air bleeding NISSAN TEANA 2003 Service Manual

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION BR
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BR

BRAKE SYSTEM
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
BRAKE PEDAL .......................................................... 6
Inspection and Adjustment ....................................... 6
ADJUSTMENT ...................................................... 6
Removal and Installation .......................................... 7
COMPONENTS .................................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 8
INSTALLATION ..................................................... 8
BRAKE FLUID ............................................................ 9
Checking Brake Fluid Level ..................................... 9
Drain and Refill ......................................................... 9
Bleeding Brake System .......................................... 10
BRAKE TUBE AND HOSE ........................................11
Hydraulic Circuit ...................................................... 11
Removal and Installation of Front Brake Tube and
Hose ....................................................................... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Removal and Installation of Rear Brake Tube and
Hose ....................................................................... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection After Installation .................................... 13
BRAKE MASTER CYLINDER .................................. 14
On-Board Inspection .............................................. 14
LEAK INSPECTION ............................................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14INSTALLATION ................................................... 14
Disassembly and Assembly .................................... 15
COMPONENTS ................................................... 15
MODELS WITHOUT VDC ................................... 16
MODELS WITH VDC .......................................... 18
BRAKE BOOSTER ................................................... 21
On-Board Inspection and Service ........................... 21
OPERATION CHECK .......................................... 21
AIR TIGHT CHECK ............................................. 21
Removal and Installation ........................................ 22
COMPONENTS ................................................... 22
REMOVAL ........................................................... 22
INSPECTION AFTER REMOVAL ....................... 23
INSTALLATION ................................................... 23
VACUUM LINES ....................................................... 24
Components ........................................................... 24
Removal and Installation ........................................ 24
Inspection ............................................................... 25
VISUAL INSPECTION ......................................... 25
CHECK VALVE INSPECTION ............................. 25
FRONT DISC BRAKE ............................................... 26
On-Board Inspection ............................................... 26
PAD WEAR INSPECTION ................................... 26
Components ........................................................... 26
Removal and Installation of Brake Pad .................. 27
REMOVAL ........................................................... 27
INSTALLATION ................................................... 27
Removal and Installation of Brake Caliper Assembly
... 28
REMOVAL ........................................................... 28
INSTALLATION ................................................... 29
Disassembly and Assembly of Brake Caliper
Assembly ................................................................ 29
DISASSEMBLY ................................................... 29
INSPECTION AFTER DISASSEMBLY ................ 30
ASSEMBLY ......................................................... 30
DISC ROTOR INSPECTION ............................... 32
BRAKE BURNISHING PROCEDURE ................. 32
REAR DISC BRAKE ................................................. 33
On-Board Inspection ............................................... 33

BRAKE FLUID
BR-9
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BRAKE FLUIDPFP:KN100
Checking Brake Fluid LevelBFS000BI

Make sure that a brake fluid level in reservoir tank is within the
standard (between MAX and MIN lines).

Visually check around reservoir tank for fluid leakage.

If fluid level is excessively low, check brake system for leakage.

Release parking brake pedal and see if brake warning lamp
goes off. If not, check brake system for fluid leakage.
Drain and RefillBFS000BJ
CAUTION:

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

Do not reuse drained brake fluid.

Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of the body, immediately wipe off them and wash it away with water
immediately.

Before working, turn ignition switch OFF and disconnect electrical connector of ABS actuator and
electric unit (control unit) or battery cables.
1. Connect a vinyl tube to bleed valve.
2. Depress brake pedal, loosen bleed valve, and gradually remove
brake fluid.
3. Clean inside of reservoir tank, and refill with new brake fluid.
4. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
brake pedal until it stops. Tighten bleed valve. Release brake
pedal. Repeat this process a few time, them pause to and new
brake fluid to master cylinder. Continue until new brake fluid
flows out.
5. Bleed air. Refer to BR-10, "
Bleeding Brake System" .
SFIA2632E
BRA0007D
PFIA0403J

BR-10
BRAKE FLUID

Bleeding Brake SystemBFS000BK
CAUTION:

Carefully monitor brake fluid level in reservoir tank during
bleeding operation.

Refill with new brake fluid “DOT 3 or DOT 4”. Make sure it is
at least half way at all times while bleeding air out of sys-
tem.

Place a container under master cylinder not to spill brake
fluid.

