oil NISSAN PATROL 2004 Electronic Repair Manual

Body Front End
+When removing or installing hood, place a cloth or other padding on front fender panel and cowl top. This
prevents vehicle body from being scratched.
+Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
+Hood adjustment: Adjust at hinge portion.
+Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood
locks engaging mechanism.
+Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.
REMOVAL Ð Front bumper assembly
j1Remove front guard bar. Refer to ªEXTERIORº for details, BT-9.
j
2Remove clips securing front grille and remove the front grille.
j3Remove left and right headlamp washer nozzle. (If equipped.)
j
4Remove screws and bolts securing left and right front bumper side bracket.
j5Remove bolts securing bumper lower to engine under cover.
j6Remove bolts securing left and right front bumper stay upper (without winch).
j7Remove bolts securing left and right front bumper stay side.
j8Extract bumper assembly.
PIIB1965E
BODY END
BT-4002

Body Rear End and Opener
+Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
+Back door lock system adjustment: Adjust lock & striker so that they are in the center.
After adjustment, check back door lock operation.
+Back door hatch lock system adjustment: Adjust lock & striker so that they are in the center.
After adjustment, check back door hatch lock operation.
+Opener cable: Do not attempt to bend cable using excessive force.
+After installation, make sure that back door and fuel ®ller lid open smoothly.
WARNING:
+Be careful not to scratch back door stay and/or back door hatch stay when installing back door
and/or back door hatch. A scratched stay may cause gas leakage.
+The contents of the back door stay and back door hatch stay are under pressure. Do not take apart,
puncture, apply heat or allow ®re near them.
REMOVAL Ð Rear bumper assembly
j1Remove rear bumper ®nisher.
j
2Remove screws securing left and right mudguard.
j
3Remove bolts securing rear bumper to bumper reinforcement.
j
4Remove nuts securing rear bumper reinforcement.
PIIB1968E
BODY END
BT-4005

Adjustments
NOTE:
Adjust valve clearance while engine is cold.
+Remove the adjusting shim for parts which are outside the
speci®ed valve clearance.
1. Remove the spill tube. Refer to ªBASIC SERVICE PROCE-
DUREº in EC section.
2. Rotate the crankshaft to face the cam nose for adjusting shims
that are to be removed upward.
3. Thoroughly wipe off engine oil on the upper side of the cylinder
head (for the air gun used in step 7).
4. Move the round hole of the adjusting shim to the front with an
extra-®ne screwdriver or like that.
CAUTION:
Perform (the above procedure) while camshaft do not contact
with adjusting shim.
5. Grip the camshaft with camshaft pliers (SST), then using the
camshaft as a support point, push the adjusting shim downward
to compress the valve spring.
CAUTION:
Do not damage the camshaft, cylinder head, and the outer cir-
cumference of the valve lifter.
6. With the valve spring in a compressed state, remove the cam-
shaft pliers (SST) by securely setting the outer circumference
of the valve lifter with the end of the lifter stopper (SST).
+Hold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as the camshaft
will be damaged.
7. Remove the adjusting shim from the valve lifter by blowing air
through the round hole of the adjusting shim with an air gun.
CAUTION:
+When blowing, use goggles to protect your eye.
+To prevent any remaining oil from being blown around,
thoroughly wipe the area clean.
PBIC0373E
FEM029A
PBIC0374E
VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
EM-4005

Removal
1. Remove the following parts.
+Undercover
+Engine oil (Drain)
+Engine coolant (Drain)
+Engine cover
+Intercooler
+Air inlet pipe
+Air cleaner case
+Throttle body
+Swirl and intake air control valve control solenoid valve and
bracket
+Vacuum tank
+Glow plate
+Rocker cover
+Spill tube
+Radiator shrouds (Rear and Lower)
+Cooling fan
+Radiator hose (Upper and Lower)
+Auxiliary belt and auto tensioner.
2. Remove the alternator.
3. Remove the A/C compressor and bracket with piping con-
nected. Move and support it at the LH side of engine bay with
a rope to avoid putting load on piping.
Refer to HA section in NISSAN Service Manual (Publication No.
SM9E-Y61CG2 or SM9E-Y61CG3).
4. Remove the chain cover, timing chain and other parts in con-
nection.
Before removing timing chain, remove injection pump sprocket
with No. 1 cylinder being positioned at TDC. Refer to the ®g-
ure. Refer to ªTIMING CHAINº, EM-37 in NISSAN Service
Manual (Publication No. SM9E-Y61CG2 or SM9E-Y61CG3).
CAUTION:
After removing timing chain, never rotate crankshaft, or the
piston will push the valve up and damage the valve.
+Do not paint the match mark on the timing chain beforehand as
the No. 1 cylinder is set at the TDC during assembly.
5. Remove the TDC sensor.
CAUTION:
+Do not drop or hit the sensor.
+Store in a clean place free of iron ®lings, etc.
+Do not place near any magnetic equipment.
6. Remove the water pump and its stud bolts.
Refer to ªWATER PUMPº in LC section in NISSAN Service
Manual (Publication No. SM9E-Y61CG2 or SM9E-Y61CG3).
7. Remove the water inlet.
SEM376G
TIMING GEARZD
EM-4009

