Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Almera 2000-2003.2006 Approved Nissan Almera 2002 Tino br
<< Back | HomeMost service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.
Image preview - the first page of the document
>> Download br documenatation <<
Text preview - extract from the document
BRAKE SYSTEM
SECTION BR
CONTENTS
PRECAUTIONS ...............................................................3 Installation..................................................................17
Supplemental Restraint System (SRS) AIR VACUUM HOSE.............................................................18
BAG and SEAT BELT PRE-TENSIONER...............3 Removal and Installation ...........................................18
Precautions for Brake System.....................................3 Inspection...................................................................19
Precautions When Working On ABS...........................4 HOSES AND CONNECTORS ...................................19
Wiring Diagrams and Trouble Diagnosis.....................4 CHECK VALVE ........................................................19
PREPARATION ...............................................................5 VACUUM PUMP ............................................................20
Commercial Service Tools ...........................................5 Removal.....................................................................20
NOISE, VIBRATION AND HARSHNESS (NVH) Installation..................................................................21
TROUBLESHOOTING .....................................................6 Inspection...................................................................21
NVH Troubleshooting Chart.........................................6 Component ................................................................22
ON-VEHICLE SERVICE ..................................................7 Disassembly...............................................................22
Checking Brake Fluid Level.........................................7 Assembly ...................................................................22
Checking Brake Line ...................................................7 FRONT DISC BRAKE ...................................................24
Changing Brake Fluid ..................................................7 Component ................................................................24
Brake Burnishing Procedure........................................7 Pad Replacement ......................................................24
Bleeding Brake System ...............................................8 Removal.....................................................................25
BRAKE HYDRAULIC LINE .............................................9 Disassembly...............................................................25
Hydraulic Circuit...........................................................9 Inspection...................................................................25
Removal.......................................................................9 CALIPER .................................................................25
Inspection.....................................................................9 ROTOR ...................................................................26
Installation..................................................................10 Assembly ...................................................................27
BRAKE PEDAL AND BRACKET..................................11 Installation..................................................................27
Removal and Installation ...........................................11 REAR DISC BRAKE (CAM & STRUT TYPE) ..............28
Inspection...................................................................11 Component ................................................................28
Adjustment .................................................................11 Pad Replacement ......................................................28
MASTER CYLINDER.....................................................13 Removal.....................................................................30
Removal.....................................................................13 Disassembly...............................................................30
Disassembly...............................................................13 Inspection...................................................................31
CALIPER .................................................................31
Inspection...................................................................14
ROTOR ...................................................................32
Assembly ...................................................................14
Assembly ...................................................................32
Installation..................................................................15
Installation..................................................................35
BRAKE BOOSTER........................................................16
REAR DISC BRAKE (BALL & RAMP TYPE) ..............36
On-vehicle Service.....................................................16
Component ................................................................36
OPERATING CHECK ...............................................16
AIRTIGHT CHECK ...................................................16
Pad Replacement ......................................................36
Removal.....................................................................16 Removal.....................................................................38
Inspection...................................................................16 Disassembly...............................................................38
OUTPUT ROD LENGTH CHECK ..............................16 Inspection...................................................................38
CONTENTS (Cont'd)
CALIPER .................................................................38 ACTIVE TEST MODE ...............................................63
ROTOR ...................................................................39 TROUBLE DIAGNOSIS - INTRODUCTION..................64
Installation..................................................................39 How to Perform Trouble Diagnoses for Quick
PARKING BRAKE CONTROL ......................................40 and Accurate Repair ..................................................64
Components...............................................................40 INTRODUCTION ......................................................64
Removal and Installation ...........................................40 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........65
Inspection...................................................................40 Preliminary Check......................................................65
Adjustment .................................................................41 Ground Circuit Check ................................................68
ABS ACTUATOR AND ELECTRIC UNIT GROUND.....68
ABS TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION ...............................................................69
DESCRIPTION ...............................................................42 Malfunction Code/Symptom Chart.............................69
Purpose......................................................................42 MODELS WITH SELF-DIAGNOSIS FUNCTION
ABS (Anti-Lock Brake System) Operation ................42 (DATA LINK CONNECTOR TERMINAL NO. 9)...........69
ABS Hydraulic Circuit ................................................42 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
System Components .................................................43 ITEMS.............................................................................71
System Description....................................................43 Wheel Sensor or Rotor..............................................71
