BRAKE SYSTEM

F BRAKES

B
SECTION
BRAKE SYSTEM C

E
CONTENTS
PRECAUTIONS .......................................................... 2 VACUUM LINES ....................................................... 13 BR
Precautions for Supplemental Restraint System Components ........................................................... 13
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- FRONT DISC BRAKE ............................................... 14
SIONER” .................................................................. 2 Components ........................................................... 14 G
Precautions for Brake System .................................. 2 Removal and Installation of Brake Pad .................. 15
PREPARATION ........................................................... 3 REMOVAL ........................................................... 15
Special Service Tools ............................................... 3 INSTALLATION ................................................... 15
H
Commercial Service Tools ........................................ 3 Removal and Installation of Brake Caliper Assembly
NOISE, VIBRATION AND HARSHNESS (NVH) ... 15
TROUBLESHOOTING ................................................ 4 REMOVAL ........................................................... 15
NVH Troubleshooting Chart ..................................... 4 INSTALLATION ................................................... 15 I
BRAKE PEDAL .......................................................... 5 Disassembly and Assembly of Brake Caliper
Inspection and Adjustment ....................................... 5 Assembly ................................................................ 15
ADJUSTMENT ...................................................... 5 DISASSEMBLY ................................................... 15 J
Removal and Installation .......................................... 6 ASSEMBLY ......................................................... 15
COMPONENTS .................................................... 6 DISC ROTOR INSPECTION ............................... 15
REMOVAL ............................................................. 6 REAR DRUM BRAKE ............................................... 17
K
INSPECTION AFTER REMOVAL ......................... 6 Components ........................................................... 17
INSTALLATION ..................................................... 7 Removal and Installation of Drum Brake Assembly... 18
BRAKE FLUID ............................................................ 8 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 19
Drain and Refill ......................................................... 8 General Specifications ............................................ 19 L
Bleeding Brake System ............................................ 8 Brake Pedal ............................................................ 19
BRAKE TUBE AND HOSE ......................................... 9 Check Valve ............................................................ 19
Hydraulic Circuit ....................................................... 9 Brake Booster ......................................................... 19 M
BRAKE MASTER CYLINDER .................................. 10 Front Disc Brake ..................................................... 19
Components ........................................................... 10 Rear Drum Brake .................................................... 20
BRAKE BOOSTER ....................................................11
Removal and Installation .........................................11
COMPONENTS ...................................................11
REMOVAL ............................................................11
INSPECTION AFTER REMOVAL ....................... 12

BR-1
 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” GFS00122

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
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.
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.
● 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.
● 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.
Precautions for Brake System GFS0012W

● Recommended fluid is brake fluid “DOT 3”. Refer to MA-12, "Fluids and Lubricants" .
● 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.
● To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use new brake fluid.
● Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
● Use a flare nut wrench when removing a brake tube and use a
flare nut torque wrench when installing a brake tube.
● When installing brake tubes and hoses, be sure to check torque.
● Before working, turn ignition switch OFF and disconnect con-
nectors of ABS actuator and electric unit (control unit) or the bat-
tery cable from the negative terminal.
● Burnish the new braking surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal
occurs at very low mileage.
WARNING: SBR820BA
Clean brake pads and shoes with a waste cloth, then wipe with
a dust collector.

BR-2
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools GFS00124

Tool number
Description
Tool name B

GG94310000 C
Flare nut torque wench Installing brake tube
a: 10 mm (0.39 in)
D
NT406

Commercial Service Tools GFS00125

E
Tool number
Description
Tool name
BR

Pin punch Removing and installing reservoir tank

Tip diameter: 4 mm (0.16 in) dia. pin G

ZZA0515D
H

BR-3
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart GFS00126

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

Pads/Lining - uneven wear

AXLE AND SUSPENSION

Rotor thickness variation
Pads/Lining damaged

Drum out of round

Rotor deformation
Rotor imbalance
Shims damaged

Rotor deflection
Possible cause and

ROAD WHEEL

DRIVE SHAFT
Rotor damage
SUSPECTED PARTS

Rotor runout

STEERING
Rotor rust

TIRES
Noise × × × × × × ×

×
Symptom BRAKE Shake × × × × ×

×
Shimmy, Judder × × × × × × × × × × × ×
×: Applicable

BR-4
 BRAKE PEDAL

BRAKE PEDAL PFP:46501

A
Inspection and Adjustment GFS00127

Play and clearance between brake pedal and floor panel with pedal depressed.
● Check brake pedal play. B
● Check brake pedal free height from dash lower panel (1).
● Make an adjustment to the following dimension if value is out-
side the standard. C

