air condition NISSAN TERRANO 2002 Service Repair Manual

Edition: February 2002
Release: February 2002 (01)
Publication No.: SM2E00-1R20E0E
GENERAL INFORMATIONGI
MAINTENANCEMA
ENGINE MECHANICALEM
ENGINE LUBRICATION &
COOLING SYSTEMSLC
ENGINE CONTROL SYSTEMEC
ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEMFE
CLUTCHCL
MANUAL TRANSMISSIONMT
AUTOMATIC TRANSMISSIONAT
TRANSFERTF
PROPELLER SHAFT &
DIFFERENTIAL CARRIERPD
FRONT AXLE & FRONT SUSPENSIONFA
REAR AXLE & REAR SUSPENSIONRA
BRAKE SYSTEMBR
STEERING SYSTEMST
RESTRAINT SYSTEMRS
BODY & TRIMBT
HEATER & AIR CONDITIONERHA
STARTING & CHARGING SYSTEMSSC
ELECTRICAL SYSTEMEL
ALPHABETICAL INDEXIDX
TERRANO
MODEL R20 SERIES
NISSAN EUROPE N.V.
NISSAN EUROPE N.V.
Produced in The Netherlands

QUICK REFERENCE INDEX

1. SPORT Indicator Lamp Does Not Come On ........94
2. SPORT or SNOW Indicator Lamp Does Not
Come On...................................................................95
3. O/D OFF Indicator Lamp Does Not Come On......95
4. SPORT Indicator Lamp Does Not Come On ........96
5. Engine Cannot Be Started In²P²and²N²
Position......................................................................97
6. In²P²Position, Vehicle Moves Forward Or
Backward When Pushed...........................................97
7. In²N²Position, Vehicle Moves .............................98
8. Large Shock.²N²->²R²Position .........................99
9. Vehicle Does Not Creep Backward In²R²
Position....................................................................100
10. Vehicle Does Not Creep Forward In²D²,²2²
Or²1²Position.........................................................101
11. Vehicle Cannot Be Started From D
1.................102
12. A/T Does Not Shift: D
1-> D2Or Does Not
Kickdown: D
4-> D2..................................................103
13. A/T Does Not Shift: D
2-> D3............................104
14. A/T Does Not Shift: D
3-> D4.............................105
15. A/T Does Not Perform Lock-up .........................106
16. A/T Does Not Hold Lock-up Condition ..............107
17. Lock-up Is Not Released ...................................107
18. Engine Speed Does Not Return To Idle (Light
Braking D
4-> D3) .....................................................108
19. Vehicle Does Not Start From D
1.......................109
20. A/T Does Not Shift: D
2-> D1When
Depressing Accelerator Pedal................................. 110
21. A/T Does Not Shift: D
4-> D3, When
Overdrive Control Switch²ON²->²OFF²............... 111
22. A/T Does Not Shift: D
3-> 22, When Selector
Lever²D²->²2²Position......................................... 111
23. A/T Does Not Shift: 2
2-> 11, When Selector
Lever²2²->²1²Position ......................................... 112
24. Vehicle Does Not Decelerate By Engine
Brake........................................................................ 112
ON-VEHICLE SERVICE.............................................. 113Control Valve Assembly and Accumulators ............. 113
Revolution Sensor Replacement ............................. 114
Rear Oil Seal Replacement ..................................... 114
Parking Components Inspection.............................. 114
Park/neutral Position Switch Adjustment ................. 114
Manual Control Linkage Adjustment........................ 115
REMOVAL AND INSTALLATION................................ 116
Removal ................................................................... 116
Installation ................................................................ 117
MAJOR OVERHAUL................................................... 119
Oil Channel ..............................................................121
Locations of Needle Bearings, Thrust Washers
and Snap Rings .......................................................122
DISASSEMBLY............................................................123
Disassembly.............................................................123
REPAIR FOR COMPONENT PARTS..........................134
Oil Pump ..................................................................134
Control Valve Assembly ...........................................138
Control Valve Upper Body .......................................144
Control Valve Lower Body .......................................149
Reverse Clutch ........................................................151
High Clutch ..............................................................155
Forward and Overrun Clutches ...............................157
Low & Reverse Brake..............................................161
Forward Clutch Drum Assembly ..............................165
Rear Internal Gear and Forward Clutch Hub ..........168
Band Servo Piston Assembly ..................................171
Parking Pawl Components ......................................175
ASSEMBLY..................................................................177
Assembly (1) ............................................................177
Adjustment ...............................................................185
Assembly (2) ............................................................188
A/T FLUID COOLER SYSTEM...................................195
A/T Fluid Cooler.......................................................195
SERVICE DATA AND SPECIFICATIONS (SDS)........196
General Specifications .............................................196
Specifications and Adjustment.................................196
When you read wiring diagrams:
IRead GI section, ªHOW TO READ WIRING DIAGRAMSº.
ISee EL section, ªPOWER SUPPLY ROUTINGº for power distribution circuit.
When you perform trouble diagnoses, read GI section, ªHOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSESº and ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRI-
CAL INCIDENTº.
CONTENTS(Cont'd)
AT- 2

