NISSAN X-TRAIL 2003 Electronic Repair Manual

BRAKE PEDAL
BR-7
C
D
E
G
H
I
J
K
L
MA
B
BR
1. Loosen stop lamp switch by rotating it counter-clockwise by
45#0#.
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#O# 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.
ComponentsEF S0 01 CI
Removal and InstallationEFS000C2
REMOVAL
Be careful not to deform brake tube.
1. Remove the instrument of the driver-side lower 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.: 16 - 21 N·m (1.6 - 2.2 kg·m, 12-15 ft·lb)
SFIA0160E
SFIA0044E
1 Snap pin 2 Stop lamp switch 3 Brake pedal assembly
4 Clevis pin

BR-8
BRAKE PEDAL
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.
lBent brake pedal
lDeformed clevis pin
lCracks in welded area
lCracked or deformed clevis pin stopper
INSTALLATION
Install in reverse order of removal. Be careful of the following:
lAdjust brake pedal assembly after installing it.
SFIA0349E
SBR997

BRAKE FLUID
BR-9
C
D
E
G
H
I
J
K
L
MA
B
BR
BRAKE FLUIDPFP:KN100
Checking Brake Fluid LevelEFS000C5
lConfirm reservoir tank fluid level is within specifications
(between MAX and MIN lines).
lVisually check around reservoir tank for fluid leaks.
lIf fluid level is excessively low, check brake system for leaks.
lIf 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:
lRefill with new brake fluid “DOT 3 or DOT 4”.
lAlways keep fluid level higher than minimum line on reservoir tank.
lNever reuse drained brake fluid.
lBe 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 toBR-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:
lCarefully monitor brake fluid level at master cylinder during bleeding operation.
lFill 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.
lPlace a container under master cylinder to avoid spillage of brake fluid.
lWhile bleeding, pay attention to master cylinder fluid level.
lFor models with ABS, turn ignition switch OFF and disconnect ABS actuator connectors or bat-
tery ground cable.
lBleed 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)

BRAKE PIPING AND HOSE
BR-11
C
D
E
G
H
I
J
K
L
MA
B
BR
BRAKE PIPING AND HOSEPFP:46210
Hydraulic PipingEFS000C6
Removal and Installation of Front Brake Piping and Brake HoseEFS000C7
REMOVAL
CAUTION:
lDo not allow brake fluid to spill or splash on painted surfaces. Brake fluid can seriously damage
paint. If it gets on a painted surface, wipe it off immediately and wash with water.
lDo not bend or twist the brake hose sharply, or strongly pull it.
lCover brake fluid line connections to prevent dust and other foreign material from entering.
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. Using a flare nut wrench, remove brake tube flare nuts and dis-
connect brake tube from the brake hose.
4. Remove union bolts and disconnect caliper assembly from the
brake hose.
5. First remove lock spring from brake tube and strut mounting
positions. Then remove brake hose.
INSTALLATION
CAUTION:
lRefill with new brake fluid “DOT 3” or “DOT4”.
lNever reuse drained brake fluid.
1. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
lSecurely connect brake hose to the protrusions on the cylinder body.
lDo not reuse the copper washer for union bolts.
2. Connect brake hose to the strut and fix with lock spring.
3. Connect brake hose to brake tube. Temporarily tighten flare nuts by hand as far as they will go. Secure
them with the lock spring.
4. Using a flare nut torque wrench, tighten to the specified torque.
SFIA0346E
SFIA0347E

BR-12
BRAKE PIPING AND HOSE
5. Refill brake fluid until new brake fluid comes out of each air bleeder.
6. Afterwards, bleed air.
Removal and Installation of Rear Brake Piping and Brake HoseEFS000C8
REMOVAL
CAUTION:
lDo not allow brake fluid to spill or splash on painted surfaces. Brake fluid can seriously damage
paint. If it gets on a painted surface, wipe it off immediately and wash with water.
lDo not bend or twist the brake hose sharply, or strongly pull it.
lCover brake fluid line connections to prevent dust and other foreign material from entering.
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. Using a flare nut wrench, remove brake tube flare nuts and dis-
connect brake tube from the brake hose.
4. Remove lock spring and union bolts.
INSTALLATION
CAUTION:
lRefill with new brake fluid “DOT 3” or “DOT 4”.
lNever reuse drained brake fluid.
1. Connect brake hose to the brake tube. Temporarily tighten flare nut by hand as far as it will go.
2. Secure brake hose with lock spring and connect wheel-side hose to the caliper assembly.
3. Tighten union bolts to the specified torque. Then, tighten flare nut to the specified torque with a flare nut
torque wrench.
4. Refill brake fluid until new brake fluid comes out of each air
bleeder.
5. Afterwards, bleed air.
InspectionEFS000C9
CAUTION:
If any connection leaks, retighten it. Replace any damaged parts.
1. Check hose, tube, and connections for fluid leaks, damage, twist, deformation, contact with other parts,
and loose connections.
2. Run the engine. Depress brake pedal and hold it for approximately 5 seconds while checking each part
for leaks.:15-17N·m(1.5-1.8kg·m,11-13ft·lb)
SFIA0046E
: 15 - 17 N·m (1.5 - 1.8 kg·m,11-13 ft·lb)
SBR686C

