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F BRAKES
SECTION BR
BRAKE SYSTEM
A
B
C
D
CONTENTS
E
PRECAUTIONS ......................................................... |
3 |
Precautions for Supplemental Restraint System |
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(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- |
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SIONER” ................................................................. |
3 |
Precautions for Brake System ................................. |
3 |
PREPARATION .......................................................... |
4 |
Commercial Service Tools ....................................... |
4 |
NOISE, VIBRATION AND HARSHNESS (NVH) |
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TROUBLESHOOTING ............................................... |
5 |
NVH Troubleshooting Chart .................................... |
5 |
BRAKE PEDAL ......................................................... |
6 |
Inspection and Adjustment ...................................... |
6 |
ADJUSTMENT ..................................................... |
7 |
Removal and Installation ......................................... |
7 |
COMPONENTS ................................................... |
7 |
REMOVAL ............................................................ |
8 |
INSPECTION AFTER REMOVAL ........................ |
8 |
INSTALLATION .................................................... |
8 |
BRAKE FLUID ........................................................... |
9 |
On-Board Inspection ............................................... |
9 |
CHECKING BRAKE FLUID LEVEL ..................... |
9 |
Drain and Refill ........................................................ |
9 |
Bleeding Brake System ......................................... |
10 |
BRAKE PIPING AND HOSE .................................... |
11 |
Hydraulic Circuit ..................................................... |
11 |
Removal and Installation of Front Brake Piping and |
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Hose ...................................................................... |
12 |
REMOVAL .......................................................... |
12 |
INSTALLATION .................................................. |
12 |
Removal and Installation of Rear Brake Piping and |
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Hose ...................................................................... |
12 |
REMOVAL .......................................................... |
12 |
INSTALLATION .................................................. |
12 |
Inspection after Installation ................................... |
13 |
BRAKE MASTER CYLINDER ................................. |
14 |
On-Board Inspection ............................................. |
14 |
LEAK INSPECTION ........................................... |
14 |
Removal and Installation ....................................... |
14 |
REMOVAL .......................................................... |
14 |
INSTALLATION .................................................. |
14 |
Disassembly and Assembly ................................... |
15 |
COMPONENTS .................................................. |
15 |
MODEL WITHOUT VDC ..................................... |
15 |
MODEL WITH VDC ............................................ |
17 |
BRAKE BOOSTER .................................................. |
21 |
On-Board Inspection and Service .......................... |
21 |
OPERATION CHECK ......................................... |
21 |
AIR TIGHT CHECK ............................................ |
21 |
Removal and Installation ....................................... |
22 |
COMPONENTS .................................................. |
22 |
REMOVAL .......................................................... |
22 |
INSPECTION AFTER REMOVAL ...................... |
22 |
INSTALLATION .................................................. |
23 |
VACUUM LINES ...................................................... |
24 |
Components .......................................................... |
24 |
Removal and Installation ....................................... |
24 |
Inspection .............................................................. |
24 |
VISUAL INSPECTION ........................................ |
24 |
CHECK VALVE INSPECTION ............................ |
24 |
FRONT DISC BRAKE .............................................. |
25 |
On-Board Inspection .............................................. |
25 |
PAD WEAR INSPECTION .................................. |
25 |
Components .......................................................... |
25 |
Removal and Installation of Brake Pad ................. |
26 |
REMOVAL .......................................................... |
26 |
INSTALLATION .................................................. |
26 |
RemovalandInstallationofBrakeCaliperAssembly |
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... 26 |
REMOVAL .......................................................... |
26 |
INSTALLATION .................................................. |
27 |
Disassembly and Assembly of Brake Caliper |
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Assembly ............................................................... |
27 |
DISASSEMBLY .................................................. |
27 |
INSPECTION AFTER DISASSEMBLY ............... |
28 |
ASSEMBLY ........................................................ |
29 |
DISC ROTOR INSPECTION .............................. |
30 |
BRAKE BURNISHING PROCEDURE ................ |
30 |
REAR DISC BRAKE ................................................ |
31 |
On-Board Inspection .............................................. |
31 |
BR
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Revision: 2006 July |
BR-1 |
2006 X-Trail |
PAD WEAR INSPECTION .................................. |
31 |
Components .......................................................... |
31 |
Removal and Installation of Brake Pad .................. |
32 |
REMOVAL .......................................................... |
32 |
INSTALLATION ................................................... |
32 |
RemovalandInstallationofBrakeCaliperAssembly |
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... 32 |
REMOVAL .......................................................... |
32 |
INSTALLATION ................................................... |
33 |
Disassembly and Assembly of Brake Caliper |
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Assembly ............................................................... |
33 |
DISASSEMBLY ................................................... |
33 |
INSPECTION AFTER DISASSEMBLY ............... |
34 |
ASSEMBLY ......................................................... |
34 |
DISC ROTOR INSPECTION .............................. |
35 |
BRAKE BURNISHING PROCEDURE ................ |
36 |
SERVICE DATA AND SPECIFICATIONS (SDS) .....37 |
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General Specifications ........................................... |
37 |
Brake Pedal ........................................................... |
37 |
Brake Booster ........................................................ |
37 |
Check Valve ........................................................... |
37 |
Front Disc Brake .................................................... |
37 |
Rear Disc Brake ..................................................... |
38 |
Revision: 2006 July |
BR-2 |
2006 X-Trail |
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PRECAUTIONS |
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PRECAUTIONS |
PFP:00001 |
A |
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Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT |
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BELT PRE-TENSIONER” |
AFS002KF |
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The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B |
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with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain |
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types of collision. Information necessary to service the system safely is included in the SRS and SB section of |
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this Service Manual. |
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WARNING: |
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●To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
●Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Brake System |
AFS002KG |
D
E
BR
● Clean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air. ● Recommended fluid is brake fluid “DOT 3”.