8. Remove the crankshaft pulley.
+To ®x the crankshaft, remove the starter motor, and set ring
gear stopper (SST).
CAUTION:
+Do not damage or magnetize the signal detection protru-
sions of the crankshaft pulley.
+After removing timing chain, never rotate crankshaft, or
the piston will push the valve up and damage the valve.
9. Remove the gear case.
+Using the grooved places shown in the ®gure, remove the gear
case by using a screwdriver and a seal cutter (SST).
10. Remove the front oil seal from the gear case by using a screw-
driver.
CAUTION:
Do not damage the gear case.
11. Fix the internal mechanism setting bolt [part No.: 81-20620-28,
screw dia.: M6, dimension below neck: 20 mm (0.79 in)] to the
bolt hole of the idler gear (A) and tighten to the speci®cation.
: 2.5 - 3.4 Nzm (0.25 - 0.35 kg-m, 22 - 30 in-lb)
CAUTION:
+Only use the genuine setting bolt, or the idler gear (A) will
be damaged.
+Do not rotate the crankshaft as the head of the setting
bolts interferes with the gear case.
+Do not remove the setting bolt from the idler gear (A) until
the timing chain and all of the parts in connection have
been installed.
+If these bolts are not installed, internal mechanism will
disengage after the idler gear is removed. This will prohibit
the idler gear from being reusable.
12. Remove the idler gears (A) and (B).
+Check the backlash of each gear before removing. Refer to
EM-52, ªBACKLASH OF EACH GEARº, ªInspectionº in
NISSAN Service Manual (Publication No. SM9E-Y61CG2 or
SM9E-Y61CG3).
CAUTION:
+Do not loosen the internal mechanism setting bolt of the
idler gear (A). (The idler gear cannot be reused when the
internal mechanism is released.)
+During removal of the idler gears (A) and (B), do not face
the rear side downward as the idler shaft will drop.
FEM051
FEM052
SEM377G
SEM348G
TIMING GEARZD
Removal (Cont'd)
EM-4010

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 ¯ange 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
®gure below.
+When installing timing gear, follow the order (j
1,j2) shown in
the dotted box in the ®gure below to facilitate installation.
SEM206H
SEM207H
FEM042
TIMING GEARZD
EM-4012

4. Install the front oil seal to the gear case.
+Apply engine oil to the ®tting side.
+Evenly insert the front oil seal using a drift [outer dia.: approx.
64 mm (2.52 in)] completely.
CAUTION:
Make sure the oil seal does not spill off the end side of the gear
case.
5. Install the gear case.
1) Before installing gear case, remove all traces of liquid gasket
from mating surface using a scraper.
2) Align gasket with dowel and install.
FEM043
FEM044
SEM353G
TIMING GEARZD
Installation (Cont'd)
EM-4013

3) Install the O-rings to the gear case.
+The O-ring at the top position shown in the ®gure can be
installed in during cylinder head installation.
4) Apply a continuous bead of liquid gasket to the gear case and
the oil pan (upper).
+Use Genuine Liquid Gasket or equivalent.
CAUTION:
Apply the liquid gasket around the bolt holes shown by the
arrows in the ®gure.
a. Coat of liquid gasket should be maintained within the
speci®ed range as shown in the ®gure.
b. Attach gear case to cylinder block within 5 minutes after
coating.
c. Wait at least 30 minutes before re®lling engine oil or start-
ing engine.
5) Install the gear case.
+Insert the gear case diagonally to prevent it from dragging over
the liquid gasket applied on the timing gear case and the oil pan
(upper).
+Align the dowel pin at the lower position of cylinder block with
the hole on the gear case side.
+Tap the area around the dowel pin with a plastic hammer if it
cannot be inserted easily.
CAUTION:
Do not pop out the O-rings.
6) Install the holding bolt referring to the ®gure.
Dimension below neck:
A: 25 mm (0.98 in)
B: 30 mm (1.18 in)
C: 50 mm (1.97 in)
D: 80 mm (3.15 in)
E: 20 mm (0.79 in)
7) Install the holding bolts from the rear side of the front plate.
6. Install the crankshaft pulley.
+Insert by aligning the 2 sides of the oil pump with the 2 sides
of the shaft on the rear side of the crankshaft pulley.
CAUTION:
Do not damage the oil seal lip when inserting.
+Refer to EM-51, ªRemovalº in NISSAN Service Manual (Publi-
cation No. SM9E-Y61CG2 or SM9E-Y61CG3) for the crank-
shaft setting procedures when tightening the holding nut.
7. Install the water pump.
+Install it before installing the TDC sensor. Refer to ªWater
Pumpº in LC section.
FEM045
SEM208H
SEM209H
FEM046
TIMING GEARZD
Installation (Cont'd)
EM-4014