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
H
H
H
H
H
H
H
H
H
TROUBLE DIAGNOSIS Ð Introduction
AT-26

Vehicle Speed Sensor×A/T (Revolution sensor)
DESCRIPTION
The revolution sensor detects the revolution of the out put shaft
parking pawl lock gear and emits a pulse signal. The pulse signal
is sent to the TCM which converts it into vehicle speed.
ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code Malfunction is detected when ...Check items
(Possible cause)
: VHCL SPEED SEN×A/T
TCM does not receive the proper volt-
age signal from the sensor.IHarness or connectors
(The sensor circuit is open or
shorted.)
IRevolution sensor
: 1st judgement flicker
SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE
After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select ªSELF-DIAG RESULTSº mode with CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in ªDº position, vehicle speed higher than
30 km/h (19 MPH), throttle opening greater than 1/8 of
the full throttle position and driving for more than 5 sec-
onds.
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------OR------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in ªDº position, vehicle speed higher than
30 km/h (19 MPH), throttle opening greater than 1/8 of
the full throttle position and driving for more than 5 sec-
onds.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-15.
YAT336
SAT252K
SAT806H
TROUBLE DIAGNOSIS FOR VHCL SPEED SEN×A/T
AT-50

Vehicle Speed Sensor×MTR
DESCRIPTION
The vehicle speed sensor×MTR is built into the speedometer
assembly. The sensor functions as an auxiliary device to the revo-
lution sensor when it is malfunctioning. The TCM will then use a
signal sent from the vehicle speed sensor×MTR.
ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code Malfunction is detected when ...Check items
(Possible cause)
: VHCL SPEED SEN×MTR
TCM does not receive the proper volt-
age signal from the sensor.IHarness or connectors
(The sensor circuit is open or
shorted.)
IVehicle speed sensor
: 2nd judgement flicker
SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE
After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select ªSELF-DIAG RESULTSº mode with CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in ªDº position and vehicle speed higher
than 20 km/h (12 MPH).
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------OR------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in ªDº position and vehicle speed higher
than 20 km/h (12 MPH).
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-15.
NAT238
SAT807H
TROUBLE DIAGNOSIS FOR VHCL SPEED SEN×MTR
AT-54

Throttle (Accelerator) Position Sensor
DESCRIPTION
The throttle (accelerator) position sensor detects the throttle valve
position and sends a signal to the TCM.
ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code Malfunction is detected when ...Check items
(Possible cause)
: THROTTLE POSI SEN
TCM receives an excessively low or
high voltage from the sensor.IHarness or connectors
(The sensor circuit is open or
shorted.)
IThrottle (accelerator) position sensor
: 3rd judgement flicker
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
Monitor item Condition Specification
Throttle (accelerator) position sensorFully-closed throttle Approximately 0.5V
Fully-open throttle Approximately 4V
SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE
After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select ªSELF-DIAG RESULTSº mode with CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in ªDº position, vehicle speed higher than
10 km/h (6 MPH), throttle opening greater than 1/2 of the
full throttle position and driving for more than 3 seconds.
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------OR------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in ªDº position, vehicle speed higher than
10 km/h (6 MPH), throttle opening greater than 1/2 of the
full throttle position and driving for more than 3 seconds.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-15.
NAT262
SAT808H
TROUBLE DIAGNOSIS FOR THROTTLE POSI SEN
AT-60

Overrun Clutch Solenoid Valve
DESCRIPTION
The overrun clutch solenoid valve is activated by the TCM in
response to signals sent from the park/neutral position switch, over-
drive control switch, vehicle speed and throttle (accelerator) posi-
tion sensors. The overrun clutch operation will then be controlled.
ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code Malfunction is detected when ...Check items
(Possible cause)
: OVERRUN CLUTCH S/V
TCM detects an improper voltage drop
when it tries to operate the solenoid
valve.IHarness or connectors
(The solenoid circuit is open or
shorted.)
IOverrun clutch solenoid valve
: 6th judgement flicker
SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE
After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select ªSELF-DIAG RESULTSº mode with CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in ªDº position, overdrive control switch in
ªOFFº position and vehicle speed higher than 10 km/h (6
MPH).
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------OR------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in ªDº position, overdrive control switch in
ªOFFº position and vehicle speed higher than 10 km/h (6
MPH).
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-15.
SAT341H
YAT351
TROUBLE DIAGNOSIS FOR OVERRUN CLUTCH S/V
AT-69

