2001 NISSAN PICK-UP service

GENERAL INFORMATIONGI
MAINTENANCEMA
ENGINE MECHANICALEM
ENGINE LUBRICATION &
COOLING SYSTEMSLC
ENGINE CONTROL SYSTEMEC
ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMSFE
CLUTCHCL
MANUAL TRANSAXLEMT
TRANSFERTF
PROPELLER SHAFT &
DIFFERENTIAL CARRIERPD
FRONT AXLE & FRONT SUSPENSIONFA
REAR AXLE & REAR SUSPENSIONRA
BRAKE SYSTEMBR
STEERING SYSTEMST
RESTRAINT SYSTEMRS
BODY & TRIMBT
HEATER & AIR CONDITIONERHA
ELECTRICAL SYSTEMEL
ALPHABETICAL INDEXIDX
PICKUP
MODEL D22 SERIES
FOREWORD
This supplement contains informa-
tion concerning necessary service
procedures and relevant data for the
model D22 series.
All information, illustrations and spe-
ci®cations contained in this supple-
ment are based on the latest product
information available at the time of
publication. If your NISSAN model
differs from the speci®cations contain-
ed in this supplement, consult your
NISSAN distributor for information.
The right is reserved to make chan-
ges in speci®cations and methods at
any time without notice.
Edition: November 2001
Printing: November 2001 (01)
Publication No.: SM1E-D22CE0E
NISSAN EUROPE S.A.S.
2001 NISSAN EUROPE S.A.S. Printed in the Netherlands
Not to be reproduced in whole or in part without the prior written permission of Nissan Europe S.A.S., Paris, France.
QUICK REFERENCE INDEX

FOREWORD
This manual contains maintenance and repair procedures for NISSAN
PICKUP, model D22 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in speci-
®cations and methods at any time without notice.
IMPORTANT SAFETY NOTICE
The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a man-
ner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not speci®cally recommended by NISSAN must
®rst completely satisfy himself that neither his safety nor the vehicle's
safety will be jeopardized by the service method selected.
NISSAN EUROPE S.A.S.
Service Engineering Section
Paris, France

CLUTCH
SECTION
CL
MODIFICATION NOTICE:
YD25DDTi engine model has been added.
CONTENTS
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 3002
General Specifications ..................................... 3002
Inspection and Adjustment .............................. 3002

CL

General Specifications
CLUTCH MASTER CYLINDER
Inner diameter mm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in) 19.05 (3/4)
CLUTCH DISC
Model 250
Engine YD25DDTi
Facing size mm (in)
(Outer dia. x inner dia. x thick-
ness)250 x 160 x 3.5
(9.84 x 6.30 x 0.138)
Thickness of disc assembly
With load mm (in)7.85 - 8.35 (0.3091 - 0.3287)
With 7,360 N (751 kg, 1,655 lb)
CLUTCH COVER
Model 250
Engine YD25DDTi
Full load N (kg, lb) 7,360 (751, 1,655)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Pedal height ªH*º
RHD model
YD25DDTi engine model203 - 213
(7.99 - 8.39)
LHD model
YD25DDTi engine model237 - 247
(9.33 - 9.72)
Pedal free play (at clevis pin) 1 - 1.5 (0.039 - 0.059)
*: Measured from surface of melt sheet to pedal pad
CLUTCH DISC
Unit: mm (in)
Mode 250
Engine model YD25DDTi
Wear limit of facing surface to
rivet head0.3 (0.012)
Runout limit of facing 0.7 (0.028)
Distance of runout check point
(from the hub center)120 (4.72)
Maximum backlash of spline
(at outer edge of disc)1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Model 250
Engine model YD25DDTi
Diaphragm spring height 39.5 - 41.5 (1.555 - 1.634)
Uneven limit of diaphragm spring
toe height0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-3002

