2001 nissan frontier service repair manual

Edition: August 2000 Revision: November 2001 Publication No. SM1E-1D22U2

Š 2001 NISSAN NORTH AMERICA, INC. All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photo-copying, recording or otherwise, without the prior written permission of Nissan North America, Inc., Gardena, California.

QUICK REFERENCE INDEX

FOREWORD This manual contains maintenance and repair procedures for the 2001 NISSAN FRONTIER. 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 specifications 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 manner 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 be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.

NISSAN NORTH AMERICA, INC. Technical Service Information Department Gardena, California

NOTES

Attachment No.12

KA24DE

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II) The following is the information specified in Mode 6 of SAE J1979.

The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG” while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored.

Items for which these data (test value and test limit) are displayed are the same as SRT code items.

These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen. : Applicable ･: Not applicable

SRT item

Self-diagnostic test item

DTC

P0420 P0420 P0440 EVAP control system (Small leak) P1440★2 EVAP SYSTEM EVAP control system purge flow monitoring P1447 EVAP control system (Very small leak) P1441★1 P0133 P0131 Heated oxygen sensor 1 P0130 P0132 HO2S P0134 P0139 P0137 Heated oxygen sensor 2 P0140 P0138 P0135 Heated oxygen sensor 1 heater P0135 HO2S HTR P0141 Heated oxygen sensor 2 heater P0141 P0400 P0400 EGR function P0400 EGR SYSTEM P0400 P1402 P0402★２ EGRC-BPT valve function P0402★２ ★ 1：Except models D22 KA24DE engine, WD22 KA24DE engine 2000MY. ★ 2：Except models L30 KA24DE engine 2000MY. CATALYST

Three way catalyst function

Test value (GST display) TID CID 01H 02H 05H 05H 06H 07H 09H 0AH 0BH 0CH 0DH 19H 1AH 1BH 1CH 29H 2AH 2DH 2EH 31H 32H 33H 34H 35H 36H 37H

01H 81H 03H 03H 83H 03H 04H 84H 04H 04H 04H 86H 86H 06H 06H 08H 88H 0AH 8AH 8CH 8CH 8CH 8CH 0CH 0CH 8CH

Te s t limit

Application

Unit

Max. Min. Max. Max. Min. Max. Max. Min. Max. Max. Max. Min. Min. Max. Max. Max. Min. Max. Min. Min. Min. Min. Min. Max. Max. Min.

X X X X X X X X X X X X X X X X X X X X X X X X X X

mV ms mV mV mV s mV/500ms mV mV mV mV mV mV mV ℃ ℃ ℃ ℃ ℃ -

Attachment No.14

VG33E/VG33ER

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II) The following is the information specified in Mode 6 of SAE J1979.

The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG” while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored.

Items for which these data (test value and test limit) are displayed are the same as SRT code items.

These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen. : Applicable ･: Not applicable

SRT item

Self-diagnostic test item

DTC

Test value (GST display) TID CID

P0420 01H P0420 02H P0430 03H Three way catalyst function (Bank 2) P0430 04H P0440 05H EVAP control system (Small leak) ★ P1440 1 05H EVAP SYSTEM EVAP control system purge flow monitoring P1447 06H EVAP control system (Very small leak) P1441★2 07H P0133 09H P0131 0AH Heated oxygen sensor 1(Bank 1) P0130 0BH P0132 0CH P0134 0DH P0153 11H P0151 12H Heated oxygen sensor 1(Bank 2) P0150 13H P0152 14H HO2S P0154 15H P0139 19H P0137 1AH Heated oxygen sensor 2(Bank 1) P0140 1BH P0138 1CH P0159 21H P0157 22H Heated oxygen sensor 2(Bank 2) P0160 23H P0158 24H P0135 29H Heated oxygen sensor 1 heater(Bank 1) P0135 2AH P0155 2BH Heated oxygen sensor 2 heater(Bank 2) P0155 2CH HO2S HTR P0141 2DH Heated oxygen sensor 2 heater(Bank 1) P0141 2EH P0161 2FH Heated oxygen sensor 2 heater(Bank 2) P0161 30H ★ 1：Except models D22 VG33E engine, WD22 VG33E engine, R50 VQ35DE engine, JR50 ★ 2：Except models A33 VQ30DE engine, CA33 VQ30DE engine 2001MY. Three way catalyst function (Bank 1)

CATALYST

Te s t limit

01H Max. 81H Min. 02H Max. 82H Min. 03H Max. 03H Max. 83H Min. 03H Max. 04H Max. 84H Min. 04H Max. 04H Max. 04H Max. 05H Max. 85H Min. 05H Max. 05H Max. 05H Max. 86H Min. 86H Min. 06H Max. 06H Max. 87H Min. 87H Min. 07H Max. 07H Max. 08H Max. 88H Min. 09H Max. 89H Min. 0AH Max. 8AH Min. 0BH Max. 8BH Min. VQ35DE engine 2001

Application

Unit

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

mV ms mV mV mV s ms mV mV mV s mV/500ms mV mV mV mV/500ms mV mV mV mV mV mV mV mV mV mV mV

GENERAL INFORMATION SECTION

GI

MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................3 Precautions ..................................................................3 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ ........3 GENERAL PRECAUTIONS .........................................4 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM ...................................................................5 PRECAUTIONS FOR THREE WAY CATALYST ...........6 PRECAUTIONS FOR HOSES .....................................6 PRECAUTIONS FOR ENGINE OILS ...........................7 PRECAUTIONS FOR FUEL ........................................7 PRECAUTIONS FOR AIR CONDITIONING ..................8

HOW TO USE THIS MANUAL........................................9 HOW TO READ WIRING DIAGRAMS..........................11 Sample/Wiring Diagram - EXAMPL - ........................11 OPTIONAL SPLICE..................................................12 Description .................................................................13 CONNECTOR SYMBOLS .........................................15 SWITCH POSITIONS ...............................................16 DETECTABLE LINES AND NON-DETECTABLE LINES .....................................................................16 MULTIPLE SWITCH .................................................17 REFERENCE AREA .................................................18

HOW TO CHECK TERMINAL .......................................20 Connector and Terminal Pin Kit.................................20 How to Probe Connectors .........................................20 PROBING FROM HARNESS SIDE ............................20 PROBING FROM TERMINAL SIDE ...........................20 How to Check Enlarged Contact Spring of Terminal .....................................................................21 Waterproof Connector Inspection ..............................22 RUBBER SEAL INSPECTION ...................................22 WIRE SEAL INSPECTION ........................................22 Terminal Lock Inspection ...........................................22 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ...............................23 Work Flow..................................................................23 Incident Simulation Tests...........................................24 INTRODUCTION ......................................................24 VEHICLE VIBRATION ..............................................24

HEAT SENSITIVE ....................................................25 FREEZING ..............................................................25 WATER INTRUSION ................................................26 ELECTRICAL LOAD .................................................26 COLD OR HOT START UP.......................................26

Circuit Inspection .......................................................26 INTRODUCTION ......................................................26 TESTING FOR ″OPENS″ IN THE CIRCUIT ................27 TESTING FOR ″SHORTS″ IN THE CIRCUIT ..............28 GROUND INSPECTION ...........................................29 VOLTAGE DROP TESTS ..........................................30 CONTROL UNIT CIRCUIT TEST ...............................31 HOW TO FOLLOW TROUBLE DIAGNOSES...............33 How to Follow Test Groups in Trouble Diagnoses....34 Harness Wire Color and Connector Number Indication....................................................................35 TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION .......................................................35 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT.........36

Key to Symbols Signifying Measurements or Procedures.................................................................36 CONSULT–II CHECKING SYSTEM ..............................38 Function and System Application ..............................38 Nickel Metal Hydride Battery Replacement...............38 Checking Equipment..................................................39 Loading Procedure ....................................................39 CONSULT-II Data Link Connector (DLC) Circuit ......39 INSPECTION PROCEDURE .....................................39 IDENTIFICATION INFORMATION ................................40 Model Variation ..........................................................40 Identification Number.................................................42 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT .....................................................42 ENGINE SERIAL NUMBER.......................................43 TRANSFER SERIAL NUMBER ..................................43 MANUAL TRANSMISSION NUMBER.........................43 AUTOMATIC TRANSMISSION NUMBER ...................44

Dimensions ................................................................44 Wheels & Tires ..........................................................45

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS LIFTING POINTS AND TOW TRUCK TOWING ...........46 Pantograph Jack........................................................46 Garage Jack and Safety Stand .................................46 2-pole Lift ...................................................................47 Tow Truck Towing ......................................................47 2-WHEEL DRIVE MODELS.......................................48 4-WHEEL DRIVE MODELS.......................................48

(Cont’d) TOWING POINT .......................................................49 VEHICLE RECOVERY (FREEING A STUCK VEHICLE) ................................................................49

TIGHTENING TORQUE OF STANDARD BOLTS ........50 SAE J1930 TERMINOLOGY LIST ................................51 SAE J1930 Terminology List .....................................51

GI-2

PRECAUTIONS Precautions

Precautions

NEGI0001

Observe the following precautions to ensure safe and proper servicing.

MA EM LC SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER” NEGI0001S01

SGI646

The Supplemental Restraint System such as “AIR BAG”and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel and in the instrument panel on the passenger side), seat belt pretensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.

The vehicle (except Crew Cab model) is equipped with a passenger air bag deactivation switch. Because no rear seat exists where a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is enabled and could inflate in a frontal collision. When the switch is turned to the OFF position, the passenger air bag is disabled and will not inflate in a frontal collision. A passenger air bag OFF indicator on the instrument panel lights up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected by the passenger air bag deactivation switch.

Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING: 쐌 To 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 should be performed by an authorized NISSAN dealer. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual.

Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) covered with yellow insulation either just before the harness connectors or for the complete harness are related to the SRS. 쐌 The vehicle (except Crew Cab model) is equipped with a passenger air bag deactivation switch which can be operated by the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and will not inflate in a frontal collision. When the passenger air bag is switched ON, the passenger air bag is enabled and could inflate in a frontal collision. After SRS maintenance

GI-3

EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

PRECAUTIONS Precautions (Cont’d)

or repair, make sure the passenger air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for service.

GENERAL PRECAUTIONS

NEGI0001S02

쐌

Do not operate the engine for an extended period of time without 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, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials.

Do not smoke while working on the vehicle.

쐌

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 before working on the vehicle.

These operations should be done on a level surface.

When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop it. Also, do not allow it to strike adjacent parts, especially the brake tubes and master cylinder.

SGI285

쐌

SGI231

쐌

Before starting repairs which do not require battery power: Turn off ignition switch.

Disconnect the negative battery terminal.

쐌

To prevent serious burns: Avoid contact with hot metal parts.

Do not remove the radiator cap when the engine is hot.

SEF289H

SGI233

GI-4

PRECAUTIONS Precautions (Cont’d)

쐌

Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers.

Take caution that keys, buckles or buttons do not scratch paint.

MA EM LC

SGI234

쐌

Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 쐌 Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 쐌 Replace inner and outer races of tapered roller bearings and needle bearings as a set. 쐌 Arrange the disassembled parts in accordance with their assembled locations and sequence. 쐌 Do not touch the terminals of electrical components which use microcomputers (such as ECMs).

Static electricity may damage internal electronic components. 쐌 After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. 쐌 Use only the fluids and lubricants specified in this manual. 쐌 Use approved bonding agents, sealants or their equivalents when required. 쐌 Use tools and recommended special tools where specified for safe and efficient service repairs. 쐌 When repairing fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. 쐌 Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. 쐌 Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow resulting in fuel spray and possibly a fire.

WARNING: To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and TCM (Transmission Control Module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC section and AT section.

EC FE CL MT AT TF PD AX SU BR ST RS

PRECAUTIONS FOR MULTIPORT FUEL INJECTION BT SYSTEM OR ENGINE CONTROL SYSTEM NEGI0001S03 쐌

쐌 쐌 SGI787

Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM: Turn ignition switch to OFF position.

Disconnect negative battery terminal.

Otherwise, there may be damage to ECM. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure.

Be careful not to jar components such as ECM and mass air flow sensor.

GI-5

HA SC EL IDX

PRECAUTIONS Precautions (Cont’d)

PRECAUTIONS FOR THREE WAY CATALYST

NEGI0001S04

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions below: 쐌 Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. 쐌 When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. 쐌 Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the catalyst.

Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst.

PRECAUTIONS FOR HOSES Hose removal and installation

NEGI0001S08 NEGI0001S0801

쐌

To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

쐌

To reinstall the rubber hose securely, make sure of hose insertion length and clamp orientation. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

SMA019D

SMA020D

Hose clamping 쐌

쐌

NEGI0001S0802

If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position.

Discard old clamps; replace with new ones.

SMA021D

GI-6

PRECAUTIONS Precautions (Cont’d)

쐌

After installing leaf spring clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around.

PRECAUTIONS FOR ENGINE OILS

NEGI0001S05

Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil.

If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

Health Protection Precautions SMA022D

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

FE CL MT AT TF PD

SU BR ST RS BT

NEGI0001S06 NEGI0001S0601

NEGI0001S0602

Use unleaded premium gasoline with an octane rating of at least 91 AKI (Anti-Knock Index) number (research octane number 96) for the VG33ER engine.

GI-7

EC

AX

Use unleaded gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (research octane number 91) for the KA24DE and VG33E engines.

VG33ER Engines

LC

NEGI0001S0502

Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. The heating system must meet the requirements of HM Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt check with the appropriate local authority and/or manufacturer of the approved appliance.

Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal facilities.

It is illegal to pour used oil onto the ground, down sewers or drains, or into water courses.

The regulations concerning the pollution vary from country to country.

PRECAUTIONS FOR FUEL KA24DE and VG33E Engines

EM

NEGI0001S0501

Avoid prolonged and repeated contact with oils, particularly used engine oils.

Wear protective clothing, including impervious gloves where practicable.

Do not put oily rags in pockets.

Avoid contaminating clothes, particularly underpants, with oil.

Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.

First Aid treatment should be obtained immediately for open cuts and wounds.

Use barrier creams, applying them before each work period, to help the removal of oil from the skin.

Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed.

Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.

If skin disorders develop, obtain medical advice without delay.

Where practicable, degrease components prior to handling.

Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields, in addition, an eye wash facility should be provided.

Environmental Protection Precautions

MA

HA SC EL IDX

PRECAUTIONS Precautions (Cont’d)

If premium gasoline is not available, unleaded regular gasoline with an octane rating of 87 AKI number (research octane number 91) may be temporarily used, but only under the following precautions: 쐌 Have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gasoline as soon as possible. 쐌 Avoid full throttle driving and abrupt acceleration.

CAUTION: Use unleaded fuel only. Under no circumstances should leaded gasoline be used. It will damage the three way catalyst and increase dangerous emissions from the vehicle exhaust.

Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

PRECAUTIONS FOR AIR CONDITIONING

NEGI0001S07

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA-66, “HFC-134a (R-134a) Service Procedure” for specific instructions.

GI-8

NEGI0002

HOW TO USE THIS MANUAL 쐌

쐌 쐌 쐌 쐌 쐌 쐌

The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle.

WARNING indicates the possibility of personal injury if instructions are not followed.

CAUTION indicates the possibility of component damage if instructions are not followed.

BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.

ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and page you are searching for.

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 matching it to the section’s black tab.

THE CONTENTS are listed on the first page of each section.

THE TITLE is indicated on the upper portion of each page and shows the part or system.

THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. “BR-5”).

THE LARGE ILLUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC.440) 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.

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

SBR364AC

쐌

쐌

쐌

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.

The UNITS given 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.

“Example” Tightening torque: 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb) TROUBLE DIAGNOSES are included in sections dealing with complicated components.

GI-9

BT HA SC EL IDX

HOW TO USE THIS MANUAL 쐌 쐌

SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data.

The following SYMBOLS AND ABBREVIATIONS are used: SYMBOL

ABBREVIATION

SYMBOL

Tightening torque

ABBREVIATION Air Conditioner

A/C

Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease.

P/S

Should be lubricated with oil.

Tool

Special Service Tools

Sealing point

SAE

Society of Automotive Engineers, Inc.

Checking point

ATF

Automatic Transmission Fluid

Always replace after every disassembly.

D1

Apply petroleum jelly.

D2

쎻 P

SDS

Power Steering

Drive range 1st gear Drive range 2nd gear

Apply ATF.

D3

Drive range 3rd gear

Service Data and Specifications

D4

Drive range 4th gear

LH, RH

Left-hand, Right-hand

FR, RR

Front, Rear

22

2nd range 2nd gear

Automatic Transaxle/Transmission

21

2nd range 1st gear

A/T ,

O/D

4-Wheel Drive

12

4WD 2WD

2-Wheel Drive

11

GI-10

Overdrive

1st range 2nd gear 1st range 1st gear

NEGI0003

HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL —

Sample/Wiring Diagram — EXAMPL — 쐌

NEGI0003S01

For Description, refer to GI-13.

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL SGI091A

GI-11

IDX

HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL — (Cont’d)

OPTIONAL SPLICE

NEGI0003S0101

SGI942

GI-12

HOW TO READ WIRING DIAGRAMS Description

Description Number

Item

=NEGI0003S02

Description

Power condition

쐌 This shows the condition when the system receives battery positive voltage (can be operated).

2

Fusible link

쐌 The double line shows that this is a fusible link. 쐌 The open circle shows current flow in, and the shaded circle shows current flow out.

3

Fusible link/fuse location

쐌 This shows the location of the fusible link or fuse in the fusible link or fuse box. For arrangement, refer to EL-9, “POWER SUPPLY ROUTING”.

