transmission 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.
QUICK REFERENCE INDEX
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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
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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.
SBR364AD
HOW TO USE THIS MANUAL
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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.
HOW TO USE THIS MANUAL
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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
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Model Variation
BodyGrade Engine Transmission Group A (RHD) Group B (South)
Group C (Cen- tral) Group D (North)
H/T SE
ªLuxury/
Eleganceº TD27Ti FS5R30A KVPNRVF-UED KVPNLVF-UGD KVPNLVF-USD
ZD30DDTi FS5R30A KWSNRVF-UED KWSNLVF-UGD KWSNLVF-USD
RE4R01A KWSNRVA-UED KWSNLVA-UGD KWSNLVA-USD
SR
ªSportº TD27Ti FS5R30A KVPNRUF-UED KVPNLUF-UGD KVPNLUF-USD
Wagon SE
ªLuxury/
Eleganceº TD27Ti FS5R30A TVPURVF-UED TVPULVF-UGD TVPULVF-USD
ZD30DDTi FS5R30A TWSURVF-UED TWSULVF-UGD TWSULVF-USD
RE4R01A TWSURVA-UED TWSULVA-UGD TWSULVA-USD
SR
ªSportº TD27Ti FS5R30A TVPURUF-UED TVPULUF-UGD TVPULUF-USD
Prefix and suffix designations:
KVPNLVFR20UGD
D : 04 model year
E : RHD models
G : South/Central Europe
S : North Europe
U : Turbo
F : 5-speed manual transmission
A : Automatic transmission
U : SR grade
V : SE grade
L : Left-hand drive
R : Right-hand drive
N : 4-wheel drive, short wheelbase
U : 4-wheel drive, long wheelbase
VP : TD27Ti engine
WS : ZD30DDTi engine
K : Hardtop
T : Wagon
IDENTIFICATION INFORMATION
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IDENTIFICATION PLATE
ENGINE SERIAL NUMBER
AUTOMATIC TRANSMISSION NUMBERMANUAL TRANSMISSION NUMBER
NGI011
NGI012SGI137A
SGI760-ANGI014
IDENTIFICATION INFORMATION
Identification Number (Cont'd)
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4-pole Lift
WARNING:
Do not use a 2-pole lift.
Due to weight balance of the vehicle and shape of underbody,
lift arms can not be attached in a safe way. Therefore it is rec-
ommended to use a 4-pole lift only.
Tow Truck Towing
CAUTION:
IAll applicable local laws regarding the towing operation
must be obeyed.
I It is necessary to use proper towing equipment to avoid
possible damage to the vehicle during a towing operation.
I Attach safety chains for all towing.
I When towing, make sure that the transmission, steering
system and power train are in good order. If any unit is
damaged, a dolly must be used.
I When towing with the front wheels on the ground:
Move both the gearshift and transfer levers to neutral (ªNº
position).
Turn the ignition key to the ªOFFº position and secure the
steering wheel in a straightahead position with a rope or
similar device. Never place the ignition key in the ªLOCKº
position. This will result in damage to the steering lock
mechanism.
I When towing with the rear wheels on the ground, release
the parking brake and move both the gearshift and trans-
fer levers to neutral (ªNº position).
I Never tow vehicle from the rear (i.e., backward) with four
wheels on the ground as this may cause serious and
expensive damage to the transmission.
LIFTING POINTS AND TOW TRUCK TOWING
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NISSAN recommends that a dolly be used as illustrated when tow-
ing 4-wheel drive models.
Towing with four wheels on ground or towing with front
(rear wheels on ground) or rear wheels (front wheels
on ground) raised
Observe the following restricted towing speeds and distances.Speed:Below 50 km/h (30 MPH)
Distance: Less than 65 km (40 miles)
If the speed or distance must necessarily be greater, remove the
front and rear propeller shafts beforehand to prevent damage to the
transmission.
TOWING POINT
I Always pull the cable straight out from the vehicle. Never
pull on the hook at a sideways angle.
I Use proper towing equipment when towing. Otherwise, the
vehicle body will be damaged.
Front
I Only R.H. hook may be used for towing purposes. Use L.H.
hook only for securing the vehicle during transportation.
Rear
I Either hook can be used for towing purposes.
A platform should be used.
EGI018
EGI019
EGI020
LIFTING POINTS AND TOW TRUCK TOWING
Tow Truck Towing (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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