NISSAN VERSA 2006 Workshop Service Repair Manual

BR-18
BRAKE MASTER CYLINDER
Revision: June 20062007 Versa
8. Secure flange of cylinder body in vise as shown.
CAUTION:

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

When securing master cylinder assembly in a vise, be
sure not to over-tighten.

Be sure to secure the flange part with the brake tube
installation side of cylinder body facing up (chamfered
pin insert hole of cylinder body facing up).
9. Using a pin punch [commercial service tool: diameter approx. 4
mm (0.16 in)], insert the reservoir tank pin into the pin hole.
WFIA0514E
WFIA0515E

BRAKE BOOSTER
BR-19
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
BRAKE BOOSTERPFP:47200
On-board InspectionEFS006JI
OPERATING CHECK
With the engine stopped, change the vacuum to the atmospheric pressure by depressing brake pedal several
times at intervals of 5 seconds.
Then with brake pedal fully depressed, start engine and when the
vacuum pressure reaches the standard, make sure that the clear-
ance between brake pedal and floor panel decreases.
AIRTIGHT CHECK

Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change the vacuum to the atmospheric pressure. Make sure
that distance between brake pedal and floor panel gradually
increases.

Depress the brake pedal while engine is running, then stop
engine with brake pedal depressed. The pedal stroke should not
change after holding pedal down for 30 seconds.
WFIA0520E
WFIA0521E

BR-20
BRAKE BOOSTER
Revision: June 20062007 Versa
Removal and Installation EFS006JJ
COMPONENTS
REMOVAL
CAUTION:

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

Be careful not to deform or bend brake tubes while removing and installing brake booster.

Replace clevis pin if it is damaged.

Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, dash panel may damage the threads.
1. Remove vacuum hose from brake booster.
2. Remove master cylinder assembly. Refer to BR-14, "
REMOVAL" .
1. Reservoir tank 2. Master cylinder 3. Brake booster
4. Clevis 5. Spacer 6. Gasket
⇐:Up
SFIA3095E

BRAKE BOOSTER
BR-21
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
3. Remove snap pin and clevis pin on the clevis of the brake
booster, and remove input rod from brake pedal.
4. Remove brake pedal nuts on pedal bracket.
5. Remove between spacer and dash panel nut from dash panel.
6. Remove brake booster and spacer from vehicle.
7. Remove spacer from brake booster.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that the length B
satisfies the specified value.
2. Install spacer to brake booster and tighten spacer nut (brake
booster side) to the specified torque.
3. After adjusting length “B”, temporarily tighten lock nut to install
brake booster assembly to dash panel. At this time, make sure
to install a gasket between brake booster and vehicle.
CAUTION:
Be sure to install the gasket between brake booster and
vehicle.
4. Connect brake pedal to clevis of input rod with the clevis pin and snap pin.
5. Install brake pedal bracket nuts and tighten them to the specified torque.
6. Adjust the height and play of brake pedal. Refer to BR-6, "
Inspection and Adjustment" .
7. Tighten lock nut of input rod to the specified torque. Refer to BR-20, "
COMPONENTS" .
8. Install vacuum hose into brake booster. Refer to BR-22, "
Removal and Installation" .
9. Bleed air from brake system. Refer to BR-10, "
Bleeding Brake System" .
SFIA2044E
Length “B” : 154 - 161 mm (6.06 - 6.34 in)
SGIA0060E

BR-22
VACUUM LINES
Revision: June 20062007 Versa
VACUUM LINESPFP:41920
ComponentEFS006JK
Removal and InstallationEFS006JL
CAUTION:

Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer
to the stamp or label to confirm correct installation. Brake booster will not operate normally if
hose is installed in the wrong direction.

Insert vacuum hose at least 24 mm (0.94 in).

Never use lubricating oil during assembly.
InspectionEF S0 06 JM
VISUAL INSPECTION
Check for improper assembly, damage and aging.
1. Clamp 2. Engine side indicator stamp (built-in
check valve)3. Vacuum hose
4. Clip 5. Clip position stamp 6. Vacuum tube
7. To brake booster A. To intake manifold B. To brake booster
WFIA0541E
SBR2 25 B

VACUUM LINES
BR-23
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
CHECK VALVE INSPECTION
Airtightness Inspection
Use a handy vacuum pump to check.
Replace vacuum hose with the check valve as a set if damage or
deformation is present at the vacuum hose.When connected to booster side (1):
Vacuum decrease should be within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under
a vacuum of –66.7 kPa (–500 mmHg, –19.69
inHg)
When connected to engine side (2):
No vacuum will be applied
SFIA0210E

BR-24
FRONT DISC BRAKE
Revision: June 20062007 Versa
FRONT DISC BRAKEPFP:41000
On-board InspectionEFS006JN
PAD WEAR INSPECTION

Check pad thickness from check hole on cylinder body.
ComponentsEFS006JO
Standard thickness : 9.5 mm (0.374 in)
Repair limit thickness : 2.0 mm (0.079 in)
WFIA0522E
1. Union bolt 2. Brake hose 3. Copper washer
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Inner shim cover 12. Inner shim
13. Inner pad 14. Pad wear sensor 15. Pad retainer
16. Outer pad 17. Outer shim 18. Outer shim cover
19. Sliding pin 20. Sliding pin boot 21. Bushing
22. Torque member mounting bolt 23. Torque member⇐: Front
: Brake fluid 1: AS-880N grease 2: Rubber grease
3: Polyglycol ether based lubricant 4: M7439 grease
Refer to GI section GI-10, "
Components" for symbol marks unless shown.
WFIA0535E

FRONT DISC BRAKE
BR-25
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
CAUTION:

Clean dust on caliper and brake pad with a vacuum dust collector. Do not blow with compressed
air.

