general NISSAN TERRANO 2002 Service User Guide

Terminal
No.Item ConditionJudgement
standard
28Power source
(Back-up)
or
When turning ignition switch to
ªOFFº.Battery voltage
When turning ignition switch to ªONº. Battery voltage
29Revolution sensor
(Measure in AC rang)
When vehicle cruises at 30 km/h (19
MPH).1V or more
Voltage rises gradually in
response to vehicle
speed.
When vehicle parks. 0V
34Park/neutral ªDº position
switch
When setting selector lever to ªDº
position.Battery voltage
When setting selector lever to other
positions.Approximately 0V
35Park/neutral ªRº position
switchWhen setting selector lever to ªRº
position.Battery voltage
When setting selector lever to other
positions.Approximately 0V
36Park/neutral ªNº or ªPº
position switchWhen setting selector lever to ªNº or
ªPº position.Battery voltage
When setting selector lever to other
positions.Approximately 0V
39 Engine speed signal
When engine runs at idle speed. 0.8V
When engine runs at 2,000 rpm. Approximately 2.2V
40 Vehicle speed sensor
When moving vehicle at 2 to 3 km/h
(1 to 2 MPH) for1m(3ft)ormore.Voltage varies between
less than 1V and more
than 4.5V
42Throttle (accelerator)
position sensor
(Power source)
Ð 4.5 - 5.5V
42 Ground Ð Ð
43 SPORT indicator lamp
When setting A/T mode switch in
ªSPORTº position.Approximately 0V
When setting A/T mode switch in
other position.Battery voltage
44A/T mode switch
ªSPORTºWhen setting A/T mode switch in
ªSPORTº position.Battery voltage
When setting A/T mode switch in
other position.Approximately 0V
47A/T fluid temperature
sensorWhen ATF temperature is 20ÉC
(68ÉF).Approximately 1.5V
When ATF temperature is 80ÉC
(176ÉF).Approximately 0.5V
TROUBLE DIAGNOSIS Ð General Description
TCM Terminals and Reference Value (Cont'd)
AT-48

General Specifications
Applied model TD27ETi engine
Automatic transmission model RE4R01A
Transmission model code number 4GX07
Stall torque ratio 2.0 : 1
Transmission gear ratio
1st 2.785
2nd 1.545
Top 1.000
OD 0.694
Reverse 2.272
Recommended fluidGenuine Nissan ATF or equiva-
lent*1
Fluid capacity
(Imp qt)8.5 (7-1/2)
*1: Refer to MA section (ªFluids and Lubricantsº, ªRECOMMENDED
FLUIDS AND LUBRICANTSº).
Specifications and Adjustment
SHIFT SCHEDULE
Vehicle speed when shifting gears
Throttle positionVehicle speed km/h (MPH)
D1,D2D2,D3D3,D4D4,D3D3,D2D2,D112,11
Full throttle32-36
(20 - 23)66-74
(41 - 46)108 - 118
(68 - 74)103 - 113
(64 - 71)61-69
(38 - 43)27-31
(17 - 19)43-47
(27 - 29)
Half throttle30-34
(19 - 21)62-68
(39 - 43)82-92
(51 - 58)67-75
(42 - 47)26-32
(16 - 20)7-11
(4-7)43-47
(27 - 29)
Vehicle speed when performing and
releasing lock-up
Throttle
positionOverdrive con-
trol switch
[Shift position]Vehicle speed km/h (MPH)
Lock-up
ªONºLock-up
ªOFFº
Full throttleON
[D
4]121 - 129
(76 - 81)116 - 124
(73 - 78)
OFF
[D
3]74-82
(46 - 51)74-82
(46 - 51)
Half throttleON
[D
4]104 - 112
(65 - 70)93 - 101
(58 - 63)
OFF
[D
3]74-82
(46 - 51)74-82
(46 - 51)
STALL REVOLUTION
Stall revolution rpm 2,450 - 2,700
LINE PRESSURE
Engine speed
rpmLine pressure kPa (bar, kg/cm2, psi)
D, 2 and 1 positions R position
Idle422 - 461
(4.22 - 4.61,
4.3 - 4.7,
61 - 67)589 - 627
(5.89 - 6.27,
6.01 - 6.40,
85.4 - 90.9)
Stall1,020 - 1,098
(10.20 - 10.98,
10.4 - 11.2,
148 - 159)1,422 - 1,500
(14.22 - 15.00,
14.5 - 15.3,
206 - 218)
SERVICE DATA AND SPECIFICATIONS (SDS)
AT-196

