NISSAN ALMERA 2001 Service Manual

Noise, Vibration and Harshness (NVH)
Troubleshooting
NJAX0025Refer to ªNoise, Vibration and Harshness (NVH) Troubleshootingº,
ªFRONT AXLEº, AX-3.
SMA525A
On-vehicle Service
REAR AXLE PARTSNJAX0026Check axle and suspension parts for excessive play, wear or dam-
age.
+Shake each rear wheel to check for excessive play.
SRA690A
REAR WHEEL BEARINGNJAX0027+Check axial end play.
Axial end play:
0.05 mm (0.0020 in)
+Check that wheel hub bearings operate smoothly.
+Check tightening torque of wheel bearing lock nut.
: 187 - 254 N´m (19 - 26 kg-m, 138 - 188 ft-lb)
+Replace wheel bearing assembly if there is axial end play or
wheel bearing does not turn smoothly. Refer to ªWheel Hubº,
ªREAR AXLEº, AX-24.
REAR AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting
AX-23

Wheel Hub
COMPONENTSNJAX0028
SAX013-A
1. Spindle
2. Baffle plate
3. Back plate4. ABS sensor rotor
5. Wheel hub bearing
6. Wheel bearing lock nut7. Hub cap
8. ABS sensor
REMOVALNJAX0029CAUTION:
+Before removing the rear wheel hub assembly, disconnect
the ABS wheel sensor from the assembly. Then move it
away from the hub assembly. Failure to do so may result
in damage to the sensor wires and the sensor becoming
inoperative.
+Wheel hub bearing does not require maintenance. If any of
the following symptoms are noted, replace wheel hub
bearing assembly.
1) Growling noise is emitted from wheel hub bearing dur-
ing operation.
2) Wheel hub bearing drags or turns roughly. This occurs
when turning hub by hand after bearing lock nut is tight-
ened to specified torque.
REAR AXLE
Wheel Hub
AX-24

SRA711A
1. Remove brake caliper assembly.
2. Remove wheel bearing lock nut.
3. Remove brake rotor (models with disk brake) or brake drum
(models with drum brakes).
4. Remove wheel hub bearing from spindle.
CAUTION:
Do not disconnect brake hose from caliper.
+Suspend caliper assembly with wire so as not to stretch
brake hose.
+Be careful not to depress brake pedal, or piston will pop
out.
Make sure brake hose is not twisted.
ARA082
5. Remove the sensor rotor using suitable puller, drift and bea
ring replacer.
SAX014
INSTALLATIONNJAX0030+With vehicles equipped with ABS, press-fit ABS sensor rotor
into wheel hub bearing using a drift.
Do not reuse ABS sensor rotor. When installing, replace it
with a new one.
SRA734AB
+Press-fit ABS sensor rotor as far as the location shown in fig-
ure at left.
Height ªhº:
Models with disk brakes
1.5 - 2.5 mm (0.059 - 0.098 in)
Models with drum brakes
17.7 - 18.7 mm (0.697 - 0.736 in)
REAR AXLE
Wheel Hub (Cont'd)
AX-25

SRA712A
+Install wheel hub bearing.
+Tighten wheel bearing lock nut.
Before tightening, apply oil to threaded portion of rear spindle.
Do not reuse wheel bearing lock nut.
: 187 - 254 N´m (19 - 26 kg-m, 138 - 188 ft-lb)
+Check that wheel bearings operate smoothly.
SRA737A
+Check wheel hub bearing axial end play.
Axial end play:
0.05 mm (0.0020 in)
SFA599B
+Clinch two places of lock nut.
SRA738A
+Install hub cap using a suitable tool.
Do not reuse hub cap. When installing, replace it with a
new one.
REAR AXLE
Wheel Hub (Cont'd)
AX-26

Service Data and Specifications (SDS)
WHEEL BEARING (REAR)=NJAX0031
Wheel bearing axial end play mm (in) 0.05 (0.0020)
Wheel bearing lock nut tightening torque N´m (kg-m, ft-lb) 187 - 254 (19 - 26, 138 - 188)
REAR AXLE
Service Data and Specifications (SDS)
AX-27

