NISSAN TERRANO 2004 Service Repair Manual

Electrical Components Inspection
WHEEL SENSOR
Check resistance for each sensor.Resistance:Front 0.9 - 1.1 k W
Rear 1.44 - 1.76 k W
G SENSOR
Condition Resistance between ter-
minals q3andq4Continuity
Installed in vehicle Approx. 1.5 kW Ye s
Tilted as shown in figure Approx. 5.1 kW No
YBR085
YBR280
TROUBLE DIAGNOSES
BR-84
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General Specifications
Applied modelWagon (LWB) Hard Top (SWB) Wagon (LWB) Hard Top (SWB)
Without ABS With ABS
Front brake LD28VA
Brake model
Cylinder bore diameter mm (in) 43 (1.69)
Pad mm (in)
length x width x thickness 144.85 x 48.5 x 15.5
(5.70 x 1.90 x 0.61)
Rotor mm (in)
outer diameter x thickness 276.7 x 26.1
(10.89 x 1.02)
Drum brake LT28
Brake model
Cylinder bore diameter mm (in)23.8 (0.94) 22.0 (0.87) 20.6 (0.81)
Lining mm (in)
Length x width x thickness Leading 111 x 55 x 8.95 (4.37 x 2.17 x 0.35)
Trailing 114 x 55 x 3.95 (4.49 x 2.17 x 0.16)
Drum inner mm (in)
Diameter 280 (11.02)
Master cylinder mm (in) Cylinder bore diameter 25.4 (1.0)
Control valve Valve model Load Sensing Valve Ð
Split point [kPa (bar, kg/cm
2, psi)] x
reducing ratio Variable x 0.23 Variable x 0.15 Ð
Brake booster Booster model Lucas LSC 115 (8² +9²)
Diaphragm diameter mm (in) Primary: 203.2 (8)
Secondary: 228.6 (9)
Specified brake fluid DOT 4
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-85
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Inspection and Adjustment
DISC BRAKE
Unit: mm (in)
Brake modelLD28VA
Pad wear limit Minimum thickness 2.0 (0.079)
Rotor repair limit Minimum thickness 24.0 (0.94)
DRUM BRAKE
Unit: mm (in)
Lining wear limit
Minimum thickness 1.52 (0.06)
Drum repair limit Maximum inner diameter 280.5 (11.04)
Out-of-roundness 0.05 (0.0020)
or less
BRAKE PEDAL
Unit: mm (in)
RHD LHD
Free pedal height (H) 196 - 206
(7.7 - 8.1) 210 - 220
(8.3 - 8.7)
Full stroke (D) 137.7 - 147.7
(5.42 - 5.81) 142.5 - 152.5
(5.61 - 6.0)
Clearance between pedal
stopper and threaded end of
stop lamp switch (C) 0.3 - 1.0 (0.012 - 0.039)
Pedal free play at clevis (A) 1 - 3 (0.039 - 0.118)
PARKING BRAKE
Control type
Item Center lever
Number of notches
[under force of 196 N (20 kg, 44 lb)] 9-10
Number of notches
(when warning switch comes on) 1
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-86
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STEERING SYSTEM
SECTION
ST
CONTENTS
PRECAUTIONS ...............................................................2
Supplemental Restraint System (SRS) ²AIR
BAG² and²SEAT BELT PRE-TENSIONER² ...............2
Precautions for SRS ²AIR BAG² and²SEAT
BELT PRE-TENSIONER² Service ...............................2
Precautions for Steering System .................................2
PREPARATION ................................................................3
Special Service Tools ..................................................3
ON-VEHICLE SERVICE ..................................................4
Checking Steering Wheel Play ....................................4
Checking Neutral Position on Steering Wheel ............4
Front Wheel Turning Angle ..........................................4
Checking and Adjusting Drive Belts ............................4
Checking Fluid Level ...................................................4
Checking Fluid Leakage ..............................................5
Bleeding Hydraulic System..........................................5
Checking Steering Wheel Turning Force ....................6
Checking Hydraulic System.........................................7 STEERING WHEEL AND STEERING COLUMN
............8
Removal and Installation .............................................8
Disassembly and Assembly .......................................10
Inspection................................................................... 11
POWER STEERING GEAR ...........................................12
Description .................................................................12
Removal and Installation ...........................................14
Inspection and Adjustment ........................................15
POWER STEERING OIL PUMP ....................................16
Removal and Installation ...........................................16
STEERING LINKAGE ....................................................17
Removal and Installation ...........................................17
Disassembly and Assembly .......................................19
Inspection...................................................................20
SERVICE DATA AND SPECIFICATIONS (SDS) ..........22
General Specifications ...............................................22
Inspection and Adjustment ........................................22
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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 composition which is available to NISSAN MODEL R20 is as follows (The composition
varies according to the destination and optional equipment.):
IFor a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing 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.
