NISSAN ALMERA N15 1995 Service Manual

BRAKESYSTEM
SECTION

CONTENTS BR
PRECAUTIONS ANDPREPARATION
3

Precautions 3
Special Service Tools 4
Commercial ServiceTools 4

CHECK ANDADJUSTMENT 5

Checking BrakeFluidLevel 5
Checking BrakeLine 5
Changing BrakeFluid 5

AIR
BLEEDING 6

Bleeding Procedure 6

BRAKE HYDRAULIC LINE 7

Removal 8
Inspection 8
Installation 8

CONTROL VALVE 9

Proportioning Valve 9

BRAKE PEDALANDBRACKET 11

Removal andInstallation 11
Inspection 11
Adjustment 11

MASTER CYLINDER 12

Removal 12
Disassembly 12
Inspection 13
Assembly 13
Installation 14

BRAKE BOOSTER 15

On-vehicle Service 15
Removal 15
Inspection 16
Installation 16

VACUUM HOSE 17

Removal andInstallation 17
Inspection 17

FRONT DISCBRAKE 19

Pad Replacement.. 19
Removal 22
Disassembly 22Inspection
-Caliper 22
Inspection -Rotor 23
Assembly '".23
Installation 24

REAR DRUM BRAKE 25

Removal 25
Inspection -Wheel Cylinder 26
Wheel Cylinder Overhaul 27
Inspection -Drum 27
Inspection -Lining 27
Installation 27

REAR DISCBRAKE 29

Pad Replacement 29

~~s:~::~'~I~':::::::::::'::: ::.::::::::.::::::.::::::::::.::::::.::::::::~~ •••

Inspection -Caliper 32
Inspection -Rotor 33
Assembly 33
Installation 35

PARKING BRAKECONTROL 36

Removal andInstallation 36
Inspection 36
Adjustment ." 37

ANTI-LOCK BRAKESYSTEM 38

Purpose 38
Operation 38
ABS Hydraulic Circuit 38
System Components 39
System Description 39
Removal andInstallation .40
Wiring Diagram -ABS - .45

TROUBLE DIAGNOSES
52

Contents 52
Component PartsandHarness Connector
Location 64

SERVICE DATAANDSPECIFICATIONS (SDS)86

General Specifications 86
Inspection andAdjustment 88

CONTENTS
(Cont'd.)

When youread wiring diagrams:
• Read GIsection, "HOWTOREAD WIRING DIAGRAMS" .
• See Elsection, "POWER SUPPLYROUTING" forpower distribution circuit.
When youperform troublediagnoses, readGIsection, "HOWTOFOllOW FLOWCHART
IN TROUBLE DIAGNOSES" and"HOW TOPERFORM EFFICIENT DIAGNOSIS FORAN
ELECTRICAL INCIDENT".

PRECAUTIONSANDPREPARATION
Precautions
SUPPLEMENTAL RESTRAINTSYSTEM(SRS)"AIRBAG"
(DUAL AIRBAG SYSTEM)

The Supplemental RestraintSystem"AirBag" usedalong with
a seat belt,helps toreduce therisk orseverity ofinjury tothe
driver andfront passenger inafrontal collision. TheSupple-
mental Restraint Systemconsists ofair bag modules (located
in the center ofthe steering wheelandonthe instrument panel
on the passenger side),adiagnosis sensorunit,warning lamp,
wiring harness andspiral cable. Information necessarytoser-
vice thesystem safelyisincluded inthe
RSsection
ofthis Ser-
vice Manual.

WARNING:
• Toavoid rendering theSRS inoperatiYe, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.
• Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual. SRSwiring harnesses arecovered withyellow insulation eitherjustbefore the
harness connectors orfor the complete harness,foreasy identification.
SUPPLEMENTAL RESTRAINTSYSTEM(SRS)"AIRBAG"
(SINGLE AIRBAG SYSTEM)

The Supplemental RestraintSystem"AirBag" andused along withaseat belt,helps toreduce therisk
or severity ofinjury tothe driver inafrontal collision. TheSupplemental RestraintSystemconsists of
an air bag module (located inthe center ofthe steering wheel),adiagnosis sensorunit,warning lamp,
wiring harness andspiral cable. Information necessarytoservice thesystem safelyisincluded inthe

RS section
ofthis Service Manual.

WARNING:
• Toavoid rendering theSRS inoperative, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.
• Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual.
BR-3
•

GG94310000or

commercial equivalent

SBR820BA

For
tightening flarenut

Tool number
Tool name
PRECAUTIONS
ANDPREPARATION
Precautions (Conl'd)

BRAKE SYSTEM

• Recommended fluidisbrake fluid"DOT 3"or"DOT 4".
• Never reusedrained brakefluid.
• Donot mix different typesofbrake fluids (DOT3,DOT 4).
• Becareful nottosplash brakefluidonpainted areas;itmay
cause paintdamage. Ifbrake fluidissplashed onpainted
areas, washitaway withwater immediately.
• Toclean master cylinder parts,discbrake caliper partsor
wheel cylinder parts,useclean brake fluid.
• Never usemineral oilssuch asgasoline orkerosene. They
will ruin rubber partsofhydraulic system.
• Use flare nutwrench whenremoving andinstalling brake
tubes.
• Always torquebrakelineswhen installing.
WARNING:
• Clean brakes withavacuum dustcollector tominimize risk
of health hazard frompowder causedbyfriction.