Turn ignition switch to the OFF and disconnect connector
for ABS actuator and electric unit (control unit) or battery
cable from negative terminal before working.
1. Connect a vinyl tube to rear right brake caliper bleed valve.
2. Fully depress brake pedal 4 or 5 times.
3. With brake pedal depressed, loosen bleed valve to bleed air in
brake line, and then tighten it immediately.
4. Repeat steps 2 and 3 until all of the air is out of the brake line.
5. Tighten bleed valve to the specified torque. Refer to front disc
brake: BR-26, "
Components" , rear disc brake: BR-33, "Compo-
nents" .
6. From step 1 to 5 above, with master cylinder reservoir tank filled
at least half way, bleed air from brake hydraulic line bleed valves
in the following order:
Rear right brake→Front left brake→Rear left brake→Front right brake
PFIA0403J
BRA0007D

BR-12
BRAKE TUBE AND HOSE

Removal and Installation of Front Brake Tube and HoseBFS000BM
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from brake caliper
assembly.
4. Remove lock plate and remove brake hose from vehicle.
INSTALLATION
1. Install brake hose by aligning with the protrusion on brake caliper assembly, and tighten union bolt to the
specified torque. Refer to BR-11, "
Hydraulic Circuit" .
CAUTION:
Do not reuse copper washer.
2. Install brake hose to brake tube. Temporarily tighten flare nut by hand as much as possible. Secure them
to bracket with lock plate.
3. Using a flare nut torque wrench, tighten flare nut to the specified torque. Refer to BR-11, "
Hydraulic Cir-
cuit" .
4. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
Removal and Installation of Rear Brake Tube and HoseBFS000BN
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from brake caliper
assembly.
4. Remove lock plate and remove brake hose from vehicle.
INSTALLATION
1. Install the L-shape metal fitting of brake hose to brake caliper
assembly positioning hole, and then tighten union bolt to the
specified torque. Refer to BR-11, "
Hydraulic Circuit" .
CAUTION:
Do not reuse copper washer.
2. Install brake hose to brake tube. Temporarily tighten flare nut by
hand as much as possible. Secure them to bracket with lock
plate.
3. Using a flare nut torque wrench, tighten flare nut to the specified
torque. Refer to BR-11, "
Hydraulic Circuit" .
4. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleed-
ing Brake System" .
SFIA2057E
SFIA2048E
SFIA2049E

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

FRONT DISC BRAKE
BR-29
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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

BRC-30
[ABS]
TROUBLE DIAGNOSIS FOR SYMPTOMS

TROUBLE DIAGNOSIS FOR SYMPTOMSPFP:00007
Excessive ABS Function Operation FrequencyBFS000DC
1. CHECK START
Check front/rear brake force distribution using a brake tester. Refer to BR-40, "
SERVICE DATA AND SPECIFI-
CATIONS (SDS)" .
OK or NG
OK >> GO TO 2.
NG >> Check brake system.
2. CHECK FRONT AND REAR AXLE
Check to make sure that there is no excessive play in the front and rear axles. Refer to Front: FAX-5, "
On-
Vehicle Inspection" , Rear: RAX-3, "On-Vehicle Inspection" .
OK or NG
OK >> GO TO 3.
NG >> Repair.
3. CHECK WHEEL SENSOR AND SENSOR ROTOR
Check wheel sensor and sensor rotor for the following.

Sensor installation for damage

Sensor rotor installation for damage

Sensor connector connection

Sensor harness inspection
OK or NG
OK >> GO TO 4.
NG >>

Replace wheel sensor or sensor rotor.

Repair harness.
4. CHECK ABS WARNING LAMP DISPLAY
Make sure that the warning lamp turns off approximately 1 second after the ignition switch is turned ON or
when driving.
OK or NG
OK >> Normal
NG >> Perform self-diagnosis. Refer to BRC-17, "
Self-Diagnosis" .
Unexpected Pedal ActionBFS000DD
1. CHECK BRAKE PEDAL STROKE
Check brake pedal stroke. Refer to BR-6, "
Inspection and Adjustment" .
Is the stroke too big?
YES >>
Bleed air from the brake piping. Refer to BR-10, "Bleeding Brake System" .

Check brake pedal, brake booster, and master cylinder for mount play, looseness, brake fluid
leakage, etc. Repair if necessary. Refer to Brake pedal: BR-7, "
COMPONENTS" , brake
booster and master cylinder: BR-22, "
COMPONENTS" .
NO >> GO TO 2.

TROUBLE DIAGNOSIS FOR SYMPTOMS
BRC-31
[ABS]
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2. CHECK FUNCTION
Disconnect ABS actuator and electric unit (control unit) connector to deactivate ABS. Check if braking force is
normal in this condition. Connect connector after inspection.
OK or NG
OK >> GO TO 3. Check Wheel Sensor and Sensor Rotor. Refer to BRC-30, "Excessive ABS Function
Operation Frequency" .
NG >> Check brake system.
Longer Stopping DistanceBFS000DE
CAUTION:
The stopping distance on slippery road surfaces might be longer with the ABS operating than when
the ABS is not operating.
1. CHECK FUNCTION
Turn ignition switch OFF. Disconnect ABS actuator and electric unit (control unit) connectors to deactivate
ABS. In this condition, check stopping distance. After inspection, connect connectors.
OK or NG
OK >> GO TO 3. Check Wheel Sensor and Sensor Rotor. Refer to BRC-30, "Excessive ABS Function
Operation Frequency" .
NG >>

Bleed air from the brake piping. Refer to BR-10, "Bleeding Brake System" .

