system NISSAN TERRANO 2002 Service Owner's Manual

Introduction
The TCM receives a signal from the vehicle-speed sensor, throttle
(accelerator) position sensor or park/neutral position switch and
provides shift control or lock-up control via solenoid valves.
Input and output signals must always be correct and stable in the
operation of the A/T system. The A/T system must be in good
operating condition and be free of valve seizure, solenoid valve
malfunction, etc.
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. Refer to AT-26.
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 (AT-24) should be used.
Start your diagnosis by looking for ªconventionalº problems first.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.
SAT631IA
SAT632I
SEF234G
TROUBLE DIAGNOSIS Ð Introduction
AT-22

Work Flow
HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR
A good understanding of the malfunction 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.
Make good use of the two sheets provided, ªINFORMATION FROM CUSTOMERº and ªDIAGNOSTIC
WORKSHEETº, to perform the best troubleshooting possible.
CHECK IN
LISTEN TO CUSTOMER COMPLAINTS AND FILL OUT
ªINFORMATION FROM CUSTOMERº, AT-23.
Check for any Service Bulletins.FRefer to FAIL-SAFE Service Notice or Precautions, AT-5.
CHECK A/T FLUID LEVEL AND CONDITION. IF NG, PLACE
CHECK ON THE DIAGNOSTIC WORKSHEET, AT-24.FRefer to A/T Fluid Check, AT-27.
PERFORM STALL TEST AND LINE PRESSURE TEST.FRefer to Stall Test and Line Pressure Test, AT-27, AT-30.
PERFORM ROAD TEST WITH SELF-DIAGNOSIS AND
PLACE CHECKS FOR NG ITEMS ON THE DIAGNOSTIC
WORKSHEET.
NG items including
self-diagnostic item
FFollow ROAD TEST procedure, AT-32.
IFOR SELF-DIAGNOSIS NG ITEMS:
-INSPECT EACH COMPONENT.
-REPAIR/REPLACE.
IPERFORM ROAD TEST AND PLACE CHECKS FOR NG
ITEMS ON THE DIAGNOSTIC WORKSHEET AGAIN.FIRefer to self-diagnosis, AT-14.
IPerform ROAD TEST for all items.
IFOR ALL REMAINING MALFUNCTIONS:
-INSPECT EACH COMPONENT.
-REPAIR/REPLACE.
IPERFORM ROAD TEST AND CONFIRM ALL MALFUNC-
TIONS ARE ELIMINATED.FRefer to
ION BOARD DIAGNOSTIC SYSTEM DESCRIPTION,
AT-14, AT-20.
ITROUBLE DIAGNOSIS FOR SELF-DIAGNOSIS CODE,
AT-50, AT-88.
IDIAGNOSTIC PROCEDURES FOR SYMPTOMS, AT-26,
AT-112.
ISymptom Chart, AT-43.
ERASE SELF-DIAGNOSIS CODE FROM TCM MEMORIES.FRefer to HOW TO ERASE SELF-DIAGNOSIS RESULTS,
AT-19.
PERFORM FINAL CHECK
OK
FRefer to SELF-DIAGNOSIS CONFIRMATION PROCEDURE,
AT-50 - AT-84.
CHECK OUT
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TROUBLE DIAGNOSIS Ð Introduction
AT-26

Road Test
DESCRIPTION
IThe purpose of the test is to determine overall performance of
A/T and analyze causes of problems.
IThe road test consists of the following three parts:
1. Check before engine is started
2. Check at idle
3. Cruise test
IBefore road test, familiarize yourself with all test procedures
and items to check.
IConduct tests on all items until specified symptom is found.
Troubleshoot items which check out No Good after road test.
Refer to ªON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONº
and ªDIAGNOSTIC PROCEDURES FOR SYMPTOMSº, AT-14
- AT-20 and AT-92 - AT-112.
SAT786A
SAT496G
TROUBLE DIAGNOSIS Ð Basic Inspection
AT-32

