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BR-19, "Exploded View"

1. BRAKE BOOSTER PRESSURE SENSOR 36 Exploded View esee 36 Removal and Installation sssse 36 Inspection i iion eee ud t iss end 36 VACUUM LINES ceeeeeeeee 37 Exploded View eese 37 Removal and Installation sse 37 InSpeCctl rn ag e EL eren ere ee Ee ee rens 37 FRONT DISC BRAKE ess 39 BRAKE PAD 1 PISTON TYPE 39 BRAKE PAD 1 PISTON TYPE Exploded View 39 BRAKE PAD 1 PISTON TYPE Removal and In STAN ATOR untere eer eoe a d aa a even eta 39 BRAKE PAD 1 PISTON TYPE Inspection and Adjustment ooo eee ceeeceecceeeeeeeeeeeeeeeeeceeeeeeseeeeenentees 40 BRAKE PAD 4 PISTON TYPE 41 BRAKE PAD 4 PISTON TYPE Exploded View 41 BRAKE PAD 4 PISTON TYPE Removal and In STAN ATION Ae ERE EEE E 41 BRAKE PAD 4 PISTON TYPE Inspection and AGUSTO sesira tie E 43 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE 43 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE REAR DISC BRAKE eene 51 BRAKE PAD 1 PISTON TYPE 51 BRAKE PAD 1 PISTON TYPE Exploded View 51 BRAKE PAD 1 PISTON TYPE Removal and In StallatiOn 3 icri ide pe bra pa PER S hai rx 51 BRAKE PAD 1 PISTON TYPE Inspection and AdjJUstiment 2 5 tin
2. 4 Cap 5 Bleeder valve 6 Sliding pin bolt 7 Cylinder body 8 Piston seal 9 Piston 10 Piston boot 11 Sliding pin boot 12 Bushing 13 Torque member 14 Inner shim cover 15 Inner shim 16 Inner pad 17 Pad wear sensor RH inner pad 18 Padretainer only 19 Outer pad 20 Outer shim 1 Apply rubber grease 2 Apply PBC Poly Butyl Cuprysil grease or silicone based grease 3 Apply polyglycol ether based lubricant al Apply brake fluid Refer to Gl 4 Components for symbols not described on the above BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Removal and Installation INFOID 0000000001647885 REMOVAL WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal Brake fluid may splash while removing the brake hose 1 Remove tires with power tool 2 Fixthe disc rotor using wheel nuts 3 Drain brake fluid Refer to BR 11 Draining CAUTION Revision 2007 June BR 56 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR Never spill or splash brake fluid on the disc rotor 4 Remove union bolt 1 and then disconnect brake hose 2 from caliper assembly 5 Remove torque member mounting bolts and remove brake cali per assembly CAUTION Never drop brake pads and caliper assembly 6 Remove disc rotor CAUTION Put matching marks on the wheel hub and bearing assem bly and the disc rotor before removing the disc r
3. JPFIA02202Z 3 Remove pad pins while holding down cross spring then remove cross spring from caliper JPFIA02212Z 4 Using pliers remove brake pads shims and shim covers from caliper CAUTION Never damage the piston boot Never drop the brake pad shims and the shim cover JPFIA02222Z INSTALLATION WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal while removing the brake pads because the piston may pop out Never spill or splash brake fluid on the disc rotor 1 Apply Copper based brake grease to the mating faces between the brake pads and shims and install shims to the brake pad CAUTION Always replace the shims together when replacing the brake pad Never damage the piston boot 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 2 Install upper pad pin from the inner side then install firmly to the outer side through the hole in the top of brake pad Revision 2007 June BR 54 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR 3 Place the top of cross spring over the upper pad pin press in the cross spring install lower pad pin from the inner side to the outer side and secure cross spring 4 Install clips to the pad pins CAUTION If clip is no
4. per assembly CAUTION Never drop brake pads and caliper assembly 6 Remove disc rotor CAUTION Put matching marks on the wheel hub and bearing assem bly and the disc rotor before removing the disc rotor Never drop disc rotor INSTALLATION WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal Brake fluid may splash while removing the brake hose 1 Install disc rotor CAUTION Align the matching marks that have been made during removal when reusing the disc rotor 2 Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the specified torque CAUTION Never spill or splash any grease and moisture on the brake caliper assembly mounting face threads mounting bolts and washers Wipe out any grease and moisture 3 Install brake hose to brake caliper assembly and tighten union bolts to the specified torque 4 Refill with new brake fluid and perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid Never spill or splash brake fluid on the disc rotor 5 Check that no drag feel is present for the front disc brake 6 Install tires Revision 2007 June BR 44 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR gt BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Disassembly and Assembly INFOID 0000000001647872 DISASSEMBLY N
5. ASCD brake switch threaded end hits the stopper rubber CAUTION The clearance C2 between the stopper rubber and the stop lamp switch threaded end must be the specified value Refer to BR 63 Brake Pedal The stop lamp must turn off when the brake pedal is released Brake Pedal Shaky Fitting 1 Disconnect the harness connector from ASCD brake switch and stop lamp switch 2 Turn the stop lamp switch 45 counterclockwise 3 Loosen ASCD brake switch lock nut Turn ASCD brake switch counterclockwise 4 Press the brake pedal pad slightly Release the brake pedal Turn ASCD brake switch 1 until ASCD brake switch threaded end hits to the stopper rubber 2 clockwise CAUTION Never press fit the input rod 5 Tighten ASCD brake switch lock nut 3 to the specification Refer to BR 19 Exploded View CAUTION The clearance C1 between the stopper rubber and the ASCD brake switch threaded end must be the specified value Refer to BR 63 Brake Pedal JPFIA00712Z JPFIA00712Z JPFIA00712Z Revision 2007 June BR 9 G37 Coupe BRAKE PEDAL lt ON VEHICLE MAINTENANCE gt 6 Press fit the stop lamp switch 4 until the stop lamp switch hits the stopper rubber 45 clockwise while pulling the brake pedal pad slightly ASCD brake switch threaded end hits the stopper rubber CAUTION The clearance C2 between the stopper rubber and the stop lamp switch threaded end must be the specified value Refer
6. BRAKE BOOSTER ON VEHICLE REPAIR gt BRAKE BOOSTER Exp loded View INFOID 000000000 1647858 SEC 470 9 18 7 1 9 14 9 17 7 1 8 13 JPFIA0241GB 1 Master cylinder assembly 2 Brake booster 3 Lock nut 4 Gasket 5 Clevis Refer to GlI 4 Components for symbols in the figure Re moval and i n stal lati O n INFOID 0000000001647859 REMOVAL 1 Remove master cylinder cover 2 Remove cowl top Refer to EXT 21 Exploded View 3 Remove brake master cylinder assembly Refer to BR 30 Exploded View CAUTION Depress the brake pedal several times to release the vacuum pressure from the brake booster Then remove the master cylinder assembly Never depress the brake pedal after the master cylinder assembly is removed The piston of the master cylinder assembly is exposed Never damage it when removing the master cylinder The piston may drop off when pulled out strongly Never hold the piston Hold the cylinder body when handling the master cylinder assembly 4 Remove vacuum hose from brake booster Refer to BR 37 Exploded View 5 Remove snap pin 1 and clevis pin 2 from inside vehicle 6 Remove nuts on brake booster and brake pedal assembly Refer to BR 19 Exploded View 7 Remove brake booster from dash panel in engine room side CAUTION Never deform or bend the brake tubes e JPFIA00192Z INSTALLATION Note the following and installation in the reverse order of removal CAUTIO
7. n stal lat i O n INFOID 0000000001706101 REMOVAL 1 Remove master cylinder cover 2 Remove brake booster pressure sensor 3 Remove vacuum hose INSTALLATION Note the following installation is the reverse order of removal CAUTION Insert vacuum hose at least 25 mm 0 98 in A Never use lubricating oil during assembly Face the marking side vehicle front when assembling brake booster side e Face the marking side connector when assembling brake booster pressure sensor side JPFIA00232Z n spect i O n INFOID 0000000001 706102 INSPECTION AFTER REMOVAL Check for correct assembly damage and deterioration Check for brake booster pressure sensor Refer to EC 352 Component Inspection Revision 2007 June BR 36 G37 Coupe VACUUM LINES ON VEHICLE REPAIR gt VACUUM LINES Exp loded View INFOID 0000000001647861 SEC 470 JPFIA00222Z 1 Grommet 2 Clamp 3 Vacuum hose built in check valve 4 Vacuum piping 5 Vacuum hose A To intake manifold B Paint mark C Stampindicating engine direction D Stamp indicating grommet installa E To brake booster tion position Re moval and Installation INFOID 0000000001647862 REMOVAL 1 Remove the engine cover Refer to EM 24 Exploded View 2 Remove the cowl top Refer to EXT 21 Exploded View 3 Remove the vacuum hose and tube INSTALLATION Installation is the reverse order of removal CAUTION Because vacuum hose contains a check
8. 6 Snappin 7 Locknut 8 ASCD brake switch 9 Stop lamp switch ETA Apply multi purpose grease Refer to GlI 4 Components for symbols not described on the above Removal and Installation INFOID 0000000001647837 REMOVAL 1 Remove instrument driver lower panel Refer to IP 11 Exploded View 2 Remove steering column assembly Refer to ST 16 WITHOUT ELECTRIC MOTOR Exploded View without electric motor ST 17 WITH ELECTRIC MOTOR Exploded View with electric motor Disconnect the stop lamp switch and ASCD brake switch harness connectors Turn the stop lamp switch counterclockwise to remove the stop lamp switch Loosen the lock nut for the ASCD brake switch and remove the ASCD brake switch Remove snap pin and clevis pin from clevis of brake booster Remove the cowl top Refer to EXT 21 Exploded View Remove the instrument panel Refer to IP 11 Exploded View Slide the steering member rearward 10 Remove the brake pedal assembly INSTALLATION Note the following and installation in the reverse order of removal OPNP YW Revision 2007 June BR 19 G37 Coupe BRAKE PEDAL ON VEHICLE REPAIR gt Apply the multi purpose grease to the clevis pin and the mating faces Not necessary if grease has been already applied NOTE The clevis pin may be inserted in either direction Inspection and Adjustment INFOID Q000000001647636 INSPECTION AFTER REMOVAL Check for the following items and replace the b
9. Inspection and Adjustment s 62 BRAKE CALIPER ASSEMBLY 4 PISTON TYPE 47 SERVICE DATA AND SPECIFICATIONS BRAKE CALIPER ASSEMBLY PISTONTYPE SDS iced esie E 63 Exploded View er 47 BRAKE CALIPER ASSEMBLY 4 PISTON TYPE SERVICE DATA AND SPECIFICATIONS Removal and Installation eee 46 SDS recenseri e edere ob epatis 63 BRAKE CALIPER ASSEMBLY 4 PISTON TYPE General Specifications sssssssss 63 Disassembly and Assembly 49 Brak Pedal cosas einst abut iai 63 BRAKE CALIPER ASSEMBLY 4 PISTON TYPE Brake Boosler naredne neret Eee 63 Inspection and Adjustment sss 50 Front Disc Brake esee 64 Rear Disc Brake cccccccecessssseceeeceesseeeeeseaaeesees 64 BR 2 Revision 2007 June G37 Coupe NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING SYMPTOM DIAGNOSIS SYMPTOM DIAGNOSIS NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Chart INFOID000000001647814 Use the chart below to help you find the cause of the symptom If necessary repair or replace these parts c 2 o 0 o 2 Te D Te cc oa Si e re eh eS c a eo a Lu e col cm col col col rm m m v Reference page ij p OL as uj ioi oj i gj Gj clei c u8v7uz uduuuuzsisiSixssS s c cmwicxcic dcciccmicmigiloilozzinil
