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Qashqai J11. Brake system - part 2

BRAKE PEDAL

BR-17

< REMOVAL AND INSTALLATION >

[LHD]

REMOVAL AND INSTALLATION

BRAKE PEDAL

Exploded View

INFOID:0000000010305353

* AT model

Removal and Installation

INFOID:0000000010305354

REMOVAL

Remove instrument lower panel LH. Refer to

IP-12, "Exploded View"

Remove the knee protector. Refer to

IP-12, "Exploded View"

Remove snap pin and clevis pin from clevis of brake booster.

Disconnect the harness connectors from the stop lamp switch and brake pedal position switch.

Remove the accelerator pedal. Refer to

ACC-3, "Removal and Installation"

Remove the brake pedal

CAUTION:

Support the brake booster and master cylinder to prevent contact with other components.

INSTALLATION

Note the following, and installation is the reverse order of removal.
• Apply the multi-purpose grease to the clevis pin and the mating faces. (Not necessary if grease has been

already applied.)

NOTE:
The clevis pin may be inserted in either direction.

Clevis pin

Brake pedal assembly

Stop lamp switch

ASCD brake switch (shift lock brake
switch)*

Clip

Snap pin

Refer to

GI-4, "Components"

for symbols not described on the above.

E1FIA0146GB

BR-18

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PEDAL

Inspection and Adjustment

INFOID:0000000010305355

INSPECTION AFTER REMOVAL

• Check the following items and replace the brake pedal assembly if necessary.
- Check the brake pedal upper rivet for deformation.
- Check the brake pedal for bend, damage, and cracks on the welded parts.

• Check clevis pin and plastic stopper (A) for damage and deforma-

tion. If any is found, replace clevis pin.

ADJUSTMENT AFTER INSTALLATION

• Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to

BR-8, "Inspection

and Adjustment"

• Perform the accelerator pedal check after installing the accelerator pedal. Refer to

ACC-3, "Inspection"

PFIA0756J

BRAKE PIPING

BR-19

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

FRONT

FRONT : Exploded View

INFOID:0000000010305360

K9K - R9M

E1FIA0148GB

Brake tube

ABS actuator and electric unit (con-
trol unit)

Connector

Master cylinder assembly

Brake booster

Lock plate

Brake hose

Union bolt

To front brake hose

To rear brake tube

Refer to

GI-4, "Components"

for symbols in the figure

BRAKE PIPING

BR-21

< REMOVAL AND INSTALLATION >

[LHD]

FRONT : Removal and Installation

INFOID:0000000010305362

REMOVAL

CAUTION:

Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
1.

Remove tires.

Drain brake fluid. Refer to

BR-11, "Draining"

Loosen the flare nut with a flare nut wrench and separate the brake tube from the hose.

CAUTION:

• Never scratch the flare nut and the brake tube.
• Never bend sharply, twist or strongly pull out the brake hoses and tubes.
• Cover open end of brake tubes and hoses when disconnecting to prevent entrance of dirt.

Remove the union bolt and remove the brake hose from the brake caliper assembly.

Remove the lock plate and remove the brake hose.

INSTALLATION

CAUTION:

Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
1.

Assemble the union bolt and the copper washer to the brake hose.

CAUTION:

Never reuse the copper washer.

Align the brake hose pin to the projection (A) of the brake caliper
assembly and tighten the union bolt (1) to the specified torque.

Install the brake tube to the brake hose, temporarily tighten the
flare nut by hand until it does not rotate further, and fix the brake
hose to the bracket with the lock plate.

CAUTION:

Check that all brake hoses and tubes are not twisted and
bent.

Tighten the flare nut to the specified torque with a flare nut
torque wrench.

CAUTION:

Never scratch the flare nut and the brake tube.

Refill with new brake fluid and perform the air bleeding. Refer to

BR-12, "Bleeding Brake System"

CAUTION:

Never reuse drained brake fluid.

Install tires.

FRONT : Inspection

INFOID:0000000010305363

INSPECTION AFTER INSTALLATOIN

Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer-
ence with other components when steering the steering wheel; no looseness at connections.

Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately
5 seconds with the engine running. Check for any fluid leakage.

ABS actuator and electric unit (con-
trol unit)

Front disc brake

Master cylinder assembly

Brake booster

Connector

Rear disc brake

Brake tube

Brake hose

: Flare nut

: Union bolt

: Connector

JPFIA0099ZZ

BR-22

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

CAUTION:

Retighten the applicable connection to the specified torque and repair any abnormal (damaged,
worn or deformed) part if any brake fluid leakage is present.

REAR

REAR : Exploded View

INFOID:0000000010305364

Brake tube

Lock plate

Brake hose

Union bolt

To front brake tube

To rear brake hose

Floor side

Caliper side

Refer to

GI-4, "Components"

for symbols in the figure.

JPFIA0077GB

BRAKE PIPING

BR-23

< REMOVAL AND INSTALLATION >

[LHD]

REAR : Hydraulic Piping

INFOID:0000000010305365

REAR : Removal and Installation

INFOID:0000000010305366

REMOVAL

CAUTION:

Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
1.

Remove tires.

Drain brake fluid. Refer to

BR-11, "Draining"

Loosen the flare nut with a flare nut wrench and separate the brake tube from the hose.

CAUTION:

• Never scratch the flare nut and the brake tube.
• Never sharply bend, twist or strongly pull the brake hoses and tubes.
• Cover the open end of brake tubes and hoses when disconnecting to prevent entrance of dirt.

Remove the union bolt and remove the brake hose from the brake caliper assembly.

Remove the lock plate and remove the brake hose from the vehicle.

INSTALLATION

CAUTION:

Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
1.

Assemble the union bolt and the copper washer to the brake hose.

CAUTION:

Never reuse copper washer.

ABS actuator and electric unit (con-
trol unit)

Front disc brake

Master cylinder

Brake booster

Connector

Rear disc brake

Brake tube

Brake hose

: Flare nut

: Union bolt

: Connector

JPFIA0078ZZ

BR-24

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

Install the brake hose L-pin by aligning it with the brake caliper
assembly positioning hole, and tighten the union bolt (1) to the
specified torque.

Connect the hose to the brake tube, temporarily tighten the flare
nut by hand until it does not rotate further, and fix the brake hose
to the bracket with the lock plate.

CAUTION:

Check that the brake hoses and tubes are not twisted and
bent.

Tighten the flare nut to the specified torque with a flare nut
torque wrench.

CAUTION:

Never scratch the flare nut and the brake tube.

Refill with new brake fluid and perform the air bleeding. Refer to

BR-12, "Bleeding Brake System"

CAUTION:

Never reuse drained brake fluid.

Install tires.

REAR : Inspection

INFOID:0000000010305367

INSPECTION AFTER REMOVAL

Check the brake hoses and tubes for the following: no scratches; no twist and deformation; no interfer-
ence with other components when steering the steering wheel; no looseness at connections.

Depress the brake pedal with a force of 785 N (80 kg, 176 lb) and hold down the pedal for approximately
5 seconds with the engine running. Check for any fluid leakage.

CAUTION:

Retighten the applicable connection to the specified torque and repair any abnormal (damaged,
worn or deformed) part if any brake fluid leakage is present.

JPFIA0012ZZ

BRAKE MASTER CYLINDER

BR-25

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE MASTER CYLINDER

Exploded View

INFOID:0000000010305368

MR20DD - HRA2DDT

JPFIA0080GB

Reservoir cap

Reservoir tank

Cylinder body

O-ring

Grommet

: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.

: Apply brake fluid.

Refer to

GI-4, "Components"

for symbols not described on the above.

BR-26

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE MASTER CYLINDER

K9K - R9M

Removal and Installation

INFOID:0000000010305369

REMOVAL

CAUTION:

Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.

Remove battery and bracket.

