NISSAN PICK-UP 2003 Repair Manual

General Specifications
COMPRESSOR
ModelZEXEL VALEO CLIMATE
CONTROL make DKS-17CH
Type Swash plate
Displacement cm
3(cu in) 168 (10.25)
Cylinder bore x stroke mm (in) 38.0 x 24.7 (1.50 x 0.972)
Direction of rotationClockwise
(Viewed from drive belt)
Drive belt Type A
LUBRICANT
ModelZEXEL VALEO CLIMATE
CONTROL make DKS-17CH
Type KLH00-PAGS0
Capacity
m!(lmp fl oz)Total in system 200 (7.0)
Compressor
(Service parts)
charging
amount200 (7.0)
Inspection and Adjustment
REFRIGERANT
YD engine Except YD engine
Type HFC-134a (R-134a)
Capacity kg (lb) 0.55 (1.21) 0.65 (1.43)
ENGINE IDLING SPEED (When A/C is ON)
lRefer to EC section.
BELT TENSION
lRefer to MA section (ªChecking Drive
Beltsº).
SERVICE DATA AND SPECIFICATIONS (SDS)AUTO
HA-4026

GENERAL INFORMATION
SECTION
GI
MODIFICATION NOTICE:
lKA24DE engine emission control system has been modified.
lAuto A/C for Europe has been modified.
CONTENTS
CONSULT-II CHECKING SYSTEM..................... 4002
Function and System Application .................... 4002
Nickel Metal Hydride Battery Replacement ..... 4002
Checking Equipment ........................................ 4003
CONSULT-II Data Link Connector (DLC)
Circuit ............................................................... 4003IDENTIFICATION INFORMATION...................... 4004
Model Variation ................................................ 4004
Identification Number ....................................... 4006
Dimensions ...................................................... 4006
This modification has been included in production starting with the following vehicle identification numbers
(Chassis number):
For Europe
JN1APGD22U0055001
JN1APUD22U0035001
JN1BPGD22U0032001
JN1BPUD22U0083001
JN1CPGD22U0045001
JN1CPUD22U0078001
JN1ADGD22U0021001
JN1BDGD22U0031001
JN1BDUD22U0031001
JN1CDUD22U0031001

GI

Function and System Application
Diagnostic test
modeFunction ENGINE A/T ABS AIR BAG
Work supportThis mode enables a technician to
adjust some devices faster and more
accurate by following the indications
on CONSULT-II.xxÐÐ
Self-diagnostic
resultsSelf-diagnostic results can be read
and erased quickly.xxxx
Trouble diagnos-
tic recordCurrent self-diagnostic results and all
trouble diagnostic records previously
stored can be read.ÐÐÐ x
ECU discrimi-
nated No.Classification number of a replace-
ment ECU can be read to prevent an
incorrect ECU from being installed.ÐÐÐ x
Data monitorInput/Output data in the ECU (ECM)
can be read.xxxÐ
DTC work sup-
portThis mode enables a technician to
set operating conditions to confirm
self-diagnosis status/results.ÐxÐÐ
Active testDiagnostic Test Mode in which CON-
SULT-II drives some actuators apart
from the ECMs and also shifts some
parameters in a specified range.xÐxÐ
ECU (ECM) part
numberECU (ECM) part number can be
read.xxxÐ
Function testConducted by CONSULT-II instead
of a technician to determine whether
each system is ªOKº or ªNGº (No
Good).xxxx
x: Applicable
Nickel Metal Hydride Battery Replacement
CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following:
WARNING:
Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another bat-
tery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard
if mistreated. Do not recharge, disassemble of dispose of in fire.
Keep the battery out of reach of children and discard used battery conforming to the local regula-
tions.
CONSULT-II CHECKING SYSTEM
GI-4002