Diagnostic Procedure 2 (Warning lamp stays on
when ignition switch is turned ON)............................69
Diagnostic Procedure 3 (ABS actuator solenoid
valve and solenoid valve relay) .................................71
Diagnostic Procedure 4 (Wheel sensor or rotor) ......73
Diagnostic Procedure 5 (Motor Relay or motor) .......75
Diagnostic Procedure 7 (Low voltage) ......................77
Diagnostic Procedure 8 (G sensor) ...........................78
Diagnostic Procedure 9 (Control unit) .......................79
Diagnostic Procedure 10 (Pedal vibration and
noise) .........................................................................80Diagnostic Procedure 11 (Long stopping
distance) ....................................................................80
Diagnostic Procedure 12 (Unexpected pedal
action) ........................................................................81
Diagnostic Procedure 13 ...........................................82
Diagnostic Procedure 14 ...........................................82
Electrical Components Inspection .............................83
SERVICE DATA AND SPECIFICATIONS (SDS)..........84
General Specifications ...............................................84
Inspection and Adjustment ........................................85
CONTENTS(Cont'd)
BR-2

General Specifications
Applied modelWagon (LWB) Hard Top (SWB) Wagon (LWB) Hard Top (SWB)
Without ABS With ABS
Front brakeLD28VA
Brake model
Cylinder bore diameter
mm (in)43 (1.69)
Pad mm (in)
length x width x thickness144.85 x 48.5 x 15.5
(5.70 x 1.90 x 0.61)
Rotor outer mm (in)
diameter x thickness27.7 x 26.1
(10.91 x 1.02)
Drum brakeLT28
Brake model
Cylinder bore diameter
mm (in)23.8 (0.94) 22.0 (0.87) 20.6 (0.81)
Lining mm (in)
Length x width x thickness
Leading 111 x 55 x 8.95 (4.37 x 2.17 x 0.35)
Trailing 114 x 55 x 3.95 (4.49 x 2.17 x 0.16)
Drum inner mm (in)
Diameter280 (11.02)
Master cylinder mm (in)
Cylinder bore diameter 25.4 (1.0)
Control valve
Valve model Load Sensing Valve Ð
Split point [kPa (bar, kg/cm
2, psi)] x
reducing ratioVariable x 0.23 Variable x 0.15 Ð
Brake booster
Booster model Lucas LSC 115 (8²+9²)
Diaphragm diameter
mm (in)Primary: 203.2 (8)
Secondary: 228.6 (9)
Specified brake fluidDOT 4
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-84

CLUTCH
SECTION
CL
CONTENTS
PRECAUTIONS AND PREPARATION............................2
Precautions ..................................................................2
Preparation ..................................................................2
CLUTCH SYSTEM...........................................................3
Clutch Pedal ................................................................4
INSPECTION AND ADJUSTMENT.................................5
Adjusting Clutch Pedal ................................................5
Bleeding Procedure .....................................................6
CLUTCH MASTER CYLINDER.......................................7
HYDRAULIC CLUTCH CONTROL.................................8Clutch Master Cylinder ................................................8
Clutch Operating Cylinder ...........................................8
CLUTCH RELEASE MECHANISM.................................9
CLUTCH DISC AND CLUTCH COVER........................ 11
Clutch Disc................................................................. 11
Clutch Cover and Flywheel .......................................12
SERVICE DATA AND SPECIFICATIONS (SDS)..........14
General Specifications ...............................................14
Inspection and Adjustment ........................................14

General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch control Hydraulic
CLUTCH MASTER CYLINDER
Inner diameter mm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in)
LHD 17.46 (11/16)
RHD 19.05 (3/4)
CLUTCH DISC
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Model 250 260
Facing size
(Outer dia. x inner dia. x
thickness)250 x 160 x 3.7
(9.84 x 6.30 x 0.1457)
Thickness of disc assembly
under load7.9 - 8.3 (0.311 - 0.327)
Under a load of 5,884 N
(600 kg, 1,323 lb)
CLUTCH COVER
Engine TD27Ti ZD30DDTi
Model 250 260
Full load N (kg, lb) 5,884 (600, 1,323) 6,760 (689, 1,520)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Handle LHD RHD
Pedal height*227 - 237
(8.94 - 9.33)210 - 220
(8.27 - 8.66)
Pedal stroke 155 - 160 (6.10 - 6.30)
Pedal free play
(Backlash at clevis)1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of melt sheet to surface of pedal
pad
CLUTCH DISC
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Disc model 250 260
Rear limit of facing
surface to rivet head0.3 (0.012)
Runout limit of facing 1 (0.04)
Distance of runout
check point (from the
hub center)120 (4.72)
Maximum of spline
backlash of spline (at
outer edge of disc)1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Cover model 250 260
Diaphragm spring height 36.5 - 38.5 (1.437 - 1.516)
Uneven limit of dia-
phragm spring toe height
ªAº0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14

