light NISSAN PATROL 2000 Electronic Service Manual

Removal and Installation
REMOVAL
1. Remove the following parts.
+Radiator under side
+Radiator shroud
+Cooling fan
+Chain cover front side
+A/T cooler hose (Disconnect)
+Vacuum hose
+Intercooler cover (When removing vacuum tank)
2. Remove the installation bolts and pull the vacuum pump from
the engine front directly.
3. If it is difficult to remove from the spline shaft connection, tap
lightly with a plastic hammer.
SEM320G
SEM321G
VACUUM PUMPZD
EM-1025

Installation
1. Install the front plate.
1) Install the O-ring and gasket to the cylinder block.
+Apply liquid gasket uniformly and thinly to the front and
reverse sides of gasket.
Use Genuine Liquid Gasket or equivalent.
2) Install the front plate.
+Before installing, apply liquid gasket to the mating surfaces
of the cylinder block and the oil pan (upper).
Use Genuine Liquid Gasket or equivalent.
+Lightly tap with a hammer if the dowel pin cannot be inserted
easily.
CAUTION:
Make sure that the O-ring does not pop out.
2. Install the fuel injection pump.
+After installing the front plate, align the 6 mm (0.24 in) dia.
hole of the pump flange and the 6 mm (0.24 in) dia. hole
position of the pump body.
3. Install each timing gear.
+Align the match marks of the timing gears by referring to the
figure below.
+When installing timing gear, follow the order (
V1,V2) shown
in the dotted box in the figure below to facilitate installation.
FEM042
SEM387G
SEM206H
SEM207H
TIMING GEARZD
EM-1047

CONNECTING ROD BEARING OIL CLEARANCE
Method by measurement
+Install connecting rod bearings to connecting rods and caps,
and tighten connecting nuts to the specified torque. Use
inside micrometer to measure connecting rod bearing inner
diameter.
Bearing clearance = Connecting rod bearing inner diameter
þ Crankshaft pin outer diameter
Standard: 0.035 - 0.077 mm (0.0014 - 0.0030 in)
+If out of specifications, check connecting rod big end inner
diameter and crankshaft pin outer diameter, and select
appropriate connecting rod bearing to adjust clearance to
specifications.
Refer to ªConnecting rod bearing undersize listº on the next
page.
Method using plastigage
+Remove contamination such as oil, dust completely from
crankshaft pins and each bearing surface.
+Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
+Install connecting rod bearings to caps, and tighten connect-
ing rod nuts to the specified torque.
CAUTION:
Never rotate crankshaft.
+Remove connecting rod caps and bearings, and measure
plastigage width using scale on plastigage bag.
CAUTION:
If out of specification, take same action mentioned in
ªMethod by measurementº.
Undersize bearing usage
+If bearing clearance is out of specifications for connecting rod
bearings in standard size, use undersize bearings.
+When using undersize bearings, measure bearing inner
diameter with bearing installed, and grind pins to adjust clear-
ance to specification.
FEM103
FEM118
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-1078

Connecting rod bearing undersize list
Unit: mm (in)
Size Thickness
US 025 1.630 - 1.638 (0.0642 - 0.0645)
US 050 1.755 - 1.763 (0.0691 - 0.0694)
US 075 1.880 - 1.888 (0.0740 - 0.0743)
US 100 2.005 - 2.013 (0.0789 - 0.0793)
CAUTION:
When grinding crank pins to use undersize bearings, avoid
damaging corners of fillet.
Corner dimension (Standard):
Pin
3.3 - 3.7 mm (0.130 - 0.146 in)
Journal
2.8 - 3.2 mm (0.110 - 0.126 in)
MAIN BEARING OIL CLEARANCE
Method by measurement
+Install main bearings to cylinder block and bearing caps, and
tighten bearing cap bolts to the specified torque. Measure
main bearing inner diameter.
Bearing clearance = Bearing inner diameter þ Crankshaft
journal outer diameter
Standard: 0.035 - 0.083 mm (0.0014 - 0.0033 in)
+If out of specification, check main bearing housing inner
diameter and crankshaft journal outer diameter, and select
appropriate main bearing to adjust clearance to specifica-
tions.
Refer to ªMain bearing undersize listº on the next page.
Method using plastigage
+Remove contamination such as oil, dust completely from
crankshaft journals and each bearing surface.
+Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
+Install main bearings to caps, and tighten connecting rod nuts
to the specified torque.
CAUTION:
Never rotate crankshaft.
+Remove bearing caps and bearings, and measure plastigage
width using scale on plastigage bag.
FEM119
FEM120
CYLINDER BLOCKZD
Inspection (Cont'd)
EM-1079

