electrical system 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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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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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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Work Flow
STEPDESCRIPTION
STEP 1 Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis:
WHATVehicle Model, Engine, Transmission and the System (i.e. Radio).
WHEN Date, Time of Day, Weather Conditions, Frequency.
WHERE Road Conditions, Altitude and Traffic Situation.
HOW System Symptoms, Operating Conditions (Other Components Interaction).
Service History and if any After Market Accessories have been installed.
STEP 2 Operate the system, road test if necessary. Verify the parameter of the incident.
If the problem cannot be duplicated, refer to ªIncident Simulation Testsº next page.
STEP 3 Get the proper diagnosis materials together including: POWER SUPPLY ROUTING
System Operation Descriptions
Applicable Service Manual Sections
Check for any Service Bulletin.
Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.
STEP 4 Inspect the system for mechanical binding, loose connectors or wiring damage. Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness
Layouts.
STEP 5 Repair or replace the incident circuit or component.
STEP 6 Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inad- vertently created a new incident during your diagnosis or repair steps.
SGI838
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
GI-22
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Incident Simulation Tests
INTRODUCTION
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the
conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The
following section illustrates ways to simulate the conditions/environment under which the owner experiences
an electrical incident.
The section is broken into the six following topics:
IVehicle vibration
I Heat sensitive
I Freezing
I Water intrusion
I Electrical load
I Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of
the problem.
VEHICLE VIBRATION
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/C on). In such a case, you will want to check for a vibration related condition. Refer to the illustration below.
Connectors & harness
Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gen-
tly shake each connector and harness while monitoring the system for the incident you are trying to dupli-
cate. This test may indicate a loose or poor electrical connection.
Hint
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector termi-
nals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs
intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean
the terminals on related connectors in the system.
Sensors & relays
Gently apply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
SGI839
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
GI-23
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Engine compartment
There are several reasons a vehicle or engine vibration could
cause an electrical complaint. Some of the things to check for are:
IConnectors not fully seated.
I Wiring harness not long enough and is being stressed due to
engine vibrations or rocking.
I Wires laying across brackets or moving components.
I Loose, dirty or corroded ground wires.
I Wires routed too close to hot components.
To inspect components under the hood, start by verifying the integ-
rity of ground connections. (Refer to GROUND INSPECTION
described later.) First check that the system is properly grounded.
Then check for loose connection by gently shakingthe wiring or
components as previously explained. Using the wiring diagrams
inspect the wiring for continuity.
Behind the instrument panel
An improperly routed or improperly clamped harness can become
pinched during accessory installation. Vehicle vibration can aggra-
vate a harness which is routed along a bracket or near a screw.
Under seating areas
An unclamped or loose harness can cause wiring to be pinched by
seat components (such as slide guides) during vehicle vibration. If
the wiring runs under seating areas, inspect wire routing for pos-
sible damage or pinching.
HEAT SENSITIVE
The owner's problem may occur during hot weather or after car has
sat for a short time. In such cases you will want to check for a heat
sensitive condition.
To determine if an electrical component is heat sensitive, heat the
component with a heat gun or equivalent.
Do not heat components above 60ÉC (140ÉF). If incident occurs
while heating the unit, either replace or properly insulate the com-
ponent.
SGI842
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont'd)
GI-24
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ISO 15031-2 Terminology List
All emission related terms used in this publication in accordance with ISO 15031-2 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
***: Not applicable
NEW TERMNEW ACRONYM/
ABBREVIATION OLD TERM
Air cleaner ACL Air cleaner
Barometric pressure BARO
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC ***
Data link connector for CONSULT DLC for CONSULT Diagnostic connector for CONSULT
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read only
memory EEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission system EVAP system Evaporative emission control system
Exhaust gas recirculation valve EGR valve EGR valve
Exhaust gas recirculation control-BPT valve EGRC-BPT valve BPT valve
Exhaust gas recirculation control-solenoid valve EGRC-solenoid valve EGR control solenoid valve
ISO 15031-2 TERMINOLOGY LIST
GI-34
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***: Not applicable
NEW TERMNEW ACRONYM/
ABBREVIATION OLD TERM
Exhaust gas recirculation temperature sensor EGR temperature sensor Exhaust gas temperature sensor
Flash electrically erasable programmable read
only memory FEEPROM ***
Flash erasable programmable read only memory FEPROM ***
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Heated Oxygen sensor HO
2S Exhaust gas sensor
Idle air control system IAC systemIdle speed control
Idle air control valve-air regulator IACV-air regulatorAir regulator
Idle air control valve-auxiliary air control valve IACV-AAC valve Auxiliary air control (AAC) valve
Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve
Idle air control valve-idle up control solenoid
valve IACV-idle up control solenoid
valve
Idle up control solenoid valve
Idle speed control-FI pot ISC-FI potFI pot
Idle speed control system ISC system***
Ignition control module ICM***
Indirect fuel injection system IFI system***
Intake air temperature sensor IATS Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator MI Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel control solenoid valve
Multiport fuel injection system MFI system Fuel injection control
Neutral position switch *** Neutral switch
Non-volatile random access memory NVRAM ***
On-board diagnostic system OBD system Self-diagnosis
Open loop OL Open loop
Oxidation catalyst OC Catalyst
Oxidation catalytic converter system OC system ***
Oxygen sensor O
2S Exhaust gas sensor
Park position switch ***Park switch
Park/neutral position switch PNP switch Park/neutral switch
Periodic trap oxidizer system PTOX system ***
ISO 15031-2 TERMINOLOGY LIST
ISO 15031-2 Terminology List (Cont'd)
GI-35
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REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT-II has two kinds of triggers and they can be selected by
touching ªSETTINGº in ªDATA MONITORº mode.
1) ªAUTO TRIGº (Automatic trigger):
IThe malfunction will be identified on the CONSULT-II screen in
real time.
In other words, DTC will be displayed if the malfunction is
detected by ECM.
At the moment a malfunction is detected by ECM, ªMONITORº
in ªDATA MONITORº screen is changed to ªRecording Data ...
xx%º as shown at left, and the data after the malfunction detec-
tion is recorded. Then when the percentage reached 100%,
ªREAL-TIME DIAGº screen is displayed. If ªSTOPº is touched
on the screen during ªRecording Data ... xx%º, ªREAL-TIME
DIAGº screen is also displayed.
The recording time after the malfunction detection and the
recording speed can be changed by ªTRIGGER POINTº and
ªRecording Speedº. Refer to CONSULT-II OPERATION
MANUAL.
2) ªMANU TRIGº (Manual trigger):
I DTC will not be displayed automatically on CONSULT-II screen
even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though
a malfunction is detected.
Use these triggers as follows:
1) ªAUTO TRIGº
I While trying to detect the DTC by performing the ªDTC Confir-
mation Procedureº, be sure to select to ªDATA MONITOR
(AUTO TRIG)º mode. You can confirm the malfunction at the
moment it is detected.
I While narrowing down the possible causes, CONSULT-II
should be set in ªDATA MONITOR (AUTO TRIG)º mode, espe-
cially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twist-
ing) the suspicious connectors, components and harness in the
ªDTC Confirmation Procedureº, the moment a malfunction is
found the DTC will be displayed. (Refer to GI section, ªIncident
Simulation Testsº in ªHOW TO PERFORM EFFICIENT DIAG-
NOSIS FOR AN ELECTRICAL INCIDENTº.)
2) ªMANU TRIGº
I If the malfunction is displayed as soon as ªDATA MONITORº is
selected, reset CONSULT-II to ªMANU TRIGº. By selecting
ªMANU TRIGº you can monitor and store the data. The data
can be utilized for further diagnosis, such as a comparison with
the value for the normal operating condition.
SEF373Y
SEF707X
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
CONSULT-II (Cont'd)
EC-44
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DESCRIPTION FOR WORK FLOW
STEPDESCRIPTION
STEP I Get detailed information about the conditions and the environment when the incident/symptom occurred using
the ªDIAGNOSTIC WORKSHEETº, EC-46.
STEP II Before confirming the concern, check and write down (print out using CONSULT-II) the DTC, then erase the
DTC. Refer to EC-33.
If the incident cannot be verified, perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
ªSymptom Matrix Chartº will be useful. Refer to EC-56.) Also check related service bulletins for information.
STEP III Try to confirm the symptom and under what conditions the incident occurs.
The ªDIAGNOSTIC WORK SHEETº is useful to verify the incident. Connect CONSULT-II to the vehicle in DATA
MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IV Try to detect the DTC by driving in (or performing) the ªDTC Confirmation Procedureº. Check and read the DTC
by using CONSULT-II.
During the DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG)
mode and check real time diagnosis results.
If the incident cannot be verified, perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
In case the ªDTC Confirmation Procedureº is not available, perform the ªOverall Function Checkº instead. The
DTC cannot be displayed by this check, however, this simplified ªcheckº is an effective alternative.
The ªNGº result of the ªOverall Function Checkº is the same as the DTC detection.
STEP V Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC XXXX.
If the normal code is indicated, proceed to the Basic Inspection, EC-50. Then perform inspections according to
the Symptom Matrix Chart. Refer to EC-56.
STEP VI Identify where to begin diagnosis based on the relationship study between symptom and possible causes.
Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) ªHarness Layoutsº.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in ªDATA MONITOR
(AUTO TRIG)º mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CON-
SULT-II. Refer to EC-69 or EC-66.
The ªDiagnostic Procedureº in EC section contains a description based on open circuit inspection. A short circuit
inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to GI section (ªCir-
cuit Inspectionº, ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENTº).
Repair or replace the malfunction parts.
If the malfunctioning part cannot be detected, perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENTº, EC-78.
STEP VII Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions
and circumstances which resulted in the customer's initial complaint.
Perform the ªDTC Confirmation Procedureº and confirm the normal code (DTC No. 0505) is detected. If the inci-
dent is still detected in the final check, perform STEP VI by using a different method from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM.
(Refer to EC-33.)
TROUBLE DIAGNOSIS Ð INTRODUCTIONZD30DDTi
Work Flow (Cont'd)
EC-49
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