Nissan Almera Tino V10 (2001 year). Manual — part 17
SBR633E
Installation
NLBR0124
1.
Assemble vacuum pump and cylinder head rear cover
assembly, referring to “Component” in the next page.
2.
Install vacuum pump and cylinder head rear cover assembly to
cylinder head.
a.
Apply ThreeBond 1207C (KP510 00150) without breaks to the
location shown in the figure to the left.
SBR632E
b.
Tighten the mounting bolts in the numerical order shown by the
figure to the left.
3.
Install rear cam sprocket installation bolts.
4.
Remove sprocket retaining two M6 bolts.
+
M6 bolts will be used for installation.
5.
Tighten rear cam sprocket installation bolts.
+
Camshaft should not be fixed. Using engine inner resistance,
tighten installation bolts.
SBR634E
6.
Install cylinder head rear cover plate.
+
Apply ThreeBond 1207C (KP510 00150) without breaks to the
location shown by the figure to the left.
7.
Install parts in the reverse order of removal.
CAUTION:
If the engine is started with vacuum pump released (vacuum
hose disconnected), it causes increase of blowby gas amount,
and engine damage may result. When starting the engine, be
sure to close vacuum circuit.
SBR611E
Inspection
NLBR0125
+
Remove vacuum hose. Then, connect vacuum gauge with
three-way connector.
+
Install three-way connector to the area where vacuum pump
negative pressure can be directly measured. (The figure
shown an example.)
+
Start the engine, then measure negative pressure.
Standard: −86.6 to −101.3 kPa (−866 to −1,013 mbar,
−650 to −760 mmHg, −25.59 to −29.92 inHg)
+
If it is not within standard, inspect for suction of air in the middle
of route and measure it again.
+
If it is still not within standard value, replace the vacuum pump.
VACUUM PUMP
Installation
BR-21
Component
NLBR0126
SBR612E
SBR613E
Disassembly
NLBR0136
Disassemble the components, referring to the “Component”, then
remove vacuum pump.
CAUTION:
Do not disassemble vacuum pump. (Do not loosen three M6
bolts.)
Assembly
NLBR0127
Install all parts to cylinder head rear cover as follows.
1.
Install vacuum pump.
2.
Install chain guide temporarily.
+
Adjust the chain guide position by the method explained in step
5.
SBR614E
3.
Install rear cam sprocket.
+
Installation direction of sprocket is not specified.
+
Insert 2 thickness gauges [3.0 mm (0.118 in)] between cover
and rear cam sprocket (shown in the figure). Insert 2 bolts [M6,
thread length: 35 - 40 mm (1.38 - 1.57 in)] into sprocket to
retain it to cover.
+
Use thickness gauges [3.0 mm (0.118 in)] for chain alignment
between vacuum pump sprocket and cam sprocket.
4.
Attach drive chain to rear cam sprocket and vacuum pump
sprocket.
5.
Tighten chain guide installation bolt while pressing chain guide
VACUUM PUMP
Component
BR-22
lightly [approximately 9.8 N (1.0 kg, 2.2 lb)].
6.
Remove thickness gauges (2).
+
Leave sprocket retaining bolts (M6) until installation.
VACUUM PUMP
Assembly (Cont’d)
BR-23
Component
NLBR0030
NBR365
1.
Main pin
2.
Pin boot
3.
Torque member fixing bolt
4.
Torque member
5.
Inner shim
6.
Inner pad
7.
Pad retainer
8.
Outer pad
9.
Outer shim
10. Connecting bolt
11. Copper washer
12. Main pin bolt
13. Bleed valve
14. Cylinder body
15. Piston seal
16. Piston
17. Piston boot
Pad Replacement
NLBR0029
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
+
When cylinder body is open, do not depress brake pedal
because piston will pop out.
+
Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
+
If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
+
It 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.
+
Burnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE
SERVICE”, BR-7.
FRONT DISC BRAKE
Component
BR-24
SBR976B
SBR932C
1.
Remove master cylinder reservoir cap.
2.
Remove pin bolt.
3.
Open cylinder body upward. Then remove pad with retainers,
inner and outer shims.
Standard pad thickness:
11 mm (0.43 in)
Pad wear limit:
2.0 mm (0.079 in)
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
SBR979B
Removal
NLBR0031
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for dis-
assembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not to stretch brake
hose.
SBR772
Disassembly
NLBR0032
WARNING:
Do not place your fingers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
1.
Push out piston with piston boot with compressed air.
2.
Remove piston seal with a suitable tool.
Inspection
NLBR0033
CALIPER
NLBR0033S01
Cylinder Body
NLBR0033S0101
+
Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
+
Minor damage from rust or foreign materials may be eliminated
by polishing surface with a fine emery paper. Replace cylinder
body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
FRONT DISC BRAKE
Pad Replacement (Cont’d)
BR-25
Piston
NLBR0033S0102
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 foreign
materials. Replace if any of the above conditions are observed.
Slide Pin, Pin Bolt and Pin Boot
NLBR0033S0103
Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.
ROTOR
NLBR0033S02
Rubbing Surface
NLBR0033S0201
Check rotor for roughness, cracks or chips.
SBR219C
Runout
NLBR0033S0202
1.
Secure rotor to wheel hub with at least two nuts (M12 x 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 AX section
(“Front Wheel Bearing”, “ON-VEHICLE SERVICE”).
Maximum runout:
0.08 mm (0.0031 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 to wheel hub with
nuts.
c.
Measure runout.
d.
Repeat steps a. to c. so that minimum runout position can be
found.
4.
If the runout is still out of specification, turn rotor with on-car
brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or
equivalent).
Thickness
NLBR0033S0203
Thickness variation (At least 8 positions):
Maximum 0.02 mm (0.0008 in)
If thickness variation exceeds the specification, turn rotor with on-
car brake lathe.
