Nissan Almera Tino V10 (2001 year). Manual — part 16
Commercial Service Tools
NLBR0004
Tool name
Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing each brake piping
a: 10 mm (0.39 in)
Brake fluid pressure
gauge
NT151
Measuring brake fluid pressure
PREPARATION
Commercial Service Tools
BR-5
NLBR0005
NVH Troubleshooting Chart
NLBR0005S01
Use the table below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
BR-24,
28
—
—
—
—
—
BR-26,
32
NVH
in
F
A
section
NVH
in
F
A
section
NVH
in
F
A
,
R
A
section
NVH
in
F
A
section
NVH
in
ST
section
SUSPECTED PARTS
(Possible cause)
Pads
-
damaged
Pads
-
uneven
wear
Shims
damaged
Rotor
imbalance
Rotor
damage
Rotor
runout
Rotor
deformation
Rotor
deflection
Rotor
rust
Rotor
thickness
variation
DRIVE
SHAFT
AXLE
AND
SUSPENSION
TIRES
ROAD
WHEEL
STEERING
Symptom BRAKE
Noise
X
X
X
X
X
X
X
X
Shake
X
X
X
X
X
X
Shimmy, Jud-
der
X
X
X
X
X
X
X
X
X
X
X
X: Applicable
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
BR-6
NBR376
Checking Brake Fluid Level
NLBR0006
+
Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
+
If fluid level is extremely low, check brake system for leaks.
+
Release parking brake lever and see if brake warning lamp
goes off. If not, check brake system for leaks.
SBR389C
Checking Brake Line
NLBR0007
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1.
Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2.
Check for oil leakage by fully depressing brake pedal while
engine is running.
SBR419C
Changing Brake Fluid
NLBR0008
CAUTION:
+
Refill with new brake fluid “DOT 4”.
+
Always keep fluid level higher than minimum line on res-
ervoir tank.
+
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, wash it away with water immediately.
1.
Clean inside of reservoir tank, and refill with new brake fluid.
2.
Connect a vinyl tube to each air bleeder valve.
3.
Drain brake fluid from each air bleeder valve by depressing
brake pedal while keeping reservoir level higher than minimum
line by adding new brake fluid.
4.
Repeat until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to “Bleeding Brake System”, BR-8 and “Air
Bleeding Procedure”, CL-10.
Brake Burnishing Procedure
NLBR0036
Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing rotors, after replacing pads, or
if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1.
Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2.
Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
ON-VEHICLE SERVICE
Checking Brake Fluid Level
BR-7
pressure such that vehicle stopping time equals 3 to 5 sec-
onds.
3.
To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4.
Repeat steps 1 to 3, 10 times or more to complete the burnish-
ing procedure.
NBR357
Bleeding Brake System
NLBR0009
CAUTION:
+
Carefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
+
Fill reservoir with new brake fluid “DOT 4”. Make sure it is
full at all times while bleeding air out of system.
+
Place a container under master cylinder to avoid spillage
of brake fluid.
+
For models with ABS, turn ignition switch OFF and dis-
connect ABS actuator connectors or battery ground cable.
SBR419C
+
Bleed air in the following order.
Right rear brake
→
Left front brake
→
Left rear brake
→
Right
front brake
1.
Connect a transparent vinyl tube to air bleeder valve.
2.
Fully depress brake pedal several times.
3.
With brake pedal depressed, open air bleeder valve to release
air.
4.
Close air bleeder valve.
5.
Release brake pedal slowly.
6.
Repeat steps 2. through 5. until clear brake fluid comes out of
air bleeder valve.
ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont’d)
BR-8
Hydraulic Circuit
NLBR0010
NBR358
Removal
NLBR0011
CAUTION:
+
Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+
All hoses must be free from excessive bending, twisting
and pulling.
+
For ball & ramp type rear caliper, care should be taken as
not to let air enter the cylinder body.
1.
Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
2.
Cover openings to prevent entrance of air and dirt whenever
disconnecting brake line.
Inspection
NLBR0012
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
BRAKE HYDRAULIC LINE
Hydraulic Circuit
BR-9
SBR686C
Installation
NLBR0013
CAUTION:
+
Refill with new brake fluid “DOT 4”.
