1987 NISSAN PULSAR wheel

Brakes 175
A pressure proportioning valve is incorporated in
each circuit to prevent premature locking of the rear
wheels during severe braking.

The four wheel hydraulically operated brakes
utilize disc brakes on each front wheel and disc brakes
or leading and trailing drum brake shoes on each rear
wheel.

The front disc brakes comprise a disc attached to
the hub assembly and a caliper bolted to the steering
knuckle.

The rear disc brakes comprise a disc and hub
assembly attached to the rear stub axle and a caliper
and anchor plate bolted to the backing plate.

The front and rear calipers are of the sliding type.
As pad wear takes place, the caliper piston is allowed
to slide outwards through the seal to take up a new
position in the caliper bore. Elastic deformation of the
seal takes place when the brakes are applied, which
returns the piston slightly when the brakes are re-
leased. Thus a constant clearance is maintained
between the pads and the disc when the brakes are in
the off position.

The disc brakes do not require periodical adjust-
ment in service to compensate for pad wear as they
are self adjusting.

The leading and trailing shoe drum brakes on the
rear wheels use a double ended wheel cylinder to
operate both brake shoes at the top. The lower end of
each brake shoe abuts a fixed anchor point. The brake
shoes are automatically adju sted when the brakes are
operated.

The handbrake operates the rear brakes via a
cable arrangement.

3. MASTER CYLINDER
Special Equipment Required:
To Install New Seals — Suitable machined drift
TO REMOVE
(1) Depress the brake pedal several times to
deplete the vacuum from the system.

(2) Raise the bonnet and install covers to
both
the front mudguards. Cover the areas of paintwork
beneath the master cylinder with absorbent cloth.
(3) Disconnect the wiring from the pressure
sensing switch. (4) Disconnect the brake pipes from the master
cylinder and plug the outlets and pipes to prevent the
loss of fluid and the ingress of dirt.
(5) Remove the nuts retaining the master cylin-
der to the brake servo unit and remove the master
cylinder from the vehicle.
TO DISMANTLE

(1) Remove the master cylinder as previously
described. (2) Remove the reservoir cap and diaphragm,
drain and discard the brake fluid from the reservoir. (3) Carefully remove the reservoir from the
master cylinder by pulling it from the reservoir
retainers by hand. Remove and discard the retainers
from the master cylinder. (4) Using internal snap ring pliers, remove the
snap ring from the primary reservoir port. (5) Remove the fast fill valve assembly and the
O ring from the port. Remove and discard the valve
washer from the fast fill valve.
(6) Remove the proportioning valve plugs and
the O rings. Discard the O rings. Withdraw the springs
and valve plungers from the master cylinder. Remove
and discard the seals from the valve plungers. (7) Remove the pressure sensing switch and
lever assembly from the master cylinder. {8) Remove the cylinder end plug from the
master cylinder. Remove and discard the O ring from
the plug.

(9) Carefully tap the front of the master cylinder
vertically on a block of wo od and remove the pressure
differential pistons from the master cylinder. Remove
and discard the O rings from the pistons. (10) Push the primary piston forward in the
cylinder with a blunt rod and while holding the
pressure, remove the stop pin from the master cylin-
der.
(11) The primary piston may now be withdrawn
from the cylinder bore. The secondary piston, retainer
and spring can also be withdrawn by carefully tapping
the master cylinder on a block of wood. (12) Prise the legs of the seal retainer upwards
and remove it from the primary piston. Remove the
seal and guide. Discard the seal and retainer.
NOTE: The secondary piston must no! be
dismantled by removing the screw. This
assembly has a factory p reset length and the
screw must not be altered in service.

(13) Remove the main seal and the guide from
the front of the secondary piston. Stretch the rear seal
from the groove and remove it from the piston. Take

Installed view of the master cylinder and servo unit. Air
duct removed for clarity. 1.8 liter model.

178 Brakes

Let the vehicle stand for 1-2 minutes, press the
brake pedal two or three times and check its opera-
tion.

If there is no vacuum assistance, the vacuum
system has developed a leak or the one way check
valve is defective.

NOTE: Before removing the servo unit from
the vehicle for inspection, disconnect the
hose from the servo unit, start the engine
and check that the manifold vacuum is in
fact reaching the servo unit. Also test the one
way check valve as described below,

TO TEST ONE WAY CHECK VALVE
(1) Disconnect the hose and remove the check
valve from the servo unit.

(2) Check the valve for sticking. Suction on the
manifold side should allo w air to flow freely. Air
blown into the valve from the manifold side should
not be able to flow through the valve. (3) Install the valve and check the operation
of
the servo unit as previously described.
NOTE: Check that there are no air leaks at
the hose connections and that the hose clips
are tight. Also check that the hose is not
bulged or collapsed due to deterioration.


