service indicator NISSAN TERRANO 2002 Service Repair Manual

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

Service Notice or Precautions
FAIL-SAFE
The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major
electrical input/output device circuit is damaged.
Under Fail-Safe, the vehicle always runs in third gear even with a shift lever position of ª1º, ª2º or ªDº. Cus-
tomer may complain of ªsluggish or poor accelerationº.
When the Fail-Safe operation occurs the next time the key is turned to the ªONº position, the SPORT indica-
tor lamp will blink for about 8 seconds. (For diagnosis, refer to AT-33.)
Fail-Safe may activate without electrical circuit damages if the vehicle is driven under extreme conditions (such
as excessive wheel spins and emergency braking immediately afterwards). In this case, turn the ignition key
ªOFFº for 5 seconds and then ªONº to recover normal shift pattern.
The blinking of the SPORT indicator lamp for about 8 seconds will appear only once and be cleared. The cus-
tomer may resume normal driving conditions by chance.
Always follow the ªWORK FLOWº (Refer to AT-26).
The SELF-DIAGNOSIS results will be as follows:
The first SELF-DIAGNOSIS will indicate the damage of the vehicle speed sensor or the revolution sensor.
During the next SELF-DIAGNOSIS performed after checking the sensor, no damages will be indicated.
PREPARATION AND PRECAUTIONS
AT- 5

Diagnostic Worksheet
INFORMATION FROM CUSTOMER
KEY POINTS
WHAT......................... Vehicle & A/T model
WHEN......................... Date, Frequencies
WHERE...................... Road conditions
HOW........................... Operating conditions, Symptoms
Customer name MR/MS Model & Year VIN
Trans. model Engine Mileage
Incident Date Manuf. Date In Service Date
FrequencylContinuouslIntermittent ( times a day)
SymptomslVehicle does not move. (lAny positionlParticular position)
lNo up-shift (l1st,2ndl2nd,3rdl3rd,O/D)
lNo down-shift (lO/D,3rdl3rd,2ndl2nd,1st)
lLockup malfunction
lShift point too high or too low.
lShift shock or slip (lN,DlLockuplAny drive position)
lNoise or vibration
lNo kickdown
lNo pattern select
lOthers
()
SPORT indicator lamp Blinks for about 8 seconds.
lContinuously litlNot lit
Malfunction indicator lamp
(MIL)lContinuously litlNot lit
TROUBLE DIAGNOSIS Ð Introduction
AT-23

ENGINE CONTROL SYSTEM
SECTION
EC
CONTENTS
ZD30DDTi
TROUBLE DIAGNOSIS - INDEX....................................7
Alphabetical & Numerical Index for DTC ....................7
PRECAUTIONS...............................................................9
Precautions ..................................................................9
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM.........................................................................12
Engine Control Component Parts Location ...............12
Circuit Diagram ..........................................................16
System Diagram ........................................................17
Vacuum Hose Drawing ..............................................18
System Chart .............................................................19
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION...............................................20
Fuel Injection Control System ...................................20
Fuel Injection Timing Control System........................22
Air Conditioning Cut Control ......................................22
Fuel Cut Control (at no load & high engine
speed) ........................................................................22
Crankcase Ventilation System ...................................23
BASIC SERVICE PROCEDURE...................................24
Injection Tube and Injection Nozzle ..........................24
Electronic Control Fuel Injection Pump .....................27
Air Bleeding ...............................................................32
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION...............................................................33
DTC and MI Detection Logic .....................................33
Diagnostic Trouble Code (DTC) ................................33
Malfunction Indicator (MI) ..........................................34
CONSULT-II ...............................................................39
TROUBLE DIAGNOSIS - INTRODUCTION..................46
Introduction ................................................................46
Work Flow ..................................................................48
TROUBLE DIAGNOSIS - BASIC INSPECTION...........50
Basic Inspection.........................................................50
TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION...............................................................56
Symptom Matrix Chart ...............................................56CONSULT-II Reference Value in Data Monitor
Mode ..........................................................................66
Major Sensor Reference Graph in Data Monitor
Mode ..........................................................................68
ECM Terminals and Reference Value .......................69
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT.......................................................................78
Description .................................................................78
Diagnostic Procedure ................................................78
TROUBLE DIAGNOSIS FOR POWER SUPPLY..........79
Main Power Supply and Ground Circuit ....................79
DTC 0102 MASS AIR FLOW SEN................................88
Component Description .............................................88
CONSULT-II Reference Value in Data Monitor
Mode ..........................................................................88
ECM Terminals and Reference Value .......................88
On Board Diagnosis Logic.........................................88
DTC Confirmation Procedure ....................................89
Wiring Diagram ..........................................................90
Diagnostic Procedure ................................................92
DTC 0103 COOLANT TEMP SEN................................95
Description .................................................................95
On Board Diagnosis Logic.........................................95
DTC Confirmation Procedure ....................................95
Wiring Diagram ..........................................................96
Diagnostic Procedure ................................................97
DTC 0104 VEHICLE SPEED SEN................................99
Description .................................................................99
ECM Terminals and Reference Value .......................99
On Board Diagnosis Logic.........................................99
Overall Function Check ...........................................100
Wiring Diagram ........................................................101
Diagnostic Procedure ..............................................103
DTC 0203 ACCEL POS SW (F/C)..............................104
Description ...............................................................104
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................104
ECM Terminals and Reference Value .....................104
On Board Diagnosis Logic.......................................104