For Israel
JN1TESY61 5XXXXXXX
Vehicle serial number
Manufacturing plant
X: Hiratsuka
Model year
5: 2005 model year
S: Long wheelbase (4WD)
Engine type
E: ZD30DDTi
Body type
T: Station Wagon K: Hardtop
Manufacturer
JN1: Japan produced vehicle
Dimensions
FOR THE MIDDLE EAST
Wagon Hardtop
Overall length*1 mm (in) 5,080 (200.0)*2, *5
5,030 (198.0)*3, *6
5,075 (199.8)*4, *74,460 (175.6)*3, *6
4,505 (177.4)*4, *7
Overall width mm (in) 1,840 (72.4)*3
1,940 (76.4)*2, *41,840 (72.4)*3
1,940 (76.4)*4
Overall height mm (in) 1,855 (73.0) 1,840 (72.4)
Front tread mm (in) 1,555 (61.2)*3
1,605 (63.2)*2, *41,555 (61.2)*3
1,605 (63.2)*4
Rear tread mm (in) 1,575 (62.0)*3
1,625 (64.0)*2, *41,575 (62.0)*3
1,625 (64.0)*4
Wheelbase mm (in) 2,970 (116.9) 2,400 (94.5)
*1: With winch, 15 mm (0.59 in) is added to the overall length. With front spoiler, 30 mm (1.18
in) is added.
*2: 275/70R16, 275/65R17 tires
*3: 235/80R16, 235/80R16LT tires
*4: 265/70R16, 265/70R16LT tires
*5: 15 mm (0.59 in) is added with pintle hook, and 50 mm (1.97 in) is added with spare tire
cover.
*6: 100 mm (3.94 in) is added with spare tire cover.
*7: 20 mm (0.79 in) is added with pintle hook, and 55 mm (2.17 in) is added with spare tire
cover.
FOR EUROPE
Wagon Hardtop
Overall length mm (in) 5,145 (202.6)*1, *4
5,045 (198.6)*2
5,095 (200.6)*34,525 (178.1)*1, *4
4,475 (176.2)*2
4,620 (181.9)*3
Overall width mm (in) 1,940 (76.4)*1, *3
1,840 (72.4)*21,940 (76.4)*1, *3
1,840 (72.4)*2
Overall height mm (in) 1,855 (73.0) 1,840 (72.4)
Front tread mm (in) 1,605 (63.2)*1, *3
1,555 (61.2)*21,605 (63.2)*1, *3
1,555 (61.2)*2
Rear tread mm (in) 1,625 (64.0)*1, *3
1,575 (62.0)*21,625 (64.0)*1, *3
1,575 (62.0)*2
Wheelbase mm (in) 2,970 (116.9) 2,400 (94.5)
*1: For models equipped with 275/65R17 tires
*2: For models equipped with 235/80R16 tires
*3: For models equipped with 265/70R16 tires
*4: 50 mm (1.97 in) is added with spare tire cover.
IDENTIFICATION INFORMATION
Identi®cation Number (Cont'd)
GI-4008

DIAGNOSTIC PROCEDURE (TB48 ENGINE EXCEPT
FOR THE MIDDLE EAST)
SYMPTOM: Magnet clutch does not engage when A/C switch
and fan control dial are ON.
CHECK INTAKE SENSOR CIRCUIT.
Refer to self-diagnosis (HA-4027) and
intake sensor circuit (HA-132 in Y61 SER-
VICE MANUAL, publication No. SM7E-
2Y61G1.)
CHECK POWER SUPPLY FOR COM-
PRESSOR.
Disconnect compressor harness connector.
Do approx. 12 volts exist between compres-
sor harness connector terminal No.j
1and
ground?
No
cYe s
Check magnet clutch coil.
NG
Replace magnet clutch.
Refer to HA-178 in Y61
SERVICE MANUAL (publi-
cation No. SM7E-2Y61G1).
Disconnect A/C relay.
Note
CHECK CIRCUIT CONTINUITY
BETWEEN A/C RELAY HARNESS CON-
NECTOR TERMINAL NO.j
3AND COM-
PRESSOR HARNESS CONNECTOR TER-
MINAL NO.j
1.
Continuity should exist.
If OK, check harness for short.
OK
CHECK POWER SUPPLY FOR A/C
RELAY.
Disconnect A/C relay.
Do approx. 12 volts exist between A/C
relay harness connector terminal Nos.j
1,
j5and ground?
Ye s
cNo
Check power supply circuit
and 10A or 20A (No.
)
located in the fuse block
(J/B).
Refer to EL section (ªWiring
Diagramº, ªPOWER SUP-
PLY ROUTINGº).
CHECK A/C RELAY AFTER DISCON-
NECTING IT.
Refer to HA-41 in Y61 SERVICE MANUAL,
publication No. SM1E-Y61EG1.
OK
cNG
Replace A/C relay.
jA(Go to next page.)
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.
RHA385I
SHA579F
SHA580FC
SHA581F
.
.
.
.
.
.
.
TROUBLE DIAGNOSESAUTO
Magnet Clutch (Cont'd)
HA-4040