NISSAN TERRANO 2004 Service Repair Manual

Preparation
SPECIAL SERVICE TOOLS
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
Removing and installing each brake pip-
ing
KV991V0010
Brake fluid pressure
gauge
Measuring brake fluid pressure
HT72480000
Rear axle shaft bearing
puller
Removing rear wheel sensor rotor
PRECAUTIONS AND PREPARATION
BR-4
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Checking Brake Fluid Level
ICheck fluid level in reservoir tank. It should be between Max.
and Min. lines on reservoir tank.
I If fluid level is extremely low, check brake system for leaks.
I When brake warning lamp comes on even when parking brake
lever is released, check brake system for leaks.
Checking Brake Line
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.
2. Check for oil leakage by fully depressing brake pedal while engine is running.
Changing Brake Fluid
CAUTION:
IRefill with new brake fluid ªDOT 4º.
I Never reuse drained brake fluid.
I 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. DO
NOT RUB IT OFF.
1. Connect a vinyl tube to each air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing brake pedal.
3. Refill 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 ªBleeding Brake Systemº, ªBRAKE
HYDRAULIC LINEº, BR-8.
Brake Burnishing Procedure
Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing rotors or drums, after replac-
ing pads or linings, 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 (31MPH).
2. Use medium brake pedal/foot to bring the vehicle to a com- plete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
pressure such that vehicle stopping time equals 3 to 5
seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3 for 10 times or more to complete the burnishing procedure.
SBR849B
SMA732A
SBR992
CHECK AND ADJUSTMENT
BR-5
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W/O ABS
YBR256
BRAKE HYDRAULIC LINE
BR-6
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WITH ABS
YBR257
BRAKE HYDRAULIC LINE
BR-7
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Bleeding Brake System
CAUTION:
ICarefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
I If master cylinder is suspected to have air inside, bleed air
from master cylinder first. Refer to ªInstallationº, ªMAS-
TER CYLINDERº, BR-17.
I Fill reservoir with recommended brake fluid ªDOT 4º. Make
sure it is full at all the times while bleeding air out of sys-
tem.
I Place a container under master cylinder to avoid spillage
of brake fluid.
I For models with ABS, turn ignition switch to the OFF posi-
tion and disconnect ABS fuse or battery cable.
I Bleed air in the following order:
Load Sensing Valve air bleeder (Models equipped with LSV)
"
Left rear brake
"
Right rear brake
"
Left front brake
"
Right front brake
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to release air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2 through 5 until clear brake fluid comes out of air bleeder valve.
7. Tighten air bleeder valve
:7-9N ×m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
SBR995
SBR419C
BRAKE HYDRAULIC LINE
BR-8
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Removal
CAUTION:
IUse suitable tool for assembly and disassembly of brake
lines and hoses.
I 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. DO
NOT RUB IT OFF.
I All hoses must be free from excessive bending, twisting
and pulling.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing brake pedal.
3. Remove flare nut securing brake tube to hose, then withdraw lock spring.
4. Cover openings to prevent entrance of dirt whenever discon- necting hydraulic line.
Inspection
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
Installation
CAUTION:
IRefill with new brake fluid ªDOT 4º.
I Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts. Flare nut:
:15-18N ×m (1.6 - 1.8 kg-m, 11 - 13 ft-lb)
Connecting bolt:
:17-20N ×m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
2. Refill until new brake fluid comes out of each air bleeder valve.
3. Bleed air. Refer to ªBleeding Brake Systemº, BR-8.
YBR293
YBR293
BRAKE HYDRAULIC LINE
BR-9
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Removal and Installation
NBR312
LOAD SENSING VALVE
BR-10
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Removal
CAUTION:
IBe 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. DO
NOT RUB IT OFF.
I Remove flare nuts and LSV bolts.
Installation
CAUTION:
IRefill with new brake fluid ªDOT 4º.
I Never reuse drained brake fluid.
I Check level in brake fluid reservoir.
1. Tighten provisionally flare nuts.
2. Tighten LSV bolts.
:20-24N ×m (2.0 - 2.4 kg-m, 14 - 17 ft-lb)
3. Tighten flare nuts.
:15-18N ×m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
4. Bleed air. Refer to ªBleeding Brake Systemº, ªBRAKE HYDRAULIC LINEº, BR-8.
5. Adjust load sensing valve (LSV). Refer to ªInspection and Adjustmentº, ªLOAD SENSING VALVEº, BR-12.
YBR293
LOAD SENSING VALVE
BR-11
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Inspection and Adjustment
CAUTION:
ICheck level in brake fluid reservoir.
I Refill with recommended brake fluid ªDOT 4º.
I Never reuse drained brake fluid.
I 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. DO
NOT RUB IT OFF.
1. Before adjusting load sensing valve spring length, check for proper installation and abnormal wear of brake pads and
shoes.
2. Remove the air bleeder from the wheel caliper, and install a pressure gauge (A) to the bleed valve hole.
3. Bleed the air from the front brake piping.
4. Remove the air bleed valve from the rear wheel cylinder, and install a pressure gauge (B) to the bleed valve hole.
EBR019
EBR020
EBR021
LOAD SENSING VALVE
BR-12
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5. Bleed the air from the rear brake piping.
6. To adjust the LSV correctly, proceed as follows:
a. With unladen vehicle (12 liters of fuel, radiator coolant andengine oil are full). Spare tire, hand tools and mats in desig-
nated positions. Ensure all doors are closed and no one is
inside of the car. Check the length of LSV spring ªLº.
b. If the spring length is different from that specified, move the regulation lever (2) until the specified value is obtained. Move
the LSV lever (1) until it contacts the stopper bolt and recheck
the spring length.Sensor spring length ªLº Hardtop: 211 mm (8.31 in)
Wagon: 209 mm (8.23 in)
NOTE: Do not disturb stopper bolt.
c. Start the engine and run it at idling speed.
d. Slowly depress the brake pedal until an input pressure of 4,805 kPa (48.1 bar, 49 kg/cm
2, 697 psi) is obtained (at the front axle
pressure gauge) and an output pressure of 1,736 - 2,501 kPa
(18 - 26 bar, 17.7 - 25.5 kg/cm
2, 252 - 363 psi) is obtained (at
the rear axle pressure gauge).
If the output pressure at the rear axle pressure gauge is not within
the specified values, adjust LSV spring length as described under
b) until the output pressure measured is within the specified range.
Unit: kPa (bar, kg/cm2, psi)
Front axle* 4,805 (48.1, 49.0, 697)
Rear axle* 1,736 - 2,501 (18 - 26, 17.7 - 25.5, 252 - 363)
* Load conditions as indicated under 6.a, driver seat occupied.
EBR022
NBR313
EBR026
LOAD SENSING VALVE
Inspection and Adjustment (Cont'd)
BR-13
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