Remove air duct and air cleaner case. Refer to

EM-279, "Exploded View"

(K9K engine models),

EM-380,

"Exploded View"

(R9M engine models),

EM-23, "Exploded View"

(HRA2DDT engine models),

EM-147,

"Exploded View"

(MR20DD engine models).

Drain brake fluid. Refer to

BR-11, "Draining"

Disconnect the brake fluid level switch harness connector.

Disconnect the brake tubes from the master cylinder assembly with a flare nut wrench.

CAUTION:

Never scratch the flare nut and the brake tube.

Remove the master cylinder assembly.

CAUTION:

• Depress the brake pedal several times to release the vacuum pressure from the brake booster.

Then remove the master cylinder assembly.

• Never depress the brake pedal after the master cylinder assembly is removed.
• The piston of the master cylinder assembly is exposed. Never damage it when removing the

master cylinder.

• The piston may drop off when pulled out strongly. Never hold the piston. Hold the cylinder body

when handling the master cylinder assembly.

E1FIA0154GB

Reservoir cap

Reservoir tank

Cylinder body

Grommet

: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.

: Apply brake fluid.

Refer to

GI-4, "Components"

for symbols not described on the above.

BRAKE MASTER CYLINDER

BR-27

< REMOVAL AND INSTALLATION >

[LHD]

INSTALLATION

CAUTION:

Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
• Note the following, and installation is the reverse order of removal.

CAUTION:

• Never depress the brake pedal after the master cylinder assembly is removed.
• Apply PBC (Poly Butyl Cuprysil) silicone-based grease to

the brake booster [see (A) in the figure] when installing the
master cylinder assembly to the brake booster.

• The piston of the master cylinder assembly is exposed.

Never damage it when handling the master cylinder and
check that no dirt and dust are present on the piston before
installation. Clean it with new brake fluid if necessary.

• The piston may drop off when pulled strongly. Never hold

the piston. Hold the cylinder body when handling the master
cylinder assembly.

• Temporarily tighten the brake tube flare nut to the master cylinder

assembly by hand. Then tighten it to the specified torque with a
flare nut torque wrench. Refer to

BR-19, "FRONT : Exploded View"

CAUTION:

Never scratch the flare nut and the brake tube.

• After installation, perform the air bleeding. Refer to

BR-12, "Bleeding Brake System"

CAUTION:

Never reuse drained brake fluid.

Disassembly and Assembly

INFOID:0000000010305370

DISASSEMBLY

CAUTION:

• Never disassemble the cylinder body.
• Remove the reservoir tank if necessary.
1.

Fix the master cylinder assembly to a vise.

CAUTION:

Always set copper plates or cloth between vise when fixing the cylinder body to a vise. Never
overtighten the vise.

Remove the reservoir tank mounting pin with a pin punch.

Remove the reservoir tank and grommet from the cylinder body.

CAUTION:

Never drop the removed parts. The parts must not be
reused if they are dropped.

ASSEMBLY

Apply new brake fluid to the grommet and install it to the cylinder body.

CAUTION:

• Never use mineral oil such as gasoline or light oil.
• Never reuse the grommets.

Install the reservoir tank to the cylinder body.

CAUTION:

• Never drop the parts when installing. The parts must not be reused if they are dropped.
• Never reuse reservoir tank.

JPFIA0013ZZ

JPFIA0015ZZ

BR-28

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE MASTER CYLINDER

Fix the cylinder body to a vise.

CAUTION:

• Place the reservoir tank with the chamfered pin hole (

)

facing up.

• Always set copper plates or cloth between vise when fix-

ing the cylinder body to a vise. Never overtighten the vise.

Tilt the reservoir tank so that a mounting pin can be inserted.
Insert a mounting pin. Return the reservoir tank to the horizontal
position. Insert another mounting pin into the pin hole on the
opposite side in the same manner after the mounting pin passes
through the cylinder body pin hole.

CAUTION:

Never reuse the mounting pin.

Inspection

INFOID:0000000010305371

INSPECTION AFTER INSTALLATION

Fluid Leak

Check for brake fluid leakage from the cylinder body-to-brake booster mounting face, reservoir tank mounting
face and brake tube connections.

