2001 NISSAN ALMERA TINO brake fluid

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS...............................................................3
Supplemental Restraint System (SRS)″AIR
BAG″and″SEAT BELT PRE-TENSIONER″...............3
Precautions for Brake System .....................................3
Precautions When Working On ABS ...........................4
Wiring Diagrams and Trouble Diagnosis .....................4
PREPARATION...............................................................5
Commercial Service Tools ...........................................5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................6
NVH Troubleshooting Chart.........................................6
ON-VEHICLE SERVICE..................................................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
Hydraulic Circuit...........................................................9
Removal .......................................................................9
Inspection.....................................................................9
Installation ..................................................................10
BRAKE PEDAL AND BRACKET.................................. 11
Removal and Installation ........................................... 11
Inspection................................................................... 11
Adjustment ................................................................. 11
MASTER CYLINDER.....................................................13
Removal .....................................................................13
Disassembly...............................................................13
Inspection...................................................................14
Assembly ...................................................................14
Installation ..................................................................15
BRAKE BOOSTER........................................................16
On-vehicle Service.....................................................16
OPERATING CHECK...............................................16
AIRTIGHT CHECK...................................................16
Removal .....................................................................16
Inspection...................................................................16
OUTPUT ROD LENGTH CHECK..............................16Installation ..................................................................17
VACUUM HOSE.............................................................18
Removal and Installation ...........................................18
Inspection...................................................................19
HOSES AND CONNECTORS...................................19
CHECK VALVE........................................................19
VACUUM PUMP............................................................20
Removal .....................................................................20
Installation ..................................................................21
Inspection...................................................................21
Component ................................................................22
Disassembly...............................................................22
Assembly ...................................................................22
FRONT DISC BRAKE...................................................24
Component ................................................................24
Pad Replacement ......................................................24
Removal .....................................................................25
Disassembly...............................................................25
Inspection...................................................................25
CALIPER.................................................................25
ROTOR...................................................................26
Assembly ...................................................................27
Installation ..................................................................27
REAR DISC BRAKE (CAM & STRUT TYPE)..............28
Component ................................................................28
Pad Replacement ......................................................28
Removal .....................................................................30
Disassembly...............................................................30
Inspection...................................................................31
CALIPER.................................................................31
ROTOR...................................................................32
Assembly ...................................................................32
Installation ..................................................................35
REAR DISC BRAKE (BALL & RAMP TYPE)..............36
Component ................................................................36
Pad Replacement ......................................................36
Removal .....................................................................38
Disassembly...............................................................38
Inspection...................................................................38

Supplemental Restraint System (SRS)“AIR
BAG”and“SEAT BELT PRE-TENSIONER”
NLBR0081The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” 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 V10 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. 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.
SBR686C
Precautions for Brake SystemNLBR0002+Recommended fluid is brake fluid“DOT 4”.
+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 rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to“Brake Burnishing Procedure”,“ON-VEHICLE
SERVICE”, BR-7.
WARNING:
+Clean brake pads with a waste cloth, then wipe with a dust
collector.
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
BR-3

Commercial Service ToolsNLBR0004
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-5

NBR376
Checking Brake Fluid LevelNLBR0006+Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
+If fluid level is extremely low, check brake system for leaks.
+Release parking brake lever and see if brake warning lamp
goes off. If not, check brake system for leaks.
SBR389C
Checking Brake LineNLBR0007CAUTION:
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.
SBR419C
Changing Brake FluidNLBR0008CAUTION:
+Refill with new brake fluid“DOT 4”.
+Always keep fluid level higher than minimum line on res-
ervoir tank.
+Never reuse drained brake fluid.
+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.
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 minimum
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“Bleeding Brake System”, BR-8 and“Air
Bleeding Procedure”, CL-10.
Brake Burnishing ProcedureNLBR0036Burnish the brake contact surfaces according to the following pro-
cedure 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).
2. Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
ON-VEHICLE SERVICE
Checking Brake Fluid Level
BR-7

pressure such that vehicle stopping time equals 3 to 5 sec-
onds.
3. To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnish-
ing procedure.
NBR357
Bleeding Brake SystemNLBR0009CAUTION:
+Carefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
+Fill reservoir with new brake fluid“DOT 4”. Make sure it is
full at all times while bleeding air out of system.
+Place a container under master cylinder to avoid spillage
of brake fluid.
+For models with ABS, turn ignition switch OFF and dis-
connect ABS actuator connectors or battery ground cable.
SBR419C
+Bleed air in the following order.
Right rear brake→Left front brake→Left rear brake→Right
front brake
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to release
air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2. through 5. until clear brake fluid comes out of
air bleeder valve.
ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont’d)
BR-8

Hydraulic CircuitNLBR0010
NBR358
RemovalNLBR0011CAUTION:
+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.
+All hoses must be free from excessive bending, twisting
and pulling.
+For ball & ramp type rear caliper, care should be taken as
not to let air enter the cylinder body.
1. Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
2. Cover openings to prevent entrance of air and dirt whenever
disconnecting brake line.
InspectionNLBR0012Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
BRAKE HYDRAULIC LINE
Hydraulic Circuit
BR-9

SBR686C
InstallationNLBR0013CAUTION:
+Refill with new brake fluid“DOT 4”.
+Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Specification:
Flare nut
15-18N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Connecting bolt
17-20N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
2. Refill until new brake fluid comes out of each air bleeder valve.
3. Bleed air. Refer to“Bleeding Brake System”, BR-8, and‘‘Air
Bleeding Procedure’’, CL-10.
BRAKE HYDRAULIC LINE
Installation
BR-10

RemovalNLBR0117
NBR360
1. Reservoir cap
2. Filter
3. Reservoir tank
4. Adapter5. Elastic pin
6. Seal
7. Washer
8. Circlip9. Piston stopper pin
10. Primary piston assembly
11. Secondary piston assembly
12. Cylinder body
CAUTION:
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.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each front caliper air bleeder valve,
depressing brake pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Disconnect hoses from adapter.
5. Remove master cylinder mounting nuts.
NBR361
DisassemblyNLBR01181. Drive out elastic pin from cylinder body.
2. Remove adapter, washer and seals.
MASTER CYLINDER
Removal
BR-13