steering NISSAN PICK-UP 1998 Repair Manual

GENERAL INFORMATIONGI
MAINTENANCEMA
ENGINE MECHANICALEM
ENGINE LUBRICATION &
COOLING SYSTEMSLC
ENGINE CONTROL SYSTEMEC
ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMSFE
CLUTCHCL
MANUAL TRANSAXLEMT
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
PICKUP
MODEL D22 SERIES
Edition: February 1998
Printing: May 1998 (01)
Publication No.: SM8E-0D22E0E
NISSAN EUROPE S.A.S.
1998 NISSAN EUROPE S.A.S. Printed 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

Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag
module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness
and spiral cable. Information necessary to service the system safely is included in theRS sectionof this
Service Manual.
WARNING:
lTo 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.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to 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.
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air
bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp and spiral
cable. Information necessary to service the system safely is included in theRS sectionof this Service
Manual.
WARNING:
lTo 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.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS.
Precautions for Brake System
lUse brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
lBe careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
lTo clean master cylinder parts, disc brake caliper parts
or wheel cylinder parts, use clean brake fluid.
lNever use mineral oils such as gasoline or kerosene.
They will ruin rubber parts of the hydraulic system.
lUse flare nut wrench when removing and installing brake
tubes.
lAlways torque brake lines when installing.
WARNING:
lClean brakes with a vacuum dust collector to minimize
the hazard of airborne materials.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR820BA
PRECAUTIONS AND PREPARATION
BR-1

Purpose
The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control of
braking force so locking of the wheels can be avoided.
The ABS:
1) Improves proper tracking performance through steering wheel operation.
2) Eases obstacle avoidance through steering wheel operation.
3) Improves vehicle stability.
Operation
lWhen the vehicle speed is less than 10 km/h (6 MPH) this system does not work.
lThe Anti-Lock Brake System (ABS) has a self-test function. The system turns on the ABS warning lamp
for 1 second each time the ignition switch is turned ``ON''. After the engine is started, the ABS warning
lamp turns off. The system performs a test the first time the vehicle reaches 6 km/h (4 MPH). A
mechanical noise may be heard as the ABS performs this self-test. This is a normal part of the self-test
feature. If a malfunction is found during this check, the ABS warning lamp will stay on.
lWhile driving, a mechanical noise may be heard during ABS operation. This is a normal condition.
ABS Hydraulic Circuit
V1Inlet solenoid valve
V2Outlet solenoid valve
V3Pump
V4Motor
V5Inlet valve
V6Outlet valve
V7Bypass check valve
V8Damper
SBR316E
ANTI-LOCK BRAKE SYSTEM
BR-32

Service Notice
lWhen removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
lHandle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soil
or damage them.
lApply sealing compound where necessary when installing parts.
lWhen applying sealing compound, be careful that the sealing compound does not protrude from parts.
lWhen replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust
prevention measures.
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag
module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness
and spiral cable. Information necessary to service the system safely is included in theRS sectionof this
Service Manual.
WARNING:
lTo 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.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to 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.
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag
module (located in the center of the steering wheel), diagnosis sensor unit, warning lamp, wiring harness
and spiral cable. Information necessary to service the system safely is included in theRS sectionof this
Service Manual.
WARNING:
lTo 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.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual.
PRECAUTIONS
BT-1

CAUTION:
lDisconnect both terminals from battery in advance.
lDisconnect air bag module connector in advance.
lBe careful not to scratch finishers and other parts.
lNever tamper with or force air bag lid open, as this may adversely affect air bag performance.
REMOVAL Ð Instrument panel assembly
Instrument panel assemblyCombination meterAudio controlHeater and A/C
controlConsole box
Remove driver's air bag module and steering wheel.
Refer to ``SUPPLEMENTAL RESTRAINT SYSTEM'' in RS section for
details.
V1Steering column coverlRemove screws.
V2Instrument lower panel driver sidelRemove screws.
V3Cluster lid AlRemove screws.
V4Combination meterlRemove screws, then disconnect harness connectors.
V5Glove box assemblylRemove screws and pins.
V6Instrument lower panel passenger sidelRemove screw.
Remove ashtray.
V7Cluster lid ClRemove screws, then disconnect harness connectors.
V8Audio and deck pocketlRemove screws, then disconnect harness connectors.
V9Heater and A/C controllRemove mask and screws.lDisconnect temperature control cable and harness connectors.
V10Instrument stay cover lower centerlRemove screws.
V11Instrument lower panel centerlRemove screws.
V12Ventilator grille driver sidelRemove screw.
V13Defroster grille
Front pillar garnish
Refer to ``Side and Floor Trim'' in ``INTERIOR
TRIM'' for details, BT-15.
V14Instrument panel assemblylRemove screws and bolts.
V15Center consolelRemove screws.
INSTRUMENT PANEL
BT-12

