BRAKES
CONTENTS
SERVICE INFORMATION ............................ 2
PRECAUTIONS ................................................... 2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 2
Precaution for Brake System .................................... 2
PREPARATION ................................................... 3
Special Service Tool ................................................. 3
Commercial Service Tool .......................................... 3
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 4
NVH Troubleshooting Chart ...................................... 4
BRAKE PEDAL ................................................... 5
Inspection and Adjustment ........................................ 5
Component ................................................................ 6
Removal and Installation ........................................... 6
BRAKE FLUID ..................................................... 8
Drain and Refill .......................................................... 8
Bleeding Brake System ............................................. 8
BRAKE TUBE AND HOSE ................................. 9
Hydraulic Circuit ........................................................ 9
LOAD SENSING VALVE ....................................10
Component .............................................................. 10
Inspection ................................................................ 10
Revision: 2008 January BR-1
SECTION
BRAKE SYSTEM
BR B
E
BRAKE MASTER CYLINDER .......................... 12 BR
Component ..............................................................12
Disassembly and Assembly .....................................12
G
BRAKE BOOSTER ........................................... 13
Component ..............................................................13
Removal and Installation .........................................13
H
VACUUM LINES ............................................... 15
Component ..............................................................15
I
FRONT DISC BRAKE ....................................... 17
Component ..............................................................17
Removal and Installation of Brake Pad ...................18
Removal and Installation of Brake Caliper Assem- J
bly ............................................................................18
Disassembly and Assembly of Brake Caliper As-
sembly .....................................................................18 K
REAR DRUM BRAKE ....................................... 20
Component ..............................................................20
Removal and Installation of Drum Brake Assembly L
....20
SERVICE DATA AND SPECIFICATIONS M
(SDS) ................................................................. 22
General Specification ..............................................22
Brake Pedal .............................................................22
N
Brake Booster ..........................................................22
Check Valve ............................................................22
Front Disc Brake ......................................................22
Rear Drum Brake .....................................................23 O
D40
 PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000003304650

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 “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” 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 performed by
an authorized NISSAN/INFINITI dealer.
• 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 “SUPPLEMENTAL RESTRAINT SYSTEM”.
• 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 har-
ness connectors.
Precaution for Brake System INFOID:0000000002978740

• Clean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air.
• Recommended fluid is 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.
• 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.
• 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 installing.
• Before working, turn ignition switch OFF and disconnect electrical
connector of ABS actuator and electric unit (control unit) or battery
negative terminal.
• Burnish the new brake surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal
occurs at very low mileage.
WARNING:
Clean brake pads and shoes with a waste cloth, then wipe with SBR820BA
a dust collector.

Revision: 2008 January BR-2 D40

 PREPARATION
< SERVICE INFORMATION >
PREPARATION
A
Special Service Tool INFOID:0000000002978741

B
Tool number
Description
Tool name

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

NT406
E

BR
KV991V0010
Measuring brake fluid pressure
Brake fluid pressure tester

G
ZZA0752D

Commercial Service Tool INFOID:0000000002978742

H

Tool name Description

I

K
PBIC0190E
Power tool Removing front caliper assembly, tires

PBIC0191E

Revision: 2008 January BR-3 D40

 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION >
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000002978743

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

Rotor runout/Drum inner diameter

Pads/Lining - uneven wear

AXLE AND SUSPENSION

Rotor thickness variation
Rotor/Drum deformation
Pads/Lining damaged

PROPELLER SHAFT
Rotor/Drum damage
Possible cause and

Drum out of round

Rotor imbalance
suspected parts

Shims damaged

DIFFERENTIAL
Rotor deflection

ROAD WHEEL

DRIVE SHAFT

STEERING
Rotor rust

TIRES
Noise × × × × × × × × ×

×
Symptom Brake Shake × × × × × ×

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

Revision: 2008 January BR-4 D40

 BRAKE PEDAL
< SERVICE INFORMATION >
BRAKE PEDAL
A
Inspection and Adjustment INFOID:0000000002978744

INSPECTION B
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). C
• Adjust height referring to the following specifications.

