Almera Tino V10 (2003 year). Manual — part 44
SFA612
4.
Pry off snap ring, then remove spider assembly.
CAUTION:
Do not disassemble spider assembly.
5.
Draw out boot.
Cover drive shaft serration with tape to prevent damage to the
boot.
SFA092A
Wheel Side (ZF90, B90, AC2300I & AC3300I)
NLAX0017S02
1.
Before separating joint assembly, put matching marks on drive
shaft and joint assembly.
2.
Separate joint assembly with a suitable tool.
Be careful not to damage threads on drive shaft.
3.
Remove boot bands.
4.
Draw out boot.
SFA442B
Support Bearing
NLAX0017S03
1.
Remove dust shield.
SFA692
2.
Remove snap ring.
SFA693
3.
Press support bearing assembly off of drive shaft.
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FRONT AXLE
Drive Shaft (Cont’d)
AX-13
SFA617
4.
Separate support bearing from retainer.
INSPECTION
NLAX0018
Thoroughly clean all parts in cleaning solvent, and dry with
compressed air. Check parts for evidence of deformation or
other damage.
Drive Shaft
NLAX0018S01
Replace drive shaft if it is twisted or cracked.
Boot
NLAX0018S02
Check boot for fatigue, cracks or wear. Replace boot with new boot
bands.
Joint Assembly (Transaxle side)
NLAX0018S03
I
Check spider assembly for needle bearing and washer dam-
age. Replace if necessary. (Tripod type)
I
Check roller surfaces for scratches, wear or other damage.
Replace if necessary. (Tripod type)
I
Replace any parts of double offset joint which show signs of
scorching, rust, wear or excessive play. (Double offset type)
I
Check serration for deformation. Replace if necessary.
I
Check slide joint housing for any damage. Replace if neces-
sary.
Joint Assembly (Wheel side)
NLAX0018S04
Replace joint assembly if it is deformed or damaged.
Support Bearing
NLAX0018S05
Make sure wheel bearing rolls freely and is free from noise, cracks,
pitting or wear.
Support Bearing Bracket
NLAX0018S06
Check support bearing bracket for cracks with a magnetic explora-
tion or dyeing test.
ASSEMBLY
NLAX0019
I
After drive shaft has been assembled, ensure that it
moves smoothly over its entire range without binding.
I
Use grease according to AX-19, SDS.
FRONT AXLE
Drive Shaft (Cont’d)
AX-14
SFA800
Wheel Side (ZF90, B90, AC2300I & AC3300I)
NLAX0019S01
1.
Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.
SFA942A
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.
SFA592B
3.
Pack drive shaft with specified amount of grease.
Specified amount of grease:
Refer to AX-19, SDS.
4.
Make sure that boot is properly installed on the drive shaft
groove.
Set boot so that it does not swell and deform when its length
is “L
1
”.
Length “L
1
”:
Refer to AX-19, SDS.
SFA443B
5.
Lock new larger and smaller boot bands.
I
Boot bands type A
a)
Lock new larger and smaller boot bands securely with a suit-
able tool.
SDIA0876J
I
Boot bands type B
a)
As shown in the figure, secure the big and small ends of the
boot with new boot bands.
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FRONT AXLE
Drive Shaft (Cont’d)
AX-15
YAX011
b)
Rotate joint part and confirm that mounting position of boot
does not deviate. When it deviates, mount a new boot band
again.
CAUTION:
When fixing boot band, fix so that the diameter “M” on the
figure becomes as follows.
Diameter “M”: 5 mm (0.20 in)
SFA313B
Dynamic Damper (where fitted)
NLAX0019S02
1.
Use new damper bands when installing.
2.
Install dynamic damper from stationary-joint side while holding
it securely.
Length:
Refer to AX-20, SDS.
SFA800
Transaxle Side (D90)
NLAX0019S03
1.
Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.
SFA514A
2.
Install ball cage, inner race and balls or spider assembly as a
unit, making sure the marks which were made during disas-
sembly are properly aligned.
3.
Install new snap ring.
SFA149A
4.
Pack drive shaft with specified amount of grease.
Specified amount of grease:
Refer to AX-19, SDS.
5.
Install slide joint housing, then install new snap ring.
6.
Make sure that boot is properly installed on the drive shaft
groove.
Set boot so that it does not swell and deform when its length
is “L
2
”.
