2002 NISSAN TERRANO brake rotor

Supplement Restraint System (SRS) ªAIR BAGº
and ªSEAT BELT PRE-TENSIONERº
The Supplemental Restraint System ªAir Bagº and ªSeat Belt Pre-tensionerº, used along with a seat belt, help
to reduce the risk or severity or injury to the driver and front passenger in a collision. The Supplemental
Restraint System consists of an air bag module (located in the center of the steering wheel and on the instru-
ment panel on the passenger side, where fitted), seat belt pre-tensioners, a diagnosis sensor unit, warning
lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the
BT sectionof this Service Manual.
WARNING:
ITo 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 must be per-
formed by an authorized NISSAN dealer.
IImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
IDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses (except ªSEAT BELT-TENSIONERº connector) can be iden-
tified with yellow harness connector and with yellow harness protector or yellow insulation tape
before the harness connectors.
Precautions
IUse only ªDOT 4º fluid from a sealed container.
INever reuse drained brake fluid.
IBe 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.
ITo clean master cylinder parts, disc brake caliper parts or
wheel cylinder parts, use clean brake fluid.
INever use mineral oils such as Petrol or kerosene. They
will ruin rubber parts of hydraulic system.
IUse flare nut wrench when removing and installing brake
tubes.
IAlways torque brake lines when installing.
IBurnish 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 speed. Refer to ªBrake
Burnishing Procedureº, ªCheck and Adjustmentº, BR-5.
WARNING:
IClean brakes with a vacuum dust collector to minimize risk
of health hazard from airborne materials.
IAvoid prolonged and repeated skin contact with brake
fluid.
IWear protective clothing, including impervious gloves.
IWhere there is a risk of eye contact, eye protection should
be worn Ð for example chemical goggles or face shield.
YBR293
PRECAUTIONS AND PREPARATION
BR-3

Preparation
SPECIAL SERVICE TOOLS
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
Removing and installing each brake pip-
ing
KV991V0010
Brake fluid pressure
gauge
Measuring brake fluid pressure
HT72480000
Rear axle shaft bearing
puller
Removing rear wheel sensor rotor
PRECAUTIONS AND PREPARATION
BR-4

Checking Brake Fluid Level
ICheck fluid level in reservoir tank. It should be between Max.
and Min. lines on reservoir tank.
IIf fluid level is extremely low, check brake system for leaks.
IWhen brake warning lamp comes on even when parking brake
lever is released, check brake system for leaks.
Checking Brake Line
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.
Changing Brake Fluid
CAUTION:
IRefill with new brake fluid ªDOT 4º.
INever reuse drained brake fluid.
IBe 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 IT OFF.
1. Connect a vinyl tube to each air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
3. Refill 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 ªBleeding Brake Systemº, ªBRAKE
HYDRAULIC LINEº, BR-8.
Brake Burnishing Procedure
Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing rotors or drums, after replac-
ing pads or linings, 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 to bring the vehicle to a com-
plete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
pressure such that vehicle stopping time equals 3 to 5
seconds.
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 for 10 times or more to complete the
burnishing procedure.
SBR849B
SMA732A
SBR992
CHECK AND ADJUSTMENT
BR-5

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

System Description
Sensor
The sensor unit consists of a gear-shaped sensor rotor and a sen-
sor element. The element contains a bar magnet around which a
coil is wound. The sensor is installed on the back of the brake rotor
and the rear brake drum.
As the wheel rotates, the sensor generates a sine-wave pattern.
The frequency and voltage increase(s) as the rotating speed
increases.
Control unit
The control unit computes the wheel rotating speed by the signal
current sent from the sensor. Then it supplies a DC current to the
actuator solenoid valve. It also controls ON-OFF operation of the
valve relay and rotor relay. If any electrical malfunction should be
detected in the ABS or EBD system, the control unit causes the
warning lamp(s) to light up, combined with an audible sound.
In this condition, the ABS or EBD will be deactivated by the control
unit, and the vehicle's brake system reverts to normal operation.
(Fail-safe mode)
YBR262
SBR124B
YBR263
ANTI-LOCK BRAKE SYSTEM
BR-38

Removal and Installation
CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
When removing the front or rear wheel hub assembly, discon-
nect the ABS wheel sensor from the assembly and move it
away.
FRONT WHEEL SENSOR
REAR WHEEL SENSOR
NBR122
SBR399D
ANTI-LOCK BRAKE SYSTEM
BR-42