Dimension Item Specification

162.3 – 172.3 mm (6.39 – D
Brake pedal free height M/T models
6.78 in)
H1 (from dash lower panel (1)
top surface) 172.4 – 182.4 mm (6.79 –
A/T models
7.18 in) E
Brake pedal depressed M/T models 90 mm (3.54 in) or more
height [under a force of
H2
490 N (50 kg, 110 lb) with A/T models 95 mm (3.74 in) or more
the engine running]
BR

Clearance between the threaded end of

0.74 – 1.96 mm (0.0291 –
C stop lamp switch (2) and brake pedal
0.0772 in)
lever (3) G
A Pedal play 3 – 11 mm (0.12 – 0.43 in)

SFIA3056J

I
ADJUSTMENT
1. Loosen stop lamp switch by rotating it counterclockwise by 45°.
2. Loosen lock nut on input rod, then rotate input rod to set pedal to
J
the specified height, and tighten lock nut.
CAUTION:
Make sure that the threaded end of input rod stays inside
clevis. K

SBR229E
M

3. With the pedal pulled and held by hand, press stop lamp switch
(2) until its threaded end contacts brake pedal lever (1).
4. With the threaded end of stop lamp switch (2) contacting brake
pedal lever (1), rotate the switch clockwise by 45° to secure.
CAUTION:
Make sure that the clearance “C” is within the standard.
5. Check the pedal play.
CAUTION:
Make sure that stop lamps go off when brake pedal is
released. PFIA0813J
6. Start engine to check brake pedal depressed height.

BR-5
 BRAKE PEDAL

Removal and Installation GFS00128

COMPONENTS

SFIA3065E

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

4. Brake pedal assembly 5. Clevis 6. Brake pedal pad
Refer to GI-11, "Components" and followings for the symbols in the figure.
: Apply multi-purpose grease.

REMOVAL
1. Remove instrument driver panel. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" .
2. Disconnect accelerator pedal position sensor and stop lamp
switch harness connector.
3. Remove stop lamp switch from brake pedal assembly.
4. Remove snap pin and clevis pin from clevis of brake booster.
5. Remove mounting nuts from brake pedal assembly, and remove
brake pedal assembly from vehicle.
6. Remove accelerator pedal from brake pedal assembly.

SFIA2044E

INSPECTION AFTER REMOVAL

● Check the items below. If any is found, replace brake pedal
assembly.
– Check brake pedal upper rivet (A) for deformation.
– Make sure that the lapping length “X” of sub-bracket (B) and
slide plate (C) is at least 6.9 mm (0.272 in) or more.
– Check brake pedal for bend, damage, and cracks on the welded
parts.

PFIA0755J

BR-6
 BRAKE PEDAL

● Check clevis pin and plastic stopper for damage and deforma-
tion. If any is found, replace clevis pin if there are. A

SBR997

D
INSTALLATION
Installation is the reverse order of the removal.
● Tighten brake pedal assembly mounting nuts and lock nut to the specified torque. Refer to BR-6, "COM- E
PONENTS" (brake pedal assembly mounting nuts), BR-11, "COMPONENTS" (lock nut).
● After installing brake pedal assembly to vehicle, adjust brake pedal. Refer to BR-5, "ADJUSTMENT" .
● After installing accelerator pedal, check accelerator pedal. Refer to ACC-3, "Removal and Installation" . BR

BR-7
 BRAKE FLUID

BRAKE FLUID PFP:KN100

Drain and Refill GFS00129

CAUTION:
● Refill with new brake fluid “DOT 3”.
● 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.
● Before working, disconnect connectors of ABS actuator and electric unit (control unit) or battery
cable from the negative terminal.
Bleeding Brake System GFS0012A

CAUTION:
● While bleeding, pay attention to reserver tank fluid level.
● Before working, disconnect connections of ABS actuator and electric unit (control unit) or the bat-
tery cable from the negative terminal.
1. Connect a vinyl tube to rear right bleed valve.
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 2, 3 until no more air comes out.
5. Tighten bleed valve to specified torque. Refer to BR-14, "Components" (front disc brake), BR-17, "Com-
ponents" (rear drum brake).
6. From steps 1 to 5 below, with master cylinder reservoir tank filled at least half way, bleed air from front left,
rear left, and front right, bleed valve, in that order.

BR-8
 BRAKE TUBE AND HOSE

BRAKE TUBE AND HOSE PFP:46300

A
Hydraulic Circuit GFS0012B

BR

G
PFIA0724E

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

4. Rear drum brake 5. Connector 6. ABS actuator and electric unit (con- H
trol unit)
7. Brake tube 8. Brake hose
: Union bolt
I
: Connector mounting bolt
: Flare nut
Refer to GI-11, "Components" , for the symbols in the figure.
J

BR-9
 BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER PFP:46010

Components GFS0012C

SFIA3094E

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

4. Grommet 5. Piston stopper 6. Cylinder body
7. Pin 8. Brake fluid level switch connector 9. O-ring
10. Secondary piston assembly 11. Primary piston assembly 12. Plate
13. Guide assembly 14. Snap-ring
Refer to GI-11, "Components" and the followings for the symbols in the figure.
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.