Length “L
2
”:
Refer to AX-19, SDS.
FRONT AXLE
Drive Shaft (Cont’d)
AX-16
SFA395
7.
Lock new larger and smaller boot bands securely with a suit-
able tool.
SFA800
Transaxle Side (TS79C, T79C, GI2300I & GI3300I)
NLAX0019S05
1.
Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.
SFA612
2.
Install spider assembly securely, making sure the marks which
were made during disassembly are properly aligned.
3.
Install new snap ring.
NAX005
4.
Pack drive shaft with specified amount of grease.
Specified amount of grease:
Refer to AX-19, SDS.
5.
Install slide joint housing.
6.
Set boot so that it does not swell and deform when its length
is “L
2
”:
Refer to AX-19, SDS.
SFA395
Make sure that the boot is properly installed on the drive shaft
groove.
7.
Lock new larger and smaller boot bands.
I
Boot bands type A
a)
Lock new larger and smaller boot bands securely with a suit-
able tool.
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FRONT AXLE
Drive Shaft (Cont’d)
AX-17
SDIA0876J
I
Boot bands type B
a)
As shown in the figure, secure the big and small ends of the
boot with new boot bands.
YAX011
b)
Rotate joint part and confirm that mounting position of boot
does not deviate. When it deviates, mount a new boot band
again.
CAUTION:
When fixing boot band, fix so that the diameter “M” on the
figure becomes as follows.
Diameter “M”: 5 mm (0.20 in)
SFA618
Support Bearing
NLAX0019S04
I
Press bearing into retainer.
SFA694
I
Press drive shaft into bearing.
SFA444B
I
Install snap ring.
I
Install new dust shield.
FRONT AXLE
Drive Shaft (Cont’d)
AX-18
Service Data and Specifications (SDS)
DRIVE SHAFT
=NLAX0020
QG
YD
M/T models
A/T models
5 M/T models
6 M/T models
LH
RH
Joint type
Transaxle side
GI2300I
T79C
TS79C
D90
GI3300I
Grease
Quality
39709-BM500
39709-2U600
39709-BM500
*2
Joint type
Wheel side
AC2300I
ZF90
B90
AC3300I
Grease
Quality
Nissan genuine
grease or equiva-
lent
39209-2U600
Nissan genuine
grease or equiva-
lent
*3
Grease
Capacity
g (oz)
Transaxle side
125.5 - 135.5
(4.42 - 4.77)
155 - 165
(5.47 - 5.82)
145 - 165
(5.11 - 5.82)
167 - 177
(5.89 - 6.24)
Wheel side
40 - 50
(1.41 - 1.76)
115 - 125
(4.06 - 4.41)
93 - 103
(3.28 - 3.63)
120 - 140
(4.41 - 4.94)
110 - 130
(3.88 - 4.59)*4
Boot length
mm (in)
Transaxle side “L
2
”
98 - 100
(3.86 - 3.94)*1
101.5 - 103.5
(4.00 - 4.07)*1
98 (3.86)*1
*1
Wheel side “L
1
”
94 - 96
(3.70 - 3.78)*1
94.1 - 96.1
(3.705 - 3.783)*1
110 (4.33)
*1
SFA961AA
SFA962A
*1: Fit boot to boot groove in bar shaft
*2: GKN-ONE LUBER C grease or Nissan genuine grease or equivalent
*3: GKN HTBJ grease or Nissan genuine grease or equivalent
*4: Preload the grease 45 to 55 g (1.59 to 1.94 oz) before assembling boot and shaft. After assembling boot and shaft, inject the grease
65 to 75 g (2.29 to 2.65 oz).
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FRONT AXLE
Service Data and Specifications (SDS)
AX-19
DYNAMIC DAMPER (WHERE FITTED)
=NLAX0033
Unit: mm (in)
QG
YD
M/T models
A/T models
LH
RH
LH
RH
LH
RH
Distance
“A”
178 - 184
(7.01 - 7.24)
375 - 381
(14.76 - 15.00)
—
398 (15.67)
172 - 178
(6.77 - 7.01)
190 -196
(7.48 - 7.72)
“B”
64 (2.52)
—
70 (2.76)
70 (2.76)
70 (2.76)
SAX015
WHEEL BEARING (FRONT)
NLAX0021
Wheel bearing axial end play limit
mm (in)
0.05 (0.0020)
Wheel bearing lock nut tightening torque
N·m (kg-m, ft-lb)
255 - 333 (26 - 34, 188 - 245)
FRONT AXLE
Service Data and Specifications (SDS) (Cont’d)
AX-20
SBR686C
Precautions
PRECAUTIONS
NLAX0022
I
When installing each rubber part, final tightening must be
carried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
I
Use flare nut wrench when removing or installing brake
tubes.
