BR
br BRAKE SYSTEM
F BRAKES
BR A
SECTION
B
BRAKE SYSTEM C
D
CONTENTS
E
PRECAUTIONS ......................................................... 3 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................. 3 PrecautionsforProcedureswithoutCowlTopCove.r.... 3 Precautions for Brake System ................................. 3
PREPARATION .......................................................... 4 Commercial Service Tools ....................................... 4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................................... 5
NVH Troubleshooting Chart .................................... 5 BRAKE PEDAL ......................................................... 6
Inspection and Adjustment ...................................... 6 PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL DEPRESSED ....................................................... 6 ADJUSTMENT ..................................................... 7
Removal and Installation ......................................... 7 COMPONENT PARTS LOCATION ...................... 7 REMOVAL ............................................................ 8 INSPECTION AFTER REMOVAL ........................ 8 INSTALLATION .................................................... 8
BRAKE FLUID ........................................................... 9 On-Board Inspection ............................................... 9 LEVEL CHECK .................................................... 9 Drain and Refill ........................................................ 9 Bleeding Brake System ......................................... 10
BRAKE PIPING AND HOSE ....................................11 Hydraulic Circuit .....................................................11 Removal and Installation of Front Brake Piping and Brake Hose ............................................................11 REMOVAL ...........................................................11 INSTALLATION ...................................................11 Removal and Installation of Rear Brake Piping and Brake Hose ........................................................... 12 REMOVAL .......................................................... 12 INSTALLATION .................................................. 12 Inspection After Installation ................................... 12
BRAKE MASTER CYLINDER ................................. 13 On-Board Inspection ............................................. 13
LEAK INSPECTION ........................................... 13 BR
Removal and Installation ....................................... 13
REMOVAL .......................................................... 13
INSTALLATION .................................................. 13 G Components .......................................................... 13
Disassembly and Assembly ................................... 14
DISASSEMBLY .................................................. 14 ASSEMBLY ........................................................ 14
H
BRAKE BOOSTER .................................................. 15
On-Vehicle Service ................................................ 15 OPERATING CHECK ......................................... 15 I
AIRTIGHT CHECK ............................................. 15
Removal and Installation ....................................... 16
REMOVAL .......................................................... 16 J
INSPECTION AFTER REMOVAL ...................... 16
INSTALLATION .................................................. 17
VACUUM LINES ...................................................... 18 K Removal and Installation ....................................... 18
Inspection .............................................................. 18
VISUAL INSPECTION ........................................ 18 CHECK VALVE INSPECTION ............................ 19 L
FRONT DISC BRAKE .............................................. 20
On-Vehicle Inspection ............................................ 20
PAD WEAR INSPECTION .................................. 20 M
Components .......................................................... 20
Removal and Installation of Brake Pad ................. 21
REMOVAL .......................................................... 21
INSTALLATION .................................................. 21
Removal and Installation of Brake Caliper Assembly
... 21
REMOVAL .......................................................... 21
INSTALLATION .................................................. 21
Disassembly and Assembly of Brake Caliper
Assembly ............................................................... 22
DISASSEMBLY .................................................. 22
CALIPER INSPECTION ..................................... 23
ASSEMBLY ........................................................ 23
DISC ROTOR INSPECTION .............................. 24
BRAKE BURNISHING PROCEDURE ................ 25
REAR DISC BRAKE ................................................ 26
Revision: 2005 July
BR-1
2005 FX
On-Vehicle Inspection ............................................ 26 PAD WEAR INSPECTION .................................. 26
Components .......................................................... 26 Removal and Installation of Brake Pad .................. 27
REMOVAL .......................................................... 27 INSTALLATION ................................................... 27 Removal and Installation of Brake Caliper Assembly
... 27 REMOVAL .......................................................... 27 INSTALLATION ................................................... 28 Disassembly and Assembly of Brake Caliper
Assembly ...............................................................28 DISASSEMBLY ...................................................28 CALIPER INSPECTION ......................................29 ASSEMBLY .........................................................29 DISC ROTOR INSPECTION ..............................30 BRAKE BURNISHING PROCEDURE ................31
SERVICE DATA AND SPECIFICATIONS (SDS) .....32 General Specifications ...........................................32 Brake Pedal ...........................................................32 Brake Booster ........................................................32 Check Valve ...........................................................32 Front Disc Brake ....................................................32 Rear Disc Brake .....................................................32
Revision: 2005 July
BR-2
2005 FX
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT A
BELT PRE-TENSIONER"
AFS0028A
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along B
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. 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.
C
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
D
q 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.
E
q 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.
BR
q 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.
G
Precautions for Procedures without Cowl Top Cover
AFS0038B
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
H
I
J
Precautions for Brake System
PIIB3706J
K
AFS001MQ
q Recommended fluid is brake fluid "DOT 3".
q Do not reuse drained brake fluid.
