mileage NISSAN PRIMERA 1999 Electronic Repair Manual

DIAGNOSTIC WORKSHEET=NCAT0023S01Information from CustomerNCAT0023S0101KEY POINTS
WHAT..... Vehicle & CVT model
WHEN..... Date, Frequencies
WHERE..... Road conditions
HOW..... Operating conditions, Symptoms
Customer name MR/MS Model & Year VIN
Trans. model Engine Mileage
Incident Date Manuf. Date In Service Date
FrequencylContinuouslIntermittent ( times a day)
lVehicle does not move. (lAny positionlParticular position)
SymptomslLockup malfunction
lShift point too high or too low.
lShift shock or slip (lN,DlLockuplAny drive position)
lNoise or vibration
lNo pattern select
lOthers
()
SPORT indicator lamp or CVT
indicator (warning) lampBlinks for about 8 seconds.
lContinuously litlNot lit
Malfunction indicator (MI)lContinuously litlNot lit
TROUBLE DIAGNOSIS Ð INTRODUCTION
Introduction (Cont'd)
AT-30

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. The SRS system composition which is available to NISSAN MODEL P11 is as follows (The
composition varies according to the destination and optional equipment.):
lFor a frontal collision
The Supplemental Restraint System consists of 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),
front seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
lFor a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of
front seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a
frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
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 should 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. For removal of Spiral Cable and
Air Bag Module, see the RS section.
lDo 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 tape either just
before the harness connectors or for the complete harness are related to the SRS.
Precautions for Brake System
lRecommended fluid is brake fluid ªDOT 4º.
lNever reuse drained brake fluid.
lBe careful not to splash brake fluid on painted areas.
lTo clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, 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
tube.
lAlways torque brake lines when installing.
lBurnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªCheck and
Adjustmentº, BR-7.
WARNING:
lClean brake pads with a waste cloth, then wipe with a
dust collector.
SBR686C Commercial service tool
PRECAUTIONS
BR-3

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 brake warning lamp comes on and fluid level is above
ªMINº mark, 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 ªDOT 4º.
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 while keeping reservoir level higher than mini-
mum line by adding new brake fluid.
4. Repeat until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to ªBleeding Brake Systemº, BR-8.
Brake Burnishing Procedure
Burnish the brake contact surfaces according to the following
procedure after refinishing or replacing rotors, after replacing
pads, or if a soft pedal occurs at very low mileage.
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).
NBR141 MAX.
MIN.
ABR159
SBR419C
CHECK AND ADJUSTMENT
BR-7

Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne particles or other materials.
CAUTION:
lWhen cylinder body is open, do not depress brake pedal
because piston will pop out.
lBe careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
lIf shims are rusted or show peeling of the rubber coat,
replace them with new shims.
lIt 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.
lBurnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªCHECK AND
ADJUSTMENTº, BR-7.
NBR438
FRONT DISC BRAKE
BR-23

Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne particles or other materials.
CAUTION:
lWhen cylinder body is open, do not depress brake pedal
because piston will pop out.
lBe careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
lIf shims are rusted or show peeling of the rubber coat,
replace them with new shims.
lIt 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.
lBurnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªCHECK AND
ADJUSTMENTº, BR-7.
NBR439
FRONT DISC BRAKESR20DE - M/T
BR-26

lIt 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.
lBurnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªCHECK AND
ADJUSTMENTº, BR-7.
1. Remove master cylinder reservoir cap.
2. Remove brake cable mounting bolt and lock spring.
3. Release parking brake control lever, then disconnect cable
from the caliper.
4. Remove upper pin bolt.
5. Open cylinder body downward. Then remove pads inner and
outer shims.
Standard pad thickness:
9.3 mm (0.366 in)
Pad wear limit:
2.0 mm (0.079 in)
6. When installing new pads, push piston into cylinder body by
gently turning piston clockwise, as shown.
Carefully monitor brake fluid level because brake fluid
will return to reservoir when pushing back piston.
7. Adjust the piston to the right angle as shown in the figure.
NBR192
SBR916C Wire
SBR641
NBR374 Alignment position of
disc pad's concave
Concave portion Piston Assembly
to the right
angle
REAR DISC BRAKE TYPE 1
Pad Replacement (Cont'd)
BR-34

Component
1. Cylinder body
2. Pin
3. Pin boot
4. Torque member5. Inner shim
6. Inner pad
7. OUter pad8. Outer shim
9. Bleed valve
10. Connecting bolt
NOTE:
The cylinder body cannot be disassembled.
Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize
the hazard of airborne particles or other materials.
CAUTION:
lWhen cylinder body is open, do not depress brake pedal
because piston will pop out.
lBe careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
lIf shims are rusted or show peeling of rubber coat,
replace them with new shims.
lIt is not necessary to remove connecting bolt except for
replacement of caliper assembly. In this case, suspend
cylinder body with wire so as not to stretch brake hose.
lBurnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªON-VEHICLE
SERVICEº, BR-7.
NBR440
REAR DISC BRAKE TYPE 2
BR-40

