NISSAN PRIMERA 1999 Electronic Repair Manual

6. Check the cylinder body retaining spring for damage if the
spring is defective, replace the spring.
7. Click the cylinder body retaining spring in position and make
sure that:
lThe two ends of spring click correctly into the locating
holes of the cylinder body.
lThe spring is in the correct position against the lugs of
the torque member.
Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
Suspend caliper assembly with wire to avoid stretching the
brake hose.
Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly.
Disassembly
WARNING:
Do not place your fingers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
1. Push out piston with dust seal with compressed air.
2. Remove piston seal with a suitable tool.
Inspection Ð Caliper
CYLINDER BODY
lCheck inside surface of cylinder for score, rust, wear, dam-
age or presence of foreign materials. If any of the above
conditions are observed, replace cylinder body.
lMinor damage from rust or foreign materials may be elimi-
nated by polishing surface with a fine emery paper. Replace
cylinder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
NBR292 Spring Cylinder bodyTorque member lug
Torque member lug Locating
holes
NBR289
NBR294
FRONT DISC BRAKESR20DE - M/T
Installation (Cont'd)
BR-29

PISTON
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign materials are stuck to sliding
surface.
Check piston for score, rust, wear, damage or presence of for-
eign materials. Replace if any of the above conditions are
observed.
GUIDE PIN, BOLT, AND RETAINING SPRING
Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.
FRONT DISC BRAKESR20DE - M/T
Inspection Ð Caliper (Cont'd)
BR-30

Inspection Ð Rotor
RUBBING SURFACE
Check rotor for roughness, cracks or chips.
RUNOUT
1. Secure rotor to wheel hub with at least two nuts (M12´1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to section FA.
Maximum runout:
0.07 mm (0.0028 in)
3. If the runout is out of specification, find minimum runout posi-
tion as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor tho wheel hub
with nuts.
c. Measure runout.
d. Repeat steps a. to c. so minimum runout position can be
found.
4. If the runout is still out of specification, turn rotor with on-car
brake lathe (ªMAD, DL-8700º, ªAMMCO 700 and 705º or
equivalent).
THICKNESS
Rotor repair limit:
Standard thickness
22 mm (0.87 in)
Minimum thickness
20.0 mm (0.787 in)
Thickness variation (At least 8 positions)
Maximum 0.02 mm (0.0008 in)
Assembly
CAUTION:
Always use new piston seal.
1. Insert new piston seal into groove in cylinder body
2. With dust seal fitted to piston, insert dust seal into groove on
cylinder body and install piston.
3. Properly secure dust seal.
SBR936A
SBR944A
SBR574 Dust seal
Piston seal
Piston
Cylinder body
FRONT DISC BRAKE
BR-31

Installation
CAUTION:
lRefill with new brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
1. Install brake hose to caliper securely.
2. Install all parts and secure all bolts.
3. Bleed air. Refer to ªBleeding Brake Systemº BR-8.
NBR160
.Protrusions
NBR298 Protrusions
FRONT DISC BRAKE
BR-32

Component
1. Cable guide
2. Cylinder
3. Toggle lever
4. Pin
5. Pin boot
6. Torque member
7. Inner shim
8. Inner pad
9. Outer pad
10. Outer shim11. Strut
12. O-ring
13. Push rod
14. Key plate
15. Retaining washer
16. Spring
17. Spring cover
18. Snap ring B
19. Piston seal
20. Snap ring A21. Washer
22. Wave washer
23. Washer
24. Bearing
25. Adjuster
26. Cup
27. Piston
28. Piston boot
29. Sleeve
Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne particles or other materials.
CAUTION:
lWhen cylinder body is open, do not depress brake pedal
because piston will pop out.
lBe careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
lIf shims are rusted or show peeling of rubber coat,
replace them with new shims.
NBR366
SEC. 440
Stopper bolt
10-12
(1.0-1.2,7-9)
31-38
(3.2 - 3.8, 23 - 28)
p1
22-32
(2.3 - 3.2,
17 - 23)
38-52
(3.9 - 5.3, 28 - 38)p10p9pPp8pP
p7
p6
p5p4pPto sliding portion
p12pR
p13pR
p14
p15
p16
p17p18
p28pR
: Do not re-use
: N´m (kg-m, ft-lb)
pR: Rubber grease point
pB: Brake fluid point
pP: PBC (Poly Butyl Cuprysil) grease
or silicone-based grease point
p23
p27pB
p26pRp25
p24pBp22p21p20
p19pR
p11pR
p3
p2
p29
REAR DISC BRAKE TYPE 1
BR-33