L
q Be careful not to splash brake fluid on painted areas.
q To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. M q Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
q Use flare nut wrench when removing and installing brake tube.
q When installing brake piping, be sure to check torque.
q Before working, turn ignition switch OFF and disconnect connectors for ABS actuator and electric unit (control unit) or battery terminal.
q Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-25, "BRAKE BURNISHING PROCEDURE" .
WARNING: q Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
SBR686C
Revision: 2005 July
BR-3
2005 FX
PREPARATION Commercial Service Tools
Tool name
PREPARATION
1. Flare nut crowfoot a:10 mm (0.39 in) / 12 mm (0.47 in)
2. Torque wrench
S-NT360
Description
PFP:00002
AFS001MR
Removing and installing each brake piping
Power tool
PBIC0190E
Removing front and rear caliper assembly, tires
PBIC0191E
Revision: 2005 July
BR-4
2005 FX
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. B
Reference page
G
Possible cause and SUSPECTED PARTS
H
Symptom BRAKE ×: Applicable
Revision: 2005 July
Noise Shake Shimmy, Judder
××× × ×××××××
Pads - damaged
BR-20, BR-26
Pads - uneven wear
BR-20, BR-26
Shims damaged
BR-20, BR-26
Rotor imbalance
--
BR-5
Rotor damage
--
Rotor runout
BR-24, BR-30
Rotor deformation
--
Rotor deflection
--
Rotor rust
--
Rotor thickness variation
BR-24, BR-31
Drum out of round
--
×× ×
PROPELLER SHAFT
NVH in PR section
DIFFERENTIAL
NHV in RFD section
××× ××× ×××
AXLE AND SUSPENSION NVH in FAX, RAX and FSU, RSU section
TIRES
NVH in WT section
ROAD WHEEL
NVH in WT section
PFP:00003
A
AFS001MS
2005 FX
× × DRIVE SHAFT
NVH in RAX section
×I
× ×
J
K
STEERING
NVH in PS section
C
D
E
BR
L
M
BRAKE PEDAL
BRAKE PEDAL
PFP:46501
Inspection and Adjustment
PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL DEPRESSED
1. Check brake pedal height from dash lower panel.
AFS001MT
2. Adjust height referring to the following specifications.
SFIA1450E
H
Brake pedal free height (from dash lower panel top surface)
161.5 - 171.5 mm (6.36 - 6.75 in)
D
Brake pedal depressed height [under a force of 490 N (50 kg, 110 lb) with engine running]
More than 80 mm (3.15 in)
Clearance between bracket and the threaded end C of stop lamp switch or ASCD cancel switch (or 0.74 - 1.96 mm (0.0291 - 0.0772 in)
brake switch)
A Pedal play
3 - 11 mm (0.12 - 0.43 in)
Revision: 2005 July
BR-6
2005 FX
BRAKE PEDAL
ADJUSTMENT 1. Loosen stop lamp switch and ASCD cancel switch (or brake
switch) by turning it counterclockwise by 45°. 2. Loosen lock nut (A) on input rod, then rotate input rod to set
pedal to the specified height, and tighten lock nut (A). CAUTION: Make sure the threaded end of input rod stays inside clevis.
Lock nut (A) :
Refer to BR-16, "Removal and Installation"
3. With pedal pulled and held by hand, press stop lamp switch and ASCD cancel switch (or brake switch) until its threaded end contacts stopper rubber.
4. With the threaded end of stop lamp switch and ASCD cancel switch (or brake switch) contacting stopper rubber, rotate switch clockwise by 45° to secure. CAUTION: Make sure that the clearance (C) between stopper rubber and threaded end of stop lamp switch and ASCD cancel switch (or brake switch) is within the standard.
5. Check pedal play. CAUTION: Make sure that stop lamps go off when pedal is released.
6. Start engine to check brake pedal depressed height.
Removal and Installation
COMPONENT PARTS LOCATION
A B C D E BR G
SFIA0160E
H
AFS001MU
I J K L M
Revision: 2005 July
BR-7
SFIA1940E
2005 FX
BRAKE PEDAL
1. Clevis pin 4. Stopper rubber
7. Stop lamp switch
2. Snap pin 5. Pedal pad
8. Clip
3. Brake pedal assembly
6. ASCD cancel switch (Models with ASCD) Brake switch (Models with ACC)
REMOVAL 1. Remove front kicking plate (driver side). EI-38, "KICKING PLATE" . 2. Remove dash side finisher (driver side). EI-37, "DASH SIDE FINISHER" . 3. Remove instrument lower panel (driver side). IP-18, "INSTRUMENT PASSENGER LOWER PANEL" . 4. Remove steering column assembly. Refer to PS-12, "Removal and Installation" . 5. Remove stop lamp switch and ASCD cancel switch (or brake switch) from pedal assembly. 6. Remove snap pin and clevis pin from brake booster clevis. 7. Remove mounting nuts and bolts from bracket, and remove
pedal assembly from the vehicle.
