Nissan Terrano r20e. Instruction — part 51

BRAKE SYSTEM

SECTION

BR

CONTENTS

PRECAUTIONS AND PREPARATION

. . . . . . . 3

Supplement Restraint System (SRS)

″

AIR BAG

″

and

″

SEAT BELT PRE-TENSIONER

″

. . . . . . .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
Inspection. . . . . . . . . . . . . . . . ...15
Adjustment . . . . . . . . . . . . . . . . .15

MASTER CYLINDER

. . . . . . . . . . . . . .16

Removal. . . . . . . . . . . . . . . . . .16
Installation. . . . . . . . . . . . . . . . ..16

BRAKE BOOSTER

. . . . . . . . . . . . . . 17

Removal and Installation . . . . . . . . . . ...17
Inspection. . . . . . . . . . . . . . . . ...17
Installation. . . . . . . . . . . . . . . . ..18

VACUUM HOSE

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

Removal and Installation . . . . . . . . . . ...19
Inspection. . . . . . . . . . . . . . . . ...21

VACUUM PUMP (TD27Ti engine model)

. . . . . 23

Removal and Installation . . . . . . . . . . ...23
Inspection. . . . . . . . . . . . . . . . ...23

VACUUM PUMP (ZD30DDTi engine model)

. . . ...25

Removal and Installation . . . . . . . . . . ...25

FRONT DISC BRAKE

. . . . . . . . . . . . ...26

Pad Replacement . . . . . . . . . . . . . ..26
Removal. . . . . . . . . . . . . . . . . .27
Disassembly. . . . . . . . . . . . . . . ...27
Inspection. . . . . . . . . . . . . . . . ...27
Assembly . . . . . . . . . . . . . . . . ...28
Inspection. . . . . . . . . . . . . . . . ...28
Installation. . . . . . . . . . . . . . . . ..30

REAR DRUM BRAKE

. . . . . . . . . . . . ...31

Removal. . . . . . . . . . . . . . . . . .32
Shoe Replacement . . . . . . . . . . . . . 33
Inspection. . . . . . . . . . . . . . . . ...33
Installation. . . . . . . . . . . . . . . . ..33

PARKING BRAKE CONTROL

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

Removal and Installation . . . . . . . . . . ...35
Inspection. . . . . . . . . . . . . . . . ...35
Adjustment . . . . . . . . . . . . . . . . .35

ANTI-LOCK BRAKE SYSTEM

. . . . . . . . . ..37

Purpose. . . . . . . . . . . . . . . . . ..37
Operation . . . . . . . . . . . . . . . . ...37
ABS Hydraulic Circuit . . . . . . . . . . . . 37
System Description. . . . . . . . . . . . . 38
Removal and Installation . . . . . . . . . . ...42

TROUBLE DIAGNOSES

. . . . . . . . . . . ...47

How to Perform Trouble Diagnoses for Quick
and Accurate Repair . . . . . . . . . . . . ..47
Component Parts and Harness Connector
Location . . . . . . . . . . . . . . . . . .48
Circuit Diagram for Quick Pinpoint Check. . . . .49
Wiring Diagram - ABS - . . . . . . . . . . . .50
CONSULT-II . . . . . . . . . . . . . . . ...58
CONSULT-II Inspection Procedure. . . . . . . 59
Preliminary Check. . . . . . . . . . . . . ..65
Ground Circuit Check . . . . . . . . . . . . 66
Diagnostic Procedure 1 (Not self-diagnostic item). 67

Diagnostic Procedure 2 (Warning lamp stays on
when ignition switch is turned ON). . . . . . . 69
Diagnostic Procedure 3 (ABS actuator solenoid
valve and solenoid valve relay) . . . . . . . . .71
Diagnostic Procedure 4 (Wheel sensor or rotor) . ..73
Diagnostic Procedure 5 (Motor Relay or motor) . ...75
Diagnostic Procedure 7 (Low voltage) . . . . . ..77
Diagnostic Procedure 8 (G sensor). . . . . . ...78
Diagnostic Procedure 9 (Control unit) . . . . . ...79
Diagnostic Procedure 10 (Pedal vibration and
noise) . . . . . . . . . . . . . . . . . . .80

Diagnostic Procedure 11 (Long stopping
distance) . . . . . . . . . . . . . . . . . 80
Diagnostic Procedure 12 (Unexpected pedal
action) . . . . . . . . . . . . . . . . . . 81
Diagnostic Procedure 13 . . . . . . . . . . ...82
Diagnostic Procedure 14 . . . . . . . . . . ...82
Electrical Components Inspection . . . . . . . .83

SERVICE DATA AND SPECIFICATIONS (SDS)

. . ..84

General Specifications. . . . . . . . . . . ...84
Inspection and Adjustment . . . . . . . . . . 85

CONTENTS

(Cont’d)

BR-2

Supplement Restraint System (SRS) “AIR BAG”
and “SEAT BELT PRE-TENSIONER”

The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, 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 section of this Service Instruction.

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 Instruction. SRS wiring harnesses (except “SEAT BELT-TENSIONER” connector) can be iden-
tified with yellow harness connector and with yellow harness protector or yellow insulation tape
before the harness connectors.

Precautions

I

Use only “DOT 4” 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 “Brake
Burnishing Procedure”, “Check and Adjustment”, 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 — for example chemical goggles or face shield.

YBR293

PRECAUTIONS AND PREPARATION

BR-3

Preparation

SPECIAL SERVICE TOOLS

Tool number
Tool name

Description

GG94310000
Flare nut torque wrench

Removing and installing each brake pip-
ing

KV991V0010
Brake fluid pressure
gauge

Measuring brake fluid pressure

HT72480000
Rear axle shaft bearing
puller

Removing rear wheel sensor rotor

PRECAUTIONS AND PREPARATION

BR-4