NISSAN PRIMERA 1999 Electronic Repair Manual

NBR434
BRAKE HYDRAULIC LINE
BR-9

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.
lAll hoses and tubes must be free from excessive
bending, twisting and pulling.
lFor rear disc caliper, care should be taken as not to let
air enter the body.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
3. Remove flare nut securing brake tube to hose, then withdraw
lock spring.
4. Cover openings to prevent entrance of dirt whenever discon-
necting hydraulic line.
Inspection
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
Installation
CAUTION:
lRefill with new brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
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 ªBleeding Brake Systemº, BR-8.
SBR419C
SBR686C Commercial service tool
BRAKE HYDRAULIC LINE
BR-10

Dual Proportioning Valve
INSPECTION
CAUTION:
lCarefully monitor brake fluid level at master cylinder.
lUse new brake fluid ªDOT 4º.
lBe 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.
lDepress pedal slowly when raising front brake pressure.
lCheck 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)5.39
(53.9, 55, 781.6)
Output pressure (Rear brake)3.132 - 3.532
(31.32 - 35.32,
31.94 - 36.02,
454.3 - 512.3)
If output pressure is out of specifications, replace dual pro-
portioning valve.
4. Bleed air after disconnecting the Tool. Refer to ªBleeding
Brake Systemº, BR-8.
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.
lAll tubes must be free from excessive bending, twisting
and pulling.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
3. Loosen flare nut.
4. Remove proportioning valve mounting bolt, then remove flare
nut.
SBR822BA Brake fluid pressure
gauge
SBR823BA Brake fluid pressure gauge
NBR145
CONTROL VALVE
BR-11

INSTALLATION
CAUTION:
lRefill with new brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
1. Temporarily fit flare nut to proportioning valve.
2. Tighten proportioning valve mounting bolt, then tighten flare
nut with wooden block placed between proportioning valve
and dash panel.
Flare nut:
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Mounting bolt:
: 5.1 - 8.8 N´m (0.52 - 0.9 kg-m, 45 - 78 in-lb)
3. Refill until new brake fluid comes out of each air bleeder
valve.
4. Bleed air. Refer to ªBleeding Brake Systemº, BR-8.
CONTROL VALVE
Dual Proportioning Valve (Cont'd)
BR-12

Removal and Installation
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 dash reinforcement panel.
H: Free height
Refer to SDS, BR-92.
D: Depressed height
Refer to SDS, BR-92.
C
1,C2: Clearance between pedal stopper rubber and
threaded end of brake lamp switch (or redun-
dant brake switch).
0.75 - 2.0 mm (0.03 - 0.08 in)
A: Pedal free play
1-3mm(0.039 - 0.118 in)
NBR435
SBR997 Stopper
SBR110B Clevis lock nut
16-22N´m
(1.6 - 2.2 kg-m, 12 - 16 ft-lb)
Input rod
Brake lamp switch
and redundant
brake switch
C
1or C2
A
H D 90É
Floor carpet
Dash insulator
Floor panelFloor carpet
Dash
insulator
Melt sheet
BRAKE PEDAL AND BRACKET
BR-13

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 brake lamps go off when pedal is released.
3. Check brake pedal's depressed height while engine is run-
ning.
If depressed height is below specified value, check brake
system for leaks, accumulation of air or any damage to com-
ponents (master cylinder, wheel cylinder, etc.); then make
necessary repairs.
SBR229E Stays inside
Clevis
Lock nut
Input rod
BRAKE PEDAL AND BRACKET
Adjustment (Cont'd)
BR-14

Removal
1. Reservoir cap
2. Oil filter
3. Reservoir tank
4. Seal5. Cylinder body
6. Elastic pin
7. Piston stopper pin8. Secondary piston assembly
9. Primary piston assembly
10. Circlip
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. Disconnect fluid level connector.
2. Connect a vinyl tube to air bleeder valve.
3. Drain brake fluid from each air bleeder valve, depressing
brake pedal to empty fluid from master cylinder.
4. Remove brake pipe flare nuts.
5. Remove master cylinder mounting nuts.
Disassembly
1. Drive out elastic pin from cylinder body.
2. Remove reservoir tank and seals.
NBR436
SBR231E
MASTER CYLINDER
BR-15

3. Remove the circlip with suitable pliers while piston is pushed
into cylinder.
4. Remove piston stopper pin while piston is pushed into cylin-
der.
5. Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
Inspection
Check for the following items.
Replace any part if damaged.
Master cylinder:
lPin holes or scratches on inner wall.
Piston:
lDeformation of or scratches on piston cups.
Assembly
1. Insert secondary piston assembly. Then insert primary piston
assembly.
lPay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body.
2. Install piston stopper pin while piston is pushed into cylinder.
Then secure the primary and secondary piston assemblies
with new circlip.
3. Push reservoir tank seals and reservoir tank into cylinder
body.
4. Install elastic pin.
NBR353
Push
Piston stop-
per pin
SBR232E
Secondary piston
Primary piston
SBR233E
Push
Piston stop-
per pin
SBR232E
MASTER CYLINDER
Disassembly (Cont'd)
BR-16

Installation
CAUTION:
lRefill with new brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque mounting nuts.
: 14 - 17 N´m (1.5 - 1.7 kg-m, 11 - 12 ft-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. Connect fluid level connector.
9. Bleed air from brake system. Refer to ªBleeding Brake
Systemº, BR-8.
SBR236E
MASTER CYLINDER
BR-17

On-vehicle Service
OPERATING CHECK
1. Depress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
2. Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
1. Start 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.
2. Depress 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.
SBR002A
SBR365AA OK NG
Third
Second
First
NBR437
BRAKE BOOSTER
BR-18