NISSAN TERRANO 2004 Service Repair Manual

Edition: February 2004
Release: February 2004 (01)
Publication No.: SM4E00-1R20E0E
Reference No.: 7711347141
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 S.A.S.
2004 NISSAN EUROPE S.A.S.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe S.A.S., Paris, France.
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FOREWORD
This manual contains maintenance and repair procedures for NISSAN
TERRANO, model R20 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in speci-
fications and methods at any time without notice.
IMPORTANT SAFETY NOTICE
The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a man-
ner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not specifically recommended by NISSAN must
first completely satisfy himself that neither his safety nor the vehicle's
safety will be jeopardized by the service method selected.
NISSAN EUROPE S.A.S.
Service Engineering SectionParis, France
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GENERAL INFORMATIONSECTION
GI
CONTENTS
PRECAUTIONS ...............................................................2
Supplemental Restraint System (SRS) ²AIR
BAG² and²SEAT BELT PRE-TENSIONER²
(Dual Air Bag System) .................................................3
Precautions for NATS ..................................................4
Precautions for Multiport Fuel Injection System
or Engine Control System ...........................................5
Precautions for Catalyst ..............................................5
Precautions for Turbocharger ......................................5
Precautions for Fuel ....................................................6
Precautions for Engine Oils .........................................6
HOW TO USE THIS MANUAL ........................................8
HOW TO READ WIRING DIAGRAMS ..........................10
Sample/Wiring Diagram - EXAMPL - ........................10
Description .................................................................12
HOW TO CHECK TERMINAL .......................................19
How to Probe Connectors .........................................19
How to Check Enlarged Contact Spring of
Terminal .....................................................................20
Waterproof Connector Inspection ..............................21
Terminal Lock Inspection ...........................................21
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR
AN ELECTRICAL INCIDENT ........................................22 Work Flow ..................................................................22
Incident Simulation Tests ...........................................23
HOW TO FOLLOW FLOW CHART IN TROUBLE
DIAGNOSES ..................................................................25
CONSULT-II CHECKING SYSTEM ...............................26
Function and System Application ..............................26
Nickel Metal Hydride Battery Replacement...............26
Checking Equipment..................................................26
IDENTIFICATION INFORMATION .................................27
Model Variation ..........................................................27
Identification Number .................................................28
Dimensions ................................................................30
Wheels and Tires .......................................................30
LIFTING POINTS AND TOW TRUCK TOWING ...........31
Garage Jack and Safety Stand .................................31
Screw Jack ................................................................31
4-pole Lift ...................................................................32
Tow Truck Towing ......................................................32
ISO 15031-2 TERMINOLOGY LIST ..............................34
ISO 15031-2 Terminology List ...................................34
TIGHTENING TORQUE OF STANDARD BOLTS ........37
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Observe the following precautions to ensure safe and proper
servicing. These precautions are not described in each indi-
vidual section.
1. Do not operate the engine for an extended period of time with-out proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.
2. Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting and towing
before working on the vehicle.
These operations should be done on a level surface.
3. When removing a heavy component such as the engine or transaxle/transmission, take care not to lose your balance and
drop it. Also, do not allow it to strike adjacent parts, especially
the brake tubes and master cylinder.
4. Before starting repairs which do not require battery power, always turn off the ignition switch, then disconnect the ground
cable from the battery to prevent accidental short circuit.
5. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe and muffler. Do
not remove the radiator cap when the engine is hot.
SGI285
SGI231
SGI232
SGI233
PRECAUTIONS
GI-2
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6. Before servicing the vehicle, protect fenders, upholstery andcarpeting with appropriate covers.
Take caution that keys, buckles or buttons on your person do
not scratch the paint.
7. Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly.
8. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones.
9. Replace inner and outer races of tapered roller bearings and needle bearings as a set.
10. Arrange the disassembled parts in accordance with their assembled locations and sequence.
11. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units).
Static electricity may damage internal electronic components.
12. After disconnecting vacuum or air hoses, attach a tag to indi- cate the proper connection.
13. Use only the lubricants specified in MA section.
14. Use approved bonding agent, sealants or their equivalents when required.
15. Use tools and recommended special tools where specified for safe and efficient service repairs.
16. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.
17. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
(Dual Air Bag System)
The Supplemental Restraint System ªAir Bagº and ªSeat Belt Pre-
tensionerº, used along with a seat belt, help to reduce the risk or
severity of injury to the driver and front passenger in a frontal col-
lision. The Supplemental Restraint System consists of air bag mod-
ules (located in the center of the steering wheel and on the instru-
ment panel on the passenger side), seat belt pre-tensioners, a
diagnosis sensor unit, warning lamp, wiring harness and spiral
cable.
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.
I Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
I Do not use electrical test equipment on any circuit related
to the SRS unless instructed to do so in this Service
Manual. SRS wiring harnesses are covered with yellow
SGI234
SGI646
PRECAUTIONS
GI-3
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insulation (either just before the harness connectors or for
the complete harness), for easy identification.
Precautions for NATS
NATS (Nissan Anti-Theft System)
NATS will immobilize the engine if someone tries to start it without
the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS
registered.
The NATS security indicator is located on the instrument panel. The
indicator blinks when the ignition switch is in ªOFFº or ªACCº posi-
tion. Therefore, NATS warns outsiders that the vehicle is equipped
with the anti-theft system.
