1999 NISSAN PRIMERA brake rotor

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS............................................................. 3
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²............. 3
Precautions for Brake System ................................... 3
Precautions When Working On ABS ......................... 4
Wiring Diagrams and Trouble Diagnosis ................... 4
PRECAUTIONS AND PREPARATION.......................... 5
Commercial Service Tools ......................................... 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLE SHOOTING.................................................. 6
NVH Troubleshooting Chart....................................... 6
CHECK AND ADJUSTMENT........................................ 7
Checking Brake Fluid Level....................................... 7
Checking Brake Line ................................................. 7
Changing Brake Fluid ................................................ 7
Brake Burnishing Procedure...................................... 7
Bleeding Brake System ............................................. 8
BRAKE HYDRAULIC LINE........................................... 9
Removal ................................................................... 10
Inspection................................................................. 10
Installation ................................................................ 10
CONTROL VALVE........................................................ 11
Dual Proportioning Valve .......................................... 11
BRAKE PEDAL AND BRACKET................................ 13
Removal and Installation ......................................... 13
Inspection................................................................. 13
Adjustment ............................................................... 13
MASTER CYLINDER................................................... 15
Removal ................................................................... 15
Disassembly............................................................. 15
Inspection................................................................. 16
Assembly ................................................................. 16
Installation ................................................................ 17BRAKE BOOSTER...................................................... 18
On-vehicle Service................................................... 18
Removal ................................................................... 18
Inspection................................................................. 19
Installation ................................................................ 19
VACUUM HOSE........................................................... 20
Removal and Installation ......................................... 21
Inspection................................................................. 21
FRONT DISC BRAKE................................................. 23
Pad Replacement .................................................... 23
Removal ................................................................... 24
Disassembly............................................................. 25
Inspection - Caliper.................................................. 25
SR20DE - M/T
FRONT DISC BRAKE................................................. 26
Pad Replacement .................................................... 26
Installation ................................................................ 28
Removal ................................................................... 29
Disassembly............................................................. 29
Inspection - Caliper.................................................. 29
FRONT DISC BRAKE................................................. 31
Inspection - Rotor .................................................... 31
Assembly ................................................................. 31
Installation ................................................................ 32
REAR DISC BRAKE TYPE 1...................................... 33
Component .............................................................. 33
Pad Replacement .................................................... 33
Removal ................................................................... 35
Disassembly............................................................. 35
BR

Inspection................................................................. 36
Assembly ................................................................. 37
Installation ................................................................ 39
REAR DISC BRAKE TYPE 2...................................... 40
Component .............................................................. 40
Pad Replacement .................................................... 40
Removal ................................................................... 42
Disassembly............................................................. 42
Inspection................................................................. 42
Installation ................................................................ 43
REAR DRUM BRAKE................................................. 44
Components............................................................. 44
Removal ................................................................... 44
Inspection - Wheel Cylinder .................................... 45
Wheel Cylinder Overhaul......................................... 46
Inspection - Drum .................................................... 46
Inspection - Lining ................................................... 46
Installation ................................................................ 46
PARKING BRAKE CONTROL.................................... 48
Removal and Installation ......................................... 48
Inspection................................................................. 49
Adjustment ............................................................... 49
ANTI-LOCK BRAKE SYSTEM.................................... 50
Purpose.................................................................... 50
Operation ................................................................. 50
ABS Hydraulic Circuit .............................................. 50
System Components ............................................... 51
System Description .................................................. 51
Removal and Installation ......................................... 53
TROUBLE DIAGNOSES............................................. 57
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ................................................ 57
Preliminary Check.................................................... 59
Component Parts and Harness Connector
Location ................................................................... 60
Circuit Diagram for Quick Pinpoint Check............... 61Wiring Diagram - ABS - ........................................... 62
Self-diagnosis (Only models with data link
connector terminal No. 8) ........................................ 67
TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION............................................................. 69
CONSULT-II ............................................................. 69
CONSULT-II Inspection Procedure.......................... 70
Ground Circuit Check .............................................. 75
TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION............................................................. 76
Malfunction Code/Symptom Chart........................... 76
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMS........................................................................... 77
Diagnostic Procedure 1 (Wheel sensor or rotor) .... 77
Diagnostic Procedure 2 (ABS actuator solenoid
valve and solenoid valve relay) ............................... 79
Diagnostic Procedure 3 (Motor Relay or motor) ..... 81
Diagnostic Procedure 4 (Low voltage) .................... 83
Diagnostic Procedure 5 (Control unit) ..................... 84
TROUBLE DIAGNOSES FOR SYMPTOMS............... 85
Diagnostic Procedure 6 (ABS works frequently) ..... 85
Diagnostic Procedure 7 (Unexpected pedal
action) ...................................................................... 86
Diagnostic Procedure 8 (Long stopping distance) .. 86
Diagnostic Procedure 9 (ABS does not work.) ....... 87
Diagnostic Procedure 10 (Pedal vibration and
noise) ....................................................................... 87
Diagnostic Procedure 11 (ABS Warning lamp
does not come on when ignition switch is turned
ON) .......................................................................... 88
Diagnostic Procedure 12 (Warning lamp stays on
when ignition switch is turned ON).......................... 90
SERVICE DATA AND SPECIFICATIONS (SDS)........ 91
General Specifications ............................................. 91
Inspection and Adjustment ...................................... 92
When you read wiring diagrams:
lRead GI section, ªHOW TO READ WIRING DIAGRAMSº.
lSee EL section, ªPOWER SUPPLY ROUTINGº for power distribution circuit.
lSee EL section for NATS information and wiring diagram.
When you perform trouble diagnoses, read GI section, ªHOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSESº and ªHOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENTº.
BR-2

