brakes NISSAN ALMERA N15 1995 Service Manual

JUDGEMENT OFSTALL TEST

Selector leverposition
TROUBLE
DIAGNOSES
Stall Tasting (Cont'd)

Judgement
D

2

R

Damaged components
Forward one-way
cluth
Hydraulic circuitfor
line pressure control
(Line pressure islow.)
D

2

R

Selector leverposition H

H

H

o

H

H

H
H
o
o
o

H

o
o
o
o

Judgement

AT-25
L

L

L

L
o
:
Stall
revolution
isnormal.
H :Stall revolution ishigher
than specified.
L :Stall revolution islower
than specified.
Engine
Torque converter
one-way clutch
Reverse clutch
Low one-way clutch
Clutches andbrakes except
high clutch, brakebandand
overrun clutchareOK.
(Condition ofhigh clutch,
brake bandandoverrun
clutch cannot beconfirmed by
stall test.)

SAT871H
•

SERVICEDATAANDSPECIFICATIONS (SOS)
Specifications andAdjustments (Cont'd)
CLUTCH ANDBRAKES

Model
34X68,
34X69,
34X81
34X70, 34X80

I
Reverse clutch
I

Number of

2

drive plates
Number of

2

driven plates
Drive plate
thickness mm(in)
Standard
2.0(0.079)

Wear limit
1.8(0.071)

Clearance mm(in)
Standard
0.5-0.8 (0.020 -0.031)

Allowable
1.2(0.047)

limit
Thicknessmm(in) Partnumber

4.4 (0.173) 31537-31XOO

Thickness 01

4.6(0.181) 31537-31X01

retaining
4.8(0.189) 31537-31X02

plates

5.0(0.197) 31537-31X03
5.2 (0.205) 31537-31X04

I
High clutch
I

Number 01

3 4

drive plates
Number 01

5 6+1

driven plates
Drive plate
thickness mm(in)
Standard
2.0(0.079) 1.6(0.063)

Wear limit
1.8
(0.071) 1.4(0.055)

Clearance mm(in)
Standard
1.4
-1.8 (0.055 -0.071)

-

Allowable
2.4(0.094) 2.6(0.102)

limit
Thicknessmm(in) Part
number

3.8 (0.150) 31537-
3.8(0.150) 31537-
31X11 31X11
4.0 (0.157) 31537-
4.0(0.157) 31537-
31X12 31X12
4.2 (0.165) 31537-
4.2(0.165) 31537-

Thickness 01
31X13
31X13

retaining
4.4(0.173) 31537-
4.4(0.173) 31537-

plates
31X1431X14
46 (0.181) 31537-
4.6(0.181) 31537-
31X15 31X15
4.8 (0.189) 31537-
4.8(0.189) 31537-
31X16 31X16
5.0 (0.197) 31537-
31X17
Model

34X68,
34X69,
34X81
34X70, 34X80

I
Forward clutch
I

Number ofdrive plates

5

Number ofdriven plates
5

Drive platethickness
mm(in)
Standard
1.8
(0.071)

Wear limit
1.6(0.063)

Clearance mm(in)
Standard
0.45-0.85 (0.0177 -0.0335)

Allowable limit
1.85
(0.0728)

Thickness Partnumber
mm (in)

3.6 (0.142) 31537-31X60
3.8 (0.150) 31537-31X61

Thickness ofretaining plate

4.0(0.157) 31537-31X62
4.2 (0.165) 31537-31X63
4.4 (0.173) 31537-31X64
4.6 (0.181) 31537-31X65

IOverrun clutch
I

Number ofdrive plates
3

Number ofdriven plates
4

Drive platethickness
mm(in)
Standard
1.6
(0.063)

Wear limit
1.4
(0.055)

Clearance mm
(in)
Standard
1.0
-1.4 (0.039 -0.055)

Allowable limit
2.0
(0.079)

Thickness Partnumber
mm (in)

3.6 (0.142) 31567-31X72

Thickness 01retaining plate
3.8
(0.150) 31567-31X73
4.0 (0.157) 31567-31X74

.

