NISSAN TERRANO 2004 Service Repair Manual

Removal and Installation
YBR446
BRAKE PEDAL AND BRACKET
BR-14
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Removal
1. Remove stop lamp switch connector and stop lamp switch.
2. Remove bolt for (LHD) or nut for (RHD) securing pedal bracketto the front panel.
3. Remove snap ring and pull clevis pin from the brake pedal.
4. Remove 4 mounting nuts securing pedal bracket to the brake booster.
Installation
Install pedal bracket in the reverse order of the removal.
NOTE:
Pay attention to the direction of the clevis pin for installation.
Inspection
Check brake pedal for following items:
IBrake pedal bend
I Clevis pin deformation
I Crack of any welded portion
I Crack or deformation of clevis pin stopper
SBR997
BRAKE PEDAL AND BRACKET
BR-15
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Adjustment
Check brake pedal free height from dash reinforcement panel.H: Free heightRefer to SDS, BR-86.
D: Full stroke Refer to SDS, BR-86.
C: Clearance between pedal stopper and threaded end of stop lamp switch0.3 - 1.0 mm (0.012 - 0.039 in)
A: Pedal free play 1.0 - 3.0 mm (0.039 - 0.118 in)
If necessary, adjust brake pedal free height.
1. Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut.
Make sure that tip of input rod stays inside of clevis as shown.
2. Loosen lock nut and adjust clearance ªCº with stop lamp switch. Then tighten lock nuts.
3. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
4. Check brake system for leaks, accumulation of air or any dam- age to components (master cylinder, etc.); then make neces-
sary repairs.
5. After installation and adjustment, operate the brake pedal to full stroke several times to confirm that strange sound interference
hitching or other do not arise working smoothly throughout the
stroke.
YBR450
YBR300
BRAKE PEDAL AND BRACKET
BR-16
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Removal
CAUTION:
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. DO NOT RUB.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brakepedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
5. Remove protector of master cylinder, and avoid scratching the surface of master cylinder during removal.
CAUTION:
Do not disassemble master cylinder.
NOTE:
If it is necessary to change the brake fluid reservoir, remove it
as shown in the illustration on the left, while holding the seals
with one hand.
It is not necessary to replace the seals if they are in a good
condition.
Installation
CAUTION:
I Refill with new brake fluid ªDOT 4º.
I Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mounting nuts lightly.
2. Fit flare nuts to master cylinder.
3. Tighten mounting nuts.
:21-29N ×m (2.1 - 3.0 kg-m, 15 - 22 ft-lb)
4. Tighten flare nuts.
:15-18N ×m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
5. Bleed air. Refer to ªBleeding Brake Systemº, ªBRAKE HYDRAULIC LINEº, BR-8.
YBR258
EBR080
MASTER CYLINDER
BR-17
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Removal and Installation
Inspection
OPERATING CHECK
IDepress brake pedal several times with engine off, and check
that there is no change in pedal stroke.
I Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
IStart engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. If pedal goes further down the
first time and gradually rises after second or third time, booster
is airtight.
I Depress brake pedal while engine is running, and stop engine
with pedal depressed. If there is no change in pedal stroke after
holding pedal down 30 seconds, brake booster is airtight.
OUTPUT ROD LENGTH CHECK
1. Apply vacuum of þ66.7 kPa (þ667 mbar, þ500 mmHg, þ19.69
inHg) to brake booster with a manual vacuum pump and check
output rod length ªAº.Specified length ªAº: 22.15 - 22.45 mm (0.872 - 0.884 in)
(The length ªAº in this case is the distance from end of output
rod to outside of brake booster, when the specified vacuum is
applied.)
YBR451
SBR002A
SBR365A
EBR090
BRAKE BOOSTER
BR-18
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2. Check output rod length ªLº when brake booster doesn't work.Specified length ªLº:129.2 - 130.2 mm (5.09 - 5.13 in)
Installation
CAUTION:
IBe careful not to deform or bend brake pipes, during instal-
lation of booster.
I Replace clevis pin if damaged.
I Refill with new brake fluid ªDOT 4º.
I Never reuse drained brake fluid.
I Take care not to damage brake booster mounting bolt
thread when installing. Due to the acute angle of
installation, the threads can be damaged on the metal sur-
rounding the dash panel holes.
1. Before fitting booster, temporarily adjust clevis to dimension shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to brake booster) lightly. (Join brake booster and brake pedal
bracket to the front end of the vehicle interior).
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
:20-25N ×m (1.3 - 1.6 kg-m, 10 - 12 ft-lb)
5. Install master cylinder. Refer to ªInstallationº, ªMASTER CYLINDERº, BR-17.
6. Bleed air. Refer to ªBleeding Brake Systemº, ªBRAKE HYDRAULIC LINEº, BR-8.
7. Adjust brake height. Refer to ªAdjustmentº, ªBRAKE PEDAL AND BRACKETº, BR-16.
8. Tighten brake booster lock nut.
:17-23N ×m (1.7 - 2.3 kg-m, 12 - 17 ft-lb)
YBR294
BRAKE BOOSTER
Inspection (Cont'd)
BR-19
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Removal and Installation
YBR453
VACUUM HOSE
BR-20
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CAUTION:
When installing vacuum hoses, pay attention to the following
points.
IDo not apply any oil or lubricants to vacuum hose and
check valve.
I Insert vacuum tube into vacuum hose over a length of min.
24 mm (0.94 in) as shown.
Take care to main vacuum hoses in their original direction and
position.
YBR454
YBR452
VACUUM HOSE
Removal and Installation (Cont'd)
BR-21
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Inspection
HOSES AND CONNECTORS
ICheck condition of vacuum hoses and connectors.
I Check vacuum hoses and check valve for air tightness.
CHECK VALVE
ICheck vacuum with a manual vacuum pump.
Connect to booster
side Vacuum should exist.
Connect to engine
side Vacuum should not exist.
VACUUM WARNING SWITCH
Test continuity though vacuum warning switch with an ohmmeter
and vacuum pump.
VacuumLess than 26.7 kPa
(267 mbar, 200 mmHg, 7.87 inHg) 0W
33.3 kPa
(333 mbar, 250 mmHg, 9.84 inHg) or more
W
YBR447
YBR448
SBR007A
VACUUM HOSE
BR-22
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VACUUM PUMP (TD27Ti ENGINE)
1. Install vacuum gauge.
2. Run engine at 1,000 rpm or more.
3. Check vacuum.Specified vacuum:93.3 kPa
(933 mbar, 700 mmHg, 27.56 inHg) or more
VACUUM PUMP (ZD30DDTi ENGINE)
Refer to EM section, ªINSPECTIONº in ªVACUUM PUMP Ð
Removal and Installationº.
NBR004
VACUUM HOSE
Inspection (Cont'd)
BR-23
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