TROUBLE DIAGNOSIS FOR POWER SUPPLY.... 75
Main Power Supply and Ground Circuit .............. 75
TROUBLE DIAGNOSIS FOR ``CAMSHAFT
POSI SEN'' (DTC 11).............................................. 82
Camshaft Position Sensor (CMPS) ..................... 82
TROUBLE DIAGNOSIS FOR ``MASS AIR
FLOW SEN'' (DTC 12)............................................ 89
Mass Air Flow Sensor (MAFS) ............................ 89
TROUBLE DIAGNOSIS FOR ``COOLANT TEMP
SEN'' (DTC 13)........................................................ 95
Engine Coolant Temperature Sensor (ECTS) ..... 95
TROUBLE DIAGNOSIS FOR ``IGN SIGNAL-
PRIMARY'' (DTC 21)............................................... 99
Ignition Signal ...................................................... 99
TROUBLE DIAGNOSIS FOR ``OVER HEAT''
(DTC 28)................................................................. 106
Overheat ............................................................ 106
TROUBLE DIAGNOSIS FOR ``INT AIR TEMP
SEN'' (DTC 41)...................................................... 109
Intake Air Temperature Sensor ......................... 109
TROUBLE DIAGNOSIS FOR ``THROTTLE POSI
SEN'' (DTC 43)...................................................... 113
Throttle Position Sensor .................................... 113
TROUBLE DIAGNOSIS FOR
NON-DETECTABLE ITEMS.................................. 118
Vehicle Speed Sensor (VSS) ............................ 118
Heated Oxygen Sensor (HO2S)
- LHD Models - .................................................. 123
Heated Oxygen Sensor Heater
- LHD Models - .................................................. 127
Idle Air Control Valve (IACV) - Auxiliary Air
Control (AAC) Valve .......................................... 131
Neutral Position Switch ...................................... 136
EVAP Canister Purge Control Solenoid Valve .. 140
Injector ............................................................... 144
Start Signal ........................................................ 149
Fuel Pump.......................................................... 151
Power Steering Oil Pressure Switch ................. 157
Swirl Control Valve Control Solenoid Valve ...... 161
IACV-FICD Solenoid Valve ................................ 168
MIL & Data Link Connectors ............................. 173
TD
INJECTION SYSTEM............................................ 176
Fuel System ....................................................... 176
INJECTION PUMP................................................. 178
Inspection ........................................................... 178
Removal ............................................................. 178
Installation and Adjustment................................ 180
Disassembly ....................................................... 183
Load Timer Adjustment...................................... 183
Start Q Adjustment Lever .................................. 184
INJECTION NOZZLE............................................. 186Removal and Installation ................................... 186
Disassembly ....................................................... 186
Inspection ........................................................... 187
Cleaning ............................................................. 187
Assembly............................................................ 189
Test and Adjustment .......................................... 189
FUEL SYSTEM CHECK........................................ 191
Bleeding Fuel System ........................................ 191
Bleeding Fuel Filter ............................................ 192
Checking Priming Pump .................................... 192
Checking Fuel Filter Switch ............................... 192
POSITIVE CRANKCASE VENTILATION.............. 193
Description ......................................................... 193
Inspection ........................................................... 193
QUICK-GLOW SYSTEM........................................ 194
Component Parts Location ................................ 194
Circuit Diagram .................................................. 195
Description ......................................................... 196
Wiring Diagram .................................................. 197
Glow Control Unit Circuit Inspection (For Cold
Areas)................................................................. 203
Glow Control Unit Circuit Inspection (Except
for Cold Areas)................................................... 206
Component Inspection ....................................... 208
EGR SYSTEM........................................................ 210
Component Parts Location ................................ 210
Description ......................................................... 211
Operation ........................................................... 212
Wiring Diagram .................................................. 213
System Inspection.............................................. 217
Component Inspection ....................................... 218
SOLENOID TIMER................................................ 220
Description ......................................................... 220
Operation ........................................................... 220
Wiring Diagram .................................................. 222
Inspection ........................................................... 224
FUEL CUT SYSTEM.............................................. 225
Wiring Diagram .................................................. 225
FUEL HEATER SYSTEM...................................... 226
Description ......................................................... 226
Wiring Diagram .................................................. 227
System Inspection.............................................. 228
Component Inspection ....................................... 228
FAST IDLE CONTROL CIRCUIT.......................... 230
Wiring Diagram .................................................. 230
Electrical Components Inspection ..................... 231
KA
SERVICE DATA AND SPECIFICATIONS (SDS). 232
General Specifications ....................................... 232
Inspection and Adjustment ................................ 232

Commercial Service Tool
FOR KA ENGINE MODELS
Tool name Description
Fuel filler cap adapter
NT653
Checking fuel tank vacuum relief valve opening
pressure
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air
bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring har-
ness and spiral cable. Information necessary to service the system safely is included in theRS sectionof
this Service Manual.
WARNING:
lTo 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.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to 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.
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models)
The Supplemental Restraint System ``AIR BAG'', used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air
bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring har-
ness and spiral cable. Information necessary to service the system safely is included in theRS sectionof
this Service Manual.
WARNING:
lTo 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.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
lDo not use electrical test equipment on any circuit related to the SRS.
PRECAUTIONS AND PREPARATION
EC-4

