Juke F15 (2012 year). Service Repair Manual — part 24
BR-78
< PERIODIC MAINTENANCE >
[RHD]
BRAKE PEDAL
Check the height between the dash lower panel (1) and the brake
pedal upper surface (H
2
) when depressing the brake pedal at 490 N
(50 kg, 110 lb) while turning engine ON.
CAUTION:
Remove the floor trim.
ADJUSTMENT
Brake Pedal Height
1.
Remove instrument lower panel. Refer to
IP-13, "Removal and Installation"
2.
Disconnect the stop lamp switch and brake switch/brake pedal position switch harness connector.
3.
Loosen the stop lamp switch and brake switch/brake pedal position switch 45
°
counterclockwise.
4.
Loosen the lock nut (2) of input rod (1).
5.
Rotate the input rod, adjust the brake pedal to the specified
height (H
1
).
CAUTION:
The threaded end of the input rod must project to the inner
side (L) of the clevis (3).
6.
Tighten the lock nut. Refer to
7.
Adjust the clearance between the brake pedal lever and the stop
lamp switch and brake switch/brake pedal position switch
threaded end after adjusting the brake pedal height.
Stop Lamp Switch
1.
Remove instrument lower panel. Refer to
IP-13, "Removal and Installation"
2.
Disconnect the harness connector from stop lamp switch.
3.
Loosen the stop lamp switch 45
°
counterclockwise.
4.
Press-fit the stop lamp switch (2) until the stop lamp switch hits
the brake pedal lever (1) 45
°
clockwise while pulling the brake
pedal pad slightly.
CAUTION:
• The clearance (C) between the brake pedal lever and stop
lamp switch threaded and must be the specified value.
• The stop lamp must be turned off when the brake pedal is
released.
Brake Switch/Brake Pedal Position Switch
H
2
: Refer to
.
JPFIA0068ZZ
JPFIA0003ZZ
H
1
: Refer to
JPFIA0279ZZ
C
: Refer to
PFIA0813J
BRAKE PEDAL
BR-79
< PERIODIC MAINTENANCE >
[RHD]
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1.
Remove instrument lower panel. Refer to
IP-13, "Removal and Installation"
.
2.
Disconnect the harness connector from brake switch/brake pedal position switch.
3.
Loosen the brake switch/brake pedal position switch 45
°
counterclockwise.
4.
Press-fit the brake switch/brake pedal position switch (2) until
the brake switch/brake pedal position switch hits the brake pedal
lever (1) 45
°
clockwise while pulling the brake pedal pad slightly.
CAUTION:
The clearance (C) between the brake pedal lever and brake
switch/brake pedal position switch threaded and must be
the specified value.
Depressed Brake Pedal Height
1.
Perform the air bleeding. Refer to
BR-81, "Bleeding Brake System"
.
2.
Check the height between the dash lower panel (1) and the
brake pedal upper surface (H
2
) when depressing the brake
pedal at 490 N (50 kg, 110 lb) while turning engine ON.
CAUTION:
Remove the floor trim.
C
: Refer to
PFIA0813J
H
2
: Refer to
.
JPFIA0068ZZ
BR-80
< PERIODIC MAINTENANCE >
[RHD]
BRAKE FLUID
BRAKE FLUID
Inspection
INFOID:0000000006589786
BRAKE FLUID LEVEL
• 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.
• Check the reservoir tank for the mixing of foreign matter (e.g. dust)
and oils other than brake fluid.
BRAKE LINE
1.
Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged
parts.
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.
Draining
INFOID:0000000006589787
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.
• Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) har-
ness connector or the battery negative terminal before performing work.
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.
Refilling
INFOID:0000000006589788
CAUTION:
• Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) har-
ness connector or the battery negative terminal before performing work.
SFIA2634J
SBR389C
BRA0007D
BRAKE FLUID
BR-81
< PERIODIC MAINTENANCE >
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• 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.
1.
