boot NISSAN ALMERA N15 1995 Service Manual

INSTRUMENTPANEL
CAUTION:
• Disconnect bothbattery cablesinadvance.
• Disconnect airbag system lineinadvance.
• Never tamper withorforce airbag lidopen, asthis may adversely affectairbag performance.
• Becareful nottoscratch padandother parts.
REMOVAL -Instrument panelassembly

Instrument panelassembly
Remove airbag module (driver's) andsteering wheel.
Refer to"SUPPLEMENTAL RESTRAINTSYSTEM"inRS section fordetails.

CD
Steering columncoverandcombination switch
• Remove screws.

l6l
Instrument lowerpanel ondriver side
• Remove screws.

@
Cluster lidC
• Remove screwsanddisconnect harnessconnectors. Audio

&AIC
control
Consolebox

@
Cluster lidA
• Remove screws.

@
Combination meter
• Remove screwsanddisconnect harnessconnectors.

cID
Audio and
AIC
control unit
• Remove screwsfromtheinstrument panel.

(J)
Glove boxassembly
• Remove gloveboxpin.
• Then disconnect passengerairbag module
connector.

@
Passenger airbag module
• Refer to"SUPPLEMENTAL RESTRAINT
SYSTEM" inRS section fordetails.
@
AIT
finisher orMIT shift lever boot

@
Rear console box
• Remove consolemaskandscrews.

@
Front console box
• Remove screwsandbolts.

@
Instrument mask
• Disconnect harnessconnector.

@
Front pillargarnish
• Refer to"Side andFloor Trim" in"INTE-
RIOR TRIM" fordetails, 8T-16.

@
Instrument panelandpads
II

• Remove boltsandnuts.
• Remove doormirror switch anddisconnect
the connector.
•

8T-13

~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

FRONTDISCBRAKE

•

SBR207D

@ Main pinbolt
@ Cylinder body
@ Piston seal
@ Piston

@
Piston boot

@J
Piston bootretainer

15
~
31-41
16

-I
(3.2-4.2, 23-30)

@
Ij]
7•9 (0.7 •0.9, 61•78)

SEC.

440

AD22VF

Ij]:
N.m (kg-m, in-Ib)

to.J :
N.
m
(kg-m, 1t-lb)

m
@:
Rubber greasepoint

f] :
Brake fluidpoint

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

G)
Plug @
Inner pad
@ Torque member @
Inner shim

@
Torque member fixingbolt @
Shim cover

@
Pinboot @
Connecting bolt

@
Outer shim
@

Brake hose

@
Outer pad
@

Copper washer

(J)
Padretainer
@

Airbleeder

BR-21

AD22VF SBR776B
SBR772 FRONT
DISCBRAKE
Removal
WARNING:
Clean brakepadswithavacuum dustcollector tominimize the
hazard ofairborne asbestos orother materials.
CAUTION:
Suspend caliperassembly withwire soasnot tostretch brake
hose.

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 pistonbootretainer withascrewdriver.

WARNING: Do not place yourfingers infront ofpiston.
CAUTION: Do not scratch orscore cylinder wall.

2. Push outpiston withdust sealwithcompressed air.
3. Remove pistonsealwith asuitable tool.

Inspection -Caliper
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.

CAUTION: Use brake fluidtoclean. Neverusemineral oil.
BR-22

Pistonbootretainer (AD22VF only)
Piston boot
Piston seal
FRONT
DISCBRAKE
Inspection -Caliper (Cont'd)
PISTON

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

CAUTION:
Piston sliding surface isplated. Donot polish withemery paper
even ifrust orforeign objects arestuck tosliding surface.
SLIDE PIN,PINBOLT ANDPINBOOT

Check forwear, cracks, rustorother damage. Replaceifany of
the above conditions areobserved.

Inspection -Rotor
RUNOUT
1: Secure rotortowheel hubwith atleast twonuts (M12 x
1.25).
2. Check runout usingadial indicator.

Make surethatwheel bearing axialendplay iswithin thespec-
ifications beforemeasuring. RefertoFA section ("FrontWheel
Bearing", "ON-VEHICLE SERVICE").
Maximum runout:
SBR936A 0.07mm(0.0028 in)

3.
If
the runout isout ofspecification, findminimum runout
position asfollows:
a. Remove nutsandrotor fromwheel hub.
b. Shift therotor onehole andsecure rotortowheel hub
with nuts.
c. Measure runout.
d. Repeat stepsa.to c.so that minimum runoutposition can
be found.
4. Ifthe runout isstill outofspecification, turnrotor withon-car
brake lathe("MAD, DL-8700", "AMMCO700and 705" or•••
equivalent).

