clutch NISSAN PATROL 2004 Electronic Repair Manual

<SUPPLEMENT-IV>
Edition: July 2004
Release: July 2004 (01)
Publication No.: SM4E00-1Y61E0E
Reference No.: 7711347233GENERAL INFORMATIONGI
MAINTENANCEMA
ENGINE MECHANICALEM
ENGINE LUBRICATION &
COOLING SYSTEMSLC
ENGINE CONTROL SYSTEMEC
ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEMFE
CLUTCHCL
MANUAL TRANSMISSIONMT
AUTOMATIC TRANSMISSIONAT
TRANSFERTF
PROPELLER SHAFT &
DIFFERENTIAL CARRIERPD
FRONT AXLE & FRONT SUSPENSIONFA
REAR AXLE & REAR SUSPENSIONRA
BRAKE SYSTEMBR
STEERING SYSTEMST
RESTRAINT SYSTEMRS
BODY & TRIMBT
HEATER & AIR CONDITIONERHA
ELECTRICAL SYSTEMEL
ALPHABETICAL INDEXIDX
PATROL
MODEL Y61 SERIES
NISSAN EUROPE S.A.S.
2004 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.
QUICK REFERENCE INDEX

Solenoid Valves
Name Resistance (Approx.) (W) Terminal No.
Line pressure solenoid valve
3-97
Torque converter clutch solenoid valve8
Input clutch solenoid valve6
High & low reverse clutch solenoid valve3
Front brake solenoid valve5
Direct clutch solenoid valve4
Low coast brake solenoid valve 20 - 40 2
A/T Fluid Temperature Sensor
Name ConditionCONSULT-II ªDATA MONITORº
(Approx.) (V)Resistance (Approx.) (kW)
A/T ¯uid temperature sensor-10ÉC (32ÉF) 2.2 15
20ÉC (68ÉF) 1.8 0.6
80ÉC (176ÉF) 0.6 0.9
A/T ¯uid temperature sensor-20ÉC (32ÉF) 2.2 10
20ÉC (68ÉF) 1.7 4
80ÉC (176ÉF) 0.45 0.5
Turbine Revolution Sensor
Name Condition Data (Approx.)
Turbine revolution
sensor-1When moving at 50 km/h (31 MPH) in 4th gear with the closed throttle position signal ªOFFº, use the
CONSULT-II pulse frequency measuring function.
CAUTION:
Connect the diagnosis data link connector to the vehicle diagnosis connector.
1.3 (kHz)
Turbine revolution
sensor-2When running at 20 km/h (12 MPH) in 1st gear with the closed throttle position signal ªOFFº, use the
CONSULT-II pulse frequency measuring function.
CAUTION:
Connect the diagnosis data link connector to the vehicle diagnosis connector.
Revolution Sensor
Name Condition Data (Approx.)
Revolution sensorWhen moving at 20 km/h (12 MPH), use the CONSULT-II pulse frequency measuring function.
CAUTION:
Connect the diagnosis data link connector to the vehicle diagnosis connector.185 (Hz)
SERVICE DATA AND SPECIFICATIONS (SDS)RE5R05A
AT-4015

<SUPPLEMENT-IV> \
CLUTCH
SECTION
CL
MODIFICATION NOTICE:
+ Clutch cover has been changed, and clutch ori®ce has been added to 2-door models based on the grade
of ZD30DDTi engine.
+ Service Data and Speci®cations (SDS) have been changed.
CONTENTS
CLUTCH PIPING .......................................................4002
Removal and Installation .......................................4002
SERVICE DATA AND SPECIFICATIONS (SDS) ......4003General Speci®cations ...........................................4003
Inspection and Adjustment ....................................4003
CL-4001

Removal and Installation
Carefully observe the following steps during clutch tube removal
and installation.
+Do not spill clutch ¯uid onto painted surfaces. If it spills, wipe
up immediately and wash the affected area with water.
+When ®xing clutch hose to bracket, align clutch hose metal ®t-
tings with bracket positioning emboss and lock plate to secure.
At this time, prevent twisting or damage of clutch hose. In
addition, be careful not to damage clutch hose.
+Tighten clutch tube ¯are nut to the speci®ed torque.
CAUTION:
Be careful not to damage ¯are nut and clutch tube.
+Tighten the union bolt to the speci®ed torque.
CAUTION:
Do not reuse the copper washer.
+After installation, bleed the clutch tube.
PCIB0685E
PCIB0681E
CLUTCH PIPING
CL-4002