10. This is a normal phenomenon due to the brake system operation Revision 2007 June BR 14 INFOID 0000000001647829 BRA0037D JPFIA0043ZZ JPFIA0044ZZ G37 Coupe FRONT DISC BRAKE lt ON VEHICLE MAINTENANCE gt FRONT DISC BRAKE BRAKE PAD B RAK E PAD F Inspecti on INFOID 0000000001647831 PAD WEAR 1 Piston Type Check pad thickness from an inspection hole on cylinder body Check using a scale if necessary Standard Standard thickness Refer to BR 64 Front Disc Brake Limit Wear limit thickness Refer to BR 64 Front Disc Brake 4 Piston Type Check pad thickness from an inspection hole on caliper Check using a scale if necessary Standard Standard thickness Refer to BR 64 Front Disc Brake Limit Wear limit thickness Refer to BR 64 Front Disc Brake PFIA0228J DISC ROTOR DISC ROTOR i Inspection INFOID 0000000001647832 APPEARANCE Check surface of disc rotor for uneven wear cracks and serious damage Replace if there are RUNOUT 1 Fix the disc rotor to the wheel hub and bearing assembly with wheel nuts 2 points at least 2 Inspect the runout with a dial gauge Measured at 10 mm 0 39 in inside the disc edge Limit Runout limit Refer to BR 64 Front Disc Brake NOTE Or Check the wheel bearing axial end play before the inspection 2 GS Refer to FAX 4 Inspection 3 Find the installation position that has a minimum runout by shifting the disc rotor to wheel
11. crowfoot and a torque wrench CAUTION Cover crowfoot with a cloth as not to damage the caliper Never scratch the flare nut and the brake tube Refill with new brake fluid and perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid Never spill or splash brake fluid on the disc rotor Check that no drag feel is present for the front disc brake Install tires BRAKE CALIPER ASSEMBLY 2 PISTON TYPE Disassembly and Assembly DISASSEMBLY m 1 Place a wooden block as shown in the figure and blow air from union bolt mounting hole to remove pistons and piston boots and retaining rings CAUTION Never get fingers caught in the pistons JPFIA02252Z 2 Remove piston seal 1 from cylinder body using suitable tool CAUTION Be careful not to damage a cylinder inner wall JPFIA0226ZZ ASSEMBLY 1 Apply brake fluid to piston seals 1 and install them to caliper CAUTION Never reuse piston seals PFIA0872E Revision 2007 June BR 61 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR gt 2 Apply rubber grease to piston boots 1 Cover the piston 2 end with piston boots and then install caliper side lip on piston boot securely into a groove on caliper CAUTION Never reuse piston boots 3 Apply brake fluid to piston Push piston into caliper by hand and push piston boot piston side lip into the piston groove CAUTION Press the piston evenly and
12. hub and bearing assembly installation position by one hole at a time if the runout exceeds the limit value 4 Replace or lathe the disc rotor if the runout is outside the limit even after performing the above operation When lathing use the Pro Cut PEM On Car brake Lathe Tool No 38 PFM90 5 or equivalent THICKNESS Revision 2007 June BR 15 G37 Coupe FRONT DISC BRAKE lt ON VEHICLE MAINTENANCE gt Check the thickness of the disc rotor using a micrometer Replace the disc rotor if the thickness is below the wear limit Limit Wear limit thickness Refer to BR 64 Front Disc Brake SBRO20B Revision 2007 June BR 16 G37 Coupe REAR DISC BRAKE lt ON VEHICLE MAINTENANCE gt REAR DISC BRAKE BRAKE PAD B RA K E PA D i n S p ecti O n INFOID 0000000001647834 PAD WEAR 1 Piston Type Check pad thickness from an inspection hole on cylinder body Check using a scale if necessary Standard Standard thickness Refer to BR 64 Rear Disc Brake Limit Wear limit thickness Refer to BR 64 Rear Disc Brake 2 Piston Type Check pad thickness from an inspection hole on caliper Check using a scale if necessary Standard Standard thickness Refer to BR 64 Rear Disc Brake Limit Wear limit thickness Refer to BR 64 Rear Z Disc Brake aac PFIA0227J DISC ROTOR DISC ROTOR i Inspection INFOID 0000000001647835 APPEARANCE Check surface of disc rotor for uneven wear cracks and serious damag
13. pad and disc rotor are securely fitted Revision 2007 June BR 62 G37 Coupe SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS General Specifications FRONT AND REAR CALIPER 1 PISTON TYPE Cylinder bore diameter INFOID 000000000 1647892 Unit mm in 57 15 2 250 Front brake Pad length x width x thickness 116 1 x 51 7 x 10 3 4 57 x 2 035 x 0 406 Rotor outer diameter x thickness 330 x 32 0 12 99 x 1 260 Cylinder bore diameter 38 1 1 500 Rear brake Pad length x width x thickness 83 0 x 33 0 x 8 5 3 268 x 1 299 x 0 335 Rotor outer diameter x thickness 330 x 16 0 12 99 x 0 630 Master cylinder Cylinder bore diameter 23 8 15 16 Control valve Valve type Electric brake force distribution Brake booster Diaphragm diameter Primary 230 9 Secondary 205 8 Recommended brake fluid DOT 3 FRONT CALIPER 4 PISTON REAR CALIPER 2 PISTON TYPE Unit mm in Cylinder bore diameter 41 3 1 626 x 2 44 45 1 750 x 2 Front brake Pad length x width x thickness 123 2 x 55 0 x 11 0 4 85 x 2 165 x 0 433 Rotor outer diameter x thickness 355 x 32 0 13 98 x 1 260 Cylinder bore diameter 41 3 1 626 x 2 Rear brake Pad length x width x thickness 95 8 x 41 5 x 9 5 3 772 x 1 634 x 0 374 Rotor outer diameter x thickness 350 x 20 0 13 7
14. piston type rear 2 piston type 1 Connect a vinyl tube to the bleed valve 2 Depress the brake pedal and loosen the bleeder valve to gradu ally discharge brake fluid BRA0007D Refi i n g INFOID 0000000001647824 CAUTION Turn the ignition switch OFF and disconnect the ABS actuator and electric unit control unit con nector or the battery negative terminal before performing work Revision 2007 June BR 11 G37 Coupe BRAKE FLUID lt ON VEHICLE MAINTENANCE gt Cover crowfoot and flare nut wrench with a cloth as not to damage the caliper front 4 piston type rear 2 piston type 1 Check that there is no foreign material in the reservoir tank and refill with new brake fluid CAUTION Never reuse drained brake fluid 2 Loosen the bleeder valve slowly depress the brake pedal to the full stroke and then release the pedal Repeat this operation at intervals of 2 or 3 seconds until all brake fluid is discharged Then close the bleeder valve with the brake pedal depressed Repeat the same work on each wheel 3 Perform the air bleeding Refer to BR 12 Bleeding Brake Sys tem PFIA0403J Bleeding Brake System INFOID 0000000001647825 CAUTION Turn the ignition switch OFF and disconnect the ABS actuator and electric unit control unit con nector or the battery negative terminal before performing the work Monitor the fluid level in the reservoir tank while performing the air bleeding Always u
15. specification Refer to BR 19 Exploded View CAUTION The clearance C1 between the stopper rubber and the ASCD brake switch threaded end must be the specified value Refer to BR 63 Brake Pedal 6 Press fit the stop lamp switch 4 until the stop lamp switch hits the stopper rubber 45 clockwise while pulling the brake pedal pad slightly ASCD brake switch threaded end hits the stopper rubber CAUTION The clearance C2 between the stopper rubber and the stop lamp switch threaded end must be the specified value Refer to BR 63 Brake Pedal The stop lamp must turn off when the brake pedal is released Brake Pedal Play 1 Disconnect the harness connector from ASCD brake switch and stop lamp switch 2 Turn the stop lamp switch 45 counterclockwise 3 Loosen ASCD brake switch lock nut Turn ASCD brake switch counterclockwise 4 Press the brake pedal pad slightly Release the brake pedal Turn ASCD brake switch 1 until ASCD brake switch threaded end hits to the stopper rubber 2 clockwise CAUTION Never press fit the input rod 5 Tighten ASCD brake switch lock nut 3 to the specification Refer to BR 19 Exploded View CAUTION The clearance C1 between the stopper rubber and the ASCD brake switch threaded end must be the specified value Refer to BR 63 Brake Pedal 6 Press fit the stop lamp switch 4 until the stop lamp switch hits the stopper rubber 45 clockwise while pulling the brake pedal pad slightly
16. tube from the brake hose CAUTION Never scratch the flare nut and the brake tube Never sharply bend twist or strongly pull the brake hoses and tubes Cover the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt Remove the union bolt and remove the brake hose from the brake caliper assembly Remove the lock plate and remove the brake hose from the vehicle 2 Piston Type CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface 1 2 3 Remove tires with power tool Drain brake fluid Refer to BR 11 Draining Loosen the flare nut with a flare nut wrench and separate the brake tube from the brake hose and caliper CAUTION Revision 2007 June BR 27 G37 Coupe BRAKE PIPING ON VEHICLE REPAIR gt Cover flare nut wrench with a cloth as not to damage the caliper Never scratch the flare nut and the brake tube Never sharply bend twist or strongly pull the brake hoses and tubes Cover the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt 4 Remove the brake hose mounting bolt 5 Remove the lock plate and remove the brake hose from the vehicle INSTALLATION 1 Piston Type CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with wat
17. valve it must be installed in the correct position Refer to the stamp to confirm correct installation Brake booster will not operate normally if the hose is installed in the wrong direction Insert vacuum hose at least 24 mm 0 94 in A Never use lubricating oil during assembly Face the marking side up when assembling JPFIA00232Z n S p e ct i O n INFOID 0000000001647863 INSPECTION AFTER REMOVAL Appearance Check for correct assembly damage and deterioration Check Valve Airtightness Revision 2007 June BR 37 G37 Coupe VACUUM LINES ON VEHICLE REPAIR Use a handy vacuum pump A to check When connected to the booster side B Vacuum should decrease within 1 3 kPa 9 8 mm Hg 0 38 inHg for 15 seconds under a vacuum of 66 7 kPa 500 mmHg 19 69 inHg When connected to the engine side C Vacuum should not exist Replace vacuum hose assembly if vacuum hose and check valve are malfunctioning JPFIAO024ZZ Revision 2007 June BR 38 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR gt FRONT DISC BRAKE BRAKE PAD 1 PISTON TYPE BRAKE PAD 1 PISTON TYPE Exploded View INFOID O000000001664763 ub 2 4 18 9 18 2 1 9 13 ES P js Si n 9 132 5 14 98 JPFIA0025GB 1 Bleeder valve 2 Cap 3 Brake hose 4 Union bolt 5 Copper washer 6 Protector 7 Bushing 8 Location pin 9 Sliding pin 10 Sliding pin boot 11 Oylinder body 12 Piston seal 13 Piston 14 P
