2002 NISSAN TERRANO engine control

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS AND PREPARATION............................3
Supplement Restraint System (SRS)²AIR BAG²
and²SEAT BELT PRE-TENSIONER².........................3
Precautions ..................................................................3
Preparation ..................................................................4
CHECK AND ADJUSTMENT..........................................5
Checking Brake Fluid Level.........................................5
Checking Brake Line ...................................................5
Changing Brake Fluid ..................................................5
Brake Burnishing Procedure........................................5
BRAKE HYDRAULIC LINE.............................................6
Bleeding Brake System ...............................................8
Removal .......................................................................9
Inspection.....................................................................9
Installation ....................................................................9
LOAD SENSING VALVE...............................................10
Removal and Installation ...........................................10
Removal ..................................................................... 11
Installation .................................................................. 11
Inspection and Adjustment ........................................12
BRAKE PEDAL AND BRACKET..................................14
Removal and Installation ...........................................14
Inspection...................................................................15
Adjustment .................................................................15
MASTER CYLINDER.....................................................16
Removal .....................................................................16
Installation ..................................................................16
BRAKE BOOSTER........................................................17
Removal and Installation ...........................................17
Inspection...................................................................17
Installation ..................................................................18
VACUUM HOSE.............................................................19
Removal and Installation ...........................................19
Inspection...................................................................21
VACUUM PUMP (TD27Ti engine model)....................23
Removal and Installation ...........................................23
Inspection...................................................................23VACUUM PUMP (ZD30DDTi engine model)...............25
Removal and Installation ...........................................25
FRONT DISC BRAKE...................................................26
Pad Replacement ......................................................26
Removal .....................................................................27
Disassembly...............................................................27
Inspection...................................................................27
Assembly ...................................................................28
Inspection...................................................................28
Installation ..................................................................30
REAR DRUM BRAKE...................................................31
Removal .....................................................................32
Shoe Replacement ....................................................33
Inspection...................................................................33
Installation ..................................................................33
PARKING BRAKE CONTROL......................................35
Removal and Installation ...........................................35
Inspection...................................................................35
Adjustment .................................................................35
ANTI-LOCK BRAKE SYSTEM......................................37
Purpose......................................................................37
Operation ...................................................................37
ABS Hydraulic Circuit ................................................37
System Description ....................................................38
Removal and Installation ...........................................42
TROUBLE DIAGNOSES...............................................47
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................47
Component Parts and Harness Connector
Location .....................................................................48
Circuit Diagram for Quick Pinpoint Check.................49
Wiring Diagram - ABS - .............................................50
CONSULT-II ...............................................................58
CONSULT-II Inspection Procedure............................59
Preliminary Check......................................................65
Ground Circuit Check ................................................66
Diagnostic Procedure 1 (Not self-diagnostic item) ....67

Removal and Installation
1. To remove parking brake cable, first remove center console.
2. Disconnect warning lamp connector.
3. Remove bolts, slacken off and remove adjusting nut.
Inspection
1. Check control lever for wear or other damage. Replace if nec-
essary.
2. Check wires for discontinuity or deterioration. Replace if nec-
essary.
3. Check warning lamp and switch. Replace if necessary.
4. Check parts at each connecting portion and, if deformed or
damaged, replace.
Adjustment
1. Adjust clearance between shoe and drum as follows:
a. Release parking brake lever and loosen adjusting nut.
b. Depress brake pedal fully at least 10 times with engine running.
2. Apply the handbrake, allowing the handbrake grip to move 6
notches. You can adjust the handbrake travel by using the
adjusting nut. To complete this adjustment, you will need a
dynamo meter to check the amount of load required to move
from 9 to 10 notches. If the load exceeds 20 kg, the cable will
have to be loosened with the help of the adjusting nut.
Number of notches:
9-10
If the load is less than 20 kg, the cable should be tightened.
NBR124
SBR101B
SBR353B
PARKING BRAKE CONTROL
BR-35

