2001 NISSAN ALMERA N16 Electronic Repair Manual

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NISSAN ALMERA N16 2001 Electronic Repair Manual Service Data and Specifications (SDS)
GENERAL SPECIFICATIONS (REAR)=NJSU0039
Suspension type Multi-link beam suspension
Shock absorber type Double-acting hydraulic
REAR WHEEL ALIGNMENT (UNLADEN*)NJSU0

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NISSAN ALMERA N16 2001 Electronic Repair Manual REAR SUSPENSION
Service Data and Specifications (SDS) (Contd)
SU-26

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NISSAN ALMERA N16 2001 Electronic Repair Manual BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS...............................................................3
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS...............................................................3
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............3
Precautions for Brake System .....................................3
Precautions When Working On ABS ...........................4
Wiring Diagrams and Trouble Diagnosis .....................4
PREPARATION...............................................................5
Commercial Service Tools ...........................................5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................6
NVH Troubleshooting Chart.........................................6
ON-VEHICLE SERVICE..................................................7
Checking Brake Fluid Level.........................................7
Checking Brake Line ...................................................7
Changing Brake Fluid ..................................................7
Brake Burnishing Procedure........................................7
Bleeding Brake System ...............................................8
BRAKE HYDRAULIC LINE.............................................9
Hydraulic Circuit...........................................................9
Removal .......................................................................9
Inspection...................................................................10
Installation ..................................................................10
DUAL PROPORTIONING VALVE................................. 11
Dual Proportioning Valve ........................................... 11
INSPECTION........................................................... 11
REMOVAL AND INSTALLATION (BUILT-IN TYPE)...... 11
BRAKE PEDAL AND BRACKET..................................12
Removal and Installation ...........................................12
Inspection...................................................................12
Adjustment .................................................................12
MASTER CYLINDER (NABCO)....................................14
Removal .....................................................................14
Disassembly...............................................................15
Inspection...................................................................15
Assembly ...................................................................15
Installation ..................................................................16
MASTER CYLINDER [BOSCH (NABCO)]...................17
Removal .....................................................................17
Disassembly...............................................................17Inspection...................................................................18
Assembly ...................................................................18
Installation ..................................................................19
BRAKE BOOSTER........................................................20
On-vehicle Service.....................................................20
OPERATING CHECK...............................................20
AIRTIGHT CHECK...................................................20
Removal .....................................................................20
Inspection...................................................................20
OUTPUT ROD LENGTH CHECK..............................20
Installation ..................................................................21
VACUUM HOSE.............................................................22
Removal and Installation ...........................................22
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 DRUM BRAKE...................................................31
Components...............................................................31
Removal .....................................................................31
Inspection - Wheel Cylinder ......................................32
Wheel Cylinder Overhaul...........................................33
Inspection - Drum ......................................................33

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NISSAN ALMERA N16 2001 Electronic Repair Manual Inspection - Lining .....................................................33
Installation ..................................................................33
REAR DISC BRAKE (CAM & STRUT TYPE)........

