Almera Tino V10 (2003 year). Manual — part 45
How to Perform Trouble Diagnosis for Quick and
Accurate Repair . . . . . . . . . . . . . . .97
. . . . . . . . . . . . . ..97
. . . . . . . . . ...98
. . . . . . . . . . . 99
. . . . . . ...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
. . . . . . . . . . . . . 112
. . . . . . . . . . . . . 115
. . . . . . . . . . . . . . 118
For Fast and Accurate Diagnosis . . . . . . . 120
. . . . . . ..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
Appears on Self-diagnostic Results Display . . ...140
Inspection 13 CAN Communication System . . ...140
Inspection 14 When
Appears on Self-diagnostic Results Display . . ...142
Inspection 15 ESP OFF Indicator Lamp Does
Not Illuminate.. . . . . . . . . . . . . . ..142
Component Inspection. . . . . . . . . . . .142
. . . . . . . . . . . . .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
. . . . . . . . . . . . . . . .149
. . . . . . . . . . . . . ..149
SENSOR ROTOR . . . . . . . . . . . . . . 150
Removal and Installation . . . . . . . . . . .150
. . . . . . . . . . . . . . . .150
. . . . . . . . . . . . . ..150
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) . 151
Removal and Installation . . . . . . . . . . .151
G SENSOR . . . . . . . . . . . . . . . . ..152
Removal and Installation . . . . . . . . . . .152
. . . . . . . . . . . . . . . .152
. . . . . . . . . . . . . ..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
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CONTENTS
(Cont’d)
BR-3
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER”
NLBR0081
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” 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 system composition which is available to NISSAN MODEL V10 is as follows (The compo-
sition varies according to the destination and optional equipment.):
I
For 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).
Information necessary to service the system safely is included in the RS section of this Service Manual.
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. For removal of Spiral Cable and Air
Bag Module, see the RS section.
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.
SBR686C
Precautions for Brake System
NLBR0002
I
Recommended fluid is brake fluid “DOT 3” or “DOT 4”.
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Never reuse drained brake fluid.
I
Be careful not to splash brake fluid on painted areas.
I
To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
I
Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of the hydraulic system.
I
Use flare nut wrench when removing and installing brake
tube.
I
Always torque brake lines when installing.
I
Burnish the brake contact surfaces after refinishing or
replacing rotors, after replacing pads, or if a soft pedal
occurs at very low mileage.
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE
SERVICE”, BR-10.
WARNING:
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Clean brake pads with a waste cloth, then wipe with a dust
collector.
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
BR-4
Precautions When Working On ABS
NLBR0149
I
Use recommended tyres in combination with ABS.
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Please fit tyres or studded tyres, etc. with the same size.
I
If different sizes of tyres, or tyres other than the ones rec-
ommended for use with the ABS, are fitted, stopping dis-
tance will increase and control and stability could deterio-
rate.
I
When changing brake pads, please use Nissan genuine
parts.
I
When fitting radios etc, do not position the radio itself,
antenna, or antenna cables within an area of about 100
mm (3.94 in) of the control unit.
I
When doing any work that requires electro-welding, first
remove the control unit.
I
Please take care when taking a power supply for the
audio, lamps etc., not to take this from any ABS-related
harness. (Please refer to the electrical wiring diagrams for
ABS-related harnesses)
I
Before working, turn ignition switch OFF and disconnect
electrical connectors of ABS actuator and electric unit
(control unit) or battery cables.
Precautions for Brake Control
NLBR0157
I
During ABS operation, brake pedal lightly vibrates and a
mechanical noise may be heard. This is normal.
I
Just after starting vehicle after ignition switch ON, brake pedal
may vibrate or motor operating noise may be heard from
engine room. This is a normal status of operation check.
I
Stopping distance may be longer than that of vehicles without
ABS when vehicle drives on rough, gravel, or snow-covered
(fresh, deep snow) roads.
