NISSAN TEANA 2003 Service Manual

BRAKE TUBE AND HOSE
BR-13
C
D
E
G
H
I
J
K
L
MA
B
BR

Inspection After InstallationBFS000BO
CAUTION:
If leakage occurs around brake tube and hose connections, retighten or, if damaged part is detected,
replace the damage part.
1. Check brake hoses, brake tubes, and connections for fluid leakage, damage, twists, deformation, contact
with other parts, and loose connections.
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately
5 seconds, check for fluid leak each part.

BR-14
BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDERPFP:46010
On-Board InspectionBFS000BP
LEAK INSPECTION

Check for leaking in a master cylinder installation surface, a reservoir tank installation surface, and brake
tube connections.
Removal and InstallationBFS000BQ
CAUTION:
Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe it off and them wash it away with water imme-
diately.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Remove brake fluid level switch harness connector.
3. Using a flare nut wrench, remove brake tubes from master cylinder assembly.
4. Remove master cylinder mounting nuts, remove master cylinder assembly from vehicle.
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT 3 or DOT 4”.

Do not reuse drained brake fluid.
1. Install in the reverse order of removal and tighten nuts to the specified torque. Refer to BR-22, "
COMPO-
NENTS" .
Models with VDC

Apply silicon grease in inner kit to O-ring and it's surrounding
areas and to booster side inner wall.
CAUTION:

Do not damage the sliding surface of primary piston rod
and do not allow foreign materials on it's surface.

Do not reuse the O-ring.
2. Install brake tube to master cylinder assembly and temporarily
tighten flare nut by hand.
3. Tighten brake tube flare nut to the specified torque using a flare
nut torque wrench. Refer to BR-11, "
Hydraulic Circuit" .
4. Install brake fluid level switch harness connector.
5. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
SFIA1302E

BRAKE MASTER CYLINDER
BR-15
C
D
E
G
H
I
J
K
L
MA
B
BR

Disassembly and AssemblyBFS000BR
COMPONENTS
1. Reservoir tank 2. Reservoir cap 3. Oil strainer
(Models with VDC)
4. Pin 5. Cylinder body 6. Piston stopper
(Models with VDC)
7. Grommet 8. Secondary piston assembly 9. Primary piston assembly
10. O-ring 11. Snap ring 12. Guide assembly
13. Plate 14. Stopper cap
Refer to GI-10, "
Components" and the followings for the symbols in the figure.
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
: Apply brake fluid.
PFIA0822E

BR-16
BRAKE MASTER CYLINDER

MODELS WITHOUT VDC
CAUTION:
Remove reservoir tank only when absolutely necessary.
Disassembly (Piston Assembly)
1. Using a flat-bladed screwdriver as shown in the figure, lift up
tabs on stopper cap and remove it from master cylinder.
NOTE:
Remove stopper cap while holding it because primary piston
assembly in master cylinder may pop out.
2. Carefully pull primary piston assembly straight out to prevent
cylinder inner wall from being damaged.
3. Tap flange using a soft block, such as wood, and carefully pull
secondary piston assembly straight out to prevent cylinder body
inner wall from being damaged.
Inspection After Disassembly (Piston Assembly)
Cylinder body

Check a inner wall of cylinder for damage, abrasions, corrosion, and pinholes. Replace cylinder body if
detected.
Assembly (Piston Assembly)
CAUTION:

Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.

Make sure there is no foreign matter such as dirt or dust attached to inner cylinder walls, piston,
or cap seal, and use care to avoid damaging parts with the assembly tools.

Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid to cylinder inner wall, piston cups and contact
surfaces between piston assemblies. Then insert secondary pis-
ton assembly and primary piston assembly into cylinder body in
this order.
CAUTION:

Do not reuse primary and secondary piston assemblies.

Be sure to replace piston assemblies without disassem-
bling new inner kit.

Pay attention to the orientation of piston cup, and insert
straight to prevent cup seal from being caught by cylin-
der inner wall.
BRA0031D
BRA0033D
SFIA2051E

BRAKE MASTER CYLINDER
BR-17
C
D
E
G
H
I
J
K
L
MA
B
BR

2. Holding down piston with stopper cap, push stopper cap tabs so
they are firmly into cylinder grooves, then install stopper cap.
CAUTION:
Do not reuse stopper cap.
Disassembly (Reservoir Tank)
1. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting master cylinder assembly with vise, be sure
not to over-tighten.

When setting with vise use copper plates or cloth to pro-
tect the flange.
2. Using a pin punch [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)], remove mounting pins on reservoir tank.
3. Remove master cylinder assembly from vise.
4. Remove reservoir tank and grommet from cylinder body.
Assembly (Reservoir Tank)
1. Apply brake fluid to grommet, and then install it into cylinder body after installing grommet to reservoir
tank.
CAUTION:
Do not reuse reservoir tank and grommet.
2. Secure master cylinder assembly into vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting master cylinder assembly in vise, be sure
not to over-tighten.

When setting in vise use copper plates or cloth to protect
the flange.
BRA0035D
PFIA0505J
SFIA2052E
PFIA0505J

BR-18
BRAKE MASTER CYLINDER

3. Using a pin punch, [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)] insert reservoir tank mounting pin into the
pin hole so that the attachment side and the opposite side are
identical.
CAUTION:

Be sure to insert pin from the chamfered pinhole of cylin-
der body.

