service NISSAN PICK-UP 1998 Repair Manual

FOREWORD
This manual contains maintenance and repair procedures for NISSAN
PICKUP, model D22 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in speci-
®cations and methods at any time without notice.
IMPORTANT SAFETY NOTICE
The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a man-
ner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not speci®cally recommended by NISSAN must
®rst completely satisfy himself that neither his safety nor the vehicle's
safety will be jeopardized by the service method selected.
NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

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

How to Perform Trouble Diagnoses for Quick
and Accurate Repair ............................................ 38
Preliminary Check ................................................ 39
Component Parts and Harness Connector
Location................................................................ 40
Schematic/2WD Models....................................... 41
Wiring Diagram - ABS -/2WD LHD Models ......... 42
Wiring Diagram - ABS -/2WD RHD Models ........ 45
Schematic/4WD Models....................................... 48
Wiring Diagram - ABS -/4WD Models ................. 49
Self-diagnosis....................................................... 53
CONSULT ............................................................ 56
CONSULT Inspection Procedure......................... 57
Ground Circuit Check .......................................... 62
TROUBLE DIAGNOSES FOR
SELF-DIAGNOSTIC ITEMS.................................... 63
Diagnostic Procedure 1
(Wheel sensor or rotor)........................................ 63
Diagnostic Procedure 2 (ABS actuator
solenoid valve and solenoid valve relay)............. 65
Diagnostic Procedure 3 (Motor relay or motor) ... 67
Diagnostic Procedure 4 (Low voltage) ................ 69Diagnostic Procedure 5 (G sensor) ..................... 70
Diagnostic Procedure 6 (Control unit) ................. 71
TROUBLE DIAGNOSES FOR SYMPTOMS........... 72
Diagnostic Procedure 7
(ABS works frequently.) ....................................... 72
Diagnostic Procedure 8
(Unexpected pedal action) ................................... 73
Diagnostic Procedure 9
(Long stopping distance) ..................................... 73
Diagnostic Procedure 10
(ABS does not work.)........................................... 74
Diagnostic Procedure 11
(Pedal vibration and noise) .................................. 74
Diagnostic Procedure 12 (Warning lamp does
not come on when ignition switch is turned
ON.)...................................................................... 75
Diagnostic Procedure 13 (Warning lamp stays
on when ignition switch is turned ON.)................ 77
SERVICE DATA AND SPECIFICATIONS (SDS)... 78
General Specifications ......................................... 78
Inspection and Adjustment .................................. 80
When you read wiring diagrams:
lRead GI section, ``HOW TO READ WIRING DIAGRAMS''.
lSee 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'' (4WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag
module (located in the center of the steering wheel), 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:
lTo 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 must be per-
formed by an authorized NISSAN dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air
bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp and spiral
cable. Information necessary to service the system safely is included in theRS sectionof this Service
Manual.
WARNING:
lTo 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 must be per-
formed by an authorized NISSAN dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS.
Precautions for Brake System
lUse brake fluid DOT 3 or DOT 4*1.
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.
lTo clean master cylinder parts, disc brake caliper parts
or wheel cylinder parts, use clean brake fluid.
lNever use mineral oils such as gasoline or kerosene.
They will ruin rubber parts of the hydraulic system.
lUse flare nut wrench when removing and installing brake
tubes.
lAlways torque brake lines when installing.
WARNING:
lClean brakes with a vacuum dust collector to minimize
the hazard of airborne materials.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR820BA
PRECAUTIONS AND PREPARATION
BR-1

Special Service Tools
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
NT406
Removing and installing each brake piping
a: 10 mm (0.39 in)
: 16.2 Nzm (1.65 kg-m, 11.9 ft-lb)
Commercial Service Tools
Tool name Description
V1Flare nut crowfoot
V2Torque wrench
NT360
Removing and installing each brake piping
a: 10 mm (0.39 in)
Brake fluid pressure gauge
NT151
Measuring brake fluid pressure
PRECAUTIONS AND PREPARATION
BR-2

On-vehicle Service
OPERATING CHECK
lDepress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
lDepress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
lStart engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. Booster is airtight if pedal
stroke is less each time.
lDepress brake pedal while engine is running, and stop
engine with pedal depressed. The pedal stroke should not
change after holding pedal down for30 seconds.
Removal
CAUTION:
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.
lBe careful not to deform or bend brake pipes during
removal of booster.
Inspection
OUTPUT ROD LENGTH CHECK
1. Apply vacuum of þ66.7 kPa (þ667 mbar, þ500 mmHg,
þ19.69 inHg) to brake booster with a hand vacuum pump.
2. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
SBR002A
SBR365AA
ABR373
SBR281A
BRAKE BOOSTER
BR-15

