Juke F15 (2012 year). Service Repair Manual — part 21

BR-30

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

3.

Install the brake tube (2) to the brake hose (1), temporarily
tighten the flare nut (3) by hand until it does not rotate further,
and fix the brake hose to the bracket (5) with the lock plate (4).

CAUTION:

Check that all brake hoses and brake tubes are not twisted
and bent.

4.

Tighten the flare nut to the specified torque with a flare nut
torque wrench (A).

CAUTION:

Never scratch the flare nut and the brake tube.

5.

Refill with new brake fluid and perform the air bleeding. Refer to

BR-13, "Bleeding Brake System"

.

CAUTION:

Never reuse drained brake fluid.

6.

Install tires. Refer to

WT-7, "Exploded View"

.

7.

Perform inspection after installation. Refer to

BR-30, "FRONT :

Inspection"

.

FRONT : Inspection

INFOID:0000000006502176

INSPECTION AFTER INSTALLATION

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 lb) 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

REAR : Exploded View

INFOID:0000000006502177

2WD (MR16DDT, HR16DE)

JPFIA0821ZZ

JPFIA0061ZZ

BRAKE PIPING

BR-31

< REMOVAL AND INSTALLATION >

[LHD]

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2WD (K9K)

1.

Brake tube

2.

Brake hose A

3.

Lock plate

4.

Brake hose bracket

5.

Union bolt

6.

Brake hose B

7.

Copper washer

A.

To connector

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JSFIA0465GB

BR-32

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

4WD

1.

Brake tube

2.

Brake hose A

3.

Lock plate

4.

Brake hose bracket

5.

Union bolt

6.

Brake hose B

7.

Copper washer

A.

To connector

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JSFIA0467GB

BRAKE PIPING

BR-33

< REMOVAL AND INSTALLATION >

[LHD]

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REAR : Hydraulic Piping

INFOID:0000000006502178

WITHOUT ESP

1.

Brake tube

2.

Brake hose A

3.

Lock plate

4.

Brake hose bracket

5.

Brake hose B

6.

Union bolt

7.

Copper washer

A.

To connector

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JSFIA0468GB

JPFIA0650ZZ

BR-34

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

WITH ESP

2WD

MR16DDT, HR16DE

K9K

1.

ABS actuator and electric unit (con-
trol unit)

2.

Front disc brake

3.

Master cylinder assembly

4.

Brake booster

5.

Connector

6.

Rear disc brake

A.

Brake tube

B.

Brake hose

: Flare nut

: Union bolt

JSFIA0463ZZ

1.

ABS actuator and electric unit (con-
trol unit)

2.

Front disc brake

3.

Pressure sensor

4.

Master cylinder assembly

5.

Brake booster

6.

Connector

7.

Rear disc brake

A.

Brake tube

B.

Brake hose

: Flare nut

: Union bolt

JPFIA0650ZZ

BRAKE PIPING

BR-35

< REMOVAL AND INSTALLATION >

[LHD]

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4WD

REAR : Removal and Installation

INFOID:0000000006502179

REMOVAL

2WD

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. For brake component parts,
never wash them with water.

• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied

with, brake fluid may splash.

1.

Remove tires.

2.

Drain brake fluid. Refer to

BR-12, "Draining"

.

1.

ABS actuator and electric unit (con-
trol unit)

2.

Front disc brake

3.

Master cylinder assembly

4.

Brake booster

5.

Connector

6.

Rear disc brake

A.

Brake tube

B.

Brake hose

: Flare nut

: Union bolt

1.

ABS actuator and electric unit (con-
trol unit)

2.

Front disc brake

3.

Pressure sensor

4.

Master cylinder assembly

5.

Brake booster

6.

Connector

7.

Rear disc brake

A.

Brake tube

B.

Brake hose

: Flare nut

: Union bolt

JSFIA0464ZZ

BR-36

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

3.

Loosen the flare nut (1) with a flare nut wrench (A) and separate
the brake tube (2) from the brake hose A (3).

CAUTION:

• 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 discon-

necting to prevent entrance of dirt.

4.

Remove the lock plate (4) and remove the brake hose A.

5.

Loosen the flare nut (1) with a flare nut wrench (A) and separate
the brake tube (2) from the hose B (3).

CAUTION:

• 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 discon-

necting to prevent entrance of dirt.

6.

Remove the lock plate (4) from brake hose bracket (5).

7.

Remove the union bolt (1) and copper washers (2), and remove
the brake hose B (3) from the brake caliper assembly.

4WD

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. For brake component parts,
never wash them with water.

• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied

with, brake fluid may splash.

1.

Remove tires.

2.

Drain brake fluid. Refer to

BR-12, "Draining"

.

3.

Loosen the flare nut (1) with a flare nut wrench (A) and separate
the brake tube (2) from the hose A (3).

CAUTION:

• 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 discon-

necting to prevent entrance of dirt.

4.

Remove the lock plate (4) and remove the brake hose A.