INSPECTION AFTER REMOVAL
q Make sure the rivets in the upper part of brake pedal are not deformed.
q Make sure sub bracket and slide plate are at least 4 mm (0.16 in) apart.
q Check brake pedal for bend, damage, and cracks on the welded parts. Replace the applicable part if a malfunction is detected.
q Check clevis pin and resin stopper for damage and deformation. If a malfunction is detected, replace clevis pin.
INSTALLATION Note the following, and install in the reverse order of removal. q After installing brake pedal assembly to the vehicle, adjust brake pedal height.
Revision: 2005 July
BR-8
SFIA0159E PFIA0223E SBR997
2005 FX
BRAKE FLUID
BRAKE FLUID On-Board Inspection
LEVEL CHECK q Make sure the fluid level in reservoir tank is within the standard
(between MAX and MIN lines). q Visually check around reservoir tank for fluid leaks. q If fluid level is excessively low, check brake system for leaks. q If brake warning lamp remains illuminated after parking lever is
released, check brake system for fluid leakage.
PFP:KN100
A
AFS001MV
B
C
D
Drain and Refill
SFIA1032E
E
AFS001MW
CAUTION:
q Refill with new brake fluid "DOT3".
BR
q Do not reuse drained brake fluid.
q Do not let brake fluid splash on the painted surfaces of the body. This might damage the paint, so
when splashing it, immediately wipe off the area and wash away with water.
G
q Before servicing, disconnect actuator connector or battery negative cable.
1. Connect a vinyl tube to each bleed valve.
H
2. Depress brake pedal, loosen each bleed valve, and gradually
remove brake fluid.
I
J
3. Make sure there is no foreign material in reservoir tank, and refill with new brake fluid.
4. Rest foot on brake pedal. Loosen bleed valve. Slowly depress pedal until it stops. Tighten bleed valve. Release brake pedal. Repeat this process a few times, then pause to add new brake fluid to master cylinder. Continue until new brake fluid flows out. Bleed Air. Refer to BR-10, "Bleeding Brake System" .
K
BRA0007D
L
M
SBR995
Revision: 2005 July
BR-9
2005 FX
BRAKE FLUID
Bleeding Brake System
AFS001MX
CAUTION: While bleeding, pay attention to master cylinder fluid level.
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 the rear right bleed valve.
3. Fully depress brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately.
5. Repeat steps 3, 4 until no more air comes out.
6. Tighten bleed valve to the specified torque. Refer to BR-20, "Components" (front disc brake), BR-26, "Components" (rear disc brake).
7. In steps 2 to 6 below, with master cylinder reservoir tank filled at least half way, bleed air from the front left, rear left, and front right bleed valve, in that order.
Revision: 2005 July
BR-10
2005 FX
BRAKE PIPING AND HOSE
BRAKE PIPING AND HOSE Hydraulic Circuit
PFP:46210
A
AFS001MY
B
C
D
E
BR
G
SFIA1941E
CAUTION:
q All hoses and piping (tubes) must be free from excessive bending, twisting and pulling. q Make sure there is no interference with other parts when turning steering both clockwise and H
counterclockwise.
q 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.
I
q Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
q Do not bend or twist brake hose sharply, or strongly pull it.
J
q When removing components, cover connections so that no dirt, dust, or other foreign matter gets
in.
q Refill with new brake fluid " DOT 3 ".
K
q Do not reuse drained brake fluid.
Removal and Installation of Front Brake Piping and Brake Hose
REMOVAL 1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from caliper assembly.
4. Remove lock plate and remove brake hose from the vehicle.
AFS001MZ
L
M
INSTALLATION 1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt to the specified torque.
NOTE: Do not reuse copper washer.
2. Install brake hose to brake tube, partially tighten flare nut as far as possible by hand, then secure it to bracket with lock plate.
3. Using a flare nut wrench, tighten flare nut to the specified torque.
4. Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
SFIA1204E
Revision: 2005 July
BR-11
2005 FX
BRAKE PIPING AND HOSE
Removal and Installation of Rear Brake Piping and Brake Hose
REMOVAL 1. Drain brake fluid. Refer to BR-9, "Drain and Refill" . 2. Using a flare nut wrench, remove brake tube from brake hose. 3. Remove bolt. 4. Remove union bolt, and then remove brake hose from caliper assembly.
INSTALLATION 1. Install brake hose to caliper assembly positioning hole and
tighten union bolt to the specified torque. NOTE: Do not reuse copper washer. 2. Install brake hose to brake tube, partially tighten flare nut as far
as possible by hand, then tighten bolt to the specified torque.