I For 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).
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 should 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. 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 SRS ªAIR BAGº and ªSEAT
BELT PRE-TENSIONERº Service
IDo not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual.
I Before servicing the SRS, turn ignition switch ªOFFº, disconnect both battery cables and wait at least 3
minutes.
For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt
pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes
have passed.
I Diagnosis sensor unit must always be installed with their arrow marks ª +º pointing towards the front of
the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before
installation and replace as required.
I The spiral cable must be aligned with the neutral position since its rotations are limited. Do not attempt to
turn steering wheel or column after removal of steering gear.
I Handle air bag module carefully. Always place driver and front passenger air bag modules with the pad
side facing upward and place front side air bag module (built-in type) standing with stud bolt side setting
bottom.
I Conduct self-diagnosis to check entire SRS for proper function after replacing any components.
I After air bag inflates, the front instrument panel assembly should be replaced if damaged.
Precautions for Steering System
IBefore disassembly, thoroughly clean the outside of the unit.
I Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
I When disassembling parts, be sure to place them in order on a part rack so they can be reinstalled
in their proper positions.
I Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
I Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
I Before assembly, apply a coat of recommended ATF* to hydraulic parts. Vaseline may be applied
to O-rings and seals. Do not use any grease.
I Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during instal-
lation. Perform functional tests whenever designated.
*: Automatic transmission fluid
PRECAUTIONS
ST-2
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Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
KV48100700
Torque adapter
Measuring pinion rotating torque
ST27180001*
Steering wheel puller
Removing and installing steering wheel
ST27850000
Ball joint remover
Removing ball joint
ST29020001*
Steering gear arm puller
Removing and installing pitman arm
ST3127S000*
q
1GG91030000
Torque wrench
q
2HT62940000
Socket adapter
q
3HT62900000
Socket adapter
Measuring turning torque
KV48100301*
Strut & steering gearbox
attachment
Steering gear is installed
KV48103500-A
Pressure gauge
Measuring oil pressure
KV48102500
Pressure gauge adapter
Measuring oil pressure
KV481009S0
Oil seal drift set
q
1KV48100910
Drift
q
2KV48100920
Adapter
q
3KV48100930
Adapter
Installing oil seal
PREPARATION
ST-3
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Checking Steering Wheel Play
1. With wheels in a straight-ahead position, check steering wheelplay.Steering wheel play: 35 mm (1.38 in) or less
2. If it is not within specification, check steering gear assembly when front suspension and axle, steering gear assembly and
steering column are mounted correctly.
Checking Neutral Position on Steering Wheel
CHECKING
1. Check that the steering wheel is in the neutral position whendriving straight ahead.
2. If it is not in the neutral position, remove the steering wheel and reinstall it correctly.
3. If the neutral position is between two serrated teeth, loosen tie-rod lock nut and move tie-rod in the opposite direction by the
same amount on both left and right sides to compensate for
error in the neutral position.
Front Wheel Turning Angle
Rotate steering wheel all the way right and left; measure turning
angle. Turning angle of full turns:Refer to section FA for SDS.
Checking and Adjusting Drive Belts
Refer to section MA for Drive Belt Inspection.
Checking Fluid Level
Check the fluid level in the reservoir when the engine is cold. If the
fluid level is below the MIN line, and fluid up to the MAX line.
CAUTION:
IDo not overfill the MAX level.
