Nissan Terrano 2004 Service And Repair Manual

FOREWORD

ThismanualcontainsmaintenanceandrepairproceduresforNISSAN TERRANO,modelR20series.

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

PRECAUTIONS

Observethefollowingprecautionstoensuresafeandproper servicing.Theseprecautionsarenotdescribedineachindividualsection.

1.Donotoperatetheengineforanextendedperiodoftimewithoutproperexhaustventilation.

Keeptheworkareawellventilatedandfreeofanyinflammable materials.Specialcareshouldbetakenwhenhandlingany inflammableorpoisonousmaterials,suchasgasoline,refrigerantgas,etc.Whenworkinginapitorotherenclosedarea,be suretoproperlyventilatetheareabeforeworkingwithhazardousmaterials.

Donotsmokewhileworkingonthevehicle.

2.Beforejackingupthevehicle,applywheelchocksorothertire blockstothewheelstopreventthevehiclefrommoving.After jackingupthevehicle,supportthevehicleweightwithsafety standsatthepointsdesignatedforproperliftingandtowing beforeworkingonthevehicle. Theseoperationsshouldbedoneonalevelsurface.

3.Whenremovingaheavycomponentsuchastheengineor transaxle/transmission,takecarenottoloseyourbalanceand dropit.Also,donotallowittostrikeadjacentparts,especially thebraketubesandmastercylinder.

4.Beforestartingrepairswhichdonotrequirebatterypower, alwaysturnofftheignitionswitch,thendisconnecttheground cablefromthebatterytopreventaccidentalshortcircuit.

5.Topreventseriousburns,avoidcontactwithhotmetalparts suchastheradiator,exhaustmanifold,tailpipeandmuffler.Do notremovetheradiatorcapwhentheengineishot.

SGI234 SGI646

PRECAUTIONS

6.Beforeservicingthevehicle,protectfenders,upholsteryand carpetingwithappropriatecovers.

Takecautionthatkeys,bucklesorbuttonsonyourpersondo notscratchthepaint.

7.Cleanalldisassembledpartsinthedesignatedliquidorsolvent priortoinspectionorassembly.

8.Replaceoilseals,gaskets,packings,O-rings,lockingwashers, cotterpins,self-lockingnuts,etc.withnewones.

9.Replaceinnerandouterracesoftaperedrollerbearingsand needlebearingsasaset.

10.Arrangethedisassembledpartsinaccordancewiththeir assembledlocationsandsequence.

11.Donottouchtheterminalsofelectricalcomponentswhichuse microcomputers(suchaselectroniccontrolunits). Staticelectricitymaydamageinternalelectroniccomponents.

12.Afterdisconnectingvacuumorairhoses,attachatagtoindicatetheproperconnection.

13.UseonlythelubricantsspecifiedinMAsection.

14.Useapprovedbondingagent,sealantsortheirequivalents whenrequired.

15.Usetoolsandrecommendedspecialtoolswherespecifiedfor safeandefficientservicerepairs.

16.Whenrepairingthefuel,oil,water,vacuumorexhaustsystems, checkallaffectedlinesforleaks.

17.Disposeofdrainedoilorthesolventusedforcleaningpartsin anappropriatemanner.

TheSupplementalRestraintSystem“AirBag”and“SeatBeltPretensioner”,usedalongwithaseatbelt,helptoreducetheriskor severityofinjurytothedriverandfrontpassengerinafrontalcollision.TheSupplementalRestraintSystemconsistsofairbagmodules(locatedinthecenterofthesteeringwheelandontheinstrumentpanelonthepassengerside),seatbeltpre-tensioners,a diagnosissensorunit,warninglamp,wiringharnessandspiral cable.

WARNING:

ToavoidrenderingtheSRSinoperative,whichcould increasetheriskofpersonalinjuryordeath(intheevent ofacollisionwhichwouldresultinairbaginflation),all maintenancemustbeperformedbyanauthorizedNISSAN dealer.

Impropermaintenance,includingincorrectremovaland installationoftheSRS,canleadtopersonalinjurycaused byunintentionalactivationofthesystem.

PRECAUTIONS

insulation(eitherjustbeforetheharnessconnectorsorfor thecompleteharness),foreasyidentification.