4

Fuse

쐌 The single line shows that this is a fuse. 쐌 The open circle shows current flow in, and the shaded circle shows current flow out.

5

Current rating

쐌 This shows the current rating of the fusible link or fuse.

6

Connectors

쐌 This shows that connector E3 is female and connector M1 is male. 쐌 The G/R wire is located in the 1A terminal of both connectors. 쐌 Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connector. Refer to “Super Multiple Junction (SMJ)”, GI-18.

7

Optional splice

쐌 The open circle shows that the splice is optional depending on vehicle application.

8

Splice

쐌 The shaded circle shows that the splice is always on the vehicle.

9

Page crossing

쐌 This arrow shows that the circuit continues to an adjacent page. 쐌 The A will match with the A on the preceding or next page.

10

Common connector

쐌 The dotted lines between terminals show that these terminals are part of the same connector.

11

Option abbreviation

쐌 This shows that the circuit is optional depending on vehicle application.

12

Relay

쐌 This shows an internal representation of the relay. For details, refer to EL-7, “STANDARDIZED RELAY”.

TF

13

Connectors

쐌 This shows that the connector is connected to the body or a terminal with bolt or nut.

PD

1

MA EM LC EC FE CL MT AT

쐌 This shows a code for the color of the wire.

AX

14

Wire color

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green

BR = Brown OR = Orange P = Pink PU = Purple GY = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green

When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe

SU BR ST

15

Option description

쐌 This shows a description of the option abbreviation used on the page.

RS

16

Switch

쐌 This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position.

BT

17

Assembly parts

쐌 Connector terminal in component shows that it is a harness incorporated assembly.

18

Cell code

쐌 This identifies each page of the wiring diagram by section, system and wiring diagram page number.

Current flow arrow

쐌 Arrow indicates electric current flow, especially where the direction of standard flow (vertically downward or horizontally from left to right) is difficult to follow. ” shows that current can flow in either direction depending on circuit 쐌 A double arrow “ operation.

19

GI-13

HA SC EL IDX

HOW TO READ WIRING DIAGRAMS Description (Cont’d) Number

Item

Description

20

System branch

쐌 This shows that the system branches to another system identified by cell code (section and system).

21

Page crossing

쐌 This arrow shows that the circuit continues to another page identified by cell code. 쐌 The C will match with the C on another page within the system other than the next or preceding pages.

22

Shielded line

쐌 The line enclosed by broken line circle shows shield wire.

23

Component box in wave line

쐌 This shows that another part of the component is also shown on another page (indicated by wave line) within the system.

24

Component name

쐌 This shows the name of a component.

25

Connector number

쐌 This shows the connector number. 쐌 The letter shows which harness the connector is located in. 쐌 Example: M: main harness. For detail and to locate the connector, refer to EL-240, “MAIN HARNESS”. A coordinate grid is included for complex harnesses to aid in locating connectors.

26

Ground (GND)

쐌 The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector.

27

Ground (GND)

쐌 This shows the ground connection. For detailed ground distribution information, refer to EL-17, “GROUND DISTRIBUTION”.

28

Connector views

쐌 This area shows the connector faces of the components in the wiring diagram on the page.

29

Common component

쐌 Connectors enclosed in broken line show that these connectors belong to the same component.

30

Connector color

쐌 This shows a code for the color of the connector. For code meaning, refer to wire color codes, Number 14 of this chart.

31

Fusible link and fuse box

쐌 This shows the arrangement of fusible link(s) and fuse(s), used for connector views of the power supply routing. Refer to EL-9, “POWER SUPPLY ROUTING”.

The open square shows current flow in, and the shaded square shows current flow out.

32

Reference area

쐌 This shows that more information on the Super Multiple Junction (SMJ), Electrical Units, etc. exists on the at the end of the manual. Refer to “REFERENCE AREA”, GI-18 for details.

GI-14

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

CONNECTOR SYMBOLS

=NEGI0003S0201

Most of connector symbols in wiring diagrams are shown from the terminal side. 쐌 Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. 쐌 Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. 쐌 Certain systems and components, especially related to OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to EL-5, “HARNESS CONNECTOR”.

MA EM LC EC FE CL MT

SGI364

쐌

Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

AT TF PD AX SU BR ST RS

SGI363

BT HA SC EL

GI-15

IDX

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

SWITCH POSITIONS

NEGI0003S0202

Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition.

A vehicle is in the “normal” condition when: 쐌 Ignition switch is OFF. 쐌 Doors, hood and trunk lid/back door are closed. 쐌 Pedals are not depressed. 쐌 Parking brake is released.

SGI860

DETECTABLE LINES AND NON-DETECTABLE LINES NEGI0003S0203 In some wiring diagrams, two kinds of lines, representing wires, with different weight are used. 쐌 A line with regular weight (wider line) represents a “detectable line for DTC (Diagnostic Trouble Code)”. A “detectable line for DTC” is a circuit in which ECM can detect its malfunctions with the on board diagnostic system. 쐌 A line with less weight (thinner line) represents a “non-detectable line for DTC”. A “non-detectable line for DTC” is a circuit in which ECM cannot detect its malfunctions with the on board diagnostic system.

AGI095

GI-16

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

MULTIPLE SWITCH

=NEGI0003S0204

The continuity of multiple switch is described in two ways as shown below. 쐌 The switch chart is used in schematic diagrams. 쐌 The switch diagram is used in wiring diagrams.

MA EM LC EC FE CL MT AT TF PD AX

SGI875

SU BR ST RS BT HA SC EL

GI-17

IDX

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

REFERENCE AREA

=NEGI0003S0205

The Reference Area of the wiring diagram contains references to additional electrical reference pages at the end of the manual. If connector numbers and titles are shown in the Reference Area of the wiring diagram, these connectors symbols are not shown in the Connector Area.

SGI092A

Super Multiple Junction (SMJ) In a wiring diagram, the SMJ connectors include a letter of the alphabet in the terminal number. SMJ connector numbers are shown in the Reference Area of the wiring diagram. SMJ terminal arrangement can be found on the electrical reference pages at the end of the manual. For terminal arrangement of these connectors, refer to the “SUPER MULTIPLE JUNCTION (SMJ)” electrical reference page at the end of the manual.

GI-18

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

Fuse block—Junction Box (J/B) Fuse block—Junction Box (J/B) connector number is shown in the Reference Area of the wiring diagram. For connector terminal and fuse arrangement, refer to the “FUSE BLOCK—Junction Box (J/B)” electrical reference page at the end of the manual.

Fuse and fusible link box For fuse arrangement in the fuse and fusible link box, refer to the “FUSE AND FUSIBLE LINK BOX” electrical reference page at the end of the manual.

Electrical units Electrical unit connector symbols are shown in the Connector Area of the wiring diagram. However, when there is not enough space to show the connector terminal arrangement in the Connector Area of the wiring diagram, the electrical unit connector number is shown in the Reference Area of the wiring diagram. For electrical unit connector terminal arrangement, refer to the “ELECTRICAL UNITS” electrical reference page at the end of the manual. Most of the electrical unit connectors on this page are shown from the harness side forth connector.

Joint Connector (J/C) Joint Connector (J/C) symbols are shown in the connector area of the wiring diagram. For connector internal wiring layout and joint connector terminal arrangement, refer to the “JOINT CONNECTOR (J/C)” electrical reference page at the end of the manual.

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GI-19

IDX

NEGI0011

HOW TO CHECK TERMINAL Connector and Terminal Pin Kit

Connector and Terminal Pin Kit

NEGI0011S01

Use the connector and terminal pin kit listed below when replacing connectors or terminals.

The connector and terminal pin kit contains some of the most commonly used NISSAN connectors and terminals.

Tool number (Kent-Moore No.) Tool name

Description

(J38751-95NI) Connector and terminal pin kit (J42992-98KIT) OBD Terminal Repair Kit

AGI121

How to Probe Connectors

NEGI0011S02

Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks.

The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip.

PROBING FROM HARNESS SIDE

NEGI0011S0201

Standard type (not waterproof type) connector should be probed from harness side with “T” pin. 쐌 If the connector has a rear cover such as an ECM connector, remove the rear cover before probing the terminal. 쐌 Do not probe waterproof connector from harness side.

Damage to the seal between wire and connector may result.

SGI841

PROBING FROM TERMINAL SIDE

NEGI0011S0202

Female Terminal 쐌 There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch.

Do not insert any object other than the same type male terminal into female terminal.

SEL265V

GI-20

HOW TO CHECK TERMINAL How to Probe Connectors (Cont’d)

쐌

Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.

MA EM LC

SEL266V

Male Terminal Carefully probe the contact surface of each terminal using a “T” pin.

Do not bend terminal.

EC FE CL MT

SEL267V

How to Check Enlarged Contact Spring of Terminal

AT NEGI0011S03

An enlarged contact spring of a terminal may create intermittent signals in the circuit.

If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal.

TF PD AX

1.

2.

Assemble a male terminal and approx. 10 cm (3.9 in) of wire.

Use a male terminal which matches the female terminal.

Disconnect the suspected faulty connector and hold it terminal side up.

SU BR ST RS

SEL270V

3.

While holding the wire of the male terminal, try to insert the male terminal into the female terminal.

Do not force the male terminal into the female terminal with your hands.

BT HA SC EL

SEL271V

GI-21

IDX

HOW TO CHECK TERMINAL How to Check Enlarged Contact Spring of Terminal (Cont’d)

4.

While moving the connector, check whether the male terminal can be easily inserted or not.

쐌

If the male terminal can be easily inserted into the female terminal, replace the female terminal.

SEL272V

SEL273V

Waterproof Connector Inspection

NEGI0011S04

If water enters the connector, it can short interior circuits. This may lead to intermittent problems.

Check the following items to maintain the original waterproof characteristics.

RUBBER SEAL INSPECTION 쐌

SEL275V

쐌

NEGI0011S0401

Most waterproof connectors are provided with a rubber seal between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications.

The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector.

WIRE SEAL INSPECTION

NEGI0011S0402

The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly.

Terminal Lock Inspection

NEGI0011S05

Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.

SEL330V

GI-22

NEGI0004

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Work Flow

Work Flow

NEGI0004S01

MA EM LC EC FE CL SGI838

STEP STEP 1

DESCRIPTION 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: WHAT

Vehicle 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 Aftermarket Accessories have been installed.

MT AT TF PD

STEP 2

Operate the system, road test if necessary.

Verify the parameter of the incident.

If the problem cannot be duplicated, refer to “Incident Simulation Tests�, GI-24.

AX

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.

SU

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 inadvertently created a new incident during your diagnosis or repair steps.

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GI-23

IDX

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests

Incident Simulation Tests INTRODUCTION

NEGI0004S02 NEGI0004S0201

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: 쐌 Vehicle vibration 쐌 Heat sensitive 쐌 Freezing 쐌 Water intrusion 쐌 Electrical load 쐌 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

NEGI0004S0202

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 and Harness Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. 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 terminals. 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 and 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

GI-24

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d)

Engine Compartment There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: 쐌 Connectors not fully seated. 쐌 Wiring harness not long enough and is being stressed due to engine vibrations or rocking. 쐌 Wires laying across brackets or moving components. 쐌 Loose, dirty or corroded ground wires. 쐌 Wires routed too close to hot components.

To inspect components under the hood, start by verifying the integrity of ground connections. Refer to “GROUND INSPECTION”, GI-29. First check that the system is properly grounded. Then check for loose connection by gently shaking the 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 aggravate 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 possible damage or pinching.

MA EM LC EC FE CL MT AT TF PD AX

HEAT SENSITIVE

NEGI0004S0203

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 60°C (140°F). If incident occurs while heating the unit, either replace or properly insulate the component.

SU BR ST RS

SGI842

FREEZING

NEGI0004S0204

The customer may indicate the incident goes away after the car warms up (wintertime). The cause could be related to water freezing somewhere in the wiring/electrical system.

There are two methods to check for this. The first is to arrange for the owner to leave the car overnight. Make sure it will get cold enough to demonstrate the complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected.

BT HA SC EL

SGI843

GI-25

IDX

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d)

The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

WATER INTRUSION

NEGI0004S0205

The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash.

Do not spray water directly on any electrical components.

SGI844

ELECTRICAL LOAD

NEGI0004S0206

The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.

COLD OR HOT START UP

NEGI0004S0207

On some occasions an electrical incident may occur only when the car is started cold. Or it may occur when the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis.

SGI845

Circuit Inspection INTRODUCTION

NEGI0004S03 NEGI0004S0302

In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation.

Then you will be able to use the appropriate equipment and follow the correct test procedure.

You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this.

OPEN

A circuit is open when there is no continuity through a section of the circuit.

SHORT There are two types of shorts. 쐌 SHORT CIR- When a circuit contacts another circuit and causes CUIT the normal resistance to change. 쐌 SHORT TO GROUND

When a circuit contacts a ground source and grounds the circuit.

NOTE: Refer to “HOW TO CHECK TERMINAL”, GI-20 to probe or check terminal.

GI-26

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

TESTING FOR “OPENS” IN THE CIRCUIT

NEGI0004S0303

Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

MA EM LC EC

AGI083

FE Continuity Check Method The continuity check is used to find an open in the circuit. The Digital Multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (no beep tone or no ohms symbol).

Make sure to always start with the DMM at the highest resistance level.

To help in understanding the diagnosis of open circuits please refer to the schematic above.

1) Disconnect the battery negative cable.

2) Start at one end of the circuit and work your way to the other end. (At the fuse block in this example) 3) Connect one probe of the DMM to the fuse block terminal on the load side.

4) Connect the other probe to the fuse block (power) side of SW1.

Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A) 5) Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B) 6) Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C) Any circuit can be diagnosed using the approach in the above example.

Voltage Check Method To help in understanding the diagnosis of open circuits please refer to the previous schematic.

In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function.

1) Connect one probe of the DMM to a known good ground.

2) Begin probing at one end of the circuit and work your way to the other end.

3) With SW1 open, probe at SW1 to check for voltage. 쐌 Voltage: open is further down the circuit than SW1. 쐌 No voltage: open is between fuse block and SW1 (point A).

4) Close SW1 and probe at relay.

GI-27

CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

쐌 Voltage: open is further down the circuit than the relay. 쐌 No voltage: open is between SW1 and relay (point B).

5) Close the relay and probe at the solenoid. 쐌 Voltage: open is further down the circuit than the solenoid. 쐌 No voltage: open is between relay and solenoid (point C).

Any powered circuit can be diagnosed using the approach in the above example.

TESTING FOR “SHORTS” IN THE CIRCUIT

NEGI0004S0304

To simplify the discussion of shorts in the system please refer to the schematic below.

AGI084

Resistance Check Method 1) Disconnect the battery negative cable and remove the blown fuse.

2) Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.

3) Connect one probe of the ohmmeter to the load side of the fuse terminal. Connect the other probe to a known good ground.

4) With SW1 open, check for continuity. 쐌 Continuity: short is between fuse terminal and SW1 (point A). 쐌 No continuity: short is further down the circuit than SW1.

5) Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. 쐌 Continuity: short is between SW1 and the relay (point B). 쐌 No continuity: short is further down the circuit than the relay.

6) Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. 쐌 Continuity: short is between relay and solenoid (point C). 쐌 No continuity: check solenoid, retrace steps.

Voltage Check Method 1) Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.

2) Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground).

3) With SW1 open and the DMM leads across both fuse terminals, check for voltage. 쐌 Voltage: short is between fuse block and SW1 (point A). 쐌 No voltage: short is further down the circuit than SW1.

4) With SW1 closed, relay and solenoid disconnected and the

GI-28

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

쐌 쐌 5) 쐌 쐌

DMM leads across both fuse terminals, check for voltage.

Voltage: short is between SW1 and the relay (point B).

No voltage: short is further down the circuit than the relay.

With SW1 closed, relay contacts jumped with fused jumper wire check for voltage.

Voltage: short is down the circuit of the relay or between the relay and the disconnected solenoid (point C).

No voltage: retrace steps and check power to fuse block.

GROUND INSPECTION

MA EM

NEGI0004S0305

Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works.

Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface.

When inspecting a ground connection follow these rules: 1) Remove the ground bolt or screw.

2) Inspect all mating surfaces for tarnish, dirt, rust, etc.

3) Clean as required to assure good contact.

4) Reinstall bolt or screw securely.

5) Inspect for “add-on” accessories which may be interfering with the ground circuit.

6) If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation.

For detailed ground distribution information, refer to EL-17, “GROUND DISTRIBUTION”.

LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA

SGI853

SC EL

GI-29

IDX

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

VOLTAGE DROP TESTS

NEGI0004S0306

Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation.

Check the wire in the illustration. When measuring resistance with ohmmeter, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop.

Unwanted resistance can be caused by many situations as follows: 쐌 Undersized wiring (single strand example) 쐌 Corrosion on switch contacts 쐌 Loose wire connections or splices.

If repairs are needed always use wire that is of the same or larger gauge.

Measuring Voltage Drop — Accumulated Method 1) Connect the voltmeter across the connector or part of the circuit you want to check. The positive lead of the voltmeter should be closer to power and the negative lead closer to ground.

2) Operate the circuit.

3) The voltmeter will indicate how many volts are being used to “push” current through that part of the circuit.

Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

SGI974

Measuring Voltage Drop — Step by Step The step by step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”).

Circuits in the “Computer Controlled System” operate on very low amperage.

The (Computer Controlled) system operations can be adversely

GI-30

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

affected by any variation in resistance in the system. Such resistance variation may be caused by poor connection, improper installation, improper wire gauge or corrosion.

