tow NISSAN PRIMERA 1999 Electronic Repair Manual

REMOVAL
1. Remove the housing retaining spring.
2. Wipe away any dirt from the guide pins between the torque
member and the cylinder body.
3. Pull out the protective caps from the guide sleeves.
4. Usea7-mmALLEN key to unscrew the guide pins
from the torque member.
5. Partially remove the guide pins from the guide sleeve.
6. Pull the cylinder body manually towards the outer side of the
vehicle so that the piston is slightly pressed back.
7. Remove the cylinder body and hang it on a wire in the wheel
arch in a suitable position.
Make sure there is no strain on the brake hose piping.
8. Remove the brake pad on the piston side from the piston.
9. Remove the second brake pad from the torque member.
NBR292 Spring Cylinder bodyTorque member lug.Torque member lug Locating
holes
NBR300 Protective
caps
NBR290
Wire
Spring
FRONT DISC BRAKESR20DE - M/T
Pad Replacement (Cont'd)
BR-27

Pin and Pin Boot
Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
Rotor
Rubbing Surface
Check rotor for roughness, cracks or chips.
Runout
1. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications
before measuring. Refer to RA section (ªREAR WHEEL
BEARINGº, ªOn-vehicle Serviceº).
3. Change relative positions of rotor and wheel hub so that
runout is minimized.
Maximum runout:
0.07 mm (0.0028 in)
Thickness
Rotor repair limit:
Standard thickness
10 mm (0.39 in)
Minimum thickness
9 mm (0.35 in)
Thickness variation (At least 8 portions)
Maximum 0.02 mm (0.0008 in)
Assembly
1. Insert cam with depression facing towards open end of cyl-
inder.
2. Generously apply rubber grease to strut and push rod to
make insertion easy.
SBR219C
NBR367Sleeve Seal Cam
O-ring
Strut
pR
Push rod
Rubber grease
SBR248B
REAR DISC BRAKE TYPE 1
Inspection (Cont'd)
BR-37

Rearview Mirror
REMOVAL
Remove rearview mirror by pushing deflect spring with screw-
driver as shown in the figure.
INSTALLATION
1. Install mounting bracket as follows:
(1) Determine mounting bracket position on windshield by mea-
suring from top of windshield to top of mounting bracket as
shown in the figure.
(2) Mark location on outside of windshield with wax pencil or
equivalent.
(3) Clean attaching point on inside of windshield with an alcohol-
saturated paper towel.
(4) Sand bonding surface of mounting bracket with sandpaper
(No. 320 or No. 360).
(5) Clean bonding surface of mounting bracket with an alcohol-
saturated paper towel.
(6) Apply Loctite Adhesive 11067-2 or equivalent to bonding sur-
face of mounting bracket.
(7) Install mounting bracket at premarked position and press
mounting bracket against glass for 30 to 60 seconds.
(8) After five minutes, wipe off excess adhesive with an alcohol-
moistened paper towel.
2. Install rearview mirror.
NBT059 Windshield
Mirror assembly
Windshield Mounting
bracket
Mounting
bracket
Side viewMirror assembly
YBT049 Bracket
Center of windshield85-90mm
(3.34 - 3.54 in) Mounting bracket location
MIRROR
BT-59

MEASUREMENT POINTS
YBT047 Rear
14 dia.
18 dia.12 dia.
16 dia.
12.5 dia.16 dia.
RH side 16 dia.
12.5 dia.
LH side
16 dia.
14 dia.
12 dia.
16 dia.
Bolt head
Bolt head
12 dia.
16 dia.
18 dia.Front and rear strut tower centers
Front
pR,pr88 dia.
Rear
pS,ps60.8 dia. Coordinates:
pR,prx : 527.3
y : þ5.1
z : 780.1
pS,psx : 478
y : 2,522
z : 527.3
FrontUnit: mmFront
coordinates
pA,pax : 330
y : þ650
z : 213
pB,pbx : 495
y : þ490
z : 356.6
pC,pcx : 455
y : þ35
z : 377.6
pD,pdx : 450
y:70
z : 254
pE,pex : 410
y : 310
z : 133.8
pF,pfx : 587
y : 405
z : 169.4
pG,pgx : 393
y : 500
z : 128.6
pH,phx : 414.5
y : 1,210
z : 124.9Rear
coordinates
pJ,pjx : 412.5
y : 1,625
z : 123.2
pK,pkx : 524
y : 2,005
z : 209
pL,plx : 555
y : 2,085
z : 259
pMx : 145
y : 2,507
z : 250
pNx : 300
y : 2,550
z : 402.3
pnx : þ300
y : 2,550
z : 428.3
pPx : 512
y : 2,900
z : 346.5
ppx : þ544
y : 2,882
z : 347.7
pQx : 542
y : 3,385.6
z : 339.4
pqx : þ570.5
y : 3,380
z : 346.5 Bottom view of vehicle
BODY ALIGNMENT
Underbody (Cont'd)
BT-63

