air suspension 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

Installation
CAUTION:
IRefill with new brake fluid ªDOT 4º.
INever reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely taking care that brake
hose is not trapped between any suspension part and that
hoses are not twisted.
3. Bleed air. Refer to ªBleeding Brake Systemº, ªBRAKE
HYDRAULIC LINEº, BR-8.
SBR014C
FRONT DISC BRAKE
BR-30

Shock Absorber
REMOVAL AND INSTALLATION
When removing and installing shock absorber, do not allow oil or
grease to come into contact with rubber parts.
INSPECTION
Wash all parts, except for nonmetallic parts, with suitable solvent
and dry with compressed air.
Blow dirt and dust off of nonmetallic parts with compressed air.
ICheck for oil leakage and cracks. Replace if necessary.
ICheck piston rod for smooth operation. Replace if necessary.
ICheck rubber parts for wear, cracks, damage or deformation.
Replace if necessary.
Torsion Bar
REMOVAL
IRemove torsion bar as follows:
(1) Remove anchor arm bolt nuts and remove anchor arm bolt and
pilot.
Remove snap ring and dust cover from rear torsion bar anchor
arm.
(2) Withdraw torsion bar and remove torsion bar and torsion bar
rear anchor arm as an assembly from front torsion bar torque
arm.
(3) Remove torsion bar from rear torsion bar anchor arm.
INSPECTION
ICheck torsion bar for wear, twist, bend and other damage.
ICheck serrations of each part for cracks, wear, twist and other
damage.
ICheck dust cover for cracks.
SFA931
EFA017
FRONT SUSPENSION
FA-30

F
Fan switch ......................................................HA-60
F/FOG - Wiring diagram .................................EL-51
Final drive disassembly............................PD-15, 37
Final drive pre-inspection .........................PD-15, 37
Final drive removal and installation ...............PD-15
Finisher, interior - See Trim ............................BT-18
Finisher, rear panel .........................................BT-18
Floor trim .........................................................BT-18
Fluid temperature sensor (A/T) .....................AT-141
Fluids .............................................MA-5, 17, 20, 36
Flywheel (clutch) .......................................CL-11, 12
Flywheel runout..............................................EM-94
Fog lamp, front .........................................EL-51, 53
Fog lamp, rear ................................................EL-54
Fork rod (M/T) ................................................MT-13
Forward clutch...............................................AT-157
Front axle ....................................................FA-4, 13
Front bumper ....................................................BT-6
Front case (Transfer) ..................................TF-9, 23
Front combination lamp removal and
installation .....................................................BT-6
Front disc brake .............................................BR-26
Front door .......................................................BT-10
Front Door Trim...............................................BT-19
Front drive shaft (Transfer) .........................TF-9, 19
Front final drive disassembly (4WD) ..............PD-14
Front final drive removal and installa-
tion (4WD) ............................................PD-12, 13
Front fog lamp ..........................................EL-51, 53
Front passenger air bag .................................RS-17
Front seat ........................................................BT-34
Front seat belt ..................................................RS-4
Front seat belt pre-tensioner ..........................RS-12
Front side air bag ...........................................RS-18
Front suspension ........................................FA-4, 29
Fuel cut control (at no load & high
engine speed) .....................................EC-22, 311
Fuel cut solenoid valve ................................EC-376
Fuel cut system ............................................EC-232
Fuel filler lid.......................................................BT-8
Fuel filter replacement...................MA-5, 20, 23, 33
Fuel gauge..................................FE-3, 6, EL-72, 80
Fuel injection system .............................EC-20, 306
Fuel injection timing feed back (Elec-
tronic Fuel Injection Pump) ......................EC-192
Fuel precautions ................................................GI-6
Fuel pump and gauge ..............................FE-3, 6, 7
Fuel system ..................................................FE-3, 6
Fuel tank .......................................................FE-3, 6
Fuel temperature sensor ......................EC-123, 372
Fuse ................................................................EL-17
Fuse and fusible link box .............................Foldout
Fuse block ....................................................Foldout
Fusible link ......................................................EL-17GGarage jack and safety stand .........................GI-32
Gauges .....................................................EL-70, 71
Gear components (M/T) ........MT-11, 14, 16, 21, 23
Generator - See Alternator .............................SC-27
GLOW - Wiring diagram...............................EC-241
Glow control system.....................EC-239, 311, 389
Glow plug .............................................EC-239, 390
Glow relay ............................................EC-241, 396
Grease .........................................MA-17, 39, 40, 44
Ground distribution..........................................EL-18
H
Harness connector ............................................EL-3
Harness connector inspection .........................GI-19
Harness layout ............EL-247, 248, 264, 276, 278,
286, 287, 288, 289, 290
Hazard warning lamp................................EL-55, 56
Headlamp ......EL-26, 29, 30, 31, 37, 38, 39, 42, 43
Headlamp aiming control .............EL-37, 38, 39, 42
Headlamp washer .........................................EL-100
Headlining - See Roof trim .............................BT-20
Heat up switch..............................................EC-258
Heated seat .......................................BT-36, EL-128
HEATER - Wiring diagram .............................HA-41
HEATUP - Wiring diagram ...........................EC-259
Height (Dimensions) ........................................GI-10
HFC134a (R134a) system precaution .............HA-3
HFC134a (R134a) system service
procedure....................................................HA-15
HFC134a (R134a) system service tools ........HA-11
High clutch ....................................................AT-155
H/LAMP - Wiring diagram ............EL-26, 31, 39, 56
Hood..................................................................BT-6
Hood lock system .............................................BT-6
Horn ..............................................................EL-104
HORN - Wiring diagram................................EL-104
How to erase DTC for OBD system ......EC-33, 321
HSEAT - Wiring diagram...............................EL-128
I
Identification .....................................................HA-2
Identification plate .....................................GI-29, 30
Idle speed...............................................EC-50, 338
Idle speed inspection ...............................MA-20, 26
ILL - Wiring diagram .......................................EL-62
Illumination ................................................EL-61, 62
Injection nozzle ......................................EC-24, 313
Injection nozzle inspection ..................MA-5, 20, 25
Injection timing control valve ........................EC-380
INJPMP - Wiring diagram ...EC-126, 164, 171, 178,
185, 195, 235
Instrument panel .............................................BT-16
INT/L - Wiring diagram....................................EL-66
ALPHABETICAL INDEX
IDX-4

