NISSAN ALMERA N16 2003 Electronic Repair Manual

SBR892
6. Install cup in the specified direction.
SBR755E
7. Install adjuster, bearing, washers and ring A with a suitable
tool.
SBR646
8. Insert piston seal into groove on cylinder body.
9. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and fit piston by turning it clockwise with long
nose pilers, or suitable tool.
SBR767E
10. Fit toggle lever, return spring and cable guide.
SBR306E
11. Adjust the piston to the right angle as shown in the figure.
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REAR DISC BRAKE (CAM & STRUT TYPE)
Assembly (Cont’d)
BR-37

SBR307E
InstallationNJBR0043CAUTION:
Refill with new brake fluid “DOT 4”.
Never reuse drained brake fluid.
1. Install caliper assembly.
As shown in the figure, align the piston’s concave to the pad’s
convex, then install the cylinder body to the torque member.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to “Bleeding Brake System”, BR-8.
REAR DISC BRAKE (CAM & STRUT TYPE)
Installation
BR-38

ComponentNJBR0141
NBR422
1. Cylinder body
2. Pin
3. Pin boot4. Torque member
5. Inner shim
6. Inner pad7. Outer pad
8. Outer shim
NOTE:
The cylinder body cannot be disassembled.
Pad ReplacementNJBR0142WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
When cylinder body is open, do not depress brake pedal
because piston will pop out.
Be careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
If shims are rusted or show peeling of rubber coat, replace
them with new shims.
It is not necessary to remove connecting bolt except for
replacement of caliper assembly. In this case, suspend
cylinder body with wire so as not to stretch brake hose.
Burnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE
SERVICE”, BR-7.
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REAR DISC BRAKE (BALL & RAMP TYPE)
Component
BR-39

NBR423
1. Remove master cylinder reservoir cap.
2. Remove brake cable lock spring.
3. Release parking brake control lever, then disconnect cable
from the caliper.
4. Remove upper pin bolt.
NBR426
5. Open cylinder body downward. Then remove pads inner and
outer shims.
Standard pad thickness:
9.3mm(0.366in)
Pad wear limit:
2.0mm(0.079in)
SBR641
6. When installing new pads, push piston into cylinder body by
gently turning piston clockwise, as shown.
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
NBR374
7. Adjust the piston to the right angle as shown in the figure.
NBR375
8. As shown in the figure, align the piston’s concave to the pad’s
convex, then install the cylinder body to the torque member.
9. Install brake cable, brake cable mounting bolt, lock spring and
master cylinder reservoir cap.
REAR DISC BRAKE (BALL & RAMP TYPE)
Pad Replacement (Cont’d)
BR-40

NBR427
RemovalNJBR0143WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
1. Remove brake cable lock spring.
2. Release parking brake control lever, then disconnect cable
from the caliper.
3. Remove torque member fixing bolts and connecting bolt.
4. Remove brake hose connecting bolt.
5. Plug off the brake hose and cylinder body to prevent air enter-
ing the system.
CAUTION:
Care should be taken as not to let:
Air enter the cylinder body and brake hose.
Brake fluid spill from the cylinder body and brake hose.
DisassemblyNJBR0144Remove pin bolts and pins.
NOTE:
Cylinder body can not be disassembled.
InspectionNJBR0145CALIPERNJBR0145S01CAUTION:
Do not drain any brake fluid from cylinder body. Cylinder body
can not be disassembled.
Cylinder BodyNJBR0145S0101Check cylinder body for score, rust, wear, damage or presence of
foreign materials. If any of the above conditions are observed,
replace cylinder body.
Torque MemberNJBR0145S0102Check for wear, cracks or other damage. Replace if necessary.
Pin and Pin BootNJBR0145S0104Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
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REAR DISC BRAKE (BALL & RAMP TYPE)
Removal
BR-41

SBR219C
ROTORNJBR0145S02Rubbing SurfaceNJBR0145S0201Check rotor for roughness, cracks or chips.
RunoutNJBR0145S02021. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications
before measuring. Refer to AX section (“REAR WHEEL
BEARING”, “On-vehicle Service”).
3. Change relative positions of rotor and wheel hub so that runout
is minimized.
Maximum runout:
0.07 mm (0.0028 in)
ThicknessNJBR0145S0203Rotor repair limit:
Standard thickness
10 mm (0.39 in)
Minimum thickness
9 mm (0.35 in)
Thickness variation (At least 8 portions)
Maximum 0.02 mm (0.0008 in)
NBR374
NBR375
InstallationNJBR0146CAUTION:
Refill with new brake fluid “DOT 4”.
Never reuse drained brake fluid.
Do not drain (factory) filled brake fluid from (new) caliper
assemblies.
1. Install caliper assembly.
As shown in the figure, align the piston’s concave to the pad’s
convex, then install the cylinder body to the torque member.
2. Remove the plug from the cylinder body and brake hose.
CAUTION:
Care should be taken as not to let:
Air enter the cylinder body and brake hose.
Brake fluid spill from the cylinder body and brake hose.
3. Install brake hose to caliper securely.
4. Install all parts and secure all bolts.
5. Bleed air. Refer to “Bleeding Brake System”, BR-8.
REAR DISC BRAKE (BALL & RAMP TYPE)
Inspection (Cont’d)
BR-42