Special Service Tools

Description

GG9431 0000

Flare nuttorque wrench

NT406
Removing
andinstalling eachbrake piping

a: 10 mm (0.39 in)
~: 16.2N'm(1.65 kg-m, 11.9f1-lb)
Commercial ServiceTools

Description
Tool name

CD
Flare nutcrows foot
@ Torque wrench
Brake fluidpressure
gauge
NT360
NT151
Removing
andinstalling eachbrake piping

a: 10 mm (0.39 in)

Measuring brakefluidpressure

BR-4

CHECKANDADJUSTMENT

OK
MINMax.
line
Min. line
SBR418C
Checking
BrakeFluidLevel

• Check fluidlevel inreservoir tank.Itshould bebetween
Max. andMin. lines onreservoir tank.
• Iffluid level isextremely low,check brakesystem forleaks.
• Ifbrake warning lampcomes on,check brakefluidlevel
switch andparking brakeswitch.

ABR159
SBR419C
Checking
BrakeLine

CAUTION: If leakage occursaround joints,retighten or,ifnecessary,
replace damaged parts.
1. Check brakelines(tubes andhoses) forcracks, deteriora-
tion orother damage. Replaceanydamaged parts.
2. Check foroilleakage byfully depressing brakepedalwhile
engine isrunning.

Changing BrakeFluid

CAUTION:
• Refill withnewbrake fluid"DOT 3"or"DOT 4".
• Always keepfluidlevel higher thanminimum lineonreser-
voir tank.
• Never reusedrained brakefluid.
• Donot mix different typesofbrake fluids(DOT3,DOT 4).
• Becareful nottosplash brakefluidonpainted areas;itmay •
cause paintdamage. Ifbrake fluidissplashed onpainted :•
areas, washitaway withwater immediately.
1. Clean inside ofreservoir tank,andrefill withnewbrake
fluid.
2. Connect avinyl tubetoeach airbleeder valve.
3. Drain brake fluidfrom each airbleeder valvebydepressing
brake pedal.
4. Refill untilnewbrake fluidcomes outofeach airbleeder
valve.
Use same procedure asinbleeding hydraulic systemto
refill brake fluid.
Refer to"Bleeding Procedure", BR-6.

BR-5

SBR995
SBR419C AIR
BLEEDING
Bleeding Procedure
CAUTION:
• Carefully monitorbrakefluidlevel atmaster cylinder during
bleeding operation.
• Ifmaster cylinder issuspected tohave airinside, bleedair
from master cylinder first.Refer to"Installation", "MASTER
CYLINDER", BR-12.
• Fill reservoir withnewbrake fluid"DOT 3"or"DOT
4".

Make sureitis full atall times whilebleeding airout of
system.
• Donot mix different typesofbrake fluids(DOT3,DOT 4).
• Place acontainer undermaster cylinder toavoid spillage of
brake fluid.
• For models withABS, turnignition switchOFFanddiscon-
nect ABS actuator connector orbattery cable.

• Bleed airinthe following order:

I
RHO models
I

Left rear brake-+Right frontbrake-+Right rearbrake-+Left
front brake

I
LAD models
I

Right rearbrake-+Left frontbrake-+Left rearbrake-+Right
front brake.
1. Connect atransparent vinyltubetoair bleeder valve.
2. Fully depress brakepedalseveral times.
3. With brake pedaldepressed, openairbleeder valveto
release air.
4. Close airbleeder valve.
5. Release brakepedalslowly.
6. Repeat steps2.through 5.until clear brake fluidcomes out
of air bleeder valve.
7. Tighten airbleeder valve.

~: 7-
9 N.m (0.7-0.9 kg-m, 61-78 in-Ib)
BR-6

BRAKEHYDRAULIC LINE

Without anti-lock brakesystem
(Models withdual proportioning valvebuiltintomaster cylinder)
(built-in type)

Proportioningvalve
(Do notdisassemble.)

