steering NISSAN PRIMERA 1999 Electronic Repair Manual

Precautions for Supplemental Restraint System
(SRS) ªAIR BAGº and ªSEAT BELT
PRE-TENSIONERº
NCAT0002The Supplemental Restraint System ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº, used along with a seat
belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The
Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and
on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning
lamp, wiring harness and spiral cable.
In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used along
with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side col-
lision. The supplemental side air bag consists of air bag modules (located in the outer side of front seats),
satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal collision),
wiring harness, warning lamp (one of components of supplemental air bags for a frontal collision). Information
necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
ITo 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 performed
by an authorized NISSAN dealer.
IImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
IDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses (except ªSEAT BELT PRE-TENSIONERº connector) can be
identified with yellow harness connector (and with yellow harness protector or yellow insulation
tape before the harness connectors).
Precautions for On Board Diagnostic (OBD)
System of CVT and Engine
NCAT0198The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver
of a malfunction causing emission deterioration.
CAUTION:
IBe sure to turn the ignition switch ªOFFº and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc.
will cause the MI to light up.
IBe sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to an open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
IBe sure to route and secure the harnesses properly after work. Interference of the harness with a
bracket, etc. may cause the MI to light up due to a short circuit.
IBe sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to a malfunction of the EGR system or fuel injection system, etc.
IBe sure to erase the unnecessary malfunction information (repairs completed) from the TCM and
ECM before returning the vehicle to the customer.
PrecautionsNCAT0003IBefore connecting or disconnecting the TCM harness
connector, turn ignition switch OFF and disconnect nega-
tive battery terminal. Failure to do so may damage the
TCM. Because battery voltage is applied to TCM even if
ignition switch is turned off.
SEF289H
PRECAUTIONS
Precautions for Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
AT-5

CVT Electrical Parts LocationNCAT0008
SAT671J Front
TCMIndicator C/USteering column
Throttle position sensor and
throttle position switch
SPORT indicator lamp
CVT indicator lamp
Manual mode switch SPORT mode switch
Dropping
resistor
Primary speed sensor Fluid temperature sensor
Fluid pressure sensor
Lock-up solenoid
Line pressure solenoid
Step motorInside control valveControl valve connectorPNP switchSecondary speed sensor
OVERALL SYSTEM
CVT Electrical Parts Location
AT-9

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

NVH Troubleshooting Chart
Use the chart to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
BR-23, 26, 33
BR-23 26, 33
BR-23, 33
Ð
BR-31, 37, 43
BR-31, 37, 43
Ð
Ð
Ð
BR-31, 37
NHV in PD section
NHV in PD section
NHV in FA, RA section
NHV in FA section
NHV in FA section
NHV in FA section
NHV in ST section
Possible cause and
SUSPECTED PARTS
Pads - damaged
Pads - uneven wear
Shims damaged
Rotor imbalance
Rotor damaged
Rotor runout
Rotor deformation
Rotor deflection
Rotor rust
Rotor thickness variation
PROPELLER SHAFT
DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
AXLE SHAFT
STEERING
Symptom BRAKENoise x x xxxxxxxx
Shake x xxxxxx
Shimmy, Judderxxxxxxx xxx x
X : Applicable
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLE SHOOTING
BR-6

Purpose
The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control of
braking force so that locking of the wheels can be avoided.
The ABS:
1) Provides improved steering control during braking (by preventing front wheel lock).
2) Provides improved vehicle stability and skid prevention during braking (by avoiding rear wheel lock).
Operation
lWhen the vehicle speed is less than 10 km/h (6 mph) this system does not work.
lThe Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning light
for 1 second after turning the ignition switch to the ªONº position. The system performs another test the
first time the vehicle reaches 6 km/h (4 mph). A mechanical noise may be heard as the ABS performs
a self-test. This is a normal part of the self-test feature. If a malfunction is found during this check, the
ABS warning light will come on.
lDuring ABS operation, a mechanical noise may be heard. This is a normal operating condition.
ABS Hydraulic Circuit
p1Inlet solenoid valve
p2Outlet solenoid valve
p3Reservoir
p4Pump
p5Motorp6Bypass check valve
p7Damper
NBR259 Rear LH
wheelFront RH
wheelFront LH
wheelRear RH
wheel
ANTI-LOCK BRAKE SYSTEM
BR-50

