2004 NISSAN TERRANO Service Repair Manual

Removal and Installation
Refer to EM section, ªVACUUM PUMP Ð Removal and Installa-
tionº.
VACUUM PUMP (ZD30DDTi engine model)
BR-26
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PRECAUTION:
Clean all brake assembly parts with a vacuum dust collector
to prevent particles from spreading through work area.
Pad Replacement
1. Loosen brake fluid reservoir cap.
2. Remove lower pin bolt.
YBR297
SBR081A
FRONT DISC BRAKE
BR-27
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3. Swing cylinder body upward. Then remove pad and anti-noiseshims.
CAUTION:
I When cylinder body is swung up, do not depress brake
pedal because piston will pop out.
I Ensure that brake fluid does not come into contact with
dustcover and rotor.
I Be careful not to twist brake hoses.
Brake pad thickness (new): 10 mm (0.39 in)
Wear limit (min. thickness): 2 mm (0.08 in)
I After installing new brake pads, check brake fluid level at
brake fluid reservoir.
Removal
IRemove torque member fixing bolts and union bolt.
Disassembly
Push out piston with dust cover with compressed air.
Use a wooden block so that the 2 pistons come out evenly.
CAUTION:
IWear protecting clothes and safety goggles.
I Do not hold your fingers in front of the pistons.
I Be careful not to scratch piston and/or cylinder faces.
Inspection
INSPECTION OF BRAKE DRAG FORCE
ªResidual pairº describes the friction pressure of the disc brake
shoes against the disc when the brake pedal is not applied.
1. Swing cylinder body upward.
2. Make sure that wheel bearing is adjusted properly. Refer to
section FA.
3. Measure rotating force (F
1).
NBR207
SBR012C
SBR085A
SBR168A
FRONT DISC BRAKE
Pad Replacement (Cont'd)
BR-28
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4. Install caliper with pads to the original position.
5. Depress brake pedal for 5 seconds.
6. Release brake pedal, rotate disc rotor 10 revolutions.
7. Measure rotating force (F
2).
8. Calculate brake drag force by subtracting F
1from F2.
Maximum brake drag force (F
2ÐF1):
103.0 N (10.5 kg, 23.2 lb)
If it is not within specification, check pins and pin boots in
caliper.
I Make sure that wheel bearing is adjusted properly.
I Disc pads and disc rotor must be dry.
DISC PAD
Check disc pad for wear or damage.
Pad wear limit (A):2.0 mm (0.079 in)
Assembly
Fit new piston seals.
Lightly apply clean brake fluid ªDOT 4º to piston outer face.
1. Insert piston seal into groove on cylinder body.
2. Install piston into cylinder body.
3. Install piston boot and secure properly.
Inspection
CYLINDER BODY
ICheck inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
I Minor damage from rust or foreign materials may be eliminated
by polishing the surface with a fine emery paper. Replace cyl-
inder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
SBR130A
SBR041A
SMA364A
NBR007
SBR574
FRONT DISC BRAKE
Inspection (Cont'd)
BR-29
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PISTON
Check outside surface of piston for score, rust, wear, damage or
presence of foreign materials. Replace if any of the above condi-
tions are observed.
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign materials are stuck to sliding
surface.
PIN, PIN BOLT AND PIN BOLT
Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.
ROTOR
Rubbing surface
Check rotor for roughness, cracks or chips.
Runout
1. Secure rotor to wheel hub with at least two nuts.
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to section FA.Maximum runout:0.07 mm (0.0028 in)
3. If the runout is out of specification, find minimum runout posi- tion as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub withnuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can be found.
4. If the runout is still out of specification, turn rotor with on-car brake lathe.
Thickness
Standard thickness: 26.0 mm (1.02 in)
Minimum thickness: 24.0 mm (0.94 in)
SBR089A
SBR090A
FRONT DISC BRAKE
Inspection (Cont'd)
BR-30
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Installation
CAUTION:
IRefill with new brake fluid ªDOT 4º.
I Never reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely taking care that brake hose is not trapped between any suspension part and that
hoses are not twisted.
3. Bleed air. Refer to ªBleeding Brake Systemº, ªBRAKE HYDRAULIC LINEº, BR-8.
SBR014C
FRONT DISC BRAKE
BR-31
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q1Wheel cylinder assembly
q
2Boot
q
3Piston
q
4Piston cup
q
5Cylinder body
q
6Spring
q
7Retaining shoe spring q
8Hold down retainer
q
9Shoe hold-down spring
q
10Shoe hold-down pin
q
11Pawl
q
12Adjuster assembly
q
13Trailing shoe
q
14Leading shoe q
15Back plate
q
16Plug
q
17Shoe return spring
q
18Toggle lever
q
19Pin
q
20Dust cap
YBR449
REAR DRUM BRAKE
BR-32
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Removal
WARNING:
Clean brake lining with a vacuum dust collector.
CAUTION:
Make sure parking brake lever is released completely.
1. Release parking brake lever fully, then remove drum.
If drum is hard to remove, screw two bolts in the provided
holes of the drum and tighten them gradually.
If the drum cannot be removed after carrying out this
operation, refer to ªInspectionº, ªPARKING BRAKE
CONTROLº, BR-36.
SBR093A
REAR DRUM BRAKE
BR-33
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