unit NISSAN TERRANO 2002 Service Repair Manual

Clutch pedal .............................................CL-3, 4, 5
Clutch release mechanism ...............................CL-9
Coil spring (rear) ......................................RA-14, 16
Collision diagnosis..........................................RS-57
Combination lamp, front, removal and
installation .....................................................BT-6
Combination lamp, rear, removal and
installation .....................................................BT-8
Combination meter (needle type) ...................EL-70
Combination meter removal and instal-
lation - See Instrument panel......................BT-16
Combination switch...................................EL-23, 24
Component Location (manual A/C) ..................HA-7
Compression pressure ...................................EM-10
Compressor clutch removal and
installation ...................................................HA-24
Compressor mounting ....................................HA-21
Connecting rod...............................................EM-73
Connecting rod bearing clearance.................EM-77
Connecting rod bushing clearance ................EM-73
Console box - See Instrument panel ..............BT-16
CONSULT for ABS .........................................BR-58
CONSULT for engine .............................EC-39, 327
CONSULT-II general information.....................GI-26
Control lever (M/T) .........................................MT-13
Control lever (Transfer) .....................................TF-8
Control sleeve position sensor .....................EC-414
Control valve (A/T) ........................................AT-113
COOL/F - Wiring diagram ............................EC-112
Coolant mixture ratio ...................MA-17, 20, 22, 31
Coolant replacement ...............MA-5, 17, 20, 22, 31
Cooling circuit (engine)...............................LC-9, 27
Cooling fan ...............................................LC-15, 33
Cooling fan control .......................................EC-109
Cooling fan relay ..........................................EC-426
Corrosion protection..........................................BT-5
Counter gear (M/T) .........................................MT-11
Counter gear (Transfer) ............................TF-10, 20
Cowl top ..........................................................BT-21
Cowl top cover ................................................BT-21
Crankcase emission control system -
See positive crankcase ventilation .....EC-23, 312
Crankcase ventilation system - See
Positive crankcase ventilation ............EC-23, 312
Crankshaft ......................................................EM-76
Crankshaft position sensor (TDC) .......EC-145, 385
Cylinder block ................................................EM-66
Cylinder head .................................................EM-52
D
Data link connector ................................EC-39, 327
Daytime light system ..........................EL-29, 30, 31
DEF - Wiring diagram ...................................EL-107
Defroster door control rod adjustment ...........HA-62
Diagnosis sensor unit .....................................RS-11
Diagnostic trouble code (DTC) for OBD
system ................................................EC-33, 321
Differential carrier assembly ....................PD-29, 53Differential carrier disassembly..........PD-18, 38, 40
Differential gear oil replacement .......MA-36, 38, 39
Dimensions ......................................................GI-31
D/LOCK - Wiring diagram .............................EL-140
Door glass .......................................................BT-10
Door lock .........................................................BT-10
Door mirror ......................................................BT-48
Door trim .........................................................BT-19
Door, front .......................................................BT-10
Door, rear ........................................................BT-12
Drive belt inspection ................................MA-20, 28
Drive chain (Transfer) .....................................TF-10
Drive pinion diff. inspection ......................PD-20, 42
Drive pinion height ...................................PD-21, 49
Drive plate runout ..........................................EM-94
Drive shaft ........................................................MA-5
Drive shaft (front)..................................FA-4, 12, 22
Driver air bag..................................................RS-14
Dropping resistor (A/T)....................................AT-86
Dual pressure switch..................................HA-9, 61
E
ECM input/output signal .........................EC-69, 346
ECM relay ......................................EC-80, 209, 353
ECMRLY - Wiring diagram ...........................EC-210
ECTS - Wiring diagram ..................................EC-96
EGR control (EGRC) - solenoid valve .........EC-431
EGR control valve ........................................EC-439
EGR volume control valve ...........................EC-222
EGVC/V - Wiring diagram ............................EC-225
Electrical unit ................................................Foldout
Electronic fuel injection pump ......................EC-318
Engine compartment .......................................BT-50
Engine control circuit diagram ...............EC-16, 302
Engine control component parts
location ...............................................EC-12, 300
Engine control module (ECM) ......EC-69, 121, 200,
202, 213, 346,
407, 444
Engine control system diagram and
chart....................................................EC-17, 303
Engine coolant temperature sensor
(ECTS)................................................EC-95, 361
Engine oil filter replacement..........MA-5, 20, 21, 30
Engine oil precautions .......................................GI-6
Engine oil replacement ......................MA-20, 21, 29
Engine removal ..............................................EM-63
Engine room - See Engine
compartment ...............................................BT-50
Engine serial number ......................................GI-30
Exhaust manifold ...........................................EM-18
Exhaust system ..........................................FE-4, 10
Exhaust system inspection ............................MA-36
Extension tube diff. ..................................PD-19, 28
Exterior ............................................................BT-21
Exterior lamp.............................................EL-45, 60
ALPHABETICAL INDEX
IDX-3

