light NISSAN TERRANO 2004 Service Manual PDF

3. Remove nuts fixing lower ball joint on lower link.
Support lower link with jack.
4. Remove upper ball joint fixing bolt.
5. Remove shock absorber lower bolt.
6. Remove drive shaft with knuckle.
Cover drive shaft boot with a suitable protector.
7. Separate drive shaft from knuckle by slightly tapping it.
SFA843
SFA842
SFA864
SFA878
SFA879
FRONT AXLE Ð Drive Shaft
Removal (Cont'd)FA-23
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Disassembly
FINAL DRIVE SIDE
Ð TS82F type Ð
1. Remove plug seal from slide joint housing by lightly tappingaround slide joint housing.
2. Remove boot bands.
3. Move boot and slide joint housing toward wheel side, and put matching marks.
4. Pry off snap ring.
5. Detach spider assembly with press.
SFA880
SFA881
SFA963
SFA964
SFA392
FRONT AXLE Ð Drive Shaft
FA-24
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7. Install new plug seal to slide joint housing by lightly tapping it.
Apply sealant to mating surface of plug seal.
WHEEL SIDE (ZF100)
1. Install new small boot band and boot on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.
2. Set joint assembly onto drive shaft by lightly tapping it.Install joint assembly securely, ensuring marks which were
made during disassembly are properly aligned.
3. Pack drive shaft with specified amount of grease. Specified amount of grease:100 - 120 g (3.53 - 4.23 oz)
4. Set boot so that is does not swell and deform when its length is ªLº.Length ªLº = 96 - 98 mm (3.78 - 3.86 in)
Make sure that boot is properly installed on the drive shaft
groove.
SFA472
SFA800
SFA884
SFA885
YFA011
FRONT AXLE Ð Drive Shaft
Assembly (Cont'd)
FA-27
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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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ICheck inner wall of vacuum pump housing for wear. If
necessary, replace.
I Check rotor shaft for wear. If necessary, replace.
I Check valve locations and copper washers for bends or defor-
mation. If necessary, replace.
I Check that valve operates smoothly when slightly pushed.
Replace if necessary.
I Check for air leakage with 98 to 490 kPa (1.0 to 4.9 bar, 1 to
5 kg/cm
2, 14 to 71 psi) of air pressure.
Replace if necessary.
NBR134
SBR194
SBR195
VACUUM PUMP (TD27Ti engine model)
Inspection (Cont'd)
BR-25
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4. Install caliper with pads to the original position.
5. Depress brake pedal for 5 seconds.
6. Release brake pedal, rotate disc rotor 10 revolutions.
7. Measure rotating force (F
2).
8. Calculate brake drag force by subtracting F
1from F2.
Maximum brake drag force (F
2ÐF1):
103.0 N (10.5 kg, 23.2 lb)
If it is not within specification, check pins and pin boots in
caliper.
I Make sure that wheel bearing is adjusted properly.
I Disc pads and disc rotor must be dry.
DISC PAD
Check disc pad for wear or damage.
Pad wear limit (A):2.0 mm (0.079 in)
Assembly
Fit new piston seals.
Lightly apply clean brake fluid ªDOT 4º to piston outer face.
1. Insert piston seal into groove on cylinder body.
2. Install piston into cylinder body.
3. Install piston boot and secure properly.
Inspection
CYLINDER BODY
ICheck inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
I Minor damage from rust or foreign materials may be eliminated
by polishing the surface with a fine emery paper. Replace cyl-
inder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
SBR130A
SBR041A
SMA364A
NBR007
SBR574
FRONT DISC BRAKE
Inspection (Cont'd)
BR-29
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Purpose
The Anti-lock Brake System (ABS) with an integrated Electronic Brake force Distribution (EBD) system con-
sists of electronic and hydraulic components. It allows you to control the braking force so that wheel lock can
be avoided during braking.
The advantages of ABS with EBD
1) Better tracking performance through improved steering wheel control.
2) Improved maneuverability and safer vehicle control.
3) Improved vehicle stability by preventing flat spins.
4) Shorter stopping distance and optimal utilisation of the rear brakes under many different circumstances.
Operation
IABS with EBD has self-test capabilities. The ABS warning lamp is illuminated for 1 second each time the
ignition switch is turned ªONº. After the engine is started, the ABS warning lamp turns off. An ABS self-test
is performed the first time the vehicle reaches 6 km/h (4 MPH) to ensure the system is operational. A
mechanical noise may be heard as the ABS performs this self-test and is a normal part of the self-test
feature. If a malfunction is detected during this check, the ABS warning lamp will stay on.
During the self-test, it also performs a EBD check when it detects a failure the ABS warning light will go
on simultaneously with the brake warning light and an audible sound will sound constantly.
I EBD system will only operate when the ABS is not in active status and it uses the inlet valves of ABS con-
trol unit to limit the pressure to the rear wheels when they tend to go into slip.
I When the vehicle speed is less than 10 km/h (6 MPH) the ABS system does not operate.
I While driving, a mechanical noise may be heard during ABS operation, this is a normal system condition.
ABS Hydraulic Circuit
q1Inlet solenoid valve
q
2Outlet solenoid valve
q
3Reservoir q
4Pump
q
5Motor q
6By pass check valve
q
7Damper
NBR346
ANTI-LOCK BRAKE SYSTEM
BR-38
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System Description
Sensor
The sensor unit consists of a gear-shaped sensor rotor and a sen-
sor element. The element contains a bar magnet around which a
coil is wound. The sensor is installed on the back of the brake rotor
and the rear brake drum.
As the wheel rotates, the sensor generates a sine-wave pattern.
The frequency and voltage increase(s) as the rotating speed
increases.
Control unit
The control unit computes the wheel rotating speed by the signal
current sent from the sensor. Then it supplies a DC current to the
actuator solenoid valve. It also controls ON-OFF operation of the
valve relay and rotor relay. If any electrical malfunction should be
detected in the ABS or EBD system, the control unit causes the
warning lamp(s) to light up, combined with an audible sound.
In this condition, the ABS or EBD will be deactivated by the control
unit, and the vehicle's brake system reverts to normal operation.
(Fail-safe mode)
YBR262
SBR124B
YBR263
ANTI-LOCK BRAKE SYSTEM
BR-39
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