engine NISSAN PATROL 2002 Electronic Repair Manual

Edition: October 2002
Release: November 2002 (01)
Publication No.: SM2E-Y61CE0E
Reference No.: 7711346700GENERAL 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 GR
MODEL Y61 SERIES
NISSAN EUROPE S.A.S.
2002 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

FOREWORD
This manual contains maintenance and repair procedures for NISSAN
PATROL GR,modelY61 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in speci-
®cations and methods at any time without notice.
IMPORTANT SAFETY NOTICE
The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a man-
ner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not speci®cally recommended by NISSAN must
®rst completely satisfy himself that neither his safety nor the vehicle's
safety will be jeopardized by the service method selected.
NISSAN EUROPE S.A.S.
Service Engineering SectionParis, France

General Specifications
BodyWagon/Hardtop
Applied modelZD30 engine
Standard Option*
Front brake
TypeCL36VE disc brake
Cylinder bore diameter
mm (in)48.1 (1.894) x 2
Pad dimension
Length x width x thickness mm (in)147 x 56.5 x 12 (5.79 x 2.224 x 0.47)
Rotor outer diameter x thickness
mm (in)306 x 32 (12.05 x 1.26)
Rear brake
Type CL18VF disc brake LT30 drum brake
Cylinder bore diameter
mm (in)48.1 (1.894) 25.4 (1.00)
Lining or pad dimension
Length x width x thickness mm (in)111 x 41.8 x 10
(4.37 x 1.646 x 0.39)296x50x6.1
(11.65 x 1.97 x 0.240)
Drum inner diameter
mm (in)Ð 295 (11.61)
Rotor outer diameter x thickness
mm (in)316 x 18 (12.44 x 0.71) Ð
Brake booster
Model235T
Diaphragm diameter
mm (in)Primary: 252 (9.92)
Secondary: 230 (9.06)
Master cylinder bore diameter
mm (in)26.9 (17/16)
Control valve
TypeLSV
Split point x reducing ratio
kPa (bar, kg/cm
2, psi)(Variable) x 0.3 (Variable) x 0.15
Recommended brake fluid DOT 3 or DOT 4
*: When ABS, diff. lock or rear disc brake is fitted as an option.
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-3011

ENGINE CONTROL SYSTEM
SECTION
EC
MODIFICATION NOTICE:
+Wiring diagrams have been modified.
CONTENTS
ZD30DDTi
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM............................................................... 3002
Circuit Diagram ................................................ 3002
TROUBLE DIAGNOSIS FOR POWER SUPPLY3003
Main Power Supply and Ground Circuit .......... 3003
DTC 0102 MASS AIR FLOW SEN...................... 3004
Wiring Diagram ................................................ 3004
DTC 0104 VEHICLE SPEED SEN...................... 3005
Wiring Diagram ................................................ 3005
DTC 0208 OVER HEAT....................................... 3006
Wiring Diagram ................................................ 3006
Diagnostic Procedure....................................... 3007Component Inspection ..................................... 3013
Main 12 Causes of Overheating ...................... 3014
DTC 0402 P9zFUEL TEMP SEN......................... 3015
Wiring Diagram ................................................ 3015
DTC 0403 ACCEL POS SENSOR...................... 3016
Wiring Diagram ................................................ 3016
DTC 0902 ECM RLY........................................... 3017
Wiring Diagram ................................................ 3017
DTC 1003 EGR VOLUME CONT/V..................... 3018
Wiring Diagram ................................................ 3018
MI (MIL) & DATA LINK CONNECTORS............ 3019
Wiring Diagram ................................................ 3019
When you read wiring diagrams:
+Read GI section, ªHOW TO READ WIRING DIAGRAMSº.
+See EL section, ªPOWER SUPPLY ROUTINGº for power distribution circuit.
When you perform trouble diagnoses, read GI section, ªHOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSESº and ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL
INCIDENTº.

