Content .. 15 16 17 18 ..

Nissan Almera Tino V10 (2001 year). Manual - part 17

SBR633E

Installation

NLBR0124

Assemble vacuum pump and cylinder head rear cover
assembly, referring to “Component” in the next page.

Install vacuum pump and cylinder head rear cover assembly to
cylinder head.

Apply ThreeBond 1207C (KP510 00150) without breaks to the
location shown in the figure to the left.

SBR632E

Tighten the mounting bolts in the numerical order shown by the
figure to the left.

Install rear cam sprocket installation bolts.

Remove sprocket retaining two M6 bolts.

M6 bolts will be used for installation.

Tighten rear cam sprocket installation bolts.

Camshaft should not be fixed. Using engine inner resistance,
tighten installation bolts.

SBR634E

Install cylinder head rear cover plate.

Apply ThreeBond 1207C (KP510 00150) without breaks to the
location shown by the figure to the left.

Install parts in the reverse order of removal.

CAUTION:

If the engine is started with vacuum pump released (vacuum
hose disconnected), it causes increase of blowby gas amount,
and engine damage may result. When starting the engine, be
sure to close vacuum circuit.

SBR611E

Inspection

NLBR0125

Remove vacuum hose. Then, connect vacuum gauge with
three-way connector.

Install three-way connector to the area where vacuum pump
negative pressure can be directly measured. (The figure
shown an example.)

Start the engine, then measure negative pressure.

Standard: −86.6 to −101.3 kPa (−866 to −1,013 mbar,
−650 to −760 mmHg, −25.59 to −29.92 inHg)

If it is not within standard, inspect for suction of air in the middle
of route and measure it again.

If it is still not within standard value, replace the vacuum pump.

VACUUM PUMP

Installation

BR-21

Component

NLBR0126

SBR612E

SBR613E

Disassembly

NLBR0136

Disassemble the components, referring to the “Component”, then
remove vacuum pump.

CAUTION:

Do not disassemble vacuum pump. (Do not loosen three M6
bolts.)

Assembly

NLBR0127

Install all parts to cylinder head rear cover as follows.
1.

Install vacuum pump.

Install chain guide temporarily.

Adjust the chain guide position by the method explained in step
5.

SBR614E

Install rear cam sprocket.

Installation direction of sprocket is not specified.

Insert 2 thickness gauges [3.0 mm (0.118 in)] between cover
and rear cam sprocket (shown in the figure). Insert 2 bolts [M6,
thread length: 35 - 40 mm (1.38 - 1.57 in)] into sprocket to
retain it to cover.

Use thickness gauges [3.0 mm (0.118 in)] for chain alignment
between vacuum pump sprocket and cam sprocket.

Attach drive chain to rear cam sprocket and vacuum pump
sprocket.

Tighten chain guide installation bolt while pressing chain guide

VACUUM PUMP

Component

BR-22

lightly [approximately 9.8 N (1.0 kg, 2.2 lb)].

Remove thickness gauges (2).

Leave sprocket retaining bolts (M6) until installation.

VACUUM PUMP

Assembly (Cont’d)

BR-23

Component

NLBR0030

NBR365

Main pin

Pin boot

Torque member fixing bolt

Torque member

Inner shim

Inner pad

Pad retainer

Outer pad

Outer shim

10. Connecting bolt
11. Copper washer
12. Main pin bolt

13. Bleed valve
14. Cylinder body
15. Piston seal
16. Piston
17. Piston boot

Pad Replacement

NLBR0029

WARNING:

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 rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE
SERVICE”, BR-7.

FRONT DISC BRAKE

Component

BR-24

SBR976B

SBR932C

Remove master cylinder reservoir cap.

Remove pin bolt.

Open cylinder body upward. Then remove pad with retainers,
inner and outer shims.

Standard pad thickness:

11 mm (0.43 in)

Pad wear limit:

2.0 mm (0.079 in)

Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.

SBR979B

Removal

NLBR0031

WARNING:

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

Disassembly

NLBR0032

WARNING:

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.

Remove piston seal with a suitable tool.

Inspection

NLBR0033

CALIPER

NLBR0033S01

Cylinder Body

NLBR0033S0101

Check 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.

CAUTION:

Use brake fluid to clean. Never use mineral oil.

FRONT DISC BRAKE

Pad Replacement (Cont’d)

BR-25

Piston

NLBR0033S0102

CAUTION:

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 Boot

NLBR0033S0103

Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.

ROTOR

NLBR0033S02

Rubbing Surface

NLBR0033S0201

Check rotor for roughness, cracks or chips.

SBR219C

Runout

NLBR0033S0202

Secure rotor to wheel hub with at least two nuts (M12 x 1.25).

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:

0.08 mm (0.0031 in)

If the runout is out of specification, find minimum runout posi-
tion as follows:

Remove nuts and rotor from wheel hub.

Shift the rotor one hole and secure rotor to wheel hub with
nuts.

Measure runout.

Repeat steps a. to c. so that minimum runout position can be
found.

If the runout is still out of specification, turn rotor with on-car
brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or
equivalent).

Thickness

NLBR0033S0203

Thickness variation (At least 8 positions):

Maximum 0.02 mm (0.0008 in)

If thickness variation exceeds the specification, turn rotor with on-
car brake lathe.