Checking for vacuum at the servo unit. The engine
must be running for this test.
TO REMOVE
(1) Raise the bonnet and install covers to both
front mudguards.

(2) On 1.6 liter models, remove the air cleaner
assembly from the vehicle. If necessary refer to the
Fuel System section.
(3) On vehicles equipped with power steering,
remove the reservoir from the bulkhead and move it
to one side. If necessary refer to the Steering section.
(4) Disconnect the vacuum supply hose from the
servo unit.

View of the brake servo unit and associated compo-
nents.
(5) Remove the master cylinder as described
under the Master Cylinder heading. (6) Working inside the vehicle, remove the clip
and clevis pin connecting the pushrod to the brake
pedal. (7) Remove the nuts retaining the servo unit to
the bulkhead and maneuver the servo unit and
spacer block from the vehicle.
TO INSTAL

Installation is a reversal of the removal procedure
with attention to the following points:

(1) With the servo unit and master cylinder
installed to the vehicle, bleed the hydraulic system as
described under the Hydr aulic System heading.
(2) Check and if necessary adjust the brake
pedal height and free play as described under the
Brake Pedal heading.
5. FRONT BRAKES
Special Equipment Required:
To Check Disc Runout — Dial gauge
To Check Disc Thickness — Micrometer

TO CHECK AND RENEW BRAKE PADS
(1) Raise the front of the vehicle and place it on
chassis stands. Remove the front wheels.

(2) Inspect the brake pads on both sides of the
vehicle. If the friction material on one or more of the
pads is less than 2 mm thick or contaminated with
fluid or grease, renew the brake pads as a set as
follows.
NOTE: If the brake pads are contaminated,
trace and rectify the cause prior to installing
the new set of pads.

(3) Drain approximately two thirds of the brake
fluid from the master cylinde r reservoir. This can be
done by loosening the bleeder valve on the caliper and
allowing the fluid to drai n into a container. Discard
this fluid.

Brakes 179


Installed view of the front brake pads, spring clips and shims.
NOTE: Do not drain all the fluid from the
reservoir or it will be necessary to bleed the
hydraulic system. The fluid is drained from
the reservoir to prevent overflow when the
caliper piston is pushed back into the caliper
bore to facilitate pad renewal.

(4) Remove the lower guide bolt and rotate the
caliper body upwards, pivoting on the upper guide
bolt.
(5) Remove the brake pad assemblies from the
anchor plate. (6) Noting the installed positions, remove the
spring clips from the anchor plate and the shims from
the brake pads.
(7) Squarely push the piston into its bore in the
caliper body. If necessary, us e a G clamp to push the
piston into the caliper b ody. Check for fluid leaks
from the calip er body.
(8) If necessary, check the disc runout and
thickness as described under the Brake Disc heading.

(9) Ensure that the guide bolts move freely in the
anchor plate and that the dust boots are in good
condition. (10) Install the brake pads, shims and spring
clips
in the position noted on removal. (11) Rotate the caliper body downwards, to re-
turn to its original position. Lubricate the lower guide
bolt with suitable grease. In stall and tighten the guide
bolt to the specified torque. (12) Repeat the procedure on the opposite front
brake assembly. (13) Replenish the master cylinder reservoir with the recommended fluid to the correct level and pump
the brake pedal several times to locate the disc pads.

(14)
Install the front wheels and lower the
vehicle
to the ground. (15) Road lest the vehicle and check for correct
brake operation.
CALIPER

To Remove and Install
(1) Raise the front of the vehicle and place it on
chassis stands. Remove the relevant front wheel. (2) Remove the brake hose retaining bolt and
plug the hose to prevent the loss of fluid and the
ingress of dirt. (3) Remove the bolts retaining the caliper an-
chor plate to the steering knuckle and slide the caliper
off the disc.

Installed view of the front brake caliper.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Tighten the caliper anch or plate bolts to the
specified torque.
(2) Install the brake hose to the caliper
body
ensuring that new seal washers are installed.
NOTE: Ensure that the brake hose is cor-
rectly located against the protrusion on the
caliper body.

(3) Bleed the brake hydraulic system as de-
scribed under the Hydraulic System heading. (4) Install the fron t wheel and lower the vehicle
to the ground. (5) Road test the vehicle and check for correct
brake operation.
To Dismantle
(1) Raise the front of the vehicle and place it on
chassis stands. Remove the relevant front wheel.

