parking brake NISSAN PICK-UP 1998 Repair Manual

BRAKE SYSTEM
SECTIONBR
CONTENTS
PRECAUTIONS AND PREPARATION..................... 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models).............................................. 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models).............................................. 1
Precautions for Brake System ............................... 1
Special Service Tools ............................................ 2
Commercial Service Tools ..................................... 2
CHECK AND ADJUSTMENT.................................... 3
Checking Brake Fluid Level ................................... 3
Checking Brake Line.............................................. 3
Changing Brake Fluid ............................................ 3
Bleeding Brake System ......................................... 4
BRAKE HYDRAULIC LINE....................................... 5
CONTROL VALVE..................................................... 7
Load Sensing Valve ............................................... 7
BRAKE PEDAL AND BRACKET............................ 10
Removal and Installation ..................................... 10
Inspection ............................................................. 11
Adjustment ........................................................... 11
MASTER CYLINDER............................................... 12
Removal ............................................................... 12
Disassembly ......................................................... 13
Inspection ............................................................. 13
Assembly.............................................................. 13
Installation ............................................................ 14
BRAKE BOOSTER.................................................. 15
On-vehicle Service ............................................... 15
Removal ............................................................... 15
Inspection ............................................................. 15
Installation ............................................................ 16
VACUUM HOSE...................................................... 17
Removal and Installation ..................................... 17Inspection ............................................................. 17
VACUUM PUMP...................................................... 19
Removal and Installation ..................................... 19
Inspection ............................................................. 19
FRONT DISC BRAKE............................................. 21
Pad Replacement ................................................ 21
Removal ............................................................... 22
Disassembly ......................................................... 23
Inspection - Caliper .............................................. 23
Inspection - Rotor ................................................ 23
Assembly.............................................................. 24
Installation ............................................................ 24
Brake Burnishing Procedure ................................ 24
REAR DRUM BRAKE............................................. 26
Removal ............................................................... 27
Inspection - Wheel Cylinder................................. 28
Wheel Cylinder Overhaul ..................................... 28
Inspection - Drum ................................................ 28
Inspection - Lining................................................ 28
Installation ............................................................ 28
PARKING BRAKE CONTROL................................ 30
Removal and Installation ..................................... 31
Inspection ............................................................. 31
Adjustment ........................................................... 31
ANTI-LOCK BRAKE SYSTEM................................ 32
Purpose ................................................................ 32
Operation ............................................................. 32
ABS Hydraulic Circuit .......................................... 32
System Components............................................ 33
System Description .............................................. 33
Removal and Installation ..................................... 35
TROUBLE DIAGNOSES......................................... 38
BR

Checking Brake Fluid Level
lCheck fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
lIf fluid level is extremely low, check brake system for leaks.
lIf the brake warning lamp comes on, check brake fluid 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:
lRefill with new brake fluid DOT 3 or DOT 4*1.
lAlways keep fluid level higher than minimum line on
reservoir tank.
lNever reuse drained brake fluid.
lBe 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.
1. Clean inside of reservoir tank, and refill with new brake fluid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
4. Refill until brake fluid comes out of each air bleeder valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to ``Bleeding Brake System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR451D
SBR389C
SBR992
CHECK AND ADJUSTMENT
BR-3

Removal
WARNING:
Clean brake lining with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
Make sure parking brake lever is completely released.
1. Release parking brake lever fully, then remove drum.
lIf drum is hard to remove, the following procedures
should be carried out.
a. Remove plug. Then shorten adjuster to make clearance
between brake shoe and drum.
b. Install two bolts as shown. Tighten the two bolts gradu-
ally.
2. After removing retainer, remove spring by rotating shoes.
lBe careful not to damage wheel cylinder piston boots.
lBe careful not to damage parking brake cable when
separating it.
3. Remove adjuster.
4. Disconnect parking brake cable from toggle lever.
5. Remove retainer clip with a suitable tool. Then separate
toggle lever and brake shoe.
SBR280B
SBR093A
ABR369
ABR408
REAR DRUM BRAKE
BR-27

3. Shorten adjuster by rotating it.
lPay attention to direction of adjuster.
Wheel Screw
Left Left-hand thread
Right Right-hand thread
4. Connect parking brake cable to toggle lever.
5. Install all parts.
lBe careful not to damage wheel cylinder piston boots.
6. Check all parts are installed properly.
lAfter installation is completed, adjust shoe-to-drum
clearance.
7. Install brake drum.
8. When installing new wheel cylinder or overhauling wheel
cylinder, bleed air. Refer to ``Bleeding Brake System'', BR-4.
9. Adjust parking brake. Refer to BR-31.
lInstall all the parts by referring to the figure below.
LT30A model
lAfter installing crank lever on back plate, make sure that
there is no play between crank lever and back plate. If play
exists, adjust bolt
VAand lock nutVB.
ABR396
ABR372
SBR099A
SBR100CA
REAR DRUM BRAKE
Installation (Cont'd)
BR-29

