ECU NISSAN 350Z 2007 Z33 Brake System Workshop Manual

BRAKE PEDAL
BR-7
C
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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

BRAKE TUBE AND HOSE
BR-13
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: 2006 November2007 350Z
CAUTION:
Do not reuse the copper washer.
3. Attach the brake hose to the brake tube, partially tighten the flare nut as far as possible by hand, then
secure it to the bracket with the lock plate.
4. Using a flare nut crowfoot and torque wrench, tighten the flare nut to the specified torque.
5. Refill brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" .
Removal and Installation of the Front Brake Tube and Brake Hose (With Brembo
Calipers)
NFS0000D
REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Using a flare nut wrench, remove the brake tube from the brake hose.
3. Using a flare nut wrench, remove the caliper-side brake tube from the brake hose.
4. Remove the lock plate and nut, and remove the brake hose from the vehicle.
INSTALLATION
1. Attach the brake hose to the vehicle and tighten the nut to the
specified torque.
2. Attach the caliper-side brake tube to the brake hose, partially
tighten the flare nut as far as possible by hand, then tighten it to
the specified torque with flare nut crowfoot and torque wrench.
3. Attach the brake hose to the brake tube, partially tighten the flare nut as far as possible by hand, then
secure to the bracket with the lock plate.
4. Using a flare nut crowfoot and torque wrench, tighten the flare nut to the specified torque with flare nut
torque.
5. Refill brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" .
Removal and Installation of the Rear Brake Tube and Brake Hose (Other than
Brembo Calipers)
NFS0000E
REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolts, and then remove brake hose from the caliper assembly.
4. Remove the lock plate and then remove the brake hose from the vehicle.: 16.7 – 19.6 N·m (1.7 – 1.9 kg-m, 13 – 14 ft-lb)
: 14.8 – 17.6 N·m (1.5 – 1.7 kg-m, 11 – 12 ft-lb)
Nut: 19.6 – 23.5 N·m (2.0 – 2.3 kg-m, 15 – 17 ft-lb)
Bolt: 10.8 – 15.6 N·m (1.1 – 1.5 kg-m, 8 – 11 ft-lb)
: 14.8 – 17.6 N·m (1.5 – 1.7 kg-m, 11 – 12 ft-lb)
: 14.8 – 17.6 N·m (1.5 – 1.7 kg-m, 11 – 12 ft-lb)
PFIA0229E

BR-14
BRAKE TUBE AND HOSE
Revision: 2006 November2007 350Z
INSTALLATION
1. Attach the brake hose L-pin to the caliper assembly positioning
hole and tighten the union bolt to the specified torque.
CAUTION:
Do not reuse the copper washer.
2. After securing the brake hose to the vehicle with the lock plate,
partially tighten the brake tube flare nut as far as possible by
hand and then tighten to the specified torque with flare nut crow-
foot and torque wrench.
3. Refill brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" .
Removal and Installation of the Rear Brake Tube and Brake Hose (With Brembo
Calipers)
NFS0000F
REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Using a flare nut wrench, remove the brake tube from the brake hose.
3. Using a flare nut wrench, remove the caliper-side brake tube from the brake hose.
4. Remove the lock plate and bolt, and remove the brake hose from the vehicle.
INSTALLATION
1. Attach the brake hose to the vehicle and tighten the bolt to the
specified torque.
2. Attach the caliper-side brake tube to brake hose, partially tighten
the flare nut as far as possible by hand, then tighten it to the
specified torque with flare nut crowfoot and torque wrench.
3. Attach the brake hose to the brake tube, partially tighten the
flare nut as far as possible by hand, then secure to the bracket
with the lock plate.
4. Using a flare nut crowfoot and torque wrench, tighten the flare nut to the specified torque.
5. Refill brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" .
Inspection after InstallationNFS0000G
CAUTION:
If a leak is detected at the connections, retighten it or, if necessary, replace the damaged part.
1. Check hose, tube, and connections for fluid leaks, damage, twist, deformation, contact with other parts,
and loose connections.
2. While depressing pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately 5
seconds, check for fluid leakage from each part.: 16.7 – 19.6 N·m (1.7 – 1.9 kg-m, 13 – 14 ft-lb)
: 14.8 – 17.6 N·m (1.5 – 1.7 kg-m, 11 – 12 ft-lb)
PFIA0293J
: 19.6 – 22.5 N·m (2.0 – 2.2 kg-m, 15 – 16 ft-lb)
: 14.8 – 17.6 N·m (1.5 – 1.7kg-m, 11 – 12 ft-lb)
: 14.8 – 17.6 N·m (1.5 – 1.7 kg-m, 11 – 12 ft-lb)
PFIA0234E

