NISSAN ALMERA N16 2001 Electronic Repair Manual

SBR229E
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
2. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3. Check brake pedal's depressed height while engine is running.
If lower than specification, check brake system for leaks, accu-
mulation of air or any damage to components (master cylinder,
wheel cylinder, etc.); then make necessary repairs.
BRAKE PEDAL AND BRACKET
Adjustment (Cont'd)
BR-13

RemovalNJBR0139
NBR351
1. Reservoir cap
2. Oil filter
3. Reservoir tank4. Seal
5. Cylinder body
6. Secondary piston assembly7. Primary piston assembly
8. Stopper cap
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake
pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
MASTER CYLINDER (NABCO)
Removal
BR-14

SBR938A
DisassemblyNJBR01521. Bend claws of stopper cap outward and remove stopper cap.
SBR113B
2. Remove valve stopper while piston is pushed into cylinder.
3. Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
4. Draw out reservoir tank.
InspectionNJBR0153Check for the following items.
Replace any part if damaged.
Master cylinder:
+Pin holes or scratches on inner wall.
Piston:
+Deformation of or scratches on piston cups.
NBR352
AssemblyNJBR01541. Insert secondary piston assembly. Then insert primary piston
assembly.
+Pay attention to alignment of secondary piston slit with valve
stopper mounting hole of cylinder body.
SBR940A
2. Install stopper cap.
Before installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.
MASTER CYLINDER (NABCO)
Disassembly
BR-15

SBR704C
InstallationNJBR0155CAUTION:
+Refill with new brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque mounting nuts.
: 12 - 15 N´m (1.2 - 1.5 kg-m,9-11ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system. Refer to ªBleeding Brake
Systemº, BR-8.
MASTER CYLINDER (NABCO)
Installation
BR-16

RemovalNJBR0117
SBR766E
1. Reservoir cap
2. Oil filter (ABS models only)
3. Reservoir tank
4. Seal5. Cylinder body
6. Elastic pin
7. Piston stopper pin8. Secondary piston assembly
9. Primary piston assembly
10. Circlip
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
1. Connect a vinyl tube to front caliper air bleeder valve.
2. Drain brake fluid from each front caliper air bleeder valve,
depressing brake pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
SBR231E
DisassemblyNJBR01181. Drive out elastic pin from cylinder body.
2. Remove reservoir tank and seals.
MASTER CYLINDER [BOSCH (NABCO)]
Removal
BR-17

NBR353
3. Remove the circlip with suitable pliers while piston is pushed
into cylinder.
SBR232E
4. Remove piston stopper pin while piston is pushed into cylinder.
5. Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
InspectionNJBR0119Check for the following items.
Replace any part if damaged.
Master cylinder:
+Pin holes or scratches on inner wall.
Piston:
+Deformation of or scratches on piston cups.
SBR233E
AssemblyNJBR01201. Insert secondary piston assembly. Then insert primary piston
assembly.
+Pay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body.
SBR232E
2. Install piston stopper pin while piston is pushed into cylinder.
Then secure the primary and secondary piston assemblies
with circlip.
3. Push reservoir tank seals and reservoir tank into cylinder body.
4. Install elastic pin.
MASTER CYLINDER [BOSCH (NABCO)]
Disassembly (Cont'd)
BR-18

SBR236E
InstallationNJBR0121CAUTION:
+Refill with new brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque mounting nuts.
: 13 - 15 N´m (1.3 - 1.5 kg-m,9-11ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system.
MASTER CYLINDER [BOSCH (NABCO)]
Installation
BR-19

SBR002A
SBR365AA
On-vehicle ServiceNJBR0023OPERATING CHECKNJBR0023S011. Stop engine and depress brake pedal several times. Check
that pedal stroke does not change.
2. Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECKNJBR0023S021. Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. The pedal should go further
down the first time, and then it should gradually rise thereaf-
ter.
2. Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change
after holding pedal down for30 seconds.
SBR232CB
RemovalNJBR0024CAUTION:
+Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+Be careful not to deform or bend brake pipes, during
removal of booster.
SBR208E
InspectionNJBR0025OUTPUT ROD LENGTH CHECKNJBR0025S011. Apply vacuum of þ66.7 kPa (þ667 mbar, þ500 mmHg, þ19.69
inHg) to brake booster with a handy vacuum pump.
2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.
3. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
BRAKE BOOSTER
On-vehicle Service
BR-20

InstallationNJBR0026CAUTION:
+Be careful not to deform or bend brake pipes, during
installation of booster.
+Replace clevis pin if damaged.
+Refill with new brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
+Take care not to damage brake booster mounting bolt
thread when installing. Due to the acute angle of
installation, the threads can be damaged with the dash
panel.
SBR237EA
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to
master cylinder) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
Specification:
13 - 16 N´m (1.3 - 1.6 kg-m,9-12ft-lb)
5. Install master cylinder. Refer to ªInstallationº in ªMASTER
CYLINDERº, BR-19.
6. Bleed air. Refer to ªBleeding Brake Systemº, BR-8.
BRAKE BOOSTER
Installation
BR-21

SBR225B
Removal and InstallationNJBR0027CAUTION:
When installing vacuum hoses, pay attention to the following
points.
+Do not apply any oil or lubricants to vacuum hose and
check valve.
+Insert vacuum tube into vacuum hose as shown.
+Install check valve, paying attention to its direction.
InspectionNJBR0028HOSES AND CONNECTORSNJBR0028S01Check vacuum lines, connections and check valve for airtightness,
improper attachment chafing and deterioration.
SBR844B
CHECK VALVENJBR0028S02Check vacuum with a vacuum pump.
Connect to booster side Vacuum should exist.
Connect to engine side Vacuum should not exist.
VACUUM HOSE
Removal and Installation
BR-22