SBR312E
PARKING BRAKE CONTROL
BR-30

Removal and Installation
lBe careful not to damage cable.
lMake sure there is no free play after installation.
Inspection
1. Check control lever for wear or other damage. Replace if
necessary.
2. Check wires for discontinuity or deterioration. Replace if nec-
essary.
3. Check warning lamp and switch. Correct if necessary.
4. Check part at each connecting portion and, if found deformed
or damaged, replace.
Adjustment
Adjust parking brake as follows:
1. Fully release parking brake lever.
2. Loosen
VAand rotateVBuntil parking brake cable loosen.
3. Depress brake pedal several times until clicking sound does
not occur from rear brakes.
4. Adjust clearance between rear brake shoe and drum.
5. Adjust parking brake lever stroke by rotating
VB.
6. Pull parking brake lever with specified force. Check lever
stroke and ensure smooth operation.
7. Readjust clearance between rear brake shoe and drum.
SBR980D
SBR981D
SBR977D
PARKING BRAKE CONTROL
BR-31

Inspection and Adjustment
DISC BRAKEUnit: mm (in)
Brake model CL28VD
Pad wear limit
Minimum thickness 2.0 (0.079)
Rotor repair limit
Minimum thickness 24.0 (0.945)
DRUM BRAKEUnit: mm (in)
Brake model LT26B LT30A
Lining wear limit
Minimum thickness 1.5 (0.059)
Drum repair limit
Maximum inner
diameter261.5 (10.30) 296.5 (11.67)
Out-of-round limit 0.15 (0.0059)
BRAKE PEDALUnit: mm (in)
Free height ``H''*
LHD 209 - 219 (8.23 - 8.62)
RHD 203 - 213 (7.99 - 8.39)
Depressed height ``D''
[under force of 490 N (50
kg, 110 lb) with engine run-
ning]120.0 (4.72)
Clearance ``C'' between
pedal stopper and threaded
end of stop lamp switch0.3 - 1.0 (0.012 - 0.039)
Pedal free play
At clevis 1.0 - 3.0 (0.039 - 0.118)
At pedal pad 4 - 12 (0.16 - 0.47)
*: Measured from surface of melt sheet to pedal pad.
PARKING BRAKE CONTROL
Control type Stick lever Center lever
Lever stroke
[under force of 196 N
(20 kg, 44 lb)]2WD 8 - 10 Ð
4WD 10-12 8-10
Lever stroke when warning
switch comes on1
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-80

Removal
CAB BODY
lRemove the following parts in engine compartment at least.
(1) Main harness and other wiring harnesses
lDisconnect brake and clutch line in engine compartment.
lRemove the following parts from underbody at least.
(1) Transmission and transfer control levers
(2) Parking brake control lever and cables
(3) Main harness and other wiring harnesses
REAR BODY
lRemove the following parts at least.
(1) Rear combination lamp and license plate lamp harness
(2) Fuel filler tube fixing screws
SBF348C
ABT189
CAB AND REAR BODY
BT-40

EARTH CONNECT TO CONN. NO. CELL CODE
M1/M54 REAR COMBINATION LAMP RH (REAR FOG)
(RHD models except A-chassis)T2 EL-R/FOG
REAR COMBINATION LAMP RH (TAIL AND
STOP) (A-chassis models, and except for
Europe, Australia and China)T1 EL-TAIL/L EL-STOP/L
REAR COMBINATION LAMP RH (TAIL AND
STOP) (For Europe, Australia and China except
A-chassis models)T2 EL-TAIL/L EL-STOP/L
REAR COMBINATION LAMP RH (TURN SIG-
NAL) (A-chassis models, and except for
Europe, Australia and China)T1 EL-TURN
REAR COMBINATION LAMP RH (TURN SIG-
NAL) (For Europe, Australia and China except
A-chassis models)T2 EL-TURN
REAR FOG LAMP LH (LHD A-chassis models) T12 EL-R/FOG
REAR FOG LAMP RH (RHD A-chassis models) T10 EL-R/FOG
DOOR LOCK ACTUATOR DRIVER SIDE
(Unlock sensor)D10 EL-MULTI
LOCK KNOB SWITCH D8 EL-D/LOCK
POWER WINDOW MAIN SWITCH (Double cab) D5 EL-WINDOW EL-D/LOCK
POWER WINDOW MAIN SWITCH (Single cab
and King cab)D6 EL-WINDOW EL-D/LOCK
M33/M207
(LHD models
with KA
engine)CONDENSER M210 EC-IGN/SG
DISTRIBUTOR (POWER TRANSISTOR) M214 EC-IGN/SG
ECM (ECCS CONTROL MODULE) M32 EC-MAIN
M208
(LHD models
with KA
engine)DATA LINK CONNECTOR FOR CONSULT M11 EC-MIL/DL
DISTRIBUTOR (CAMSHAFT POSITION
SENSOR)M214 EC-CMPS
ECM (ECCS CONTROL MODULE) M32 EC-MAIN
NATS IMMU M68 EL-NATS
SHIELD WIRE (CAMSHAFT POSITION
SENSOR)M214 EC-CMPS
SHIELD WIRE (MASS AIR FLOW SENSOR) M204 EC-MAFS
SHIELD WIRE (THROTTLE POSITION
SENSOR)M302 EC-TPS
SHIELD WIRE (HEATED OXYGEN SENSOR) E3 EC-HO2S
E6/E39 NATS IMMU (Diesel engine) M69 EL-NATS
ABS ACTUATOR AND ELECTRIC UNIT E4 BR-ABS
BRAKE FLUID LEVEL SWITCH E2 EL-WARN
COOLING FAN MOTOR E24 LC-COOL/F
DAYTIME LIGHT UNIT E64 EL-DTRL
DIM-DIP LAMP UNIT E67 EL-DIMDIP
FRONT COMBINATION LAMP LH (PARKING)
(Except for Europe, Australia and China)E11 EL-TAIL/L
FRONT COMBINATION LAMP LH (PARKING)
(For Europe, Australia and China)E12 EL-TAIL/L
FRONT COMBINATION LAMP LH (TURN SIG-
NAL) (Except for Europe, Australia and China)E11 EL-TURN
FRONT COMBINATION LAMP LH (TURN SIG-
NAL) (For Europe, Australia and China)E12 EL-TURN
FRONT COMBINATION LAMP RH (PARKING)
(Except for Europe, Australia and China)E27 EL-TAIL/L
FRONT COMBINATION LAMP RH (PARKING)
(For Europe, Australia and China)E28 EL-TAIL/L
FRONT COMBINATION LAMP RH (TURN SIG-
NAL) (Except for Europe, Australia and China)E27 EL-TURN
FRONT COMBINATION LAMP RH (TURN SIG-
NAL) (For Europe, Australia and China)E28 EL-TURN
FUEL FILTER (FUEL HEATER) E56 EC-F/HEAT
FUEL FILTER SWITCH (RHD models with die-
sel engine)E5 EL-WARN EL-BUZZER
FUEL RETURN CONTROL SOLENOID VALVE
(RHD models with NA engine)E40 EC-F/RTN
GROUND DISTRIBUTION
EL-16