General Speci®cations
CLUTCH DISC
Applied modelTB45E TB48DE ZD30DDTi TD42 TD42Ti
275 300 275
Pickup H/T Wagon H/T Wagon Wagon and Pickup
Facing size
(Outer dia. x inner dia.
x thickness) mm (in)275 x 180 x 3.5
(10.83 x 7.09 x 0.14)300 x 190 x 3.5
(11.81 x 7.48 x
0.14)275 x 180 x 3.5
(10.83 x 7.09 x 0.14)
Thickness of disc
assembly with load
mm (in)/N (kg, lb)7.7 - 8.3
(0.30 -
0.33)/
6,865
(700,
1,543)7.8 - 8.4 (0.31 - 0.33)/
7,845 (800, 1,764)7.7 - 8.3 (0.30 -
0.33)/
8,340 (851, 1,875)7.8 - 8.4 (0.31 - 0.33)/
7,845 (800, 1,764)7.8 - 8.2
(0.31 - 0.32)/
6,865 (700, 1,543)7.9 - 8.5
(0.31 -
0.34)/
7,845
(800,
1,764)
CLUTCH COVER
Applied
modelTB45E TB48DE ZD30DDTi TD42 TD42Ti
275 300 275
Pickup H/T Wagon H/T and Wagon Wagon and Pickup
Full load
N (kg, lb)7,355 - 8,335
(750 - 850, 1,653 -
1,874)7,670 - 9,010
(780 - 920, 1,724 - 2,025)7,650 - 9,030
(780 - 921, 1,720 -
2,030)7,670 - 9,010
(780 - 920, 1,724 - 2,025)6,473 -
7,257
(660 - 740,
1,455 -
1,631)7,355 -
8,335
(750 - 850,
1,653 -
1,874)
Inspection and Adjustment
CLUTCH DISC
Unit: mm (in)
Applied modelTB45E TB48DE ZD30DDTi TD42 TD42Ti
275 300 275
Pickup H/T Wagon H/T Wagon Wagon and Pickup
Wear limit of facing surface to rivet head 0.3 (0.012)
Runout limit of facing 1.3 (0.051)
Distance of runout check point (from the
hub center)130 (5.12)145
(5.71)130 (5.12)
Maximum backlash of spline (at outer
edge of disc)1.1 (0.043)1.2
(0.047)1.1 (0.043)
CLUTCH COVER
Unit: mm (in)
Applied modelTB45E TB48DE ZD30DDTi TD42 TD42Ti
275 300 275
Pickup H/T Wagon H/T Wagon Wagon and Pickup
Diaphragm spring height ªAº 44 - 46 (1.732 - 1.811)
Uneven limit of diaphragm spring toe
height0.7 (0.028)1.0
(0.039)0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-4003

<SUPPLEMENT-IV> \
HEATER&
AIR CONDITIONER
SECTION
HA
MODIFICATION NOTICE:
+ Wiring diagram has been changed.
+ Automatic A/C controller has been changed.
+ Front thermo amp. for auto A/C has been eliminated.
CONTENTS
AUTO
DESCRIPTION ...........................................................4002
Features (TB48 Engine Models) ...........................4002
REAR HEATER
TROUBLE DIAGNOSES ...........................................4003
Wiring Diagram Ð R/HEAT Ð/LHD Models .........4003
Wiring Diagram Ð R/HEAT Ð/RHD Models .........4004
MANUAL
TROUBLE DIAGNOSES ...........................................4005
Wiring Diagram Ð A/C, M Ð/Wagon and
Hardtop Models with ZD Engine ...........................4005
AUTO
DESCRIPTION...........................................................4007
Control Operation ..................................................4007
TROUBLE DIAGNOSES ...........................................4008
Circuit Diagram Ð A/C, A Ð/TB48 Engine ...........4008
Wiring Diagram Ð A/C, A Ð/TB48 Engine ...........4009
Circuit Diagram Ð A/C, A Ð/TB45 Engine ...........4013
Wiring Diagram Ð A/C, A Ð/TB45 Engine ...........4014
Circuit Diagram Ð A/C, A Ð/TD Engine ...............4017
Wiring Diagram Ð A/C, A Ð/TD Engine ...............4018
Circuit Diagram Ð A/C, A Ð/ZD Engine ...............4021
Wiring Diagram Ð A/C, A Ð/ZD Engine ...............4022
Self-diagnosis ........................................................4025
Operational Check .................................................4032
A/C System ............................................................4034 Mode Door Motor...................................................4035
Air Mix Door Motor ................................................4036
Intake Door Motor ..................................................4037
Blower Motor..........................................................4038
Magnet Clutch........................................................4039
Insufficient Cooling ................................................4052
Insufficient Heating ................................................4053
Self-diagnosis ........................................................4054
REAR COOLER
TROUBLE DIAGNOSES ...........................................4055
Wiring Diagram Ð R/COOL Ð/LHD Models with
Front Auto A/C .......................................................4055
Wiring Diagram Ð R/COOL Ð/LHD Models with
Front Manual A/C Except for TB45E Engine ........4057
Wiring Diagram Ð R/COOL Ð/LHD Models with
Front Manual A/C for TB45E Engine.....................4059
Wiring Diagram Ð R/COOL Ð/RHD Models with
Front Auto A/C .......................................................4061
Wiring Diagram Ð R/COOL Ð/RHD Models with
Front Manual A/C...................................................4063
COOL BOX
TROUBLE DIAGNOSES ...........................................4065
Wiring Diagram Ð COOL/B Ð/All Engines
Except TB48 and TB45E Wagon Models for the
Middle East ............................................................4065
Wiring Diagram Ð COOL/B Ð/TB48 and TB45E
Engine Wagon Models for the Middle East...........4066
HA-4001