Check that there is no foreign material in the reservoir tank, and refill with new brake fluid.
CAUTION:
• Never reuse drained brake fluid.
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank.
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 new 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-81, "Bleeding Brake System"
.
Bleeding Brake System
INFOID:0000000006589789
CAUTION:
• Turn the ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) har-
ness connector or the battery negative terminal before performing the work.
• Monitor the fluid level in the reservoir tank while performing the air bleeding
• 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.
1.
Check that there is no foreign material in the reservoir tank, and refill with new brake fluid.
CAUTION:
• Never reuse drained brake fluid.
• Never allow oils other than brake fluid to enter the reservoir tank.
2.
Connect a vinyl tube to the bleeder valve of the rear left brake.
3.
Fully depress the brake pedal 4 to 5 times.
4.
Loosen the bleeder valve and bleed air with the brake pedal depressed, and then quickly tighten the
bleeder valve.
5.
Repeat steps 3 and 4 until all of the air is out of the brake line.
6.
Tighten the bleeder valve to the specified torque.
• Front disc brake: refer to
BR-122, "BRAKE CALIPER ASSEMBLY : Exploded View"
.
• Rear disc brake: refer to
BR-130, "BRAKE CALIPER ASSEMBLY : Exploded View"
7.
Perform steps 2 to 6. Occasionally fill with the brake fluid in order to keep it in the reservoir tank at least
half of MAX line. Bleed air in the following order: rear left brake
→
front right brake
→
rear right brake
→
and front left brake in order.
8.
Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to
9.
Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to
.
BR-82
< PERIODIC MAINTENANCE >
[RHD]
BRAKE MASTER CYLINDER
BRAKE MASTER CYLINDER
Inspection
INFOID:0000000006589790
FLUID LEAK
Check for brake fluid leakage from the master cylinder mounting face, reservoir tank mounting face and brake
tube connections.
BRAKE BOOSTER
BR-83
< PERIODIC MAINTENANCE >
[RHD]
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BRAKE BOOSTER
Inspection
INFOID:0000000006589791
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
1.
Run the engine at idle for 1 minute to apply vacuum to the brake booster, and stop the engine.
2.
Depress the brake pedal several 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 each time the brake pedal is depressed when performing this operation.
3.
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 sec-
onds or more.
BR-84
< PERIODIC MAINTENANCE >
[RHD]
FRONT DISC BRAKE
FRONT DISC BRAKE
BRAKE PAD
BRAKE PAD : Inspection and Adjustment
INFOID:0000000006589792
INSPECTION
Check brake pad wear thickness from an inspection hole on cylinder
body. Check using a scale if necessary.
ADJUSTMENT
Burnish contact surfaces between disc rotor and brake pads according to the following procedure after refin-
ishing or replacing brake pads, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate firmly/securely 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.
Repeat steps 1 to 3 until pad and disc rotor are securely fitted.
DISC ROTOR
DISC ROTOR : Inspection and Adjustment
INFOID:0000000006589793
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary.
• MR16DDT: Refer to
FAX-11, "Removal and Installation"
.
• HR16DE: Refer to
FAX-43, "Removal and Installation"
• K9K: Refer to
FAX-68, "Removal and Installation"
Runout
1.
Fix the disc rotor to the wheel hub and bearing assembly with
wheel nuts (2 points at least).
2.
Check the wheel bearing axial end play before the inspection.
• MR16DDT: Refer to
.
• HR16DE: Refer to
.
• K9K: Refer to
.
3.
Inspect the runout with a dial indicator to measure at 10 mm
(0.39 in) inside the disc edge.
4.
Find the 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.
• Refinish the disc rotor if the runout is outside the limit even after performing the above operation.
CAUTION:
Wear thickness
: Refer to
BRA0010D
Runout (with it attached
to the vehicle)
.
SBR019B
FRONT DISC BRAKE
BR-85
< PERIODIC MAINTENANCE >
[RHD]
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• Check in advance that the thickness of the disc rotor is wear thickness + 0.3 mm (0.012 in) or more.
