coolant level NISSAN TERRANO 2002 Service Repair Manual

REMOVAL
1. Remove the following:
IEngine coolant draining
ICharge air cooler
IAir inlet pipe
IThrottle body
IRocker cover
IOil level gauge guide
IEGR cooler
IEGR guide tube
IEGR volume control solenoid valve
IFuel hose
IInjection tube
IRadiator upper hose
IRadiator shroud
ICooling fan
IDrive belt
IVacuum pipe
IVacuum pump
2. Move the power steering pump.
3. Remove the harness connector from the fuel injection pump.
IAfter pulling the connector stopper all the way back, remove the
connector.
IWhen the stopper is pulled all the way back, the interlocked-
connector will come off.
As for installation, when the connector is pushed all the way
forward until the stopper locks, the interlocked-connector is
inserted.
4. Remove the fuel injection pump rear bracket.
5. Remove the chain cover.
IRemove the installation bolts A, B, and C shown in the figure
(left).
CAUTION:
During chain cover removal, seal the opening to prevent for-
eign objects from getting into the engine.
6. Fix the internal mechanism of the idler gear (scissors gear
structure).
a. Remove the plug on the front side of the gear case.
b. While turning the crankshaft pulley clockwise, check the tight-
ening bolt hole of the idler gear internal mechanism through the
plug hole.
IConduct the visual check using a mirror.
IWhen checking, note that there are 2 other holes (with no
thread) beside the tightening bolt hole on the idler gear.
JEF260Z
JEF261Z
JEF262Z
BASIC SERVICE PROCEDUREZD30DDTi
Electronic Control Fuel Injection Pump (Cont'd)
EC-28

ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TER-
MINAL
NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
14 LG/R Cooling fan relayEngine is running.
Cooling fan is not operatingBATTERY VOLTAGE
(11 - 14V)
Engine is running.
Cooling fan is operatingApproximately 0.1V
On Board Diagnosis Logic
This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
Malfunction is detected when ... Check Items (Possible Cause)
ICooling fan does not operate properly (Overheat).
ICooling fan system does not operate properly (Overheat).
IEngine coolant was not added to the system using the proper
filling method.IHarness or connectors
(The cooling fan circuit is open or shorted.)
ICooling fan
IRadiator hose
IRadiator
IRadiator cap
IWater pump
IThermostat
IFan belt
IEngine coolant temperature sensor
For more information, refer to ªMAIN 12 CAUSES OF
OVERHEATINGº, EC-120.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (ªChanging Engine Coolantº, ªENGINE MAINTENANCEº). Also, replace the engine oil.
1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA section (ªAnti-freeze Coolant Mixture Ratioº,
ªRECOMMENDED LUBRICANTS AND FLUIDSº).
2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.
DTC 0208 OVER HEATZD30DDTi
EC-110

Overall Function Check
Use this procedure to check the overall function of the cooling fan.
During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
WITH CONSULT-II
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-114.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-114.
3) Turn ignition switch ªONº.
4) Perform ªCOOLING FANº in ªACTIVE TESTº mode with CON-
SULT-II and make sure that cooling fans operate when touch-
ing ªHIGHº or ªLOWº.
If NG, go to ªDiagnostic Procedureº, EC-114.
WITHOUT CONSULT-II
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-114.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-114.
3) Disconnect engine coolant temperature sensor harness con-
nector.
4) Connect 150Wresistor to engine coolant temperature sensor
harness connector.
5) Start engine and make sure that cooling fan operates.
Be careful not to overheat engine.
6) If NG, go to ªDiagnostic Procedureº, EC-114.
AEC640
SEF111X
MEC475B
DTC 0208 OVER HEATZD30DDTi
EC-111

18 CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to ªMAIN 12 CAUSES OF OVERHEATINGº, EC-120.
EINSPECTION END
Main 12 Causes of Overheating
Engine Step Inspection item Equipment Standard Reference page
OFF 1IBlocked radiator
IBlocked condenser
IBlocked radiator grille
IBlocked bumperIVisual No blocking Ð
2ICoolant mixtureICoolant tester 30 - 50% coolant mixture See ªRECOMMENDED
FLUIDS AND LUBRI-
CANTSº in MA section.
3ICoolant levelIVisual Coolant up to MAX level
in reservoir tank and
radiator filler neckSee ªChanging Engine
Coolantº, ªENGINE MAIN-
TENANCEº in MA section.
4IRadiator capIPressure tester 78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0
kg/cm
2, 11 - 14 psi)
59 - 98 kPa (0.59 - 0.98
bar, 0.6 - 1.0 kg/cm
2,
9 - 14 psi) (Limit)See ªSystem Checkº,
ªENGINE COOLING SYS-
TEMº in LC section.
ON*2 5ICoolant leaksIVisual No leaks See ªSystem Checkº,
ªENGINE COOLING SYS-
TEMº in LC section.
ON*2 6IThermostatITouch the upper and
lower radiator hosesBoth hoses should be hot. See ªThermostatº and
ªRadiatorº, ªENGINE
COOLING SYSTEMº in
LC section.
ON*1 7ICooling fanIVisual Operating See ªDTC 0208 OVER
HEATº, EC-109.
OFF 8ICombustion gas leakIColor checker chemical
tester 4 gas analyzerNegative Ð
ON*3 9ICoolant temperature
gaugeIVisual Gauge less than 3/4
when drivingÐ
ICoolant overflow to res-
ervoir tankIVisual No overflow during driving
and idlingSee ªChanging Engine
Coolantº, ªENGINE MAIN-
TENANCEº in MA section.
OFF*4 10ICoolant return from res-
ervoir tank to radiatorIVisual Should be initial level in
reservoir tankSee ªENGINE MAINTE-
NANCEº in MA section.
OFF 11ICylinder headIStraight gauge feeler
gauge0.1 mm (0.004 in) Maxi-
mum distortion (warping)See ªInspectionº, ªCYLIN-
DER HEADº in EM sec-
tion.
12ICylinder block and pis-
tonsIVisual No scuffing on cylinder
walls or pistonSee ªInspectionº, ªCYLIN-
DER BLOCKº in EM sec-
tion.
*1: Engine running at idle.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to ªOVERHEATING CAUSE ANALYSISº in LC section.
DTC 0208 OVER HEATZD30DDTi
Diagnostic Procedure (Cont'd)
EC-120

