NISSAN X-TRAIL 2003 Service Repair Manual

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

FRONT DISC BRAKEPFP:41000
ComponentEFS000CG
WARNING:

Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or
other materials.
CAUTION:

When cylinder body is open, do not depress brake pedal because piston will pop out.

Be careful not to damage piston boot or spill brake fluid oil on rotor. Always replace shims when
replacing pads.

If shims are rusted or show peeling of the rubber coat, replace them with new shims.

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

Burnish the brake pad contact surfaces after refinishing or replacing drums or rotors, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-31, "
BRAKE BUR-
NISHING PROCEDURE" .
InspectionEFS000CH
PAD THICKNESS
Check pad thickness by lifting vehicle, removing the wheel, and
looking through check hole on cylinder body. If necessary, use a
scale.
1. Torque member 2. Slid pin boot 3. Slid pin
4. Outer shim cover 5. Outer shim 6. Outer pad
7. Pad retainer 8. Inner pad 9. Inner shim
10. Inner shim cover 11. Piston boots 12. Piston
13. piston seal 14. Cylinder body 15. Slid pin bolt
16. Copper washer 17. Bleed valve 18. Brake hose union bolt
SFIA2142E
Standard pad thickness : 11 mm (0.43 in)
Pad wear limit : 2.0 mm (0.079 in)
MAA0439D

BR-28
FRONT DISC BRAKE

Pad ReplacementEFS000CI
REMOVAL
CAUTION:
When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
1. Remove master cylinder reservoir tank cap.
2. Remove lower sliding pin bolt.
3. Hang cylinder body with a wire, and remove pads, pad retainers,
shims and pad return springs.
INSTALLATION
1. Apply brake grease on back of the pad and both sides of the shim. Install inner shim and inner shim cover
to inner pad, outer shim to outer pad.
2. Apply brake grease on a pad sliding part of pad retainer. Install pad retainers, pads and pad return springs
to torque member.
3. Connect cylinder body to torque member.
CAUTION:
When replacing pads with new ones, press piston in until the pads can be installed. Carefully mon-
itor brake master cylinder reservoir fluid level. Brake fluid will return, raising master cylinder res-
ervoir tank fluid level.
4. Insert lower sliding pin bolt and tighten to the specified torque.
5. Check brakes for drag.
Caliper Removal and InstallationEFS000CJ
REMOVAL
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve while depressing brake pedal.
3. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
4. Remove disc rotor.
SBR433D
SBR932C
SBR979B

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”.

Never reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Before installing caliper assembly, wipe brake fluid and grease on steering knuckle washer seats
and caliper assembly mounting surface.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:

Do not reuse copper washer for union bolts.

Securely assemble brake hose to protrusions on cylinder body.
4. Bleed air. Refer to BR-9, "
Bleeding Brake System" .
Caliper Disassembly and Assembly EFS000CK
DISASSEMBLY
WARNING:
Be careful not to pinch your fingers in the piston.
CAUTION:
Be careful not to damage the cylinder inner wall.
1. Place a wooden block as shown in the figure. Blow air into union
bolt mounting hole to remove pistons and piston boots.
2. Using flat-bladed screwdriver, remove piston seals.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.

Check cylinder inner wall for corrosion, wear and damage. If corrosion, wear or damage is detected,
replace the cylinder body.

Minor flaws caused by corrosion or foreign material can be removed by polishing the surface with fine
sandpaper. Replace the cylinder body, if necessary.
To r q u e M e m b e r
Check for wear, cracks and damage. If wear, cracks or damage is detected, replace the applicable part.
BRB0032D
SFIA0141E