18. vary the pressing point to pre vent caliper inner wall from being rubbed 4 Install the caliper to tighten the caliper mounting bolts to the specified torque PFIA0906J BRAKE CALIPER ASSEMBLY 2 PISTON TYPE Inspection and Adjustment INFOID 0000000001664898 INSPECTION AFTER DISASSEMBLY Caliper Check the inner wall of the caliper for rust wear cracks or damage Replace the caliper if any abnormal con dition is detected CAUTION Always clean with new brake fluid Never clean with mineral oil such as gasoline and light oil Pistons Check the surface of the piston for rust wear cracks or damage Replace the piston if any abnormal condition is detected CAUTION A piston sliding surface is plated Never polish with sandpaper ADJUSTMENT AFTER INSTALLATION Brake Burnishing Procedure Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or replacing disc rotor or if a soft pedal occurs at very low mileage CAUTION Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are securely fitted Only perform this procedure under safe road and traffic conditions Use extreme caution 1 Drive vehicle on straight flat road 2 Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops 3 Drive without depressing brake for a few minutes to cool the brake 4 Repeat steps 1 to 3 until
19. 001647879 REMOVAL WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal while removing the brake pads or the cylinder body because the pis ton may pop out Never spill or splash brake fluid on the disc rotor Revision 2007 June BR 51 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR 1 Remove tires with power tool 2 Remove the upper sliding pin bolt 3 Suspend the cylinder body with suitable wire so that the brake hose will not stretch Remove the brake pads from the torque member CAUTION Never deform the pad retainers if removing the pad retainers Never damage the piston boot Never drop the brake pad shims and the shim cover INSTALLATION WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal while removing the brake pads or the cylinder body because the pis ton may pop out Never spill or splash brake fluid on the disc rotor 1 Apply PBC Poly Butyl Cuprysil grease or silicone based grease to the pad retainers before installing it to the torque member if the pad retainers has been removed CAUTION Securely assemble the pad retainers so that it will not be lifted up from the torque member Never deform the pad retainers 2 Apply PBC Poly Butyl Cuprysil grease or silicone base
20. 01647875 REMOVAL WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal Brake fluid may splash while removing the brake hose and brake tube 1 Remove tires with power tool 2 Fixthe disc rotor using wheel nuts 3 Drain brake fluid Refer to BR 11 Draining CAUTION Never spill or splash brake fluid on the disc rotor 4 Loosen the flare nut with a flare nut wrench and separate the brake tube from caliper CAUTION Cover flare nut wrench with a cloth as not to damage the caliper Never scratch the flare nut and the brake tube Never bend sharply twist or strongly pull out the brake tube Cover open end of brake tube when disconnecting to prevent entrance of dirt 5 Remove caliper mounting bolts and remove caliper CAUTION NXE Never drop brake pad and caliper i 7 G oe 6 Remove disc rotor OO a CAUTION A Fay Put matching marks on the wheel hub and bearing assem bly and the disc rotor before removing the disc rotor Never drop disc rotor Ay ORAN AER T 6 amp L KV c NS gt SO TE INSTALLATION WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal Brake fluid may splash while removing the brake hose 1 Install disc rotor CAUTION Align the matching marks that h
21. 37D Air Tight Run the engine at idle for 1 minute to apply vacuum to the brake booster and stop the engine Then depress the brake pedal sev eral times at 5 second intervals until the accumulated vacuum is released to atmospheric pressure Check that the clearance between brake pedal and dash lower panel gradually increases A B C each time the brake pedal is depressed when perform ing this operation JPFIA00432Z Revision 2007 June BR 34 G37 Coupe BRAKE BOOSTER ON VEHICLE REPAIR gt Depress the brake pedal with the engine running Then stop the engine while holding down the brake pedal Check that the brake pedal stroke does not change after holding down the brake pedal for 30 seconds or more NOTE A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed This is a normal phenomenon due to the brake system operation JPFIA00442Z ADJUSTMENT AFTER INSTALLTION Perform the brake pedal adjustment after installing the brake pedal assembly Refer to BR 7 Inspection and Adjustment Revision 2007 June BR 35 G37 Coupe BRAKE BOOSTER PRESSURE SENSOR ON VEHICLE REPAIR gt BRAKE BOOSTER PRESSURE SENSOR Exp loded View INFOID 0000000001 706100 SEC 223 9 7 0 0 71 62 JPFIA0240GB 1 Brake booster 2 Clamp 3 Vacuum hose 4 Brake booster pressure sensor A Paint mark Refer to GlI 4 Components for symbols in the figure Re m oval a nd
22. 8 x 0 787 Master cylinder Cylinder bore diameter 25 4 1 Control valve Valve type Electric brake force distribution Primary 230 9 Brake booster Diaphragm diameter Secondary 205 8 Recommended brake fluid DOT 3 Brake Pedal InFo100000000001647699 Unit mm in Brake pedal height H1 171 5 181 5 6 75 7 15 Clearance C1 between ASCD brake switch threaded end and the stopper rubber 0 0 6 0 0 024 Clearance C2 between the stop lamp switch threaded end and the stopper rubber 0 74 1 96 0 0291 0 0772 Brake pedal play A 2 0 8 0 0 079 0 315 Brake pedal shaky fitting B 0 1 4 0 0 0 055 Depressed brake pedal height H2 Depressing 490 N 50 kg 110 Ib while turning the engine ON Brake Booster Vacuum type Input rod length B Revision 2007 June BR 63 124 0 4 88 or more INFOID 0000000001647894 Unit mm in 128 0 5 04 G37 Coupe SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS Front Disc Brake 1 PISTON TYPE INFOID 0000000001647895 Unit mm in Standard thickness 10 3 0 406 Brake pad mE Wear limit thickness 2 0 0 079 Standard thickness 32 0 1 260 Wear limit thickness 30 0 1 181 Disc rotor Thickness variation measured at 8 positions 0 015 0 0006 Runout limit with it attached
23. AKE MASTER CYLINDER Inspection INFOID 000000000 1647827 FLUID LEAK Check for brake fluid leakage from the master cylinder mounting face reservoir tank mounting face and brake tube connections Revision 2007 June BR 13 G37 Coupe BRAKE BOOSTER ON VEHICLE MAINTENANCE gt BRAKE BOOSTER Inspection OPERATION Depress the brake pedal several times at 5 second intervals with the engine stopped Start the engine with the brake pedal fully depressed Check that the clearance between brake pedal and dash lower panel decreases NOTE A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed This is a normal phenomenon due to the brake system operation AIR TIGHT Run the engine at idle for 1 minute to apply vacuum to the brake booster and stop the engine Then depress the brake pedal sev eral times at 5 second intervals until the accumulated vacuum is released to atmospheric pressure Check that the clearance between brake pedal and dash lower panel gradually increases A B C each time the brake pedal is depressed when perform ing this operation Depress the brake pedal with the engine running Then stop the engine while holding down the brake pedal Check that the brake pedal stroke does not change after holding down the brake pedal for 30 seconds or more NOTE A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed
24. BR 46 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR gt Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or replacing disc rotor or if a soft pedal occurs at very low mileage CAUTION Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are securely fitted Only perform this procedure under safe road and traffic conditions Use extreme caution 1 Drive vehicle on straight flat road 2 Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops 3 Drive without depressing brake for a few minutes to cool the brake 4 Repeatsteps 1 to 3 until pad and disc rotor are securely fitted BRAKE CALIPER ASSEMBLY 4 PISTON TYPE BRAKE CALIPER ASSEMBLY 4 PISTON TYPE Exploded View INFOID 0000000001647574 SEC 440 JPFIA0212GB 1 Piston 2 Piston seal 3 Piston boot 4 Retaining ring 5 Cap 6 Bleeder valve 7 Cap 8 Clip 9 Padpin 10 Caliper 11 Inner shim 12 Inner pad 13 Pad wear sensor RH inner pad 14 Cross spring 15 Outer pad only 16 Outer shim Kr Apply rubber grease Kr Apply copper based brake grease al Apply brake fluid Refer to GlI 4 Components for symbols not described on the above Revision 2007 June BR 47 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR gt BRAKE CALIPER ASSEMBLY 4 PISTON TYPE Removal and Installation INFOID 00000000
25. BRAKES SECTION B H BRAKE SYSTEM CONTENTS SYMPTOM DIAGNOSIS S DISCROTOBR tector a ct oit DISC ROTOR Inspection NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING 3 REAR DISC BRAKE esee 17 TVEICTrOUDIGSD oH nC ONG regu erit dsfendent BRAKE PAD ainaani n etis cie 17 PRECAUTION 3 nni nre 4 BRAKE PAD Inspection eeren 17 DISC ROTOR o ceeeooce cree tootco re aes ees e eec pe dest 17 PRECAUTIONS 1 cirer itn natu innuit naa mannna 4 DISC ROTORS IRSDGCOn i e riter runs i Precaution for Supplemental Restraint System SRS CAIR BAG and SEATBELT PRE TEN ON VEHICLE REPAIR 19 DIONE Rie rr 4 Precaution Necessary for Steering Wheel Rota BRAKE PEDAL ccivciccisiiciesteivcininsincentavineedetvine 19 tion after Battery Disconnect s es 4 Exploded VIEW empti tert onitete saini 19 Precaution for Procedure without Cowl Top Cover 5 Removal and Installation eeeeeeeee 19 Precaution for Brake System sss 5 Inspection and Adjustment ssssss 20 PREPARATION eren rnnt 6 BRAKE PIPING eene 21 PREPARATION eene nennen nennen nnns 6 FRONT noue ncI Ee iris 21 Commercial Service Tool sss 6 FRONT Exploded View ssie 21 FRONT Hydraulic Piping sssssssss 22 ON VEHICLE MAINTE
26. IA0034ZZ 4 Install sliding pin and sliding pin boots to torque member 5 Install the cylinder body to the torque member and tighten the location pin and sliding pin bolt to the spec ified torque 6 Install the protector BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Inspection and Adjustment INFOID 0000000001647873 INSPECTION AFTER DISASSEMBLY Oylinder Body Check the inner wall of the cylinder for rust wear cracks or damage Replace the cylinder if any abnormal condition is detected CAUTION Always clean with new brake fluid Never clean with mineral oil such as gasoline and light oil Torque Member Check the torque member for wear cracks or damage Replace the torque member if any abnormal condi tion is detected Eliminate rust on the torque member Replace them if rust is excessively attached Piston Check the surface of the piston for rust wear cracks or damage Replace the piston if any abnormal condition is detected CAUTION A piston sliding surface is plated Never polish with sandpaper Location Pin Protector and Bushing Check the location pin protector and bushing for rust wear cracks or damage Replace the parts if any abnor mal condition is detected Sliding Pin and Sliding Pin Boot Check the sliding pin and sliding boots for rust wear cracks or damage Replace the parts if any abnormal condition is detected ADJUSTMENT AFTER INSTALLATION Brake Burnishing Procedure Revision 2007 June