The step by step voltage drop test can identify a component or wire with too much resistance.

MA EM LC EC FE CL MT SGI854

AT TF PD AX

CONTROL UNIT CIRCUIT TEST

NEGI0004S0307

System Description: When the switch is ON, the control unit lights up the lamp.

SU BR ST RS BT

MGI034A

HA SC EL

GI-31

IDX

HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

Input-output voltage chart Pin No.

Item

Condition

Voltage value [V]

In case of high resistance such as single strand [V] *

1

Switch

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF

Approx. 0

Approx. 0

Switch ON

Battery voltage

Approx. 0 (Inoperative lamp)

Switch OFF

Approx. 0

Approx. 0

2

Lamp

The voltage value is based on the body ground. * : If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp.

MGI035A

Input-output voltage chart Pin No.

Item

Condition

Voltage value [V]

In case of high resistance such as single strand [V] *

1

Lamp

Switch ON

Approx. 0

Battery voltage (Inoperative lamp)

Switch OFF

Battery voltage

Battery voltage

Switch ON

Approx. 0

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

Approx. 5

2

Switch

The voltage value is based on the body ground. * : If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.

GI-32

NEGI0005

HOW TO FOLLOW TROUBLE DIAGNOSES NOTICE: Trouble diagnoses indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing.

1) Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the “Work Flow”.

2) After repairs, re-check that the problem has been completely eliminated.

3) Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors.

4) Refer to the Circuit Diagram for quick pinpoint check.

If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in EL section for identification of harness connectors.

5) When checking circuit continuity, ignition switch should be OFF. 6) Before checking voltage at connectors, check battery voltage.

7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

GI-33

IDX

HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses

How to Follow Test Groups in Trouble Diagnoses

NEGI0005S01

WGI027

1)

2)

3)

4)

Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups.

Questions and required results.

Questions and required results are indicated in bold type in test group.

The meaning of are as follows: a. Battery voltage → 11 - 14V or approximately 12V b. Voltage: Approximately 0V → Less than 1V c. Resistance: Continuity should exist → Approximately 0Ω Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Refer to “CONNECTOR SYMBOLS”, GI-15 and “Key to Symbols Signifying Measurements or Procedures”, GI-36.

Action items Next action for each test group is indicated based on result of each question. Test group number is shown in the left upper portion of each test group.

GI-34

HOW TO FOLLOW TROUBLE DIAGNOSES Harness Wire Color and Connector Number Indication

Harness Wire Color and Connector Number Indication

NEGI0005S03

There are two types of harness wire color and connector number indication.

MA EM LC TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION NEGI0005S0301 쐌 쐌 쐌

Letter designations next to test meter probe indicate harness wire color.

Connector numbers in a single circle (e.g. M33) indicate harness connectors.

Connector numbers in a double circle indicate component connectors.

EC FE CL MT AT TF PD AX

AGI070

SU BR ST RS BT HA SC EL

GI-35

IDX

HOW TO FOLLOW TROUBLE DIAGNOSES Harness Wire Color and Connector Number Indication (Cont’d)

TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT =NEGI0005S0302

SGI144A

Key to Symbols Signifying Measurements or Procedures

NEGI0005S02

Symbol

Symbol explanation

Symbol

Symbol explanation

Check after disconnecting the connector to be measured.

Procedure with Generic Scan Tool (GST, OBD-II scan tool)

Check after connecting the connector to be measured.

Procedure without CONSULT-II or GST

Insert key into ignition switch.

A/C switch is OFF.

Remove key from ignition switch.

A/C switch is ON.

Turn ignition switch to OFF position.

REC switch is ON.

Turn ignition switch to ON position.

REC switch is OFF.

GI-36

HOW TO FOLLOW TROUBLE DIAGNOSES Key to Symbols Signifying Measurements or Procedures (Cont’d) Symbol

Symbol explanation

Symbol

Symbol explanation

Turn ignition switch to “START” position.

DEF switch is ON.

Turn ignition switch from OFF to ACC position.

VENT switch is ON.

Turn ignition switch from ACC to OFF position.

Fan switch is ON. (At any position except for OFF position)

Turn ignition switch from OFF to ON position.

Fan switch is OFF.

Turn ignition switch from ON to OFF position.

Apply positive voltage from battery with fuse directly to components.

Do not start engine, or check with engine stopped.

Drive vehicle.

MA EM LC EC FE CL

Start engine, or check with engine running.

Disconnect battery negative cable.

Apply parking brake.

Depress brake pedal.

Release parking brake.

Release brake pedal.

MT AT TF PD

Check after engine is warmed up sufficiently.

Depress accelerator pedal.

Voltage should be measured with a voltmeter.

Release accelerator pedal.

Circuit resistance should be measured with an ohmmeter.

Pin terminal check for SMJ type ECM and TCM connectors.

For details regarding the terminal arrangement, refer to the foldout page.

Current should be measured with an ammeter.

AX SU BR ST RS

Procedure with CONSULT-II

BT

Procedure without CONSULT-II

HA SC EL

GI-37

IDX

NEGI0006

CONSULT–II CHECKING SYSTEM Function and System Application

Function and System Application Diagnostic test mode

NEGI0006S01

Function

Engine

A/T

Air bag

ABS

Work support

This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-II.

x

—

—

—

DTC work support

Select the operating condition to confirm Diagnosis Trouble Codes.

—

x

—

—

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

x

x

x

x

Trouble diagnostic record

Current self-diagnostic results and all trouble diagnostic records previously stored can be read.

—

—

x

—

ECU discriminated No.

Classification number of a replacement ECU can be read to prevent an incorrect ECU from being installed.

—

—

x

—

Data monitor

Input/Output data in the ECU (ECM) can be read.

x

x

—

x

Data monitor (Spec.)

The specified values will be displayed when an OK/NG judgment is difficult for the DATA MONITOR items by Bar Chart and Line Graph.

x

—

—

—

Active test

Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECUs and also shifts some parameters in a specified range.

x

—

—

x

SRT & DTC confirmation

The results of SRT (System Readiness Test) and the self-diagnosis status/result can be confirmed.

x

x*

—

—

x

x

—

x

ECU (ECM) part number

ECU (ECM) part number can be read.

x: Applicable *: For VG33E engine

Nickel Metal Hydride Battery Replacement

NEGI0006S02

CONSULT-II contains a Nickel Metal Hydride battery. When replacing the battery obey the following: WARNING: Replace the Nickel Metal Hydride battery with genuine CONSULT-II battery only. Use of another battery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if mistreated. Do not recharge, disassemble, or dispose of in fire.

Keep the battery out of reach of children and discard used battery conforming to the local regulations.

GI-38

CONSULT–II CHECKING SYSTEM Checking Equipment

Checking Equipment

=NEGI0006S03

When ordering the below equipment, contact your NISSAN distributor.

Tool name

Description

NISSAN CONSULT-II 쎻 1 CONSULT-II unit (Tester internal soft: Resident Version 3.2.0) and accessories 쎻 2 Program card AED00A-1 (Version 4.11) For details, refer to Consult-II Operation Manual.

MA EM LC EC AGI123

FE

Loading Procedure

NEGI0006S04

NOTE: 쐌 The CONSULT-II must be used in conjunction with a program card. CONSULT-II does not require loading (Initialization) procedure. 쐌 Be sure the CONSULT-II is turned off before installing or removing a program card.

CONSULT-II Data Link Connector (DLC) Circuit

NEGI0006S05

CL MT AT TF PD AX

SGI122A

SU INSPECTION PROCEDURE

NEGI0006S0501

If the CONSULT-II cannot diagnose the system properly, check the following items.

Symptom CONSULT-II cannot access any system.

BR

Check item 쐌 CONSULT-II DLC power supply circuit (Terminal 8) and ground circuit (Terminal 4) (For detailed circuit, refer to EC-615 (KA24DE), EC-1216 (VG33E) or EC-1819 (VG33ER), “MIL & Link Connectors Wiring Diagram”. 쐌 CONSULT-II DDL cable

CONSULT-II cannot access 쐌 CONSULT-II program card (Check the appropriate CONSULT-II program card for the system. individual system. (Other sysRefer to “Checking Equipment”, GI-39. tems can be accessed.) 쐌 Power supply and ground circuit for the control unit of the system Refer to “Function and Sys(For detailed circuit, refer to wiring diagram for each system.) tem Application”, GI-38 for the 쐌 Open or short circuit between the system and CONSULT-II DLC systems supported by CON(For detailed circuit, refer to wiring diagram for each system.)

SULT-II.

NOTE: The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system.

A short in a DDL circuit connected to a control unit in one system may affect CONSULT-II access to other systems.

GI-39

ST RS BT HA SC EL IDX

NEGI0007

IDENTIFICATION INFORMATION Model Variation

Model Variation Drive Type

4x2

Body

Regular Cab

Engine

KA24DE

King Cab

VG33E

Transmission

Crew Cab

4X4

King Cab

VG33E

Auto

XE

ABGALEBD22EUN

N/A

Manual

XE

BBGGLEFD22EUN

BBGGLEFD22ENN

Auto

XE

BBGGLEBD22EUN

BBGGLEBD22ENN

Manual

XE

BLPGLEFD22EUN

BLPGLEFD22ENN

SE

BLPGLFFD22EUN

N/A

XE

BLPGLEAD22EUN

BLPGLEAD22ENN

SE

BLPGLFAD22EUN

N/A

XE

CLPGLEFD22EUN

CLPGLEFD22ENN

SE

CLPGLFFD22EUN

CLPGLFFD22ENN

XE

CLPGLEAD22EUN

CLPGLEAD22ENN

SE

CLPGLFAD22EUN

CLPGLFAD22ENN

Manual

SC

BLPGLMFD22RUN

N/A

Auto

SC

BLPGLMAD22RUN

N/A

Manual

SC

CLPGLMFD22RUN

CLPGLMFD22RNN

Auto

SC

CLPGLMAD22RUN

CLPGLMAD22RNN

Manual

XE

BLPULEFD22EUN

BLPULEFD22ENN

SE

BLPULFFD22EUN

N/A

XE

BLPULEAD22EUN

BLPULEAD22ENN

SE

BLPULFAD22EUN

N/A

XE

CLPULEFD22EUN

CLPULEFD22ENN

SE

CLPULFFD22EUN

CLPULFFD22ENN

XE

CLPULEAD22EUN

CLPULEAD22ENN

SE

CLPULFAD22EUN

CLPULFAD22ENN

Manual

SC

BLPULMFD22RUN

N/A

Auto

SC

BLPULMAD22RUN

N/A

Manual

SC

CLPULMFD22RUN

CLPULMFD22RNN

Auto

SC

CLPULMAD22RUN

CLPULMAD22RNN

Manual

Auto

King Cab

Crew Cab

VG33ER

Canada N/A

Auto

Crew Cab

U.S.A. ABGALEFD22EUN

Manual

VG33ER

Model

XE

Auto

King Cab

Grade

Manual

Auto

Crew Cab

NEGI0007S01

GI-40

IDENTIFICATION INFORMATION Model Variation (Cont’d)

MA EM LC EC FE CL MT AT WGI030

TF PD AX SU BR ST RS BT HA SC EL

GI-41

IDX

IDENTIFICATION INFORMATION Identification Number

Identification Number

=NEGI0007S02

WGI021

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT NEGI0007S0201

WGI041

GI-42

IDENTIFICATION INFORMATION Identification Number (Cont’d)

ENGINE SERIAL NUMBER

NEGI0007S0203

MA EM LC

AGI106

EC FE CL MT

WGI029

TRANSFER SERIAL NUMBER

NEGI0007S0207

AT TF PD AX

AGI108

MANUAL TRANSMISSION NUMBER

NEGI0007S0210

SU BR ST RS

AGI109

BT HA SC EL

GI-43

IDX

IDENTIFICATION INFORMATION Identification Number (Cont’d)

AUTOMATIC TRANSMISSION NUMBER

NEGI0007S0205

AGI110

AGI111

Dimensions

NEGI0007S03

Unit: mm (in) Drive Type Body Wheelbase Overall Length*1 Overall Width

2WD Regular Cab

King Cab

Crew Cab

King Cab

Crew Cab

Short

Long

Long

Long

Long

4699 (185)

4999 (196.8)

4906 (193.1)

4999 (196.8)

4906 (193.1)

1720 (67.7)

1664 (65.5)*5 1808 (71.2)*4

1664 (65.5)*5 1808 (71.2)*4

1664 (65.5)*5 1808 (71.2)*4

1664 (65.5)*5 1808 (71.2)*4

1613 (63.5)

1605 (63.2)*2 1694 (66.7)*3 1687 (66.4)*6

1687 (66.4)

1694 (66.7)*3 1687 (66.4)*6

1687 (66.4)

1395 (54.9)

1395 (54.9)*2 1525 (60)*3, *6

1525 (60)

1525 (60)

1525 (60)

1390 (54.7)

1390 (54.7)*2 1507 (59.3)*3, *6

1507 (59.3)

1507 (59.3)

1507 (59.3)

2648 (104.3)

2950 (116.1)

2950 (116.1)

2950 (116.1)

2950 (116.1)

N/A

N/A*2 N/A*6 229 (9.0)*7 246 (9.7)*8

209 (8.2)*7 226 (8.9)*6, *8

201 (7.9)*6 229 (9.0)*7 244 (9.6)*8

209 (8.2)*7 226 (8.9)*6, *8

Overall Height

Front Tread Rear Tread

Wheelbase Minimum Running Ground Clearance (at Front Suspension)

*1: *2: *3: *4: *5: *6: *7: *8:

4WD

The step bumper adds 175 mm (6.9 in) to the overall length.

XE with KA24DE engine.

XE with VG33E engine and SE models.

With over-fender.

Without over-fender.

SC with VG33ER engine.

XE with VG33E engine.

SE models.

GI-44

IDENTIFICATION INFORMATION Wheels & Tires

Wheels & Tires Drive Type

Grade

Tire

Spare tire size

P225/70R15

T135/90D16

15x7JJ Steel, 15x7JJ Alloy

P265/70R15*

P265/70R15*

SE

16x7JJ Alloy

P255/65R16

P255/65R16

SC

17x8JJ Alloy

P265/55R17

P265/55R17

XE

15x7JJ Steel, 15x7JJ Alloy

P265/70R15

P265/70R15

SE

16x7JJ Alloy

P265/70R16

P265/70R16

SC

17x8JJ Alloy

P265/55R17

P265/55R17

4x2

Road wheel

NEGI0007S04

15x6JJ Steel, 15x7JJ Alloy XE

4x4

MA EM LC EC

*: Not available with KA24DE engine.

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

GI-45

IDX

NEGI0008

LIFTING POINTS AND TOW TRUCK TOWING WARNING: 쐌 Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. 쐌 Place wheel chocks at both front and back of the wheels on the ground.

Pantograph Jack

NEGI0008S01

AGI133

Garage Jack and Safety Stand

NEGI0008S02

CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.

AGI113

GI-46

LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift

2-pole Lift

=NEGI0008S03

WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced.

When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, or fuel lines.

MA EM LC EC FE CL MT AT

WGI025

TF PD AX

Tow Truck Towing

AGI077

NEGI0008S04

CAUTION: 쐌 All applicable State or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. 쐌 It is necessary to use proper towing equipment to avoid possible damage during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. 쐌 Always attach safety chains before towing. 쐌 When towing, make sure that the transmission, steering system and power train are in good order. If any unit is damaged, dollies must be used. 쐌 Never tow an automatic transmission model from the rear (i.e., backward) with four wheels on the ground as this may cause serious and expensive damage to the transmission.

SU BR ST RS BT HA SC EL

GI-47

IDX

LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont’d)

2-WHEEL DRIVE MODELS

SGI976

4-WHEEL DRIVE MODELS

SGI973

NEGI0008S0406

NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated.

CAUTION: 쐌 When towing with the front wheels on the ground: Turn the ignition key to the OFF position and move the transmission shift lever to the neutral position. On automatic transmission models, to move the selector lever to N (neutral) position, turn the ignition key to OFF position and secure the steering wheel in a straight ahead position with a rope or similar device. Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism. 쐌 When towing manual transmission models with the rear wheels on the ground (if you do not use a towing dollies): Always release the parking brake and move the transmission shift lever to the neutral position.

Observe the following restricted towing speeds and distances.

Speed: Below 95 km/h (60 MPH) Distance: Less than 800 km (500 miles) If the speed or distance must necessarily be greater, remove the propeller shaft before hand to prevent damage to the transmission.

NISSAN recommends that the vehicle be towed with the driving (front) wheels off the ground as illustrated.

NEGI0008S0407

NISSAN recommends that a dolly be used as illustrated when towing 4–wheel drive models.

CAUTION: 쐌 When towing with the front wheels on the ground or rear wheels on the ground (If you do not use towing dollies): Set the free-running hubs to the free position and move the transfer case shift lever into the “2H” position. 쐌 When towing with the front on the ground: Turn the ignition key to the OFF position and secure the steering wheel in a straight ahead position with a rope or similar device.

Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism. 쐌 When towing manual transmission models with the rear wheels on the ground: Always release the parking brake and move the transmission shift lever to the neutral position.

Observe the following restricted towing speeds and distances.

Speed: Below 95 km/h (60 MPH) Distance: Less than 800 km (500 miles) If the speed or distance must necessarily be greater, remove the propeller shaft before hand to prevent damage to the transmission.

GI-48

LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont’d)

TOWING POINT

NEGI0008S0409

Never tow the vehicle using only the towing points. To avoid damaging the vehicle body, use proper towing equipment when towing.