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL P11 is as follows (The
composition varies according to the destination and optional equipment.):
lFor a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the instrument panel on passenger side),
front seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
lFor a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a
frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and
Air Bag Module, see the RS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.
Precautions for Brake System
lRecommended fluid is brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
lBe careful not to splash brake fluid on painted areas.
lTo clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
lNever use mineral oils such as gasoline or kerosene.
They will ruin rubber parts of the hydraulic system.
lUse flare nut wrench when removing and installing brake
tube.
lAlways torque brake lines when installing.
lBurnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªCheck and
Adjustmentº, BR-7.
WARNING:
lClean brake pads with a waste cloth, then wipe with a
dust collector.
SBR686C Commercial service tool
PRECAUTIONS
BR-3

NVH Troubleshooting Chart
Use the chart to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
BR-23, 26, 33
BR-23 26, 33
BR-23, 33
Ð
BR-31, 37, 43
BR-31, 37, 43
Ð
Ð
Ð
BR-31, 37
NHV in PD section
NHV in PD section
NHV in FA, RA section
NHV in FA section
NHV in FA section
NHV in FA section
NHV in ST section
Possible cause and
SUSPECTED PARTS
Pads - damaged
Pads - uneven wear
Shims damaged
Rotor imbalance
Rotor damaged
Rotor runout
Rotor deformation
Rotor deflection
Rotor rust
Rotor thickness variation
PROPELLER SHAFT
DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
AXLE SHAFT
STEERING
Symptom BRAKENoise x x xxxxxxxx
Shake x xxxxxx
Shimmy, Judderxxxxxxx xxx x
X : Applicable
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLE SHOOTING
BR-6

Checking Brake Fluid Level
lCheck fluid level in reservoir tank. It should be between Max.
and Min. lines on reservoir tank.
lIf fluid level is extremely low, check brake system for leaks.
lIf brake warning lamp comes on and fluid level is above
ªMINº mark, check brake fluid level switch and parking brake
switch.
Checking Brake Line
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.
Changing Brake Fluid
CAUTION:
lRefill with new brake fluid ªDOT 4º.
lAlways keep fluid level higher than minimum line on
reservoir tank.
lNever reuse drained brake fluid.
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.
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 mini-
mum 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 ªBleeding Brake Systemº, BR-8.
Brake Burnishing Procedure
Burnish the brake contact surfaces according to the following
procedure 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).
NBR141 MAX.
MIN.
ABR159
SBR419C
CHECK AND ADJUSTMENT
BR-7

Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne particles or other materials.
CAUTION:
lWhen cylinder body is open, do not depress brake pedal
because 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.
lBurnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªCHECK AND
ADJUSTMENTº, BR-7.
NBR438
FRONT DISC BRAKE
BR-23

Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne particles or other materials.
CAUTION:
lWhen cylinder body is open, do not depress brake pedal
because 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.
lBurnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªCHECK AND
ADJUSTMENTº, BR-7.
NBR439
FRONT DISC BRAKESR20DE - M/T
BR-26

Inspection Ð Rotor
RUBBING SURFACE
Check rotor for roughness, cracks or chips.
RUNOUT
1. Secure rotor to wheel hub with at least two nuts (M12´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 section FA.
Maximum runout:
0.07 mm (0.0028 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 tho wheel hub
with nuts.
c. Measure runout.
d. Repeat steps a. to c. so minimum runout position can be
found.
4. If the runout is still out of specification, turn rotor with on-car
brake lathe (ªMAD, DL-8700º, ªAMMCO 700 and 705º or
equivalent).
THICKNESS
Rotor repair limit:
Standard thickness
22 mm (0.87 in)
Minimum thickness
20.0 mm (0.787 in)
Thickness variation (At least 8 positions)
Maximum 0.02 mm (0.0008 in)
Assembly
CAUTION:
Always use new piston seal.
1. Insert new piston seal into groove in cylinder body
2. With dust seal fitted to piston, insert dust seal into groove on
cylinder body and install piston.
3. Properly secure dust seal.
SBR936A
SBR944A
SBR574 Dust seal
Piston seal
Piston
Cylinder body
FRONT DISC BRAKE
BR-31