Rotor repair limit:

26.0 mm (1.024 in)

FRONT DISC BRAKE

Inspection (Cont’d)

BR-26

SBR574

Assembly

NLBR0034

Insert piston seal into groove on cylinder body.

With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.

Properly secure piston boot.

SBR980B

Installation

NLBR0035

CAUTION:

Refill with new brake fluid “DOT 4”.

Never reuse drained brake fluid.

Install brake hose to caliper securely.

Install all parts and secure all bolts.

Bleed air. Refer to “Bleeding Brake System”, BR-8.

FRONT DISC BRAKE

Assembly

BR-27

Component

NLBR0038

NBR366

Cable guide

Cylinder

Toggle lever

Pin boot

Torque member

Inner shim

Inner pad

Outer pad

10. Outer shim

11. Strut
12. O-ring
13. Push rod
14. Key plate
15. Retaining washer
16. Spring
17. Spring cover
18. Snap ring B
19. Piston seal
20. Snap ring A

21. Washer
22. Wave washer
23. Washer
24. Bearing
25. Adjuster
26. Cup
27. Piston
28. Piston boot
29. Sleeve

Pad Replacement

NLBR0037

WARNING:

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.

REAR DISC BRAKE (CAM & STRUT TYPE)

Component

BR-28

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.

SBR764E

SBR916C

Remove master cylinder reservoir cap.

Remove brake cable mounting bolt and lock spring.

Release parking brake control lever, then disconnect cable
from the caliper.

Remove upper pin bolt.

Open cylinder body downward. Then remove pads inner and
outer shims.

Standard pad thickness:

9.3 mm (0.366 in)

Pad wear limit:

2.0 mm (0.079 in)

SBR641

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

Adjust the piston to the right angle as shown in the figure.

REAR DISC BRAKE (CAM & STRUT TYPE)

Pad Replacement (Cont’d)

BR-29

NBR375

As shown in the figure, align the piston’s concave to the pad’s
convex, then install the cylinder body to the torque member.

Install brake cable, brake cable mounting bolt, lock spring and
master cylinder reservoir cap.

NBR167

Removal

NLBR0039

WARNING:

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.

Release parking brake control lever, then disconnect cable
from the caliper.

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

Disassembly

NLBR0040

Remove piston by turning it counterclockwise with long nose
pliers or suitable tool.

SBR889

Pry off snap ring A from piston with suitable pliers and remove
adjusting nut.

REAR DISC BRAKE (CAM & STRUT TYPE)

Pad Replacement (Cont’d)

BR-30

SBR088B

Disassemble cylinder body.

Pry off snap ring B with suitable pliers, then remove spring
cover, spring and seat.

Remove washer, key plate, push rod, O-ring and strut.

SBR656

Remove piston seal.
Be careful not to damage cylinder body.

SBR767E

Remove return spring, toggle lever and cable guide.

Inspection

NLBR0041

CALIPER

NLBR0041S01

CAUTION:

Use brake fluid to clean cylinder. Never use mineral oil.

Cylinder Body

NLBR0041S0101

Check 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 Member

NLBR0041S0102

Check for wear, cracks or other damage. Replace if necessary.

Piston

NLBR0041S0103

CAUTION:

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-31

Pin and Pin Boot

NLBR0041S0104

Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.

SBR219C

ROTOR

NLBR0041S02

Rubbing Surface

NLBR0041S0201

Check rotor for roughness, cracks or chips.

Runout

NLBR0041S0202

Secure rotor to wheel hub with two nuts (M12 x 1.25).

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)

Thickness

NLBR0041S0203

Rotor 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)

NBR367

Assembly

NLBR0042

Insert cam with depression facing towards open end of cylin-
der.

REAR DISC BRAKE (CAM & STRUT TYPE)

Inspection (Cont’d)

BR-32

SBR248B

Generously apply rubber grease to strut and push rod to make
insertion easy.

SBR893

Fit push rod into square hole in key plate. Also match convex
portion of key plate with concave portion of cylinder.

SBR754E

Install rod, push rod and key plate.

SBR869CB

SBR879-B

Install seat, spring, spring cover and snap ring B with suitable
press and drift.

REAR DISC BRAKE (CAM & STRUT TYPE)

Assembly (Cont’d)

BR-33

SBR892

Install cup in the specified direction.

SBR755E

Install adjuster, bearing, washers and snap ring A with a suit-
able tool.

SBR646

Insert piston seal into groove on cylinder body.

With piston boot fitted to piston, insert piston boot into groove
on cylinder body and fit piston by turning it clockwise with long
nose pliers, or suitable tool.

SBR767E

10. Fit toggle lever, return spring and cable guide.

NBR374

11. Adjust the piston to the right angle as shown in the figure.

REAR DISC BRAKE (CAM & STRUT TYPE)

Assembly (Cont’d)

BR-34

NBR375

Installation

NLBR0043

CAUTION:

Refill with new brake fluid “DOT 4”.

Never reuse drained brake fluid.

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.

Install brake hose to caliper securely.

Install all parts and secure all bolts.

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

REAR DISC BRAKE (CAM & STRUT TYPE)

Installation

BR-35

Component

NLBR0150

NBR422

Cylinder body

Pin boot

Torque member

Inner shim

Inner pad

Outer pad

Outer shim

NOTE:
The cylinder body cannot be disassembled.

Pad Replacement

NLBR0151

WARNING:

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.

REAR DISC BRAKE (BALL & RAMP TYPE)

Component

BR-36

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