Brake pedal height (from dash lower D

H1
panel top surface)
H2 Brake pedal depressed height
Clearance between threaded end of the
C stop lamp switch and/or ASCD brake
switch (2) and stopper bracket (3)
A Pedal play
Refer to BR-22, "Brake Pedal".
Refer to BR-22, "Brake Pedal".
E
Refer to BR-22, "Brake Pedal".
Refer to BR-22, "Brake Pedal".
BR

I
SFIA2743J

ADJUSTMENT
1. Loosen the stop lamp switch and/or ASCD brake switch, and by J
turning it counterclockwise 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). Refer to K
BR-13, "Component".
CAUTION:
Make sure the threaded end of the input rod stays inside the
L
clevis.
3. With the pedal pulled and held by hand, press the stop lamp
switch and/or ASCD brake switch, and until its threaded end
contacts the stopper bracket. M
4. With the threaded end of the stop lamp switch and/or ASCD
brake switch, and contacting the stopper, turn the switch clock-
wise by 45° to secure. N
CAUTION:
Make sure that the clearance (C) between the bracket and
threaded end of the stop lamp switch and/or ASCD brake
O
switch, and are within the standard.
5. Check the pedal play.
CAUTION:
Make sure that the stop lamp goes off when the pedal is P
released.
PFIA0824E
6. Start the engine to check the brake pedal depressed height.
Refer to "Inspection and Adjustment".

Revision: 2008 January BR-5 D40

 BRAKE PEDAL
< SERVICE INFORMATION >
Component INFOID:0000000002978745

SFIA3000E

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

4. ASCD brake switch (if equipped) 5. Snap pin 6. Brake pedal pad
7. Clevis pin
: Multi-purpose grease
Refer to GI-7, "Component" for symbol marks except in the above.

Removal and Installation INFOID:0000000002978746

REMOVAL
1. Remove lower instrument panel. Refer to IP-5, "Removal and Installation".
2. Remove stop lamp switch and/or ASCD brake 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

INSPECTION AFTER REMOVAL

Revision: 2008 January BR-6 D40

 BRAKE PEDAL
< SERVICE INFORMATION >
• Check brake pedal upper rivet for deformation.
• Make sure that the lapping length of sub-bracket and slide plate is A
at 5.0 mm (0.197 in) or more.
• Check brake pedal for bend, damage, and cracks on the welded
parts.
B
• Replace brake pedal assembly if any non-standard condition is
detected.

SFIA2866E

D
• Check clevis pin and plastic stopper for damage and deformation.
Replace clevis pin if there are.
E

BR

G
SBR997

INSTALLATION H
Installation is in the reverse order of the removal. Tightening torques for brake pedal assembly mounting nut
and bolt are referred to BR-6, "Component". Tightening torque for lock nut is referred to Refer to BR-13, "Com-
ponent".
• After installing the brake pedal assembly to the vehicle, adjust the brake pedal. Refer to BR-5, "Inspection I
and Adjustment".

Revision: 2008 January BR-7 D40

 BRAKE FLUID
< SERVICE INFORMATION >
BRAKE FLUID
Drain and Refill INFOID:0000000002978747

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, immediately wipe off them and wash it away with water.
• Before working, disconnect connector of ABS actuator and electric unit (control unit) or the battery
negative terminal.
Bleeding Brake System INFOID:0000000002978748

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 negative terminal.
LHD
1. Connect a vinyl tube to the load sensing 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 3, 4 until no more air comes out.
5. Tighten bleed valve to specified torque. Refer to BR-10, "Component"(load sensing valve), BR-17, "Com-
ponent" (front disc brake), BR-20, "Component" (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
rear left, front right, rear right, and front left brake, in that order.
RHD
1. Connect a vinyl tube to the load sensing 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 3, 4 until no more air comes out.
5. Tighten bleed valve to specified torque. Refer to BR-10, "Component"(load sensing valve), BR-17, "Com-
ponent" (front disc brake), BR-20, "Component" (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
rear right, front left, rear left, front right brake, in that order.

Revision: 2008 January BR-8 D40

 BRAKE TUBE AND HOSE
< SERVICE INFORMATION >
BRAKE TUBE AND HOSE
A
Hydraulic Circuit INFOID:0000000002978749

With ABS B

BR

G
SFIA3193E

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

H
4. Connector 5. ABS actuator and electric unit (con- 6. Rear drum brake
trol unit)
7. Load sensing valve :Brake tube :Brake hose
I
: Flare nut : Connector mounting bolt : Union bolt
: 16.2 N·m (1.7 kg-m, 12 ft-lb) : 7.0 N·m (0.71 kg-m, 62 in-lb) : 18.2 N·m (1.9 kg-m, 13 ft-lb)

Without ABS J

O
PFIA0883E

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

P
4. Connector 5. Rear drum brake 6. Load sensing valve
:Brake tube :Brake hose
: Flare nut : Connector mounting bolt : Union bolt
: 16.2 N·m (1.7 kg-m, 12 ft-lb) : 7.0 N·m (0.71 kg-m, 62 in-lb) : 18.2 N·m (1.9 kg-m, 13 ft-lb)

Revision: 2008 January BR-9 D40

 LOAD SENSING VALVE
< SERVICE INFORMATION >
LOAD SENSING VALVE
Component INFOID:0000000002978750

JPFIA0301GB

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

4. Stopper 5. Sensor spring 6. Rear axle tube
Refer to GI-7, "Component" for symbol marks in the figure.

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-9, "Hydraulic Circuit".
• Refill with new brake fluid “DOT 3”.
• Never reuse drained brake fluid.
Inspection INFOID:0000000002978751

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 tire, 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 (with the vehicle in unladen condition).