(2) Remove the brake hose retaining bolt from

180 Brakes
the caliper body. Plug the brake hose to prevent the
loss of fluid and the ingress of dirt. Remove and
discard the sealing washers.

(3) Remove the guide bolts and slide the caliper
body from the anchor plate and pad assembly. (4) Remove the piston dust cover retaining clip.
Remove and discard the dust cover.
BRAKEPAD BRAKE PAD
Dismantled view of the front brake caliper.
(5) Place a piece of wood in front of the piston
and using low air pressure applied to the brake hose
aperture, gently force the piston from the caliper bore.
(6) Using a thin blunt probe, preferably made
from wood or plastic, remove and discard the piston
seal from the groove in the caliper bore. (7) Clean all the caliper components in methyl-
ated spirits and arrange the components in order, on
a clean, dry surface to aid in assembly.
To Inspect

(1) Inspect the caliper bore and piston for pit-
ting, wear or damage. Renew the caliper assembly or
piston if damage is evident.

NOTE: Slight rust spots in the caliper bore
may he removed with fine emery paper. The
piston must not be polished as the plated
surface wilt be damaged.

(2) Inspect the guide bolts for wear or damage.
Renew as necessary.

To Assemble
(1) Dip a new piston seal in clean hydraulic
brake fluid. Insert the seal into the groove in the
caliper bore ensuring that the seal is correctly seated
and not twisted.
(2) Install a new dust cover to the piston prior to
installing the piston to the caliper bore. (3) Coat the piston and caliper bore with clean
hydraulic brake fluid and insert the piston squarely
into the caliper bore.
(4) Locate the dust seal in the groove of the
caliper body and install the retaining clip.
(5) Lubricate the guide bolts using a suitable
grease. Install the caliper body to the anchor plate and
install and tighten the guide bolts to the
specified
torque. (6) Replenish the master cylinder reservoir with
the recommended fluid and bleed the brakes as
described under the Hydr aulic System heading.
(7) Install the front wheels and lower the vehicle
to the ground. (8) Road test the vehicle and check for correct
brake operation.
BRAKE DISC

To Check Runout
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the relevant front wheel. (2) Install the wheel nuts with the flat side of
the
wheel nut towards the disc. Lightly tighten the nuts to
secure the disc against the hub.

Rotate the hub and check for disc runout.
(3) Mount a dial gauge stand to a suspension
component and position the dial gauge plunger
against the wheel hub. Check that the end float is less
than 0.05 mm. Excessive e nd float will necessitate
renewal of the hub bearing. (4) Position the dial gauge plunger against the
centre of the brake disc. Ro tate the hub and measure
the runout. Maximum allowable runout is 0.07 mm. (5) If the runout exceeds Specifications, machine
or renew the brake disc. (6) Install the fron t wheel and lower the vehicle
to the ground.
To Remove and Install

(1) Raise the front of the vehicle and support it
on chassis stands. Remove the relevant wheel. (2) Remove the bolts retaining the caliper an-

Brakes 181

chor plate to the steering knuckle and slide the caliper
off the brake disc. Suspend the caliper clear of the
work area using wire or cord.

(3) Suitably mark the location of the disc in
relation to the hub.

(4) Slide the disc off the hub. If the disc is
difficult to remove, install two M8 x 1.25 mm bolts in
the disc and by alternatively tightening the bolts,
remove the disc.

Do not use a hammer to remove the disc.
Installation is a reversal of the removal procedure
ensuring that the mating face s of the disc and hub are
clean and free from burrs and that the marks made on
removal are aligned.

To Inspect
(1) Inspect the machined faces of the disc for
scores, cracks, wear and signs of overheating. (2) Using a micrometer, measure the thickness
of the disc at several positi ons around the face of the
disc. Renew the disc if the minimum thickness is
below Specifications.

Inspect the brake discs for scoring and wear.
(3) If the disc thickness is satisfactory but the
disc is scored, machine equal amounts from the
machined face on each side of the disc, to restore the
serviceability of the disc.

NOTE: Disc machining is best entrusted to
a reliable brake specialist who can advise on
disc serviceability.

6. REAR DISC BRAKES
Special Equipment Required:
To Check Disc Runout — Dial gauge
To Check Disc Thickness — Micrometer
TO CHECK AND RENEW BRAKE PADS
( 1 ) Raise the rear of the vehicle and place it on
chassis stands. Remove the rear wheels.


Renew the rear brake pads if the friction material is less
than 2 mm thick.
(2) Inspect the brake pads on both sides of the
vehicle. If the friction material on one or more of the
pads is less than 2 mm thick or contaminated with
fluid or grease, renew the brake pad as a set as follows.

