FOREWORD
ThismanualcontainsmaintenanceandrepairproceduresforNISSAN PICKUP,modelD22series.
Inordertoassureyoursafetyandtheefficientfunctioningofthevehicle, thismanualshouldbereadthoroughly.Itisespeciallyimportantthatthe PRECAUTIONSintheGIsectionbecompletelyunderstoodbeforestarting anyrepairtask.
Allinformationinthismanualisbasedonthelatestproductinformation atthetimeofpublication.Therightisreservedtomakechangesinspecificationsandmethodsatanytimewithoutnotice.
IMPORTANTSAFETYNOTICE
Theproperperformanceofserviceisessentialforboththesafetyofthe technicianandtheefficientfunctioningofthevehicle. TheservicemethodsinthisServiceManualaredescribedinsuchamannerthattheservicemaybeperformedsafelyandaccurately.
Servicevarieswiththeproceduresused,theskillsofthetechnicianandthe toolsandpartsavailable.Accordingly,anyoneusingserviceprocedures, toolsorpartswhicharenotspecificallyrecommendedbyNISSANmust firstcompletelysatisfyhimselfthatneitherhissafetynorthevehicle’s safetywillbejeopardizedbytheservicemethodselected.
NISSANEUROPES.A.S.
ServiceEngineeringSection
Paris,France
GENERALINFORMATION SECTION GI
PRECAUTIONS .........................................................1 PrecautionsforSupplementalRestraint System(SRS)‘‘AIRBAG’’(4WDmodels).............1 PrecautionsforSupplementalRestraint System(SRS)‘‘AIRBAG’’(2WDmodels).............1 PrecautionsforNATS............................................2 GeneralPrecautions..............................................2 PrecautionsforMultiportFuelInjectionSystem orECCSEngine....................................................4 PrecautionsforThreeWayCatalyst (Ifsoequipped)......................................................4 PrecautionsforEngineOils...................................4 PrecautionsforFuel...............................................5 PrecautionsforAirConditioning............................6 HOWTOUSETHISMANUAL ..................................7 HOWTOREADWIRINGDIAGRAMS ......................9 Sample/WiringDiagram-EXAMPL-....................9 Description...........................................................11 HOWTOCHECKTERMINAL .................................18 HowtoProbeConnectors...................................18 HowtoCheckEnlargedContactSpringof Terminal...............................................................19 WaterproofConnectorInspection........................20 TerminalLockInspection.....................................20 HOWTOPERFORMEFFICIENTDIAGNOSIS FORANELECTRICALINCIDENT .........................21 WorkFlow............................................................21 HOWTOPERFORMEFFICIENTDIAGNOSIS ......22 IncidentSimulationTests.....................................22 CircuitInspection.................................................25 HOWTOFOLLOWFLOWCHARTIN TROUBLEDIAGNOSES .........................................31 HowtoFollowThisFlowChart...........................32 CONSULTCHECKINGSYSTEM ............................34 FunctionandSystemApplication........................34 LithiumBatteryReplacement...............................34 CheckingEquipment............................................35 LoadingProcedure...............................................36 CONSULTDataLinkConnector(DLC)Circuit...36 IDENTIFICATIONINFORMATION ..........................37 ModelVariation....................................................37 IdentificationNumber...........................................40 Dimensions..........................................................44 WheelsandTires.................................................46 LIFTINGPOINTSANDTOWTRUCKTOWING.....47 PantographJack..................................................47 ScrewJack...........................................................48 GarageJackandSafetyStand...........................49 2-poleLift.............................................................50 TowTruckTowing...............................................51 TowingPoint........................................................53 TIGHTENINGTORQUEOFSTANDARDBOLTS ..54 SAEJ1930TERMINOLOGYLIST ..........................55 SAEJ1930TerminologyList...............................55 GI
CONTENTS
PRECAUTIONS
Observethefollowingprecautionstoensuresafeand properservicing.Theseprecautionsarenotdescribedin eachindividualsection.