I Do not reuse any used power steering fluid.
I Use only ªDEXRON
TMº or equivalent.
SST103B
SST900A
SMA127
NST030
ON-VEHICLE SERVICE
ST-4
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Checking Fluid Leakage
Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing or deterioration.
1. Run engine between idle speed and 1,000 rpm.
Make sure temperature of fluid in oil tank rises to 50 to 80ÉC
(122 to 176ÉF).
2. Turn steering wheel right-to-left several times.
3. Hold steering wheel at each ªlockº position for five seconds andcarefully check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 10 seconds (There is possibility that oil pump may be
damaged.).
4. If fluid leakage at connectors is noticed, loosen flare nut and then retighten.
Do not overtighten connector as this can damage O-ring,
washer and connector.
5. If fluid leakage at the connectors are noticed, then loosen the flare nut and retighten it.
Bleeding Hydraulic System
1. Raise front end of vehicle until wheels are clear of the ground.
2. Add fluid into oil tank to specified level. Meanwhile quickly turnsteering wheel fully to right and left and lightly touch steering
stoppers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine. Repeat step 2 above.
I Incomplete air bleeding will cause the following to occur. When
this happens, bleed air again.
a. Generation of air bubbles in reservoir tank
b. Generation of clicking noise in oil pump
c. Excessive buzzing in oil pump
While the vehicle is stationary or while moving the steering wheel
slowly, fluid noise may occur in the valve or oil pump. This noise is
inherent in this steering system, and it will not affect performance
or durability of the system.
SST621A
ON-VEHICLE SERVICE
ST-5
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Checking Steering Wheel Turning Force
1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating tempera-ture.Temperature: 50É - 80ÉC (122 - 176ÉF)
Tires need to be inflated to normal pressure.
4. Check steering wheel turning force when steering wheel has been turned 360É from neutral position.Steering wheel turning force: 39 N (4 kg, 9 lb) or less
I If steering wheel turning force is not within specification,
perform the following inspection procedure:
E
Measure steering
wheel
turning force
39 N (4 kg, 9 lb) or less.
NG
EOK Test end
Measure preload of the
power steering gear input shaft.
Refer to ªInspection and Adjustmentº in
ªPOWER STEERING GEARº.
NG
EOK Check oil pump
pressure.
Refer to ªChecking
Hydraulic Systemº in ªON-VEHICLESERVICEº.
NG
EOK Check ball joints,
swivel joints and
linkage for smooth operation.
See ªInspectionº in
ªSTEERING LINKAGEº.
NG OK
Adjust preload.Replace oil pump.Replace joints.Replace power
steering gear.
SST108B
H
HHHH
HHHH
ON-VEHICLE SERVICE
ST-6
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Checking Hydraulic System
Before starting, check belt tension, driving pulley and tire pressure.
1. Set Tool. Open shut-off valve, then bleed air. (Refer to ªBleed-ing Hydraulic Systemº, ST-5.)
2. Run engine.
Make sure temperature of fluid in tank rises to 60 to 80ÉC (140
to 176ÉF).
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, oil pressure in oil pump will
increase to relief pressure, resulting in an abnormal rise in oil
temperature.
3. Check pressure with steering wheel fully turned to left and right positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds. Oil pump maximum standard pressure:TD27Ti engine8,800 - 9,200 kPa (88 - 92 bar,
89 - 93 kg/cm
2, 1,276 - 1,334 psi)
ZD30DTi engine 9,800 - 10,500 kPa (98.0 - 105.0 bar,
99.96 - 107.10 kg/cm
2, 1,421 - 1,523 psi)
4. If oil pressure is below the maximum pressure, slowly close shut-off valve and check pressure.
I When pressure reaches maximum pressure, gear is damaged.
I When pressure remains below maximum pressure, pump is
damaged.
CAUTION:
Do not close shut-off valve for more than 15 seconds.
5. If oil pressure is higher than maximum pressure, check oil pump flow control valve.
6. After checking hydraulic system, remove Tool and add fluid if necessary, then completely bleed air out of system.NST033
ON-VEHICLE SERVICE
ST-7
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