Use the chart below to find out what each wiring diagram code
stands for.
Refer to the wiring diagram code in the alphabetical index to find
the location (page number) of each wiring diagram.
Code Section Wiring Diagram Name
AAC/V EC IACV-AAC Valve
ABS BR Anti-lock Brake System
A/C, M HA Manual Air Conditioner
AUDIO EL Audio
BACK/L EL Back-up Lamp
BUZZER EL Warning Buzzer
CHARGE EL Charging System
CHOKE EC Automatic Choke
CIGAR EL Cigarette Lighter
CLOCK EL Clock
CMPS EC Camshaft Position Sensor
COOL/F LC Cooling Fan Control
DEF EL Rear Window Defogger
DIMDIP ELHeadlamp Ð With Dim-dip Lamp
System
D/LOCK EL Power Door Lock
DTRL ELHeadlamp Ð With Daytime Light
System
ECTS ECEngine Coolant Temperature
Sensor
EGRC/V EC EGRC Ð Solenoid Valve
FCUT EC Fuel Cut Solenoid Valve
F/HEAT EC Fuel Heater System
FICD EC IACV-FICD Solenoid Valve
FIPOT EC ISC-FI Pot
FPCM EC Fuel Pump Control Module
F/PUMP EC Fuel Pump
F/RTN EC Fuel Return Control Solenoid Valve
GLOW EC Quick-glow System
H/AIM EL Headlamp Aiming Control
HEATER HA Heater
H/LAMP EL Headlamp
HLC EL Headlamp Washer
HO2S EC Heated Oxygen Sensor
HORN EL Horn
H/SEAT EL Heated Seat
IATS EC Intake Air Temperature Sensor
IDLE EC IACV-Idle Up ControlCode Section Wiring Diagram Name
IGN EC Ignition System
IGN/SG EC Ignition Signal
ILL EL Illumination
INJECT EC Injector
INT/L EL Interior and Spot Lamps
MAFS EC Mass Air Flow Sensor
MAIN ECMain Power Supply and Ground Cir-
cuit
METER ELSpeedometer, Tachometer, Temp.
and Fuel Gauges
MIL/DL ECMIL and Data Link Connector For
CONSULT
MIRROR EL Power Door Mirror
MULTI EL Multi-remote Control System
NATS EL Nissan Anti-theft System
P/ANT EL Power Antenna
PGC/V ECCanister Purge
Control Solenoid Valve
PLA EC Partial Load Advance Control
PNP/SW EC Park/Neutral Position Switch
POWER EL Power Supply Routing
PST/SW EC Power Steering Oil Pressure Switch
R/FOG EL Rear Fog Lamp
SRS RS Supplemental Restraint System
S/SIG EC Start Signal
START EL Starting System
STOP/L EL Stop Lamp
SWL/V ECSwirl Control Valve Control Solenoid
Valve
TAIL/L EL Parking, License and Tail Lamps
TPS EC Throttle Position Sensor
TURN ELTurn Signal and Hazard Warning
Lamps
VSS EC Vehicle Speed Sensor
WARN EL Warning Lamps
WINDOW EL Power Window
WIPER EL Front Wiper and Washer
WIRING DIAGRAM CODES (CELL CODES)
EL-253