NISSAN PICK-UP 1998 User Guide

Load Sensing Valve
SBR964D
SBR965D
CONTROL VALVE
BR-7

REMOVAL AND INSTALLATION
CAUTION:
lRefill with new brake fluid DOT 3 or DOT 4*1.
lBe 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. Replace damaged load sensing valve linkage as an assem-
bly.
2. When disassembling, apply multi-purpose grease to linkage.
3. Tighten all flare nuts and bolts.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
4. Bleed air. Refer to ``Bleeding Brake System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR966D
CONTROL VALVE
Load Sensing Valve (Cont'd)
BR-8

INSPECTION
1. Ensure vehicle is unladen condition*.
* Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
2. Have a driver sit in the driver's seat and one person sit on
the rear of the vehicle. Then have the person on the rear of
the vehicle slowly get off. This is necessary to stabilize sus-
pension deflection.
3. Adjust length ``L'' as follows:
a. Loosen stopper bolt locknut (2WD JIDOSHA KIKI make).
b. Pull lever against stopper bolt and adjust by turning stopper
bolt.
c. Tighten stopper bolt locknut (2WD JIDOSHA KIKI make).
Length ``L'':
2WD models
Approx. 187.3 mm (7.37 in)
4WD models
Approx. 158.1 mm (6.22 in)
4. Install pressure gauge to front and rear brake air bleeder.
5. Bleed air from the Tool.
6. Raise front brake pressure to 4,904 kPa (49.0 bar, 50
kg/cm
2, 711 psi) and 9,807 kPa (98.1 bar, 100 kg/cm2, 1,422
psi) and check rear brake pressure.
Rear brake pressure:
Refer to table below.
7. Set down weight slowly over axle center so that sensor
spring length becomes the same as when in loaded condi-
tion (refer to table below). Check rear brake pressure in the
same way described in step 6.
Unit: kPa (bar, kg/cm2, psi)
Front brake
pressureRear brake pressure
2WD 4WD
Unladen
condition
L = 187.3 mm
(7.37 in)Loaded
condition
L = 204.0 mm
(8.03 in)Unladen
condition
L = 158.1 mm
(6.22 in)Loaded
condition
L = 184.0 mm
(7.24 in)
4,904
(49.0, 50, 711)1,667 - 2,648
(16.7 - 26.5, 17
- 27, 242 - 384)3,334 - 4,315
(33.3 - 43.2, 34
- 44, 483 - 626)1,863 - 2,844
(18.6 - 28.4, 19
- 29, 270 - 412)3,334 - 4,315
(33.3 - 43.2, 34
- 44, 483 - 626)
9,807
(98.1, 100,
1,422)2,844 - 3,825
(28.4 - 38.2, 29
- 39, 412 - 555)3,629 - 5,590
(36.3 - 55.9, 37
- 57, 526 - 811)2,059 - 4,021
(20.6 - 40.2, 21
- 41, 299 - 583)3,629 - 5,590
(36.3 - 55.9, 37
- 57, 526 - 811)
SBR967D
SBR968D
SBR013B
SBR014B
CONTROL VALVE
Load Sensing Valve (Cont'd)
BR-9

Removal and Installation
SBR969DA
BRAKE PEDAL AND BRACKET
BR-10

Inspection
Check brake pedal for following items:
lBrake pedal bend
lClevis pin deformation
lCrack of any welded portion
lCrack or deformation of clevis pin stopper
Adjustment
Check brake pedal free height from melt sheet.
H: Free height
Refer to SDS, BR-80.
D: Depressed height
Refer to SDS, BR-80.
Under force of 490 N (50 kg, 110 lb)
with engine running
C: Clearance between pedal stopper and
threaded end of stop lamp switch
0.3 - 1.0 mm (0.012 - 0.039 in)
A: Pedal free play at clevis
1-3mm(0.04 - 0.12 in)
If necessary, adjust brake pedal free height.
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
lMake sure that the tip of input rod stays inside.
2. Loosen lock nut and adjust clearance ``C'' with stop lamp
switch respectively. Then tighten lock nuts.
3. Check pedal free play.
lMake sure that stop lamp is off when pedal is released.
4. Check brake pedal's depressed height while engine is run-
ning. If lower than specification, check for leaks, air in
system, or damage to components (master cylinder, wheel
cylinder, etc.). Then make necessary repairs.
SBR997
SBR278AB
SBR930
BRAKE PEDAL AND BRACKET
BR-11

Removal
CAUTION:
lBe 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.
lIn the case of brake fluid leakage from the master
cylinder, disassemble the cylinder. Then check piston
cups for deformation or scratches and replace neces-
sary parts.
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.
SBR970D
MASTER CYLINDER
BR-12

Disassembly
1. Bend claws of stopper cap outward.
2. Remove piston assemblies.
lIf it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
3. Draw out reservoir tank.
Inspection
Check master cylinder inner wall for pin holes or scratches.
Replace if damaged.
Assembly
1. Insert secondary piston assembly. Then insert primary piston
assembly.
lPay attention to direction of piston cups in figure at left.
Also, insert pistons squarely to avoid scratches on cyl-
inder bore.
SBR938A
SBR939A
SBR012AB
SBR089CA
MASTER CYLINDER
BR-13

2. Install stopper cap.
lBefore installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.
Installation
CAUTION:
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Tighten mounting nuts.
: 12 - 15 N´m (1.2 - 1.5 kg-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-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR940A
ABR190
MASTER CYLINDER
Assembly (Cont'd)
BR-14

On-vehicle Service
OPERATING CHECK
lDepress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
lDepress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
lStart engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. Booster is airtight if pedal
stroke is less each time.
lDepress brake pedal while engine is running, and stop
engine with pedal depressed. The pedal stroke should not
change after holding pedal down for30 seconds.
Removal
CAUTION:
lBe 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.
lBe careful not to deform or bend brake pipes during
removal of booster.
Inspection
OUTPUT ROD LENGTH CHECK
1. Apply vacuum of þ66.7 kPa (þ667 mbar, þ500 mmHg,
þ19.69 inHg) to brake booster with a hand vacuum pump.
2. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
SBR002A
SBR365AA
ABR373
SBR281A
BRAKE BOOSTER
BR-15

Installation
CAUTION:
lBe careful not to deform or bend brake pipes during
installation of booster.
lReplace clevis pin if damaged.
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
lTake care not to damage brake booster mounting bolt
thread when installing. Due to the narrow angle of
installation, the threads can be damaged by the dash
panel.
A: S230, M215T
LHD 165 mm (6.50 in)
RHD 185 mm (7.28 in)
M195T
LHD 160 mm (6.30 in)
RHD 180 mm (7.09 in)
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket
to brake booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
: 13 - 16 N´m (1.3 - 1.6 kg-m,9-12ft-lb)
5. Install master cylinder. Refer to ``Installation'', ``MASTER
CYLINDER'', BR-14.
6. Adjust brake pedal height and free play. Refer to BR-11.
7. Secure lock nut for clevis.
: 16 - 22 N´m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)
8. Bleed air. Refer to ``Bleeding Brake System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR116BE
BRAKE BOOSTER
BR-16