INT/V - Wiring diagram ................................EC-274
Intake air control valve control solenoid
valve .........................................................EC-273
Intake Air Volume .........................................EC-143
Intake door control linkage adjustment ..........HA-63
Intake manifold...............................................EM-12
Interior .............................................................BT-18
Interior lamp ..............................................EL-61, 66
ISO 15031-2 Terminology................................GI-35
K
Knuckle spindle ...............................................FA-20
L
License lamp ...................................................EL-45
Limited slip diff. adjustment............................PD-45
Limited slip diff. assembly ..............................PD-47
Limited slip diff. disassembly ...................PD-43, 44
Limited slip diff. inspection .............................PD-44
Line pressure solenoid valve ..........................AT-84
Line pressure test (A/T) ..........................AT-30, 196
Liquid gasket application .................................EM-3
Location of electrical units ............EL-241, 242, 244
Lock, door ...........................................BT-10, 12, 14
Low and reverse brake .................................AT-161
LSV (Load sensing valve) ..............................BR-10
Lubricants.......................................................MA-17
Lubrication circuit (engine) .........................LC-3, 20
Lubrication oil A/C ....................................HA-22, 64
Lubrication-locks, hinges and hood
latches ..................................................MA-36, 45
Luggage compartment trim .............................BT-18
M
MAFS - Wiring diagram..................................EC-90
MAIN - Wiring diagram...................................EC-80
Main drive gear (M/T) .....................................MT-11
Main gear (Transfer) .................................TF-10, 21
Mainshaft (M/T) ..............................................MT-11
Mainshaft (Transfer)..................................TF-10, 17
Maintenance ...........MA-5, 8, 11, 14, 20, 36, 48, 49
MAJOR OVERHALL ......................................AT-119
Major overhaul (Transfer) .................................TF-9
Malfunction indicator (MI).......................EC-34, 322
Manifold tightening torque (intake &
exhaust) ...............................................MA-20, 28
Manual transmission number ..........................GI-30
Manual transmission oil replacement ......MA-36, 37
Map lamp ........................................................EL-66
Mass air flow sensor (MAFS) ................EC-88, 356
Master cylinder (brake) ..................................BR-16
Meter .........................................................EL-70, 71
METER - Wiring diagram................................EL-72
MIL/DL - Wiring diagram ..............................EC-291MIRROR - Wiring diagram............................EL-131
Mirror, door......................................................BT-48
Model variation ................................................GI-28
Molding - See Exterior ....................................BT-21
M/T major overhaul ........................................MT-10
M/T removal and installation ........................MT-7, 8
Mud guard - See Exterior ...............................BT-21
MULTI - Wiring diagram................................EL-169
Multi-remote control system .........EL-168, 177, 179
Multiport fuel injection precautions ....................GI-5
N
NATS (Nissan anti-theft
system) .....................EL-186, 187, 188, 195, 208
NATS - Wiring diagram .................................EL-189
NATS V2.0 precautions (For Europe) ...............GI-4
Needle lift sensor .........................................EC-427
NVH troubleshooting (EM) ...............................EM-8
O
Oil change (capacity) ............MA-21, 29, 37, 38, 39
Oil change (interval) ..................................MA-5, 35
Oil cooler (engine) ............................................LC-8
Oil pan (engine) .............................................EM-22
Oil pump (A/T)...............................................AT-134
Oil seal replacement (engine)........................EM-50
Oil seal replacement (front final drive
4WD)...........................................................PD-10
OILPSW - Wiring diagram............................EC-451
On board diagnostic system ..................EC-33, 321
Overdrive control switch..................................AT-95
Overheat .......................................................EC-109
Overrun clutch solenoid valve ..................AT-69, 70
Oversize piston ..............................................EM-74
P
Park/Neutral position switch .........................EC-251
Park/neutral position switch (A/T) ...........AT-88, 114
Parking drum brake ........................................BR-35
Parking lamp ...................................................EL-45
PCV (positive crankcase ventilation) .....EC-23, 312
Periodic maintenance ......................................MA-5
Piston pin inspection ......................................EM-71
Piston ring inspection.....................................EM-72
PNP/SW - Wiring diagram ...........................EC-252
POWER - Wiring diagram.................................EL-8
Power door lock ...EL-137, 138, 145, 146, 148, 158
Power steering fluid level...............MA-36, 44, ST-4
Power steering gear .................................ST-12, 22
Power steering hydraulic pressure ...................ST-7
Power steering oil pump ...........................ST-16, 22
Power steering system bleeding.......................ST-5
Power supply routing ....................................EL-6, 8
Power window ...............................................EL-133
ALPHABETICAL INDEX
IDX-5

