BR PDF

BRAKES
BR
A
B
SECTION
BRAKE SYSTEM C
E
CONTENTS
PRECAUTION ............................................... 3 BRAKE MASTER CYLINDER .......................... 11 BR
Inspection ................................................................11
PRECAUTIONS ................................................... 3
Precaution for Supplemental Restraint System BRAKE TUBE AND HOSE ............................... 12 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Hydraulic Circuit ......................................................12
SIONER" ................................................................... 3
FRONT BRAKE .........................................................12
Precaution for Procedure without Cowl Top Cover...... 3
FRONT BRAKE : Inspection ....................................12 H
Precaution for Brake System .................................... 3
REAR BRAKE ............................................................13
PREPARATION ............................................ 5 REAR BRAKE : Inspection ......................................13
I
PREPARATION ................................................... 5
PERIODIC MAINTENANCE ........................ 14
Special Service Tool ................................................. 5
Commercial Service Tool .......................................... 5 BRAKE PEDAL ................................................. 14 J
Inspection and Adjustment ......................................14
SYMPTOM DIAGNOSIS ............................... 6
BRAKE FLUID .................................................. 16
NOISE, VIBRATION AND HARSHNESS Inspection ................................................................16 K
(NVH) TROUBLESHOOTING ............................. 6 Drain and Refill ........................................................16
NVH Troubleshooting Chart ...................................... 6 Bleeding Brake System ...........................................16
BASIC INSPECTION .................................... 7 L
REMOVAL AND INSTALLATION ............... 18
FRONT DISC BRAKE ......................................... 7 BRAKE PEDAL ................................................. 18
BRAKE PAD ................................................................ 7 Exploded View .........................................................18 M
BRAKE PAD : Inspection of Pad ............................... 7 Removal and Installation .........................................18
DISC ROTOR ............................................................... 7 BRAKE TUBE AND HOSE ............................... 20

N
DISC ROTOR : Inspection of Rotor .......................... 7 Hydraulic Circuit ......................................................20
Removal and Installation of Front Brake Piping
REAR DISC BRAKE ........................................... 8 and Brake Hose .......................................................20
Removal and Installation of Rear Brake Piping O
BRAKE PAD ................................................................ 8 and Brake Hose .......................................................21
BRAKE PAD : Inspection of Pad ............................... 8 Inspection After Installation .....................................22
DISC ROTOR ............................................................... 8 P
BRAKE MASTER CYLINDER .......................... 24
DISC ROTOR : Inspection of Rotor .......................... 8
Exploded View .........................................................24
BRAKE BOOSTER ............................................. 9 Removal and Installation .........................................24
Inspection .................................................................. 9 BRAKE BOOSTER ........................................... 26
VACUUM LINES .................................................10 Exploded View .........................................................26
Inspection ................................................................ 10 Removal and installation .........................................26
Revision: August 2012 BR-1 2012 Maxima

VACUUM LINES ................................................ 28 UNIT DISASSEMBLY AND ASSEMBLY ... 39
Exploded View ........................................................ 28
Removal and Installation ........................................ 28 FRONT DISC BRAKE ....................................... 39
Disassembly and Assembly .................................... 39
FRONT DISC BRAKE ........................................ 30
Exploded View of Brake Pads ................................ 30 REAR DISC BRAKE .......................................... 42
Removal and Installation of Brake Pads ................. 30 Disassembly and Assembly .................................... 42
Brake Burnishing Procedure ................................... 31
Exploded View of Brake Caliper ............................. 32 SERVICE DATA AND SPECIFICATIONS
Removal and Installation of Brake Caliper and Ro- (SDS) .......................................................... 45
tor ........................................................................... 32
SERVICE DATA AND SPECIFICATIONS
REAR DISC BRAKE .......................................... 35 (SDS) ................................................................. 45
Exploded View of Brake Pads ................................ 35 General Specifications ............................................ 45
Removal and Installation of Brake Pads ................. 35 Brake Pedal ............................................................ 45
Brake Burnishing Procedure ................................... 36 Check Valve ............................................................ 46
Exploded View of Brake Caliper ............................. 37 Brake Booster ......................................................... 46
Removal and Installation of Brake Caliper and Ro- Front Disc Brake ..................................................... 46
tor ........................................................................... 37 Rear Disc Brake ...................................................... 46

PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000007254761
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. D
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING: E
• 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 performed by
an authorized NISSAN/INFINITI dealer.
BR
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this G
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS H
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a I
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the J
battery, and wait at least 3 minutes before performing any service.
Precaution for Procedure without Cowl Top Cover INFOID:0000000007254762
K
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
L
N
PIIB3706J
Precaution for Brake System INFOID:0000000007254763

O
• Clean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air.
• Always use recommended brake fluid. Refer to MA-18, "FOR USA AND CANADA : Fluids and Lubricants"
(for United States and Canada) or, MA-19, "FOR MEXICO : Fluids and Lubricants" (for Mexico). P
• 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 with water immediately.
• Use clean brake fluid to clean or wash all parts of master cylinder and disc brake caliper, etc.
• Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.

PRECAUTIONS
< PRECAUTION >
• Use flare nut torque wrench when installing brake tube.
• When installing brake tube and hose, be sure to check torque.
• Before working, turn ignition switch OFF and disconnect connec-
tors of ABS actuator and electric unit (control unit) or battery cable
from the negative terminal.
• Burnish the brake contact surfaces after refinishing or replacing
rotors, after replacing pads, or if a soft pedal occurs at very low
mileage. Refer to BR-31, "Brake Burnishing Procedure".
WARNING:
• Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector. SBR686C

PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000007254764
B
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.) C
Tool name
— Measuring brake pedal height
(J-46532) D
Brake and clutch pedal height mea-
surement tool
LFIA0227E
38-PFM90.5 Refinishing rotors

BR
( — )
Pro-Cut PFM90 On-Car Brake Lathe
G
ALFIA0092ZZ
H
Commercial Service Tool INFOID:0000000007254765
Tool name Description

1. Flare nut crowfoot Installing brake tubes and hoses J
2. Torque wrench a:10 mm (0.39 in) / 12 mm (0.47 in)
NT360
L
Power tool Loosening nuts, screws and bolts
N
PIIB1407E

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000007254766
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
WT-55, "NVH Troubleshooting Chart"
WT-55, "NVH Troubleshooting Chart"
FAX-2, "NVH Troubleshooting Chart"
ST-8, "NVH Troubleshooting Chart"

FAX-2, RAX-2
BR-7, BR-8
BR-7, BR-8
BR-7, BR-8
BR-7, BR-8
BR-7, BR-8
FSU-2
Reference page
Rotor thickness variation