Inspection - Lining .....................................................33
Installation ..................................................................33
REAR DISC BRAKE (CAM & STRUT TYPE)..............35
Component ................................................................35
Pad Replacement ......................................................35
Removal .....................................................................37
Disassembly...............................................................37
Inspection...................................................................38
CALIPER.................................................................38
ROTOR...................................................................39
Assembly ...................................................................39
Installation ..................................................................42
REAR DISC BRAKE (BALL & RAMP TYPE)..............43
Component ................................................................43
Pad Replacement ......................................................43
Removal .....................................................................45
Disassembly...............................................................45
Inspection...................................................................45
CALIPER.................................................................45
ROTOR...................................................................46
Installation ..................................................................46
PARKING BRAKE CONTROL......................................47
Components...............................................................47
Removal and Installation ...........................................47
Inspection...................................................................47
Adjustment .................................................................48
ABS
DESCRIPTION...............................................................49
Purpose......................................................................49
ABS (Anti-Lock Brake System) Operation ................49
ABS Hydraulic Circuit ................................................49
System Components .................................................50
System Description ....................................................50
SENSOR.................................................................50
CONTROL UNIT......................................................50
ABS ACTUATOR AND ELECTRIC UNIT....................50
Component Parts and Harness Connector
Location .....................................................................52
Schematic ..................................................................53
Wiring Diagram - ABS - .............................................54
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION...............................................................58
CONSULT-II ...............................................................58
CONSULT-II APPLICATION TO ABS..........................58
ECU (ABS CONTROL UNIT) PART NUMBER
MODE
.....................................................................58
CONSULT-II Inspection Procedure............................58
SELF-DIAGNOSIS PROCEDURE..............................58
SELF-DIAGNOSTIC RESULTS MODE.......................60
DATA MONITOR PROCEDURE................................61
ACTIVE TEST PROCEDURE....................................62
DATA MONITOR MODE...........................................63
ACTIVE TEST MODE...............................................63
TROUBLE DIAGNOSIS - INTRODUCTION..................64
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................64
INTRODUCTION......................................................64
TROUBLE DIAGNOSIS - BASIC INSPECTION...........65
Preliminary Check......................................................65
Ground Circuit Check ................................................68
ABS ACTUATOR AND ELECTRIC UNIT GROUND.....68
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMS.............................................................................69
Wheel Sensor or Rotor ..............................................69
DIAGNOSTIC PROCEDURE.....................................69
ABS Actuator Solenoid Valve or Solenoid Valve
Relay ..........................................................................72
DIAGNOSTIC PROCEDURE.....................................72
Motor Relay or Motor.................................................75
DIAGNOSTIC PROCEDURE.....................................75
Low Voltage ...............................................................77
DIAGNOSTIC PROCEDURE.....................................77
Control Unit ................................................................79
DIAGNOSTIC PROCEDURE.....................................79
TROUBLE DIAGNOSES FOR SYMPTOMS.................80
1. ABS Works Frequently ..........................................80
2. Unexpected Pedal Action ......................................80
3. Long Stopping Distance ........................................81
4. ABS Does Not Work ..............................................82
5. Pedal Vibration and Noise.....................................83
6. ABS Warning Lamp Does Not Come On
When Ignition Switch Is Turned On...........................84
7. ABS Warning Lamp Stays On When Ignition
Switch Is Turned On ..................................................86
REMOVAL AND INSTALLATION.................................88
Wheel Sensors ..........................................................88
ABS Actuator and Electric Unit..................................89
REMOVAL...............................................................89
INSTALLATION........................................................89
Sensor Rotor..............................................................90
REMOVAL...............................................................90
INSTALLATION........................................................90
SERVICE DATA AND SPECIFICATIONS (SDS).........91
General Specifications ...............................................91
Disc Brake .................................................................91
Drum Brake................................................................91
Brake Pedal ...............................................................92
Parking Brake ............................................................92
CONTENTS(Cont'd)
BR-2

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NISSAN ALMERA N16 2001 Electronic Repair Manual Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJBR0139The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat bel

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NJBR0139The 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 system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+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.
+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 theRS sectionof this Service Manual.
WARNING:
+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.
+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.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
SBR686C
Precautions for Brake SystemNJBR0002+Recommended fluid is brake fluid ªDOT 4º.
+Never reuse drained brake fluid.
+Be careful not to splash brake fluid on painted areas.
+To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
+Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of the hydraulic system.
+Use flare nut wrench when removing and installing brake
tube.
+Always torque brake lines when installing.
+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 mileage.
Refer to ªBrake Burnishing Procedureº, ªON-VEHICLE
SERVICEº, BR-7.
WARNING:
+Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
BR-3

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NISSAN ALMERA N16 2001 Electronic Repair Manual Precautions When Working On ABSNJBR0140+Use recommended tyres in combination with ABS.
+Please fit tyres or studded tyres, etc. with the same size.
+If different sizes of tyres, or tyres other than th

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NISSAN ALMERA N16 2001 Electronic Repair Manual Commercial Service ToolsNJBR0004
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing each brake piping
a: 10 mm (0.39 in)
Brake fluid pressure
gauge
NT151
Measurin

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NISSAN ALMERA N16 2001 Electronic Repair Manual NJBR0005
NVH Troubleshooting ChartNJBR0005S01Use the table below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page
BR-27, 33, 35
BR-27, 33, 35
BR-3

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