JPFIA0848ZZ

JSFIA0470ZZ

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BRAKE PIPING

BR-37

< REMOVAL AND INSTALLATION >

[LHD]

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5.

Loosen the flare nut (1) with a flare nut wrench (A) and separate
the brake tube (2) from the hose B (3).

CAUTION:

• 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 discon-

necting to prevent entrance of dirt.

6.

Remove the lock plate (4) from brake hose bracket (5).

7.

Remove the union bolt (1) and copper washers (2), and remove
the brake hose B (3) from the brake caliper assembly.

INSTALLATION

2WD

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. For brake component parts,
never wash them with water.

• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied

with, brake fluid may splash.

1.

Assemble the union bolt (1) and the copper washer (2) to the
brake hose B.

CAUTION:

Never reuse the copper washer.

2.

Align the brake hose B L-pin (A) with the brake caliper assembly
hole (B), and tighten the union bolt (1) to the specified torque.

3.

Install the brake tube (2) to the brake hose B (1), temporarily
tighten the flare nut (3) by hand until it does not rotate further,
and fix the brake hose B to the brake hose bracket (5) with the
lock plate (4).

CAUTION:

Check that all brake hoses and brake tubes are not twisted
and bent.

JSFIA0470ZZ

JSFIA0471ZZ

JSFIA0472ZZ

JSFIA0473ZZ

BR-38

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

4.

Tighten the flare nut to the specified torque with a flare nut
torque wrench (A).

CAUTION:

Never scratch the flare nut and the brake tube.

5.

Install the brake tube (2) to the brake hose A (1), temporarily
tighten the flare nut (3) by hand until it does not rotate further,
and fix the brake hose with the lock plate (4).

CAUTION:

Check that all brake hoses and brake tubes are not twisted
and bent.

6.

Tighten the flare nut to the specified torque with a flare nut
torque wrench (A).

CAUTION:

Never scratch the flare nut and the brake tube.

7.

Refill with new brake fluid and perform the air bleeding. Refer to

BR-13, "Bleeding Brake System"

.

CAUTION:

Never reuse drained brake fluid.

8.

Install tires. Refer to

WT-7, "Exploded View"

.

9.

Perform inspection after installation. Refer to

BR-39, "REAR :

Inspection"

.

4WD

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. For brake component parts,
never wash them with water.

• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied

with, brake fluid may splash.

1.

Assemble the union bolt (1) and the copper washer (2) to the
brake hose B.

CAUTION:

Never reuse the copper washer.

2.

Align the brake hose B L-pin (A) with the brake caliper assembly
hole (B), and tighten the union bolt (1) to the specified torque.

JPFIA0061ZZ

JPFIA0849ZZ

JPFIA0061ZZ

JSFIA0472ZZ

BRAKE PIPING

BR-39

< REMOVAL AND INSTALLATION >

[LHD]

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3.

Install the brake tube (2) to the brake hose B (1), temporarily
tighten the flare nut (3) by hand until it does not rotate further,
and fix the brake hose B to the brake hose bracket (5) with the
lock plate (4).

CAUTION:

Check that all brake hoses and brake tubes are not twisted
and bent.

4.

Tighten the flare nut to the specified torque with a flare nut
torque wrench (A).

CAUTION:

Never scratch the flare nut and the brake tube.

5.

Install the brake tube (2) to the brake hose A (3), temporarily
tighten the flare nut (1) by hand until it does not rotate further,
and fix the brake hose A to the bracket with the lock plate (4).

CAUTION:

Check that all brake hoses and brake tubes are not twisted
and bent.

6.

Tighten the flare nut to the specified torque with a flare nut
torque wrench (A).

CAUTION:

Never scratch the flare nut and the brake tube.

7.

Refill with new brake fluid and perform the air bleeding. Refer to

BR-13, "Bleeding Brake System"

.

CAUTION:

Never reuse drained brake fluid.

8.

Install tires. Refer to

WT-7, "Exploded View"

.

9.

Perform inspection after installation. Refer to

BR-39, "REAR :

Inspection"

.

REAR : Inspection

INFOID:0000000006502180

INSPECTION AFTER INSTALLATION

1.

Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no looseness
at connections.

2.

Depress the brake pedal with a force of 785 N (80kg, 176 lb) and hold down the pedal for approximately 5
seconds with the engine running. Check for any fluid leakage.

CAUTION:

JSFIA0473ZZ

JPFIA0061ZZ

JSFIA0474ZZ

JPFIA0061ZZ

BR-40

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

Retighten the applicable connection to the specified torque and repair any abnormal (damaged,
worn or deformed) part if any brake fluid leakage is present.

BRAKE MASTER CYLINDER

BR-41

< REMOVAL AND INSTALLATION >

[LHD]

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BRAKE MASTER CYLINDER

Exploded View

INFOID:0000000006502181

2WD

4WD

1.

Reservoir cap

2.

Oil strainer

3.

Reservoir tank

4.

Cylinder body

5.

Pin

6.

O-ring

7.

Grommet

: Apply polyglycol ether based lubricant.