DIAGNOSTIC PROCEDURE
Perform diagnostic test mode II (self-
diagnostic results) for engine control.
Refer to EC section [ªMalfunction Indicator
Lamp (MIL)º, ªON BOARD DIAGNOSTIC
SYSTEM DESCRIPTIONº].
OK
ENG
Check throttle (accelerator)
position sensor circuit for
engine control. Refer to
EC section [ªTROUBLE
DIAGNOSIS FOR ªTHRTL
(ACCEL) POSI SENº].
CHECK INPUT SIGNAL.
1. Turn ignition switch to ªONº posi-
tion.
(Do not start engine.)
2. Select ªECU INPUT SIGNALSº in
Data Monitor.
3. Read out the value of ªTHRTL
POS SENº.
Voltage:
Fully-closed throttle:
Approximately 0.5V
Fully-open throttle:
Approximately 4V
-----------------------------------------------------------------------------------------------------------------------OR -----------------------------------------------------------------------------------------------------------------------
1. Turn ignition switch to ªONº posi-
tion. (Do not start engine.)
2. Check voltage between TCM ter-
minalsq
32andq42while accelerator
pedal is depressed slowly.
Voltage:
Fully-closed throttle valve:
Approximately 0.4V
Fully-open throttle valve:
Approximately 4V
(Voltage rises gradually in
response to throttle position)
OK
ENG
Check harness for short or
open between ECM and
TCM regarding throttle
(accelerator) position sen-
sor circuit. (Main harness)
CHECK THROTTLE (ACCELERATOR)
POSITION SWITCH.
Refer to ªCHECK THROTTLE (ACCEL-
ERATOR) POSITION SWITCHº, AT-88.
OK
ENG
Repair or replace dam-
aged parts.
Perform ªSELF-DIAGNOSIS CODE CON-
FIRMATION PROCEDUREº, AT-60.
OK
ENG
1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.
INSPECTION END
YAT299
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TROUBLE DIAGNOSIS FOR THROTTLE POSI SEN
Throttle (Accelerator) Position Sensor (Cont'd)
AT-61

5. Engine Cannot Be Started In ªPº and ªNº
Position
SYMPTOM:
IEngine cannot be started with selector lever in ªPº or ªNº
position.
IEngine can be started with selector lever in ªDº, ª2º, ª1º
or ªRº position.
Does ªECU INPUT SIGNALSº in
Data Monitor show damage to park/
neutral position switch circuit?
-----------------------------------------------------------------------------------------------------------------------OR -----------------------------------------------------------------------------------------------------------------------
Does self-diagnosis show damage to
park/neutral position switch circuit?
No
EYe s
Check park/neutral position
switch. Refer to AT-88.
Check for short or open of park/neutral
position switch 2-pin connector. Refer to
AT-88.
OK
ENG
Repair or replace park/
neutral position switch.
Check starting system. Refer to EL sec-
tion (ªSystem Descriptionº, ªSTARTING
SYSTEMº).
OK
ENG
Repair or replace dam-
aged parts.
INSPECTION END
6. In ªPº Position, Vehicle Moves Forward Or
Backward When Pushed
SYMPTOM:
Vehicle moves when it is pushed forward or backward with
selector lever in ªPº position.
Check parking pawl components. Refer to
AT-175.
OK
ENG
Repair or replace dam-
aged parts.
INSPECTION END
SAT146BA
NAT275
SAT133B
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DIAGNOSTIC PROCEDURES FOR SYMPTOMS
AT-97

7. Check foreign materials in oil pan to help determine cause of
malfunction. If the fluid is very dark, smells burned, or contains
foreign particles, the frictional material (clutches, band) may
need replacement. A tacky film that will not wipe clean indicates
varnish build up. Varnish can cause valves, servo, and clutches
to stick and may inhibit pump pressure.
IIf frictional material is detected, replace radiator after
repair of A/T. Refer to LC section (ªRadiatorº, ªENGINE
COOLING SYSTEMº).
8. Remove torque converter clutch solenoid valve and A/T fluid
temperature sensor connectors.
IBe careful not to damage connector.
9. Remove oil strainer.
a. Remove oil strainer from control valve assembly then remove
O-ring from oil strainer.
b. Check oil strainer screen for damage.
10. Remove control valve assembly.
a. Straighten terminal clips to free terminal cords then remove
terminal clips.
SAT171B
NAT228
SAT008B
SAT025B
SAT009B
DISASSEMBLY
Disassembly (Cont'd)
AT-124

A/T Fluid Cooler
REMOVAL AND INSTALLATION
1. Remove front radiator grill. Refer to BT section (ªBODY ENDº).
2. Disconnect fluid hoses from fluid cooler unit.
3. Remove fluid cooler unit.
4. Remove fluid cooler bracket.
5. Remove clips securing fluid hose (cooler unit to radiator) and
loosen hose clamps, then remove the fluid hose.
6. Loosen clamps securing fluid hose (A/T assembly to fluid
cooler), then remove the fluid hose.
7. Remove bolts securing fluid cooler tube bracket.
8. Remove fluid hose with bracket.
Reverse the removal procedure to install the A/T fluid cooler
unit. Refer to the component drawing and specified tightening
torque.
Check A/T fluid level and refill if necessary. Refer to MA sec-
tion (ªCHASSIS AND BODY MAINTENANCEº).
NAT288
NAT289
A/T FLUID COOLER SYSTEM
AT-195