BR-30
FRONT DISC BRAKE

Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear and damage. If corrosion, wear or damage is detected, replace the
applicable part.
Sliding Pin, Pin Bolt, and Pin Boot
Check sliding pin and sliding pin boot for wear, damage and cracks. If corrosion, wear or damage is detected,
replace the applicable part.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks and serious damage. If uneven wear, cracks or serious
damage is detected, replace it.
Run Out Inspection
1. Using wheel nuts, fix disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check run out.
NOTE:
Make sure that wheel bearing axial endplay is with in the specifi-
cations before measuring runout. Refer to FAX-7, "
On-Vehicle
Inspection" .
3. If the run out is outside the limit, find the minimum run out point
by shifting the mounting positions of disc rotor and wheel hub by one hole.
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If the thickness is
outside the standard, replace the disc rotor.
ASSEMBLY
CAUTION:
When assembling, do not use rubber grease.
1. Apply rubber lubricant to piston seals, and install them to cylin-
der body.
CAUTION:
Do not reuse piston seals.Measurement point:
At a point of 10 mm (0.39 in) from the outer edge of
the disc.
Run out limit : 0.04 mm (0.0016 in) or less
BRA0013D
Standard thickness : 28.0 mm (1.102 in)
Wear limit : 26.0 mm (1.024 in)
Maximum uneven wear (measured at 8 positions):
0.02 mm (0.0008 in) or less
SBR020B
SFIA0154E

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

2. Apply brake fluid or rubber lubricant to piston boots. Cover pis-
ton end with piston boot. Install cylinder side boot lip properly
into groove on cylinder body.
CAUTION:
Do not reuse piston boot.
3. Apply brake fluid to piston. Press piston into cylinder body by
hand. Assemble piston side boot lip properly into groove on pis-
ton.
CAUTION:
Press piston evenly and change pressing point to prevent
cylinder inner wall from being rubbed.
BRAKE BURNISHING PROCEDURE
Burnish the brake pad 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 vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring 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 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.
SFIA0155E
SBR574

BR-32
REAR DISC BRAKE

REAR DISC BRAKEPFP:44000
ComponentEFS0017X
WARNING:

Clean dust on brake caliper and pad with a vacuum dust collector. Do not blow with compressed
air.
CAUTION:

Never depress brake pedal while removing cylinder body because piston will pop out.

Do not remove brake hose and torque member mounting bolts unless disassembling or replacing
caliper assembly. Hang the cylinder body with a wire so that the brake hose is not under tension.

Be careful not to damage piston boot. Do not allow brake fluid to get the rotor.

When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
InspectionEFS0017Y
PAD WEAR INSPECTION
Check pad thickness by lifting vehicle, removing tyre and wheel, and
looking through check hole on cylinder body. If necessary, use a
scale.
1. Pad retainer 2. Outer shim cover 3. Outer shim
4. Outer pad 5. Pad retainer 6. Inner pad
7. Inner shim 8. Inner shim cover 9. Sliding pin boot
10. Sliding pin 11. Sliding pin bolt 12. Cylinder body
13. Copper washer 14. Brake hose 15. Union bolt
16. Copper washer 17. Bleed valve 18. Piston seal
19. Piston 20. Piston boot 21. Retaining ring
22. Torque member
SFIA2143E
standard thickness : 8.5 mm (0.335 in)
pad wear limit : 2.0 mm (0.079 in)
BRA0010D

REAR DISC BRAKE
BR-33
C
D
E
G
H
I
J
K
L
MA
B
BR

Pad ReplacementEFS0017Z
REMOVAL
CAUTION:
When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
1. Remove master cylinder reservoir tank cap.
2. Remove lower sliding pin bolt.
3. Hang cylinder body with a wire, and remove pads, pad retainers,
and shims.
INSTALLATION
1. Apply brake grease on back of the pad and both sides of the shim. Install inner shim and inner shim cover
to inner pad, outer shim to outer pad.
2. Install pad retainers to torque member and install pads.
3. Connect cylinder body to torque member.
CAUTION:
When replacing pads with new ones, press piston in until the pads can be installed. Carefully mon-
itor brake master cylinder reservoir fluid level. Brake fluid will return, raising master cylinder res-
ervoir tank fluid level.
4. Insert lower sliding pin bolt and tighten to the specified torque.
5. Check brakes for drag.
BRB0302D
SBR042C

