Nissan Almera Tino V10. Instruction — part 238

ATC-148

SERVICE DATA AND SPECIFICATIONS (SDS)

BRAKE SYSTEM

SECTION

BR

CONTENTS

PRECAUTIONS . . . . . . . . . . . . . . . ...4

Supplemental Restraint System (SRS)

″

AIR

BAG

″

and

″

SEAT BELT PRE-TENSIONER

″

. . . ...4

Precautions for Brake System. . . . . . . . . .4
Precautions When Working On ABS. . . . . . ...5
Precautions for Brake Control . . . . . . . . . .5
Diagnosis Precaution. . . . . . . . . . . . ...6

CAN SYSTEM

. . . . . . . . . . . . . . ...6

Precaution for Harness Repair . . . . . . . . . 6

CAN SYSTEM

. . . . . . . . . . . . . . ...6

Wiring Diagrams and Trouble Diagnosis. . . . . .7

PREPARATION . . . . . . . . . . . . . . . ...8

Commercial Service Tools . . . . . . . . . . ...8

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . . . .9

NVH Troubleshooting Chart. . . . . . . . . . .9

ON-VEHICLE SERVICE . . . . . . . . . . . . 10

Checking Brake Fluid Level. . . . . . . . . ...10
Checking Brake Line . . . . . . . . . . . . .10
Changing Brake Fluid . . . . . . . . . . . . 10
Brake Burnishing Procedure. . . . . . . . . ..10
Bleeding Brake System . . . . . . . . . . . . 11

BRAKE HYDRAULIC LINE . . . . . . . . . . ...12

Hydraulic Circuit. . . . . . . . . . . . . . .12
Removal. . . . . . . . . . . . . . . . . .12
Inspection. . . . . . . . . . . . . . . . ...12
Installation. . . . . . . . . . . . . . . . ..13

BRAKE PEDAL AND BRACKET. . . . . . . . ..14

Removal and Installation . . . . . . . . . . ...14
Inspection. . . . . . . . . . . . . . . . ...14
Adjustment . . . . . . . . . . . . . . . . .14

MASTER CYLINDER. . . . . . . . . . . . . .16

Removal. . . . . . . . . . . . . . . . . .16
Disassembly. . . . . . . . . . . . . . . ...16
Inspection. . . . . . . . . . . . . . . . ...17
Assembly . . . . . . . . . . . . . . . . ...17
Installation. . . . . . . . . . . . . . . . ..18

BRAKE BOOSTER. . . . . . . . . . . . . . 19

On-vehicle Service. . . . . . . . . . . . . .19

OPERATING CHECK

. . . . . . . . . . . ...19

AIRTIGHT CHECK

. . . . . . . . . . . . ...19

Removal. . . . . . . . . . . . . . . . . .19
Inspection. . . . . . . . . . . . . . . . ...19

OUTPUT ROD LENGTH CHECK

. . . . . . . ..19

Installation. . . . . . . . . . . . . . . . ..20

VACUUM HOSE. . . . . . . . . . . . . . . .21

Removal and Installation . . . . . . . . . . ...21
Inspection. . . . . . . . . . . . . . . . ...22

HOSES AND CONNECTORS

. . . . . . . . ...22

CHECK VALVE

. . . . . . . . . . . . . . 22

VACUUM PUMP . . . . . . . . . . . . . . . 23

Removal. . . . . . . . . . . . . . . . . .23
Installation. . . . . . . . . . . . . . . . ..24
Inspection. . . . . . . . . . . . . . . . ...24
Component . . . . . . . . . . . . . . . . 25
Disassembly. . . . . . . . . . . . . . . ...25
Assembly . . . . . . . . . . . . . . . . ...25

FRONT DISC BRAKE . . . . . . . . . . . . ...27

Component . . . . . . . . . . . . . . . . 27
Pad Replacement . . . . . . . . . . . . . ..27
Removal. . . . . . . . . . . . . . . . . .28
Disassembly. . . . . . . . . . . . . . . ...28
Inspection. . . . . . . . . . . . . . . . ...28

