service NISSAN PICK-UP 2003 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
FOREWORD
This supplement contains informa-
tion concerning necessary service
procedures and relevant data for the
model D22 series.
All information, illustrations and spe-
ci®cations contained in this supple-
ment are based on the latest product
information available at the time of
publication. If your NISSAN model
differs from the speci®cations contain-
ed in this supplement, consult your
NISSAN distributor for information.
The right is reserved to make chan-
ges in speci®cations and methods at
any time without notice.
Edition: March 2003
Printing: April 2003 (01)
Publication No.: SM3E-D22DE0E
Reference No.: 7711346915
NISSAN EUROPE S.A.S.
2003 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

FOREWORD
This manual contains maintenance and repair procedures for NISSAN
PICKUP, model D22 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 Section
Paris, France

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 system composition which is available to NISSAN MODEL D22 is as follows (The com-
position 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.
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. For removal of Spiral Cable and
Air Bag Module, see the RS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral Cable and wiring harnesses (except ªSEAT BELT PRE-TENSIONERº) cov-
ered with yellow insulation either just before the harness connectors or for the complete harness
are related to the SRS.
PRECAUTIONS AND PREPARATION
EC-4002

7 CHECK IACV-FICD SOLENOID VALVE
Disconnect IACV-FICD solenoid valve harness connector.
SEF610YCheck for clicking sound when applying 12V direct current to terminals.
Check plunger for seizing or sticking.
Check for broken spring.
SEC953D
OK or NG
OKcGO TO 8.
NGcReplace IACV-FICD solenoid valve.
8 CHECK AMBIENT AIR TEMPERATURE SWITCH
Refer to HA section, ªTROUBLE DIAGNOSISº.
OK or NG
OKcGO TO 9.
NGcReplace ambient air temperature switch.
9 CHECK INTERMITTENT INCIDENT
Perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-192 in Service Manual (Pub. No. SM1E-1D22FG1).
cINSPECTION END
IACV-FICD SOLENOID VALVEKA24DE (EURO OBD)
Diagnostic Procedure (Cont'd)
EC-4012

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

A
A/C relay ............................................... HA-4025
A/C service data specification .... HA-4015, 4026
A/C trouble diagnoses (auto A/C) ......... HA-4017
A/C trouble diagnoses (manual A/C) .... HA-4005
A/C, A - Wiring diagram ........................ HA-4018
A/C, M - Wiring diagram ... HA-4006, 4009, 4012
C
CHIME - Wiring diagram ....................... EL-4049
Combination meter ................................ EL-4028
Cooling fan control system .................... LC-4002
Cooling fan control ................................ EC-4014
D
Door trim ................................................ BT-4006
E
Exterior .................................................. BT-4003
F
F/FOG - Wiring diagram ........................ EL-4016
FICD - Wiring diagram .......................... EC-4005
Fog lamp, front ...................................... EL-4016
Fog lamp, rear ....................................... EL-4018
Front fog lamp ....................................... EL-4016
G
Gauges .................................................. EL-4028
H
H/AIM - Wiring diagram ......................... EL-4012
Harness layout ....................................... EL-4056
Headlamp aiming control ....................... EL-4012
I
ILL - Wiring diagram .............................. EL-4024
Illumination ............................................. EL-4024
Interior lamp ........................................... EL-4023
L
LOAD - Wiring diagram ........................ EC-4003LSV (Load sensing valve) ..................... BR-4002
License lamp ......................................... EL-4014
M
METER - Wiring diagram ...................... EL-4028
Meter ...................................................... EL-4028
Model variation ....................................... GI-4004
N
NATS (Nissan Anti-theft System) .......... EL-4054
NATS - Wiring diagram ......................... EL-4054
P
POWER - Wiring diagram ..................... EL-4004
Parking lamp .......................................... EL-4014
Power supply routing ............................. EL-4003
R
R/FOG - Wiring diagram ............. EL-4018, 4020
ROOM/L - Wiring diagram ..................... EL-4023
Rear bumper ......................................... BT-4002
Rear fog lamp ........................................ EL-4018
Refrigerant connection precaution ........ HA-4003
Refrigeration cycle ................................ HA-4004
S
SMJ (super multiple junction) ................ EL-4075
Steering wheel and column ................... ST-4002
Supplemental restraint system - Wiring
diagram ............................................. RS-4002
T
TAIL/L - Wiring diagram ........................ EL-4014
Tail lamp ................................................ EL-4014
V
Vehicle identification number ................. GI-4006
W
WARN - Wiring diagram ........................ EL-4032
Warning chime ....................................... EL-4049
Warning lamps ....................................... EL-4030
Wiring diagram (cell code) list ............... EL-4074
ALPHABETICAL INDEX
IDX-4002

HEATER &
AIR CONDITIONER
SECTION
HA
MODIFICATION NOTICE:
lCompressor has been changed. (KA engine models)
lRefrigerant amount has been changed.
lFusible plug attached to liquid tank has been deleted.
lPressure relief valve has been added to compressor.
lWiring diagrams have been changed.
lThermo control amp. of auto A/C has been abolished and trouble diagnosis of magnet clutch has been
changed.
lPressure relief valve has been added to compressor. (KA24DE and YD25DDT engine models)
lRefrigerant amount has been changed. (YD25DDT engine models) Refer to SDS.
CONTENTS
MANUAL
PRECAUTIONS AND PREPARATION............... 4002
Supplemental Restraint System (SRS) ``AIR
BAG'' and ``SEAT BELT PRE-TENSIONER'' .. 4002
Precautions for Refrigerant Connection .......... 4003
DESCRIPTION..................................................... 4004
Refrigeration Cycle .......................................... 4004
TROUBLE DIAGNOSES..................................... 4005
Circuit Diagram - A/C, M - ............................... 4005
Wiring Diagram - A/C, M -/LHD Models with
KA, YD and ZD Engines .................................. 4006
Wiring Diagram - A/C, M -/RHD Models with
KA Engine ........................................................ 4009
Wiring Diagram - A/C, M -/RHD Models with
VG, YD and ZD Engines ................................. 4012
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 4015General Specifications ..................................... 4015
Inspection and Adjustment .............................. 4015
AUTO
PRECAUTIONS AND PREPARATION............... 4016
Supplemental Restraint System (SRS) ``AIR
BAG'' and ``SEAT BELT PRE-TENSIONER'' .. 4016
TROUBLE DIAGNOSES..................................... 4017
Circuit Diagram - A/C, A -................................ 4017
Wiring Diagram - A/C, A -................................ 4018
Magnet Clutch .................................................. 4023
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 4026
General Specifications ..................................... 4026
Inspection and Adjustment .............................. 4026

HA

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 AND PREPARATIONMANUAL
HA-4002

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)MANUAL
HA-4015

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 AND PREPARATIONAUTO
HA-4016