Rotor repair limit:
26.0 mm (1.024 in)
FRONT DISC BRAKE
Inspection (Cont’d)
BR-26
SBR574
Assembly
NLBR0034
1.
Insert piston seal into groove on cylinder body.
2.
With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.
3.
Properly secure piston boot.
SBR980B
Installation
NLBR0035
CAUTION:
+
Refill with new brake fluid “DOT 4”.
+
Never reuse drained brake fluid.
1.
Install brake hose to caliper securely.
2.
Install all parts and secure all bolts.
3.
Bleed air. Refer to “Bleeding Brake System”, BR-8.
FRONT DISC BRAKE
Assembly
BR-27
Component
NLBR0038
NBR366
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 shim
11. 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 A
21. Washer
22. Wave washer
23. Washer
24. Bearing
25. Adjuster
26. Cup
27. Piston
28. Piston boot
29. Sleeve
Pad Replacement
NLBR0037
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
+
When cylinder body is open, do not depress brake pedal
because piston will pop out.
+
Be careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
+
If shims are rusted or show peeling of rubber coat, replace
them with new shims.
REAR DISC BRAKE (CAM & STRUT TYPE)
Component
BR-28
+
It 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.
+
Burnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE
SERVICE”, BR-7.
SBR764E
SBR916C
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)
SBR641
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.
NBR374
7.
Adjust the piston to the right angle as shown in the figure.
REAR DISC BRAKE (CAM & STRUT TYPE)
Pad Replacement (Cont’d)
BR-29
NBR375
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.
NBR167
Removal
NLBR0039
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 dis-
assembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not to stretch brake
hose.
SBR646
Disassembly
NLBR0040
1.
Remove piston by turning it counterclockwise with long nose
pliers or suitable tool.
SBR889
2.
Pry off snap ring A from piston with suitable pliers and remove
adjusting nut.
REAR DISC BRAKE (CAM & STRUT TYPE)
Pad Replacement (Cont’d)
BR-30
SBR088B
3.
Disassemble cylinder body.
a.
Pry off snap ring B with suitable pliers, then remove spring
cover, spring and seat.
b.
Remove washer, key plate, push rod, O-ring and strut.
SBR656
c.
Remove piston seal.
Be careful not to damage cylinder body.
SBR767E
4.
Remove return spring, toggle lever and cable guide.
Inspection
NLBR0041
CALIPER
NLBR0041S01
CAUTION:
Use brake fluid to clean cylinder. Never use mineral oil.
Cylinder Body
NLBR0041S0101
+
Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
+
Minor damage from rust or foreign materials may be eliminated
by polishing surface with a fine emery paper.
Replace cylinder body if necessary.
Torque Member
NLBR0041S0102
Check for wear, cracks or other damage. Replace if necessary.
Piston
NLBR0041S0103
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign matter is stuck to sliding surface.
Check piston for score, rust, wear, damage or presence of foreign
materials.
Replace if any of the above conditions are observed.
REAR DISC BRAKE (CAM & STRUT TYPE)
Disassembly (Cont’d)
BR-31
Pin and Pin Boot
NLBR0041S0104
Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
SBR219C
ROTOR
NLBR0041S02
Rubbing Surface
NLBR0041S0201
Check rotor for roughness, cracks or chips.
Runout
NLBR0041S0202
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 (“REAR WHEEL
BEARING”, “On-vehicle Service”).
3.
Change relative positions of rotor and wheel hub so that runout
is minimized.
Maximum runout:
0.07 mm (0.0028 in)
Thickness
NLBR0041S0203
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)
NBR367
Assembly
NLBR0042
1.
Insert cam with depression facing towards open end of cylin-
der.
REAR DISC BRAKE (CAM & STRUT TYPE)
Inspection (Cont’d)
BR-32
SBR248B
2.
Generously apply rubber grease to strut and push rod to make
insertion easy.
SBR893
3.
Fit push rod into square hole in key plate. Also match convex
portion of key plate with concave portion of cylinder.
SBR754E
4.
Install rod, push rod and key plate.
SBR869CB
SBR879-B
5.
Install seat, spring, spring cover and snap ring B with suitable
press and drift.
REAR DISC BRAKE (CAM & STRUT TYPE)
Assembly (Cont’d)
BR-33
SBR892
6.
Install cup in the specified direction.
SBR755E
7.
Install adjuster, bearing, washers and snap ring A with a suit-
able tool.
SBR646
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.
SBR767E
10. Fit toggle lever, return spring and cable guide.
NBR374
11. Adjust the piston to the right angle as shown in the figure.
REAR DISC BRAKE (CAM & STRUT TYPE)
Assembly (Cont’d)
BR-34
NBR375
Installation
NLBR0043
CAUTION:
+
Refill with new brake fluid “DOT 4”.
+
Never reuse drained brake fluid.
1.
Install caliper assembly.
+
As 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 “Bleeding Brake System”, BR-8 and “Air
Bleeding Procedure”, CL-10.
REAR DISC BRAKE (CAM & STRUT TYPE)
Installation
BR-35
Component
NLBR0150
NBR422
1.
Cylinder body
2.
Pin
3.
Pin boot
4.
Torque member
5.
Inner shim
6.
Inner pad
7.
Outer pad
8.
Outer shim
NOTE:
The cylinder body cannot be disassembled.
Pad Replacement
NLBR0151
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
+
When cylinder body is open, do not depress brake pedal
because piston will pop out.
+
Be careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
+
If shims are rusted or show peeling of rubber coat, replace
them with new shims.
+
It 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.
+
Burnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE
SERVICE”, BR-7.
REAR DISC BRAKE (BALL & RAMP TYPE)
Component
BR-36
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