Checking Equipment
When ordering the below equipment, contact your NISSAN distributor.
Tool name Description
NISSAN CONSULT-II
V1CONSULT-II unit (Tester internal soft:
Resident version 3.3.0) and accesso-
ries
V2Program card AED01C for diagnostic,
AEN00A/00B for NATS.
To confirm the best combination of
those softwares, refer to CONSULT-II
Operation Manual.
SGI083A
NOTE:
lThe CONSULT-II must be used in conjunction with a program card.
CONSULT-II does not require loading (Initialization) procedure.
lBe sure the CONSULT-II is turned off before installing or removing a program card.
CONSULT-II Data Link Connector (DLC)
Circuit
INSPECTION PROCEDURE
If the CONSULT-II cannot diagnose the system properly, check the following items.
Symptom Check item
CONSULT-II cannot access
any system.
lCONSULT-II DLC power supply circuit (Terminal 7) and ground circuit (Terminal 8)
(For detailed circuit, refer to ªMIL & Data Link Connectors Wiring Diagramº in EC section.)
lCONSULT-II DDL cable
CONSULT-II cannot access
individual system. (Other sys-
tems can be accessed.)
lCONSULT-II program card (Check the appropriate CONSULT-II program card for the system.
Refer to ªChecking Equipmentº above.)
lPower supply and ground circuit for the control unite of the system
(For detailed circuit, refer to wiring diagram for each system.)
lOpen or short circuit between the system and CONSULT-II DLC
(For detailed circuit, refer to wiring diagram for each system.)
SGI984-B
CONSULT-II CHECKING SYSTEM
GI-4003

Model Variation
PICKUP (2WD)DestinationClass Model
Engine Transmission Differential carrier
Cab Wheelbase Grade LH drive RH drive
EuropeSingle Cab
LongSTDABGGLCFD22EQL
ÐKA24DE FS5W71C
C200* AVLGLCFD22UQL YD25DDTi FS5R30A
DXABGGLDFD22EQL Ð KA24DE FS5W71C
AVLGLDFD22UQL AVLGRDFD22UQL YD25DDTi FS5R30A
King Cab DXBBGGLDFD22EQN Ð KA24DE FS5W71C
BVLGLDFD22UQN BVLGRDFD22UQN YD25DDTi FS5R30A
4WD appearanceDX BVLGLDFD22UQG Ð
YD25DDTi FS5R30A ST BVLGLEFD22UQG Ð
Double Cab DX CVLGLDFD22UQN CVLGRDFD22UQN
4WD appearanceDX CVLGLDFD22UQG Ð
ST CVLGLEFD22UQG ÐPICKUP (4WD)DestinationClass Model
Engine TransmissionDifferential carrier
Transfer
Cab Wheelbase Grade LH drive RH drive Front Rear
EuropeSingle Cab
LongSTD AVLULCFD22UQL AVLURCFD22UQL
YD25DDTi FS5R30A
R180 C200* TX10 DX AVLULDFD22UQL AVLURDFD22UQL
King CabDXBBGULDFD22EQN Ð KA24DE FS5W71C
BVLULDFD22UQN BVLURDFD22UQN YD25DDTi FS5R30A
STBBGULEFD22EQN Ð KA24DE FS5W71C
BVLULEFD22UQN BVLUREFD22UQN
YD25DDTi FS5R30A
SE BVLULFFD22UQN BVLURFFD22UQN
Double CabDXCBGULDFD22EQN Ð KA24DE FS5W71C
CVLULDFD22UQN CVLURDFD22UQN YD25DDTi FS5R30A
STCBGULEFD22EQN Ð KA24DE FS5W71C
CVLULEFD22UQN CVLUREFD22UQN
YD25DDTi FS5R30A
SE CVLULFFD22UQN CVLURFFD22UQN
IDENTIFICATION INFORMATION
GI-4004

Prefix and suffix designations
(Pickup)
ABGGLCFD22 EWL
L: Regular rear body
N: Smooth rear body
G: 4WD appearance model (2WD)
W: Except for Australia, the Middle East and Europe
M: Australia
K: Middle East
Q: Europe
S: Carburetor engine
E: Multiport fuel injection system engine
N: Diesel engine
T: Turbocharged engine
U: Turbocharged engine with intercooler
F: 5-speed floor shift manual transmission
B: 4-speed column shift automatic transmission
A: 4-speed floor shift automatic transmission
C: STD model D: DX model E: GL, ST model F: SGL, SE model
L: LH drive R: RH drive
A: Standard wheelbase (2WD) G: Long wheelbase (2WD)
U: Long wheelbase (4WD)
BE: Z24S engine BG: KA24DE engine LB: VG30E engine LP: VG33E engine
VL: YD25DDTi engine VP: TD27 engine WS: ZD30DDT engine VR: QD32 engine
A: Single Cab B: King Cab C: Double Cab
IDENTIFICATION INFORMATION
Model Variation (Cont'd)
GI-4005