Pads - uneven wear
Rotor deformation
Pads - damaged
Rotor imbalance
Shims damaged
Rotor deflection
ROAD WHEEL
Possible cause and
DRIVE SHAFT
SUSPENSION
Rotor damage
WHEEL HUB
Rotor runout
SUSPECTED PARTS
STEERING
Rotor rust
TIRES
Noise × × × × × × × ×
×
Symptom Shake × × x × × ×
×
Shimmy, Shudder × × × × × × × x × × ×
×: Applicable

FRONT DISC BRAKE
< BASIC INSPECTION >
BASIC INSPECTION A
FRONT DISC BRAKE
BRAKE PAD
B
BRAKE PAD : Inspection of Pad INFOID:0000000007254767
PAD WEAR C
• Check pad thickness from the inspection hole on cylinder body.
Check using a scale if necessary.
D
Standard thickness : Refer to BR-46, "Front Disc
Brake".
Repair limit thickness : Refer to BR-46, "Front Disc E
Brake".
BR
ALFIA0154ZZ
DISC ROTOR
G
DISC ROTOR : Inspection of Rotor INFOID:0000000007254768
VISUAL H
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace as necessary.
RUNOUT
I
1. Attach disc rotor to wheel hub using wheel nuts (at two or more
positions).
2. Inspect runout using a dial gauge placed at 10 mm (0.39 in) J
inside the disc edge.
Runout limit : Refer to BR-46, "Front Disc Brake".

K
(with it attached to the vehicle)
NOTE:
Before measuring, make sure that wheel bearing axial end play L
is within the specification. Refer to FAX-5, "Inspection". BRA0580D
3. When runout exceeds limit value, displace mounting positions of

disc rotor by one hole. Then find a position of the minimum value for runout.
M
4. If runout is outside the specified value after performing the above operation, refinish disc rotor using Tool.
Tool number : 38-PFM90.5 N

THICKNESS
Check thickness of the disc rotor using a micrometer. Replace disc
rotor if thickness is under the wear limit. O
Standard thickness : Refer to BR-46, "Front

Disc Brake". P
Repair limit thickness : Refer to BR-46, "Front
Disc Brake".
Thickness variation : Refer to BR-46, "Front
(Measured at 8 positions) Disc Brake".
SBR020B

REAR DISC BRAKE
REAR DISC BRAKE
BRAKE PAD
BRAKE PAD : Inspection of Pad INFOID:0000000007254769
PAD WEAR
• Check pad thickness from the inspection hole on cylinder body.
Check using a scale if necessary.
Standard thickness : Refer to BR-46, "Rear Disc

Brake".
Repair limit thickness : Refer to BR-46, "Rear Disc
Brake".
ALFIA0155ZZ
DISC ROTOR
DISC ROTOR : Inspection of Rotor INFOID:0000000007254770
VISUAL
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace if necessary.
RUNOUT
1. Attach disc rotor to wheel hub using wheel nuts (at two or more
positions).
2. Inspect runout using dial gauge placed at 10 mm (0.39 in) inside
disc edge.
Runout limit : Refer to BR-46, "Rear Disc

Brake".
(With it attached to the vehicle)
NOTE:
Before measuring, make sure that wheel bearing axial end play BRA0697D
is within the specification. Refer to RAX-5, "Inspection".
3. When runout exceeds limit value, displace mounting positions of disc rotor by one hole. Then find a posi-
tion of the minimum value for runout.
4. If runout is outside the specified value after performing the above operation, refinish the disc rotor using
Tool.
Tool number : 38-PFM90.5
THICKNESS
Check the thickness of the disc rotor using a micrometer. Replace
disc rotor if the thickness is less than the wear limit.
Standard thickness : Refer to BR-46, "Rear

Disc Brake".
Repair limit thickness : Refer to BR-46, "Rear
Disc Brake".
Thickness variation : Refer to BR-46, "Rear
(Measured at 8 positions) Disc Brake".
SFIA2284E

BRAKE BOOSTER
BRAKE BOOSTER
A
Inspection INFOID:0000000007254771
OPERATION B
With engine stopped, change vacuum to atmospheric pressure by
depressing brake pedal several times. Then with brake pedal fully
depressed, start engine and when vacuum pressure reaches the C
standard, make sure that clearance between brake pedal and floor
panel decreases.
D
E
BRA0037D
AIR TIGHT
BR
• Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change vacuum to atmospheric pressure. Make sure that distance
at intervals of 5 seconds between brake pedal and floor panel G
gradually increases.
I
SBR365AA
• Depress brake pedal while engine is running, and stop engine with pedal depressed. The pedal stroke
J
should not change after holding pedal down for 30 seconds.

VACUUM LINES
VACUUM LINES
VISUAL INSPECTION
Check for improper assembly, damage and deterioration. Replace as necessary.
CHECK VALVE INSPECTION
Airtightness Inspection
Use a suitable tool to check the built-in check valve. Replace the
vacuum hose with the built-in check valve as an assembly if the vac-
uum hose is out of specification.
When suitable tool (A) is con- Refer to BR-46, "Check

nected to booster side (B) Valve".
When suitable tool (A) is con- Refer to BR-46, "Check
nected to engine side (C) Valve".
JPFIA0024ZZ

BRAKE MASTER CYLINDER
A
LEAK INSPECTION B
Check for leaks at master cylinder to brake booster attachment point, reservoir tank, and brake tube connec-
tions.
C
BR

BRAKE TUBE AND HOSE
BRAKE TUBE AND HOSE
Hydraulic Circuit INFOID:0000000007254774
AWFIA0432ZZ
1. Actuator 2. Master cylinder 3. Brake booster

4. Connector A. Union bolt B. Flare nut M12
18.2 N·m (1.9 kg-m, 13 ft-lb) 22.0 N·m (2.2 kg-m, 16 ft-lb)
C. Flare nut M10
16.2 N·m (1.7 kg-m, 12 ft-lb)
CAUTION:
• All hoses and piping (tubes) must be free from excessive bending, twisting and pulling.
• Make sure there is no interference with other parts when turning the steering wheel both clockwise
and counterclockwise.
• The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble the
parts. Replace applicable part with a new one, if necessary.
• Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
• Do not bend or twist brake hose sharply, or strongly pull it.
• When removing components, cover connections so that no dirt, dust, or other foreign matter gets in.
• Refill with new specified brake fluid. Refer to MA-18, "FOR USA AND CANADA : Fluids and Lubri-
cants" (for United States and Canada) or MA-19, "FOR MEXICO : Fluids and Lubricants" (for Mexico).
• Do not reuse drained brake fluid.
FRONT BRAKE
FRONT BRAKE : Inspection INFOID:0000000007254775
INSPECTION AFTER REMOVAL

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.

BRAKE TUBE AND HOSE
1. Check brake lines (tubes and hoses) and connections for fluid leaks, damage, twists, deformation, con-
tacts with other parts, and loose connections. Replace any parts as necessary. Refer to BR-20, "Removal A
and Installation of Front Brake Piping and Brake Hose".
2. While depressing brake pedal under a force of 785 N (80 kg-f, 177 lb-f) with engine running for approxi-
mately 5 seconds, check each part for fluid leaks. B
REAR BRAKE
REAR BRAKE : Inspection INFOID:0000000007254776
C

CAUTION: D
tings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is
detected.
E
1. Check brake lines (tubes and hoses) and connections for fluid leaks, damage, twists, deformation, con-
tacts with other parts, and loose connections. Replace any parts as necessary. Refer to BR-21, "Removal
and Installation of Rear Brake Piping and Brake Hose".
2. While depressing brake pedal under a force of 785 N (80 kg-f, 177 lb-f) with engine running for approxi- BR
mately 5 seconds, check each part for fluid leaks.

BRAKE PEDAL
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE
BRAKE PEDAL
Inspection and Adjustment INFOID:0000000007254777
INSPECTION
1. Inspect the brake pedal free height (H) from the floor using Tool
at a 90° angle to the floor as shown.
Tool number : — (J-46532)

2. Adjust the brake pedal free height (H) to specifications.
AWFIA0557ZZ
Brake pedal free height (H) Refer to BR-45, "Brake Pedal".

Brake pedal full stroke (S) Refer to BR-45, "Brake Pedal".
Clearance between brake pedal bracket and threaded end of stop lamp switch
Refer to BR-45, "Brake Pedal".
(C1) and ASCD cancel switch (C2)
ADJUSTMENT
1. Loosen the stop lamp switch and ASCD cancel switch by turning 45° counterclockwise.

BRAKE PEDAL
2. Loosen lock nut (A) on the input rod, then turn input rod to adjust
the brake pedal to specified height. When finished adjusting, A
tighten lock nut (A) to specification.
Lock nut (A) : 18.7 N·m (1.9 kg-m, 14 ft-lb) B

CAUTION:
Make sure that the screw portion of the end of input rod is
located inside the clevis. C
3. With the brake pedal pulled up and held by hand, press the stop
lamp switch and the ASCD cancel switch in until threaded ends
contact the brake pedal bracket.
D
4. With the threaded ends of the stop lamp switch and ASCD can-
cel switch contacting the pedal bracket, turn the switches 45°
clockwise to lock in place. Check that the stop lamp switch and
ASCD cancel switch threaded end to brake pedal bracket gap E
(C) is within specifications.
CAUTION:
Make sure that the gap (C) between the brake pedal bracket BR
and stop lamp switch and ASCD cancel switch threaded
ends are within specification.
5. Check the brake pedal for smooth operation. G
CAUTION: PFIA0436E
Make sure that the stop lamp goes off when the brake pedal
is released.
H

BRAKE FLUID
BRAKE FLUID
LEVEL CHECK
• Make sure that a brake fluid level in reservoir tank is between MAX
and MIN lines as shown.
• Visually check around reservoir tank for fluid leakage.
• If the level is excessively low, check brake system for leaks.
• If brake warning lamp remains illuminated after parking brake
pedal is released, check brake system for fluid leaks.
SFIA2484E
Drain and Refill INFOID:0000000007254779
CAUTION:
• Refill with new brake fluid. Refer to MA-18, "FOR USA AND CANADA : Fluids and Lubricants" (for
United States and Canada) or MA-19, "FOR MEXICO : Fluids and Lubricants" (for Mexico).
• Do not let brake fluid splash on the painted surfaces of the body. This might damage the paint. If
brake fluid is splashed on painted areas, wash it away with water immediately.
• Before working, disconnect ABS actuator and electric unit (control unit) connector or battery nega-
tive terminal.
1. Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector or battery
negative terminal.
2. Connect a vinyl tube to bleed valve.
3. Depress brake pedal, loosen bleed valve, and gradually remove
brake fluid.
BRA0007D
4. Make sure there is no foreign material in the reservoir tank, and

refill with new brake fluid.
5. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
brake pedal until it stops. Tighten bleed valve. Release brake
pedal. Repeat the process a few times, then pause to add new
brake fluid to master cylinder. Continue until the new brake fluid
flows out of bleed valve.
Bleed the air out of the brake hydraulic system. Refer to BR-16,
"Bleeding Brake System".
PFIA0403J
Bleeding Brake System INFOID:0000000007254780
BLEEDING BRAKE SYSTEM

CAUTION:
• While bleeding, pay attention to master cylinder fluid level.

BRAKE FLUID
• Before working, disconnect ABS actuator and electric unit (control unit) connectors or battery nega-
tive terminal. A
1. Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector or battery
negative terminal.
2. Connect a vinyl tube to rear right brake caliper bleed valve. B
3. Fully depress brake pedal 4 or 5 times.
4. With brake pedal depressed, loosen bleed valve to bleed air in brake line, and then tighten it immediately.
5. Repeat steps 3 and 4 until all of the air is out of the brake line. C
6. Tighten the bleed valve to the specified torque. Refer to BR-32, "Exploded View of Brake Caliper" (front
disc brake), BR-37, "Exploded View of Brake Caliper" (rear brake).
7. Repeat steps 2 through 6, with master cylinder reservoir tank filled at least halfway, bleed the air in order D
from the front left, rear left, front right bleed valves.
BR

BRAKE PEDAL
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
BRAKE PEDAL
Exploded View INFOID:0000000007254781
AWFIA0434GB
1. Clevis pin 2. Snap pin 3. Stop lamp switch

4. ASCD cancel switch 5. Clip 6. Brake pedal assembly
7. Brake pedal pad
NOTE:
The clevis pin must be installed from the RH side as shown.
Removal and Installation INFOID:0000000007254782
REMOVAL
1. Remove instrument lower cover (LH) and lower knee protector. Refer to IP-10, "Exploded View".
2. Remove the accelerator pedal assembly. Refer to ACC-3, "Removal and Installation".
3. Disconnect stop lamp switch and ASCD cancel switch connector.
4. Remove stop lamp switch and ASCD cancel switch from brake pedal assembly.
5. Remove snap pin and clevis pin from brake booster clevis.
6. Disconnect the steering column upper joint and reposition it out of the way.
7. Remove brake pedal assembly to brake booster nuts. Pull brake booster toward engine room to the extent
that does not deform the brake tubes.
WARNING:
Do not bend the brake tubing.
8. Remove brake booster clevis from input rod.
9. Remove top nut and then remove brake pedal assembly.
• Temporarily install the brake pedal assembly to brake booster nuts by hand to support the brake
booster.
CAUTION:
Avoid damage from dropping the brake pedal assembly during handling.
Check the brake assembly for the following items:
• Crack or deformation of the clevis pin.
• Crack of any welded portion of the brake pedal assembly.
• Brake pedal bend or deformation.