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

pA
CHECK INJECTION TIMING.
1. Set No. 1 piston at TDC on its com-
pression stroke.
TDC: Without painted mark
2. Remove injection tubes and air
bleeder on the back of injection
pump.
3. Set dial gauge so its indicator points
to somewhere between 1.0 and 2.0
mm (0.039 and 0.079 in) on the
scale.
4. Turn crankshaft 2 turns clockwise
and check that dial gauge indicates
the same value again.
5. Turn crankshaft counterclockwise
about 100 degrees, then turn crank-
shaft slowly clockwise, and set dial
gauge indicator to 0 mm at the posi-
tion it stops.
6. Turn crankshaft clockwise and set it
at plunger lift timing mark using the
mark on the crankshaft pulley.
plunger lift timing mark: Yellow
painted mark
7. Read plunger lift.
Plunger lift:
0.89   0.08 mm (0.0350   0.0031
in) at plunger lift timing mark
lWhen repeating the checking,
start with step 5.
NG
EOK
Bleed air from fuel sys-
tem.
After this inspection,
unnecessary diagnostic
trouble code No. might
be displayed.
Erase the stored
memory in ECM.
Refer to ªON BOARD
DIAGNOSTIC SYSTEM
DESCRIPTIONº.
OK
INSPECTION END
Adjusting
1. If plunger lift is not within the speci-
fied value, adjust by turning injec-
tion pump.
lIf indication is smaller than the
specified value, turn pump body
away from engine.
lIf indication is larger than the
specified value, turn pump body
towards engine.
2. Tighten injection pump securing
bolts and nuts.
Nut:
: 20-25N´m
(2.0 - 2.6 kg-m, 15 - 18 ft-lb)
Bolt:
: 25-35N´m
(2.6 - 3.6 kg-m, 18 - 26 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 14-20N´m
(1.4 - 2.0 kg-m, 10 - 15 ft-lb)
5. Bleed air from fuel system.
Refer to ªWater Draining, Fuel Filter
Check and Replacementº of
ªENGINE MAINTENANCEº in MA
section.
EGo to
SEF661S
SEF655S
Plunger lift timing mark
(Yellow painted mark)
TDC (Without painted mark)
SEF662S
Increase
Decrease
SEF657S
H
H
H
TROUBLE DIAGNOSIS Ð Basic InspectionCD20T
Basic Inspection (Cont'd)
EC-38

DIAGNOSTIC PROCEDURE
INSPECTION START
CHECK POWER SUPPLY.
1. Turn ignition switch to ªLOCKº posi-
tion.
2. Disconnect engine coolant tempera-
ture sensor harness connector.
3. Turn ignition switch to ªONº position.
4. Check voltage between engine cool-
ant temperature sensor connector
terminal
p2and ground with CON-
SULT-II or tester.
Voltage:
Approximately 4.9V
OK
ENG
Repair harness or con-
nectors.
CHECK GROUND CIRCUIT.
1. Turn ignition switch to ªLOCKº posi-
tion.
2. Check harness continuity between
engine coolant temperature sensor
connector terminal
p1and engine
ground.
Continuity should exist.
If OK, check harness for short-cir-
cuit.
OK
ENG
Repair harness or con-
nectors.
CHECK COMPONENT
(Engine coolant temperature sensor).
Refer to ªCOMPONENT INSPECTIONº
on next page.
OK
ENG
Replace engine coolant
temperature sensor.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
Trouble is not fixed.
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
INSPECTION END
NEF401
.RH strut tower
.Engine coolant temperature
sensor harness connector
NEF193A
Engine coolant temperature
sensor connector
SEF542P
Engine coolant temperature
sensor connector
H
H
H
H
H
H
TROUBLE DIAGNOSIS 2CD20T
Engine Coolant Temperature (ECT) Sensor
(Cont'd)
EC-68