Identification Number
VEHICLE IDENTIFICATION NUMBER
Prefix and suffix designations
JN1: Japan produced vehicle
For Europe
JN1BPUD22UOXXXXXX
Vehicle serial number
O: Stopgap (no meaning)
U: For Europe
Model
G: Long wheelbase (2WD) U: Long wheelbase (4WD)
D: KA24DE engine P: YD25DDTi engine
A: Single Cab B: King Cab C: Double Cab
JN1: Japan produced vehicle
Dimensions
DestinationEurope
Vehicle type 2-wheel drive model 4-wheel drive model
Wheelbase Long Long
Cab or bed type Single cab King cab Double cab Single cab King cab Double cab
Overall length*1 mm (in)5,020 (197.6)
5,180 (203.9)*15,045 (198.6)
5,180 (203.9)*14,955 (195.1)
5,090 (200.4)*15,020 (197.6)
5,180 (203.9)*15,045 (198.6)
5,180 (203.9)*14,955 (195.1)
5,090 (200.4)*1
Overall width mm (in) 1,690 (66.5)1,690 (66.5)
1,825 (71.9)*21,690 (66.5)
1,825 (71.9)*21,825 (71.9) 1,825 (71.9) 1,825 (71.9)
Overall height mm (in)1,610 (63.4)
1,620 (63.8)*41,610 (63.4)
1,620 (63.8)*4
1,700 (66.9)*21,620 (63.8)
1,630 (64.2)*4
1,710 (67.3)*2
1,810 (71.3)*2, *61,700 (66.9)1,700 (66.9)
1,705 (67.1)*3
1,695 (66.7)*51,715 (67.5)
1,815 (71.5)*6
1,720 (67.7)*3
1,820 (71.7)*6, *3
1,710 (67.3)*5
1,810 (71.3)*6, *5
Wheelbase mm (in) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1) 2,950 (116.1)
TreadFront mm (in) 1,395 (54.9)1,395 (54.9)
1,525 (60.0)*21,395 (54.9)
1,525 (60.0)*21,525 (60.0) 1,525 (60.0) 1,525 (60.0)
Rear mm (in) 1,390 (54.7)1,390 (54.7)
1,505 (59.3)*21,390 (54.7)
1,505 (59.3)*21,505 (59.3) 1,505 (59.3) 1,505 (59.3)
Ground clearance mm (in)180 (7.1)
190 (7.5)*4180 (7.1)
190 (7.5)*4
240 (9.4)*2180 (7.1)
190 (7.5)*4
240 (9.4)*2230 (9.4)230 (9.4)
240 (9.4)*3
225 (8.9)*5230 (9.1)
240 (9.4)*3
225 (8.9)*5
*1: On step bumper equipped models
*2: 4WD appearance models
*3: With optional 255/70R16 tires
*4: With optional 195R15C tires
*5: With optional 255/60R17 tires
*6: Roof rail equipped models
IDENTIFICATION INFORMATION
GI-4006

Terminal Arrangement
GEL314A
SUPER MULTIPLE JUNCTION (SMJ)
EL-4075

FRONT AXLE &
FRONT SUSPENSION
SECTION
FA
MODIFICATION NOTICE:
The grease application capacity on the drive shaft has been changed.
CONTENTS
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 4002Inspection and Adjustment .............................. 4002

FA

Inspection and Adjustment
DRIVE SHAFT (4WD)
Drive shaft joint type
Final drive side TS82F
Wheel side ZF100*
Fixed joint axial end play
limit mm (in)1 (0.04)
Diameter mm (in)
Wheel side (D
1) 29.0 (1.142)
Grease
QualityNissan genuine grease or
equivalent
Capacity g (oz)
Final drive side 95 - 105 (3.35 - 3.70)
Wheel side* 115 - 125 (4.06 - 4.41)
Boot length mm (in)
Final drive side (L
1) 95 - 97 (3.74 - 3.82)
Wheel side (L
2)* 96 - 98 (3.78 - 3.86)
SFA877A
*: ZF100 (Wheel side) joint type has two types of material boot; one is
made of rubber and the other is made of plastic. Do not disas-
semble joint assembly made of plastic boot. If the boot or joint is
damaged, replace the drive shaft assembly.
SERVICE DATA AND SPECIFICATIONS (SDS)
FA-4002