THICKNESS Thickness variation(Atleast 8positions):
Maximum 0.02mm(0.0008 in)

If thickness variationexceedsthespecification, turnrotor with
on-car brakelathe.

Rotor repair limit:
CL22VD andCL22VE 16.0mm(0.630 in)
CL22VF 24.0mm(0.945 in)
SBR944A Assembly
1. With piston bootfitted topiston, insertpiston bootinto
groove oncylinder bodyandinstall piston.
2. Properly securepistonboot.
3. Secure pistonbootwithretainer.
(AD22VF modelonly)

Piston

SBR777B BR-23

SEC.441
REAR
DRUM BRAKE

Front
m,W.
Rubber greasePOint
• .Brake grease point
~ :N.m (kg-m, f1-lb)

/il.
N.m(kg-m, in-Ib)

SBR772BC

Cl)
Wheel
cylinder assembly
(J)
Return spring
@

Shoe hold-down spring

@
Boot
@

Adjuster
@
Toggle lever

@
Piston
@

Shoe
@
Washer

@
Piston cup
@)
Adjuster lever
@

Retainer ring

@
Cylinder body
@

Adjuster spring
@

Shoe hold-down pin

@
Spring
@

Retainer
@
Plug

Removal
WARNING:
Clean brakeliningwithavacuum dustcollector tominimize the
hazard ofairborne particles orother materials.
CAUTION: Make sureparking brakeleverisreleased completely.
BR-25
•

Bolts
(M8
x
1.25) Wheel
cylinder
Adjuster
SBR280B
SBR020A REAR
DRUM BRAKE
Removal (Cont'd)

1. Release parkingbrakeleverfully,thenremove drum.

If drum ishard toremove, thefollowing procedures shouldbe
carried out.
a. Remove plug.Thenshorten adjuster tomake clearance
between brakeshoeanddrum asshown.
b. Tighten thetwo bolts gradually.
SBR785BA
2.
After removing retainer,removespringbyrotating shoes.

• Becareful nottodamage wheelcylinder pistonboots.
• Becareful nottodamage parkingbrakecablewhensepa-
rating it.

3. Remove adjuster.
4. Disconnect parkingbrakecablefromtoggle lever.
5. Remove retainerringwith asuitable tool.Then separate
toggle leverandbrake shoe.

Inspection -Wheel Cylinder

• Check wheelcylinder forleakage.
• Check forwear, damage andloose conditions.
Replace ifany such condition exists.

BR-26

SBR216B
~ ~Vohi'" 'COol
DepreSSi~~
"
~

/

SBR217B
SBR279B
REAR
DRUM BRAKE

Installation (Cont'd)

2. Apply brake grease tothe contact areasshown atleft.
3. Shorten adjuster byrotating it.

• Pay attention todirection ofadjuster.

Wheel Screw Depression
Left Left-handthread
Yes

Right Right-handthread No

4. Connect parkingbrakecabletotoggle
lever.

5. Install allparts.

Be careful nottodamage wheelcylinder pistonboots.

6. Check allparts areinstalled properly.

Pay attention todirection ofadjuster assembly.

7. Install brakedrum.
8. When installing newwheel cylinder oroverhauling wheel
cylinder, bleedair.Refer to"Bleeding procedure", BR-6.
9. Adjust parking brake.RefertoBR-37.

BR-28

SBR023DREAR
DISCBRAKE
Pad Replacement
WARNING:
Clean brakepadswithavacuum dustcollector tominimize the
hazard ofairborne particles orother materials.
CAUTION:
• When cylinder bodyisopen, donot depress brakepedal,
otherwise pistonwillpop out.
• Becareful nottodamage pistonbootorget oilonrotor.
Always replace shimswhenreplacing pads.
• Ifshims arerusted orshow peeling ofrubber coat,replace
them withnewshims.
• Itis not necessary toremove connecting boltexcept for
disassembly orreplacement ofcaliper assembly. Inthis
case, suspend cylinderbodywithwire soas nol tostreich
brake hose
• Carefully monitorbrakefluidlevel because brakefluidwill
return toreservoir whenpushing backpiston.

1. Remove mastercylinder reservoir cap.
2. Remove brakecablelockspring.
3. Remove cableguide fromcaliper assembly.
4. Disconnect cable.
5. Remove lockspring frombrake hose.Thenremove brake
hose from bracket.
6. Remove lowerpinbolt.
7. Open cylinder bodyupward. Thenremove padretainers,
and inner andouter shims.

Standard padthickness:
10 mm (0.39 in)
Pad wear limit:
1.5 mm (0.059 in)

•

Commercial

service tool

SBR868C
8.
When installing newpads, pushpiston intocylinder bodyby
turning pistonclockwise.

Carefully monitorbrakefluidlevel because brakefluidwill
return toreservoir whenpushing backpiston.
BR-29