Purpose
The Anti-lock Brake System (ABS) with an integrated Electronic Brake force Distribution (EBD) system con-
sists of electronic and hydraulic components. It allows you to control the braking force so that wheel lock can
be avoided during braking.
The advantages of ABS with EBD
1) Better tracking performance through improved steering wheel control.
2) Improved maneuverability and safer vehicle control.
3) Improved vehicle stability by preventing flat spins.
4) Shorter stopping distance and optimal utilisation of the rear brakes under many different circumstances.
Operation
IABS with EBD has self-test capabilities. The ABS warning lamp is illuminated for 1 second each time the
ignition switch is turned ªONº. After the engine is started, the ABS warning lamp turns off. An ABS self-test
is performed the first time the vehicle reaches 6 km/h (4 MPH) to ensure the system is operational. A
mechanical noise may be heard as the ABS performs this self-test and is a normal part of the self-test
feature. If a malfunction is detected during this check, the ABS warning lamp will stay on.
During the self-test, it also performs a EBD check when it detects a failure the ABS warning light will go
on simultaneously with the brake warning light and an audible sound will sound constantly.
IEBD system will only operate when the ABS is not in active status and it uses the inlet valves of ABS con-
trol unit to limit the pressure to the rear wheels when they tend to go into slip.
IWhen the vehicle speed is less than 10 km/h (6 MPH) the ABS system does not operate.
IWhile driving, a mechanical noise may be heard during ABS operation, this is a normal system condition.
ABS Hydraulic Circuit
q1Inlet solenoid valve
q
2Outlet solenoid valve
q
3Reservoirq
4Pump
q
5Motorq
6By pass check valve
q
7Damper
NBR346
ANTI-LOCK BRAKE SYSTEM
BR-37

CONSULT-II Inspection Procedure
SELF-DIAGNOSIS PROCEDURE
1) Turn ignition switch to OFF position.
2) Connect CONSULT-II to Data Link Con-
nector.
1) Start engine.
2) Drive vehicle over 30 km/h (19 MPH)
for at least one minute.
1) Stop vehicle with engine running
and touch ªSTARTº on CON-
SULT-II screen.
2) Touch ªABSº.
3) Touch ªSELF-DIAG RESULTSº.
IThe screen shows the detected malfunc-
tion and how many times the ignition
switch has been turned since the mal-
function.
Make the necessary repairs following the
diagnostic procedures.
After the malfunctions are repaired, erase
the self-diagnostic results stored in the
control unit by touching ªERASEº.
Check warning lamp(s) for deactivation
after driving vehicle over 30 km/h (19
MPH) for at least one minute.
Test the ABS system in a safe area to
verify that it functions properly.
END
Note: ªSELF-DIAG RESULTSº screen shows the detected malfunction and
how many times the ignition switch has been turned since the mal-
function.
YBR265
C2NCS01
C2SSE01
C2SDM01
C2SDR01
H
H
H
H
H
H
H
TROUBLE DIAGNOSES
BR-59

SELF-DIAGNOSTIC RESULTS MODE
Diagnostic item Diagnostic item is detected when...Diagnostic
procedure
FR RH SENSORH
[OPEN]ICircuit for front right wheel sensor is open.
(An abnormally high input voltage is entered.)4
FR LH SENSORH
[OPEN]ICircuit for front left wheel sensor is open.
(An abnormally high input voltage is entered.)4
RR RH SENSORH
[OPEN]ICircuit for rear right sensor is open.
(An abnormally high input voltage is entered.)4
RR LH SENSORH
[OPEN]ICircuit for rear left sensor is open.
(An abnormally high input voltage is entered.)4
FR RH SENSORH
[SHORT]ICircuit for front right wheel sensor is shorted.
(An abnormally low input voltage is entered.)4
FR LH SENSORH
[SHORT]ICircuit for front left wheel sensor is shorted.
(An abnormally low input voltage is entered.)4
RR RH SENSORH
[SHORT]ICircuit for rear right sensor is shorted.
(An abnormally low input voltage is entered.)4
RR LH SENSORH
[SHORT]ICircuit for rear left sensor is shorted.
(An abnormally low input voltage is entered.)4
ABS SENSORH
[ABNORMAL SIGNAL]ITeeth damage on sensor rotor or misalignment of wheel sensor.
(Abnormal wheel sensor signal is entered.)4
FR RH IN ABS SOL
[OPEN, SHORT]ICircuit for front right inlet solenoid valve is open or shorted.
(An abnormally low output voltage is entered.)3
FR LH IN ABS SOL
[OPEN, SHORT]ICircuit for front left inlet solenoid valve is open or shorted.
(An abnormally low output voltage is entered.)3
FR RH OUT ABS SOL
[OPEN, SHORT]ICircuit for front right outlet solenoid valve is open or shorted.
(An abnormally low output voltage is entered.)3
FR LH OUT ABS SOL
[OPEN, SHORT]ICircuit for front left outlet solenoid valve is open or shorted.
(An abnormally low output voltage is entered.)3
RR IN ABS SOL
[OPEN, SHORT]ICircuit for rear right outlet solenoid valve is open or shorted.
(An abnormally high output voltage is entered.)3
RR OUT ABS SOL
[OPEN, SHORT]ICircuit for rear left outlet solenoid valve is open or shorted.
(An abnormally high output voltage is entered.)3
ABS ACTUATOR RELAY
[ABNORMAL]IActuator solenoid valve relay is ON, even if control unit sends OFF signal.
IActuator solenoid valve relay is OFF, even if control unit sends ON signal.6
ABS MOTOR RELAY
[ABNORMAL]ICircuit for ABS motor relay is open or shorted.
ICircuit for actuator motor is open or shorted.
IActuator motor relay is stuck.5
BATTERY VOLT
[VB-LOW]IPower source voltage supplied to ABS control unit is abnormally low. 7
CONTROL UNITIFunction of calculation in ABS control unit has failed. 9
G-SENSOR
[ABNORMAL]IG sensor is open.8
HIf a tire slips on rough roads for more than 10 seconds, the ABS warning lamp may come on. In this case, the malfunctioning code
regarding the wheel sensors may be memorized. Turn off the ignition switch, restart the engine and drive the vehicle at speeds
above 30 km/h (19 MPH).
TROUBLE DIAGNOSES
CONSULT-II Inspection Procedure (Cont'd)
BR-60

