NISSAN TERRANO 2002 Service Repair Manual

Battery
Applied model TD27Ti ZD30DDTi
Type L2-580 R (65 Ah) L2-580 L (65 Ah) L3-760 R (75 Ah) L3-760 L (75 Ah)
Capacity V-AH 12-55 12-64
Starter
TypeS13-327 S13-527B S14-405B
HITACHI make
Applied model TD27Ti ZD30DDTi
System voltage V 12
No-loadTerminal voltage V 11.0
Current A Less than 160
Revolution rpm More than 4,000 More than 3,300 More than 2,700
Minimum diameter of commutator mm (in) 35.5 (1.398) 35.5 (1.398)
Minimum length of brush mm (in) 9.0 (0.354) 11.0 (0.433) 11.0 (0.433)
Brush spring tension N (kg, lb) Ð28.4 - 34.3
(2.9 - 3.5, 6.4 - 7.7)28.4 - 34.3
(2.9 - 3.5, 6.4 - 7.7)
Clearance between bearing metal and armature shaft
mm (in)ÐÐÐ
Clearance ªº between pinion front edge and
pinion stopper mm (in)ÐÐÐ
Movement ªº in height of pinion assembly mm (in)0.3 - 1.5
(0.012 - 0.059)0.3 - 2.0
(0.012 - 0.079)0.3 - 2.0
(0.012 - 0.079)
Alternator
TypeLR190-752 0 123 310 051
HITACHI make BOSCH make
Applied model ZD30DDTi TD27Ti
Nominal rating V-A 12-90 12-70
Ground polarityNegative
Minimum revolutions under no-load (When
13.5V is applied) rpmLess than 1,000 Less than 1,000
Hot output current (When 13.5V is applied)
A/rpmMore than 23/1,300
More than 65/2,500
More than 87/5,000More than 26/1,300
More than 58/2,500
More than 72/5,000
Regulated output voltage V 14.1 - 14.7
Minimum length of brush mm (in) More than 6.0 (0.237) 2 (0.08)
Brush spring pressure N (g, oz) 1.00 - 3.43 (102 - 350, 3.60 - 12.34) 1.80 - 2.40 (184.6 - 244.8, 6.47 - 8.63)
Slip ring minimum diameter mm (in) More than 26.0 (1.024) 13.8 (0.543)
Rotor coil resistance at 20É (68ÉF)W2.67 2.47 - 2.73
SERVICE DATA AND SPECIFICATIONS (SDS)
SC-30

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

Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
KV48100700
Torque adapter
Measuring pinion rotating torque
ST27180001*
Steering wheel puller
Removing and installing steering wheel
ST27850000
Ball joint remover
Removing ball joint
ST29020001*
Steering gear arm puller
Removing and installing pitman arm
ST3127S000*
q
1GG91030000
Torque wrench
q
2HT62940000
Socket adapter
q
3HT62900000
Socket adapter
Measuring turning torque
KV48100301*
Strut & steering gearbox
attachment
Steering gear is installed
KV48103500-A
Pressure gauge
Measuring oil pressure
KV48102500
Pressure gauge adapter
Measuring oil pressure
KV481009S0
Oil seal drift set
q
1KV48100910
Drift
q
2KV48100920
Adapter
q
3KV48100930
Adapter
Installing oil seal
PREPARATION
ST-3

Checking Steering Wheel Play
1. With wheels in a straight-ahead position, check steering wheel
play.
Steering wheel play:
35 mm (1.38 in) or less
2. If it is not within specification, check steering gear assembly
when front suspension and axle, steering gear assembly and
steering column are mounted correctly.
Checking Neutral Position on Steering Wheel
CHECKING
1. Check that the steering wheel is in the neutral position when
driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel and
reinstall it correctly.
3. If the neutral position is between two serrated teeth, loosen
tie-rod lock nut and move tie-rod in the opposite direction by the
same amount on both left and right sides to compensate for
error in the neutral position.
Front Wheel Turning Angle
Rotate steering wheel all the way right and left; measure turning
angle.
Turning angle of full turns:
Refer to section FA for SDS.
Checking and Adjusting Drive Belts
Refer to section MA for Drive Belt Inspection.
Checking Fluid Level
Check the fluid level in the reservoir when the engine is cold. If the
fluid level is below the MIN line, and fluid up to the MAX line.
CAUTION:
IDo not overfill.
IUse only ªDEXRON
TMº type automatic transmission fluid.
SST103B
SST900A
SMA127
NST030
ON-VEHICLE SERVICE
ST-4