CONSULT-II Reference Value in Data Monitor
Mode ........................................................................281
ECM Terminals and Reference Value .....................282
Wiring Diagram ........................................................283
Diagnostic Procedure ..............................................284
AIR CONDITIONER CONTROL..................................289
Wiring Diagram ........................................................289
MI (MIL) & DATA LINK CONNECTORS.....................291
Wiring Diagram ........................................................291
SERVICE DATA AND SPECIFICATIONS (SDS)........292
General Specifications .............................................292
Injection Pump Numbers .........................................292
Injection Nozzle .......................................................292
Engine Coolant Temperature Sensor ......................292
Crankshaft Position Sensor (TDC) ..........................292
Glow Plug ................................................................292
Accelerator Position Sensor ....................................292
EGR Volume Control Valve .....................................292
TD27Ti
TROUBLE DIAGNOSIS - INDEX................................293
Alphabetical & Numerical Index for DTC ................293
PRECAUTIONS AND PREPARATION........................295
Special Service Tools ..............................................295
Engine Fuel & Emission Control System ................297
Precautions ..............................................................298
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM.......................................................................300
Engine Control Component Parts Location .............300
Circuit Diagram ........................................................302
System Diagram ......................................................303
Vacuum Hose Drawing ............................................304
System Chart ...........................................................305
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION.............................................306
Fuel Injection System ..............................................306
Fuel Injection Timing System ..................................309
Air Conditioning Cut Control .................................... 311
Fuel Cut Control (at high engine speed) ................. 311
Glow Control ............................................................ 311
CRANKCASE VENTILATION SYSTEM......................312
Description ...............................................................312
Blow-by Control Valve .............................................312
Ventilation Hose .......................................................312
INJECTION NOZZLE...................................................313
Removal and Installation .........................................313
Disassembly (No.2-4nozzle) ...............................313
Inspection (No.2-4nozzle) ...................................314
Cleaning (No.2-4nozzle) .....................................314
Assembly (No.2-4nozzle) ....................................315
Test and Adjustment ................................................316
ELECTRONIC FUEL INJECTION PUMP....................318Removal ...................................................................318
Installation ................................................................319
Disassembly and Assembly .....................................320
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION.............................................................321
DTC and MI Detection Logic ...................................321
Diagnostic Trouble Code (DTC) ..............................321
Malfunction Indicator (MI) ........................................322
CONSULT-II .............................................................327
TROUBLE DIAGNOSES.............................................334
Introduction ..............................................................334
Diagnostic Worksheet ..............................................335
Work Flow ................................................................336
Description for Work Flow .......................................337
Basic Inspection.......................................................338
Symptom Matrix Chart .............................................340
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................343
Major Sensor Reference Graph in Data Monitor
Mode ........................................................................345
ECM Terminals and Reference Value .....................346
TROUBLE DIAGNOSIS FOR POWER SUPPLY........352
Wiring Diagram ........................................................352
Diagnostic Procedure ..............................................353
DTC P0100 MASS AIR FLOW SEN...........................356
Component Description ...........................................356
On Board Diagnosis Logic.......................................356
DTC Confirmation Procedure ..................................356
Wiring Diagram ........................................................357
Diagnostic Procedure ..............................................359
Component Inspection .............................................360
DTC P0115 COOLANT TEMP SEN............................361
Component Description ...........................................361
On Board Diagnosis Logic.......................................361
DTC Confirmation Procedure ..................................361
Wiring Diagram ........................................................362
Diagnostic Procedure ..............................................363
Component Inspection .............................................364
DTC P0120 ACCEL POS SENSOR............................365
Component Description ...........................................365
On Board Diagnosis Logic.......................................365
DTC Confirmation Procedure A (For General
Plausibility) ...............................................................365
DTC Confirmation Procedure B (For Accelerator
Sticking) ...................................................................366
Wiring Diagram ........................................................367
Diagnostic Procedure ..............................................368
Component Inspection .............................................371
DTC P0180 FUEL TEMP SENSOR............................372
Component Description ...........................................372
On Board Diagnosis Logic.......................................372
DTC Confirmation Procedure ..................................372
CONTENTS(Cont'd)
EC-4