27. N Revision 2007 June BR 33 G37 Coupe BRAKE BOOSTER ON VEHICLE REPAIR gt Be careful not to damage brake booster stud bolt threads If brake booster is tilted during installa tion the dash panel may damage the threads Never deform or bend the brake tubes when installing the brake booster Always use a new gasket between the brake booster and the dash panel Replace the clevis pin if it is damaged Refer to BR 20 Inspection and Adjustment Install the brake pedal assembly and brake booster mounting nuts and tighten it to the specified torque After installation perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid Inspection and Adjustment INFOID 0000000001647860 INSPECTION AFTER REMOVAL Input Rod Length Inspection 1 Loosen the lock nut 1 and adjust the input rod 2 to the speci fied length B Standard i L I Input rod length B Refer to BR 63 Brake Booster 2 Tighten the lock nut to the specified torque INSPECTION AFTER INSTALLATION Operation Depress the brake pedal several times at 5 second intervals with the engine stopped Start the engine with the brake pedal fully depressed Check that the clearance between brake pedal and dash lower pane decreases NOTE A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed This is a normal phenomenon due to the brake system operation BRA00
28. NANCE 7 FRONT Removal and Installation 23 FRONT Inspection eesssseeeeenne 25 BRAKE PEDAL ssssssssssssssssssssssssssssssssssessessessee 7 p Inspection and Adjustment sssessss T REAR bo eR peti 25 REAR Exploded View sseeeeeeee 25 BRAKE FLUID subaanudeusunessntewciatucuseGiuwuisscaenesctanen es 11 REAR Hydraulic Piping ee 26 Inspection Miu edicit Mt oia ood tha ats haat e 11 REAR Removal and Installation sss 27 Draining ERE 11 REAR Inspection eee 28 REMING areta onaniaa etes 11 Bleeding Brake System sss 12 BRAKE MASTER CYLINDER 30 Exploded View ssssesssssssseeeenee 30 BRAKE MASTER CYLINDER eene 13 Removal and Installation sse 30 In S peCctlOn tieni a 13 Disassembly and Assembly eee 31 BRAKE BOOSTER sss 14 Inspection iiuuaucui ccce ete teres 32 IniSDeCtlOnr sec net ettet ed e her tr et ren puteus 14 BRAKE BOOSTER Rennes 33 FRONT DISC BRAKE sss 15 Exploded View Meet nennennennnennnnn nennen 33 Removal and installation ssss 33 BRAKE PAD iusto on dl na gud t did tede 15 Inspection and Adjustment sss 34 BRAKE PAD Inspection eenen 15 BR 1 Revision 2007 June G37 Coupe
29. OID 0000000001647868 REMOVAL WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal while removing the brake pads because the piston may pop out Never spill or splash brake fluid on the disc rotor 1 Remove tires with power tool Revision 2007 June BR 41 G37 Coupe FRONT DISC BRAKE lt ON VEHICLE REPAIR gt 2 Remove clips 1 from pad pins 3 Remove pad pins while holding down cross spring then remove cross spring from caliper 4 Using pliers remove brake pads and shims from caliper CAUTION Never damage the piston boot Never drop the brake pads shims JPFIA02152Z INSTALLATION WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal while removing the brake pads because the piston may pop out Never spill or splash brake fluid on the disc rotor 1 Apply copper based brake grease to the mating faces between the brake pads and shims and install shims to the brake pad CAUTION Always replace the shims together when replacing the brake pad Never damage the piston boot 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 2 Install upper pad
30. OTE The torque member brake pads pad return spring and pad retainers never need to be removed when disas sembling and assembling the cylinder body 1 Remove the protector and location pin and the sliding pin bolt and remove the cylinder body from the torque member CAUTION Never drop pads pad return spring and pad retainers from torque member 2 Remove sliding pin and sliding pin boot from torque member 3 Place a wooden block as shown in the figure and blow air from union bolt mounting hole to remove piston and piston boot CAUTION Never get fingers caught in the pistons MAA0272D 4 Remove piston seal from cylinder body using suitable tool CAUTION Be careful not to damage a cylinder inner wall JPFIA00382Z ASSEMBLY 1 Apply brake fluid to piston seal 1 and install them to cylinder body CAUTION Never reuse piston seal JPFIA00392Z Revision 2007 June BR 45 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR gt 2 Apply rubber grease to piston boot 1 Cover the piston 2 end with piston boot and then install cylinder side lip on piston boot securely into a groove on cylinder body CAUTION Never reuse piston boot JPFIA00402Z 3 Apply brake fluid to piston 1 Push piston into cylinder body by hand and push piston boot 2 piston side lip into the piston groove CAUTION Press the piston evenly and vary the pressing point to pre vent cylinder inner wall from being rubbed JPF
31. Remove the reservoir tank and grommet from the cylinder body CAUTION Never drop the removed parts The parts must not be reused if they are dropped JPFIA00152Z ASSEMBLY 1 Apply new brake fluid to the grommet and install it to the cylinder body CAUTION Never use mineral oil such as gasoline or light oil Never reuse the grommets 2 Install the reservoir tank to the cylinder body CAUTION Never drop the parts when installing The parts must not be reused if they are dropped Revision 2007 June BR 31 G37 Coupe BRAKE MASTER CYLINDER ON VEHICLE REPAIR 3 Fixthe cylinder body to a vise CAUTION Place the reservoir tank with the chamfered pin hole 4m facing up Always set copper plates or cloth between them when fix ing the cylinder body to a vise Never overtighten the vise JPFIA00162Z 4 Tilt the reservoir tank so that a mounting pin can be inserted Insert a mounting pin Return the reservoir tank to the horizontal position Insert another mounting pin into the pin hole on the opposite side in the same manner after the mounting pin passes through the cylinder body pin hole CAUTION Never reuse the mounting pins JPFIA00152Z n S pect i O n INFOID 0000000001647854 INSPECTION AFTER INSTALLATION Fluid Leak Check for brake fluid leakage from the cylinder body to brake booster mounting face reservoir tank mounting face and brake tube connections Revision 2007 June BR 32 G37 Coupe
32. TION Never depress the brake pedal after the master cylinder assembly is removed Apply PBC Poly Butyl Cuprysil silicone based grease to the brake booster see A in the figure when installing the mas ter cylinder assembly to the brake booster The piston of the master cylinder assembly is exposed Never damage it when handling the master cylinder and check that no dirt and dust are present on the piston before installation Clean it with new brake fluid if necessary The piston may drop off when pulled strongly Never hold the piston Hold the cylinder body when handling the master cyl inder assembly Never reuse the O ring Temporarily tighten the brake tube flare nut to the master cylinder assembly by hand Then tighten it to the specified torque with a flare nut crowfoot and torque wrench Refer to BR 21 FRONT Exploded View CAUTION Never scratch the flare nut and the brake tube After installation perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid Disassembly and Assembly INFOID 0000000001647853 JPFIA0013ZZ DISASSEMBLY CAUTION Never disassemble the cylinder body Remove the reservoir tank only when necessary 1 Fixthe master cylinder assembly to a vise CAUTION Always set copper plates or cloth between them when fixing the cylinder body to a vise Never overtighten the vise 2 Remove the reservoir tank mounting pin with a pin punch 3
33. and pad retainers from torque member 2 Remove 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 piston and piston boot CAUTION Never get fingers caught in the piston BRD0041D Revision 2007 June BR 57 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR gt 4 Remove piston seal from cylinder body using suitable tool ASSEMBLY 1 3 4 5 CAUTION Be careful not to damage a cylinder inner wall JPFIA0038Z2Z Apply rubber grease to piston seal 1 and install them to cylin der body CAUTION Never reuse piston seal JPFIA00392Z Apply rubber grease to piston boot 1 Cover the piston 2 end with the piston boot and then install cylinder side lip on the pis ton boot securely into the groove on cylinder body CAUTION Never reuse piston boot JPFIA00402Z Apply brake fluid to piston 1 Push piston into cylinder body by hand and push piston boot 2 piston side lip into the piston groove CAUTION Press the piston evenly and vary the pressing point to pre vent cylinder inner wall from being rubbed JPFIA00412Z Install sliding pin boot to torque member Install the cylinder body to the torque member and tighten the sliding pin bolt to the specified torque BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Inspection and Adjustment INFOID 0000000001647887 INSPECTION AFTER DISASSEMBLY Cylinder Body R
34. ave been made during removal when reusing the disc rotor 2 Install the brake caliper to the vehicle and tighten the caliper mounting bolts to the specified torque CAUTION Never spill or splash any grease and moisture on the caliper mounting face threads mounting bolts and washers Wipe out any grease and moisture 3 Tighten the flare nut to the specified torque with a flare nut crowfoot and a torque wrench CAUTION Cover crowfoot with a cloth as not to damage the caliper Never scratch the flare nut and the brake tube 4 Refill with new brake fluid and perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid Never spill or splash brake fluid on the disc rotor 5 Check that no drag feel is present for the front disc brake 6 Install tires Revision 2007 June BR 48 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR gt BRAKE CALIPER ASSEMBLY 4 PISTON TYPE Disassembly and Assembly INFOID 0000000001647876 DISASSEMBLY 1 Place a wooden block as shown in the figure and blow air from union bolt mounting hole to remove pistons and piston boots and retaining rings CAUTION Never get fingers caught in the pistons BRB0261D 2 Remove piston seal 1 from cylinder body using suitable tool A CAUTION Be careful not to damage a cylinder inner wall JPFIA0217ZZ ASSEMBLY 1 Apply brake fluid to piston seals 1 and install them to caliper CAUTION Never r