MA EM LC EC FE CL MT WGI022

VEHICLE RECOVERY (FREEING A STUCK VEHICLE) NEGI0008S0403 쐌 쐌 쐌 쐌

Tow chains or cables must be attached only to the main structural members of the vehicle.

Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or cooling systems Always pull the cable straight out from the front or rear of the vehicle. Never pull the vehicle at a sideways angle.

Pulling devices such as ropes or canvas straps are not recommended for use for vehicle towing or recovery.

AT TF PD AX SU BR ST RS BT HA SC EL

GI-49

IDX

NEGI0009

TIGHTENING TORQUE OF STANDARD BOLTS

Pitch mm

M6

6.0

M8

8.0

Grade Bolt size

4T

M10

M12

7T

Hexagon head bolt

Hexagon flange bolt

N·m

kg-m

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

1.0

5.1

0.52

3.8

45.1

6.1

0.62

4.5

53.8

1.25

13

1.3

9

—

15

1.5

11

—

1.0

13

1.3

9

—

16

1.6

12

—

1.5

25

2.5

18

—

29

3.0

22

—

1.25

25

2.6

19

—

30

3.1

22

—

1.75

42

4.3

31

—

51

5.2

38

—

1.25

46

4.7

34

—

56

5.7

41

—

10.0

12.0

M14

14.0

1.5

74

7.5

54

—

88

9.0

65

—

M6

6.0

1.0

8.4

0.86

6.2

74.6

10

1.0

7

87

1.25

21

2.1

15

—

25

2.5

18

—

M8

8.0 1.0

22

2.2

16

—

26

2.7

20

—

1.5

41

4.2

30

—

48

4.9

35

—

1.25

43

4.4

32

—

51

5.2

38

—

1.75

71

7.2

52

—

84

8.6

62

—

1.25

77

7.9

57

—

92

9.4

68

—

M10

M12

9T

Tightening torque (Without lubricant)

Bolt diameter * mm

10.0

12.0

M14

14.0

1.5

127

13.0

94

—

147

15.0

108

—

M6

6.0

1.0

12

1.2

9

—

15

1.5

11

—

1.25

29

3.0

22

—

35

3.6

26

—

M8

8.0 1.0

31

3.2

23

—

37

3.8

27

—

1.5

59

6.0

43

—

70

7.1

51

—

1.25

62

6.3

46

—

74

7.5

54

—

1.75

98

10.0

72

—

118

12.0

87

—

1.25

108

11.0

80

—

137

14.0

101

—

1.5

177

18.0

130

—

206

21.0

152

—

M10

M12 M14

10.0

12.0 14.0

*: Nominal diameter 1) Special parts are excluded.

2) This standard is applicable to bolts having the following marks embossed on the bolt head.

MGI044A

GI-50

NEGI0010

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List

SAE J1930 Terminology List

NEGI0010S01

All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart.

NEW ACRONYM / ABBREVIATION

NEW TERM

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

Canister

***

Canister

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

***

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

EC

***

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

***

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS

GI-51

BT HA SC EL IDX

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Cont’d) NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Evaporative emission canister

EVAP canister

Canister

Evaporative emission system

EVAP system

Canister control solenoid valve

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

Exhaust gas recirculation temperature sensor

EGRT 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

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

Fuel trim

FT

***

Heated Oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air 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 pot

FI pot

Idle speed control system

ISC system

***

Ignition control

IC

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

IA

Air

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

KS

Detonation sensor

Malfunction indicator lamp

MIL

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

EGR temperature sensor

GI-52

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Cont’d) NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

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 ratio control solenoid valve

Multiport fuel injection system

MFI system

Fuel injection control

Nonvolatile 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

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch Inhibitor switch Neutral position switch

Periodic trap oxidizer system

PTOX system

***

Positive crankcase ventilation

PCV

Positive crankcase ventilation

Positive crankcase ventilation valve

PCV valve

PCV valve

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

***

MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC

GI-53

EL IDX

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Cont’d) NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

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

Transmission control module

TCM

A/T control unit

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 sys- WU-OC system tem

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter system

WU-TWC system

***

Wide open throttle position switch

WOTP switch

Full switch

GI-54

MAINTENANCE SECTION

MA

GI

EM LC EC

CONTENTS PRECAUTIONS ...............................................................3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............3 PREPARATION ...............................................................4 Special Service Tools ..................................................4 Commercial Service Tool.............................................4 GENERAL MAINTENANCE ............................................5 PERIODIC MAINTENANCE ............................................7 Schedule 1...................................................................8 EMISSION CONTROL SYSTEM MAINTENANCE .........8 CHASSIS AND BODY MAINTENANCE ........................9 Schedule 2.................................................................11 EMISSION CONTROL SYSTEM MAINTENANCE .......11 CHASSIS AND BODY MAINTENANCE ......................12 RECOMMENDED FLUIDS AND LUBRICANTS...........13 Fluids and Lubricants ................................................13 SAE Viscosity Number ..............................................14 GASOLINE ENGINE OIL ..........................................14 GEAR OIL ...............................................................15 Anti-freeze Coolant Mixture Ratio .............................15 KA24DE ENGINE MAINTENANCE ..............................................16 Checking Drive Belts .................................................16 DRIVE BELT DEFLECTION AND TENSION ...............17 Changing Engine Coolant..........................................17 -DRAINING ENGINE COOLANT- ..............................17 -REFILLING ENGINE COOLANT-..............................17 -FLUSHING COOLING SYSTEM- ..............................18 Checking Fuel Lines ..................................................19 Changing Fuel Filter ..................................................19 WITH CONSULT - II ............................................19 WITHOUT CONSULT - II .....................................20 Changing Air Cleaner Filter .......................................20 Changing Engine Oil..................................................20 Changing Oil Filter.....................................................21 Changing Spark Plugs...............................................22 Checking EVAP Vapor Lines .....................................23

FE

Changing Positive Crankcase Ventilation (PCV) Filter ...........................................................................23 SERVICE DATA AND SPECIFICATIONS (SDS) .........24 Engine Maintenance ..................................................24 KA24DE ..................................................................24

CL MT AT

VG33E AND VG33ER ENGINE MAINTENANCE ..............................................25 Checking Drive Belts .................................................25 DRIVE BELT DEFLECTION AND TENSION ...............27 Changing Engine Coolant..........................................27 -DRAINING ENGINE COOLANT- ...............................27 -REFILLING ENGINE COOLANT- ..............................28 -FLUSHING COOLING SYSTEM- ..............................29 Checking Fuel Lines ..................................................29 Changing Fuel Filter ..................................................29 WITH CONSULT - II ............................................29 WITHOUT CONSULT - II .....................................30 Changing Air Cleaner Filter .......................................30 VISCOUS PAPER TYPE ...........................................30 Changing Engine Oil..................................................30 Changing Oil Filter.....................................................31 Changing Spark Plugs...............................................32 Checking EVAP Vapor Lines .....................................35 SERVICE DATA AND SPECIFICATIONS (SDS) .........36 Engine Maintenance ..................................................36 VG33E AND VG33ER ..............................................36 CHASSIS AND BODY MAINTENANCE .......................37 Checking Exhaust System.........................................37 Checking Clutch Fluid Level and Leaks....................37 Checking M/T Oil .......................................................37 Changing M/T Oil.......................................................37 Checking A/T Fluid ....................................................38 Changing A/T Fluid ....................................................38 Checking Transfer Fluid.............................................39 Changing Transfer Fluid ............................................39 Checking Propeller Shaft...........................................39 Greasing Propeller Shaft ...........................................40

TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS Checking Differential Gear Oil...................................40 Changing Differential Gear Oil ..................................40 LIMITED-SLIP DIFFERENTIAL GEAR........................41 Balancing Wheels ......................................................41 Tire Rotation ..............................................................41 Checking Brake Fluid Level and Leaks.....................41 Checking Brake Lines and Cables ............................41 Checking Disc Brake .................................................42 ROTOR ...................................................................42 CALIPER .................................................................42 PAD ........................................................................42 Checking Drum Brake ...............................................42 WHEEL CYLINDER ..................................................42

(Cont’d)

LINING ....................................................................42 Checking Steering Gear and Linkage .......................43 STEERING GEAR ....................................................43 STEERING LINKAGE ...............................................43 Checking Power Steering Fluid and Lines ................43 CHECKING FLUID LEVEL ........................................43 CHECKING LINES ...................................................43 Lubricating Locks, Hinges and Hood Latches...........44 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters...............................................45 SERVICE DATA AND SPECIFICATIONS (SDS) .........46 Chassis and Body Maintenance................................46 WHEEL BALANCE ...................................................46

MA-2

PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NEMA0001

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.

The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pretensioners, a diagnosis sensor unit, warning lamp, wiring harness, and spiral cable.

The vehicle (except Crew Cab model) is equipped with a passenger air bag deactivation switch. Because no rear seat exists where a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is enabled and could inflate in a frontal collision. When the switch is turned to the OFF position, the passenger air bag is disabled and will not inflate in a frontal collision. A passenger air bag OFF indicator on the instrument panel lights up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected by the passenger air bag deactivation switch.

Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING: 쐌 To 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 should be performed by an authorized NISSAN dealer. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) are covered with yellow insulation either just before the harness connectors or for the complete harness are related to the SRS. 쐌 The vehicle (except Crew Cab model) is equipped with a passenger air bag deactivation switch which can be operated by the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and will not inflate in a frontal collision. When the passenger air bag is switched ON, the passenger air bag is enabled and could inflate in a frontal collision. After SRS maintenance or repair, make sure the passenger air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for service.

GI

EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

MA-3

IDX

PREPARATION Special Service Tools

Special Service Tools

NEMA0002

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

Description Removing oil filter a: 64.3 mm (2.531 in)

KV10115801 (J38956) Oil filter cap wrench

NT375

Commercial Service Tool Tool name (Kent-Moore No.)

Description

Belt tension gauge (BT3373-F)

Checking drive belt tension

AMA126

MA-4

NEMA0052

NEMA0003

GENERAL MAINTENANCE General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform checks and inspections themselves or have their NISSAN dealers do them.

OUTSIDE THE VEHICLE

GI

The maintenance items listed here should be performed from time to time, unless otherwise specified.

Item Tires

Reference page Check the pressure with a gauge periodically when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive wear.

“Tire Rotation”, MA-41

EM

Wheel nuts

When checking the tires, make sure no nuts are missing, and check for any loose nuts. Tighten if necessary.

“Tire Rotation”, MA-41

LC

Tire rotation

Tires should be rotated every 12,000 km (7,500 miles).

“Tire Rotation”, MA-41

Wheel alignment and balance

If the vehicle pulls to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed.

Windshield wiper blades Doors and engine hood

Lamps

Check for cracks or wear if they do not wipe properly.

“Balancing Wheels”, MA-41, SU-7, “Front Wheel Alignment” —

Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also make sure that all latches lock securely. Lubri“Lubricating Locks, Hinges cate if necessary. Make sure that the secondary latch keeps the hood from and Hood Latches”, opening when the primary latch is released.

MA-44 When driving in areas using road salt or other corrosive materials, check lubrication frequently.

Make sure that the headlamps, stop lamps, tail lamps, turn signal lamps, and other lamps are all operating properly and installed securely. Also check headlamp aim.

EL-37, “Aiming Adjustment”

EC FE CL MT AT TF PD

INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc.

Item

AX

Reference page Make sure that all warning lamps and buzzers/chimes are operating properly.

—

SU

Windshield wiper and Check that the wipers and washer operate properly and that the wipers do washer not streak.

—

BR

Warning lamps and buzzers/chimes

Windshield defroster

Check that the air comes out of the defroster outlets properly and in sufficient quantity when operating the heater or air conditioner.

Steering wheel

Check that it has the specified play. Be sure to check for changes in the steering condition, such as excessive play, hard steering or strange noises.

ST-6, “Checking Steering Wheel Play”

Seats

Check seat position controls such as seat adjusters, seatback recliner, etc. to make sure they operate smoothly and that all latches lock securely in every position. Check that the head restraints move up and down smoothly and that the locks (if equipped) hold securely in all latched positions. Check that the latches lock securely for folding-down rear seatbacks.

—

Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly and are installed securely.

Check the belt webbing for cuts, fraying, wear or damage.

“Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters”, MA-45, RS-9, “Seat Belt Inspection”

Seat belts

Accelerator pedal

Check that pedal for smooth operation and make sure the pedal does not catch or require uneven effort. Keep the floor mats away from the pedal.

MA-5

—

FE-3, “Adjusting Accelerator Wire”

ST RS BT HA SC EL IDX

GENERAL MAINTENANCE Item

Reference page

Clutch pedal

Make sure the pedal operates smoothly and check that it has the proper free play.

CL-6, “Adjusting Clutch Pedal”

Brakes

Check that the brake does not pull the vehicle to one side when applied.

Brake pedal and booster

Check the pedal for smooth operation and make sure it has the proper distance under it when depressed fully. Check the brake booster function. Be sure to keep floor mats away from the pedal.

BR-17, “Brake Pedal and Bracket” and BR-22, “Brake Booster”

Parking brake

Check that the lever has the proper travel and make sure that the vehicle is held securely on a fairly steep hill when only the parking brake is applied.

BR-36, “Parking Brake Control”

Automatic transmission “Park” mechanism

Check that the lock release button on the selector lever operates properly and smoothly. On a fairly steep hill check that the vehicle is held securely with the selector lever in the P position without applying any brakes.

—

—

UNDER THE HOOD AND VEHICLE The maintenance items listed here should be checked periodically (e.g. each time you check the engine oil or refuel).

Reference page Item KA24DE Windshield washer fluid

Check that there is adequate fluid in the tank.

Engine coolant level

Check the coolant level when the engine is cold.

Radiator and hoses

Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, deterioration or loose connections.

VG33E —

MA-17

MA-28 —

Brake and clutch fluid levels

Make sure that the brake and clutch fluid levels are between the “MAX” and “MIN” lines on the reservoirs

Battery

Check the fluid level in each cell. It should be between the “MAX” and “MIN” lines.

Engine drive belts

Make sure that no belt is frayed, worn, cracked or oily.

MA-16

MA-25

Engine oil level

Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine.

MA-20

MA-30

Power steering fluid level and lines

Check the level on the reservoir with the engine off. Check the lines for improper attachment, leaks, cracks, etc.

MA-43

Automatic transmission fluid level

Check the level on the dipstick after putting the selector lever in “P” with the engine idling.

MA-38

Exhaust system

Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it.

MA-37

The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. It is very important to remove these substances, otherwise rust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end of winter, the underbody should be thoroughly flushed with plain water, being careful to clean those areas where mud and dirt can easily accumulate.

—

Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately.

—

Underbody

Fluid leaks

MA-6

MA-37, 41 —

NEMA0004

PERIODIC MAINTENANCE Two different maintenance schedules are provided, and should be used, depending upon the conditions in which the vehicle is mainly operated. After 60,000 miles (96,000 km) or 48 months, continue the periodic maintenance at the same mileage/time intervals.

Schedule 1

Follow Periodic Maintenance Schedule 1 if your driving habits frequently includes one or more of the following driving conditions: 쐌 Repeated short trips of less than 5 miles (8 km). 쐌 Repeated short trips of less than 10 miles (16 km) with outside temperatures remaining below freezing. 쐌 Operating in hot weather in stop-and-go “rush hour” traffic. 쐌 Extensive idling and/or low speed driving for long distances, such as police, taxi or door-to-door delivery use. 쐌 Driving in dusty conditions. 쐌 Driving on rough, muddy, or salt spread roads. 쐌 Towing a trailer, using a camper or a car-top carrier.

Emission Control System Maintenance

Follow Periodic Maintenance Schedule 2 if none of the driving conditions shown in Schedule 1 apply to the driving habits.

Emission Control System Maintenance

MA-11

Chassis and Body Maintenance

MA-12

GI

MA-8

EM Chassis and Body Maintenance MA-9

LC EC

Schedule 2

Maintenance for off-road driving ( only) Whenever you drive off-road through sand, mud or water, more frequent maintenance may be required of the following items: 왖 Brake pads and rotors 왖 Brake lining and drums 왖 Brake lines and hoses 왖 Wheel bearing grease and free-running hub grease 왖 Differential, transmission and transfer oil 왖 Steering linkage 왖 Propeller shaft and drive shafts 왖 Air cleaner filter

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

MA-7

IDX

NOTE (3)

Engine coolant

MA-8 R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R*

I*

I*

[R]

[R]

EM-85, “Timing Belt”

—

EM-38, “Valve Clearance”

MA-32

MA-31

MA-30

MA-27

MA-29

MA-29

MA-35

—

MA-30

MA-25

—

MA-22

MA-21

MA-20

MA-17

MA-19

MA-19

MA-23

MA-23

MA-20

MA-16

VG33E and VG33ER

Schedule 1

EMISSION CONTROL SYSTEM MAINTENANCE

NOTE: (1) If operating mainly in dusty conditions, more frequent maintenance may be required.

(2) When the filter becomes clogged, the vehicle speed cannot be increased as the driver wishes. In such an event, replace the filter.

(3) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months.

(4) If valve noises increases, inspect valve clearance. ★ Maintenance items and intervals with “*” are recommended by NISSAN for reliable vehicle operation. The owner need not perform such maintenance in order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.

Intake and Exhaust valve clearance ★

Replace every 105,000 miles (169,000 km)

R

R

Timing belt

R

R

Replace every 105,000 miles (169,000 km)

R

Engine oil filter (Use part No. 15208 31U00, 15208 9E000, 15208 7B000 or equivalent for VG engine.)

