NISSAN ALMERA N15 1995 Service Manual

SEC.465

iii :
N'm (kg-m, in-Ib)
~ :N'm (kg-m, ft-Ib)
BRAKE
PEDALANDBRACKET
Removal andInstallation

Sloplamp sWitch

SBR205D

o
Inspection

Check brakepedalforfollowing items:
• Brake pedalbend
• Clevis pindeformation
• Crack ofany welded portion
• Crack ordeformation ofclevis pinstopper

•

SBR997
Adjustment

Check brakepedalfreeheight fromdash reinforcement panel
(RHD) anddash lower panel (LHD). Adjust ifnecessary.

H: Freeheight
Refer to
50S
(BR-SS).
0: Depressed height
Refer to
50S
(BR-SS).
Under forceof
490
N
(50
kg,
110
Ib)
with engine running

1. Loosen locknutand adjust pedalfreeheight byturning
brake booster inputrod.Then tighten locknut.
2. Check pedalfreeplay.

Make surethatstop lamps gooff when pedal isreleased.

3. Check brakepedal's depressed heightwhileengine isrun-
ning. If lower thanspecification, checkforleaks, airinsystem or
damage tocomponents (mastercylinder, wheelcylinder,
etc.). Then make necessary repairs.

SBR034D BR-11

MASTERCYLINDER
Removal
CAUTION:
• Becareful nottosplash brakefluidonpainted areas;itmay
cause paintdamage. Ifbrake fluidissplashed onpainted
areas, washitaway withwater immediately.
• Inthe case ofbrake fluidleakage fromthemaster cylinder,
disassemble thecylinder. Thencheck piston cupsfordefor-
mation orscratches andreplace necessary parts.

1. Connect avinyl tubetoair bleeder valve.
2. Drain brake fluidfrom each airbleeder valve,depressing
brake pedaltoempty fluidfrom master cylinder.
3. Remove brakepipeflare nuts.
4. Remove mastercylinder mounting nuts.

Models withASS

/O-ring~

'V
(ModelswithABS only)
'\~ /'Valve stopper

T@" ~
1.5.2.9
(0.15.0.3, 13.0•26.0)

o

l-~

~ 11.7 -14.7 \
(1.2 -1.5, 8.7-10.8)

SBR019DB

Seal~
___
Reservoir tank

jJ'JD~----

~ ..-:'J

C'9 ---
Secondarypiston
Stopper cap~assembly
~f]

Cylinder
body
N.m (kg-m, in-Ib)
N.m (kg-m. ft-Ib)
Brake fluidpoint
Reservoir
cap
----g

Oil strainer ----. ~

L------- -

SEC.
460
Disassembly
1. Bend claws ofstopper capoutward.

BR-12

SBR435B
SBR939A
Secondary piston
Primary piston
SBR012A
Models withABS
Secondary piston
Primary piston

_-rnIJ
SBR221BAMASTER
CYLINDER
Disassembly (Cont'd)

2. Remove valvestopper whilepiston ispushed intocylinder
(Models withASS only).
3. Remove pistonassemblies.

If itis difficult toremove secondary pistonassembly, gradually
apply compressed airthrough fluidoutlet.

4. Draw outreservoir tank.

Inspection

Check master cylinder innerwallforpin holes orscratches.
Replace ifdamaged.

Assembly
1. Insert secondary pistonassembly. Theninsert primary pis-
ton assembly.

• Pay attention todirection ofpiston cupsinfigure atleft.
Also, insert pistons squarely toavoid scratches oncylinder
bore.
• Pay attention toalignment ofsecondary pistonslitwith
valve stopper mounting holeofcylinder body(Formodels
with ABS only).
BR-13
•

SBR435BMASTER
CYLINDER
Assembly (Cont'd)

2. Install stopper cap.
Before installing stoppercap,ensure thatclaws arebent
inward.
3. Push reservoir tankseals intocylinder body.
4. Push reservoir tankintocylinder body.
5. Install valvestopper whilepiston ispushed intocylinder
(Models withABS only).

Installation

CAUTION:
• Refill withnewbrake fluid"DOT 3"or"DOT 4".
• Never reusedrained brakefluid.
• Donot mix different typesofbrake fluids(DOT3,DOT 4).
1. Place master cylinder ontobrake booster andsecure
mounting nutslightly.
2. Torque mounting nuts.
~: 11.7 -14.7 N'm(1.2-1.5 kg-m, 8.7-10.8 ft-Ib)
3. Fillupreservoir tankwith newbrake fluid.
4. Plug allports onmaster cylinder withfingers toprevent air
suction whilereleasing brakepedal.
5. Have driver depress brakepedalslowly several timesuntil
no air comes outofmaster cylinder.
6. Fitbrake linestomaster cylinder.
7. Tighten flarenuts.
~: 15-18 N'm (1.5-1.8 kg-m, 11-13 ft-Ib)
8. Bleed airfrom brake system. Referto"Bleeding
Procedure", BR-6."

BR-14

OKNGBRAKE
BOOSTER
On-vehicle Service
OPERATING CHECK

• Depress brakepedalseveral timeswithengine off.After
exhausting vacuum,makesurethere isno change inpedal
stroke.
• Depress brakepedal, thenstart engine. Ifpedal goesdown
slightly, operation isnormal.

AIRTIGHT CHECK

• Start engine, andstop itafter oneortwo minutes. Depress

SBR002A
brakepedalseveral timesslowly. Booster isairtight ifpedal
stroke isless each time.
• Depress brakepedalwhileengine isrunning, andstop
engine withpedal depressed. Thepedal stroke should not
change afterholding pedaldownfor
30seconds.
SBR365AA Removal
CAUTION:
• Becareful nottosplash brakefluidonpainted areas;itmay
cause paintdamage. Ifbrake fluidissplashed onpainted
areas, washitaway withwater immediately.
• Be careful nottodeform orbend brake pipes, during
removal ofbooster.

