system NISSAN TERRANO 2002 Service Repair Manual

q1Fuel gauge
q
2O-ring
q
3Fuel tank protectorq
4Fuel tank
q
5Fuel check valveq
6Fuel return tube
q
7Fuel feed tube
NFE027
FUEL SYSTEMTD27Ti
FE-6

WARNING:
When replacing fuel line parts, be sure to observe the following:
IDisplay a ªCAUTION:INFLAMMABLEº sign in workshop.
IBe sure to furnish workshop with a CO
2fire extinguisher service.
IDo not smoke while servicing fuel system. Keep open flames and sparks away from work area.
IBe sure to disconnect battery ground cable before conducting operations.
IPour drained fuel into an explosion-proof container, then ensure container lid is installed securely.
CAUTION:
IFor ECM models, release fuel pressure from fuel line. Refer to EC section (ªFuel Pressure Releaseº,
ªBASIC SERVICE PROCEDUREº).
IDo not disconnect any fuel line unless absolutely necessary.
IPlug hose and pipe openings to prevent entry of dust or dirt.
IAlways replace top lid seal and hose clamps with new ones.
IDo not kink or twist hoses and tubes during installation.
IDo not tighten hose clamps excessively because this could cause damage to the hose.
IEnsure fuel check valve is installed in the correct orientation.
IRefer to EC section (ªFUEL CHECK VALVEº, ªEVAPORATIVE EMISSION SYSTEMº).
IAfter installation, run engine and check for fuel leaks at connections.
Fuel Pump and Gauge
REMOVAL
Petrol engine
1. Release fuel pressure from fuel line.
Refer to EC section (ªFuel Pressure Releaseº, ªBASIC SER-
VICE PROCEDUREº).
2. Remove inspection hole cover located under the luggage com-
partment carpet.
3. Remove fuel filler lid.
4. Disconnect fuel outlet, return tube and connectors.
CAUTION:
Mark the fuel tubes to ensure correct position during installa-
tion.
5. Remove the fuel gauge assembly and disconnect tubes and
connector.
EFE016
EFE017
EFE018
FUEL SYSTEMTD27Ti
FE-7

6. Remove fuel pump with fuel tank chamber assy as follows:
a. Push the locking clip upwards and slide the pump chamber
assy towards the rear of the vehicle.
b. Lift the pump chamber assy from the bracket.
c. Carefully remove the pump chamber assy and top plate from
the tank.
7. Take off the fuel pump chamber lid by opening out the 4 clips.
Remove the fuel pump from the fuel pump chamber.
INSTALLATION
Installation is reverse procedure of removal.
CAUTION:
IAlways use a new top plate seal.
ITighten to specified torque.
Diesel engine
1. Remove inspection hole cover located under the luggage com-
partment carpet.
2. Disconnect fuel feed and return tubes and connector.
3. Remove the screws by which the fuel gauge is mounted to the
fuel tank.
NFE015
NFE016
EFE016
NFE031
FUEL SYSTEMTD27Ti
Fuel Pump and Gauge (Cont'd)
FE-8

4. Remove fuel gauge assembly.
INSTALLATION
Installation procedure is the reverse order of removal.
CAUTION:
ITighten to specified torque.
IAlways use a new top plate seal.
EFE018
FUEL SYSTEMTD27Ti
Fuel Pump and Gauge (Cont'd)
FE-9

CAUTION:
IBe careful not to drop or damage catalytic converter.
INever wet catalytic converter with water, oil, etc.
IAlways replace exhaust gaskets with new ones when reas-
sembling.
If gasket is left on flange surface, scrape off complete as
shown at left.
IWith engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
IAfter installation, but before fully tightening exhaust joints,
check to ensure that mounting brackets and mounting
insulators are free from undue stress. If any of the above
parts are not installed properly, excessive noise or vibra-
tion may be transmitted to the vehicle body.
SFE180A
EXHAUST SYSTEMTD27Ti
FE-10

q1Gasket
q
2Muffler assembly
q
3Frame
q
4Front tube
q
5Transfer caseq
6Crossmember
q
7Support bracket (Wagon models
only)
: Tightening torques
q
A: 13-16N×m(1.3 - 1.6 kg-m,9-12ft-lb)
q
B: 43-50N×m
(4.4 - 5.1 kg-m, 32 - 37 ft-lb)
q
C: 43-50N×m
(4.4 - 5.1 kg-m, 32 - 37 ft-lb)
MFE040A
EXHAUST SYSTEMTD27Ti
FE-11

GENERAL INFORMATION
SECTION
GI
CONTENTS
PRECAUTIONS...............................................................2
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²
(Dual Air Bag System) .................................................3
Precautions for NATS ..................................................4
Precautions for Multiport Fuel Injection System
or Engine Control System ...........................................5
Precautions for Catalyst ..............................................5
Precautions for Turbocharger ......................................5
Precautions for Fuel ....................................................6
Precautions for Engine Oils .........................................6
HOW TO USE THIS MANUAL........................................8
HOW TO READ WIRING DIAGRAMS..........................10
Sample/Wiring Diagram - EXAMPL - ........................10
Description .................................................................12
HOW TO CHECK TERMINAL.......................................19
How to Probe Connectors .........................................19
How to Check Enlarged Contact Spring of
Terminal .....................................................................20
Waterproof Connector Inspection ..............................21
Terminal Lock Inspection ...........................................21
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR
AN ELECTRICAL INCIDENT........................................22Work Flow ..................................................................22
Incident Simulation Tests ...........................................23
HOW TO FOLLOW FLOW CHART IN TROUBLE
DIAGNOSES..................................................................25
CONSULT-II CHECKING SYSTEM...............................26
General ......................................................................26
Function and System Application ..............................26
Nickel Metal Hydride Battery Replacement...............27
Checking Equipment..................................................27
IDENTIFICATION INFORMATION.................................28
Model Variation ..........................................................28
Identification Number .................................................29
Dimensions ................................................................31
Wheels and Tires .......................................................31
LIFTING POINTS AND TOW TRUCK TOWING...........32
Garage Jack and Safety Stand .................................32
Screw Jack ................................................................32
4-pole Lift ...................................................................33
Tow Truck Towing ......................................................33
ISO 15031-2 TERMINOLOGY LIST..............................35
ISO 15031-2 Terminology List ...................................35
TIGHTENING TORQUE OF STANDARD BOLTS........38