R

Spark plugs (Double PLATINUM–TIPPED type)

R

Engine oil

NOTE (4)

NOTE (2)

I*

Fuel lines

Fuel filter*

I*

EVAP vapor lines

R

NOTE (2)

Positive crankcase ventilation (PCV) filter [R]

[R]

NOTE (1)

I*

KA24DE

Reference Section - Page or - Content Title

[ ]: At the mileage intervals only

7.5 11.25 15 18.75 22.5 26.25 30 33.75 37.5 41.25 45 48.75 52.5 56.25 60 (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) (78) (84) (90) (96) 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

Air cleaner filter

3.75 (6) 3 I*

Miles x 1,000 (km x 1,000) Months

I = Inspect. Correct or replace if necessary.

MAINTENANCE INTERVAL

Drive belts

Perform at number of miles, kilometers or months, whichever comes first.

MAINTENANCE OPERATION

Abbreviations: R = Replace.

Schedule 1

PERIODIC MAINTENANCE NEMA0004S01

NEMA0004S0101

MA-9

)

)

4x2

NOTE (6)

NOTE (5)

NOTE (4)

NOTE (3)

NOTE (1)

NOTE (2)

NOTE (1)

NOTE (1)

Miles x 1,000 (km x 1,000) Months

3.75 (6) 3

I

L

I

I

I

I

I

L

I

I

I

I

I

I

I

I

I

L

I

I

I

I

R

I

L

I

I

I

R

I

I

I

I

I

L

I

I

I

I

I

L

I

I

I

I

I

I

I

I

I

L

I

I

I

I

R

I

L

I

I

[R]

R

I

I

I

I

7.5 11.25 15 18.75 22.5 26.25 30 33.75 37.5 41.25 45 48.75 52.5 56.25 60 (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) (78) (84) (90) (96) 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

MAINTENANCE INTERVAL

RS-18, “Maintenance Items”

MA-37

AX-5, “Front Wheel Bearing”

AX-5, “Front Wheel Bearing”

MA-39

AX-7, “Drive Shaft”

MA-5

MA-43 NOTE (7)

MA-37

MA-40

MA-39, 40

MA-38

MA-42, 42

MA-41

Reference Section - Page or - Content Title

CHASSIS AND BODY MAINTENANCE

NOTE: (1) If towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) oil (exc. LSD) at every 30,000 miles (48,000 km) or 24 months.

(2) If towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) oil (exc. LSD) at every 30,000 miles (48,000 km) or 24 months, and change LSD gear oil every 15,000 miles (24,000 km) or 12 months.

(3) Refer to “Tire rotation” under the “General maintenance” heading earlier in this section.

(4) The propeller shaft should be re-greased after being immersed in water.

Supplemental air bag system

Exhaust system

Front wheel bearing grease and free-running hub grease

Front wheel bearing grease

Propeller shaft (

Drive shaft boots (

Tire Rotation

Steering gear, linkage, axle & suspension parts

Manual transmission gear oil

LSD gear oil

Transfer fluid & differential gear oil (exc. LSD)

Automatic transmission fluid

Brake pads, rotors, drums & linings

Brake lines & cables

Perform at number of miles, kilometers or months, whichever comes first.

MAINTENANCE OPERATION

Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. L = Lubricate. [ ]: At the mileage intervals only.

PERIODIC MAINTENANCE Schedule 1 (Cont’d) NEMA0004S0102

GI

EM

LC

EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

(5) If operating frequently in water, replace grease every 3,750 miles (6,000 km) or 3 months.

(6) Inspect the air bag system 10 years after the date of manufacture noted on the FMVSS certification label.

(7) Refer to “Front Suspension Parts”, SU-7, “Rear Suspension Parts”, SU-27, “Front Axle Parts”, AX-4, “Rear Axle Parts”, AX-27.

Schedule 1 (Cont’d)

PERIODIC MAINTENANCE

MA-10

MA-11 NOTE (3)

NOTE (2)

NOTE (1)

NOTE (1)

Miles x 1,000 (km x 1,000) Months

R

R

7.5 (12) 6

R R

R R

R

R

I*

I*

[R]

[R]

I*

30 (48) 24

R

R

37.5 (60) 30

R

R

45 (72) 36

Replace every 105,000 miles (169,000 km)

Replace every 105,000 miles (169,000 km)

22.5 (36) 18

15 (24) 12

MAINTENANCE INTERVAL

R

R

52.5 (84) 42

R

R

R*

I*

I*

[R]

[R]

I*

60 (96) 48

I = Inspect. Correct or replace if necessary.

EM-38, “Valve Clearance”

—

MA-22

MA-21

MA-20

MA-17

MA-19

MA-19

MA-23

MA-23

MA-20

MA-16

KA24DE

—

EM-85, “Timing Belt”

MA-32

MA-31

MA-30

MA-27

MA-29

MA-29

MA-35

—

MA-30

MA-25

VG33E and VG33ER

Reference Section - Page or - Content Title

[ ]: At the mileage intervals only

NOTE: (1) When the filter becomes clogged, the vehicle speed cannot be increased as the driver wishes. In such an event, replace the filter.

(2) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months.

(3) If valve noises increase, inspect valve clearance. ★ Maintenance items and intervals with “*” are recommended by NISSAN for reliable vehicle operation. The owner need not perform such maintenance in order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.

Intake and Exhaust valve clearance ★

Timing belt

Spark plugs (Double PLATINUM–TIPPED type)

Engine oil filter (Use part No. 15208 31U00, 15208 9E000, 15208 7B000,or equivalent for VG engine.)

Engine oil

Engine coolant

Fuel filter*

Fuel lines

EVAP vapor lines

Positive crankcase ventilation (PCV) filter

Air cleaner filter

Drive belts

Perform at number of miles, kilometers or months, whichever comes first.

MAINTENANCE OPERATION

Abbreviations: R = Replace.

PERIODIC MAINTENANCE Schedule 2

Schedule 2

EMISSION CONTROL SYSTEM MAINTENANCE NEMA0004S02

NEMA0004S0201

GI

EM

LC

EC

FE

CL

MT

AT

TF

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

I

Manual transmission gear oil

MA-12 NOTE (3)

I

37.5 (60) 30

I

L

I

I

I

I

I

I

I

45 (72) 36

NOTE: (1) Refer to “Tire rotation” under the “General maintenance” heading earlier in this section.

(2) The propeller shaft should be re-greased after being immersed in water.

(3) Inspect the air bag system 10 years after the date of manufacture noted on the FMVSS certification label.

(4) Refer to “Front Suspension Parts”, SU-7, “Rear Suspension Parts”, SU-27, “Front Axle Parts”, AX-4, “Rear Axle Parts”, AX-27.

Supplemental air bag system

Exhaust system

R

I

L

Front wheel bearing grease and free-run) ning hub grease(

L

I

I

I

R

I

I

I

I

30 (48) 24

I

)

22.5 (36) 18

Front wheel bearing grease (4x2)

Propeller shaft (

Drive shaft boots ) (

Tire rotation

NOTE (2)

I

LSD gear oil

I

I

Transfer fluid & differential gear oil (exc.

LSD)

NOTE (1)

I

Automatic transmission fluid

Steering gear, linkage, axle & suspension parts.

I

15 (24) 12

Brake pads, rotors, drums & linings

7.5 (12) 6 I

Miles x 1,000 (km x 1,000) Months

MAINTENANCE INTERVAL

I = Inspect. Correct or replace if necessary.

Brake lines & cables

Perform at number of miles, kilometers or months, whichever comes first.

MAINTENANCE OPERATION

Abbreviations: R = Replace.

52.5 (84) 42

I

R

I

L

I

I

[R]

R

I

I

I

I

60 (96) 48

RS-18, “Maintenance Items”

MA-37

AX-5, “Front Axle Wheel Bearing”

AX-5, “Front Axle Wheel Bearing”

MA-39

AX-7, “Drive Shaft”

MA-5

MA-43 NOTE (4)

MA-37

MA-40

MA-39, 40

MA-38

MA-42, 42

MA-41

Reference Section - Page or - Content Title

L = Lubricate. [ ]: At the mileage interval only.

Schedule 2 (Cont’d)

PERIODIC MAINTENANCE

CHASSIS AND BODY MAINTENANCE NEMA0004S0202

NEMA0005

RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants

Fluids and Lubricants

NEMA0005S01

KA24DE

GI Capacity (Approximate) Recommended Fluids/Lubricants US measure Imp measure

Drain and Refill Engine oil

Liter

With oil filter

3-3/4 qt

3-1/8 qt

3.5

Without oil filter

3-1/2 qt

2-7/8 qt

3.3

4-1/2 qt

3-3/4 qt

4.1

MT

7-3/4 qt

6-3/8 qt

7.3

AT

7-1/2 qt

6-1/4 qt

7.1

Genuine NISSAN anti-freeze coolant or equivalent

4-1/4 pt

3-1/2 pt

2.0

API GL-4, Viscosity SAE 75W-90 only

Dry engine (Engine overhaul) Cooling system (With reservoir)

Manual transmission gear oil (FS5W71C)

쐌 API Certification Mark*1 쐌 API grade SG/SH, Energy Conserving I & II or API grade SJ, Energy Conserving*1 쐌 ILSAC grade GF-I & GF-II*1

2-3/8 pt

2-1/4 pt

1.3

Standard differential gear: API GL-5*1 Limited-slip differential (LSD) gear: Use only LSD gear oil API GL-5 and SAE 80W-90*3 approved for NISSAN LSD*4.

8-3/8 qt

7 qt

7.9

NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid *5

30.4-33.8 fl oz

31.7-35.2 fl oz

0.9-1.0

Genuine NISSAN PSF II or equivalent*6

Brake and clutch fluid

—

—

—

Genuine NISSAN Brake Fluid*2 or equivalent DOT 3 (US FMVSS No. 116)

Multi-purpose grease

—

—

—

NLGI No. 2 (Lithium soap base)

Differential carrier gear oil

C200

Automatic transmission fluid

Power steering fluid

*1: For further details, see “SAE Viscosity Number”. *2: Available in mainland U.S.A. through your NISSAN dealer. *3: SAE 90 is acceptable in ambient temperatures above −18°C (0°F). *4: Contact a NISSAN dealer for a list of approved oils. *5: DEXRONTMIII, MERCONTM or equivalent may also be used. Outside the Continental United States and Alaska contact a NISSAN dealership for more information regarding suitable fluids, including recommended brand(s) of DEXRONTMIII, MERCONTM Automatic Transmission Fluid. *6: Genuine NISSAN PSF, Canada NISSAN Automatic Transmission Fluid, DEXRONTMIII, MERCONTM, or equivalent ATF may also be used.

EM LC EC FE CL MT AT TF PD AX SU BR

VG33E and VG33ER

ST

Capacity (Approximate) Recommended Fluids/Lubricants US measure Imp measure Drain and refill Engine oil

With oil filter

3-1/2 qt

2-7/8 qt

3.3

Without oil filter

3-1/8 qt

2-5/8 qt

3.0

4 qt

3-3/8 qt

3.8

11-5/8 qt

9-5/8 qt

10.95

5-7/8 pt

4-7/8 pt

2.8

Dry engine (Engine overhaul) Cooling system (With reservoir) Manual transmission gear oil (FS5R30A)

Liter

2WD

쐌 API Certification Mark*1 쐌 API grade SG/SH, Energy Conserving I & II or API grade SJ, Energy Conserving*1 쐌 ILSAC grade GF-I & GF-II*1

RS BT HA

Genuine NISSAN anti-freeze coolant or equivalent

SC API GL-4, Viscosity SAE 75W-90 only

4WD

10-3/4 pt

9 pt

5.1

EL

MA-13

IDX

RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants (Cont’d) Capacity (Approximate) Recommended Fluids/Lubricants US measure Imp measure

Transfer fluid (TX10A)

Liter NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid*2 or API GL-4*1

2-3/8 qt

2 qt

2.2

Front (4WD) R200A

3-1/8 pt

2-5/8 pt

1.5

Rear H233B

5-7/8 pt

4-7/8 pt

2.8

2WD

8-3/4 qt

7-1/4 qt

8.3

4WD

9 qt

7-1/2 qt

8.5

33.8-37.2 fl oz

35.2-38.7 fl oz

1.0-1.1

Genuine NISSAN PSF II or equivalent*6

Brake and clutch fluid

—

—

—

Genuine NISSAN Brake Fluid*3 or equivalent DOT 3 (US FMVSS No. 116)

Propeller shaft grease

—

—

—

NLGI No. 2 (Molybdenum disulphide lithium soap base)

Multi-purpose grease

—

—

—

NLGI No. 2 (Lithium soap base)

Free-running hub grease (Auto-lock)

—

—

—

Genuine NISSAN grease or equivalent

Differential carrier gear oil

Automatic transmission fluid

Power steering fluid

Standard differential gear: API GL-5*1 Limited-slip differential (LSD) gear: Use only LSD gear oil API GL-5 and SAE 80W-90*4 approved for NISSAN LSD*5.

NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid *2

*1: For further details, see “SAE Viscosity Number”. *2: DEXRONTMIII, MERCONTM or equivalent may also be used. Outside the continental United States and Alaska contact a NISSAN dealership for more information regarding suitable fluids, including recommended brand(s) of DEXRONTMIII, MERCONTM Automatic Transmission Fluid. *3: Available in mainland U.S.A. through your NISSAN dealer. *4: SAE 90 is acceptable in ambient temperatures above −18°C (0°F). *5: Contact a NISSAN dealer for a list of approved oils. *6: Genuine NISSAN PSF, Canada NISSAN Automatic Transmission Fluid, DEXRONTMIII, MERCONTM, or equivalent ATF may also be used.

SAE Viscosity Number GASOLINE ENGINE OIL

NEMA0005S02 NEMA0005S0201

SAE 5W-30 viscosity oil is preferred for all ambient temperatures.

SAE 10W-30 and 10W-40 viscosity oil may be used if the ambient temperature is above −18°C (0°F).

TI1028-C

MA-14

RECOMMENDED FLUIDS AND LUBRICANTS SAE Viscosity Number (Cont’d)

GEAR OIL

NEMA0005S0202

SAE rated 75W-90 for transfer fluid, and 80W-90 for differential gear oil are preferable.

GI

EM LC EC FE CL MT

MMA118A

Anti-freeze Coolant Mixture Ratio

NEMA0005S03

The engine cooling system is filled at the factory with a high-quality, year-round, anti-freeze coolant solution. The anti-freeze solution contains rust and corrosion inhibitors. Therefore, additional cooling system additives are not necessary.

CAUTION: When adding or replacing coolant, be sure to use only a Genuine NISSAN anti-freeze coolant or equivalent with the proper mixture.

Outside temperature down to °C

°F

Genuine NISSAN Anti-freeze Coolant or equivalent

-35

-30

50%

Demineralized water or distilled water 50%

Other types of coolant solutions may damage the engine cooling system.

AT TF PD AX SU BR ST RS BT HA SC EL

MA-15

IDX

ENGINE MAINTENANCE

KA24DE

Checking Drive Belts

Checking Drive Belts

NEMA0055

AMA150

1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace.

2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys.

Check belt tension using belt tension gauge (BT3373-F or equivalent).

Inspect drive belt deflection or tension when engine is cold. ě?Œ Adjust if belt deflections exceed the limit or if belt tension is not within specifications. ě?Œ Drive belt tension can be checked at other points on the belt.

MA-16

ENGINE MAINTENANCE

KA24DE Checking Drive Belts (Cont’d)

DRIVE BELT DEFLECTION AND TENSION Deflection adjustment

NEMA0055S01

Unit: mm (in)

Tension adjustment

Used belt

*1 Unit: N (kg, lb)

GI

Used belt New belt

New belt

Limit

After adjustment

Generator

17 (0.67)

10 - 12 (0.39 0.47)

8 - 10 (0.31 0.39)

222.4 (22.7, 50)

355.8 - 444.8 489.3 - 578.2 (36.3 - 45.4, 80 - (49.9 - 59.0, 110 100) - 130)

Air conditioner compressor

16 (0.63)

10 - 12 (0.39 0.47)

8 - 10 (0.31 0.39)

200.2 (20.4, 45)

355.8 - 444.8 489.3 - 578.2 (36.3 - 45.4, 80 - (49.9 - 59.0, 110 100) - 130)

LC

Power steering oil pump

17 (0.67)

10 - 13 (0.39 0.51)

8 - 10 (0.31 0.39)

222.4 (22.7, 50)

355.8 - 444.8 489.3 - 578.2 (36.3 - 45.4, 80 - (49.9 - 59.0, 110 100) - 130)

EC

Applied pushing force

Limit

After adjustment

98 N (10 kg, 22 lb)

EM

FE

—

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.

CL MT

Changing Engine Coolant

NEMA0056

WARNING: To avoid being scalded, never change the coolant when the engine is hot.

—DRAINING ENGINE COOLANT— 1. a.

AMA118

b.

AT TF

NEMA0056S01

Set air conditioner system as follows to prevent coolant from remaining in the system.

Turn ignition switch ON and set temperature control lever all the way to “HOT” position or the highest temperature position.

Wait 10 seconds before turning ignition switch OFF.

2.

Open drain plug at the bottom of radiator, and remove radiator cap.

3. Remove reservoir tank, drain coolant, then clean reservoir tank.

Install it temporarily.

Be careful not to allow coolant to contact drive belts.

4. Remove cylinder block drain plug.

PD AX SU BR ST RS

SMA919C

5.

