NISSAN ALMERA N16 2003 Electronic Repair Manual

SBR451D
Checking Brake Fluid LevelNJBR0006Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
If fluid level is extremely low, check brake system for leaks.
Release parking brake lever and see if brake warning lamp
goes off. If not, check brake system for leaks.
SBR389C
Checking Brake LineNJBR0007CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
SBR419C
Changing Brake FluidNJBR0008CAUTION:
Refill with new brake fluid “DOT 4”.
Always keep fluid level higher than minimum line on res-
ervoir tank.
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
1. Clean inside of reservoir tank, and refill with new brake fluid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal while keeping reservoir level higher than minimum
line by adding new brake fluid.
4. Repeat until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to “Bleeding Brake System”, BR-8.
Brake Burnishing ProcedureNJBR0036Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing drums or rotors, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
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ON-VEHICLE SERVICE
Checking Brake Fluid Level
BR-7

pressure such that vehicle stopping time equals 3 to 5 sec-
onds.
3. To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnish-
ing procedure.
SBR995
Bleeding Brake SystemNJBR0009CAUTION:
Carefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
Fill reservoir with new brake fluid “DOT 4”. Make sure it is
full at all times while bleeding air out of system.
Place a container under master cylinder to avoid spillage
of brake fluid.
For models with ABS, turn ignition switch OFF and dis-
connect ABS actuator connectors or battery ground cable.
SBR419C
Bleed air in the following order.
Right rear brake,Left front brake,Left rear brake,Right
front brake
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to release
air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2. through 5. until clear brake fluid comes out of
air bleeder valve.
ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont’d)
BR-8

Hydraulic CircuitNJBR0010
YBR317
RemovalNJBR0011CAUTION:
Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
All hoses must be free from excessive bending, twisting
and pulling.
For ball & ramp type rear caliper, care should be taken as
not to let air enter the body.
1. Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
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BRAKE HYDRAULIC LINE
Hydraulic Circuit
BR-9

2. Cover openings to prevent entrance of air and dirt whenever
disconnecting brake line.
InspectionNJBR0012Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
SBR686C
InstallationNJBR0013CAUTION:
Refill with new brake fluid “DOT 4”.
Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Specification:
Flare nut
15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Connecting bolt
17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
2. Refill until new brake fluid comes out of each air bleeder valve.
3. Bleed air. Refer to “Bleeding Brake System”, BR-8.
BRAKE HYDRAULIC LINE
Removal (Cont’d)
BR-10

SBR822BA
SBR823BA
Dual Proportioning ValveNJBR0149INSPECTIONNJBR0149S01CAUTION:
Carefully monitor brake fluid level at master cylinder.
Use new brake fluid “DOT 4”.
Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
paint areas, wash it away with water immediately.
Depress pedal slowly when raising front brake pressure.
Check rear brake pressure at least 2 seconds after front
brake pressure reaches specified value.
1. Connect brake fluid pressure gauge to air bleeders of front and
rear brakes on either LH or RH side.
2. Bleed air from the tool.
3. Check fluid pressure by depressing brake pedal.
Unit: kPa (bar, kg/cm2, psi)
Applied pressure (Front brake) 5,884 (58.8, 60, 853.2)
Output pressure (Rear brake)3,430 - 4,800
(34.3 - 45, 35 - 45.70, 497 - 649.5)
If output pressure is out of specifications, replace the master
assembly (built-in type).
4. Bleed air after disconnecting the Tool. Refer to “Bleeding Brake
System”, BR-8.
REMOVAL AND INSTALLATION (BUILT-IN TYPE)NJBR0149S02Always replace together with master cylinder as an assembly.
Refer to “MASTER CYLINDER (NABCO)”, BR-14.
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DUAL PROPORTIONING VALVE
Dual Proportioning Valve
BR-11

Removal and InstallationNJBR0015
JBR752E
SBR997
InspectionNJBR0016Check brake pedal for following items.
Brake pedal bend
Clevis pin deformation
Crack of any welded portion
Crack or deformation of clevis pin stopper
SBR657EA
AdjustmentNJBR0017Check brake pedal free height from metal panel. Adjust if neces-
sary.
H: Free height
Refer to SDS, BR-73.
C
1,C2: Clearance between pedal stopper and threaded
end of stop lamp switch and brake switch
0.74 - 1.96 mm (0.0291 - 0.0772 in)
D: Depressed height
LHD (M/T): More than 90 mm (3.54 in)
LHD (A/T): More than 95 mm (3.74 in)
RHD (M/T): More than 90 mm (3.54 in)
RHD (A/T): More than 95 mm (3.74 in)
Under force of 490 N (50 kg, 110 lb) with engine run-
ning
A: Pedal free play at pedal pad
1.0-3.0mm(0.039-0.118in)
BRAKE PEDAL AND BRACKET
Removal and Installation
BR-12

SBR229E
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
2. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3. Check brake pedal’s depressed height while engine is running.
If lower than specification, check brake system for leaks, accu-
mulation of air or any damage to components (master cylinder,
wheel cylinder, etc.); then make necessary repairs.
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BRAKE PEDAL AND BRACKET
Adjustment (Cont’d)
BR-13

RemovalNJBR0151
NBR351
1. Reservoir cap
2. Oil filter
3. Reservoir tank4. Seal
5. Cylinder body
6. Secondary piston assembly7. Primary piston assembly
8. Stopper cap
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake
pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
MASTER CYLINDER (NABCO)
Removal
BR-14

SBR938A
DisassemblyNJBR01521. Bend claws of stopper cap outward and remove stopper cap.
SBR113B
2. Remove valve stopper while piston is pushed into cylinder.
3. Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
4. Draw out reservoir tank.
InspectionNJBR0153Check for the following items.
Replace any part if damaged.
Master cylinder:
Pin holes or scratches on inner wall.
Piston:
Deformation of or scratches on piston cups.
NBR352
AssemblyNJBR01541. Insert secondary piston assembly. Then insert primary piston
assembly.
Pay attention to alignment of secondary piston slit with valve
stopper mounting hole of cylinder body.
SBR940A
2. Install stopper cap.
Before installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.
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MASTER CYLINDER (NABCO)
Disassembly
BR-15

SBR704C
InstallationNJBR0155CAUTION:
Refill with new brake fluid “DOT 4”.
Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque mounting nuts.
:12-15N·m(1.2-1.5kg-m,9-11ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system. Refer to “Bleeding Brake
System”, BR-8.
MASTER CYLINDER (NABCO)
Installation
BR-16