CALIPER

. . . . . . . . . . . . . . . . .28

ROTOR

. . . . . . . . . . . . . . . . ...29

Assembly . . . . . . . . . . . . . . . . ...30
Installation. . . . . . . . . . . . . . . . ..30

REAR DISC BRAKE (CAM & STRUT TYPE) . . . ..31

Component . . . . . . . . . . . . . . . . 31
Pad Replacement . . . . . . . . . . . . . ..31
Removal. . . . . . . . . . . . . . . . . .33
Disassembly. . . . . . . . . . . . . . . ...33
Inspection. . . . . . . . . . . . . . . . ...34

CALIPER

. . . . . . . . . . . . . . . . .34

ROTOR

. . . . . . . . . . . . . . . . ...35

Assembly . . . . . . . . . . . . . . . . ...35
Installation. . . . . . . . . . . . . . . . ..38

REAR DISC BRAKE (BALL & RAMP TYPE) . . . ..39

GI

MA

EM

LC

EC

FE

CL

MT

AT

AX

SU

ST

RS

BT

HA

SC

EL

IDX

Component . . . . . . . . . . . . . . . . 39
Pad Replacement . . . . . . . . . . . . . ..39
Removal. . . . . . . . . . . . . . . . . .41
Disassembly. . . . . . . . . . . . . . . ...41
Inspection. . . . . . . . . . . . . . . . ...41

CALIPER

. . . . . . . . . . . . . . . . .41

ROTOR

. . . . . . . . . . . . . . . . ...42

Installation. . . . . . . . . . . . . . . . ..42

PARKING BRAKE CONTROL . . . . . . . . . ..43

Components. . . . . . . . . . . . . . . ...43
Removal and Installation . . . . . . . . . . ...43
Inspection. . . . . . . . . . . . . . . . ...43
Adjustment . . . . . . . . . . . . . . . . .44

ABS

DESCRIPTION . . . . . . . . . . . . . . . ...45

Purpose. . . . . . . . . . . . . . . . . ..45
ABS (Anti-Lock Brake System) Operation . . . . 45
ABS Hydraulic Circuit . . . . . . . . . . . . 45
System Components . . . . . . . . . . . . .46
System Description. . . . . . . . . . . . . 46

SENSOR

. . . . . . . . . . . . . . . . .46

CONTROL UNIT

. . . . . . . . . . . . . ..46

ABS ACTUATOR AND ELECTRIC UNIT

. . . . . 46

Component Parts and Harness Connector
Location . . . . . . . . . . . . . . . . . .48
Schematic . . . . . . . . . . . . . . . . ..49
Wiring Diagram - ABS - . . . . . . . . . . . .50

CAN COMMUNICATION . . . . . . . . . . . ...53

System Description. . . . . . . . . . . . . 53
CAN Communication Unit. . . . . . . . . . ..53

TYPE 1

. . . . . . . . . . . . . . . . ...54

TYPE 2/TYPE 3

. . . . . . . . . . . . . ...56

TYPE 4

. . . . . . . . . . . . . . . . ...58

TYPE 5/TYPE 6

. . . . . . . . . . . . . ...60

ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . ...61

Trouble Diagnosis Chart by Symptom. . . . . ...61

CHECK ITEMS LIST

. . . . . . . . . . . . 61

ABS actuator and electric unit Input/Output
Signal Standard . . . . . . . . . . . . . . .61

SPECIFICATIONS DEFINED BY CONSULT-II

. . . 61

CONSULT-II Functions . . . . . . . . . . . ..62

CONSULT-II FUNCTION APPLICATION TABLE

. . ..62

SELF-DIAGNOSIS

. . . . . . . . . . . . ...63

DATA MONITOR

. . . . . . . . . . . . . ..66

ACTIVE TEST

. . . . . . . . . . . . . . ..67

TROUBLE DIAGNOSIS - BASIC INSPECTION . . ...70

ABS Actuator and Electric Unit. . . . . . . . ..70
Basic Inspection 1 Brake Fluid Level and
Leakage Inspection. . . . . . . . . . . . . 70
Basic Inspection 2 Inspection for Loose Power
Supply Terminal . . . . . . . . . . . . . . .70

Basic Inspection 3 ABS Warning Lamp
Inspection. . . . . . . . . . . . . . . . ...71