6.

Open air relief plug.

Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated flush engine cooling system, “Refer to FLUSHING COOLING SYSTEM”, MA-18.

—REFILLING ENGINE COOLANT— 1. 쐌

NEMA0056S02

Install reservoir tank, radiator drain plug and cylinder block drain plug.

Apply sealant to the thread of drain plug. : 34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb)

BT HA SC EL

SMA580C

MA-17

IDX

ENGINE MAINTENANCE

KA24DE

Changing Engine Coolant (Cont’d)

2.

쐌

Fill radiator until coolant spills from the air relief hole, then install air relief plug.

Air relief plug: : 7 - 8 N·m (0.7 - 0.8 kg-m, 61 - 69 in-lb) Use 50% Genuine NISSAN anti-freeze coolant or equivalent mixed with 50% demineralized water or distilled water.

Unit: (US qt, Imp qt)

Description

Coolant capacity

Without reservoir MT tank AT

6.5 (6-7/8, 5-5/8)

Reservoir tank

쐌

6.3 (6-5/8, 5-1/2) 0.8 (7/8, 3/4)

Pour coolant through coolant filler neck slowly to allow air in system to escape.

3.

4.

SMA182B

SMA412B

Fill radiator and reservoir tank to specified level.

Warm up engine to normal operating temperature without radiator cap installed. 쐌 If coolant overflows radiator filler hole, install filler cap.

5. Install radiator cap and run engine at 2,500 rpm for 10 seconds and return to idle speed. 쐌 Repeat two or three times.

CAUTION: Watch coolant temperature gauge so as not to overheat the engine.

6. Stop engine and cool it down. 쐌 Cool down using a fan to reduce the time. 쐌 If necessary, refill radiator up to filler neck.

7. Refill reservoir tank to MAX level line.

8. Repeat steps 5 through 7 two or more times with radiator cap installed until coolant no longer drops.

9. Check cooling system for leaks with engine running.

10. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control lever set at several positions between COOL and WARM. 쐌 Sound may be noticeable at heater water cock.

11. If sound is heard, bleed air from cooling system by repeating steps 5 through 7 until coolant level no longer drops. 쐌 Clean excess coolant from engine.

—FLUSHING COOLING SYSTEM— 1.

2.

3.

4.

NEMA0056S03

Open air relief plug.

Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and reservoir tank with water and reinstall radiator cap.

Run engine and warm it up to normal operating temperature.

Rev engine two or three times under no-load.

MA-18

ENGINE MAINTENANCE

KA24DE Changing Engine Coolant (Cont’d)

5.

6.

7.

Stop engine and wait until it cools down.

Drain water.

Repeat steps 1 through 6 until clear water begins to drain from radiator.

GI

EM LC

Checking Fuel Lines

NEMA0057

Inspect fuel lines and tank for improper attachment, leaks, cracks, damage, chafing and deterioration. If necessary, repair or replace.

EC FE CL MT

SMA215C

Changing Fuel Filter

NEMA0058

CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end.

Tightening torque specifications are the same for all rubber hose clamps.

Ensure that the screw does not contact adjacent parts.

WARNING: Before removing fuel filter, release fuel pressure from fuel line.

AMA123

WITH CONSULT - II 1.

2.

3.

4.

AT TF PD AX

NEMA0058S01

Start engine.

Perform “FUEL PRES RELEASE” in “WORK SUPPORT” mode to release fuel pressure to zero.

After engine stalls, crank engine two or three times to make sure that fuel pressure is released.

Turn ignition switch “OFF”.

SU BR ST RS

5.

6.

7. 쐌 쐌 쐌

Remove the fuel filter shield.

Loosen fuel hose clamps.

Replace fuel filter.

Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel.

Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter.

Tighten fuel hose clamps. Refer to “Checking Fuel Lines”, MA-19.

BT HA SC EL

AMA151

MA-19

IDX

ENGINE MAINTENANCE

KA24DE

Changing Fuel Filter (Cont’d)

WITHOUT CONSULT - II 1.

2.

3.

4.

NEMA0058S02

Remove fuel pump fuse.

For correct fuse location, refer to label on fuse block cover.

Start engine.

After engine stalls, crank engine two or three times to make sure that fuel pressure is released.

Turn ignition switch “OFF” and install fuel pump fuse.

AMA114

5.

6.

7. 쐌 쐌 쐌

Remove the fuel filter shield.

Loosen fuel hose clamps.

Replace fuel filter.

Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel.

Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter.

Tighten fuel hose clamps. Refer to “Checking Fuel Lines”, MA-19.

AMA151

Changing Air Cleaner Filter

NEMA0059

The viscous paper type filter does not need cleaning between renewals.

SMA243C

Changing Engine Oil

AMA113

NEMA0060

WARNING: 쐌 Be careful not to burn yourself, as the engine oil is hot. 쐌 Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

1. Warm up engine, and check for oil leakage from engine components.

2. Remove drain plug and oil filler cap.

3. Drain oil and refill with new engine oil.

Oil specification and viscosity: 쐌 API Certification Mark 쐌 API grade SG/SH, Energy Conserving I & II or API grade SJ, Energy Conserving. 쐌 ILSAC grade GF-I & GF-II 쐌 Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

MA-20

ENGINE MAINTENANCE

KA24DE Changing Engine Oil (Cont’d)

Oil capacity (Approximately): Unit: (US qt, Imp qt) With oil filter change

3.5 (3-3/4, 3-1/8)

Without oil filter change

3.3 (3-1/2, 2-7/8)

GI

Drain and refill Dry engine (engine overhaul)

4.1 (4-1/2, 3-3/4)

CAUTION: 쐌 Be sure to clean drain plug and install with new washer.

Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) 쐌 The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only.

Always use the dipstick to determine when the proper amount of oil is in the engine.

EM LC EC FE CL MT

4.

5.

6.

Check oil level.

Start engine and check area around drain plug and oil filter for oil leakage.

Run engine for a few minutes, then turn it off. After several minutes, check oil level.

AT TF PD AX

SMA885B

Changing Oil Filter

NEMA0061

1. Remove oil filter with Tool. 쐌 a: 64.3 mm (2.531 in) WARNING: Be careful not to burn yourself. Engine and engine oil are hot.

SU BR ST RS

NT375

2.

Clean oil filter mounting surface on cylinder block. Coat rubber seal of new oil filter with engine oil.

BT HA SC EL

SMA010

MA-21

IDX

ENGINE MAINTENANCE

KA24DE

Changing Oil Filter (Cont’d)

3.

Screw in the oil filter until a slight resistance is felt, then tighten additionally more than 2/3 of a turn.

4. Add engine oil.

Refer to “Changing Engine Oil”, MA-20. 쐌 Clean excess oil from engine.

SMA229B

Changing Spark Plugs 1.

NEMA0062

Disconnect ignition wires from spark plugs at boot.

Do not pull on the wire.

SMA356CA

2. Remove spark plugs with spark plug wrench.

Spark plug: Make

SMA581C

NGK (Double Platimnum Tipped)

Standard type

PFR5G-11

Cold type

PFR6G-11

Use standard type spark plug under normal conditions.

The cold type spark plug is suitable when spark knock occurs with the standard type spark plug under conditions such as: 쐌 extended highway driving 쐌 frequent high engine revolution 쐌 Do not use a wire brush for cleaning. 쐌 If plug tip is covered with carbon, spark plug cleaner may be used.

Cleaner air pressure: Less than 588 kPa (6 kg/cm2, 85 psi) Cleaning time: Less than 20 seconds

SMA673B

쐌

3.

Checking and adjusting plug gap is not required between change intervals.

Spark plug (Double platinum-tipped type) Gap (Nominal):1.1 mm (0.043 in) Install spark plugs. Reconnect ignition wires according to numbers indicated on them.

Spark plug: : 20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

SMA806C

MA-22

ENGINE MAINTENANCE

KA24DE Checking EVAP Vapor Lines

Checking EVAP Vapor Lines 1.

2.

NEMA0063

Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deterioration.

Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc.

Refer to EC-40, “EVAPORATIVE EMISSION SYSTEM”.

GI

EM LC EC FE CL MT

AMA116

Changing Positive Crankcase Ventilation (PCV) AT Filter NEMA0064

Remove air cleaner cover and take out PCV filter located inside air cleaner cover. Then install new PCV filter.

TF PD AX SU BR ST RS BT HA SC EL

MA-23

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

KA24DE

Engine Maintenance

Engine Maintenance KA24DE Drive Belt Deflection and Tension Deflection adjustment

NEMA0065 NEMA0065S01

Unit: mm (in)

Tension adjustment

Used belt

*1 Unit: N (kg, lb)

Used belt New belt

Limit

After adjustment

Generator

17 (0.67)

10 - 12 (0.39 0.47)

Air conditioner compressor

16 (0.63)

Power steering oil pump

17 (0.67)

Applied pushing force

New belt Limit

After adjustment

8 - 10 (0.31 - 0.39)

222.4 (22.7, 50)

355.8-444.8 (36.345.4, 80-100)

489.3-578.2 (49.959.0, 110-130)

10 - 12 (0.39 0.47)

8 - 10 (0.31 - 0.39)

200.2 (20.4, 45)

355.8-444.8 (36.345.4, 80-100)

489.3-578.2 (49.959.0, 110-130)

10 - 13 (0.39 0.51)

8 - 10 (0.31 - 0.39)

222.4 (22.7, 50)

355.8-444.8 (36.345.4, 80-100)

489.3-578.2 (49.959.0, 110-130)

98 N (10 kg, 22 lb)

—

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.

Spark Plug

NEMA0065S02

Make

NGK (Double Platimnum Tipped)

Hot type

—

Standard type

PFR5G-11

Cold type

PFR6G-11

Gap (nominal)

1.1 mm (0.043 in)

MA-24

ENGINE MAINTENANCE

VG33E AND VG33ER Checking Drive Belts

Checking Drive Belts

NEMA0016

VG33E

GI

EM LC EC FE CL MT AT TF AMA152

PD AX SU BR ST RS BT HA SC EL

MA-25

IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Checking Drive Belts (Cont’d)

VG33ER

WMA040

1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace.

2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys.

Check belt tension using belt tension gauge (BT3373-F or equivalent).

Inspect drive belt deflection or tension when engine is cold. 쐌 Adjust if belt deflections exceed the limit or if belt tension is not within specifications 쐌 Drive belt tension can be checked at other points on the belt.

MA-26

ENGINE MAINTENANCE

VG33E AND VG33ER Checking Drive Belts (Cont’d)

DRIVE BELT DEFLECTION AND TENSION Deflection adjustment

NEMA0016S01

Unit: mm (in)

Tension adjustment

Used belt

*1 Unit: N (kg, lb)

New belt Limit

After adjustment

Generator

11 (0.43)

7 - 8 (0.24 0.31)

Air conditioner compressor VG33E

18 (0.71)

Air conditioner compressor and supercharger VG33ER Power steering oil pump Applied pushing force

GI

Used belt New belt Limit

After adjustment

6 - 7 (0.24 0.28)

226 (23, 51)

554.1 - 642.4 (56.5 - 65.5, 124.6 - 144.4)

671.8 - 760.0 (68.5 - 77.5, 151.0 - 170.9)

12 - 13 (0.47 0.51)

10.5 - 11.5 (0.413 - 0.453)

196 (20, 44)

495.3 - 583.5 (50.5 - 59.5, 111.4 - 131.2)

603.1 - 691.4 (61.5 -70.5, 135.6 - 155.5)

16.5 (0.65)

9.5 - 10.5 (0.37 0.41)

8.5-9.5 (0.33 0.37)

294 (30 , 66)

15 (0.59)

9.5 - 10.5 (0.374 - 0.413)

8 - 9 (0.31 0.35)

730 - 818 (75.5 - 838 - 926 (85.5 83.5, 166.5 94.5, 188.5 208.4) 184.1)

275 (28, 62)

554.1 - 642.4 (56.5 - 65.5, 124.6 - 144.4)

98 N (10 kg, 22 lb)

671.8 - 760.0 (68.5 - 77.5, 151.0 - 170.9)

Changing Engine Coolant

—DRAINING ENGINE COOLANT—

AMA118

b.

2.

EC FE CL MT

NEMA0017

WARNING: To avoid the danger of being scalded, never change the coolant when the engine is hot.

a.

LC

—

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.

1.

EM

AT TF

NEMA0017S01

Set air conditioning system as follows to prevent coolant from remaining in the system.

Turn ignition switch “ON” and set temperature controller to maximum hot position.

Wait 10 seconds before turning ignition switch “OFF”.

Open radiator drain plug at the bottom of radiator and remove radiator filler cap.

PD AX SU BR ST RS

3. 쐌

Remove reservoir tank, drain coolant, then clean reservoir tank.

Install it temporarily.

Be careful not to allow coolant to contact drive belts.

BT HA SC EL

SMA858C

MA-27

IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Changing Engine Coolant (Cont’d)

4.

5.

Remove cylinder block drain plugs and air relief plug.

Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated flush engine cooling system. Refer to “FLUSHING COOLING SYSTEM”, MA-29.

SMA952C

SMA860C

—REFILLING ENGINE COOLANT— 1.

SMA182B

SMA412B

NEMA0017S02

Install reservoir tank, radiator drain plug, and cylinder block drain plugs. 쐌 Apply sealant to the thread of cylinder block drain plug. : 34.3 - 44.1 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb) 2. Fill radiator slowly until coolant spills from the air relief plug, then install air relief plug.

Air relief plug: : 7 - 8 N·m (0.7 - 0.8 kg-m, 61 - 69 in-lb) 3. Fill radiator and reservoir tank to specified level. 쐌 Pour coolant through coolant filler neck slowly to allow air in system to escape. 쐌 Use 50% genuine NISSAN anti-freeze coolant or equivalent mixed with 50% demineralized water or distilled water.

Coolant capacity (Without reservoir tank): 10.15 (10–3/4 US qt, 8–7/8 Imp qt) Reservoir tank capacity (for MAX level): 0.8 (7/8 US qt, 3/4 Imp qt) 4. Warm up engine to normal operating temperature without radiator cap installed.

If coolant overflows radiator filler hole, install filler cap.

5. Run engine at 3,000 rpm for 10 seconds and return to idle speed with radiator cap installed. 쐌 Repeat two or three times.

Watch coolant temperature gauge so as not to overheat the engine.

6. Stop engine and cool it down. 쐌 Cool down using a fan to reduce the time. 쐌 If necessary, refill radiator up to filler neck with coolant.

7. Refill reservoir tank to Max line with coolant.

8. Repeat step 5 through step 7 two or more times with radiator cap installed until coolant level no longer drops.

MA-28

ENGINE MAINTENANCE

VG33E AND VG33ER Changing Engine Coolant (Cont’d)

9. Check cooling system for leaks with engine running.

10. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control set at several positions between COOL and HOT. 쐌 Sound may be noticeable at heater water cock.

11. If sound is heard, bleed air from cooling system by repeating steps 5 through 7 until coolant level no longer drops. 쐌 Clean excess coolant from engine.

—FLUSHING COOLING SYSTEM— 1.

2.

3.

4.

5.

6.

7.

GI

EM

NEMA0017S04

Open air relief plug.

Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and reservoir tank with water and reinstall radiator cap.

Run engine and warm it up to normal operating temperature.

Rev engine two or three times under no-load.

Stop engine and wait until it cools down.

Drain water.

Repeat steps 1 through 6 until clear water begins to drain from radiator.

LC EC FE CL MT

Checking Fuel Lines

NEMA0018

Inspect fuel lines and tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration.

If necessary, repair or replace faulty parts.

AT TF PD AX

SMA803A

Changing Fuel Filter

NEMA0019

CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end.

Tightening torque specifications are the same for all rubber hose clamps.

Ensure that screw does not contact adjacent parts.

WARNING: Before removing fuel filter, release fuel pressure from fuel line.

SU BR ST RS

AMA123

WITH CONSULT - II 1.

2.

3.

4.

NEMA0019S01

Start engine.

Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode to release fuel pressure to zero.

After engine stalls, crank engine two or three times to make sure that fuel pressure is released.

Turn ignition switch “OFF”.

BT HA SC EL

PEF823K

MA-29

IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Changing Fuel Filter (Cont’d)

5.

6.

7. 쐌 쐌 쐌

Remove the fuel filter shield.

Loosen fuel hose clamps.

Replace fuel filter.

Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel.

Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter.

Tighten fuel hose clamps. Refer to “Checking Fuel Lines”, MA-29.

AMA151

WITHOUT CONSULT - II 1.

2.

3.

4.

NEMA0019S02

Remove fuel pump fuse.

For correct fuse location, refer to label on fuse block cover.

Start engine.

After engine stalls, crank engine two or three times to make sure that fuel pressure is released.

Turn ignition switch “OFF” and install fuel pump fuse.

SMA869C

5.

6.

7. 쐌 쐌 쐌

Remove the fuel filter shield.

Loosen fuel hose clamps.

Replace fuel filter.

Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel.

Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter.

Tighten fuel hose clamps. Refer to “Checking Fuel Lines”, MA-29.

AMA151

Changing Air Cleaner Filter VISCOUS PAPER TYPE

NEMA0020 NEMA0020S01

The viscous paper type filter does not need cleaning between replacement intervals.