● Do not reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.
● Use clean brake fluid, to clean or wash all parts of master cylinder and disc brake caliper,etc.
● Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
● Use flare nut torque wrench when removing and installing brake tube.
● When installing brake piping, be sure to check torque.
● Before working, turn ignition switch OFF and disconnect electrical connectors of ABS actuator and electric unit (control unit), VDC/TCS/ABS control unit or battery cable at negative terminal.
● Burnish the brake contact surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-30, "BRAKE BURNISHING PROCE-
DURE" (front disc brake), BR-36, "BRAKE BURNISHING PRO- |
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CEDURE" (rear disc brake). |
SBR686C |
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WARNING:
Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.
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Revision: 2006 July |
BR-3 |
2006 X-Trail |
PREPARATION
PREPARATION
Commercial Service Tools
PFP:00002
AFS002KI
Tool name |
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Description |
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1.Flare nut crowfoot |
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Removing and installing each brake |
a:10 mm (0.39 in) / 12 mm (0.47 in) |
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piping |
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2.Torque wrench |
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NT360 |
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Power tool |
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Removing front and rear caliper |
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assembly, tires |
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PBIC0190E |
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Pin punch |
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Removing and installing reservoir |
Tip diameter:4 mm (0.16in)dia |
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tank pin |
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ZZA0515D |
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Revision: 2006 July |
BR-4 |
2006 X-Trail |
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING |
PFP:00003 |
NVH Troubleshooting Chart |
AFS002PD |
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
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RSU section |
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Reference page |
BR,25-BR-31 |
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BR,25-BR-31 |
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BR,25-BR-31 |
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BR,30-BR-35 |
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BR,30-BR-35 |
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sectionPR |
sectionRFD |
andRAXFAX,FSU, |
sectionWT |
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sectionWT |
sectionRAX |
sectionPS |
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NVH in |
NHV in |
NVH in |
NVH in |
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NVH in |
NVH in |
NVH in |
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Possible cause and |
damaged-Pads |
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uneven-Padswear |
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damagedShims |
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imbalanceRotor |
damageRotor |
runoutRotor |
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deformationRotor |
deflectionRotor |
rustRotor |
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thicknessRotorvariation |
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roundofoutDrum |
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PROPELLERSHAFT |
DIFFERENTIAL |
SUSPENSIONANDAXLE |
TIRES |
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WHEELROAD |
SHAFTDRIVE |
STEERING |
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SUSPECTED PARTS |
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Noise |
× |
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× |
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× |
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× |
× |
× |
× |
× |
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× |
× |
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Symptom |
BRAKE |
Shake |
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× |
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× |
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× |
× |
× |
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× |
× |
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Shimmy, Judder |
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× |
× |
× |
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× × |
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× |
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× |
× |
× |
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× |
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× : Applicable |
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A
B
C
D
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Revision: 2006 July |
BR-5 |
2006 X-Trail |
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BRAKE PEDAL |
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BRAKE PEDAL |
PFP:46501 |
Inspection and Adjustment |
AFS002KK |
Play and clearance inspection between brake pedal and floor panel with pedal depressed.
●Check brake pedal play.
●Check brake pedal height from dash lower panel.
●Adjust height referring to the following specifications.
