warning NISSAN TERRANO 2004 Service Repair Manual

FOR SIDE COLLISION
To repair the SRS for a side collision, perform the following steps.
When the side air bag is activated in the side collision:
1) Replace the following component:
Ð All parts of front seatback (including front seatback frame) with side air bag module (on the side on whichside air bag is activated)
Ð Diagnosis sensor unit
Ð Side air bag (satellite) sensor (on the side on which side air bag is activated)
2) Check the SRS components and the related parts using the table shown below.
I Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
3) Conduct self-diagnosis using CONSULT-II or ªAIR BAGº warning lamp. Refer to ªSRS Operation Checkº for details (RS-38). Ensure entire SRS operation properly.
When SRS is not activated in the side collision:
1) Check the SRS components and the related parts using the table shown below.
I Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
2) Conduct self-diagnosis using CONSULT-II or ªAIR BAGº warning lamp. Refer to ªSRS Operation Checkº for details (RS-38). Ensure entire SRS operation properly.
SRS Inspection (For side collision)
Part Side air bag is activated SRS is NOT activated
Front (LH or RH) side air
bag modules REPLACE all parts of
front seatback with
deployed front side air
bag module.1. Check for visible signs of damage (dents, tears, deformation) of the seat
back on the collision side.
2. If damagedÐREPLACE the damaged seat parts with new bolts and remove the front side air bag module.
3. Check for visible signs of damage (tears etc.) of the side air bag module.
4. Check harness and connectors for damage, and terminals for deformities.
5. If no damaged is found, reinstall the front side air bag module with new nuts.
6. If damagedÐREPLACE the front side air bag module with new nuts. Air bag must be deployed before disposal.
(LH or RH) side air bag
(satellite) sensor REPLACE the side air
bag (satellite) sensor on
the collision side with
new nuts coated with
bonding agent.
(Repair the center pillar
inner, etc. before install-
ing new one if dam-
aged.)1. Remove the satellite sensor on the collision side. Check harness connec-
tors for damage, terminals for deformities, and harness for binding.
2. Check for visible signs of damage (dents, cracks, deformation) of the satel- lite sensor.
3. Install the side air bag (satellite) sensor to check fit.
4. If no damage is found, reinstall the side air bag (satellite)sensor with new nuts.
5. If damagedÐREPLACE the side air bag sensor with new nuts coated with bonding agent.
Diagnosis sensor unit REPLACE the diagnosis sensor unit with the new
bolts.1. Check case and bracket for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall the diagnosis sensor unit with new special
bolts and ground bolt.
4. If damagedÐREPLACE. Install the diagnosis sensor unit with new special bolts and ground bolt.
Front seat belt pre-ten-
sioner assembly 1. Check if the seat belt can be extended smoothly.
If the seat belt cannot be extended smoothly.
Ð Check for deformities of the center pillar inner.
Ð If the center pillar inner has no damage, REPLACE the front seat belt pre-tensioner assembly.
2. Remove the front seat belt pre-tensioner assembly on the collision side. Check harness cover and connectors for damage, terminals for deformities, and harness for binding.
3. Check for visible signs of damage (dents, cracks, deformation) of the front seat belt pre-tensioner assembly.
4. If no damage is found, reinstall the front seat belt pre-tensioner assembly.
5. If damagedÐREPLACE the front seat belt pre-tensioner assembly with new bolts coated with bonding agent. The front seat belt pre-tensioner assembly must be deployed before disposal.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Collision Diagnosis (Cont'd)
RS-61
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Service Notice
IWhen removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
I Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to oil
or damage them.
I Apply sealing compound where necessary when installing parts.
I When applying sealing compound, be careful that the sealing compound does not protrude from parts.
I When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust pre-
vention measures.
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 for certain types of
collision. The SRS system composition which is available to NISSAN MODEL R20 is as follows (The compo-
sition varies according to the destination and optional equipment.):
IFor a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
I For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RSsection of this Service Manual.
WARNING:
I To 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 should be per-
formed by an authorized NISSAN dealer.
I Improper 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.