4.2(0.165) 31567-31X75
4.4 (0.173) 31567-31X76
AT-168

BRAKESYSTEM
SECTION

CONTENTS BR
PRECAUTIONS ANDPREPARATION
3

Precautions 3
Special Service Tools 4
Commercial ServiceTools 4

CHECK ANDADJUSTMENT 5

Checking BrakeFluidLevel 5
Checking BrakeLine 5
Changing BrakeFluid 5

AIR
BLEEDING 6

Bleeding Procedure 6

BRAKE HYDRAULIC LINE 7

Removal 8
Inspection 8
Installation 8

CONTROL VALVE 9

Proportioning Valve 9

BRAKE PEDALANDBRACKET 11

Removal andInstallation 11
Inspection 11
Adjustment 11

MASTER CYLINDER 12

Removal 12
Disassembly 12
Inspection 13
Assembly 13
Installation 14

BRAKE BOOSTER 15

On-vehicle Service 15
Removal 15
Inspection 16
Installation 16

VACUUM HOSE 17

Removal andInstallation 17
Inspection 17

FRONT DISCBRAKE 19

Pad Replacement.. 19
Removal 22
Disassembly 22Inspection
-Caliper 22
Inspection -Rotor 23
Assembly '".23
Installation 24

REAR DRUM BRAKE 25

Removal 25
Inspection -Wheel Cylinder 26
Wheel Cylinder Overhaul 27
Inspection -Drum 27
Inspection -Lining 27
Installation 27

REAR DISCBRAKE 29

Pad Replacement 29

~~s:~::~'~I~':::::::::::'::: ::.::::::::.::::::.::::::::::.::::::.::::::::~~ •••

Inspection -Caliper 32
Inspection -Rotor 33
Assembly 33
Installation 35

PARKING BRAKECONTROL 36

Removal andInstallation 36
Inspection 36
Adjustment ." 37

ANTI-LOCK BRAKESYSTEM 38

Purpose 38
Operation 38
ABS Hydraulic Circuit 38
System Components 39
System Description 39
Removal andInstallation .40
Wiring Diagram -ABS - .45

TROUBLE DIAGNOSES
52

Contents 52
Component PartsandHarness Connector
Location 64

SERVICE DATAANDSPECIFICATIONS (SDS)86

General Specifications 86
Inspection andAdjustment 88

GG94310000or

commercial equivalent

SBR820BA

For
tightening flarenut

Tool number
Tool name
PRECAUTIONS
ANDPREPARATION
Precautions (Conl'd)

BRAKE SYSTEM

• Recommended fluidisbrake fluid"DOT 3"or"DOT 4".
• Never reusedrained brakefluid.
• Donot mix different typesofbrake fluids (DOT3,DOT 4).
• Becareful nottosplash brakefluidonpainted areas;itmay
cause paintdamage. Ifbrake fluidissplashed onpainted
areas, washitaway withwater immediately.
• Toclean master cylinder parts,discbrake caliper partsor
wheel cylinder parts,useclean brake fluid.
• Never usemineral oilssuch asgasoline orkerosene. They
will ruin rubber partsofhydraulic system.
• Use flare nutwrench whenremoving andinstalling brake
tubes.
• Always torquebrakelineswhen installing.
WARNING:
• Clean brakes withavacuum dustcollector tominimize risk
of health hazard frompowder causedbyfriction.