Air Conditioner Cut Control
The Air Conditioner relay is controlled by the ECM. During the
following conditions, the ECM will cut the power supply towards
the air conditioner relay:
lStarting engine
lQuick acceleration from low speed
lUndershooting of idle speed
lHigh engine coolant temperature [above 107ÉC (225ÉF)].
lMalfunctioning of engine speed sensor, accelerator position
sensor or vehicle speed sensor when engine speed is below
2,100 rpm.
Malfunction is detected when ....Check Items
(Possible cause)
lAir conditioner relay signal circuit is shorted.lHarness or connectors
(The air conditioner relay signal circuit is shorted).
lAir conditioner relay
DIAGNOSTIC TROUBLE CONFIRMATION
PROCEDURE
1) Turn ignition switch and air conditioner switch to the
ªONº position.
2) Select ªDATA MONITORº mode with CONSULT-II.
3) Wait at least 2 seconds.
TROUBLE DIAGNOSES 15CD20T
EC-126

DATA MONITOR MODENCEC0034S06
Monitored item [Unit]ECM
input
signalsMain
signalsDescription Remarks
ENG SPEED
[rpm]qqIIndicates the engine speed computed from the
POS signal of the crankshaft position sensor.IAccuracy becomes poor if
engine speed drops below the
idle rpm.
IIf the signal is interrupted while
the engine is running, an abnor-
mal value may be indicated.
MAS A/F SE-B1 [V]qqIThe signal voltage of the mass air flow sensor is
displayed.IWhen the engine is stopped, a
certain value is indicated.
COOLAN TEMP/S
[ÉC] or [ÉF]qqIThe engine coolant temperature (determined by
the signal voltage of the engine coolant tem-
perature sensor) is displayed.IWhen the engine coolant tem-
perature sensor is open or
short-circuited, ECM enters fail-
safe mode. The engine coolant
temperature determined by the
ECM is displayed.
HO2S1 (B1) [V]qqIThe signal voltage of the heated oxygen sensor
1 (front) is displayed.
HO2S2 (B1) [V]qIThe signal voltage of the heated oxygen sensor
2 (rear) is displayed.
HO2S1 MNTR (B1)
[RICH/LEAN]qIDisplay of heated oxygen sensor 1 (front) signal
during air-fuel ratio feedback control:
RICH ... means the mixture became ªrichº, and
control is being affected toward a leaner mix-
ture.
LEAN ... means the mixture became ªleanº, and
control is being affected toward a rich mixture.IAfter turning ON the ignition
switch, ªRICHº is displayed until
air-fuel mixture ratio feedback
control begins.
IWhen the air-fuel ratio feedback
is clamped, the value just
before the clamping is dis-
played continuously.
HO2S2 MNTR (B1)
[RICH/LEAN]qIDisplay of heated oxygen sensor 2 (rear) signal:
RICH ... means the amount of oxygen after
three way catalyst is relatively small.
LEAN ... means the amount of oxygen after
three way catalyst is relatively large.IWhen the engine is stopped, a
certain value is indicated.
VHCL SPEED SE
[km/h] or [mph]qqIThe vehicle speed computed from the vehicle
speed sensor signal or ABS actuator and elec-
tric unit (control unit) signal is displayed.
BATTERY VOLT [V]qIThe power supply voltage of ECM is displayed.
THRTL POS SEN [V]qqIThe throttle position sensor signal voltage is dis-
played.
EGR TEMP SEN [V]
(If so equipped)qqIThe signal voltage of the EGR temperature sen-
sor is displayed.
INT/A TEMP SE
[ÉC] or [ÉF]qIThe intake air temperature determined by the
signal voltage of the intake air temperature sen-
sor is indicated.
START SIGNAL
[ON/OFF]qqIIndicates [ON/OFF] condition from the starter
signal.IAfter starting the engine, [OFF]
is displayed regardless of the
starter signal.
CLSD THL POS
[ON/OFF]qqIIndicates idle position [ON/OFF] computed by
ECM according to the throttle position sensor
signal.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONQG16I18DE
CONSULT-II (Cont'd)
EC-59

SEF189X Intake manifold
collectorFuel pressure
regulatorHeadlamp
(Left side)
Front
Refrigerant
pressure sensor and
harness connector
Power transistorTerminal for ignition coil
Camshaft position sensor,
power transistor and ignition
coil (built into distributor)
Terminal for camshaft position sensor
and power transistor Camshaft position
sensor
Metal tip of ignition coil tower
(Terminal of coil circuit)
NOTE: Power transistor, camshaft position sensor,
and ignition coil have to be replaced as a
distributor assembly.
ENGINE AND EMISSION CONTROL OVERALL SYSTEMSR20DE
Engine Control Component Parts Location (Cont'd)
EC-18