WMA041

Changing Engine Oil

SMA862C

NEMA0021

WARNING: 쐌 Be careful not to burn yourself, as the engine oil is hot. 쐌 Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

1. Warm up engine, and check for oil leakage from engine components.

2. Stop engine and wait for more than 10 minutes.

3. Remove drain plug and oil filler cap.

MA-30

ENGINE MAINTENANCE

VG33E AND VG33ER Changing Engine Oil (Cont’d)

4. Drain oil and refill with new engine oil.

Oil specification and viscosity 쐌 API SG or SH and Energy Conserving I & II or API grade SJ, Energy Conserving 쐌 API Certification Mark 쐌 ILSAC grade GF-I and GF-II 쐌 See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

Refill oil capacity (Approximately) :

GI

EM

Unit: (US qt, Imp qt) Drain and refill

LC

with oil filter change

3.3 (3-1/2, 2-7/8)

without oil filter change

3.0 (3-1/8, 2-5/8)

Dry engine (engine overhaul)

EC

3.8 (4, 3-3/8)

CAUTION: 쐌 Be sure to clean drain plug and install with new washer.

Oil pan drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) 쐌 The refill capacity depends on the oil temperature and drain time; use the “Refill oil capacity” values as a reference and be certain to check with the dipstick when changing the oil.

FE CL MT AT TF PD AX

5.

6.

7.

Warm up engine and check area around drain plug and oil filter for oil leakage.

Stop engine and wait for more than 10 minutes.

Check oil level.

SU BR ST RS

SMA878C

Changing Oil Filter

NEMA0022

1. Remove oil filter with Tool.

WARNING: Be careful not to burn yourself, as the engine and engine oil are hot.

The filter is a full-flow cartridge type and is provided with a relief valve.

Refer to LC-23, “Oil Filter”.

BT HA SC EL

SMA863C

MA-31

IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Changing Oil Filter (Cont’d)

2.

Clean oil filter mounting surface on cylinder block. Coat rubber seal of new oil filter with engine oil.

SMA010

3.

Screw in the oil filter until a slight resistance is felt, then tighten an additional 2/3 turn.

4. Add engine oil.

Refer to “Changing Engine Oil”, MA-30. 쐌 Clean excess oil from engine.

SMA702C

Changing Spark Plugs 1.

2. 쐌

NEMA0023

Disconnect ignition wires from spark plugs at boot.

Do not pull on the wire.

Remove spark plugs with 16 mm (0.63 in) spark plug wrench.

For VG33ER engine only; to remove the No. 2, and 4 spark plugs, the following components must be removed:

ADI1076

a) b)

Disconnect the accelerator cable from the throttle body and the air inlet tube bracket.

Disconnect the ASCD cable from the throttle body and the air inlet tube bracket, if equipped.

LEM105

MA-32

ENGINE MAINTENANCE

VG33E AND VG33ER Changing Spark Plugs (Cont’d)

c) 쐌 쐌

Remove the air inlet duct.

Disconnect the PCV hoses.

Disconnect the resonator hose.

GI

EM LC

LEM110

d)

Remove the air inlet tube upper and lower supports.

EC FE CL MT

LEM107

e)

Remove the air inlet tube bolts, nuts, and studs. Position the air inlet tube aside. 쐌 Disconnect the evaporative emission vacuum hose. 쐌 Disconnect the brake booster vacuum hose. 쐌 Disconnect the TPS sensor electrical connector. 쐌 Disconnect the TPS switch electrical connector.

3. Check type and gap of new spark plug.

Spark plug (VG33E): Description LEM108

NGK (Double Platinum Tipped)

Hot type

PFR4G-11

Standard type

PFR5G-11

Cold type

PFR6G-11

Spark Plug Gap (nominal)

1.1 mm (0.043 in)

PD AX SU BR

NGK (Double Platinum Tipped)

Hot type

PFR5G-11

Standard type

PFR6G-11

Cold type

PFR7G-11

Spark Plug Gap (nominal)

TF

ST

Spark plug (VG33ER): Description

AT

RS BT

1.1 mm (0.043 in)

HA Use standard type spark plug under normal conditions.

The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions such as: 쐌 frequent engine starts 쐌 low ambient temperatures The cold type spark plug is suitable when spark knock occurs with the standard type spark plug under conditions such as:

MA-33

SC EL IDX

ENGINE MAINTENANCE

VG33E AND VG33ER

Changing Spark Plugs (Cont’d)

쐌 쐌

extended highway driving frequent high engine revolution

쐌 쐌

Do not use a wire brush for cleaning.

If plug tip is covered with carbon, spark plug cleaner may be used.

Cleaner air pressure: Less than 588 kPa (6 kg/cm2, 85 psi) Cleaning time: Less than 20 seconds

쐌

Checking and adjusting plug gap is not required between spark plug change intervals.

SMA773C

SMA806C

When installing ignition wires to No. 2 and 4 cylinders, securely fit each ignition wire mounting hole onto the ignition wire fixing pin (VG33E only).

Spark plug: : 20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

SMA213C

MA-34

ENGINE MAINTENANCE

VG33E AND VG33ER Checking EVAP Vapor Lines

Checking EVAP Vapor Lines 1.

NEMA0024

Visually inspect EVAP vapor lines for improper attachment, cracks, damage, loose connections, chafing or deterioration.

2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc.

Refer to EC-640, “EVAPORATIVE EMISSION SYSTEM”.

GI

EM LC EC FE CL MT

AMA145

AT TF PD AX SU BR ST RS BT HA SC EL

MA-35

IDX

Engine Maintenance

SERVICE DATA AND SPECIFICATIONS (SDS)

VG33E AND VG33ER

Engine Maintenance VG33E AND VG33ER Drive Belt Deflection and Tension Deflection adjustment

NEMA0054 NEMA0054S01

Unit: mm (in)

Tension adjustment

Used belt

*1 Unit: N (kg, lb)

Used belt New belt

New belt

Limit

After adjustment

Generator

11 (0.43)

7 - 8 (0.24 - 0.31)

6 - 7 (0.24 - 0.28)

226 (23, 51)

554.1 - 642.4 (56.5 671.8 - 760.0 (68.5 - 65.5, 124.6 - 77.5, 151.0 144.4) 170.9)

Air conditioner compressor (VG33E)

18 (0.71)

12 - 13 (0.47 0.51)

10.5 - 11.5 (0.413 0.435)

196 (20, 44)

495.3 - 583.5 (50.5 603.1 - 691.4 (61.5 - 59.5, 111.4 - 70.5, 135.6 131.2) 155.5)

16.5 (0.65)

9.5 - 10.5 (0.37 0.41)

8.5 - 9.5 (0.33 0.39)

294 (30, 66)

15 (0.59)

9.5 - 10.5 (0.374 0.413)

8 - 9 (0.31 - 0.35)

275 (28, 62)

Air conditioner compressor and supercharger (VG33ER) Power steering oil pump Applied pushing force

Limit

98 N (10 kg, 22 lb)

After adjustment

730 - 818 (75.5 83.5, 166.5 184.1)

838 - 926 (85.5 94.5, 188.5 208.4)

554.1 - 642.4 (56.5 671.8 - 760.0 (68.5 - 65.5, (124.6 - 77.5, 151.0 144.4) 170.9) —

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.

Spark Plug NGK (Double Platimnum Tipped)

NEMA0054S02

VG33E

VG33ER

Hot type

PFR4G-11

PFR5G-11

Standard type

PFR5G-11

PFR6G-11

Cold type

PFR6G-11

PFR7G-11

1.1 mm ( 0.043 in)

1.1 mm ( 0.043 in)

Gap (nominal)

MA-36

CHASSIS AND BODY MAINTENANCE Checking Exhaust System

Checking Exhaust System

NEMA0025

Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration.

GI

EM LC

SMA211A

Checking Clutch Fluid Level and Leaks

NEMA0026

If fluid level is extremely low, check clutch system for leaks.

EC FE CL MT

SMA956C

Checking M/T Oil

NEMA0027

Check for oil leakage and oil level.

Never start engine while checking oil level.

Filler plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

AT TF PD AX

SMA103

Changing M/T Oil 1.

2.

NEMA0028

Drain oil from drain plug and refill with new gear oil.

Check oil level.

Oil grade and viscosity: API GL-4. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

Oil capacity: FS5W71C 2WD 2.0 (4-1/4 US pt, 3-1/2 Imp pt) FS5R30A 2WD 2.8 (5-7/8 US pt, 4-7/8 Imp pt) 4WD 5.1 (10-3/4 US pt, 9 Imp pt) Drain plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

SU BR ST RS BT HA SC EL

MA-37

IDX

CHASSIS AND BODY MAINTENANCE Checking A/T Fluid

Checking A/T Fluid 1.

2.

3. a. b.

LMA052

c. d. e. f.

Do 4.

5.

6. 쐌 쐌

NEMA0030

Warm up engine.

Check for fluid leakage.

Before driving, fluid level can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on dipstick.

Park vehicle on level surface and set parking brake.

Start engine and move selector lever through each gear position. Leave selector lever in “P” position.

Check fluid level with engine idling.

Remove dipstick and note reading. If level is at low side of either range, and fluid to the charging pipe.

Re-insert dipstick into charging pipe as far as it will go.

Remove dipstick and note reading. If reading is at low side of range, add fluid to the charging pipe. not overfill.

Drive vehicle for approximately 5 minutes in urban areas.

Re-check fluid level at fluid temperatures of 50° to 80°C (122° to 176°F) using “HOT” range on dipstick.

Check fluid condition.

If fluid is very dark or smells burned, refer to AT section for checking operation of A/T. Flush cooling system after repair of A/T. If A/T fluid contains frictional material (clutches, bands, etc.), replace radiator and flush cooler line using cleaning solvent and compressed air after repair of A/T. Refer to LC-14 (KA24DE), LC-32 (VG33E and VG33ER), “Radiator”.

SMA853B

Changing A/T Fluid 1.

2.

3.

SMA515C

4.

5.

NEMA0031

Warm up A/T fluid.

Stop engine.

Drain A/T fluid from drain plug and refill with new A/T fluid.

Always refill same volume with drained fluid.

Fluid grade: Nissan Matic “D” (Continental U.S. and Alaska) or Canada Nissan Automatic Transmission Fluid. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

Fluid capacity (With torque converter): KA24DE 2WD 7.9 (8-3/8 US qt, 7 Imp qt) VG33E and VG33ER 2WD 8.3 (8-3/4 US qt, 7-1/4 Imp qt) 4WD 8.5 (9 US qt, 7-1/2 Imp qt) Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) Run engine at idle speed for five minutes.

Check fluid level and condition. Refer to “Checking A/T Fluid”, MA-38. If fluid is still dirty, repeat steps 2 through 5.

MA-38

CHASSIS AND BODY MAINTENANCE Checking Transfer Fluid

Checking Transfer Fluid

NEMA0032

Check for fluid leakage and fluid level.

A/T fluid is used for the transfer in the factory.

Never start engine while checking fluid level.

Filler plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

GI

EM LC

SMA439B

Changing Transfer Fluid

SMA444B

NEMA0033

When changing transfer fluid completely, A/T fluid may be used.

Fluid grade: Nissan Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid or API GL-4 Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

Fluid capacity: 2.2 (2-3/8 US qt, 2 Imp qt) Drain plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

EC FE CL MT AT TF PD AX

Checking Propeller Shaft

NEMA0034

Check propeller shaft for damage, looseness or grease leakage.

Tightening torque: Refer to PD-5, “Components”.

SU BR ST RS

SMA231

BT HA SC EL SMA872C

MA-39

IDX

CHASSIS AND BODY MAINTENANCE Greasing Propeller Shaft

Greasing Propeller Shaft

NEMA0035

Apply specified grease to nipples provided on propeller shaft.

Grease grade: Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

SMA873C

Checking Differential Gear Oil

NEMA0036

Check for oil leakage and oil level.

Filler plug: Front — R200A : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — H233B : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — C200 : 39 - 59 N·m (4 - 6 kg-m, 29 - 43 ft-lb) SMA440B

Changing Differential Gear Oil 1.

2.

SMA632C

SMA631C

NEMA0037

Drain oil from drain plug and refill with new gear oil.

Check oil level.

Oil grade and viscosity: See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13, 14.

Oil capacity: Front — R200A 1.5 (3-1/8 US pt, 2-5/8 Imp pt) Rear — H233B 2.8 (5-7/8 US pt, 4-7/8 Imp pt) Rear — C200 1.3 (2-3/4 US pt, 2-1/4 Imp pt) Filler plug: Front — R200A : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — H233B : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — C200 : 39 - 59 N·m (4 - 6 kg-m, 29 - 43 ft-lb) Drain plug: Front — R200A : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — H233B : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear — C200 : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb)

MA-40

CHASSIS AND BODY MAINTENANCE Changing Differential Gear Oil (Cont’d)

LIMITED-SLIP DIFFERENTIAL GEAR 쐌 쐌 1.

2.

3.

NEMA0037S01

Use only approved limited-slip differential gear oil.

Limited-slip differential identification.

Lift both rear wheels off the ground.

Turn one rear wheel by hand.

If both rear wheels turn in the same direction simultaneously, vehicle is equipped with limited-slip differential.

GI

EM LC

Balancing Wheels

NEMA0038

Adjust wheel balance using the road wheel center.

Wheel balance (Maximum allowable unbalance): Refer to “WHEEL BALANCE”, MA-46.

EC FE CL MT

Tire Rotation 쐌 쐌

NEMA0039

After rotating the tires, adjust the tire pressure.

Retighten the wheel nuts when the vehicle has been driven for 1,000 km (600 miles) (also in cases of a flat tire, etc.).

Wheel nuts: : 118 - 147 N·m (12 - 15 kg-m, 87 - 108 ft-lb)

AT TF PD AX

AMA159

Checking Brake Fluid Level and Leaks

NEMA0040

If fluid level is extremely low, check brake system for leaks.

SU BR ST RS

SBR451D

Checking Brake Lines and Cables

NEMA0041

Check brake fluid lines and parking brake cables for improper attachment, leaks, chafing, abrasions and deterioration.

BT HA SC EL

SBR389C

MA-41

IDX

CHASSIS AND BODY MAINTENANCE Checking Disc Brake

Checking Disc Brake ROTOR

NEMA0042 NEMA0042S01

Check condition and thickness.

Standard thickness: 26 mm (1.02 in) Minimum thickness: 24 mm (0.94 in)

SMA260A

CALIPER

NEMA0042S02

Check for leakage.

SMA922A

PAD

NEMA0042S03

Check wear or damage.

Standard thickness: 10 mm (0.39 in) Minimum thickness: 2 mm (0.08 in)

SMA847B

Checking Drum Brake WHEEL CYLINDER

NEMA0043 NEMA0043S01

Check for leakage.

DRUM

NEMA0043S02

Check condition and inner surface.

Standard inner diameter: 295 mm (11.61 in) Drum repair limit (Inner diameter): 296.5 mm (11.67 in) SMA848B

LINING Check wear or damage.

Standard thickness: 5.8 mm (0.23 in) Lining wear limit (Minimum thickness): 1.5 mm (0.059 in)

SMA849B

MA-42

NEMA0043S03

CHASSIS AND BODY MAINTENANCE Checking Steering Gear and Linkage

Checking Steering Gear and Linkage STEERING GEAR 쐌 쐌

NEMA0044S01

Check steering gear housing for looseness, damage and oil leakage.

Check connection with steering column for looseness.

STEERING LINKAGE 쐌

NEMA0044

NEMA0044S02

Check ball joint, dust cover and other component parts for looseness, wear, damage and grease leakage.

EM LC

AMA144

Checking Power Steering Fluid and Lines CHECKING FLUID LEVEL 쐌 쐌

AMA155

GI

NEMA0045 NEMA0045S01

Check fluid level with engine off.

Check fluid level on reservoir. Use “HOT” range at fluid temperatures of 50 to 80°C (122 to 176°F). Use “COLD” range at fluid temperatures of 0 to 30°C (32 to 86°F).

CAUTION: 쐌 Do not overfill. 쐌 Recommended fluid is Genuine NISSAN PSF II or equivalent.

Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13.

EC FE CL MT AT TF PD AX

CHECKING LINES 쐌

NEMA0045S02

Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.