I
When an error is indicated by ABS or another warning lamp,
collect all necessary information from customer (what symp-
toms are present under what conditions) and check for simple
causes before starting diagnostic servicing. Besides electrical
system inspection, check brake booster operation, brake fluid
level, and fluid leaks.
I
If tire size and type are used in an improper combination, or
brake pads are not Genuine NISSAN parts, stopping distance
or steering stability may deteriorate.
I
If there is a radio, antenna, or antenna lead-in wire (including
wiring) near control module, ABS function may have a malfunc-
tion or error.
I
If aftermarket parts (car stereo, CD player, etc.) have been
installed, check for incidents such as harness pinches, open
circuits, and improper wiring.
I
If the following components are replaced with non-genuine
components or converted, the ESP OFF indicator lamp and
SLIP indicator lamp may turn on or the ESP system may not
operate properly. Components related to suspension (Shock
Absorber, Strut, Spring, Bush, etc.), Tires, wheels (exclude
specified size), components related to brake (Pad, Rotor,
Caliper, etc.), Components related to engine (Muffler, ECM,
etc.), Components related to body reinforcement (Roll bar,
Tower bar, etc.).
I
Driving in the condition of breakage or excessive wear of the
suspension, tires or components related to the brakes may
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PRECAUTIONS
Precautions When Working On ABS
BR-5
cause the ESP OFF indicator lamp and the SLIP indicator lamp
to turn on, and the ESP system may not operate properly.
I
When the TCS or ESP is activated by sudden acceleration or
sudden turn, some noise may occur. The noise is a result of
the normal operation of the TCS and ESP.
I
When driving on roads which have extreme slopes (such as
mountainous roads) or high banks (such as sharp carves on a
freeway), the ESP may not operate normally, or the ESP warn-
ing lamp and the SLIP indicator lamp may turn on. However,
this is not a problem if normal operation can be resumed after
restarting the engine.
I
Sudden turns (such as spin turns, acceleration turns), drifting,
etc. When ESP function is OFF (ESP SW ON) may cause the
yaw rate/side G sensor system indicate a malfunction. How-
ever this is not a malfunction if normal operation can be
resumed after restarting the engine.
Diagnosis Precaution
NLBR0158
CAN SYSTEM
NLBR0158S01
I
Do not apply voltage of 7.0V or higher to terminal to be mea-
sured.
I
Maximum open terminal voltage of tester in use shall be 7.0V
or lower.
I
Before checking harnesses, turn ignition switch to OFF and
disconnect battery negative cable.
PKIA0306E
Precaution for Harness Repair
NLBR0159
CAN SYSTEM
NLBR0159S01
I
Area to be repaired shall be soldered, and wrapped with a tape
[Be sure that fraying of twisted wire shall be within 110 mm
(4.33 in)].
PKIA0307E
I
Do not make a bypass connection to repaired area. (If it is
done, branch part will be removed and characteristics of
twisted wire will be lost.)
PRECAUTIONS
Precautions for Brake Control (Cont’d)
BR-6
Wiring Diagrams and Trouble Diagnosis
NLBR0003
When you read wiring diagrams, refer to the following:
I
GI-11, “HOW TO READ WIRING DIAGRAMS”
I
EL-12, “POWER SUPPLY ROUTING”
When you perform trouble diagnosis, refer to the following:
I
GI-32, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS”
I
GI-21, “HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT”
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PRECAUTIONS
Wiring Diagrams and Trouble Diagnosis
BR-7
Commercial Service Tools
NLBR0004
Tool name
Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing each brake piping
a: 10 mm (0.39 in)/12 mm (0.47 in)
Brake fluid pressure
gauge
NT151
Measuring brake fluid pressure
PREPARATION
Commercial Service Tools
BR-8
NLBR0005
NVH Troubleshooting Chart
NLBR0005S01
Use the table below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
—
—
—
—
—
NVH
in
AX
section
NVH
in
AX,
SU
section
NVH
in
AX
section
NVH
in
AX
section
NVH
in
ST
section
SUSPECTED PARTS
(Possible cause)
Pads
-
damaged
Pads
-
uneven
wear
Shims
damaged
Rotor
imbalance
Rotor
damage
Rotor
runout
Rotor
deformation
Rotor
deflection
Rotor
rust
Rotor
thickness
variation
DRIVE
SHAFT
AXLE
AND
SUSPENSION
TIRES
ROAD
WHEEL
STEERING
Symptom BRAKE
Noise
X
X
X
X
X
X
X
X
Shake
X
X
X
X
X
X
Shimmy, Jud-
der
X
X
X
X
X
X
X
X
X
X
X
X: Applicable
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
BR-9
NBR376
Checking Brake Fluid Level
NLBR0006
I
Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
I
If fluid level is extremely low, check brake system for leaks.
