Shop manual ô tô NISSAN 2000 Xterra CONTENTS FRONT AXLE 2 Precautions 2 PRECAUTIONS .2 Preparation 2 SPECIAL SERVICE TOOLS 2 COMMERCIAL SERVICE TOOLS 2
BRAKE SYSTEMSECTIONBRCONTENTSPRECAUTIONS .3Supplemental Restraint System (SRS) ″AIRBAG″ and ″SEAT BELT PRE-TENSIONER″ .3Precautions for Brake System .3Wiring Diagrams and Trouble Diagnosis .3PREPARATION .4Special Service Tools 4Commercial Service Tools .4NOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING .5NVH Troubleshooting Chart .5ON-VEHICLE SERVICE 6Checking Brake Fluid Level .6Checking Brake Line .6Changing Brake Fluid 6Brake Burnishing Procedure 7Bleeding Brake System .8BRAKE HYDRAULIC LINE .9Hydraulic Circuit .9Removal .9Inspection .10Installation 10BRAKE PEDAL AND BRACKET 11Removal and Installation .11Inspection .11Adjustment .12MASTER CYLINDER .13Removal .13Disassembly .13Inspection .14Assembly .14Installation 15BRAKE BOOSTER 16On-vehicle Service .16OPERATING CHECK .16AIRTIGHT CHECK .16Removal .16Inspection .16OUTPUT ROD LENGTH CHECK 16Installation 17VACUUM PIPING .18Removal and Installation .18Inspection .18HOSES AND CONNECTORS .18CHECK VALVE 18FRONT DISC BRAKE .19Pad Replacement 19Removal .20Disassembly .20Inspection .21CALIPER .21ROTOR .21Assembly .22Installation 22Brake Burnishing Procedure 22REAR DRUM BRAKE .23Components .23Removal .23Inspection .24WHEEL CYLINDER 24Wheel Cylinder Overhaul .24Inspection .25DRUM .25LINING 25Installation 25PARKING BRAKE CONTROL 27Components .27Removal and Installation .27Inspection .27Adjustment .28ABSDESCRIPTION .29Purpose 29Operation .29ABS Hydraulic Circuit 29System Components .30System Description 30GIMAEMLCECFECLMTATTFPDAXSUSTRSBTHASCELIDX WHEEL SENSOR 30CONTROL UNIT (BUILT-IN ABS ACTUATOR ANDELECTRIC UNIT) .30ABS ACTUATOR AND ELECTRIC UNIT 31G SENSOR (4WD MODELS) 31Component Parts and Harness ConnectorLocation .32Schematic 332–WHEEL DRIVE 334–WHEEL DRIVE 34Wiring Diagram - ABS - 2WD - .35Wiring Diagram - ABS - 4WD - .38ON BOARD DIAGNOSTIC SYSTEMDESCRIPTION .41Self-diagnosis 41FUNCTION 41SELF-DIAGNOSIS PROCEDURE 41HOW TO READ SELF-DIAGNOSTIC RESULTS(MALFUNCTION CODES) 42HOW TO ERASE SELF-DIAGNOSTIC RESULTS(MALFUNCTION CODES) 42TROUBLE DIAGNOSIS - INTRODUCTION 43How to Perform Trouble Diagnoses for Quickand Accurate Repair 43INTRODUCTION 43TROUBLE DIAGNOSIS - BASIC INSPECTION .44Preliminary Check 44Ground Circuit Check 47ABS ACTUATOR AND ELECTRIC UNIT GROUND .47TROUBLE DIAGNOSIS - GENERALDESCRIPTION .48Malfunction Code/Symptom Chart .48TROUBLE DIAGNOSES FOR SELF-DIAGNOSTICITEMS .49Wheel Sensor or Rotor 49DIAGNOSTIC PROCEDURE .49ABS Actuator Solenoid Valve or Solenoid ValveRelay 52DIAGNOSTIC PROCEDURE .52Motor Relay or Motor .54DIAGNOSTIC PROCEDURE .54Low Voltage .56DIAGNOSTIC PROCEDURE .56G Sensor and Circuit .58DIAGNOSTIC PROCEDURE .58Control Unit 60DIAGNOSTIC PROCEDURE .60TROUBLE DIAGNOSES FOR SYMPTOMS .611. ABS Works Frequently 612. Unexpected Pedal Action 613. Long Stopping Distance 634. ABS Does Not Work 635. Pedal Vibration and Noise .646. Warning Lamp Does Not Come On WhenIgnition Switch Is Turned On .647. Warning Lamp Stays On When Ignition SwitchIs Turned On 66REMOVAL AND INSTALLATION .69Front Wheel Sensor .69Rear Wheel Sensor .694WD MODELS .692WD MODELS .70Front Sensor Rotor 70REMOVAL .70INSTALLATION 71Rear Sensor Rotor (4WD) .71REMOVAL .71INSTALLATION 71Rear Sensor Rotor (2WD) .71REMOVAL AND INSTALLATION .71G Sensor 71ABS Actuator and Electric Unit 72REMOVAL .72INSTALLATION 72SERVICE DATA AND SPECIFICATIONS (SDS) .73General Specifications .73Disc Brake .73Drum Brake 73Brake Pedal .73Parking Brake Control .74CONTENTS(Cont’d)BR-2 Supplemental Restraint System (SRS) “AIRBAG” and “SEAT BELT PRE-TENSIONER”NGBR0001The supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along witha seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types ofcollision. The Supplemental Restraint System consists of driver air bag module (located in the center of thesteering wheel), front passenger air bag module (located on the instrument panel on passenger side), seatbelt pre-tensioners, a diagnosis sensor unit, a crash zone sensor (4WD models), warning lamp, wiring har-ness and spiral cable.Information necessary to service the system safely is included in the RS section of this Service Manual.WARNING:¼ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or deathin the event of a collision which would result in air bag inflation, all maintenance must be performedby an authorized NISSAN dealer.