2003 NISSAN ALMERA N16 boot

Service Data and Specifications (SDS)
DRIVE SHAFT=NJAX0020
Applied modelEngine QG YD22T
Transaxle A/T M/T M/T
Joint typeTransaxle side TS79C GI2300I DS90 + B
Wheel side ZF90 AC2300I BF90
Grease Quality Nissan genuine grease or equivalent*2
Capacity
g(oz)Transaxle side155 - 165
(5.47 - 5.82)125.5 - 135.5
(4.42 - 4.77)145 - 165
(5.11 - 5.82)
Wheel side —*340 - 50
(1.41 - 1.76)100 - 120
(3.53 - 4.23)
Boot length
mm (in)Transaxle side “L
2”101.5 - 103.5
(3.996 - 4.075)98 - 100
(3.86 - 3.94)*197 - 99
(3.82 - 3.90)
Wheel side “L
1”—*394 - 96
(3.70 - 3.78)*184.5 - 96.5
(3.327 - 3.799)
SFA961AA
SFA962A
*1: Fit boot to boot groove in bar shaft
*2: Use grease sachet 39209 BM510 in service for wheel side and 39709 BM500 for transaxle side. (Genuine GKN grease for 20001
joints)
*3: ZF90F type joint assembly cannot be disassembled because a plastic boot and special boot band are used. Do not use other drive
shaft boots. If the boot or joint is damaged, replace the drive shaft assembly.
FRONT AXLE
Service Data and Specifications (SDS)
AX-20

SFA449BB
Install stabilizer bar with ball joint socket properly placed.
ARA027
Check stabilizer for deformation or cracks. Replace if neces-
sary.
Check rubber bushings for deterioration or cracks. Replace if
necessary.
Check ball joint can rotate in all directions. If movement is not
smooth and free, replace stabilizer bar connecting rod.
SFA181A
Transverse Link and Lower Ball Joint
REMOVAL AND INSTALLATIONNJSU00181. Remove wheel bearing lock nut.
2. Remove tie-rod ball joint.
3. Remove strut lower bracket fixing bolts and nuts.
4. Separate drive shaft from knuckle by slightly tapping drive
shaft end.
Cover boots with shop towel so as not to damage them when
removing drive shaft.
SFA113AD
5. Separate lower ball joint stud from knuckle with suitable tool.
Refer to AX-5, “FRONT AXLE — Wheel Hub and Knuckle”.
SSU033
6. Remove fixing bolts.
7. Remove transverse link and lower ball joint.
8. During installation, final tightening must be carried out at curb
weight with tires on the ground.
Tightening torque:
Refer to “FRONT SUSPENSION”, SU-9.
9. After installation, check wheel alignment. Refer to “ON-VE-
HICLE SERVICE — Front Wheel Alignment”, SU-7.
FRONT SUSPENSION
Stabilizer Bar (Cont’d)
SU-12

ComponentNJBR0030
NBR429
1. Main pin
2. Pin boot
3. Torque member fixing bolt
4. Torque member
5. Shim cover
6. Inner shim7. Inner pad
8. Pad retainer
9. Outer pad
10. Outer shim
11. Connecting bolt
12. Copper washer13. Main pin bolt
14. Bleed valve
15. Cylinder body
16. Piston seal
17. Piston
18. Piston boot
Pad ReplacementNJBR0029WARNING:
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 when replacing pads.
If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
It 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.
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 “Brake Burnishing Procedure”, “ON-VEHICLE
SERVICE”, BR-7.
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FRONT DISC BRAKE
Component
BR-27

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

CAUTION:
Use brake fluid to clean. Never use mineral oil.
PistonNJBR0033S0102CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign materials are 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.
Slide Pin, Pin Bolt and Pin BootNJBR0033S0103Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.
ROTORNJBR0033S02Rubbing SurfaceNJBR0033S0201Check rotor for roughness, cracks or chips.
SBR219C
RunoutNJBR0033S02021. Secure rotor to wheel hub with at least two nuts (M12 x 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 AX section
(“Front Wheel Bearing”, “ON-VEHICLE SERVICE”).
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 to wheel hub with
nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can be
found.
4. If the runout is still out of specification, turn rotor with on-car
brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or
equivalent).
ThicknessNJBR0033S0203Thickness variation (At least 8 positions):
Maximum 0.01 mm (0.0004 in)
If thickness variation exceeds the specification, turn rotor with on-
car brake lathe.
Rotor repair limit:
20.0 mm (0.787 in)
GI
MA
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LC
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AX
SU
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FRONT DISC BRAKE
Inspection (Cont’d)
BR-29

SBR574
AssemblyNJBR00341. 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.
SBR980B
InstallationNJBR0035CAUTION:
Refill with new brake fluid “DOT 4”.
Never reuse drained brake fluid.
1. Install brake hose to caliper securely.
2. Install all parts and secure all bolts.
3. Bleed air. Refer to “Bleeding Brake System”, BR-8.
FRONT DISC BRAKE
Assembly
BR-30

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.
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
REAR DISC BRAKE (CAM & STRUT TYPE)
Component
BR-31

Pin and Pin BootNJBR0041S0104Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
SBR219C
ROTORNJBR0041S02Rubbing SurfaceNJBR0041S0201Check rotor for roughness, cracks or chips.
RunoutNJBR0041S02021. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications
before measuring. Refer to AX section (“REAR WHEEL
BEARING”, “On-vehicle Service”).
3. Change relative positions of rotor and wheel hub so that runout
is minimized.
Maximum runout:
0.07 mm (0.0028 in)
ThicknessNJBR0041S0203Rotor repair limit:
Standard thickness
10 mm (0.39 in)
Minimum thickness
9 mm (0.35 in)
Thickness variation (At least 8 portions)
Maximum 0.02 mm (0.0008 in)
SBR247B
AssemblyNJBR00421. Insert cam with depression facing towards open end of cylin-
der.
GI
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LC
EC
FE
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MT
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AX
SU
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BT
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REAR DISC BRAKE (CAM & STRUT TYPE)
Inspection (Cont’d)
BR-35