I
After installing removed suspension parts, check wheel
alignment.
I
Do not jack up at the trailing arm and lateral link.
I
Always torque brake lines when installing.
Preparation
SPECIAL SERVICE TOOLS
NLAX0032
Tool number
Tool name
Description
KV40104710
Drift
NT474
Install ABS sensor rotor
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia.
ST3072000
Drift
NT115
Install ABS sensor rotor
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
COMMERCIAL SERVICE TOOLS
NLAX0024
Tool name
Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing brake piping
a: 10 mm (0.39 in)
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REAR AXLE
Precautions
AX-21
Noise, Vibration and Harshness (NVH)
Troubleshooting
NLAX0025
Refer to “Noise, Vibration and Harshness (NVH) Troubleshooting”,
“FRONT AXLE”, AX-3.
SMA525A
On-vehicle Service
REAR AXLE PARTS
NLAX0026
Check axle and suspension parts for excessive play, wear or dam-
age.
I
Shake each rear wheel to check for excessive play.
SRA690A
REAR WHEEL BEARING
NLAX0027
I
Check axial end play.
Axial end play:
0.05 mm (0.0020 in)
I
Check that wheel hub bearings operate smoothly.
I
Check tightening torque of wheel bearing lock nut.
: 187 - 254 N·m (19 - 26 kg-m, 138 - 188 ft-lb)
I
Replace wheel bearing assembly if there is axial end play or
wheel bearing does not turn smoothly. Refer to “Wheel Hub”,
“REAR AXLE”, AX-23.
REAR AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting
AX-22
Wheel Hub
COMPONENTS
NLAX0028
NAX001
1.
Spindle
2.
Baffle plate
3.
ABS sensor rotor
4.
Wheel hub bearing
5.
Wheel bearing lock nut
6.
Hub cap
7.
ABS sensor
REMOVAL
NLAX0029
CAUTION:
I
Before removing the rear wheel hub assembly, disconnect
the ABS wheel sensor from the assembly. Then move it
away from the hub assembly. Failure to do so may result
in damage to the sensor wires and the sensor becoming
inoperative.
I
Wheel hub bearing does not require maintenance. If any of
the following symptoms are noted, replace wheel hub
bearing assembly.
1)
Growling noise is emitted from wheel hub bearing dur-
ing operation.
2)
Wheel hub bearing drags or turns roughly. This occurs
when turning hub by hand after bearing lock nut is tight-
ened to specified torque.
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REAR AXLE
Wheel Hub
AX-23
SRA711A
1.
Remove brake caliper assembly.
2.
Remove wheel bearing lock nut.
3.
Remove brake rotor (models with disk brake) or brake drum
(models with drum brakes).
4.
Remove wheel hub bearing from spindle.
CAUTION:
Do not disconnect brake hose from caliper.
I
Suspend caliper assembly with wire so as not to stretch
brake hose.
I
Be careful not to depress brake pedal, or piston will pop
out.
Make sure brake hose is not twisted.
ARA082
5.
Remove the sensor rotor using suitable puller, drift and bea
ring replacer.
SAX014
INSTALLATION
NLAX0030
I
With vehicles equipped with ABS, press-fit ABS sensor rotor
into wheel hub bearing using a drift.
Do not reuse ABS sensor rotor. When installing, replace it
with a new one.
SRA734AB
I
Press-fit ABS sensor rotor as far as the location shown in fig-
ure at left.
Height “h”:
12.5 - 13.5 mm (0.492 - 0.531 in)
REAR AXLE
Wheel Hub (Cont’d)
AX-24
SRA712A
I
Install wheel hub bearing.
I
Tighten wheel bearing lock nut.
Before tightening, apply oil to threaded portion of rear spindle.
Do not reuse wheel bearing lock nut.
: 187 - 254 N·m (19 - 26 kg-m, 138 - 188 ft-lb)
I
Check that wheel bearings operate smoothly.
SRA737A
I
Check wheel hub bearing axial end play.
