Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Almera 2000-2003.2006 Approved Nissan Almera 2001 N16 2001 Nissan Almera UK br
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BRAKE SYSTEM
SECTION BR
CONTENTS
PRECAUTIONS ...............................................................3 Inspection...................................................................18
Supplemental Restraint System (SRS) AIR Assembly ...................................................................18
BAG and SEAT BELT PRE-TENSIONER...............3 Installation..................................................................19
Precautions for Brake System.....................................3 BRAKE BOOSTER........................................................20
Precautions When Working On ABS...........................4 On-vehicle Service.....................................................20
Wiring Diagrams and Trouble Diagnosis.....................4 OPERATING CHECK ...............................................20
PREPARATION ...............................................................5 AIRTIGHT CHECK ...................................................20
Commercial Service Tools ...........................................5 Removal.....................................................................20
NOISE, VIBRATION AND HARSHNESS (NVH) Inspection...................................................................20
TROUBLESHOOTING .....................................................6 OUTPUT ROD LENGTH CHECK ..............................20
NVH Troubleshooting Chart.........................................6 Installation..................................................................21
ON-VEHICLE SERVICE ..................................................7 VACUUM HOSE.............................................................22
Checking Brake Fluid Level.........................................7 Removal and Installation ...........................................22
Checking Brake Line ...................................................7 Inspection...................................................................22
Changing Brake Fluid ..................................................7 HOSES AND CONNECTORS ...................................22
CHECK VALVE ........................................................22
Brake Burnishing Procedure........................................7
VACUUM PUMP ............................................................23
Bleeding Brake System ...............................................8
Removal.....................................................................23
BRAKE HYDRAULIC LINE .............................................9
Installation..................................................................24
Hydraulic Circuit...........................................................9
Inspection...................................................................24
Removal.......................................................................9
Component ................................................................25
Inspection...................................................................10
Disassembly...............................................................25
Installation..................................................................10
Assembly ...................................................................25
DUAL PROPORTIONING VALVE .................................11
FRONT DISC BRAKE ...................................................27
Dual Proportioning Valve ...........................................11
INSPECTION ...........................................................11
Component ................................................................27
REMOVAL AND INSTALLATION (BUILT-IN TYPE) ......11 Pad Replacement ......................................................27
BRAKE PEDAL AND BRACKET..................................12 Removal.....................................................................28
Removal and Installation ...........................................12 Disassembly...............................................................28
Inspection...................................................................12 Inspection...................................................................28
Adjustment .................................................................12 CALIPER .................................................................28
ROTOR ...................................................................29
MASTER CYLINDER (NABCO) ....................................14
Assembly ...................................................................30
Removal.....................................................................14
Installation..................................................................30
Disassembly...............................................................15
REAR DRUM BRAKE ...................................................31
Inspection...................................................................15
Components...............................................................31
Assembly ...................................................................15
Removal.....................................................................31
Installation..................................................................16
Inspection - Wheel Cylinder ......................................32
MASTER CYLINDER [BOSCH (NABCO)] ...................17
Wheel Cylinder Overhaul...........................................33
Removal.....................................................................17
Inspection - Drum ......................................................33
Disassembly...............................................................17
CONTENTS (Cont'd)
Inspection - Lining .....................................................33 DATA MONITOR PROCEDURE ................................61
Installation..................................................................33 ACTIVE TEST PROCEDURE ....................................62
REAR DISC BRAKE (CAM & STRUT TYPE) ..............35 DATA MONITOR MODE ...........................................63
Component ................................................................35 ACTIVE TEST MODE ...............................................63
Pad Replacement ......................................................35 TROUBLE DIAGNOSIS - INTRODUCTION..................64
Removal.....................................................................37 How to Perform Trouble Diagnoses for Quick
Disassembly...............................................................37 and Accurate Repair ..................................................64
INTRODUCTION ......................................................64
Inspection...................................................................38
CALIPER .................................................................38
TROUBLE DIAGNOSIS - BASIC INSPECTION ...........65
ROTOR ...................................................................39 Preliminary Check......................................................65
Assembly ...................................................................39 Ground Circuit Check ................................................68
Installation..................................................................42 ABS ACTUATOR AND ELECTRIC UNIT GROUND.....68
REAR DISC BRAKE (BALL & RAMP TYPE) ..............43 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
Component ................................................................43 ITEMS.............................................................................69
Pad Replacement ......................................................43 Wheel Sensor or Rotor..............................................69
