NISSAN X-TRAIL 2001 Service Repair Manual

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
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M
SECTION
A
B
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
On-Vehicle Inspection and Adjustment .................... 6
Components ............................................................. 7
Removal and Installation .......................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 8
BRAKE FLUID ............................................................ 9
Checking Brake Fluid Level ..................................... 9
Checking Brake Line ................................................ 9
Changing Brake Fluid ............................................... 9
Brake Burnishing Procedure .................................. 10
Bleeding Brake System .......................................... 10
BRAKE PIPING AND HOSE .....................................11
Hydraulic Piping ...................................................... 11
Removal and Installation of Front Brake Piping and
Brake Hose ............................................................. 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
Removal and Installation of Rear Brake Piping and
Brake Hose ............................................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection ............................................................... 12
BRAKE MASTER CYLINDER .................................. 13
Components ........................................................... 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13INSTALLATION ................................................... 13
Disassembly and Assembly .................................... 14
DISASSEMBLY ................................................... 14
INSPECTION AFTER REMOVAL ....................... 14
ASSEMBLY ......................................................... 15
BRAKE BOOSTER ................................................... 17
On-Vehicle Inspection and Service ......................... 17
FUNCTION INSPECTION ................................... 17
AIRTIGHTNESS INSPECTION ........................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 18
VACUUM LINES ....................................................... 19
Removal and Installation ........................................ 19
Inspection ............................................................... 19
VISUAL INSPECTION ......................................... 19
CHECK VALVE INSPECTION ............................. 20
FRONT DISC BRAKE ............................................... 21
Component ............................................................. 21
Inspection ............................................................... 21
PAD THICKNESS ................................................ 21
Pad Replacement ................................................ ... 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 22
Caliper Removal and Installation ............................ 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 23
Caliper Disassembly and Assembly ....................... 23
DISASSEMBLY ................................................... 23
INSPECTION AFTER DISASSEMBLY ................ 23
DISC ROTOR INSPECTION ............................... 24
ASSEMBLY ......................................................... 24
BRAKE BURNISHING PROCEDURE ................. 25
REAR DISC BRAKE ................................................. 26
Component ............................................................. 26
Inspection ............................................................... 26
PAD WEAR INSPECTION ................................... 26
Pad Replacement ................................................ ... 27
REMOVAL ........................................................... 27

BR-2
INSTALLATION .................................................... 27
Caliper Removal and Installation ............................ 28
REMOVAL ........................................................... 28
INSTALLATION .................................................... 28
Caliper Disassembly and Assembly ....................... 28
DISASSEMBLY ................................................... 28
INSPECTION AFTER DISASSEMBLY ................ 29
DISC ROTOR INSPECTION ............................... 29
ASSEMBLY ......................................................... 30SERVICE DATA AND SPECIFICATIONS (SDS) ...... 32
General Specifications ......................................... ... 32
Brake Pedal ............................................................ 32
Check Valve ............................................................ 32
Brake Booster ......................................................... 32
Front Disc Brake ..................................................... 32
Rear Disc Brake ...................................................... 33

PRECAUTIONS
BR-3
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MA
B
BR
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS002F9
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
●To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
●Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connec-
tors.
Precautions for Brake SystemEFS000BZ
●Clean dust on brake pads, shoes, drums, and back plates with a vacuum dust collector. Do not blow with
compressed air.
●Recommended fluid is brake fluid “DOT 3” or “DOT 4”.
●Never reuse drained brake fluid.
●Be careful not to splash brake fluid on painted areas such as the body. If brake fluid is splashed or spilled
on paint, wipe it off and flush the area with water immediately.
●Use only clean brake fluid when cleaning master cylinder and disc brake components.
●Never use mineral oils such as gasoline or kerosene to clean. They will ruin the rubber parts and cause
improper operation.
●Always use a flare nut torque wrench to securely tighten brake
tube flare nuts.
●The brake system is an important safety part. If a brake fluid
leak is detected, always disassemble the related parts. If dam-
age, deformation or excessive wear is detected, replace
affected parts with new ones.
●Before staring operation, be sure to turn the ignition switch OFF
and disconnect the ABS actuator and control module connector
or battery cables.
●When installing brake piping, be sure to check torque.SBR820BA

BR-4
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEFS00217
Commercial Service ToolsEFS00218
Tool number
Tool nameDescription
GG94310000
Flare nut torque wench
a: 10 mm (0.39 in)Removing and installing brake piping
NT406
Tool nameDescription
Brake fluid pressure gauge Measuring fluid pressure
S-NT151

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
BR-5
C
D
E
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MA
B
BR
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEFS000TK
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
X: ApplicableReference page
BR-21
,BR-26
BR-21
,BR-26
.
BR-21
,BR-26—
—
BR-24,BR-29—
—
—
BR-24,BR-30—
NVH in PR section
NHV in RFD section
NVH in FAX, RAX and FSU, RSU section
NVH in WT section
NVH in WT section
NVH in RAX section
NVH in PS section
Possible cause and
SUSPECTED PARTS
Pads - damaged
Pads - uneven wear
Shims damaged
Rotor imbalance
Rotor damage
Rotor runout
Rotor deformation
Rotor deflection
Rotor rust
Rotor thickness variation
Drum out of round
PROPELLER SHAFT
DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
STEERING
Symptom BRAKENoise××× ×× ×××
××
Shake×××××
××
Shimmy, Judder××××××× ××× ×

