air bleeding NISSAN 350Z 2007 Z33 Brake System Workshop Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 2007, Model line: 350Z, Model: NISSAN 350Z 2007 Z33Pages: 54, PDF Size: 1.91 MB
Page 1 of 54
BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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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
Page 10 of 54
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
Page 11 of 54
BRAKE FLUID
BR-11
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Revision: 2006 November2007 350Z
Bleeding Brake SystemNFS0000A
CAUTION:
While bleeding, pay attention to master cylinder fluid level.
1. Before working, turn the ignition switch OFF and disconnect the connectors of ABS actuator and control
unit or battery negative terminal.
2. Connect a vinyl tube to the rear right bleed valve.
3. Fully depress brake pedal 4 to 5 times.
4. With the brake pedal depressed, loosen the bleed valve to let the air out, and then tighten it immediately.
5. Repeat steps 3, 4 until no more air comes out.
6. Tighten the bleed valve to the specified torque. Refer to BR-27, "
Components" (Front) and BR-40, "Com-
ponents" (Rear).
7. In steps 2 to 6 below, with the master cylinder reservoir tank filled at least half way, bleed air from the front
left, rear left, and front right tires, in that order.
Page 13 of 54
BRAKE TUBE AND HOSE
BR-13
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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
Page 14 of 54
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
Page 15 of 54
BRAKE MASTER CYLINDER
BR-15
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Revision: 2006 November2007 350Z
BRAKE MASTER CYLINDERPFP:46010
On-Vehicle InspectionNFS0000H
LEAK INSPECTION
Check for leaking in the master cylinder installation surface, the reservoir tank installation surface, and the
brake tube connections.
Removal and InstallationNFS0000I
CAUTION:
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.
REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Remove the fluid surface sensor harness connector.
3. Using a flare nut wrench, disconnect master cylinder assembly and brake tube.
4. Remove the master cylinder assembly nut and remove the master cylinder assembly from the vehicle.
Refer to BR-24, "
Removal and Installation" .
INSTALLATION
CAUTION:
Refill with new brake fluid “DOT3”.
Do not reuse drained brake fluid.
1. Attach the master cylinder assembly to the brake booster
assembly and tighten the nut to the specified torque. BR-23,
"Components" .
CAUTION:
Vehicles equipped with VDC require particular attention
when conducting the following installation.
Make sure the sliding surface of the primary piston rod is
not damaged, and that no foreign matter become
attached.
Do not reuse the O-ring on the rear end of the master cyl-
inder as it is a non-reusable part.
Apply the silicon grease in the inner kit to and around the O-ring at the rear end of the master
cylinder and to the inside of the booster.
2. Install brake tube to master cylinder assembly and temporarily tighten flare nuts by hand.
3. Tighten the brake tube flare nut to the specified torque with flare nut crowfoot and torque wrench. Refer to
BR-12, "
Hydraulic Circuit" .
4. Refill brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" .
PFIA0296E
Page 24 of 54
BR-24
BRAKE BOOSTER
Revision: 2006 November2007 350Z
Removal and InstallationNFS0000M
REMOVAL
CAUTION:
Be careful not to deform or bend brake piping while removing and installing the 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, the dash panel may damage the threads.
Attach the check valve in the correct orientation.
1. Remove vacuum hose from the brake booster. Refer to BR-25, "
VACUUM LINES" .
2. Remove the brake master cylinder. Refer to BR-24, "
Removal and Installation" .
3. Remove the brake piping between brake master cylinder and ABS actuator and electric unit (control unit).
Refer to BR-12, "
Hydraulic Circuit" .
CAUTION:
For M/T vehicles with remove the brake piping after removing the clutch reservoir tank bolt.
4. Remove the brake pedal attachment snap pin and clevis pin from inside the vehicle.
5. Remove the nuts on the brake booster and brake pedal assembly.
6. Remove brake booster assembly from the engine compartment side.
INSPECTION AFTER REMOVAL
Output Rod Length Inspection
1. Using a handy vacuum pump, apply a vacuum of −66.7 kPa (−
500 mmHg,−19.69 inHg) to the brake booster.
2. Check output rod length.
INSTALLATION
1. Loosen the lock nut to adjust the input rod length so that the
length “B” (in the figure on the right) satisfies the specified value.
2. After adjusting “B”, temporarily tighten the lock nut to install the
booster assembly to the vehicle. At this time, make sure to
install a gasket between the booster assembly and the vehicle.
3. Connect the brake pedal with the clevis of the input rod.
4. Install the pedal bracket mounting nuts and tighten them to the
specified torque.
5. Install the brake piping between brake master cylinder and ABS
actuator and electric unit (control unit). Refer to BR-12, "
Hydraulic Circuit" .
6. Install the master cylinder to the booster assembly. Refer to BR-24, "
Removal and Installation" .
7. Adjust the height and play of the brake pedal. Refer to BR-7, "
ADJUSTMENT" .
8. Tighten the lock nut of the input rod to the specified torque. Refer to BR-23, "
Components" .
9. Refill new brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" . Standard dimension when vacuum −66.7 kPa
(−500 mmHg, −19.69 inHg)
With TCS : 10.4 mm (0.409 in)
With VDC : −6.2 mm (−0.244 in)
SBR208E
Length “B” : 125 mm (4.92 in)
SGIA0060E
Page 32 of 54
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
Page 33 of 54
FRONT DISC BRAKE
BR-33
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Revision: 2006 November2007 350Z
4. Attach the brake tube bracket to the knuckle spindle and tighten
to the specified torque.
5. Using a flare nut crowfoot and torque wrench, tighten the caliper
assembly and brake tube connection flare nut to the specified
torque.
6. Attach brake pad. Refer to BR-30, "
Removal and Installation of
Brake Pad (With Brembo Calipers)" .
7. Refill new brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" .
8. Install tires to vehicle.
Disassembly and Assembly of Brake Caliper Assembly (Other than Brembo
Calipers)
NFS000AW
NOTE:
Do not remove torque member, brake pads, shims, shim covers and pad retainers, when disassembling or
assembling cylinder body.
DISASSEMBLY
1. Remove caliper assembly from vehicle. Refer to BR-31,
"Removal and Installation of Brake Caliper Assembly (Other
than Brembo Calipers)" .
2. Remove sliding pin bolts from cylinder body, and remove pads,
shims, shim cover and pad retainers from torque member.
CAUTION:
When removing pad retainer from torque member, lift the
pad retainer in the direction shown by arrow (shown in the
figure) so as not to deform it.
3. Remove sliding pins and sliding pin boots from torque member.
4. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Do not get fingers caught in the pistons.
5. Using a flat-bladed screwdriver, remove piston seals from cylin-
der body.
CAUTION:
Be careful not to damage the inner wall of cylinder.: 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)
PFIA0229E
SBR556E
BRB0032D
SFIA0141E
Page 35 of 54
FRONT DISC BRAKE
BR-35
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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