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Almera Tino V10 (2003 year). Manual - part 47

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.

IDX

REAR DISC BRAKE (CAM & STRUT TYPE)

Inspection (Cont’d)

BR-35

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-36

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.

IDX

REAR DISC BRAKE (CAM & STRUT TYPE)

Assembly (Cont’d)

BR-37

NBR375

Installation

NLBR0043

CAUTION:

Refill with new brake fluid “DOT 3” or “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-11 and “Air
Bleeding Procedure”, CL-10.

REAR DISC BRAKE (CAM & STRUT TYPE)

Installation

BR-38

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.

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-10.

IDX

REAR DISC BRAKE (BALL & RAMP TYPE)

Component

BR-39

NBR423

Remove master cylinder reservoir cap.

Remove brake cable lock spring.

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

Remove upper pin bolt.

NBR426

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.

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.

REAR DISC BRAKE (BALL & RAMP TYPE)

Pad Replacement (Cont’d)

BR-40

NBR427

Removal

NLBR0152

WARNING:

Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
1.

Remove brake cable lock spring.

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

Remove torque member fixing bolts and connecting bolt.

Remove brake hose connecting bolt.

Plug off the brake hose and cylinder body to prevent air enter-
ing the system.

CAUTION:

Care should be taken as not to let:

Air enter the cylinder body and brake hose.

Brake fluid spill from the cylinder body and brake hose.

Disassembly

NLBR0153

Remove pin bolts and pins.
NOTE:
Cylinder body cannot be disassembled.

Inspection

NLBR0154

CALIPER

NLBR0154S01

CAUTION:

Do not drain any brake fluid from cylinder body. Cylinder body
can not be disassembled.

Cylinder Body

NLBR0154S0101

Check cylinder body for score, rust, wear, damage or presence of
foreign materials. If any of the above conditions are observed,
replace cylinder body.

Torque Member

NLBR0154S0102

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

Pin and Pin Boot

NLBR0154S0104

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

IDX

REAR DISC BRAKE (BALL & RAMP TYPE)

Removal

BR-41

SBR219C

ROTOR

NLBR0154S02

Rubbing Surface

NLBR0154S0201

Check rotor for roughness, cracks or chips.

Runout

NLBR0154S0202

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

NLBR0154S0203

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)

NBR374

NBR375

Installation

NLBR0156

CAUTION:

Refill with new brake fluid “DOT 3” or “DOT 4”.

Never reuse drained brake fluid.

Do not drain (factory) filled brake fluid from (new) caliper
assemblies.

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.

Remove the plug from the cylinder body and brake hose.

CAUTION:

Care should be taken as not to let:

Air enter the cylinder body and brake hose.

Brake fluid spill from the cylinder body and brake hose.

Install brake hose to caliper securely.

Install all parts and secure all bolts.

Bleed air. Refer to “Bleeding Brake System”, BR-11 and “Air
Bleeding Procedure”, CL-10.

REAR DISC BRAKE (BALL & RAMP TYPE)

Inspection (Cont’d)

BR-42

Components

NLBR0044

NBR368

SBR897D

Removal and Installation

NLBR0045

To remove parking brake cable, first remove center console.

Disconnect warning lamp switch connector.

Remove adjusting nut.

Remove bolts and nuts securing parking brake cable.

Remove parking brake device.

SBR025D

Remove lock plate and disconnect cable.

Inspection

NLBR0046

Check control lever for wear or other damage. Replace if nec-
essary.

Check wires for discontinuity or deterioration. Replace if nec-
essary.

Check warning lamp and switch. Replace if necessary.

Check parts at each connecting portion and, if found deformed
or damaged, replace.

IDX

PARKING BRAKE CONTROL

Components

BR-43

SBR768E

Adjustment

NLBR0047

Before or after adjustment, pay attention to the following points.

For rear disc brake be sure that toggle lever returns to stop-
per when parking brake lever is released.

There is no drag when parking brake lever is released.

Vehicle is unladen.

Adjust clearance between pad and rotor as follows:

Release parking brake lever and loosen adjusting nut.