: Apply brake fluid.

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JSFIA0475GB

BR-42

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE MASTER CYLINDER

Removal and Installation

INFOID:0000000006502182

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. For brake component parts,
never wash them with water.

• Never depress the brake pedal while removing the brake tube. If this is not complied with, brake fluid

may splash.

1.

Perform inspection before removal. Refer to

BR-45, "Inspection"

.

2.

Depress the brake pedal several times to release the vacuum pressure from the brake booster.

3.

Drain brake fluid. Refer to

BR-12, "Draining"

.

4.

Disconnect the brake fluid level switch harness connector.

5.

Remove air duct and air cleaner case.
• MR16DDT: Refer to

EM-26, "Removal and Installation"

.

• HR16DE: Refer to

EM-161, "Removal and Installation"

.

• K9K: Refer to

EM-280, "Removal and Installation"

.

1.

Reservoir cap

2.

Oil strainer

3.

Reservoir tank

4.

Cylinder body

5.

Pin

6.

O-ring

7.

Grommet

: Apply polyglycol ether based lubricant.

: Apply brake fluid.

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JSFIA0476GB

BRAKE MASTER CYLINDER

BR-43

< REMOVAL AND INSTALLATION >

[LHD]

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6.

Separate the brake tube from master cylinder assembly with a
flare nut wrench (A).

CAUTION:

Never scratch the flare nut and the brake tube.

7.

Remove the master cylinder assembly.

CAUTION:

• Never deform or bend the brake tubes.
• Never depress the brake pedal after the master cylinder

assembly is removed.

• The piston (A) of the master cylinder assembly is

exposed. Never damage it when removing the master cyl-
inder.

• The piston may drop off when pulled out strongly. Never

hold the piston. Hold the cylinder body when handling the
master cylinder assembly.

8.

Remove the O-ring.

INSTALLATION

Note the following, and install in the reverse order of removal.
• 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. For brake component parts, never wash
them with water.

• Never depress the brake pedal while removing the brake tube. If this is not complied with, brake fluid may

splash.

• Never depress the brake pedal after the master cylinder assembly is removed.
• Apply polyglycol ether based lubricant to the brake booster [see

(A) in the figure] when installing the master cylinder assembly to
the brake booster.

• The piston (A) of the master cylinder assembly is exposed. Never

damage it when handling the master cylinder.

• Check that no dirt and dust are present on the piston before instal-

lation. Clean it with new brake fluid if necessary.

• The piston may drop off when pulled strongly. Never hold the pis-

ton. Hold the cylinder body when handling the master cylinder
assembly.

• Never reuse the O-ring.
• Never deform or bend the brake tubes.

JPFIA0844ZZ

JPFIA0824ZZ

JPFIA0013ZZ

JPFIA0824ZZ

BR-44

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE MASTER CYLINDER

• 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 torque wrench (A). Refer to

BR-24, "FRONT : Exploded

View"

.

• Perform the air bleeding. Refer to

BR-13, "Bleeding Brake System"

• Perform inspection after installation. Refer to

BR-45, "Inspection"

.

Disassembly and Assembly

INFOID:0000000006502183

DISASSEMBLY

CAUTION:

• Never disassemble the cylinder body.
• Remove the reservoir tank only when necessary.

1.

Fix the master cylinder assembly to a vise.

CAUTION:

• Always set copper plates or cloth between vise grips when fixing the cylinder body to a vise.
• Never overtighten the vise.

2.

Remove the reservoir tank mounting pin with a pin punch (A) [4
mm (0.157 in)].

3.

Remove the reservoir tank and grommet from the cylinder body.

ASSEMBLY

CAUTION:

• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and

assembly process.

• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank.
• Never drop the when installing. The parts must not be reused if they are dropped.

1.

Apply new brake fluid to the grommet and install it to the cylinder body.

CAUTION:

Never reuse the grommets.

2.

Install the reservoir tank to the cylinder body.

3.

Fix the cylinder body to a vise.

CAUTION:

• Place the reservoir tank with the chamfered pin hole (

)

facing up.

• Always set copper plates or cloth between vise grips

when fixing the cylinder body to a vise.

• Never overtighten the vise.

JPFIA0844ZZ

JPFIA0825ZZ

JPFIA0826ZZ

BRAKE MASTER CYLINDER

BR-45

< REMOVAL AND INSTALLATION >

[LHD]

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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 pin.

Inspection

INFOID:0000000006502184

INSPECTION BEFORE REMOVAL

Check the brake fluid level switch.
• Without ESP: Refer to

BRC-73, "Component Inspection"

.

• With ESP: Refer to

BRC-194, "Component Inspection"

.

INSPECTION AFTER INSTALLATION

Check the following items and replace if necessary.
• Check the master cylinder for deformation, twist, contact with other parts or looseness of connection.
• Check for fluid leakage from connection. Refer to

BR-30, "FRONT : Inspection"

.

CAUTION:

If the fluid leakage is present, retighten to the specified torque. Replace if necessary.