2003 NISSAN X-TRAIL ECU

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

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-18
BRAKE BOOSTER
2. Place an output rod gauge in the master cylinder. Rotate the
screw until the gauge contacts the primary piston.
3. Turn output rod gauge upside down to secure A. Adjust it with B
until clearance between output rod and screw is 0 mm.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that length B (in the
figure) satisfies the specified value.
2. After adjusting B, temporarily tighten lock nut to install booster
assembly to vehicle.
3. Connect brake pedal to input rod clevis.
4. Connect brake pedal assembly mounting nuts and tighten to the
specified torque.
5. Connect master cylinder to the booster assembly.
6. Adjust brake pedal height and play.
7. Tighten input rod lock nut to the specified torque.
8. Bleed air. Refer toBR-10, "
Bleeding Brake System". Reference value at vacuum of -66.7 kPa (-500 mmHg, -
19.69 inHg):
10.4 mm (0.409 in)
SBR208E
Length B standard : 125 mm (4.92 in)
SGIA0060E

FRONT DISC BRAKE
BR-23
C
D
E
G
H
I
J
K
L
MA
B
BR
3. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
4. Remove disc rotor.
INSTALLATION
CAUTION:
lRefill with new brake fluid “DOT 3” or “DOT 4”.
lNever 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 oil and grease on the trailing arm washer seats and cali-
per assembly mounting surface.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
lDo not reuse the copper washer for union bolts.
lSecurely assemble brake hose to protrusions on cylinder body.
4. Bleed air. Refer toBR-10, "
Bleeding Brake System".
Caliper Disassembly and AssemblyEF S0 00 CK
DISASSEMBLY
WA RN ING:
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.
SBR979B
BRB0032D

REAR DISC BRAKE
BR-29
C
D
E
G
H
I
J
K
L
MA
B
BR
Caliper Removal and InstallationEFS00180
REMOVAL
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from air bleeder while depressing
brake pedal.
3. Remove brake hose connected to caliper assembly and union
bolts. Remove brake hose from caliper assembly.
4. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
5. Remove disc rotor.
INSTALLATION
CAUTION:
lRefill with new brake fluid “ DOT 3 or DOT 4”.
lNever reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Wipe oil and grease on axle assembly washer seats and caliper assembly mounting surface.
Install caliper assembly.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
lDo not reuse the copper washer for union bolts.
lSecurely assemble brake hose to protrusions on cylinder body.
4. Bleed air. Refer toBR-10, "
Bleeding Brake System".
Caliper Disassembly and AssemblyEFS00181
DISASSEMBLY
WA RN ING:
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 a slotted screwdriver (as shown in the figure), remove pis-
ton seals.
SBR656
SBR028A

BR-32
REAR DISC BRAKE
4. Fix piston boot with retaining ring.
CAUTION:
lBe sure boot is securely engaged in groove on cylinder
body.
lDo not reuse retaining ring.
5. Connect sliding pins and sliding pin boots to torque member.
6. Connect torque member to axle assembly and tighten mounting
bolts to specified torque.
CAUTION:
Wipe oil and grease on axle assembly washer seats and torque
member mounting surface. Install torque member to axle
assembly.
7. Connect pads, pad retainers, shims, and shim covers to torque member and assemble cylinder body.
8. Tighten sliding pin bolts to the specified torque.
9. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
Do not reuse union bolt copper washer.
10. After installing caliper assembly, refill with new brake fluid and bleed air. Refer toBR-10, "
Bleeding Brake
System"
SFIA0158E