NISSAN VERSA 2006 Workshop Service Repair Manual

BR-8
BRAKE PEDAL
Revision: June 20062007 Versa
REMOVAL
1. Disconnect accelerator pedal position sensor harness connec-
tor.
2. Remove stop lamp switch from brake pedal assembly.
3. Remove snap pin and clevis pin from clevis of brake booster.
4. Remove nuts from brake pedal bracket, and remove brake pedal
assembly from vehicle.
5. Remove accelerator pedal from brake pedal assembly.
INSPECTION AFTER REMOVAL

Check brake pedal upper rivet for deformation.

Make sure that the lapping length of sub-bracket and slide plate
is at least 6.9 mm (0.272 in).

Check brake pedal for bend, damage, and cracks on the welded
parts.

Replace brake pedal assembly if any non-standard condition is
detected.

Check clevis pin and plastic stopper for damage and deforma-
tion. Replace clevis pin as necessary.
INSTALLATION
Installation is in the reverse order of the removal.

After installing brake pedal assembly to vehicle, adjust brake pedal. Refer to BR-7, "ADJUSTMENT" .

After installing accelerator pedal, check accelerator pedal. Refer to ACC-3, "INSPECTION AFTER
INSTALLATION" .
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SBR9 97

BRAKE FLUID
BR-9
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Revision: June 20062007 Versa
BRAKE FLUIDPFP:KN100
On-board InspectionEFS006J8
CHECKING BRAKE FLUID LEVEL

Make sure the fluid level in the reservoir tank is within the stan-
dard (between MAX and MIN lines).

Visually check around the reservoir tank for fluid leakage.

If fluid level is excessively low, check brake system for fluid leak-
age.

Release parking brake lever and see if brake warning lamp goes
off. If not, check brake system for fluid leakage.
Drain and RefillEFS006J9
CAUTION:

Refill using recommended brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .

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, immediately wipe them with cloth and wash it away with water.

Before working, disconnect connectors of ABS actuator and electric unit (control unit) or battery
cable from the negative terminal.
1. Connect a vinyl tube to bleed valve.
2. Depress the brake pedal, loosen the bleed valve, and gradually
remove the brake fluid.
3. Clean inside of reservoir tank, and refill with new brake fluid.
4. Loosen bleed valve, depress brake pedal slowly to full stroke
and then release it. Repeat the procedure every 2 or 3 seconds
until the new brake fluid comes out, then close the bleed valve
while depressing the brake pedal. Repeat the same procedure
for each wheel.
5. Bleed air. Refer to BR-10, "
Bleeding Brake System" .
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BR-10
BRAKE FLUID
Revision: June 20062007 Versa
Bleeding Brake SystemEFS006JA
CAUTION:

While bleeding, pay attention to master cylinder fluid level.

Before working, disconnect connectors of ABS actuator and electric unit (control unit) or the bat-
tery cable from the negative terminal.
1. Connect a vinyl tube to the rear right bleed valve.
2. Fully depress brake pedal 4 to 5 times.
3. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately.
4. Repeat steps 2, 3 until no more air comes out.
5. Tighten bleed valve to specified torque. Refer to BR-24, "
Components" (front disc brake), BR-30, "Com-
ponents" (rear drum brake).
6. Following the steps 1 to 5 above, with master cylinder reservoir tank filled at least half way, bleed air from
the rear right, front left, rear left, and front right brake, in that order.

BRAKE TUBE AND HOSE
BR-11
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Revision: June 20062007 Versa
BRAKE TUBE AND HOSEPFP:46300
Hydraulic CircuitEFS006JB
CAUTION:

All tubes and hoses must be free from excessive bending, twisting and pulling.

Make sure there is no interference with other parts when turning steering both clockwise and
counterclockwise.

Brake tubes and hoses are an important safety part. Always disassemble the parts and retighten
their fittings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged
part is detected.

Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe them with cloth and then wash it away
with water.

Do not bend or twist brake hose sharply, or strongly pull it.

When removing components, cover brake line connections so that dirt, dust, or other foreign mat-
ters do not get in.