REAR AXLE
Service Data and Specifications (SDS) (Cont'd)
AX-28

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS...............................................................4
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............4
Precautions for Brake System .....................................4
Precautions When Working On ABS ...........................5
Wiring Diagrams and Trouble Diagnosis .....................5
PREPARATION...............................................................6
Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................7
NVH Troubleshooting Chart.........................................7
ON-VEHICLE SERVICE..................................................8
Checking Brake Fluid Level.........................................8
Checking Brake Line ...................................................8
Changing Brake Fluid ..................................................8
Brake Burnishing Procedure........................................8
Bleeding Brake System ...............................................9
BRAKE HYDRAULIC LINE...........................................10
Hydraulic Circuit.........................................................10
Removal .....................................................................10
Inspection................................................................... 11
Installation .................................................................. 11
BRAKE PEDAL AND BRACKET..................................12
Removal and Installation ...........................................12
Inspection...................................................................12
Adjustment .................................................................12
MASTER CYLINDER (TOKICO)...................................14
Removal .....................................................................14
Disassembly...............................................................15
Inspection...................................................................15
Assembly ...................................................................15
Installation ..................................................................16
MASTER CYLINDER [BOSCH (NABCO)]...................17
Removal .....................................................................17
Disassembly...............................................................17
Inspection...................................................................18
Assembly ...................................................................18
Installation ..................................................................19BRAKE BOOSTER........................................................20
On-vehicle Service.....................................................20
OPERATING CHECK...............................................20
AIRTIGHT CHECK...................................................20
Removal .....................................................................20
Inspection...................................................................20
OUTPUT ROD LENGTH CHECK..............................20
Installation ..................................................................21
VACUUM HOSE.............................................................22
Removal and Installation ...........................................22
Inspection...................................................................22
HOSES AND CONNECTORS...................................22
CHECK VALVE........................................................22
VACUUM PUMP............................................................23
Removal .....................................................................23
Installation ..................................................................24
Inspection...................................................................24
Component ................................................................25
Disassembly...............................................................25
Assembly ...................................................................25
FRONT DISC BRAKE...................................................27
Component ................................................................27
Pad Replacement ......................................................27
Removal .....................................................................28
Disassembly...............................................................28
Inspection...................................................................28
CALIPER.................................................................28
ROTOR...................................................................29
Assembly ...................................................................30
Installation ..................................................................30
REAR DRUM BRAKE...................................................31
Components...............................................................31
Removal .....................................................................31
Inspection - Wheel Cylinder ......................................32
Wheel Cylinder Overhaul...........................................33
Inspection - Drum ......................................................33
Inspection - Lining .....................................................33
Installation ..................................................................33