+
Never reuse drained brake fluid.
1.
Tighten all flare nuts and connecting bolts.
Specification:
Flare nut
15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Connecting bolt
17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
2.
Refill until new brake fluid comes out of each air bleeder valve.
3.
Bleed air. Refer to “Bleeding Brake System”, BR-8, and ‘‘Air
Bleeding Procedure’’, CL-10.
BRAKE HYDRAULIC LINE
Installation
BR-10
Removal and Installation
NLBR0015
NBR359
SBR997
Inspection
NLBR0016
Check brake pedal for following items.
+
Brake pedal bend
+
Clevis pin deformation
+
Crack of any welded portion
+
Crack or deformation of clevis pin stopper
SBR657EA
Adjustment
NLBR0017
Check brake pedal free height from metal panel. Adjust if neces-
sary.
H: Free height
Refer to SDS, BR-93.
C
1
, C
2
: Clearance between pedal stopper and threaded
end of stop lamp switch and brake switch.
0.75 - 2.00 mm (0.0295 - 0.0787 in)
D: Depressed height
LHD/RHD (M/T): 60 -70 (2.36 - 2.76 in)
LHD/RHD (CVT): 69 -79 (2.72 - 3.11 in)
Under force of 490 N (50 kg, 110 lb) with engine run-
ning.
A: Pedal free play at pedal pad
1.0 - 3.0 mm (0.039 - 0.118 in)
BRAKE PEDAL AND BRACKET
Removal and Installation
BR-11
SBR229E
1.
Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
2.
Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3.
Check brake pedal’s depressed height while engine is running.
If lower than specification, check brake system for leaks, accu-
mulation of air or any damage to components (master cylinder,
wheel cylinder, etc.), then make necessary repairs.
BRAKE PEDAL AND BRACKET
Adjustment (Cont’d)
BR-12
Removal
NLBR0117
NBR360
1.
Reservoir cap
2.
Filter
3.
Reservoir tank
4.
Adapter
5.
Elastic pin
6.
Seal
7.
Washer
8.
Circlip
9.
Piston stopper pin
10. Primary piston assembly
11. Secondary piston assembly
12. Cylinder body
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
1.
Connect a vinyl tube to air bleeder valve.
2.
Drain brake fluid from each front caliper air bleeder valve,
depressing brake pedal to empty fluid from master cylinder.
3.
Remove brake pipe flare nuts.
4.
Disconnect hoses from adapter.
5.
Remove master cylinder mounting nuts.
NBR361
Disassembly
NLBR0118
1.
Drive out elastic pin from cylinder body.
2.
Remove adapter, washer and seals.
MASTER CYLINDER
Removal
BR-13
NBR353
3.
Remove the circlip with suitable pliers while piston is pushed
into cylinder.
SBR232E
4.
Remove piston stopper pin while piston is pushed into cylinder.
5.
Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
Inspection
NLBR0119
Check for the following items.
Replace any part if damaged.
Master cylinder:
+
Pin holes or scratches on inner wall.
Piston:
+
Deformation or scratches on piston cups.
SBR233E
Assembly
NLBR0120
1.
Insert secondary piston assembly. Then insert primary piston
assembly.
+
Pay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body.
SBR232E
2.
Install piston stopper pin while piston is pushed into cylinder.
Then secure the primary and secondary piston assemblies
with new circlip.
3.
Insert washer and push reservoir seals and adapter into cylin-
der body.
4.
Install elastic pin.
MASTER CYLINDER
Disassembly (Cont’d)
BR-14
Installation
NLBR0121
CAUTION:
+
Refill with new brake fluid “DOT 4”.
+
Never reuse drained brake fluid.
1.
Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2.
Torque mounting nuts.
: 13 - 15 N·m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
NBR363
NBR364
3.
Check hoses for damage. If the hoses show cracks or damage,
replace the hose.
4.
Insert the dot (coloured) mark hoses to the primary - and sec-
ondary inlet ports adapter. Then secure it with clamps.
Hose marking
Booster model
M215T
S255
Primary-inlet port
White dot
Blue dot
Secondary-inlet port
Yellow dot
Green dot
NBR362
5.
Fill up reservoir tank with new brake fluid.
