oil NISSAN PATROL 1998 Y61 / 5.G Brake System Workshop Manual

Supplemental Restraint System (SRS) ``AIR
BAG'' and ``SEAT BELT PRE-TENSIONER''
The Supplemental Restraint System such as ``AIR BAG'' and ``SEAT BELT PRE-TENSIONER'' used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The composition var-
ies according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
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 in¯ation, all maintenance must be performed
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. Spiral Cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.
Precautions for Brake System
+Use brake ¯uid ``DOT 3''.
+ Never reuse drained brake ¯uid.
+ Be careful not to splash brake ¯uid on painted areas; it
may cause paint damage. If brake ¯uid is splashed on
painted areas, wash it away with water immediately.
+ To clean master cylinder parts, disc brake caliper parts or
wheel cylinder parts, use clean brake ¯uid.
+ Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of hydraulic system.
+ Use ¯are nut wrench when removing and installing brake
tubes.
+ Always torque brake lines when installing.
WARNING:
Clean brakes with a vacuum dust collector to minimize risk of
health hazard from powder caused by friction.
Commercial Service Tools
Tool name Description
j
1Flare nut crowfoot
j
2Torque wrench
NT360
Removing and installing each brake piping
a: 10 mm (0.39 in)
Brake ¯uid pressure gauge
NT151
Measuring brake ¯uid pressure
SBR686C
PRECAUTIONS AND PREPARATION
BR-1

Checking Brake Fluid Level
+Check ¯uid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
+ If ¯uid level is extremely low, check brake system for leaks.
+ If the brake warning lamp comes on, check brake ¯uid level
switch and parking brake switch.
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:
+Re®ll with new brake ¯uid ``DOT 3''.
+ Always keep ¯uid level higher than minimum line on res-
ervoir tank.
+ Never reuse drained brake ¯uid.
+ Be careful not to splash brake ¯uid on painted areas; it
may cause paint damage. If brake ¯uid is splashed on
painted areas, wash it away with water immediately.
1. Clean inside of reservoir tank, and re®ll with new brake ¯uid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake ¯uid from each air bleeder valve by depressing brake pedal.
4. Re®ll until brake ¯uid comes out of each air bleeder valve. Use same procedure as in bleeding hydraulic system to re®ll
brake ¯uid. Refer to ``Bleeding Brake System'', BR-4.
SBR451D
SBR389C
SBR419C
CHECK AND ADJUSTMENT
BR-3

1. Ensure vehicle is unladen condition*.* Fuel, radiator coolant and engine oil full. Spare tire, jack,hand tools and mats in designated positions.
2. Have a driver sit in the driver's seat and one person sit on the rear end. Then have the person on the rear end slowly get off
the vehicle. This is necessary to stabilize suspension de¯ec-
tion.
3. Gradually depress brake pedal and attach a lever to the stop- per bolt, then adjust length ``L'' as follows:Length ``L'': Approx. 175.2 - 178.2 mm (6.90 - 7.02 in)
4. Remove front LH tire.
5. Connect tool to air bleeders on front LH brake caliper and rear LH or RH brake wheel cylinder.
6. Install front LH tire.
Before installing front LH tire, con®rm the tool is not touching
the front LH wheel.
7. Bleed air from Tool.
8. Raise front brake pressure to 4,904 kPa (49.0 bar, 50 kg/cm
2,
711 psi) and 9,807 kPa (98.1 bar, 100 kg/cm2, 1,422 psi) and
check rear brake pressure. Rear brake pressure: Refer to table on next page.
SBR287E
SBR822BA
SBR823BA
SBR377D
BRAKE HYDRAULIC LINE/CONTROL VALVE
Load Sensing Valve (Cont'd)
BR-7

REMOVAL AND INSTALLATION
CAUTION:
When installing vacuum hoses, pay attention to the following
points.
+Do not apply any oil or lubricants to vacuum hose and
check valve.
+ Insert vacuum tube into vacuum hose as shown.
+ Install check valve, paying attention to its direction.
INSPECTION
Hoses and connectors
Check vacuum lines, connections and check valve for airtightness,
improper attachment cha®ng and deterioration.
Check valve
Check vacuum with a vacuum pump.
Connect to booster
side Vacuum should exist.
Connect to engine
side Vacuum should not exist.
Vacuum warning switch*
Test continuity through vacuum warning switch with an ohmme-
ter and vacuum pump.
VacuumLess than 26.7 kPa
(267 mbar, 200 mmHg, 7.87 inHg) 0
W
33.3 kPa
(333 mbar, 250 mmHg, 9.84 inHg) or more ¥W
* Diesel engine models except Australia
SBR454D
SBR844B
SBR321E
VACUUM PIPING
BR-19

