2002 NISSAN TERRANO Service Repair Manual

Inspection
Check brake pedal for following items:
IBrake pedal bend
IClevis pin deformation
ICrack of any welded portion
ICrack or deformation of clevis pin stopper
Adjustment
Check brake pedal free height from dash reinforcement panel.
H: Free height
Refer to SDS, BR-85.
D: Full stroke
Refer to SDS, BR-85.
C: Clearance between pedal stopper and threaded end
of stop lamp switch
0.3 - 1.0 mm (0.012 - 0.039 in)
A: Pedal free play
1.0 - 3.0 mm (0.039 - 0.118 in)
If necessary, adjust brake pedal free height.
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
Make sure that tip of input rod stays inside of clevis as shown.
2. Loosen lock nut and adjust clearance ªCº with stop lamp switch.
Then tighten lock nuts.
3. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
4. Check brake system for leaks, accumulation of air or any dam-
age to components (master cylinder, etc.); then make neces-
sary repairs.
SBR997
EBR200
YBR300
BRAKE PEDAL AND BRACKET
BR-15

Removal
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. DO NOT RUB.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake
pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
5. Remove protector of master cylinder, and avoid scratching the
surface of master cylinder during removal.
CAUTION:
Do not disassemble master cylinder.
NOTE:
If it is necessary to change the brake fluid reservoir, remove it
as shown in the illustration on the left, while holding the seals
with one hand.
It is not necessary to replace the seals if they are in a good
condition.
Installation
CAUTION:
IRefill with new brake fluid ªDOT 4º.
INever reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mounting
nuts lightly.
2. Fit flare nuts to master cylinder.
3. Tighten mounting nuts.
:21-29N×m (2.1 - 3.0 kg-m, 15 - 22 ft-lb)
4. Tighten flare nuts.
:15-18N×m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
5. Bleed air. Refer to ªBleeding Brake Systemº, ªBRAKE
HYDRAULIC LINEº, BR-8.
YBR258
EBR080
MASTER CYLINDER
BR-16

Removal and Installation
Inspection
OPERATING CHECK
IDepress brake pedal several times with engine off, and check
that there is no change in pedal stroke.
IDepress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
IStart engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. If pedal goes further down the
first time and gradually rises after second or third time, booster
is airtight.
IDepress brake pedal while engine is running, and stop engine
with pedal depressed. If there is no change in pedal stroke after
holding pedal down30 seconds, brake booster is airtight.
OUTPUT ROD LENGTH CHECK
1. Apply vacuum of þ66.7 kPa (þ667 mbar, þ500 mmHg, þ19.69
inHg) to brake booster with a manual vacuum pump and check
output rod length ªAº.
Specified length ªAº:
22.15 - 22.45 mm (0.872 - 0.884 in)
(The length ªAº in this case is the distance from end of output
rod to outside of brake booster, when the specified vacuum is
applied.)
YBR259
SBR002A
SBR365A
EBR090
BRAKE BOOSTER
BR-17

2. Check output rod length ªLº when brake booster doesn't work.
Specified length ªLº:
129.2 - 130.2 mm (5.09 - 5.13 in)
Installation
CAUTION:
IBe careful not to deform or bend brake pipes, during instal-
lation of booster.
IReplace clevis pin if damaged.
IRefill with new brake fluid ªDOT 4º.
INever reuse drained brake fluid.
ITake care not to damage brake booster mounting bolt
thread when installing. Due to the acute angle of
installation, the threads can be damaged on the metal sur-
rounding the dash panel holes.
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to
brake booster) lightly. (Join brake booster and brake pedal
bracket to the front end of the vehicle interior).
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
:20-25N×m (1.3 - 1.6 kg-m, 10 - 12 ft-lb)
5. Install master cylinder. Refer to ªInstallationº, ªMASTER
CYLINDERº, BR-16.
6. Bleed air. Refer to ªBleeding Brake Systemº, ªBRAKE
HYDRAULIC LINEº, BR-8.
YBR294
BRAKE BOOSTER
Inspection (Cont'd)
BR-18

Removal and Installation
YBR260
VACUUM HOSE
BR-19

CAUTION:
When installing vacuum hoses, pay attention to the following
points.
IDo not apply any oil or lubricants to vacuum hose and
check valve.
IInsert vacuum tube into vacuum hose over a length of min.
24 mm (0.94 in) as shown.
Take care to main vacuum hoses in their original direction and
position.
YBR292
SBR225B
VACUUM HOSE
Removal and Installation (Cont'd)
BR-20

Inspection
HOSES AND CONNECTORS
ICheck condition of vacuum hoses and connectors.
ICheck vacuum hoses and check valve for air tightness.
CHECK VALVE
ICheck vacuum with a manual vacuum pump.
Connect to booster
sideVacuum should exist.
Connect to engine
sideVacuum should not exist.
VACUUM WARNING SWITCH
Test continuity though vacuum warning switch with an ohmmeter
and vacuum pump.
VacuumLess than 26.7 kPa
(267 mbar, 200 mmHg,
7.87 inHg)0W
33.3 kPa
(333 mbar, 250 mmHg,
9.84 inHg) or more
W
EBR008
EBR009
SBR007A
VACUUM HOSE
BR-21

VACUUM PUMP (TD27Ti ENGINE)
1. Install vacuum gauge.
2. Run engine at 1,000 rpm or more.
3. Check vacuum.
Specified vacuum:
93.3 kPa
(933 mbar, 700 mmHg, 27.56 inHg) or more
VACUUM PUMP (ZD30DDTi ENGINE)
Refer to EM section, ªINSPECTIONº in ªVACUUM PUMP Ð
Removal and Installationº.
NBR004
VACUUM HOSE
Inspection (Cont'd)
BR-22