While removing brake pad or cylinder body, do not depress brake pedal because piston will pop
out.

It is not necessary to remove torque member mounting bolts and brake hose except for disassem-
bly or replacement of caliper assembly. In this case, hang cylinder body with a wire so that brake
hose is not under tension.

Do not damage piston boot.

If any shim is subject to serious corrosion, replace it with a new one.

Keep rotor free from brake fluid.

When replacing brake pad, replace shim with a new one.
Removal and Installation of Brake PadEFS006JP
REMOVAL
1. Remove tires from vehicle.
2. Remove sliding pin bolt (lower side).
3. Hang cylinder body with a wire, and remove pads, shims and
pad retainers from torque member.
CAUTION:
When removing pad retainer from torque member, lift pad
retainer in the direction shown by arrow, so as not to
deform it.
INSTALLATION
1. Apply AS-880N grease or equivalent to the shims. Install shims to pads.
CAUTION:
Securely install shims according to mounting direction of pads.
2. Apply M7439 grease or equivalent to pad contact surface on pad retainers. Install pad retainers and pads
to the torque member.
CAUTION:

When installing pad retainer, attach it firmly so that it is
not lifted up from torque member, as shown.
3. Install cylinder body to torque member.
NOTE:
Use a disc brake piston tool (commercial service tool) to easily press to piston in.
CAUTION:
Check the brake fluid level in the reservoir tank for fluid level because brake fluid returns to mas-
ter cylinder reservoir tank when pressing piston in.
4. Install lower sliding pin bolt (lower side), and tighten it to the specified torque. Refer to BR-24, "
Compo-
nents" .
SBR5 56 E
PFIA0273E

BR-26
FRONT DISC BRAKE
Revision: June 20062007 Versa
5. Check brake for drag.
6. Install tires to the vehicle.
Removal and Installation of Brake Caliper Assembly EFS006JQ
REMOVAL
1. Remove tires from vehicle.
2. Secure disc rotor using wheel nuts.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor, if it is necessary to remove disc rotor.
3. Drain brake fluid. Refer to BR-9, "
Drain and Refill" .
4. Remove union bolt, and then remove brake hose from caliper
assembly.
5. Remove torque member mounting bolts from torque member,
and remove caliper assembly from vehicle.
INSTALLATION
1. Install caliper assembly to vehicle, and tighten mounting bolts to the specified torque. Refer to BR-24,
"Components" .
CAUTION:
Before installing torque member to vehicle, wipe oil and grease on mounting surface of steering
knuckle and torque member.
2. Install brake hose to caliper assembly. Refer to BR-11, "
Hydraulic Circuit" .
3. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
4. Check front disc brake for drag.
5. Install tires to the vehicle.
Disassembly and Assembly of Brake Caliper Assembly EFS006JR
NOTE:
Do not remove torque member, brake pads, shims and pad retainers, when disassembling or assembling cyl-
inder body.
DISASSEMBLY
1. Remove caliper assembly from vehicle. Refer to BR-26,
"REMOVAL" .
2. Remove sliding pin bolts from cylinder body, and remove pads,
shims and pad retainers from torque member, if necessary.
CAUTION:
When removing pad retainer from torque member, lift the
pad retainer in the direction shown by arrow, so as not to
deform it.
WFIA0524E
SBR5 56 E

FRONT DISC BRAKE
BR-27
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
3. Remove sliding pins and sliding pin boots from torque member.
4. Place a wooden block as shown, and blow air from union bolt
mounting hole to remove piston and piston boot.
CAUTION:
Do not get fingers caught in the piston.
5. Remove piston seal with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage the inner wall of cylinder.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
Check the inner wall of cylinder for corrosion, wear, and damage. Replace cylinder body as necessary.
CAUTION:
Clean cylinder body using new brake fluid. Never use mineral oils such as gasoline or kerosene.
Torque Member
Check for wear, cracks, and damage. Replace torque member as necessary..
Piston
Check piston surface for corrosion, wear, and damage. Replace piston as necessary.
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check sliding pins, sliding pin bolts and sliding pin boots for wear, damage, and cracks. Replace applicable
part as necessary.
ASSEMBLY
CAUTION:
When assembling, use only specified rubber lubricant.
1. Apply polyglycol ether based lubricant to new piston seal and
install them to cylinder body.
WFIA0525E
SFIA2277E
SFIA2278E