Nissan Juke Service and Repair Manual : Brake piping
Front : Exploded View
WITHOUT ESP
1. Brake booster
2. Master cylinder assembly
3. Brake tube
4. Connector bracket
5. Connector
6. ABS actuator and electric unit (control
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.
WITH ESP
MR16DDT
1. Brake booster
2. Master cylinder assembly
3. Brake tube
4. Connector bracket
5. Connector
6. ABS actuator and electric unit (control
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.
HR16DE
1. Brake booster
2. Master cylinder assembly
3. Brake tube
4. Connector bracket
5. Connector
6. ABS actuator and electric unit (control
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.
K9K
1. Brake booster
2. Master cylinder assembly
3. Brake tube
4. Connector bracket
5. Connector
6. ABS actuator and electric unit (control
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.
Front : Hydraulic Piping
2WD
1. Brake booster
2. Master cylinder assembly
3. Front disc brake
4. ABS actuator and electric unit (control
unit)
5. Connector
6. Rear disc brake
A. Brake tube
B. Brake hose
: Flare nut
: Union bolt
4WD
1. Brake booster
2. Master cylinder assembly
3. Front disc brake
4. ABS actuator and electric unit (control
unit)
5. Connector
6. Rear disc brake
A. Brake tube
B. Brake hose
: Flare nut
: Union bolt
Front : Removal and Installation
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 hose or brake tube. If this is not complied with, brake fluid may splash.
1. Remove tires.
2. Drain brake fluid. Refer to BR-80, "Draining".
3. Loosen the flare nut (1) with a flare nut wrench (A) and separate the brake tube (2) from the brake hose (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 disconnecting to prevent entrance of dirt.
4. Remove the union bolt (1) and copper washers (2), and remove the brake hose (3) from the brake caliper assembly.
5. Remove the lock plate (4) and remove the brake hose.
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. 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.
CAUTION:
Never reuse the copper washe
r.
2. Align the brake hose pin (A) with the brake caliper assembly projection (B), and tighten the union bolt (1) to the specified torqu
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-81, "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-97, "FRONT : Inspection".
Front : Inspection
INSPECTION AFTER INSTALLATION
1. Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interference 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 : Exploded View
2WD (MR16DDT, HR16DE)
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.
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.
4WD
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.
Rear : Hydraulic Piping
2WD
1. Brake booster
2. Master cylinder assembly
3. Front disc brake
4. ABS actuator and electric unit (control
unit)
5. Connector
6. Rear disc brake
A. Brake tube
B. Brake hose
: Flare nut
: Union bolt
4WD
1. Brake booster
2. Master cylinder assembly
3. Front disc brake
4. ABS actuator and electric unit (control
unit)
5. Connector
6. Rear disc brake
A. Brake tube
B. Brake hose
: Flare nut
: Union bolt
Rear : Removal and Installation
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-80, "Draining".
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 disconnecting 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 disconnecting 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-80, "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 disconnecting 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 disconnecting 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.
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-81, "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-105, "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.
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-81, "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-105, "REAR : Inspection".
Rear : Inspection
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
:
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 pedal
Exploded View
WITHOUT 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)
WITH ESP
...
Brake master cylinder
Exploded View
2WD
1. Reservoir cap
2. Oil strainer
3. Reservoir tank
4. Cylinder body
5. O-ring
6. Grommet
7. Pin
: Apply polyglycol ether
lubricant
: Apply brake fluid.
: N·m (kg-m ...
Other materials:
How to select piston and bearing
Description
• The identification grade stamped on each part is the grade for the
dimension measured in new condition. This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the
grade by comparing the
measurement with the values o ...
Symptom diagnosis
SYSTEM SYMPTOM
Symptom Table
The diagnostics item numbers show the sequence for inspection. Inspect in
order from item 1.
...
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
NOTE:
• Before removing and installing any control units, first turn the ignition
switch to the LOCK position, 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 CONS ...