Depress brake pedal fully at least 10 times with engine run-
ning.

SBR756E

Pull control lever 10 times or more to make a lever stroke of
195 mm (7.68 in). At 5 - 6 notches, adjust the parking brake
cable by turning the adjusting nut.

SBR033A

Pull control lever with specified amount of force. Check lever
stroke and ensure smooth operation.

Number of notches

5 - 6

Bend warning lamp switch plate to ensure:

Warning lamp comes on when lever is lifted “A” notches.

Warning lamp goes out when lever is fully released.

Number of “A” notches: 1

PARKING BRAKE CONTROL

Adjustment

BR-44

Purpose

NLBR0082

The ABS consists of electronic and hydraulic components. It allows to control the braking force so that lock-
ing of the wheels can be avoided.
The ABS:
1) Ensures proper tracking performance through steering wheel operation.
2) Enables obstacles to be avoided through steering wheel operation.
3) Ensures vehicle stability by preventing flat spins.

ABS (Anti-Lock Brake System) Operation

NLBR0083

When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.

The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning lamp
for 1 second after turning the ignition switch ON. The system performs another test the first time the vehicle
reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs a self-test. This is a
normal part of the self-test feature. If a malfunction is found during this check, the ABS warning lamp will
come on.

During ABS operation, a mechanical noise may be heard. This is a normal condition.

ABS Hydraulic Circuit

NLBR0084

SBR757E

Inlet solenoid valve

Outlet solenoid valve

Reservoir

Pump

Motor

Bypass check valve

Damper

IDX

DESCRIPTION

ABS

Purpose

BR-45

System Components

NLBR0086

NBR369

SBR124B

System Description

NLBR0087

SENSOR

NLBR0087S01

The sensor unit consists of a gear-shaped sensor rotor and a sen-
sor element. The element contains a bar magnet around which a
coil is wound. The sensor is installed on the back side of the brake
rotor. Sine-wave current is generated by the sensor as the wheel
rotates. The frequency and voltage increase(s) as the rotating
speed increases.

SBR759E

CONTROL UNIT

NLBR0087S02

The control unit computes the wheel rotating speed by the signal
current sent from the sensor. Then it supplies a DC current to the
actuator solenoid valve. It also controls ON-OFF operation of the
valve relay and motor relay. If any electrical malfunction should be
detected in the system, the control unit causes the warning lamp
to light up. In this condition, the ABS will be deactivated by the
control unit, and the vehicle’s brake system reverts to normal
operation.

YBR327

ABS ACTUATOR AND ELECTRIC UNIT

NLBR0087S03

The ABS actuator and electric unit contains:

An electric motor and pump

Two relays

Eight solenoid valves, each inlet and outlet for
— LH front
— RH front
— LH rear
— RH rear

ABS control unit

DESCRIPTION

ABS

System Components

BR-46

This components controls the hydraulic circuit and increases, holds
or decreases hydraulic pressure to all or individual wheels. The
ABS actuator and electric unit can not be disassemble and will be
service as an assembly.

ABS Actuator Operation

NLBR0087S0301

Inlet solenoid
valve

Outlet solenoid
valve

Normal brake operation

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is directly
transmitted to caliper via the inlet solenoid valve.

ABS operation

Pressure hold

ON (Closed)

OFF (Closed)

Hydraulic circuit is shut off to hold the caliper brake
fluid pressure.

Pressure
decrease

ON (Closed)

ON (Open)

Caliper brake fluid is sent to reservoir via the outlet
solenoid valve. Then it is pushed up to the master
cylinder by pump.

Pressure
increase

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is transmitted
to caliper.

IDX

DESCRIPTION

ABS

System Description (Cont’d)

BR-47

Component Parts and Harness Connector
Location

NLBR0088

YBR366

DESCRIPTION

ABS

Component Parts and Harness Connector Location

BR-48

Schematic

NLBR0089

YBR327A

IDX

DESCRIPTION

ABS

Schematic

BR-49

Wiring Diagram — ABS —

NLBR0090

YBR328A

DESCRIPTION

ABS

Wiring Diagram — ABS —

BR-50

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