ENGINE CONTROL SYSTEM
SECTION
EC
CONTENTS
PRECAUTIONS AND PREPARATION............... 3008
Special Service Tool (YD25DDTi) ................... 3008
Supplemental Restraint System (SRS)²AIR
BAG²................................................................ 3008
KA24DE (EURO OBD)
Trouble Diagnosis - Index................................. 3009
Alphabetical & P No. Index for DTC................ 3009
Precautions......................................................... 3012
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER².. 3012
Precautions for On Board Diagnostic (OBD)
System of Engine............................................. 3012
Engine Fuel & Emission Control System ........ 3013
Precautions ...................................................... 3014
Wiring Diagrams and Trouble Diagnosis ......... 3015
Preparation.......................................................... 3016
Special Service Tools ...................................... 3016
Commercial Service Tools ............................... 3016
Engine and Emission Control Overall System3018
Engine Control Component Parts Location ..... 3018
Circuit Diagram ................................................ 3020
System Diagram .............................................. 3021
Vacuum Hose Drawing .................................... 3022
System Chart ................................................... 3023
Engine and Emission Basic Control System
Description.......................................................... 3024
Multiport Fuel Injection (MFI) System.............. 3024
Distributor Ignition (DI) System........................ 3026
Air Conditioning Cut Control ............................ 3028
Fuel Cut Control (at no load & high engine
speed) .............................................................. 3028Evaporative Emission System ......................... 3029
Positive Crankcase Ventilation ........................ 3032
Basic Service Procedure................................... 3033
Fuel Pressure Release .................................... 3033
Fuel Pressure Check ....................................... 3033
Fuel Pressure Regulator Check ...................... 3034
Injector ............................................................. 3034
Fast Idle Cam (FIC) ......................................... 3035
Idle Speed/Ignition Timing/Idle Mixture Ratio
Adjustment ....................................................... 3035
On Board Diagnostic System Description...... 3049
Introduction ...................................................... 3049
Two Trip Detection Logic ................................. 3049
Emission-related Diagnostic Information ......... 3049
NVIS (Nissan Vehicle Immobilizer System -
NATS) .............................................................. 3061
Malfunction Indicator (MI) ................................ 3061
OBD System Operation Chart ......................... 3064
CONSULT-II ..................................................... 3070
Generic Scan Tool (GST) ................................ 3080
Trouble Diagnosis - Introduction..................... 3082
Introduction ...................................................... 3082
Work Flow ........................................................ 3084
Trouble Diagnosis - Basic Inspection.............. 3086
Basic Inspection ............................................... 3086
Trouble Diagnosis - General Description........ 3100
DTC Inspection Priority Chart .......................... 3100
Fail-safe Chart ................................................. 3101
Symptom Matrix Chart ..................................... 3102
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3106
Major Sensor Reference Graph in Data
Monitor Mode ................................................... 3107

BR

DTC Confirmation Procedure .......................... 3308
Diagnostic Procedure....................................... 3309
DTC P1143 HO2S1.............................................. 3310
Component Description ................................... 3310
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3310
ECM Terminals and Reference Value ............. 3310
On Board Diagnosis Logic ............................... 3311
DTC Confirmation Procedure .......................... 3311
Overall Function Check ................................... 3312
Diagnostic Procedure....................................... 3312
DTC P1144 HO2S1.............................................. 3317
Component Description ................................... 3317
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3317
ECM Terminals and Reference Value ............. 3317
On Board Diagnosis Logic ............................... 3318
DTC Confirmation Procedure .......................... 3318
Overall Function Check ................................... 3319
Diagnostic Procedure....................................... 3319
DTC P1146 HO2S2.............................................. 3324
Component Description ................................... 3324
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3324
ECM Terminals and Reference Value ............. 3324
On Board Diagnosis Logic ............................... 3324
DTC Confirmation Procedure .......................... 3325
Overall Function Check ................................... 3326
Wiring Diagram ................................................ 3327
Diagnostic Procedure....................................... 3328
DTC P1147 HO2S2.............................................. 3334
Component Description ................................... 3334
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3334
ECM Terminals and Reference Value ............. 3334
On Board Diagnosis Logic ............................... 3334
DTC Confirmation Procedure .......................... 3335
Overall Function Check ................................... 3336
Wiring Diagram ................................................ 3337
Diagnostic Procedure....................................... 3338
DTC P1217 Engine Over Temperature............. 3344
On Board Diagnosis Logic ............................... 3344
Overall Function Check ................................... 3344
Diagnostic Procedure....................................... 3345
Main 11 Causes of Overheating ...................... 3348
DTC P1336 CKP Sensor (OBD)......................... 3349
Component Description ................................... 3349
ECM Terminals and Reference Value ............. 3349
On Board Diagnosis Logic ............................... 3350
DTC Confirmation Procedure .......................... 3350
Wiring Diagram ................................................ 3351
Diagnostic Procedure....................................... 3352
DTC P1706 PNP Switch..................................... 3355
Component Description ................................... 3355CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3355
ECM Terminals and Reference Value ............. 3355
On Board Diagnosis Logic ............................... 3355
DTC Confirmation Procedure .......................... 3356
Overall Function Check ................................... 3357
Wiring Diagram ................................................ 3358
Diagnostic Procedure....................................... 3359
Ignition Signal..................................................... 3361
Component Description ................................... 3361
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3361
ECM Terminals and Reference Value ............. 3362
Wiring Diagram ................................................ 3363
Diagnostic Procedure....................................... 3365
Injector................................................................. 3369
Component Description ................................... 3369
ECM Terminals and Reference Value ............. 3369
Wiring Diagram ................................................ 3370
Diagnostic Procedure....................................... 3371
Start Signal......................................................... 3374
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3374
ECM Terminals and Reference Value ............. 3374
Wiring Diagram ................................................ 3375
Diagnostic Procedure....................................... 3376
Fuel Pump........................................................... 3378
System Description .......................................... 3378
Component Description ................................... 3378
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3378
ECM Terminals and Reference Value ............. 3379
Wiring Diagram ................................................ 3380
Diagnostic Procedure....................................... 3381
Power Steering Oil Pressure Switch................ 3385
Component Description ................................... 3385
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3385
ECM Terminals and Reference Value ............. 3385
Wiring Diagram ................................................ 3386
Diagnostic Procedure....................................... 3387
IACV-FICD Solenoid Valve................................ 3389
Component Description ................................... 3389
ECM Terminals and Reference Value ............. 3389
Wiring Diagram ................................................ 3390
Diagnostic Procedure....................................... 3392
MI & Data Link Connectors............................... 3396
Wiring Diagram ................................................ 3396
Service Data and Specifications (SDS)............ 3398
Fuel Pressure Regulator .................................. 3398
Idle Speed and Ignition Timing ........................ 3398
Ignition Coil ...................................................... 3398
Mass Air Flow Sensor...................................... 3398
Engine Coolant Temperature Sensor .............. 3398
EC-3004