Refill using recommended brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .

Never reuse drained brake fluid.
1. Front disc brake 2. Brake master cylinder 3. Brake booster
4. Rear drum brake 5. Connector 6.ABS actuator and electric unit (con-
trol unit)
7. Brake tube 8. Brake hose
:Union bolt
:Connector bolt
:Flare nut
18.2 N.m (1.9 kg-m, 13.0 ft-lb) 10.0 N.m (1.0 kg-m, 87.0 in-lb) 16.2 N.m (1.7 kg-m, 12.0 ft-lb)
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BR-12
BRAKE TUBE AND HOSE
Revision: June 20062007 Versa
Front Brake Tube and HoseEFS006JC
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt, and remove brake hose from caliper assem-
bly.
4. Remove lock plate, and remove brake hose from vehicle.
INSTALLATION
1. Assemble union bolt and copper washers to brake hose.
2. Position the L-shape metal fitting of the brake hose to the brake
caliper assembly positioning hole.
3. Tighten union bolt to the specified torque. Refer to BR-11,
"Hydraulic Circuit" .
4. Connect brake hose to brake tube on vehicle, and temporarily
tighten flare nut by hand as much as possible.
5. Secure it with lock plate.
6. Tighten flare nut to the specified torque with a flare nut torque
wrench. Refer to BR-11, "
Hydraulic Circuit" .
7. Install brake hose to vehicle, and tighten nuts to the specified
torque.
8. Bleed air from brake system. Refer to BR-10, "
Bleeding Brake System" .
Rear Brake Tube and HoseEFS006JD
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove lock plate, and remove brake hose from vehicle.
INSTALLATION
1. Connect brake hose to brake tube on vehicle, and temporarily tighten flare nut by hand as much as possi-
ble.
2. Secure it to bracket with lock plate.
3. Tighten flare nut to the specified torque with a flare nut torque wrench. Refer to BR-11, "
Hydraulic Circuit"
.
4. Bleed air from brake system. Refer to BR-10, "
Bleeding Brake System" .
Inspection After InstallationEFS006JE
CAUTION:

Always disassemble the parts and retighten their fittings, if a brake fluid leak is detected. Replace
applicable part with a new one, if damaged part is detected.

If leak is detected at the connections, retighten it or replace the damaged part.
SF I A 1118 E
SF IA113 7E
SF IA112 0E

BRAKE TUBE AND HOSE
BR-13
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Revision: June 20062007 Versa
1. Check brake hose, tube, and connections for fluid leaks, damage, twist, deformation, contact with other
parts, and loose connections.
2. While depressing pedal under a force of 785 N (80 kg-f, 177 lb-f) with the engine running for approxi-
mately 5 seconds, check for fluid leak from each part.

BR-14
BRAKE MASTER CYLINDER
Revision: June 20062007 Versa
BRAKE MASTER CYLINDERPFP:46010
On-Board InspectionEFS006JF
LEAK INSPECTION

Check for leaking in a master cylinder installation surface, a reservoir tank installation surface, and brake
tube connections.
Removal and InstallationEFS006JG
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, immediately wipe them with cloth and wash it away with water.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Remove battery. Refer to SC-9, "
Removal and Installation" .
3. Remove air duct. Refer to EM-16, "
Removal and Installation" .
4. Remove air cleaner. Refer to EM-16, "
Removal and Installation" .
5. Disconnect brake fluid level switch harness connector.
6. Using a flare nut wrench, remove brake tube from master cylinder.
7. Remove master cylinder assembly nuts, and remove master cylinder assembly from vehicle..
INSTALLATION
CAUTION:

Refill using recommended brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .

Never reuse drained brake fluid.

Check if the rod of primary piston has dust or scratches.
1. Install master cylinder to brake booster assembly, and tighten nuts to the specified torque. Refer to BR-20,
"Removal and Installation" .
CAUTION:

Do not damage or strain rod of primary piston.

