ECU NISSAN PICK-UP 1998 Repair Manual

2. Install stopper cap.
lBefore installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.
Installation
CAUTION:
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Tighten mounting nuts.
: 12 - 15 N´m (1.2 - 1.5 kg-m,9-11ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system. Refer to ``Bleeding Brake
System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR940A
ABR190
MASTER CYLINDER
Assembly (Cont'd)
BR-14

Installation
CAUTION:
lBe careful not to deform or bend brake pipes during
installation of booster.
lReplace clevis pin if damaged.
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
lTake care not to damage brake booster mounting bolt
thread when installing. Due to the narrow angle of
installation, the threads can be damaged by the dash
panel.
A: S230, M215T
LHD 165 mm (6.50 in)
RHD 185 mm (7.28 in)
M195T
LHD 160 mm (6.30 in)
RHD 180 mm (7.09 in)
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket
to brake booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
: 13 - 16 N´m (1.3 - 1.6 kg-m,9-12ft-lb)
5. Install master cylinder. Refer to ``Installation'', ``MASTER
CYLINDER'', BR-14.
6. Adjust brake pedal height and free play. Refer to BR-11.
7. Secure lock nut for clevis.
: 16 - 22 N´m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)
8. Bleed air. Refer to ``Bleeding Brake System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR116BE
BRAKE BOOSTER
BR-16

THICKNESS
Thickness variation (At least 8 positions):
Maximum 0.02 mm (0.0008 in)
If thickness variation exceeds the specification, machine rotor
with on-car brake lathe.
Rotor repair limit:
CL28VD 24.0 mm (0.945 in)
Assembly
1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.
3. Properly secure piston boot.
CAUTION:
lSecure dust seal properly.
lLubricate with new brake fluid before installing plastic
pistons (CL28VD) into cylinder body.
Installation
CAUTION:
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to ``Bleeding Brake System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
Brake Burnishing Procedure
When experiencing soft brake pedal feel at very low mileage, or
after replacing the rotor, burnish the brake pad contact surfaces
according to the following procedures.
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 (31
MPH).
SBR090A
SBR178C
SBR179CA
SBR084A
FRONT DISC BRAKE
Inspection Ð Rotor (Cont'd)
BR-24

CONSULT
CONSULT APPLICATION TO ABS
EE960 program card is not applicable to ABS. Use on board diagnostic system with ABS warning lamp until
the next program card will be introduced. (Refer to ``Self-diagnosis'', BR-53.)
ITEMSELF-DIAGNOSTIC
RESULTSDATA MONITOR ACTIVE TEST
Front right wheel sensor X X Ð
Front left wheel sensor X X Ð
Rear wheel sensor.1X X Ð
Rear right wheel sensor.2X X Ð
Rear left wheel sensor.2X X Ð
G switch (G sensor).2XXX
Stop lamp switch Ð X Ð
Front right inlet solenoid valve X X X
Front right outlet solenoid valve X X X
Front left inlet solenoid valve X X X
Front left outlet solenoid valve X X X
Rear inlet solenoid valve X X X
Rear outlet solenoid valve X X X
Actuator solenoid valve relay X X Ð
Actuator motor relay
(ABS MOTOR is shown on the Data Monitor
screen.)XXX
ABS warning lamp Ð X Ð
Battery voltage X X Ð
X : Applicable
Ð : Not applicable
.1: 2WD model only
.2: 4WD model only
ECU (ABS control unit) part number mode
Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order
the ECU.
TROUBLE DIAGNOSES
BR-56

Body Front End
lWhen removing or installing hood, place a cloth or other padding on hood. This prevents vehicle body
from being scratched.
lBumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
lHood adjustment: Adjust at hinge portion.
lHood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood
locks engaging mechanism.
lHood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.
REMOVAL Ð Front bumper assembly
V1Remove screws securing left and right combination lamps and remove the lamps.
V2Remove clips securing front grille and remove the front grille.
V3Remove bolts securing left and right bumper stays.
V4Remove bolts securing left and right bumper side brackets.
V5Remove bolts securing left and right bumper side stays.
V6Extract bumper assembly.
BODY END
BT-5

