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

Ground Circuit Check ................................................56
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMS ........................................................................\
.....57
Diagnostic Procedure 1 (Wheel sensor or rotor) ......57
Diagnostic Procedure 2 (ABS actuator solenoid
valve and solenoid valve relay) .................................59
Diagnostic Procedure 3 (Motor relay or motor).........61
Diagnostic Procedure 4 (Low voltage) ......................63
Diagnostic Procedure 5 (G sensor) ...........................64
Diagnostic Procedure 6 (Control unit) .......................65
TROUBLE DIAGNOSES FOR SYMPTOMS .................66
Diagnostic Procedure 7 (ABS works frequently.) ......66
Diagnostic Procedure 8 (Unexpected pedal
action) ........................................................................\
67 Diagnostic Procedure 9 (Long stopping distance) ....67
Diagnostic Procedure 10 (ABS does not work.) .......68
Diagnostic Procedure 11 (Pedal vibration and
noise) ........................................................................\
.68
Diagnostic Procedure 12 (Warning lamp does
not come on when ignition switch is turned ON.) .....69
Diagnostic Procedure 13 (Warning lamp stays on
when ignition switch is turned ON.)...........................71
SERVICE DATA AND SPECIFICATIONS (SDS) ..........72
General Speci®cations ...............................................72
Inspection and Adjustment ........................................73
When you read wiring diagrams:
+ Read GI section, ``HOW TO READ WIRING DIAGRAMS''.
+ See EL section, ``POWER SUPPLY ROUTING'' for power distribution circuit.
When you perform trouble diagnoses, read GI section, ``HOW TO FOLLOW FLOW CHART
IN TROUBLE DIAGNOSES'' and ``HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN
ELECTRICAL INCIDENT''.

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

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

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

Removal
1. Disconnect harness connector.
2. Disconnect control cable from control lever and bracket.
3. Remove control lever and bracket.
4. Disconnect control cable from center brake and remove controlcable.
Inspection
1. Check control lever and ratchet for evidence of wear or otherdamage. Replace if necessary.
2. Check wires for evidence of discontinuity or other deterioration. Replace if necessary.
3. Check parts at each connection for deformation or damage. Replace if necessary.
4. Check warning lamp and switch. Replace if necessary.
SBR437A
SBR209E
PARKING CENTER BRAKE CONTROL
BR-29

Installation
1. Apply a coating of grease to sliding contact surfaces.
2. Insert clevis pin from left side.
3. After installation is completed, adjust entire system.
Adjustment
1. Pull control lever with speci®ed amount of force. Check leverstroke and ensure smooth operation.Number of notches :7-9
2. Bend parking brake warning lamp switchplate so that brake warning lamp comes on when ratchet at parking brake lever is
pulled notches and goes out when fully released.Number of notches: 2
SBR033A
SBR438A
PARKING CENTER BRAKE CONTROL
BR-30