Special Service Tools

Description

GG9431 0000

Flare nuttorque wrench

NT406
Removing
andinstalling eachbrake piping

a: 10 mm (0.39 in)
~: 16.2N'm(1.65 kg-m, 11.9f1-lb)
Commercial ServiceTools

Description
Tool name

CD
Flare nutcrows foot
@ Torque wrench
Brake fluidpressure
gauge
NT360
NT151
Removing
andinstalling eachbrake piping

a: 10 mm (0.39 in)

Measuring brakefluidpressure

BR-4

CHECKANDADJUSTMENT

OK
MINMax.
line
Min. line
SBR418C
Checking
BrakeFluidLevel

• Check fluidlevel inreservoir tank.Itshould bebetween
Max. andMin. lines onreservoir tank.
• Iffluid level isextremely low,check brakesystem forleaks.
• Ifbrake warning lampcomes on,check brakefluidlevel
switch andparking brakeswitch.

ABR159
SBR419C
Checking
BrakeLine

CAUTION: If leakage occursaround joints,retighten or,ifnecessary,
replace damaged parts.
1. Check brakelines(tubes andhoses) forcracks, deteriora-
tion orother damage. Replaceanydamaged parts.
2. Check foroilleakage byfully depressing brakepedalwhile
engine isrunning.

Changing BrakeFluid

CAUTION:
• Refill withnewbrake fluid"DOT 3"or"DOT 4".
• Always keepfluidlevel higher thanminimum lineonreser-
voir tank.
• Never reusedrained brakefluid.
• Donot mix different typesofbrake fluids(DOT3,DOT 4).
• Becareful nottosplash brakefluidonpainted areas;itmay •
cause paintdamage. Ifbrake fluidissplashed onpainted :•
areas, washitaway withwater immediately.
1. Clean inside ofreservoir tank,andrefill withnewbrake
fluid.
2. Connect avinyl tubetoeach airbleeder valve.
3. Drain brake fluidfrom each airbleeder valvebydepressing
brake pedal.
4. Refill untilnewbrake fluidcomes outofeach airbleeder
valve.
Use same procedure asinbleeding hydraulic systemto
refill brake fluid.
Refer to"Bleeding Procedure", BR-6.

BR-5

BRAKEHYDRAULIC LINE

Without anti-lock brakesystem
(Models withdual proportioning valvebuiltintomaster cylinder)
(built-in type)

Proportioningvalve
(Do notdisassemble.)

With anti-lock brakesystem

ASS actuator

L
Master cylinder
=
.
Primary line
- .Secondary line

~ 0:Flare nut

15 -18 (1.5 -1.8, 11-13)

• :Connecting bolt

17 -20 (1.7 -2.0, 12-14)

~ :N.m (kg-m. ft-Ib)

SBR086D
•

BR-7

CONTROLVALVE
Proportioning Valve
INSPECTION
CAUTION:
• Carefully monitorbrakefluidlevel atmaster cylinder.
• Use new brake fluid"DOT 3"or"DOT 4".
• Donot mix different typesofbrake fluids(DOT3,DOT 4).
• Becareful nottosplash brakefluidonpainted areas;itmay
cause paintdamage. Ifbrake fluidissplashed onpaint
areas, washitaway withwater immediately.
• Depress pedalslowly whenraising frontbrake pressure.
• Check rearbrake pressure 2seconds afterfront brake pres-
sure reaches specified value.
• For models withABS disconnect harnessconnectors from
ABS actuator relaybefore checking.

1.
Connect Tooltoair bleeders offront andrear brakes on
either
LH
or
RH
side.
2. Bleed airfrom theTool.
3. Check rearbrake pressure bydepressing brakepedal
(increasing frontbrake pressure).

Unit:kPa(bar, kg/cm
2,
psi)

Without ABS
I
With
ABS
Applied models
GA14DE,GA16DE,CD20 GA16DE'
SR20DE
Applied pressure 7.3556.375
5,394
(Front brake) (73.6,
75,1,067) (63.7,65,924)
(53.9,55,782)
3,432 -3,825 2,452-2,844
Output pressure 5,100
-5,492 (34.3-38.2, (245-28.4,
(Rear brake) (51.0
-54.9, 52-56, 739 -796) 35-39, 25-29,
498 -555) 356-412)

*
Models forAustralia

If
output pressure isout ofspecifications, replacedualpro- •••
portioning valve(separated type)ormaster cylinder assem-
bly (built-in type).
4. Bleed airafter disconnecting theTool. Refer to"Bleeding
Procedure", BR-5.

