air bleeding NISSAN ALMERA 2001 Service Manual

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS...............................................................4
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............4
Precautions for Brake System .....................................4
Precautions When Working On ABS ...........................5
Wiring Diagrams and Trouble Diagnosis .....................5
PREPARATION...............................................................6
Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................7
NVH Troubleshooting Chart.........................................7
ON-VEHICLE SERVICE..................................................8
Checking Brake Fluid Level.........................................8
Checking Brake Line ...................................................8
Changing Brake Fluid ..................................................8
Brake Burnishing Procedure........................................8
Bleeding Brake System ...............................................9
BRAKE HYDRAULIC LINE...........................................10
Hydraulic Circuit.........................................................10
Removal .....................................................................10
Inspection................................................................... 11
Installation .................................................................. 11
BRAKE PEDAL AND BRACKET..................................12
Removal and Installation ...........................................12
Inspection...................................................................12
Adjustment .................................................................12
MASTER CYLINDER (TOKICO)...................................14
Removal .....................................................................14
Disassembly...............................................................15
Inspection...................................................................15
Assembly ...................................................................15
Installation ..................................................................16
MASTER CYLINDER [BOSCH (NABCO)]...................17
Removal .....................................................................17
Disassembly...............................................................17
Inspection...................................................................18
Assembly ...................................................................18
Installation ..................................................................19BRAKE BOOSTER........................................................20
On-vehicle Service.....................................................20
OPERATING CHECK...............................................20
AIRTIGHT CHECK...................................................20
Removal .....................................................................20
Inspection...................................................................20
OUTPUT ROD LENGTH CHECK..............................20
Installation ..................................................................21
VACUUM HOSE.............................................................22
Removal and Installation ...........................................22
Inspection...................................................................22
HOSES AND CONNECTORS...................................22
CHECK VALVE........................................................22
VACUUM PUMP............................................................23
Removal .....................................................................23
Installation ..................................................................24
Inspection...................................................................24
Component ................................................................25
Disassembly...............................................................25
Assembly ...................................................................25
FRONT DISC BRAKE...................................................27
Component ................................................................27
Pad Replacement ......................................................27
Removal .....................................................................28
Disassembly...............................................................28
Inspection...................................................................28
CALIPER.................................................................28
ROTOR...................................................................29
Assembly ...................................................................30
Installation ..................................................................30
REAR DRUM BRAKE...................................................31
Components...............................................................31
Removal .....................................................................31
Inspection - Wheel Cylinder ......................................32
Wheel Cylinder Overhaul...........................................33
Inspection - Drum ......................................................33
Inspection - Lining .....................................................33
Installation ..................................................................33

SBR451D
Checking Brake Fluid LevelNJBR0006+Check 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 ªDOT 4º.
+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 ªBleeding Brake Systemº, BR-9.
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
ON-VEHICLE SERVICE
Checking Brake Fluid Level
BR-8

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 ªDOT 4º. 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-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 ªDOT 3 or DOT 4º.
+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 ªBleeding Brake Systemº, BR-9.
BRAKE HYDRAULIC LINE
Inspection
BR-11

SBR222B
5. Install valve stopper while piston is pushed into cylinder.
SBR704C
InstallationNJBR0116CAUTION:
+Refill with new brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque 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 ªBleeding Brake
Systemº, BR-9.
MASTER CYLINDER (TOKICO)
Assembly (Cont'd)
BR-16

InstallationNJBR0026CAUTION:
+Be careful not to deform or bend brake pipes, during
installation of booster.
+Replace clevis pin if damaged.
+Refill with new brake fluid ªDOT 3 or DOT 4º.
+Never reuse drained brake fluid.
+Take care not to damage brake booster mounting bolt
thread when installing. Due to the acute angle of
installation, the threads can be damaged with the dash
panel.
SBR237EA
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to
master cylinder) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
Specification:
13 - 16 N´m (1.3 - 1.6 kg-m,9-12ft-lb)
5. Install master cylinder. Refer to ªInstallationº in ªMASTER
CYLINDERº, BR-16, 19.
6. Bleed air. Refer to ªBleeding Brake Systemº, BR-9.
BRAKE BOOSTER
Installation
BR-21

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

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

SBR307E
InstallationNJBR0043CAUTION:
+Refill with new brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
1. Install caliper assembly.
+As shown in the figure, align the piston's concave to the pad's
convex, then install the cylinder body to the torque member.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to ªBleeding Brake Systemº, BR-9.
REAR DISC BRAKE (CAM & STRUT TYPE)
Installation
BR-42

SBR219C
ROTORNJBR0145S02Rubbing SurfaceNJBR0145S0201Check rotor for roughness, cracks or chips.
RunoutNJBR0145S02021. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications
before measuring. Refer to AX section (ªREAR WHEEL
BEARINGº, ªOn-vehicle Serviceº).
3. Change relative positions of rotor and wheel hub so that runout
is minimized.
Maximum runout:
0.07 mm (0.0028 in)
ThicknessNJBR0145S0203Rotor repair limit:
Standard thickness
10 mm (0.39 in)
Minimum thickness
9 mm (0.35 in)
Thickness variation (At least 8 portions)
Maximum 0.02 mm (0.0008 in)
NBR374
NBR375
InstallationNJBR0146CAUTION:
+Refill with new brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
+Do not drain (factory) filled brake fluid from (new) caliper
assemblies.
1. Install caliper assembly.
+As shown in the figure, align the piston's concave to the pad's
convex, then install the cylinder body to the torque member.
2. Remove the plug from the cylinder body and brake hose.
CAUTION:
Care should be taken as not to let:
+Air enter the cylinder body and brake hose.
+Brake fluid spill from the cylinder body and brake hose.
3. Install brake hose to caliper securely.
4. Install all parts and secure all bolts.
5. Bleed air. Refer to ªBleeding Brake Systemº, BR-9.
REAR DISC BRAKE (BALL & RAMP TYPE)
Inspection (Cont'd)
BR-46