Body Rear End
lAdjustment: Adjust at hinge portion for proper fit.
lLock system adjustment: Adjust striker so that it is in the center of the lock. After adjustment, check trunk
lid lock operation.
lAfter installation, make sure that rear gate opens smoothly.
REMOVAL Ð Rear bumper assembly
V1Remove connectors securing license plate lamps.
V2Remove nuts securing bumper side stay.
V3Extract bumper assembly.
SBT429
BODY END
BT-8

Door Trim
REMOVAL Ð Door trim
Front door trim
V1Remove inside handle escutcheon.
V2Remove power window switch, then disconnect the connector.
V3Remove window regulator handle.
V4Remove door armrest.
V5Remove screw securing pull handle and remove pull handle.
V6Remove bolt, screw and clip securing door finisher.
V7Lift out door finisher.
Rear door trim
V8Remove inside handle escutcheon.
V9Remove screws securing door handle and remove door handle.
V10Remove clips and lift out door finisher, then disconnect power window switch connector.
INTERIOR TRIM
BT-18

REMOVE Ð Headlining (King cab model)
V1Remove front seats and jump seats. Refer to ``SEAT'' for details, BT-30, 34.
V2Remove body side trim. Refer to ``Side and Floor Trim'' (King cab model) for details, BT-15.
V3Remove assist grip.
V4Remove roof side garnishes.
V5Remove interior lamp assembly.
V6Remove back window upper garnish.
V7Remove inside mirror assembly.
V8Remove sun visors.
V9Remove windshield upper welt.
V10Remove clips securing headlining.
SBT632
INTERIOR TRIM
Roof Trim (Cont'd)
BT-23

REMOVAL
After removing moldings, remove glass using piano wire or
power cutting tool and an inflatable pump bag.
WARNING:
When cutting the glass from the vehicle, always wear safety
glasses and heavy gloves to help prevent glass splinters
from entering your eyes or cutting your hands.
CAUTION:
lBe careful not to scratch the glass when removing.
lDo not set or stand the glass on its edge. Small chips
may develop into cracks.
INSTALLATION
lUse a genuine Nissan Urethane Adhesive Kit or equiva-
lent and follow the instructions furnished with it.
lWhile the urethane adhesive is curing, open a door win-
dow. This will prevent the glass from being forced out by
passenger compartment air pressure when a door is
closed.
lThe molding must be installed securely so that it is in
position and leaves no gap.
lInform the customer that the vehicle should remain sta-
tionary until the urethane adhesive has completely cured
(preferably 24 hours). Curing time varies with tempera-
ture and humidity.
WARNING:
lKeep heat and open flames away as primers and adhe-
sive are flammable.
lThe materials contained in the kit are harmful if
swallowed, and may irritate skin and eyes. Avoid contact
with the skin and eyes.
lUse in an open, well ventilated location. Avoid breathing
the vapors. They can be harmful if inhaled. If affected by
vapor inhalation, immediately move to an area with fresh
air.
lDriving the vehicle before the urethane adhesive has
completely cured may affect the performance of the
windshield in case of an accident.
CAUTION:
lDo not use an adhesive which is past its usable term.
Shelf life of this product is limited to six months after the
date of manufacture. Carefully adhere to the expiration
or manufacture date printed on the box.
lKeep primers and adhesive in a cool, dry place. Ideally,
they should be stored in a refrigerator.
lDo not leave primers or adhesive cartridge unattended
with their caps open or off.
lThe vehicle should not be driven for at least 24 hours or
until the urethane adhesive has completely cured. Cur-
ing time varies depending on temperature and humidi-
ties. The curing time will increase under higher tempera-
tures and lower humidities.
SBF034B
SBT472
SBT473
WINDSHIELD AND WINDOWS
BT-36

Side Window
REMOVE Ð Side window
V1Remove screws.
V2Remove rear pillar finisher. Refer to ``Side and Floor Trim'' (King cab model) for details, BT-15.
V3Remove nuts securing side window, then remove side window assembly.
SBT638
WINDSHIELD AND WINDOWS
BT-38