EC

Circuit Diagram
TEC395M
ENGINE AND EMISSION CONTROL OVERALL SYSTEMZD30DDTi
EC-3002

Diagnostic Procedure
1 INSPECTION START
Do you have CONSULT-II?
Yes or No
YescGO TO 2.
NocGO TO 3.
2 CHECK COOLING FAN OPERATION
With CONSULT-II
1. Turn ignition switch ªONº.
2. Perform ªCOOLING FANº in ªACTIVE TESTº mode with CONSULT-II.
SEF646X
3. Make sure that cooling fan-1 operates.
OK or NG
OKcGO TO 12.
NGcGO TO 4.
3 CHECK COOLING FAN OPERATION
Without CONSULT-II
1. Turn ignition switch ªOFFº.
2. Disconnect engine coolant temperature sensor harness connector.
3. Connect 150Wresistor to engine coolant temperature sensor harness connector.
4. Restart engine and make sure that cooling fan operates.
MEC475B
OK or NG
OKcGO TO 12.
NGcGO TO 4.
DTC 0208 OVER HEATZD30DDTi
EC-3007

15 CHECK THERMOSTAT
1. Remove thermostat.
2. Check valve seating condition at normal room temperatures.
It should seat tightly.
3. Check valve opening temperature and valve lift.
SLC343
Valve opening temperature:
82ÉC (180ÉF) [standard] (Models for cold areas)
76.5ÉC (170ÉF) [standard] (Models for except cold areas)
Valve lift:
More than 10 mm/95ÉC (0.394 in/203ÉF)
4. Check if valve is closed at 5ÉC (9ÉF) below valve opening temperature. For details, refer to LC section, ªThermostatº.
OK or NG
OKcGO TO 16.
NGcReplace thermostat.
16 CHECK ENGINE COOLANT TEMPERATURE SENSOR
1. Remove engine coolant temperature sensor.
2. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure.
SEF304X
OK or NG
OKcGO TO 17.
NGcReplace engine coolant temperature sensor.
DTC 0208 OVER HEATZD30DDTi
Diagnostic Procedure (Cont'd)
EC-3012

Main 12 Causes of Overheating
Engine Step Inspection item Equipment Standard Reference page
OFF 1+Blocked radiator
+Blocked condenser
+Blocked radiator grille
+Blocked bumper+Visual No blocking Ð
2+Coolant mixture+Coolant tester 30 - 50% coolant mixture See ªRECOMMENDED
FLUIDS AND LUBRI-
CANTSº in MA section.
3+Coolant level+Visual Coolant up to MAX level
in reservoir tank and
radiator filler neckSee ªChanging Engine
Coolantº, ªENGINE MAIN-
TENANCEº in MA sec-
tion.
4+Radiator cap+Pressure tester 59 - 98 kPa (0.59 - 0.98
bar, 0.6 - 1.0 kg/cm
2,
9 - 14 psi) (Limit)See ªSystem Checkº,
ªENGINE COOLING SYS-
TEMº in LC section.
ON*2 5+Coolant leaks+Visual No leaks See ªSystem Checkº,
ªENGINE COOLING SYS-
TEMº in LC section.
ON*2 6+Thermostat+Touch the upper and
lower radiator hosesBoth hoses should be hot. See ªThermostatº and
ªRadiatorº, ªENGINE
COOLING SYSTEMº in
LC section.
ON*1 7+Cooling fan+Visual Operating See ªDTC 0208 OVER
HEATº.
OFF 8+Combustion gas leak+Color checker chemical
tester 4 gas analyzerNegative Ð
ON*3 9+Coolant temperature
gauge+Visual Gauge less than 3/4
when drivingÐ
+Coolant overflow to res-
ervoir tank+Visual No overflow during driving
and idlingSee ªChanging Engine
Coolantº, ªENGINE MAIN-
TENANCEº in MA sec-
tion.
OFF*4 10+Coolant return from res-
ervoir tank to radiator+Visual Should be initial level in
reservoir tankSee ªENGINE MAINTE-
NANCEº in MA section.
OFF 11+Cylinder head+Straight gauge feeler
gauge0.1 mm (0.004 in) Maxi-
mum distortion (warping)See ªInspectionº, ªCYLIN-
DER HEADº in EM sec-
tion.
12+Cylinder block and pis-
tons+Visual No scuffing on cylinder
walls or pistonSee ªInspectionº, ªCYLIN-
DER BLOCKº in EM sec-
tion.
*1: Engine running at idle.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to ªOVERHEATING CAUSE ANALYSISº in LC section.
DTC 0208 OVER HEATZD30DDTi
EC-3014

