Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 2003-2005 Approved Nissan Frontier 2005 BR
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>> Download BR documenatation <<Text preview - extract from the documentF BRAKES
A
SECTION
BRAKE SYSTEM
BR B
C
D
E
CONTENTS
PRECAUTIONS ......................................................... 3
. REMOVAL .......................................................... 14
. BR
Precautions for Supplemental Restraint System INSTALLATION .................................................. 15 .
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Disassembly and Assembly ................................... 15 .
SIONER" ................................................................. 3
. DISASSEMBLY .................................................. 15 . G
Precautions for Brake System ................................. 3 . ASSEMBLY ........................................................ 15.
PREPARATION .......................................................... 4
. BRAKE BOOSTER .................................................. 16 .
Special Service Tool ................................................ 4
. On-Vehicle Service ................................................ 16.
H
Commercial Service Tools ....................................... 4 . OPERATING CHECK ......................................... 16 .
NOISE, VIBRATION, AND HARSHNESS (NVH) AIRTIGHT CHECK ............................................. 16 .
TROUBLESHOOTING ............................................... 5 . Removal and Installation ....................................... 17 .
NVH Troubleshooting Chart .................................... 5 . REMOVAL .......................................................... 17
. I
BRAKE PEDAL ......................................................... 6
. INSTALLATION .................................................. 18 .
Inspection and Adjustment ...................................... 6 . VACUUM LINES ...................................................... 19 .
INSPECTION ....................................................... 6
. Removal and Installation ....................................... 19 . J
ADJUSTMENT ..................................................... 6. Inspection .............................................................. 19
.
Removal and Installation ......................................... 7. VISUAL INSPECTION ........................................ 19 .
COMPONENTS ................................................... 7 . CHECK VALVE INSPECTION ............................ 20 .
K
REMOVAL ............................................................ 7
. FRONT DISC BRAKE .............................................. 21 .
INSPECTION AFTER REMOVAL ........................ 8 . On-vehicle Inspection ............................................ 21 .
INSTALLATION .................................................... 8
. PAD WEAR INSPECTION .................................. 21 .
BRAKE FLUID ........................................................... 9
. Components .......................................................... 22
. L
On-board Inspection ................................................ 9
. Removal and Installation of Brake Pad ................. 23 .
LEVEL CHECK .................................................... 9. REMOVAL .......................................................... 23
.
Drain and Refill ........................................................ 9
. INSTALLATION .................................................. 23 . M
Bleeding Brake System ......................................... 10 . Removal and Installation of Brake Caliper Assembly
BRAKE PIPING AND HOSE ....................................11 . and Disc Rotor ....................................................... 23
.
Hydraulic Circuit .....................................................11
. REMOVAL .......................................................... 23
.
Removal and Installation of Front Brake Piping and INSTALLATION .................................................. 23 .
Brake Hose ............................................................11
. Disassembly and Assembly of Brake Caliper
REMOVAL ...........................................................11
. Assembly ............................................................... 24
.
INSTALLATION .................................................. 12. DISASSEMBLY .................................................. 24 .
Removal and Installation of Rear Brake Piping and CALIPER INSPECTION ..................................... 25 .
Brake Hose ........................................................... 12
. ASSEMBLY ........................................................ 25.
REMOVAL .......................................................... 12
. DISC ROTOR INSPECTION .............................. 26 .
INSTALLATION .................................................. 12. BRAKE BURNISHING PROCEDURE ................ 27 .
Inspection After Installation ................................... 13. REAR DISC BRAKE ................................................ 28 .
BRAKE MASTER CYLINDER ................................. 14 . On-vehicle Inspection ............................................ 28 .
On-board Inspection .............................................. 14
. PAD WEAR INSPECTION .................................. 28 .
LEAK INSPECTION ........................................... 14 . Components .......................................................... 28
.
Removal and Installation ....................................... 14 . Removal and Installation of Brake Pad ................. 29 .
Revision: November 2005 BR-1 2005 Frontier
REMOVAL .......................................................... 29
. Assembly ...............................................................30
.
INSTALLATION ................................................... 29
. DISASSEMBLY ...................................................30 .
Removal and Installation of Brake Caliper Assembly CALIPER INSPECTION ......................................30 .
and Disc Rotor ....................................................... 29
. ASSEMBLY .........................................................31
.
REMOVAL .......................................................... 29
. DISC ROTOR INSPECTION ..............................31 .
INSTALLATION ................................................... 29
. BRAKE BURNISHING PROCEDURE ................32 .
Disassembly and Assembly of Brake Caliper SERVICE DATA AND SPECIFICATIONS (SDS) .....33 .
General Specifications ...........................................33 .
Brake Pedal ...........................................................33
.
Brake Booster ........................................................34
.
Front Disc Brake ....................................................34
.
Rear Disc Brake .....................................................34
.
Revision: November 2005 BR-2 2005 Frontier
PRECAUTIONS
PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" EFS004YT
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along B
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front C
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING: D
G 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. E
G 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. BR
G 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.
G
Precautions for Brake System EFS004YU
G Recommended fluid is Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent. Refer to MA-11,
"RECOMMENDED FLUIDS AND LUBRICANTS" . H
G Do not reuse drained brake fluid.
G Be careful not to splash brake fluid on painted areas.
I
G To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid.
G Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
G Use flare nut wrench when removing and installing brake tube. J
G Always check tightening torque when installing brake lines.
G Before working, turn ignition switch to OFF and disconnect con-
nectors for ABS actuator and electric unit (control unit) or battery K
terminals.
G Burnish the brake contact surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal L
occurs at very low mileage.
Refer to BR-27, "BRAKE BURNISHING PROCEDURE" .
WARNING:
G Clean brake pads and shoes with a waste cloth, then wipe
SBR686C M
with a dust collector.
Revision: November 2005 BR-3 2005 Frontier
PREPARATION
PREPARATION PFP:00002
Special Service Tool EFS004YV
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
-- Measuring brake pedal height
(J-46532)
Brake and clutch pedal height measure-
ment tool
LFIA0227E
Commercial Service Tools EFS004YW
Tool name Description
1. Flare nut crowfoot Removing and installing each brake pip-
2. Torque wrench ing
a: 10 mm (0.39 in) / 12 mm (0.47 in)
S-NT360
Power tool Removing nuts, bolts and screws
PBIC0190E
PBIC0191E
Revision: November 2005 BR-4 2005 Frontier
Symptom
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