lIt is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to
stretch brake hose.
lBurnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªCHECK AND
ADJUSTMENTº, BR-7.
1. Remove master cylinder reservoir cap.
2. Remove brake cable mounting bolt and lock spring.
3. Release parking brake control lever, then disconnect cable
from the caliper.
4. Remove upper pin bolt.
5. Open cylinder body downward. Then remove pads inner and
outer shims.
Standard pad thickness:
9.3 mm (0.366 in)
Pad wear limit:
2.0 mm (0.079 in)
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.
7. Adjust the piston to the right angle as shown in the figure.
NBR192
SBR916C Wire
SBR641
NBR374 Alignment position of
disc pad's concave
Concave portion Piston Assembly
to the right
angle
REAR DISC BRAKE TYPE 1
Pad Replacement (Cont'd)
BR-34

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.
Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne particles or other materials.
1. Remove brake cable mounting bolt and lock spring.
2. Release parking brake control lever, then disconnect cable
from the caliper.
3. Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend caliper assembly with wire so as not to
stretch brake hose.
Disassembly
1. Remove piston by turning it counterclockwise with long nose
pliers or suitable tool.
2. Pry off snap ring A from piston with suitable pliers and
remove adjusting nut.
NBR375 Concave portion
Convex portion
NBR167
SBR646
SBR889 Ring ªAº
REAR DISC BRAKE TYPE 1
Pad Replacement (Cont'd)
BR-35

3. Disassemble cylinder body.
a. Pry off snap ring B with suitable pliers, then remove spring
cover, spring and retaining washer.
b. Remove key plate, push rod, O-ring and strut.
c. Remove piston seal.
Be careful not to damage cylinder body.
4. Remove return spring, toggle lever and cable guide.
Inspection
Caliper
CAUTION:
Use brake fluid to clean cylinder. Never use mineral oil.
Cylinder Body
lCheck inside surface of cylinder for score, rust, wear, dam-
age or presence of foreign materials. If any of the above
conditions are observed, replace cylinder body.
lMinor damage from rust or foreign materials may be elimi-
nated by polishing surface with a fine emery paper.
Replace cylinder body if necessary.
Torque Member
Check for wear, cracks or other damage. Replace if necessary.
Piston
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign matter is stuck to sliding sur-
face.
Check piston for score, rust, wear, damage or presence of for-
eign materials.
Replace if any of the above conditions are observed.
SBR088B
SBR656
SBR767E Stopper boltReturn spring
Lever
REAR DISC BRAKE TYPE 1
Disassembly (Cont'd)
BR-36

Pin and Pin Boot
Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
Rotor
Rubbing Surface
Check rotor for roughness, cracks or chips.
Runout
1. 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 RA section (ªREAR WHEEL
BEARINGº, ªOn-vehicle Serviceº).
3. Change relative positions of rotor and wheel hub so that
runout is minimized.
Maximum runout:
0.07 mm (0.0028 in)
Thickness
Rotor 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)
Assembly
1. Insert cam with depression facing towards open end of cyl-
inder.
2. Generously apply rubber grease to strut and push rod to
make insertion easy.
SBR219C
NBR367Sleeve Seal Cam
O-ring
Strut
pR
Push rod
Rubber grease
SBR248B
REAR DISC BRAKE TYPE 1
Inspection (Cont'd)
BR-37

3. Install rod, push rod and key plate.
4. Fit push rod into square hole in key plate. Also match con-
vex portion of key plate with concave portion of cylinder.
5. Install retaining washer, spring, spring cover and snap ring B
with suitable press and drift.
6. Install cup in the specified direction.
SBR754E Key plate
Push rod
Rod
SBR893 Concave portion
Convex portion
SBR869CB Ring B
Spring cover
Spring
Retaining
washerCommer-
cial service
tool
SBR879-B Ring B
Spring cover
Spring
Retaining
washerPush
Tool
SBR892 Adjusting nut
REAR DISC BRAKE TYPE 1
Assembly (Cont'd)
BR-38