I
Release parking brake lever and see if brake warning lamp
goes off. If not, check brake system for leaks.
SBR389C
Checking Brake Line
NLBR0007
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1.
Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2.
Check for oil leakage by fully depressing brake pedal while
engine is running.
SBR419C
Changing Brake Fluid
NLBR0008
CAUTION:
I
Refill with new brake fluid “DOT 3” or “DOT 4”.
I
Always keep fluid level higher than minimum line on res-
ervoir tank.
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.
1.
Clean inside of reservoir tank, and refill with new brake fluid.
2.
Connect a vinyl tube to each air bleeder valve.
3.
Drain brake fluid from each air bleeder valve by depressing
brake pedal while keeping reservoir level higher than minimum
line by adding new brake fluid.
4.
Repeat until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to “Bleeding Brake System”, BR-11 and “Air
Bleeding Procedure”, CL-10.
Brake Burnishing Procedure
NLBR0036
Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing rotors, after replacing pads, or
if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1.
Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2.
Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
ON-VEHICLE SERVICE
Checking Brake Fluid Level
BR-10
pressure such that vehicle stopping time equals 3 to 5 sec-
onds.
3.
To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4.
Repeat steps 1 to 3, 10 times or more to complete the burnish-
ing procedure.
NBR357
Bleeding Brake System
NLBR0009
CAUTION:
I
Carefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
I
Fill reservoir with new brake fluid “DOT 3” or “DOT 4”.
Make sure it is full at all times while bleeding air out of
system.
I
Place a container under master cylinder to avoid spillage
of brake fluid.
I
For models with ABS, turn ignition switch OFF and dis-
connect ABS actuator connectors or battery ground cable.
SBR419C
I
Bleed air in the following order.
Right rear brake
,
Left front brake
,
Left rear brake
,
Right
front brake
1.
Connect a transparent vinyl tube to air bleeder valve.
2.
Fully depress brake pedal several times.
3.
With brake pedal depressed, open air bleeder valve to release
air.
4.
Close air bleeder valve.
5.
Release brake pedal slowly.
6.
Repeat steps 2. through 5. until clear brake fluid comes out of
air bleeder valve.
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ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont’d)
BR-11
Hydraulic Circuit
NLBR0010
YBR362
Removal
NLBR0011
CAUTION:
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
All hoses must be free from excessive bending, twisting
and pulling.
I
For ball & ramp type rear caliper, care should be taken as
not to let air enter the cylinder body.
1.
Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
2.
Cover openings to prevent entrance of air and dirt whenever
disconnecting brake line.
Inspection
NLBR0012
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
BRAKE HYDRAULIC LINE
Hydraulic Circuit
BR-12
SBR686C
Installation
NLBR0013
CAUTION:
I
Refill with new brake fluid “DOT 3” or “DOT 4”.
I
Never reuse drained brake fluid.
1.
Tighten all flare nuts and connecting bolts.
Specification:
Flare nut
14.8 - 17.6 N·m (1.5 - 1.7 kg-m, 11 - 12 ft-lb)
Connecting bolt
17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
2.
Refill until new brake fluid comes out of each air bleeder valve.
3.
Bleed air. Refer to “Bleeding Brake System”, BR-11, and ‘‘Air
Bleeding Procedure’’, CL-10.