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor.
- MR16DDT: Refer to
FAX-11, "Removal and Installation"
- HR16DE: Refer to
FAX-43, "Removal and Installation"
.
- K9K: Refer to
FAX-68, "Removal and Installation"
Thickness
Check the thickness of the disc rotor using a micrometer. Replace
the disc rotor if the thickness is below the wear limit.
• MR16DDT: Refer to
FAX-11, "Removal and Installation"
.
• HR16DE: Refer to
FAX-43, "Removal and Installation"
• K9K: Refer to
FAX-68, "Removal and Installation"
ADJUSTMENT
Burnish contact surfaces between disc rotors and brake pads according to the following procedure after refin-
ishing 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 firmly/securely 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.
Wear thickness
.
Wear thickness
: Refer to
.
SBR020B
BR-86
< PERIODIC MAINTENANCE >
[RHD]
REAR DISC BRAKE
REAR DISC BRAKE
BRAKE PAD
BRAKE PAD : Inspection and Adjustment
INFOID:0000000006589794
INSPECTION
Check brake pad wear thickness from an inspection hole on cylinder
body. Check using a scale if necessary.
ADJUSTMENT
Burnish contact surfaces between disc rotor and brake pads according to the following procedure after refin-
ishing or replacing brake pads, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate firmly/securely 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.
Repeat steps 1 to 3 until pad and disc rotor are securely fitted.
DISC ROTOR
DISC ROTOR : Inspection and Adjustment
INFOID:0000000006589795
INSPECTION
Appearance
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary.
• 2WD: Refer to
RAX-5, "Removal and Installation"
• 4WD: Refer to
RAX-14, "Removal and Installation"
.
Runout
1.
Fix the disc rotor to the wheel hub and bearing assembly with
wheel nuts (2 points at least).
2.
Check the wheel bearing axial end play before the inspection.
• 2WD: Refer to
.
• 4WD: Refer to
3.
Inspect the runout with a dial indicator to measure at 10 mm
(0.39 in) inside the disc edge.
4.
Find the installation position that has a minimum runout by shift-
ing the disc rotor-to-wheel hub and bearing assembly installation position by one hole at a time if the
runout exceeds the limit value.
• Refinish the disc rotor if the runout is outside the limit even after performing the above operation.
CAUTION:
• Check in advance that the thickness of the disc rotor is wear thickness + 0.3 mm (0.012 in) or more.
Wear thickness
: Refer to
BRA0010D
Runout (with it attached
to the vehicle)
: Refer to
.
SBR019B
REAR DISC BRAKE
BR-87
< PERIODIC MAINTENANCE >
[RHD]
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• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor.
- 2WD: Refer to
RAX-5, "Removal and Installation"
.
- 4WD: Refer to
RAX-14, "Removal and Installation"
Thickness
Check the thickness of the disc rotor using a micrometer. Replace
the disc rotor if the thickness is below the wear limit.
• 2WD: Refer to
RAX-5, "Removal and Installation"
• 4WD: Refer to
RAX-14, "Removal and Installation"
.
ADJUSTMENT
Burnish contact surfaces between disc rotors and brake pads according to the following procedure after refin-
ishing 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 firmly/securely 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.
Wear thickness
: Refer to
.
Wear thickness
: Refer to
.
SBR020B
BR-88
< REMOVAL AND INSTALLATION >
[RHD]
BRAKE PEDAL
REMOVAL AND INSTALLATION
BRAKE PEDAL
Exploded View
INFOID:0000000006589796
WITHOUT ESP
WITH ESP
1.
Clevis pin
2.
Brake pedal assembly
3.
Brake pedal pad
4.
Stop lamp switch
5.
Clip
6.
Snap pin
: Apply multi-purpose grease.