BRAKE PEDAL
INSTALLATION
Installation is in the reverse order of removal. A
• Check the brake pedal for smooth operation. There should be no binding or sticking when applying or
releasing the brake pedal.
• Adjust brake pedal height after installing brake pedal assembly. Refer to BR-14, "Inspection and Adjust- B
ment".
BR

BRAKE TUBE AND HOSE
BRAKE TUBE AND HOSE
Hydraulic Circuit INFOID:0000000007254783
AWFIA0432ZZ
1. Actuator 2. Master cylinder 3. Brake booster

4. Connector A. Union bolt B. Flare nut M12
18.2 N·m (1.9 kg-m, 13 ft-lb) 22.0 N·m (2.2 kg-m, 16 ft-lb)
C. Flare nut M10
16.2 N·m (1.7 kg-m, 12 ft-lb)
CAUTION:
• All hoses and piping (tubes) must be free from excessive bending, twisting and pulling.
• Make sure there is no interference with other parts when turning the steering wheel both clockwise
and counterclockwise.
• The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble the
parts. Replace applicable part with a new one, if necessary.
• Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
• Do not bend or twist brake hose sharply, or strongly pull it.
• When removing components, cover connections so that no dirt, dust, or other foreign matter gets in.
• Refill with new specified brake fluid. Refer to MA-18, "FOR USA AND CANADA : Fluids and Lubri-
cants" (for United States and Canada) or MA-18, "FOR USA AND CANADA : Fluids and Lubricants"
(for Mexico).
Removal and Installation of Front Brake Piping and Brake Hose INFOID:0000000007254784
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
REMOVAL
1. Remove the front wheel and tire. Refer to WT-60, "Adjustment".
2. Remove the reservoir cap.
BRAKE TUBE AND HOSE
3. Disconnect brake hose from brake tube, using a suitable tool.
4. Remove lock plate and then remove brake hose from bracket. A
LFIA0213E
D
5. Remove union bolt (A) and then remove brake hose and copper
sealing washers from brake caliper assembly.
CAUTION:
E
Do not reuse copper sealing washers.
BR
G
ALFIA0156ZZ
INSTALLATION
H
1. Install brake hose by aligning with the protrusion on brake cali-
per assembly, then install the union bolt (A) and new copper
sealing washers (1) and tighten union bolt (A) to specification.
Refer to BR-20, "Hydraulic Circuit". I
CAUTION:
J
K
AWFIA0795ZZ
2. Connect brake hose to brake tube, partially tighten flare nut by

hand as much as possible, then secure it to the bracket with lock L
plate.
3. Tighten flare nut to the specified torque, using a suitable tool.
Refer to BR-20, "Hydraulic Circuit". M
LFIA0213E
O
4. Refill brake fluid and bleed air. Refer to BR-16, "Bleeding Brake System".
5. Install the front wheel and tire. Refer to WT-60, "Adjustment".
P
Removal and Installation of Rear Brake Piping and Brake Hose INFOID:0000000007254785
NOTE:
ing.
REMOVAL
1. Remove the rear wheel and tire. Refer to WT-60, "Adjustment".

BRAKE TUBE AND HOSE
3. Disconnect brake hose from brake tube, using a suitable tool.
4. Remove lock plate and then remove brake hose from bracket.
LFIA0213E
5. Remove union bolt (A), and then remove brake hose and copper
sealing washers from brake caliper assembly.
CAUTION:
ALFIA0157ZZ
INSTALLATION
1. Install brake hose by aligning with the protrusion on brake cali-
per assembly, then install the union bolt (A) and new copper
sealing washers (1) and tighten union bolt (A) to specification.
Refer to BR-20, "Hydraulic Circuit".
CAUTION:
AWFIA0795ZZ
2. Connect brake hose to brake tube, partially tighten flare nut by

hand as much as possible, then secure it to the bracket with lock
plate.
3. Tighten flare nut to the specified torque, using a suitable tool.
Refer to BR-20, "Hydraulic Circuit".
LFIA0213E
4. Refill brake fluid and bleed air. Refer to BR-16, "Bleeding Brake System".
5. Install the rear wheel and tire. Refer to WT-60, "Adjustment".
Inspection After Installation INFOID:0000000007254786
CAUTION:
tings if a brake fluid leak is detected. Replace applicable part with a new one, if a damaged part is
detected.

BRAKE TUBE AND HOSE
1. Check brake lines (tubes and hoses), and connections for fluid leaks, damage, twist, deformation, contact
with other parts, and loose connections. Replace any parts as necessary. Refer to BR-20, "Hydraulic Cir- A
cuit".
2. While depressing brake pedal under a force of 785 N (80 kg-f, 177 lb-f) with engine running for approxi-
mately 5 seconds, check each part for fluid leaks. B
BR

AWFIA0660GB
1. Reservoir cap 2. Oil strainer (blue) 3. Master cylinder assembly

4. Brake fluid level switch connector 5. O-ring
B. PBC (Poly Butyl Cuprysil) grease or silicone-based grease
CAUTION:
• Do not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed
on painted areas, wash it away with water immediately.
• Refill with new brake fluid.
NOTE:
ing.
REMOVAL
1. Remove the engine room cover.
2. Remove the air cleaner and air duct. Refer to EM-24, "Removal and Installation".
3. Disconnect brake fluid level switch harness connector.
4. Disconnect master cylinder brake tubes, using a suitable tool.
5. Remove master cylinder nuts, master cylinder assembly and O-ring.
CAUTION:
Do not reuse O-ring.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:

• Apply silicone grease to brake booster at position (A) as
shown, be sure the O-ring is in proper position when install- A
ing master cylinder to brake booster.
• Do not reuse O-ring.
• Tighten brake tube flare nut to the specified torque using a suitable
B
tool. Refer to BR-20, "Hydraulic Circuit".
• Refill the brake hydraulic system with new brake fluid and bleed
brake system. Refer to BR-16, "Bleeding Brake System".
C
SFIA2847J
BR

BRAKE BOOSTER
BRAKE BOOSTER
ALFIA0158GB
1. Master cylinder assembly 2. Brake booster 3. Brake pedal