35. ccurs at very low mileage Refer to BR 40 BRAKE PAD 1 PISTON TYPE Inspection and Adjustment front brake pad 1 piston type BR 46 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Inspection and Adjustment front disc rotor 1 piston type BR 43 BRAKE PAD 4 PISTON TYPE Inspection and Adjustment front brake pad 4 piston type BR 50 BRAKE CALIPER ASSEMBLY 4 PISTON TYPE Inspection and Adjustment front disc rotor 4 piston type BR 52 BRAKE PAD 1 PISTON TYPE Inspection and Adjustment rear brake pad 1 piston type BR 58 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Inspection and Adjustment rear disc rotor 1 piston type BR 55 BRAKE PAD 2 PISTON TYPE Inspection and Adjustment rear brake pad 2 piston type BR 62 BRAKE CALIPER ASSEMBLY 2 PISTON TYPE Inspection and Adjustment rear disc rotor 2 piston type JPFIA00012Z Revision 2007 June BR 5 G37 Coupe PREPARATION PREPARATION PREPARATION Commercial Service Tool PREPARATION INFOID 0000000001647819 Tool name Description Power tool Loosening bolts and nuts PBICO190E Pin punch a 4 mm 0 16 in dia Revision 2007 June e NT410 BR 6 Removing and installing reservoir tank pin G37 Coupe BRAKE PEDAL lt ON VEHICLE MAINTENANCE gt ON VEHICLE MAINTENANCE BRAKE PEDAL Inspection and Adjustment INFOID 0000000001647821 INSPECTION Brake Pedal Height Check the he
36. d grease to the mating faces between the shims and the shim cover and install them to the brake pad CAUTION Always replace the shims together with the shim cover when replacing the brake pad 3 Install cylinder body and brake pads to torque member CAUTION Never damage the piston boot In the case of replacing a pads 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 NOTE Use a disc brake piston tool to easily press piston 4 Install the upper sliding pin bolt and tighten it to the specified torque 5 Depress the brake pedal several times to check that no drag feel is present for the rear disc brake 6 Install tires BRAKE PAD 1 PISTON TYPE Inspection and Adjustment INFOID 0000000001647860 INSPECTION AFTER REMOVAL Replace the shims and the shim cover if rust is excessively attached ADJUSTMENT AFTER INSTALLATION Brake Burnishing Procedure Burnish contact surfaces between pads according to following procedure after refinishing or replacing pads or if a soft pedal occurs at very low mileage CAUTION Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are securely fitted Only perform this procedure under safe road and traffic conditions Use extreme caution 1 Drive vehicle on straight flat road 2 Depress brake pedal with the power to stop vehicle within 3 to 5 seconds u
37. d sharply twist or strongly pull out the brake hoses and tubes Cover open end of brake tubes and hoses when disconnecting to prevent entrance of dirt Remove the union bolt and remove the brake hose from the brake caliper assembly Remove the brake hose mounting nut Remove the lock plate and remove the brake hose gt onp Piston Type Revision 2007 June BR 23 G37 Coupe BRAKE PIPING ON VEHICLE REPAIR CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface 1 Remove tires with power tool 2 Drain brake fluid Refer to BR 11 Draining 3 Loosen the flare nut with a flare nut wrench and separate the brake tube from the brake hose and caliper CAUTION Cover flare nut wrench with a cloth as not to damage the caliper Never scratch the flare nut and the brake tube Never bend sharply twist or strongly pull out the brake hoses and tubes Cover open end of brake tubes and hoses when disconnecting to prevent entrance of dirt 4 Remove the brake tube mounting bolt and remove the brake tube 5 Remove the brake hose mounting nut 6 Remove the lock plate and remove the brake hose INSTALLATION 1 Piston Type CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface 1 Assemb
38. e Replace if there are RUNOUT 1 Fix the disc rotor to the wheel hub and bearing assembly with wheel nuts 2 points at least 2 Inspect the runout with a dial gauge Measured at 10 mm 0 39 in inside disc edge Limit Runout limit Refer to BR 64 Rear Disc Brake NOTE NN Check the wheel bearing axial end play before the inspection 4 SRIUSUID Refer to RAX 5 Inspection 3 Findthe installation position that has a minimum runout by shifting the disc rotor to wheel hub and bearing assembly installation position by one hole at a time if the runout exceeds the limit value 4 Replace or lathe the disc rotor if the runout is outside the limit even after performing the above operation When lathing use the Pro Cut PEM On Car brake Lathe Tool No 38 PFM90 5 or equivalent THICKNESS Revision 2007 June BR 17 G37 Coupe REAR DISC BRAKE lt ON VEHICLE MAINTENANCE gt Check the thickness of the disc rotor using a micrometer Replace the disc rotor if the thickness is below the wear limit Limit Wear limit thickness Refer to BR 64 Rear Disc Brake SFIA2284E Revision 2007 June BR 18 G37 Coupe BRAKE PEDAL ON VEHICLE REPAIR gt ON VEHICLE REPAIR BRAKE PEDAL Exp loded View INFOID 0000000001647836 SEC 465 8 0 0 82 71 C 14 2 1 4 10 JPFIA0210GB 1 Brake pedal stroke sensor with pre 2 Clevis pin 3 Brake pedal assembly crash seat belt 4 Brake pedal pad 5 Clip
39. eoisg col m col col ol ol mimm o 99 rc 8253 23 9 ag o z z gt o o x m ms z EIEI E cei aoalajlrzi izmc o dp E I a Me T I gt pe eS 2 2 1T gt gt gt gt gt zZz 2 Z2 2 2 z S o D a 5 ue g S ZE ME m 5 Q 9 Possible cause and Bic E 9s Slo 2 8 9 z g dk SUSPECTED PARTS S Lge gls gls EIS v m iEJo wm lt E co E c o o o x o 1 z a zE I 58 18 2 l l a l l2 582 LEE m EIS 2 5 5 ll w EE lt Gu ra 8 8 E 8 B 8 8 8 8 B 5 O i juja zw Sco clo olo lo o olo 2c tix cio mirc aA al E dc ccc dcaciaoaocilaixi i tai o Noise x xi x x x x x xIx x Symptom BRAKE Shake x x x x xI x x Shimmy Judder xi xixi X xix x x x x x x Applicable Revision 2007 June BR 3 G37 Coupe PRECAUTIONS PRECAUTION gt PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT P R E TE N S ON E R INFOID 0000000001647815 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 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 f
40. er if it gets on a painted surface 1 Assemble the union bolt and the copper washer to the brake hose CAUTION Never reuse copper washer 2 Install the brake hose L pin by aligning it with the brake caliper assembly positioning hole and tighten the union bolt 1 to the specified torque 3 Connect the hose to the brake tube temporarily tighten the flare nut by hand until it does not rotate further and fix the brake hose to the bracket with the lock plate CAUTION Check that the brake hoses and tubes are not twisted and bent 4 Tighten the flare nut to the specified torque with a flare nut crow foot and torque wrench JPFIAQO12ZZ CAUTION Never scratch the flare nut and the brake tube 5 Refill with new brake fluid and perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid 6 Install tires 2 Piston Type CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface 1 Connect the hose to the brake tube temporarily tighten the flare nut by hand until it does not rotate fur ther and fix the brake hose to the bracket with the lock plate CAUTION Check that the brake hoses and tubes are not twisted and bent 2 Tighten the brake hose mounting bolt to the specified torque 3 Tighten the flare nut to the specified torque with a flare nut c
41. er reuse the brake hose mounting nuts 3 Tighten the brake tube mounting bolt to the specified torque 4 Tighten the flare nut to the specified torque with a flare nut crowfoot and a torque wrench CAUTION Revision 2007 June BR 24 G37 Coupe BRAKE PIPING ON VEHICLE REPAIR gt Cover crowfoot with a cloth as not to damage the caliper Never scratch the flare nut and the brake tube 5 Refill with new brake fluid and perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid 6 Install tires F R O N T B n S pect i O n INFOID 0000000001647842 INSPECTION AFTER INSTALLATOIN 1 Check the brake hoses and tubes for the following no scratches no twist and deformation no interfer ence with other components when steering the steering wheel no looseness at connections 2 Depress the brake pedal with a force of 785 N 80 kg 176 Ib and hold down the pedal for approximately 5 seconds with the engine running Check for any fluid leakage CAUTION Retighten the applicable connection to the specified torque and repair any abnormal damaged worn or deformed part if any brake fluid leakage is present REAR E Exploded View INFOID 0000000001647843 1 PISTON TYPE SEC 462 a JPFIA0009GB 1 Brake tube 2 Brake hose 3 Lock plate 4 Union bolt 5 Copper washer A To front brake tube B To rear brake hose C To rear brake tube Refer to GlI 4 Components for symbols
42. euse piston seals JPFIA02182Z Revision 2007 June BR 49 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR gt 2 Apply rubber grease to piston boots 1 Cover the piston 2 end with piston boots and then install caliper side lip on piston boot securely into a groove on caliper CAUTION Never reuse piston boots 3 Apply brake fluid to piston Push piston into caliper by hand and push piston boot piston side lip into the piston groove CAUTION Press the piston evenly and vary the pressing point to pre vent caliper inner wall from being rubbed 4 Install the caliper to tighten the caliper mounting bolts to the specified torque PFIA0905J BRAKE CALIPER ASSEMBLY 4 PISTON TYPE Inspection and Adjustment INFOID 0000000001647877 INSPECTION AFTER DISASSEMBLY Caliper Check the inner wall of the caliper for rust wear cracks or damage Replace the caliper if any abnormal con dition is detected CAUTION Always clean with new brake fluid Never clean with mineral oil such as gasoline and light oil Pistons Check the surface of the piston for rust wear cracks or damage Replace the piston if any abnormal condition is detected CAUTION A piston sliding surface is plated Never polish with sandpaper ADJUSTMENT AFTER INSTALLATION Brake Burnishing Procedure Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or replacing disc rotor or if a sof
43. evision 2007 June BR 58 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR Check the inner wall of the cylinder for rust wear cracks or damage Replace the cylinder if any abnormal condition is detected CAUTION Always clean with new brake fluid Never clean with mineral oil such as gasoline and light oil Torque Member Check the torque member for rust wear cracks or damage Replace the member if any abnormal condition is detected Piston Check the piston for rust wear cracks or damage Replace the piston if any abnormal condition is detected CAUTION A piston sliding surface is plated Never polish with sandpaper Sliding Pin Bolt and Sliding Pin Boot Check the sliding pin bolts and sliding pin boots for rust wear cracks or damage Replace the parts if any abnormal condition is detected ADJUSTMENT AFTER INSTALLATION Brake Burnishing Procedure Burnish contact surfaces between disc rotors and pads according to the following procedure after refinishing or replacing disc rotor or if a soft pedal occurs at very low mileage CAUTION Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are securely fitted Only perform this procedure under safe road and traffic conditions Use extreme caution 1 Drive vehicle on straight flat road 2 Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops 3 Drive without depressing brake for a few m
