NISSAN PRIMERA 1999 Electronic Repair Manual

7. Install cup adjuster, bearing, washers and snap ring A with a
suitable tool.
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 pliers, or suitable tool.
10. Fit toggle lever, return spring and cable guide.
11. Adjust the piston to the right angle as shown in the figure.
Installation
CAUTION:
lRefill with new brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
1. Install caliper assembly.
lAs 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 ªBleeding Brake Systemº, BR-8
SBR755E Ring A
Washer
Wave washer
Washer
Ball bearing
Adjuster
Cup
Piston
SBR646
SBR767E Stopper boltReturn spring
Lever
NBR374 Alignment position of
disc pad's concave
Concave portion Piston Assembly
to the right
angle
NBR375 Concave portion
Convex portion
REAR DISC BRAKE TYPE 1
Assembly (Cont'd)
BR-39

Component
1. Cylinder body
2. Pin
3. Pin boot
4. Torque member5. Inner shim
6. Inner pad
7. OUter pad8. Outer shim
9. Bleed valve
10. Connecting bolt
NOTE:
The cylinder body cannot be disassembled.
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.
lIt 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.
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, ªON-VEHICLE
SERVICEº, BR-7.
NBR440
REAR DISC BRAKE TYPE 2
BR-40

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.
5. Open cylinder body downward. Then remove pad 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.
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.
NBR423
NBR426
SBR641
NBR374
NBR375
REAR DISC BRAKE TYPE 2
Pad Replacement (Cont'd)
BR-41

Removal
WARNING:
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
entering the system.
CAUTION:
Care should be taken as not to let:
lAir enter the cylinder body and brake hose.
lBrake fluid spill from the cylinder body and brake hose.
Disassembly
Remove pin bolts and pins.
NOTE:
Cylinder body can not be disassembled.
Inspection
CALIPER
CAUTION:
Do not drain any brake fluid from cylinder body. Cylinder
body can not be disassembled.
Cylinder Body
Check cylinder body for score, rust, wear, damage or presence
of foreign materials. If any of the above conditions are observed,
replace cylinder body.
Torque Member
Check for wear, cracks or other damage. Replace if necessary.
Pin and Pin Boot
Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
NBR427
REAR DISC BRAKE TYPE 2
BR-42

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 AX 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)
Installation
CAUTION:
lRefill with new brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
lDo not drain (factory) filled brake fluid from (new) cali-
per assemblies.
1. Install caliper assembly.
lAs 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:
lAir enter the cylinder body and brake hose.
lBrake 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 ªBleeding Brake Systemº, BR-8.
SBR219C
NBR374
NBR375
REAR DISC BRAKE TYPE 2
Inspection (Cont'd)
BR-43

Components
1. Boot
2. Piston
3. Piston cap
4. Spring
5. Wheel cylinder6. Shoe hold-down pin
7. Plug
8. Brake drum
9. Shoe hold-down spring
10. Adjuster11. Retainer ring
12. Return spring (Upper)
13. Return spring (Lower)
14. Spring
15. Toggle lever
Removal
WARNING:
Clean brake lining with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
Make sure parking brake lever is completely released.
SBR616E
REAR DRUM BRAKE
BR-44

1. Release parking brake lever fully, then remove drum.
If drum is hard to remove, the following procedures
should be carried out.
a. Remove plug. To make shoe clearance, push shoe hold-
down spring to free toggle lever.
b. Install two bolts as shown. Tighten the two bolts gradu-
ally.
2. After removing retainer, remove spring by rotating shoes.
lBe careful not to damage wheel cylinder piston boots.
lBe careful not to damage parking brake cable when
separating it.
3. Remove adjuster.
4. Disconnect parking brake cable from toggle lever.
5. Remove retainer ring with a suitable tool. Then separate
toggle lever and brake shoe.
Inspection Ð Wheel Cylinder
lCheck wheel cylinder for leakage.
lCheck for wear, damage and loose conditions. Replace if any
such condition exists.
SBR617E
SBR020A
SBR214B
SBR329C
SBR330C
REAR DRUM BRAKE
Removal (Cont'd)
BR-45

Wheel Cylinder Overhaul
lCheck all internal parts for wear, rust and damage. Replace
if necessary.
lPay attention so as not to scratch cylinder when installing
pistons.
Inspection Ð Drum
Maximum inner diameter:
204.5 mm (8.05 in)
Maximum out-of-round:
0.03 mm (0.0012 in)
lContact surface should be fine finished with No. 120 to 150
emery paper.
lUsing a drum lathe, resurface brake drum if it shows scoring,
partial wear or stepped wear.
lAfter brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.
Inspection Ð Lining
Check lining thickness.
Standard lining thickness:
4.5 mm (0.177 in)
Lining wear limit:
1.5 mm (0.059 in)
Installation
lAlways perform shoe clearance adjustment. Refer to
BR-49.
lBurnish 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 ªBrake Burnishing Procedureº, ªON-VEHICLE
SERVICEº, BR-7.
1. Fit toggle lever to brake shoe with retainer ring.
2. Apply brake grease to the contact areas shown at left.
SBR215B
SBR022A
SMA849B
SBR618E
REAR DRUM BRAKE
BR-46

3. Shorten adjuster by rotating it.
lTo tighten loosened brake shoes, first, insert a screw driver
in the direction shown in the left. Then, move the adjuster in
the direction shown by the arrow while disengaging the tooth
contact. Never tap the area E.
4. Connect parking brake cable to toggle lever.
5. Install all parts.
Be careful not to damage wheel cylinder piston boots.
6. Check all parts are installed properly.
Pay attention to direction of adjuster assembly.
7. Install brake drum.
8. When installing new wheel cylinder or overhauling wheel
cylinder, bleed air. Refer to ªBleeding Brake Systemº, BR-8.
9. Adjust parking brake. Refer to BR-49.
SBR619E
REAR DRUM BRAKE
Installation (Cont'd)
BR-47

Removal and Installation
1. To remove parking brake cable, first remove center console.
2. Disconnect warning lamp connector.
3. Remove adjusting nut.
4. Remove bolts and nuts securing parking brake cable.
5. Remove parking brake device.
6. Remove cable mounting bracket and lock plate (disc brake
only).
For drum brake models, refer to ªRemovalº, ªREAR DRUM
BRAKEº, BR-44.
NBR441
NBR171 Adjusting nut
Warning lamp connec-
tor
NBR163
PARKING BRAKE CONTROL
BR-48