Features (TB48 Engine Models)
CAN COMMUNICATION SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many
electronic control units are equipped onto a vehicle, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected with
2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wir-
ing. Each control unit transmits/receives data but selectively reads required data only.
SYSTEM CONSTRUCTION
Magnet clutch control
When A/C switch is pressed, turn fan control dial to ON or set mode control dial to DEF position, A/C auto
amp. inputs compressor ON signal to ECM.
ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant pressure sen-
sor signal, throttle angle, etc.).
When sending compressor ON signal to ECM from A/C auto amp., ECM simultaneously sends compressor
feedback signal to uni®ed meter C/U via CAN communication line.
Uni®ed meter control unit sends compressor feedback signal to A/C auto amp. Then, A/C auto amp. uses input
compressor feedback signal to control air inlet.
RHA408I
DESCRIPTIONAUTO
HA-4002

jC
STEP 4 - OPERATION OF EACH ACTUA-
TOR IS CHECKED.
Engine running.
Refer to the following chart and con®rm
discharge air ¯ow, air temperature, blower
motor voltage and compressor operation.
Checks must be made visually, by lis-
tening to any noise, or by touching air
outlets with your hand, etc. for
improper operation.
OK
cNG
+Air outlet does not
change.
Go to HA-4035.
+Intake door does not
change.
Go to HA-4037.
+Discharge air tempera-
ture does not change.
Go to HA-4036.
+Magnet clutch does not
engage.
Go to HA-4039.
+Blower motor operation is
malfunctioning.
Go to HA-4038.
Turn ignition switch OFF or press intake
switch.
END
Mode
control
dial
positionActuator test pattern
Mode doorIntake
doorAir mix
doorBlower
motorCom-
pressor
AUTOVENT
RECFull
Cold4-5V ON
VENTVENT
RECFull
Cold9 - 11V ON
B/LB/L
RECFull
Cold7-9V OFF
FOOTFOOT
FREFull
Hot7-9V OFF
D/FD/F
FREFull
Hot7-9V ON
DEFDEF
FREFull
Hot10 -
12VON
RHA654FF
.
.
.
.
TROUBLE DIAGNOSESAUTO
Self-diagnosis (Cont'd)
HA-4030

Operational Check
The purpose of the operational check is to con®rm that the system
is as it should be. The systems which will be checked are the
blower, mode (discharge air), intake air, temperature decrease,
temperature increase and A/C switch.
CONDITIONS:
+Engine running and at normal operating temperature.
PROCEDURE:
1. Check blower
1) Turn fan control dial to 1st speed. Blower should operate at low
speed.
2) Turn fan control dial to 2nd speed, and continue checking
blower speed until all speeds are checked.
3) Leave blower on MAX speed.
2. Check discharge air
1) Turn mode control dial to each position.
2) Con®rm that discharge air comes out according to the air dis-
tribution table at left.
Refer to ªDischarge Air Flowº, ªDESCRIPTIONº (HA-14) in Y61
SERVICE MANUAL, Publication No. SM7E-2Y61G1.
NOTE:
Con®rm that the compressor clutch is engaged (sound or
visual inspection) and intake door position is at FRESH when
the DEF position is selected.
Intake door position is checked in the next step.
RHA373I
RHA374I
RHA654FF
TROUBLE DIAGNOSESAUTO
HA-4032

3. Check intake door
1) Press intake switch. Recirculation indicator should illuminate.
2) Press intake switch again. Fresh indicator should illuminate.
3) Listen for intake door position change (you should hear blower
sound change slightly).
4. Check temperature decrease
1) Turn temperature control dial until 18ÉC.
2) Check for cold air at discharge air outlets.
5. Check temperature increase
1) Turn temperature control dial until 32ÉC.
2) Check for hot air at discharge air outlets.
6. Check A/C switch
1) Turn fan control dial to AUTO position.
2) Press A/C switch. (LED will turn ON.)
Con®rm that the compressor clutch engages (sound or visual
inspection).
(Discharge air and suction air will depend on ambient, in-ve-
hicle and set temperatures.)
RHA375I
RHA376I
RHA377I
RHA378I
TROUBLE DIAGNOSESAUTO
Operational Check (Cont'd)
HA-4033