1998 NISSAN PICK-UP brake fluid

2. Install stopper cap.
lBefore installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.
Installation
CAUTION:
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Tighten mounting nuts.
: 12 - 15 N´m (1.2 - 1.5 kg-m,9-11ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system. Refer to ``Bleeding Brake
System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR940A
ABR190
MASTER CYLINDER
Assembly (Cont'd)
BR-14

On-vehicle Service
OPERATING CHECK
lDepress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
lDepress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
lStart engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. Booster is airtight if pedal
stroke is less each time.
lDepress brake pedal while engine is running, and stop
engine with pedal depressed. The pedal stroke should not
change after holding pedal down for30 seconds.
Removal
CAUTION:
lBe 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.
lBe careful not to deform or bend brake pipes during
removal of booster.
Inspection
OUTPUT ROD LENGTH CHECK
1. Apply vacuum of þ66.7 kPa (þ667 mbar, þ500 mmHg,
þ19.69 inHg) to brake booster with a hand vacuum pump.
2. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
SBR002A
SBR365AA
ABR373
SBR281A
BRAKE BOOSTER
BR-15

Installation
CAUTION:
lBe careful not to deform or bend brake pipes during
installation of booster.
lReplace clevis pin if damaged.
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
lTake care not to damage brake booster mounting bolt
thread when installing. Due to the narrow angle of
installation, the threads can be damaged by the dash
panel.
A: S230, M215T
LHD 165 mm (6.50 in)
RHD 185 mm (7.28 in)
M195T
LHD 160 mm (6.30 in)
RHD 180 mm (7.09 in)
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket
to brake booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
: 13 - 16 N´m (1.3 - 1.6 kg-m,9-12ft-lb)
5. Install master cylinder. Refer to ``Installation'', ``MASTER
CYLINDER'', BR-14.
6. Adjust brake pedal height and free play. Refer to BR-11.
7. Secure lock nut for clevis.
: 16 - 22 N´m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)
8. Bleed air. Refer to ``Bleeding Brake System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR116BE
BRAKE BOOSTER
BR-16

Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
lWhen cylinder body is open, do not depress brake pedal
or caliper piston will pop out.
lBe careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
lIf shims are rusted or show peeling of the rubber coat,
replace them with new shims.
lIt 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.
1. Remove master cylinder reservoir cap.
2. Remove lower pin bolt.
3. Open cylinder body upward. Then remove pad retainers,
return spring and inner and outer shims.
Standard pad thickness:
CL28VD model
10 mm (0.39 in)
Pad wear limit:
2.0 mm (0.079 in)
lCarefully monitor brake fluid level because brake fluid
will return to reservoir when pushing back piston.
SBR081A
SBR010B
FRONT DISC BRAKE
BR-21

Disassembly
WARNING:
Do not place your fingers in front of piston.
CAUTION:
lDo not scratch or score cylinder wall.
lCL28VD type front disc brake uses plastic pistons,
handle them carefully.
1. Push out piston and dust cover with compressed air.
For CL28VD (2-piston type), use a wooden block so that both
pistons come out evenly.
2. Remove piston seal with a suitable tool.
Inspection Ð Caliper
CYLINDER BODY
lCheck inside surface of cylinder for score, rust, wear, dam-
age or presence of foreign objects. If any of the above con-
ditions are observed, replace cylinder body.
lMinor damage from rust or foreign objects may be eliminated
by polishing the surface with a fine emery sandpaper.
Replace cylinder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
PISTON
Ð for plastic piston (CL28VD) Ð
Check pistons for uneven surface, chips or cracks. Replace if
any of these conditions are observed.
SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks or other damage. Replace if any of these
conditions are observed.
Inspection Ð Rotor
RUNOUT
1. Check runout using a dial indicator.
lMake sure that wheel bearing axial end play is within the
specifications before measuring. Refer to FA section
(``Front Wheel Bearing'', ``ON-VEHICLE SERVICE'').
Maximum runout:
0.07 mm (0.0028 in)
2. If the runout is out of specification, machine rotor with on-car
brake lathe (``MAD, DL-8700'', ``AMMCO 700 and 705'' or
equivalent).
SBR085A
SBR177C
SBR089A
FRONT DISC BRAKE
BR-23

THICKNESS
Thickness variation (At least 8 positions):
Maximum 0.02 mm (0.0008 in)
If thickness variation exceeds the specification, machine rotor
with on-car brake lathe.
Rotor repair limit:
CL28VD 24.0 mm (0.945 in)
Assembly
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.
CAUTION:
lSecure dust seal properly.
lLubricate with new brake fluid before installing plastic
pistons (CL28VD) into cylinder body.
Installation
CAUTION:
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to ``Bleeding Brake System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
Brake Burnishing Procedure
When experiencing soft brake pedal feel at very low mileage, or
after replacing the rotor, burnish the brake pad contact surfaces
according to the following procedures.
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).
SBR090A
SBR178C
SBR179CA
SBR084A
FRONT DISC BRAKE
Inspection Ð Rotor (Cont'd)
BR-24

G SENSOR (4WD models only)
The G sensor senses deceleration during braking to determine whether the vehicle is being driven on a high
 road (asphalt road, etc.) or a low  road (snow-covered road, etc.). It then sends a signal to the ABS con-
trol unit.
The reed switch turns on when it is affected by a magnetic field. During sudden deceleration (braking on a
high  road), the weight moves and the magnet in the weight moves away from the reed switch. The mag-
netic field then diminishes and the reed switch turns off.
ABS ACTUATOR AND ELECTRIC UNIT
The ABS actuator and electric unit contains:
lAn electric motor and pump
lTwo relays
lSix solenoid valves, each inlet and outlet for
Ð LH front
Ð RH front
Ð Rear
lABS control unit
This component controls the hydraulic circuit and increases,
holds or decreases hydraulic pressure to all or individual wheels.
The ABS actuator and electric unit are not disassemble.
ABS actuator operation
Inlet solenoid
valveOutlet solenoid
valve
Normal brake operation OFF (Open) OFF (Closed)Master cylinder brake fluid pressure is directly trans-
mitted to wheel cylinder via the inlet solenoid valve.
ABS operationPressure hold ON (Closed) OFF (Closed)Hydraulic circuit is shut off to hold the wheel cylinder
brake fluid pressure.
Pressure
decreaseON (Closed) ON (Open)Wheel cylinder brake fluid is sent to reservoir via the
outlet solenoid valve. Then it is pushed up to the
master cylinder by pump.
Pressure
increaseOFF (Open) OFF (Closed)Master cylinder brake fluid pressure is transmitted to
wheel cylinder.
SBR070E
SBR071E
ANTI-LOCK BRAKE SYSTEM
System Description (Cont'd)
BR-34

G SENSOR
Always replace G sensor if bumped or dropped. Otherwise,
performance characteristics of G sensor will be changed,
which in turn changes ABS control performance character-
istics.
ABS ACTUATOR AND ELECTRIC UNIT
Removal
1. Disconnect battery cable.
2. Drain brake fluid. Refer to ``Changing Brake Fluid'', BR-3.
3. Remove mounting bracket fixing bolts and nuts.
4. Disconnect connector, brake pipes and remove fixing nuts.
Installation
CAUTION:
After installation, refill brake fluid. Then bleed air. Refer to
``Bleeding Brake System'', BR-4.
1. Connect brake pipes temporarily.
2. Tighten fixing bolts and nuts.
3. Tighten brake pipes.
4. Connect connector and battery cable.
SBR074E
SBR075E
ANTI-LOCK BRAKE SYSTEM
Removal and Installation (Cont'd)
BR-37