NISSAN NAVARA 2005 Repair Workshop Manual

LOAD SENSING VALVE
BR-15
C
D
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B
BR
LOAD SENSING VALVEPFP:46400
Removal and InstallationEFS006A7
CAUTION:
lAlways use a flare nut wrench to remove brake tube. Be careful not to damage flare nut and brake
tube. Also, use flare nut torque wrench for brake tube installation and tightening to the specified
torque. Refer toBR-12, "
Hydraulic Circuit".
lRefill with new brake fluid “DOT 3” or “DOT 4”.
lNever reuse drained brake fluid.
REMOVAL
1. Drain brake fluid.
2. Cover brake line connections/openings to protect them from foreign material such as dust or dirt.
3. Using a flare nut wrench, remove flare nut on brake tube from load sensing valve.
4. Remove mounting bolts to remove load sensing valve.
INSTALLATION
lCarefully performing the following, install in the reverse order of removal.
lAfter installing load sensing valve to vehicle, perform the following: bleed air from brake line. Refer toBR-
11 , "Bleeding Brake System", and check mounting length “L” of sensor spring.
1. Torsion member 2. Load sensing valve bracket 3. Load sensing valve
4. Stopper 5. Sensor spring 6. Rear axle tube
Refer to GI section for symbol marks in the figure.
SFIA3190E

BR-16
LOAD SENSING VALVE
Inspection
EFS006A8
INSPECTION
1. With the vehicle in unladen condition, a person should sit in driver's seat at the rear. Then he/she should
get out of car gently. (This is to stabilize suspension deflection.)
NOTE:
“Unladen condition”: with full coolant, lubricant, 6 to 8 litters of fuel, spare tyre, jack, and hand tools
loaded.
2. Press load sensing valve against stopper bolt. Check if center-to-center length “L” between adjusting ref-
erence hole and reference pin is as specified below.
lIf measurement is outside the standard, perform following;
loosen mounting bolt of sensor spring bracket. By moving
sensor spring bracket, adjust so that the length “L” comes into
specified range.
3. Connect brake fluid pressure tester (special service tool) to
bleed valves of front caliper and rear wheel cylinder.
4. Bleed air from brake fluid pressure tester (special service tool).
5. With brake pedal depressed, check brake fluid pressure at front
caliper and rear wheel cylinder. The respective measurements
should be as specified in the table below.
6. Under condition of step 2 above, adjust rear shaft weight with
weights to obtain 143.9-146.9 mm (5.67-5.78 in) as length
“L”. Then, check brake fluid pressure as described in step 5
above. If measurements are outside the standards, replace load
sensing valve main body.
Standard
7. After inspection, remove brake fluid pressure tester (special service tool) and bleed air. Refer toBR-11,
"Bleeding Brake System". Length “L” : 143.9-146.9 mm (5.67-5.78 in)
SFIA0245E
BRA0515D
Front caliper brake fluid pressure
MPa (kg/cm
2)Rear wheel cylinder brake fluid pressure MPa (kg/cm
2)
2WD 4WD
unladen loaded unladen loaded
4.9 (50)3.2-4.2
(33-43)3.9-5.9
(40-60)1.8-2.7
(18-28)3.9-5.9
(40-60)
9.8 (100)4.1-5.1
(42-52)6.3-8.3
(65-85)2.6-3.6
(27-37)7.0-8.9
(71-91)

BRAKE MASTER CYLINDER
BR-17
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B
BR
BRAKE MASTER CYLINDERPFP:46010
On-Board InspectionEFS005SP
LEAK INSPECTION
lCheck for fluid leakage from master cylinder attachment portion such as reservoir tank and brake tube
connections.
Removal and InstallationEFS005SQ
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas immediately wipe off then and wash it away with water.
REMOVAL
1. Drain brake fluid. Refer toBR-10, "Drain and Refill".
2. Using flare nut wrench, disconnect brake tube from master cylinder assembly.
3. Remove master cylinder assembly mounting nuts and master cylinder assembly.
INSTALLATION
lInstallation is in the reverse order of the removal.
lRefill brake fluid and bleed air. Refer toBR-11, "Bleeding Brake System".
CAUTION:
lRefill with new brake fluid “DOT 3” or “DOT 4”.
lNever reuse drained brake fluid.
ComponentsEFS005SR
1. Reservoir cap 2. Brake fluid level switch 3. Grommet
4. Master cylinder assembly 5. Reservoir tank 6. Screw
7. Screw : Brake fluid
Refer to GI section for symbol marks except in the above.
SFIA3101E

BR-18
BRAKE MASTER CYLINDER
Disassembly and Assembly
EFS005SS
DISASSEMBLY
CAUTION:
lMaster cylinder assembly cannot be disassembled.
lRemove reservoir tank only when absolutely necessary.
Pull reservoir tank off master cylinder sub-assembly, then remove grommets from master cylinder sub-assem-
bly body.
ASSEMBLY
CAUTION:
lDo not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
lDo not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid to the grommet and attach to the cylinder body.
2. Install reservoir tank onto the cylinder body.