Checking Fluid Leakage
Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing or deterioration.
1. Run engine between idle speed and 1,000 rpm.
Make sure temperature of fluid in oil tank rises to 60 to 80ÉC
(140 to 176ÉF).
2. Turn steering wheel right-to-left several times.
3. Hold steering wheel at each ªlockº position for five seconds and
carefully check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
4. If fluid leakage at connectors is noticed, loosen flare nut and
then retighten.
Do not overtighten connector as this can damage O-ring,
washer and connector.
Bleeding Hydraulic System
1. Raise front end of vehicle until wheels are clear of the ground.
2. Add fluid into oil tank to specified level. Meanwhile quickly turn
steering wheel fully to right and left and lightly touch steering
stoppers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2 above.
IIncomplete air bleeding will cause the following to occur. When
this happens, bleed air again.
a. Generation of air bubbles in reservoir tank
b. Generation of clicking noise in oil pump
c. Excessive buzzing in oil pump
While the vehicle is stationary or while moving the steering wheel
slowly, fluid noise may occur in the valve or oil pump. This noise is
inherent in this steering system, and it will not affect performance
or durability of the system.
SST621A
ON-VEHICLE SERVICE
ST-5

Checking Steering Wheel Turning Force
1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating tempera-
ture.
Temperature:
60É - 80ÉC (140 - 176ÉF)
Tires need to be inflated to normal pressure.
4. Check steering wheel turning force when steering wheel has
been turned 360É from neutral position.
Steering wheel turning force:
39 N (4 kg, 9 lb) or less
IIf steering wheel turning force is not within specification,
perform the following inspection procedure:
E
Measure steering
wheel
turning force
39 N (4 kg, 9 lb) or less.
NG
EOK Test end
Measure preload of the
power steering gear
input shaft.
Refer to ªInspection
and Adjustmentº in
ªPOWER STEERING
GEARº.
NG
EOKCheck oil pump
pressure.
Refer to ªChecking
Hydraulic Systemº in
ªON-VEHICLE
SERVICEº.
NG
EOKCheck ball joints,
swivel joints and
linkage for smooth
operation.
See ªInspectionº in
ªSTEERING LINKAGEº.
NGOK
Adjust preload.Replace oil pump.Replace joints.Replace power
steering gear.
SST108B
H
HHHH
HHHH
ON-VEHICLE SERVICE
ST-6

Checking Hydraulic System
Before starting, check belt tension, driving pulley and tire pressure.
1. Set Tool. Open shut-off valve, then bleed air. (Refer to ªBleed-
ing Hydraulic Systemº, ST-5.)
2. Run engine.
Make sure temperature of fluid in tank rises to 60 to 80ÉC (140
to 176ÉF).
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, oil pressure in oil pump will
increase to relief pressure, resulting in an abnormal rise in oil
temperature.
3. Check pressure with steering wheel fully turned to left and right
positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
Oil pump maximum standard pressure:
TD27Ti engine
8,800 - 9,200 kPa (88 - 92 bar,
89 - 93 kg/cm
2, 1,276 - 1,334 psi)
ZD30DTi engine
9,800 - 10,500 kPa (98.0 - 105.0 bar,
99.96 - 107.10 kg/cm
2, 1,421 - 1,523 psi)
4. If oil pressure is below the maximum pressure, slowly close
shut-off valve and check pressure.
IWhen pressure reaches maximum pressure, gear is damaged.
IWhen pressure remains below maximum pressure, pump is
damaged.
CAUTION:
Do not close shut-off valve for more than 15 seconds.
5. If oil pressure is higher than maximum pressure, check oil
pump flow control valve.
6. After checking hydraulic system, remove Tool and add fluid if
necessary, then completely bleed air out of system.NST033
ON-VEHICLE SERVICE
ST-7

Removal and Installation
CAUTION:
IThe rotation of the spiral cable (SRS ªAir bagº component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not
rotate the steering column while the steering gear is
removed.
IRemove the steering wheel before removing the steering
lower joint to avoid damaging the SRS spiral cable.
STEERING WHEEL
IRemove remote audio control (if applied).
IRemove air bag module and spiral cable.
Refer to RS-26, ªRemoval Ð Air Bag Module and Spiral Cableº.
YST020
SBF812E
STEERING WHEEL AND STEERING COLUMN
ST-8

IAlign spiral cable correctly when installing steering wheel.
a) Set the front wheels in the straight-ahead position.
b) Make sure that the spiral cable is in the neutral position.
The neutral position is detected by turning left 2.5 revolutions
from the right end position. Align the two marks (
).
CAUTION:
The spiral cable may snap due to steering operation if the
cable is installed in an improper position.
Also, with the steering linkage disconnected, the cable may
snap by turning the steering wheel beyond the limited number
of turns. (The spiral cable can be turned up to 2.5 turns from
the neutral position to both the right and left.)
IRemove steering wheel with Tool.
STEERING COLUMN
IWhen installing steering column, fingertighten upper support
bracket bolts and lower support bracket nuts; then tighten them
to the specified torque. Do not apply undue stress to steering
column.
IWhen attaching coupling joint, be sure tightening bolt faces
cutout portion.
IWhen inserting coupling joint onto steering gear axle, make
sure that it is positioned correctly.
CAUTION:
After installing steering column, turn steering wheel to make
sure it moves smoothly and that the number of turns from the
straight-ahead forward position to left and right locks are
equal. Be sure that the steering wheel is in a neutral position
when driving straight ahead.
Number of steering wheel turns from straight-ahead
position:
Right 1.93
Left 1.93
SRS266
SST777C
NST005
STEERING WHEEL AND STEERING COLUMN
Removal and Installation (Cont'd)
ST-9