warning NISSAN TERRANO 2004 Service Service Manual

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
IBefore proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to
prevent the internal parts from becoming contaminated by dirt or other foreign matter.
I Disassembly should be done in a clean work area.
I Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could inter-
fere with the operation of the transmission.
I Place disassembled parts in order for easier and proper assembly.
I All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
I Gaskets, seals and O-rings should be replaced any time the transmission is disassembled.
I It is very important to perform functional tests whenever they are indicated.
I The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place removed parts in a parts rack in order to replace them in correct positions and sequences. Care will
also prevent springs and small parts from becoming scattered or lost.
I Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
PREPARATION AND PRECAUTIONS
AT- 4
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Throttle (accelerator) position switch
Closed throttle position switch (idle position)
ICheck continuity between terminals q
5andq6.
Accelerator pedal condition
Continuity
Released Yes
Depressed No
ITo adjust closed throttle (accelerator) position switch, refer to
EC section (ªBasic Inspectionº, ªTROUBLE DIAGNOSIS Ð
Basic Inspectionº).
Wide open throttle position switch
I Check continuity between terminals q
4andq5.
Accelerator pedal condition
Continuity
Released No
Depressed Yes
A/T fluid temperature switch
1. Make sure the A/T fluid warning lamp lights when the key is
inserted and turned to ªONº.
2. Make sure the A/T fluid warning lamp goes off when turning the ignition switch to ªONº.
3. For removal, refer to AT-118.
4. Check resistance between terminal q
6and ground while
changing temperature as shown at left.
Temperature ÉC (ÉF) Continuity
140 (284) or more Yes
140 (284) or less No
YAT425
YAT426
YAT335
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Park/neutral Position, Overdrive Control or
Throttle (Accelerator) Position Switches
(Cont'd)
AT-98
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1. SPORT Indicator Lamp Does Not Come On
SYMPTOM:
POWER indicator lamp does not come on for about 2 seconds
when turning ignition switch to ªONº.
CHECK TCM POWER SOURCE.
1. Turn ignition switch to ªONº position.(Do not start engine.)
2. Check voltage between TCM terminals q
10,q19and ground.
Battery voltage should exist.
OK
ENG Check the following items:
IHarness for short or
open between ignition
switch and TCM (Main
harness)
I Ignition switch and fuse
Refer to EL section
(ªPOWER SUPPLY
ROUTINGº).
CHECK TCM GROUND CIRCUIT.
1. Turn ignition switch to ªOFFº position.
2. Disconnect TCM harness connector.
3. Check resistance between TCM termi- nals q
25,q48and ground.
Resistance: Approximately 0W
If OK, check harness for short to
ground and short to power.
OK
ENG Repair open circuit or short
to ground or short to
power in harness or con-
nector.
CHECK LAMP CIRCUIT.
1. Turn ignition switch to ªONº position.
2. Set overdrive control, A/T check or power switch to ªONº position.
3. Check voltage between TCM terminal q
13and ground.
Voltage: Battery voltage
4. Reinstall any part removed.
OK
ENG Check the following items:
IFuse (7.5A)
I SPORT indicator lamp
Refer to EL section
(ªWARNING LAMPSº).
I Harness for short or
open between ignition
switch and SPORT indi-
cator lamp (Main har-
ness)
Refer to EL section
(ªPOWER SUPPLY
ROUTINGº).
I Harness for short or
open between SPORT
indicator lamp and TCM
Check again.
OK
ENG
1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin terminals for damage or
loose connection with
harness connector.
INSPECTION END
YAT427
YAT428
YAT429
H
H
HH
H
DIAGNOSTIC PROCEDURES FOR SYMPTOMS
AT-99
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Removal
IDrain oil from transfer and transmission.
I Remove front and rear propeller shafts Ð Refer to PD section.
I Insert plug into oil seal after removing propeller shaft.
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal,
when removing propeller shaft.
I Remove torsion bar spring Ð Refer to removal and installation
of lower link in FA section. Then remove fifth crossmember.
I Remove transfer control lever from transfer outer shift lever.
I Remove transfer from transmission.
WARNING:
Support transfer while removing it.
Installation
I Apply recommended sealant to mating surface to transmission.
Recommended sealant: Nissan genuine part (KP610-00250) or equivalent
I Tighten bolts securing transfer.
Bolt No. Tightening torque
N×m (kg-m, ft-lb) 
mm (in)
q
127 - 36 (2.8 - 3.6, 20 - 26) 45 (1.77)
q
227 - 36 (2.8 - 3.6, 20 - 26) 60 (2.36)
SMT478A
YTF001
SMT495A
SMT496A
REMOVAL AND INSTALLATION
TF-7
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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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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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Checking Brake Fluid Level
ICheck fluid level in reservoir tank. It should be between Max.
and Min. lines on reservoir tank.
I If fluid level is extremely low, check brake system for leaks.
I When brake warning lamp comes on even when parking brake
lever is released, check brake system for leaks.
Checking Brake Line
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while engine is running.
Changing Brake Fluid
CAUTION:
IRefill with new brake fluid ªDOT 4º.
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. DO
NOT RUB IT OFF.
1. Connect a vinyl tube to each air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing brake pedal.
3. Refill until new brake fluid comes out of each air bleeder valve. Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to ªBleeding Brake Systemº, ªBRAKE
HYDRAULIC LINEº, BR-8.
Brake Burnishing Procedure
Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing rotors or drums, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31MPH).
2. Use medium brake pedal/foot to bring the vehicle to a com- plete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
pressure such that vehicle stopping time equals 3 to 5
seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3 for 10 times or more to complete the burnishing procedure.
SBR849B
SMA732A
SBR992
CHECK AND ADJUSTMENT
BR-5
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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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Removal
WARNING:
Clean brake lining with a vacuum dust collector.
CAUTION:
Make sure parking brake lever is released completely.
1. Release parking brake lever fully, then remove drum.
If drum is hard to remove, screw two bolts in the provided
holes of the drum and tighten them gradually.
If the drum cannot be removed after carrying out this
operation, refer to ªInspectionº, ªPARKING BRAKE
CONTROLº, BR-36.
SBR093A
REAR DRUM BRAKE
BR-33
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Removal and Installation
1. To remove parking brake cable, first remove center console.
2. Disconnect warning lamp connector.
3. Remove bolts, slacken off and remove adjusting nut.
Inspection
1. Check control lever for wear or other damage. Replace if nec-essary.
2. Check wires for discontinuity or deterioration. Replace if nec- essary.
3. Check warning lamp and switch. Replace if necessary.
4. Check parts at each connecting portion and, if deformed or damaged, replace.
Adjustment
1. Adjust clearance between shoe and drum as follows:
a. Release parking brake lever and loosen adjusting nut.
b. Depress brake pedal fully at least 10 times with engineswitched off.
2. Apply the handbrake, allowing the handbrake grip to move 6 notches. You can adjust the handbrake travel by using the
adjusting nut. To complete this adjustment, you will need a
dynamo meter to check the amount of load required to move
from 9 to 10 notches. If the load exceeds 20 kg, the cable will
have to be loosened with the help of the adjusting nut.Number of notches: 9-10
If the load is less than 20 kg, the cable should be tightened.
NBR124
SBR101B
SBR353B
PARKING BRAKE CONTROL
BR-36
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