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS AND PREPARATION............................3
Supplement Restraint System (SRS)²AIR BAG²
and²SEAT BELT PRE-TENSIONER².........................3
Precautions ..................................................................3
Preparation ..................................................................4
CHECK AND ADJUSTMENT..........................................5
Checking Brake Fluid Level.........................................5
Checking Brake Line ...................................................5
Changing Brake Fluid ..................................................5
Brake Burnishing Procedure........................................5
BRAKE HYDRAULIC LINE.............................................6
Bleeding Brake System ...............................................8
Removal .......................................................................9
Inspection.....................................................................9
Installation ....................................................................9
LOAD SENSING VALVE...............................................10
Removal and Installation ...........................................10
Removal ..................................................................... 11
Installation .................................................................. 11
Inspection and Adjustment ........................................12
BRAKE PEDAL AND BRACKET..................................14
Removal and Installation ...........................................14
Inspection...................................................................15
Adjustment .................................................................15
MASTER CYLINDER.....................................................16
Removal .....................................................................16
Installation ..................................................................16
BRAKE BOOSTER........................................................17
Removal and Installation ...........................................17
Inspection...................................................................17
Installation ..................................................................18
VACUUM HOSE.............................................................19
Removal and Installation ...........................................19
Inspection...................................................................21
VACUUM PUMP (TD27Ti engine model)....................23
Removal and Installation ...........................................23
Inspection...................................................................23VACUUM PUMP (ZD30DDTi engine model)...............25
Removal and Installation ...........................................25
FRONT DISC BRAKE...................................................26
Pad Replacement ......................................................26
Removal .....................................................................27
Disassembly...............................................................27
Inspection...................................................................27
Assembly ...................................................................28
Inspection...................................................................28
Installation ..................................................................30
REAR DRUM BRAKE...................................................31
Removal .....................................................................32
Shoe Replacement ....................................................33
Inspection...................................................................33
Installation ..................................................................33
PARKING BRAKE CONTROL......................................35
Removal and Installation ...........................................35
Inspection...................................................................35
Adjustment .................................................................35
ANTI-LOCK BRAKE SYSTEM......................................37
Purpose......................................................................37
Operation ...................................................................37
ABS Hydraulic Circuit ................................................37
System Description ....................................................38
Removal and Installation ...........................................42
TROUBLE DIAGNOSES...............................................47
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................47
Component Parts and Harness Connector
Location .....................................................................48
Circuit Diagram for Quick Pinpoint Check.................49
Wiring Diagram - ABS - .............................................50
CONSULT-II ...............................................................58
CONSULT-II Inspection Procedure............................59
Preliminary Check......................................................65
Ground Circuit Check ................................................66
Diagnostic Procedure 1 (Not self-diagnostic item) ....67

Supplement Restraint System (SRS) ªAIR BAGº
and ªSEAT BELT PRE-TENSIONERº
The Supplemental Restraint System ªAir Bagº and ªSeat Belt Pre-tensionerº, used along with a seat belt, help
to reduce the risk or severity or injury to the driver and front passenger in a collision. The Supplemental
Restraint System consists of an air bag module (located in the center of the steering wheel and on the instru-
ment panel on the passenger side, where fitted), seat belt pre-tensioners, a diagnosis sensor unit, warning
lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the
BT sectionof this Service Manual.
WARNING:
ITo 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.
IImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
IDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses (except ªSEAT BELT-TENSIONERº connector) can be iden-
tified with yellow harness connector and with yellow harness protector or yellow insulation tape
before the harness connectors.
Precautions
IUse only ªDOT 4º fluid from a sealed container.
INever reuse drained brake fluid.
IBe careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
ITo clean master cylinder parts, disc brake caliper parts or
wheel cylinder parts, use clean brake fluid.
INever use mineral oils such as Petrol or kerosene. They
will ruin rubber parts of hydraulic system.
IUse flare nut wrench when removing and installing brake
tubes.
IAlways torque brake lines when installing.
IBurnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings,
or if a soft pedal occurs at very low speed. Refer to ªBrake
Burnishing Procedureº, ªCheck and Adjustmentº, BR-5.
WARNING:
IClean brakes with a vacuum dust collector to minimize risk
of health hazard from airborne materials.
IAvoid prolonged and repeated skin contact with brake
fluid.
IWear protective clothing, including impervious gloves.
IWhere there is a risk of eye contact, eye protection should
be worn Ð for example chemical goggles or face shield.
YBR293
PRECAUTIONS AND PREPARATION
BR-3

Checking Brake Fluid Level
ICheck fluid level in reservoir tank. It should be between Max.
and Min. lines on reservoir tank.
IIf fluid level is extremely low, check brake system for leaks.
IWhen brake warning lamp comes on even when parking brake
lever is released, check brake system for leaks.
Checking Brake Line
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
Changing Brake Fluid
CAUTION:
IRefill with new brake fluid ªDOT 4º.
INever reuse drained brake fluid.
IBe careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately. DO
NOT RUB IT OFF.
1. Connect a vinyl tube to each air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
3. Refill until new brake fluid comes out of each air bleeder valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to ªBleeding Brake Systemº, ªBRAKE
HYDRAULIC LINEº, BR-8.
Brake Burnishing Procedure
Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing rotors or drums, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot to bring the vehicle to a com-
plete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
pressure such that vehicle stopping time equals 3 to 5
seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3 for 10 times or more to complete the
burnishing procedure.
SBR849B
SMA732A
SBR992
CHECK AND ADJUSTMENT
BR-5