: Apply brake fluid.

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

BR-10
 BRAKE BOOSTER

BRAKE BOOSTER PFP:47200

A
Removal and Installation GFS0012D

COMPONENTS
B

BR

SFIA3095E
K
1. Reservoir tank 2. Master cylinder 3. Brake booster
4. Clevis 5. Spacer 6. Gasket
L
Refer to GI-11, "Components" , for the symbols in the figure.

REMOVAL
CAUTION: M
● 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.
● Be careful not to deform or bend brake tubes while removing and installing 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, dash panel may damage the threads.
● Be sure to install the gasket between spacer and brake booster.
● Be sure to install the gasket between brake booster and vehicle.

BR-11
 BRAKE BOOSTER

INSPECTION AFTER REMOVAL

Output Rod Length Inspection
1. Apply a vacuum of –66.7 kPa (–500 mmHg, –19.69 inHg) to
brake booster using a handy vacuum pump.
2. Check output rod length. Refer to BR-19, "Brake Booster" .

SFIA2146E

Input Rod Length Inspection

● When installing, loosen lock nut to adjust input rod length so that
length “B” satisfies the specified value. Refer to BR-19, "Brake
Booster" .

SGIA0060E

BR-12
 VACUUM LINES

VACUUM LINES PFP:41920

A
Components GFS0012E

BR

G
SFIA3069E

1. To intake manifold 2. Clamp 3. Engine side indicator stamp (Built-in

check valve)
H
4. Vacuum hose 5. Clip 6. Clip position stamp
7. Vacuum tube 8. To brake booster

BR-13
 FRONT DISC BRAKE

FRONT DISC BRAKE PFP:41000

Components GFS0012F

PFIA0856E

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

4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Inner shim 12. Inner pad
13. Pad return spring 14. Pad retainer 15. Outer pad
16. Outer shim 17. Sliding pin 18. Sliding pin boot
19. Torque member mounting bolt 20. Bushing 21. Torque member
22. Pad wear sensor 23. Inner pad (RH)
Refer to GI-11, "Components" and the followings for the symbols in the figure.
1: Apply rubber grease.
2: Apply polyglycol ether based lubricant.

: Apply brake fluid.

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 cylinder body, 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. In this case, 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 shims as a set when replacing brake pads.
● Keep rotor free from brake fluid.

BR-14
 FRONT DISC BRAKE

● 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. A
Removal and Installation of Brake Pad GFS0012G

REMOVAL
B
CAUTION:
Deform pad retainer when removing pad retainer from torque member.
INSTALLATION C
CAUTION:
In the case of replacing a pad with new one, check a brake fluid level in the reservoir tank because
brake fluid returns to master cylinder reservoir tank when pressing piston in.
D
NOTE:
Use a disc brake piston tool (commercial service tool) to easily press piston.
Removal and Installation of Brake Caliper Assembly GFS0012H E
REMOVAL
CAUTION:
● Do not drop brake pad. BR
● Put matching marks on wheel hub assembly and disc rotor, if it necessary to remove disc rotor.
INSTALLATION
CAUTION: G
● Refill with new brake fluid “DOT 3”.
● Never reuse drained brake fluid.
H
● Alignment marks of disc rotor and wheel hub put at the time of removal when reusing disc rotor.
● Before installing caliper assembly, wipe off oil and moisture on all mounting surfaces of steering
kncukle and torque member.
I
● Do not reuse copper washer.
Disassembly and Assembly of Brake Caliper Assembly GFS0012I

NOTE: J
Do not remove torque member, pad return spring, pads, shims and pad retainers when disassembling and
assembling cylinder body assembly.
DISASSEMBLY K
CAUTION:
● Do not drop pads, shims and pad retainers from torque member.
L
● Do not get fingers caught in the piston.
● Be careful not to damage a cylinder inner wall.
ASSEMBLY M
CAUTION:
● Do not reuse piston seal.
● Do not reuse piston boot.
● Press the piston evenly and vary the pressing point to prevent cylinder inner wall from being
rubbed.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace if there are.

