steering 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

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS system composition which is available to NISSAN MODEL R20 is as follows (The composition var-
ies according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
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 per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
IDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before
the harness connectors or for the complete harness are related to the SRS.
Precautions
IBefore proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to
prevent the internal parts from becoming contaminated by dirt or other foreign matter.
IDisassembly should be done in a clean work area.
IUse lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could inter-
fere with the operation of the transmission.
IPlace disassembled parts in order for easier and proper assembly.
IAll parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
IGaskets, seals and O-rings should be replaced any time the transmission is disassembled.
IIt is very important to perform functional tests whenever they are indicated.
IThe valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place removed parts in a parts rack in order to replace them in correct positions and sequences. Care will
also prevent springs and small parts from becoming scattered or lost.
IProperly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
IBefore assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, and to hold bearings and washers in place during assembly. Do not use grease.
IExtreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
IAfter overhaul, refill the transmission with new ATF.
IWhen the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque
converter and ATF cooling system.
Always follow the procedures under ªChanging A/T Fluidº in the MA section when changing A/T fluid.
PREPARATION AND PRECAUTIONS
AT- 4

Supplement Restraint System (SRS) ªAIR BAGº
and ªSEAT BELT PRE-TENSIONERº
The Supplemental Restraint System ªAir Bagº and ªSeat Belt Pre-tensionerº, used along with a seat belt, help
to reduce the risk or severity or injury to the driver and front passenger in a collision. The Supplemental
Restraint System consists of an air bag module (located in the center of the steering wheel and on the instru-
ment panel on the passenger side, where fitted), seat belt pre-tensioners, a diagnosis sensor unit, warning
lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the
BT sectionof this Service Manual.
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 per-
formed by an authorized NISSAN dealer.
IImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
IDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses (except ªSEAT BELT-TENSIONERº connector) can be iden-
tified with yellow harness connector and with yellow harness protector or yellow insulation tape
before the harness connectors.
Precautions
IUse only ªDOT 4º fluid from a sealed container.
INever reuse drained brake fluid.
IBe careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
ITo clean master cylinder parts, disc brake caliper parts or
wheel cylinder parts, use clean brake fluid.
INever use mineral oils such as Petrol or kerosene. They
will ruin rubber parts of hydraulic system.
IUse flare nut wrench when removing and installing brake
tubes.
IAlways torque brake lines when installing.
IBurnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings,
or if a soft pedal occurs at very low speed. Refer to ªBrake
Burnishing Procedureº, ªCheck and Adjustmentº, BR-5.
WARNING:
IClean brakes with a vacuum dust collector to minimize risk
of health hazard from airborne materials.
IAvoid prolonged and repeated skin contact with brake
fluid.
IWear protective clothing, including impervious gloves.
IWhere there is a risk of eye contact, eye protection should
be worn Ð for example chemical goggles or face shield.
YBR293
PRECAUTIONS AND PREPARATION
BR-3

Purpose
The Anti-lock Brake System (ABS) with an integrated Electronic Brake force Distribution (EBD) system con-
sists of electronic and hydraulic components. It allows you to control the braking force so that wheel lock can
be avoided during braking.
The advantages of ABS with EBD
1) Better tracking performance through improved steering wheel control.
2) Improved maneuverability and safer vehicle control.
3) Improved vehicle stability by preventing flat spins.
4) Shorter stopping distance and optimal utilisation of the rear brakes under many different circumstances.
Operation
IABS with EBD has self-test capabilities. The ABS warning lamp is illuminated for 1 second each time the
ignition switch is turned ªONº. After the engine is started, the ABS warning lamp turns off. An ABS self-test
is performed the first time the vehicle reaches 6 km/h (4 MPH) to ensure the system is operational. A
mechanical noise may be heard as the ABS performs this self-test and is a normal part of the self-test
feature. If a malfunction is detected during this check, the ABS warning lamp will stay on.
During the self-test, it also performs a EBD check when it detects a failure the ABS warning light will go
on simultaneously with the brake warning light and an audible sound will sound constantly.
IEBD system will only operate when the ABS is not in active status and it uses the inlet valves of ABS con-
trol unit to limit the pressure to the rear wheels when they tend to go into slip.
IWhen the vehicle speed is less than 10 km/h (6 MPH) the ABS system does not operate.
IWhile driving, a mechanical noise may be heard during ABS operation, this is a normal system condition.
ABS Hydraulic Circuit
q1Inlet solenoid valve
q
2Outlet solenoid valve
q
3Reservoirq
4Pump
q
5Motorq
6By pass check valve
q
7Damper
NBR346
ANTI-LOCK BRAKE SYSTEM
BR-37

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

Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
IShift lever is in neutral position,
IHeat up switch is OFF,
IHeadlamp switch is OFF,
IAir conditioner switch is OFF,
IRear defogger switch is OFF,
ISteering wheel is in the straight-ahead position, etc.
1 INSPECTION START
1. Check service records for any recent repairs that may indicate a related problem.
2. Check the current need for scheduled maintenance, especially for fuel filter and air cleaner filter. Refer to MA section.
3. Open engine hood and check the following:
IHarness connectors for improper connections
IVacuum hoses for splits, kinks, or improper connections
IWiring for improper connections, pinches, or cuts
SEF142I
4. Start engine and warm it up to the normal operating temperature.
EGO TO 2.
2 PREPARATION FOR CHECKING IDLE SPEED
With CONSULT-II
Connect CONSULT-II to the data link connector.
Without CONSULT-II
Install diesel tacho tester to the vehicle.
EGO TO 3.
TROUBLE DIAGNOSIS Ð BASIC INSPECTIONZD30DDTi
EC-50

Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
IHeadlamp switch is OFF,
IAir conditioner switch is OFF,
IRear defogger switch is OFF,
ISteering wheel is in the straight-ahead position, etc.
BEFORE STARTING
1. Check service records for any recent
repairs that may indicate a related
problem, or the current need for
scheduled maintenance.
2. Open engine hood and check the fol-
lowing:
IHarness connectors for improper con-
nections
IVacuum hoses for splits, kinks, or
improper connections
IWiring for improper connections,
pinches, or cuts
3.Using priming pump, bleed air from fuel
system. Refer to ªFuel Filter Checkº in
MA section.
CONNECT CONSULT-II TO THE
VEHICLE.
Connect ªCONSULT-IIº to the data link
connector for CONSULT-II and select
ªENGINEº from the menu.
DOES ENGINE START?
Ye s
ENo
Turn ignition switch to
ªLOCKº position, wait 5
seconds and then start
engine. If engine fails to
start, check diagnostic
trouble code (DTC).
Run engine for 10 minutes.
CHECK IDLE SPEED.
Read engine idle speed in ªDATA
MONITORº mode with CONSULT-II.
725 rpm   50 (in N position)
------------------------------------------------------------------------------------------------------------------------------------OR------------------------------------------------------------------------------------------------------------------------------------
Check idle speed using tachometer
tester.
725 rpm   50 (in N position)
(Go toqAon next page.)
SEF142I
NEF463
YEC237A
NEF464
SEF817Y
H
H
H
H
H
TROUBLE DIAGNOSESTD27Ti
EC-338

ELECTRICAL SYSTEM
SECTION
EL
When you read wiring diagrams:
IRead GI section, ªHOW TO READ WIRING DIAGRAMSº.
CONTENTS
HARNESS CONNECTOR................................................3
Description ...................................................................3
STANDARDIZED RELAYS..............................................4
Description ...................................................................4
POWER SUPPLY ROUTING...........................................6
Schematic ....................................................................6
Wiring Diagram - POWER - ........................................8
Fuse ...........................................................................17
Fusible Link................................................................17
Circuit Breaker Inspection .........................................17
GROUND DISTRIBUTION.............................................18
COMBINATION SWITCH...............................................23
Check .........................................................................23
Replacement ..............................................................24
STEERING SWITCH......................................................25
Check .........................................................................25
HEADLAMP - Without Daytime Light System -.........26
Wiring Diagram - H/LAMP -.......................................26
HEADLAMP - Daytime Light System -.......................29
Operation ...................................................................29
Schematic ..................................................................30
Wiring Diagram - DTRL - ...........................................31
HEADLAMP - Headlamp Aiming Control -.................37
Description .................................................................37
Replacing Headlamp Aiming Actuator .......................38
Wiring Diagram - H/AIM - ..........................................39
Trouble Diagnoses.....................................................42
HEADLAMP...................................................................43
Bulb Replacement .....................................................43
Aiming Adjustment .....................................................43
EXTERIOR LAMP..........................................................45
Wiring Diagram - TAIL/L - ..........................................45
Wiring Diagram - STOP/L - .......................................48
Wiring Diagram - BACK/L - .......................................49
Wiring Diagram - F/FOG - .........................................51
Front Fog Lamp Aiming Adjustment ..........................53
Wiring Diagram - R/FOG -.........................................54
Schematic ..................................................................55Wiring Diagram - TURN - ..........................................56
Bulb Specifications ....................................................60
INTERIOR LAMP...........................................................61
Schematic ..................................................................61
Wiring Diagram - ILL - ...............................................62
Wiring Diagram - INT/L - ...........................................66
METER AND GAUGES.................................................70
Combination Meter ....................................................70
Schematic ..................................................................71
Wiring Diagram - METER - .......................................72
Combination Meter Self-Diagnosis ............................76
Components Inspection .............................................78
Trouble Diagnoses.....................................................79
Fuel Tank Gauge Unit Check ....................................80
Thermal Transmitter Check .......................................80
Oil Pressure Switch Check ........................................80
WARNING LAMPS AND CHIME...................................81
Schematic ..................................................................81
Wiring Diagram - WARN - .........................................82
Diode Check ..............................................................92
Wiring Diagram - CHIME - ........................................93
WIPER AND WASHER..................................................94
Wiring Diagram - WIPER - ........................................94
Wiring Diagram - WIP/R -..........................................96
Installation ..................................................................98
Washer Nozzle Adjustment .......................................99
Check Valve ...............................................................99
Wiring Diagram - HLC - ...........................................100
HORN, CIGARETTE LIGHTER AND CLOCK............104
Wiring Diagram - HORN - .......................................104
Wiring Diagram - CIGAR -.......................................105
Wiring Diagram - CLOCK -......................................106
REAR WINDOW DEFOGGER AND DOOR
MIRROR DEFOGGER.................................................107
Wiring Diagram - DEF - ...........................................107
Filament Check ........................................................109
Filament Repair ....................................................... 110
AUDIO.......................................................................... 111

Replacement
ITo remove combination switch base, remove base attaching
screws.
CAUTION:
For removal of the airbag module steering wheel and spiral
cable, refer to BT-section.
NEL075
COMBINATION SWITCH
EL-24

Check
YEL279D
STEERING SWITCH
EL-25