Fuel Pump........................................................ 3398
IACV-AAC Valve .............................................. 3398
Injector ............................................................. 3398
Throttle Position Sensor .................................. 3399
Heated Oxygen Sensor 1 Heater .................... 3399
Calculated Load Value..................................... 3399
Intake Air Temperature Sensor ....................... 3399
Heated Oxygen Sensor 2 Heater .................... 3399
Crankshaft Position Sensor (OBD) .................. 3399
YD25DDTi
TROUBLE DIAGNOSIS - INDEX........................ 3400
Alphabetical & Numerical Index for DTC......... 3400
PRECAUTIONS................................................... 3402
Precautions ...................................................... 3402
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM............................................................... 3405
Engine Control Component Parts Location ..... 3405
Circuit Diagram ................................................ 3408
System Diagram .............................................. 3409
System Chart ................................................... 3410
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION..................................... 3411
Fuel Injection Control System.......................... 3411
Fuel Injection Timing Control System.............. 3413
Air Conditioning Cut Control ............................ 3413
Fuel Cut Control (at no load & high engine
speed) .............................................................. 3413
Crankcase Ventilation System ......................... 3414
BASIC SERVICE PROCEDURE......................... 3415
Injection Tube and Injection Nozzle ................ 3415
Electronic Control Fuel Injection Pump ........... 3419
Air Bleeding...................................................... 3426
Water Draining ................................................. 3426
Accelerator Position Sensor Idle Position
Learning ........................................................... 3427
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION..................................................... 3428
DTC and MIL Detection Logic ......................... 3428
Diagnostic Trouble Code (DTC) ...................... 3428
Malfunction Indicator Lamp (MIL) .................... 3429
CONSULT-II ..................................................... 3434
TROUBLE DIAGNOSIS - INTRODUCTION........ 3440
Introduction ...................................................... 3440
Work Flow ........................................................ 3442
TROUBLE DIAGNOSIS - BASIC INSPECTION. 3444
Basic Inspection ............................................... 3444
TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION..................................................... 3450
Symptom Matrix Chart ..................................... 3450
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3460Major Sensor Reference Graph in Data
Monitor Mode ................................................... 3462
ECM Terminals and Reference Value ............. 3463
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT............................................................. 3469
Description ....................................................... 3469
Diagnostic Procedure....................................... 3469
TROUBLE DIAGNOSIS FOR POWER SUPPLY3470
Main Power Supply and Ground Circuit .......... 3470
DTC 0103 COOLANT TEMP SEN...................... 3480
Description ....................................................... 3480
On Board Diagnosis Logic ............................... 3480
DTC Confirmation Procedure .......................... 3480
Wiring Diagram ................................................ 3481
Diagnostic Procedure....................................... 3482
DTC 0104 VEHICLE SPEED SEN...................... 3484
Description ....................................................... 3484
ECM Terminals and Reference Value ............. 3484
On Board Diagnosis Logic ............................... 3484
Overall Function Check ................................... 3485
Wiring Diagram ................................................ 3486
Diagnostic Procedure....................................... 3488
DTC 0208 OVER HEAT....................................... 3489
Description ....................................................... 3489
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3489
ECM Terminals and Reference Value ............. 3490
On Board Diagnosis Logic ............................... 3490
Overall Function Check ................................... 3491
Wiring Diagram ................................................ 3492
Diagnostic Procedure....................................... 3493
Main 12 Causes of Overheating ...................... 3500
DTC 0301 ECM 2, DTC 901 ECM 12................. 3501
Description ....................................................... 3501
On Board Diagnosis Logic ............................... 3501
DTC Confirmation Procedure .......................... 3501
Diagnostic Procedure....................................... 3502
DTC 0401 INTAKE AIR TEMPERATURE
SENSOR.............................................................. 3503
Component Description ................................... 3503
On Board Diagnosis Logic ............................... 3503
DTC Confirmation Procedure .......................... 3503
Wiring Diagram ................................................ 3505
Diagnostic Procedure....................................... 3506
DTC 0402 P9zFUEL TEMP SEN......................... 3508
Description ....................................................... 3508
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3509
ECM Terminals and Reference Value ............. 3509
On Board Diagnosis Logic ............................... 3510
DTC Confirmation Procedure .......................... 3510
Wiring Diagram ................................................ 3511
Diagnostic Procedure....................................... 3513
EC-3005