ENGINE CONTROL SYSTEM
SECTION
EC
CONTENTS
ZD30DDTi
TROUBLE DIAGNOSIS - INDEX....................................7
Alphabetical & Numerical Index for DTC ....................7
PRECAUTIONS...............................................................9
Precautions ..................................................................9
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM.........................................................................12
Engine Control Component Parts Location ...............12
Circuit Diagram ..........................................................16
System Diagram ........................................................17
Vacuum Hose Drawing ..............................................18
System Chart .............................................................19
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION...............................................20
Fuel Injection Control System ...................................20
Fuel Injection Timing Control System........................22
Air Conditioning Cut Control ......................................22
Fuel Cut Control (at no load & high engine
speed) ........................................................................22
Crankcase Ventilation System ...................................23
BASIC SERVICE PROCEDURE...................................24
Injection Tube and Injection Nozzle ..........................24
Electronic Control Fuel Injection Pump .....................27
Air Bleeding ...............................................................32
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION...............................................................33
DTC and MI Detection Logic .....................................33
Diagnostic Trouble Code (DTC) ................................33
Malfunction Indicator (MI) ..........................................34
CONSULT-II ...............................................................39
TROUBLE DIAGNOSIS - INTRODUCTION..................46
Introduction ................................................................46
Work Flow ..................................................................48
TROUBLE DIAGNOSIS - BASIC INSPECTION...........50
Basic Inspection.........................................................50
TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION...............................................................56
Symptom Matrix Chart ...............................................56CONSULT-II Reference Value in Data Monitor
Mode ..........................................................................66
Major Sensor Reference Graph in Data Monitor
Mode ..........................................................................68
ECM Terminals and Reference Value .......................69
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT.......................................................................78
Description .................................................................78
Diagnostic Procedure ................................................78
TROUBLE DIAGNOSIS FOR POWER SUPPLY..........79
Main Power Supply and Ground Circuit ....................79
DTC 0102 MASS AIR FLOW SEN................................88
Component Description .............................................88
CONSULT-II Reference Value in Data Monitor
Mode ..........................................................................88
ECM Terminals and Reference Value .......................88
On Board Diagnosis Logic.........................................88
DTC Confirmation Procedure ....................................89
Wiring Diagram ..........................................................90
Diagnostic Procedure ................................................92
DTC 0103 COOLANT TEMP SEN................................95
Description .................................................................95
On Board Diagnosis Logic.........................................95
DTC Confirmation Procedure ....................................95
Wiring Diagram ..........................................................96
Diagnostic Procedure ................................................97
DTC 0104 VEHICLE SPEED SEN................................99
Description .................................................................99
ECM Terminals and Reference Value .......................99
On Board Diagnosis Logic.........................................99
Overall Function Check ...........................................100
Wiring Diagram ........................................................101
Diagnostic Procedure ..............................................103
DTC 0203 ACCEL POS SW (F/C)..............................104
Description ...............................................................104
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................104
ECM Terminals and Reference Value .....................104
On Board Diagnosis Logic.......................................104