A
A/T - Wiring diagram ............................. AT-1009
A/T control ............................................. EC-1148
A/T fluid temperature sensor ................. AT-1081
A/T mode switch .................................... AT-1095
A/T self-diagnoses ................................. AT-1028
A/T shift lock system - Wiring
diagram .............................................. AT-1117
A/T shift lock system ............................. AT-1116
A/T trouble diagnoses ........................... AT-1036
APS - Wiring diagram ........................... EC-1125
ASCD (automatic speed control
device) ............................................... EL-1110
ASCD - Wiring diagram ......................... EL-1111
AT/C - Wiring diagram .......................... EC-1150
Accelerator control system .................... FE-1007
Accelerator position sensor .................. EC-1125
Air bag disposal .................................... RS-1015
Air bag precautions ................................ GI-1002
Air bag ................................................... RS-1003
Air cleaner filter replacement ............... MA-1019
Air conditioner cut control ..................... EC-1021
Air flow meter - See Mass air flow
sensor ................................................ EC-1086
Alternator ............................................... EL-1041
Angular tightening application .............. EM-1003
Anti-lock brake system - Wiring
diagram ............................................. BR-1002
Audio ...................................................... EL-1108
Automatic speed control system - See
ASCD ................................................. EL-1110
Automatic transmission fluid
replacement ...................................... MA-1021
B
BACK/L - Wiring diagram ...................... EL-1051
BOOST - Wiring diagram ...................... EC-1204
Back-up lamp ......................................... EL-1051
Basic inspection .................................... EC-1049
Battery ................................................... EL-1035
Boring/horning cylinder block ............... EM-1075
C
CHARGE - Wiring diagram ................... EL-1040
CKPS - Wiring diagram ........................ EC-1140
CONSULT for engine ............................ EC-1038
CONSULT general information .............. GI-1003
COOL/F - Wiring diagram ..................... EC-1105
CORNER - Wiring diagram ................... EL-1054
Camshaft inspection ............................. EM-1032
Charging system .................................... EL-1040
Chassis and body maintenance ........... MA-1020
Clutch operating cylinder ....................... CL-1003
Collision diagnosis ................................ RS-1052
Combination meter ................................ EL-1073Combination switch ............................... EL-1042
Compression pressure ......................... EM-1010
Compressor mounting ........................... HA-1023
Connecting rod bearing clearance ....... EM-1078
Connecting rod bushing clearance ....... EM-1074
Connecting rod ..................................... EM-1074
Control valve (A/T) ................................ AT-1148
Converter housing installation ............... AT-1128
Coolant mixture ratio ............................ MA-1010
Coolant replacement ............................ MA-1014
Cooling fan control ................................ EC-1105
Cornering lamp ...................................... EL-1054
Crankcase emission control system -
See Positive crankcase ventilation ... EC-1022
Crankcase ventilation system - See
Positive crankcase ventilation ........... EC-1022
Crankshaft position sensor (TDC) ........ EC-1140
Crankshaft ............................................ EM-1077
Cruise control - See ASCD ................... EL-1110
Cylinder block boring ............................ EM-1020
Cylinder block ....................................... EM-1067
Cylinder head bolt tightening ................ EM-1034
Cylinder head ....................................... EM-1053
D
DEF - Wiring diagram ............................ EL-1102
DTRL - Wiring diagram ......................... EL-1044
Data link connector for Consult ............ EC-1038
Daytime light system ............................. EL-1044
Diagnosis sensor unit ........................... RS-1008
Diagnostic trouble code (DTC) for
OBD system ...................................... EC-1032
Dome light - See Interior lamp .............. EL-1067
Door mirror ............................................ BT-1007
Door trim ................................................ BT-1004
Drive belt inspection ............................. MA-1011
Drive plate runout ................................. EM-1095
Dropping resistor (A/T) .......................... AT-1086
E
ECCS-D control module .. EC-1068, 1117, 1189,
1191, 1196, 1200
ECM input/output signal ........................ EC-1068
ECTS - Wiring diagram ......................... EC-1092
EGR - Wiring diagram .......................... EC-1209
EGR volume control valve .................... EC-1207
Electrical unit ......................................... EL-1231
Electrical units location .......................... EL-1185
Electronic fuel injection pump .... EC-1119, 1153,
1159, 1165, 1171, 1177, 1180, 1215
Engine control circuit diagram .............. EC-1015
Engine control component parts
location .............................................. EC-1011
Engine control system diagram and
chart .................................................. EC-1016
ALPHABETICAL INDEX
IDX-1002