44. he brake pedal upper surface H2 when depressing the brake pedal at 490 N 50 kg 110 Ib while turning engine ON Standard Depressed brake pedal Refer to BR 63 Brake height H2 Pedal CAUTION Remove the floor trim JPFIA00682Z ADJUSTMENT Brake Pedal Height 1 Disconnect the harness connector from ASCD brake switch and stop lamp switch 2 Turn the stop lamp switch 45 counterclockwise 3 Loosen ASCD brake switch lock nut Turn ASCD brake switch counterclockwise 4 Loosen the input rod lock nut 1 Adjust the brake pedal to the specification Tighten the input lock nut to the specification Refer to BR 33 Exploded View CAUTION The threaded end of the input rod must project to the inner side L of the clevis 3 JPFIA0003Z2Z Standard Brake pedal height H1 Refer to BR 63 Brake Pedal JPFIA00652Z ASCD Brake Switch and Stop Lamp Switch 1 Disconnect the harness connector from ASCD brake switch and stop lamp switch 2 Turn the stop lamp switch 45 counterclockwise 3 Loosen ASCD brake switch lock nut Turn ASCD brake switch counterclockwise Revision 2007 June BR 8 G37 Coupe BRAKE PEDAL lt ON VEHICLE MAINTENANCE gt 4 Press the brake pedal pad slightly Release the brake pedal Turn ASCD brake switch 1 until ASCD brake switch threaded end hits to the stopper rubber 2 clockwise CAUTION Never press fit the input rod 5 Tighten ASCD brake switch lock nut 3 to the
45. he brake tube from caliper CAUTION Cover flare nut wrench with a cloth as not to damage the caliper Never scratch the flare nut and the brake tube Never bend sharply twist or strongly pull out the brake tube Cover open end of brake tube when disconnecting to prevent entrance of dirt 5 Remove brake hose mounting bolt 6 Remove caliper mounting bolts and remove caliper CAUTION Never drop brake pad and caliper 7 Remove disc rotor CAUTION Put matching marks on the wheel hub and bearing assem bly and the disc rotor before removing the disc rotor Never drop disc rotor JPFIA02242Z INSTALLATION WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal Brake fluid may splash while removing the brake hose 1 Install disc rotor CAUTION Align the matching marks that have been made during removal when reusing the disc rotor 2 Install the brake caliper to the vehicle and tighten the caliper mounting bolts to the specified torque Revision 2007 June BR 60 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR gt 6 7 CAUTION Never spill or splash any grease and moisture on the caliper mounting face threads mounting bolts and washers Wipe out any grease and moisture Install the brake hose mounting bolt to the specified torque Tighten the flare nut to the specified torque with a flare nut
46. ight H1 between the dash lower panel 1 and the brake pedal upper surface Standard Brake pedal height H1 Refer to BR 63 Brake Pedal CAUTION Remove the floor trim ASCD Brake Switch and Stop Lamp Switch Check the clearance C1 and C2 among ASCD brake switch 1 threaded end stop lamp switch 2 threaded end and the stopper rubber 3 Standard Clearance C1 between Refer to BR 63 Brake ASCD brake switch threaded Pedal end and the stopper rubber Clearance C2 between the Refer to BR 63 Brake stop lamp switch threaded Pedal end and the stopper rubber CAUTION The stop lamp must turn off when the brake pedal is released NOTE Pull the brake pedal pad to make the clearance between the stop lamp switch threaded end and the stopper rubber The stopper rubber hits ASCD brake switch threaded end Brake Pedal Play Press the brake pedal Check the brake pedal play A stroke until fluid pressure occurs JPFIA00042Z Standard Pedal play A Refer to BR 63 Brake Pedal JPFIA00662Z Brake Pedal Shaky Fitting Revision 2007 June BR 7 G37 Coupe BRAKE PEDAL lt ON VEHICLE MAINTENANCE gt Check the brake pedal shaky fitting B the stroke when pulling the brake pedal pad slightly from the free play Standard Brake pedal shaky fitting B Refer to BR 63 Brake Pedal JPFIA0067Z2Z Depressed Brake Pedal Height Check the height between the dash lower panel 1 and t
47. in the figure Revision 2007 June BR 25 G37 Coupe BRAKE PIPING ON VEHICLE REPAIR gt 2 PISTON TYPE SEC 462 C 16 2 1 7 12 1 Brake tube 2 Brake hose 3 Lock plate 4 Brake hose bracket A Tofront brake tube B Torear brake hose C To rear brake tube Refer to GlI 4 Components for symbols in the figure R EA R k H yd rau ic Pi pi n g INFOID 0000000001647844 1 PISTON TYPE SEC 462 JPFIA0010ZZ 1 ABS actuator and electric unit con 2 Front disc brake 3 Master cylinder trol unit 4 Brake booster 5 Connector 6 Rear disc brake A Brake hose B Brake tube Flare nut Revision 2007 June BR 26 G37 Coupe BRAKE PIPING ON VEHICLE REPAIR gt Bl Union bolt Bi Connector EEO 2 PISTON TYPE JPFIA0211ZZ ABS actuator and electric unit con 2 Front disc brake 3 Master cylinder trol unit Brake booster 5 Connector 6 Rear disc brake Brake hose B Brake tube Flare nut Union bolt Connector REAR Removal and Installation Mri ana CO dd us REMOVAL 1 Piston Type CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface 1 2 3 4 5 Remove tires with power tool Drain brake fluid Refer to BR 11 Draining Loosen the flare nut with a flare nut wrench and separate the brake
48. inutes to cool the brake 4 Repeatsteps 1 to 3 until pad and disc rotor are securely fitted BRAKE CALIPER ASSEMBLY 2 PISTON TYPE BRAKE CALIPER ASSEMBLY 2 PISTON TYPE Exploded View INFOID 0000000001647868 TT E e p 6g 7 9 0 81 70 9 37 7 3 8 28 M I CUT yA Pom 7 9 0 81 70 TR j JPFIA0219GB Revision 2007 June BR 59 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR gt 1 Piston 2 Piston seal 3 Piston boot 4 Retaining ring 5 Cap 6 Bleeder valve 7 Cap 8 Clip 9 Padpin 10 Caliper 11 Inner shim cover 12 Inner shim 13 Inner pad 14 Pad wear sensor RH inner pad 15 Cross spring only 16 Outer pad 17 Outer shim 18 Outer shim cover 1 Apply rubber grease 2 Apply copper based brake grease al Apply brake fluid Refer to Gl 4 Components for symbols not described on the above BRAKE CALIPER ASSEMBLY 2 PISTON TYPE Removal and Installation INFOID 0000000001664896 REMOVAL WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal Brake fluid may splash while removing the brake hose and brake tube 1 Remove tires with power tool 2 Fixthe disc rotor using wheel nuts 3 Drain brake fluid Refer to BR 11 Draining CAUTION Never spill or splash brake fluid on the disc rotor 4 Loosen the flare nut with a flare nut wrench and separate t
49. iston boot 15 Torque member 16 Inner pad 17 Pad wear sensor 18 Padretainer 19 Padreturn spring 20 Outer pad E Apply rubber grease Kr Apply bentonite noise damping brake grease al Apply brake fluid Refer to Gl 4 Components for symbols not described on the above BRAKE PAD 1 PISTON TYPE Removal and Installation INFOID 0000000001647865 REMOVAL WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal while removing the brake pads because the piston may pop out Never spill or splash brake fluid on the disc rotor 1 Remove tires with power tool Remove the protector and location pin 2 3 Suspend the cylinder body with suitable wire so that the brake hose will not stretch Remove the pad return spring and remove the brake pads from the torque member CAUTION Never deform the pad return spring when removing the pad return spring Never deform the pad retainers when removing the pad retainers from the torque member Never damage the piston boot Never remove the shims from the brake pads Never drop the brake pads Revision 2007 June BR 39 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR INSTALLATION WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal while removi
50. le the union bolt and the copper washer to the brake hose CAUTION Never reuse the copper washer 2 Align the brake hose pin to the projection A of the brake caliper assembly and tighten the union bolt 1 to the specified torque 3 Install the brake tube to the brake hose temporarily tighten the flare nut by hand until it does not rotate further and fix the brake hose to the bracket with the lock plate CAUTION Check that all brake hoses and tubes are not twisted and bent 4 Tighten the flare nut to the specified torque with a flare nut crow foot and a torque wrench J CAUTION JPFIA0011ZZ Never scratch the flare nut and the brake tube 5 Tighten the brake hose mounting nuts to the specified torque CAUTION Never reuse the brake hose mounting nuts 6 Refill with new brake fluid and perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid 7 Install tires 4 Piston Type CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface 1 Install the brake tube to the brake hose temporarily tighten the flare nut by hand until it does not rotate further and fix the brake hose to the bracket with the lock plate CAUTION Check that all brake hoses and tubes are not twisted and bent 2 Tighten the brake hose mounting nuts to the specified torque CAUTION Nev
51. ls not described on the above Re m oval a nd n stal lat i O n INFOID 0000000001647852 REMOVAL CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface 1 2 3 4 Remove the master cylinder cover Drain brake fluid Refer to BR 11 Draining Separate the brake fluid level switch harness connector Separate the brake tube from the master cylinder assembly with a flare nut wrench CAUTION Never scratch the flare nut and the brake tube Remove the master cylinder assembly CAUTION Depress the brake pedal several times to release the vacuum pressure from the brake booster Then remove the master cylinder assembly Never depress the brake pedal after the master cylinder assembly is removed The piston of the master cylinder assembly is exposed Never damage it when removing the master cylinder Revision 2007 June BR 30 G37 Coupe BRAKE MASTER CYLINDER ON VEHICLE REPAIR gt The piston may drop off when pulled out strongly Never hold the piston Hold the cylinder body when handling the master cylinder assembly INSTALLATION CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface Note the following and installation in the reverse order of removal CAU
52. ng the brake pads because the piston may pop out Never spill or splash brake fluid on the disc rotor 1 Apply bentonite noise damping brake grease to the pad retainers before it to installing the torque member if the pad retainers has been removed CAUTION Securely assemble the pad retainers so that it will not be lifted up from the torque member Never deform the pad retainers 2 Install the brake pads to the torque member CAUTION The brake pads is directional Never mistake the direction See the figure A Direction of disc rotor rotation Forward direction JPFIA00292Z 3 Install the pad return spring 1 to the brake pad 2 CAUTION Correctly insert the pad return spring into the pad return spring hole on the brake pad 4 Install cylinder body to torque member CAUTION Never damage the piston boot 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 NOTE Use a disc brake piston tool to easily press piston JPFIA00282Z 5 Install the location pin and tighten it to the specified torque 6 Install the protector 7 Depress the brake pedal several times to check that no drag feel is present for the front disc brake 8 Install tires BRAKE PAD 1 PISTON TYPE Inspection and Adjustment INFOID 0000000001647866 INSPECTION AFTER REMOVAL Eliminate rust on the pad
