2004 NISSAN TERRANO Service Repair Manual

Removal and Installation
Inspection
OPERATING CHECK
IDepress brake pedal several times with engine off, and check
that there is no change in pedal stroke.
I Depress 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.
I Depress brake pedal while engine is running, and stop engine
with pedal depressed. If there is no change in pedal stroke after
holding pedal down 30 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.)
YBR451
SBR002A
SBR365A
EBR090
BRAKE BOOSTER
BR-18
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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.
I Replace clevis pin if damaged.
I Refill with new brake fluid ªDOT 4º.
I Never reuse drained brake fluid.
I Take 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-17.
6. Bleed air. Refer to ªBleeding Brake Systemº, ªBRAKE HYDRAULIC LINEº, BR-8.
7. Adjust brake height. Refer to ªAdjustmentº, ªBRAKE PEDAL AND BRACKETº, BR-16.
8. Tighten brake booster lock nut.
:17-23N ×m (1.7 - 2.3 kg-m, 12 - 17 ft-lb)
YBR294
BRAKE BOOSTER
Inspection (Cont'd)
BR-19
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Removal and Installation
YBR453
VACUUM HOSE
BR-20
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CAUTION:
When installing vacuum hoses, pay attention to the following
points.
IDo not apply any oil or lubricants to vacuum hose and
check valve.
I Insert 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.
YBR454
YBR452
VACUUM HOSE
Removal and Installation (Cont'd)
BR-21
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Inspection
HOSES AND CONNECTORS
ICheck condition of vacuum hoses and connectors.
I Check vacuum hoses and check valve for air tightness.
CHECK VALVE
ICheck vacuum with a manual vacuum pump.
Connect to booster
side Vacuum should exist.
Connect to engine
side Vacuum 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
YBR447
YBR448
SBR007A
VACUUM HOSE
BR-22
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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-23
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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.
I Install vane so that its round surface faces pump housing.
I After 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:
I Check 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.
I Check for wear or scratches on vanes. If necessary, replace.
NBR131
NBR132
NBR133
VACUUM PUMP (TD27Ti engine model)
BR-24
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ICheck inner wall of vacuum pump housing for wear. If
necessary, replace.
I Check rotor shaft for wear. If necessary, replace.
I Check valve locations and copper washers for bends or defor-
mation. If necessary, replace.
I Check that valve operates smoothly when slightly pushed.
Replace if necessary.
I Check 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-25
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