Removal and Installation
1. Rotate crankshaft so intake cam nose for No. 1 cylinder facesstraight up when viewed through oil ®ller cap mounting hole.
2. Rotate crankshaft approximately 240É counterclockwise.
3. Remove vacuum pump.
CAUTION: Loosen mounting nuts equally and gradually.
Always remove mounting nuts by pushing to keep the
vacuum pump from jumping up.
Do not disassemble vacuum pump.
4. Install the vacuum pump in the location from which it was removed with cam nose set in position.
SBR319E
RD28 engine models
Vacuum pump
17 - 22 (1.7 - 2.2 kg-m, 12 - 16 ft-lb)
Rocker cover gasket
Rocker cover
VACUUM PUMP
BR-20

Pad Replacement
WARNING:
Clean brakes with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
+When cylinder body is removed, do not depress brake
pedal, or piston will pop out.
+ Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
+ If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
+ It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to stretch
brake hose.
+ Carefully monitor brake ¯uid level because brake ¯uid will
return to reservoir when pushing back piston.
+ Always remove pad retainer in the direction of the arrow.
Failure to do so will damage pawl areas, causing pad
retainer to be unsuitable for further use.
1. Remove master cylinder reservoir cap.
2. Remove upper and lower pin bolts.
3. Remove cylinder body from torque member. Then remove pads, pad retainers, and inner and outer shims.Standard pad thickness: 12.0 mm (0.472 in)
Pad wear limit: 2.0 mm (0.079 in)
Carefully monitor brake ¯uid level because brake ¯uid will
return to reservoir when pushing back piston.
SBR171E
SBR172E
FRONT DISC BRAKE
BR-21

Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
Suspend caliper assembly with wire so as not to stretch brake
hose.
Remove torque member ®xing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for dis-
assembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not to stretch brake
hose.
Disassembly
WARNING:
Do not place your ®ngers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
1. Push out piston with dust seal with compressed air.
2. Remove piston seal with a suitable tool.
Inspection Ð Caliper
CYLINDER BODY
+Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign objects. If any of the above conditions
are observed, replace cylinder body.
+ Minor damage from rust or foreign objects may be eliminated
by polishing surface with a ®ne emery paper. Replace cylinder
body if necessary.
CAUTION:
Use brake ¯uid to clean. Never use mineral oil.
PISTON
Check piston for score, rust, wear, damage or presence of foreign
objects. Replace if any of the above conditions are observed.
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign objects are stuck to sliding sur-
face.
SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks, rust or other damage. Replace if any of the
above conditions are observed.
SBR174E
SBR085A
FRONT DISC BRAKE
BR-23

Pad Replacement
WARNING:
Clean brakes 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,
or piston will pop out.
+ Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
+ If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
+ It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to stretch
brake hose.
+ Carefully monitor brake ¯uid level because brake ¯uid will
return to reservoir when pushing back piston.
1. Remove master cylinder reservoir cap.
2. Remove lower pin bolt.
3. Open cylinder body upward. Then remove pad retainers, and inner and outer shims.Standard pad thickness: 10.0 mm (0.394 in)
Pad wear limit: 2.0 mm (0.079 in)
Carefully monitor brake ¯uid level because brake ¯uid will
return to reservoir when pushing back piston.
SBR181E
REAR DISC BRAKE
BR-25

Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
Suspend caliper assembly with wire so as not to stretch brake
hose.
Remove torque member ®xing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for dis-
assembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not to stretch brake
hose.
Disassembly
WARNING:
Do not place your ®ngers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
1. Push out piston with dust seal with compressed air.
2. Remove piston seal with a suitable tool.
Inspection Ð Caliper
CYLINDER BODY
+Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign objects. If any of the above conditions
are observed, replace cylinder body.
+ Minor damage from rust or foreign objects may be eliminated
by polishing surface with a ®ne emery paper. Replace cylinder
body if necessary.
CAUTION:
Use brake ¯uid to clean. Never use mineral oil.
PISTON
Check piston for score, rust, wear, damage or presence of foreign
objects. Replace if any of the above conditions are observed.
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign objects are stuck to sliding sur-
face.
SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks, rust or other damage. Replace if any of the
above conditions are observed.
SBR183E
SBR772
REAR DISC BRAKE
BR-27

System Components
System Description
WHEEL SENSOR
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 of the brake rotor.
As the wheel rotates, the sensor generates a sine-wave pattern.
The frequency and voltage increase(s) as the rotating speed
increases.
CONTROL UNIT (built in ABS actuator and electric unit)
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. (For control unit layout, refer to ABS ACTUATOR AND
ELECTRIC UNIT, BR-34.)
SBR185E
SBR186E
ANTI-LOCK BRAKE SYSTEM
BR-34