ELECTRICAL SYSTEM
SECTION
EL
When you read wiring diagrams:
+Read GI section, ªHOW TO READ WIRING DIAGRAMSº.
When you perform trouble diagnoses, read GI section, ªHOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSESº and ªHOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENTº.
+Check for any service bulletins before servicing the vehicle.
MODIFICATION NOTICE:
+Combination meter has been changed.
+Wiring Diagram has been changed.
CONTENTS
PRECAUTIONS AND PREPARATION............... 3004
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº ... 3004
Precautions for Trouble Diagnoses ................. 3004
Precautions for Harness Repair ...................... 3004
POWER SUPPLY ROUTING............................... 3006
Schematic ........................................................ 3006
Wiring Diagram Ð POWER Ð ........................ 3007
GROUND DISTRIBUTION................................... 3017
Engine Room Harness/LHD Models................ 3017
Engine Room Harness/RHD Models ............... 3019
Main Harness/LHD Models .............................. 3021
Main Harness/RHD Models ............................. 3024
Body Harness/LHD Models ............................. 3027
Body Harness/RHD Models ............................. 3029
Body No. 2 Harness/LHD Models ................... 3030
Body No. 2 Harness/RHD Models ................... 3031
Back Door and Rear Window Defogger
Harness/LHD Models ....................................... 3032
Back Door and Rear Window Defogger
Harness/RHD Models ...................................... 3033
COMBINATION SWITCH.................................... 3034
Check ............................................................... 3034
STEERING SWITCH............................................ 3036
Check ............................................................... 3036
BATTERY............................................................. 3037
Service Data and Specifications (SDS) ........... 3037
STARTING SYSTEM........................................... 3038Service Data and Specifications (SDS) ........... 3038
CHARGING SYSTEM.......................................... 3039
Wiring Diagram Ð CHARGE Ð ...................... 3039
Service Data and Specifications (SDS) ........... 3040
HEADLAMP Ð Conventional Type Ð.............. 3041
Wiring Diagram Ð H/LAMP Ð ........................ 3041
HEADLAMP Ð Headlamp Aiming Control Ð.. 3042
Wiring Diagram Ð H/AIM Ð ........................... 3042
HEADLAMP Ð Daytime Light System Ð........ 3044
Wiring Diagram Ð DTRL Ð ............................ 3044
PARKING, LICENSE AND TAIL LAMPS........... 3046
Wiring Diagram Ð TAIL/L Ð/Type A .............. 3046
Wiring Diagram Ð TAIL/L Ð/Type B .............. 3048
Wiring Diagram Ð TAIL/L Ð/Type C .............. 3050
FRONT FOG LAMP............................................. 3052
Wiring Diagram Ð F/FOG Ð/For Israel .......... 3052
Wiring Diagram Ð F/FOG Ð/RHD Models
for Europe ........................................................ 3053
Wiring Diagram Ð F/FOG Ð/LHD Models
for Europe ........................................................ 3054
REAR FOG LAMP............................................... 3055
Wiring Diagram Ð R/FOG Ð/For Europe ....... 3055
TURN SIGNAL AND HAZARD WARNING
LAMPS................................................................. 3058
Wiring Diagram Ð TURN Ð/Type A ............... 3058
Wiring Diagram Ð TURN Ð/Type C............... 3060
ILLUMINATION.................................................... 3062
Schematic ........................................................ 3062