DIAGNOSTIC PROCEDURE .....................................69
Removal.....................................................................45
ABS Actuator Solenoid Valve or Solenoid Valve
Disassembly...............................................................45
Relay..........................................................................72
Inspection...................................................................45
DIAGNOSTIC PROCEDURE .....................................72
CALIPER .................................................................45
ROTOR ...................................................................46
Motor Relay or Motor.................................................75
DIAGNOSTIC PROCEDURE .....................................75
Installation..................................................................46
Low Voltage ...............................................................77
PARKING BRAKE CONTROL ......................................47
DIAGNOSTIC PROCEDURE .....................................77
Components...............................................................47
Control Unit................................................................79
Removal and Installation ...........................................47
DIAGNOSTIC PROCEDURE .....................................79
Inspection...................................................................47
TROUBLE DIAGNOSES FOR SYMPTOMS .................80
Adjustment .................................................................48
1. ABS Works Frequently ..........................................80
2. Unexpected Pedal Action ......................................80
ABS 3. Long Stopping Distance ........................................81
DESCRIPTION ...............................................................49 4. ABS Does Not Work..............................................82
Purpose......................................................................49 5. Pedal Vibration and Noise.....................................83
ABS (Anti-Lock Brake System) Operation ................49 6. ABS Warning Lamp Does Not Come On
ABS Hydraulic Circuit ................................................49 When Ignition Switch Is Turned On...........................84
System Components .................................................50 7. ABS Warning Lamp Stays On When Ignition
System Description....................................................50 Switch Is Turned On ..................................................86
SENSOR .................................................................50 REMOVAL AND INSTALLATION .................................88
CONTROL UNIT ......................................................50 Wheel Sensors ..........................................................88
ABS ACTUATOR AND ELECTRIC UNIT ....................50 ABS Actuator and Electric Unit..................................89
Component Parts and Harness Connector REMOVAL ...............................................................89
Location .....................................................................52 INSTALLATION........................................................89
Schematic ..................................................................53 Sensor Rotor..............................................................90
Wiring Diagram - ABS - .............................................54 REMOVAL ...............................................................90
ON BOARD DIAGNOSTIC SYSTEM INSTALLATION........................................................90
DESCRIPTION ...............................................................58
CONSULT-II ...............................................................58
CONSULT-II APPLICATION TO ABS..........................58
SERVICE DATA AND SPECIFICATIONS (SDS) .........91
ECU (ABS CONTROL UNIT) PART NUMBER General Specifications...............................................91
MODE .....................................................................58 Disc Brake .................................................................91
CONSULT-II Inspection Procedure............................58 Drum Brake................................................................91
SELF-DIAGNOSIS PROCEDURE ..............................58 Brake Pedal ...............................................................92
SELF-DIAGNOSTIC RESULTS MODE.......................60 Parking Brake ............................................................92
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" NJBR0139
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 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 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. SRS wiring harnesses can be identified by yellow harness connector.
Precautions for Brake System NJBR0002
+ 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 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.
WARNING:
+ Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
BR-3
PRECAUTIONS
Precautions When Working On ABS
Precautions When Working On ABS NJBR0140
+ 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 NJBR0003
When you read wiring diagrams, refer to the following:
+ GI-12, "HOW TO READ WIRING DIAGRAMS"
+ EL-10, "POWER SUPPLY ROUTING"
When you perform trouble diagnosis, refer to the following:
+ GI-31, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES"
+ GI-21, "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT"
+ On board self-diagnosis is available everywhere except for Europe.
BR-4
PREPARATION
Commercial Service Tools
Commercial Service Tools NJBR0004
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
X: Applicable
Use the table below to help you find the cause of the symptom. If necessary, repair or replace these parts.
NVH Troubleshooting Chart
tom
Symp-
(Possible cause)
SUSPECTED PARTS
Reference page
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
BRAKE
der
Shimmy, Jud-
Shake
Noise
Linings or pads - damaged BR-27, 33, 35
X
Linings or pads - uneven wear BR-27, 33, 35
X
Return springs damaged BR-31
X
NVH Troubleshooting Chart
Shims damaged BR-27, 35
X
BR-6
Rotor or drum imbalance --
X
X
Rotor or drum damage --
X
Rotor runout BR-29, 39
X
Rotor or drum deformation --
X
Rotor or drum deflection --
X
Rotor or drum rust --
X
Rotor thickness variation BR-29, 39
X
Drum out of round BR-33
X DRIVE SHAFT NVH in FA section
X
X
X AXLE AND SUSPENSION NVH in FA section
X
X TIRES NVH in FA, RA section
X
X
X
ROAD WHEEL NVH in FA section
X
X
X
NJBR0005S01
NJBR0005
STEERING NVH in ST section
X
X
X
ON-VEHICLE SERVICE
Checking Brake Fluid Level
Checking Brake Fluid Level NJBR0006
+ 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.
SBR451D
Checking Brake Line NJBR0007
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 NJBR0008
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.
Brake Burnishing Procedure NJBR0036
Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing drums or rotors, after replac-
ing pads or linings, 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 NJBR0009
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.
SBR995
+ 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 NJBR0010
NBR430
Removal NJBR0011
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 body.
1. Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
BR-9
BRAKE HYDRAULIC LINE
Inspection
2. Cover openings to prevent entrance of air and dirt whenever
disconnecting brake line.
Inspection NJBR0012
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
Installation NJBR0013
CAUTION:
+ Refill with new brake fluid "DOT 4".
+ Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Specification:
Flare nut
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