Almera Tino V10 (2003 year). Manual — part 46
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:
I
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.
I
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:
Without ESP
10.275 - 10.525 mm (0.4045 - 0.4144 in)
With ESP
4.9 - 5.1 mm (0.193 - 0.201 in)
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BRAKE BOOSTER
On-vehicle Service
BR-19
Installation
NLBR0026
CAUTION:
I
Be careful not to deform or bend brake pipes, during
booster installation.
I
Replace clevis pin if damaged.
I
Refill with new brake fluid “DOT 3” or “DOT 4”.
I
Never reuse drained brake fluid.
I
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-18.
6.
Bleed air. Refer to “Bleeding Brake System”, BR-11 and “Air
Bleeding Procedure”, CL-10.
BRAKE BOOSTER
Installation
BR-20
SBR225B
Removal and Installation
NLBR0027
CAUTION:
When installing vacuum hoses, pay attention to the following
points.
I
Do not apply any oil or lubricants to vacuum hose and
check valve.
I
Insert vacuum tube into vacuum hose as shown.
SBR498A
NBR385
I
Install check valve, paying attention to its direction.
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VACUUM HOSE
Removal and Installation
BR-21
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-22
Removal
NLBR0123
SBR631E
1.
Remove parts shown below.
I
Air duct, air cleaner case (upper)
I
Engine cover
I
Rocker cover
I
Exhaust manifold cover
I
EGR tube
2.
Disconnect vacuum hose from vacuum pump.
3.
Remove cylinder head rear cover plate.
I
Use a tool such as seal cutter (SST) to remove.
4.
Loosen and remove rear cam sprocket installation bolts.
I
Camshaft should not be attached. Using engine inner
resistance, loosen installation bolts.
SBR632E
5.
Remove vacuum pump and cylinder head rear cover assem-
bly.
I
Remove and install vacuum pump, sprocket, drive chain, and
chain guide as an assembly.
I
Loosen mounting bolts in the reverse order of the numbers
shown in the figure to the left.
I
Remove only bolts that are shown in the figure. (Be especially
careful not to remove M6 bolts on the vacuum pump.)
I
Use a tool such as a seal cutter (SST).
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VACUUM PUMP
Removal
BR-23
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.
I
M6 bolts will be used for installation.
5.
Tighten rear cam sprocket installation bolts.
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Camshaft should not be fixed. Using engine inner resistance,
tighten installation bolts.
SBR634E
6.
Install cylinder head rear cover plate.
I
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
I
Remove vacuum hose. Then, connect vacuum gauge with
three-way connector.
I
Install three-way connector to the area where vacuum pump
negative pressure can be directly measured. (The figure
shown an example.)
I
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)
I
If it is not within standard, inspect for suction of air in the middle
of route and measure it again.
I
If it is still not within standard value, replace the vacuum pump.
VACUUM PUMP
Installation
BR-24
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.
I
Adjust the chain guide position by the method explained in step
5.
SBR614E
3.
Install rear cam sprocket.
I
Installation direction of sprocket is not specified.
I
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.
I
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
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VACUUM PUMP
Component
BR-25
lightly [approximately 9.8 N (1.0 kg, 2.2 lb)].
6.
Remove thickness gauges (2).
I
Leave sprocket retaining bolts (M6) until installation.
VACUUM PUMP
Assembly (Cont’d)
BR-26
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:
I
When cylinder body is open, do not depress brake pedal
because piston will pop out.
I
Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
I
If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
I
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.
I
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-10.
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FRONT DISC BRAKE
Component
BR-27
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
I
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.
I
Minor damage from rust or foreign materials may be eliminated
by polishing surface with a fine emery paper. Replace cylinder
body if necessary.
FRONT DISC BRAKE
Pad Replacement (Cont’d)
BR-28
CAUTION:
Use brake fluid to clean. Never use mineral oil.
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)
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FRONT DISC BRAKE
Inspection (Cont’d)
BR-29
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:
I
Refill with new brake fluid “DOT 3” or “DOT 4”.
I
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-11.
FRONT DISC BRAKE
Assembly
BR-30
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:
I
When cylinder body is open, do not depress brake pedal
because piston will pop out.
I
Be careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
I
If shims are rusted or show peeling of rubber coat, replace
them with new shims.
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REAR DISC BRAKE (CAM & STRUT TYPE)
Component
BR-31
I
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.
I
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-10.
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-32
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.
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REAR DISC BRAKE (CAM & STRUT TYPE)
Pad Replacement (Cont’d)
BR-33
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
I
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.
I
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-34
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