Wheel Cylinder Overhaul
lCheck all internal parts for wear, rust and damage. Replace
if necessary.
lPay attention so as not to scratch cylinder when installing
pistons.
Inspection Ð Drum
Maximum inner diameter:
204.5 mm (8.05 in)
Maximum out-of-round:
0.03 mm (0.0012 in)
lContact surface should be fine finished with No. 120 to 150
emery paper.
lUsing a drum lathe, resurface brake drum if it shows scoring,
partial wear or stepped wear.
lAfter brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.
Inspection Ð Lining
Check lining thickness.
Standard lining thickness:
4.5 mm (0.177 in)
Lining wear limit:
1.5 mm (0.059 in)
Installation
lAlways perform shoe clearance adjustment. Refer to
BR-49.
lBurnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or
linings, or if a soft pedal occurs at very low mileage.
Refer to ªBrake Burnishing Procedureº, ªON-VEHICLE
SERVICEº, BR-7.
1. Fit toggle lever to brake shoe with retainer ring.
2. Apply brake grease to the contact areas shown at left.
SBR215B
SBR022A
SMA849B
SBR618E
REAR DRUM BRAKE
BR-46

Diagnostic Worksheet
There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can
make troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one shown below in order
to organize all the information for troubleshooting.
WORKSHEET SAMPLE
Customer name MR/MS Model & Year VIN
Engine # Trans. Mileage
Incident Date Manuf. Date In Service Date
SymptomslStartabilitylImpossible to startlNo combustionlPartial combustion
lPartial combustion when warming-up engine
lPartial combustion when cooling down engine
lPossible but hard to startlOthers
[]
lIdlinglNo fast idlelUnstablelHigh idlelLow idle
lOthers [ ]
lDriveabilitylStumblelSurgelKnocklLack of power
lOthers [ ]
lEngine stalllAt the time of startlWhile idling
lWhile acceleratinglWhile decelerating
lJust after stoppinglWhile loading
Incident occurrencelJust after deliverylRecently
lIn the morninglAt nightlIn the daytime
FrequencylAll the timelUnder certain conditionslSometimes
Weather conditionslNot affected
WeatherlFinelRaininglSnowinglOthers
[]
TemperaturelHotlWarmlCoollColdlHumid ÉF
Engine conditionslColdlDuring warm-uplAfter warm-up
Engine speed
0 2,000 4,000 6,000 8,000 rpm
Road conditionslIn townlIn suburbslHighwaylOff road (up/down)
Driving conditionslNot affected
lAt startinglWhile idlinglAt racing
lWhile acceleratinglWhile cruising
lWhile deceleratinglWhile turning (RH/LH)
Vehicle speed
0 102030405060708090100mph
Malfunction indicatorlTurned onlNot turned on
SEF907L
KEY POINTS
WHAT..... Vehicle & engine model
WHEN..... Date, Frequencies
WHERE..... Road conditions
HOW..... Operating conditions,
Weather conditions,
Symptoms
TROUBLE DIAGNOSIS Ð IntroductionCD20T
EC-34

MAINTENANCE
SECTION
MA
CONTENTS
PRECAUTIONS AND PREPARATION.......................... 3
Special Service Tools ................................................ 3
Commercial Service Tool ........................................... 3
PRE-DELIVERY INSPECTION ITEMS.......................... 4
GENERAL MAINTENANCE.......................................... 5
PERIODIC MAINTENANCE.......................................... 6
Maintenance Schedule for Petrol Engines
(Annual Mileage < 30,000 km/year) .......................... 6
Chassis and Body Maintenance ................................ 7
Maintenance Schedule for Diesel Engines
(Annual Mileage < 30,000 km/year) .......................... 8
Chassis and Body Maintenance ................................ 9
Maintenance Under Severe Driving Conditions
(Annual Driving Distance < 30,000 km/year) .......... 10
Maintenance Schedule for Petrol Engines
(Annual Mileage > 30,000 km/year) ......................... 11
Chassis and Body Maintenance .............................. 12
Maintenance Schedule for Diesel Engines
(Annual Mileage > 30,000 km/year) ........................ 13
Chassis and Body Maintenance .............................. 14
Maintenance Under Severe Driving Conditions
(Annual Driving Distance > 30,000 km) .................. 15
RECOMMENDED FLUIDS AND LUBRICANTS......... 16
Fluids and Lubricants .............................................. 16
SAE Viscosity Number ............................................ 17
QG
ENGINE MAINTENANCE............................................ 18
Checking Drive Belts ............................................... 18
Changing Engine Coolant........................................ 19
Checking Cooling System ....................................... 21
Checking Radiator Cap ........................................... 21
Checking Fuel Lines ................................................ 22Changing Fuel Filter ................................................ 23
Changing Air Cleaner Filter ..................................... 23
Changing Engine Oil................................................ 24
Changing Engine Oil Filter ...................................... 24
Checking and Changing Spark Plugs ..................... 25
Checking Positive Crankcase Ventilation (PCV)
System ..................................................................... 26
Checking Vacuum Hoses and Connections ............ 26
Checking EVAP Vapour Lines ................................. 26
Checking Front Heated Oxygen Sensor (HO2S) .... 27
SR20DE
ENGINE MAINTENANCE............................................ 28
Checking Drive Belts ............................................... 28
Changing Engine Coolant........................................ 29
Checking Cooling System ....................................... 31
Checking Fuel Lines ................................................ 33
Changing Fuel Filter ................................................ 33
Changing Air Cleaner Filter ..................................... 34
Changing Engine Oil................................................ 34
Changing Engine Oil Filter ...................................... 35
Checking and Changing Spark Plugs ..................... 35
Checking Ignition Leads .......................................... 36
Checking Positive Crankcase Ventilation (PCV)
System ..................................................................... 36
Checking Vacuum Hoses and Connections ............ 37
Checking EVAP Vapor Lines ................................... 37
Checking Front Heated Oxygen Sensor (HO2S) .... 38
CD20T
ENGINE MAINTENANCE............................................ 39
Checking Drive Belts ............................................... 39
Changing Engine Coolant........................................ 40
MA