Disassembly
WARNING:
Do not place your fingers in front of piston.
CAUTION:
lDo not scratch or score cylinder wall.
lCL28VD type front disc brake uses plastic pistons,
handle them carefully.
1. Push out piston and dust cover with compressed air.
For CL28VD (2-piston type), use a wooden block so that both
pistons come out evenly.
2. Remove piston seal with a suitable tool.
Inspection Ð Caliper
CYLINDER BODY
lCheck inside surface of cylinder for score, rust, wear, dam-
age or presence of foreign objects. If any of the above con-
ditions are observed, replace cylinder body.
lMinor damage from rust or foreign objects may be eliminated
by polishing the surface with a fine emery sandpaper.
Replace cylinder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
PISTON
Ð for plastic piston (CL28VD) Ð
Check pistons for uneven surface, chips or cracks. Replace if
any of these conditions are observed.
SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks or other damage. Replace if any of these
conditions are observed.
Inspection Ð Rotor
RUNOUT
1. Check runout using a dial indicator.
lMake sure that wheel bearing axial end play is within the
specifications before measuring. Refer to FA section
(``Front Wheel Bearing'', ``ON-VEHICLE SERVICE'').
Maximum runout:
0.07 mm (0.0028 in)
2. If the runout is out of specification, machine rotor with on-car
brake lathe (``MAD, DL-8700'', ``AMMCO 700 and 705'' or
equivalent).
SBR085A
SBR177C
SBR089A
FRONT DISC BRAKE
BR-23

Diagnostic Procedure 7
(ABS works frequently.)
CHECK BRAKE FLUID PRESSURE.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check brake fluid pressure distribution.
Refer to proportioning valve inspection.
OK
cNG
Perform Preliminary
Check, refer to BR-39.
CHECK WHEEL SENSOR.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Check wheel sensor connector for ter-
minal damage or loose connections.
2. Perform wheel sensor mechanical
check.
Refer to Diagnostic Procedure 1,
BR-63.
OK
cNG
Repair.
CHECK FRONT AXLES.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check front axles for excessive loose-
ness. Refer to FA section (``Front Wheel
Bearing'', ``ON-VEHICLE SERVICE'').
OK
cNG
Repair.
Go toin Diagnostic Procedure 8,
BR-73.
.
.
.
TROUBLE DIAGNOSES FOR SYMPTOMS
BR-72

General Specifications
2WD MODELS
Applied model Without ABS With ABS
Front brake
CL28VD disc brake
Type
Cylinder bore diameter mm (in) 42.8 (1.685) x 2
Pad dimension mm (in)
Length x width x thickness146.6 x 48.5 x 10.0
(5.77 x 1.909 x 0.394)
Rotor outer diameter x thickness
mm (in)260x26
(10.24 x 1.02)
Rear brake
TypeLT26B drum brake
Wheel cylinder bore diameter
mm (in)23.81 (15/16)
Lining dimension mm (in)
Length x width x thickness249.6 x 50 x 5.5
(9.83 x 1.97 x 0.217)
Drum inner diameter mm (in) 260 (10.24)
Master cylinder bore diameter
mm (in)23.81 (15/16) 25.4 (1)
Control valve
TypeLSV
Split point x reducing ratio
kPa (bar, kg/cm
2, psi)(Variable) x 0.15
Brake booster
ModelM195T
Diaphragm diameter mm (in)Primary: 205 (8.07)
Secondary: 180 (7.09)
Recommended brake fluid DOT 3 or DOT 4*1
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOMMENDED FLUIDS AND LUBRICANTS'').
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-78

4WD MODELS
Applied modelAll
Front brake
TypeCL28VD disc brake
Cylinder bore diameter mm (in) 42.8 (1.685) x 2
Pad dimension mm (in)
Length x width x thickness146.6 x 48.5 x 10
(5.77 x 1.909 x 0.39)
Rotor outer diameter x thickness
mm (in)277 x 26 (10.91 x 1.02)
Rear brake
TypeLT30A drum brake
Wheel cylinder bore diameter
mm (in)22.22 (7/8)
Lining dimension mm (in)
Length x width x thickness296.0 x 50.0 x 6.1 (11.65 x 1.969 x 0.240)
Drum inner diameter mm (in) 295 (11.61)
Master cylinder bore diameter
mm (in)23.81 (15/16)
Control valve
TypeLSV
Split point x reducing ratio
kPa (bar, kg/cm
2, psi)(Variable) x 0.15
Brake booster
ModelM215T
Diaphragm diameter mm (in)Primary: 230 (9.06)
Secondary: 205 (8.07)
Recommended brake fluid DOT 3 or DOT 4*1
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOMMENDED FLUIDS AND LUBRICANTS'').
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications (Cont'd)
BR-79