Liquid Gasket Application Procedure
a. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
b. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
IFor oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
IFor areas except oil pan, be sure liquid gasket diameter is
2.0 to 3.0 mm (0.079 to 0.118 in).
c. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
d. Assembly should be done within 5 minutes after coating.
e. Wait at least 30 minutes before refilling engine oil and engine
coolant.
Special Service Tools*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST25051001*
Oil pressure gauge
NT558
Measuring oil pressure
Maximum measuring range:
2,452 kPa (24.5 bar, 25
kg/cm
2, 356 psi)
ST25052000*
Hose
NT559
Adapting oil pressure gauge
to cylinder block
EG17650301
Radiator cap tester
adapter
NT564
Adapting radiator cap tester
to radiator filler neck and reser-
voir tank cap
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
SEM164F
AEM080
PRECAUTIONS AND PREPARATIONZD
LC-2

OIL PUMP INSPECTION
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)
Body to outer gear radial clearanceq10.114 - 0.200
(0.0045 - 0.0079)
Inner gear to outer gear tip clearanceq
2Less than 0.180 (0.0071)
Body to inner gear axial clearanceq
30.05 - 0.09
(0.0020 - 0.0035)
Body to outer gear axial clearanceq
40.050 - 0.105
(0.0020 - 0.0041)
Inner gear to brazed portion of housing
clearanceq
5
0.045 - 0.091
(0.0018 - 0.0036)
Regulator valve to oil pump cover
clearanceq
6
0.040 - 0.097
(0.0016 - 0.0038)
IIf the tip clearance (q2) exceeds the limit, replace gear set.
IIf body to gear clearances (q
1,q3,q4,q5) exceed the limit,
replace oil pump body assembly.
REGULATOR VALVE INSPECTION
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls smoothly
into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump cover.
4. Check regulator valve to oil pump cover clearance.
Clearance:
q
6: 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump cover.
JLC365B
JLC366B
JLC367B
SLC369B
ENGINE LUBRICATION SYSTEMZD
Oil Pump (Cont'd)
LC-6

Water Pump
CAUTION:
IWhen removing water pump assembly, be careful not to
get coolant on drive belt.
IWater pump cannot be disassembled and should be
replaced as a unit.
IAlways replace with new gasket.
IAfter installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
Refer to MA section.
REMOVAL AND INSTALLATION
1. Drain coolant from radiator and cylinder block.
Refer to MA section (ªChanging Engine Coolantº, ªENGINE
MAINTENANCEº).
2. Remove radiator upper hose.
3. Remove radiator shroud.
4. Remove cooling fan.
5. Remove drive belt. Refer to MA section, ªChecking Drive Beltº.
6. Remove insulator.
7. Remove vacuum pipe.
8. Remove TDC sensor. Refer to EM section, ªTDC sensor
removal and installationº in ªTIMING GEARº.
9. Remove fan coupling with water pump.
10. Install in the reverse order of removal.
JLC373B
ENGINE COOLING SYSTEMZD
LC-11