¼ Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and AirBag Module, refer toRS-16.¼ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in thisService Manual. Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) cov-ered with yellow insulation either just before the harness connectors or for the complete harnessare related to the SRS.SBR686CPrecautions for Brake SystemNGBR0002¼ Use brake fluid “DOT 3”.¼ Never reuse drained brake fluid.¼ Be careful not to splash brake fluid on painted areas; itmay cause paint damage. If brake fluid is splashed onpainted areas, wash it away with water immediately.¼ To clean master cylinder parts, disc brake caliper parts orwheel cylinder parts, use clean brake fluid.¼ Never use mineral oils such as gasoline or kerosene. Theywill ruin rubber parts of hydraulic system.¼ Use flare nut wrench when removing and installing braketubes.¼ Always torque brake lines when installing.WARNING:¼ Clean brakes with a vacuum dust collector to minimizerisk of health hazard from powder caused by friction.Wiring Diagrams and Trouble DiagnosisNGBR0003When you read wiring diagrams, refer to the followings:¼ “HOW TO READ WIRING DIAGRAMS” refer toGI-10.¼ “POWER SUPPLY ROUTING” for power distribution circuit refer toEL-9.When you perform trouble diagnosis, refer to the followings:¼ “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” refer toGI-34.¼ “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” refer toGI-23.GIMAEMLCECFECLMTATTFPDAXSUSTRSBTHASCELIDXPRECAUTIONSSupplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”BR-3 Special Service ToolsNGBR0004The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool number(Kent-Moore No.)Tool nameDescriptionKV40106500(JS25852-B)Wheel bearing pullerNT724Removing rear wheel sensor rotorCommercial Service ToolsNGBR0005Tool name Description1 Flare nut crowfoot2 Torque wrenchNT360Removing and installing each brake pipinga: 10 mm (0.39 in)Brake fluid pressuregaugeNT151Measuring brake fluid pressureRear wheel sensorrotor driftNT509Installing rear wheel sensor rotora: 75 mm (2.95 in) dia.b: 63 mm (2.48 in) dia.PREPARATIONSpecial Service ToolsBR-4 NGBR0085NVH Troubleshooting ChartNGBR0085S01Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.Reference pageBR-25BR-19, 25BR-23BR-18——BR-21, 25———BR-21BR-25NVH,PD-4.NVH,PD-14,PD-40,PD-62.NVH,AX-3.NVH,AX-3.NVH,SU-3.NVH,SU-3.NVH,SU-3.NVH,ST-5.Possible causeand SUSPECTED PARTSLinings or pads - damagedLinings or pads - uneven wearReturn spring damagedShims damagedRotor or drum imbalanceRotor or drum damageRotor or drum runoutRotor or drum deformationRotor or drum deflectionRotor or drum rustRotor thickness variationDrum out of roundPROPELLER SHAFTDIFFERENTIALDRIVE SHAFTAXLESUSPENSIONTIRESROAD WHEELSTEERINGSymptom BRAKENoise ×××× × × ××××××Shake × × ××××××Shimmy, Judder ×××××××× ××××××: ApplicableGIMAEMLCECFECLMTATTFPDAXSUSTRSBTHASCELIDXNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGNVH Troubleshooting ChartBR-5 SBR451DChecking Brake Fluid LevelNGBR0006¼ Check fluid level in reservoir tank. It should be between Maxand Min lines on reservoir tank.¼ If fluid level is extremely low, check brake system.¼ If the brake warning lamp comes on, check brake fluid levelswitch and parking brake switch.SBR389CChecking Brake LineNGBR0007CAUTION:If leakage occurs around joints, retighten or, if necessary,replace damaged parts.1. Check brake lines (tubes and hoses) for cracks, deteriorationand other damage. Replace any damaged parts.2. Check for oil leakage by fully depressing brake pedal whileengine is running.SBR419CChanging Brake FluidNGBR0008CAUTION:¼ Refill with new brake fluid “DOT 3”.