NGBR0085
NVH Troubleshooting Chart
NGBR0085S01
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
BR-25
BR-19, 25
BR-23
BR-18
—
—
BR-21, 25
—
—
—
BR-21
BR-25
NVH,
PD-4
.
NVH,
PD-14
,
PD-40
,
PD-62
.
NVH,
AX-3
.
NVH,
AX-3
.
NVH,
SU-3
.
NVH,
SU-3
.
NVH,
SU-3
.
NVH,
ST-5
.
Possible cause
and SUSPECTED PARTS
Linings or pads - damaged
Linings or pads - uneven wear
Return spring damaged
Shims damaged
Rotor or drum imbalance
Rotor or drum damage
Rotor or drum runout
Rotor or drum deformation
Rotor or drum deflection
Rotor or drum rust
Rotor thickness variation
Drum out of round
PROPELLER SHAFT
DIFFERENTIAL
DRIVE SHAFT
AXLE
SUSPENSION
TIRES
ROAD WHEEL
STEERING
Symptom BRAKE
Noise ×××× × × ××××××
Shake × × ××××××
Shimmy, Judder ×××××××× ×××××
×: Applicable
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
ST
RS
BT
HA
SC
EL
IDX
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
BR-5
SBR451D
Checking Brake Fluid Level
NGBR0006
¼ Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
¼ If fluid level is extremely low, check brake system.
¼ If the brake warning lamp comes on, check brake fluid level
switch and parking brake switch.
SBR389C
Checking Brake Line
NGBR0007
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
and other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
SBR419C
Changing Brake Fluid
NGBR0008
CAUTION:
¼ Refill with new brake fluid “DOT 3”.
¼ Always keep fluid level higher than minimum line on res-
ervoir tank.
¼ Never reuse drained brake fluid.
¼ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
1. Clean inside of reservoir tank, and refill with new brake fluid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
4. Refill until brake fluid comes out of each air bleeder valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid.
Refer to “Bleeding Brake System”, BR-8.
ON-VEHICLE SERVICE
Checking Brake Fluid Level
BR-6
Brake Burnishing Procedure
=NGBR0120
Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing drums or rotors, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a
pressure such that vehicle stopping time equals to 3 to 5 sec-
onds.
3. To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnish-
ing procedure.
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
ST
RS
BT
HA
SC
EL
IDX
ON-VEHICLE SERVICE
Brake Burnishing Procedure
BR-7
SBR995
Bleeding Brake System
=NGBR0009
CAUTION:
¼ Carefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
¼ If master cylinder is suspected to have air inside, bleed air
from master cylinder first. Refer to “Installation”, “MAS-
TER CYLINDER”, BR-15.
¼ Fill reservoir with new brake fluid “DOT 3”. Make sure it is
full at all times while bleeding air out of system.
¼ Place a container under master cylinder to avoid spillage
of brake fluid.
¼ Turn ignition switch OFF and disconnect ABS actuator
connectors or battery ground cable.
¼ Bleed air in the following order.
1. Left rear brake
2. Right rear brake
3. Left front brake
4. Right front brake
SBR419C
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to release
air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 1. through 4. until clear brake fluid comes out of
air bleeder valve.
7. Tighten air bleeder valve to specified torque.
:7-9N·m(0.7 - 0.9 kg-m, 61 - 78 in-lb)
ON-VEHICLE SERVICE
Bleeding Brake System
BR-8
Hydraulic Circuit
NGBR0010
ABR676
SBR992
Removal
NGBR0011
CAUTION:
¼ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
¼ All hoses must be free from excessive bending, twisting
and pulling.
1. Connect vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
3. Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
4. Cover openings to prevent entrance of dirt whenever discon-
necting brake line.
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BRAKE HYDRAULIC LINE
Hydraulic Circuit
BR-9
Inspection
NGBR0012
Check brake lines (tubes and hoses) for cracks, deterioration and
other damage. Replace any damaged parts.
SBR686C
Installation
NGBR0013
CAUTION:
¼ Refill with new brake fluid “DOT 3”.
¼ Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Flare nut:
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Connecting bolt:
: 17 - 19 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
2. Refill until new brake fluid comes out of each air bleeder valve.
3. Bleed air. Refer to “Bleeding Brake System”, BR-8.
BRAKE HYDRAULIC LINE
Inspection
BR-10
Removal and Installation
NGBR0016
ABR824
SBR997
Inspection
NGBR0017
Check brake pedal for following items.
¼ Brake pedal bend
¼ Clevis pin deformation
¼ Crack of any welded portion
¼ Crack or deformation of clevis pin stopper
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BRAKE PEDAL AND BRACKET
Removal and Installation
BR-11
SBR278AB
Adjustment
NGBR0018
Check brake pedal free height from metal floor.
H: Free height
Refer to SDS (BR-73).
D: Depressed height
Refer to SDS (BR-73).
Under force of 490 N (50 kg, 110 lb) with engine run-
ning
C
1
,C
2
: Clearance between pedal stopper and
threaded end of stop lamp switch and ASCD switch
0.3 - 1.0 mm (0.012 - 0.039 in)
A: Pedal free play
1-3mm(0.04 - 0.12 in)
If necessary, adjust brake pedal free height.
SBR930
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
Make sure that tip of input rod stays inside.
2. Adjust clearance “C
1
” and “C
2
” with stop lamp switch and
ASCD switch respectively. Then tighten lock nuts.
3. Check pedal free play.
Make sure that stop lamp is off when pedal is released.
4. Check brake pedal’s depressed height while engine is running.
If depressed height is below specified value, check brake sys-
tem for leaks, accumulation of air or any damage to compo-
nents (master cylinder, wheel cylinder, etc.). Then make nec-
essary repairs.
BRAKE PEDAL AND BRACKET
Adjustment
BR-12
Removal
NGBR0019
CAUTION:
¼ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
¼ In the case of brake fluid leakage from the master cylinder,
disassemble the cylinder. Then check piston cups for
deformation and scratches and replace necessary parts.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake
pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
ABR873
SBR938A
Disassembly
NGBR0020
1. Bend claws of stopper cap outward.
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
ST
RS
BT
HA
SC
EL
IDX
MASTER CYLINDER
Removal
BR-13
SBR939A
2. Remove piston stopper while piston is pushed into cylinder.
3. Remove piston assemblies.
If it is difficult to remove secondary piston assembly, gradu-
ally apply compressed air through fluid outlet.
4. Draw out reservoir tank.
Inspection
NGBR0021
Check master cylinder inner wall for pin holes and scratches.
Replace if damaged.
ABR767
Assembly
NGBR0022
1. Insert secondary piston assembly. Then insert primary piston
assembly.
¼ Pay attention to direction of piston cups in figure at left.
Also, insert pistons squarely to avoid scratches on cylin-
der bore.
SBR940A
2. Install stopper cap.
Before installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.
MASTER CYLINDER
Disassembly (Cont’d)
BR-14
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