Service Notice
lWhen removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
lHandle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soil
or damage them.
lApply sealing compound where necessary when installing parts.
lWhen applying sealing compound, be careful that the sealing compound does not protrude from parts.
lWhen replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust
prevention measures.
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
The Supplemental Restraint System 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 in a frontal collision. The
Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and
on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning
lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the
RS sectionof the Service Manual.
If the vehicle is equipped with side air bag as the Supplemental Restraint System, the side air bag used along
with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side
collision. The side air bag consists of air bag modules (located in the outer side of front seats), satellite
sensor, diagnosis sensor unit (which is one of components of air bags for a frontal collision), wiring harness,
warning lamp (which is one of components of air bags for a frontal collision).
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 do so
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.
PRECAUTIONS
BT-2

CAUTION:
lDisconnect both battery cables in advance.
lDisconnect air bag system line in advance.
lNever tamper with or force air bag lid open, as this may adversely affect air bag performance.
lBe careful not to scratch pad and other parts.
REMOVAL Ð Instrument panel assembly
Instrument panel assemblyCombination meterAudio & A/C controlConsole box
Remove air bag module (driver's) and steering wheel.
Refer to ªSUPPLEMENTAL RESTRAINT SYSTEMº in RS section for details.
p1Steering column cover and combination switchlRemove screws.
p2Instrument lower panel on driver sidelRemove screws.
p3Cluster lid AlRemove screws.
p4Combination meterlRemove screws and disconnect harness connectors.
p5Audio
p6Center ventilatorlRemove screws.lPull out with a miniature flat-bladed screwdriver.
p7A/C or heated controllRemove screws.
p8Audio bracket
p9Glove box assemblylRemove glove box pin.lThen disconnect passenger air bag module connector.
p10Passenger air bag modulelRefer to ªSUPPLEMENTAL RESTRAINT SYSTEMº in RS section for
details.
p11Lower coverlRemove clip
p12AT finisher or MT shift lever boot
p13Rear console boxlRemove console mask and screws.
p14Front console boxlRemove screws and bolts.
p15Front defroster grilllDisconnect harness connector.
p16Front pillar garnishlRefer to ªSide and Floor Trimº in ªINTERIOR TRIMº for details, BT-18.
p17Instrument panel and padslRemove nuts and bolts.lRemove door mirror switch and disconnect the connector.
INSTRUMENT PANEL
BT-15

INSPECITON
Pedal stroke
Check clutch pedal stroke using a 1-meter rule to measure the total pedal stroke. Place end of rule onto the
middle of the clutch pedal pad. Place a book/clipboard on the driver's set to set a reference point, ensure
the book/clipboard does not move during pedal depression. Mark (A) the pedal fully up position on the rule.
Depress the clutch pedal and mark (B) the rule again next to the reference point on the book/clipboard.
Measure the distance between the marks (A and B), this is the actual pedal stroke (S). Check the specified
pedal stroke in the table, adjust actual pedal stroke if necessary (refer toªADJUSTMENTº).
Note:
lDo not use steering wheel as a reference point, angle gives incorrect reading.
lEnsure there is no interference between the floor carpet and clutch pedal when fully depressed.
Pedal free play
Check pedal free play. If out of specification, refer toªADJUSTMENTº.
lPush on the clutch pedal until resistance is felt, and check the distance the pedal moves.
ADJUSTMENT
Pedal stroke
1. Loosen the pedal stopper bolt completely (so there is no contact between pedal and stopper bolt).
2. Adjust pedal stroke to the specified value with the master cylinder push rod.
3. Adjust the pedal stopper bolt until it is just in contact with the pedal, then tighten the lock nut.
4. Once stroke is set to specification, adjust clutch pedal free play.
Pedal free play
1. Adjust pedal free play to the specified value with the master cylinder push rod.
2. Tighten lock nut of the master cylinder push rod.
lPush on the clutch pedal until resistance is felt, and check the distance the pedal moves.
Pedal free play ªAº:
Refer to SDS, CL-16.
SCL702
INSPECTION AND ADJUSTMENT
Inspecting and Adjusting Clutch Pedal
(Cont'd)
CL-6

