedal EFS005T9

Unit: mm (in)
H
A/T 164.1 − 174.1 (6.46 − 6.85)
LHD model
M/T 171.2 − 181.2 (6.74 − 7.13)
Brake pedal height (From dash lower panel top surface)
A/T 174.7 − 184.7 (6.88 − 7.27) I
RHD model
M/T 182.1 − 192.1 (7.17 − 7.56)

Brake pedal depressed height [Under a force of 490 N (50 kg, 110 lb) LHD model 120 (4.72) or more
with the engine running] J
RHD model 110 (4.33) or more
Clearance between bracket and the threaded end of the stop lamp switch 0.74 - 1.96 (0.0291 - 0.0772)
Pedal play 3 - 11 (0.12 - 0.43) K
Brake Booster EFS005TA

Vacuum type
Unit: mm (in) L
Input rod installation standard dimension 145 - 152 (5.71 - 5.98)

Check Valve EFS005TB M

Vacuum leakage
within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
[at vacuum of –66.7 kPa (–500 mmHg, –19.69 inHg)]

Front Disc Brake EFS005TC

Unit: mm (in)
Brake model CLZ33VB
Standard thickness 11.0 (0.43)
Brake pad
Repair limit thickness 2.0 (0.08)
Standard thickness 28.0 (1.102)
Repair limit 26.0 (1.024)
Disc rotor
Thickness variation (measured at 8 positions) 0.005 (0.0002)
Runout limit (with it attached to the vehicle) 0.05 (0.002)

BR-35
 SERVICE DATA AND SPECIFICATIONS (SDS)

Rear Disc Brake EFS005TD

Unit: mm (in)
Brake model LT30
Standard thickness 5.5 (0.22)
Brake lining
Repair limit thickness 1.5 (0.06)
Standard inner diameter 295 (11.61)
Drum
Repair limit inner diameter 296.5 (11.67)

BR-36