SFIA2380E
H |
Brake pedal height (from dash lower panel top surface) |
M/T model |
156 − |
166 mm ( 6.14 − |
6.54 in) |
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A/T model |
164 − |
174 mm ( 6.46 − |
6.85 in) |
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Brake pedal depressed height |
M/T model |
80 mm ( 3.15 in) or more |
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[under a force of 490 N (50 kg, 110 lb) with engine running] |
A/T model |
85 mm ( 3.35 in) or more |
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C |
Clearance between stopper rubber and threaded end of the stop lamp switch |
0.74 − |
1.96 mm ( 0.0291 − 0.0772 in) |
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and ASCD cancel switch |
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A |
Pedal play |
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3 − 11 mm ( 0.12 − 0.43 in) |
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Revision: 2006 July |
BR-6 |
2006 X-Trail |
BRAKE PEDAL
ADJUSTMENT
1.Loosen stop lamp switch and ASCD cancel switch by turning it counterclockwise by 45° .
2.Loosen lock nut (A) on the input rod to rotate input rod for adjusting brake pedal height to the specified one, and tighten lock nut
(A).
Refer to brake pedal height BR-6, "Inspection and Adjustment" , specified torque BR-22, "COMPONENTS" .
CAUTION:
Make sure the threaded end of input rod stays inside clevis.
3.With the pedal pulled and held by hand, press stop lamp switch and ASCD cancel switch until its threaded end contacts stopper rubber.
4.With the threaded end of the stop lamp switch and ASCD cancel switch contacting the bracket, rotate the switch clockwise by 45° to secure.
CAUTION:
Make sure that the clearance (C) between bracket and end of stop lamp switch and ASCD cancel switch is within the standard. Refer to BR-6, "Inspection and Adjustment" .
5.Check pedal play.
CAUTION: |
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Make sure that stop lamps goes off when pedal is released. |
SFIA2489E |
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6.Start engine to check brake pedal depression height when depressed. Refer to BR-6, "Inspection and Adjustment" .
A
B
C
D
E
BR
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Removal and Installation |
AFS002P8 |
COMPONENTS
SFIA2381E
1. |
Snap pin |
2. |
Stop lamp switch |
3. |
ASCD cancel switch |
4. |
Clip |
5. |
Clevis pin |
6. |
Brake pedal assembly |
7.Stopper rubber
NOTE:
Clevis pin can be installed from both left and right.
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Revision: 2006 July |
BR-7 |
2006 X-Trail |
BRAKE PEDAL
REMOVAL
1.Remove instrument driver lower panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
2.Remove steering column assembly from steering member. Refer to PS-12, "STEERING COLUMN" .
3.Remove stop lamp switch and ASCD cancel switch from brake pedal assembly.
4.Remove snap pin and clevis pin from clevis of brake booster.
5.Remove brake pedal assembly mounting nuts. Pull brake booster toward engine room to the extent that does not deform brake tube.
6.Remove brake booster clevis from input rod.
7.Remove mounting bolt and then remove brake pedal assembly from vehicle.
INSPECTION AFTER REMOVAL
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Check brake pedal upper rivet for deformation.
Make sure that joint length (L) of sub-bracket and sliding plate is 4 mm (0.16 in) or more.
●Check brake pedal for bend, damage, and cracks on the welded parts.
●Replace brake pedal assembly if any non-standard condition is detected.
SFIA2487E
●Check clevis pin and plastic stopper for damage and deformation. Replace clevis pin if there are.
SBR997
INSTALLATION
Install in the reverse order of the removal. Tightening torques for brake pedal assembly mounting nuts and bolt are referred to BR-7, "COMPONENTS" . Tightening torque for lock nut (A) is referred to BR-22, "COMPONENTS" .
●Adjust brake pedal height after installing brake pedal assembly to vehicle. Refer to BR-6, "Inspection and Adjustment" .
Revision: 2006 July |
BR-8 |
2006 X-Trail |
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BRAKE FLUID |
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BRAKE FLUID |
PFP:KN100 |
On-Board Inspection |
AFS002KM |
CHECKING BRAKE FLUID LEVEL |
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●Make sure that a brake fluid level in reservoir tank is within the standard (between MAX and MIN lines).
●Visually check around reservoir tank for fluid leakage.
●If the level is excessively low, check brake system for leakage.
●Release parking brake lever and see if brake warning lamp goes off. If not, check brake system for fluid leakage.
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SFIA0066J |
Drain and Refill |
AFS002KN |
CAUTION:
●Refill with new brake fluid “DOT 3”.
●Do not reuse drained brake fluid.
●Do not let brake fluid splash on painted surfaces of body. This might damage paint, so when
splashing it on the surfaces, immediately wipe off them and wash it away with water.