53. ntil the vehicle stops 3 Drive without depressing brake for a few minutes to cool the brake 4 Repeat steps 1 to 3 until pad and disc rotor are securely fitted BRAKE PAD 2 PISTON TYPE Revision 2007 June BR 52 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR gt BRAKE PAD 2 PISTON TYPE Exploded View INFOID 0000000001647655 SEC 441 ral 0 OQ o 6 9 7 9 0 81 70 9 37 7 3 8 28 N CTT g 7 9 0 81 70 JPFIA0219GB 1 Piston 2 Piston seal 3 Piston boot 4 Retaining ring 5 Cap 6 Bleeder valve 7 Cap 8 Clip 9 Padpin 10 Caliper 11 Inner shim cover 12 Inner shim 13 Inner pad 14 Pad wear sensor RH inner pad 15 Cross spring only 16 Outer pad 17 Outer shim 18 Outer shim cover 1 Apply rubber grease 2 Apply copper based brake grease al Apply brake fluid Refer to Gl 4 Components for symbols not described on the above BRAKE PAD 2 PISTON TYPE Removal and Installation INFOID 0000000001647882 REMOVAL WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal while removing the brake pads or the cylinder body because the pis ton may pop out Never spill or splash brake fluid on the disc rotor 1 Remove tires with power tool Revision 2007 June BR 53 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR 2 Remove clips from pad pins
54. o rear brake tube B Connector ABS actuator and electric unit con trol unit Brake hose bracket To front brake hose Refer to Gl 4 Components for symbols in the figure FRONT Hydraulic Piping SEC 462 1 PISTON TYPE Revision 2007 June BR 22 Master cylinder 6 Lock plate 9 Brake hose C To front brake tube INFOID 000000000 1647840 JPFIA00102Z G37 Coupe BRAKE PIPING ON VEHICLE REPAIR gt ABS actuator and electric unit con 2 Front disc brake 3 Master cylinder trol unit Brake booster 5 Connector 6 Rear disc brake Brake hose B Brake tube Flare nut Union bolt mEEO Connector 4 PISTON TYPE JPFIAO211ZZ k ABS actuator and electric unit con 2 Front disc brake 3 Master cylinder trol unit Brake booster 5 Connector 6 Rear disc brake Brake hose B Brake tube Flare nut Union bolt mEO Connector FRONT Removal and Installation NOBO REMOVAL 1 Piston Type CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface 1 Remove tires with power tool 2 Drain brake fluid Refer to BR 11 Draining 3 Loosen the flare nut with a flare nut wrench and separate the brake tube from the hose CAUTION Never scratch the flare nut and the brake tube Never ben
55. otor Never drop disc rotor INSTALLATION WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal Brake fluid may splash while removing the brake hose 1 Install disc rotor CAUTION Align the matching marks that have been made during removal when reusing the disc rotor 2 Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the specified torque CAUTION Never spill or splash any grease and moisture on the brake caliper assembly mounting face threads mounting bolts and washers Wipe out any grease and moisture 3 Install brake hose to brake caliper assembly and tighten union bolts to the specified torque 4 Refill with new brake fluid and perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid Never spill or splash brake fluid on the disc rotor 5 Checkthat no drag feel is present for the rear disc brake 6 Install tires BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Disassembly and Assembly INFOID 0000000001647886 DISASSEMBLY NOTE The torque member brake pads shims shim cover and pad retainers never need to be removed when disas sembling and assembling the cylinder body 1 Remove the sliding pin bolt and remove the cylinder body from the torque member CAUTION Never drop pads shims shim cover
56. peatsteps 1 to 3 until pad and disc rotor are securely fitted BRAKE CALIPER ASSEMBLY 1 PISTON TYPE BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Exploded View INFOID 0000000001647952 SEC 440 0 0 92 80 T 2 4 18 oy 18 2 b Mr JPFIA0025GB 1 Bleeder valve 2 Cap 3 Brake hose 4 Union bolt 5 Copper washer 6 Protector 7 Bushing 8 Location pin 9 Sliding pin 10 Sliding pin boot 11 Oylinder body 12 Piston seal 13 Piston 14 Piston boot 15 Torque member Revision 2007 June BR 43 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR gt 16 Inner pad 17 Pad wear sensor 18 Padretainer 19 Padreturn spring 20 Outer pad Kr Apply rubber grease Eri Apply bentonite noise damping brake grease Apply brake fluid Refer to GlI 4 Components for symbols not described on the above BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Removal and Installation INFOID 0000000001647871 REMOVAL WARNING Clean any dust from the brake caliper and brake pads with a vacuum dust collector Never blow with compressed air CAUTION Never depress the brake pedal Brake fluid may splash while removing the brake hose 1 Remove tires with power tool 2 Fixthe disc rotor using wheel nuts 3 Drain brake fluid Refer to BR 11 Draining CAUTION Never spill or splash brake fluid on the disc rotor 4 Remove union bolt and then disconnect brake hose from caliper assembly 5 Remove torque member mounting bolts and remove brake cali
57. pin from the inner side then install firmly to the outer side through the hole in the top of brake pad Revision 2007 June BR 42 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR 3 Place the top of cross spring 1 over the upper pad pin 2 press in the cross spring install lower pad pin from the inner side to the outer side and secure cross spring 4 Install clips to the pad pins CAUTION If clip is not fully attached pad pin or brake pad could fall out while vehicle is in motion 5 Depress the brake pedal several times to check that no drag feel is present for the front disc brake 6 Install tires JPFIA02162Z BRAKE PAD 4 PISTON TYPE Inspection and Adjustment INFOID 0000000001647869 INSPECTION AFTER REMOVAL Replace the shims if rust is excessively attached ADJUSTMENT AFTER INSTALLATION Brake Burnishing Procedure en Burnish contact surfaces between pads according to following procedure after refinishing or replacing pads or if a soft pedal occurs at very low mileage CAUTION Be careful of vehicle speed because the brake does not operate easily until pads and disc rotor are securely fitted Only perform this procedure under safe road and traffic conditions Use extreme caution 1 Drive vehicle on straight flat road 2 Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops 3 Drive without depressing brake for a few minutes to cool the brake 4 Re
58. quipped with a push button ignition switch and a steering lock unit If the battery is disconnected or discharged the steering wheel will lock and cannot be turned If turning the steering wheel is required with the battery disconnected or discharged follow the procedure below before starting the repair operation OPERATION PROCEDURE 1 Connect both battery cables NOTE Supply power using jumper cables if battery is discharged 2 Carry the Intelligent Key or insert it to the key slot and turn the push button ignition switch to ACC position At this time the steering lock will be released 3 Disconnect both battery cables The steering lock will remain released with both battery cables discon nected and the steering wheel can be turned 4 Perform the necessary repair operation 5 When the repair work is completed re connect both battery cables With the brake pedal released turn the push button ignition switch from ACC position to ON position then to LOCK position The steering wheel will lock when the push button ignition switch is turned to LOCK position 6 Perform self diagnosis check of all control units using CONSULT III Revision 2007 June BR 4 G37 Coupe PRECAUTIONS PRECAUTION Precaution for Procedure without Cowl Top Cover INFOID Q00000000 1647817 When performing the procedure after removing cowl top cover cover the lower end of windshield with urethane etc PIIB3706J Precaution for Brake Sy
59. rake pedal assem bly if necessary A Vehicle front Check the brake pedal upper rivet A for deformation Check the brake pedal for bend damage and cracks on the welded parts JPFIA00062Z Check clevis pin and plastic stopper A for damage and deforma tion If any is found replace clevis pin PFIA0756J ADJUSTMENT AFTER INSTALLATION Perform the brake pedal adjustment after installing the brake pedal assembly Refer to BR 7 Inspection and Adjustment Revision 2007 June BR 20 G37 Coupe BRAKE PIPING ON VEHICLE REPAIR gt BRAKE PIPING FRONT F RONT Exploded View INFOID 0000000001647839 1 PISTON TYPE SEC 462 jl 16 2 1 7 12 fg 7 0 amp 0 71 62 Gr 18 2 m 1 9 13 5 e 16 2 1 7 12 2217 el wea 2 2 16 1 a D 16 2 a YS j 1 7 12 JPFIA0008GB 1 Brake tube 2 Connector 3 Master cylinder 4 Brake booster 5 ABS actuator and electric unit con 6 Lock plate trol unit 7 Union bolt 8 Brake hose 9 Copper washer 10 Brake hose bracket 11 Brake tube A To rear brake tube B To front brake hose C To front brake tube Refer to Gl 4 Components for symbols in the figure Revision 2007 June BR 21 G37 Coupe ON VEHICLE REPAIR gt SEC 462 19 i j C 16 2 1 7 12 M9 7 0 0 71 62 BRAKE PIPING 4 PISTON TYPE 1 3 10 1 Brake tube 4 Brake booster 7 Brake tube A T
60. retainers and the torque member Replace them if rust is excessively attached ADJUSTMENT AFTER INSTALLATION Brake Burnishing Procedure Burnish contact surfaces between pads according to following procedure after refinishing or replacing pads or if a soft pedal occurs at very low mileage CAUTION Be careful of vehicle speed because the brake does not operate easily until pads and disc rotor are securely fitted Only perform this procedure under safe road and traffic conditions Use extreme caution 1 Drive vehicle on straight flat road 2 Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops Revision 2007 June BR 40 G37 Coupe FRONT DISC BRAKE ON VEHICLE REPAIR gt 3 Drive without depressing brake for a few minutes to cool the brake 4 Repeat steps 1 to 3 until pad and disc rotor are securely fitted BRAKE PAD 4 PISTON TYPE BRAKE PAD 4 PISTON TYPE Exploded View INFOID 000000000164756 SEC 440 JPFIA0212GB 1 Piston 2 Piston seal 3 Piston boot 4 Retaining ring 5 Cap 6 Bleeder valve 7 Cap 8 Clip 9 Pad pin 10 Caliper 11 Inner shim 12 Inner pad 13 Pad wear sensor RH inner pad 14 Cross spring 15 Outer pad only 16 Outer shim Kr Apply rubber grease E2 Apply copper based brake grease al Apply brake fluid Refer to GlI 4 Components for symbols not described on the above BRAKE PAD 4 PISTON TYPE Removal and Installation INF
