NISSAN ALMERA 2001 Service Manual

ComponentNJBR0126
SBR612E
SBR613E
DisassemblyNJBR0136Disassemble the components, referring to the ªComponentº, then
remove vacuum pump.
CAUTION:
Do not disassemble vacuum pump. (Do not loosen three M6
bolts.)
AssemblyNJBR0127Install all parts to cylinder head rear cover as follows.
1. Install vacuum pump.
2. Install chain guide temporarily.
+Adjust the chain guide position by the method explained in step
5.
SBR614E
3. Install rear cam sprocket.
+Installation direction of sprocket is not specified.
+Insert 2 thickness gauges [3.0 mm (0.118 in)] between cover
and rear cam sprocket (shown in the figure). Insert 2 bolts [M6,
thread length: 35 - 40 mm (1.38 - 1.57 in)] into sprocket to
retain it to cover.
+Use thickness gauges [3.0 mm (0.118 in)] for chain alignment
between vacuum pump sprocket and cam sprocket.
4. Attach drive chain to rear cam sprocket and vacuum pump
sprocket.
5. Tighten chain guide installation bolt while pressing chain guide
VACUUM PUMP
Component
BR-25

lightly [approximately 9.8 N (1.0 kg, 2.2 lb)].
6. Remove thickness gauges (2).
+Leave sprocket retaining bolts (M6) until installation.
VACUUM PUMP
Assembly (Cont'd)
BR-26

ComponentNJBR0030
NBR429
1. Main pin
2. Pin boot
3. Torque member fixing bolt
4. Torque member
5. Shim cover
6. Inner shim7. Inner pad
8. Pad retainer
9. Outer pad
10. Outer shim
11. Connecting bolt
12. Copper washer13. Main pin bolt
14. Bleed valve
15. Cylinder body
16. Piston seal
17. Piston
18. Piston boot
Pad ReplacementNJBR0029WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
+When cylinder body is open, do not depress brake pedal
because piston will pop out.
+Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
+If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
+It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to stretch
brake hose.
+Burnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings,
or if a soft pedal occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªON-VEHICLE
SERVICEº, BR-8.
FRONT DISC BRAKE
Component
BR-27

SBR976B
SBR932C
1. Remove master cylinder reservoir cap.
2. Remove pin bolt.
3. Open cylinder body upward. Then remove pad with retainers,
inner and outer shims.
Standard pad thickness:
11 mm (0.43 in)
Pad wear limit:
2.0 mm (0.079 in)
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
SBR979B
RemovalNJBR0031WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for dis-
assembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not to stretch brake
hose.
SBR772
DisassemblyNJBR0032WARNING:
Do not place your fingers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
1. Push out piston with piston boot with compressed air.
2. Remove piston seal with a suitable tool.
InspectionNJBR0033CALIPERNJBR0033S01Cylinder BodyNJBR0033S0101+Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
+Minor damage from rust or foreign materials may be eliminated
by polishing surface with a fine emery paper. Replace cylinder
body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
FRONT DISC BRAKE
Pad Replacement (Cont'd)
BR-28

PistonNJBR0033S0102CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign materials are stuck to sliding
surface.
Check piston for score, rust, wear, damage or presence of foreign
materials. Replace if any of the above conditions are observed.
Slide Pin, Pin Bolt and Pin BootNJBR0033S0103Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.
ROTORNJBR0033S02Rubbing SurfaceNJBR0033S0201Check rotor for roughness, cracks or chips.
SBR219C
RunoutNJBR0033S02021. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to AX section
(ªFront Wheel Bearingº, ªON-VEHICLE SERVICEº).
Maximum runout:
0.07 mm (0.0028 in)
3. If the runout is out of specification, find minimum runout posi-
tion as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with
nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can be
found.
4. If the runout is still out of specification, turn rotor with on-car
brake lathe (ªMAD, DL-8700º, ªAMMCO 700 and 705º or
equivalent).
ThicknessNJBR0033S0203Thickness variation (At least 8 positions):
Maximum 0.01 mm (0.0004 in)
If thickness variation exceeds the specification, turn rotor with on-
car brake lathe.
Rotor repair limit:
20.0 mm (0.787 in)
FRONT DISC BRAKE
Inspection (Cont'd)
BR-29

