warning NISSAN TERRANO 2004 Service Manual PDF

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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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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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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RESTRAINT SYSTEM
SECTION
RS
CONTENTS
SEAT BELTS ...................................................................2
Precautions ..................................................................2
Front Seat Belt.............................................................4
Rear Seat Belt .............................................................6
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ............8
Precautions ..................................................................8
Preparation ..................................................................9
SRS Configuration .....................................................10
Seat Belt Pre-tensioner with Load Limiter................. 11
Built-in Type Side Air Bag.......................................... 11
SRS Component Parts Location ...............................12
Maintenance Items ....................................................12
Diagnosis Sensor Unit ...............................................13
Front Seat Belt Pre-tensioner ....................................14
Side Air Bag (Satellite) Sensor ..................................15
Driver Air Bag Module and Spiral Cable ...................16
Front Passenger Air Bag Module ..............................19 Front Side Air Bag Module ........................................20
Disposal of Air Bag Module and Seat Belt Pre-
tensioner ....................................................................22
Trouble Diagnoses Introduction.................................28
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................31
Schematic ..................................................................33
Wiring Diagram - SRS -.............................................34
SRS Operation Check ...............................................38
Trouble Diagnoses with CONSULT-II..................39
Trouble Diagnoses without CONSULT-II.............48
Trouble Diagnoses: ²AIR BAG² Warning Lamp
Does Not Turn Off .....................................................56
Trouble Diagnoses: ²AIR BAG² Warning Lamp
Does Not Turn On .....................................................58
Collision Diagnosis ....................................................59
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Precautions
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.
Precaution for Seat Belt Service
CAUTION:
IBefore removing the seat belt pre-tensioner assembly, turn the ignition switch off, disconnect both
battery cables and wait at least 3 minutes.
I Do not use electrical test equipment for seat belt pre-tensioner connector.
I After replacing or reinstalling seat belt pre-tensioner assembly, or reconnecting seat belt pre-ten-
sioner connector, check the system function. Refer to ªSRS Operation Checkº for details. (RS-38)
I Do not disassemble buckle or seat belt assembly.
I Replace anchor bolts if they are deformed or worn out.
I Never oil tongue and buckle.
I If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt
assembly.
I If webbing is cut, frayed, or damaged, replace seat belt assembly.
I When replacing seat belt assembly, use a genuine seat belt assembly.
After A Collision
WARNING:
Inspect all seat belt assemblies including retractors and attaching hardware after any collision.
NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the
collision was minor and the belts show no damage and continue to operate properly. Failure to do so
could result in serious personal injury in an accident. Seat belt assemblies not in use during a colli-
sion should also be replaced if either damage or improper operation is noted. Seat belt pre-tensioner
should be replaced even if the seat belts are not in use during a frontal collision in which the air bags
are deployed.
Replace any seat belt assembly if:
IThe seat belt was in use at the time of a collision (except for minor collisions and the belts, retractors and
buckles show no damage and continue to operate properly).
I The seat belt was damaged in an accident. (i.e. torn webbing, bent retractor or guide, etc.)
I The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for dam-
age or distortion and repair as necessary before installing a new seat belt assembly.
I Anchor bolts are deformed or worn out.
SEAT BELTS
RS-2
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Precautions
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.
WIRING DIAGRAMS AND TROUBLE DIAGNOSIS
When you read wiring diagrams, refer to the following:
IGI-10, ªHOW TO READ WIRING DIAGRAMSº
I EL-8, ªPOWER SUPPLY ROUTINGº for power distribution circuit
When you perform trouble diagnosis, refer to the following:
I GI-25, ªHOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSISº
I GI-22, ªHOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENTº
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
RS-8
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SRS Component Parts Location
Maintenance Items
CAUTION:
Do not use electrical test equipment to check SRS circuit.
1. Check operation of ªAIR BAGº warning lamp.After turning ignition key to ªONº position, ªAIR BAGº warning
lamp illuminates. The ªAIR BAGº warning lamp will go off after
about 7 seconds if no malfunction is detected. If any of the fol-
lowing ªAIR BAGº warning lamp conditions occur, immediately
check the air bag system. Refer to RS-38 for details.
I The ªAIR BAGº warning lamp does not illuminate when the
ignition switch is turned ªONº.
I The ªAIR BAGº warning lamp does not go off about 7 seconds
after the ignition switch is turned ªONº.
I The ªAIR BAGº warning lamp blinks after about 7 seconds after
the ignition switch is turned ªONº.
2. Visually check SRS components.
1) Diagnosis sensor unit
I Check diagnosis sensor unit and bracket for dents, cracks and
deformities.
I Check connectors for damage, and terminals for deformities.
2) Air bag module and steering wheel
I Remove air bag module from steering wheel, instrument panel
or seatback. Check harness cover and connectors for damage,
terminals for deformities, and harness for binding.
NRS102
SRS797-A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
RS-12
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IInstall driver air bag module to steering wheel to check fit or
alignment with the wheel.
I Check steering wheel for excessive free play.
I Install front passenger air bag module to instrument panel to
check fit or alignment with the instrument panel.
I Install front side air bag module to seatback to check fit and
alignment with the seat.
3) Spiral cable
I Check spiral cable for dents, cracks, or deformities.