4. Wipe clean fuel filter mounting surface on fuel filter bracket
and smear a little fuel on rubber seal of fuel filter.
5. Screw fuel filter on until a slight resistance is felt, then tighten
an additional more than 2/3 of a turn.
6. Install fuel filter sensor to new fuel filter. (Type A)
7. Bleed air from fuel filter.
Refer to ªAir Bleedingº in EC section.
8. Start engine and check for leaks.
DRAINING WATER
1. Drain water as follows.
Type A
Loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it exces-
sively.
If water does not drain properly, move the priming pump up and
down.
Type B
Loosen air bleeder screw from the sedimentor cover and then
loosen drain cock and drain water.
Loosening drain cock four to five turns causes water to start
draining. Do not remove drain cock by loosening it exces-
sively.
2. Bleed air.
Refer to ªAir Bleedingº in EC section.
Checking Fuel Lines
Check fuel lines and tank for proper attachment, leaks, cracks,
damage, loose connections, chafing and deterioration.
CAUTION:
Keep clean parts with compressed air when assembling.
SMA010
SMA825B
SMA281C
SMA803A
ENGINE MAINTENANCEZD
Checking and Replacing Fuel Filter and
Draining Water (Cont'd)
MA-1018

10. Remove mainshaft bearing snap ring.
11. Pull out mainshaft bearing.
12. Support mainshaft with hoist.
13. Remove bolts securing front cover and then remove front
cover.
14. Remove counter gear front bearing outer race.
lTap rear end of counter gear lightly before removing
bearing.
15. Remove counter gear rear bearing outer race.
lTap front end of counter gear lightly before removing
bearing.
16. Settle counter gear assembly down on bottom of transmis-
sion case.
17. Remove main drive gear assembly.
lSet cutting portion of clutch gear on main drive gear to
upper side.
SMT281D Mainshaft bearing
Puller Rear
SMT319D Rear
SMT282D
SMT283D (Outer race)
Counter gear rear bearing
(Inner race)
SMT284D Upper
Rear view
Front
DISASSEMBLYFS5R50B
Gear Components (Cont'd)
MT-1020

