general NISSAN TERRANO 2002 Service Manual PDF

How to Perform Trouble Diagnoses for Quick
and Accurate Repair
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a malfunction. It is important to fully understand the symp-
toms or conditions for a customer complaint.
INFORMATION FROM CUSTOMER
WHAT ..... Vehicle model
WHEN ..... Date, Frequencies
WHERE ..... Road conditions
HOW ..... Operating conditions, Symptoms
PRELIMINARY CHECK
Check that the following parts are in good order.
IBattery [Refer to SC-3, ªBATTERYº.]
IFuse [Refer to EL-10, ªFuseº, ªPOWER SUPPLY ROUTINGº.]
ISystem component-to-harness connections
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
RS-29

STEERING SYSTEM
SECTION
ST
CONTENTS
PRECAUTIONS...............................................................2
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²
(Dual Air Bag System) .................................................2
Precautions for Steering System .................................2
PREPARATION................................................................3
Special Service Tools ..................................................3
ON-VEHICLE SERVICE..................................................4
Checking Steering Wheel Play ....................................4
Checking Neutral Position on Steering Wheel ............4
Front Wheel Turning Angle ..........................................4
Checking and Adjusting Drive Belts ............................4
Checking Fluid Level ...................................................4
Checking Fluid Leakage ..............................................5
Bleeding Hydraulic System..........................................5
Checking Steering Wheel Turning Force ....................6
Checking Hydraulic System.........................................7STEERING WHEEL AND STEERING COLUMN............8
Removal and Installation .............................................8
Disassembly and Assembly .......................................10
Inspection................................................................... 11
POWER STEERING GEAR...........................................12
Description .................................................................12
Removal and Installation ...........................................14
Inspection and Adjustment ........................................15
POWER STEERING OIL PUMP....................................16
Removal and Installation ...........................................16
STEERING LINKAGE....................................................17
Removal and Installation ...........................................17
Disassembly and Assembly .......................................19
Inspection...................................................................20
SERVICE DATA AND SPECIFICATIONS (SDS)..........22
General Specifications ...............................................22
Inspection and Adjustment ........................................22

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
(Dual Air Bag System)
The Supplemental Restraint System ªAir Bagº and ªSeat Belt Pre-tensionerº, used along with a seat belt, help
to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemen-
tal Restraint System consists of air bag modules (located in the center of the steering wheel and on the
instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wir-
ing harness and spiral cable.
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 do so
in this Service Manual. SRS wiring harnesses are covered with yellow insulation (either just before
the harness connectors or for the complete harness), for easy identification.
Precautions for Steering System
IBefore disassembly, thoroughly clean the outside of the unit.
IDisassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
IWhen disassembling parts, be sure to place them in order on a part rack so they can be reinstalled
in their proper positions.
IUse nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
IBefore inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
IBefore assembly, apply a coat of recommended ATF* to hydraulic parts. Vaseline may be applied
to O-rings and seals. Do not use any grease.
IReplace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during instal-
lation. Perform functional tests whenever designated.
*: Automatic transmission fluid
PRECAUTIONS
ST-2

General Specifications
Models All
Steering gear type ZF 8054
Turns of steering
wheel
(Lock to lock)3.86
Overall gear ratio 17.1 : 1
Steering column type Collapsible, adjustable height
Inspection and Adjustment
STEERING WHEEL AND COLUMN
Applied model AIR BAG
Steering wheel axial play mm (in) 0 (0)
Steering wheel play mm (in) 35 (1.38) or less
Steering column length ªLº mm (in)830.5 - 832.7
(32.697 - 32.783)
EST018
STEERING GEAR AND LINKAGE
Ball joint and swivel joint
Rotating torque ªBº N×m (kg-m, in-lb)0.5 - 5.0
(0.05 - 0.51,
4 - 44)
Axial end play ªCº mm (in) 0 - 0.2 (0 - 0.008)
Radial play ªDº mm (in) 0 (0)
Length ªLº mm (in) 287 (11.30)
SST583B
OIL PUMP
Unit: kPa (bar, kg/cm2, psi)
Engine ZD30DDTi TD27Ti
Make UNISIA
Max. pressure9,800 - 10,500
(98.0 - 105.0,
99.96 - 107.10,
1,421 - 1,523)8,800 - 9,200
(88 - 92,
89 - 93,
1,276 - 1,334)
SERVICE DATA AND SPECIFICATIONS (SDS)
ST-22

TRANSFER
SECTION
TF
CONTENTS
PREPARATION................................................................2
ON-VEHICLE SERVICE..................................................4
Replacing Oil Seal .......................................................4
REMOVAL AND INSTALLATION....................................7
Removal .......................................................................7
Installation ....................................................................7
TRANSFER GEAR CONTROL.......................................8
MAJOR OVERHAUL.......................................................9
Case Components .......................................................9
Gear Components .....................................................10
Shift Control Components ......................................... 11
DISASSEMBLY..............................................................12
REPAIR FOR COMPONENT PARTS............................17Mainshaft ...................................................................17
Front Drive Shaft .......................................................19
Counter Gear .............................................................20
Main Gear ..................................................................21
Front Case .................................................................23
Front Case Cover ......................................................23
Bearing Retainer ........................................................23
Rear Case..................................................................24
Shift Control Components .........................................24
ASSEMBLY....................................................................26
SERVICE DATA AND SPECIFICATIONS (SDS)..........33
General Specifications ...............................................33
Inspection and Adjustment ........................................33

General Specifications
Transfer model TX10A
Gear ratioHigh 1.000
Low 2.020
Number of teethMain gear 29
Low gear 37
Counter
gearHigh 38
Low 24
Front drive sprocket 41
Front drive shaft 41
Oil capacity(Imp qt) 2.3 (2)
Inspection and Adjustment
GEAR END PLAY
Unit: mm (in)
Front drive sprocket 0.2 - 0.35 (0.0079 - 0.0138)
Low gear 0.2 - 0.35 (0.0079 - 0.0138)
Counter gear 0 - 0.2 (0 - 0.008)
CLEARANCE BETWEEN BAULK RING AND
CLUTCH GEAR
Unit: mm (in)
Standard Wear limit
1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020)
AVAILABLE SNAP RING
Mainshaft front bearing
Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)
Thickness mm (in) Part number
3.1 (0.122)
3.2 (0.126)
3.3 (0.130)
3.4 (0.134)33138-33G10
33138-33G11
33138-33G12
33138-33G13
Mainshaft rear bearing
Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)
Thickness mm (in) Part number
1.8 (0.071)
1.9 (0.075)
2.0 (0.079)
2.1 (0.083)
2.2 (0.087)33138-33G20
33138-33G21
33138-33G22
33138-33G23
33138-33G24
Main gear bearing
Allowable clearance 0 - 0.15 mm (0.0059 in)
Thickness mm (in) Part number
2.6 (0.102)
2.7 (0.106)
2.8 (0.110)
2.9 (0.114)33114-33G00
33114-33G01
33114-33G02
33114-33G03
SERVICE DATA AND SPECIFICATIONS (SDS)
TF-33