BR-15
 FRONT DISC BRAKE

Runout Inspection
1. Fix disc rotor to wheel hub using wheel nuts (2 or more posi-
tions).
2. Inspect runout using dial gauge. [Measured at 10 mm (0.39 in)
inside disc edge.]
Runout limit : 0.070 mm (0.0028 in)
(With it attached to the vehicle)
NOTE:
Before measuring, make sure that wheel bearing axial end play
is within the specification. Refer to FAX-10, "Wheel Bearing" .
3. When runout exceeds limit value, displace mounting positions of BRA0697D

disc rotor by one hole. And then find a position of the minimum
value for runout.
4. Replace disc rotor if it is outside repair limit after performing the above operation.
Thickness Inspection
Check the thickness of the disc rotor using a micrometer. Replace
disc rotor if the thickness is under the wear limit.
Standard thickness : 22.0 mm (0.866 in)
Repair limit thickness : 20.0 mm (0.787 in)
Thickness variation : 0.020 mm (0.0008in)
(Measured at 8 positions) or less

SFIA2284E

BR-16
 REAR DRUM BRAKE

REAR DRUM BRAKE PFP:43206

A
Components GFS0012J

BR

PFIA0878E

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

4. Parking brake rear cable 5. Boot 6. Piston
7. Piston cup 8. Spring 9. Cap
10. Bleed valve 11. Wheel cylinder 12. Retainer ring K
13. Operating lever 14. Brake shoe 15. Adjuster
16. Adjuster spring 17. Return spring (upper side) 18. Return spring (lower side)
19. Adjuster lever 20. Spring 21. Retainer L
22. Brake drum 23. Plug
Refer to GI-11, "Components" and the followings for the symbols in the figure.
1: Apply rubber grease. M
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.

: Apply brake fluid.

WARNING:
Clean dust on drum and back plate with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.

BR-17
 REAR DRUM BRAKE

Removal and Installation of Drum Brake Assembly GFS0012K

● If removing brake drum is difficult, then remove as follows.

– Pull up adjuster lever (1) with a wire or equivalent (A) from plug
hole on brake drum (2) as shown in the figure. Turn frame of
adjuster assembly (3) with a flat bladed screw driver (B) in the
direction that narrows frame to narrow enlarged brake shoe.

PFIA0879E

● When disassembled adjuster, confirm the difference between

left and right wheel for assemble.
: Front
Adjuster position A B C
Left side Yellow Yellow Gray
Right side Green Green Gray

PFIA0781J

BR-18
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
General Specifications GFS0012P

Unit: mm (in)
Cylinder bore diameter 53.96 (2.124) B
Front brake Pad length × width × thickness 115.0 × 41.0 × 9.0 (4.528 × 1.614 × 0.354)
Rotor outer diameter × thickness 260 × 22.0 (10.24 × 0.866)
Cylinder bore diameter 19.05 (0.750)
C

Rear brake Lining length × width × thickness 218.0 × 35.0 × 4.0 (8.58 × 1.378 × 0.157)
Drum outer diameter 228.6 (9.00) D
Master cylinder Cylinder bore diameter 22.22 (0.875)
Control valve Valve type Electric brake force distribution
Brake booster Diaphragm diameter 255 (10.04) E
Recommended brake fluid DOT 3

Brake Pedal GFS0012Q BR

Unit: mm (in)
Brake pedal free height (from dash panel top M/T models 162.3 – 172.3 (6.39 – 6.78)
surface) A/T models 172.4 – 182.4 (6.79 – 7.18) G
Brake pedal depressed height M/T models 90 (3.54) or more
[under a force of 490 N (50 kg, 110 lb) with the
engine running] A/T models 95 (3.74) or more H
Clearance between the threaded end of stop lamp switch and
0.74 – 1.96 (0.0291 – 0.0772)
brake pedal lever
Pedal play 3 – 11 (0.12 – 0.43) I

Check Valve GFS0012R

Vacuum leakage J
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]

Brake Booster GFS0012S

Vacuum type K
Unit: mm (in)
Vacuum leakage
[at vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg)]
Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 seconds L

Output rod length 6.2 (0.244)

Input rod length 159 (6.26)
M
Front Disc Brake GFS0012T

Unit: mm (in)
Standard thickness 9.0 (0.354)
Brake pad
Repair limit thickness 2.0 (0.079)
Standard thickness 22.0 (0.866)
Repair limit thickness 20.0 (0.787)
Disc rotor
Thickness variation 0.020 (0.0008)
Runout limit 0.070 (0.0028)

BR-19
 SERVICE DATA AND SPECIFICATIONS (SDS)

Rear Drum Brake GFS0012U

Unit: mm (in)
Standard thickness 4.0 (0.157)
Brake lining
Repair limit thickness 1.5 (0.059)
Standard inner diameter 228.6 (9.00)
Drum
Repair limit inner diameter 230.0 (9.06)

BR-20