: 23.5 N·m (2.4 kg-m, 17 ft-lb)
AFS001N0
3. Using a flare nut wrench, tighten flare nut to the specified torque.
4. Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
SFIA1942E
Inspection After Installation
AFS001N1
CAUTION: If a leak is detected at the connections, retighten it or, if necessary, replace the damaged part.
1. Check brake lines (tubes and hoses), and connections for fluid leaks, damage, twist, deformation, contact with other parts, and loose connections. Replace any damage parts.
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately 5 seconds, check for fluid leakage from each part.
Revision: 2005 July
BR-12
2005 FX
BRAKE MASTER CYLINDER
BRAKE MASTER CYLINDER
On-Board Inspection
LEAK INSPECTION
PFP:46010
A
AFS001N2
q Check for leaking in master cylinder attachment portion, reservoir tank, and brake tube connections.
B
Removal and Installation
AFS001N3
CAUTION: Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is C splashed on painted areas, wash it away with water immediately.
REMOVAL
D
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Disconnect harness connectors for fluid level sensor and pressure sensor.
3. Using a flare nut wrench, disconnect brake tube from master cylinder assembly.
E
4. Remove master cylinder assembly fixing nut, remove master cylinder assembly from the vehicle. Refer to
BR-16, "Removal and Installation" .
INSTALLATION q Install in the reverse order of removal. Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" . CAUTION: q Refill with new brake fluid "DOT3". q Do not reuse drained brake fluid.
Components
BR
G
H
AFS001N4
I
J
K
L
M
Revision: 2005 July
BR-13
SFIA2157E
2005 FX
BRAKE MASTER CYLINDER
1. Reservoir cap 4. Reservoir tank 7. Clip
2. Strainer 5. Grommet 8. Pressure sensor
Disassembly and Assembly
DISASSEMBLY
CAUTION: q Master cylinder can not be disassembled.
q Remove reservoir tank only when absolutely necessary.
1. Remove clip.
2. Remove reservoir tank and grommet from master cylinder assembly.
3. Float 6. Master cylinder sub-assembly 9. Pressure sensor (Only ICC models)
AFS001N5
SFIA1132E
ASSEMBLY CAUTION: q Never use mineral oil such as kerosene, gasoline during the cleaning and assembly process. q Do not drop parts. If a part is dropped, do not use it. 1. Apply brake fluid grommet and attach to master cylinder assembly.
CAUTION: Do not reuse grommet. 2. Install reservoir tank onto master cylinder assembly. 3. Install clip.
SFIA1132E
Revision: 2005 July
BR-14
2005 FX
BRAKE BOOSTER
BRAKE BOOSTER
On-Vehicle Service
OPERATING CHECK With engine stopped, change the vacuum to the atmospheric pressure by depressing brake pedal several times. Then with brake pedal fully depressed, start engine and when the vacuum pressure reaches the standard, make sure the clearance between brake pedal and floor panel decreases. CAUTION: Depressing pedal interval is approximately 5 seconds.
AIRTIGHT CHECK
q Run engine at idle for approximately 1 minute, and stop it after applying vacuum to booster. Depress brake pedal normally to change the vacuum to the atmospheric pressure. Make sure distance between brake pedal and floor panel gradually increases.
q Depress brake pedal while engine is running,
and stop
engine with pedal depressed. The pedal stroke should not
change after holding pedal down for 30 seconds.
CAUTION: Depressing pedal interval is approximately 5 seconds.
PFP:47200
A
AFS001N6
B
C
D
BRA0037D
E
BR
G
H
SBR365AA
I
J
K
L
M
Revision: 2005 July
BR-15
2005 FX
Removal and Installation
BRAKE BOOSTER
AFS001N7
1. Reservoir tank 4. Brake pedal
2. Master cylinder 5. Lock nut
3. Gasket 6. Brake booster
SFIA1033E
REMOVAL CAUTION: q Be careful not to deform or bend brake piping while removing and installing brake booster. q Replace clevis pin if it is damaged. q 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. q Attach the check valve in the correct direction. 1. Remove brake piping from brake master cylinder. 2. Remove brake master cylinder. Refer to BR-13, "Removal and Installation" . 3. Remove vacuum hose from brake booster. Refer to BR-18, "VACUUM LINES" . 4. Disconnect harness connector from brake booster assembly. (ICC model) 5. Remove brake pedal attachment snap pin and clevis pin from inside the vehicle. 6. Remove nuts on brake booster and brake pedal assembly. 7. Remove brake booster assembly from dash panel.
INSPECTION AFTER REMOVAL Output Rod Length Inspection 1. Using a handy vacuum pump, apply a vacuum of 66.7 kPa (
500 mmHg, 19.69 inHg) to brake booster.
