2003 NISSAN ALMERA N16 torque

SBR976B
SBR932C
1. Remove master cylinder reservoir cap.
2. Remove pin bolt.
3. Open cylinder body upward. Then remove pad with retainers,
inner and outer shims.
Standard pad thickness:
11 m m ( 0 . 4 3 i n )
Pad wear limit:
2.0mm(0.079in)
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
SBR979B
RemovalNJBR0031WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for dis-
assembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not to stretch brake
hose.
SBR772
DisassemblyNJBR0032WARNING:
Do not place your fingers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
1. Push out piston with piston boot with compressed air.
2. Remove piston seal with a suitable tool.
InspectionNJBR0033CALIPERNJBR0033S01Cylinder BodyNJBR0033S0101Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
Minor damage from rust or foreign materials may be eliminated
by polishing surface with a fine emery paper. Replace cylinder
body if necessary.
FRONT DISC BRAKE
Pad Replacement (Cont’d)
BR-28

ComponentNJBR0038
SBR753E
1. Cable guide
2. Cylinder
3. Toggle lever
4. Pin
5. Pin boot
6. Torque member
7. Inner shim
8. Inner pad
9. Pad retainer
10. Outer pad11. Outer shim
12. Strut
13. O-ring
14. Push rod
15. Key plate
16. Retaining washer
17. Spring
18. Spring cover
19. Snap ring B
20. Piston seal21. Snap ring A
22. Washer
23. Wave washer
24. Washer
25. Bearing
26. Adjuster
27. Cup
28. Piston
29. Piston boot
Pad ReplacementNJBR0037WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
When cylinder body is open, do not depress brake pedal
because piston will pop out.
Be careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
If shims are rusted or show peeling of rubber coat, replace
them with new shims.
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REAR DISC BRAKE (CAM & STRUT TYPE)
Component
BR-31

SBR307E
8. As shown in the figure, align the piston’s concave to the pad’s
convex, then install the cylinder body to the torque member.
9. Install brake cable, brake cable mounting bolt, lock spring and
master cylinder reservoir cap.
NBR167
RemovalNJBR0039WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
1. Remove brake cable mounting bolt and lock spring.
2. Release parking brake control lever, then disconnect cable
from the caliper.
3. Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for dis-
assembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not to stretch brake
hose.
SBR646
DisassemblyNJBR00401. Remove piston by turning it counterclockwise with long nose
pliers or suitable tool.
SBR889
2. Pry off ring A from piston with suitable pliers and remove
adjusting nut.
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REAR DISC BRAKE (CAM & STRUT TYPE)
Pad Replacement (Cont’d)
BR-33

SBR088B
3. Disassemble cylinder body.
a. Pry off ring B with suitable pliers, then remove spring cover,
spring and seat.
b. Remove washer, key plate, push rod, O-ring and strut.
SBR656
c. Remove piston seal.
Be careful not to damage cylinder body.
SBR767E
4. Remove return spring, toggle lever and cable guide.
InspectionNJBR0041CALIPERNJBR0041S01CAUTION:
Use brake fluid to clean cylinder. Never use mineral oil.
Cylinder BodyNJBR0041S0101Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
Minor damage from rust or foreign materials may be eliminated
by polishing surface with a fine emery paper.
Replace cylinder body if necessary.
Torque MemberNJBR0041S0102Check for wear, cracks or other damage. Replace if necessary.
PistonNJBR0041S0103CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign matter is stuck to sliding surface.
Check piston for score, rust, wear, damage or presence of foreign
materials.
Replace if any of the above conditions are observed.
REAR DISC BRAKE (CAM & STRUT TYPE)
Disassembly (Cont’d)
BR-34

SBR307E
InstallationNJBR0043CAUTION:
Refill with new brake fluid “DOT 4”.
Never reuse drained brake fluid.
1. Install caliper assembly.
As shown in the figure, align the piston’s concave to the pad’s
convex, then install the cylinder body to the torque member.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to “Bleeding Brake System”, BR-8.
REAR DISC BRAKE (CAM & STRUT TYPE)
Installation
BR-38

ComponentNJBR0141
NBR422
1. Cylinder body
2. Pin
3. Pin boot4. Torque member
5. Inner shim
6. Inner pad7. Outer pad
8. Outer shim
NOTE:
The cylinder body cannot be disassembled.
Pad ReplacementNJBR0142WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
When cylinder body is open, do not depress brake pedal
because piston will pop out.
Be careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
If shims are rusted or show peeling of rubber coat, replace
them with new shims.
It is not necessary to remove connecting bolt except for
replacement of caliper assembly. In this case, suspend
cylinder body with wire so as not to stretch brake hose.
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.
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REAR DISC BRAKE (BALL & RAMP TYPE)
Component
BR-39

NBR423
1. Remove master cylinder reservoir cap.
2. Remove brake cable lock spring.
3. Release parking brake control lever, then disconnect cable
from the caliper.
4. Remove upper pin bolt.
NBR426
5. Open cylinder body downward. Then remove pads inner and
outer shims.
Standard pad thickness:
9.3mm(0.366in)
Pad wear limit:
2.0mm(0.079in)
SBR641
6. When installing new pads, push piston into cylinder body by
gently turning piston clockwise, as shown.
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
NBR374
7. Adjust the piston to the right angle as shown in the figure.
NBR375
8. As shown in the figure, align the piston’s concave to the pad’s
convex, then install the cylinder body to the torque member.
9. Install brake cable, brake cable mounting bolt, lock spring and
master cylinder reservoir cap.
REAR DISC BRAKE (BALL & RAMP TYPE)
Pad Replacement (Cont’d)
BR-40

NBR427
RemovalNJBR0143WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
1. Remove brake cable lock spring.
2. Release parking brake control lever, then disconnect cable
from the caliper.
3. Remove torque member fixing bolts and connecting bolt.
4. Remove brake hose connecting bolt.
5. Plug off the brake hose and cylinder body to prevent air enter-
ing the system.
CAUTION:
Care should be taken as not to let:
Air enter the cylinder body and brake hose.
Brake fluid spill from the cylinder body and brake hose.
DisassemblyNJBR0144Remove pin bolts and pins.
NOTE:
Cylinder body can not be disassembled.
InspectionNJBR0145CALIPERNJBR0145S01CAUTION:
Do not drain any brake fluid from cylinder body. Cylinder body
can not be disassembled.
Cylinder BodyNJBR0145S0101Check cylinder body for score, rust, wear, damage or presence of
foreign materials. If any of the above conditions are observed,
replace cylinder body.
Torque MemberNJBR0145S0102Check for wear, cracks or other damage. Replace if necessary.
Pin and Pin BootNJBR0145S0104Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
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REAR DISC BRAKE (BALL & RAMP TYPE)
Removal
BR-41