2002 NISSAN TERRANO Service Repair Manual

Removal and Installation
IDrain oil from vacuum pump before removal.
Manually rotate fan belt clockwise to discharge any oil which
may have accumulated in vacuum pump.
IInstall vane so that its round surface faces pump housing.
IAfter installing vacuum pump assembly, apply 5 m(0.2 Imp fl
oz) of engine oil into vacuum pump assembly. Then, make sure
that pulley can be smoothly rotated by hand.
Inspection
Clean all parts and check them as follows:
ICheck for wear or scratches on mating surfaces of rotor and
vacuum pump housing and on rotor and center plate. If wear
or scratches are noted, replace those parts.
ICheck for wear or scratches on vanes. If necessary, replace.
NBR131
NBR132
NBR133
VACUUM PUMP (TD27Ti engine model)
BR-23

ICheck inner wall of vacuum pump housing for wear. If
necessary, replace.
ICheck rotor shaft for wear. If necessary, replace.
ICheck valve locations and copper washers for bends or defor-
mation. If necessary, replace.
ICheck that valve operates smoothly when slightly pushed.
Replace if necessary.
ICheck for air leakage with 98 to 490 kPa (1.0 to 4.9 bar, 1 to
5 kg/cm
2, 14 to 71 psi) of air pressure.
Replace if necessary.
NBR134
SBR194
SBR195
VACUUM PUMP (TD27Ti engine model)
Inspection (Cont'd)
BR-24

Removal and Installation
Refer to EM section, ªVACUUM PUMP Ð Removal and Installa-
tionº.
VACUUM PUMP (ZD30DDTi engine model)
BR-25

PRECAUTION:
Clean all brake assembly parts with a vacuum dust collector
to prevent particles from spreading through work area.
Pad Replacement
1. Loosen brake fluid reservoir cap.
2. Remove lower pin bolt.
YBR297
SBR081A
FRONT DISC BRAKE
BR-26

3. Swing cylinder body upward. Then remove pad and anti-noise
shims.
CAUTION:
IWhen cylinder body is swung up, do not depress brake
pedal because piston will pop out.
IEnsure that brake fluid does not come into contact with
dustcover and rotor.
IBe careful not to twist brake hoses.
Brake pad thickness (new):
10 mm (0.39 in)
Wear limit (min. thickness):
2 mm (0.08 in)
IAfter installing new brake pads, check brake fluid level at
brake fluid reservoir.
Removal
IRemove torque member fixing bolts and union bolt.
Disassembly
Push out piston with dust cover with compressed air.
Use a wooden block so that the 2 pistons come out evenly.
CAUTION:
IWear protecting clothes and safety goggles.
IDo not hold your fingers in front of the pistons.
IBe careful not to scratch piston and/or cylinder faces.
Inspection
INSPECTION OF BRAKE DRAG FORCE
ªResidual pairº describes the friction pressure of the disc brake
shoes against the disc when the brake pedal is not applied.
1. Swing cylinder body upward.
2. Make sure that wheel bearing is adjusted properly. Refer to
section FA.
3. Measure rotating force (F
1).
NBR207
SBR012C
SBR085A
SBR168A
FRONT DISC BRAKE
Pad Replacement (Cont'd)
BR-27

4. Install caliper with pads to the original position.
5. Depress brake pedal for 5 seconds.
6. Release brake pedal, rotate disc rotor 10 revolutions.
7. Measure rotating force (F
2).
8. Calculate brake drag force by subtracting F
1from F2.
Maximum brake drag force (F
2ÐF1):
103.0 N (10.5 kg, 23.2 lb)
If it is not within specification, check pins and pin boots in
caliper.
IMake sure that wheel bearing is adjusted properly.
IDisc pads and disc rotor must be dry.
DISC PAD
Check disc pad for wear or damage.
Pad wear limit (A):
2.0 mm (0.079 in)
Assembly
Fit new piston seals.
Lightly apply clean brake fluid ªDOT 4º to piston outer face.
1. Insert piston seal into groove on cylinder body.
2. Install piston into cylinder body.
3. Install piston boot and secure properly.
Inspection
CYLINDER BODY
ICheck inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
IMinor damage from rust or foreign materials may be eliminated
by polishing the surface with a fine emery paper. Replace cyl-
inder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
SBR130A
SBR041A
SMA364A
NBR007
SBR574
FRONT DISC BRAKE
Inspection (Cont'd)
BR-28

PISTON
Check outside surface of piston for score, rust, wear, damage or
presence of foreign materials. Replace if any of the above condi-
tions are observed.
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign materials are stuck to sliding
surface.
PIN, PIN BOLT AND PIN BOLT
Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.
ROTOR
Rubbing surface
Check rotor for roughness, cracks or chips.
Runout
1. Secure rotor to wheel hub with at least two nuts.
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to section FA.
Maximum runout:
0.07 mm (0.0028 in)
3. If the runout is out of specification, find minimum runout posi-
tion as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with
nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can
be found.
4. If the runout is still out of specification, turn rotor with on-car
brake lathe.
Thickness
Standard thickness:
26.0 mm (1.02 in)
Minimum thickness:
24.0 mm (0.94 in)
SBR089A
SBR090A
FRONT DISC BRAKE
Inspection (Cont'd)
BR-29

Installation
CAUTION:
IRefill with new brake fluid ªDOT 4º.
INever reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely taking care that brake
hose is not trapped between any suspension part and that
hoses are not twisted.
3. Bleed air. Refer to ªBleeding Brake Systemº, ªBRAKE
HYDRAULIC LINEº, BR-8.
SBR014C
FRONT DISC BRAKE
BR-30