Pre-delivery inspection.....................................MA-3
Priming pump .................................................EC-50
Propeller shaft ............................................PD-5, 57
Propeller shaft greasing...........................MA-36, 38
Propeller shaft inspection ........................MA-36, 38
Propeller shaft on vehicle service ....................PD-6
Pump communication line (Electronic
Fuel Injection Pump) ................................EC-175
Pump control module (Electronic Fuel
Injection Pump).........................................EC-189
R
Radiator ....................................................LC-14, 32
Rear axle................................................RA-4, 6, 12
Rear bumper .....................................................BT-8
Rear case (Transfer)...................................TF-9, 24
Rear combination lamp removal and
installation .....................................................BT-8
Rear door ........................................................BT-12
Rear door trim...........................................BT-18, 19
Rear drum brake ............................................BR-31
Rear fog lamp .................................................EL-54
Rear side window .....................................BT-21, 43
Rear suspension ........................................RA-4, 12
Rear window defogger..................EL-107, 109, 110
Refrigerant connection precaution ...................HA-4
Refrigerant general precaution.........................HA-3
Refrigerant lines .............................................HA-17
Refrigeration cycle............................................HA-9
REMOTE - Wiring diagram ...........................EL-122
Removal and installation (A/T) ......................AT-116
Removal and installation (Transfer) ..................TF-7
Reverse clutch ..............................................AT-151
Reverse idler shaft (M/T)................................MT-11
Reverse main gear (M/T) ...............................MT-11
Revolution sensor (A/T) ..........................AT-50, 114
R/FOG - Wiring diagram .................................EL-54
Ring gear diff. inspection .........................PD-20, 42
Rocker cover ..................................................EM-20
Roof trim .........................................................BT-20
Rotor disc (front) .............................................FA-18
S
Screw jack .......................................................GI-32
Seal - See Exterior .........................................BT-21
Seat belt inspection .................................MA-36, 45
Seat belt pre-tensioner.................................RS-2, 9
Seat belt pre-tensioner disposal ....................RS-20
Seat belt, front ..................................................RS-4
Seat, front .......................................................BT-34
Seat, second (2nd) .........................................BT-37
Seat, third (3rd) ...............................................BT-39
Second (2nd) seat ..........................................BT-37
Self-diagnostic results ............................EC-35, 324
Shift control (Transfer) ..............................TF-11, 24Shift control components
(M/T) ............................MT-13, 14, 15, 21, 23, 31
Shift fork (M/T) ...............................................MT-13
Shift schedule................................................AT-196
Shift solenoid valve A (A/T).............................AT-63
Shift solenoid valve B (A/T) ............................AT-66
Shock absorber (front) ....................................FA-30
Shock absorber (rear) ..............................RA-14, 16
Side air bag ....................................................RS-18
Side air bag (satellite) sensor ........................RS-13
Side bearing preload diff. ...............................PD-24
Side trim....................................................BT-18, 21
Side window - See Rear side window ............BT-21
S/LOCK - Wiring diagram .............................EL-150
SMJ (super multiple junction) .......................Foldout
Speedometer...................................................EL-72
Spill valve .....................................................EC-182
Spiral cable.....................................................RS-14
SROOF - Wiring diagram .............................EL-130
SRS - See Supplemental Restraint
System ..........................................................RS-6
SRS - Wiring diagram ....................................RS-32
SRS Trouble diagnoses .................................RS-26
S/SIG - Wiring diagram ................................EC-248
Stabilizer bar (front) ....................................FA-4, 33
Stabilizer bar (rear) ..................................RA-15, 16
Stall test (A/T) .........................................AT-27, 196
Standardized relay ............................................EL-4
START - Wiring diagram ................................SC-14
Start signal ...................................................EC-248
Starter .............................................................SC-17
Starting system...............................................SC-13
Steering gear and linkage inspection ......MA-36, 43
Steering gear oil level ..............................MA-36, 44
Steering gear, linkage and transfer
gear inspection ..............................MA-36, 43, 44
Steering linkage ........................................ST-17, 22
Steering switch................................................EL-25
Steering wheel and column ........................ST-8, 22
Steering wheel play ..........................................ST-4
Steering wheel turning force .............................ST-6
Stop lamp ........................................................EL-48
Stop lamp switch ..................................EC-204, 403
STOP/L - Wiring diagram................................EL-48
Striking rod (M/T) ...........................................MT-13
Sub-gear (M/T) ...............................................MT-11
Sun roof, electric ...........................................EL-130
Sunroof............................................................BT-40
Super lock ............................EL-145, 146, 148, 158
Supplemental Restraint System .......................RS-6
Swirl control valve control solenoid
valve .........................................................EC-263
SWL/V - Wiring diagram ..............................EC-265
Symptom matrix chart ............................EC-56, 340
T
Tachometer .....................................................EL-72
Tail lamp ..........................................................EL-45
ALPHABETICAL INDEX
IDX-6

