NISSAN ALMERA N15 1995 Service Manual

((I

~i

i
U

Commercial service tool
SBR025D
SBR646
SBR868C! SBR889 REAR
DISCBRAKE
Removal

WARNING:

Clean brakepadswithavacuum dustcollector tominimize the
hazard ofairborne particles orother materials.
1. Remove
parkingbrakecablelockplate.
2. Remove torquemember fixingboltsandconnecting bolt.

It is not necessary toremove connecting boltexcept fordisas-
sembly orreplacement ofcaliper assembly. Inthis case, sus-
pend caliper assembly withwire soas not tostretch brake
hose.
Disassembly
1. Remove pistonbyturning itcounterclockwise withsuitable
long nose pliers orcommercial
service
tool.
2. Remove snapringfrom piston withsuitable pliersand
remove adjusting nut.
•

3. Disassemble cylinderbody.
a. Pry offsnap ringwith suitable pliers,thenremove spring
cover, spring andseat.
b. Remove snapring,then remove keyplate, pushrod,rod
and strut.

BR-31

l

--,II

~//

SBR656
SBR026D REAR
DISCBRAKE
Disassembly (Cont'd)

c. Remove pistonseal.

Be careful nottodamage cylinderbody.

4. Remove returnspring, toggleleverandcable guide.

Inspection -Caliper
CAUTION: Use brake fluidtoclean cylinder. Neverusemineral
oil.

CYLINDER BODY

• Check insidesurface ofcylinder forscore, rust,wear, dam-
age orpresence offoreign objects. Ifany ofthe above con-
ditions areobserved, replacecylinder body.
• Minor damage fromrustorforeign objects maybeelimi-
nated bypolishing surfacewithafine emery paper.
Replace cylinder bodyifnecessary.

TORQUE MEMBER

Check forwear, cracks orother damage. Replaceifnecessary.

PISTON
CAUTION:
Piston sliding surface ;splated. Donot polish withemery paper
even ifrust orforeign objects isstuck tosliding surface.

Check pistonforscore, rust,wear, damage orpresence offor-
eign objects. Replace ifany ofthe above conditions are
observed.

SLIDE PIN,PINBOLT, ANDPINBOOT

Check forwear, cracks orother damage.
Replace ifany ofthe above conditions areobserved.

BR-32

SBR847
SBR247B REAR
DISCBRAKE
Inspection -Rotor
RUBBING SURFACE

Check rotorforroughness, cracksorchips.

RUNOUT
1. Secure rotortowheel hubwith atleast twonuts (M12 x1.25).
2. Check runout usingadial indicator.

Make surethatwheel bearing axialendplay iswithin thespec-
ifications beforemeasuring. Referto"Rear Wheel Bearing" of
"ON-VEHICLE SERVICE"inRA section.

3. Change relativepositions ofrotor andwheel hubsothat
runout isminimized.

Maximum runout:
0.07 mm(0.0028 in)
THICKNESS Rotor repair limit:
Minimum thickness
CL7HB 6.0mm (0.236 in)
CL9HC 8.0mm (0.315 in)
Thickness variation(Atleast 8portions)
Maximum 0.02mm(0.0008 in)

Replace rotorifany ofthe above donot meet thespecifications .

Assembly
1. Insert camwithdepression facingtowards openendofcyl-
inder.
2. Generously applyrubber grease tostrut andpush rodto
make insertion easy.

BR-33
•

Snapring

~

Keyplate~

Rod
---{[J

Snaprjng-~
Spring cover~
Spring-l Seat--@
Snap ring-o
Spacer
------L81

VVave washer~
Spacer----i9'J

Ball bearmg~

AdjUSler-i

Cup---@)

P"'o0-e
Convex
portion

SBR809B
Press
SBR810B
SBR078D REAR
DISCBRAKE
Assembly (Cont'd)

3. Match protrusion onkey plate withdepression incylinder.
4. Install snapringwith asuitable tool.
5. Install seat,spring, springcoverandsnap ringwhile
depressing withsuitable tool.
6. Install adjuster inthe specified direction.
7. Install cup,adjuster, bearing,spacers, washersandsnap
ring with asuitable tool.

BR-34

SBR646REAR
DISCBRAKE
Assembly (Cont'd)

8. Insert piston sealintogroove oncylinder body.
9. With piston bootfitted topiston, insertpiston bootinto
groove oncylinder bodyandfitpiston byturning itclock-
wise withlong nose pliers, orsuitable tool.

Commercial
service
1001

SBR868C
10.Fittoggle lever,return spring andcable guide.

Installation
CAUTION:
• Refill withnewbrake fluid"DOT 3"or"DOT
4".

• Never reusedrained brakefluid.
• Donot mix different typesofbrake fluids(DOT3,DOT
4).

1. Install caliper assembly.
2. Install brakehosetocaliper securely.
3. Install allparts andsecure allbolts.
4. Bleed air.Refer to"Bleeding Procedure", BR-6.

