Qashqai J11. Brake system - part 5

 

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Qashqai J11. Brake system - part 5

 

 

BR-66

< REMOVAL AND INSTALLATION >

[RHD]

BRAKE PIPING

REAR : Hydraulic Piping

INFOID:0000000010305457

REAR : Removal and Installation

INFOID:0000000010305458

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.

2.

Drain brake fluid. Refer to 

BR-55, "Draining"

.

3.

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.

4.

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

5.

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.

Brake tube

2.

Lock plate

3.

Brake hose

4.

Union bolt

A.

To front brake tube

B.

To rear brake hose

C.

Floor side

D.

Caliper side

Refer to 

GI-4, "Components"

 for symbols in the figure.

1.

Brake booster

2.

Master cylinder assembly

3.

Front disc brake

4.

ABS actuator and electric unit (con-
trol unit)

5.

Connector

6.

Rear disc brake

A.

Brake tube

B.

Brake hose

 : Flare nut

 : Union bolt

 : Connector

JPFIA0079ZZ

BRAKE PIPING

BR-67

< REMOVAL AND INSTALLATION >

[RHD]

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1.

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

CAUTION:

Never reuse copper washer.

2.

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.

3.

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.

4.

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

CAUTION:

Never scratch the flare nut and the brake tube.

5.

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

BR-56, "Bleeding Brake System"

.

CAUTION:

Never reuse drained brake fluid.

6.

Install tires.

REAR : Inspection

INFOID:0000000010305459

INSPECTION AFTER REMOVAL

1.

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.

2.

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

BR-68

< REMOVAL AND INSTALLATION >

[RHD]

BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER

Exploded View

INFOID:0000000010305460

HRA2DDT - MR20DD

JPFIA0080GB

1.

Reservoir cap

2.

Reservoir tank

3.

Cylinder body

4.

Pin

5.

O-ring

6.

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-69

< REMOVAL AND INSTALLATION >

[RHD]

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K9K - R9M

Removal and Installation

INFOID:0000000010305461

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.

Drain brake fluid. Refer to 

BR-55, "Draining"

.

2.

Disconnect the brake fluid level switch harness connector.

3.

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

CAUTION:

Never scratch the flare nut and the brake tube.

4.

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.

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.

E1FIA0154GB

1.

Reservoir cap

2.

Reservoir tank

3.

Cylinder body

4.

Pin

5.

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-70

< REMOVAL AND INSTALLATION >

[RHD]

BRAKE MASTER CYLINDER

• 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-63, "FRONT : Exploded View"

.

CAUTION:

Never scratch the flare nut and the brake tube.

• After installation, perform the air bleeding. Refer to 

BR-56, "Bleeding Brake System"

.

CAUTION:

Never reuse drained brake fluid.

Disassembly and Assembly

INFOID:0000000010305462

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.

2.

Remove the reservoir tank mounting pin with a pin punch.

3.

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

1.

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.

2.

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

BRAKE MASTER CYLINDER

BR-71

< REMOVAL AND INSTALLATION >

[RHD]

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3.

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.

4.

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:0000000010305463

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

BR-72

< REMOVAL AND INSTALLATION >

[RHD]

BRAKE BOOSTER

BRAKE BOOSTER

Exploded View

INFOID:0000000010305464

MR20DD - HRA2DDT

K9K - R9M

Removal and installation

INFOID:0000000010305465

REMOVAL

1.

Remove battery and bracket.

2.

Remove cowl top cover. Refer to 

EXT-29, "Exploded View"

.

3.

Remove the instrument lower panel RH.

4.

Remove the knee protector.

E1FIA0152GB

1.

Master cylinder assembly

2.

Brake booster

3.

Lock nut

4.

Gasket

Refer to 

GI-4, "Components"

 for symbols in the figure.

E1FIA0153GB

1.

Master cylinder assembly

2.

Brake booster

3.

Lock nut

4.

Gasket

Refer to 

GI-4, "Components"

 for symbols in the figure.

BRAKE BOOSTER

BR-73

< REMOVAL AND INSTALLATION >

[RHD]

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5.

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

6.

Disconnect vacuum hose from brake booster..

7.

Remove master cylinder assembly. Refer to 

BR-69, "Removal and Installation"

.

8.

Disconnect the harness connector from the brake booster pressure sensor.

9.

Remove the brake booster pressure sensor.

10. Remove the nuts on the brake booster and brake pedal.

CAUTION:

Secure the brake booster to avoid damage to components.

11. 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-62, "Inspection and Adjustment"

.

• After installation, perform the air bleeding. Refer to 

BR-56, "Bleeding Brake System"

.

CAUTION:

Never reuse drained brake fluid.

Inspection and Adjustment

INFOID:0000000010305466

INSPECTION AFTER REMOVAL

Output Rod Length Inspection

1.

With a handy vacuum pump, apply vacuum pressure of 

66.7

kPa (

500 mmHg, 

19.70 inHg, 

0.667 bar) to the brake

booster.

2.

Check the output rod length (A).