Shown below are Pre-delivery Inspection items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD Ð engine off
lRadiator coolant level and coolant hose connections for leaks
lBattery fluid level, specific gravity and conditions of battery terminals
lBrake and clutch reservoirs fluid level and fluid lines for leaks
lWindshield and rear window washer and headlamp cleaner reservoir fluid level
lDrive belts tension
lFuel filter for water or dust, and fuel lines and connections for leaks
lPower steering reservoir fluid level and hose connections for leaks
lEngine oil level and oil leaks
INSIDE AND OUTSIDE
lOperation of all instruments, gauges, lights, anti-theft system and accessories
lOperation of horn(s), wiper and washer
lSteering lock for operation
lAir conditioner for gas leaks
lFront and rear seats, and seat belts for operation
lAll moldings, trims and fittings for fit and alignment
lAll windows for operation and alignment
lHood, tailgate, door panels for fit and alignment
lLatches, keys and locks for operation
lWeatherstrips for adhesion and fit
lHeadlamp aiming
lTighten wheel nuts
lTire pressure (Inc. spare tire)
lCheck front wheels for toe-in
lInstall clock/room lamp fuse
lRemove wiper blade protectors (if necessary)
UNDER BODY
lManual transmission/transaxle and differential gear oil level
lBrake and fuel lines and oil/fluid reservoirs for leaks
lTighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
ROAD TEST
lClutch operation
lParking brake operation
lService brake operation
lSteering control and returnability
lEngine performance
lSqueaks and rattles
ENGINE OPERATING AND HOT
lAdjust idle mixture and speed (and ignition timing) (Petrol only)
FINAL INSPECTION
lInstall necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
lInspect for interior and exterior metal and paint damage
lCheck for spare tire, jack, tools and literature
lWash, clean interior and exterior
PRE-DELIVERY INSPECTION ITEMS
MA-3