BR-6
BRAKE PEDAL
BRAKE PEDAL
PFP:46501
On-Vehicle Inspection and AdjustmentEFS000C1
Adjust clearance between dash panel and brake pedal upper surface
to the following dimensions.
1. Loosen stop lamp switch by rotating it counter-clockwise by 45°.
2. Loosen input rod lock nut (A), then rotate input rod, set pedal to
the specified height, and tighten lock nut (A).
CAUTION:
Confirm threaded end of input rod remains inside the cle-
vis.
3. Pull pedal by hand and hold it. Press stop lamp switch until its
threaded end contacts the stopper rubber.
4. While holding it against the stopper rubber, turn the switch clock-
wise by 45° and secure it.
CAUTION:
Be sure stopper rubber to stop lamp switch screw threaded
end gap (C) is within specifications.
5. Check pedal free play.
CAUTION:
Be sure stop lamps go off when pedal is released.
6. Start the engine and check brake pedal depressed height.
SFIA0348E
H1Brake pedal heightM/T model 156 - 166 mm (6.10 - 6.54 in)
A/T model 164 - 174 mm (6.46 - 6.85 in)
H
2Pedal height when depressed
[With engine running and at depression force of 490 N (50 kg,110.6 lb)]M/T model 80 mm (3.15 in) or more
A/T model 85 mm (3.35 in) or more
C Clearance between stopper rubber and threaded end of the stop Stop lamp switch 0.74 - 1.96 mm (0.0291 - 0.0772 in)
A Pedal play3 - 11 mm (0.12 - 0.43 in)
: 16 - 21 N·m (1.6 - 2.2 kg-m, 12 - 15 ft-lb)
SFIA0160E

BRAKE PEDAL
BR-7
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BR
ComponentsEFS001CI
Removal and InstallationEFS000C2
REMOVAL
Be careful not to deform brake tube.
1. Remove the instrument lower drive panel.
2. Remove stop lamp switch from brake pedal assembly.
3. Remove snap pin and clevis pin from brake booster clevis.
4. Remove brake pedal assembly mounting nuts. Pull brake booster toward the engine compartment. Be
careful not to deform the brake tube.
5. Remove brake booster clevis from input rod.
6. Remove steering column assembly from steering member.
7. Push brake pedal assembly toward the right. When removing it,
avoid the steering post bracket stay.
INSPECTION AFTER REMOVAL
Check brake pedal for the following.
●Bent brake pedal
●Deformed clevis pin
●Cracks in welded area
1. Snap pin 2. Stop lamp switch 3. Brake pedal assembly
4. Clevis pin
SFIA0044E
SFIA0349E

BR-8
BRAKE PEDAL
●Cracked or deformed clevis pin stopper
INSTALLATION
Install in reverse order of removal. Be careful of the following:
●Adjust brake pedal assembly after installing it.
SBR997

BRAKE FLUID
BR-9
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B
BR
BRAKE FLUIDPFP:KN100
Checking Brake Fluid Level EFS000C5
●Confirm reservoir tank fluid level is within specifications
(between MAX and MIN lines).
●Visually check around 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.
Checking Brake LineEFS001C5
CAUTION:
If leakage occurs around joints, retighten or, if necessary, replace damaged parts.
1. Check brake line (tube and hoses) for cracks, deterioration or
other damage. Replace and damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
Changing Brake FluidEFS000C3
CAUTION:
●Refill with new brake fluid “DOT 3 or DOT 4”.
●Always keep fluid level higher than minimum line on reservoir tank.
●Never reuse drained brake fluid.
●Be careful not to splash brake fluid on spill or splash on painted areas; it may cause paint damage.
If brake fluid is splashed on painted areas, wash it away water immediately.
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from the air bleeder of each wheel
while depressing the brake pedal.
3. Turn OFF ignition switch. Remove ABS actuator connector.
SFIA0066J
SBR389C
BRA0007D

BR-10
BRAKE FLUID
4. Be sure there is no foreign material in reservoir tank. Refill with
new brake fluid.
5. Connect a vinyl tube to the air bleeder.
6. Rest foot on brake pedal. Loosen air bleeder. Slowly depress
pedal until it stops. Tighten air bleeder. 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.
For bleeding procedure. Refer to BR-10, "
Bleeding Brake Sys-
tem" .
Brake Burnishing ProcedureEFS001C8
Burnish the brake contact surfaces according to the following procedure after refinishing or replacing drums or
rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.
Bleeding Brake SystemEFS000C4
CAUTION:
●Carefully monitor brake fluid level at master cylinder during bleeding operation.
●Fill reservoir with new brake fluid “DOT 3” or “DOT 4”. Make sure it is full at all times while bleed-
ing air out of system.
●Place a container under master cylinder to avoid spillage of brake fluid.
●While bleeding, pay attention to master cylinder fluid level.
●For models with ABS, turn ignition switch OFF and disconnect ABS actuator connectors or bat-
tery ground cable.
●Bleed air in the following order.
Right rear brake, Left front brake, Left rear brake, Right front brake
1. Turn OFF ignition switch. Remove ABS actuator connector.
2. Connect a vinyl tube to the air bleeder.
3. Fully depress the brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen air bleeder and bleed air.
5. Close air bleeder.
6. Slowly release brake pedal.
7. Tighten air bleeder to the specified torque.
8. Repeat steps 2 - 7. Occasionally refill master cylinder reservoir tank. Be sure to keep it at least half-full.
BRA0006D
: 6.9 - 8.8 N·m (0.7 - 0.9 kg-m, 61- 78 in-lb)