¼ Always keep fluid level higher than minimum line on res-ervoir tank.¼ Never reuse drained brake fluid.¼ Be careful not to splash brake fluid on painted areas; itmay cause paint damage. If brake fluid is splashed onpainted areas, wash it away with water immediately.1. Clean inside of reservoir tank, and refill with new brake fluid.2. Connect a vinyl tube to each air bleeder valve.3. Drain brake fluid from each air bleeder valve by depressingbrake pedal.4. Refill until brake fluid comes out of each air bleeder valve.Use same procedure as in bleeding hydraulic system to refillbrake fluid.Refer to “Bleeding Brake System”, BR-8.ON-VEHICLE SERVICEChecking Brake Fluid LevelBR-6 Brake Burnishing Procedure=NGBR0120Burnish the brake contact surfaces according to the following pro-cedure after refinishing or replacing drums or rotors, 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 (31MPH).2. Use medium brake pedal/foot effort to bring the vehicle to apressure such that vehicle stopping time equals to 3 to 5 sec-onds.3. To cool the brake system, drive the vehicle at 50 km/h (31MPH) for 1 minute without stopping.4. Repeat steps 1 to 3, 10 times or more to complete the burnish-ing procedure.GIMAEMLCECFECLMTATTFPDAXSUSTRSBTHASCELIDXON-VEHICLE SERVICEBrake Burnishing ProcedureBR-7 SBR995Bleeding Brake System=NGBR0009CAUTION:¼ Carefully monitor brake fluid level at master cylinder dur-ing bleeding operation.¼ If master cylinder is suspected to have air inside, bleed airfrom master cylinder first. Refer to “Installation”, “MAS-TER CYLINDER”, BR-15.¼ Fill reservoir with new brake fluid “DOT 3”. Make sure it isfull at all times while bleeding air out of system.¼ Place a container under master cylinder to avoid spillageof brake fluid.¼ Turn ignition switch OFF and disconnect ABS actuatorconnectors or battery ground cable.¼ Bleed air in the following order.1. Left rear brake2. Right rear brake3. Left front brake4. Right front brakeSBR419C1. Connect a transparent vinyl tube to air bleeder valve.2. Fully depress brake pedal several times.3. With brake pedal depressed, open air bleeder valve to releaseair.4. Close air bleeder valve.5. Release brake pedal slowly.6. Repeat steps 1. through 4. until clear brake fluid comes out ofair bleeder valve.7. Tighten air bleeder valve to specified torque.:7-9N·m(0.7 - 0.9 kg-m, 61 - 78 in-lb)ON-VEHICLE SERVICEBleeding Brake SystemBR-8 Hydraulic CircuitNGBR0010ABR676SBR992RemovalNGBR0011CAUTION:¼ Be careful not to splash brake fluid on painted areas; itmay cause paint damage. If brake fluid is splashed onpainted areas, wash it away with water immediately.¼ All hoses must be free from excessive bending, twistingand pulling.1. Connect vinyl tube to air bleeder valve.2. Drain brake fluid from each air bleeder valve by depressingbrake pedal.3. Remove flare nut connecting brake tube and hose, then with-draw lock spring.4. Cover openings to prevent entrance of dirt whenever discon-necting brake line.GIMAEMLCECFECLMTATTFPDAXSUSTRSBTHASCELIDXBRAKE HYDRAULIC LINEHydraulic CircuitBR-9 InspectionNGBR0012Check brake lines (tubes and hoses) for cracks, deterioration andother damage. Replace any damaged parts.SBR686CInstallationNGBR0013CAUTION:¼ Refill with new brake fluid “DOT 3”.¼ Never reuse drained brake fluid.1. Tighten all flare nuts and connecting bolts.Flare nut:: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)Connecting bolt:: 17 - 19 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)2. Refill until new brake fluid comes out of each air bleeder valve.3. Bleed air. Refer to “Bleeding Brake System”, BR-8.BRAKE HYDRAULIC LINEInspectionBR-10 [...]