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NCEC0002
The Supplemental Restraint System ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº, used along with a seat
belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The
Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and
on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning
lamp, wiring harness and spiral cable.
In addition to the supplemental air bag modules for a frontal collision, the supplemental side air bag used
along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a
side collision. The supplemental side air bag consists of air bag modules (located in the outer side of front
seats), satellite sensor, diagnosis sensor unit (one of components of supplemental air bags for a frontal
collision), wiring harness, warning lamp (one of components of supplemental 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 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 (except ªSEAT BELT PRE-TENSIONERº connector) can be
identified with yellow harness connector (and with yellow harness protector or yellow insulation
tape before the harness connectors).
Precautions for On Board Diagnostic (OBD)
System of Engine
NCEC0003
The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver
of a malfunction causing emission deterioration.
CAUTION:
lBe sure to turn the ignition switch ªOFFº and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MI to light up.
lBe sure to connect and lock the connectors securely after work. A loose (unlocked) connector
will cause the MI to light up due to the open circuit. (Be sure the connector is free from water,
grease, dirt, bent terminals, etc.)
lCertain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector.
For description and how to disconnect, refer to EL section, ªDescriptionº, ªHARNESS CONNEC-
TORº.
lBe sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.
lBe sure to connect rubber tubes properly after work. A misconnected or disconnected rubber
tube may cause the MI to light up due to the malfunction of the EGR system or fuel injection
system, etc.
lBe sure to erase the unnecessary malfunction information (repairs completed) from the ECM
before returning the vehicle to the customer.
PRECAUTIONS AND PREPARATIONCD20T
EC-6

Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
lHeadlamp switch is off,
lAir Conditioner switch is off,
lRear defogger switch is off,
lSteering wheel is in the straight-ahead position, etc.
BEFORE STARTING
1. Check service records for any
recent repairs that may indicate a
related problem, or the current need
for scheduled maintenance.
2. Open engine hood and check the
following:
lHarness connectors for faulty con-
nections
lVacuum hoses for splits, kinks, or
faulty connections
lWiring for faulty connections,
pinches, or cuts
3. Using priming pump, bleed air from
fuel system. Refer to ªFuel Filter
Checkº in MA section.
CONNECT CONSULT-II TO THE
VEHICLE.
Connect ªCONSULT-IIº to the data link
connector for CONSULT-II and select
ªENGINEº from the menu. Refer to EC-
CD-27.
DOES ENGINE START?
Ye s
ENo
Turn ignition switch to
the ªLOCKº position, wait
5 seconds and then start
engine. If engine fails to
start, check malfunction
item.
Run engine for 10 minutes.
CHECK IDLE SPEED.
Read engine idle speed in
ªDATA MONITORº mode with
CONSULT-II.
825 rpm   25 (in N position)
---------------------------------------------------------------------------------------------------------------------------------OR---------------------------------------------------------------------------------------------------------------------------------
Check idle speed using tachom-
eter tester.
825 rpm   25 (in N position)
(Go topAon next page.)
SEF142I
SEF671S
Priming pump
SEF689S
.Diesel tacho tester
.Injection tube
PEF190P
H
H
H
H
H
TROUBLE DIAGNOSIS Ð Basic InspectionCD20T
EC-37