FLUID NISSAN ALMERA N16 2003 Electronic Repair Manual

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[3
Supplemental Restraint System (SRS)″AIR
BAG″and″SEAT BELT PRE-TENSIONER″...............3
Precautions for Brake System .....................................3
Precautions When Working On ABS ...........................4
Wiring Diagrams and Trouble Diagnosis .....................4
PREPARATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[5
Commercial Service Tools ...........................................5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011>6
NVH Troubleshooting Chart.........................................6
ON-VEHICLE SERVICE..................................................7
Checking Brake Fluid Level.........................................7
Checking Brake Line ...................................................7
Changing Brake Fluid ..................................................7
Brake Burnishing Procedure........................................7
Bleeding Brake System ...............................................8
BRAKE HYDRAULIC LINE.............................................9
Hydraulic Circuit...........................................................9
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[...............9
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............10
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............10
DUAL PROPORTIONING VALVE................................. 11
Dual Proportioning Valve ........................................... 11
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 11
REMOVAL AND INSTALLATION (BUILT-IN TYPE)..... 11
BRAKE PEDAL AND BRACKET..................................12
Removal and Installation ...........................................12
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............12
Adjustment <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............12
MASTER CYLINDER (NABCO)....................................14
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............14
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........15
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............15
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............15
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............16
MASTER CYLINDER [BOSCH (NABCO)]...................17
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............17
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........17Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............18
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............18
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............19
BRAKE BOOSTER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>0
On-vehicle Service.....................................................20
OPERATING CHECK...............................................20
AIRTIGHT CHECK<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11>0
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............20
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............20
OUTPUT ROD LENGTH CHECK..............................20
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............21
VACUUM HOSE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>2
Removal and Installation ...........................................22
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............22
HOSES AND CONNECTORS...................................22
CHECK VALVE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>2
VACUUM PUMP<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011>3
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............23
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............24
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............24
Component <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[..........25
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........25
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............25
FRONT DISC BRAKE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11>7
Component <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[..........27
Pad Replacement ......................................................27
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............28
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........28
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............28
CALIPER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..28
ROTOR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....29
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............30
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............30
REAR DISC BRAKE (CAM & STRUT TYPE)..............31
Component <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[..........31
Pad Replacement ......................................................31
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............33
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........33
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............34
GI
MA
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LC
EC
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RS
BT
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IDX

CALIPER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..34
ROTOR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....35
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............35
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............38
REAR DISC BRAKE (BALL & RAMP TYPE)..............39
Component <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[..........39
Pad Replacement ......................................................39
Removal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[.............41
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........41
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............41
CALIPER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..41
ROTOR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....42
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............42
PARKING BRAKE CONTROL......................................43
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........43
Removal and Installation ...........................................43
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............43
Adjustment <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............44
ABS
DESCRIPTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[45
Purpose<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[..............45
ABS (Anti-Lock Brake System) Operation ................45
ABS Hydraulic Circuit ................................................45
System Components .................................................46
System Description ....................................................46
SENSOR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..46
CONTROL UNIT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>6
ABS ACTUATOR AND ELECTRIC UNIT....................46
Component Parts and Harness Connector
Location <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[..............48
Schematic <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[............49
Wiring Diagram - ABS - .............................................50
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[54
Trouble Diagnosis Chart by Symptom.......................54
CHECK ITEMS LIST................................................54
ABS actuator and electric unit Input/Output
Signal Standard .........................................................54
SPECIFICATIONS DEFINED BY CONSULT-II............54
CONSULT-II Functions ..............................................55
CONSULT-II FUNCTION APPLICATION TABLE..........55
SELF-DIAGNOSIS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11>6
DATA MONITOR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>8
ACTIVE TEST<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011>0
TROUBLE DIAGNOSIS - BASIC INSPECTION...........62
ABS Actuator and Electric Unit..................................62
Basic Inspection 1 Brake Fluid Level and
Leakage Inspection....................................................62
Basic Inspection 2 Inspection for Loose Power
Supply Terminal .........................................................62
Basic Inspection 3 ABS Warning Lamp
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............63
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..............64
Wheel Sensor System ...............................................64
ABS Warning Lamp Does Not Illuminate. (ABS
Warning Lamp Does Not Come on When the
Ignition Switch is Turned ON.)...................................65
ABS Warning Lamp Illuminates with Ignition ON,
but Does Not Illuminates Off After a Few
Seconds. (ABS Warning Lamp has been
Illuminated.) ...............................................................65
TROUBLE DIAGNOSES FOR SYMPTOMS.................66
1. ABS Works Frequently ..........................................66
2. Unexpected Pedal Action ......................................66
3. Longer Stopping Distance .....................................67
4. ABS Does Not Work ..............................................68
5. Pedal Vibration and Noise.....................................68
REMOVAL AND INSTALLATION.................................70
Wheel Sensors <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[.......70
ABS Actuator and Electric Unit..................................71
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[71
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>1
Sensor Rotor<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..........72
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[72
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>2
SERVICE DATA AND SPECIFICATIONS (SDS).........73
General Specifications ...............................................73
Disc Brake <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[...........73
Brake Pedal <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........73
Parking Brake <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[.........74
CONTENTS(Cont’d)
BR-2

Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
NJBR0139The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removalofSpiralCableandAir
Bag Module, see the RS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow or/and orange harness connec-
tor.
SBR686C
Precautions for Brake SystemNJBR0002Recommended fluid is brake fluid “DOT 4”.
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas.
To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of the hydraulic system.
Use flare nut wrench when removing and installing brake
tube.
Always torque brake lines when installing.
Burnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings,
or if a soft pedal occurs at very low mileage.
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE
SERVICE”, BR-7.
WARNING:
Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
GI
MA
EM
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EC
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CL
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BT
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IDX
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
BR-3

Commercial Service ToolsNJBR0004
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing each brake piping
a: 10 mm (0.39 in)
Brake fluid pressure
gauge
NT151
Measuring brake fluid pressure
GI
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IDX
PREPARATION
Commercial Service Tools
BR-5

SBR451D
Checking Brake Fluid LevelNJBR0006Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
If fluid level is extremely low, check brake system for leaks.
Release parking brake lever and see if brake warning lamp
goes off. If not, check brake system for leaks.
SBR389C
Checking Brake LineNJBR0007CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
SBR419C
Changing Brake FluidNJBR0008CAUTION:
Refill with new brake fluid “DOT 4”.
Always keep fluid level higher than minimum line on res-
ervoir tank.
Never reuse drained brake fluid.
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. Clean inside of reservoir tank, and refill with new brake fluid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal while keeping reservoir level higher than minimum
line by adding new brake fluid.
4. Repeat until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to “Bleeding Brake System”, BR-8.
Brake Burnishing ProcedureNJBR0036Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing drums or rotors, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
GI
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ON-VEHICLE SERVICE
Checking Brake Fluid Level
BR-7

pressure such that vehicle stopping time equals 3 to 5 sec-
onds.
3. To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnish-
ing procedure.
SBR995
Bleeding Brake SystemNJBR0009CAUTION:
Carefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
Fill reservoir with new brake fluid “DOT 4”. Make sure it is
full at all times while bleeding air out of system.
Place a container under master cylinder to avoid spillage
of brake fluid.
For models with ABS, turn ignition switch OFF and dis-
connect ABS actuator connectors or battery ground cable.
SBR419C
Bleed air in the following order.
Right rear brake,Left front brake,Left rear brake,Right
front brake
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to release
air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2. through 5. until clear brake fluid comes out of
air bleeder valve.
ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont’d)
BR-8

Hydraulic CircuitNJBR0010
YBR317
RemovalNJBR0011CAUTION:
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.
All hoses must be free from excessive bending, twisting
and pulling.
For ball & ramp type rear caliper, care should be taken as
not to let air enter the body.
1. Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
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BRAKE HYDRAULIC LINE
Hydraulic Circuit
BR-9

2. Cover openings to prevent entrance of air and dirt whenever
disconnecting brake line.
InspectionNJBR0012Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
SBR686C
InstallationNJBR0013CAUTION:
Refill with new brake fluid “DOT 4”.
Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Specification:
Flare nut
15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Connecting bolt
17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
2. Refill until new brake fluid comes out of each air bleeder valve.
3. Bleed air. Refer to “Bleeding Brake System”, BR-8.
BRAKE HYDRAULIC LINE
Removal (Cont’d)
BR-10

SBR822BA
SBR823BA
Dual Proportioning ValveNJBR0149INSPECTIONNJBR0149S01CAUTION:
Carefully monitor brake fluid level at master cylinder.
Use new brake fluid “DOT 4”.
Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
paint areas, wash it away with water immediately.
Depress pedal slowly when raising front brake pressure.
Check rear brake pressure at least 2 seconds after front
brake pressure reaches specified value.
1. Connect brake fluid pressure gauge to air bleeders of front and
rear brakes on either LH or RH side.
2. Bleed air from the tool.
3. Check fluid pressure by depressing brake pedal.
Unit: kPa (bar, kg/cm2, psi)
Applied pressure (Front brake) 5,884 (58.8, 60, 853.2)
Output pressure (Rear brake)3,430 - 4,800
(34.3 - 45, 35 - 45.70, 497 - 649.5)
If output pressure is out of specifications, replace the master
assembly (built-in type).
4. Bleed air after disconnecting the Tool. Refer to “Bleeding Brake
System”, BR-8.
REMOVAL AND INSTALLATION (BUILT-IN TYPE)NJBR0149S02Always replace together with master cylinder as an assembly.
Refer to “MASTER CYLINDER (NABCO)”, BR-14.
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DUAL PROPORTIONING VALVE
Dual Proportioning Valve
BR-11

RemovalNJBR0151
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