Axial end play:
0.05 mm (0.0020 in)
SFA599B
I
Clinch two places of lock nut.
SRA738A
I
Install hub cap using a suitable tool.
Do not reuse hub cap. When installing, replace it with a
new one.
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REAR AXLE
Wheel Hub (Cont’d)
AX-25
Service Data and Specifications (SDS)
WHEEL BEARING (REAR)
=NLAX0031
Wheel bearing axial end play
mm (in)
0.05 (0.0020)
Wheel bearing lock nut tightening torque
N·m (kg-m, ft-lb)
187 - 254 (19 - 26, 138 - 188)
REAR AXLE
Service Data and Specifications (SDS)
AX-26
BRAKE SYSTEM
CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . ...4
Supplemental Restraint System (SRS)
. . . ...4
Precautions for Brake System. . . . . . . . . .4
Precautions When Working On ABS. . . . . . ...5
Precautions for Brake Control . . . . . . . . . .5
Diagnosis Precaution. . . . . . . . . . . . ...6
. . . . . . . . . . . . . . ...6
Precaution for Harness Repair . . . . . . . . . 6
. . . . . . . . . . . . . . ...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
. . . . . . . . . . . ...19
. . . . . . . . . . . . ...19
Removal. . . . . . . . . . . . . . . . . .19
Inspection. . . . . . . . . . . . . . . . ...19
. . . . . . . ..19
Installation. . . . . . . . . . . . . . . . ..20
VACUUM HOSE. . . . . . . . . . . . . . . .21
Removal and Installation . . . . . . . . . . ...21
Inspection. . . . . . . . . . . . . . . . ...22
. . . . . . . . ...22
. . . . . . . . . . . . . . 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
. . . . . . . . . . . . . . . . .28
. . . . . . . . . . . . . . . . ...29
Assembly . . . . . . . . . . . . . . . . ...30
Installation. . . . . . . . . . . . . . . . ..30
REAR DISC BRAKE (CAM & STRUT TYPE) . . . ..31
Component . . . . . . . . . . . . . . . . 31
Pad Replacement . . . . . . . . . . . . . ..31
Removal. . . . . . . . . . . . . . . . . .33
Disassembly. . . . . . . . . . . . . . . ...33
Inspection. . . . . . . . . . . . . . . . ...34
. . . . . . . . . . . . . . . . .34
. . . . . . . . . . . . . . . . ...35
Assembly . . . . . . . . . . . . . . . . ...35
Installation. . . . . . . . . . . . . . . . ..38
REAR DISC BRAKE (BALL & RAMP TYPE) . . . ..39
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Component . . . . . . . . . . . . . . . . 39
Pad Replacement . . . . . . . . . . . . . ..39
Removal. . . . . . . . . . . . . . . . . .41
Disassembly. . . . . . . . . . . . . . . ...41
Inspection. . . . . . . . . . . . . . . . ...41
. . . . . . . . . . . . . . . . .41
. . . . . . . . . . . . . . . . ...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
. . . . . . . . . . . . . . . . .46
. . . . . . . . . . . . . ..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
. . . . . . . . . . . . . . . . ...54
. . . . . . . . . . . . . ...56
. . . . . . . . . . . . . . . . ...58
. . . . . . . . . . . . . ...60
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . ...61
Trouble Diagnosis Chart by Symptom. . . . . ...61
. . . . . . . . . . . . 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
. . . . . . . . . . . . ...63
. . . . . . . . . . . . . ..66
. . . . . . . . . . . . . . ..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
. . . . . . . . . . . . . . . ...80
. . . . . . . . . . . . . . 80
Sensor Rotor. . . . . . . . . . . . . . . ..81
. . . . . . . . . . . . . . . ...81
. . . . . . . . . . . . . . 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
. . . . . . . . . . . . ..87
. . . . . . . . . . . . .87
Hydraulic Circuit Diagram. . . . . . . . . . ..88
CAN COMMUNICATION . . . . . . . . . . . ...89
System Description. . . . . . . . . . . . . 89
CAN Communication Unit. . . . . . . . . . ..89
. . . . . . . . . . . . . . . . ...90
. . . . . . . . . . . . . ...92
. . . . . . . . . . . . . . . . ...94
. . . . . . . . . . . . . ...96
TROUBLE DIAGNOSIS . . . . . . . . . . . . .97
CONTENTS
(Cont’d)
BR-2
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