2003 NISSAN TEANA brake rotor

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
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
I
J
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

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
BR-5
C
D
E
G
H
I
J
K
L
MA
B
BR

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartBFS000BF
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
BR-26
, BR-33
BR-26
, BR-33
BR-26
, BR-33—
—
BR-32, BR-39—
—
—
BR-32, BR-39
NVH in FAX, RAX and FSU, RSU section
NVH in WT section
NVH in WT section
NVH in FAX 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
AXLE AND SUSPENSION
TYRES
ROAD WHEEL
DRIVE SHAFT
STEERING
Symptom BrakeNoise××× ×××
××
Shake× ×××
××
Shimmy, Judder×××××××××× ×

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


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

Do not damage piston boot.

If any shim is subject to serious corrosion, replace it with a new one.

Always replace shim and inner shim cover as a set when replacing brake pads.

Keep rotor clean from brake fluid.

Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft
pedal occurs at very low mileage. Refer toBR-32, "
BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake PadBFS000BZ
REMOVAL
1. Remove tyres from vehicle.
2. Remove lower sliding pin bolt.
3. Suspend cylinder body with wire, and remove pads, pad retain-
ers, shims, and shim cover from torque member.
CAUTION:
When removing pad retainers from torque member, lift pad
retainers in the direction by the arrow (shown in the figure)
so as not to damage it.
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based
grease to the both sides of inner shim and outer shim, install
inner shim and inner shim cover to inner pad and outer shim to
outer pad.
CAUTION:
Securely install shim cover according to shim mounting
direction.
2. Install pad retainers and pads to torque member.
CAUTION:
Securely assemble pad retainers so that they are not being
lifted up from torque member.
3. Press in piston until pads can be installed, and then install cylin-
der body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool) to easily
press piston in.
CAUTION:
When replacing pads with new ones, press in piston until
pads can be installed. In this case, carefully monitor brake fluid level in reservoir tank because
brake fluid will return to master cylinder reservoir tank.
4. Install lower sliding pin bolt, and tighten it to the specified torque. Refer to BR-26, "
Components" .
5. Secure disc rotor with wheel nut. Depress brake pedal a few times until it gets a responsive touch.
6. Check front disc brake for drag.
7. Install tyres to vehicle.
SBR556E
PFIA0267E
PFIA0273E

BR-28
FRONT DISC BRAKE

Removal and Installation of Brake Caliper AssemblyBFS000C0
REMOVAL
1. Remove tyres from vehicle.
2. Secure disc rotor using wheel nut.
CAUTION:

Do not drop brake pad.
3. Drain brake fluid. Refer to BR-9, "
Drain and Refill" .
4. Remove union bolt and then disconnect brake hose from caliper
assembly.
5. Remove torque member bolts, and remove brake caliper
assembly.
6. Remove disc rotor.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor,
if it necessary to remove disc rotor.
SFIA2057E
SFIA1410J
SDIA2608E

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”.

Do not reuse drained brake fluid.
1. Install disc rotor.
CAUTION:
Align the matching marks of disc rotor and wheel hub,
which were marked at the time of removal when reusing
disc rotor.
2. Install brake caliper assembly to vehicle, and tighten torque
member mounting bolts to the specified torque. Refer to BR-26,
"Components" .
CAUTION:
Before installing torque member to vehicle, wipe oil and
grease on washer seats on steering knuckle and mounting
surface of torque member.
3. Install brake hose to brake caliper assembly, and tighten union bolts to the specified torque. Refer to BR-
26, "Components" .
CAUTION:

Do not reuse copper washers for union bolts.

Connect brake hose aligning with caliper assembly mounting protrusion.
4. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
5. Check front disc brake for drag.
6. Install tyres to vehicle.
Disassembly and Assembly of Brake Caliper AssemblyBFS000C1
NOTE:
Do not remove torque member, pads, shims, inner shim cover, and pad retainers when disassembling and
assembling cylinder body.
DISASSEMBLY
1. Remove caliper assembly from Vehicle. Refer to BR-28, "Removal and Installation of Brake Caliper
Assembly" .
2. Remove sliding pin bolts, from cylinder body, and remove pads
shims shim cover and pad retainers from torque member.
CAUTION:

When removing pad retainers from torque member, lift
pad retainer in the direction by the arrow (shown in the
figure) so as not to damage it.

Do not drop pads, shims, inner shim cover and pad
retainers from torque member.
3. Remove sliding pins and sliding pin boots from torque member.
SDIA2608E
SBR556E

BR-32
FRONT DISC BRAKE

DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any of them is detected, replace
applicable part.
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check runout.
CAUTION:
Before measuring, make sure that axle end play within the
specification before measuring runout. FAX-5 , "
WHEEL
BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting the mounting positions of disc rotor and wheel hub by
one hole.
4. If runout is still out of specification, turn rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and
705” or equivalent).
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is out-
side the specification, replace disc rotor.
BRAKE BURNISHING PROCEDURE
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:

Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are
securely fitted.

Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.Measurement point: At a point 10.0 mm (0.394 in)
from outer edge of disc.
Runout limit : 0.040 mm (0.0016 in) or less
SBR019B
Standard thickness : 24.0 mm (0.945 in)
Wear limit : 22.0 mm (0.866 in)
Maximum uneven wear
(measured at 8 positions): 0.010 mm (0.0004 in)
or less
SBR020B