4. Lock nut 5. Gasket
Removal and installation INFOID:0000000007254790
NOTE:
ing.
REMOVAL
1. Release the fuel pressure. Refer to EC-587, "Inspection".
2. Disconnect the battery negative terminal.
3. Remove the engine room cover.
4. Remove the air cleaner and air duct. Refer to EM-24, "Removal and Installation".
5. Remove cowl top and cowl top extension LH. Refer to EXT-21, "Removal and Installation".
6. Disconnect fuel line from engine, clip and main line and reposition out of the way.
7. Disconnect the brake lines and brake fluid level switch connector.
8. Remove master cylinder from booster assembly. Refer to BR-24, "Removal and Installation".
9. Disconnect vacuum hose from brake booster.
10. Remove instrument lower panel LH. Refer to IP-10, "Exploded View".
11. Disconnect the accelerator pedal connector.
12. Remove snap pin and clevis pin from inside vehicle.
13. Disconnect the steering column upper joint and reposition it out
of the way.
14. Disconnect the ASCD cancel switch and stop lamp switch con-
nectors.
15. Remove nuts on brake booster and brake pedal assembly, then
remove brake pedal. Refer to BR-18, "Exploded View".
16. Remove brake booster from dash panel on engine room side.
CAUTION:
Be careful not to deform or bend brake tube while removing SFIA2044E
brake booster.

BRAKE BOOSTER
INSTALLATION
CAUTION: A
• Be careful not to deform or bend brake tube while installing brake booster.
• Replace clevis pin if it is damaged.
• Do not damage brake booster stud bolt threads. If brake booster is tilted during installation, the dash B
panel may damage the threads.
1. Loosen lock nut to adjust input rod length (B) to the specified
value as shown.
C
Input rod length (B) : Refer to BR-46, "Brake Booster".

2. After adjusting input rod length (B), temporarily tighten the lock D
nut to install the booster assembly. At this time, make sure that a
gasket between booster assembly and dash panel is installed.
CAUTION:
E
Always install gasket between brake booster and dash
panel.
SGIA0060E
3. Install and connect brake pedal with clevis of input rod.
BR
4. Install brake pedal bracket nuts and tighten them to the specified torque. Refer to BR-18, "Exploded
View".
5. Connect the ASCD cancel switch and stop lamp switch connectors.
G
6. Connect the steering column upper joint.
7. Connect the accelerator pedal connector.
8. Install instrument lower panel LH. Refer to IP-10, "Exploded View". H
9. Install vacuum hose into brake booster.
10. Install master cylinder to booster assembly. Refer to BR-24, "Removal and Installation".
11. Connect the brake lines and brake fluid level switch connector. I
12. Position fuel line and connect to engine, clip and main line.
13. Install the air cleaner and air duct. Refer to EM-24, "Removal and Installation".
14. Install the engine room cover. J
15. Install cowl top and cowl top extension LH. Refer to EXT-21, "Removal and Installation".
16. Connect the battery negative terminal.
K
17. Adjust the brake pedal height of the brake pedal. Refer to BR-14, "Inspection and Adjustment".
18. Tighten lock nut of input rod to the specified torque. Refer to BR-26, "Exploded View".
19. Refill new brake fluid and bleed air. Refer to BR-16, "Bleeding Brake System". L

VACUUM LINES
VACUUM LINES
AWFIA0436ZZ
1. Clamp 2. Check valve direction stamp 3. Vacuum hose

4. Vacuum pipe 5. Clip A. To intake manifold
B. To brake booster Front
REMOVAL
1. Disconnect the vacuum hose from the brake booster.
2. Disconnect the vacuum hose from the intake manifold.
3. Release the clips and remove the vacuum pipe with the vacuum hoses attached.
4. Remove the vacuum hoses from the vacuum pipe.
Visual Inspection
Check for correct installation, damage and deterioration of the vacuum hoses and pipe.
Valve Air-tightness Check
• Connect a suitable tool (hand vacuum pump) at each end of the vacuum hose to inspect the check valve
operation.
Vacuum applied at booster end : Refer to BR-46, "Check Valve".

Vacuum applied at intake manifold end : Refer to BR-46, "Check Valve".
• Replace the vacuum hose with check valve if out of specification.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
VACUUM LINES
• Because the vacuum hose contains a check valve, the vac-
uum hose must be installed in the correct position for proper A
operation. Refer to the stamp on the end of the vacuum hose
to confirm correct installation. The brake booster will not
operate normally if the vacuum hose with the check valve is
B
installed in the wrong direction.
• Insert the vacuum pipe into the vacuum hose at least 24 mm
(0.94 in) as shown.
• Do not use lubricating oil during installation. C
SBR225B
BR

FRONT DISC BRAKE
FRONT DISC BRAKE
Exploded View of Brake Pads INFOID:0000000007254793
ALFIA0176ZZ
1. Inner shim cover 2. Inner shim 3. Inner pad

4. Outer pad 5. Outer shim 6. Outer shim cover
7. Anti-rattle clips 8. Pad retainers A. Molykote AS-880N grease
B. Molykote 7439 grease
Removal and Installation of Brake Pads INFOID:0000000007254794
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.
CAUTION:
• While removing brake pads, do not depress brake pedal because piston will pop out.
• It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. For brake pad removal, hang cylinder body with a wire so as not to
stretch brake hose.
• Do not damage piston boot.
• If any shim is subject to serious corrosion, replace it with a new one.
• Always replace shim and shim cover as a set when replacing brake pads.
• Keep rotor free from grease and brake fluid.
• Burnish the brake pads and disc rotor contacting surfaces, after refinishing or replacing rotors, after
replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-31, "Brake Burnishing Pro-
cedure".
REMOVAL
1. Remove front wheel and tire.

FRONT DISC BRAKE
2. Partially drain brake fluid from master cylinder.
3. Remove upper and lower sliding pin bolts (2) without discon- A
necting the union bolt (1).
ALFIA0160ZZ
D
4. Hang cylinder body with a wire, and do not twist or stretch the brake hose.
5. Remove anti-rattle clips, pads, shims, and shim covers from torque member. E
INSTALLATION
1. Apply Molykote AS-880N grease or equivalent between the inner and outer shims and the back of the
BR
brake pads.
2. Install the inner and outer shims and shim covers to the inner pad and outer pad.
CAUTION:
Do not get grease on the inner and outer pad friction surfaces. G
3. Apply Molykote 7439 grease (A) or equivalent to the pad
retainer and attach the pad retainer to the torque member.
4. Install the assembled inner and outer shims, shim covers, pads H
and anti-rattle clips to the torque member.
CAUTION:
Do not get grease on the inner and outer pad or rotor fric- I
tion surfaces.
5. Press piston into cylinder body using suitable tool, then install
the cylinder body on the torque member. J
CAUTION:
When replacing pads with new set, check the brake fluid AWFIA0039ZZ
level in the reservoir tank because brake fluid returns to the

master cylinder reservoir tank when pressing in the piston. K
6. Install the upper and lower sliding pin bolts (2) and tighten it to
the specified torque.
• Union bolt (1) L
N
ALFIA0160ZZ
7. Check front disc brakes for drag. O

9. Check brake fluid level and refill as necessary. Refer to BR-16, "Inspection".
P
Brake Burnishing Procedure INFOID:0000000007254795
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are
securely fitted.