Length “L” 2WD : 142.0 − 145.0 mm (5.59 − 5.71 in)

4WD : 143.5 − 146.5 mm (5.65 − 5.77 in)

Revision: 2008 January BR-10 D40

 LOAD SENSING VALVE
< SERVICE INFORMATION >
• If measurement is outside the standard, perform following;
loosen mounting bolt of sensor spring bracket. By moving sen- A
sor spring bracket, adjust so that the length “L” comes into
specified range.
3. Connect brake fluid pressure tester (special service tool) to B
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 C
caliper and rear wheel cylinder. The respective measurements
should be as specified in the table below.
SFIA0245E

Standard
D

Front caliper brake fluid Rear wheel cylinder brake fluid pressure MPa (bar, kg/cm2, psi)
pressure 2WD 4WD E
MPa (bar, kg/cm2, psi) Unladen Loaded Unladen Loaded
3.1 – 4.1 3.9 – 5.9 2.9 – 3.9 3.9 – 5.9
BR
4.9 (49, 50, 711) (31 – 41, 32 – 41, (39 – 59, 40 – 60, (29 – 39, 30 – 39, (39 – 59, 40 – 60,
450 – 594) 566 – 855) 421 – 565) 566 – 855)
4.6 – 5.6 8.8 – 10.8 4.0 – 5.0 8.8 – 10.0 G
9.8 (98, 100, 1421) (46 – 56, 47 – 57, (88 – 108, 90 – (40 – 50, 41 – 51, (88 – 100, 90 –
667 – 812) 110, 1276 – 1566) 580 – 725) 102, 1276 – 1450)
6. Under condition of step 2 above, adjust rear shaft weight with H
weights to obtain 174.7 – 177.7 mm (6.88 – 7.00 in) (2WD),
167.7 – 170.7 mm (6.60 – 6.72 in) (4WD) as length “L”. Then,
check brake fluid pressure as described in step 5 above. If mea-
I
surements are outside the standards, replace load sensing valve
main body.
7. After inspection, remove brake fluid pressure tester (special ser-
vice tool) and bleed air. Refer to BR-8, "Bleeding Brake Sys- J
tem".

BRA0515D K

Revision: 2008 January BR-11 D40

 BRAKE MASTER CYLINDER
< SERVICE INFORMATION >
BRAKE MASTER CYLINDER
Component INFOID:0000000002978752

PFIA0885E

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

4. Master cylinder assembly 5. Piston stopper (with ABS) 6. Grommet
7. Pin
: Brake fluid
Refer to GI-7, "Component" for symbol marks except in the above.

Disassembly and Assembly INFOID:0000000002978753

CAUTION:
• Never use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
• Never drop parts. If a part is dropped, do not use it.
• Master cylinder assembly cannot be disassembly.
• Remove reservoir tank only when absolutely necessary.

Revision: 2008 January BR-12 D40

 BRAKE BOOSTER
< SERVICE INFORMATION >
BRAKE BOOSTER
A
Component INFOID:0000000002978754

BR

G
PFIA0896E

1. Master cylinder 2. Brake booster 3. Lock nut

4. Clevis 5. Gasket 6. Spacer
H
Refer to GI-7, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000002978755 I

REMOVAL
CAUTION: J
• 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 during
K
installation, the dash panel may damage the threads.
INSPECTION AFTER REMOVAL
Output Rod Length Inspection L
1. Using a handy vacuum pump, apply a vacuum of −66.7 kPa (−
500 mmHg, −19.69 inHg, –0.667 bar) to the brake booster.
2. Check output rod length. Refer to BR-22, "Brake Booster". M

O
SBR208E

Input Rod Length Inspection P

Revision: 2008 January BR-13 D40

 BRAKE BOOSTER
< SERVICE INFORMATION >
• Loosen the lock nut to adjust the input rod length so that the length
B (in the figure) satisfies the specified value. Refer to BR-22,
"Brake Booster".
CAUTION:
• Be sure to install the gasket between spacer and brake
booster.
• Be sure to install the gasket between brake booster and
vehicle.
• After installing brake booster to vehicle, adjust brake pedal.
Refer to BR-5, "Inspection and Adjustment".
SGIA0060E

