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Nissan Juke (2012 year). Service Repair Manual - part 22

BRAKE PIPING

BR-29

< REMOVAL AND INSTALLATION >

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.

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

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.

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

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.

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

CAUTION:

Never reuse the copper washer.

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.

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BR-30

< REMOVAL AND INSTALLATION >

BRAKE PIPING

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.

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

CAUTION:

Never scratch the flare nut and the brake tube.

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.

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

CAUTION:

Never scratch the flare nut and the brake tube.

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

BR-11, "Bleeding Brake System"

CAUTION:

Never reuse drained brake fluid.

Install tires. Refer to

WT-43, "Removal and Installation"

Perform inspection after installation. Refer to

BR-32, "REAR :

Inspection"

AWD

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.

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BRAKE PIPING

BR-31

< REMOVAL AND INSTALLATION >

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

CAUTION:

Never reuse the copper washer.

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.

CAUTION:

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

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

CAUTION:

Never scratch the flare nut and the brake tube.

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.

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BR-32

< REMOVAL AND INSTALLATION >

BRAKE PIPING

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

CAUTION:

Never scratch the flare nut and the brake tube.

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

BR-11, "Bleeding Brake System"

CAUTION:

Never reuse drained brake fluid.

Install tires. Refer to

WT-43, "Removal and Installation"

Perform inspection after installation. Refer to

BR-32, "REAR :

Inspection"

REAR : Inspection

INFOID:0000000007579956

INSPECTION AFTER INSTALLATION

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

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.

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BRAKE MASTER CYLINDER

BR-33

< REMOVAL AND INSTALLATION >

BRAKE MASTER CYLINDER

Exploded View

INFOID:0000000007579957

Removal and Installation

INFOID:0000000007579958

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.

Perform inspection before removal. Refer to

BR-36, "Inspection"

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

Drain brake fluid. Refer to

BR-10, "Draining"

Disconnect the brake fluid level switch harness connector.

Remove air duct and air cleaner case. Refer to

EM-25, "Removal and Installation"

Reservoir cap

Oil strainer

Reservoir tank

Cylinder body

O-ring

Grommet

: Apply polyglycol ether based lubricant.

: Apply brake fluid.

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

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BR-34

< REMOVAL AND INSTALLATION >

BRAKE MASTER CYLINDER

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

CAUTION:

Never scratch the flare nut and the brake tube.

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.

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.

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BRAKE MASTER CYLINDER

BR-35

< REMOVAL AND INSTALLATION >

• Temporarily tighten the brake tube flare nut to the master cylinder

assembly by hand. Then tighten it to the specified torque with a
crowfoot and torque wrench (A). Refer to

BR-21, "FRONT :

Exploded View"

• Perform the air bleeding. Refer to

BR-11, "Bleeding Brake System"

• Perform inspection after installation. Refer to

BR-36, "Inspection"

Disassembly and Assembly

INFOID:0000000007579959

DISASSEMBLY

CAUTION:

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

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.

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

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.

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

CAUTION:

Never reuse the grommets.

Install the reservoir tank to the cylinder body.

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.

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BR-36

< REMOVAL AND INSTALLATION >

BRAKE MASTER CYLINDER

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:0000000007579960

INSPECTION BEFORE REMOVAL

Check the brake fluid level switch. Refer to

BRC-97, "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-24, "FRONT : Inspection"

CAUTION:

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

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BRAKE BOOSTER

BR-37

< REMOVAL AND INSTALLATION >

BRAKE BOOSTER

Exploded View

INFOID:0000000007579961

Removal and installation

INFOID:0000000007579962

REMOVAL

Perform inspection before removal. Refer to

BR-38, "Inspection and Adjustment"

Remove cowl top and cowl top extension. Refer to

EXT-20, "Removal and Installation"

Remove air duct and air cleaner case. Refer to

EM-25, "Removal and Installation"

Remove brake master cylinder assembly. Refer to

BR-33, "Removal and Installation"

Remove vacuum hose from brake booster. Refer to

BR-40, "Removal and Installation"

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

BR-18,

"Exploded View"

Remove nuts on brake booster and brake pedal assembly.

CAUTION:

Hold the brake booster so as to avoid dropping out.

Remove brake booster and spacer.

CAUTION:

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

Remove spacer from brake booster.

10. Perform inspection after removal. Refer to

BR-38, "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.
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installation, the

dash panel may damage the threads.

