suspension NISSAN PULSAR 1987 Owner's Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 164 of 238
164
REAR SUSPENSION
SPECIFICATIONS
Type........................... Independent MacPherson strut
Shock absorber.................... Oil filled, non-repairable
Maximum hub bearing end float ................. 0.05 mm
Rear wheel alignment:
Toe out ........................................3 mm ± 2 mm
Camber ............................................. - 1 ° ± 4 5 '
TORQUE WRENCH SETTINGS
Hub retaining nut ......................................... 255 Nm
Suspension unit retaining nuts ....................... 29 Nm
Upper mounting retaining nut ........................ 72 Nm
Suspension unit to knuckle nuts .................. 118 Nm
Control arms to knuckle nut ........................ 118 Nm
Control arms to crossmember nut ............... 118 Nm
Stabiliser bar mounting bracket bolts .......... 108 Nm
Stabiliser bar retaining nut.............................. 83 Nm
Backing plate bolts........................................... 45 Nm
1. REAR SUSPENSION TROUBLE SHOOTING
REAR END NOISE
( 1 ) Defective suspension unit or mounting: Re-
new the faulty components.
(2) Loose or worn control arm bushes or pivot
bolts: Check and tighten or renew the worn compo-
nents. (3) Broken coil spring: Renew the coil spring,
preferably in matching pairs. (4) Worn rear hub bearing: Check and renew the
hub bearing as necessary. (5) Loose or worn stabilizer bar bushes: Check
and tighten or renew the worn components.
NOTE: As a quick guide to suspension unit
condition, bounce the vehicle up and down
(one side at a time) and observe if the vehicle
comes to rest in a single movement If the
vehicle bounces two or three times before
coming to rest the susp ension unit is suspect.
If suspect, remove the suspension unit and
check for fractures and leaks. If the
suspension unit is found to be unserviceable,
it is good practice to install two new
suspension units as a matching pair.
To check the control arm bushes or pivot
bolts, insert a lever between the suspect unit
and its mounting and lever the unit back
and forth checking for excessive movement.
Check the coil springs visually for breaks.
If the spring is found to be unserviceable, it
is good practice to install two new coil
springs as a matching pair.
Rear hub bearing noise can be diagnosed
by raising and supporting the rear of the
vehicle, spinning one wheel at a time and
listening for a rumbling noise.
POOR OR ERRATIC ROAD HOLDING ABILITY
(1) Low or uneven tire pressure: Inflate to the
recommended pressures.
(2) Incorrect rear wheel alignment: Check and
adjust the rear wheel alignment as necessary.
(3) Defective suspension unit: Renew the faulty
suspension unit, preferably in pairs. (4) Loose or broken stabilizer bar: Check and
tighten or renew the faulty components.
Check the stabilizer bar bushes and mounting rubbers
for wear and deterioration.
Page 165 of 238
Rear Suspension 165
Checking the rear control arm outer pivot bolt for security.
(5) Loose or worn control arm bushes or pivot
bolts: Check and tighten or renew the worn compo-
nents.
NOTE: Check the service ability of the sus-
pension units, control arm bushes and pivot
bolts as previously described.
If incorrect rear wheel alignment is sus-
pected, it is recommended that the vehicle be
taken to a wheel alignment specialist or a
Nissan dealer to be checked and if necessary
adjusted.
Visually inspect the stabilizer bar for
damage.
2. DESCRIPTION
The independent type rear suspension consists of
a suspension unit, a knuckle assembly which incorpo-
rates the stub axle, inboard control arms and a
stabilizer bar.
The suspension unit consists of a sealed, oil filled
shock absorber, enclosed at the upper end by a coil
spring on which an upper mounting assembly is
located and attached to the body.
The shock absorber piston rod is attached to the
centre of the suspension unit upper mounting assem-
bly.
The lower end of the suspension unit is attached
to the knuckle assembly to which the brake caliper
and/or the brake backing plate is mounted.
The control arms are attached to the knuckle
assembly at the outer end, and the crossmember at the
inner end.
The stabilizer bar is attached to the knuckle
assembly and mounted to the underbody. As well as
reducing body roll when cornering it also secures the
knuckle assembly, preventing fore and aft movement.
Adjustment of the toe out is provided by a
graduated cam mounted on the rear control arm inner
pivot bolt. Each graduation on the cam is equivalent
to 2 mm adjustment.
Camber is set in production and cannot be
adjusted. If the camber is not within Specifications,
inspect the suspension components and renew the
damaged or worn components as necessary.