REMOVAL AND INSTALLATION
1. Remove under cover.
2. Drain engine coolant. Refer to MA section, ªChanging Engine
Coolantº.
3. Remove air cleaner case, air duct and resonator.
4. Remove battery (right side).
5. Remove radiator shroud (lower).
6. Remove radiator shroud (front).
7. Disconnect radiator hose (upper and lower).
8. Disconnect reservoir tank hose.
9. Disconnect A/T oil cooler hose (Only A/T models).
10. Remove radiator.
11. After repairing or replacing radiator, install all removed parts in
reverse order of removal.
Cooling Fan (Crankshaft driven)
DISASSEMBLY AND INSTALLATION
IDo not release the drive belt tension by removing the fan/water
pump pulley.
IFan coupling cannot be disassembled and should be replaced
as a unit. If front markq
Fis present, install fan so that side
markedq
Ffaces the front.
IProper alignment of these components is essential. Improper
alignment will cause them to wobble and may eventually cause
the fan to separate from the water pump causing extensive
damage.
JLC379B
ENGINE COOLING SYSTEMZD
Radiator (Cont'd)
LC-15

Engine Lubrication System
Oil pressure check
Engine speed
rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
Idle speed More than 147 (1.47, 1.5, 21)
2,000 More than 539 (5.39, 5.5, 78)
4,000 More than 736 (7.36, 7.5, 107)
Oil pump
Unit: mm (in)
Body to outer gear radial clearanceq10.114 - 0.200
(0.0045 - 0.0079)
Inner gear to outer gear tip clearanceq
2Less than 0.180 (0.0071)
Body to inner gear axial clearanceq
30.05 - 0.09
(0.0020 - 0.0035)
Body to outer gear axial clearanceq
40.050 - 0.105
(0.0020 - 0.0041)
Inner gear to brazed portion of housing
clearanceq
50.045 - 0.091
(0.0018 - 0.0036)
Regulator valve to oil pump cover clear-
anceq
60.040 - 0.097
(0.0016 - 0.0038)
Engine Cooling System
Radiator
Unit: kPa (bar, kg/cm2, psi)
Cap relief pressure78-98
(0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Leakage test pressure 157 (1.57, 1.6, 23)
Thermostat
Valve opening temperature ÉC (ÉF) 82 (180)
Valve lift mm/ÉC (in/ÉF) More than 10/95 (0.39/203)
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
LC-17

SPECIAL SERVICE TOOLS
Tool number
Tool nameDescription
ST25051001
Oil pressure gauge
NT558
Measuring oil pressure
Maximum measuring range:
2,452 kPa (24.5 bar, 25 kg/cm
2, 356 psi)
ST25052000
Hose
NT559
Adapting oil pressure gauge to cylinder block
EG17650301
Radiator cap tester adapter
NT564
Adapting radiator cap tester to radiator filler
neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
PREPARATIONTD27Ti
LC-18

Water Pump
REMOVAL AND INSTALLATION
Drain coolant from drain plugs on cylinder block and radiator.
Cylinder block drain plug:
(Use proper sealant)
:20-29N×m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)
CAUTION:
IWhen removing water pump assembly, be careful not to
spill coolant on drive belt.
IWater pump cannot be disassembled and should be
replaced as a unit.
IAlways replace with new gasket.
IAfter installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
NLC012
NLC058
ENGINE COOLING SYSTEMTD27Ti
LC-29

INSPECTION
1. Check for badly rusted or corroded body assembly and vane.
2. Check the water pump bushing for excessive end play and
irregular movement.
3. Check fan coupling for rough operation, oil leakage or bent
bimetal.
The water pump and fan coupling cannot be disassembled and
should be replaced as a unit.
SLC979
SLC244
SLC245
ENGINE COOLING SYSTEMTD27Ti
Water Pump (Cont'd)
LC-30