BRAKE MASTER CYLINDER
BR-17
C
D
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H
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MA
B
BR
Revision: 2006 November2007 350Z
2. Attach the attachment in the inner kit to the reservoir cap as
shown in the figure.
CAUTION:
When attaching the attachment to the reservoir cap, make
sure it is pointing in the right direction.
3. Place the side of the cylinder body with chamfering around the
pin insertion hole facing up, and secure the master cylinder
assembly with a vise.
CAUTION:

Tighten without letting the pin securing the reservoir tank
and cylinder body come in contact with the pin insertion
hole of the reservoir tank.

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

When securing in a vise, use copper plates or cloth to
protect the flange.
4. Using a pin punch [commercial service tool: diameter approx. 4
mm (0.16 in)], remove mounting pin on the reservoir tank.
5. Remove master cylinder assembly from the vise.
6. Remove reservoir tank and grommet from cylinder body.
7. Using a Phillips flat-bladed screwdriver, push in the primary pis-
ton and remove the piston stopper from the cylinder body sec-
ondary-side tank boss hole.
8. Carefully pull the primary piston assembly straight out to prevent
cylinder inner wall from being damaged.
9. Tap flange using a soft block such as wood, and carefully pull
the secondary piston assembly straight out to prevent cylinder
inner wall from being damaged.
PFIA0262E
SFIA0699E
SFIA0250E
BRA0519D
BRA0033D

BRAKE MASTER CYLINDER
BR-19
C
D
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B
BR
Revision: 2006 November2007 350Z
NOTE:
Attach the reservoir tank in the orientation shown in the figure.
8. Using a pin punch [commercial service tool: diameter Approx. 4
mm (0.16 in)], attach the reservoir tank mounting pin so that the
attachment side and the opposite side are identical.
CAUTION:
Do not reuse reservoir tank and mounting pin.
MODELS WITH VDC
Disassembly
CAUTION:

While working, cover the primary piston rod with cloth to prevent it from being damaged.

Only remove the reservoir tank when absolutely necessary.
1. Place the side of the cylinder body with chamfering around the
pin insertion hole up, and secure the cylinder body flange sec-
tion with a vise as shown in the figure.
CAUTION:
When securing in a vise, use copper plates or cloth to pro-
tect the flange.
2. Using a pin punch [commercial service tool: diameter Approx 4
mm (0.16 in)], remove the reservoir tank mounting pin.
3. Remove master cylinder assembly from the vise.
4. Remove reservoir tank and grommet from cylinder body.
BRA0568D
SFIA0250E
BRA0558D
BRA0559D

BRAKE MASTER CYLINDER
BR-21
C
D
E
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H
I
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B
BR
Revision: 2006 November2007 350Z

Pay attention to the orientation of the piston cup, and insert straight to prevent the cup from
being caught by cylinder inner wall.
3. Perform a visually inspection of the secondary piston slit through
the tank boss hole on the secondary-side of the cylinder body,
and install the piston stopper.
4. Insert the plate and guide into the cylinder body.
CAUTION:

Make sure not to damage the primary piston rod.

Pay attention to the direction of the guide.

Do not drop the O-ring.

Make sure the guide and/or plate are not inserted at an
angle.
5. Cover the primary piston rod with cloth to prevent it getting dam-
aged, and attach the snap ring with the primary piston pushed
in.
CAUTION:

Make sure the area around the snap ring is snug in the
cylinder body bore groove.

