NISSAN PICK-UP 2003 Repair Manual

General Specifications
Applied model2WD 4WD
KA24DE YD25DDTi KA24DE YD25DDTi
Transmission model FS5W71C FS5R30A FS5W71C FS5R30A
Transmission model code number VJ301 VK505 VJ361 VK511
Number of speed5
Shift pattern
Synchromesh typeWarner
Gear ratio
1st 3.592 3.580 3.592 3.580
2nd 2.246 2.077 2.246 2.077
3rd 1.415 1.360 1.415 1.360
4th 1.000 1.000 1.000 1.000
OD 0.821 0.760 0.821 0.760
Reverse 3.657 3.636 3.657 3.636
Number of teeth
Mainshaft Drive 21 22 21 22
1st 33 32 33 32
2nd 28 30 28 30
3rd 26 29 26 29
OD 21 23 21 23
Reverse 36 30 36 30
Countershaft Drive 32 32 32 32
1st 14 13 14 13
2nd 19 21 19 21
3rd 28 31 28 31
OD 39 44 39 44
Reverse 15 12 15 12
Reverse idler gear 21 22 21 22
Oil capacity!(lmp pt) 2.0 (3-1/2) 2.8 (4-7/8) 4.9 (8-5/8) 5.1 (9)
RemarksSub-gearCounter
drive gearInstalled Not installed Installed
Reverse
idler gearInstalled Not installed Installed
Double baulk ring type
synchronizer2nd and 3rd gears
Reverse synchronizer Installed
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-4002

Clearance Between Baulk Ring and Gear
Unit: mm (in)
Transmission model FS5W71C FS5R30A
Standard1st & 2nd
1.20 - 1.60 (0.0473 - 0.0629)1st
1.05 - 1.3 (0.0414 - 0.0511) 3rd & main drive Main drive
Overdrive Overdrive
Reverse 1.10 - 1.55 (0.0433 - 0.0610) Reverse þ0.1 to 0.35 (þ0.0039 to 0.0138)
Wear limit1st & 2nd
0.80 (0.0315)1st
0.7 (0.028) 3rd & main drive Main drive
Overdrive Overdrive
Reverse 0.70 (0.0276) Reverse
2nd & 3rd Baulk Ring
Unit: mm (in)
SMT733C
Transmission model Dimension Standard Wear limit
FS5W71C* & FS5R30AA 0.7 - 0.9 (0.028 - 0.035)
0.2 (0.008)
B 0.6 - 1.1 (0.024 - 0.043)
*: FS5W71C; For Europe
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-4003

ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION
LC
MODIFICATION NOTICE:
lWiring diagrams have been changed for KA24DE models.
CONTENTS
ENGINE ROOM FAN MOTOR ELECTRICAL
CIRCUIT...............................................................4002
Wiring Diagram ................................................ 4002ENGINE ROOM FAN MOTOR............................ 4003
Cooling Fan (Motor driven) .............................. 4003

LC

Wiring Diagram
GLC012A
ENGINE ROOM FAN MOTOR ELECTRICAL CIRCUITKA24DE
LC-4002

Cooling Fan (Motor driven)
SLC507BA
ENGINE ROOM FAN MOTORKA24DE
LC-4003

ELECTRICAL SYSTEM
SECTION
EL
MODIFICATION NOTICE:
lWiring diagrams have been changed.
lHarness layouts have been changed.
lFog lamp system has been changed.
lCD auto-changer has been added.
CONTENTS
PRECAUTIONS................................................... 4002
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER².. 4002
POWER SUPPLY ROUTING............................... 4003
Schematic ........................................................ 4003
Wiring Diagram - POWER -............................. 4004
COMBINATION SWITCH.................................... 4011
HEADLAMP - Headlamp Aiming Control -....... 4012
Wiring Diagram - H/AIM - ................................ 4012
PARKING, LICENSE AND TAIL LAMPS........... 4014
Wiring Diagram - TAIL/L -/LHD Models........... 4014
FRONT FOG LAMP............................................. 4016
Wiring Diagram - F/FOG -/LHD Models .......... 4016
Wiring Diagram - F/FOG -/RHD Models.......... 4017
REAR FOG LAMP............................................... 4018
Wiring Diagram - R/FOG -/LHD Models
without Front Fog Lamp................................... 4018
Wiring Diagram - R/FOG -/RHD Models
without Front Fog Lamp................................... 4019
Wiring Diagram - R/FOG -/LHD Models with
Front Fog Lamp ............................................... 4020
Wiring Diagram - R/FOG -/RHD Models with
Front Fog Lamp ............................................... 4022
INTERIOR ROOM LAMP..................................... 4023
Wiring Diagram - ROOM/L - ............................ 4023
ILLUMINATION.................................................... 4024
Wiring Diagram - ILL -/LHD Models ................ 4024
Wiring Diagram - ILL -/RHD Models................ 4026
METER AND GAUGES....................................... 4028
Wiring Diagram - METER -/Gasoline Engine
with Tachometer .............................................. 4028WARNING LAMPS.............................................. 4030
Schematic/With Tachometer ............................ 4030
Schematic/Without Tachometer ....................... 4031
Wiring Diagram - WARN -/Gasoline Engine
with Tachometer .............................................. 4032
Wiring Diagram - WARN -/Gasoline Engine
without Tachometer ......................................... 4036
Wiring Diagram - WARN -/Diesel Engine with
Tachometer ...................................................... 4040
Wiring Diagram - WARN -/Diesel Engine
without Tachometer ......................................... 4044
WARNING CHIME............................................... 4049
Wiring Diagram - CHIME -/LHD Models.......... 4049
AUDIO.................................................................. 4050
Wiring Diagram - AUDIO -/LHD Models .......... 4050
Wiring Diagram - AUDIO -/RHD Models ......... 4052
NATS (Nissan Anti-Theft System).................... 4054
Wiring Diagram - NATS -/LHD Models............ 4054
Wiring Diagram - NATS -/RHD Models ........... 4055
HARNESS LAYOUT............................................ 4056
Main Harness ................................................... 4056
Engine Room Harness..................................... 4062
Engine Control Harness................................... 4068
Chassis Harness and Tail Harness ................. 4071
Room Lamp Harness/LHD Models .................. 4072
Room Lamp Harness/RHD Models ................. 4073
WIRING DIAGRAM CODES (CELL CODES)..... 4074
SUPER MULTIPLE JUNCTION (SMJ)............... 4075
Terminal Arrangement ..................................... 4075

EL

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along
with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal
collision. The SRS composition which is available to NISSAN MODEL D22 is as follows (The composition
varies according to the destination and optional equipment.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
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 can be identified by yellow harness connector.
PRECAUTIONS
EL-4002

Schematic
GEL661A
POWER SUPPLY ROUTING
EL-4003

Wiring Diagram Ð POWER Ð
BATTERY POWER SUPPLY Ð IGNITION SWITCH IN ANY POSITION
GEL359A
POWER SUPPLY ROUTING
EL-4004

GEL662A
POWER SUPPLY ROUTING
Wiring Diagram Ð POWER Ð (Cont'd)
EL-4005