BRAKE BOOSTER
BR-19
C
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B
BR
BRAKE BOOSTERPFP:47200
On-Vehicle ServiceEFS005ST
OPERATING CHECK
With engine stopped, change vacuum to atmospheric pressure by
depressing brake pedal several times. Then with brake pedal fully
depressed, start engine and when vacuum pressure reaches the
standard, make sure that clearance between brake pedal and floor
panel decreases.
AIRTIGHT CHECK
lRun engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change vacuum to atmospheric pressure. Make sure that dis-
tance at intervals of 5 seconds between brake pedal and floor
panel gradually increases.
lDepress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change after
holding pedal down for 30 seconds.
BRA0037D
SBR365AA

BR-20
BRAKE BOOSTER
Removal and Installation
EFS005SU
COMPONENTS
REMOVAL
CAUTION:
lBe careful not to deform or bend brake tube while removing and installing the brake booster.
lReplace clevis pin if it is damaged.
lBe careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, the dash panel may damage the threads.
1. Remove ABS actuator and electric unit (control unit). Refer toBRC-40, "
Removal and Installation".
2. Remove brake tube from brake master cylinder.
3. Remove brake master cylinder. Refer toBR-17, "
Removal and Installation".
4. Remove vacuum hose from brake booster. Refer toBR-23, "
Removal and Installation".
5. Remove brake pedal attachment snap pin and clevis pin from inside vehicle.
6. Remove nuts on brake booster and brake pedal assembly.
7. Remove brake booster assembly from dash panel.
INSPECTION AFTER REMOVAL
Output Rod Length Inspection
1. Using a handy vacuum pump, apply a vacuum of –66.7 kPa (–
500 mmHg, –19.69 inHg) to the brake booster.
2. Check output rod length.
1. Reservoir tank 2. Master cylinder 3. Gasket
4. Brake pedal 5. Lock nut 6. Brake booster
7. Spacer
Refer to GI section for symbol marks in the figure.
SFIA3194E
Standard dimension at a vacuum of –66.7 kPa
(–500 mmHg, –19.69 inHg)
: –15.6 mm - 15.9 mm (–0.614 - 0.626 in)
SBR208E

BRAKE BOOSTER
BR-21
C
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B
BR
INSTALLATION
1. Loosen the lock nut to adjust the input rod length so that the
length B (in the figure) satisfies the specified value.
2. After adjusting “B”, temporarily tighten the lock nut to install the
booster assembly to the vehicle. At this time, securely install a
gasket and spacer block between the booster assembly and the
dash panel.
3. Connect brake pedal with the clevis of the input rod.
4. Install brake booster mounting nuts and tighten them to the
specified torque.Refer toBR-20, "
COMPONENTS".
5. Install brake tube from brake master cylinder to ABS actuator and electric unit (control unit). Refer toBR-
12, "Hydraulic Circuit".
6. Connect vacuum hose to brake booster.
7. Install master cylinder to brake booster assembly. Refer toBR-17, "
Removal and Installation".
8. Adjust the height and play of brake pedal.Refer toBR-6, "
Inspection and Adjustment".
9. Tighten lock nut of input rod to the specified torque. Refer toBR-7, "
ADJUSTMENT".
10. Refill new brake fluid and bleed air. Refer toBR-11, "
Bleeding Brake System". Length“B” :145-152mm(5.71-5.98in)
SGIA0060E

BR-22
VACUUM LINES
VACUUM LINES
PFP:41920
ComponentEFS005SV
LHD MODEL
RHD MODEL
SFIA3009E
1. Clamp 2. Vacuum hose 3. Vacuum tube
4. Vacuum hose 5. Clip 6. Connector
7. Vacuum hose 8. For brake booster 9. For vacuum pump
Refer to GI section for symbol marks in the figure.
SFIA3010E

VACUUM LINES
BR-23
C
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B
BR
Removal and InstallationEFS005SW
CAUTION:
lBecause vacuum hose contains a check valve, it must be
installed in the correct position. Refer to the stamp to con-
firm correct installation. Brake booster will not operate nor-
mally if the hose is installed in the wrong direction.
lInsert vacuum hose at least 24 mm (0.94 in).
lDo not use lubricating oil during assembly.
InspectionEFS005SX
VISUAL INSPECTION
Check for correct assembly, damage and deterioration.
CHECK VALVE INSPECTION
Airtightness Inspection
Check vacuum with a handy vacuum pump.
lReplace vacuum hose assembly if vacuum hose and check
valve are malfunctioning.
1. Clamp 2. Vacuum hose 3. Vacuum tube
4. Vacuum hose 5. For vacuum pump 6. For brake booster
Refer to GI section for symbol marks in the figure.
SBR225B
When connected to the booster side (1):
Vacuum should decrease within 1.3 kPa (10
mmHg, 0.39 inHg) for 15 seconds under a vacuum
of-66.7 kPa (-500 mmHg,-19.69 inHg).
When connected to the engine side (2):
Vacuum should not exist.
SFIA0210E

BR-24
FRONT DISC BRAKE
FRONT DISC BRAKE
PFP:41000
On-Board InspectionEFS005SY
PAD WEAR INSPECTION
lCheck pad thickness from a inspection hole on cylinder body.
Check using a scale if necessary.
ComponentsEFS005SZ
Standard thickness : 11.0 mm (0.43 in)
Repair limit thickness : 2.0 mm (0.08 in)
MAA0439D
1. Union bolt 2. Copper washer 3. Brake hose
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Sliding pin 12. Sliding pin boot
13. Bushing 14. Torque member mounting bolt 15. Torque member
16. Inner shim 17. Inner pad 18. Pad wear sensor (RH side)
19. Pad retainer 20. Outer pad 21. Outer shim
1: Rubber grease 2: PBC (Poly Butyl Cuprysil) grease
or silicone-based grease3: Polyglycol ether based lubricant
SFIA3168E