2. Check output rod length.
Standard dimension when applying a vacuum of -66.7 kPa ( 500 mmHg, -19.69 inHg):
15.6 - 15.9 mm (0.614 - 0.626 in)
SFIA2146E
Revision: 2005 July
BR-16
2005 FX
BRAKE BOOSTER
INSTALLATION 1. Loosen lock nut to adjust input rod length so that the length B (in
the figure) satisfies the specified value.
Length "B" : 126.5 mm (4.98 in)
2. After adjusting "B", temporarily tighten lock nut to install booster assembly to the vehicle. At this time, make sure to install a gasket between booster assembly and the dash panel.
3. Connect brake pedal with clevis of input rod. 4. Install pedal bracket mounting nuts and tighten them to the
specified torque. 5. Install brake piping from brake master cylinder to ABS actuator.
Refer to BR-11, "Hydraulic Circuit" . 6. Install master cylinder to booster assembly. Refer to BR-16, "Removal and Installation" . 7. Adjust the height and play of brake pedal. 8. Tighten lock nut of input rod to the specified torque. 9. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
A B C D
SGIA0060E
E BR
G H I J K L M
Revision: 2005 July
BR-17
2005 FX
VACUUM LINES Removal and Installation
VACUUM LINES
PFP:41920
AFS001N8
1. Clamp 4. Vacuum piping 7. Vacuum hose
2. Vacuum hose 5. Clamp 8. Clamp
SFIA1134E
3. Clamp 6. Check valve inclusion position stamp 9. Brake booster
CAUTION: q Because vacuum hose contains a check valve, it must be installed in the correct direction. Refer to
the stamp or label to confirm correct installation. The brake booster will not operate normally if hose is installed in the wrong direction.
q Insert vacuum hose for at least 24 mm (0.94 in).
q Do not use lubricating oil during assembly.
Inspection
VISUAL INSPECTION
Check for improper assembly, damage and deterioration.
Revision: 2005 July
BR-18
SBR225B AFS001N9
2005 FX
VACUUM LINES
CHECK VALVE INSPECTION Airtightness Inspection Use a handy vacuum pump to check.
When connected to booster side (1): Vacuum decrease should be within 1.3 kPa (10 mmHg, 0.39 inHg) for 15 seconds under a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg)
When connected to engine side (2): No vacuum will be applied
A B C D
SFIA0210E
E BR
G H I J K L M
Revision: 2005 July
BR-19
2005 FX
FRONT DISC BRAKE
FRONT DISC BRAKE
On-Vehicle Inspection
PAD WEAR INSPECTION
q Inspect the thickness of pad through cylinder body inspection hole. Use a scale for inspection if necessary.
Standard thickness Repair limit thickness
: 9.5 mm (0.374 in) : 2.0 mm (0.079 in)
Components
PFP:41000
AFS001RX
BRA0010D AFS001RY
1. Brake hose
2. Union bolt
4. Sliding pin bolt
5. Bleed valve
7. Cylinder body
8. Sliding pin
10. Piston seal
11. Piston
13. Torque member
14. Torque member bolt
16. Inner shim
17. Inner pad
19. Pad retainer (Lower)
20. Outer pad
Refer to GI-10, "Components" and the followings for the symbols in the figure.
1: Rubber grease
Revision: 2005 July
BR-20
3. Copper washer 6. Cap 9. Sliding pin boot 12. Piston boot 15. Inner shim cover 18. Pad retainer (Upper) 21. Outer shim
PFIA0687E
2005 FX
FRONT DISC BRAKE
2: PBC (Poly Butyl Cuprysil) grease or silicone-based grease
3: Polyglycol ether based lubricant
A
: Brake fluid
WARNING:
B
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne
particles or other materials.
CAUTION:
C
q While removing cylinder body never depress brake pedal because piston will pop out.
q 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 D
brake hose.
q Do not damage piston boot.
q If any shim is subject to serious corrosion, replace it with a new one.
E
q Always replace shims and shim covers as a set when replacing brake pads.
q Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft
pedal occurs at very low mileage. Refer to BR-25, "BRAKE BURNISHING PROCEDURE" .
BR
Removal and Installation of Brake Pad
REMOVAL
1. Remove tires from vehicle with power tool.
AFS001RZ
G
2. Remove lower sliding pin bolt.
3. Suspend cylinder body with a wire and remove pad and shim from torque member.
H
INSTALLATION
1. Attach inner shim and shim cover to inner pad, and outer shim to outer pad.
2. Push piston in so that pad is firmly installed and mount cylinder body to torque member.
I
NOTE:
Using a disc brake piston tool (commercial service tool), etc., makes it easier to push in piston.
CAUTION:
J
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
3. Attach pat retainer to torque member.
K
CAUTION:
When attaching pad retainer, attach it firmly so that it does
not float up higher than torque member, as shown in the fig-
L
ure.