Check brake system.
ABS Function Does Not OperateBFS000DF
CAUTION:
ABS does not operate when speed is 10 km/h (6 MPH) or lower.
1. CHECK ABS WARNING LAMP DISPLAY
Make sure that the warning lamp turns off approximately 1 second after the ignition switch is turned ON or
when driving.
OK or NG
OK >> GO TO 3. Check Wheel Sensor and Sensor Rotor. Refer to BRC-30, "Excessive ABS Function
Operation Frequency" .
NG >> Perform self-diagnosis. Refer to BRC-17, "
Self-Diagnosis" .
Pedal Vibration and ABS Operation Sound OccursBFS000DG
CAUTION:
Under the following conditions, ABS is activated and vibration is felt when brake pedal is lightly
depressed (just place a foot on it). However, this is normal.

When shifting gears

When driving on slippery road

During cornering at high speed

When passing over bumps or grooves [at approximately 50 mm (1.97 in) or more]

When pulling away just after starting engine [at approximately 10 km/h (6 MPH) or more]
1. SYMPTOM CHECK 1
Check if there is pedal vibration and operation sound when the engine is started.
OK or NG
OK >> GO TO 2.
NG >> Perform self-diagnosis. Refer to BRC-17, "
Self-Diagnosis" .

BRC-36
[ABS]
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)

REMOVAL
1. Disconnect ABS actuator and electric unit (control unit) connector.
2. Loosen brake tube flare nuts, then remove brake tubes from ABS actuator and electric unit (control unit).
3. Remove ABS actuator and electric unit (control unit) mounting bolts.
4. Remove ABS actuator and electric unit (control unit) from vehicle.
CAUTION:
Be careful of the following when removing ABS actuator and electric unit (control unit).

If the part number on the part number label (pasted on actuator upper surface) is the same, ABS
actuator and electric unit (control unit) cannot be used on another vehicle.
If it is used on another vehicle, ABS warning lamp, may turn ON or ABS may not operate normally.
When replacing ABS actuator and electric unit (control unit), must use new service parts.

Before servicing, disconnect both battery cables.

To remove brake tube, use a flare nut torque wrench to prevent flare nuts and brake tube from
being damaged. To install, use a flare nut torque wrench (commercial service tool) and tighten
with the specified torque.

Do not apply excessive impact to actuator, such as dropping it.

Do not remove and install ABS actuator and electric unit (control unit) by holding harness.
INSTALLATION
Install is in the reverse order of the removal.
CAUTION:
Be careful of the following when installing ABS actuator and electric unit (control unit).

Tighten the mounting bolts and nuts with the specified torque.

After the work, bleed air from brake piping. Refer to BR-10, "Bleeding Brake System" .

After installing body harness connector in the actuator, make sure connector is securely locked.

TROUBLE DIAGNOSIS FOR SYMPTOMS
BRC-83
[VDC/TCS/ABS]
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Unexpected Pedal ReactionBFS000EL
1. CHECK BRAKE PEDAL STROKE
Check brake pedal stroke. Refer to BR-6, "
Inspection and Adjustment" .
Is the stroke too big?
YES >>
Bleed air from the brake piping. Refer to BR-10, "Bleeding Brake System" .

Check brake pedal, brake booster, and master cylinder mount for play, looseness, and brake
system fluid leakage, etc. Repair if necessary. Refer to Brake pedal: BR-7, "
COMPONENTS" ,
brake booster and master cylinder: BR-22, "
COMPONENTS" .
NO >> GO TO 2.
2. CHECK FUNCTION
Disconnect ABS actuator and electric unit (control unit) connector to deactivate ABS. Check if braking force is
normal in this condition. Connect connector after inspection.
OK or NG
OK >> GO TO 3. Check Wheel Sensor and Sensor Rotor. Refer to BRC-82, "Excessive ABS Function
Operation Frequently" .
NG >> Check brake system.
Longer Stopping DistanceBFS000EM
CAUTION:
The stopping distance on slippery road surfaces might be longer with the ABS operating than when
the ABS is not operating.
1. CHECK FUNCTION
Turn ignition switch OFF. Disconnect ABS actuator and electric unit (control unit) connector to deactivate ABS.
In this condition, check stopping distance. After inspection, connect connector.
OK or NG
OK >> GO TO 3. Check Wheel Sensor and Sensor Rotor. Refer to BRC-82, "Excessive ABS Function
Operation Frequently" .
NG >>

Bleed air from the brake piping. Refer to BR-10, "Bleeding Brake System" .

Check brake system.