2002 NISSAN TERRANO Full system

6. Loosen/remove mounting nuts between actuator and bracket.
Installation
CAUTION:
After installation, pay attention to the following points:
IRefill brake fluid and bleed air. Refer to ªCHECK AND
ADJUSTMENTº, BR-5 and ªBleeding Brake Systemº,
ªBRAKE HYDRAULIC LINEº, BR-8, respectively.
1. Install actuator on bracket without tightening fixings.
2. Assemble brake tubes to actuator without tightening tube nuts.
Ensure that correct tubes are connected to each port.
3. Fully tighten actuator and bracket fixings to specified torque.
4. Fully tighten flare nuts to specified torque, BR-9.
5. Secure ABS control unit harness connector and battery cable.
ANTI-LOCK BRAKE SYSTEM
Removal and Installation (Cont'd)
BR-46

Service Notice
IWhen removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
IHandle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to oil
or damage them.
IApply sealing compound where necessary when installing parts.
IWhen applying sealing compound, be careful that the sealing compound does not protrude from parts.
IWhen replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust pre-
vention measures.
Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL R20 is as follows (The compo-
sition varies according to the destination and optional equipment.):
IFor a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
IFor a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in theRSsection of this Service Manual.
WARNING:
ITo 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 per-
formed by an authorized NISSAN dealer.
IImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
IDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.
PRECAUTIONS
BT-2

General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch control Hydraulic
CLUTCH MASTER CYLINDER
Inner diameter mm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in)
LHD 17.46 (11/16)
RHD 19.05 (3/4)
CLUTCH DISC
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Model 250 260
Facing size
(Outer dia. x inner dia. x
thickness)250 x 160 x 3.7
(9.84 x 6.30 x 0.1457)
Thickness of disc assembly
under load7.9 - 8.3 (0.311 - 0.327)
Under a load of 5,884 N
(600 kg, 1,323 lb)
CLUTCH COVER
Engine TD27Ti ZD30DDTi
Model 250 260
Full load N (kg, lb) 5,884 (600, 1,323) 6,760 (689, 1,520)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Handle LHD RHD
Pedal height*227 - 237
(8.94 - 9.33)210 - 220
(8.27 - 8.66)
Pedal stroke 155 - 160 (6.10 - 6.30)
Pedal free play
(Backlash at clevis)1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of melt sheet to surface of pedal
pad
CLUTCH DISC
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Disc model 250 260
Rear limit of facing
surface to rivet head0.3 (0.012)
Runout limit of facing 1 (0.04)
Distance of runout
check point (from the
hub center)120 (4.72)
Maximum of spline
backlash of spline (at
outer edge of disc)1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Cover model 250 260
Diaphragm spring height 36.5 - 38.5 (1.437 - 1.516)
Uneven limit of dia-
phragm spring toe height
ªAº0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14

Fuel Injection Timing Control System
DESCRIPTION
The target fuel injection timing in accordance with the engine speed and the fuel injection amount are recorded
as a map in the ECM beforehand. The ECM and the injection pump control unit exchange signals and per-
form feedback control for optimum injection timing in accordance with the map.
Air Conditioning Cut Control
DESCRIPTION
Input/output signal chart
Sensor Input Signal to ECM ECM Function Actuator
Air conditioner switch Air conditioner ªONº signal
Air conditioner cut
controlAir conditioner relay Accelerator position sensorAccelerator valve opening
angle
Vehicle speed sensor Vehicle speed
Engine coolant temperature sensor Engine coolant temperature
System description
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This continues
until the engine coolant temperature returns to normal.
Fuel Cut Control (at no load & high engine
speed)
DESCRIPTION
Input/output signal chart
Sensor Input Signal to ECM ECM Function Actuator
Vehicle speed sensor Vehicle speed
Fuel cut controlElectronic control fuel injec-
tion pump Park/Neutral position (PNP) switch Neutral position
Accelerator position switch or Accelerator
switch (F/C)Accelerator position
Engine coolant temperature sensor Engine coolant temperature
Crankshaft position sensor (TDC) Engine speed
If the engine speed is above 2,700 rpm with no load (for example, in neutral and engine speed over 2,700
rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed.
Fuel cut will operate until the engine speed reaches 1,500 rpm, then fuel cut is cancelled.
NOTE:
This function is different from deceleration control listed under ªFuel Injection Control Systemº, EC-20.
ENGINE AND EMISSION BASIC CONTROL SYSTEM
DESCRIPTIONZD30DDTi
EC-22

