lock NISSAN 350Z 2007 Z33 Brake System Workshop Manual

BRAKE PEDAL
BR-7
C
D
E
G
H
I
J
K
L
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-12
BRAKE TUBE AND HOSE
Revision: 2006 November2007 350Z
BRAKE TUBE AND HOSEPFP:46300
Hydraulic CircuitNFS0000B
CAUTION:

Make sure it does not twist or break when being attached.

Make sure there is no interference with other parts when turning steering both clockwise and
counterclockwise.

The brake tube is an important safety part. If a brake fluid leak is detected, always disassemble the
parts. Replace applicable part with a new one, if necessary.

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.

Do not bend or twist brake hose sharply, or strongly pull it.

When removing components, cover connections so that no dirt, dust, or other foreign matter gets
in.

Refill with new brake fluid “ DOT 3 ”.

Do not reuse drained brake fluid.
Removal and Installation of the Front Brake Tube and Brake Hose (Other than
Brembo Calipers)
NFS0000C
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 bolt and remove the brake hose from the caliper assembly.
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.
NOTE:
When removed bracket attaching the bolt is tightened with provi-
sions torque.
2. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolts to the specified torque.
SFIA1869E
: 19.6 – 23.5 N·m (2.0 – 2.3 kg-m, 15 – 17 ft-lb)
: 10.8 – 15.6 N·m (1.1 – 1.5 kg-m, 8 – 11 ft-lb)
PFIA0230E

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
E
G
H
I
J
K
L
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

BR-20
BRAKE MASTER CYLINDER
Revision: 2006 November2007 350Z
5. Push in the primary piston and remove the piston stopper from
the cylinder body secondary-side tank boss hole.
6. Remove the snap ring while pushing the primary piston in to pre-
vent the piston from popping out.
7. Holding the primary piston rod, pull the primary piston assembly,
the plate, and the guide straight out.
8. Remove the plate and guide from the primary piston.
CAUTION:
When removing the plate from the primary piston rod, make
sure the inside of the plate does not damage the rod.
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.
Inspection after Disassembly
Master cylinder

Check that there is no damage, friction, rusting, or pinholes on the cylinder inner wall, and replace if there
are any non-standard conditions.
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 the inner cylinder walls, the
piston, or the 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 body and contact surface
of the piston assembly, and apply the silicon grease in the inner
kit to the primary piston rod.
2. Insert the secondary piston and primary piston into cylinder
body in this order.
CAUTION:

Do not reuse the primary and secondary piston assem-
blies.

Be sure to replace the assembly without disassembling
the new inner kit.
BRA0560D
BRA0561D
BRA0033D
PFIA0263E

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

FRONT DISC BRAKE
BR-33
C
D
E
G
H
I
J
K
L
MA
B
BR
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

BR-46
REAR DISC BRAKE
Revision: 2006 November2007 350Z
3. As shown in the figure, using a flat-bladed screwdriver, remove
the retaining ring from the cylinder body.
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 piston.
5. Using a flat-bladed screwdriver, remove piston seals from cylin-
der body.
CAUTION:
Be careful not to damage cylinder inner wall.
CALIPER INSPECTION
Cylinder Body
CAUTION:

Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.

Check inner wall of cylinder for corrosion, wear, and damage. If any non-standard condition is
detected, replace cylinder body.

Minor flaws caused by corrosion or a foreign material can be removed by polishing the surface
with a fine sandpaper. Replace the cylinder body, if necessary.
To r q u e M e m b e r
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
CAUTION:
Since the piston surface is plated, do not repair using sandpaper.
Check piston surface for corrosion, wear, and damage. If any non-standard condition is detected, replace
applicable part.
Sliding Pin Bolts and Sliding Pin Boots
Check that there is no wear, damage, or cracks in the sliding pin bolts and sliding pin boots, and if there are,
replace them.
SBR028A
BRD0041D
SFIA0999E