Installed view of the rear suspension.
Page 166 of 238
166 Rear Suspension
3. REAR HUB
Special Equipment Required
To Check Hub Bearing End Float — Dial gauge
To Renew Bearing — Press and suitable drift
TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands. Remove the rear wheel and release
the handbrake.
(2) On models with rear drum brakes, proceed
to operation (6).
(3) Remove the clip securing the brake hose to
the suspension unit and disengage the hose.
(4) Remove the bolts securing the brake caliper
to the knuckle assembly. (5) Slide the caliper from the disc and support it
away from the working area, ensuring that no excess
strain is placed on the brake hose. (6) Rotate the hub and check that it rotates
smoothly. If it does not rotate smoothly, renew the
hub bearing. (7) Mount a dial gauge with the plunger posi-
tioned against the outer face of the hub. Move the hub
back and forth in line with the stub axle and note the
reading on the dial gauge. If the end float exceeds
Specifications, renew the hub bearing.
(8) Remove the hub grease cap from the rear
hub. (9) Remove the split pin from the stub axle and
remove the nut retainer, the hub retaining nut and
washer. Remove the hub assembly from the stub axle. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Tighten the hub retaining nut to the specified
torque. (2) Check the hub bearing end float as previ-
ously described.
(3) On models with disc brakes, install the brake
caliper and tighten the retaining bolts to the torque
specified in the Brakes section. Install the brake hose to
the suspension unit and secure with the retaining clip.
TO RENEW BEARING
(1) Remove the rear hub as previously de-
scribed. (2) Remove the snap ring from the rear of the
hub assembly. (3) Support the rear of the hub around the
bearing housing, ensuring that the bearing will not be
obstructed when being pressed out. (4) Using a suitable drift, press the bearing out
of the hub.
Dismantled view of the rear hub assembly. Drum brake
model.
Tightening the hub retaining nut with a torque wrench. Dismantled view of the rear hub assembly. Disc brake
model.
Page 167 of 238
Rear Suspension 167
NOTE: When a wheel bearing has been
removed from the hub it must be renewed.
(5) Press the new bearing into the hub, ensuring
that pressure is not exerted on the inner race of the
bearing and that the bearin g seal is not damaged. Do
not apply grease or oil to the mating surfaces of the
bearing and the hub.
NOTE: When installing the new bearing,
the press load must not exceed 3 tonnes.
(6) Inspect the snap ring for wear or cracks and
renew as necessary. Install the snap ring into the hub
ensuring that it is secur ely located in the groove.
(7) Apply multi-purpose grease to the bearing
sealing lip and install the hub as previously described.
4. SUSPENSION UNIT
Special Equipment Required:
To Dismantle — Spring compressor
TO REMOVE AND DISMANTLE
(1) On hatchback models, remove the rear par-
cel shelf and lower the rear seat backrests. Remove the
parcel shelf side panel re taining screws and remove
the relevant side panel.
(2) On sedan models, prise out the parcel shelf
retaining buttons using a suitable instrument and
withdraw the parcel shelf from the vehicle. If the rear
radio speakers are installed, remove the speaker grille
retaining screws and separate the speaker grilles from
the speakers prior to withdrawing the parcel shelf
from the vehicle. (3) Raise the rear of the vehicle and support it
on chassis stands as describe d in the Wheels and Tires
section. Remove the rear wheel from the vehicle.
View of the suspension unit with the spring compres-
sors installed.
(4) Remove the clip securing the brake hose to
the suspension unit and disengage the hose from the
suspension unit. (5) Support the weight of the knuckle assembly
and remove the bolts and nuts securing the suspension
unit to the knuckle assembly.
(6) Remove the nuts securing the suspension
unit to the body panel and maneuver the suspension
unit from the vehicle. (7) Thoroughly clean the suspension unit and
secure it in a soft jawed vice.
(8) Remove the dust cap from the upper mount-
ing and while holding the end of the piston rod with
an adjustable spanner, loosen the upper mounting
retaining nut. Do not re move the retaining nut.
(9) Using a suitable spring compressor, com-
press the coil spring and remove the upper mounting
retaining nut and washer. (10) Remove the upper mounting, insulator and
spring seat from th e suspension unit.
(11) Withdraw the upper insulator, coil spring,
lower insulator and dust cover from the suspension
unit. (12) Check the coil spring for cracks, deformation
and damage. Compare the free length with a new coil
spring and renew as necessary.