BRAKE MASTER CYLINDER
BR-13
C
D
E
G
H
I
J
K
L
MA
B
BR
BRAKE MASTER CYLINDERPFP:46010
ComponentsEF S0 00 CB
Removal and InstallationEFS001CG
REMOVAL
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
1. Drain brake fluid.
2. Remove fluid level sensor harness connector.
3. Using a flare nut wrench, disconnect master cylinder assembly and brake tube.
4. First remove master cylinder assembly mounting nuts. Then remove master cylinder assembly.
INSTALLATION
1. Connect brake tube to master cylinder assembly and temporarily tighten flare nut by hand.
2. Connect master cylinder assembly to brake booster assembly and tighten mounting nuts to the specified
torque.
3. Tighten brake tube flare nuts.
4. Refill with new brake fluid and bleed air from the brake piping.
SFIA0047E
1 Cap 2 Strainer 3 Reservoir tank
4 Grommet 5 Piston stopper 6 Pin
7 Secondary piston 8 Primary piston assembly 9 Stopper cap
:15-17N·m(1.5-1.8kg·m,11-13ft·lb)

BR-14
BRAKE MASTER CYLINDER
Disassembly and Assembly
EFS001CH
DISASSEMBLY
CAUTION:
Remove master cylinder reservoir tank only when necessary.
1. Using a slotted screwdriver as shown in the figure, lever stopper
cap tabs up and remove stopper cap. While removing, be sure
to hold cap securely to prevent the master cylinder piston from
popping out.
2. Secure cylinder body flange in a vise as shown in the figure.
CAUTION:
lSecure with chamfered pin insert hole on the cylinder
body facing upward.
lWhen securing in the vise, use copper plates or cloth to
protect the flange.
3. Using a pin punch [tool: diameter Approx. 4 mm (0.16 in)],
remove reservoir tank mounting pins.
4. Remove master cylinder assembly from the vise.
5. Remove reservoir tank and grommet from the cylinder body.
6. Using a Phillips screwdriver, press and hold piston pin as shown
in the figure. Remove piston stopper from the cylinder body.
7. Carefully pull primary piston assembly straight out to prevent
damage to the cylinder inner wall.
8. Tap flange against a wood block to loosen secondary piston
assembly. Carefully pull secondary piston assembly straight out
to prevent damage to the cylinder inner wall.
INSPECTION AFTER REMOVAL
lCheck cylinder inner wall for damage, wear, corrosion, and pinholes. Replace cylinder if damage, wear, or
corrosion is detected.
BRA0533D
BRA0588D
SFIA0342E
BRA0590D

BRAKE MASTER CYLINDER
BR-15
C
D
E
G
H
I
J
K
L
MA
B
BR
ASSEMBLY
CAUTION:
lNever use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.
lBe sure there is no foreign material on the cylinder inner wall, piston, and cup seal. Be careful not
to damage parts with a service tool during assembly.
lDo not drop the parts. Do not use any dropped parts.
1. Apply brake fluid to the inner wall of cylinder body and contact
surface of the piston assembly. Then insert secondary piston
assembly and primary piston assembly into cylinder body in this
order.
CAUTION:
lDo not reuse primary and secondary piston assemblies.
lAlways replace the inner kit as an assembly.
lPay attention to orientation of the piston cup. Insert it
straight in order to prevent it from catching on the cylin-
der's inner wall.
2. Visually check secondary piston slit position through cylinder
body secondary tank boss hole and install piston stopper.
3. Hold piston with stopper cap. Press stopper cap in until its tabs
fully engage groove on the cylinder body.
CAUTION:
Do not reuse stopper cap.
4. Apply brake fluid to grommet before pressing it into cylinder
body.
CAUTION:
Do not reuse grommet.
5. Secure cylinder body flange in a vise as shown in the figure.
CAUTION:
lSecure with chamfered pin insert hole on the cylinder body
facing upward.
lWhen securing in the vise, use copper plates or cloth to
protect the flange.
6. Install reservoir tank to the cylinder body. Tilt reservoir tank as
shown in the figure and insert mounting pin. When mounting pin
passes through pinhole in the master cylinder, return reservoir
tank to the upright position. Push mounting pin all the way
through the opposite pinhole in the reservoir tank.
CAUTION:
lDo not reuse reservoir tank mounting pin.
SFIA0248E
BRA0590D
BRA0535D
SFIA0343E

BR-16
BRAKE MASTER CYLINDER
lDo not reuse reservoir tank.
lBe sure to insert pin from the chamfered pinhole on the cylinder body.