PrecautionsforSupplementalRestraint
System(SRS)‘‘AIRBAG’’(4WDmodels)
TheSupplementalRestraintSystem‘‘AIRBAG’’,usedalongwith aseatbelt,helpstoreducetheriskorseverityofinjurytothe driverinafrontalcollision.TheSupplementalRestraintSystem consistsofanairbagmodule(locatedinthecenterofthesteeringwheel),adiagnosissensorunit,warninglamp,wiringharness andspiralcable.Informationnecessarytoservicethesystem safelyisincludedinthe RSsection ofthisServiceManual.
WARNING:
● ToavoidrenderingtheSRSinoperative,whichcould increasetheriskofpersonalinjuryordeathintheevent ofacollisionwhichwouldresultinairbaginflation,all maintenancemustbeperformedbyanauthorized NISSANdealer.
● Impropermaintenance,includingincorrectremovaland installationoftheSRS,canleadtopersonalinjury causedbyunintentionalactivationofthesystem.
● Donotuseelectricaltestequipmentonanycircuit relatedtotheSRSunlessinstructedtointhisService Manual.SRSwiringharnessesarecoveredwithyellow insulationeitherjustbeforetheharnessconnectorsor forthecompleteharness,foreasyidentification.
PrecautionsforSupplementalRestraint System(SRS)‘‘AIRBAG’’(2WDmodels)
TheSupplementalRestraintSystem‘‘AIRBAG’’,usedalongwith aseatbelt,helpstoreducetheriskorseverityofinjurytothe driverinafrontalcollision.TheSupplementalRestraintSystem consistsofanairbagmodule(locatedinthecenterofthesteeringwheel),adiagnosissensorunit,warninglampandspiral cable.Informationnecessarytoservicethesystemsafelyis includedinthe RSsection ofthisServiceManual.
WARNING:
● ToavoidrenderingtheSRSinoperative,whichcould increasetheriskofpersonalinjuryordeathintheevent ofacollisionwhichwouldresultinairbaginflation,all maintenancemustbeperformedbyanauthorized NISSANdealer.
● Impropermaintenance,includingincorrectremovaland installationoftheSRS,canleadtopersonalinjury causedbyunintentionalactivationofthesystem.
● Donotuseelectricaltestequipmentonanycircuit relatedtotheSRS.
SGI646
GI-1
PRECAUTIONS
PrecautionsforNATS
NATS(NissanAnti-TheftSystem)
NATSwillimmobilizetheengineifsomeonetriestostartitwithouttheregisteredkeyofNATS.
AlloftheoriginallysuppliedignitionkeyIDshavebeenNATS registered.
TheNATSsecurityindicatorislocatedontheinstrumentpanel. Theindicatorblinkswhentheignitionswitchisin‘‘OFF’’or ‘‘ACC’’position.Therefore,NATSwarnsoutsidersthatthe vehicleisequippedwiththeanti-theftsystem.
● Gasolineengine:
WhenNATSdetectstrouble,themalfunctionindicatorlamp (MIL)blinks.
Thisblinkingindicatesthattheanti-theftisnotfunctioning,so promptserviceisrequired.
● Dieselengine:
WhenNATSdetectstroublewhileengineisrunningorignitionswitchin‘‘ON’’position,theNATSsecurityindicator comeson.
Thisindicatesthattheanti-theftisnotfunctioning,soprompt serviceisrequired.
● WhenservicingNATS(troublediagnoses,systeminitialisationandadditionalregistrationofotherNATSignitionkey IDs),CONSULThardwareandCONSULTNATSsoftwareis necessary.
RegardingtheproceduresofNATSinitialisationandNATS ignitionkeyIDregistration,refertoCONSULToperation manual,NATS.
Therefore,CONSULTNATSsoftware(programcardand operationmanual)mustbekeptstrictlyconfidentialtomaintaintheintegrityoftheanti-theftfunction.
● WhenservicingNATS(troublediagnoses,systeminitialisationandadditionalregistrationofotherNATSignitionkey IDs),itmaybenecessarytore-registeroriginalkeyidentification.Therefore,besuretoreceiveallkeysfromvehicle owner.
AmaximumoffourkeyIDscanberegisteredintoNATS.