Location of the suspension unit retaining nuts. Hatch-
back model.
Page 168 of 238
168 Rear Suspension
NOTE: If a coil spring is defective it is
advisable to renew both coil springs as a
matched set.
(13) Check the spring seat for cracks, deforma-
tion or wear and renew as necessary.
(14) Check the upper mounting and the insulator
for wear, damage, signs of melting rubber or deterio-
ration. (15) Check that the piston rod is not cracked,
bent or damaged.
Dismantled view of the suspension unit.
(16 ) Check the hydraulic operation of the suspen-
sion unit. With the suspension unit vertical, move the
piston rod up and down severa l times. A firm pressure
with no slack spots should be evident in both direc-
tions. Also check the suspen sion unit for fluid leakage.
If fluid leakage is present, renew the suspension unit,
preferably in pairs.
TO ASSEMBLE AND INSTAL
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:
(1) Install the coil spring and lower insulator to
the suspension unit ensuring th at the flat end of the
spring is positioned at the top and the lower end of the
spring is located correctly in the suspension unit.
(2) Install the remaining co mponents to the sus-
pension unit, ensuring that the arrow on the spring
seat will be facing the stub axle when installed.
(3) Install a new upper mounting retaining nut,
tighten to the specified tor que and remove the spring
compressor. (4) Position the suspension unit inside the rear
wheel housing and maneuver the mounting studs
into position. With the aid of an assistant, install the
suspension unit retaining nuts and tighten to the
specified torque.
View of the suspension unit removed from the vehicle.
(5) Install the bolts securin g the suspension unit
to the knuckle assembly and tighten the nuts to the
specified torque.
(6) Install the brake hose to the suspension unit
and secure with the retaining clip. (7) Install the rear wheel and lower the vehicle to
the ground. (8) On hatchback models, install the parcel shelf
side panel and the parcel shelf. (9) On sedan models, install the parcel shelf and
insert the retaining buttons firmly. If removed, install
the radio speaker grilles.
Page 169 of 238
Rear Suspension 169
5. CONTROL ARM
Special Equipment Required:
To Renew Control Arm Bush — Press and suitable
removal tool
TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands as describe d in the Wheels and Tires
section.
(2) Suitably mark the front and rear control
arms to ensure installation to the original locations.
NOTE: The front and rear control arms are
identical in appearance, however, on models
manufactured prior to March 1988 the
compound of the rubber bushes differ.
(3) Remove the nut and bolt securing the control
arms to the knuckle assembly.
(4) Suitably mark the rear inner pivot bolt cams
in relation to the crossmember to ensure correct
installation.
(5) Remove the rear control arm inner pivot
bolt, adjusting cam, nut and control arm from the
vehicle. (6) Remove the front control arm inner pivot
bolt, washer, nut and control arm from the vehicle.
(7) Inspect the control arm bushes for wear,
cracks and deterioration and renew as necessary. (8) Inspect the control arms for cracks, damage
and distortion and renew as necessary.
(9) Inspect the pivot bolts for damage and renew
as necessary. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Install the control arms to the original
loca-
tions, ensuring that the inner pivot bolts are installed
from the front of the crossmember.
(2) Align the marks on the rear inner pivot bolt
Dismantled view of the control arms and associated
components. Disc brake model.
cams and the crossmember that were made prior to
removal. Install the inner pivot bolt nuts but do not
tighten.
(3) Install the bolt that secures the control arms
to the knuckle assembly and tighten the nut finger
tight. (4) Lower the vehicle to the ground. With the
weight of the vehicle on th e rear wheels, ensure that
the marks on the inner pivot bolt cams and the
crossmember are aligned. (5) Tighten the inner and outer control arm
bolts and nuts to the specified torque. (6) Check and if necessary adjust the rear wheel
alignment. Refer to the Re ar Wheel Alignment head-
ing in this section.
TO RENEW CONTROL ARM BUSH
(1) Remove the control arm as previously de-
scribed. (2) Using a press and press plates or a bush
removal tool, remove the bush from the control arm.
NOTE: If a press or bush removal tool is not
available, a simple alternative can be made
using a long bolt, large and small washers, a
nut and a tubular spacer. This method is
illustrated in the General Information sec-
tion under the General Repair Procedures
heading.
(3) Install a new bush to the control arm
ensuring
that it is pressed squarely into the control arm. When
installed, the bush should be equidistant from either
end of the control arm bore. (4) Install the control arm as previously de-
scribed.