6. Before servicing the vehicle, protect fenders, upholstery and
carpeting with appropriate covers.
Take caution that keys, buckles or buttons on your person do
not scratch the paint.
7. Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
8. Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
9. Replace inner and outer races of tapered roller bearings and
needle bearings as a set.
10. Arrange the disassembled parts in accordance with their
assembled locations and sequence.
11. Do not touch the terminals of electrical components which use
microcomputers (such as electronic control units).
Static electricity may damage internal electronic components.
12. After disconnecting vacuum or air hoses, attach a tag to indi-
cate the proper connection.
13. Use only the lubricants specified in MA section.
14. Use approved bonding agent, sealants or their equivalents
when required.
15. Use tools and recommended special tools where specified for
safe and efficient service repairs.
16. When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
17. Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
(Dual Air Bag System)
The Supplemental Restraint System ªAir Bagº and ªSeat Belt Pre-
tensionerº, used along with a seat belt, help to reduce the risk or
severity of injury to the driver and front passenger in a frontal col-
lision. The Supplemental Restraint System consists of air bag mod-
ules (located in the center of the steering wheel and on the instru-
ment panel on the passenger side), seat belt pre-tensioners, a
diagnosis sensor unit, warning lamp, wiring harness and spiral
cable.
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 performed by an authorized NISSAN
dealer.
IImproper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
IDo not use electrical test equipment on any circuit related
to the SRS unless instructed to do so in this Service
Manual. SRS wiring harnesses are covered with yellow
SGI234
SGI646
PRECAUTIONS
GI-3

insulation (either just before the harness connectors or for
the complete harness), for easy identification.
Precautions for NATS
NATS (Nissan Anti-Theft System)
NATS will immobilize the engine if someone tries to start it without
the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS
registered.
The NATS security indicator is located on the instrument panel. The
indicator blinks when the ignition switch is in ªOFFº or ªACCº posi-
tion. Therefore, NATS warns outsiders that the vehicle is equipped
with the anti-theft system.
IWhen NATS detects trouble, the malfunction indicator lamp
(MIL) blinks.
This blinking indicates that the anti-theft is not functioning, so
prompt service is required.
IIf the malfunction indicator lamp comes on while the engine is
running, return the vehicle to the workshop before turning the
ignition switch ªOFFº.
Once the ignition switch is turned ªOFFº, the engine can not be
started.
IWhen servicing NATS (trouble diagnoses, system initialization
and additional registration of other NATS ignition key IDs) CON-
SULT-II hardware and CONSULT-II NATS software is neces-
sary.
Regarding the procedures of NATS initialization and NATS igni-
tion key ID registration, refer to CONSULT-II operation manual,
NATS.
Therefore, CONSULT-II NATS software (program card and
operation manual) must be kept strictly confidential to main-
tain the integrity of the anti-theft function.
IWhen servicing NATS (trouble diagnoses, system initialization
and additional registration of other NATS ignition key IDs), it
may be necessary to re-register original key identification.
Therefore, be sure to receive all keys from vehicle owner.
A maximum of five key IDs can be registered into NATS.
IWhen failing to start the engine first-time using the key of
NATS, starts as follows:
(1) Turn ignition key to ªOFFº.
(2) Wait approx. 5 seconds.
(3) Turn ignition key to ªSTARTº again while keeping the key
apart from any others on key-chain.
SGI916
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
(Dual Air Bag System) (Cont'd)
GI-4

Precautions for Multiport Fuel Injection System
or Engine Control System
1. Before connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM (Engine Control
Module):
Turn ignition switch to ªOFFº position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
2. Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure to eliminate danger.
3. Be careful not to jar components such as control unit and air
flow meter.
Precautions for Catalyst
If a large amount of unburned fuel enters the converter, the con-
verter temperature will rise to excessively high values. To prevent
this, follow the procedure below:
1. Use unleaded gasoline only. Leaded gasoline will seriously
damage the catalytic converter.
2. When checking for ignition spark or measuring engine
compression, perform tests quickly and only when necessary.
3. Do not run engine when the fuel tank level is low, as a result
the engine may misfire causing damage to the converter.
4. Do not place the vehicle on inflammable material. Keep inflam-
mable material off the exhaust pipe.
Precautions for Turbocharger
The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean
supply of oil flowing through the turbocharger and to follow all
required maintenance instructions and operating procedures.
For proper operation of the system, follow the procedure below:
1. Always use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
2. Avoid accelerating engine to a high rpm immediately after start-
ing.
3. If engine had been operating at high rpm for an extended period
of time, let it idle for a few minutes prior to shutting it off.
SGI787
SGI290
SGI292
PRECAUTIONS
GI-5