Description
SYSTEM DESCRIPTION
Sensor Input signal to ECM ECM function Actuator
Engine coolant temperature
sensorEngine coolant temperature
Cooling fan control Cooling fan relay
Air conditioner switch Air conditioner ªONº signal
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air condi-
tioner ON signal.
On Board Diagnosis Logic
This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
DTC Malfunction is detected when ... Check Items (Possible Cause)
P1217
0208ICooling fan does not operate properly (Overheat).
ICooling fan system does not operate properly (Over-
heat).
IEngine coolant was not added to the system using
the proper filling method.IHarness or connectors
(The cooling fan circuit is open or shorted.)
ICooling fan
IRadiator hose
IRadiator
IRadiator cap
IWater pump
IThermostat
IEngine coolant temperature sensor
For more information, refer to ªMAIN 12 CAUSES OF
OVERHEATINGº, EC-425.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the LC
section, ªChanging Engine Coolantº. Also, replace the engine oil.
1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA section, ªEngine Coolant Mixture Ratioº.
2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.
DTC P1217 OVER HEATTD27Ti
EC-418

Overall Function Check
Use this procedure to check the overall function of the cooling fan.
During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
WITH CONSULT-II
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-421.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-421.
3) Turn ignition switch ªONº.
4) Perform ªCOOLING FANº in ªACTIVE TESTº mode with CON-
SULT-II and make sure that cooling fans operate.
If NG, go to ªDiagnostic Procedureº, EC-421.
WITHOUT CONSULT-II
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-421.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-421.
3) Start engine.
Be careful not to overheat engine.
4) Set temperature control lever to full cold position.
5) Turn air conditioner switch ªONº.
6) Turn blower fan switch ªONº.
7) Run engine at idle for a few minutes with air conditioner oper-
ating.
Be careful not to overheat engine.
8) Make sure that cooling fans operate at low speed.
9) Turn ignition switch ªOFFº.
10) Turn air conditioner switch and blower fan switch ªOFFº.
11) Disconnect engine coolant temperature sensor harness con-
nector.
12) Connect 150Wresistor to engine coolant temperature sensor
harness connector.
13) Start engine and make sure that cooling fans operate at higher
speed than low speed.
Be careful not to overheat engine.
14) If NG, go to ªDiagnostic Procedureº, EC-421.
AEC640
SEF111X
SEC163BA
MEC475B
DTC P1217 OVER HEATTD27Ti
EC-419

Main 12 Causes of Overheating
Engine Step Inspection item Equipment Condition Reference page
OFF1IBlocked radiator
IBlocked radiator grille
IBlocked bumperIVisual No blocking Ð
2ICoolant mixtureICoolant tester 50 - 50% coolant mixtureSee MA section, ªRECOM-
MENDED FLUIDS AND
LUBRICANTSº.
3ICoolant levelIVisualCoolant up to MAX level in
reservoir tank and radiator
filler neckSee LC section, ªChanging
Engine Coolantº.
4IRadiator capIPressure tester78 - 98 kPa (0.78 - 0.98
bar, 0.8 - 1.0 kg/cm
2,11-14
psi)See LC section, ªSystem
Checkº.
ON*
25ICoolant leaksIVisual No leaksSee LC section, ªSystem
Checkº.
ON*
26IThermostatITouch the upper and
lower radiator hosesBoth hoses should be hotSee LC section, ªThermo-
statº and ªRadiatorº.
ON*
17ICooling fanICONSULT-II OperatingSee Trouble Diagnosis for
DTC P1217, EC-418.
OFF 8ICombustion gas leakIColor checker chemical
tester 4 Gas analyzerNegative Ð
ON*
39ICoolant temperature
gaugeIVisualGauge less than 3/4 when
drivingÐ
ICoolant overflow to res-
ervoir tankIVisualNo overflow during driving
and idlingSee LC section, ªChanging
Engine Coolantº.
OFF*
410ICoolant return from res-
ervoir tank to radiatorIVisualShould be initial level in
reservoir tankSee LC section, ªREFILL-
ING ENGINE COOLANTº.
OFF11ICylinder headIStraight gauge feeler
gauge0.1 mm (0.004 in) Maxi-
mum distortion (warping)See EM section, ªInspec-
tionº.
12ICylinder block and pis-
tonsIVisualNo scuffing on cylinder
walls or pistonSee EM section, ªInspec-
tionº.
*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to LC section, ªOVERHEATING CAUSE ANALYSISº.
DTC P1217 OVER HEATTD27Ti
EC-425

