2003 NISSAN TEANA service

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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M
SECTION BR
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
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

BR-2 PAD WEAR INSPECTION ................................... 33
Components ........................................................... 33
Removal and Installation of Brake Pad ................... 34
REMOVAL ........................................................... 34
INSTALLATION .................................................... 34
Removal and Installation of Brake Caliper Assembly
... 35
REMOVAL ........................................................... 35
INSTALLATION .................................................... 35
Disassembly and Assembly of Brake Caliper Assembly ................................................................ 36
DISASSEMBLY .................................................... 36
INSPECTION AFTER DISASSEMBLY ................ 37
ASSEMBLY .......................................................... 37
DISC ROTOR INSPECTION ............................... 39
BRAKE BURNISHING PROCEDURE ................. 39
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 40
General Specifications ............................................ 40
Brake Pedal ............................................................ 40
Brake Booster ......................................................... 40
Check Valve ............................................................ 40
Front Disc Brake ..................................................... 40
Rear Disc Brake ...................................................... 41

PRECAUTIONS
BR-3
C
D
E
G
H
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K
L
MA
B
BR

PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
BFS000BB
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 harnesses or
harness connectors.
Precautions for Brake SystemBFS000BC

Clean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air.

Recommended fluid is brake fluid “DOT 3 or DOT 4”. Refer to MA-14, "Fluids and Lubricants" .

Do not 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 surfaces of body, immediately wipe it off and them wash it away with water immediately.

To clean or wash all parts of master cylinder, disc brake caliper, use clean brake fluid.

Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.

Use a flare nut torque wrench when installing brake tube.

When installing brake tube, be sure to check torque.

Before working, turn ignition switch OFF and disconnect electri-
cal connector of ABS actuator and electric unit (control unit) or
battery cables.

Burnish the brake contact surfaces after refinishing or replacing
rotors, after replacing pads, or if a soft pedal occurs at very low
mileage. Refer to BR-32, "
BRAKE BURNISHING PROCE-
DURE" (Front disc brake), BR-39, "BRAKE BURNISHING
PROCEDURE" (Rear disc brake).
WARNING:

Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.
SBR820BA

BR-4
PREPARATION

PREPARATIONPFP:00002
Special Service ToolsBFS000BD
Commercial Service ToolsBFS000BE
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
a:10 mm (0.39 in) / 12 mm (0.47 in)Installing each brake tube
NT406
Tool nameDescription
Pin punch
Tip diameter: 4 mm (0.16 in) dia.Removing and installing reservoir tank
pin
ZZA0515D

BRAKE MASTER CYLINDER
BR-17
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MA
B
BR

2. Holding down piston with stopper cap, push stopper cap tabs so
they are firmly into cylinder grooves, then install stopper cap.
CAUTION:
Do not reuse stopper cap.
Disassembly (Reservoir Tank)
1. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting master cylinder assembly with vise, be sure
not to over-tighten.

When setting with vise use copper plates or cloth to pro-
tect the flange.
2. Using a pin punch [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)], remove mounting pins on reservoir tank.
3. Remove master cylinder assembly from vise.
4. Remove reservoir tank and grommet from cylinder body.
Assembly (Reservoir Tank)
1. Apply brake fluid to grommet, and then install it into cylinder body after installing grommet to reservoir
tank.
CAUTION:
Do not reuse reservoir tank and grommet.
2. Secure master cylinder assembly into vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting master cylinder assembly in vise, be sure
not to over-tighten.

When setting in vise use copper plates or cloth to protect
the flange.
BRA0035D
PFIA0505J
SFIA2052E
PFIA0505J

BR-18
BRAKE MASTER CYLINDER

3. Using a pin punch, [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)] insert reservoir tank mounting pin into the
pin hole so that the attachment side and the opposite side are
identical.
CAUTION:

Be sure to insert pin from the chamfered pinhole of cylin-
der body.

Do not reuse mounting pin.
MODELS WITH VDC
Disassembly
CAUTION:

Cover primary piston rod using cloths during disassembly to prevent damage to it.
1. Secure master cylinder assembly into vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting master cylinder assembly in vise, be sure
not to overtighten.

When setting with vise use copper plates or cloth to pro-
tect the flange.
2. Using a pin punch [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)], remove mounting pin on reservoir tank.
3. Remove master cylinder assembly from vise.
4. Remove reservoir tank and grommet from cylinder body.
5. Push in primary piston assembly, and then remove piston stop-
per pin from cylinder body secondary-side tank boss hole.
CAUTION:
Be careful not to damage an inner wall of cylinder body.
SFIA2052E
PFIA0505J
SFIA2052E
BRA0560D

BR-20
BRAKE MASTER CYLINDER

3. Insert plate and guide assembly into cylinder body as shown.
CAUTION:

Make sure not to damage primary piston rod.

Pay attention to the orientation of guide assembly.

Do not drop O-ring.

Make sure guide assembly and plate are not inserted at
angle.
4. Cover primary piston assembly rod with cloths to prevent dam-
age to it, and then install snap ring when pressing in primary pis-
ton assembly.
CAUTION:

Make sure that snap ring is securely engaged in cylinder
body inner diameter groove.

Do not reuse snap ring.
5. Apply brake fluid to a grommet, and then install it into cylinder body after installing grommet to reservoir
tank.
CAUTION:
Do not reuse reservoir tank and grommet.
6. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting master cylinder assembly with vise, be sure
not to over-tighten.

When setting in a vise use copper plates or cloth to pro-
tect the flange.
7. Using a pin punch, [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)] insert reservoir tank mounting pin into the
pin hole so that the attachment side and the opposite side are
identical.
CAUTION:

Be sure to insert pin from the chamfered pinhole of cylin-
der body.

Do not reuse mounting pin.
SFIA2054E
BRA0561D
PFIA0505J
SFIA2052E

BRAKE BOOSTER
BR-21
C
D
E
G
H
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K
L
MA
B
BR

BRAKE BOOSTERPFP:47200
On-Board Inspection and ServiceBFS000BS
OPERATION CHECK
With engine stopped, change the vacuum to the atmospheric pres-
sure by depressing brake pedal several times. Then with brake
pedal fully depressed, start engine and when the vacuum pressure
reaches the standard, make sure that clearance between brake
pedal and floor panel decreases.
CAUTION:
Depressing pedal interval is approximately 5 seconds.
AIR TIGHT CHECK

Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change the vacuum to the atmospheric pressure. Make sure
distance between brake pedal and floor panel gradually
increases.

Depress brake pedal while engine is running, and stop engine
with brake pedal is depressed. Brake pedal stroke should not
change after holding brake pedal down for 30 seconds.
CAUTION:
Depressing brake pedal interval is approximately at intervals 5
seconds.
BRA0037D
SBR365AA