Apply silicone grease for O-ring, primary piston rod and
to inside of booster.
2. Install brake tube to master cylinder, and temporarily tighten the flare nuts on the brake tube to master cyl-
inder by hand.
3. Install brake tube to brake hose, then tighten flare nut to the specified torque using a flare nut torque
wrench. Refer to BR-11, "
Hydraulic Circuit" .
4. Connect brake fluid level switch harness connector.
5. Refill new brake fluid and bleed air. Refer toBR-10, "
Bleeding Brake System" .
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BRAKE MASTER CYLINDER
BR-15
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Revision: June 20062007 Versa
Disassembly and AssemblyEFS006JH
COMPONENTS
DISASSEMBLY
CAUTION:
While working, cover primary piston rod with cloth to prevent it from being damaged.
1. Secure flange of cylinder body in vise as shown.
CAUTION:

Use copper plate or cloth to cover flange when securing
in vise.

When securing master cylinder assembly in a vise, be
sure not to over-tighten.
2. Using a pin-punch [commercial service tool: diameter approx. 4
mm (0.16 in)], remove pin from reservoir tank.
3. Remove master cylinder assembly from vise.
4. Remove reservoir tank and grommet from cylinder body.
1. Reservoir cap 2. Oil filter 3. Reservoir tank
4. Grommet 5. Piston stopper 6. Cylinder body
7. Pin 8. Brake fluid level switch connector 9. O-ring
10. Secondary piston assembly 11. Primary piston assembly 12. Plate
13. Guide assembly 14. Snap ring
:PBC (Poly Butyl Cuprysil) grease
or silicone-based grease:Brake fluid
Refer to GI section GI-10, "
Components" for symbol marks unless shown.
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BR-16
BRAKE MASTER CYLINDER
Revision: June 20062007 Versa
5. While pushing primary piston, remove piston stopper through
secondary tank boss hole in the cylinder body.
6. Remove snap ring with pushing primary piston.
CAUTION:
Be careful not to pop out piston.
7. Holding rod of primary piston, remove primary piston assembly,
plate and guide assembly by pulling straight to prevent piston
cup from being caught by the inner wall of cylinder.
8. Remove plate and guide assembly from primary piston.
CAUTION:
Be careful not to damage rod from the inner wall of plate.
9. Tap flange using a soft block such as wood, and carefully pull
secondary piston assembly straight out to prevent cylinder inner
wall from being damaged.
INSPECTION AFTER DISASSEMBLY
Cylinder Body

Check the inner wall of cylinder for damage, wear, corrosion, and pin holes. Replace cylinder body if nec-
essary.
ASSEMBLY
CAUTION:

Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.

Make sure that there is no foreign material such as dirt and dust on the inner wall of cylinder, pis-
ton, and piston cup. Be careful not to damage parts with a service tool when assembling.

Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid to the inner wall of cylinder body, primary pis-
ton assembly and secondary piston assembly.
2. Insert secondary piston and primary piston assembly into cylin-
der body in this order.
CAUTION:

Pay attention to the orientation of piston cup, and insert
straight to prevent cup from being caught by the inner
wall of cylinder.

Always replace inner kit as a set.
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SBR0 89 C

BRAKE MASTER CYLINDER
BR-17
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Revision: June 20062007 Versa
3. Set the slit of secondary piston towards the piston stopper
mounting hole of cylinder body while pushing in the primary pis-
ton. Then install the piston stopper through the slit of secondary
piston.
4. Insert plate and guide assembly into cylinder body.
CAUTION:

Be careful not to damage rod of primary piston.

Pay attention to the orientation of guide assembly.

Do not drop O-ring.

Be careful the guide and/or plate are not inserted at an
angle to cylinder inner wall.
5. Be careful not to damage rod of primary piston with the cloth.
Then insert snap ring to cylinder body while pushing primary pis-
ton.
CAUTION:
Make sure that snap ring is securely engaged in cylinder
body inner diameter groove.
6. Apply brake fluid to a grommet, and press it into reservoir tank to install.
7. Install reservoir tank to cylinder body.
CAUTION:
Pay attention to the orientation of reservoir tank. Make sure
reservoir tank is fully seated on master cylinder.
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