Ensure that the cam and the crossmember are suitably
marked prior to loosening the nut.
Page 170 of 238
170 Rear Suspension
6. KNUCKLE ASSEMBLY
TO REMOVE AND INSTAL
(1) Remove the rear hub as previously de-
scribed.
(2) On drum brake models, disconnect the brake
pipe from the wheel cylinder and plug the cylinder
and brake pipe apertures to prevent the loss of brake
fluid and the entry of dirt. (3) Remove the backing plate retaining bolts and
remove the backing plate from the knuckle assembly. (4) Remove the nut and bolt securing the control
arms to the knuckle assembly. (5) Remove the bolts and nuts securing the
suspension unit to the knuckle assembly. (6) Remove the nut, washers and bush securing
the stabilizer bar to the knuckle assembly, rotate the
knuckle assembly and remove it from the stabilizer
bar. (7) Carefully clean the knuckle assembly. Do not
immerse the rubber bush in solvent as damage will
occur.
(8) Check the knuckle assembly for wear, cracks
and damage. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Install the knuckle assembly onto the stabi-
liser bar, maneuver it into position with the suspen-
sion unit and install the retaining bolts and nuts.
Tighten the bolts and nuts to the specified torque.
(2) Install the control arms to the knuckle
assem-
bly and install the retaining bolt and nut. Do
not
tighten the retaining bolt and nut at this stage. (3) Install the bush, washers and retaining nut to
the stabilizer bar. Do not tighten the retaining nut at
this stage. (4) Install the backing plate to the knuckle as-
sembly and tighten the retaining bolts to the specified
torque.
(5) On drum brake models, connect the brake
pipe to the wheel cylinder and tighten the flare nut
securely.
(6) Install the rear hub as previously described.
(7) On drum brake models, bleed the brake
hydraulic system as described in the Brakes section.
(8) With the weight of the vehicle on the road
wheels, tighten the control arms retaining bolt and nut
and the stabilizer bar retaining nut to the specified
torque. (9) Check and if necessary adjust the rear wheel
alignment. Refer to the Re ar Wheel Alignment head-
ing in this section.
7. STABILISER BAR
TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands as describe d in the Wheels and Tires
section. Remove the rear wheels.
(2) Remove the nut. washer and bush retaining
the stabilizer bar to each knuckle assembly. (3) Remove the bolts retain ing the intermediate
exhaust pipe to the rear of the catalytic converter,
remove the bolt securing the exhaust mounting to the
underbody and slightly lower the intermediate exhaust
pipe. Support the intermediate pipe to prevent the
tailpipe contacting the lower bumper panel. (4) Remove the bolts retaining the stabilizer bar
mounting brackets to the underbody and withdraw
the stabilizer ba r from each knuckle assembly. Ma-
noeuvre the stabilizer bar from the vehicle.
(5) Remove the mounting rubbers from the
stabilizer bar and the rubber bush and spacer from
each knuckle assembly. (6) Inspect the stabilizer bar for cracks and
damage and renew as necessary. (7) Inspect the stabilizer bar mounting brackets
for wear and damage and renew as necessary. (8) Inspect the mounting rubbers, the rubber
bushes and spacers for wear and deterioration and
renew as necessary.
View of the knuckle assembly removed from the
vehicle. Disc brake model. View of the stabilizer bar mounting bracket and rubber
removed from the stabilizer bar.
Page 171 of 238
Rear Suspension 171
Installation is a reversal of the removal procedure
with attention to the following points:
(1) When installing the stabilizer bar to the
knuckle assembly bushes, ensu re that the thicker bush
is installed to the front of the knuckle assembly. Install
the rear bush, washers and nut but do not tighten at
this stage. (2) Install the stabil izer bar mounting
brackets,
ensuring that the end with the large bevel is facing the
front of the vehicle. Tighte n the retaining bolts to the
specified torque. (3) Using a new gasket, install the intermediate
exhaust pipe to the catalytic converter, ensuring that
the earth wire terminal is installed, and tighten the
bolts securely. Install the exhaust mounting
retaining
bolt. (4) Install the rear wheels and lower the
vehicle
to the ground. With the wei ght of the vehicle on the
road wheels, tighten the stabilizer bar retaining nuts to
the specified torque.
8. REAR WHEEL ALIGNMENT
Specialized equipment is required to measure the
rear wheel alignment. It is therefore recommended
that the vehicle be referred to a specialist suspension
workshop or an authorized dealer for measurement
and adjustment. The suspension components should
be inspected and renewed as necessary prior to having
the wheel alignment checked. If any suspension com-
ponents are renewed, the re ar wheel toe out may be
temporarily adjusted as described below.