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMS. . . . . . . . . . . . . . . . . . . .72

Wheel Sensor System . . . . . . . . . . . ...72
CAN Communication Lines . . . . . . . . . ...73
ABS Warning Lamp Does Not Illuminate. (ABS
Warning Lamp Does Not Come on When the
Ignition Switch is Turned ON.). . . . . . . . ...73
ABS Warning Lamp Illuminates with Ignition ON,
but Does Not Illuminates Off After a Few
Seconds. (ABS Warning Lamp has been
Illuminated.) . . . . . . . . . . . . . . . ...74

TROUBLE DIAGNOSES FOR SYMPTOMS . . . . .75

1. ABS Works Frequently . . . . . . . . . . ..75
2. Unexpected Pedal Action . . . . . . . . . ..75
3. Longer Stopping Distance . . . . . . . . . .76
4. ABS Does Not Work. . . . . . . . . . . ..77
5. Pedal Vibration and Noise. . . . . . . . . .77

REMOVAL AND INSTALLATION . . . . . . . . .79

Wheel Sensors . . . . . . . . . . . . . . ..79
ABS Actuator and Electric Unit. . . . . . . . ..80

REMOVAL

. . . . . . . . . . . . . . . ...80

INSTALLATION

. . . . . . . . . . . . . . 80

Sensor Rotor. . . . . . . . . . . . . . . ..81

REMOVAL

. . . . . . . . . . . . . . . ...81

INSTALLATION

. . . . . . . . . . . . . . 81

ESP/TCS/ABS

ON-VEHICLE SERVICE . . . . . . . . . . . . 82

Adjustment of Steering Angle Sensor Neutral
Position . . . . . . . . . . . . . . . . . ..82

SYSTEM DESCRIPTION . . . . . . . . . . . ...84

System Diagram . . . . . . . . . . . . . . 84
System Component Parts. . . . . . . . . . ..85
ESP Function. . . . . . . . . . . . . . . .85
TCS Function. . . . . . . . . . . . . . . .86
ABS Function. . . . . . . . . . . . . . . .86
EBD Function. . . . . . . . . . . . . . . .86
Fail-safe Function . . . . . . . . . . . . . ..87

ESP/TCS SYSTEM

. . . . . . . . . . . . ..87

ABS, EBD SYSTEM

. . . . . . . . . . . . .87

Hydraulic Circuit Diagram. . . . . . . . . . ..88

CAN COMMUNICATION . . . . . . . . . . . ...89

System Description. . . . . . . . . . . . . 89
CAN Communication Unit. . . . . . . . . . ..89

TYPE 1

. . . . . . . . . . . . . . . . ...90

TYPE 2/TYPE 3

. . . . . . . . . . . . . ...92

TYPE 4

. . . . . . . . . . . . . . . . ...94

TYPE 5/TYPE 6

. . . . . . . . . . . . . ...96

TROUBLE DIAGNOSIS . . . . . . . . . . . . .97

CONTENTS

(Cont’d)

BR-2

How to Perform Trouble Diagnosis for Quick and
Accurate Repair . . . . . . . . . . . . . . .97

INTRODUCTION

. . . . . . . . . . . . . ..97

DIAGNOSIS FLOWCHART

. . . . . . . . . ...98

ASKING COMPLAINTS

. . . . . . . . . . . 99

EXAMPLE OF DIAGNOSIS SHEET

. . . . . . ...99

Component Parts Location . . . . . . . . . ..100
Schematic . . . . . . . . . . . . . . . . 101
Wiring Diagram - ESP/TCS/ABS - . . . . . . ..102
Control Unit Input/Output Signal Standard. . . ..107

REFERENCE VALUE FROM CONSULT-II

. . . . 107

CONSULT-II Functions . . . . . . . . . . . 110

CONSULT-II FUNCTION APPLICATION TABLE
(MAIN ITEMS)