Chassis and Body Maintenance
Abbreviations: R = Replace I = Inspect. Correct or replace if necessary L = Lubricate T = Tighten
[ ] = At the specified mileage only
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Refer-
ence
page Perform on a kilometer basis, but on
a semi-annual basis when driving
less than 20,000 km (12,000 miles)
per year.km x 1,000 10 20 30 40 50 60 70 80 90 100 110 120
(miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72)
Months 6 12 18 24 30 36 42 48 54 50 66 72
Underhood and under vehicle
Headlamp aimingIIIIIIEL-37
Wheel alignment (if necessary, rotate & balance wheels)IIIIIIMA-43
Brake pads, discs & other components*IIIIIIMA-40
Brake linings, drums & other components*IIIIIIMA-41
Foot brake, parking brake & clutch (for free play, stroke &
operation)IIIIIIMA-42
Brake booster vacuum hoses, connections, check valve I I I MA-40
Brake & clutch, systems and fluid (for level and leaks)IIIIIIMA-36/
MA-40
Brake fluid*R R R MA-43
Power steering fluid and lines (for level and leaks)IIIIIIMA-44
Air bag system See NOTE (1)RS-15
Ventilation air filter*RRRRMA-44
Transfer and standard differential gear oil* I I R I I RMA-37/
MA-38
Manual transmission oil I I I [R] I I MA-36
LSD gear oil (for level and leaks)* I I R I I R MA-38
Steering gear & linkage, axle & suspension parts, propeller
shaft and exhaust system*IIIIIIMA-43/
FA-4/
RA-4/
MA-38/
MA-36
Greasing points of steering gear linkage,
propeller shaft and suspension*See NOTE (2)LLLLLLMA-44/
MA-38
Drive shafts*IIIIIIFA-13
Front wheel bearing grease*IRIRIRMA-39
Free running hub grease*IIIIIIMA-40
Body mounting bolts and nutsTTTTTTBT-48
Body corrosion See NOTE (3)MA-47
NOTE: (1) Inspect after 10 years, then every 2 years.
(2) The propeller shaft should be re-greased daily if it is immersed in water.
(3) Inspect once per year.
* Maintenance items with ª*º should be performed more frequently according to ªMaintenance under severe driving
conditionsº.
PERIODIC MAINTENANCE
Maintenance Schedule for Diesel Engine
Models (annual mileage < 30,000 km/year)
(Cont'd)
MA-7

Chassis and Body Maintenance
Abbreviations: R = Replace I = Inspect. Correct or replace if necessary L = Lubricate T = Tighten
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Refer-
ence
page Perform on a kilometer basis only.km x 1,000 10 20 30 40 50 60 70 80 90 100 110 120
(miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72)
Underhood and under vehicle
Headlamp aimingIIIIEL-37
Wheel alignment (it necessary, rotate & balance wheels)IIIIMA-43
Brake pads, discs & other components*IIIIMA-40
Brake linings, drums & other components*IIIIMA-41
Foot brake, parking brake & clutch (for free play, stroke &
operation)IIIIMA-42
Brake booster vacuum hoses, connections, check valve I I MA-40
Brake & clutch, systems and fluid (for level and leaks)IIIIMA-36/
MA-40
Brake fluid*R R MA-43
Power steering fluid and lines (for level and leaks)IIIIMA-44
Air bag system See NOTE (1)RS-15
Ventilation air filter*RRRRMA-44
Transfer and standard differential gear oil*IRIRMA-37/
MA-38
Manual transmission oil I I R I MA-36
LSD gear oil*IRIRMA-38
Steering gar & linkage, axle & suspension parts, propeller shaft
and exhaust system*IIIIMA-43/
FA-4/
RA-4/
MA-38/
MA-36
Greasing points of steering gear linkage,
propeller shaft and suspension*See NOTE (2)LLLLMA-44/
MA-38
Drive shafts*IIIIFA-13
Front wheel bearing grease*IRIRMA-39
Free running hub grease*IIIIMA-40
Body mounting bolts and nutsTTTTBT-48
Body corrosion See NOTE (3)MA-47
NOTE: (1) Inspect after 10 years, then every 2 years.
(2) The propeller shaft should be re-greased daily if it is immersed in water.
(3) Inspect once per year.
* Maintenance items with ª*º should be performed more frequently according to ªMaintenance under severe driving
conditionsº.
PERIODIC MAINTENANCE
Maintenance Schedule for Diesel Engine
Models (annual mileage > 30,000 km/year)
(Cont'd)
MA-10

