hydraulic fluid 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

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

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

PRECAUTIONSANDPREPARATION

Precautions

• Recommended fluidisbrake fluid"DOT 3".
• Donot reuse drained brakefluid.
• Becareful nottosplash brakefluidonpainted areas.
• When removing andinstalling clutchpiping, useTool.
• Use new brake fluidtoclean orwash allparts ofmaster
cylinder, operating cylinderandclutch damper.
• Never usemineral oilssuch asgasoline orkerosene. Itwill
ruin therubber partsofthe hydraulic system.

Tool number
Tool name
SBR820B

WARNING:
After cleaning clutchdisc,wipe itwith adust collector. Donot
use compressed air.

Preparation

SPECIAL SERVICE TOOLS

Description

New

GG94310000
Flare nuttorque wrench
KV30101600 (New)
KV30101000 (Former)
Clutch aligning bar
ST20050240 Diaphragm spring
adjusting wrench
NT406
NT645
NT404
Removing
andinstalling clutchpiping

a:
10
mm
(0.39
in)

Installing clutchcoverandclutch disc:
a:
15.9
mm
(0.626 In)dia.
b: 17.9 mm(0.705 in)dia.
c: 40 mm (1.57 in)

Adjusting unevenness ofdiaphragm spring
of clutch cover

a: 150 mm (5.91 in)
b: 25
mm
(0.98
in)

Tool name
Description
COMMERCIAL
SERVICETOOLS

Equivalent to
GG9431 0000

CD
Flare nutcrows foot

@
Torque wrench

NT360
Removing
andinstalling clutchpiping

a: 10 mm (0.39 in)

CL-2

INSPECTIONANDADJUSTMENT

Pedal stopper
Dash lower
panel (except
CD20 engine //
model)

/L
Floor car-pet

L
Dash reinforcement panel
(CD20 engine model)
Adjusting
ClutchPedal

1. Adjust pedalheight withpedal stopper.

Pedal height
"H":

Refer to
50S,
CL-14.

•

SCL625
SCL423 -
For mechanical type-

2. Adjust withdrawal leverplay"8"according tothe following
procedure_
a. Push withdrawal leverbyhand untilresistance isfelt, and
then tighten adjusting nut.
b. Turn backadjusting nut2.5to3.5 turns, andthen tighten lock
nut.

Withdrawal leverplay
"B":

2.5 -3.5 mm (0.098 -0.138 in)
lock nut:

~: 3-
4 N'm (0.3-0.4 kg-m, 26-35 in-Ib)
- For hydraulic typeandmechanical type-

3. Asafinal check, measure pedalfreetravel "A"atcenter of
pedal pad.

Pedal freetravel
"A":

Refer to
50S,
CL-14.
B
Bleeding Procedure -Hydraulic type
Bleed airaccording tothe following procedure.
• Carefully monitorfluidlevel atmaster cylinder during
bleeding operation.

1. Top upreservoir withrecommended brakefluid.
2. Connect atransparent vinyltubetoair bleeder valve.
3. Fully depress clutchpedalseveral times.
4. With clutch pedaldepressed, openbleeder valvetorelease
air, then close bleeder valve.
5. Repeat steps3through 5above untilclear brake fluid

SCL613
comesoutofair bleeder valve.

SCL341-A

Adjusting
nut
Lock
nut

CL-5

HYDRAULICCLUTCHCONTROL
Clutch Master Cylinder

SEC. 305

SCL669

~
2.9 •5.9 (0.30 •0.60, 26.0•52.2)

@
@
m
CD
Rubbing surfaceto
piston assembly
@LHD
models
m @:Apply silicone grease,
m
CD:
Apply rubber lubricant.

Iil :
N.m (kg-m. in-Ib)
CD

/

(1), ~
1'.

~'. ~". @liJa-
11

( ~I'
(08.'.1,

,<
I
~f
/@O@I1I!@(A':o'::"'1

~ @
m@(LHDmodels)
Rubbing surfaceto

@.
Apply brakefluidwhen assembling.
(jJ)
m @(RHD models) pushrod
~ m@(LHD models)

*
Take careofthe bolt direction Contactsurfacetopiston assembly
m@ :Apply rubber grease.

@~
1.5-2.9 (0.15 -0.30, 13.0-26.0)

• Remove thisstopper, when
removing pistonandreturn spring.

(j)
~
2.5 -3.9 (0.25 -0.40, 21.7-34.7)

(1)
Piston assembly

@
Reservoir
cap

@
Piston cup

(])
Reservoir
band

@
Return spring
@
Cylinder body

@
Reservoir
tank

@
Packing

@
Reservoir hose
@)

Valve stopper
@

Push rod

@
Stopper

@
Stopper ring

@
Dustcover

@
Lock nut

DISASSEMBLY ANDASSEMBLY

• Push piston intocylinder bodywithscrewdriver when
removing andinstalling valvestopper.
• Align groove ofpiston assembly andvalve stopper when
installing valvestopper.
• Check direction ofpiston cups.

c;D.=:
=.J3@

Groove
SCL214 CL-6

CHASSISANDBODY MAINTENANCE
Checking ExhaustSystem

Check exhaust pipes,muffler andmounting forimproper attach-
ment andforleaks, cracks, damage, looseconnections, chafing
and deterioration. •

SMA211A Checking ClutchFluidLevel andLeaks

If fluid level isextremely low,check clutch system forleaks.