FRONT DISC BRAKE
• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.
Exploded View of Brake Caliper INFOID:0000000007254796
AWFIA0597GB
1. Union bolt 2. Copper sealing washer 3. Brake hose

4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Piston seal 8. Piston 9. Piston boot
10. Cylinder body 11. Sliding pin 12. Torque member bolt
13. Washer 14. Sliding pin boot 15. Bushing
16. Torque member A. Rubber grease B. Brake fluid
Removal and Installation of Brake Caliper and Rotor INFOID:0000000007254797
WARNING:
CAUTION:
• When removing and installing the cylinder body, do not depress the brake pedal because the piston
will pop out.
• Do not damage the piston boot.
• Keep the brake rotor free from grease and brake fluid.
• Refill the brake reservoir with new brake fluid only.
• Never reuse the drained brake fluid.
NOTE:
ing.
REMOVAL
1. Remove front wheel and tire.

FRONT DISC BRAKE
2. Secure the disc rotor using a wheel nut.
3. Remove the reservoir cap. A
4. Remove the union bolt (1) and then disconnect the brake hose
from the caliper assembly. Discard the copper sealing washers.
CAUTION: B
5. Remove the torque member bolts (2), and remove the brake cal-
iper assembly. C
CAUTION:
Do not drop the brake pads.
D
ALFIA0161ZZ
6. Remove the disc rotor. If reusing the disc rotor, apply a matching E
mark as shown for installation.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor, BR
if reusing the disc rotor.
SDIA2608E H
INSTALLATION
1. Install the disc rotor. If reusing the disc rotor, align the matching I
mark on the disc rotor and wheel hub assembly for installation
as shown.
CAUTION:
Align the matching marks on wheel hub assembly and disc J
rotor, if reusing the disc rotor.
SDIA2608E
L
2. Install the brake caliper assembly, and tighten the torque member bolts to the specified torque.
CAUTION:
Do not allow oil or any moisture on all contact surfaces between steering knuckle and caliper M
assembly, bolts, and washer.
3. Install the brake hose with two new copper sealing washers (1), N
using the L-shaped pin for alignment as shown, then tighten the
union bolt (A) to the specified torque.
CAUTION:
Do not reuse copper sealing washers. O
AWFIA0795ZZ
4. Refill the brake hydraulic system with new brake fluid and bleed brake system. Refer to BR-16, "Bleeding
Brake System".
5. Check the front disc brakes for drag.

FRONT DISC BRAKE

REAR DISC BRAKE
REAR DISC BRAKE
A
Exploded View of Brake Pads INFOID:0000000007254798
BR
I
AWFIA0637ZZ
1. Inner shim cover 2. Inner shim 3. Inner pad J

4. Pad retainer 5. Outer pad 6. Outer shim
7. Outer shim cover A. Molykote AS-880N grease B. Molykote 7439 grease
K
Removal and Installation of Brake Pads INFOID:0000000007254799
WARNING:
L
CAUTION:
• While removing and installing cylinder body, do not depress brake pedal because piston will pop M
out.
• It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. For pad removal and installation, hang cylinder body with a wire so
N
as not to stretch brake hose.
• Do not damage piston boot.
• If any shim is subject to serious corrosion, replace it with a new one.
• Always replace shim and shim covers as a set when replacing brake pads. O
• Burnish the brake pads and disc rotor mutually contacting surfaces after refinishing or replacing
rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-31, "Brake Bur- P
nishing Procedure".
REMOVAL
1. Remove the rear wheel and tire.
2. Remove the upper sliding pin bolt and loosen the lower sliding pin bolt to swing the cylinder body down.
3. Remove the pads, pad retainers, shims, and shim covers from the torque member.
CAUTION:

REAR DISC BRAKE
Do not deform the pad retainers when removing them from the torque member.
INSTALLATION
1. Apply Molykote AS-880N grease or equivalent to between shim covers and shims. Install inner shim, inner
shim cover to inner pad. Install outer shim and outer shim cover to outer pad.
2. Apply Molykote 7439 grease (A) or equivalent to between pad
retainer and pad. Install pad retainers and pads to torque mem-
ber.
3. Press in piston using suitable tool, until the pads can be
installed, and then install the cylinder body in the torque mem-
ber.
CAUTION:
When replacing pads with new set, check the brake fluid
level in the reservoir tank because brake fluid returns to the
master cylinder reservoir tank when pressing in the piston.
4. Install upper sliding pin bolt and tighten the upper and lower slid- AWFIA0039ZZ
ing pin bolts to the specified torque.

5. Check the rear disc brakes for drag.
7. Check brake fluid level and refill as necessary. Refer to BR-16, "Inspection".
Brake Burnishing Procedure INFOID:0000000007254800
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are
securely fitted.
• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.

REAR DISC BRAKE
Exploded View of Brake Caliper INFOID:0000000007254801
BR
AWFIA0438GB
I
1. Union bolt 2. Brake hose 3. Copper sealing washer
7. Cylinder body 8. Piston seal 9. Piston J
10. Piston boot 11. Retaining ring 12. Sliding pin boot
13. Bushing 14. Torque member bolt 15. Washer
16. Torque member A. Molykote AS-880N grease B. Rubber grease K
C. Brake fluid
Removal and Installation of Brake Caliper and Rotor INFOID:0000000007254802 L
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne M
CAUTION:
• While removing and installing the cylinder body, do not depress the brake pedal because the piston
will pop out. N
• Do not damage the piston boot.
• Refill the brake reservoir with new brake fluid. O
NOTE:
ing. P
REMOVAL
1. Remove the rear wheel and tire.
2. Hold the disc rotor in place by installing a wheel nut.