: N·m (kg-m, ft-lb)
JPFIA0814GB
BRAKE PEDAL
BR-89
< REMOVAL AND INSTALLATION >
[RHD]
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Removal and Installation
INFOID:0000000006589797
REMOVAL
1.
Remove instrument lower panel. Refer to
IP-13, "Removal and Installation"
.
2.
Disconnect the stop lamp switch and the brake switch/brake pedal position switch harness connectors.
3.
Rotate the stop lamp switch and the brake switch/brake pedal
position switch (1) counter clockwise to remove.
4.
Disconnect the accelerator pedal harness connector and har-
ness clip.
1.
Clevis pin
2.
Brake pedal assembly
3.
Brake pedal pad
4.
Brake switch/brake pedal position
switch
5.
Clip
6.
Stop lamp switch
7.
Snap pin
: Apply multi-purpose grease.
: N·m (kg-m, ft-lb)
JSFIA0499GB
JPFIA0815ZZ
BR-90
< REMOVAL AND INSTALLATION >
[RHD]
BRAKE PEDAL
5.
Remove snap pin (1) and clevis pin (2) from clevis (3) of brake
booster.
6.
Remove the brake pedal assembly.
CAUTION:
Hold the brake booster and master cylinder assembly so as
not to drop out or contact them other parts.
7.
Remove accelerator pedal from brake pedal assembly. Refer to
ACC-3, "Removal and Installation"
8.
Perform inspection after removal. Refer to
INSTALLATION
Note the following, and install in the reverse order of removal.
• 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.
• Perform adjustment after installation. Refer to
BR-90, "Inspection and Adjustment"
.
Inspection and Adjustment
INFOID:0000000006589798
INSPECTION AFTER REMOVAL
• Check for the following items and replace the brake pedal assembly if necessary.
- Check the brake pedal upper rivet (made by aluminum) (A) and pin
(B) for deformation.
- Check the brake pedal for bend, damage, and cracks on the
welded parts.
- Check the lapping length (E) of sub-bracket (C) and slide plate (D).
• Check clevis pin and plastic stopper (A) for damage and deforma-
tion. If any is found, replace clevis pin.
ADJUSTMENT AFTER INSTALLATION
• Adjust each item of brake pedal after installing the brake pedal assembly to the vehicle. Refer to
.
• Perform the release position learning of the accelerator pedal.
- HR16DE: Refer to
.
- MR16DDT: Refer to
JPFIA0816ZZ
E
: 5.5 mm (0.217 in) or more
JPFIA0817ZZ
PFIA0756J
BRAKE PIPING
BR-91
< REMOVAL AND INSTALLATION >
[RHD]
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BRAKE PIPING
FRONT
FRONT : Exploded View
INFOID:0000000006589799
WITHOUT ESP
WITH ESP
1.
Brake booster
2.
Master cylinder assembly
3.
Brake tube
4.
Connector bracket
5.
Connector
6.
ABS actuator and electric unit (con-
trol unit)
7.
Lock plate
8.
Brake hose
9.
Union bolt
10. Copper washer
A.
To rear brake tube
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
JSFIA0500GB
BR-92
< REMOVAL AND INSTALLATION >
[RHD]
BRAKE PIPING
MR16DDT
JSFIA0502GB
1.
Brake booster
2.
Master cylinder assembly
3.
Brake tube
4.
Connector bracket
5.
Connector
6.
ABS actuator and electric unit (con-
trol unit)
7.
Lock plate
8.
Brake hose
9.
Union bolt
10. Copper washer
A.
To rear brake tube
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
BRAKE PIPING
BR-93
< REMOVAL AND INSTALLATION >
[RHD]
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HR16DE
JSFIA0501GB
1.
Brake booster
2.
Master cylinder assembly
3.
Brake tube
4.
Connector bracket
5.
Connector
6.
ABS actuator and electric unit (con-
trol unit)
7.
Lock plate
8.
Brake hose
9.
Union bolt
10. Copper washer
A.
To rear brake tube
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
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