Nissan Navara D21 1986-97 factory workshop and repair manual download

workshop manual
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  1. Replacing the brake lines on a 1997 Nissan Navara D21 involves several key components and steps. Here’s a breakdown of the main components and considerations involved in the process:

    ### Main Components:

    1. **Brake Lines**:
    – The primary component being replaced. Brake lines can be made of steel or flexible rubber. Ensure you have the correct replacement lines that fit your model.

    2. **Brake Fluid**:
    – You’ll need new brake fluid for the system. Make sure to use the type specified in your owner’s manual (usually DOT 3 or DOT 4).

    3. **Fittings and Connectors**:
    – These are used to connect the brake lines to the brake system components (calipers, master cylinder, etc.). Inspect and replace any damaged fittings.

    4. **Brake Line Tools**:
    – Tools such as a flare wrench, line cutter, and benders are essential for removing old lines and installing new ones without damaging them.

    5. **Brake Bleeder Kit**:
    – After installation, it’s necessary to bleed the brake system to remove any air trapped in the lines. A bleeder kit can simplify this process.

    6. **Safety Equipment**:
    – Safety goggles and gloves should be worn to protect against brake fluid, which is corrosive and can damage paint and other surfaces.

    ### Steps to Replace Brake Lines:

    1. **Preparation**:
    – Park the vehicle on a flat surface and ensure it is secure. Loosen the wheel lug nuts and raise the vehicle with jack stands. Remove the wheel for access.

    2. **Remove Old Brake Lines**:
    – Locate the brake lines you need to replace. Use a flare wrench to carefully loosen the fittings. Be prepared for some brake fluid to leak out.

    3. **Install New Brake Lines**:
    – Cut the new brake line to the appropriate length, if necessary, and bend it to match the shape of the old line. Connect the new line to the fittings and tighten securely.

    4. **Refill Brake Fluid**:
    – Once all lines are replaced, top off the brake fluid reservoir with new brake fluid.

    5. **Bleed the Brakes**:
    – Start bleeding the brakes from the furthest wheel from the master cylinder to the closest. This usually means starting with the passenger side rear, then driver side rear, passenger side front, and finally driver side front.

    6. **Check for Leaks**:
    – After bleeding, check all connections for leaks. Tighten fittings if necessary.

    7. **Reassemble**:
    – Reinstall the wheel, lower the vehicle, and torque the lug nuts to the manufacturer’s specifications.

    8. **Test Drive**:
    – Before driving, pump the brakes to ensure they feel firm and test the brakes at low speeds to ensure proper operation.

    ### Safety Note:
    Always ensure that the brake system is thoroughly bled and checked for leaks before operating the vehicle. If you’re uncomfortable with any part of the process, consulting a professional mechanic is advisable.

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