JPFIA0016ZZ

JPFIA0015ZZ

BRAKE BOOSTER

BR-29

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE BOOSTER

Exploded View

INFOID:0000000010305372

HRA2DDT - MR20DD

K9K - R9M

Removal and installation

INFOID:0000000010305373

REMOVAL

Remove battery and bracket.

Remove the cowl top. Refer to

EXT-29, "Removal and Installation"

Remove the instrument lower panel LH. Refer to

IP-13, "Removal and Installation"

E1FIA0152GB

Master cylinder assembly

Brake booster

Lock nut

Gasket

Spacer

Refer to

GI-4, "Components"

for symbols in the figure.

E1FIA0153GB

Master cylinder assembly

Brake booster

Lock nut

Gasket

Spacer

Refer to

GI-4, "Components"

for symbols in the figure.

BR-30

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE BOOSTER

Remove snap pin (1) and clevis pin (2) from inside vehicle.

Disconnect vacuum hose from brake booster. Refer to

BR-32, "Exploded View"

Remove master cylinder assembly. Refer to

BR-26, "Removal and Installation"

Disconnect the harness connector from the brake booster pressure sensor.

Remove the brake booster pressure sensor.

Remove the nuts on the brake booster and brake pedal.

CAUTION:

Secure the brake booster to avoid damage to components.

10. Remove the brake booster.

CAUTION:

Never deform or bend the brake pipes.

INSTALLATION

Note the following, and installation is the reverse order of removal.

CAUTION:

• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installa-

tion, the dash panel may damage the threads.

• Never deform or bend the brake tubes when installing the brake booster.
• Always use a new gasket between the brake booster and the spacer.
• Replace the clevis pin if it is damaged. Refer to

BR-18, "Inspection and Adjustment"

• After installation, perform the air bleeding. Refer to

BR-12, "Bleeding Brake System"

CAUTION:

Never reuse drained brake fluid.

Inspection and Adjustment

INFOID:0000000010305374

INSPECTION AFTER REMOVAL

Output Rod Length Inspection

With a handy vacuum pump, apply vacuum pressure of

−

66.7

kPa (

−

500 mmHg,

−

19.70 inHg,

−

0.667 bar) to the brake

booster.

Check the output rod length (A).

Input Rod Length Inspection

JPFIA0019ZZ

Standard

Output rod length (A)

: Refer to

BR-47, "Brake

Booster"

JPFIA0021ZZ

BRAKE BOOSTER

BR-31

< REMOVAL AND INSTALLATION >

[LHD]

Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (B).

Tighten the lock nut to the specified torque.

INSPECTION AFTER INSTALLATION

Operation

Depress the brake pedal several times at 5-second intervals with the
engine stopped. Start the engine with the brake pedal fully
depressed. Check that the clearance between brake pedal and dash
lower pane decreases.
NOTE:
A slight impact with a small click may be felt on the pedal when the
brake pedal is fully depressed. This is a normal phenomenon due to
the brake system operation.

Air Tight

• Idle the engine for 1 minute to apply vacuum to the brake booster,

and stop the engine. Then depress the brake pedal several times
at 5-second intervals until the accumulated vacuum is released to
atmospheric pressure. Check that the clearance between brake
pedal and dash lower panel gradually increases (A

→

C) each

time the brake pedal is depressed during this operation.

• Depress the brake pedal with the engine running. Then stop the

engine while holding down the brake pedal. Check that the brake
pedal stroke does not change after holding down the brake pedal
for 30 seconds or more.
NOTE:
A slight impact with a small click may be felt on the pedal when the
brake pedal is fully depressed. This is a normal phenomenon due
to the brake system operation.

ADJUSTMENT AFTER INSTALLTION

Perform the brake pedal adjustment after installing the brake pedal assembly. Refer to

BR-8, "Inspection and

Adjustment"

Standard

Input rod length (B)

: Refer to

BR-47, "Brake

Booster"

JPFIA0020ZZ

BRA0037D

JPFIA0043ZZ