. . . . . . . . . . . . . ... 110

CONSULT-II BASIC OPERATION PROCEDURE

. .. 111

SELF-DIAGNOSIS

. . . . . . . . . . . . . 112

DATA MONITOR

. . . . . . . . . . . . . 115

ACTIVE TEST

. . . . . . . . . . . . . . 118

For Fast and Accurate Diagnosis . . . . . . . 120

PRECAUTIONS FOR DIAGNOSIS

. . . . . . ..120

Basic Inspection. . . . . . . . . . . . . ...122

BASIC INSPECTION 1 BRAKE FLUID LEVEL,
LEAKS, AND BRAKE PADS

. . . . . . . . ...122

BASIC INSPECTION 2 POWER SYSTEM
TERMINAL LOOSENESS AND BATTERY
INSPECTION

. . . . . . . . . . . . . . .122

BASIC INSPECTION 3 ABS WARNING LAMP,
ESP OFF INDICATOR LAMP, SLIP INDICATOR
LAMP INSPECTION

. . . . . . . . . . . ...122

Inspection 1 Wheel Sensor System . . . . . . 123
Inspection 2 Engine System. . . . . . . . . 126
Inspection 3 ESP/TCS/ABS Control Unit System ...127
Inspection 4 Pressure Sensor System . . . . . 127
Inspection 5 Steering Angle Sensor System. . ...129
Inspection 6 Yaw Rate/Side G sensor System . ...130
Inspection 7 Solenoid and ESP Change-over
Valve System . . . . . . . . . . . . . . ...132
Inspection 8 Actuator Motor, Motor Relay, and
Circuit. . . . . . . . . . . . . . . . . ...134
Inspection 9 ABS Actuator and Electric Unit
(Control Unit) Power Supply and Ground Circuit . 136
Inspection 10 Stop Lamp Switch System. . . . 138
Inspection 11 Brake Fluid Level Sensor System . 139

Inspection 12 When

″

ST ANG SEN SIGNAL

″

Appears on Self-diagnostic Results Display . . ...140
Inspection 13 CAN Communication System . . ...140
Inspection 14 When

″

ESTM VEH SPD SIG

″

Appears on Self-diagnostic Results Display . . ...142
Inspection 15 ESP OFF Indicator Lamp Does
Not Illuminate.. . . . . . . . . . . . . . ..142
Component Inspection. . . . . . . . . . . .142

ESP OFF SWITCH

. . . . . . . . . . . . .142

Symptom 1 Excessive ABS Function Operation
Frequency . . . . . . . . . . . . . . . . 143
Symptom 2 Unexpected Pedal Reaction . . . . 143
Symptom 3 The Braking Distance Is Long . . . .144
Symptom 4 ABS Function Does Not Operate. . .145
Symptom 5 Pedal Vibration or ABS Operation
Sound Occurs . . . . . . . . . . . . . . ..145
Symptom 6 Vehicle Jerks During ESP/TCS/ABS
Control . . . . . . . . . . . . . . . . . .147

WHEEL SENSORS. . . . . . . . . . . . . ..149

Removal and Installation . . . . . . . . . . .149

REMOVAL

. . . . . . . . . . . . . . . .149

INSTALLATION

. . . . . . . . . . . . . ..149

SENSOR ROTOR . . . . . . . . . . . . . . 150

Removal and Installation . . . . . . . . . . .150

REMOVAL

. . . . . . . . . . . . . . . .150

INSTALLATION

. . . . . . . . . . . . . ..150

ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) . 151

Removal and Installation . . . . . . . . . . .151

G SENSOR . . . . . . . . . . . . . . . . ..152

Removal and Installation . . . . . . . . . . .152

REMOVAL

. . . . . . . . . . . . . . . .152

INSTALLATION

. . . . . . . . . . . . . ..152

STEERING ANGLE SENSOR . . . . . . . . . .153

Removal and Installation . . . . . . . . . . .153

SERVICE DATA AND SPECIFICATIONS (SDS) . ...154

General Specifications. . . . . . . . . . . .154
Disc Brake . . . . . . . . . . . . . . . ...154
Brake Pedal . . . . . . . . . . . . . . . .154
Parking Brake . . . . . . . . . . . . . . ..154

GI

MA

EM

LC

EC

FE

CL

MT

AT

AX

SU

ST

RS

BT

HA

SC

EL

IDX

CONTENTS

(Cont’d)

BR-3