●Before servicing, disconnect electrical connectors of ABS actuator and electric unit (control unit), VDC/TCS/ABS control unit or battery cable at negative terminal.
1.Connect a vinyl tube to bleed valve.
2.Depress brake pedal, loosen bleed valve, and gradually remove brake fluid.
BRA0007D
3.Clean inside of reservoir tank, and refill with new brake fluid.
4.Loosen bleed valve, depress brake pedal slowly to full stroke and then release it. Repeat the procedure every 2 or 3 seconds until the new brake fluid comes out, then close the bleed valve while depressing the pedal. Repeat the same work for each wheel.
5.Bleed air. Refer to BR-10, "Bleeding Brake System" .
SFIA2433E
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Revision: 2006 July |
BR-9 |
2006 X-Trail |
BRAKE FLUID
Bleeding Brake System |
AFS002KO |
CAUTION:
●While bleeding, pay attention to master cylinder fluid level.
●Turn ignition switch OFF and disconnect electrical connectors of ABS actuator and electric unit (control unit), VDC/TCS/ABS control unit or battery cable at negative terminal before working.
1.Connect a vinyl tube to rear right brake caliper bleed valve.
2.Fully depress brake pedal 4 or 5 times.
3.With brake pedal depressed, loosen bleed valve to bleed air in brake line, and then tighten it immediately.
4.Repeat steps 2 and 3 until all of the air is out of the brake line.
5.Tighten the bleed valve to the specified torque. Refer to front disc brake: BR-25, "Components" , rear disc brake: BR-31, "Components" .
6.From step 1 to 5, with master cylinder reservoir tank filled at least half way, bleed air from brake hydraulic
line bleed valves in the following order:
Rear right brake→ Front left brake→ Rear left brake→ Front right brake
Revision: 2006 July |
BR-10 |
2006 X-Trail |
BRAKE PIPING AND HOSE
BRAKE PIPING AND HOSE
Hydraulic Circuit
PFP:46210
A
AFS002KP
B
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BR
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SFIA2382E
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SFIA2383E
CAUTION:
●All brake hoses and tubes must be free from excessive bending, twisting and pulling.
●Make sure that there is no interference with other parts when turning steering both clockwise and counterclockwise.
●Brake tubes and hoses are important safety parts. Always disassemble the parts and retighten their fittings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is detected.
●Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted surfaces of body, immediately wipe off them and wash it away with water immediately.
●Cover the open end of brake pipes and hoses when disconnecting to prevent entrance of dirt.
●Refill with new brake fluid “DOT 3”.
●Do not reuse drained brake fluid.
Revision: 2006 July |
BR-11 |
2006 X-Trail |
BRAKE PIPING AND HOSE
Removal and Installation of Front Brake Piping and Hose
REMOVAL
1.Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2.Disconnect brake hose from brake tube, using a flare nut wrench.
3.Remove union bolt, and then remove brake hose from brake caliper assembly.
4.Remove lock plate, and then disconnect brake hose from vehicle.
INSTALLATION
1.Install brake hose by aligning with the projections on brake caliper assembly, and tighten union bolt to the specified torque. Refer to BR-11, "Hydraulic Circuit" .
CAUTION:
Do not reuse copper washer.
2.Connect brake hose to brake tube. Temporarily tighten flare nut by hand as much as possible. Secure them to bracket with lock plate.
3.Tighten flare nut to the specified torque using a flare nut torque wrench. Refer to BR-11, "Hydraulic Circuit" .
4.Refill with new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
5.Check it after the installation. Refer to BR-13, "Inspection after Installation" .
Removal and Installation of Rear Brake Piping and Hose
REMOVAL
1.Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2.Using a flare nut wrench, disconnect brake hose from brake tube.
3.Remove union bolt, and then remove brake hose from brake caliper assembly.
4.Remove lock plate, and then disconnect brake hose from vehicle.
INSTALLATION
1.Attach L-shape metal fitting of the brake hose to brake caliper assembly positioning hole, and then tighten union bolt to the specified torque. Refer to BR-11, "Hydraulic Circuit" .
CAUTION:
Do not reuse the copper washer.
2.Install brake tube to brake hose after securing brake hose to vehicle using lock plate. Tighten flare nut to the specified torque after temporarily tightening them by hand using a flare nut torque wrench. Refer to BR-11, "Hydraulic Circuit" .
3.Refill with new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
4.Check it after the installation. Refer to BR-13, "Inspection after Installation" .
AFS002KQ
SFIA2229E
SFIA2431E
AFS002KR
SFIA2228E
SFIA2049E
Revision: 2006 July |
BR-12 |
2006 X-Trail |
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