Juke F15 (2012 year). Service Repair Manual - part 26

BR-110

< REMOVAL AND INSTALLATION >

[RHD]

BRAKE MASTER CYLINDER

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.

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:0000000006589810

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-97, "FRONT : Inspection"

.

CAUTION:

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

JPFIA0826ZZ

BRAKE BOOSTER

BR-111

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BRAKE BOOSTER

Exploded View

INFOID:0000000006589811

2WD

MR16DDT, HR16DE

K9K

4WD

JSFIA0506GB

1.

Master cylinder assembly

2.

Vacuum pipe

3.

Brake booster

4.

Lock nut

5.

Clevis

6.

Gasket

: N·m (kg-m, ft-lb)

JSFIA0507GB

1.

Master cylinder assembly

2.

Vacuum pipe

3.

Brake booster

4.

Lock nut

5.

Clevis

6.

Gasket

: N·m (kg-m, ft-lb)

BR-112

< REMOVAL AND INSTALLATION >

[RHD]

BRAKE BOOSTER

Removal and installation

INFOID:0000000006589812

REMOVAL

1.

Perform inspection before removal. Refer to 

BR-113, "Inspection and Adjustment"

.

2.

Remove cowl top and cowl top extension. Refer to 

EXT-20, "Removal and Installation"

.

3.

Remove brake master cylinder assembly. Refer to 

BR-108, "Removal and Installation"

.

4.

Remove vacuum hose from brake booster.
• MR16DDT: Refer to 

BR-115, "MR16DDT : Removal and Installation"

.

• HR16DE: Refer to 

BR-116, "HR16DE : Removal and Installation"

.

• K9K: Refer to 

BR-117, "K9K : Removal and Installation"

.

5.

Remove low-pressure flexible hose.
• HR16DE: Refer to 

HA-35, "LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation"

.

• MR16DDT: Refer to 

HA-91, "LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation"

.

• K9K: Refer to HA.

6.

Remove snap pin (1) and clevis pin (2). Refer to 

BR-88,

"Exploded View"

.

7.

Remove nuts on brake booster and brake pedal assembly.

CAUTION:

Hold the brake booster so as to avoid dropping out.

8.

Remove brake booster.

CAUTION:

Never deform or bend the brake tubes.
NOTE:
If removing brake booster is difficult, remove clevis from brake
booster.

9.

Remove vacuum pipe from brake booster. (2WD)

10. Perform inspection after removal. Refer to 

BR-113, "Inspection and Adjustment"

.

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 install in the reverse order of removal.

1.

Master cylinder assembly

2.

Brake booster

3.

Lock nut

4.

Clevis

5.

Gasket

: N·m (kg-m, ft-lb)

JSFIA0624GB

JPFIA0019ZZ

BRAKE BOOSTER

BR-113

< REMOVAL AND INSTALLATION >

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• Set vacuum pipe angle (A) as shown in the figure. [2WD

(MR16DDT and HR16DE)]

• Set vacuum pipe angle (A) as shown in the figure. [2WD (K9K)]

• Be careful not to damage brake booster stud bolt threads. If brake

booster is tilted during installation, the dash panel may damage the
threads.

• Never deform or bend the brake tubes when installing the brake

booster.

• Always use a gasket between the brake booster and the dash

panel.

• Replace the clevis pin if it is damaged. Refer to 

BR-90, "Inspection

and Adjustment"

.

• Perform the air bleeding. Refer to 

BR-81, "Bleeding Brake System"

.

• Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to 

BR-77,

"Inspection and Adjustment"

.

Inspection and Adjustment

INFOID:0000000006589813

INSPECTION BEFORE REMOVAL

Air Tight

CAUTION:

Check the air tight condition when the master cylinder and the brake booster is installed.
1.

Check the air tight use a handy vacuum pump.

2.

If the air tight condition cannot be maintained, perform the following operation.

a.

Check the no dirt and dust are present on the brake booster and brake master cylinder mating faces.
Clean it if necessary.

b.

Check the O-ring on the master cylinder. If anything is found, replace the O-ring. Refer to 

BR-108,

"Removal and Installation"

.

c.

Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster.

INSPECTION AFTER REMOVAL

Input Rod Length Inspection

A

: 28 – 38

°

JSFIA0508ZZ

A

: 28 – 38

°

JSFIA0509ZZ

At vacuum of 

−

66.7 kPa (

−

500 mmHg, 

−

19.69 inHg, 

−

0.067 bar)

Vacuum should decrease within 3.3 kPa (24.8 mmHg, 
0.98 inHg, 0.033 bar) for 15 seconds.

BR-114

< REMOVAL AND INSTALLATION >

[RHD]

BRAKE BOOSTER

1.

Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (A).

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 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.

ADJUSTMENT AFTER INSTALLATION

Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to 

BR-77, "Inspection and

Adjustment"

.

A

: Refer to 

BR-136, "Brake Booster"

.

JPFIA0238ZZ

VACUUM LINES

BR-115

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VACUUM LINES

MR16DDT

MR16DDT : Exploded View

INFOID:0000000006589817

MR16DDT : Removal and Installation

INFOID:0000000006589818

REMOVAL

1.

Remove the vacuum hose and vacuum piping.

2.

Perform inspection after removal. Refer to 

BR-115, "MR16DDT : Inspection"

.

INSTALLATION

Note the following, install the vacuum hose.
• When installing vacuum hose, insert it until its tip reaches the

back-end of length (A) or further as shown in the figure.

CAUTION:

Never use lubricating oil during assembly.

- Face the paint mark of vacuum hose (engine side) upward to

assemble.

- Face the paint mark of vacuum hose (brake booster side) to the

vehicle front side to assemble.

- For clamp mounting direction (the orientation of pawl), refer to 

BR-

115, "MR16DDT : Exploded View"

.

MR16DDT : Inspection

INFOID:0000000006589819

INSPECTION AFTER REMOVAL

Appearance

Check for correct assembly, damage and deterioration.

Check Valve Airtightness

1.

Clamp

2.

Vacuum hose

A.

To engine side

B.

Paint mark

C.

To brake booster

JSFIA0510ZZ

A

: 24 mm (0.95 in) or more

JPFIA0023ZZ

BR-116

< REMOVAL AND INSTALLATION >

[RHD]

VACUUM LINES

• Use a handy vacuum pump (A) to check.

• Replace vacuum hose if vacuum hose is malfunctioning.

HR16DE

HR16DE : Exploded View

INFOID:0000000006589814

HR16DE : Removal and Installation

INFOID:0000000006589815

REMOVAL

1.

Remove the vacuum hose and vacuum piping.

2.

Perform inspection after removal. Refer to 

BR-117, "HR16DE : Inspection"

.

INSTALLATION

Note the following, install the vacuum hose.
• When installing vacuum hose, insert it until its tip reaches the

back-end of length (A) or further as shown in the figure.

CAUTION:

Never use lubricating oil during assembly.

- Face the paint marks upward to assemble.
- For clamp mounting direction (the orientation of pawl), refer to 

BR-

116, "HR16DE : Exploded View"

.

When connected to the booster side (B):

Vacuum should decrease within 1.3 kPa (9.8 mmHg, 
0.38 inHg, 0.013 bar) for 15 seconds under a vacuum 
of 

−

66.7 kPa (

−

500 mmHg, 

−

19.70 inHg, 

−

0.667 bar).

When connected to the engine side (C):

Vacuum should not exist.

JPFIA0024ZZ

1.

Clamp

2.

Vacuum hose (built-in check valve)

A.

To intake manifold

B.

Paint mark

C.

Stamp indicating engine direction

D.

To brake booster

JPFIA0830ZZ

A

: 24 mm (0.95 in) or more

JPFIA0023ZZ

VACUUM LINES

BR-117

< REMOVAL AND INSTALLATION >

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HR16DE : Inspection

INFOID:0000000006589816

INSPECTION AFTER REMOVAL

Appearance

Check for correct assembly, damage and deterioration.

Check Valve Airtightness

• Use a handy vacuum pump (A) to check.

• Replace vacuum hose assembly if vacuum hose and check valve

are malfunctioning.

K9K

K9K : Exploded View

INFOID:0000000006589820

K9K : Removal and Installation

INFOID:0000000006589821

REMOVAL

1.

Remove air duct and air cleaner case. Refer to 

EM-280, "Removal and Installation"

.

When connected to the booster side (B):

Vacuum should decrease within 1.3 kPa (9.8 mmHg, 
0.38 inHg, 0.013 bar) for 15 seconds under a vacuum 
of 

−

66.7 kPa (

−

500 mmHg, 

−

19.70 inHg, 

−

0.667 bar).

When connected to the engine side (C):

Vacuum should not exist.

JPFIA0024ZZ

1.

Clamp

2.

Vacuum hose

3.

Vacuum piping

4.

Vacuum hose (built-in check valve)

5.

Connector

A.

To brake booster

B.

Paint mark

C.

Stamp indicating engine direction

D.

To vacuum pump

JSFIA0511ZZ

BR-118

< REMOVAL AND INSTALLATION >

[RHD]

VACUUM LINES

2.

Remove the vacuum hose and connector.

INSTALLATION

Note the following, install the vacuum hose.
• When installing vacuum hose, insert it until its tip reaches the

back-end of length (A) or further as shown in the figure.