PrecautionsforNATS

NATS(NissanAnti-TheftSystem)

NATSwillimmobilizetheengineifsomeonetriestostartitwithout theregisteredkeyofNATS.

BothoftheoriginallysuppliedignitionkeyIDshavebeenNATS registered.

TheNATSsecurityindicatorislocatedontheinstrumentpanel.The indicatorblinkswhentheignitionswitchisin“OFF”or“ACC”position.Therefore,NATSwarnsoutsidersthatthevehicleisequipped withtheanti-theftsystem.

WhenNATSdetectstrouble,themalfunctionindicatorlamp (MIL)blinks.

Thisblinkingindicatesthattheanti-theftisnotfunctioning,so promptserviceisrequired.

Ifthemalfunctionindicatorlampcomesonwhiletheengineis running,returnthevehicletotheworkshopbeforeturningthe ignitionswitch“OFF”.

Oncetheignitionswitchisturned“OFF”,theenginecannotbe started.

WhenservicingNATS(troublediagnoses,systeminitialization andadditionalregistrationofotherNATSignitionkeyIDs)CONSULT-IIhardwareandCONSULT-IINATSsoftwareisnecessary.

RegardingtheproceduresofNATSinitializationandNATSignitionkeyIDregistration,refertoCONSULT-IIoperationmanual, NATS.

Therefore,CONSULT-IINATSsoftware(programcardand operationmanual)mustbekeptstrictlyconfidentialtomaintaintheintegrityoftheanti-theftfunction.

WhenservicingNATS(troublediagnoses,systeminitialization andadditionalregistrationofotherNATSignitionkeyIDs),it maybenecessarytore-registeroriginalkeyidentification. Therefore,besuretoreceiveallkeysfromvehicleowner. AmaximumoffivekeyIDscanberegisteredintoNATS.

Whenfailingtostarttheenginefirst-timeusingthekeyof NATS,startsasfollows:

(1)Turnignitionkeyto“OFF”.

(2)Waitapprox.5seconds.

(3)Turnignitionkeyto“START”againwhilekeepingthekey apartfromanyothersonkey-chain.

PRECAUTIONS

PrecautionsforMultiportFuelInjectionSystem orEngineControlSystem

1.Beforeconnectingordisconnectinganyharnessconnectorfor themultiportfuelinjectionsystemorECM(EngineControl Module):

Turnignitionswitchto“OFF”position. Disconnectnegativebatteryterminal. Otherwise,theremaybedamagetoECM.

2.Beforedisconnectingpressurizedfuellinefromfuelpumpto injectors,besuretoreleasefuelpressuretoeliminatedanger.

3.Becarefulnottojarcomponentssuchascontrolunitandair flowmeter.

PrecautionsforCatalyst

Ifalargeamountofunburnedfuelenterstheconverter,theconvertertemperaturewillrisetoexcessivelyhighvalues.Toprevent this,followtheprocedurebelow:

1.Useunleadedgasolineonly.Leadedgasolinewillseriously damagethecatalyticconverter.

2.Whencheckingforignitionsparkormeasuringengine compression,performtestsquicklyandonlywhennecessary.

3.Donotrunenginewhenthefueltanklevelislow,asaresult theenginemaymisfirecausingdamagetotheconverter.

4.Donotplacethevehicleoninflammablematerial.Keepinflammablematerialofftheexhaustpipe.

PrecautionsforTurbocharger

Theturbochargerturbinerevolvesatextremelyhighspeedsand becomesveryhot.Therefore,itisessentialtomaintainaclean supplyofoilflowingthroughtheturbochargerandtofollowall requiredmaintenanceinstructionsandoperatingprocedures.

Forproperoperationofthesystem,followtheprocedurebelow:

1.Alwaysusetherecommendedoil.Followtheinstructionsfor propertimetochangetheoilandproperoillevel.

2.Avoidacceleratingenginetoahighrpmimmediatelyafterstarting.

3.Ifenginehadbeenoperatingathighrpmforanextendedperiod oftime,letitidleforafewminutespriortoshuttingitoff.

PRECAUTIONS

DIESELENGINE*:

Dieselfuelofatleast50cetaneforZD30DDTiengine.