GeneralPrecautions
● Donotoperatetheengineforanextendedperiodoftime withoutproperexhaustventilation.
Keeptheworkareawellventilatedandfreeofanyinflammablematerials.Specialcareshouldbetakenwhenhandlinganyinflammableorpoisonousmaterials,suchas gasoline,refrigerantgas,etc.Whenworkinginapitorother enclosedarea,besuretoproperlyventilatetheareabefore workingwithhazardousmaterials.
Donotsmokewhileworkingonthevehicle.
SGI916 SGI285
GI-2
PRECAUTIONS GeneralPrecautions(Cont’d)
● Beforejackingupthevehicle,applywheelchocksorother tireblockstothewheelstopreventthevehiclefrommoving. Afterjackingupthevehicle,supportthevehicleweightwith safetystandsatthepointsdesignatedforproperliftingbefore workingonthevehicle. Theseoperationsshouldbedoneonalevelsurface.
● Whenremovingaheavycomponentsuchastheengineor transaxle/transmission,becarefulnottoloseyourbalance anddropthem.Also,donotallowthemtostrikeadjacent parts,especiallythebraketubesandmastercylinder.
● Beforestartingrepairswhichdonotrequirebatterypower: Turnoffignitionswitch. Disconnectthenegativebatteryterminal.
● Topreventseriousburns: Avoidcontactwithhotmetalparts. Donotremovetheradiatorcapwhentheengineishot.
● Beforeservicingthevehicle: Protectfenders,upholsteryandcarpetingwithappropriate covers. Takecautionthatkeys,bucklesorbuttonsdonotscratch paint.
● Cleanalldisassembledpartsinthedesignatedliquidorsolventpriortoinspectionorassembly.
● Replaceoilseals,gaskets,packings,O-rings,locking washers,cotterpins,self-lockingnuts,etc.withnewones.
● Replaceinnerandouterracesoftaperedrollerbearingsand needlebearingsasaset.
● Arrangethedisassembledpartsinaccordancewiththeir assembledlocationsandsequence.
● Donottouchtheterminalsofelectricalcomponentswhich usemicrocomputers(suchasECMs). Staticelectricitymaydamageinternalelectroniccomponents.
SGI231
SGI233 SGI234
SEF289H
GI-3
PRECAUTIONS
● Afterdisconnectingvacuumorairhoses,attachatagto indicatetheproperconnection.
● Useonlythefluidsandlubricantsspecifiedinthismanual.
● Useapprovedbondingagent,sealantsortheirequivalents whenrequired.
● Usetoolsandrecommendedspecialtoolswherespecified forsafeandefficientservicerepairs.
● Whenrepairingthefuel,oil,water,vacuumorexhaust systems,checkallaffectedlinesforleaks.
● Disposeofdrainedoilorthesolventusedforcleaningparts inanappropriatemanner.
WARNING:
TopreventECMfromstoringthediagnostictroublecodes, donotcarelesslydisconnecttheharnessconnectorswhich arerelatedtotheECCSsystemandTCM(Transmission ControlModule)system.TheconnectorsshouldbedisconnectedonlywhenworkingaccordingtotheWORKFLOWof TROUBLEDIAGNOSESinECsection.
PrecautionsforMultiportFuelInjection SystemorECCSEngine
● Beforeconnectingordisconnectinganyharnessconnector forthemultiportfuelinjectionsystemorECM(EngineControlModule):
Turnignitionswitchto‘‘OFF’’position. Disconnectnegativebatteryterminal. Otherwise,theremaybedamagetoECM.
● Beforedisconnectingpressurizedfuellinefromfuelpumpto injectors,besuretoreleasefuelpressure.
● BecarefulnottojarcomponentssuchasECMandmassair flowsensor.
PrecautionsforThreeWayCatalyst (Ifsoequipped)
Ifalargeamountofunburnedfuelflowsintothecatalyst,the catalysttemperaturewillbeexcessivelyhigh.Topreventthis, followtheinstructionsbelow:
● Useunleadedgasolineonly.Leadedgasolinewillseriously damagethethreewaycatalyst.
