NISSAN 350Z 2007 Z33 Brake System Workshop Manual

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
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M
SECTION BR
A
B
BR
Revision: 2006 November2007 350Z
BRAKE SYSTEM
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Battery Service ................................ 3
Precautions for Procedures without Cowl Top Cover ..... 3
Precautions for Brake System .................................. 3
PREPARATION ........................................................... 5
Commercial Service Tools ........................................ 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
BRAKE PEDAL .......................................................... 7
Inspection and Adjustment ....................................... 7
PLAY AND CLEARANCE BETWEEN THE
BRAKE PEDAL AND FLOOR PANEL WITH
PEDAL DEPRESSED ........................................... 7
ADJUSTMENT ...................................................... 7
Components ............................................................. 8
Removal and Installation .......................................... 8
REMOVAL ............................................................. 8
INSPECTION AFTER REMOVAL ......................... 8
INSTALLATION ..................................................... 9
BRAKE FLUID .......................................................... 10
On-Vehicle Inspection ............................................ 10
LEVEL CHECK ................................................... 10
Drain and Refill ....................................................... 10
Bleeding Brake System ........................................... 11
BRAKE TUBE AND HOSE ....................................... 12
Hydraulic Circuit ..................................................... 12
Removal and Installation of the Front Brake Tube
and Brake Hose (Other than Brembo Calipers) ..... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Removal and Installation of the Front Brake Tube
and Brake Hose (With Brembo Calipers) ............... 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
Removal and Installation of the Rear Brake Tube
and Brake Hose (Other than Brembo Calipers) ..... 13REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
Removal and Installation of the Rear Brake Tube
and Brake Hose (With Brembo Calipers) ............... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Inspection after Installation ..................................... 14
BRAKE MASTER CYLINDER .................................. 15
On-Vehicle Inspection ............................................. 15
LEAK INSPECTION ............................................ 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
Components ........................................................... 16
Disassembly and Assembly .................................... 16
MODELS WITHOUT VDC ................................... 16
MODELS WITH VDC .......................................... 19
BRAKE BOOSTER ................................................... 23
On-Vehicle Inspection ............................................. 23
OPERATING CHECK .......................................... 23
AIRTIGHT CHECK .............................................. 23
Components ........................................................... 23
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
VACUUM LINES ....................................................... 25
Components ........................................................... 25
Removal and Installation ........................................ 25
Inspection ............................................................... 25
VISUAL INSPECTION ......................................... 25
CHECK VALVE INSPECTION ............................. 25
FRONT DISC BRAKE ............................................... 26
On-Vehicle Inspection ............................................. 26
PAD WEAR INSPECTION ................................... 26
Components ........................................................... 27
OTHER THAN BREMBO CALIPERS .................. 27
WITH BREMBO CALIPERS ................................ 28
Removal and Installation of Brake Pad (Other than
Brembo Calipers) .................................................... 29

BR-2Revision: 2006 November2007 350Z REMOVAL ........................................................... 29
INSTALLATION .................................................... 29
Removal and Installation of Brake Pad (With
Brembo Calipers) .................................................... 30
REMOVAL ........................................................... 30
HOW TO APPLY GREASE TO THE BRAKE PAD ... 30
INSTALLATION .................................................... 30
Removal and Installation of Brake Caliper Assembly
(Other than Brembo Calipers) ................................ 31
REMOVAL ........................................................... 31
INSTALLATION .................................................... 31
Removal and Installation of Brake Caliper Assembly
(With Brembo Calipers) .......................................... 32
REMOVAL ........................................................... 32
INSTALLATION .................................................... 32
Disassembly and Assembly of Brake Caliper
Assembly (Other than Brembo Calipers) ................ 33
DISASSEMBLY ................................................... 33
INSPECTION AFTER DISASSEMBLY ................ 34
ASSEMBLY ......................................................... 34
DISC ROTOR INSPECTION ............................... 35
Disassembly and Assembly of Brake Caliper
Assembly (With Brembo Calipers) .......................... 36
DISASSEMBLY ................................................... 36
CALIPER INSPECTION ...................................... 36
ASSEMBLY ......................................................... 36
DISC ROTOR INSPECTION ............................... 37
Brake Burnishing Procedure ................................... 38
REAR DISC BRAKE ................................................. 39
On-Vehicle Inspection ............................................. 39
PAD WEAR INSPECTION ................................... 39
Components ........................................................... 40
OTHER THAN BREMBO CALIPERS .................. 40
WITH BREMBO CALIPERS ................................ 41
Removal and Installation of Brake Pad (Other than Brembo Calipers) .................................................... 42
REMOVAL ............................................................ 42
INSTALLATION .................................................... 42
Removal and Installation of Brake Pad (With
Brembo Calipers) .................................................... 42
REMOVAL ............................................................ 42
HOW TO APPLY GREASE TO THE BRAKE PAD ... 43
INSTALLATION .................................................... 43
Removal and Installation of Brake Caliper Assembly
(Other than Brembo Calipers) ................................. 44
REMOVAL ............................................................ 44
INSTALLATION .................................................... 44
Removal and Installation of Brake Caliper Assembly
(With Brembo Calipers) ........................................... 45
REMOVAL ............................................................ 45
INSTALLATION .................................................... 45
Disassembly and Assembly of Brake Caliper
Assembly (Other than Brembo Calipers) ................ 45
DISASSEMBLY .................................................... 45
CALIPER INSPECTION ....................................... 46
ASSEMBLY .......................................................... 47
DISC ROTOR INSPECTION ............................... 48
Disassembly and Assembly of Brake Caliper
Assembly (With Brembo Calipers) .......................... 49
DISASSEMBLY .................................................... 49
CALIPER INSPECTION ....................................... 49
ASSEMBLY .......................................................... 49
DISC ROTOR INSPECTION ............................... 50
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 52
General Specifications ............................................ 52
Brake Pedal ............................................................ 52
Brake Booster ......................................................... 52
Check Valve ............................................................ 52
Front Disc Brake ..................................................... 52
Rear Disc Brake ...................................................... 53