SENSOR .................................................................43 DIAGNOSTIC PROCEDURE .....................................71
CONTROL UNIT ......................................................43 ABS Actuator Solenoid Valve or Solenoid Valve
ABS ACTUATOR AND ELECTRIC UNIT ....................43 Relay..........................................................................74
Component Parts and Harness Connector DIAGNOSTIC PROCEDURE .....................................74
Location .....................................................................45 Motor Relay or Motor.................................................77
Schematic ..................................................................46 DIAGNOSTIC PROCEDURE .....................................77
MODELS WITH SELF-DIAGNOSIS FUNCTION Low Voltage ...............................................................79
(DATA LINK CONNECTOR TERMINAL NO. 9)...........46 DIAGNOSTIC PROCEDURE .....................................79
MODELS WITHOUT SELF-DIAGNOSIS Control Unit................................................................81
FUNCTION (DATA LINK CONNECTOR TERMINAL DIAGNOSTIC PROCEDURE .....................................81
NO. 9) .....................................................................47 TROUBLE DIAGNOSES FOR SYMPTOMS .................82
Wiring Diagram - ABS - .............................................48 1. ABS Works Frequently ..........................................82
MODELS WITH SELF-DIAGNOSIS FUNCTION
2. Unexpected Pedal Action ......................................82
(DATA LINK CONNECTOR TERMINAL NO. 9)...........48
3. Long Stopping Distance ........................................83
MODELS WITHOUT SELF-DIAGNOSIS
FUNCTION (DATA LINK CONNECTOR TERMINAL
4. ABS Does Not Work..............................................84
NO. 9) .....................................................................52 5. Pedal Vibration and Noise.....................................85
ON BOARD DIAGNOSTIC SYSTEM 6. ABS Warning Lamp Does Not Come On
DESCRIPTION ...............................................................56 When Ignition Switch Is Turned On...........................86
Self-diagnosis (Only models with data link 7. ABS Warning Lamp Stays On When Ignition
connector terminal No. 9) ..........................................56 Switch Is Turned On ..................................................88
FUNCTION ..............................................................56 REMOVAL AND INSTALLATION .................................90
SELF-DIAGNOSIS PROCEDURE ..............................56 Wheel Sensors ..........................................................90
HOW TO READ SELF-DIAGNOSTIC RESULTS ABS Actuator and Electric Unit..................................91
(MALFUNCTION CODES) ........................................57 REMOVAL ...............................................................91
HOW TO ERASE SELF-DIAGNOSTIC RESULTS INSTALLATION........................................................91
(MALFUNCTION CODES) ........................................57 Sensor Rotor..............................................................92
CONSULT-II ...............................................................58 REMOVAL ...............................................................92
CONSULT-II APPLICATION TO ABS..........................58 INSTALLATION........................................................92
ECU (ABS CONTROL UNIT) PART NUMBER
MODE .....................................................................58
CONSULT-II Inspection Procedure............................58 SERVICE DATA AND SPECIFICATIONS (SDS) .........93
SELF-DIAGNOSIS PROCEDURE ..............................58 General Specifications...............................................93
SELF-DIAGNOSTIC RESULTS MODE.......................60 Disc Brake .................................................................93
DATA MONITOR PROCEDURE ................................61 Brake Pedal ...............................................................93
ACTIVE TEST PROCEDURE ....................................62 Parking Brake ............................................................93
DATA MONITOR MODE ...........................................63
BR-2
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER" NLBR0081
The 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 the RS section of 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.
Precautions for Brake System NLBR0002
+ 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.
SBR686C
+ 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.
BR-3
PRECAUTIONS
Precautions When Working On ABS
Precautions When Working On ABS NLBR0149
+ Use recommended tyres in combination with ABS.
+ Please fit tyres or studded tyres, etc. with the same size.
+ If different sizes of tyres, or tyres other than the ones rec-
ommended for use with the ABS, are fitted, stopping dis-
tance will increase and control and stability could deterio-
rate.
+ When changing brake pads, please use Nissan genuine
parts.
+ When fitting radios etc, do not position the radio itself,
antenna, or antenna cables within an area of about 100
mm (3.94 in) of the control unit.
+ When doing any work that requires electro-welding, first
remove the control unit.
+ Please take care when taking a power supply for the
audio, lamps etc., not to take this from any ABS-related
harness. (Please refer to the electrical wiring diagrams for
ABS-related harnesses)
Wiring Diagrams and Trouble Diagnosis NLBR0003
When you read wiring diagrams, refer to the following:
+ GI-11, "HOW TO READ WIRING DIAGRAMS"
+ EL-10, "POWER SUPPLY ROUTING"
When you perform trouble diagnosis, refer to the following:
+ GI-32, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS"
+ GI-21, "HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT"
BR-4
PREPARATION
Commercial Service Tools
Commercial Service Tools NLBR0004
Tool name Description
1 Flare nut crowfoot Removing and installing each brake piping
2 Torque wrench a: 10 mm (0.39 in)
NT360
Brake fluid pressure Measuring brake fluid pressure
gauge
NT151
BR-5
NLBR0005
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
NVH Troubleshooting Chart NLBR0005S01
Use the table below to help you find the cause of the symptom. If necessary, repair or replace these parts.
NVH in FA, RA section
NVH in ST section
NVH in FA section
NVH in FA section
NVH in FA section
BR-24, 28
BR-24, 28
BR-24, 28
BR-26, 32
BR-26, 32
--
--
--
--
--
Reference page
AXLE AND SUSPENSION
Rotor thickness variation
Pads - uneven wear
Rotor deformation
Pads - damaged
Rotor imbalance
Shims damaged
Rotor deflection
SUSPECTED PARTS
ROAD WHEEL
DRIVE SHAFT
Rotor damage
(Possible cause)
Rotor runout
STEERING
Rotor rust
TIRES
Noise X X X X X X X X
Shake X X X X X X
Symptom BRAKE
Shimmy, Jud-
X X X X X X X X X X X
der
X: Applicable
BR-6
ON-VEHICLE SERVICE
Checking Brake Fluid Level
Checking Brake Fluid Level NLBR0006
+ 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.
NBR376
Checking Brake Line NLBR0007
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.
SBR389C
Changing Brake Fluid NLBR0008
CAUTION:
+ 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.
SBR419C
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 Procedure NLBR0036
Burnish 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
BR-7
ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont'd)
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.
Bleeding Brake System NLBR0009
CAUTION:
+ 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.
NBR357
+ 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
SBR419C air bleeder valve.
BR-8
BRAKE HYDRAULIC LINE
Hydraulic Circuit
Hydraulic Circuit NLBR0010
NBR358
Removal NLBR0011
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.
+ 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.
Inspection NLBR0012
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
BR-9
BRAKE HYDRAULIC LINE
Installation
Installation NLBR0013
CAUTION:
+ Refill with new brake fluid "DOT 4".
+ Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Specification:
Flare nut
15 - 18 N◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo