Nissan Almera Tino V10 (2001 year). Manual

NLBR0005

NVH Troubleshooting Chart

NLBR0005S01

Use the table below to help you find the cause of the symptom. If necessary, repair or replace these parts.

Reference page

BR-24,

—

BR-26,

—

BR-26,

NVH

section

NVH

section

NVH

section

NVH

section

NVH

section

SUSPECTED PARTS
(Possible cause)

Pads

damaged

Pads

uneven

wear

Shims

damaged

Rotor

imbalance

Rotor

damage

Rotor

runout

Rotor

deformation

Rotor

deflection

Rotor

rust

Rotor

thickness

variation

DRIVE

SHAFT

AXLE

AND

SUSPENSION

TIRES

ROAD

WHEEL

STEERING

Symptom BRAKE

Noise

Shake

Shimmy, Jud-
der

X: Applicable

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

BR-6

NBR376

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.

SBR389C

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.

Check for oil leakage by fully depressing brake pedal while
engine is running.

SBR419C

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.

Clean inside of reservoir tank, and refill with new brake fluid.

Connect a vinyl tube to each air bleeder valve.

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.

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).

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.

To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.

Repeat steps 1 to 3, 10 times or more to complete the burnish-
ing procedure.

NBR357

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.

SBR419C

Bleed air in the following order.
Right rear brake

→

Left front brake

→

Left rear brake

→

Right

front brake

Connect a transparent vinyl tube to air bleeder valve.

Fully depress brake pedal several times.

With brake pedal depressed, open air bleeder valve to release
air.

Close air bleeder valve.

Release brake pedal slowly.

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 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.

Remove flare nut connecting brake tube and hose, then with-
draw lock spring.

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.

BRAKE HYDRAULIC LINE

Hydraulic Circuit

BR-9

SBR686C

Installation

NLBR0013

CAUTION:

Refill with new brake fluid “DOT 4”.

Never reuse drained brake fluid.

Tighten all flare nuts and connecting bolts.

Specification:

Flare nut

15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

Connecting bolt

17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)

Refill until new brake fluid comes out of each air bleeder valve.

Bleed air. Refer to “Bleeding Brake System”, BR-8, and ‘‘Air
Bleeding Procedure’’, CL-10.

BRAKE HYDRAULIC LINE

Installation

BR-10

Removal and Installation

NLBR0015

NBR359

SBR997

Inspection

NLBR0016

Check brake pedal for following items.

Brake pedal bend

Clevis pin deformation

Crack of any welded portion

Crack or deformation of clevis pin stopper

SBR657EA

Adjustment

NLBR0017

Check brake pedal free height from metal panel. Adjust if neces-
sary.

H: Free height

Refer to SDS, BR-93.

, C

: Clearance between pedal stopper and threaded

end of stop lamp switch and brake switch.

0.75 - 2.00 mm (0.0295 - 0.0787 in)

D: Depressed height
LHD/RHD (M/T): 60 -70 (2.36 - 2.76 in)
LHD/RHD (CVT): 69 -79 (2.72 - 3.11 in)

Under force of 490 N (50 kg, 110 lb) with engine run-
ning.

A: Pedal free play at pedal pad

1.0 - 3.0 mm (0.039 - 0.118 in)

BRAKE PEDAL AND BRACKET

Removal and Installation

BR-11

Removal

NLBR0117

NBR360

Reservoir cap

Filter

Reservoir tank

Adapter

Elastic pin

Seal

Washer

Circlip

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.

Drain brake fluid from each front caliper air bleeder valve,
depressing brake pedal to empty fluid from master cylinder.

Remove brake pipe flare nuts.

Disconnect hoses from adapter.

Remove master cylinder mounting nuts.

NBR361

Disassembly

NLBR0118

Drive out elastic pin from cylinder body.

Remove adapter, washer and seals.

MASTER CYLINDER

Removal

BR-13

NBR353

Remove the circlip with suitable pliers while piston is pushed
into cylinder.

SBR232E

Remove piston stopper pin while piston is pushed into cylinder.

Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.

Inspection

NLBR0119

Check for the following items.
Replace any part if damaged.
Master cylinder:

Pin holes or scratches on inner wall.

Piston:

Deformation or scratches on piston cups.

SBR233E

Assembly

NLBR0120

Insert secondary piston assembly. Then insert primary piston
assembly.

Pay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body.

SBR232E

Install piston stopper pin while piston is pushed into cylinder.
Then secure the primary and secondary piston assemblies
with new circlip.

Insert washer and push reservoir seals and adapter into cylin-
der body.

Install elastic pin.

MASTER CYLINDER

Disassembly (Cont’d)

BR-14

Installation

NLBR0121

CAUTION:

Refill with new brake fluid “DOT 4”.

Never reuse drained brake fluid.

Place master cylinder onto brake booster and secure mount-
ing nuts lightly.

Torque mounting nuts.

: 13 - 15 N·m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)

NBR363

NBR364

Check hoses for damage. If the hoses show cracks or damage,
replace the hose.

Insert the dot (coloured) mark hoses to the primary - and sec-
ondary inlet ports adapter. Then secure it with clamps.

Hose marking

Booster model

M215T

S255

Primary-inlet port

White dot

Blue dot

Secondary-inlet port

Yellow dot

Green dot

NBR362

Fill up reservoir tank with new brake fluid.

Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.

Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.

Fit brake lines to master cylinder.

Tighten flare nuts.

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

10. Bleed air procedure from brake and clutch system. Refer to

“Bleeding Brake System”, BR-8 and “Air Bleeding Procedure”,
CL-10.

MASTER CYLINDER

Installation

BR-15

SBR002A

On-vehicle Service

NLBR0023

OPERATING CHECK

NLBR0023S01

Stop engine and depress brake pedal several times. Check
that pedal stroke does not change.

Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.

SBR365AA

AIRTIGHT CHECK

NLBR0023S02

Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. The pedal should go further
down at the first time, and then it should gradually rise there-
after.

Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change
after holding pedal down for 30 seconds.

SBR232CB

Removal

NLBR0024

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.

Be careful not to deform or bend brake pipes, during
booster removal.

SBR208E

Inspection

NLBR0025

OUTPUT ROD LENGTH CHECK

NLBR0025S01

Apply vacuum of −66.7 kPa (−667 mbar, −500 mmHg, −19.69
inHg) to brake booster with a handy vacuum pump.

Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.

Check output rod length.

Specified length:

10.275 - 10.525 mm (0.4045 - 0.4144 in)

BRAKE BOOSTER

On-vehicle Service

BR-16

Installation

NLBR0026

CAUTION:

Be careful not to deform or bend brake pipes, during
booster installation.

Replace clevis pin if damaged.

Refill with new brake fluid “DOT 4”.

Never reuse drained brake fluid.

Take care not to damage brake booster mounting bolt
thread during installation. Due to the acute angle of
installation, the threads can be damaged with the dash
panel.

SBR237EA

Before fitting booster, temporarily adjust clevis to dimension
shown.

Fit booster, then secure mounting nuts (brake pedal bracket to
master cylinder) lightly.

Connect brake pedal and booster input rod with clevis pin.

Secure mounting nuts.

Specification:

13 - 16 N·m (1.3 - 1.6 kg-m, 9 - 12 ft-lb)

Install master cylinder. Refer to “Installation” in “MASTER
CYLINDER”, BR-15.

Bleed air. Refer to “Bleeding Brake System”, BR-8 and “Air
Bleeding Procedure”, CL-10.

BRAKE BOOSTER

Installation

BR-17

Removal

NLBR0123

SBR631E

Remove parts shown below.

Air duct, air cleaner case (upper)

Engine cover

Rocker cover

Exhaust manifold cover

EGR tube

Disconnect vacuum hose from vacuum pump.

Remove cylinder head rear cover plate.

Use a tool such as seal cutter (SST) to remove.

Loosen and remove rear cam sprocket installation bolts.

Camshaft should not be attached. Using engine inner
resistance, loosen installation bolts.

SBR632E

Remove vacuum pump and cylinder head rear cover assem-
bly.

Remove and install vacuum pump, sprocket, drive chain, and
chain guide as an assembly.

Loosen mounting bolts in the reverse order of the numbers
shown in the figure to the left.

Remove only bolts that are shown in the figure. (Be especially
careful not to remove M6 bolts on the vacuum pump.)

Use a tool such as a seal cutter (SST).

VACUUM PUMP

Removal

BR-20

Nissan Almera Tino V10 (2001 year). Manual - part 16