service NISSAN TERRANO 2004 Service Repair Manual

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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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
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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.
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PRECAUTIONS
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
(Dual Air Bag System) (Cont'd)
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1.A QUICK REFERENCE INDEX , a black tab (e.g.) is provided on the first page. You can quickly find
the first page of each section by mating it to the section's black tab.
2. THE CONTENTS are listed on the first page of each section.
3. THE TITLE is indicated on the upper portion of each page and shows the part or system.
4. THE PAGE NUMBER of each section consists of two letters which designate the particular section and a
number (e.g. ªBR-5º).
5. THE LARGE ILLUSTRATIONS are exploded views (See below) and contain tightening torques, lubrica-
tion points and other information necessary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriate PARTS CATALOG .
6. THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks
of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle
or transmission, etc. are presented in a step-by-step format where necessary.
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7. The followingSYMBOLS AND ABBREVIATIONS are used:
,: Tightening torque
: Should be lubricated with grease.
Unless otherwise indicated, use rec-
ommended multi-purpose grease.
: Should be lubricated with oil.
: Sealing point
: Checking point
: Always replace after every disassem- bly.
L.H., R.H.: Left-Hand, Right-Hand
FR, RR : Front, Rear
2WD : 2-Wheel Drive
4WD : 4-Wheel Drive
qP: Apply petroleum jelly.
: Apply A.T.F.
A.T.F. : Automatic Transmission Fluid
H : Select with proper thickness.
I : Adjustment is required.
M/T : Manual Transaxle/Transmission
A/C : Air Conditioner
P/S : Power Steering
S.S.T. : Special Service Tools
S.D.S. : Service Data and Specifications
SAE : Society of Automotive Engineers, Inc.
L.H.D. : Left-Hand Drive
R.H.D. : Right-Hand Drive
8. The UNITSgiven in this manual are primarily expressed as the SI UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system. ªExampleºTightening torque:59-78N ×m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
9. TROUBLE DIAGNOSES are included in sections dealing with complicated components.
10. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of
data.
11. The captions WARNINGandCAUTION warn you of steps that must be followed to prevent personal injury
and/or damage to some part of the vehicle.
I WARNING indicates the possibility of personal injury if instructions are not followed.
I CAUTION indicates the possibility of component damage if instructions are not followed.
I BOLD TYPED STATEMENTS exceptWARNING andCAUTION give you helpful information.
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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.
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HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
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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.
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HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
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***: Not applicable
NEW TERMNEW ACRONYM/
ABBREVIATION OLD TERM
Powertrain control module PCM ***
Programmable read only memory PROM ***
Pulsed secondary air injection control solenoid
valve PAIRC solenoid valve AIV control solenoid valve
Pulsed secondary air injection system PAIR system Air induction valve (AIV) control
Pulsed secondary air injection valve PAIR valve Air induction valve
Random access memory RAM ***
Read only memory ROM ***
Scan tool ST ***
Secondary air injection pump AIR pump ***
Secondary air injection system AIR system ***
Sequential multiport fuel injection system SFI system Sequential fuel injection
Service reminder indicator SRI ***
Simultaneous multiport fuel injection system *** Simultaneous fuel injection
Smoke puff limiter system SPL system ***
Supercharger SC ***
Supercharger bypass SCB ***
System readiness test SRT ***
Thermal vacuum valve TVV Thermal vacuum valve
Three way catalyst TWC Catalyst
Three way catalytic converter system TWC system ***
Three way + oxidation catalyst TWC + OC Catalyst
Three way + oxidation catalytic converter system TWC + OC system ***
Throttle body TB Throttle chamber
SPI body
Throttle body fuel injection system TBI system Fuel injection control
Throttle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Throttle switch
Torque converter clutch solenoid valve TCC solenoid valve Lock-up cancel solenoid
lock-up solenoid
Turbocharger TC Turbocharger
Vehicle speed sensor VSS Vehicle speed sensor
Volume air flow sensor VAFS Air flow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter system WU-OC system ***
Warm up three-way catalyst WU-TWC Catalyst
Warm up three-way catalytic converter system WU-TWC system ***
Wide open throttle position switch WOP switch Full switch
ISO 15031-2 TERMINOLOGY LIST
ISO 15031-2 Terminology List (Cont'd)
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Greasing Steering Linkage ........................................44
Ventilation Air Filter ....................................................44
Body ........................................................................\
...45
Checking Body Corrosion ..........................................47SERVICE AND SPECIFICATIONS (SDS)
.....................48
Engine Maintenance ..................................................48
Chassis and Body Maintenance ................................49
CONTENTS(Cont'd)
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Shown below are Pre-delivery Inspection items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD Ð engine off
lRadiator coolant level and coolant hose connections for leaks
l Battery fluid level, specific gravity and conditions of battery terminals
l Drive belts tension
l Fuel filter for water or dust, and fuel lines and connections for leaks
l Engine oil level and oil leaks
l Brake and clutch reservoirs fluid level and fluid lines for leaks
l Windshield and rear window washer and headlamp cleaner reservoir fluid level
l Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
lRemove front spring/strut spacer (if applicable)
l Operation of all instruments, gauges, lights and accessories
l Operation of horn(s), wiper and washer
l Steering lock for operation
l Check air conditioner for gas leaks
l Front and rear seats, and seat belts for operation
l All moldings, trims and fittings for fit and alignment
l All windows for operation and alignment
l Hood, tailgate, door panels for fit and alignment
l Latches, keys and locks for operation
l Weatherstrips for adhesion and fit
l Headlamp aiming
l Tighten wheel nuts (Inc. inner nuts if applicable)
l Tire pressure (Inc. spare tire)
l Check front wheels for toe-in
l Install clock/voltmeter/room lamp fuse (if applicable)
l Install deodorizing filter to air conditioner (if applicable)
l Remove wiper blade protectors (if applicable)
UNDER BODY
lManual transmission/transaxle, transfer and differential gear oil level
l Brake and fuel lines and oil/fluid reservoirs for leaks
l Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
l Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
lClutch operation
l Parking brake operation
l Service brake operation
l Automatic transmission/transaxle shift timing and kickdown (if applicable)
l Steering control and returnability
l Engine performance
l Squeaks and rattles
ENGINE OPERATING AND HOT
lAdjust idle speed
l Automatic transmission/transaxle fluid level (if applicable)
l Engine idling and stop knob operation
FINAL INSPECTION
lInstall necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
l Inspect for interior and exterior metal and paint damage
l Check for spare tire, jack, tools (wheel check) and literature
l Wash, clean interior and exterior
PRE-DELIVERY INSPECTION ITEMS
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