CAUTION:

Never use lubricating oil during assembly.

- Face the paint mark of vacuum hose (built-in check valve, connec-

tor side) upward to assemble.

- Face the other paint marks to vehicle front side to assemble.
- For clamp mounting direction (the orientation of pawl), refer to 

BR-

117, "K9K : Exploded View"

.

K9K : Inspection

INFOID:0000000006589822

INSPECTION AFTER REMOVAL

Appearance

Check for correct assembly, damage and deterioration.

Check Valve Airtightness

• Use a handy vacuum pump (A) to check.

• Replace vacuum hose assembly if vacuum hose and check valve

are malfunctioning.

A

: 24 mm (0.95 in) or more

JPFIA0023ZZ

When connected to the booster side (B):

Vacuum should decrease within 1.3 kPa (9.8 mmHg, 
0.38 inHg, 0.013 bar) for 15 seconds under a vacuum 
of 

−

66.7 kPa (

−

500 mmHg, 

−

19.70 inHg, 

−

0.667 bar).

When connected to the engine side (C):

Vacuum should not exist.

JPFIA0024ZZ

FRONT DISC BRAKE

BR-119

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FRONT DISC BRAKE

BRAKE PAD

BRAKE PAD : Exploded View

INFOID:0000000006589823

MR16DDT

HR16DE, K9K

1.

Cylinder body

2.

Inner shim

3.

Inner pad (with pad wear sensor)

4.

Pad retainer

5.

Torque member

6.

Outer pad

7.

Outer shim

1: Apply MOLYKOTE

®

 AS880N or silicone-based grease.

2: Apply MOLYKOTE

®

 7439 or equivalent.

: N·m (kg-m, ft-lb)

JSFIA0483GB

1.

Cylinder body

2.

Inner shim cover

3.

Inner shim

4.

Inner pad (with pad wear sensor)

5.

Pad retainer

6.

Torque member

7.

Outer pad

8.

Outer shim

JSFIA0482GB

BR-120

< REMOVAL AND INSTALLATION >

[RHD]

FRONT DISC BRAKE

BRAKE PAD : Removal and Installation

INFOID:0000000006589824

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.
• If the brake fluid or grease adheres to the disc rotor, quickly wipe it off.

1.

Remove tires.

2.

Remove lower sliding pin bolt.

3.

Suspend the cylinder body with suitable wire so that the brake
hose will not stretch.

4.

Remove the brake pads, shims, shim covers and pad retainers from the torque member.

CAUTION:

• Never deform the pad retainer (2) when removing the pad

retainer from the torque member (1). 

• Never damage the piston boot.
• Never drop the brake pads, shims, and the shim covers.
• Remember each position of the removed brake pads.

5.

Perform inspection after removal. Refer to 

BR-121, "BRAKE

PAD : Inspection"

.

INSTALLATION

WARNING:

Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.

CAUTION:

1: Apply MOLYKOTE

®

 AS880N or silicone-based grease.

2: Apply MOLYKOTE

®

 7439 or equivalent.

: N·m (kg-m, ft-lb)

JPFIA0832ZZ

JPFIA0850ZZ

JPFIA0118ZZ

FRONT DISC BRAKE

BR-121

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• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis-

ton may pop out.

• If the brake fluid or grease adheres to the disc rotor, quickly wipe it off.

1.

Install the pad retainers (1) to the torque member (2) 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 MOLYKOTE

®

 AS880N or silicone-based grease to the

mating faces (A) between the brake pads and the shims, and
install the shims to the brake pad. 

CAUTION:

Always replace the shim together with the shim cover when
replacing the brake pad.

3.

Apply MOLYKOTE

®

 7439 or equivalent to the mating faces (B)

between the brake pads and the pad retainers.

4.

Install the brake pads to the torque member.

CAUTION:

• Both inner and outer pads have a pad return system on

the pad retainer. Install pad return lever (1) securely to pad
retainer (2).

• Never deform the pad retainers.

5.

Install cylinder body to torque member.

CAUTION:

• Never damage the piston boot.
• When replacing brake 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. 

6.

Install the lower sliding pin bolt and tighten it to the specified
torque.

7.

Depress the brake pedal several times to check that no drag feel
is present for the front disc brake. Refer to 

BR-121, "BRAKE

PAD : Inspection"

.

8.

Install tires. Refer to 

WT-7, "Exploded View"

.

BRAKE PAD : Inspection

INFOID:0000000006589825

INSPECTION AFTER REMOVAL

• Replace the shims and the shim covers if rust is excessively attached.

PFIA0763J

JSFIA0484ZZ

JPFIA0027ZZ

JPFIA0832ZZ

BR-122

< REMOVAL AND INSTALLATION >

[RHD]

FRONT DISC BRAKE

• Eliminate rust on the pad retainers and the torque member. Replace them if rust is excessively attached.

