2001 NISSAN ALMERA service

SBR686C
Precautions
PRECAUTIONSNJAX0022+When installing each rubber part, final tightening must be
carried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
+Use flare nut wrench when removing or installing brake
tubes.
+After installing removed suspension parts, check wheel
alignment.
+Do not jack up at the trailing arm and lateral link.
+Always torque brake lines when installing.
Preparation
SPECIAL SERVICE TOOLSNJAX0032
Tool number
Tool nameDescription
KV40104710
Drift
NT474
Install ABS sensor rotor
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia.
ST3072000
Drift
NT115
Install ABS sensor rotor
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
COMMERCIAL SERVICE TOOLSNJAX0024
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing brake piping
a: 10 mm (0.39 in)
REAR AXLE
Precautions
AX-22

Noise, Vibration and Harshness (NVH)
Troubleshooting
NJAX0025Refer to ªNoise, Vibration and Harshness (NVH) Troubleshootingº,
ªFRONT AXLEº, AX-3.
SMA525A
On-vehicle Service
REAR AXLE PARTSNJAX0026Check axle and suspension parts for excessive play, wear or dam-
age.
+Shake each rear wheel to check for excessive play.
SRA690A
REAR WHEEL BEARINGNJAX0027+Check axial end play.
Axial end play:
0.05 mm (0.0020 in)
+Check that wheel hub bearings operate smoothly.
+Check tightening torque of wheel bearing lock nut.
: 187 - 254 N´m (19 - 26 kg-m, 138 - 188 ft-lb)
+Replace wheel bearing assembly if there is axial end play or
wheel bearing does not turn smoothly. Refer to ªWheel Hubº,
ªREAR AXLEº, AX-24.
REAR AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting
AX-23

Service Data and Specifications (SDS)
WHEEL BEARING (REAR)=NJAX0031
Wheel bearing axial end play mm (in) 0.05 (0.0020)
Wheel bearing lock nut tightening torque N´m (kg-m, ft-lb) 187 - 254 (19 - 26, 138 - 188)
REAR AXLE
Service Data and Specifications (SDS)
AX-27

REAR AXLE
Service Data and Specifications (SDS) (Cont'd)
AX-28

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS...............................................................4
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............4
Precautions for Brake System .....................................4
Precautions When Working On ABS ...........................5
Wiring Diagrams and Trouble Diagnosis .....................5
PREPARATION...............................................................6
Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................7
NVH Troubleshooting Chart.........................................7
ON-VEHICLE SERVICE..................................................8
Checking Brake Fluid Level.........................................8
Checking Brake Line ...................................................8
Changing Brake Fluid ..................................................8
Brake Burnishing Procedure........................................8
Bleeding Brake System ...............................................9
BRAKE HYDRAULIC LINE...........................................10
Hydraulic Circuit.........................................................10
Removal .....................................................................10
Inspection................................................................... 11
Installation .................................................................. 11
BRAKE PEDAL AND BRACKET..................................12
Removal and Installation ...........................................12
Inspection...................................................................12
Adjustment .................................................................12
MASTER CYLINDER (TOKICO)...................................14
Removal .....................................................................14
Disassembly...............................................................15
Inspection...................................................................15
Assembly ...................................................................15
Installation ..................................................................16
MASTER CYLINDER [BOSCH (NABCO)]...................17
Removal .....................................................................17
Disassembly...............................................................17
Inspection...................................................................18
Assembly ...................................................................18
Installation ..................................................................19BRAKE BOOSTER........................................................20
On-vehicle Service.....................................................20
OPERATING CHECK...............................................20
AIRTIGHT CHECK...................................................20
Removal .....................................................................20
Inspection...................................................................20
OUTPUT ROD LENGTH CHECK..............................20
Installation ..................................................................21
VACUUM HOSE.............................................................22
Removal and Installation ...........................................22
Inspection...................................................................22
HOSES AND CONNECTORS...................................22
CHECK VALVE........................................................22
VACUUM PUMP............................................................23
Removal .....................................................................23
Installation ..................................................................24
Inspection...................................................................24
Component ................................................................25
Disassembly...............................................................25
Assembly ...................................................................25
FRONT DISC BRAKE...................................................27
Component ................................................................27
Pad Replacement ......................................................27
Removal .....................................................................28
Disassembly...............................................................28
Inspection...................................................................28
CALIPER.................................................................28
ROTOR...................................................................29
Assembly ...................................................................30
Installation ..................................................................30
REAR DRUM BRAKE...................................................31
Components...............................................................31
Removal .....................................................................31
Inspection - Wheel Cylinder ......................................32
Wheel Cylinder Overhaul...........................................33
Inspection - Drum ......................................................33
Inspection - Lining .....................................................33
Installation ..................................................................33

REMOVAL...............................................................98
INSTALLATION........................................................98
Sensor Rotor..............................................................99
REMOVAL...............................................................99
INSTALLATION........................................................99
SERVICE DATA AND SPECIFICATIONS (SDS).......100
General Specifications .............................................100Disc Brake ...............................................................101
Drum Brake..............................................................101
Brake Pedal .............................................................101
Parking Brake ..........................................................101
CONTENTS(Cont'd)
BR-3

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJBR0139The 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 N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing 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.
+For 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:
+To 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.
+Improper 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.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
SBR686C
Precautions for Brake SystemNJBR0002+Recommended fluid is brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
+Be careful not to splash brake fluid on painted areas.
+To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
+Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of the hydraulic system.
+Use flare nut wrench when removing and installing brake
tube.
+Always torque brake lines when installing.
+Burnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings,
or if a soft pedal occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªON-VEHICLE
SERVICEº, BR-8.
WARNING:
+Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
BR-4

Commercial Service ToolsNJBR0004
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-6