SU BR ST RS

AST255

BT HA SC EL

MA-43

IDX

CHASSIS AND BODY MAINTENANCE Lubricating Locks, Hinges and Hood Latches

Lubricating Locks, Hinges and Hood Latches

NEMA0046

WMA032

MA-44

CHASSIS AND BODY MAINTENANCE Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters

Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters

NEMA0047

GI

EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA WMA037

SC EL

MA-45

IDX

SERVICE DATA AND SPECIFICATIONS (SDS) Chassis and Body Maintenance

Chassis and Body Maintenance WHEEL BALANCE

NEMA0050

Dynamic (At rim flange)

10g (0.35oz) (one side)

Maximum allowable unbalance Static

20g (0.71oz)

MA-46

ENGINE MECHANICAL SECTION

EM

GI MA

LC EC

CONTENTS KA24DE PRECAUTIONS ...............................................................4 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............4 Parts Requiring Angular Tightening.............................5 Liquid Gasket Application Procedure ..........................5 PREPARATION ...............................................................6 Special Service Tools ..................................................6 Commercial Service Tools ...........................................8 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................10 NVH Troubleshooting Chart - Engine Noise .............11 OUTER COMPONENT PARTS .....................................12 Removal and Installation ...........................................12 MEASUREMENT OF COMPRESSION PRESSURE ....15 OIL PAN.........................................................................16 Components...............................................................16 Removal.....................................................................16 Installation..................................................................17 TIMING CHAIN ..............................................................18 Components...............................................................18 LIQUID GASKET APPLICATION PLACES..................19 Removal.....................................................................20 UPPER TIMING CHAIN ............................................20 IDLER SPROCKET ..................................................21 LOWER TIMING CHAIN ...........................................21 Inspection...................................................................22 Installation..................................................................23 LOWER TIMING CHAIN ...........................................23 IDLER SPROCKET ..................................................24 UPPER TIMING CHAIN ............................................24 OIL SEAL.......................................................................26 Replacement..............................................................26 VALVE OIL SEAL .....................................................26 OIL SEAL INSTALLING DIRECTION .........................26 FRONT OIL SEAL ....................................................26 REAR OIL SEAL ......................................................27 CYLINDER HEAD..........................................................29 Components...............................................................29

Removal.....................................................................30 Installation..................................................................31 Disassembly...............................................................31 Inspection...................................................................31 CYLINDER HEAD DISTORTION ...............................31 CAMSHAFT VISUAL CHECK ....................................32 CAMSHAFT RUNOUT ..............................................32 CAMSHAFT CAM HEIGHT .......................................32 CAMSHAFT JOURNAL CLEARANCE ........................32 CAMSHAFT END PLAY............................................33 CAMSHAFT SPROCKET RUNOUT ...........................33 VALVE GUIDE CLEARANCE ....................................33 VALVE GUIDE REPLACEMENT ................................34 VALVE SEATS .........................................................35 REPLACING VALVE SEAT FOR SERVICE PARTS ....35 VALVE DIMENSIONS ...............................................36 VALVE SPRING .......................................................37 VALVE LIFTER AND VALVE SHIM ............................37 Assembly ...................................................................38 Valve Clearance.........................................................38 CHECKING .............................................................38 ADJUSTING ............................................................39 ENGINE ASSEMBLY.....................................................41 Removal and Installation ...........................................41 REMOVAL ...............................................................42 INSTALLATION........................................................43 CYLINDER BLOCK .......................................................44 Components...............................................................44 Removal and Installation ...........................................45 Disassembly...............................................................45 PISTON AND CRANKSHAFT ....................................45 Inspection...................................................................45 PISTON AND PISTON PIN CLEARANCE ..................45 PISTON RING SIDE CLEARANCE ............................46 PISTON RING END GAP..........................................46 CONNECTING ROD BEND AND TORSION ...............46 CYLINDER BLOCK DISTORTION AND WEAR ...........47 PISTON-TO-BORE CLEARANCE ..............................47 CRANKSHAFT.........................................................48 BEARING CLEARANCE ...........................................49

FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX

CONTENTS CONNECTING ROD BUSHING CLEARANCE (SMALL END) ..........................................................51 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) ..........................................51 FLYWHEEL RUNOUT ..............................................52

Assembly ...................................................................52 PISTON ..................................................................52 CRANKSHAFT.........................................................53 REPLACING PILOT BUSHING ..................................54 SERVICE DATA AND SPECIFICATIONS (SDS) .........55 General Specifications...............................................55 COMPRESSION PRESSURE ...................................55 Cylinder Head ............................................................55 Valve ..........................................................................56 VALVE ....................................................................56 VALVE SPRING .......................................................56 VALVE GUIDE .........................................................57 VALVE LIFTER ........................................................57 VALVE CLEARANCE ADJUSTMENT .........................57 AVAILABLE SHIMS ..................................................58 VALVE SEAT ...........................................................59 Cylinder Block............................................................60 Camshaft and Camshaft Bearing ..............................61 Piston, Piston Ring and Piston pin............................62 PISTON ..................................................................62 PISTON PIN ............................................................62 PISTON RING .........................................................62 Connecting Rod .........................................................63 Crankshaft..................................................................63 Bearing Clearance .....................................................64 Available Main Bearing..............................................64 STANDARD .............................................................64 UNDERSIZE (SERVICE) ..........................................64 Available Connecting Rod Bearing............................64 STANDARD .............................................................64 UNDERSIZE (SERVICE) ..........................................64 Miscellaneous Components.......................................65 VG33E AND VG33ER PRECAUTIONS .............................................................66 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″.............66 Parts Requiring Angular Tightening...........................67 Liquid Gasket Application Procedure ........................67 PREPARATION .............................................................68 Special Service Tools ................................................68 Commercial Service Tools .........................................70 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................72 NVH Troubleshooting Chart - Engine Noise .............73 OUTER COMPONENT PARTS .....................................75 Removal and Installation ...........................................75 MEASUREMENT OF COMPRESSION PRESSURE ....78

(Cont’d)

OIL PAN.........................................................................80 Removal.....................................................................80 Installation..................................................................81 TIMING BELT ................................................................83 Components...............................................................83 Removal.....................................................................84 Inspection...................................................................85 BELT TENSIONER AND TENSIONER SPRING ..........86 Installation..................................................................86 Tension Adjustment....................................................87 AFTER BELT REPLACEMENT..................................87 AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY (WITH ROCKER COVERS REMOVED) .............................................................88

OIL SEAL.......................................................................90 Replacement..............................................................90 VALVE OIL SEAL .....................................................90 OIL SEAL INSTALLING DIRECTION .........................90 CAMSHAFT OIL SEAL .............................................91 FRONT OIL SEAL ....................................................91 REAR OIL SEAL ......................................................91 CYLINDER HEAD..........................................................92 Components...............................................................92 Removal.....................................................................93 Disassembly...............................................................95 Inspection...................................................................96 CYLINDER HEAD DISTORTION ...............................96 CAMSHAFT VISUAL CHECK ....................................96 CAMSHAFT RUNOUT ..............................................96 CAMSHAFT CAM HEIGHT .......................................96 CAMSHAFT JOURNAL CLEARANCE ........................96 CAMSHAFT END PLAY............................................97 CAMSHAFT SPROCKET RUNOUT ...........................97 VALVE GUIDE CLEARANCE ....................................98 VALVE GUIDE REPLACEMENT ................................98 VALVE SEATS .........................................................99 REPLACING VALVE SEAT FOR SERVICE PARTS ..100 VALVE DIMENSIONS .............................................100 VALVE SPRING .....................................................101 ROCKER SHAFT AND ROCKER ARM ....................101 HYDRAULIC VALVE LIFTER ..................................102 Assembly .................................................................102 Installation................................................................103 SUPERCHARGER .......................................................107 Components.............................................................107 Removal...................................................................108 Inspection.................................................................109 SUPERCHARGER FLANGE ...................................109 ROTOR SYSTEM ..................................................109 SUPERCHARGER BYPASS VALVE ACTUATOR .....110 Installation................................................................110 ENGINE ASSEMBLY................................................... 111 Removal and Installation ......................................... 111 REMOVAL .............................................................112 CYLINDER BLOCK .....................................................114

EM-2

CONTENTS Components.............................................................114 Removal and Installation .........................................115 Disassembly.............................................................115 PISTON AND CRANKSHAFT ..................................115 Inspection.................................................................116 PISTON AND PISTON PIN CLEARANCE ................116 PISTON RING SIDE CLEARANCE ..........................116 PISTON RING END GAP........................................117 CONNECTING ROD BEND AND TORSION .............117 CYLINDER BLOCK DISTORTION AND WEAR .........117 PISTON-TO-BORE CLEARANCE ............................118 CRANKSHAFT.......................................................119 BEARING CLEARANCE .........................................120 CONNECTING ROD BUSHING CLEARANCE (SMALL END) ........................................................122 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) ........................................123 FLYWHEEL/DRIVE PLATE RUNOUT ......................123

Assembly .................................................................123 PISTON ................................................................123 CRANKSHAFT.......................................................124 REPLACING PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T) ................................................125

SERVICE DATA AND SPECIFICATIONS (SDS) .......126 General Specifications.............................................126 Cylinder Head ..........................................................127 Valve ........................................................................127

(Cont’d) VALVE ..................................................................127 VALVE SPRING .....................................................128 HYDRAULIC VALVE LIFTER ..................................128 VALVE GUIDE .......................................................128 ROCKER SHAFT AND ROCKER ARM ....................128

Valve Seat................................................................129 INTAKE VALVE SEAT ............................................129 EXHAUST VALVE SEAT.........................................130 Camshaft and Camshaft Bearing ............................131 Cylinder Block..........................................................132 Piston, Piston Ring and Piston Pin .........................133 AVAILABLE PISTON ..............................................133 PISTON RING .......................................................133 PISTON PIN ..........................................................134 Connecting Rod .......................................................134 Crankshaft................................................................134 Available Main Bearing............................................135 NO. 1 MAIN BEARING ...........................................135 NO. 2 AND 3 MAIN BEARING ................................135 NO. 4 MAIN BEARING ...........................................135 UNDER SIZE .........................................................135 Available Connecting Rod Bearing..........................136 CONNECTING ROD BEARING UNDERSIZE ...........136 Miscellaneous Components.....................................136 BEARING CLEARANCE .........................................136

GI MA

LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL

EM-3

IDX

PRECAUTIONS

KA24DE

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NEEM0125

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of a driver air bag module (located in the center of the steering wheel), a front passenger air bag module (located on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness, and spiral cable.

The vehicle (except Crew Cab model) is equipped with a passenger air bag deactivation switch. Because no rear seat exists where a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is enabled and could inflate in a frontal collision. When the switch is turned to the OFF position, the passenger air bag is disabled and will not inflate in a frontal collision. A passenger air bag OFF indicator on the instrument panel lights up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected by the passenger air bag deactivation switch.

Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING: 쐌 To 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 should be performed by an authorized NISSAN dealer. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual.

Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) covered with yellow insulation either just before the harness connectors or for the complete harness are related to the SRS. 쐌 The vehicle (except Crew Cab model) is equipped with a passenger air bag deactivation switch which can be operated by the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and will not inflate in a frontal collision. When the passenger air bag is switched ON, the passenger air bag is enabled and could inflate in a frontal collision. After SRS maintenance or repair, make sure the passenger air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for service.

EM-4

PRECAUTIONS

KA24DE Parts Requiring Angular Tightening

Parts Requiring Angular Tightening 쐌 a) b) 쐌 쐌 쐌

NEEM0126

Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Connecting rod cap nuts Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.

GI MA

LC

Liquid Gasket Application Procedure 1)

2) 쐌 쐌 SEM371C

3) 4) 5)

NEEM0127

Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also completely clean any oil stains from these portions.

Apply a continuous bead of liquid gasket to mating surfaces.

(Use Genuine RTV Silicone Sealant Part No. 999MP-A7007 or equivalent.)

Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) dia. (for oil pan).

Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) dia. (in areas except oil pan).

Apply liquid gasket to inner surface around hole perimeter area (unless otherwise specified).

Assembly should be done within 5 minutes after coating.

Wait at least 30 minutes before refilling engine oil and engine coolant.

EC FE CL MT AT TF PD AX

AEM080

SU BR ST RS BT HA SC EL

EM-5

IDX

PREPARATION

KA24DE

Special Service Tools

Special Service Tools

NEEM0128

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

Description Disassembling and assembling

ST0501S000 ( — ) Engine stand assembly 1 ST05011000 ( — ) Engine stand 2 ST05012000 ( — ) Base NT042

KV10105001 ( — ) Engine attachment

NT031

KV101092S0 (J26336-B) Valve spring compressor 1 KV10109210 ( — ) Compressor 2 KV100109220 ( — ) Adapter

Disassembling and assembling valve components

NT021

Tightening bearing cap, cylinder head bolts, etc.

KV10112100 (BT8653-A) Angle wrench

NT014

Installing valve oil seal a: 25 (0.98) dia. b: 14.4 (0.567) dia. c: 11.8 (0.465) dia. d: 10 (0.39) dia. e: 11 (0.43) f: 9 (0.35)

KV10116300 (J-38955) Valve oil seal drift

NT602

EM-6

PREPARATION

KA24DE Special Service Tools (Cont’d)

Tool number (Kent-Moore No.) Tool name KV10110300 ( — ) Piston pin press stand assembly 1 KV10110310 ( — ) Cap 2 KV10110330 ( — ) Spacer 3 ST13030020 ( — ) Press stand 4 ST13030030 ( — ) Spring 5 KV10110340 ( — ) Drift 6 KV10110320 ( — ) Center shaft

Description

GI Disassembling and assembling piston with connecting rod

MA

LC EC FE NT036

CL MT Installing piston assembly into cylinder bore

EM03470000 (J8037) Piston ring compressor

AT TF NT044

Removing valve oil seal

(J36467) Valve oil seal remover

PD AX

NT034

Removing crankshaft pilot bushing

ST16610001 (J23907) Pilot bushing puller

BR ST

NT045

Removing oil pan

KV10111100 (J37228) Seal cutter

RS BT

NT046

WS39930000 ( — Tube presser

SU

Pressing the tube of liquid gasket

HA

)

SC NT052

EL

EM-7

IDX

PREPARATION

KA24DE

Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name KV101151S0 (J38972) Lifter stopper set 1 KV10115110 (J38972-1) Camshaft pliers 2 KV10115120 (J38972-2) Lifter stopper

Description Changing valve lifter shims

NT041

Loosening or tightening heated oxygen sensor For 22 mm (0.87 in) hexagon nut

KV10117100 (J36471-A) Front heated oxygen sensor wrench

NT379

Commercial Service Tools Tool name (Kent Moore No.)

NEEM0129

Description Removing and installing spark plug

Spark plug wrench

NT047

Pulley holder

Holding camshaft pulley while tightening or loosening camshaft bolt

NT035

Finishing valve seat dimensions

Valve seat cutter set

NT048

Removing and installing piston ring

Piston ring expander

NT030

Valve guide drift

Removing and installing valve guide Intake & Exhaust: a = 10.5 mm (0.413 in) dia. b = 6.6 mm (0.260 in) dia.

NT015

EM-8

PREPARATION

KA24DE Commercial Service Tools (Cont’d)

Tool name (Kent Moore No.)

Description

GI Reaming valve guide 1 or hole for oversize valve guide 2 Intake: d1 = 7.0 mm (0.276 in) dia. d2 = 11.2 mm (0.441 in) dia.

Exhaust: d1 = 8.0 mm (0.315 in) dia. d2 = 12.2 mm (0.480 in) dia.

Valve guide reamer

NT016

Front oil seal drift

Installing front oil seal a: 52 mm (2.05 in) dia. b: 44 mm (1.73 in) dia.

MA

LC EC

NT049

FE Installing rear oil seal a: 46 mm (1.81 in) b: 110 mm (4.33 in) c: 84 mm (3.31 in) d: 96 mm (3.78 in)

Rear oil seal drift

CL MT AT

NT719

a: 18 mm (0.71 in) b: 12 mm (0.47 in)

a: (J-43897-18) b: (J-43897-12) Thread repair tool for oxygen sensor

TF PD AX

AEM488

For preventing corrosion, seizing, and galling on high temperature applications.

Anti-seize thread compound

SU BR ST RS

AEM489

BT HA SC EL

EM-9

IDX

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NEEM0085

KA24DE

AEM466

EM-10

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

KA24DE

NVH Troubleshooting Chart — Engine Noise

NVH Troubleshooting Chart — Engine Noise

NEEM0085S01

Use the chart below to help you find the cause of the symptom.

1. Locate the area where noise occurs.

2. Confirm the type of noise.

3. Specify the operating condition of the engine.

4. Check the specified noise source.

If necessary, repair or replace these parts.

GI MA

Operating condition of engine Location of noise

Top of engine Rocker cover Cylinder head

Type of noise

When idling

When revving

While driving

Source of noise

Check item

Reference page

C

A

—

A

B

—

Tappet noise

Valve clearance

EM-38

Rattle

C

A

—

A

B

C

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-32

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

A

Piston slap noise

Piston ring side clearance Piston ring end gap Connecting rod bend and EM-47, 46 torsion Piston-to-bore clearance Connecting rod bearing clearance (Big end) Connecting rod bushing clearance (Small end)

EM-50, 51

Crankshaft runout Main bearing oil clearance

EM-48

Slap or rap

—

A

A

—

—

—

B

B

B

B

—

Knock

A

B

C

B

B

B

Connecting rod-bearing noise

Knock

A

B

—

A

B

C

Main bearing noise

B

Timing chain and Timing chain cracks and chain tenwear sioner noise

C

Other drive belts (StickDrive belt deflection ing or slipping)

Front of engine Tapping Timing or ticking chain cover

Front of engine

When starting

Ticking or clicking

Slap or knock

Crankshaft pulley Cylinder block (upper side of engine) Oil pan

Before After warm- warmup up

A

Squeaking or fizzing

A

Creaking

A

Squall creak A: Closely related

A

B: Related

A

B

B

B

—

—

A

—

B

B

B

B

B

—

A

A

B

Other drive belts (Slipping)

B

Water Water pump operation pump noise

LC EC FE CL

EM-45, 51

MT AT TF PD AX SU EM-22

BR MA-16, “Checking Drive Belts”

Idler pulley bearing operation LC-12, “Water Pump Inspection”

ST RS BT HA

C: Sometimes related —: Not related:

SC EL

EM-11

IDX

OUTER COMPONENT PARTS

KA24DE

Removal and Installation

Removal and Installation

NEEM0086

WEM146

EM-12

OUTER COMPONENT PARTS

KA24DE Removal and Installation (Cont’d)

GI MA

LC EC FE CL MT AT WEM073

1.

2.

3.

Spark plug Ignition wires Camshaft position sensor built into distributor

4.

5.

6.

EGR tube Exhaust manifold Heated oxygen sensor 1 (front)

7.

8.

Exhaust manifold cover TWC (manifold)

TF PD AX SU BR ST RS BT HA SC EL

EM-13

IDX

OUTER COMPONENT PARTS

KA24DE

Removal and Installation (Cont’d)

AEM467

EM-14

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