System Chart
Camshaft position sensorc
ECM
(ECCS
control
module)
Mass air flow sensorc
Engine coolant temperature sensorc
Heated oxygen sensor*c
Ignition switchc
Throttle position sensorc
Neutral position switchc
Vehicle speed sensorc
Air conditioner switchc
Battery voltagec
Power steering oil pressure switchc
Intake air temperature sensorc
*: LHD models
Fuel injection &
mixture ratio controlcInjectors
Distributor ignition systemcPower transistor
Idle air control systemcIACV-AAC valve
IACV-FICD solenoid valve
Swirl control valve controlcSwirl control valve control
solenoid valve
EVAP canister controlcEVAP canister purge control
solenoid valve
Fuel pump controlcFuel pump relay
Heated oxygen sensor moni-
tor & on board diagnostic
systemcMalfunction indicator lamp
(On the instrument panel)
Acceleration cut controlcAir conditioner relay
Heated oxygen sensor
heater control*cHeated oxygen sensor
heater
ENGINE AND EMISSION CONTROL OVERALL SYSTEMKA
EC-13

ECCS COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
ItemDIAGNOSTIC TEST MODE
WORK
SUPPORTSELF-DIAG-
NOSTIC
RESULTSDATA
MONITORACTIVE
TESTFUNCTION
TEST
ECCS COMPONENT PARTS
INPUT
Camshaft position sensor X X
Mass air flow sensor X X
Engine coolant temperature
sensorXXX
Heated oxygen sensor X
Vehicle speed sensor X X
Throttle position sensor X X X X
Intake air temperature sensor X X
Ignition switch (start signal) X X
Closed throttle position switch X X
Air conditioner switch X
Neutral position switch X X
Power steering oil pressure
switchXX
Battery voltage X
OUTPUT
Injectors X X X
Power transistor (Ignition timing) XX (Ignition
signal)XXX
IACV-AAC valve X X X X
Air conditioner relay X
Fuel pump relay X X X X
Swirl control valve control
solenoid valveXXX
EVAP canister purge control
solenoid valve*XXX
X: Applicable
* : This item is indicated as ``EGRC SOL/V'' on the CONSULT screen.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONKA
CONSULT (Cont'd)
EC-47

SELF-DIAGNOSTIC MODE
Regarding items detected in ``SELF-DIAG RESULTS'' mode, refer to ``DIAGNOSTIC TROUBLE CODE
INDEX'', EC-1.
DATA MONITOR MODE
Monitored item
[Unit]ECM
input
signalsMain
signalsDescription Remarks
CMPSRPM
(POS) [rpm]
jj
lIndicates the engine speed computed
from the POS signal (1É signal) of the
camshaft position sensor.
MAS AIR/FL SE [V]
jjlThe signal voltage of the mass air flow
sensor is displayed.lWhen the engine is stopped, a certain
value is indicated.
COOLAN TEMP/S
[ÉC] or [ÉF]
jj
lThe engine coolant temperature (deter-
mined by the signal voltage of the engine
coolant temperature sensor) is displayed.lWhen the engine coolant temperature
sensor is open or short-circuited, ECM
enters fail-safe mode. The engine coolant
temperature determined by the ECM is
displayed.
O2 SEN [V]
jjlThe signal voltage of the heated oxygen
sensor is displayed.lLHD models only
M/R F/C MNT
[RICH/LEAN]
jj
lDisplay of heated oxygen sensor signal
during air-fuel ratio feedback control:
RICH ... means the mixture became
``rich'', and control is being affected
toward a leaner mixture.
LEAN ... means the mixture became
``lean'', and control is being affected
toward a rich mixture.lAfter turning ON the ignition switch,
``RICH'' is displayed until air-fuel mixture
ratio feedback control begins.
lWhen the air-fuel ratio feedback is
clamped, the value just before the clamp-
ing is displayed continuously.
lLHD models only
VHCL SPEED SE
[km/h] or [mph]
jjlThe vehicle speed computed from the
vehicle speed sensor signal is displayed.
BATTERY VOLT [V]
jjlThe power supply voltage of ECM is dis-
played.
THRTL POS SEN [V]
jjlThe throttle position sensor signal volt-
age is displayed.
INT/A TEMP SE
[ÉC] or [ÉF]
j
lThe intake air temperature (determined
by the signal voltage of the intake air
temperature sensor) is indicated.
START SIGNAL
[ON/OFF]
jjlIndicates [ON/OFF] condition from the
starter signal.lAfter starting the engine, [OFF] is
displayed regardless of the starter signal.
CLSD THL/POSI
[ON/OFF]
jj
lIndicates [ON/OFF] condition from the
throttle position sensor signal.
AIR COND SIG
[ON/OFF]
jj
lIndicates [ON/OFF] condition of the air
conditioner switch as determined by the
air conditioner signal.
P/N POSI SW
[ON/OFF]
jj
lIndicates [ON/OFF] condition from the
park/neutral position switch signal.
PW/ST SIGNAL
[ON/OFF]
jj
l[ON/OFF] condition of the power steering
oil pressure switch determined by the
power steering oil pressure signal is indi-
cated.
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONKA
CONSULT (Cont'd)
EC-48