● Whencheckingforignitionsparkormeasuringengine compression,maketestsquicklyandonlywhennecessary.
● Donotrunenginewhenthefueltanklevelislow,otherwise theenginemaymisfirecausingdamagetothecatalyst.
Donotplacethevehicleonflammablematerial.Keepflammable materialofftheexhaustpipeandthethreewaycatalyst.
PrecautionsforEngineOils
Prolongedandrepeatedcontactwithusedengineoilmaycause skincancer.Trytoavoiddirectskincontactwithusedoil.
GeneralPrecautions(Cont’d) GI-4
SGI787
PRECAUTIONS
PrecautionsforEngineOils(Cont’d)
Ifskincontactismade,washthoroughlywithsoaporhand cleanerassoonaspossible.
HEALTHPROTECTIONPRECAUTIONS
● Avoidprolongedandrepeatedcontactwithoils,particularly usedengineoils.
● Wearprotectiveclothing,includingimperviousgloveswhere practicable.
● Donotputoilyragsinpockets.
● Avoidcontaminatingclothes,particularlyunderpants,withoil.
● Heavilysoiledclothingandoil-impregnatedfootwearshould notbeworn.Overallsmustbecleanedregularly.
● FirstAidtreatmentshouldbeobtainedimmediatelyforopen cutsandwounds.
● Usebarriercreams,applyingthembeforeeachworkperiod, tohelptheremovalofoilfromtheskin.
● Washwithsoapandwatertoensurealloilisremoved(skin cleansersandnailbrusheswillhelp).Preparationscontaininglanolinreplacethenaturalskinoilswhichhavebeen removed.
● Donotusegasoline,kerosine,dieselfuel,gasoil,thinners orsolventsforcleaningskin.
● Ifskindisordersdevelop,obtainmedicaladvicewithout delay.
● Wherepracticable,degreasecomponentspriortohandling.
● Wherethereisariskofeyecontact,eyeprotectionshould beworn,forexample,chemicalgogglesorfaceshields;in additionaneyewashfacilityshouldbeprovided.
ENVIRONMENTALPROTECTIONPRECAUTIONS
Burningusedengineoilinsmallspaceheatersorboilerscanbe recommendedonlyforunitsofapproveddesign.Theheating systemmustmeettherequirementsofHMInspectorateofPollutionforsmallburnersoflessthan0.4MW.Ifindoubtcheck withtheappropriatelocalauthorityand/ormanufacturerofthe approvedappliance.
Disposeofusedoilandusedoilfiltersthroughauthorizedwaste disposalcontractorstolicensedwastedisposalsites,ortothe wasteoilreclamationtrade.Ifindoubt,contactthelocalauthorityforadviceondisposalfacilities.
Itisillegaltopourusedoilontotheground,downsewersor drains,orintowatercourses.
Theregulationsconcerningthepollutionoftheenvironment willvaryfromcountrytocountry.
PrecautionsforFuel
GASOLINEENGINE:
Threewaycatalystequippedmodels...unleadedgasolineofat least91octane(RON)
CAUTION:
Donotuseleadedgasoline.Usingleadedgasolinewilldamagethethreewaycatalyst.
Exceptfortheabovemodels...unleadedorleadedgasolineof above88octane(RON)
Useunleadedfuelifinstructedonthefuelfillerlid.
GI-5
PRECAUTIONS
DIESELENGINE*:
ForEurope:dieselfuelofabove50cetane
*Iftwotypesofdieselfuelareavailable,usesummerorwinterfuelproperlyaccordingtothefollowingtemperatureconditions.
● Above−7°C(20°F)...Summertypedieselfuel.
● Below−7°C(20°F)...Wintertypedieselfuel.
CAUTION:
● Donotusehomeheatingoil,gasoline,orotheralternate fuelsinyourdieselengine.Theuseofthosecancause enginedamage.
● Donotusesummerfuelattemperaturebelow−7°C (20°F).Thecoldtemperaturewillcausewaxtoformin thefuel.Asaresult,itmaypreventtheenginefromrunningsmoothly.
● Donotaddgasolineorotheralternatefuelstodiesel fuel.