4. Install lower sliding pin bolt and tighten it to the specified torque.
5. Check brake for drag.
M
6. Attach tires to the vehicle.
PFIA0273E
Removal and Installation of Brake Caliper Assembly
REMOVAL
AFS001S0
1. Remove tires from vehicle with power tool.
2. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
3. Remove union bolts and torque member bolts, and remove brake caliper assembly from the vehicle.
4. Remove disc rotor.
INSTALLATION
CAUTION: q Refill with new brake fluid "DOT3".
Revision: 2005 July
BR-21
2005 FX
FRONT DISC BRAKE
q Do not reuse drained brake fluid. 1. Install disc rotor. 2. Install caliper assembly to the vehicle, and tighten bolts to the
specified torque. CAUTION: When attaching caliper assembly to the vehicle, wipe any oil off knuckle spindle, washers and caliper assembly attachment surfaces.
3. Install brake hose to brake caliper assembly, and tighten union bolt to the specified torque.
CAUTION: q Do not reuse copper washers for union bolt.
q Attach brake hose to caliper assembly together with union bolt and washers.
SFIA1205E
SFIA1204E
4. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" . 5. Attach tires to the vehicle.
Disassembly and Assembly of Brake Caliper Assembly
DISASSEMBLY
AFS001S1
1. Remove sliding pin bolt, and then remove the pad, shim, shim cover, and pad retainer from the torque
member.
2. Remove sliding pins and sliding pin boots from torque member.
3. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots.
CAUTION: Do not get your fingers caught in piston.
MAA0272D
Revision: 2005 July
BR-22
2005 FX
FRONT DISC BRAKE
4. Using a flat-bladed screwdriver, remove piston seal from cylin-
der body.
A
CAUTION: Be careful not to damage cylinder inner wall.
B
C
CALIPER INSPECTION
SFIA0999E
D
Cylinder Body
CAUTION:
E
q Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene.
q Check inside surface of cylinder for score, rust, wear, damage or foreign materials. If any of the
above conditions are observed, replace cylinder body.
BR
q Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
Torque Member
G
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con- H dition are observed.
CAUTION: Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials are I stuck to sliding surface.
Sliding Pins and Sliding Pin Boots
J
Check sliding pin and sliding pin boot for wear, damage, and cracks. If damage or deformation is present,
replace the affected part.
ASSEMBLY
K
CAUTION: When assembling, use only rubber lubricant specified below.
1. Apply polyglycol ether based lubricant to the piston seal, and
L
install them to the cylinder body.
M
SFIA2278E
Revision: 2005 July
BR-23
2005 FX
FRONT DISC BRAKE
2. Apply brake fluid to piston, rubber grease to piston boot, then install piston boot in to piston groove. CAUTION: Do not reuse piston boot.
SFIA2279E
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove. CAUTION: Press piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
4. Install sliding pins and sliding pin boots to torque member.
5. Attach inner shim and inner shim cover to inner pad, and attach the outer shim to the outer pad. 6. Install cylinder body. Tighten sliding pin bolt to the specified torque.
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, fix disc rotor to wheel hub. (2 or more positions)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in) inside the disc edge.]
Runout limit (with the disc rotor attached to the vehicle)
Runout limit (just the disc rotor)
: 0.04 mm (0.0016 in) : 0.02 mm (0.0008 in)
NOTE: Make sure that wheel bearing axial end play is within the specifications before measuring runout. Refer to FAX-4, "On-Vehicle Inspection and Service" .
BRA0013D
3. If runout is outside the limit, find the minimum runout point by shifting mounting positions of disc rotor and wheel hub by one hole.
4. If runout is still out of specification, turn rotor with on-car brake lathe. ("MAD DL-8700", "AMMCO 700 and 705" or equivalent.)
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is outside the standard, replace disc rotor.
Standard thickness
: 28.0 mm (1.102 in)
Repair limit thickness
: 26.0 mm (1.024 in)
Maximum uneven wear : 0.015 mm (0.0006 in) (measured at 8 positions)
Revision: 2005 July
BR-24
SBR020B
2005 FX
FRONT DISC BRAKE
BRAKE BURNISHING PROCEDURE Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after A replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
B
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal /foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal /foot pressure such that vehicle stopping time equals 3 to 5 seconds.
