NISSAN TERRANO 2004 Service Repair Manual

ISecure lock nut by bending one portion of lock washer.
Installation
Install the sensor rotor using suitable drift and press.
IAlways replace sensor rotor with new one.
I Pay attention to the direction of front sensor rotor as shown in
figure.
I Install new oil seal to rear axle housing using a suitable tool.
After installing new oil seal, coat sealing lip with multi-purpose
grease.
I Position axle shafts in rear axle housing.
Be careful not to damage oil seal.
I When the ball-bearing holder and the brake are installed in the
base of the axle, they need to be correctly positioned.
A quick way to determine on which side the holder should be
located, is to look at the brake adjustment screw. Left-hand thread:Install the holder on the left side.
Right-hand thread (Normal) Install the holder on the right side.
SRA104
SBR402D
SRA292A
ERA017
REAR AXLE
Installation (Cont'd)
RA-10
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IInsert axle shaft with Tool as a guide.
When inserting axle shaft, be careful not to damage oil seal.
I Tighten nuts to the specified torque.
:53-63N ×m (5.4 - 6.4 kg-m, 39 - 46 ft-lb)
I Install ABS-sensor.
I Measure end play of axle shaft.
Axial end play: 0.0 mm (0.0000 in)
YRA006
ERA013
YRA003
REAR AXLE
Installation (Cont'd)
RA-11
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Removal and Installation
IDisconnect brake hydraulic line and parking brake cable.
CAUTION:
Use Tool when removing or installing brake tubes.
I Remove stabilizer bar from body
I Remove upper links and lower links from body.
I Remove panhard rod from body.
I Disconnect propeller shaft.
I Remove upper end nuts of shock absorber.
Final tightening for rubber parts requires to be carried out
under unladen condition with tires on ground.
SRA906
SBR820B
SRA935
REAR AXLE AND REAR SUSPENSION
RA-12
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Components
YRA009
REAR SUSPENSION
RA-13
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Coil Spring Shock Absorber
REMOVAL AND INSTALLATION
IRefer to Removal and Installation of REAR AXLE AND REAR
SUSPENSION, RA-12.
When installing coil spring and lower spring seat, pay atten-
tion to its direction.
Be sure spring rubber seat is not twisted and has not slipped
off when installing coil spring.
INSPECTION
I Check coil spring for yield, deformation or cracks.
I Check coil spring specifications. Refer to SDS, RA-16.
I Check shock absorber for oil leakage, cracks or deformation.
I Check shock absorber specifications. Refer to SDS, RA-16.
I Check all rubber parts for wear, cracks or deformation. Replace
if necessary.
Upper Link, Lower Link and Panhard Rod
INSPECTION
Check for cracks, distortion or other damage. Replace if necessary.
BUSHING REPLACEMENT
Check for cracks or other damage. Replace with suitable tool if
necessary.
IRemove bushing with suitable tool.
When installing bushing, apply a coating of 1% soap water to
outer wall of bushing.
Always install new bushing.
Do not tap end face of bushing directly with a hammer.
SRA910
SRA898
SRA900
REAR SUSPENSION
RA-14
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INSTALLATION
When installing each link, pay attention to direction of bolts
and nuts. Refer to REAR SUSPENSION - Components, RA-13.
When installing each rubber part, final tightening must be car-
ried out under unladen condition with tires on ground.
Stabilizer Bar
REMOVAL AND INSTALLATION
IWhen removing and installing stabilizer bar, fix portion A.
SRA909
REAR SUSPENSION
Upper Link, Lower Link and Panhard Rod
(Cont'd)
RA-15
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General Specifications
COIL SPRING AND SHOCK ABSORBER
ModelHardtopWagon
Coil spring Wire diameter mm (in) 13.0 (0.512) 13.5 (0.531)
Free length mm (in) 400 (15.75) 417 (16.42)
Spring constant N/mm (kg/mm, lb/in) 25.5 (2.6, 146) 29 (3.0, 168)
Shock absorber Shock absorber type Non-adjustable (hydraulic)
Maximum length mm (in) 586 (23.07) 596 (23.46)
Minimum length mm (in) 350 (13.78) 356 (14.02)
Damping force
[at 0.3 m (1.0 ft)/sec.] N (kg, lb)
Expansion 990 - 1,330
(101 - 136, 223 - 229) 1,169 - 1,563
(119 - 159,223 - 351)
Compression 346 - 524
(35.3 - 53.4,
77.8 - 117.8) 301 - 461
(30.7 - 47.0,
67.7 - 103.6)
RA260
STABILIZER BAR
Model HardtopWagon
Diameter mm (in) 23 (0.91) 24 (0.94)
Spring constant N/mm (kg/mm, lb/in) 24.5 (2.5, 140) 29.0 (3.0, 166)
Inspection and Adjustment
WHEEL BEARING
Total end play mm (in)
0 (0)
SERVICE DATA AND SPECIFICATIONS (SDS)
RA-16
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BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS AND PREPARATION ............................3
Supplement Restraint System (SRS) ²AIR BAG²
and ²SEAT BELT PRE-TENSIONER² .........................3
Precautions ..................................................................3
Preparation ..................................................................4
CHECK AND ADJUSTMENT ..........................................5
Checking Brake Fluid Level.........................................5
Checking Brake Line ...................................................5
Changing Brake Fluid ..................................................5
Brake Burnishing Procedure........................................5
BRAKE HYDRAULIC LINE .............................................6
Bleeding Brake System ...............................................8
Removal .......................................................................9
Inspection.....................................................................9
Installation ....................................................................9
LOAD SENSING VALVE ...............................................10
Removal and Installation ...........................................10
Removal ..................................................................... 11
Installation .................................................................. 11
Inspection and Adjustment ........................................12
BRAKE PEDAL AND BRACKET ..................................14
Removal and Installation ...........................................14
Removal .....................................................................15
Installation ..................................................................15
Inspection...................................................................15
Adjustment .................................................................16
MASTER CYLINDER .....................................................17
Removal .....................................................................17