REAR DISC BRAKE
4. Remove the union bolt and copper sealing washers, then dis-
connect the brake hose from the cylinder body. Discard the cop-
per sealing washers.
CAUTION:
5. Remove the torque member bolts, and remove the brake caliper
assembly.
CAUTION:
Do not drop brake the pads.
SFIA2972E
6. Remove the disc rotor. If reusing the disc rotor, before removing
the disc rotor apply matching mark as shown.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor,
if reusing the disc rotor.
SDIA2638E
INSTALLATION
1. Install the disc rotor. If reusing the disc rotor, align the matching
mark to position the disc rotor on the wheel hub assembly.
CAUTION:
Align the matching mark on wheel hub assembly and disc
rotor, if reusing the disc rotor.
SDIA2638E
2. Install the brake caliper assembly, and tighten the torque member bolts to the specified torque.
CAUTION:
Before installing caliper assembly, wipe off oil and moisture on all mounting surfaces of rear axle
and caliper assembly and threads, bolts and washers.
3. Install the brake hose with two new copper sealing washers (1),
using the L-shaped pin for alignment as shown, then tighten the
union bolt (A) to the specified torque.
CAUTION:
AWFIA0795ZZ
4. Refill the brake hydraulic system with new brake fluid and bleed brake system. Refer to BR-16, "Bleeding
Brake System".
5. Check the rear disc brakes for drag.

FRONT DISC BRAKE
< UNIT DISASSEMBLY AND ASSEMBLY >
UNIT DISASSEMBLY AND ASSEMBLY A
FRONT DISC BRAKE
Disassembly and Assembly INFOID:0000000007254803
B
BR
AWFIA0597GB J
1. Union bolt 2. Copper sealing washer 3. Brake hose

K
7. Piston seal 8. Piston 9. Piston boot
10. Cylinder body 11. Sliding pin 12. Torque member bolt
13. Washer 14. Sliding pin boot 15. Bushing L
16. Torque member A. Rubber grease B. Brake fluid
NOTE:
Do not remove the torque member, pads, shims, shim covers, and anti-rattle clips when disassembling and M
assembling the cylinder body.
DISASSEMBLY
N
1. Remove the sliding pin bolts, and then remove the cylinder body from the torque member.
CAUTION:
Do not drop pads, shims, shim cover and anti-rattle clips from torque member.
O
2. Remove the sliding pins, bushing and sliding pin boots from the torque member.
3. Remove the cap and the bleed valve from the cylinder body.
P

FRONT DISC BRAKE
4. Place a wooden block in the cylinder body and blow air through
the union bolt hole to push out the piston and piston boot as
shown. Discard the piston boot.
WARNING:
Do not get fingers caught between the piston and cylinder
body.
CAUTION:
Do not reuse the piston boot.
BRD0041D
5. Remove the piston seal from the cylinder body using a suitable
tool as shown. Discard the piston seal.
CAUTION:
• Be careful not to damage the inner cylinder wall.
• Do not reuse the piston seal.
SFIA2277E
INSPECTION AFTER DISASSEMBLY

Cylinder Body
Check the inner cylinder wall for corrosion, wear, and damage. If a defect is detected, replace the cylinder
body.
CAUTION:
Clean the cylinder body using new brake fluid. Never use mineral oils such as gasoline or kerosene.
Torque Member
Check the torque member for wear, cracks, and damage. If a defect is detected, replace the torque member.
Piston
Check the piston surface for corrosion, wear, and damage. If a defect is detected, replace the piston.
CAUTION:
The piston sliding surface is plated. Do not polish the piston with sandpaper.
Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check the sliding pin, sliding pin bolt, and sliding pin boot for wear, damage, and cracks. If a defect is
detected, replace the components as necessary.
ASSEMBLY
1. Apply rubber grease to the new piston seal, and install it in the
cylinder body.
CAUTION:
Do not reuse piston seal.
SFIA2278E

FRONT DISC BRAKE
2. Apply rubber grease to new piston boot and apply brake fluid to
the piston. Cover the piston end with the piston boot, and then A
install the cylinder side lip on the piston boot securely into a
groove on the cylinder body.
CAUTION:
B
Do not reuse piston boot.
SFIA2498E
D
3. Push the piston into the cylinder body by hand and push the pis-
ton boot piston-side lip into the piston groove.
CAUTION:
E
Press the piston evenly and vary the pressing point to pre-
vent cylinder inner wall from being rubbed.
BR
G
SFIA2279E
4. Install the bleed valve and cap to the cylinder body.

H
5. Install the sliding pins, bushing and sliding pin boots on the torque member.
6. Install the cylinder body to the torque member, and then tighten the sliding pin bolts to the specified
torque. I

REAR DISC BRAKE
REAR DISC BRAKE
Disassembly and Assembly INFOID:0000000007254804
AWFIA0438GB
1. Union bolt 2. Brake hose 3. Copper sealing washer

7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Retaining ring 12. Sliding pin boot
13. Bushing 14. Torque member bolt 15. Washer
16. Torque member A. Molykote AS-880N grease B. Rubber grease
C. Brake fluid
NOTE:
Do not remove the torque member, pads, shims, shim covers, and pad retainers when disassembling and
assembling the cylinder body.
DISASSEMBLY
1. Remove the sliding pin bolts, and then remove the cylinder body from the torque member.
CAUTION:
Do not drop pads, shims, shim cover and pad retainers from torque member.
2. Remove the sliding pin boots from the torque member.
3. Remove the cap and the bleed valve from the cylinder body.

REAR DISC BRAKE
4. Remove the retaining ring from the cylinder body using a suit-
able tool as shown. Discard the retaining ring. A
CAUTION:
Do not reuse the retaining ring.
B
SBR028A
D
5. Place a wooden block in the cylinder body and blow air through
the union bolt hole to push out the piston and piston boot as
shown. Discard the piston boot.
E
WARNING:
Do not get fingers caught between the piston and cylinder
body.
CAUTION: BR
Do not reuse the piston boot.
G
BRD0041D
6. Remove the piston seal from the cylinder body using a suitable
H
tool as shown. Discard the piston seal.
CAUTION:
• Be careful not to damage the inner cylinder wall.
• Do not reuse the piston seal. I
SFIA2277E
K
INSPECTION AFTER DISASSEMBLY

Cylinder Body L
Check the inner cylinder wall for corrosion, wear, and damage. If a defect is detected, replace the cylinder
body.
CAUTION: M
Clean the cylinder body using new brake fluid. Never use mineral oils such as gasoline or kerosene.
Torque Member
Check the torque member for wear, cracks, and damage. If a defect is detected, replace the torque member. N
Piston
Check the piston surface for corrosion, wear, and damage. If a defect is detected, replace the piston.
CAUTION: O
The piston sliding surface is plated. Do not polish the piston with sandpaper.
Sliding Pin Bolt and Sliding Pin Boot
Check the sliding pin bolt and sliding pin boot for wear, damage, and cracks. If a defect is detected, replace P
the components as necessary.
ASSEMBLY

REAR DISC BRAKE
1. Apply rubber grease to the new piston seal, and install it in the
cylinder body.
CAUTION:
Do not reuse piston seal.
SFIA2278E
2. Apply rubber grease to the new piston boot and brake fluid to
the piston. Cover the piston end with the piston boot, and then
install the cylinder side lip on the piston boot securely into the
groove on the cylinder body.
CAUTION:
Do not reuse piston boot.
SFIA2498E
3. Push the piston into the cylinder body by hand and push the pis-
ton 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. Secure piston boot with retaining ring.