Bulb Replacement
The headlamp is a semi-sealed beam type which uses a replacable
halogen bulb. The bulb can be replaced from the engine compart-
ment side without removing the headlamp body.
IGrasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnect the battery cable.
2. Disconnect the harness connector from the back side of the
bulb.
3. Pull off the rubber cap.
4. Press end of the retaining pin together to release bulb.
5. Remove the headlamp bulb. Do not shake or rotate the bulb
when removing it.
6. Install the new bulb in reverse order of removal.
CAUTION:
IDo not leave the bulb out of the headlamp reflector for a
long period of time as dust, moisture, smoke, etc. may
enter the headlamp body and affect the performance of the
headlamp. Thus, the headlamp bulb should not be
removed from the headlamp reflector until just before a
replacement bulb is to be installed.
Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. For operating
instructions, of any aimer, it should be in good repair, calibrated and
used according to respective operation manuals supplied with the
unit.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
CAUTION:
a. Keep all tires inflated to correct pressures.
b. Place vehicle and tester on one and same flat surface.
c. See that there is noload in vehicle other than coolant,
engine oil filled up to correct level, full fuel tank and the
driver (or equivalent weight placed in driver's position).
CAUTION:
Be sure aiming switch is set to ª0º when performing aiming
adjustment on vehicles equipped with headlamp aiming con-
trol.
NEL623
HEADLAMP
EL-43

Front Fog Lamp Aiming Adjustment
When performing fog lamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. The aimer should
be in good operational condition, calibrated and used according to
the relevant operation manuals supplied with the unit.
If an aimer is not available, aiming adjustment can be done as fol-
lows:
For details, refer to the regulations in your own country.
CAUTION:
IKeep all tires inflated to correct pressures.
IPlace vehicle and tester on one and the same flat surface.
IEnsure that there is no-load in the vehicle other than
coolant, engine oil (filled up to correct level), full fuel tank
and the driver (or equivalent weight placed in driver's posi-
tion).
For details of front fog lamp aiming adjustment, refer to ªAiming
Adjustmentº, EL-43.
Check the distance between the vehicle and the ground illumina-
tion point of the main axis of the fog lamp beam. Keep the distance
to approximately 40 m (131 ft).
NEL331
EXTERIOR LAMP
EL-53

Engine room (Left)
3. Remove air duct and air cleaner case.
4. Disconnect vacuum hose to the vehicle on the engine.
5. Disconnect harness connectors from alternator and air com-
pressor.
6. Remove alternator.
7. After removing refrigerant, remove pipes of air compressor and
inlet/outlet.
8. Disconnect heating hose, install blank cap to hose to prevent
coolant from leaking.
9. Remove heating pipe.
10. Remove heat insulator.
11. Remove catalytic converter.
Engine room (Right)
12. Remove power steering reservoir tank from bracket, and fix it
to the vehicle with a rope.
CAUTION:
Keep the reservoir tank level when fixing to prevent oil leak.
13. Remove fuel feed and return hoses.
CAUTION:
Install blank caps immediately to avoid fuel leakage.
14. Remove all harness connectors on the engine, and move har-
nesses to the side of the vehicle.
Vehicle underfloor
15. Remove starter motor.
16. Detach A/T oil cooler pipes from oil pan. (A/T model)
17. Remove rear propeller shaft.
18. Remove mounting bolts to secure the engine to transmission.
1) Remove torque converter installation bolt. (A/T model)
2) Lift transmission bottom with transmission jack, and remove
rear mount members from the vehicle.
3) Lower transmission with the jack, and remove upper mounting
bolts securing the engine to transmission.
4) Lift transmission with the jack, and reinstall rear mount mem-
bers to the vehicle.
5) Position the jack to the front side of transmission.
6) Remove remaining mounting bolts securing the engine to trans-
mission.
Removal operation
19. Remove air conditioner high pressure pipes at the rear of the
engine room.
IThis is due to some inconvenience in the rear slinger installa-
tion.
20. Install the engine slingers (standard service part) to front-left
and rear-right.
:25-28N×m (2.5 - 2.9 kg-m, 18 - 20 ft-lb)
WARNING:
For engines without engine slingers, attach proper slingers
and bolts described in the PARTS CATALOG.
FEM082
ENGINE REMOVALZD
Removal (Cont'd)
EM-64