PrecautionsforAirConditioning
Useanapprovedrefrigerantrecoveryunitanytimetheairconditioningsystemmustbedischarged.RefertoHAsection (‘‘HFC-134a(R-134a)ServiceProcedure’’,‘‘SERVICEPROCEDURES’’)forspecificinstructions.
PrecautionsforFuel(Cont’d) GI-6
HOWTOUSETHISMANUAL
● ALPHABETICALINDEX isprovidedattheendofthismanualsothatyoucanrapidlyfindtheitemand pageyouaresearchingfor.
● AQUICKREFERENCEINDEX, ablacktab(e.g. )isprovidedonthefirstpage.Youcanquickly findthefirstpageofeachsectionbymatingittothesection’sblacktab.
● THECONTENTS arelistedonthefirstpageofeachsection.
● THETITLE isindicatedontheupperportionofeachpageandshowsthepartorsystem.
● THEPAGENUMBER ofeachsectionconsistsoftwoletterswhichdesignatetheparticularsectionand anumber(e.g.‘‘BR-5’’).
● THELARGEILLUSTRATIONS areexplodedviews(Seebelow)andcontaintighteningtorques,lubricationpoints,sectionnumberofthe PARTSCATALOG (e.g.SEC.440)andotherinformationnecessarytoperformrepairs.
Theillustrationsshouldbeusedinreferencetoservicemattersonly.Whenorderingparts,refertothe appropriate PARTSCATALOG.
● THESMALLILLUSTRATIONS showtheimportantstepssuchasinspection,useofspecialtools, knacksofworkandhiddenortrickystepswhicharenotshowninthepreviouslargeillustrations.
Assembly,inspectionandadjustmentproceduresforthecomplicatedunitssuchastheautomatictransaxleortransmission,etc.arepresentedinastep-by-stepformatwherenecessary.
SBR364AC
GI-7
● Thefollowing SYMBOLSANDABBREVIATIONS areused: , :Tighteningtorque
:Shouldbelubricatedwithgrease. Unlessotherwiseindicated,use recommendedmulti-purpose grease.
:Shouldbelubricatedwithoil.
:Sealingpoint
:Checkingpoint
:Alwaysreplaceaftereverydisassembly.
V P :Applypetroleumjelly.
:ApplyATF.
. :Selectwithproperthickness. > :Adjustmentisrequired.
● The UNITS giveninthismanualareprimarilyexpressedastheSIUNIT(InternationalSystemofUnit), andalternativelyexpressedinthemetricsystemandintheyard/poundsystem.
Tighteningtorque: 59-78N·m(6.0-8.0kg-m,43-58ft-lb)
● TROUBLEDIAGNOSES areincludedinsectionsdealingwithcomplicatedcomponents.
● SERVICEDATAANDSPECIFICATIONS arecontainedattheendofeachsectionforquickreference ofdata.
● Thecaptions WARNING and CAUTION warnyouofstepsthatmustbefollowedtopreventpersonal injuryand/ordamagetosomepartofthevehicle.
WARNING indicatesthepossibilityofpersonalinjuryifinstructionsarenotfollowed. CAUTION indicatesthepossibilityofcomponentdamageifinstructionsarenotfollowed.
BOLDTYPEDSTATEMENTS except WARNING and CAUTION giveyouhelpfulinformation.
LH,RH:Left-Hand,Right-Hand FR,RR:Front,Rear M/T:ManualTransaxle/Transmission A/T:AutomaticTransaxle/Transmission , 4WD:4-WheelDrive 2WD:2-WheelDrive A/C:AirConditioner P/S:PowerSteering SST:SpecialServiceTools
ATF:AutomaticTransmissionFluid D1 :Driverange1stgear D2 :Driverange2ndgear D3 :Driverange3rdgear D4 :Driverange4thgear OD:Overdrive 22 :2ndrange2ndgear 21 :2ndrange1stgear 12 :1strange2ndgear 11 :1strange1stgear
SDS:ServiceDataandSpecifications
SAE:SocietyofAutomotiveEngineers, Inc.
‘‘Example’’
HOWTOUSETHISMANUAL GI-8
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