REAR DISC BRAKE (CAM & STRUT TYPE)..............35
Component ................................................................35
Pad Replacement ......................................................35
Removal .....................................................................37
Disassembly...............................................................37
Inspection...................................................................38
CALIPER.................................................................38
ROTOR...................................................................39
Assembly ...................................................................39
Installation ..................................................................42
REAR DISC BRAKE (BALL & RAMP TYPE)..............43
Component ................................................................43
Pad Replacement ......................................................43
Removal .....................................................................45
Disassembly...............................................................45
Inspection...................................................................45
CALIPER.................................................................45
ROTOR...................................................................46
Installation ..................................................................46
PARKING BRAKE CONTROL......................................47
Components...............................................................47
Removal and Installation ...........................................47
Inspection...................................................................47
Adjustment .................................................................48
ABS
DESCRIPTION...............................................................49
Purpose......................................................................49
ABS (Anti-Lock Brake System) Operation ................49
ABS Hydraulic Circuit ................................................49
System Components .................................................50
System Description ....................................................50
SENSOR.................................................................50
CONTROL UNIT......................................................50
ABS ACTUATOR AND ELECTRIC UNIT....................50
Component Parts and Harness Connector
Location .....................................................................52
Schematic/Sedan .......................................................53
Wiring Diagram - ABS -/Sedan..................................54
Schematic/Hatchback ................................................58
Wiring Diagram - ABS -/Hatchback ...........................59
MODELS WITH SELF-DIAGNOSIS FUNCTION
(DATA LINK CONNECTOR TERMINAL NO. 9)
...........59
MODELS WITHOUT SELF-DIAGNOSIS
FUNCTION (DATA LINK CONNECTOR TERMINAL
NO. 9)
.....................................................................60
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION...............................................................63
Self-diagnosis (Only Models with Data Link
Connector Terminal No. 9) ........................................63
FUNCTION..............................................................63
SELF-DIAGNOSIS PROCEDURE..............................63
HOW TO READ SELF-DIAGNOSTIC RESULTS
(MALFUNCTION CODES)
........................................64
HOW TO ERASE SELF-DIAGNOSTIC RESULTS
(MALFUNCTION CODES)
........................................64
CONSULT-II ...............................................................65
CONSULT-II APPLICATION TO ABS..........................65
ECU (ABS CONTROL UNIT) PART NUMBER
MODE
.....................................................................65
CONSULT-II Inspection Procedure............................65
SELF-DIAGNOSIS PROCEDURE..............................65
SELF-DIAGNOSTIC RESULTS MODE.......................67
DATA MONITOR PROCEDURE................................68
ACTIVE TEST PROCEDURE....................................69
DATA MONITOR MODE...........................................70
ACTIVE TEST MODE...............................................70
TROUBLE DIAGNOSIS - INTRODUCTION..................71
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................71
INTRODUCTION......................................................71
TROUBLE DIAGNOSIS - BASIC INSPECTION...........72
Preliminary Check......................................................72
Ground Circuit Check ................................................75
ABS ACTUATOR AND ELECTRIC UNIT GROUND.....75
TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION...............................................................76
Malfunction Code/Symptom Chart.............................76
MODELS WITH SELF-DIAGNOSIS FUNCTION
(DATA LINK CONNECTOR TERMINAL NO. 9)
...........76
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMS.............................................................................78
Wheel Sensor or Rotor ..............................................78
DIAGNOSTIC PROCEDURE.....................................78
ABS Actuator Solenoid Valve or Solenoid Valve
Relay ..........................................................................81
DIAGNOSTIC PROCEDURE.....................................81
Motor Relay or Motor.................................................84
DIAGNOSTIC PROCEDURE.....................................84
Low Voltage ...............................................................86
DIAGNOSTIC PROCEDURE.....................................86
Control Unit ................................................................88
DIAGNOSTIC PROCEDURE.....................................88
TROUBLE DIAGNOSES FOR SYMPTOMS.................89
1. ABS Works Frequently ..........................................89
2. Unexpected Pedal Action ......................................89
3. Long Stopping Distance ........................................90
4. ABS Does Not Work ..............................................91
5. Pedal Vibration and Noise.....................................92
6. ABS Warning Lamp Does Not Come On
When Ignition Switch Is Turned On...........................93
7. ABS Warning Lamp Stays On When Ignition
Switch Is Turned On ..................................................95
REMOVAL AND INSTALLATION.................................97
Wheel Sensors ..........................................................97
ABS Actuator and Electric Unit..................................98
CONTENTS(Cont'd)
BR-2

REMOVAL...............................................................98
INSTALLATION........................................................98
Sensor Rotor..............................................................99
REMOVAL...............................................................99
INSTALLATION........................................................99
SERVICE DATA AND SPECIFICATIONS (SDS).......100
General Specifications .............................................100Disc Brake ...............................................................101
Drum Brake..............................................................101
Brake Pedal .............................................................101
Parking Brake ..........................................................101
CONTENTS(Cont'd)
BR-3

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJBR0139The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
+To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
SBR686C
Precautions for Brake SystemNJBR0002+Recommended fluid is brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
+Be careful not to splash brake fluid on painted areas.
+To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
+Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of the hydraulic system.
+Use flare nut wrench when removing and installing brake
tube.
+Always torque brake lines when installing.
+Burnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings,
or if a soft pedal occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªON-VEHICLE
SERVICEº, BR-8.
WARNING:
+Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
BR-4