NISSAN TEANA 2003 Service Manual

BRAKE BOOSTER
BR-23
C
D
E
G
H
I
J
K
L
MA
B
BR

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 brake booster.
2. Check output rod length.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that the length “B”
(shown in the figure) satisfies the specified value.
2. Temporarily tighten lock nut after adjusting the length “B” to the
specified value, and then install brake booster on dash panel.
CAUTION:
Always install gasket between brake booster and dash-
board panel.
3. Install brake booster and brake pedal assembly nuts and bolt,
and then tighten to the specified torque. Refer to BR-7,
"Removal and Installation" .
4. Connect brake pedal with clevis of input rod.
5. Install brake master cylinder. Refer to BR-14, "
Removal and Installation" .
6. Install vacuum hose. Refer to BR-24, "
VACUUM LINES" .
7. Adjust brake pedal free height and the play of brake pedal. Refer to BR-6, "
Inspection and Adjustment" .
8. Tighten input rod lock nut to the specified torque. Refer to BR-22, "
COMPONENTS" .
9. Refill with new brake fluid and bleed air. Refer to BR-11, "
Hydraulic Circuit" . Standard dimension when applying vacuum of −66.7
kPa (−500 mmHg, −19.69 inHg) (Reference value)
Models without VDC : 10.4 mm (0.409 in)
Models with VDC : −6.2 mm (−0.244 in)
SBR208E
Length “B” : 125 mm (4.92 in)
SGIA0060E

BR-24
VACUUM LINES

VACUUM LINESPFP:41920
ComponentsBFS000BU
Removal and InstallationBFS000BV
CAUTION:

Because vacuum hose contains a check valve, it must be installed in the correct direction. Refer to
the stamp or label to confirm correct installation. Brake booster will not operate normally if hose is
installed in the wrong direction.

Insert vacuum hose at least 24 mm (0.94 in).

Do not use lubricating oil during assembly.
1. Clamp 2. Vacuum hose 3. Hose clamp
4. Vacuum tube 5. Vacuum hose (Build in check valve) 6. Engine side indicator stamp
A: To intake manifold
B: To brake booster
PFIA0823E
SBR225B

VACUUM LINES
BR-25
C
D
E
G
H
I
J
K
L
MA
B
BR

InspectionBFS000BW
VISUAL INSPECTION
Check for improper assembly, damage and deterioration.
CHECK VALVE INSPECTION
Airtightness Inspection
Use a handy vacuum pump to check.

Replace vacuum hose assembly if vacuum hose and check
valve are malfunctioning.When connected to booster side (1):
Vacuum decrease should decrease within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under a vac-
uum of −66.7 kPa (−500 mmHg, −19.69 inHg).
When connected to engine side (2):
No vacuum will be applied.
SFIA1306E

BR-26
FRONT DISC BRAKE

FRONT DISC BRAKEPFP:41000
On-Board InspectionBFS000BX
PAD WEAR INSPECTION

Check pad thickness from the inspection hole on cylinder body.
Check use a scale for inspection necessary.
ComponentsBFS000BY
WARNING:
Clean dust on caliper and brake pads with a vacuum dust collector to minimize the hazard of airborne
particles or other materials.
CAUTION:

While removing cylinder body, never depress brake pedal because piston will pop out. Standard thickness : 11.0 mm (0.433 in)
Repair limit thickness : 2.0 mm (0.079 in)
BRA0010D
1. Union bolt 2. Brake hose 3. Copper washer
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Inner shim cover 12. Inner shim
13. Pad wear sensor
(Only for inner pad RH)14. Inner pad 15. Pad retainer
16. Outer pad 17. Outer shim 18. Sliding pin
19. Sliding pin boot 20. Bushing 21. Torque member
22. Torque member mounting bolt
Refer to GI-10, "
Components" and the followings for the symbols in the figure.
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
3: Apply polyglycol ether based lubricant.
: Apply brake fluid.
PFIA0837E

FRONT DISC BRAKE
BR-27
C
D
E
G
H
I
J
K
L
MA
B
BR


It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch
brake hose.

Do not damage piston boot.

If any shim is subject to serious corrosion, replace it with a new one.

Always replace shim and inner shim cover as a set when replacing brake pads.

Keep rotor clean from brake fluid.

Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft
pedal occurs at very low mileage. Refer toBR-32, "
BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake PadBFS000BZ
REMOVAL
1. Remove tyres from vehicle.
2. Remove lower sliding pin bolt.
3. Suspend cylinder body with wire, and remove pads, pad retain-
ers, shims, and shim cover from torque member.
CAUTION:
When removing pad retainers from torque member, lift pad
retainers in the direction by the arrow (shown in the figure)
so as not to damage it.
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based
grease to the both sides of inner shim and outer shim, install
inner shim and inner shim cover to inner pad and outer shim to
outer pad.
CAUTION:
Securely install shim cover according to shim mounting
direction.
2. Install pad retainers and pads to torque member.
CAUTION:
Securely assemble pad retainers so that they are not being
lifted up from torque member.
3. Press in piston until pads can be installed, and then install cylin-
der body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool) to easily
press piston in.
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-26, "
Components" .
5. Secure disc rotor with wheel nut. Depress brake pedal a few times until it gets a responsive touch.
6. Check front disc brake for drag.
7. Install tyres to vehicle.
SBR556E
PFIA0267E
PFIA0273E