SEC.
465.470

BR-15Gasket

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

SBR223BB
•

Approx.125mm (4.92 In) BRAKE
BOOSTER

Inspection

OUTPUT RODLENGTH CHECK

1. Supply brakebooster withvacuum of-66.7 kPa(-667 mbar,
-500 mmHg, -19.69inHg)usingahand vacuum pump.
2. Check output rodlength.
Specified length:
M195, S205orC205
10.275 -10.525 mm(0.4045 -0.4144 in)
Installation
CAUTION: • Becareful nottodeform orbend brake pipesduring instal-
lation ofbooster.
• Replace clevispinifdamaged.
• Refill withnewbrake fluid"DOT 3"or"DOT 4".
• Never reusedrained brakefluid.
• Donol mix different typesofbrake fluids(DOT3,DOT 4).
• Due tothe angle ofinstallation, threadcanbedamaged by
the dash panel.
1. Before fittingbooster, temporarily adjustclevistodimen-
sion shown. (Doesnotapply tovehicles fittedwithABS.)
2. Fitbooster, thensecure mounting nuts(brake pedalbracket
to booster) lightly.
3. Connect brakepedalandbooster inputrodwith clevis pin.
4. Secure mounting nuts.
Specification:
~: 13-16 N'm (1.3-1.6 kg-m, 9-12 ft-Ib)
5. Install master cylinder. RefertoBR-12.
6. Bleed air.Refer to"Bleeding Procedure", BR-6.

BR-16

SBR225B

----a

MoreIh.. 24mm

(0.94 In)

----------r:~
---------~~~----------

Connect hoseuntilitcontacts
protrusion onvacuum tube.
VACUUM
HOSE
Removal andInstallation
CAUTION:
When installing vacuumhoses,payattention tothe following
points.
• Donot apply anyoilorlubricants tovacuum hoseandcheck
valve.
• Insert vacuum tubeintovacuum hoseasshown.
• Install checkvalve, paying attention toits direction.
TYPE 1

Intake manifold Brakebooster

; C::::::::'::::~:d
q

SBR498A
CAUTION
~
... ENG. TYPE
2
Inspection
HOSES ANDCONNECTORS

Check vacuum lines,connections andcheck valvefor
airtightness, improperattachment, chafinganddeterioration.

BR-17
•

VACUUMHOSE
Inspection (Cont'd)
CHECK VALVE

Check vacuum withavacuum pump.

~

Booster side

SBR943A
Connect
to
booster side
Connect to
engine side Vacuum
shouldexist.
Vacuum shouldnotexist.
Engine side

VACUUM WARNING SWITCH(Dieselenginemodels)

Test continuity throughvacuum warning switchwithanohmme-
ter and vacuum pump.

Booster
side
Arrowindicates
engine side

SBR826B
SBR007A
Vacuum
condition
Less than26.7kPa
(267 mbar, 200mmHg, 7.87inHg)
33.3 kPa
(333 mbar, 250mmHg, 9.84inHg) or
more Continuity

Yes
No
VACUUM PUMP

1. Install vacuum gauge.
2. Run engine at1,000 rpmormore.
3. Check vacuum.

Specified vacuum:
86.6 kPa
(8~6
mbar, 650mmHg, 25.59inHg) ormore
BR-18

~0
tJ

L:{SR020D
FRONT
DISCBRAKE
Pad Replacement

WARNING:
Clean brakepadswithavacuum dustcollector tominimize the
hazard ofairborne particles orother materials.
CAUTION:
• When cylinder bodyisopen, donot depress brakepedalor
piston willpop out.
• Becareful nottodamage pistonbootorget oilonrotor.
Always replace shimswhenreplacing pads.
• Ifshims arerusted orshow peeling ofthe rubber coat,
replace themwithnewshims.
• Itis not necessary toremove connecting boltexcept for
disassembly orreplacement ofcaliper assembly. Inthis
case, suspend cylinderbodywithwire soasnot tostretch
. brake hose.
1. Remove mastercylinder reservoir cap.
2. Remove lowerpinbolt.
3. Open cylinder bodyupward. Thenremove padretainers,
return spring (Except AD22VF brakemodel) andinner/ol,lter
shims. Standard padthickness:
CL22VD andCL22VE 11mm (0.43 in)
CL22VF 10mm (0.39 in)
Pad wear limit:
2.0 mm (0.079 in)
Carefully monitorbrakefluidlevel because brakefluidwill
return toreservoir whenpushing backpiston.

BR-19
•

FRONTDISCBRAKE

m
@
tosliding portion

SEC.
440

CL22VD ANDCL22VE

t~m@

~ I
0

@~@'~I~_\ '~
'j/0

\ ~ ~m@

tOJ
22-
31
(2.2 -3.2,
16-
23)
'1r~
m'8'
(fJJ;18~
-=a
18\

iii:
N'm(kg-m, in-Ib)
\!.o/WLJ\SI
~WIlI[LJ;I\OI

(OJ :
N'm (kg-m, ft-Ib)
17
fJ@

m
@:
Rubber greasepoint

(] @ :
Brake fluidpoint

m
@:
PBC (Poly ButylCuprysil) greaseorsilicone-based greasepoint
SBR206D

CD
Main pin

@
Pinboot

@
Torque member fixingbolt

@
Torque member

@
Shim cover

@
Inner shim

(j)
Inner pad
@

Padretainer

@
Outer pad

@J
Outer shim

@
Connecting bolt

@
Copper washer

@
Main pinbolt
@

Bleed valve

@
Cylinder body

@
Piston seal

@
Piston

@
Piston boot

@
Padreturn spring

BR-20