CAUTION:
• Make sure that boot is securely engaged in the groove on
cylinder body.
• Do not reuse retainer ring.
SFIA2280E
5. Install the bleed valve and cap to the cylinder body.

6. Install the sliding pin boots and bushing on the torque member.
7. Install the cylinder body to the torque member, and then tighten the sliding pin bolts to the specified
torque.

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
General Specifications INFOID:0000000007254805
B
Unit: mm (in)
Brake model Kiriu C

Cylinder bore diameter 57.15 (2.250)
Front brake Pad length × width × thickness 123.6 × 47.5 × 11 (4.866 × 1.870 × 0.433)
Rotor outer diameter × thickness 320 × 28 (12.598 × 1.102) D
Brake model Kiriu
Cylinder bore diameter 34.93 (1.375)
Rear brake E
Pad length × width × thickness 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335)
Rotor outer diameter × thickness 308 × 16 (12.126 × 0.630)
Master cylinder Cylinder bore diameter 23.81 (0.937) BR
Control valve Valve model Electric brake force distribution
Brake booster Booster model Bosch
G
Refer to MA-18, "FOR USA AND CANADA : Fluids and Lubricants" for United
Recommended brake fluid States and Canada, or MA-19, "FOR MEXICO : Fluids and Lubricants" for Mex-
ico.
H
Brake Pedal INFOID:0000000007254806
Unit: mm (in)
I
AWFIA0557ZZ
P
Brake pedal free height (H) 190.7 - 202.7 (7.51 - 7.98)
Brake pedal full stroke (S) 130.0 (5.12)
Clearance between brake pedal bracket (C1) and threaded end of stop lamp switch and
0.74 - 1.96 (0.0291 - 0.0772)
ASCD cancel switch (C2)

Check Valve INFOID:0000000007254807
JPFIA0024ZZ
When suitable tool (A) is connected to booster side 1.3 kPa (10 mmHg, 0.39 inHg) maximum vacuum loss for 15 seconds at vacuum
(B) of -26.6 ± 1.3 kPa (200 ± 1.0 mmHg, -7.87 ± 0.04 inHg)
When suitable tool (A) is connected to engine side
No vacuum should exist.
(C)
Brake Booster INFOID:0000000007254808
Unit: mm (in)
SGIA0060E
Input rod installation length (B) 125 ± 0.5 (4.92 ± 0.02)
Front Disc Brake INFOID:0000000007254809
Unit: mm (in)
Brake model Kiriu

Standard thickness (new) 11.0 (0.433)
Brake pad
Minimum thickness 2.0 (0.079)
Disc rotor
Thickness variation (measured at 8 positions) 0.015 (0.0006)
Maximum runout (with it attached to the vehicle) 0.035 (0.0014)
Rear Disc Brake INFOID:0000000007254810
Unit: mm (in)
Brake model Kiriu

Brake pad

Brake model Kiriu
A
Disc rotor
Thickness variation (measured at 8 positions) 0.015 (0.0006) B
Maximum runout (with it attached to the vehicle) 0.05 (0.002)
BR

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Available Formats

BRAKES

DISC ROTOR ............................................................... 7 BRAKE TUBE AND HOSE ............................... 20

Revision: August 2012 BR-1 2012 Maxima

Revision: August 2012 BR-2 2012 Maxima

Precaution for Brake System INFOID:0000000007254763

Revision: August 2012 BR-3 2012 Maxima

Revision: August 2012 BR-4 2012 Maxima

38-PFM90.5 Refinishing rotors

Commercial Service Tool INFOID:0000000007254765

Tool name Description

Revision: August 2012 BR-5 2012 Maxima

WT-55, "NVH Troubleshooting Chart"

WT-55, "NVH Troubleshooting Chart"

FAX-2, "NVH Troubleshooting Chart"

ST-8, "NVH Troubleshooting Chart"

Rotor thickness variation

Revision: August 2012 BR-6 2012 Maxima

Runout limit : Refer to BR-46, "Front Disc Brake".

3. When runout exceeds limit value, displace mounting positions of

Tool number : 38-PFM90.5 N

Standard thickness : Refer to BR-46, "Front

Revision: August 2012 BR-7 2012 Maxima

Standard thickness : Refer to BR-46, "Rear Disc

Runout limit : Refer to BR-46, "Rear Disc

Tool number : 38-PFM90.5

Standard thickness : Refer to BR-46, "Rear

Revision: August 2012 BR-8 2012 Maxima

Revision: August 2012 BR-9 2012 Maxima

When suitable tool (A) is con- Refer to BR-46, "Check

Revision: August 2012 BR-10 2012 Maxima

Revision: August 2012 BR-11 2012 Maxima

1. Actuator 2. Master cylinder 3. Brake booster

INSPECTION AFTER REMOVAL

Revision: August 2012 BR-12 2012 Maxima

INSPECTION AFTER REMOVAL

Revision: August 2012 BR-13 2012 Maxima

Tool number : — (J-46532)

Brake pedal free height (H) Refer to BR-45, "Brake Pedal".

Revision: August 2012 BR-14 2012 Maxima

Lock nut (A) : 18.7 N·m (1.9 kg-m, 14 ft-lb) B

Revision: August 2012 BR-15 2012 Maxima

Drain and Refill INFOID:0000000007254779

4. Make sure there is no foreign material in the reservoir tank, and

Bleeding Brake System INFOID:0000000007254780

BLEEDING BRAKE SYSTEM

Revision: August 2012 BR-16 2012 Maxima

Revision: August 2012 BR-17 2012 Maxima

1. Clevis pin 2. Snap pin 3. Stop lamp switch

Revision: August 2012 BR-18 2012 Maxima

Revision: August 2012 BR-19 2012 Maxima

1. Actuator 2. Master cylinder 3. Brake booster

2. Connect brake hose to brake tube, partially tighten flare nut by

Revision: August 2012 BR-21 2012 Maxima

2. Connect brake hose to brake tube, partially tighten flare nut by

Revision: August 2012 BR-22 2012 Maxima

Revision: August 2012 BR-23 2012 Maxima

1. Reservoir cap 2. Oil strainer (blue) 3. Master cylinder assembly

Removal and Installation INFOID:0000000007254788

Revision: August 2012 BR-24 2012 Maxima