Diagnostic Procedure....................................... 3599
DTC 0905 TURBO PRESSURE.......................... 3600
Component Description ................................... 3600
ECM Terminals and Reference Value ............. 3600
On Board Diagnosis Logic ............................... 3600
DTC Confirmation Procedure .......................... 3601
Wiring Diagram ................................................ 3602
Diagnostic Procedure....................................... 3603
DTC 1003 EGR VOLUME CONT/V..................... 3605
Description ....................................................... 3605
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3606
ECM Terminals and Reference Value ............. 3606
DTC Confirmation Procedure .......................... 3606
Wiring Diagram ................................................ 3607
Diagnostic Procedure....................................... 3609
DTC 1004 FUEL CUT SYSTEM1........................ 3614
Description ....................................................... 3614
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3615
ECM Terminals and Reference Value ............. 3615
On Board Diagnosis Logic ............................... 3615
DTC Confirmation Procedure .......................... 3616
Wiring Diagram ................................................ 3617
Diagnostic Procedure....................................... 3619
GLOW CONTROL SYSTEM............................... 3621
Description ....................................................... 3621
ECM Terminals and Reference Value ............. 3622
Wiring Diagram ................................................ 3623
Diagnostic Procedure....................................... 3624
START SIGNAL................................................... 3630Wiring Diagram ................................................ 3630
Diagnostic Procedure....................................... 3631
PARK/NEUTRAL POSITION (PNP) SWITCH.... 3633
Description ....................................................... 3633
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3633
ECM Terminals and Reference Value ............. 3633
Wiring Diagram ................................................ 3634
Diagnostic Procedure....................................... 3635
HEAT UP SWITCH.............................................. 3638
Component Description ................................... 3638
CONSULT-II Reference Value in Data Monitor
Mode ................................................................ 3638
ECM Terminals and Reference Value ............. 3638
Wiring Diagram ................................................ 3639
Diagnostic Procedure....................................... 3640
AIR CONDITIONER CONTROL.......................... 3644
Wiring Diagram ................................................ 3644
MIL & DATA LINK CONNECTORS.................... 3646
Wiring Diagram ................................................ 3646
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 3650
General Specifications ..................................... 3650
Injection Pump Numbers ................................. 3650
Injection Nozzle................................................ 3650
Engine Coolant Temperature Sensor .............. 3650
Intake Air Temperature Sensor ....................... 3650
Crankshaft Position Sensor (TDC) .................. 3650
Glow Plug......................................................... 3650
Accelerator Position Sensor ............................ 3650
EGR Volume Control Valve ............................. 3650
EC-3007