Do not reuse the snap ring.
6. Place the side of the cylinder body with chamfering around the
pin insertion hole up, and secure the cylinder body flange sec-
tion with a vise.
CAUTION:
When securing in a vise, use copper plates or cloth to pro-
tect the flange.
7. Apply brake fluid to the grommet and attach the reservoir tank to
the master cylinder.
CAUTION:
Do not reuse the grommet.
BRA0560D
SFIA1729E
BRA0561D
BRA0558D

FRONT DISC BRAKE
BR-29
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: 2006 November2007 350Z

Burnish the brake pads and disc rotor mutually contacting surfaces after refinishing or replacing
rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-38, "
Brake
Burnishing Procedure" .
Removal and Installation of Brake Pad (Other than Brembo Calipers)NFS000AU
REMOVAL
1. Remove tires from vehicle with a power tool.
2. Remove lower sliding pin bolt.
3. Hang cylinder body with a wire, and remove pads, shims and
pad retainers from torque member.
CAUTION:

When removing pad retainer from torque member, lift pad
retainer in the direction shown by arrow (shown in the
figure) so as not to deform it.

Do not damage piston boot.

Keep disc rotor clean of brake fluid.
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based
grease between pad retainer and pad.
2. Install pad retainers and pad assemblies to torque member.
CAUTION:
Inner pad and outer pad have pad-return mechanism on
upper side of pad retainer. When installing pad to torque
member, be sure to install pad return lever to pad wear sen-
sor securely.
3. Install cylinder body to torque member.
CAUTION:
When replacing pads with new ones, press in piston until
pads can be installed. In this case, carefully monitor brake fluid level in reservoir tank because
brake fluid will return to master cylinder reservoir tank.
4. Install lower sliding pin bolt, and tighten it to the specified torque. Refer to BR-27, "
Components" .
5. Secure disc rotor with wheel nuts. Depress brake pedal a few times until it gets a responsive touch.
6. Check front disc brake for drag.
7. Install tires to vehicle.
SBR433D
SBR556E
SBR557E

FRONT DISC BRAKE
BR-31
C
D
E
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H
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MA
B
BR
Revision: 2006 November2007 350Z
2. Attach pad.
CAUTION:

Attach the pad with wear sensor to the outer side.

The side of the shim with the larger cutouts should be on
the entry side of the disc rotor spin.
3. Insert the upper pad pin from the inner cylinder side, then insert
firmly to the outer cylinder side through the hole in the top of the
pad.
4. As shown in the figure, place the top of the cross spring over the
top pad pin, press in the cross spring, push the lower pad pin
from the inner cylinder side to the outer cylinder side, and
secure the cross spring.
5. Insert the clip in the small hole at the end of the pad pin.
CAUTION:
If the clip is not fully attached, the pad pin or the pad could
fall out while the vehicle is in motion.
6. Install tires to vehicle.
Removal and Installation of Brake Caliper Assembly (Other than Brembo Cali-
pers)
NFS000AV
REMOVAL
1. Remove tires from vehicle with a power tool.
2. Fasten disc rotor using wheel nut.
3. Drain brake fluid gradually (from bleed valve while depressing brake pedal). Refer to BR-10, "
Drain and
Refill" .
4. Remove union bolt, and then remove brake hose from caliper
assembly.
5. Remove torque member mounting bolts (from torque member),
and remove caliper assembly (from vehicle with a power tool).
CAUTION:
Do not drop brake pad.
6. Remove disc rotor.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor,
if it is necessary to remove disc rotor.
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT 3”.