TO INSPECT
Examine the tread of the tires. Excessive or
uneven wear will indicate misalignment or damaged
or worn components. Refer to the Tire Wear Trouble
Shooting Chart in the Wheels and Tires section for
possible causes and renew the faulty components.
Badly worn tires should be renewed prior to
having the wheel alignment checked.
TO CHECK AND ADJUST TOE OUT
NOTE: The following procedures are only a
temporary measure. Th e vehicle should be
referred to a specialis t suspension work-
shop or authorized dealer for accurate
measurement and adjustment.
(1) Position the vehicle on a level floor and
bounce the vehicle several tim es to settle the suspen-
sion. (2) Move the vehicle forward approximately 5
meters, with the front wheels straight ahead, to settle
the tires and suspension to the normal running
position.
(3) Place a chalk line across both tire treads at a
point equivalent to the stub axle height and to the rear
of the suspension. Place a vertical mark at the chalk line in the
centre of each tire.
(4) Using a telescopic gauge or tape measure,
measure the distance between both vertical marks and
record the measurement. (5) Move the vehicle forward until the marks are
to the front of the suspen sion, with the horizontal
marks at the same height as in operation (3). (6) Measure the distance between both vertical
marks. (7) The difference between the two measure-
ments will be the amount of toe out of the rear wheels. (8) If the toe out is not as specified, adjust the
rear control arm cams as follows: (9) Measure the distance between the inner
wheel rim and the adjusting flange on the rear
crossmember. Measure the distance on the other side
of the vehicle in the corresponding positions. (10) If the measurements are equal, loosen the
cam nut and turn the cam bolt to move the rear
control arm half the distance required to bring the
rear wheel toe out to specifications. Repeat this
operation on the other side of the vehicle.
(11) If the measurements obtained in operation
(9) are not equal, proceed as follows:
(a) If the toe out is less than specifications,
decrease the length of the shorter arm.
(b) If the toe out is greater than specifications,
increase the length of the longer arm.
NOTE: The toe out will alter approximately
2 mm with each graduation of the adjusting
cam.
Diagram indicating rear wheel toe out. B should be less than A. Refer to Specifications.
Page 180 of 238
180 Brakes
the caliper body. Plug the brake hose to prevent the
loss of fluid and the ingress of dirt. Remove and
discard the sealing washers.
(3) Remove the guide bolts and slide the caliper
body from the anchor plate and pad assembly. (4) Remove the piston dust cover retaining clip.
Remove and discard the dust cover.
BRAKEPAD BRAKE PAD
Dismantled view of the front brake caliper.
(5) Place a piece of wood in front of the piston
and using low air pressure applied to the brake hose
aperture, gently force the piston from the caliper bore.
(6) Using a thin blunt probe, preferably made
from wood or plastic, remove and discard the piston
seal from the groove in the caliper bore. (7) Clean all the caliper components in methyl-
ated spirits and arrange the components in order, on
a clean, dry surface to aid in assembly.
To Inspect
(1) Inspect the caliper bore and piston for pit-
ting, wear or damage. Renew the caliper assembly or
piston if damage is evident.
NOTE: Slight rust spots in the caliper bore
may he removed with fine emery paper. The
piston must not be polished as the plated
surface wilt be damaged.
(2) Inspect the guide bolts for wear or damage.
Renew as necessary.
To Assemble
(1) Dip a new piston seal in clean hydraulic
brake fluid. Insert the seal into the groove in the
caliper bore ensuring that the seal is correctly seated
and not twisted.
(2) Install a new dust cover to the piston prior to
installing the piston to the caliper bore. (3) Coat the piston and caliper bore with clean
hydraulic brake fluid and insert the piston squarely
into the caliper bore.
(4) Locate the dust seal in the groove of the
caliper body and install the retaining clip.
(5) Lubricate the guide bolts using a suitable
grease. Install the caliper body to the anchor plate and
install and tighten the guide bolts to the
specified
torque. (6) Replenish the master cylinder reservoir with
the recommended fluid and bleed the brakes as
described under the Hydr aulic System heading.
(7) Install the front wheels and lower the vehicle
to the ground. (8) Road test the vehicle and check for correct
brake operation.
BRAKE DISC
To Check Runout
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the relevant front wheel. (2) Install the wheel nuts with the flat side of
the
wheel nut towards the disc. Lightly tighten the nuts to
secure the disc against the hub.