C
3. To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure. D
E
BR
G
H
I
J
K
L
M
Revision: 2005 July
BR-25
2005 FX
REAR DISC BRAKE
REAR DISC BRAKE On-Vehicle Inspection
PAD WEAR INSPECTION q Inspect the thickness of pad through cylinder body inspection
hole. Use a scale for inspection if necessary. Standard thickness : 8.5 mm (0.335 in) Repair limit thickness : 2.0 mm (0.079 in)
Components
PFP:44000
AFS001NA
BRA0010D AFS001NB
1. Union bolt
2. Brake hose
4. Cap
5. Bleed valve
7. Cylinder body
8. Piston seal
10. Piston boot
11. Retaining ring
13. Bushing
14. Torque member bolt
16. Inner shim cover
17. Inner shim
19. Pad retainer (Upper)
20. Pad retainer (Lower)
22. Outer shim
23. Outer shim cover
Refer to GI-10, "Components" and the followings for the symbols in the figure.
Revision: 2005 July
BR-26
3. Copper washer 6. Sliding pin bolt 9. Piston 12. Sliding pin boot 15. Torque member 18. Inner pad 21. Outer pad
PFIA0688E
2005 FX
REAR DISC BRAKE
1: Rubber grease
2: PBC (Poly Butyl Cuprysil) grease or silicone-based grease
A
3: Polyglycol ether based lubricant
: Brake fluid
B
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne particles or other materials.
C
CAUTION:
q While removing cylinder body, never depress brake pedal because piston will pop out. q It is not necessary to remove bolts on torque member and brake hose except for disassembly or D
replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch
brake hose.
q Do not damage piston boot.
E
q If any shim is subject to serious corrosion, replace it with a new one.
q Always replace shims and shim covers as a set when replacing brake pads.
BR
q Burnish brake contact surface 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"
Removal and Installation of Brake Pad
REMOVAL 1. Remove tires from vehicle with power tool.
2. Remove sliding pin bolt (one on top).
3. Suspend cylinder body with a wire, and remove pads, pad retainers, shim from torque member.
AFS001NC
G
H
INSTALLATION 1. Apply PBC (Poly Butyl Cuprysil) grease or silicon-based grease to the backside of pad and to both sides I
of shim, and attach inner shim and shim cover to inner pad, and attach the outer shim and outer shim
cover to outer pad.
2. Install pad retainer and mount pad to torque member.
J
3. Push piston in so that pad is firmly attached and mount cylinder body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool), etc., makes it easier to push in piston.
K
CAUTION:
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
L
4. Install sliding pin bolt (one on top) and tighten to the specified torque.
5. Check brake for drag.
6. Install tires to the vehicle.
M
Removal and Installation of Brake Caliper Assembly
REMOVAL 1. Remove tires from vehicle with power tool.
2. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
3. Remove union bolt and torque member bolts, and remove brake caliper assembly from the vehicle.
4. Remove disc rotor.
AFS001ND
Revision: 2005 July
BR-27
PFIA0413E
2005 FX
REAR DISC BRAKE
INSTALLATION CAUTION: q Refill with new brake fluid "DOT 3". q Do not reuse drained brake fluid. 1. Install disc rotor. 2. Install caliper assembly to the vehicle, and tighten bolts to the specified torque.
CAUTION: Before installing caliper assembly to the vehicle, wipe off oil and grease on washer seats on axle assembly and mounting surface of caliper assembly. 3. Install brake hose to caliper assembly and tighten union bolt to the specified torque. CAUTION: q Do not reuse copper washer for union bolt. q Securely attach brake hose to protrusion on caliper assembly. 4. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" . 5. Install tires to the vehicle.
Disassembly and Assembly of Brake Caliper Assembly
DISASSEMBLY
AFS001NE
1. Remove sliding pin bolt, and then remove pad, shim, shim cover, and pad retainer from torque member and cylinder.
2. Remove sliding pin boot from torque member.
3. As shown in the figure, using a flat-bladed screwdriver, remove retaining ring from cylinder body.
4. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots. CAUTION: Do not get your fingers caught in piston.
5. Using a flat-bladed screwdriver, remove piston seals from cylinder body. CAUTION: Be careful not to damage cylinder inner wall.
Revision: 2005 July
BR-28
SBR028A
BRD0041D
SFIA0999E
2005 FX
REAR DISC BRAKE
CALIPER INSPECTION
Cylinder Body
A
CAUTION: q Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene. q Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the B
above conditions are observed, replace cylinder body.
q Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
C
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
D
Piston
CAUTION: q Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials E
are stuck to sliding surface.
q Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the
above condition are observed.
BR
Sliding Pin Bolts and Sliding Pin Boots
Make sure there is no wear, damage, or cracks in sliding pin bolts and sliding pin boots, and if there are,
replace them.
G
ASSEMBLY
CAUTION: When assembling, use only rubber lubricant specified below.
H
1. Apply polyglycol ether based lubricant to the piston seal, and install them to the cylinder body. I
J
2. Apply brake fluid to piston rubber grease to piston boot, then install piston boot in to piston groove.
CAUTION: Do not reuse piston boot.