Installation ..................................................................17
BRAKE BOOSTER ........................................................18
Removal and Installation ...........................................18
Inspection...................................................................18
Installation ..................................................................19
VACUUM HOSE .............................................................20
Removal and Installation ...........................................20
Inspection...................................................................22
VACUUM PUMP (TD27Ti engine model) ....................24
Removal and Installation ...........................................24
Inspection...................................................................24 VACUUM PUMP (ZD30DDTi engine model)
...............26
Removal and Installation ...........................................26
FRONT DISC BRAKE ...................................................27
Pad Replacement ......................................................27
Removal .....................................................................28
Disassembly...............................................................28
Inspection...................................................................28
Assembly ...................................................................29
Inspection...................................................................29
Installation ..................................................................31
REAR DRUM BRAKE ...................................................32
Removal .....................................................................33
Shoe Replacement ....................................................34
Inspection...................................................................34
Installation ..................................................................34
PARKING BRAKE CONTROL ......................................36
Removal and Installation ...........................................36
Inspection...................................................................36
Adjustment .................................................................36
ANTI-LOCK BRAKE SYSTEM ......................................38
Purpose......................................................................38
Operation ...................................................................38
ABS Hydraulic Circuit ................................................38
System Description ....................................................39
Removal and Installation ...........................................43
TROUBLE DIAGNOSES ...............................................48
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................48
Component Parts and Harness Connector
Location .....................................................................49
Circuit Diagram for Quick Pinpoint Check.................50
Wiring Diagram - ABS - .............................................51
CONSULT-II ...............................................................59
CONSULT-II Inspection Procedure............................60
Preliminary Check......................................................66
Ground Circuit Check ................................................67
Diagnostic Procedure 1 (Not self-diagnostic item) ....68
Diagnostic Procedure 2 (Warning lamp stays on
when ignition switch is turned ON)............................70
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Diagnostic Procedure 3 (ABS actuator solenoid
valve and solenoid valve relay) .................................72
Diagnostic Procedure 4 (Wheel sensor or rotor) ......74
Diagnostic Procedure 5 (Motor Relay or motor) .......76
Diagnostic Procedure 7 (Low voltage) ......................78
Diagnostic Procedure 8 (G sensor) ...........................79
Diagnostic Procedure 9 (Control unit) .......................80
Diagnostic Procedure 10 (Pedal vibration and
noise) ........................................................................\
.81
Diagnostic Procedure 11 (Long stopping
distance) ....................................................................81Diagnostic Procedure 12 (Unexpected pedal
action) ........................................................................\
82
Diagnostic Procedure 13 ...........................................83
Diagnostic Procedure 14 ...........................................83
Electrical Components Inspection .............................84
SERVICE DATA AND SPECIFICATIONS (SDS) ..........85
General Specifications ...............................................85
Inspection and Adjustment ........................................86
CONTENTS(Cont'd)
BR-2
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Supplement 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, help
to reduce the risk or severity or injury to the driver and front passenger in a collision. The Supplemental
Restraint System consists of an air bag module (located in the center of the steering wheel and on the instru-
ment panel on the passenger side, where fitted), 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
BT sectionof this Service Manual.
WARNING:
I To 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.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
I Do 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-TENSIONERº connector) can be iden-
tified with yellow harness connector and with yellow harness protector or yellow insulation tape
before the harness connectors.
Precautions
IUse only ªDOT 4º fluid from a sealed container.
I Never reuse drained brake fluid.
I Be 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.
I To clean master cylinder parts, disc brake caliper parts or
wheel cylinder parts, use clean brake fluid.
I Never use mineral oils such as Petrol or kerosene. They
will ruin rubber parts of hydraulic system.
I Use flare nut wrench when removing and installing brake
tubes.
I Always torque brake lines when installing.
I Burnish 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 speed. Refer to ªBrake
Burnishing Procedureº, ªCheck and Adjustmentº, BR-5.
WARNING:
I Clean brakes with a vacuum dust collector to minimize risk
of health hazard from airborne materials.
I Avoid prolonged and repeated skin contact with brake
fluid.
I Wear protective clothing, including impervious gloves.
I Where there is a risk of eye contact, eye protection should
be worn Ð for example chemical goggles or face shield.
YBR293
PRECAUTIONS AND PREPARATION
BR-3
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