Rotate the hub and check for disc runout.
(3) Mount a dial gauge stand to a suspension
component and position the dial gauge plunger
against the wheel hub. Check that the end float is less
than 0.05 mm. Excessive e nd float will necessitate
renewal of the hub bearing. (4) Position the dial gauge plunger against the
centre of the brake disc. Ro tate the hub and measure
the runout. Maximum allowable runout is 0.07 mm. (5) If the runout exceeds Specifications, machine
or renew the brake disc. (6) Install the fron t wheel and lower the vehicle
to the ground.
To Remove and Install
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the relevant wheel. (2) Remove the bolts retaining the caliper an-
Page 183 of 238
Brakes 183
To Dismantle
(1) Raise the rear of the vehicle and place it on
chassis stands. Remove the relevant rear wheel.
(2) Remove the brake hose retaining bolt from
the caliper body and plug the hose to prevent the loss
of fluid and the ingress of dirt. (3) Remove the handbrake cable bracket retain-
ing bolt and disconnect the handbrake cable from the
cam lever.
(4) Remove the guide bolts and slide the caliper
body off the pads. (5) Using a pair of long nose pliers with the nose
located in the recesses of the piston, rotate the piston
anticlockwise to remove it from the caliper body.
(6) Remove the dust cover retaining clip and dust
cover. Discard the dust cover. (7) Using a thin blunt probe, preferably made
from wood or plastic, remove and discard the piston
seal from the groove in the caliper bore. (8) Using internal snap ring pliers, remove the
snap ring from the caliper bore. (9) Withdraw the spring cover, spring, key plate,
pushrod and link from the caliper bore. Do not mix
these components from the left and right hand sides as
they differ. (10) Remove and discard the O ring from the
pushrod. (11) Remove the spring, nut and washer from the
cam lever. Remove the cam lever and cam from the
caliper body. (12) Remove the cam seal from the caliper using a
screwdriver.
(13) Clean all the caliper components in methy-
lated spirits and arrange the components in order on a
clean dry surface to aid assembly.
To Inspect
(1) Inspect the caliper bore and piston for pit-
ting, wear or damage. Renew the caliper assembly or
piston if damage is evident.
NOTE: Slight rust spots in the caliper bore
may be removed with fine emery paper. The
piston must not be polished as the plated
surface will be damaged.
(2) Inspect the guide bolts for wear or damage
and renew as necessary.
(3) Inspect the threads of the pushrod for wear or
damage and renew as necessary. (4) Inspect the nut inside the piston for wear,
damage and security. Renew the piston if any damage
is evident. (5) Inspect the cam for wear, damage or pitting,
renew as necessary. (6) Inspect the cam bearing in the caliper body
for wear, damage or pitting and renew the seal and
bearing as necessary. (7) Inspect the guide bolt rubbers for deteriora-
tion, wear or damage. Renew as required. To Assemble
(1)
Lubricate the cam bearing with multipurpose
grease and install the seal. (2) Install the cam and cam lever to the
caliper
body. Install the cam lever spring, washer and nut, and
tighten the nut to the specified torque. (3) Install a new O ring to the pushrod and
install
the link, pushrod, key plate, spring and spring cover to
the caliper body. The key plate must engage the caliper
body. Secure the assembly with the snap ring. (4) Dip a new piston seal in clean hydraulic brake
fluid. Insert the seal into the groove in the caliper bore
ensuring that the seal is correctly seated and not
twisted. (5) Install a new dust cover to the piston prior
to
installing the piston to the caliper bore.
(6) Coat the piston and caliper bore with clean
hydraulic brake fluid and using long nose pliers rotate
the piston clockwise into the caliper bore. (7) Locate the dust seal in the groove of the
caliper body and install the retaining clip.
(8) Lubricate the guide bolts using a suitable
grease. Install the caliper body and tighten the guide
bolts to the specified torque. (9) Replenish the master cylinder reservoir with
the recommended fluid and bleed the brakes as
described under the Hydraulic System heading. (10) Install the rear wheel and lower the vehicle to
the ground. (11) Road test the vehicle and check for correct
brake operation.
BRAKE DISC
To Check Runout
(1) Raise the rear of the vehicle and support it on
chassis stands. Remove the relevant rear wheel.
(2) Mount a dial gauge stand to a suspension
component and position the dial gauge plunger
against the wheel hub. Check that the end float is less
Using a dial gauge to measure the rear disc runout.