IWhen NATS detects trouble, the malfunction indicator lamp
(MIL) blinks.
This blinking indicates that the anti-theft is not functioning, so
prompt service is required.
I If the malfunction indicator lamp comes on while the engine is
running, return the vehicle to the workshop before turning the
ignition switch ªOFFº.
Once the ignition switch is turned ªOFFº, the engine can not be
started.
I When servicing NATS (trouble diagnoses, system initialization
and additional registration of other NATS ignition key IDs) CON-
SULT-II hardware and CONSULT-II NATS software is neces-
sary.
Regarding the procedures of NATS initialization and NATS igni-
tion key ID registration, refer to CONSULT-II operation manual,
NATS.
Therefore, CONSULT-II NATS software (program card and
operation manual) must be kept strictly confidential to main-
tain the integrity of the anti-theft function.
I When servicing NATS (trouble diagnoses, system initialization
and additional registration of other NATS ignition key IDs), it
may be necessary to re-register original key identification.
Therefore, be sure to receive all keys from vehicle owner.
A maximum of five key IDs can be registered into NATS.
I When failing to start the engine first-time using the key of
NATS, starts as follows:
(1) Turn ignition key to ªOFFº.
(2) Wait approx. 5 seconds.
(3) Turn ignition key to ªSTARTº again while keeping the key
apart from any others on key-chain.
SGI916
PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
(Dual Air Bag System) (Cont'd)
GI-4
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Precautions for Multiport Fuel Injection System
or Engine Control System
1. Before connecting or disconnecting any harness connector forthe multiport fuel injection system or ECM (Engine Control
Module):
Turn ignition switch to ªOFFº position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
2. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure to eliminate danger.
3. Be careful not to jar components such as control unit and air flow meter.
Precautions for Catalyst
If a large amount of unburned fuel enters the converter, the con-
verter temperature will rise to excessively high values. To prevent
this, follow the procedure below:
1. Use unleaded gasoline only. Leaded gasoline will seriouslydamage the catalytic converter.
2. When checking for ignition spark or measuring engine compression, perform tests quickly and only when necessary.
3. Do not run engine when the fuel tank level is low, as a result the engine may misfire causing damage to the converter.
4. Do not place the vehicle on inflammable material. Keep inflam- mable material off the exhaust pipe.
Precautions for Turbocharger
The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean
supply of oil flowing through the turbocharger and to follow all
required maintenance instructions and operating procedures.
For proper operation of the system, follow the procedure below:
1. Always use the recommended oil. Follow the instructions forproper time to change the oil and proper oil level.
2. Avoid accelerating engine to a high rpm immediately after start- ing.
3. If engine had been operating at high rpm for an extended period of time, let it idle for a few minutes prior to shutting it off.
SGI787
SGI290
SGI292
PRECAUTIONS
GI-5
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Precautions for Fuel
DIESEL ENGINE*:
Diesel fuel of at least 50 cetane for ZD30DDTi engine.
* If two types of diesel fuel are available, use summer or winterfuel properly according to the following temperature conditions.
I Above þ7ÉC (20ÉF) ... Summer type diesel fuel.
I Below þ7ÉC (20ÉF) ... Winter type diesel fuel.
CAUTION:
I Do not use home heating oil, gasoline, or other alternate
fuels in your diesel engine. The use of those can cause
engine damage.
I Do not use summer fuel at temperature below þ7ÉC (20ÉF).
The cold temperature will cause wax to form in the fuel. As
a result, it may prevent the engine from running smoothly.
I Do not add gasoline or other alternate fuels to diesel fuel.
Precautions for Engine Oils
Prolonged and repeated contact with mineral oil will result in the
removal of natural fats from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer. Adequate
means of skin protection and washing facilities must be provided.
HEALTH PROTECTION PRECAUTIONS
1. Avoid prolonged and repeated contact with oils, particularly
used engine oils.
2. Wear protective clothing, including impervious gloves where practicable.
3. Do not put oily rags in pockets.
4. Avoid contaminating clothes, particularly underwear, with oil.
5. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.
6. First Aid treatment should be obtained immediately for open cuts and wounds.
7. Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
8. Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing
lanolin replace the natural skin oils which have been removed.
9. Do not use petrol, kerosine, diesel fuel, gas oil, thinners or sol- vents for cleaning skin.
10. If skin disorders develop, obtain medical advice without delay.
11. Where practicable, degrease components prior to handling.
12. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition
an eye wash facility should be provided.
(For the United Kingdom, see also HSE Cautionary Notice SHW
397 ªEffects of Mineral Oil on the Skinº.)
ENVIRONMENTAL PROTECTION PRECAUTIONS
Burning used engine oil in small space heaters or boilers can be
recommended only for units of approved design. The heating sys-
tem must meet the requirements of HM Inspectorate of Pollution for
small burners of less than 0.4 MW. If in doubt check with the
appropriate local authority and/or manufacturer of the approved
appliance.
PRECAUTIONS
GI-6
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Dispose of used oil and used oil filters through authorized waste
disposal contractors to licensed waste disposal sites, or to the
waste oil reclamation trade. If in doubt, contact the local authority
for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or drains,
or into water courses.
The regulations concerning the pollution of the environment
will vary from country to country.
PRECAUTIONS
Precautions for Engine Oils (Cont'd)GI-7
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