Login to enhance your online experience. Login or Create an Account
Logo
Shopping Cart

Shopping Cart 0 Items (Empty)

Nissan VG30E and KA24E engine factory workshop and repair manual download

Tools & supplies
- Floor jack and rated jack stands (2). Wheel chocks.
- 1/2" breaker bar + 3/8" breaker or impact (as available). Torque wrench (range to at least 150 ft·lb).
- Lug wrench or socket (typically 19mm for many Nissans; verify).
- Socket set (metric 10–19mm), extensions.
- Hex/Allen or Torx bits for caliper slider/retainer (if applicable).
- Ratchet, combination wrenches.
- C‑clamp or piston retraction tool (caliper compressor).
- Pry bar / large flat screwdriver.
- Hammer / dead‑blow and penetrating oil (PB Blaster).
- Impact driver or Phillips screwdriver for rotor retaining screw (if present).
- Wire brush, brake cleaner, shop rags.
- Caliper hanger / wire / bungee to hang caliper off suspension (do NOT hang by hose).
- Anti‑seize compound and high‑temp brake grease.
- New rotors (part‑specific for VG30E/KA24E vehicle application), recommended new pads, and brake hardware kit (pad clips, slide pin boots/grease). Replace parking‑brake shoes if rear rotor has integrated drum‑in‑hat.
- Optional: rotor puller if rotor is rusted to hub.

Safety precautions (do these, no exceptions)
- Work on level ground. Chock opposite wheels. Set parking brake.
- Never rely only on the jack — always use properly rated jack stands under a reinforced jacking point.
- Wear eye protection and gloves. Avoid getting grease on friction surfaces.
- If you open hydraulic lines and/or disconnect caliper, be prepared to bleed brakes; do not drive until pedal is firm.
- After reassembly, pump pedal until firm before moving vehicle, then test at low speed.

Step‑by‑step rotor replacement (front or rear disc; adapt for left/right)

1. Preparation
- Loosen wheel lug nuts slightly with vehicle on ground (break the torque) before jacking.
- Mark wheel orientation if reusing wheels (not required if new).

2. Lift vehicle & remove wheel
- Place floor jack at manufacturer jacking point; raise vehicle. Install jack stands under pinch weld or designated stand points. Lower jack so car rests on stands.
- Remove lug nuts and wheel.

3. Expose braking assembly
- Use a wire brush to remove heavy rust from around caliper and bracket — makes bolt removal easier.
- Spray penetrating oil on caliper bracket bolts and rotor retaining screw; let sit a few minutes.

4. Remove caliper
- Remove the caliper mounting bolts (usually on the back of caliper). Use appropriate socket or hex key.
- Carefully pull caliper off rotor. Support caliper with wire or bungee to suspension — do NOT let it hang by the brake hose.
- If replacing pads, slide them out now and note pad orientation.

How the tools are used: breaker bar/ratchet for bolts; pry bar helps to pry caliper off if stuck; wire/bungee holds caliper.

5. Remove caliper bracket (if rotor won’t come off with bracket on)
- Remove bracket mounting bolts (larger bolts behind caliper). Keep bolts and note their locations.
- Use penetrating oil and breaker bar if bolts are tight.

6. Remove rotor
- If there is a small retaining screw, remove it (impact driver if stuck).
- If rotor is stuck due to corrosion, strike the rotor face near the hub with a dead‑blow or hammer working around the hat to break corrosion. Use a rotor puller if necessary.
- Pull rotor straight off hub.

Common pitfall: trying to pry rotor off with little force — can warp hub or damage studs. Use penetrating oil and controlled hammer blows. Don’t hit studs.

7. Clean hub & prepare new rotor
- Using wire brush, clean mating surface on hub until bare metal and flat.
- Apply a thin coat of anti‑seize to hub mating surface (avoid contacting rotor friction surface).
- If new rotor is coated, remove packaging and spray rotor face with brake cleaner per instructions to remove preservative.

8. Install new rotor
- Seat rotor on hub. If rotor has a retaining screw, install lightly — don’t over‑tighten.
- Reinstall caliper bracket and torque to spec (see torque notes below).

9. Compress caliper piston
- If replacing pads, use old pad and a C‑clamp or piston tool against piston and clamp to push piston back into bore slowly. Keep brake fluid reservoir cap loosely installed or remove excess fluid first to avoid overflow.
- Use a caliper piston tool (fits into piston face) to avoid cocking or damaging piston. Compress evenly.

Common pitfall: forcing piston too quickly can overflow master cylinder or damage seal. Compress slowly and check fluid level.

10. Reinstall pads, caliper, hardware
- Grease guide pins and pad contact points with high‑temp brake grease.
- Install new pad clips/hardware if available.
- Hang caliper over pads/rotor and reinstall caliper mounting bolts. Torque all bolts to spec.
- Ensure hose is not twisted and pad moves freely.

11. Reinstall wheel & lower vehicle
- Hand‑thread lug nuts, lower vehicle from stands carefully, then torque lug nuts in star pattern to proper torque with torque wrench.

12. Before driving
- If you opened anything hydraulic, bleed brakes or at minimum pump pedal repeatedly until firm (if closed system and you didn’t open lines, just pump pedal).
- Check fluid level and top up.
- Test brakes at low speed in a safe area. Confirm no noises, pulling, or soft pedal.
- Perform bedding procedure (see below).

Parts commonly replaced (recommended)
- Rotors (both sides recommended to avoid uneven braking).
- Brake pads (recommended with rotor replacement).
- Pad hardware kit (clips, shims).
- Slide pin boots and grease.
- If caliper piston or slide pins are corroded, replace or rebuild caliper.
- Parking‑brake shoes if rear rotor has drum‑in‑hat design.

Torque references (verify with factory manual for your exact model/year)
- Wheel lug nuts: commonly 80–100 ft·lb (110–135 N·m). Use manufacturer spec.
- Caliper bracket bolts: commonly 70–100 ft·lb range.
- Caliper slider/pin bolts: commonly 25–35 ft·lb.
- Rotor retaining screws (if present): low torque ~ 7–15 ft·lb.
Note: These are typical ranges; confirm exact numbers in the service manual for your specific year/model.

Common pitfalls & how to avoid them
- Not using jack stands — catastrophic risk. Always use stands.
- Hanging caliper by hose — will damage hose. Use wire/bungee.
- Not cleaning hub mating surface — causes wobble, noise, runout.
- Over‑torquing or under‑torquing lug nuts — use torque wrench and star pattern.
- Contaminating pads/rotors with grease, oil, or anti‑seize — keep friction surfaces clean.
- Not compressing piston evenly — can damage caliper piston or seals.
- Driving before pedal is firm — always pump pedal and test at low speed.
- Replacing only one rotor — causes uneven braking and premature wear.

Bed‑in procedure (basic)
- After reassembly, let vehicle cool if needed. Make several controlled stops from ~30–35 mph to ~5 mph, accelerating back to speed between stops. Perform 8–12 stops. Avoid heavy braking for first 100–200 miles and avoid towing/heavy loads.

Estimated time
- 1–1.5 hours per axle for an experienced tech with no stuck parts; more time if bolts/rotors are rusted.

Final notes
- Always confirm exact hardware sizes and torque specs for the specific Nissan model/year you’re working on (VG30E or KA24E are engine codes; the brake hardware specs are vehicle‑specific). Replace pads and hardware when changing rotors for best results.
rteeqp73

You Might Also Like...

Kryptronic Internet Software Solutions