Monitored item
[Unit]ECM
input
signalsMain
signalsDescription Remarks
FUEL TEMP SEN
[ÉC] or [ÉF]qqIThe fuel temperature (sent from elec-
tronic control fuel injection pump) is dis-
played.
ACCEL POS SEN [V]
qqIThe accelerator position sensor signal
voltage is displayed.
FULL ACCEL SW
[ON/OFF]qqIIndicates [ON/OFF] condition from the
accelerator position switch signal.
ACCEL SW (FC)
[OPEN/CLOSE]qqIIndicates [OPEN/CLOSE] condition from
the accelerator switch (FC) signal.
OFF ACCEL SW
[ON/OFF]qqIIndicates [ON/OFF] condition from the
accelerator position switch signal.
SPILL/V [ÉCA]
qIThe control position of spill valve (sent
from electronic control fuel injection
pump) is displayed.
BATTERY VOLT [V]
qqIThe power supply voltage of ECM is dis-
played.
P/N POSI SW
[ON/OFF]qqIIndicates [ON/OFF] condition from the
park/neutral position switch signal.
START SIGNAL
[ON/OFF]qqIIndicates [ON/OFF] condition from the
starter signal.IAfter starting the engine, [OFF] is dis-
played regardless of the starter signal.
AIR COND SIG
[ON/OFF]qqIIndicates [ON/OFF] condition of the air
conditioner switch as determined by the
air conditioner signal.
BRAKE SW [ON/OFF]
qqIIndicates [ON/OFF] condition from the
stop lamp switch signal.
IGN SW
[ON/OFF]qqIIndicates [ON/OFF] condition from igni-
tion switch signal.
WARM UP SW
[ON/OFF]qIIndicates [ON/OFF] condition from the
heat up switch signal.
MAS AIR/FL SE [V]
qqIThe signal voltage of the mass air flow
sensor is displayed.IWhen the engine is stopped, a certain
value is indicated.
DECELER F/CUT
[ON/OFF]qIThe [ON/OFF] condition from decelera-
tion fuel cut signal (sent from electronic
control fuel injection pump) is displayed.
INJ TIMG C/V [%]
qIThe duty ratio of fuel injection timing
control valve (sent from electronic control
fuel injection pump) is displayed.
AIR COND RLY
[ON/OFF]qIIndicates the control condition of the air
conditioner relay (determined by ECM
according to the input signals).
GLOW RLY [ON/OFF]
qIThe glow relay control condition (deter-
mined by ECM according to the input
signal) is displayed.
COOLING FAN
[ON/OFF]
qIIndicates the control condition of the
cooling fans (determined by ECM
according to the input signal).
ION ... Operates.
OFF ... Stopped.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
CONSULT-II (Cont'd)
EC-41

ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
COOLING FANIIgnition switch: ON
IOperate the cooling fan at
ªLOWº, ªHIº speed and turn
ªOFFº using CONSULT-II.Cooling fan moves at ªLOWº, ªHIº
speed and stops.IHarness and connector
ICooling fan motor
ICooling fan relay
OFF ACCEL PO
SIGIClears the self-learning fully closed accelerator position, detected by accelerator position sensor, from the
ECM.
GLOW RLYIIgnition switch: ON (Engine
stopped)
ITurn the glow relay ªONº and
ªOFFº using CONSULT-II and
listen to operating sound.Glow relay makes the operating
sound.IHarness and connector
IGlow relay
INJ TIMING*IEngine: Return to the original
trouble condition
IRetard the injection timing using
CONSULT-II.If trouble symptom disappears, see
CHECK ITEM.IElectronic control fuel injection
pump
SWIRL CONT S/V1IIgnition switch: ON
ITurn solenoid valve ªONº and
ªOFFº with the CONSULT-II and
listen to operating sound.Solenoid valve makes an operating
sound.IHarness and connector
ISolenoid valve
EGR VOL CONT/VIIgnition switch: ON
IChange EGR volume control
valve opening step using CON-
SULT-II.EGR volume control valve makes
an operating sound.IHarness and connector
IEGR volume control valve
*: When using this item, DTC 0707 ªP7×F/INJ TIMG FBº may be detected. If so, erase it because it is not a malfunction.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
CONSULT-II (Cont'd)
EC-43

Introduction
The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control system,
etc. The ECM accepts input signals from sensors and instantly
drives electronic control fuel injection pump. It is essential that both
input and output signals are proper and stable. At the same time,
it is important that there are no problems such as vacuum leaks,
or other problems with the engine.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT-II or a circuit tester connected should be per-
formed. Follow the ªWork Flowº, EC-48.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus-
tomer can supply good information about such problems, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A ªDiagnostic Worksheetº like the
example on next page should be used.
Start your diagnosis by looking for ªconventionalº problems first.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.
DIAGNOSTIC WORKSHEET
There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can make
troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
SEF858S
SEF233G
SEF234G
SEF907L
TROUBLE DIAGNOSIS Ð INTRODUCTIONZD30DDTi
EC-46

SYSTEM Ð ENGINE CONTROL system
Malfunction
SYMPTOM
Reference page
Feature of symptom, Check pointHARD/NO START/RESTART
(EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE NO START (with first firing)
NO START (without first firing)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGWarranty symptom code AA AB AC AD AE AF
ENGINE CONTROL
Start signal circuit *a, *b 1 1 EC-248 *3
PNP switch circuit*a, *b 1
EC-251
*c
Accelerator position switch (Idle) cir-
cuit*a, *c 1 1 1
EC-130
*b 1 1 1 *4
Accelerator position switch (Full) cir-
cuit*a, *b 1 1 1 EC-130
Ignition switch circuit*a 1 111
EC-79
*b*5
Power supply for ECM circuit*a
EC-79
*b
1 - 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*3: Start control does not function.
*4: Accelerator position sensor NG signal is output.
*5: Engine does not stop.
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONZD30DDTi
Symptom Matrix Chart (Cont'd)
EC-62