I Check connectors and protective tape for damage.
I Check steering wheel for noise, binding or heavy operation.
4) Main harness, body harness, side air bag module sub-harness
I Check connectors for poor connections, damage, and terminals
for deformities.
I Check harnesses for binding, chafing or cut.
5) Front seat belt pre-tensioner
I Check harness cover and connectors for damage, terminals for
deformities, and harness for binding.
I Check belts for damage and anchors for loose mounting.
I Check retractor for smooth operation.
I Perform self-diagnosis for seat belt pre-tensioner using ªAIR
BAGº warning lamp or CONSULT-II.
Refer to ªSRS Operation Checkº for details. (RS-38)
6) Side air bag (satellite) sensor
I Check side air bag (satellite) sensor (including bracket portion)
for dents, cracks or deformities.
I Check connectors for damage, and terminals for deformities.
CAUTION:
Replace previously used special bolts and ground bolt with
new ones.
Diagnosis Sensor Unit
REMOVAL AND INSTALLATION
CAUTION:
I Before servicing SRS, turn the ignition switch off, discon-
nect both battery cables and wait at least 3 minutes.
I The special bolts are coated with bonding agent while the
other bolt is for ground. Do not use old bolts after removal;
replace with new ones.
I Check diagnosis sensor unit for proper installation.
I Check diagnosis sensor unit to ensure it is free of
deformities, dents, cracks or rust. If they show any visible
signs of damage, replace them with new ones.
I Check diagnosis sensor unit brackets to ensure they are
free of deformities or rust.
I Replace diagnosis sensor unit if it has been dropped or
sustained an impact.
I After replacement of diagnosis sensor unit, perform self-
diagnosis for SRS. Refer to ªSRS Operation Checkº for
details. (RS-38)
1. Disconnect driver, front passenger and front side air bag mod- ule connectors. Also, disconnect front seat belt pre-tensioner
connector.
2. Remove console box. Refer to BT-22, ªINSTRUMENT PANEL ASSEMBLYº.
3. Disconnect diagnosis sensor unit connector.
4. Remove ground bolt and also remove special bolts using the TAMPER RESISTANT TORX (Size T50), from diagnosis sen-
sor unit.
Then remove the diagnosis sensor unit.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Maintenance Items (Cont'd)
RS-13
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8. Install steering switch.
9. Install the air bag module by pressing the center of the horn tomake the contacts (RH, LH) ON.
10. Connect driver air bag module connector, and push the black locking clip to secure the connector to the air bag module.
11. Conduct self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or warning lamp check.)
Before performing self-diagnosis, connect both battery cables.
12. Turn steering wheel to the left end and then to the right end fully to make sure that spiral cable is set in the neutral position.
If ªAIR BAGº warning lamp blinks or stays ON (at the user
mode), it shows the spiral cable may be snapped due to its
improper position. Perform self-diagnosis again (use CON-
SULT-II or warning lamp). If a malfunction is detected, replace
the spiral cable with a new one.
13. Perform self-diagnosis again to check that no malfunction is detected.
Front Passenger Air Bag Module
REMOVAL
CAUTION:
Before servicing SRS, turn the ignition switch off, disconnect
both battery cables and wait for at least 3 minutes.
Always work from the side of (or under) front passenger air
bag module.
1. Remove glove box assembly. Refer to BT-16, ªINSTRUMENTPANEL ASSEMBLYº for details.
2. Disconnect inflator connector.
3. Remove bolts holding the passenger air bag module to the instrument panel.
4. Remove upper special bolts, as indicated.
5. Remove the passenger air bag module.
SHIA0184E
YRS126
NRS046
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Driver Air Bag Module and Spiral Cable
(Cont'd)
RS-19
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CAUTION:
IAlways place front passenger air bag module with pad side
facing upward.
I Do not attempt to disassemble front passenger air bag
module.
I The special bolts are coated with bonding agent. Do not
use old bolts after removal; replace with new coated bolts.
I Do not insert any foreign objects (screwdriver, etc.) into
front passenger air bag module connector.
I Replace front passenger air bag module if it has been
dropped or sustained an impact.
I Do not expose the front passenger air bag module to tem-
peratures exceeding 90ÉC (194ÉF).
I Do not allow oil, grease or water to come in contact with
the front passenger air bag module.
I After front passenger air bag inflates, the front instrument
panel assembly should be replaced if damaged.
INSTALLATION
CAUTION:
IAlways work from the side of or under front passenger air
bag module.
1. Install front passenger air bag module. Tighten special bolts and side mounting bolts to the specified torque as shown in the
figure.
I Ensure harness is not caught between rear of front passenger
air bag module and steering member.
2. Connect the front passenger air bag module connector.
3. Install glove box.
4. Connect both battery cables.
5. Conduct self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or warning lamp check.)
Front Side Air Bag Module
REMOVAL
CAUTION:
IBefore servicing SRS, turn the ignition switch OFF, discon-
nect both battery cables and wait at least 3 minutes.
I Always work from the rear of the front side air bag mod-
ule.
1. Disconnect front side air bag module connector under the seat.
2. Open the seatback zipper.
NRS110
SBF814E
NRS046
YRS126
YRS127
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Front Passenger Air Bag Module (Cont'd)
RS-20
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