... mounting nuts Specification: 13 - 16 N·m (1.3 - 1.6 kg-m, 9 - 12 ft-lb) 5 Install master cylinder Refer to “Installation” in “MASTER CYLINDER”, BR-15 6 Adjust brake pedal height and free play Refer to “Adjustment” in “BRAKE PEDAL AND BRACKET”, BR-12 7 Secure lock nut for clevis : 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb) 8 Bleed air Refer to “Bleeding Brake System”, BR-8 GI MA EM LC EC FE CL MT AT... until no air comes out of master cylinder 6 Fit brake lines to master cylinder 7 Tighten flare nuts : 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) 8 Bleed air Refer to “Bleeding Brake System”, BR-8 GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL BR-15 IDX BRAKE BOOSTER On-vehicle Service On-vehicle Service OPERATING CHECK 1 2 SBR002A 2 NGBR0024S01 Depress brake pedal several times with engine... EL BR-11 IDX BRAKE PEDAL AND BRACKET Adjustment Adjustment NGBR0018 Check brake pedal free height from metal floor H: Free height Refer to SDS (BR-73) D: Depressed height Refer to SDS (BR-73) Under force of 490 N (50 kg, 110 lb) with engine running C1, C2: Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch 0.3 - 1.0 mm (0.012 - 0.039 in) A: Pedal free play 1 - 3 mm... cylinder body 4 Push reservoir tank into cylinder body SBR940A BR-14 MASTER CYLINDER Installation Installation ABR190 =NGBR0023 CAUTION: ¼ Refill with new brake fluid “DOT 3” ¼ Never reuse drained brake fluid 1 Place master cylinder onto brake booster and secure mounting nuts lightly 2 Torque mounting nuts : 12 - 15 N·m (1.2 - 1.5 kg-m, 9 - 11 ft-lb) 3 Fill up reservoir tank with new brake fluid 4 Plug all... boots 6 ¼ ABR372 depression Right-hand thread Right Screw Left-hand thread Left ABR396 SU Check all parts are installed properly After installations completed, adjust shoe-to-drum clearance Pay attention to direction of adjuster assembly 7 Install brake drum 8 When installing new wheel cylinder or overhauling wheel cylinder, bleed air Refer to “Bleeding Brake System”, BR-8 9 Adjust parking brake Refer... The Anti-Lock Brake System (ABS) has a self-test function The system turns on the ABS warning lamp for 1 second each time the ignition switch is turned ON After the engine is started, the ABS warning lamp turns off The system performs a test the first time the vehicle reaches 6 km/h (4 MPH) A mechanical noise may be heard as the ABS performs this self-test This is a normal part of the self-test feature... NGBR0094 ABR860 BR-32 DESCRIPTION ABS Schematic Schematic 2–WHEEL DRIVE NGBR0095 NGBR0095S01 GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL ABR816 BR-33 IDX DESCRIPTION ABS Schematic (Cont’d) 4–WHEEL DRIVE NGBR0095S02 ABR820 BR-34 DESCRIPTION ABS Wiring Diagram — ABS — 2WD — Wiring Diagram — ABS — 2WD — NGBR0096 GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC ABR817 BR-35 EL IDX DESCRIPTION... kPa (−500 mmHg, −19.69 inHg) to brake booster with a hand vacuum pump Add preload of 19.6 N (2.0 kg, 4.4 lb) to output rod length Check output rod length Specified length: 10.275 - 10.525 mm (0.4045 - 0.4144 in) ABR908 BR-16 BRAKE BOOSTER Installation Installation SBR116BE =NGBR0027 CAUTION: ¼ Be careful not to deform or bend brake pipes during installation of booster ¼ Replace clevis pin if damaged... brake Refer to “Adjustment”, “PARKING BRAKE CONTROL”, BR-28 ¼ Install all the parts by referring to to the figure below ¼ After installing crank lever on back plate, make sure that there BR-25 ST RS BT HA SC EL IDX REAR DRUM BRAKE Installation (Cont’d) is no play between crank lever and back plate If play exists, adjust bolt A and lock nut B ABR827 BR-26 PARKING BRAKE CONTROL Components Components NGBR0044... sure that wheel bearing axial end play is within the specifications before measuring Refer to AX-4 “Front Wheel Bearing” in AX section (“Front Wheel Bearing”,”ON VEHICLE SERVICE”) Maximum runout: 0.07 mm (0.0028 in) 2 If the runout is out of specification, machine rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equivalent) TF PD AX SU ST RS Thickness NGBR0035S0202 Thickness variation . parts.Reference pageBR-25BR-19, 25BR-23BR-18——BR-21, 25———BR-21BR-25NVH,PD-4.NVH,PD-14,PD-40,PD-62.NVH,AX-3.NVH,AX-3.NVH,SU-3.NVH,SU-3.NVH,SU-3.NVH,ST-5.Possible. connecting bolts.Flare nut:: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)Connecting bolt:: 17 - 19 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)2. Refill until new brake