Input Rod Length Inspection

JPFIA0019ZZ

Standard

Output rod length (A)

: Refer to 

BR-90, "Brake 

Booster"

.

JPFIA0021ZZ

BR-74

< REMOVAL AND INSTALLATION >

[RHD]

BRAKE BOOSTER

1.

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

2.

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 

 B 

 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-52, "Inspection and

Adjustment"

.

Standard

Input rod length (B)

: Refer to 

BR-90, "Brake 

Booster"

.

JPFIA0020ZZ

BRA0037D

JPFIA0043ZZ

JPFIA0044ZZ

VACUUM LINES

BR-75

< REMOVAL AND INSTALLATION >

[RHD]

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VACUUM LINES

Exploded View

INFOID:0000000010450972

MR20DD - HRA2DDT

K9K

JPFIA0087ZZ

1.

Clamp

2.

Vacuum hose

A.

To intake manifold

B.

To brake booster

C.

Paint mark

D.

Stamp indicating engine direction

JPFIA0088ZZ

1.

Clamp

2.

Vacuum hose (built in check valve)

3.

Vacuum tube

1.

Clip

2.

Vacuum hose

A.

To vacuum pump

B.

To brake booster

C.

Paint mark

D.

Stamp indicating engine direction

BR-76

< REMOVAL AND INSTALLATION >

[RHD]

VACUUM LINES

R9M

Removal and Installation

INFOID:0000000010450973

REMOVAL

1.

Remove the cowl top. Refer to 

EXT-29, "Removal and Installation"

.

2.

Remove the air duct assembly to the electric throttle control actuator. Refer to 

EM-23, "Exploded View"

(HRA2DDT engine models), 

EM-279, "Exploded View"

 (K9K engine models), 

EM-380, "Exploded View"

(R9M engine models), 

EM-147, "Exploded View"

 (MR20 engine models).

3.

Disconnect the vacuum hose from the engine intake manifold.

4.

Disconnect the vacuum hose from the brake booster.

5.

Disconnect the vacuum hose from the clip.

6.

Remove the vacuum hoses.

INSPECTION AFTER REMOVAL

Appearance

Check for correct assembly, damage and deterioration.

Check Valve Airtightness

• Use a handy vacuum pump (A) to check. 

• Replace vacuum hose assembly if vacuum hose and check valve

are malfunctioning.

INSTALLATION

IInstall the vacuum hose and tube.

CAUTION:

JPFIA0135ZZ

1.

Clamp

2.

Vacuum hose (built in check valve)

3.

Vacuum tube

4.

Clip

5.

Vacuum hose

6.

Grommet

A.

To vacuum pump 

B.

To brake booster

C.

Paint mark

D.

Stamp indicating engine direction

When connected to the brake booster side (B) : 

Vacuum should decrease within 1.3 kPa (10 mm-
Hg, 0.39 inHg, 0.013 bar) for 15 seconds under a 
vacuum of -66.7 kPa (-500 mmHg, -19.70 inHg, -
0,667 bar).

When connected to the engine side (C) :

Vacuum should not exist.

JPFIA0024ZZ

VACUUM LINES

BR-77

< REMOVAL AND INSTALLATION >

[RHD]

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• Because vacuum hose contains a check valve, it must be

installed in the correct position. Refer to the stamp to confirm
correct installation. Brake booster will not operate normally if
the hose is installed in the wrong direction. 

• Insert vacuum hose at least 24 mm (0.94 in) (A).
• Never use lubricating oil during assembly.
• Face the marking side up when assembling of vacuum hose.
• Face the marking side vehicle front when assembling of vac-

uum hose (built in check valve).

JPFIA0023ZZ

BR-78

< REMOVAL AND INSTALLATION >

[RHD]

FRONT DISC BRAKE

FRONT DISC BRAKE

BRAKE PAD

BRAKE PAD : Exploded View

INFOID:0000000010305476

BRAKE PAD : Removal and Installation

INFOID:0000000010305477

REMOVAL

WARNING:

Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.

CAUTION:

• Never depress the brake pedal while removing the brake pads because the piston may pop out.
• Never spill or splash brake fluid on the disc rotor.
1.

Remove tires.

2.

Remove lower sliding pin bolt.

3.

Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the
brake pad from the torque member.

CAUTION:

• Never deform the pad retainer when removing the pad retainer from the torque member. 
• Never damage the piston boot.
• Never drop the brake pads, shims, and the shim covers.

INSTALLATION

1.

Brake hose

2.

Union bolt

3.

Copper washer

4.

Cap

5.

Bleeder valve

6.

Cylinder body

7.

Sliding pin

8.

Sliding pin boot

9.

Bushing

10.

Piston seal

11.

Piston

12.

Piston boot

13.

Torque member

14.

Inner shim cover

15.

Inner shim

16.

Inner pad

17.

Pad retainer

18.

Outer pad

19.

Outer shim

20.

Outer shim cover

1: Apply rubber grease.

2: Apply copper based brake grease.

: Apply brake fluid.