BR-34
REAR DISC BRAKE

Caliper Removal and InstallationEFS00180
REMOVAL
1. Connect a vinyl tube to bleed valve.
2. Drain brake fluid gradually from bleed valve while depressing
brake pedal.
3. Remove union bolt and remove brake hose from caliper assem-
bly.
4. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
5. Remove disc rotor.
INSTALLATION
CAUTION:

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

Never reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Wipe brake fluid and grease on axle assembly washer seats and caliper assembly mounting sur-
face. Install caliper assembly.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:

Do not reuse the copper washer for union bolts.

Securely assemble brake hose to protrusions on cylinder body.
4. Bleed air. Refer to BR-9, "
Bleeding Brake System" .
Caliper Disassembly and AssemblyEFS00181
DISASSEMBLY
WARNING:
Be careful not to pinch your fingers in the piston.
CAUTION:
Be careful not to damage the cylinder inner wall.
1. Remove caliper assembly from vehicle.
2. Remove sliding pin from cylinder body. Then remove pads, shims, shim covers, and pad retainers from
caliper assembly.
3. Remove sliding pin boots from torque member.
4. Using flat-bladed screwdriver (as shown in the figure), remove
retaining ring.
SFIA0143E
SBR028A

REAR DISC BRAKE
BR-35
C
D
E
G
H
I
J
K
L
MA
B
BR

5. Place a wooden block as shown in the figure. Blow air into union
bolt mounting hole to remove pistons and piston boots.
6. Using flat-bladed screwdriver, remove piston seals.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.

Check cylinder inner wall for corrosion, wear and damage. If corrosion, wear or damage is detected,
replace the cylinder body.

Minor flaws caused by corrosion or foreign material can be removed by polishing the surface with fine
sandpaper. Replace the cylinder body, if necessary.
To r q u e M e m b e r
Check for wear, cracks and damage. If wear, cracks or damage is detected, replace the applicable part.
Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear and damage. If corrosion, wear or damage is detected, replace the
applicable part.
Sliding Pin, Pin Bolt and Pin Boot
Check sliding pin and sliding pin boot for wear, damage and cracks. If corrosion, wear or damage is detected,
replace the applicable part.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of the disc rotor for uneven wear, cracks and serious damage. If uneven wear, cracks or seri-
ous damage is detected, replace it.
Run Out Inspection
1. Using wheel nuts, fix the disc rotor to wheels hub. (2 or more positions)
BRD0041D
SFIA0340E

BR-36
REAR DISC BRAKE

2. Using a dial indicator, check run out.
NOTE:
Make sure that wheel bearing axial endplay is with in the specifi-
cation before measuring runout. Refer to FA X - 7 , "
On-Vehicle
Inspection" .
3. If the run out is outside the limit, find the minimum run out point by shifting the mounting positions of disc
rotor and wheel hub by one hole.
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If the thickness is
outside the standard, replace disc rotor.
ASSEMBLY
CAUTION:
When assembling, do not use rubber grease.
1. Apply rubber lubricant to piston seals, and install them to the cyl-
inder body.
CAUTION:
Do not reuse piston seals.
2. Apply brake fluid to piston boots. Cover piston end with piston
boot. Install cylinder side boot lip properly into groove on cylin-
der body.
CAUTION:
Do not reuse piston boot.
3. Press piston into cylinder body by hand. Assemble piston side
boot lip properly into groove on the piston.
CAUTION:
Press piston evenly and change pressing point to prevent
the cylinder inner wall from being rubbed.Measurement point:
At a point of 10 mm (0.39 in) from the outer
edge of the disc.
Run out limit:
0.07 mm (0.0028 in) or less
BRA0013D
Standard thickness : 16.0 mm (0.630 in)
Wear limit : 14.0 mm (0.551 in)
Maximum uneven wear (measured at 8 positions):
0.02 mm (0.0008 in) or less
SBR020B
SFIA0156E
SFIA0157E