With anti-lock brakesystem

ASS actuator

L
Master cylinder
=
.
Primary line
- .Secondary line

~ 0:Flare nut

15 -18 (1.5 -1.8, 11-13)

• :Connecting bolt

17 -20 (1.7 -2.0, 12-14)

~ :N.m (kg-m. ft-Ib)

SBR086D
•

BR-7

BRAKEHYDRAULIC LINE
SBR419C

For tightening flarenut

~GG94310000
or

commercial equivalent

SBR820BA
Removal

CAUTION: • Becareful nottosplash brakefluidonpainted areas;itmay
cause paintdamage. Ifbrake fluidissplashed onpainted
areas, washitaway withwater immediately.
• Allhoses mustbefree from excessive bending,tWistingand
pulling.
1 ~ Connect a
vinyl
tubetoair bleeder
valve~

2. Drain brake fluidfrom each airbleeder
valve
bydepressing
brake pedal.

3. Remove
flarenutsecuring braketubetohose, thenwith-
draw lockspring.

4. Cover
openings to
prevent
entrance ofdirt
whenever
dis-
connecting hydraulicline.

Inspection

Check brakelines(tubes andhoses) forcracks, deterioration or
other damage. Replaceanydamaged parts.

Installation

CAUTION:
• Refill withnewbrake fluid"DOT 3"or"DOT 4".
• Never reusedrained brakefluid.
• Donot mix different typesofbrake fluids(DOT3,DOT 4).
1. Tighten allflare nutsandconnecting bolts.
Flare nut: .
~: 15-18 N'm (1.5-1.8 kg-m, 11-13 ft-Ib)
Connecting bolt:
~: 17-20 N'm (1.7-2.0 kg-m, 12-14 ft-Ib)
2. Refill untilnewbrake fluidcomes outofeach airbleeder

valve.

3. Bleed air.Refer to"Bleeding Procedure", BR-6.

BR-8

CONTROLVALVE
Proportioning Valve
INSPECTION
CAUTION:
• Carefully monitorbrakefluidlevel atmaster cylinder.
• Use new brake fluid"DOT 3"or"DOT 4".
• Donot mix different typesofbrake fluids(DOT3,DOT 4).
• Becareful nottosplash brakefluidonpainted areas;itmay
cause paintdamage. Ifbrake fluidissplashed onpaint
areas, washitaway withwater immediately.
• Depress pedalslowly whenraising frontbrake pressure.
• Check rearbrake pressure 2seconds afterfront brake pres-
sure reaches specified value.
• For models withABS disconnect harnessconnectors from
ABS actuator relaybefore checking.

1.
Connect Tooltoair bleeders offront andrear brakes on
either
LH
or
RH
side.
2. Bleed airfrom theTool.
3. Check rearbrake pressure bydepressing brakepedal
(increasing frontbrake pressure).

Unit:kPa(bar, kg/cm
2,
psi)

Without ABS
I
With
ABS
Applied models
GA14DE,GA16DE,CD20 GA16DE'
SR20DE
Applied pressure 7.3556.375
5,394
(Front brake) (73.6,
75,1,067) (63.7,65,924)
(53.9,55,782)
3,432 -3,825 2,452-2,844
Output pressure 5,100
-5,492 (34.3-38.2, (245-28.4,
(Rear brake) (51.0
-54.9, 52-56, 739 -796) 35-39, 25-29,
498 -555) 356-412)

*
Models forAustralia

If
output pressure isout ofspecifications, replacedualpro- •••
portioning valve(separated type)ormaster cylinder assem-
bly (built-in type).
4. Bleed airafter disconnecting theTool. Refer to"Bleeding
Procedure", BR-5.

BR-9

CONTROLVALVE
Proportioning Valve(Cont'd)

REMOVAL (Separated type)

CAUTION:
• Becareful nottosplash brakefluidonpainted areas;itmay
cause paintdamage. Ifbrake fluidissplashed onpainted
areas, washitaway withwater immediately.
• Allhoses mustbefree from excessive bending,twistingand
pulling.
1. Connect avinyl tubetoair bleeder valve.
2. Drain brake fluidfrom each airbleeder valvebydepressing
brake pedal.
3. Loosen flarenut.
4. Remove proportioning valvemounting bolt,then remove
flare nut.

INSTAllATION (Separatedtype)

CAUTION:
• Refill withnewbrake fluid"DOT 3"or"DOT 4".
• Never reusedrained brakefluid.
• Donot mix different typesofbrake fluids(DOT3,DOT 4).
1. Temporarily fitflare nuttoproportioning valve.
2. Tighten proportioning valvemounting bolt,then tighten flare
nut with wooden blockplaced between proportioning valve
and dash panel.
Flare nut:

tDJ:
15-18 N'm (1.5-1.8 kg-m, 11-13 ft-Ib)
Mounting bolt:

11]:
5.1-8.8 N'm (0.52 -0.9 kg-m, 45.1-78.1 in-Ib)
3. Refill untilnewbrake fluidcomes outofeach airbleeder
valve.
4. Bleed air.Refer to"Bleeding Procedure", BR-6.

REMOVAL ANDINSTAllATION (Built-intype)

Always replace together withmaster cylinder asan assembly.
• Refer to"MASTER CYLINDER", BR-12.

BR-10