I Do 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 tape either just
before the harness connectors or for the complete harness are related to the SRS.
PRECAUTIONS
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Removal and Installation
REMOVAL
After removing moldings, remove glass using piano wire or power
cutting tool and an inflatable pump bag.
WARNING:
When cutting the glass from the vehicle, always wear safety
glasses and heavy gloves to help prevent glass splinters from
entering your eyes or cutting your hands.
CAUTION:
IBe careful not to scratch the glass when removing.
I Do not set or stand the glass on its edge. Small chips may
develop into cracks.
INSTALLATION
IUse a genuine Nissan Urethane Adhesive Kit or equivalent
and follow the instructions furnished with it.
I While the urethane adhesive is curing, open a door win-
dow. This will prevent the glass from being forced out by
passenger compartment air pressure when a door is
closed.
I The molding must be installed securely so that it is in
position and leaves no gap.
I Inform the customer that the vehicle should remain sta-
tionary until the urethane adhesive has completely cured
(preferably 24 hours). Curing time varies with temperature
and humidity.
WARNING:
I Keep heat and open flames away as primers and adhesive
are flammable.
I The materials contained in the kit are harmful if swallowed,
and may irritate skin and eyes. Avoid contact with the skin
and eyes.
I Use in an open, well ventilated location. Avoid breathing
the vapors. They can be harmful if inhaled. If affected by
vapor inhalation, immediately move to an area with fresh
air.
I Driving the vehicle before the urethane adhesive has com-
pletely cured may affect the performance of the windshield
in case of an accident.
CAUTION:
I Do not use an adhesive which is past its usable term. Shelf
life of this product is limited to six months after the date
of manufacture. Carefully adhere to the expiration or
manufacture date printed on the box.
I Keep primers and adhesive in a cool, dry place. Ideally,
they should be stored in a refrigerator.
I Do not leave primers or adhesive cartridge unattended
with their caps open or off.
I The vehicle should not be driven for at least 24 hours or
SBF034BA
SBT472
SBT473
WINDSHIELD AND WINDOWS
BT-42
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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 for certain types of
collision. The SRS composition which is available to NISSAN MODEL R20 is as follows (The composition
varies according to the destination and optional equipment.):
IFor a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
I For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
WARNING:
I To 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 should be per-
formed by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal 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 in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.
Introduction
To prevent the ozone layer from being destroyed, the HFC-134a (R-134a) refrigerant has replaced the previ-
ously used CFC-12 (R-12).
The new and previous service tools, refrigerant, lubricant, etc. are not interchangeable due to differences in
their physical properties and characteristics.
Always service the HFC-134a (R-134a) air conditioning system using the specified tools, lubricant and
refrigerant, observing the following precautions:
PRECAUTIONS
HA-2
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Precautions for Working with HFC-134a
(R-134a)
WARNING:I CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant must never be mixed, even in the
smallest amounts, as they are incompatible with each other. If the refrigerants are mixed, com-
pressor failure is likely to occur.
I Use only specified lubrication oil for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a)
components. If lubrication oil other than that specified is used, compressor failure is likely to
occur.
I The specified HFC-134a (R-134a) lubrication oil absorbs moisture from the atmosphere at a rapid
rate, therefore the following handling precautions must be observed:
a: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere.
b: When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Also, complete the connection of all refrigerant loop
components as quickly as possible to minimize the entry of moisture into the system.
c: Use the specified lubrication oil from a sealed container only. Containers must be re-sealed immediately after dispensing the lubrication oil. Lubrication oil in containers which are not
properly sealed will become moisture saturated, and such lubrication oil is no longer suitable
for use and should be properly disposed of.
d: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a)
system. If accidental system discharge occurs, ventilate work area before resuming service.
Additional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
e: Do not allow lubrication oil (Nissan A/C System Oil Type S or Type R) to come in contact with styrofoam parts. Damage may result.
General Refrigerant Precautions
WARNING:
I Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
I Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
I Do not store or heat refrigerant containers above 52ÉC (125ÉF).
I Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
I Do not drop, puncture, or incinerate refrigerant containers.
I Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
I Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
I Do not introduce compressed air to any refrigerant container or refrigerant component.
PRECAUTIONS
HA-4
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Precautions for Refrigerant Connection
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system
is less than atmospheric. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
IDo not leave compressor on its side or upside down for more than 10 minutes, as compressor oil
will enter low pressure chamber.
I When connecting tubes, always use a torque wrench and a back-up wrench.
I After disconnecting tubes, plug all openings immediately to prevent entrance of dirt and moisture.
I When installing an air conditioner in the vehicle, the pipes must be connected at the final stage of
the operation. The seal caps of the pipes and other components must not be removed until their
removal is required for connection.
I To prevent the condensation of moisture inside A/C components, components stored in cool areas
should be allowed to warm to the working area temperature before removing the seal caps.
I Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
I Always replace used O-rings.
I When connecting tube, apply lubrication oil to portions shown in illustration. Be careful not to
apply oil to threaded portion.
Lubrication oil name: NISSAN A/C System Oil Type S
Part number: KLH00-PAGS0
I O-ring must be closely attached to inflated portion of tube.
I After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
I After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten
connections of seal seat to the specified torque.
SHA525D
PRECAUTIONS
HA-5
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HFC-134a (R-134a) Service Procedure
DISCHARGING REFRIGERANT
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. To remove HFC-134a (R-134a) from the A/C system, use service equipment certified to meet the
requirements of HFC-134a (R-134a) recycling equipment or HFC-134a (R-134a) recovery equipment. If
accidental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.
EVACUATING SYSTEM AND CHARGING REFRIGERANT
SHA559D
SHA560D
SERVICE PROCEDURES
HA-16
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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 for certain types of
collision. The SRS system composition which is available to NISSAN MODEL R20 is as follows (The compo-
sition varies according to the destination and optional equipment.):
IFor a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
I For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS sectionof this Service Manual.
WARNING:
I To 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 should be per-
formed by an authorized NISSAN dealer.
I Improper 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.
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
Wiring Diagrams and Trouble Diagnoses
When you read wiring diagrams, refer to the following:
IGI section, ªHOW TO READ WIRING DIAGRAMSº
I EL section, ªPOWER SUPPLY ROUTINGº for power distribution circuit
When you perform trouble diagnoses, refer to the following:
I GI section, ªHOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSESº
I GI section, ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENTº
PRECAUTIONS
SC-2
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How to Handle Battery
CAUTION:
If it becomes necessary to start the engine with a booster bat-
tery and jumper cables,
1) Use a 12-volt booster battery.
2) After connecting battery cables, ensure that they aretightly clamped to battery terminals for good contact.
METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-discharg-
ing a battery.
IThe battery surface (particularly its top) should always be kept
clean and dry.
I The terminal connections should be clean and tight.
I At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as ªlow maintenanceº
and ªmaintenance-freeº.
I When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal.
I Check the charge condition of the battery.
Periodically check the specific gravity of the electrolyte. Keep
a close check on charge condition to prevent over-discharge.
CHECKING ELECTROLYTE LEVEL
WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If acid contacts eyes, skin or clothing, immediately
flush with water for 15 minutes and seek medical attention.
MEL040F
MEL041F
MEL042F
BATTERY
SC-3
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System Description
The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
Power is supplied at all times to alternator terminal 4 (S) (ZD30DDTi engine models) through:
I10A fuse (No. 31, located in the fuse and fusible link box).
Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage
is controlled by the IC regulator at terminal 4 (S) detecting the input voltage (ZD30DDTi engine models). The
charging circuit is protected by the 100A fusible link.
The alternator is grounded to the engine block.
With the ignition switch in the ON or START position, power is supplied
I through 10A fuse [No. 12, located in the fuse block (J/B)]
I to combination meter terminal 28 for the charge warning lamp.
Ground is supplied to terminal 2 of the combination meter through terminal 1(L) (TD27Ti engine models) or
3(L) (ZD30DDTi engine models) of the alternator. With power and ground supplied, the charge warning lamp
will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened
and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a malfunction is indicated.
CHARGING SYSTEM
SC-23
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