NOTE: If the brake pads are contaminated
trace and rectify the cause prior to installing
the new set of pads.

(3) Drain approximately two thirds of the brake
fluid from the master cylinder reservoir. This can be
done by loosening the bleeder valve on the caliper and
allowing the fluid to drai n into a container. Discard
this fluid.

NOTE: Do not drain all the fluid from the
reservoir otherwise it will be necessary to
bleed the hydraulic system. The fluid is
drained from the reservoir to prevent over-
flow when the caliper piston is pushed back
into the caliper bore to facilitate pad re-
newal.

(4) Remove the guide bolts and lift the caliper
body clear of the disc.

NOTE: Do not allow the caliper to hang on
the brake hose.

(5) Noting the installed positions, remove the
brake pads, shims and spring clips from the anchor
plate.
(6) Using a pair of long nosed pliers with the
nose located in the recesses of the piston, rotate the
piston clockwise to retract it into the cylinder body.
Align the recesses between the brake pad retaining
lugs on the caliper body. Refer to the illustration. (7) If necessary, check the disc runout and
thickness as described under the Brake Disc heading.
(8) Ensure that the guide bolts move freely in the
caliper body and that the dust boots are in good
condition.

182 Brakes


Illustration of the rear disc caliper showing the correct
piston alignment.

(9) Install the brake pads, shims and spring
clips
in the position noted on removal. (10) Install the caliper body to its original posi-
tion. Lubricate the guide bolts with suitable grease.
Install and tighten the guide bolts to the specified
torque. (11) Repeat the procedure on the opposite rear
brake assembly.
(12) Replenish the master cylinder reservoir with
the recommended fluid to the correct level and pump
the brake pedal several times to locate the disc pads. (13) Install the rear wheels and lower the vehicle
to the ground. (14) Road test the vehicle and check for correct
brake operation.
CALIPER

To Remove and Install
(1) Raise the rear of the vehicle and place it on
chassis stands. Remove the relevant rear wheel. (2) Remove the brake hose retaining bolt from
the caliper body and plug the hose to prevent the
loss of fluid and the ingress of dirt.

Installed view of the rear brake caliper.
(3) Remove the handbrake cable bracket retain-
ing bolts and disconnect the handbrake cable from the
cam lever. (4) Remove the bolts retaining the caliper an-
chor plate. Remove the caliper from the disc. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Tighten the caliper anch or plate bolts to the
specified torque. (2) Install the brake hose to the caliper body
ensuring that new seal washers are installed.
NOTE: Ensure that the brake hose locating
pin is correctly installed in the caliper body.

de-
(3) Bleed the brake hydraulic system as
scribed under the Hydraulic System heading. (4) Install the rear wheel and lower the vehicle to
the ground. (5) Road test the vehicle and check for correct
brake operation.

Dismantled view of the rear brake caliper

Brakes 183

To Dismantle
(1) Raise the rear of the vehicle and place it on
chassis stands. Remove the relevant rear wheel.
(2) Remove the brake hose retaining bolt from
the caliper body and plug the hose to prevent the loss
of fluid and the ingress of dirt. (3) Remove the handbrake cable bracket retain-
ing bolt and disconnect the handbrake cable from the
cam lever.
(4) Remove the guide bolts and slide the caliper
body off the pads. (5) Using a pair of long nose pliers with the nose
located in the recesses of the piston, rotate the piston
anticlockwise to remove it from the caliper body.
(6) Remove the dust cover retaining clip and dust
cover. Discard the dust cover. (7) Using a thin blunt probe, preferably made
from wood or plastic, remove and discard the piston
seal from the groove in the caliper bore. (8) Using internal snap ring pliers, remove the
snap ring from the caliper bore. (9) Withdraw the spring cover, spring, key plate,
pushrod and link from the caliper bore. Do not mix
these components from the left and right hand sides as
they differ. (10) Remove and discard the O ring from the
pushrod. (11) Remove the spring, nut and washer from the
cam lever. Remove the cam lever and cam from the
caliper body. (12) Remove the cam seal from the caliper using a
screwdriver.
(13) Clean all the caliper components in methy-
lated spirits and arrange the components in order on a
clean dry surface to aid assembly.
To Inspect

(1) Inspect the caliper bore and piston for pit-
ting, wear or damage. Renew the caliper assembly or
piston if damage is evident.

NOTE: Slight rust spots in the caliper bore
may be removed with fine emery paper. The
piston must not be polished as the plated
surface will be damaged.

