NISSAN X-TRAIL 2003 Service Repair Manual

BRAKE PEDAL
BR-7
C
D
E
G
H
I
J
K
L
MA
B
BR

ComponentsEFS001CI
Removal and InstallationEFS000C2
REMOVAL
Be careful not to deform brake tube.
1. Remove instrument lower driver panel. Refer to IP-10, "
INSTRUMENT PANEL ASSEMBLY" .
2. Remove steering column assembly from steering member. Refer to PS-10, "
STEERING COLUMN" .
3. Remove stop lamp switch from brake pedal assembly.
4. Remove snap pin and clevis pin from brake booster clevis.
5. Remove brake pedal assembly mounting nuts. Pull brake booster toward engine compartment to the
extent that does not deform brake tube.
6. Remove brake booster clevis from input rod.
7. Remove the mounting bolts from the bracket, and remove the pedal assembly from the vehicle.
INSPECTION AFTER REMOVAL
Check brake pedal for the following.

Bent brake pedal

Deformed clevis pin

Cracks in welded area

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.
1. Snap pin 2. Stop lamp switch 3. Clip
4. Clevis pin 5. Brake pedal assembly
SFIA1797E
SBR997

BR-8
BRAKE FLUID

BRAKE FLUIDPFP:KN100
Checking Brake Fluid Level EFS000C5

Confirm reservoir tank fluid level is within the 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 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 bleed valve.
2. Drain brake fluid gradually from bleed valve of each wheel while
depressing brake pedal.
3. Turn OFF ignition switch. Remove ABS actuator connector.
SFIA0066J
SBR389C
BRA0007D

BRAKE FLUID
BR-9
C
D
E
G
H
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L
MA
B
BR

4. Be sure there is no foreign material in reservoir tank. Refill with
new brake fluid.
5. Connect a vinyl tube to bleed valve.
6. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
pedal until it stops. Tighten bleed valve. Release brake pedal.
Repeat this process a few times at 2-3 second intervals until
new brake fluid flows out.
For bleeding procedure. Refer to BR-9, "
Bleeding Brake Sys-
tem" .
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 bleed valve.
3. Fully depress the brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen air bleeder and bleed air.
5. Close bleed valve.
6. Slowly release brake pedal.
7. Tighten bleed valve 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)

BR-10
BRAKE PIPING AND HOSE

BRAKE PIPING AND HOSEPFP:46210
Hydraulic Piping EFS000C6
RHD MODELS
SFIA1798E
SFIA1799E

BRAKE PIPING AND HOSE
BR-11
C
D
E
G
H
I
J
K
L
MA
B
BR

LHD MODELS
Removal and Installation of Front Brake Piping and Brake HoseEFS000C7
REMOVAL
CAUTION:

Do 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 it away with water.

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

Cover brake fluid line joints to prevent dust and other foreign material.
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve of each wheel while depressing brake pedal.
SFIA2137E
SFIA2138E

BR-12
BRAKE PIPING AND HOSE

3. Using a flare nut wrench, loosen brake tube flare nuts and dis-
connect brake tube from brake hose.
4. Remove union bolts and disconnect caliper assembly from
brake hose.
5. First remove lock spring from brake tube and strut mounting
positions. Then remove brake hose.
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT 3” or “DOT4”.

Never reuse drained brake fluid.
1. Connect brake hose to caliper assembly and tighten union bolt to the specified torque.
CAUTION:

Securely connect brake hose to the protrusion on the cylinder body.

Do not reuse the copper washer for union bolt.
2. Connect brake hose to 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.
5. Refill brake fluid until new brake fluid comes out of each bleed valve.
6. Afterwards, bleed air.
Removal and Installation of Rear Brake Piping and Brake HoseEFS000C8
REMOVAL
CAUTION:

Do 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 it away with water.

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

Cover brake fluid line joints to prevent dust and other foreign material.
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve of each wheel while depressing brake pedal.
3. Using a flare nut wrench, remove brake tube flare nuts and dis-
connect brake tube from brake hose.
4. Remove lock spring.
INSTALLATION
CAUTION:

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

Never 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. Fix brake hose by lock plate.
SFIA0347E
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
SFIA0046E

BRAKE PIPING AND HOSE
BR-13
C
D
E
G
H
I
J
K
L
MA
B
BR

3. Tighten flare nut by using a flare nut wrench with the specified
torque.
4. Refill brake fluid until new brake fluid comes out of each bleed
valve.
5. Afterwards, bleed air.
InspectionEFS000C9
CAUTION:
If any leaks on joints, retighten it. Replace any damaged parts.
1. Check hose, tube, and joints for fluid leaks, damage, twist, deformation, contact with other parts, and
loose connections.
2. Run engine. Depress brake pedal and hold it for approximately 5 seconds while checking each part for
leaks.: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
SBR820BA

BR-14
BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDERPFP:46010
ComponentsEFS000CB
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, wipe it off immediately and wash it away with water.
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. Connect fluid level sensor harness connector.
1. Reservoir tank 2. Reservoir cap 3. Oil strainer
4. Pin 5. Cylinder body 6. Piston stopper (Some models with
ABS does not apply.)
7. Grommet 8. O-ring 9. Secondary piston assembly
10. Primary piston assembly 11. Snap ring 12. Guide assembly
13. Plate 14. Stopper cap 15. Primary piston assembly
16. Secondary piston assembly
SFIA1800E
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

BRAKE MASTER CYLINDER
BR-15
C
D
E
G
H
I
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K
L
MA
B
BR

5. Refill with new brake fluid and bleed air from the brake piping.
Disassembly and AssemblyEFS001CH
MODELS WITHOUT ESP (PISTON STOPPER APPLIED.)
Disassembly
CAUTION:
Remove master cylinder reservoir tank only when necessary.
1. Using a slotted flat-bladed screwdriver as shown in the figure,
lever up stopper cap tabs 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:

Secure cylinder body flange with chamfered pin insert
hole, facing upward.

When 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 flat-bladed screwdriver, press and hold piston
pin as shown in the figure. Remove piston stopper from the cyl-
inder 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 Disassembly

Check cylinder inner wall for damage, wear, corrosion, and pinholes. Replace cylinder if damage, wear, or
corrosion is detected.
BRA0533D
BRA0588D
SFIA0342E
BRA0590D

BR-16
BRAKE MASTER CYLINDER

Assembly
CAUTION:

Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.

Be 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.

Do 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 piston assembly. Then insert secondary piston
assembly and primary piston assembly into the cylinder body in
this order.
CAUTION:

Do not reuse primary and secondary piston assemblies.

Always replace primary and secondary piston assemblies
as kit.

Pay attention to orientation of the piston cup. Insert it
straight in order to prevent the cups from catching between
the cylinder's inner wall and piston.
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:

Secure cylinder body flange with chamfered pin insert hole
facing upward.

When securing in the vise, use copper plates or cloth to
protect the flange.
6. Install reservoir tank to cylinder body. Tilt reservoir tank as
shown in the figure to the extent that the mounting pin can be
inserted and insert mounting pin. When mounting pin passes
through pinhole in master cylinder, return reservoir tank to the
upright position. Push mounting pin all the way through the
opposite pinhole in the reservoir tank.
SFIA0248E
BRA0590D
BRA0535D
SFIA0343E