Diagnostic Worksheet
There are many operating conditions that lead to the malfunction
of engine components. A good understanding of such conditions
can make troubleshooting easier 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.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
WORKSHEET SAMPLE
Customer name MR/MS Model & Year VIN
Engine # Trans. Mileage
Incident Date Manuf. Date In Service Date
SymptomslStartabilitylImpossible to startlNo combustionlPartial combustion
lPartial combustion when warming-up engine
lPartial combustion when cooling down engine
lPossible but hard to startlOthers [ ]
lIdlinglNo fast idlelUnstablelHigh idlelLow idle
lOthers [ ]
lDriveabilitylStumblelSurgelKnocklLack of power
lOthers [ ]
lEngine stalllAt the time of startlWhile idling
lWhile acceleratinglWhile decelerating
lJust after stoppinglWhile loading
Incident occurrencelJust after deliverylRecently
lIn the morninglAt nightlIn the daytime
FrequencylAll the timelUnder certain conditionslSometimes
Weather conditionslNot affected
WeatherlFinelRaininglSnowinglOthers [ ]
TemperaturelHotlWarmlCoollColdlHumid ÉF
Engine conditionslColdlDuring warm-uplAfter warm-up
Engine speed
0 2,000 4,000 6,000 8,000 rpm
Road conditionslIn townlIn suburbslHighwaylOff road (up/down)
Driving conditionslNot affected
lAt startinglWhile idlinglAt racing
lWhile acceleratinglWhile cruising
lWhile deceleratinglWhile turning (RH/LH)
Vehicle speed
0 102030 405060708090100mph
Malfunction indicator lamplTurned onlNot turned on
SEF907L
TROUBLE DIAGNOSESTD27Ti
EC-335

CONSULT-II
CONSULT-II INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Connect ªCONSULT-IIº to Data link connector.
3. Insert NATS program card into CONSULT-II.
: Program card
NATS (AEN00A)
4. Turn ignition switch ON.
5. Touch ªSTARTº.
6. Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT-II Operation Manual,
NATS.
CONSULT-II DIAGNOSTIC TEST MODE FUNCTION
CONSULT-II DIAGNOSTIC TEST
MODEDescription
C/U INITIALIZATION When replacing any of the following components, C/U initialization is necessary.
[NATS ignition key/IMMU/ECM/Dongle]
SELF-DIAGNOSTIC RESULTS Detected items (screen terms) are as shown in the chart below.
NOTE:
When any initialisation is performed, all ID previously regis-
tered will be erased and all NATS ignition keys must be regis-
tered again.
The engine cannot be started with an unregistered key. In this
case, the system may show ªDIFFERENCE OF KEYº or ªLOCK
MODEº as a self-diagnostic result on the CONSULT-II screen.
When initialisation is performed for RHD models for Europe,
security indicator will flash six times to demonstrate recogni-
tion of dongle ID.
NRS071
PBR455D
SEL150X
NATS (Nissan Anti-Theft System)
EL-193