CONSULT-II Reference Value in Data Monitor
Mode ........................................................................281
ECM Terminals and Reference Value .....................282
Wiring Diagram ........................................................283
Diagnostic Procedure ..............................................284
AIR CONDITIONER CONTROL..................................289
Wiring Diagram ........................................................289
MI (MIL) & DATA LINK CONNECTORS.....................291
Wiring Diagram ........................................................291
SERVICE DATA AND SPECIFICATIONS (SDS)........292
General Specifications .............................................292
Injection Pump Numbers .........................................292
Injection Nozzle .......................................................292
Engine Coolant Temperature Sensor ......................292
Crankshaft Position Sensor (TDC) ..........................292
Glow Plug ................................................................292
Accelerator Position Sensor ....................................292
EGR Volume Control Valve .....................................292
TD27Ti
TROUBLE DIAGNOSIS - INDEX................................293
Alphabetical & Numerical Index for DTC ................293
PRECAUTIONS AND PREPARATION........................295
Special Service Tools ..............................................295
Engine Fuel & Emission Control System ................297
Precautions ..............................................................298
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM.......................................................................300
Engine Control Component Parts Location .............300
Circuit Diagram ........................................................302
System Diagram ......................................................303
Vacuum Hose Drawing ............................................304
System Chart ...........................................................305
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION.............................................306
Fuel Injection System ..............................................306
Fuel Injection Timing System ..................................309
Air Conditioning Cut Control .................................... 311
Fuel Cut Control (at high engine speed) ................. 311
Glow Control ............................................................ 311
CRANKCASE VENTILATION SYSTEM......................312
Description ...............................................................312
Blow-by Control Valve .............................................312
Ventilation Hose .......................................................312
INJECTION NOZZLE...................................................313
Removal and Installation .........................................313
Disassembly (No.2-4nozzle) ...............................313
Inspection (No.2-4nozzle) ...................................314
Cleaning (No.2-4nozzle) .....................................314
Assembly (No.2-4nozzle) ....................................315
Test and Adjustment ................................................316
ELECTRONIC FUEL INJECTION PUMP....................318Removal ...................................................................318
Installation ................................................................319
Disassembly and Assembly .....................................320
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION.............................................................321
DTC and MI Detection Logic ...................................321
Diagnostic Trouble Code (DTC) ..............................321
Malfunction Indicator (MI) ........................................322
CONSULT-II .............................................................327
TROUBLE DIAGNOSES.............................................334
Introduction ..............................................................334
Diagnostic Worksheet ..............................................335
Work Flow ................................................................336
Description for Work Flow .......................................337
Basic Inspection.......................................................338
Symptom Matrix Chart .............................................340
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................343
Major Sensor Reference Graph in Data Monitor
Mode ........................................................................345
ECM Terminals and Reference Value .....................346
TROUBLE DIAGNOSIS FOR POWER SUPPLY........352
Wiring Diagram ........................................................352
Diagnostic Procedure ..............................................353
DTC P0100 MASS AIR FLOW SEN...........................356
Component Description ...........................................356
On Board Diagnosis Logic.......................................356
DTC Confirmation Procedure ..................................356
Wiring Diagram ........................................................357
Diagnostic Procedure ..............................................359
Component Inspection .............................................360
DTC P0115 COOLANT TEMP SEN............................361
Component Description ...........................................361
On Board Diagnosis Logic.......................................361
DTC Confirmation Procedure ..................................361
Wiring Diagram ........................................................362
Diagnostic Procedure ..............................................363
Component Inspection .............................................364
DTC P0120 ACCEL POS SENSOR............................365
Component Description ...........................................365
On Board Diagnosis Logic.......................................365
DTC Confirmation Procedure A (For General
Plausibility) ...............................................................365
DTC Confirmation Procedure B (For Accelerator
Sticking) ...................................................................366
Wiring Diagram ........................................................367
Diagnostic Procedure ..............................................368
Component Inspection .............................................371
DTC P0180 FUEL TEMP SENSOR............................372
Component Description ...........................................372
On Board Diagnosis Logic.......................................372
DTC Confirmation Procedure ..................................372
CONTENTS(Cont'd)
EC-4

Diagnostic Procedure ..............................................443
DTC PD1603 ECM 12, DTC P1607 ECM2.................444
Description ...............................................................444
On Board Diagnosis Logic.......................................444
DTC Confirmation Procedure ..................................444
Diagnostic Procedure ..............................................445
DTC P1620 ECM RLY.................................................446
On Board Diagnosis Logic.......................................446
DTC Confirmation Procedure ..................................446
Wiring Diagram ........................................................447
Diagnostic Procedure ..............................................448START SIGNAL...........................................................449
Wiring Diagram ........................................................449
Diagnostic Procedure ..............................................450
OIL PRESSURE SWITCH...........................................451
Wiring Diagram ........................................................451
MI & DATA LINK CONNECTORS...............................452
Wiring Diagram ........................................................452
SERVICE DATA AND SPECIFICATIONS (SDS)........453
General Specifications .............................................453
Injection Nozzle .......................................................453
Inspection and Adjustment ......................................453
CONTENTS(Cont'd)
EC-6

Introduction
The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control system,
etc. The ECM accepts input signals from sensors and instantly
drives electronic control fuel injection pump. It is essential that both
input and output signals are proper and stable. At the same time,
it is important that there are no problems such as vacuum leaks,
or other problems with the engine.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT-II or a circuit tester connected should be per-
formed. Follow the ªWork Flowº, EC-48.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus-
tomer can supply good information about such problems, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A ªDiagnostic Worksheetº like the
example on next page should be used.
Start your diagnosis by looking for ªconventionalº problems first.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.
DIAGNOSTIC WORKSHEET
There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can make
troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
SEF858S
SEF233G
SEF234G
SEF907L
TROUBLE DIAGNOSIS Ð INTRODUCTIONZD30DDTi
EC-46