Do not reuse drained brake fluid.
1. Install disc rotor.
CAUTION:
Put alignment marks on disc rotor and wheel hub at the time of removal when reusing disc rotor.
2. Install caliper assembly to vehicle, and tighten torque member mounting bolts to the specified torque.
Refer to BR-27, "
Components" .
CAUTION:
Before installing torque member to vehicle, wipe oil and grease on washer seats on steering
knuckle and mounting surface of torque member.
PFIA0275E
PFIA0276E
SFIA0140E

BR-32
FRONT DISC BRAKE
Revision: 2006 November2007 350Z
3. Install a projection of brake hose metal fitting by aligning with protrusions on cylinder body, and tighten
union bolt to the specified torque. Refer to BR-27, "
Components" .
CAUTION:

Do not reuse copper washers for union bolts.

Assemble brake hose securely on caliper assembly.
4. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake
System" .
5. Install tires to vehicle.
Removal and Installation of Brake Caliper Assembly (With Brembo Calipers)NFS0000X
REMOVAL
1. Remove tires from vehicle with a power tool.
2. Drain brake fluid. Refer to BR-10, "
Drain and Refill" .
3. Remove the brake pad. Refer to BR-30, "
Removal and Installation of Brake Pad (With Brembo Calipers)" .
4. Remove the brake tube flare nut using a flare wrench.
5. Remove the brake tube bracket from the knuckle spindle.
6. Remove the caliper bolt and remove the caliper assembly from the vehicle.
7. Remove disc rotor.
CAUTION:
Put matching marks of wheel hub assembly and disc rotor, if it is necessary to remove when
removing disc rotor.
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT 3”.

Never reuse drained brake fluid.
1. Install disc rotor.
CAUTION:
Put alignment marks on disc rotor and wheel hub at the time of removal when reusing disc rotor.
2. Install caliper assembly to the vehicle, and tighten bolts to the specified torque.
CAUTION:
When attaching the caliper assembly to the vehicle, wipe
any oil off the knuckle spindle washers and caliper assem-
bly attachment surfaces.
3. Attach the brake tube to the caliper assembly and partially tighten the flare nut.
PFIA0226E
PFIA0226E

FRONT DISC BRAKE
BR-35
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: 2006 November2007 350Z
5. Install the torque member to the steering knuckle and tighten the
mounting bolts to the specified torque. Refer to BR-27, "
Compo-
nents" .
CAUTION:
Before installing torque member to vehicle, wipe off oil and
grease on the washer seats on steering knuckle and the
mounting surface of the torque member.
6. Install pad retainers to torque member.
7. Press in piston until pads can be installed, and then install cylin-
der body to torque member.
8. Install cylinder body, and tighten sliding pin bolt to the specified
torque. Refer to BR-27, "
Components" .
9. Position a projection of brake hose metal fitting by aligning with protrusions on cylinder body and tighten
union bolt to specified torque. Refer to BR-12, "
Hydraulic Circuit" .
CAUTION:

Assemble brake hose securely to cylinder body.

Do not reuse copper washer for union bolts.
10. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake
System" .
DISC ROTOR INSPECTION
Visual Inspection
Check surfaces of disc rotor for uneven wear, cracks, and serious damage. If a malfunction is detected,
replace applicable part.
Runout Inspection
1. Using wheel nuts, secure disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check runout.
NOTE:
Make sure that wheel bearing axial end play is with in the speci-
fication before measuring runout. Refer to FA X - 4 , "
On-Vehicle
Inspection" .
3. If runout is outside limit, find the minimum runout point by shift-
ing the mounting positions of disc rotor and wheel hub by one hole.
4. If runout is still outside the limit after performing the above operation, replace or lathe the disc rotor.
[When lathing, use the Pro–Cut PFM On–Car Brake Lathe (Tool No. 38–PFM90.5) or equivalent.]
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is out-
side standard, replace disc rotor.
SBR557E
Measurement point:
At a point 10.0 mm (0.394 in) from outer edge of disc
Runout limit (with it attached to the vehicle):
0.035 mm (0.0014 in) or less
SBR019B
Standard thickness : 28.0 mm (1.10 in)
Repair limit thickness : 26.0 mm (1.02 in)
Maximum uneven wear (measured at 8 positions)
: 0.015 mm (0,0006 in) or less
SBR020B