6.
Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
7.
Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
8.
Fit brake lines to master cylinder.
9.
Tighten flare nuts.
: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
10. Bleed air procedure from brake and clutch system. Refer to
“Bleeding Brake System”, BR-8 and “Air Bleeding Procedure”,
CL-10.
MASTER CYLINDER
Installation
BR-15
SBR002A
On-vehicle Service
NLBR0023
OPERATING CHECK
NLBR0023S01
1.
Stop engine and depress brake pedal several times. Check
that pedal stroke does not change.
2.
Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
SBR365AA
AIRTIGHT CHECK
NLBR0023S02
1.
Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. The pedal should go further
down at the first time, and then it should gradually rise there-
after.
2.
Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change
after holding pedal down for 30 seconds.
SBR232CB
Removal
NLBR0024
CAUTION:
+
Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
+
Be careful not to deform or bend brake pipes, during
booster removal.
SBR208E
Inspection
NLBR0025
OUTPUT ROD LENGTH CHECK
NLBR0025S01
1.
Apply vacuum of −66.7 kPa (−667 mbar, −500 mmHg, −19.69
inHg) to brake booster with a handy vacuum pump.
2.
Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.
3.
Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
BRAKE BOOSTER
On-vehicle Service
BR-16
Installation
NLBR0026
CAUTION:
+
Be careful not to deform or bend brake pipes, during
booster installation.
+
Replace clevis pin if damaged.
+
Refill with new brake fluid “DOT 4”.
+
Never reuse drained brake fluid.
+
Take care not to damage brake booster mounting bolt
thread during installation. Due to the acute angle of
installation, the threads can be damaged with the dash
panel.
SBR237EA
1.
Before fitting booster, temporarily adjust clevis to dimension
shown.
2.
Fit booster, then secure mounting nuts (brake pedal bracket to
master cylinder) lightly.
3.
Connect brake pedal and booster input rod with clevis pin.
4.
Secure mounting nuts.
Specification:
13 - 16 N·m (1.3 - 1.6 kg-m, 9 - 12 ft-lb)
5.
Install master cylinder. Refer to “Installation” in “MASTER
CYLINDER”, BR-15.
6.
Bleed air. Refer to “Bleeding Brake System”, BR-8 and “Air
Bleeding Procedure”, CL-10.
BRAKE BOOSTER
Installation
BR-17
SBR225B
Removal and Installation
NLBR0027
CAUTION:
When installing vacuum hoses, pay attention to the following
points.
+
Do not apply any oil or lubricants to vacuum hose and
check valve.
+
Insert vacuum tube into vacuum hose as shown.
SBR498A
NBR385
+
Install check valve, paying attention to its direction.
VACUUM HOSE
Removal and Installation
BR-18
Inspection
=NLBR0028
HOSES AND CONNECTORS
NLBR0028S01
Check vacuum lines, connections and check valve for airtightness,
improper attachment chafing and deterioration.
SBR844B
CHECK VALVE
NLBR0028S02
Check vacuum with a vacuum pump.
Connect to booster side
Vacuum should exist.
Connect to engine side
Vacuum should not exist.
SBR943A
VACUUM HOSE
Inspection
BR-19
Removal
NLBR0123
SBR631E
1.
Remove parts shown below.
+
Air duct, air cleaner case (upper)
+
Engine cover
+
Rocker cover
+
Exhaust manifold cover
+
EGR tube
2.
Disconnect vacuum hose from vacuum pump.
3.
Remove cylinder head rear cover plate.
+
Use a tool such as seal cutter (SST) to remove.
4.
Loosen and remove rear cam sprocket installation bolts.
+
Camshaft should not be attached. Using engine inner
resistance, loosen installation bolts.
SBR632E
5.
Remove vacuum pump and cylinder head rear cover assem-
bly.
+
Remove and install vacuum pump, sprocket, drive chain, and
chain guide as an assembly.
+
Loosen mounting bolts in the reverse order of the numbers
shown in the figure to the left.
+
Remove only bolts that are shown in the figure. (Be especially
careful not to remove M6 bolts on the vacuum pump.)
+
Use a tool such as a seal cutter (SST).
VACUUM PUMP
Removal
BR-20
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