SMA449C Checking ClutchSystem
HYDRAULIC TYPE

Check fluidlines andoperating cylinderforimproper
attachment, cracks,damage, looseconnections, chafingand
deterioration.

jJ
I
SMA"",

MECHANICAL TYPE

Check cableandlinks forimproper attachment, chafing,wear
and deterioration.

SMA141A Checking MITOil

• Check thatoilisnot leaking fromtransaxle oraround it.
• Remove speedometer pinionandcheck thattheoillevel L
at vehicle rearside iswithin specification.

Specified
Specifiedoillevel (Dimension L):

oil level
RS5F30A58-66 mm (2.28 -2.60 in)
RS5F31A GA engine 57-66 mm (2.24 -2.60 in)
CD engine 54-61 mm (2.13 -2.40 in)
RS5F32A 39-44 mm (1.54 -1.73 in)
SMT512C
MA-45

CHASSISANDBODY MAINTENANCE
OK MINMax,
line
Min, line
SBR418C Changing
AITFluid

1. Warm up
AIT
fluid.
2. Stop engine.
3. Drain
AIT
fluid from drain plugandrefill withnew
AIT
fluid .•
Always refillwithsame volume asdrained fluid.
i

Fluid grade:
Genuine NissanATForequivalent
See "RECOMMENDED FLUIDSANDlUBRICANTS",
MA-14.
Fluid capacity (Withtorque converter):
7.0£
(6-1/8
Impqt)
Drain plug:

toJ:
29.39
N'm
(3.0-4.0
kg-m,
22-29
ft-Ib)

4. Run engine atidle speed forfive minutes.
5. Check fluidlevel andcondition. Referto"Checking
AIT

Fluid". Iffluid isstill dirty, repeat steps2through 5.

Checking BrakeFluidLevel andLeaks
If
fluid level isextremely low,check brakesystem forleaks.

Checking BrakeSystem

Check brakefluidlines andparking brakecables forimproper
attachment andforleaks, chafing, abrasions, deterioration, etc.

SBR404C Changing
BrakeFluid

1. Drain brake fluidfrom each airbleeder valve.
2. Refill untilnewbrake fluidcomes outfrom each airbleeder
valve. Use same procedure asinbleeding hydraulic systemto
refill brake fluid.
Refer to"CHECK ANDADJUSTMENT" inBR section.

• Refill withrecommended brakefluid.
See "RECOMMENDED FLUIDSANDlUBRICANTS".
• Never reusedrained brakefluid.
• Becareful nottosplash brakefluidonpainted areas.
MA-47

SRA696A
SRA697A

S
Control rod

Lateral link
~H";""I"

ITorsion
beam
SRA698AREAR
SUSPENSION
Removal andInstallation
CAUTION:
• Before removing therear suspension assembly,disconnect
the ABS wheel sensor fromtheassembly. Failuretodo so
may result indamage tothe sensor wiresandthesensor
becoming inoperative.

• Remove suspension assembly.
1. Disconnect brakehydraulic linesandparking brakecableat
toggle lever.(Models withdrum brakes.)
• Drain brake fluidbefore disconnecting brakelines.
2. Disconnect parkingbrakecablefromcaliper andremove
brake caliper androtor. (Models withdiscbrakes.)

Suspend caliperassembly withwire soasnot tostretch brake
hose.
Be careful nottodepress brakepedal, orpiston willpop out.
Make surebrake hoseisnot twisted.

3. Using atransmission jack,raise torsion beamalittle, and
remove nutsandbolts fromthetrailing arm,shock absorber
assembly (lowerside)andlateral link.
4. Lower transmission jack,andremove suspension.
5. Remove luggagecompartment trim.Refer toBT section.
6. Remove strutsecuring nuts(upper side).Thenpulloutstrut
assembly.
• Install suspension assembly.

CAUTION: Refill withnewbrake fluid"DOT
3".

Never reusedrained brakefluid.

1. Attach torsion beam,attrailing armandlateral link,tovehi-
cle. Donot tighten boltsatthis time.
2. Using atransmission jack,place lateral linkand control rod
horizontally againsttorsionbeam.Tighten laterallinkon
vehicle.
3. Attach shockabsorber assembly tovehicle. Thentighten the
lower sideofshock absorber assembly.
4. Lower torsion beamtofully extended position.Remove
transmission jackandtighten torsion beam,attrailing arm,
to specified torque.RefertoRA-8.
5. Install brakehydraulic linesandtighten flarenuts.

~: 15-18 N'm (1.5.1.8 kg-m,11-13 ft-Ib)
Coil Spring andShock Absorber
REMOVAL

Remove shockabsorber upperandlower fixing nuts.

Do not remove pistonrodlock nutonvehicle.
RA-9
•