9. Install fork rod caps by tapping lightly.
10. Install reverse and neutral position switches.
Gear Components
MAIN DRIVE GEAR
1. Press main drive gear bearing.
2. Select proper main drive gear snap ring to minimize clear-
ance of groove, then install it.
Allowable clearance of groove:
0 - 0.15 mm (0 - 0.0059 in)
Main drive gear snap ring:
Refer to SDS, MT-1038.
MAIN SHAFT
1. Assemble synchronizers.
1st & 2nd synchronizer
lOpening of shifting insert springs must not be aligned
with each other.
SMT303D Striking rod cap
Fork rod cap
Striking
lever cap
Fork rod cap
Gear shift housing
Shift rod cap
SMT295D Interlock plunger
Plug
Interlock pin
Check ballNeutral position switch Reverse position switch
SMT425AA
SMT426A
SMT914A Synchronizer
hubCoupling sleeve
Shifting insert
Shifting insert
Shifting insert spring
ASSEMBLYFS5R50B
Shift Control Components (Cont'd)
MT-1028

4. Place mainshaft assembly on top of counter gear assembly
and then support it with hoist.
lAlign matching portion of counter gear and sub-gear
tooth to upper side.
5. Install main drive gear assembly by tapping front end of it
lightly.
lSet cutting portion of clutch gear on main drive gear to
the upper side.
6. Install counter gear front bearing outer race by tapping it
lightly while holding counter gear assembly.
lPay attention to direction.
7. Install counter gear rear bearing outer race by tapping it
lightly while holding counter gear assembly.
lPay attention to direction.
8. Take off hoist from mainshaft.
SMT308D Mainshaft
assembly
Front
SMT309D
SMT310D Upper
Rear view
Soft hammer
SMT311D Front
Soft hammer
SMT312D Front
Tool
ASSEMBLYFS5R50B
Gear Components (Cont'd)
MT-1032

Propeller Shaft
GENERAL SPECIFICATIONS
Front propeller shaft
Applied modelZD30ETi engine
M/T A/T
Propeller shaft model 2F80B
Number of joints 2
Type of journal bearing Solid (Disassembly type)
Coupling type with trans-
mission Flange type
Distance between yokes mm (in) 73 (2.87)
Shaft length (Spider-to-
spider) mm (in) 832 (32.76) 796 (31.34)
Shaft outer diameter mm (in) 50.8 (2.000)
Rear propeller shaft
Applied model
Engine ZD30ETi
Transmission M/T A/T A/T M/T
Body Hardtop Wagon Hardtop Wagon
Propeller shaft model 2F100H
Number of joints 2
Type of journal bearing Solid (Disassembly type)
Coupling type with trans-
mission Flange type
Distance between yokes mm (in) 94 (3.70) 94 (3.70) 94 (3.70) 94 (3.70)
Shaft length (Spider-to-
spider) mm (in) 440 (17.32) 1,044 (41.10) 480 (18.90) 957 (37.68)
Shaft outer diameter mm (in) 57 (2.24) 89.6 (3.528) 75.2 (2.961) 89.6 (3.528)
Available snap rings
2F80B
Thickness mm (in) Color Part number
1.99 (0.0783) White 37146-C9400
2.02 (0.0795) Yellow 37147-C9400
2.05 (0.0807) Red 37148-C9400
2.08 (0.0819) Green 37149-C9400
2.11 (0.0831) Blue 37150-C9400
2.14 (0.0843) Light brown 37151-C9400
2.17 (0.0854) Black 37152-C9400
2.20 (0.0866) Colorless 37153-C9400
2F100H
Thickness mm (in) Color Part number1.95 (0.0768) White 37146-61502
1.98 (0.0780) Yellow 37147-61502
2.01 (0.0791) Red 37148-61502
2.04 (0.0803) Green 37149-61502
2.07 (0.0815) Blue 37150-61502
2.10 (0.0827) Light brown 37151-61502
2.13 (0.0839) Pink 37146-61503
2.16 (0.0850) Gold 37147-61503
2.19 (0.0862) Black 37148-61503
2.22 (0.0874) Colorless 37149-61503
SERVICE DATA AND SPECIFICATIONS (SDS)
PD-1010