K
SFIA2278E
L
M
SFIA2279E
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove. CAUTION: Press piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
Revision: 2005 July
BR-29
2005 FX
REAR DISC BRAKE
4. Fix piston boot with retaining ring. CAUTION: q Make sure boot is firmly in cylinder body groove. q Do not reuse retaining ring.
SFIA2280E
5. Install sliding pin bolt and sliding pin boots to torque member. 6. Apply PBC (Poly Butyl Cuprysil) grease or silicon-based grease to the backside of pad and to both sides
of shim, and attach inner shim and shim cover to inner pad, and the outer shim and outer shim cover to outer pad. 7. Assembling shims and shim covers to pad. CAUTION: When attaching pad retainer, attach it firmly so that it does not float up higher than torque member, as shown in the figure. 8. Attach pad retainer and pad to torque member. 9. Install cylinder body. Tighten sliding pin bolts to the specified torque.
PFIA0273E
DISC ROTOR INSPECTION Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is detected, replace applicable part.
Runout Inspection 1. Using wheel nuts, fix disc rotor to wheel hub. (2 or more positions)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in) inside disk edge.]
Runout limit (with it
: 0.05 mm (0.0020 in)
attached to the vehicle)
NOTE: Make sure that wheel bearing axial end play is within the specification before measuring runout. Refer to RAX-5, "On-Vehicle Inspection and Service" .
3. If runout is outside the limit, find the minimum runout point by shifting mounting positions of disc rotor and wheel hub by one hole.
BRA0013D
4. If runout still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or equivalent).
Revision: 2005 July
BR-30
2005 FX
REAR DISC BRAKE
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is out-
A
side the standard, replace disc rotor.
Standard thickness
: 16.0 mm (0.630 in)
Wear limit
: 14.0 mm (0.551 in)
B
Maximum uneven wear
: 0.015 mm (0.0006 in)
(measured at 8 positions)
C
D
SBR020B
BRAKE BURNISHING PROCEDURE
Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after E replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
BR
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal /foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal /foot pressure such that vehicle stopping time equals 3 to 5 seconds.
G
3. To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.
H
I
J
K
L
M
Revision: 2005 July
BR-31
2005 FX
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications
Front brake
Rear brake Master cylinder Control valve
Rotor outer diameter × thickness Pad length × width × thickness Cylinder bore diameter Rotor outer diameter × thickness Pad length × width × thickness Cylinder bore diameter Cylinder bore diameter Valve model
Brake booster
Diaphragm diameter
Recommended brake fluid
Primary Secondary
PFP:00030
AFS001NF
Unit: mm (in) 320 × 28 (12.60 × 1.10) 111.0 × 73.5 × 9.5 (4.73 × 2.894 × 0.374)
63.6 (2.504) 308 × 16 (12.13 × 0.63) 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335)
42.86 (1.6874) 25.4 (1.00)
Electric brake force distribution 228.5 (9.0) 203.0 (8.0) DOT 3
Brake Pedal
AFS001NG
Brake pedal height (from dash panel top surface)
Depressed pedal height [under a force of 490 N (50 kg, 110 lb) with engine running]
Clearance between stopper rubber and the threaded end of stop lamp switch
Pedal play
Brake Booster
Vacuum type
161.5 - 171.5 mm (6.36 - 6.75 in) More than 80 mm (3.15 in)
0.74 - 1.96 mm (0.0291 - 0.0772 in) 3 - 11 mm (0.12 - 0.43 in)
AFS001NH
Input rod installation standard dimension
126.5 mm (4.98 in)
Check Valve
AFS001NI
Vacuum leakage [at a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg)]
Within a vacuum of 1.3 kPa (10 mmHg, 0.39 inHg) for 15 seconds
Front Disc Brake
AFS001NJ
Brake pad Disc rotor
Standard thickness (new) Repair limit thickness Standard thickness (new) Repair limit thickness Maximum uneven wear (measured at 8 positions) Runout limit (with the disc rotor attached to the vehicle)
9.5 mm (0.374 in) 2.0 mm (0.079 in) 28.0 mm (1.102 in) 26.0 mm (1.024 in) 0.015mm (0.0006 in) 0.04 mm (0.0016 in)
Rear Disc Brake
AFS001NK
Brake pad Disc rotor
Standard thickness (new) Repair limit thickness Standard thickness (new) Repair limit thickness Maximum uneven wear (measured at 8 positions) Runout limit (with the disc rotor attached to the vehicle)
8.5 mm (0.335 in) 2.0 mm (0.079 in) 16.0 mm (0.630 in) 14.0 mm (0.551 in) 0.015 mm (0.0006 in)
0.05 mm (0.0020 in)
Revision: 2005 July
BR-32
2005 FX
Acrobat Distiller 4.05 for Windows FrameMaker SGML 5.5.6p145J