SBR574
AssemblyNJBR00341. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.
3. Properly secure piston boot.
SBR980B
InstallationNJBR0035CAUTION:
+Refill with new brake fluid ªDOT 3 or DOT 4º.
+Never reuse drained brake fluid.
1. Install brake hose to caliper securely.
2. Install all parts and secure all bolts.
3. Bleed air. Refer to ªBleeding Brake Systemº, BR-9.
FRONT DISC BRAKE
Assembly
BR-30

ComponentsNJBR0128
SBR616E
1. Boot
2. Piston
3. Piston cap
4. Spring
5. Wheel cylinder6. Shoe hold-down pin
7. Plug
8. Brake drum
9. Shoe hold-down spring
10. Adjuster11. Retainer ring
12. Return spring (Upper)
13. Return spring (Lower)
14. Spring
15. Toggle lever
RemovalNJBR0129WARNING:
Clean brake lining with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
Make sure parking brake lever is completely released.
REAR DRUM BRAKE
Components
BR-31

SBR617E
1. Release parking brake lever fully, then remove drum.
If drum is hard to remove, the following procedures
should be carried out.
a.Remove plug. To make shoe clearance, push shoe hold-
down spring to free toggle lever.
SBR020A
b.Install two bolts as shown. Tighten the two bolts gradually.
SBR214B
2. After removing retainer, remove spring by rotating shoes.
+Be careful not to damage wheel cylinder piston boots.
+Be careful not to damage parking brake cable when sepa-
rating it.
3. Remove adjuster.
4. Disconnect parking brake cable from toggle lever.
SBR329C
5. Remove retainer ring with a suitable tool. Then separate toggle
lever and brake shoe.
SBR330C
Inspection Ð Wheel CylinderNJBR0130+Check wheel cylinder for leakage.
+Check for wear, damage and loose conditions. Replace if any
such condition exists.
REAR DRUM BRAKE
Removal (Cont'd)
BR-32

SBR215B
Wheel Cylinder OverhaulNJBR0131+Check all internal parts for wear, rust and damage. Replace if
necessary.
+Pay attention so as not to scratch cylinder when installing pis-
tons.
SBR022A
Inspection Ð DrumNJBR0132Maximum inner diameter:
204.5 mm (8.05 in)
Maximum out-of-round:
0.03 mm (0.0012 in)
+Contact surface should be fine finished with No. 120 to 150
emery paper.
+Using a drum lathe, resurface brake drum if it shows scoring,
partial wear or stepped wear.
+After brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.
SMA849B
Inspection Ð LiningNJBR0133Check lining thickness.
Standard lining thickness:
4.5 mm (0.177 in)
Lining wear limit:
1.5 mm (0.059 in)
SBR618E
InstallationNJBR0134+Always perform shoe clearance adjustment. Refer to
BR-48.
+Burnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings,
or if a soft pedal occurs at very low mileage. Refer to
ªBrake Burnishing Procedureº, ªON-VEHICLE SERVICEº,
BR-8.
1. Fit toggle lever to brake shoe with retainer ring.
2. Apply brake grease to the contact areas shown at left.
REAR DRUM BRAKE
Wheel Cylinder Overhaul
BR-33

SBR619E
3. Shorten adjuster by rotating it.
+To tighten loosened brake shoes, first, insert a screw driver in
the direction shown in the left. Then, move the adjuster in the
direction shown by the arrow while disengaging the tooth con-
tact. Never tap the area E.
4. Connect parking brake cable to toggle lever.
5. Install all parts.
Be careful not to damage wheel cylinder piston boots.
6. Check all parts are installed properly.
Pay attention to direction of adjuster assembly.
7. Install brake drum.
8. When installing new wheel cylinder or overhauling wheel
cylinder, bleed air. Refer to ªBleeding Brake Systemº, BR-9.
9. Adjust parking brake. Refer to BR-48.
REAR DRUM BRAKE
Installation (Cont'd)
BR-34