*Iftwotypesofdieselfuelareavailable,usesummerorwinter fuelproperlyaccordingtothefollowingtemperatureconditions. Above−7°C(20°F)...Summertypedieselfuel. Below−7°C(20°F)...Wintertypedieselfuel.

CAUTION:

Donotusehomeheatingoil,gasoline,orotheralternate fuelsinyourdieselengine.Theuseofthosecancause enginedamage.

Donotusesummerfuelattemperaturebelow−7°C(20°F). Thecoldtemperaturewillcausewaxtoforminthefuel.As aresult,itmaypreventtheenginefromrunningsmoothly.

Donotaddgasolineorotheralternatefuelstodieselfuel.

PrecautionsforEngineOils

Prolongedandrepeatedcontactwithmineraloilwillresultinthe removalofnaturalfatsfromtheskin,leadingtodryness,irritation anddermatitis.Inaddition,usedengineoilcontainspotentially harmfulcontaminantswhichmaycauseskincancer.Adequate meansofskinprotectionandwashingfacilitiesmustbeprovided.

HEALTHPROTECTIONPRECAUTIONS

1.Avoidprolongedandrepeatedcontactwithoils,particularly usedengineoils.

2.Wearprotectiveclothing,includingimperviousgloveswhere practicable.

3.Donotputoilyragsinpockets.

4.Avoidcontaminatingclothes,particularlyunderwear,withoil.

5.Heavilysoiledclothingandoil-impregnatedfootwearshouldnot beworn.Overallsmustbecleanedregularly.

6.FirstAidtreatmentshouldbeobtainedimmediatelyforopen cutsandwounds.

7.Usebarriercreams,applyingthembeforeeachworkperiod,to helptheremovalofoilfromtheskin.

8.Washwithsoapandwatertoensurealloilisremoved(skin cleansersandnailbrusheswillhelp).Preparationscontaining lanolinreplacethenaturalskinoilswhichhavebeenremoved.

9.Donotusepetrol,kerosine,dieselfuel,gasoil,thinnersorsolventsforcleaningskin.

10.Ifskindisordersdevelop,obtainmedicaladvicewithoutdelay. 11.Wherepracticable,degreasecomponentspriortohandling.

12.Wherethereisariskofeyecontact,eyeprotectionshouldbe worn,forexample,chemicalgogglesorfaceshields;inaddition aneyewashfacilityshouldbeprovided.

(FortheUnitedKingdom,seealsoHSECautionaryNoticeSHW 397“EffectsofMineralOilontheSkin”.)

ENVIRONMENTALPROTECTIONPRECAUTIONS

Burningusedengineoilinsmallspaceheatersorboilerscanbe recommendedonlyforunitsofapproveddesign.TheheatingsystemmustmeettherequirementsofHMInspectorateofPollutionfor smallburnersoflessthan0.4MW.Ifindoubtcheckwiththe appropriatelocalauthorityand/ormanufactureroftheapproved appliance.

PRECAUTIONS PrecautionsforEngineOils(Cont’d)

Disposeofusedoilandusedoilfiltersthroughauthorizedwaste disposalcontractorstolicensedwastedisposalsites,ortothe wasteoilreclamationtrade.Ifindoubt,contactthelocalauthority foradviceondisposalfacilities.

Itisillegaltopourusedoilontotheground,downsewersordrains, orintowatercourses. Theregulationsconcerningthepollutionoftheenvironment willvaryfromcountrytocountry.

1. AQUICKREFERENCEINDEX,ablacktab(e.g. )isprovidedonthefirstpage.Youcanquicklyfind thefirstpageofeachsectionbymatingittothesection’sblacktab.

2. THECONTENTS arelistedonthefirstpageofeachsection.

3. THETITLE isindicatedontheupperportionofeachpageandshowsthepartorsystem.

4. THEPAGENUMBER ofeachsectionconsistsoftwoletterswhichdesignatetheparticularsectionanda number(e.g.“BR-5”).

5. THELARGEILLUSTRATIONS areexplodedviews(Seebelow)andcontaintighteningtorques,lubricationpointsandotherinformationnecessarytoperformrepairs.

Theillustrationsshouldbeusedinreferencetoservicemattersonly.Whenorderingparts,refertothe appropriate PARTSCATALOG

SBR364AD

6. THESMALLILLUSTRATIONS showtheimportantstepssuchasinspection,useofspecialtools,knacks ofworkandhiddenortrickystepswhicharenotshowninthepreviouslargeillustrations.