Master cylinder assembly

Brake booster

Lock nut

Clevis

Gasket

Spacer

: N·m (kg-m, ft-lb)

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BR-38

< REMOVAL AND INSTALLATION >

BRAKE BOOSTER

• Never deform or bend the brake tubes when installing the brake booster.
• Always use a gasket between the brake booster and the spacer.
• Replace the clevis pin if it is damaged. Refer to

BR-19, "Inspection and Adjustment"

• Perform the air bleeding. Refer to

BR-11, "Bleeding Brake System"

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

BR-7,

"Inspection and Adjustment"

Inspection and Adjustment

INFOID:0000000007579963

INSPECTION BEFORE REMOVAL

Air Tight

CAUTION:

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

Check the air tight use a handy vacuum pump.

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

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

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

BR-33,

"Removal and Installation"

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

INSPECTION AFTER REMOVAL

Input Rod Length Inspection

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

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

Run the engine at idle for 1 minute to apply vacuum to the brake booster, and stop the engine.

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.

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

At vacuum of

−

66.7 kPa (

−

500 mmHg,

−

19.69 inHg)

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

: Refer to

BR-58, "Brake Booster"

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BRAKE BOOSTER

BR-39

< REMOVAL AND INSTALLATION >

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

BR-7, "Inspection and

Adjustment"

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BR-40

< REMOVAL AND INSTALLATION >

VACUUM LINES

VACUUM LINES

Exploded View

INFOID:0000000007579964

Removal and Installation

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REMOVAL

Remove air duct and air cleaner case. Refer to

EM-25, "Removal and Installation"

Remove the vacuum hose and vacuum piping.

Perform inspection after removal. Refer to

BR-40, "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 A (engine 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-

40, "Exploded View"

Inspection

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INSPECTION AFTER REMOVAL

Appearance

Check for correct assembly, damage and deterioration.

Check Valve Airtightness

Clamp

Vacuum hose A

Vacuum piping

Vacuum hose B

To engine side

Paint mark

To brake booster

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: 24 mm (0.95 in) or more

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VACUUM LINES

BR-41

< REMOVAL AND INSTALLATION >

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

• Replace vacuum hose if vacuum hose is malfunctioning.

When connected to the booster side (B):

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

−

66.7

kPa (

−

500 mmHg,

−

19.70 inHg).

When connected to the engine side (C):

Vacuum should not exist.

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BR-42

< REMOVAL AND INSTALLATION >

FRONT DISC BRAKE

FRONT DISC BRAKE

BRAKE PAD

BRAKE PAD : Exploded View

INFOID:0000000007579967

BRAKE PAD : Removal and Installation

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REMOVAL

WARNING:

Since dust covering the front brake has an affect on human body, the dust must be removed with a
dust collector. Never splatter the dust with an air blow gun.

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.

Remove tires with power tool.

Remove lower sliding pin bolt.

Cylinder body

Inner shim

Inner pad (with pad wear sensor)

Pad retainer

Torque member

Outer pad

Outer shim

Outer shim cover

1: Apply MOLYKOTE

AS880N or silicone-based grease.

2: Apply MOLYKOTE

7439 or equivalent.

: N·m (kg-m, ft-lb)

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FRONT DISC BRAKE

BR-43

< REMOVAL AND INSTALLATION >

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

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.

Perform inspection after removal. Refer to

BR-44, "BRAKE PAD

: Inspection"

INSTALLATION

WARNING:

Since dust covering the front brake has an affect on human body, the dust must be removed with a
dust collector. Never splatter the dust with an air blow gun.

CAUTION:

• 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.

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.

Apply MOLYKOTE

AS880N or silicone-based grease to the

mating faces (A) between the inner pad and the inner shim, and
install the inner shims to the inner pad.

CAUTION:

Always replace the shim together when replacing the brake
pad.

Apply MOLYKOTE

7439 or equivalent to the mating faces (B)

between the inner pad and the pad retainers.

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BR-44

< REMOVAL AND INSTALLATION >

FRONT DISC BRAKE

Apply MOLYKOTE

AS880N or silicone-based grease to the

mating faces (A) between the outer shim cover and the outer
shim, and install the outer shim and outer shim cover to the
outer pad.

CAUTION:

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

Apply MOLYKOTE

7439 or equivalent to the mating faces (B)

between the outer pad and the pad retainers.

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.

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.

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

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

BR-44, "BRAKE PAD

: Inspection"

10. Install tires. Refer to

WT-43, "Removal and Installation"

BRAKE PAD : Inspection

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INSPECTION AFTER REMOVAL

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

INSPECTION AFTER INSTALLATION

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

Remove brake pads. Refer to

BR-42, "BRAKE PAD : Removal and Installation"

Press the pistons. Refer to

BR-42, "BRAKE PAD : Removal and Installation"

Install brake pads. Refer to

BR-42, "BRAKE PAD : Removal and Installation"

Securely depress the brake pedal several times.

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

BR-47, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly"

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