PRECAUTIONS
BR-3
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K
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MA
B
BR
Revision: 2006 November2007 350Z
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
NFS00001
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:

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 per-
sonal 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 Battery ServiceNFS00002
Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Precautions for Procedures without Cowl Top CoverNFS000HT
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
Precautions for Brake SystemNFS00003

Recommended fluid is brake fluid “DOT 3”. Refer to MA-11, "Fluids and Lubricants" .

Do not reuse drained brake fluid.

Do not let brake fluid come in contact with painted surfaces on the body. This might damage the paint, so
if it does come in contact, immediately wipe area and wash off with water.

To clean or wash all parts of master cylinder and disc brake caliper, use clean brake fluid.

Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
PIIB3706J

BR-4
PRECAUTIONS
Revision: 2006 November2007 350Z

Use flare nut crowfoot and torque wrench when removing and
installing brake tube.

When installing brake piping, be sure to check torque.

Before working, turn the ignition switch OFF and disconnect the
connectors of ABS actuator and control unit or the battery nega-
tive terminal.

Burnish the brake contact surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal
occurs at very low mileage.
Refer to BR-38, "
Brake Burnishing Procedure" .
WARNING:
Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.SBR686C

PREPARATION
BR-5
C
D
E
G
H
I
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K
L
MA
B
BR
Revision: 2006 November2007 350Z
PREPARATIONPFP:00002
Commercial Service ToolsNFS00004
Tool nameDescription
1. Flare nut crowfoot
a:10 mm (0.39 in)/12mm(0.47 in)
2. Torque wrenchInstalling each brake piping
Power toolLoosening bolts and nuts
Pin punch
Tip diameter: 4 mm (0.16 in) dia Removing and installing reservoir tank
pin
S-NT360
PBIC0190E
ZZA0515D

BR-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: 2006 November2007 350Z
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartNFS00005
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
BR-29
, BR-31
, BR-42
, BR-45
BR-26
, BR-39
BR-27
, BR-40—
—
BR-35
, BR-37
, BR-48
, BR-50
—
—
—
BR-35
, BR-37
, BR-48
, BR-50
—
NVH in PR section
NHV in RFD section
NVH in FAX, RAX and FSU, RSU section
NVH in WT section
NVH in WT section
NVH in RAX section
NVH in PS section
Possible cause and
SUSPECTED PARTS
Pads - damaged
Pads - uneven wear
Shims damaged
Rotor imbalance
Rotor damage
Rotor runout
Rotor deformation
Rotor deflection
Rotor rust
Rotor thickness variation
Drum out of round
PROPELLER SHAFT
DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
STEERING
Symptom BRAKENoise××× ×× ×××
××
Shake× × ×××
××
Shimmy, Judder×××××××× ××× ×