Torque Converter Clutch Solenoid Valve
DESCRIPTION
The torque converter clutch solenoid valve is activated, with the
gear in D
4, by the TCM in response to signals sent from the vehicle
speed and throttle (accelerator) position sensors. Torque converter
clutch piston operation will then be controlled.
Lock-up operation, however, is prohibited when A/T fluid tempera-
ture is too low.
ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code Malfunction is detected when ...Check items
(Possible cause)
: T/C CLUTCH SOL/V
TCM detects an improper voltage drop
when it tries to operate the solenoid
valve.IHarness or connectors
(The solenoid circuit is open or
shorted.)
IT/C clutch solenoid valve
: 7th judgement flicker
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
Monitor item Condition Specification
Torque converter clutch solenoid valve
dutyLock-up ªOFFº
"
Lock-up ªONºApproximately
4%
"
Approximately
94%
SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE
After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select ªSELF-DIAG RESULTSº mode with CONSULT-II.
3) Drive vehicle in D
1,D2,D3,D4,D4lock-up
position.
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------OR------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1) Start engine.
2) Drive vehicle in D
1,D2,D3,D4,D4lock-up
position.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-15.
SAT342HA
SAT818H
TROUBLE DIAGNOSIS FOR T/C CLUTCH SOL/V
AT-72

A/T Fluid Temperature Sensor and TCM Power
Source
DESCRIPTION
The A/T fluid temperature sensor detects the A/T fluid temperature
and sends a signal to the TCM.
ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code Malfunction is detected when ...Check items
(Possible cause)
:
BATT/FLUID TEMP SEN
TCM receives an excessively low or
high voltage from the sensor.IHarness or connectors
(The sensor circuit is open or
shorted.)
IA/T fluid temperature sensor
: 8th judgement flicker
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
Monitor item Condition Specification
A/T fluid temperature sensorCold [20ÉC (68ÉF)]
"
Hot [80ÉC (176ÉF)]Approximately
1.5V
"
Approximately
0.5V
SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE
After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select ªSELF-DIAG RESULTSº mode with CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in ªDº position, vehicle speed higher than
10 km/h (6 MPH), throttle opening greater than 1/8 of the
full open position, engine speed higher than 450 rpm
and driving for more than 10 minutes.
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------OR------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in ªDº position, vehicle speed higher than
10 km/h (6 MPH), throttle opening greater than 1/8 of the
full open position, engine speed higher than 450 rpm
and driving for more than 10 minutes.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-15.
SAT342HA
SAT821H
TROUBLE DIAGNOSIS FOR BATT/FLUID TEMP SEN
AT-76

Engine Speed Signal
DESCRIPTION
The engine speed signal is sent from the ECM to the TCM.
ON BOARD DIAGNOSIS LOGIC
Diagnostic trouble code Malfunction is detected when ...Check items
(Possible cause)
:
ENGINE SPEED SIG
TCM does not receive the proper volt-
age signal from ECM.IHarness or connectors
(The sensor circuit is open or
shorted.)
:
9th judgement flicker
SELF-DIAGNOSIS CODE CONFIRMATION PROCEDURE
After the repair, perform the following procedure to confirm the
malfunction is eliminated.
1) Start engine.
2) Select ªSELF-DIAG RESULTSº mode with CONSULT-II.
3) Drive vehicle under the following conditions:
Selector lever in ªDº position, vehicle speed higher than
10 km/h (6 MPH), throttle opening greater than 1/8 of the
full throttle position and driving for more than 10 sec-
onds.
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------OR------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1) Start engine.
2) Drive vehicle under the following conditions:
Selector lever in ªDº position, vehicle speed higher than
10 km/h (6 MPH), throttle opening greater than 1/8 of the
full throttle position and driving for more than 10 sec-
onds.
3) Perform self-diagnosis.
Refer to SELF-DIAGNOSTIC PROCEDURE (Without
CONSULT-II), AT-15.SAT823H
TROUBLE DIAGNOSIS FOR ENGINE SPEED SIG
AT-80