Maintenance Under Severe Driving Conditions
(annual mileage < 30,000 km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
TD27Ti engine
Severe driving conditions
A Ð Driving under dusty conditions
B Ð Driving repeatedly short distances
C Ð Towing a trailer
D Ð Extensive idling
E Ð Driving in extremely adverse weather conditions or in areas where ambient temperature is either
extremely low or extremely high
F Ð Driving in high humidity areas or in mountainous areas
G Ð Driving in areas using salt or other corrosive materials
H Ð Driving on rough and/or muddy roads or in the desert
I Ð Driving with frequent use of brakes or in mountainous areas
J Ð Frequent driving in water
Driving condition Maintenance itemMaintenance
operationMaintenance interval Reference page
ABCD......Engine oil & engine oil filter
ReplaceEvery 5,000 km (3,000 miles) or
3 monthsMA-21
A.........Air cleaner filter (dry paper type)
CleanEvery 10,000 km (6,000 miles) or
6 months
MA-24
ReplaceEvery 20,000 km (12,000 miles)
or 12 months
A...E.....Fuel filter
ReplaceEvery 20,000 km (12,000 miles)
or 12 monthsMA-23
A....F....Ventilation air filter
ReplaceEvery 20,000 km (12,000 miles)
or 12 monthsMA-44
.....F....Brake fluid
ReplaceEvery 20,000 km (12,000 miles)
or 12 monthsMA-43
..C....H..Limited-slip differential (L.S.D.) gear oil
ReplaceEvery 30,000 km (18,000 miles)
or 18 monthsMA-38
..C....H..Transfer & standard differential gear oil
ReplaceEvery 60,000 km (36,000 miles)
or 24 monthsMA-36/MA-37/
MA-38
A.C...GHI.Brake pads/linings, discs/drums & other brake system components
InspectEvery 10,000 km (6,000 miles) or
6 monthsMA-40/MA-41
......GH.JGreasing points of steering linkage, propeller shafts and suspension
LubricateEvery 10,000 km (6,000 miles) or
6 monthsMA-44/MA-38
......GH..Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system
InspectEvery 10,000 km (6,000 miles) or
6 monthsMA-43/FA-4/
RA-4/MA-38/
MA-36
PERIODIC MAINTENANCE
MA-11

Driving condition Maintenance itemMaintenance
operationMaintenance interval Reference page
..C....H..Drive shafts
InspectEvery 10,000 km (6,000 miles) or
6 monthsFA-22
.........JFront wheel bearing grease & free running hub grease
InspectEvery 10,000 km (6,000 miles) or
6 monthsMA-39/MA-40
ZD30DDTi engine
Severe driving conditions
A Ð Driving under dusty conditions
B Ð Driving repeatedly short distances
C Ð Towing a trailer or caravan
D Ð Extensive idling
E Ð Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F Ð Driving in high humidity areas or in mountainous areas
G Ð Driving in areas using salt or other corrosive materials
H Ð Driving on rough and/or muddy roads or in the desert
I Ð Driving with frequent use of braking or in mountainous areas
J Ð Frequent off road use or driving in water
Driving condition Maintenance itemMaintenance
operationMaintenance interval
ABCD......Engine oil & engine oil filter
Replace Every 7,500 km (4,500 miles) or 6 months
A.........Air cleaner filter
Replace Every 30,000 km (18,000 miles) or 24 months
A...E.....Fuel filter
Replace Every 22,500 km (13,500 miles) or 18 months
A.C...GHI.Brake pads, rotors & other brake components
Inspect Every 7,500 km (4,500 miles) or 6 months
.....F....Brake fluid
Replace Every 15,000 km (9,000 miles) or 12 months
A.........Ventilation air filter
Replace Every 15,000 km (9,000 miles) or 12 months
..C....H..Automatic transmission fluid
Replace Every 30,000 km (18,000 miles) or 24 months
..C....H..Transfer fluid and limited-slip differential (LSD) gear oil
Replace Every 30,000 km (18,000 miles) or 24 months
..C....H..Drive shaft & steering damper
Inspect Every 7,500 km (4,500 miles) or 6 months
.........JFront wheel bearing grease
Inspect Every 7,500 km (4,500 miles) or 6 months
.........JFree-running hub grease
Inspect Every 7,500 km (4,500 miles) or 6 months
......GH..Steering gear & linkage, axle & suspension parts, propeller shaft & exhaust system
Inspect Every 7,500 km (4,500 miles) or 6 months
PERIODIC MAINTENANCE
Maintenance Under Severe Driving Conditions
(annual mileage < 30,000 km/year) (Cont'd)
MA-12