Trouble Diagnoses
WORK FLOW
CHECK IN
Listen to customer complaints or request. (Get symptoms)
TROUBLEKEY SERVICE REQUEST (Additional key ID registration)H
Verify the security indicator and MI*.INITIALISATION
(Refer to CONSULT-II operation
manual NATS.)
EUsing the CONSULT-II program card for NATS check the
ªSELF-DIAG RESULTSº with CONSULT-II.F
Self-diagnostic results referring to NATS, but no information
about engine self-diagnostic results is displayed on CONSULT-
II.
Turn ignition switch ªOFFº.
Repair NATS.
(If necessary, carry out ªC/U INITIALIZATIONº with CONSULT-
II.)
Turn ignition switch ªONº.
Erase the NATS ªSELF-DIAG RESULTSº by using CONSULT-
II. (Touch ªERASEº.)
Start the engine.
NGVerify no lighting up of the security indicator.
OK
CHECK OUT
Perform running test with CONSULT-II in engine ªSELF-DIAG
RESULTSº mode.
NGVerify ªNO DTC IS DETECTEDº displayed on the CONSULT-II
screen.
OK
CHECK OUT
Self-diagnostic results referring to NATS and ªDON'T
ERASE BEFORE CHECKING ENG DIAGº are displayed on
CONSULT-II.
(This means that engine trouble data has been detected in
ECM.)
Turn ignition switch ªOFFº.
Repair NATS according to self-diagnostic results referring to
NATS.
(If necessary, carry out ªC/U INITIALIZATIONº with CON-
SULT-II.)
Do not erase the NATS ªSELF-DIAG RESULTSº by using
CONSULT-II.
Check the engine ªSELF-DIAG RESULTSº with CONSULT-II
by using the CONSULT-II generic program card.
(Engine diagnostic software included)
OK
F
Repair engine control system (Refer to EC section.) when
self-diagnostic results except ªNATS MALFUNCTIONº are
detected. When only ªNATS MALFUNCTIONº is detected,
erase the self-diagnostic results and go to the next step.
Start the engine. Does the engine start properly?NG
Erase the NATS and engine ªSELF-DIAG RESULTSº by
using the CONSULT-II program card for NATS and generic
program card.
Start the engine.
H
H
H
HH
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
H
NATS (Nissan Anti-Theft System)
EL-195

3. Remove injection tube and injection nozzle assembly. Refer to
EC section, ªInjection Tube and Injection Nozzleº in ªBASIC
SERVICE PROCEDUREº.
4. Remove the camshaft.
IPlace distinguishing marks on the right and left sides with paint.
ILoosen and remove the installation bolt in reverse order shown
in the figure.
5. Remove the adjusting shim and valve lifter.
IRemove by taking notice of the installation position, and place
outside engine in order to prevent confusion.
Inspection
VISUAL CHECK OF CAMSHAFT
ICheck the camshaft for one sided wear or scratches.
IReplace the camshaft if there are abnormalities.
CAMSHAFT RUNOUT
IPrepare V-block on a flat surface and secure camshaft journals
No. 1 and No. 5.
ISet the dial gauge vertically on journal No. 3.
IRotate camshaft in one direction by hand, then read needle
movement on dial indicator.
Camshaft bend value is 1/2 of needle movement.
Limit: 0.02 mm (0.0008 in)
HEIGHT OF CAM NOSE
Measure by using a micrometer.
Standard:
Intake
40.488 0.02 mm (1.5940 0.0008 in)
Exhaust
40.850 0.02 mm (1.6083 0.0008 in)
CAMSHAFT OIL CLEARANCE
Measure by using a micrometer.
Cam journal outer diameter:
Standard
29.931 - 29.955 mm (1.1784 - 1.1793 in) dia.
FEM012
FEM013
FEM014
FEM015
CAMSHAFTZD
Removal (Cont'd)
EM-31

Camshaft and Camshaft Bearing
Unit: mm (in)
Standard Limit
Camshaft journal to bearing clearance 0.045 - 0.090 (0.0018 - 0.0035) 0.09 (0.0035)
Inner diameter of camshaft bearing 30.000 - 30.021 (1.1811 - 1.1819) Ð
Outer diameter of camshaft journal 29.931 - 29.955 (1.1784 - 1.1793) Ð
Camshaft runout [TIR*] Ð 0.02 (0.0008)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) Ð
Camshaft end play 0.065 - 0.169 (0.0026 - 0.0067) 0.2 (0.008)
*: Total indicator reading
EM671
Cam height ªAºIntake 40.468 - 40.508 (1.5932 - 1.5948)
Exhaust 40.830 - 40.870 (1.6075 - 1.6091)
Wear limit of cam height0.15 (0.0059)
Valve timing
SEM372G
Unit: degree
abcde
234 220 10 34 50
SERVICE DATA AND SPECIFICATIONS (SDS)ZD
EM-89