Revision: 2008 January BR-14 D40

 VACUUM LINES
< SERVICE INFORMATION >
VACUUM LINES
A
Component INFOID:0000000002978756

LHD B
QR25DE
C

BR

JPFIA0272ZZ
H
1. Clamp 2. Clip 3. Vacuum hose
A. To intake manifold B. To brake booster C. Stamp indicating engine direction
I
YD25DDTi

SFIA3009E

1. Clamp 2. Vacuum hose 3. Vacuum tube

4. Vacuum hose 5. Clip 6. Connector
7. Vacuum hose 8. To vacuum pump 9. To brake booster
Refer to GI-7, "Component" for symbol marks in the figure.

Revision: 2008 January BR-15 D40

 VACUUM LINES
< SERVICE INFORMATION >
RHD

PFIA0887E

1. Clamp 2. Vacuum hose 3. Vacuum tube

4. Vacuum hose 5. To brake booster 6. To vacuum pump
Refer to GI-7, "Component" for symbol marks in the figure.

Revision: 2008 January BR-16 D40

 FRONT DISC BRAKE
< SERVICE INFORMATION >
FRONT DISC BRAKE
A
Component INFOID:0000000002978757

BR

J
PFIA0888E

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

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 L
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. Pad return spring 21. Outer pad M
22. Outer shim 23. Outer shim cover
1: Rubber grease 2: PBC (Poly Butyl Cuprysil) grease 3: Polyglycol ether based lubricant
or silicone-based grease N
: Brake fluid

Refer to GI-7, "Component" for symbol marks except in the above.

O
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air- borne
particles or other materials. P
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.
• Never damage piston boot.
• If any shims and shim cover is subject to serious corrosion, replace it with a new one.
• Always replace shims and shim cover as a set when replacing brake pads.

Revision: 2008 January BR-17 D40

 FRONT DISC BRAKE
< SERVICE INFORMATION >
• Keep rotor out of brake fluid.
Removal and Installation of Brake Pad INFOID:0000000002978758

REMOVAL
CAUTION:
When removing the pad retainers from the torque member, lift it so that it does not deform.
INSTALLATION
CAUTION:
• When installing pad retainers, attach it firmly so that it does not flat up higher than torque member.
• In the case of replacing 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.
Removal and Installation of Brake Caliper Assembly INFOID:0000000002978759

REMOVAL
CAUTION:
Align the matching marks of disc rotor and wheel hub, which were marked at the time of removal when
reusing disc rotor.
INSTALLATION
CAUTION:
• Refill with new brake fluid “DOT 3”.
• Never reuse drained brake fluid.
• Before installing caliper assembly, wipe off oil and moisture on all mounting surfaces of steering
knuckle and caliper assembly and threads, bolts.
Disassembly and Assembly of Brake Caliper Assembly INFOID:0000000002978760

NOTE:
Do not remove torque member, pads, shims, shim cover and pad retainers when disassembly and assembly
cylinder body assembly.
DISASSEMBLY
CAUTION:
• When removing the pad retainers from the torque member, lift it so that it does not deform.
• Never get fingers caught in the piston.
• Be careful not to damage cylinder inner wall.
ASSEMBLY
CAUTION:
• Never reuse piston seal.
• Never 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. 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)

Revision: 2008 January BR-18 D40

 FRONT DISC BRAKE
< SERVICE INFORMATION >
2. Check runout using a dial indicator.
[measured at 10 mm (0.39 in) inside the disc edge] A

Runout limit : 0.05 mm (0.0020 in)

(with it attached to the vehicle) B
CAUTION:
Make sure that wheel bearing axial end play is within the
specifications before measuring runout. Refer to FAX-7, C
"Wheel Bearing".
3. If runout is outside the limit, find the minimum runout point by
BRA0013D
shifting mounting positions of disc rotor and wheel hub by one D
hole.
4. If runout is still out of the specification, refinish the disc rotor with on-car brake lathe. Or replace the disc
rotor.
E
Thickness Inspection
Using a micrometer, check thickness of the disc rotor. If thickness is
outside the standard, replace disc rotor.
BR
Standard thickness : 28.0 mm (1.102 in)
Repair limit thickness : 26.0 mm (1.024 in)
G
Thickness variation : 0.005 mm (0.0002 in)
(measured at 8 positions)
H