Refer to 

GI-4, "Components"

 for symbols not described on the above.

JPFIA0090GB

FRONT DISC BRAKE

BR-79

< REMOVAL AND INSTALLATION >

[RHD]

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WARNING:

Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.

CAUTION:

• Never depress the brake pedal while removing the brake pads or the cylinder body because the pis-

ton may pop out.

• Never spill or splash brake fluid on the disc rotor.

1.

Install pad retainer to the torque member if pad retainer is removed.

CAUTION:

• Securely assemble the pad retainers so that it will not be lifted up from the torque member.
• Never deform the pad retainers.

2.

Apply copper based brake grease to the mating faces between the pads, shims and shim covers, and
install them to the brake pad.

CAUTION:

Always replace the shims together with the shim covers when replacing the brake pad.

3.

Install the cylinder body and brake pads to the torque member.

CAUTION:

• Never damage the piston boot.
• When replacing a pads with new ones, check the brake fluid level in the reservoir tank because

brake fluid returns to master cylinder reservoir tank when pressing piston in.

NOTE:
Use a disc brake piston tool to easily press piston. 

4.

Install the lower sliding pin bolt and tighten it to the specified torque.

5.

Depress the brake pedal several times to check that no drag feel is present for the front disc brake.

6.

Install tires.

BRAKE PAD : Inspection and Adjustment

INFOID:0000000010305478

INSPECTION AFTER REMOVAL

Replace the shims and the shim covers if rust is excessively attached.

ADJUSTMENT AFTER INSTALLATION

Brake Burnishing Procedure

Burnish contact surfaces between pads according to following procedure after refinishing or 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 pads 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 the 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.

BRAKE CALIPER ASSEMBLY

BR-80

< REMOVAL AND INSTALLATION >

[RHD]

FRONT DISC BRAKE

BRAKE CALIPER ASSEMBLY : Exploded View

INFOID:0000000010305479

BRAKE CALIPER ASSEMBLY : Removal and Installation

INFOID:0000000010305480

REMOVAL

WARNING:

Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.

CAUTION:

Never depress the brake pedal. Brake fluid may splash while removing the brake hose.
1.

Remove tires.

2.

Fix the disc rotor using wheel nuts.

3.

Drain brake fluid. Refer to 

BR-55, "Draining"

.

CAUTION:

Never spill or splash brake fluid on the disc rotor.

4.

Remove union bolt, and then disconnect brake hose from caliper assembly.

1.

Brake hose

2.

Union bolt

3.

Copper washer

4.

Cap

5.

Bleeder valve

6.

Cylinder body

7.

Sliding pin

8.

Sliding pin boot

9.

Bushing

10.

Piston seal

11.

Piston

12.

Piston boot

13.

Torque member

14.

Inner shim cover

15.

Inner shim

16.

Inner pad

17.

Pad retainer

18.

Outer pad

19.

Outer shim

20.

Outer shim cover

1: Apply rubber grease.

2: Apply copper based brake grease.

: Apply brake fluid.

Refer to 

GI-4, "Components"

 for symbols not described on the above.

JPFIA0090GB

FRONT DISC BRAKE

BR-81

< REMOVAL AND INSTALLATION >

[RHD]

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5.

Remove torque member mounting bolts, and remove brake cali-
per assembly.

CAUTION:

Never drop brake pads and caliper assembly.

6.

Remove disc rotor.

CAUTION:

• Put matching marks on the wheel hub and bearing assem-

bly and the disc rotor before removing the disc rotor.

• Never drop disc rotor.

INSTALLATION

WARNING:

Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.

CAUTION:

Never depress the brake pedal. Brake fluid may splash while removing the brake hose.
1.

Install disc rotor.

CAUTION:

Align the matching marks made during removal when reusing the disc rotor.

2.

Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts at 120N.m
(12,3 ; 88,5).

CAUTION:

Never spill or splash any grease and moisture on the brake caliper assembly mounting face,
threads, mounting bolts and washers. Wipe out any grease and moisture.

3.

Install brake hose to brake caliper assembly, and tighten union bolts to the specified torque.

4.

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

BR-56, "Bleeding Brake System"

.

CAUTION:

• Never reuse drained brake fluid.
• Never spill or splash brake fluid on the disc rotor.

5.

Check that no drag feel is present for the front disc brake.

6.

Install tires.

BRAKE CALIPER ASSEMBLY : Disassembly and Assembly

INFOID:0000000010305481

DISASSEMBLY

NOTE:
Never remove the torque member, brake pads, shims, shim covers and pad retainers when disassembling and
assembling the cylinder body.

1.

Remove the sliding pin bolts, and remove the cylinder body from the torque member.

CAUTION:

Never drop pads, shims, shim covers and pad retainers from torque member.

2.

Remove sliding pins and sliding pin boots from torque member.

3.

Remove bushing from sliding pin.

4.

Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.

CAUTION:

Never get fingers caught in the piston.

JPFIA0030ZZ

MAA0272D

 

 

 

 

 

 

 

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