ComponentsNJBR0044
YBR318
SBR897D
Removal and InstallationNJBR00451. To remove parking brake cable, first remove center console.
2. Disconnect warning lamp switch connector.
3. Remove adjusting nut.
4. Remove bolts and nuts securing parking brake cable.
5. Remove parking brake device.
SBR025D
6. Remove lock plate and disconnect cable.
InspectionNJBR00461. Check control lever for wear or other damage. Replace if nec-
essary.
2. Check wires for discontinuity or deterioration. Replace if nec-
essary.
3. Check warning lamp and switch. Replace if necessary.
4. Check parts at each connecting portion and, if found deformed
or damaged, replace.
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PARKING BRAKE CONTROL
Components
BR-43

SBR768E
AdjustmentNJBR0047Before or after adjustment, pay attention to the following points.
For rear disc brake be sure that toggle lever returns to stop-
per when parking brake lever is released.
There is no drag when parking brake lever is released.
Vehicle is unladen.
1. Adjust clearance between pad and rotor as follows:
a. Release parking brake lever and loosen adjusting nut.
b. Depress brake pedal fully at least 10 times with engine run-
ning.
SBR756E
2. Pull control lever 10 times or more to make a (full) lever stroke
of 195 mm (7.68 in). At 4 to 6 notches, adjust the parking brake
cable by turning the adjusting nut.
SBR033A
3. Pull control lever with specified amount of force. Check lever
stroke and ensure smooth operation.
Number of notches
5-6
4. Bend warning lamp switch plate to ensure:
Warning lamp comes on when lever is lifted “A” notches.
Warning lamp goes out when lever is fully released.
Number of “A” notches: 1
PARKING BRAKE CONTROL
Adjustment
BR-44

PurposeNJBR0082The ABS consists of electronic and hydraulic components. It allows for control of braking force so that lock-
ing of the wheels can be avoided.
The ABS:
1) Ensures proper tracking performance through steering wheel operation.
2) Enables obstacles to be avoided through steering wheel operation.
3) Ensures vehicle stability by preventing flat spins.
ABS (Anti-Lock Brake System) OperationNJBR0083When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.
The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning lamp
for 1 second after turning the ignition switch ON. The system performs another test the first time the vehicle
reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs a self-test. This is a
normal part of the self-test feature. If a malfunction is found during thischeck, the ABS warning lamp will
come on.
During ABS operation, a mechanical noise may be heard. This is a normal condition.
ABS Hydraulic CircuitNJBR0084
SBR757E
1. Inlet solenoid valve
2. Outlet solenoid valve
3. Reservoir4. Pump
5. Motor6. Bypass check valve
7. Damper
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DESCRIPTIONABS
Purpose
BR-45

System ComponentsNJBR0086
NBR433
SBR124B
System DescriptionNJBR0087SENSORNJBR0087S01The sensor unit consists of a gear-shaped sensor rotor and a sen-
sor element. The element contains a bar magnet around which a
coil is wound. The sensor is installed on the back side of the brake
rotor. Sine-wave current is generated by the sensor as the wheel
rotates. The frequency and voltage increase(s) as the rotating
speed increases.
SBR759E
CONTROL UNITNJBR0087S02The control unit computes the wheel rotating speed by the signal
current sent from the sensor. Then it supplies a DC current to the
actuator solenoid valve. It also controls ON-OFF operation of the
valve relay and motor relay. If any electrical malfunction should be
detected in the system, the control unit causes the warning lamp
to light up. In this condition, the ABS will be deactivated by the
control unit, and the vehicle’s brake system reverts to normal
operation.
SBR176E
ABS ACTUATOR AND ELECTRIC UNITNJBR0087S03The ABS actuator and electric unit contains:
An electric motor and pump
Two relays
Eight solenoid valves, each inlet and outlet for
— LH front
—RHfront
— LH rear
— RH rear
ABS control unit
DESCRIPTIONABS
System Components
BR-46