BR-9

Bolts
(M8
x
1.25) Wheel
cylinder
Adjuster
SBR280B
SBR020A REAR
DRUM BRAKE
Removal (Cont'd)

1. Release parkingbrakeleverfully,thenremove drum.

If drum ishard toremove, thefollowing procedures shouldbe
carried out.
a. Remove plug.Thenshorten adjuster tomake clearance
between brakeshoeanddrum asshown.
b. Tighten thetwo bolts gradually.
SBR785BA
2.
After removing retainer,removespringbyrotating shoes.

• Becareful nottodamage wheelcylinder pistonboots.
• Becareful nottodamage parkingbrakecablewhensepa-
rating it.

3. Remove adjuster.
4. Disconnect parkingbrakecablefromtoggle lever.
5. Remove retainerringwith asuitable tool.Then separate
toggle leverandbrake shoe.

Inspection -Wheel Cylinder

• Check wheelcylinder forleakage.
• Check forwear, damage andloose conditions.
Replace ifany such condition exists.

BR-26

ANTI-LOCKBRAKESYSTEM
Purpose

The Anti-Lock BrakeSystem (ABS)consists ofelectronic andhydraulic components. Itallows forcon-
trol ofbraking forcesothat locking ofthe wheels canbeavoided.
The ABS:
1) Improves propertracking performance throughsteering wheeloperation.
2) Eases obstacles tobe avoided throughsteering wheeloperation.
3) Improves vehiclestability bypreventing flatspins.

Operation

• When thevehicle speedisless than 10km/h (6MPH) thissystem doesnotwork.
• The Anti-Lock BrakeSystem (ABS)hasself-test capabilities. Thesystem turnsonthe ABS warning
light for1second afterturning theignition switchON.The system performs anothertestthefirst time
the vehicle reaches 6km/h (4MPH). Amechanical noisemaybeheard asthe ABS performs aself-
test. This isanormal partofthe self-test feature.Ifa malfunction isfound during thischeck, theABS
warning lightwillcome on.
• During ABSoperation, amechanical noisemaybeheard. Thisisanormal condition.

ABS Hydraulic Circuit

G)
Inletsolenoid valve

@
Outlet solenoid valve

@
Reservoir

@)
Pump
)(

@

@
Motor

@
Inletvalve

(J)
Outlet valve
@ Bypass checkvalve

BR-38 @

Check valve

@)
Damper

@
Gradient switch
SBR918C

ANTI-LOCKBRAKESYSTEM
System Components

Dual proportioning
valve
Rearwheel sensors
For LHD models, controlunit
is located onthe opposite side.

SBR048DB

Control unit

s::';o~'~W.
r<ca!bvJsteJ
Magnetic flux~ _~-Coil

I .I

Tooth~ Sensorrotor
/ ~m~f onetooth

v:~-- System
Description
SENSOR

The sensor unitconsists ofagear-shaped sensorrotoranda
sensor element. Theelement contains abar magnet around
which acoil iswound. Thesensor isinstalled onthe back side
of the brake rotor.Sine-wave currentisgenerated bythe sen-
sor asthe wheel rotates. Thefrequency andvoltage increase(s) •
as the rotating speedincreases. :•

V: Induced electromotive force

SBR124B
SBR049DA CONTROL
UNIT

The control unitcomputes thewheel rotating speedbythe sig-
nal current sentfrom thesensor. Thenitsupplies aDC current
to the actuator solenoid valve.Italso controls ON-OFFopera-
tion ofthe valve relayandmotor relay.Ifany electrical malfunc-
tion should bedetected inthe system, thecontrol unitcauses
the warning lamptolight up.Inthis condition, theASS willbe
deactivated bythe control unit,andthevehicle&#39;s brakesystem
reverts tonormal operation.

BR-39