(2) Inspect the guide bolts for wear or damage
and renew as necessary.
(3) Inspect the threads of the pushrod for wear or
damage and renew as necessary. (4) Inspect the nut inside the piston for wear,
damage and security. Renew the piston if any damage
is evident. (5) Inspect the cam for wear, damage or pitting,
renew as necessary. (6) Inspect the cam bearing in the caliper body
for wear, damage or pitting and renew the seal and
bearing as necessary. (7) Inspect the guide bolt rubbers for deteriora-
tion, wear or damage. Renew as required. To Assemble

(1)
Lubricate the cam bearing with multipurpose
grease and install the seal. (2) Install the cam and cam lever to the
caliper
body. Install the cam lever spring, washer and nut, and
tighten the nut to the specified torque. (3) Install a new O ring to the pushrod and
install
the link, pushrod, key plate, spring and spring cover to
the caliper body. The key plate must engage the caliper
body. Secure the assembly with the snap ring. (4) Dip a new piston seal in clean hydraulic brake
fluid. Insert the seal into the groove in the caliper bore
ensuring that the seal is correctly seated and not
twisted. (5) Install a new dust cover to the piston prior
to
installing the piston to the caliper bore.
(6) Coat the piston and caliper bore with clean
hydraulic brake fluid and using long nose pliers rotate
the piston clockwise into the caliper bore. (7) Locate the dust seal in the groove of the
caliper body and install the retaining clip.
(8) Lubricate the guide bolts using a suitable
grease. Install the caliper body and tighten the guide
bolts to the specified torque. (9) Replenish the master cylinder reservoir with
the recommended fluid and bleed the brakes as
described under the Hydraulic System heading. (10) Install the rear wheel and lower the vehicle to
the ground. (11) Road test the vehicle and check for correct
brake operation.
BRAKE DISC

To Check Runout
(1) Raise the rear of the vehicle and support it on
chassis stands. Remove the relevant rear wheel.
(2) Mount a dial gauge stand to a suspension
component and position the dial gauge plunger
against the wheel hub. Check that the end float is less

Using a dial gauge to measure the rear disc runout.

184 Brakes
than 0.05 mm. If the wheel hub end float exceeds
Specifications, the bearing must be renewed as de-
scribed in the Rear Suspension section.

(3) Position the dial gauge plunger against the
centre of the brake disc contact area. Rotate the hub
and measure the runout. Ma ximum allowable runout
is 0.07 mm. (4) If the runout exceeds the specified amount,
machine or renew the brake disc. (5) Install the rear wheel and lower the vehicle to
the ground. (6) Road test the vehicle and check for correct
brake operation.
To Remove and Install

(1) Raise the rear of the vehicle and support it
on chassis stands. Remove the relevant rear wheel.
(2) Remove the clip securing the brake hose to
the suspension unit and disengage the hose. (3) Remove the bolts retaining the caliper an-
chor plate. (4) Slide the caliper from the brake disc and
suspend the caliper clear of the work area using wire
or cord.
NOTE: Do not allow the caliper to hang on
the brake hose.

(5) Remove the grease cap from the rear hub.
(6) Remove the split pin, nut retainer, hub nut
and washer from the stub axle. (7) Remove the hub assembly from the stud
axle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Tighten the rear hub to the specified torque.
(2) Install the brake caliper and tighten all the
bolts to the specified torque. (3) Rotate the hub and check for roughness. If
the hub does not rotate smoothly, renew the hub
bearing as described in the Rear Suspension section. (4) Install the rear wheel and lower the vehicle to
the ground.
(5) Road test the vehicle and check for correct
brake operation.
To Inspect

(1) Inspect the machined faces of the disc for
scores, cracks, wear and signs of overheating. (2) Using a micrometer, measure the thickness
of the disc at several posit ions around the face of the
disc. Renew the disc if the minimum thickness is
below Specifications.

(3) If the disc thickness is satisfactory but the
disc is scored, machine equal amounts from the
machined face on each side of the disc, to restore the
serviceability of the disc.


Inspect the machined faces of the disc for scores,
cracks, wear and signs of overheating.
NOTE: Disc machining is best entrusted to
a reliable brake specialist who can advise on
disc serviceability.

7. REAR DRUM BRAKES
TO REMOVE AND DISMANTLE
(1) Raise the rear of the vehicle and support it
on chassis stands. Remove th e rear wheels and release
the handbrake.
(2) Remove the grease cap from the rear hub.
(3) Remove the split pin, nut retainer, hub nut
and washer from the stub axle. Remove the brake
drum and hub assembly.

(4) Mark each brake shoe and spring to ensure
correct assembly. (5) Rotate the star wheel until the adjuster
assembly is at its shortest length.
Installed view of the left hand side rear drum brake
components.