Assembly,inspectionandadjustmentproceduresforthecomplicatedunitssuchastheautomatictransaxle ortransmission,etc.arepresentedinastep-by-stepformatwherenecessary.

7.Thefollowing SYMBOLSANDABBREVIATIONS areused:

, :Tighteningtorque

:Shouldbelubricatedwithgrease. Unlessotherwiseindicated,userecommendedmulti-purposegrease.

:Shouldbelubricatedwithoil.

:Sealingpoint :Checkingpoint

:Alwaysreplaceaftereverydisassembly.

L.H.,R.H.:Left-Hand,Right-Hand FR,RR:Front,Rear

2WD:2-WheelDrive

4WD:4-WheelDrive

P :Applypetroleumjelly.

:ApplyA.T.F.

A.T.F.:AutomaticTransmissionFluid

★ :Selectwithproperthickness.

✩ :Adjustmentisrequired.

M/T:ManualTransaxle/Transmission

A/C:AirConditioner

P/S:PowerSteering

S.S.T.:SpecialServiceTools

S.D.S.:ServiceDataandSpecifications

SAE:SocietyofAutomotiveEngineers,Inc. L.H.D.:Left-HandDrive

R.H.D.:Right-HandDrive

8.The UNITS giveninthismanualareprimarilyexpressedastheSIUNIT(InternationalSystemofUnit), andalternativelyexpressedinthemetricsystemandintheyard/poundsystem. “Example”

Tighteningtorque: 59-78N⋅m(6.0-8.0kg-m,43-58ft-lb)

9. TROUBLEDIAGNOSES areincludedinsectionsdealingwithcomplicatedcomponents.

10. SERVICEDATAANDSPECIFICATIONS arecontainedattheendofeachsectionforquickreferenceof data.

11.Thecaptions WARNING and CAUTION warnyouofstepsthatmustbefollowedtopreventpersonalinjury and/ordamagetosomepartofthevehicle.

WARNING indicatesthepossibilityofpersonalinjuryifinstructionsarenotfollowed.

CAUTION indicatesthepossibilityofcomponentdamageifinstructionsarenotfollowed.

BOLDTYPEDSTATEMENTS except WARNING and CAUTION giveyouhelpfulinformation.

ForDescription,refertoGI-10.

Thisshowstheconditionwhenthesystemreceivesbatterypositivevoltage(can beoperated).

Thedoublelineshowsthatthisisafusiblelink.

Theopencircleshowscurrentflowin,andtheshadedcircleshowscurrentflow out.

Thisshowsthelocationofthefusiblelinkorfuseinthefusiblelinkorfusebox. Forarrangement,refertoELsection(“POWERSUPPLYROUTING”).

Thesinglelineshowsthatthisisafuse.

Theopencircleshowscurrentflowin,andtheshadedcircleshowscurrentflow out.

Thisshowsthecurrentratingofthefusiblelinkorfuse.

Thisshowsthatconnector E3 isfemaleandconnector M1 ismale. TheG/Rwireislocatedinthe1Aterminalofbothconnectors.

Terminalnumberwithanalphabet(1A,5B,etc.)indicatesthattheconnectoris SMJconnector.RefertoGI-18.

Theopencircleshowsthatthespliceisoptionaldependingonvehicleapplication.

Theshadedcircleshowsthatthespliceisalwaysonthevehicle.

Thisarrowshowsthatthecircuitcontinuestoanadjacentpage. TheAwillmatchwiththeAontheprecedingornextpage.

Thedottedlinesbetweenterminalsshowthattheseterminalsarepartofthesame connector.

Thisshowsthatthecircuitisoptionaldependingonvehicleapplication.

Thisshowsaninternalrepresentationoftherelay.Fordetails,refertoELsection (“STANDARDIZEDRELAY”).

Thisshowsthattheconnectorisconnectedtothebodyoraterminalwithboltor nut.

Thisshowsadescriptionoftheoptionabbreviationusedonthepage.

Connectorterminalincomponentshowsthatitisaharnessincorporatedassembly.

Thisidentifieseachpageofthewiringdiagrambysection,systemandwiringdiagrampagenumber.