61. ront occupants are belted or unbelted Information necessary to service the system safely is included in the SRS AIRBAG and SEAT BELT 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 SRS AIRBAG 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 Necessary for Steering Wheel Rotation after Battery Disconnect INFOID 0000000001647816 NOTE Before removing and installing any control units first turn the push button ignition switch to the LOCK posi tion then disconnect both battery cables After finishing work confirm that all control unit connectors are connected properly then re connect both battery cables Always use CONSULT III to perform self diagnosis as a part of each function inspection after finishing work If a DTC is detected perform trouble diagnosis according to self diagnosis results This vehicle is e
62. rowfoot and torque wrench CAUTION Cover crowfoot with a cloth as not to damage the caliper Never scratch the flare nut and the brake tube 4 Refill with new brake fluid and perform the air bleeding Refer to BR 12 Bleeding Brake System CAUTION Never reuse drained brake fluid 5 Install tires R E A R n S pe cti O n INFOID 0000000001647846 INSPECTION AFTER REMOVAL 1 Check the brake hoses and tubes for the following no scratches no twist and deformation no interfer ence with other components when steering the steering wheel no looseness at connections Revision 2007 June BR 28 G37 Coupe BRAKE PIPING ON VEHICLE REPAIR 2 Depress the brake pedal with a force of 785 N 80kg 176 Ib and hold down the pedal for approximately 5 seconds with the engine running Check for any fluid leakage CAUTION Retighten the applicable connection to the specified torque and repair any abnormal damaged worn or deformed part if any brake fluid leakage is present Revision 2007 June BR 29 G37 Coupe BRAKE MASTER CYLINDER lt ON VEHICLE REPAIR gt BRAKE MASTER CYLINDER Exp loded View INFOID 0000000001647851 SEC 460 JPFIA0069GB 1 Reservoir cap 2 Oil strainer 3 Reservoir tank 4 Brake fluid level switch connector 5 Oylinder body 6 Pin 7 O ring 8 Grommet Apply PBC Poly Butyl Cuprysil grease or silicone based grease Y Apply brake fluid Refer to GlI 4 Components for symbo
63. se new brake fluid for refilling Never reuse the drained brake fluid Cover crowfoot and flare nut wrench with a cloth as not to damage the caliper front 4 piston type rear 2 piston type 1 Connect a vinyl tube to the bleeder valve of the rear right brake 2 Fully depress the brake pedal 4 to 5 times 3 Loosen the bleeder valve and bleed air with the brake pedal depressed and then quickly tighten the bleeder valve 4 Repeat steps 2 and 3 until all of the air is out of the brake line 5 Tighten the bleeder valve to the specified torque Refer to BR 43 BRAKE CALIPER ASSEMBLY 1 PIS TON TYPE Exploded View front disc brake 1 piston type BR 47 BRAKE CALIPER ASSEMBLY 4 PISTON TYPE Exploded View front disc brake 4 piston type BR 56 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Exploded View rear disc brake 1 piston type BR 59 BRAKE CALIPER ASSEM BLY 2 PISTON TYPE Exploded View rear disc brake 2 piston type 6 Perform steps 1 to 5 for the rear right brake front left brake rear left brake and front right brake in order 7 Check that the fluid level in the reservoir tank is within the specified range after air bleeding Refer to BR 11 Inspection 8 Check each item of brake pedal Adjust it if the measurement value is not the standard Refer to BR 7 Inspection and Adjustment Revision 2007 June BR 12 G37 Coupe BRAKE MASTER CYLINDER lt ON VEHICLE MAINTENANCE gt BR
64. stem INFOID O000000001647818 WARNING Clean any dust from the front brake and rear brake with a vacuum dust collector Never blow with com pressed air CAUTION Only use DOT 3 brake fluid Refer to MA 10 Fluids and Lubricants Never reuse drained brake fluid Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface After pressing the brake pedal more deeply or harder than normal driving such as air bleeding check each item of brake pedal Adjust brake pedal if it is outside the standard value Always clean with new brake fluid when cleaning the master cylinder brake caliper and other com ponents Never use mineral oils such as gasoline or light oil to clean They may damage rubber parts and cause improper operation Always loosen the brake tube flare nut with a flare nut wrench Tighten the brake tube flare nut to the specified torque with a crowfoot A and torque wrench B Always confirm the specified tightening torque when install ing the brake pipes Turn the ignition switch OFF and disconnect the ABS actuator and electric unit control unit connector or the battery nega tive terminal before performing the work Check that no brake fluid leakage is present after replacing the parts Burnish the brake contact surfaces after refinishing or replac ing rotors after replacing pads or if a soft pedal o
65. t fully attached pad pin or brake pad could fall out while vehicle is in motion 5 Depress the brake pedal several times to check that no drag fell is present for the rear disk brake 6 Install tires JPFIA02232Z BRAKE PAD 2 PISTON TYPE Inspection and Adjustment INFOID 0000000001647865 INSPECTION AFTER REMOVAL Replace the shims and the shim cover if rust is excessively attached ADJUSTMENT AFTER INSTALLATION Brake Burnishing Procedure en Burnish contact surfaces between pads according to following procedure after refinishing or replacing pads or if a soft pedal occurs at very low mileage CAUTION Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are securely fitted Only perform this procedure under safe road and traffic conditions Use extreme caution 1 Drive vehicle on straight flat road 2 Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops 3 Drive without depressing brake for a few minutes to cool the brake 4 Repeatsteps 1 to 3 until pad and disc rotor are securely fitted BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Revision 2007 June BR 55 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR gt BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Exploded View INFOID O000000001647984 SEC 441 Em 0 43 1 4 4 32 3 zis on ET 6 o JPFIA0064GB 1 Brake hose 2 Union bolt 3 Copper washer
66. t pedal occurs at very low mileage CAUTION Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are securely fitted Only perform this procedure under safe road and traffic conditions Use extreme caution 1 Drive vehicle on straight flat road 2 Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops 3 Drive without depressing brake for a few minutes to cool the brake 4 Repeat steps 1 to 3 until pad and disc rotor are securely fitted Revision 2007 June BR 50 G37 Coupe REAR DISC BRAKE ON VEHICLE REPAIR gt REAR DISC BRAKE BRAKE PAD 1 PISTON TYPE BRAKE PAD 1 PISTON TYPE Exploded View INFO1D 0000000001824833 SEC 441 r2 0 43 1 4 4 32 Ems x CY Em Qe D Ez JPFIA0064GB 1 Brake hose 2 Union bolt 3 Copper washer 4 Cap 5 Bleeder valve 6 Sliding pin bolt 7 Cylinder body 8 Piston seal 9 Piston 10 Piston boot 11 Sliding pin boot 12 Bushing 13 Torque member 14 Inner shim cover 15 Inner shim 16 Inner pad 17 Pad wear sensor RH inner pad 18 Padretainer only 19 Outer pad 20 Outer shim 1 Apply rubber grease 2 Apply PBC Poly Butyl Cuprysil grease or silicone based grease 3 Apply polyglycol ether based lubricant al Apply brake fluid Refer to GlI 4 Components for symbols not described on the above BRAKE PAD 1 PISTON TYPE Removal and Installation INFOID 0000000
67. te rsen orte E dated 52 BRAKE PAD 2 PISTON TYPE 52 BRAKE PAD 2 PISTON TYPE Exploded View 53 BRAKE PAD 2 PISTON TYPE Removal and In SLAM ATOM 5 5 Pero tetceret uen cora T EE noue tune es 53 BRAKE PAD 2 PISTON TYPE Inspection and AdJUstirighiE oni te toten eec RR 55 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE 55 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Exploded View 00 0 peda reira Eaa Haera asai 56 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Removal and Installation sssssses 56 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Disassembly and Assembly 57 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE Inspection and Adjustment 58 BRAKE CALIPER ASSEMBLY 2 PISTON TYPE 59 BRAKE CALIPER ASSEMBLY 2 PISTON TYPE Exploded View ou 43 Exploded View stetisse a e E HASSLE 59 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE BRAKE CALIPER ASSEMBLY 2 PISTON TYPE Removal and Installation 44 Removal and Installation ssssss 60 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE BRAKE CALIPER ASSEMBLY 2 PISTON TYPE Disassembly and Assembly sss 45 Disassembly and Assembly s sese 61 BRAKE CALIPER ASSEMBLY 1 PISTON TYPE BRAKE CALIPER ASSEMBLY 2 PISTON TYPE Inspection and Adjustment sss 46
68. to BR 63 Brake Pedal The stop lamp must turn off when the brake pedal is released Revision 2007 June BR 10 G37 Coupe BRAKE FLUID lt ON VEHICLE MAINTENANCE gt BRAKE FLUID n S p e ct i O n INFOID 0000000001647822 BRAKE FLUID LEVEL e Check that the fluid level in the reservoir tank is within the specified range MAX MIN lines Visually check for any brake fluid leakage around the reservoir tank Check the brake system for any leakage if the fluid level is extremely low lower than MIN Check the brake system for fluid leakage if the warning lamp remains illuminated even after the parking brake is released JPFIA0007ZZ BRAKE LINE 1 Check brake line tubes and hoses for cracks deterioration or other damage Replace any damaged parts 2 Check for fluid leakage by fully depressing brake pedal while engine is running CAUTION If leakage occurs around joints retighten or if necessary replace damaged parts SBR389C D ral n l n g INFOID 0000000001647823 CAUTION Never spill or splash brake fluid on painted surfaces Brake fluid may seriously damage paint Wipe it off immediately and wash with water if it gets on a painted surface Turn the ignition switch OFF and disconnect the ABS actuator and electric unit control unit con nector or the battery negative terminal before performing work Cover crowfoot and flare nut wrench with a cloth as not to damage the caliper front 4
69. to the vehicle 0 035 0 0014 4 PISTON TYPE Unit mm in Standard thickness 11 0 0 433 Brake pad mE Wear limit thickness 2 0 0 079 Standard thickness 32 0 1 260 Wear limit thickness 30 0 1 181 Disc rotor Thickness variation measured at 8 positions 0 015 0 0006 Runout limit with it attached to the vehicle 0 035 0 0014 Rear Disc Brake INFOID 0000000001647896 1 PISTON TYPE Unit mm in Standard thickness 8 5 0 335 Brake pad Wear limit thickness 2 0 0 079 Standard thickness 16 0 0 631 Wear limit thickness 15 0 0 591 Disc rotor Thickness variation measured at 8 positions 0 015 0 0006 Runout limit with it attached to the vehicle 0 055 0 0022 2 PISTON TYPE Unit mm in Standard thickness 8 5 0 335 Brake pad Wear limit thickness 2 0 0 079 Standard thickness 20 0 0 787 Wear limit thickness 18 0 0 709 Disc rotor Thickness variation measured at 8 positions 0 015 0 0006 Runout limit with it attached to the vehicle 0 055 0 0022 Revision 2007 June BR 64 G37 Coupe

BR-19, "Exploded View"

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BR-19, &quot;Exploded View&quot;

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BR-19, "Exploded View"