EL

Wiring Diagram Ð ILL Ð ................................ 3063
INTERIOR ROOM LAMP Ð With Timer Ð....... 3069
Schematic/LHD Models for Israel .................... 3069
Wiring Diagram Ð ROOM/L Ð/LHD Models
for Israel ........................................................... 3070
Wiring Diagram Ð ROOM/L Ð/LHD Models
for Europe ........................................................ 3073
Wiring Diagram Ð ROOM/L Ð/RHD Models
for Europe ........................................................ 3075
INTERIOR ROOM LAMP Ð Without Timer Ð. 3077
Wiring Diagram Ð ROOM/L Ð/LHD Models .. 3077
Wiring Diagram Ð ROOM/L Ð/RHD Models.. 3078
METER AND GAUGES....................................... 3079
Combination Meter........................................... 3079
Schematic ........................................................ 3080
Wiring Diagram Ð METER Ð ......................... 3081
COMPASS AND THERMOMETER..................... 3083
Wiring Diagram Ð COMPAS Ð ...................... 3083
WARNING LAMPS.............................................. 3084
Schematic ........................................................ 3084
Wiring Diagram Ð WARN Ð .......................... 3086
WARNING CHIME............................................... 3098
Wiring Diagram Ð CHIME Ð/Except for
Europe and with Theft Warning System
Models.............................................................. 3098
Wiring Diagram Ð CHIME Ð/LHD Models
for Europe ........................................................ 3099
FRONT WIPER AND WASHER.......................... 3100
Wiring Diagram Ð WIPER Ð/Except for
Europe.............................................................. 3100
HEADLAMP WASHER........................................ 3101
Wiring Diagram Ð HLC Ð .............................. 3101
Washer Tube Layout ....................................... 3103
CIGARETTE LIGHTER........................................ 3104
Wiring Diagram Ð CIGAR Ð/LHD Models ..... 3104
Wiring Diagram Ð CIGAR Ð/RHD Models .... 3105
WIPER DEICER................................................... 3106
Wiring Diagram Ð DEICER Ð ........................ 3106
REAR WINDOW DEFOGGER............................. 3107
Wiring Diagram Ð DEF Ð/LHD Models
for Europe ........................................................ 3107
AUDIO.................................................................. 3109
Schematic/Except for Europe .......................... 3109
Schematic/For Europe ..................................... 3110
Wiring Diagram Ð AUDIO Ð/LHD Models
Except for Europe ............................................ 3111
Wiring Diagram Ð AUDIO Ð/LHD Models for
Europe.............................................................. 3114
Wiring Diagram Ð CD/CHG Ð/With IDIN
Type CD Auto Changer ................................... 3117
Wiring Diagram Ð REMOTE Ð ...................... 3118
CLOCK................................................................. 3119
Wiring Diagram Ð CLOCK Ð ......................... 3119
POWER DOOR LOCK......................................... 3120Schematic/Without Theft Warning System
Models.............................................................. 3120
Wiring Diagram Ð D/LOCK Ð/Without Theft
Warning System Models .................................. 3121
Schematic/With Theft Warning System
Models.............................................................. 3124
Wiring Diagram Ð D/LOCK Ð/With Theft
Warning System Models .................................. 3125
POWER DOOR LOCK Ð Super Lock Ð.......... 3133
Schematic ........................................................ 3133
Wiring Diagram Ð S/LOCK Ð/LHD Models ... 3134
Wiring Diagram Ð S/LOCK Ð/RHD Models... 3139
MULTI-REMOTE CONTROL SYSTEM............... 3144
Schematic/With Theft Warning System
Models.............................................................. 3144
Wiring Diagram Ð MULTI Ð/Except for
Europe and With Theft Warning System
Models.............................................................. 3145
Wiring Diagram Ð MULTI Ð/LHD Models with
Theft Warning System ..................................... 3149
Wiring Diagram Ð MULTI Ð/RHD Models
with Theft Warning System.............................. 3153
THEFT WARNING SYSTEM............................... 3156
Schematic ........................................................ 3156
Wiring Diagram Ð THEFT Ð/LHD Models ..... 3157
Wiring Diagram Ð THEFT Ð/RHD Models .... 3162
UNIFIED METER CONTROL UNIT (TIME
CONTROL SYSTEM)........................................... 3167
Schematic/Except for Europe and With Theft
Warning System Models .................................. 3167
NATS (Nissan Anti-Theft System)/ZD ENGINE
MODELS.............................................................. 3168
Wiring Diagram Ð NATS Ð/For Europe......... 3168
Wiring Diagram Ð NATS Ð/LHD Models for
Europe.............................................................. 3169
Wiring Diagram Ð NATS Ð/RHD Models for
Europe.............................................................. 3170
Wiring Diagram Ð NATS Ð/Except for
Europe.............................................................. 3171
LOCATION OF ELECTRICAL UNITS................. 3172
Engine Compartment ....................................... 3172
Passenger Compartment Ð LHD Models ....... 3174
Passenger Compartment Ð RHD Models ...... 3176
HARNESS LAYOUT............................................ 3179
How to Read Harness Layout ......................... 3179
Main Harness/LHD Models .............................. 3180
Main Harness/RHD Models ............................. 3184
Engine Room Harness/LHD Models................ 3188
Engine Room Harness/RHD Models ............... 3192
Engine Harness ............................................... 3196
Body Harness/LHD Models ............................. 3198
Body Harness/RHD Models ............................. 3202
Body No. 2 Harness/LHD Models ................... 3204
Body No. 2 Harness/RHD Models ................... 3206
EL-3002