INSPECTION AFTER INSTALLATION

1.

Check a drag of rear disc brake. If any drag is found, follow the procedure described below.

2.

Remove brake pads. Refer to 

BR-128, "BRAKE PAD : Removal and Installation"

.

3.

Press the pistons. Refer to 

BR-128, "BRAKE PAD : Removal and Installation"

.

4.

Install brake pads. Refer to 

BR-128, "BRAKE PAD : Removal and Installation"

.

5.

Securely depress the brake pedal several times.

6.

Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body and replace if
necessary. Refer to 

BR-132, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly"

7.

Burnish contact surfaces brake pads and disc rotor after refinishing or replacing brake pads, or if a soft
pedal occurs at very low mileage. Refer to 

BR-86, "BRAKE PAD : Inspection and Adjustment"

.

BRAKE CALIPER ASSEMBLY

BRAKE CALIPER ASSEMBLY : Exploded View

INFOID:0000000006589826

REMOVAL

DISASSEMBLY

1.

Brake caliper assembly

: N·m (kg-m, ft-lb)

JPFIA0834GB

FRONT DISC BRAKE

BR-123

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BRAKE CALIPER ASSEMBLY : Removal and Installation

INFOID:0000000006589827

REMOVAL

WARNING:

Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.

CAUTION:

• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it

out immediately and wash with water if it gets on a protect surface. For brake component parts,
never wash them with water.

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

fluid may splash.

• Never drop removed parts.
• If the brake fluid or grease adheres to the disc rotor, quickly wipe it off.

1.

Remove tires.

2.

Fix the disc rotor using wheel nuts.

3.

Drain brake fluid. Refer to 

BR-80, "Draining"

.

4.

Separate brake hose from caliper assembly. Refer to 

BR-95, "FRONT : Removal and Installation"

.

1.

Cap

2.

Bleeder valve

3.

Cylinder body

4.

Piston seal

5.

Piston

6.

Piston boot

7.

Sliding pin

8.

Sliding pin boot

9.

Bushing

10.

Torque member

: Apply rubber grease.

: Apply brake fluid.

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPFIA0511GB

BR-124

< REMOVAL AND INSTALLATION >

[RHD]

FRONT DISC BRAKE

5.

Remove torque member mounting bolts, and remove brake cali-
per assembly.

CAUTION:

Never drop brake pad and caliper assembly.

6.

When removing 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"

.

INSTALLATION

WARNING:

Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.

CAUTION:

• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it

out immediately and wash with water if it gets on a protect surface. For brake component parts,
never wash them with water.

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

fluid may splash.

• If the brake fluid or grease adheres to the disc rotor, quickly wipe it off.

1.

Install 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"

.

2.

Install the brake caliper assembly to the steering knuckle 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. Refer to 

BR-95, "FRONT : Removal and

Installation"

.

4.

Perform the air bleeding. Refer to 

BR-81, "Bleeding Brake Sys-

tem"

.

5.

Check a drag of front disc brake. If any drag is found, refer to

BR-126, "BRAKE CALIPER ASSEMBLY : Inspection"

.

6.

Install tires. Refer to 

WT-7, "Exploded View"

.

7.

Perform inspection after installation. Refer to 

BR-126, "BRAKE CALIPER ASSEMBLY : Inspection"

.

BRAKE CALIPER ASSEMBLY : Disassembly and Assembly

INFOID:0000000006589828

DISASSEMBLY

NOTE:
Never remove the torque member, brake pad and pad retainers when disassembling and assembling the cyl-
inder body.

1.

Remove the sliding pin bolt, and remove the cylinder body from the torque member. Refer to 

BR-120,

"BRAKE PAD : Removal and Installation"

.

CAUTION:

Fix the brake pad at suitable tape so that the brake pad will not drop.

2.

Remove sliding pins and sliding pin boots from torque member.

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FRONT DISC BRAKE

BR-125

< REMOVAL AND INSTALLATION >

[RHD]

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3.

Remove bushing (1) from sliding pin (2).

4.

Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots.

CAUTION:

Never get fingers caught in the pistons.

5.

Remove piston seal from cylinder body using seal pick tool.

CAUTION:

Be careful not to damage a cylinder inner wall.

6.

Remove bleeder valve and cap.

7.

Perform inspection after disassembly. Refer to 

BR-126, "BRAKE

CALIPER ASSEMBLY : Inspection"

.

ASSEMBLY

1.

Install bleeder valve and cap.

2.

Apply rubber grease to piston seals (1), and install them to cylin-
der body.

CAUTION:

Never reuse piston seals.

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