SBR020B

Revision: 2008 January BR-19 D40

 REAR DRUM BRAKE
< SERVICE INFORMATION >
REAR DRUM BRAKE
Component INFOID:0000000002978761

PFIA0889E

1. Plug 2. Plug 3. Shoe hold pin

4. Back plate 5. Pin 6. Adjuster lever
7. Adjuster 8. Toggle lever 9. Adjuster spring
10. Shoe (leading side) 11. Return spring (lower side) 12. Return spring (upper side)
13. Drum 14. Retainer 15. Retainer ring
16. Shoe (trailing side) 17. Cap 18. Bleed valve
19. Boot 20. Piston 21. Piston cup
22. Spring 23. Wheel cylinder
1: Rubber grease 2: Polyglycol ether based lubri- : Brake fluid
cant
Refer to GI-7, "Component" 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.
Removal and Installation of Drum Brake Assembly INFOID:0000000002978762

REMOVAL

Revision: 2008 January BR-20 D40

 REAR DRUM BRAKE
< SERVICE INFORMATION >
• With the parking brake lever released, remove the brake drum. If it
is difficult to remove brake drum, remove as follows: 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 bladed
B
screw driver in the direction that narrows frame to narrow enlarged
brake shoe.
CAUTION:
• Never damage the wheel cylinder boots. C
• Never bend the parking brake cable.
SFIA3080E

D
• Apply rubber grease to screw and confirm the difference between
right and left wheel for assembling when disassembled.
E
Right rear Thread cutting : Right-hand screw
wheel direction
Left rear Thread cutting : Left-hand screw BR
wheel direction

G
SFIA3076E

Revision: 2008 January BR-21 D40

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000002978763

Unit: mm (in)

Wheel size 15 inch 16 inch

Cylinder bore diameter
Front brake Pad length × width × thickness
Rotor outer diameter × thickness
Cylinder bore diameter
Rear brake Lining length × width × thickness
Drum inner diameter
Master cylinder Cylinder bore diameter
Control valve Valve type
46.4 (1.827) × 2
140 × 50.5 × 11 (5.51 × 1.988 × 0.43)
238 × 28 (9.37 × 1.10) 296 × 28 (11.65 × 1.10)
22.22 (7/8)
295 × 55 × 5.5 (11.61 × 2.17 × 0.217)
295 (11.61)
25.4 (1.0)
Linkage type load sensing valve

Diaphragm di- Primary 246.4 (9.70)

Brake booster
ameter Secondary 213.4 (8.40)
Recommended brake fluid DOT 3

Brake Pedal INFOID:0000000002978764

Unit: mm (in)

M/T 174.1 – 184.1 (6.85 – 7.25)

LHD
A/T 182.1 – 192.1 (7.17 – 7.56)
Brake pedal height (from dash lower panel top surface)
M/T 164.7 − 174.7 (6.48 − 6.88)
RHD
A/T 172.5 − 182.5 (6.79 − 7.19)
M/T 102.1 (4.02) or more
LHD
A/T 107.9 (4.25) or more
Brake pedal depressed height
M/T 93.5 (3.681) or more
RHD
A/T 99.2 (3.906) or more
Clearance between threaded end of the stop lamp switch and stopper 0.74 − 1.96 (0.0291 − 0.0772)
Pedal play 3 − 11 (0.12 − 0.43)

Brake Booster INFOID:0000000002978765

Vacuum type
Unit: mm (in)
Output rod length 10.3 − 10.5 (0.406 − 0.413)
Input rod length 209.4 – 210.4 (8.24 – 8.28)

Check Valve INFOID:0000000002978766

Vacuum leakage Within 1.3 kPa (10 mmHg, 0.38 inHg, 0.013 bar) of
[at vacuum of −66.7 kPa (−500 mmHg, −19.70 inHg, −0.667 bar)] vacuum for 15 seconds

Front Disc Brake INFOID:0000000002978767

Unit: mm (in)
Standard thickness 11.0 (0.433)
Brake pad
Repair limit thickness 2.0 (0.079)

Revision: 2008 January BR-22 D40

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
Standard thickness 28.0 (1.102)
A
Repair limit thickness 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 (0.0020) B

Rear Drum Brake INFOID:0000000002978768

Unit: mm (in) C
Standard thickness 5.5 (0.217)
Brake lining
Repair limit thickness 1.5 (0.059)
D
Standard inner diameter 295 (11.61) dia.
Drum
Repair limit inner diameter 296.5 (11.67) dia.
E

BR

Revision: 2008 January BR-23 D40