Do not reuse mounting pin.
MODELS WITH VDC
Disassembly
CAUTION:

Cover primary piston rod using cloths during disassembly to prevent damage to it.
1. Secure master cylinder assembly into vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting master cylinder assembly in vise, be sure
not to overtighten.

When setting with vise use copper plates or cloth to pro-
tect the flange.
2. Using a pin punch [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)], remove mounting pin on reservoir tank.
3. Remove master cylinder assembly from vise.
4. Remove reservoir tank and grommet from cylinder body.
5. Push in primary piston assembly, and then remove piston stop-
per pin from cylinder body secondary-side tank boss hole.
CAUTION:
Be careful not to damage an inner wall of cylinder body.
SFIA2052E
PFIA0505J
SFIA2052E
BRA0560D

BRAKE MASTER CYLINDER
BR-19
C
D
E
G
H
I
J
K
L
MA
B
BR

6. Remove snap ring while pressing in primary piston assembly
into prevent piston from popping out.
7. Hold primary piston rod, and then pull primary piston assembly,
plate, and guide assembly straight out.
8. Remove plate and guide assembly from primary piston assem-
bly.
CAUTION:
When removing plate from primary piston rod, make sure
inside of plate dose not damage rod.
9. Tap flange using a soft block, such as wood, and carefully pull
secondary piston assembly straight out to prevent a cylinder
body inner wall from being damaged.
Inspection After Disassembly
Cylinder body

Check a inner wall of cylinder for damage, abrasions, corrosion, and pinholes. Replace cylinder body if
detected.
Assembly
CAUTION:

Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.

Make sure there is no foreign matter such as dirt or dust attached to inner cylinder wall, piston, or
piston cup seal, and use care to avoid damaging parts with assembly tools.

Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid to cylinder inner wall, piston cup seal and con-
tact surfaces between piston assembly. Then insert secondary
piston assembly and primary piston assembly into cylinder body
in this order.
CAUTION:

Do not reuse primary and secondary piston assemblies.

Be sure to replace piston assemblies without disassem-
bling new inner kit.

Pay attention to the orientation of piston cup, and insert
straight to prevent piston cup seal from being caught by
cylinder inner wall.
2. Visually inspect secondary piston assembly slit through piston
stopper mounting hole and then install piston stopper while
pushing in primary piston assembly.
BRA0561D
BRA0033D
PFIA0263E
BRA0560D

BR-20
BRAKE MASTER CYLINDER

3. Insert plate and guide assembly into cylinder body as shown.
CAUTION:

Make sure not to damage primary piston rod.

Pay attention to the orientation of guide assembly.

Do not drop O-ring.

Make sure guide assembly and plate are not inserted at
angle.
4. Cover primary piston assembly rod with cloths to prevent dam-
age to it, and then install snap ring when pressing in primary pis-
ton assembly.
CAUTION:

Make sure that snap ring is securely engaged in cylinder
body inner diameter groove.

Do not reuse snap ring.
5. Apply brake fluid to a grommet, and then install it into cylinder body after installing grommet to reservoir
tank.
CAUTION:
Do not reuse reservoir tank and grommet.
6. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting master cylinder assembly with vise, be sure
not to over-tighten.

When setting in a vise use copper plates or cloth to pro-
tect the flange.
7. Using a pin punch, [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)] insert reservoir tank mounting pin into the
pin hole so that the attachment side and the opposite side are
identical.
CAUTION:

Be sure to insert pin from the chamfered pinhole of cylin-
der body.

Do not reuse mounting pin.
SFIA2054E
BRA0561D
PFIA0505J
SFIA2052E

BRAKE BOOSTER
BR-21
C
D
E
G
H
I
J
K
L
MA
B
BR

BRAKE BOOSTERPFP:47200
On-Board Inspection and ServiceBFS000BS
OPERATION CHECK
With engine stopped, change the vacuum to the atmospheric pres-
sure by depressing brake pedal several times. Then with brake
pedal fully depressed, start engine and when the vacuum pressure
reaches the standard, make sure that clearance between brake
pedal and floor panel decreases.
CAUTION:
Depressing pedal interval is approximately 5 seconds.
AIR TIGHT CHECK

Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change the vacuum to the atmospheric pressure. Make sure
distance between brake pedal and floor panel gradually
increases.

Depress brake pedal while engine is running, and stop engine
with brake pedal is depressed. Brake pedal stroke should not
change after holding brake pedal down for 30 seconds.
CAUTION:
Depressing brake pedal interval is approximately at intervals 5
seconds.
BRA0037D
SBR365AA

BR-22
BRAKE BOOSTER

Removal and InstallationBFS000BT
COMPONENTS
CAUTION:

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 it off and them wash it away with water
immediately.

Be careful not to deform or bend brake tube while removing and installing brake booster.

Replace clevis pin if it is damaged.

Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, dash panel may damage the threads.

Install check valve in the correct direction.
REMOVAL
1. Remove vacuum hose from brake booster. Refer to BR-24, "VACUUM LINES" .
2. Remove brake master cylinder. Refer to BR-14, "
Removal and Installation" .
3. Remove snap pin and clevis pin from brake pedal.
4. Remove nuts on brake booster and brake pedal assembly.
5. Remove brake booster from dash panel in engine room side.
1. Reservoir tank 2. Master cylinder 3. Brake booster
4. Gasket 5. Lock nut
SFIA2633E
SFIA2044E