DATA MONITOR MODE
MONITOR ITEM CONDITION SPECIFICATION
FR RH SENSOR
FR LH SENSOR
REAR RH SENSOR
REAR LH SENSORDrive vehicle.
(Each wheel is rotating.)Wheel speed signal
Almost the same speed as speedometer.
STOP LAMP SW Brake is depressed.Depress the pedal: ON
Release the pedal: OFF
G-SWITCHVehicle is driven.
Vehicle is stopped.
Brake is applied.When driving or stopping vehicle with a force of less than 0.3G:
ON
When driving or stopping vehicle with a force of 0.3G or more:
OFF
FR RH IN SOL
FR RH OUT SOL
FR LH IN SOL
FR LH OUT SOL
RR IN SOL
RR OUT SOL1. Drive vehicle at speeds over
30 km/h (19 MPH) for at
least one minute.
2. Engine is running.Operating conditions for each solenoid valve are indicated.
ABS is not operating: OFF
MOTOR RELAYABS is not operating: OFF
ABS is operating: ON
ACTUATOR RELAY
Ignition switch is set to the
ªONº position or engine is run-
ning.Ignition switch in the ªONº position (Engine stops): OFF
Engine running: ON
WARNING LAMPWarning lamp is turned on: ON
Warning lamp is turned off: OFF
BATTERY VOLT Power supply voltage for control unit
TROUBLE DIAGNOSES
CONSULT-II Inspection Procedure (Cont'd)
BR-62

ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT
FR RH SOLENOID
FR LH SOLENOID
RR SOLENOID
Engine is running.Brake fluid pressure control operation
IN SOL OUT SOL
UP (Increase):
KEEP (Hold):
DOWN (Decrease):OFF
ON
ONOFF
OFF
ON
ABS MOTORABS actuator motor
ON: Motor runs (ABS motor relay ON)
OFF: Motor stops (ABS motor relay OFF)
G-SWITCHIgnition switch is ON or
engine is running.Check G-switch circuit
OFF: G-switch OFF
ON: G-switch ON
Note: Active test will automatically stop ten seconds after the test starts. (LIMIT SIGNAL monitor shows
ON.)
TROUBLE DIAGNOSES
CONSULT-II Inspection Procedure (Cont'd)
BR-64

General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch control Hydraulic
CLUTCH MASTER CYLINDER
Inner diameter mm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in)
LHD 17.46 (11/16)
RHD 19.05 (3/4)
CLUTCH DISC
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Model 250 260
Facing size
(Outer dia. x inner dia. x
thickness)250 x 160 x 3.7
(9.84 x 6.30 x 0.1457)
Thickness of disc assembly
under load7.9 - 8.3 (0.311 - 0.327)
Under a load of 5,884 N
(600 kg, 1,323 lb)
CLUTCH COVER
Engine TD27Ti ZD30DDTi
Model 250 260
Full load N (kg, lb) 5,884 (600, 1,323) 6,760 (689, 1,520)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Handle LHD RHD
Pedal height*227 - 237
(8.94 - 9.33)210 - 220
(8.27 - 8.66)
Pedal stroke 155 - 160 (6.10 - 6.30)
Pedal free play
(Backlash at clevis)1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of melt sheet to surface of pedal
pad
CLUTCH DISC
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Disc model 250 260
Rear limit of facing
surface to rivet head0.3 (0.012)
Runout limit of facing 1 (0.04)
Distance of runout
check point (from the
hub center)120 (4.72)
Maximum of spline
backlash of spline (at
outer edge of disc)1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Cover model 250 260
Diaphragm spring height 36.5 - 38.5 (1.437 - 1.516)
Uneven limit of dia-
phragm spring toe height
ªAº0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14