BR-28
FRONT DISC BRAKE

Removal and Installation of Brake Caliper AssemblyBFS000C0
REMOVAL
1. Remove tyres from vehicle.
2. Secure disc rotor using wheel nut.
CAUTION:

Do not drop brake pad.
3. Drain brake fluid. Refer to BR-9, "
Drain and Refill" .
4. Remove union bolt and then disconnect brake hose from caliper
assembly.
5. Remove torque member bolts, and remove brake caliper
assembly.
6. Remove disc rotor.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor,
if it necessary to remove disc rotor.
SFIA2057E
SFIA1410J
SDIA2608E

FRONT DISC BRAKE
BR-29
C
D
E
G
H
I
J
K
L
MA
B
BR

INSTALLATION
CAUTION:

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

Do not reuse drained brake fluid.
1. Install disc rotor.
CAUTION:
Align the matching marks of disc rotor and wheel hub,
which were marked at the time of removal when reusing
disc rotor.
2. Install brake caliper assembly to vehicle, and tighten torque
member mounting bolts to the specified torque. Refer to BR-26,
"Components" .
CAUTION:
Before installing torque member to vehicle, wipe oil and
grease on washer seats on steering knuckle and mounting
surface of torque member.
3. Install brake hose to brake caliper assembly, and tighten union bolts to the specified torque. Refer to BR-
26, "Components" .
CAUTION:

Do not reuse copper washers for union bolts.

Connect brake hose aligning with caliper assembly mounting protrusion.
4. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
5. Check front disc brake for drag.
6. Install tyres to vehicle.
Disassembly and Assembly of Brake Caliper AssemblyBFS000C1
NOTE:
Do not remove torque member, pads, shims, inner shim cover, and pad retainers when disassembling and
assembling cylinder body.
DISASSEMBLY
1. Remove caliper assembly from Vehicle. Refer to BR-28, "Removal and Installation of Brake Caliper
Assembly" .
2. Remove sliding pin bolts, from cylinder body, and remove pads
shims shim cover and pad retainers from torque member.
CAUTION:

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

Do not drop pads, shims, inner shim cover and pad
retainers from torque member.
3. Remove sliding pins and sliding pin boots from torque member.
SDIA2608E
SBR556E

BR-30
FRONT DISC BRAKE

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 pistons.
5. Using a flat-bladed screwdriver, remove piston seal from cylin-
der body.
CAUTION:
Be careful not to damage a cylinder inner wall.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
CAUTION:
Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.

Check inner wall of cylinder for corrosion, wear, and damage. If a malfunction is detected, replace cylinder
body.

Minor flaws caused by corrosion or a foreign material can be removed by polishing a surface of inner wall
with a fine sandpaper. Replace cylinder body, if necessary.
To r q u e M e m b e r
Check for wear, cracks, and damage. If a malfunction is detected, replace torque member.
Piston
CAUTION:
Piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear, and damage. If a malfunction is detected, replace applicable part.
Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check sliding pins and sliding pin boots for wear, damage, and cracks. If a malfunction is detected, replace
applicable part.
ASSEMBLY
1. Apply polyglycol ether based lubricant to piston seal, and install
them to cylinder body.
CAUTION:
Do not reuse piston seal.
MAA0272D
SFIA0999E
SFIA2278E

FRONT DISC BRAKE
BR-31
C
D
E
G
H
I
J
K
L
MA
B
BR

2. Apply rubber grease to piston boot. Cover piston end with piston
boot, and install cylinder side lip on piston boot properly into a
groove on cylinder body.
CAUTION:
Do not reuse piston boot.
3. Apply brake fluid to piston, and press piston into cylinder body
by hand to assemble piston side lip on piston boot properly into
groove on piston.
CAUTION:
Press piston evenly and vary the pressing point to prevent
cylinder inner wall from being rubbed.
4. Install sliding pins and sliding pin boots to torque member.
5. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based
grease to the both side of inner shim and outer shim, install
inner shim and inner shim cover to inner pad and outer shim to
outer pad.
CAUTION:
Securely install inner shim cover according to shim mount-
ing direction.
6. Install pad retainer, inner pad assembly and outer pad assembly
to torque member.
CAUTION:

Securely assemble pad retainers so that it is not being
lifted up from torque member.
7. Press in piston until pads can be installed, and then install cylinder body to torque member.
NOTE:
Use a disc brake piston tool (commercial service tool) to easily press piston in.
8. Tighten sliding pin bolts to the specified torque.BR-26, "
Components"
SFIA2498E
SFIA2279E
PFIA0267E
PFIA0273E

BR-32
FRONT DISC BRAKE

DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any of them is detected, replace
applicable part.
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check runout.
CAUTION:
Before measuring, make sure that axle end play within the
specification before measuring runout. FAX-5 , "
WHEEL
BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting the mounting positions of disc rotor and wheel hub by
one hole.
4. If runout is still out of specification, turn rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and
705” or equivalent).
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is out-
side the specification, replace disc rotor.
BRAKE BURNISHING PROCEDURE
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:

Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are
securely fitted.

Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.Measurement point: At a point 10.0 mm (0.394 in)
from outer edge of disc.
Runout limit : 0.040 mm (0.0016 in) or less
SBR019B
Standard thickness : 24.0 mm (0.945 in)
Wear limit : 22.0 mm (0.866 in)
Maximum uneven wear
(measured at 8 positions): 0.010 mm (0.0004 in)
or less
SBR020B