HOWTOREADWIRINGDIAGRAMS Description(Cont’d)

Arrowindicateselectriccurrentflow,especiallywherethedirectionofstandard flow(verticallydownwardorhorizontallyfromlefttoright)isdifficulttofollow. Adoublearrow“ ”showsthatcurrentcanflowineitherdirectiondependingon circuitoperation.

Thisshowsthatthesystembranchestoanothersystemidentifiedbycellcode (sectionandsystem).

Thisarrowshowsthatthecircuitcontinuestoanotherpageidentifiedbycellcode. TheCwillmatchwiththeConanotherpagewithinthesystemotherthanthenext orprecedingpages.

Thelineenclosedbybrokenlinecircleshowsshieldwire.

Thisshowsthatanotherpartofthecomponentisalsoshownonanotherpage (indicatedbywaveline)withinthesystem.

Thisshowsthenameofacomponent.

Thisshowstheconnectornumber.

Thelettershowswhichharnesstheconnectorislocatedin.

Example: M:mainharness.Fordetailandtolocatetheconnector,refertoELsection(“MainHarness”,“HARNESSLAYOUT”).Acoordinategridisincludedforcomplexharnessestoaidinlocatingconnectors.

Thelinesplicedandgroundedunderwirecolorshowsthatgroundlineisspliced atthegroundedconnector.

Thisareashowstheconnectorfacesofthecomponentsinthewiringdiagramon thepage.

Connectorsenclosedinbrokenlineshowthattheseconnectorsbelongtothe samecomponent.

Thisshowsacodeforthecoloroftheconnector.Forcodemeaning,refertowire colorcodes,Number 14 ofthischart.

Thisshowsthearrangementoffusiblelink(s)andfuse(s),usedforconnector viewsof“POWERSUPPLYROUTING”inELsection.

Theopensquareshowscurrentflowin,andtheshadedsquareshowscurrent flowout.

ThisshowsthatmoreinformationontheSuperMultipleJunction(SMJ)andJoint Connectors(J/C)existsonthefoldoutpage.RefertoGI-18fordetails.

HOWTOREADWIRINGDIAGRAMS Description(Cont’d)

CONNECTORSYMBOLS

Mostofconnectorsymbolsinwiringdiagramsareshownfromthe terminalside.

Connectorsymbolsshownfromtheterminalsideareenclosed byasinglelineandfollowedbythedirectionmark .

Connectorsymbolsshownfromtheharnesssideareenclosed byadoublelineandfollowedbythedirectionmark

Maleandfemaleterminals

Connectorguidesformaleterminalsareshowninblackand femaleterminalsinwhiteinwiringdiagrams.

HOWTOREADWIRINGDIAGRAMS Description(Cont’d)

Harnessindication

Letterdesignationsnexttotestmeterprobeindicateharness (connector)wirecolor.

Connectornumbersinasinglecircle M33 indicateharnessconnectors.

Componentindication

Connectornumbersinadoublecircleindicatecomponentconnectors.

SWITCHPOSITIONS

Switchesareshowninwiringdiagramsasifthevehicleisinthe “normal”condition. Avehicleisinthe“normal”conditionwhen: ignitionswitchis“OFF”, doors,hoodandtrunklid/backdoorareclosed, pedalsarenotdepressed,and parkingbrakeisreleased.

DETECTABLELINESANDNON-DETECTABLELINES

Insomewiringdiagrams,twokindsoflines,representingwires, withdifferentweightareused.

Alinewithregularweight(widerline)representsa“detectable lineforDTC(DiagnosticTroubleCode)”.A“detectablelinefor DTC”isacircuitinwhichECM(EngineControlModule)can detectitsmalfunctionswiththeonboarddiagnosticsystem.

Alinewithlessweight(thinnerline)representsa“non-detectablelineforDTC”.A“non-detectablelineforDTC”isacircuit inwhichECMcannotdetectitsmalfunctionswiththeonboard diagnosticsystem.

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MULTIPLESWITCH

Thecontinuityofmultipleswitchisdescribedintwowaysasshown below.

Theswitchchartisusedinschematicdiagrams. Theswitchdiagramisusedinwiringdiagrams.

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Description(Cont’d) GI-17 http://vnx.su/