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BRAKE HYDRAULIC LINE
Installation
BR-13
Removal and Installation
NLBR0015
YBR360
SBR997
Inspection
NLBR0016
Check brake pedal for following items.
I
Brake pedal bend
I
Clevis pin deformation
I
Crack of any welded portion
I
Crack or deformation of clevis pin stopper
YBR361
Adjustment
NLBR0017
Check brake pedal free height from metal panel. Adjust if neces-
sary.
H: Free height
Refer to SDS, BR-154.
C
1
, C
2
: Clearance between pedal stopper and threaded
end of stop lamp switch and brake switch.
0.75 - 2.00 mm (0.0295 - 0.0787 in)
D: Depressed height
LHD/RHD (M/T): 60 -70 (2.36 - 2.76 in)
Under force of 490 N (50 kg, 110 lb) with engine run-
ning.
A: Pedal free play at pedal pad
1.0 - 3.0 mm (0.039 - 0.118 in)
BRAKE PEDAL AND BRACKET
Removal and Installation
BR-14
SBR229E
1.
Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
2.
Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3.
Check brake pedal’s depressed height while engine is running.
If lower than specification, check brake system for leaks, accu-
mulation of air or any damage to components (master cylinder,
wheel cylinder, etc.), then make necessary repairs.
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BRAKE PEDAL AND BRACKET
Adjustment (Cont’d)
BR-15
Removal
NLBR0117
NBR360
1.
Reservoir cap
2.
Filter
3.
Reservoir tank
4.
Adapter
5.
Elastic pin
6.
Seal
7.
Washer
8.
Circlip
9.
Piston stopper pin
10. Primary piston assembly
11. Secondary piston assembly
12. Cylinder body
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.
1.
Connect a vinyl tube to air bleeder valve.
2.
Drain brake fluid from each front caliper air bleeder valve,
depressing brake pedal to empty fluid from master cylinder.
3.
Remove brake pipe flare nuts.
4.
Disconnect hoses from adapter.
5.
Remove master cylinder mounting nuts.
NBR361
Disassembly
NLBR0118
1.
Drive out elastic pin from cylinder body.
2.
Remove adapter, washer and seals.
MASTER CYLINDER
Removal
BR-16
NBR353
3.
Remove the circlip with suitable pliers while piston is pushed
into cylinder.
SBR232E
4.
Remove piston stopper pin while piston is pushed into cylinder.
5.
Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
Inspection
NLBR0119
Check for the following items.
Replace any part if damaged.
Master cylinder:
I
Pin holes or scratches on inner wall.
Piston:
I
Deformation or scratches on piston cups.
SBR233E
Assembly
NLBR0120
1.
Insert secondary piston assembly. Then insert primary piston
assembly.
I
Pay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body.
SBR232E
2.
Install piston stopper pin while piston is pushed into cylinder.
Then secure the primary and secondary piston assemblies
with new circlip.
3.
Insert washer and push reservoir seals and adapter into cylin-
der body.
4.
Install elastic pin.
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MASTER CYLINDER
Disassembly (Cont’d)
BR-17
Installation
NLBR0121
CAUTION:
I
Refill with new brake fluid “DOT 3” or “DOT 4”.
I
Never reuse drained brake fluid.
1.
Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2.
Torque mounting nuts.
: 13 - 15 N·m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
NBR363
NBR364
3.
Check hoses for damage. If the hoses show cracks or damage,
replace the hose.
4.
Insert the dot (coloured) mark hoses to the primary - and sec-
ondary inlet ports adapter. Then secure it with clamps.
Hose marking
Booster model
M215T
S255
Primary-inlet port
White dot
Blue dot
Secondary-inlet port
Yellow dot
Green dot
NBR362
5.
Fill up reservoir tank with new brake fluid.
6.
Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
7.
Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
8.
Fit brake lines to master cylinder.
9.
Tighten flare nuts.
: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
10. Bleed air procedure from brake and clutch system. Refer to
“Bleeding Brake System”, BR-11 and “Air Bleeding Procedure”,
CL-10.
MASTER CYLINDER
Installation
BR-18
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