BR-35
•

PARKINGBRAKECONTROL

ItJ
3.'.'~ (0.33.0.... 28.6 •38.2)~

Rear RHcable "'"

SEC.
443
\;..,Reardrum model

,Lever assembly
~r.iil
~4.3-6.5

I
llrJ
3.2•4.3 "~(0.44 •0.66, 38.2•57.3)
~ ~15.7 -19.6 (0.33.0.44,28.6.38.2)
','(5' ..--,

jjf ..
(y -
2.0, 11.6 •14.5) ~1iI3.2 •4.3
"""'...~)\)')'))Jl--'

/, f
(0.33-0.44, 28.6-38.2)
m

" ,RearLHcab7e

Ad'
t t~
J,
e
r
<~
3.2•4.3 (0.33 -0.44, 28.6•38.2)

IUS
Ing nu~ ~'
I
Front \

~/ i
!cablem. ~\ I
Parking brake ,,~'::\'
I'
<> ~ ~

warning lampswitch
I
(~./?' ~
Boot /-

JJ~?
iii
3.2•4.3 ~3.2.4.3 (0.33 •0.44, 28.6-38.2)

~ M___
(0.33•0.44, 28.6-38.2)
iii
~ci~3; ~'~.44,
II]
3.2•4.3 (0.33 •0.44',28.6 -38.2)

Bracket
28.6_38.2)
Ill:
N.m(kg-m, In-Ib)

~: N.m(kg-m, ft-Ib) SBR028DA

Removal andInstallation

1. To remove parkingbrakecable, firstremove centercon-
sole.
2. Disconnect warninglampconnector.
3. Remove bolts,slacken offand remove adjusting nut.
4. Remove lockplate anddisconnect cable(discbrake only).
For drum brake models, refertoBR-25.

Inspection
1. Check control leverforwear orother damage. Replaceif
necessary.
2. Check wiresfordiscontinuity ordeterioration. Replaceif
necessary.
3. Check warning lampandswitch. Replace ifnecessary.
4. Check partsateach connecting portionand,ifdeformed or
damaged, replace.

BR-36

Togglelever
Stopper
Front

V
PARKING
BRAKECONTROL
Adjustment
Before orafter adjustment, payattention tothe following points.
a. For rear discbrake besure thattoggle leverreturns to
stopper whenparking brakeleverisreleased.
b. There isno drag when parking brakeleverisreleased.

SBR029D
SBR042D
1.
Adjust clearance betweenshoeanddrum/pad androtor as
follows:
a. Release parkingbrakeleverandloosen adjusting nut.
b.- Depress brakepedalfullyatleast 10times withengine run-
ning.
2. Pull control lever4-5 notches. Thenadjust control leverby
turning adjusting nut.

196 N(20 kg,44Ib)

/

SBR073D
3.
Pull control leverwithspecified amountofforce. Check
lever stroke andensure smooth operation.

Number ofnotches:
Drum brake: 7-
8

Disc brake: 8-
9

4. Bend warning lampswitchplate toensure following. Warn-
ing lamp comes onwhen leverispulled "A"notches and
goes outwhen fullyreleased.

Number of
"A"
notches: 1or less
BR-37
•

ANTI-LOCKBRAKESYSTEM
Purpose

The Anti-Lock BrakeSystem (ABS)consists ofelectronic andhydraulic components. Itallows forcon-
trol ofbraking forcesothat locking ofthe wheels canbeavoided.
The ABS:
1) Improves propertracking performance throughsteering wheeloperation.
2) Eases obstacles tobe avoided throughsteering wheeloperation.
3) Improves vehiclestability bypreventing flatspins.

Operation

• When thevehicle speedisless than 10km/h (6MPH) thissystem doesnotwork.
• The Anti-Lock BrakeSystem (ABS)hasself-test capabilities. Thesystem turnsonthe ABS warning
light for1second afterturning theignition switchON.The system performs anothertestthefirst time
the vehicle reaches 6km/h (4MPH). Amechanical noisemaybeheard asthe ABS performs aself-
test. This isanormal partofthe self-test feature.Ifa malfunction isfound during thischeck, theABS
warning lightwillcome on.
• During ABSoperation, amechanical noisemaybeheard. Thisisanormal condition.

ABS Hydraulic Circuit

G)
Inletsolenoid valve

@
Outlet solenoid valve

@
Reservoir

@)
Pump
)(

@

@
Motor

@
Inletvalve

(J)
Outlet valve
@ Bypass checkvalve

BR-38 @

Check valve

@)
Damper

@
Gradient switch
SBR918C

ANTI-LOCKBRAKESYSTEM
System Components

Dual proportioning
valve
Rearwheel sensors
For LHD models, controlunit
is located onthe opposite side.

SBR048DB

Control unit

s::';o~'~W.
r Magnetic flux~ _~-Coil

I .I

Tooth~ Sensorrotor
/ ~m~f onetooth

v:~-- System
Description
SENSOR

The sensor unitconsists ofagear-shaped sensorrotoranda
sensor element. Theelement contains abar magnet around
which acoil iswound. Thesensor isinstalled onthe back side
of the brake rotor.Sine-wave currentisgenerated bythe sen-
sor asthe wheel rotates. Thefrequency andvoltage increase(s) •
as the rotating speedincreases. :•

V: Induced electromotive force

SBR124B
SBR049DA CONTROL
UNIT

The control unitcomputes thewheel rotating speedbythe sig-
nal current sentfrom thesensor. Thenitsupplies aDC current
to the actuator solenoid valve.Italso controls ON-OFFopera-
tion ofthe valve relayandmotor relay.Ifany electrical malfunc-
tion should bedetected inthe system, thecontrol unitcauses
the warning lamptolight up.Inthis condition, theASS willbe
deactivated bythe control unit,andthevehicle's brakesystem
reverts tonormal operation.

BR-39

ANTI-LOCKBRAKESYSTEM
Removal andInstallation
CAUTION: Be careful nottodamage sensoredgeandsensor rotorteeth.
When removing thefront orrear wheel hubassembly, discon-
nect theABS wheel sensor fromtheassembly andmove it
away.
FRONT WHEEL SENSOR
Front wheel sensor (LH) ~!Ii

3.9-5.9 (0.4 -0.6, 35-52)
~: Nom (kg-m, ft-lb)
~: Nom(kg-m, in-Ib)

SBR030DA
REAR WHEEL SENSOR
BR-40
\

L
Rear wheel sensor (LH)

~: Nom (kg-m, ft-Ib)
~: Nom(kg-m, in-Ib)

SBR031DA