BRAKE PEDAL
BR-7
C
D
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K
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MA
B
BR
Revision: 2006 November2007 350Z
BRAKE PEDALPFP:46501
Inspection and AdjustmentNFS00006
PLAY AND CLEARANCE BETWEEN THE BRAKE PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED
1. Check the brake pedal free height from the dash lower panel (1).
2. Adjust the height referring to the following specifications.
ADJUSTMENT
1. Loosen the stop lamp switch and ASCD cancel switch by rotat-
ing it counterclockwise by 45°.
2. Loosen the lock nut (A) on the input rod, then rotate the input
rod to set the pedal to the specified height, and tighten the lock
nut (A) to the specified torque. Refer to BR-23, "
Components" .
CAUTION:
Check that the threaded end of the input rod stays inside
the clevis.
3. With the pedal pulled and held by hand, press the stop lamp
switch and ASCD cancel switch until its threaded end contacts
the stopper rubber.
4. With the threaded end of the stop lamp switch contacting the
stopper rubber and ASCD cancel switch, rotate the switch clock-
wise by 45° to secure.
CAUTION:
Make sure that the clearance “C” between the stopper rub-
ber and threaded end of the stop lamp switch and ASCD
cancel switch is within the standard.
5. Check the pedal play.
CAUTION:
Make sure that the stop lamps go off when the pedal is
released.
6. Start the engine to check the brake pedal's depressed height.Brake pedal height “H
1 ” (from dash lower panel top sur-
face)
M/T models : 153.2 – 163.2 mm (6.03 – 6.43 in)
A/T models : 161.5 – 171.5 mm (6.36 – 6.75 in)
Depressed pedal height “H
2 ” [under a force of 490 N (50
kg, 110 lb) with the engine running]
M/T models : More than 90 mm (3.54 in)
A/T models : More than 95 mm (3.74 in)
Clearance “C ” between threaded end of the stop lamp
switch/ASCD cancel switch (2) and stopper rubber (3).
: 0.74 – 1.96 mm (0.0291 – 0.0772 in)
Pedal play “A” : 3 – 11 mm (0.12 – 0.43 in)
PFIA0877E
PFIA0819E

BR-8
BRAKE PEDAL
Revision: 2006 November2007 350Z
ComponentsNFS000IF
Removal and InstallationNFS00007
REMOVAL
1. Remove instrument driver lower panel. Refer to IP-10,
"INSTRUMENT PANEL ASSEMBLY" .
2. Remove the steering column. Refer to PS-10, "
STEERING
COLUMN" .
3. Remove the stop lamp switch and ASCD cancel switch from the
pedal assembly.
4. Remove the snap pin and clevis pin from the brake booster cle-
vis.
5. Remove the mounting nuts and bolt from the bracket, and
remove the pedal assembly from the vehicle.
INSPECTION AFTER REMOVAL

Check that the rivets in the upper part of the brake pedal are not
deformed.

Make sure the sub bracket and the slide plate are at least 5.0 –
6.0 mm (0.197 – 0.236 in) apart.
1. Clevis pin 2. Snap pin 3. Stop lamp switch
4. Clip 5. Stopper rubber 6. Pedal pad
7. Brake pedal assembly 8. ASCD cancel switch
SFIA1868E
SFIA0159E
PFIA0223E

BRAKE PEDAL
BR-9
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B
BR
Revision: 2006 November2007 350Z

Check the brake pedal for bend, damage, and cracks on the
welded parts. Replace the applicable part if a failure is detected.

Check the clevis pin and resin stopper for damage and deforma-
tion. If a failure is detected, replace the clevis pin.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.

After installing the brake pedal assembly to the vehicle, adjust the brake pedal.
SBR997

BR-10
BRAKE FLUID
Revision: 2006 November2007 350Z
BRAKE FLUIDPFP:KN100
On-Vehicle InspectionNFS00008
LEVEL CHECK

Check that the fluid level in the reservoir tank is within the stan-
dard (between MAX and MIN lines).

Visually check around the reservoir tank for fluid leaks.

If fluid level is excessively low, check brake system for leaks.

If warning lamp remains illuminated after parking lever is
released, check brake system for fluid leakage.
Drain and RefillNFS00009
CAUTION:

Refill with new brake fluid “DOT3”.

Do not reuse drained brake fluid.

Do not let brake fluid come in contact with painted surfaces on the body. This might damage the
paint, so if it does come in contact, immediately wipe area and wash off with water.
1. Connect a vinyl tube to bleed valve.
2. Depress the brake pedal, loosen the bleed valve, and gradually
remove the brake fluid.
3. Before working, turn the ignition switch OFF and disconnect the
connectors of ABS actuator and control unit or battery negative
terminal.
4. Make sure there is no foreign material in the reservoir tank, and
refill with new brake fluid.
5. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
pedal until it stops. Tighten bleed valve. Release brake pedal.
Repeat this process a few times, then pause to add new brake
fluid to master cylinder. Continue until new brake fluid flows out.
Bleed Air. Refer to BR-11, "
Bleeding Brake System" .
SBR451D
BRA0007D
BRA0006D