2002 NISSAN TERRANO warning

Precautions
IRecommended fluid is brake fluid ªDOT 4º.
IDo not reuse drained brake fluid.
IBe careful not to splash brake fluid on painted areas.
IWhen removing and installing clutch piping, use Tool.
ITo clean or wash all parts of master cylinder, operating
cylinder and clutch damper, use clean brake fluid.
INever use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
Remove all dust from clutch disc with a dust collector after
cleaning with waste cloth.
Preparation
SPECIAL SERVICE TOOLS
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST20050010
Base plate
Inspecting diaphragm spring of clutch cover
ST20050100
Distance piece
Inspecting diaphragm spring of clutch cover
GG94310000
Flare nut torque
wrench
Removing and installing each clutch piping
KV30100100*
Clutch aligning bar
Installing clutch cover and clutch disc
ST20050240*
Diaphragm spring
adjusting wrench
Adjusting unevenness of diaphragm spring of clutch
cover
SBR820B
PRECAUTIONS AND PREPARATION
CL-2

Installation
IInstall the injection tubes, referring to the markings made dur-
ing removal.
IInstall the injection tubes in the order of No. 3, No. 4, No. 1, and
No. 2.
Injection nozzle oil seal
Removal
Using a tool such as a flat-bladed screwdriver, pry the flange of the
seal, then remove it.
Installation
After the injection nozzle assembly is installed, push the seal from
the cylinder head side until it contacts the flange.
IReplace the oil seal with new one when the injection nozzle
assembly is removed. (It is not necessary to replace the oil
seal when only injection tubes are removed.)
Spill tube
Installation
IAfter the spill tube is installed, check the airtightness of
the spill tube.
IAfter the bolts are tightened, the joint of the spill tube gasket
might be broken. However, this will not affect function.
Injection nozzle assembly
Removal
1. Remove the nozzle support, then pull out the injection nozzle
assembly by turning it clockwise/counterclockwise.
2. Using a tool such as a flat-head screwdriver, remove the cop-
per washer inside the cylinder head.
CAUTION:
Do not disassemble the injection nozzle.
Installation
1. Insert the nozzle gasket to the cylinder head hole.
2. Attach the O-ring to the mounting groove of the nozzle side,
then insert it in the cylinder head.
TEST AND ADJUSTMENT
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and make
sure your eyes are properly protected with goggles.
JEF248Z
JEF249Z
BASIC SERVICE PROCEDUREZD30DDTi
Injection Tube and Injection Nozzle (Cont'd)
EC-25

IIf the battery is disconnected, the emission-related diagnostic information will be lost after approx.
24 hours.
IErasing the emission-related diagnostic information using CONSULT-II is easier and quicker than
switching the diagnostic test mode using the data link connector.
NATS (Nissan Anti-Theft System)
IIf the security indicator lights up with the ignition switch in
the ªONº position or ªNATS MALFUNCTIONº is displayed
on ªSELF-DIAG RESULTSº screen, perform self-diagnostic
results mode with CONSULT-II using NATS program card.
Refer to ªNATS (Nissan Anti-Theft System)º in EL section.
IConfirm no self-diagnostic results of NATS is displayed
before touching ªERASEº in ªSELF-DIAG RESULTSº mode
with CONSULT-II.
IWhen replacing ECM, initialization of NATS system and
registration of all NATS ignition key IDs must be carried out
with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedures of NATS initialization and NATS
ignition key ID registration, refer to CONSULT-II operation
manual, NATS.
Malfunction Indicator (MI)
DESCRIPTION
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON with-
out the engine running. This is a bulb check.
IIf the MI does not light up, refer to EL section (ªWARNING
LAMPS AND CHIMEº) or see EC-291.
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has
detected an engine system malfunction.
If MI illuminates or blinks irregularly after starting engine,
water may have accumulated in fuel filter. Drain water from
fuel filter. Refer to MA section.
SEF252Z
SAT652J
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
Diagnostic Trouble Code (DTC) (Cont'd)
EC-34

On board diagnostic system function
The on board diagnostic system has the following three functions.
Diagnostic Test Mode KEY and ENG. Status Function Explanation of Function
Mode I Ignition switch in ON
position
Engine stopped
BULB CHECK This function checks the MI bulb for damage
(blown, open circuit, etc.).
If the MI does not come on, check MI circuit.
(See EC-291.)
Engine running
MALFUNCTION
WARNINGThis is a usual driving condition. When ECM
detects a malfunction, the MI will light up to
inform the driver that a malfunction has been
detected.
Mode II Ignition switch in ON
position
Engine stopped
SELF-DIAGNOSTIC RESULTS This function allows DTCs to be read.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
Malfunction Indicator (MI) (Cont'd)
EC-35

Diagnostic test mode I Ð Bulb check
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to EL
section, ªWARNING LAMPS AND CHIMEº or see EC-291.
Diagnostic test mode I Ð Malfunction warning
MI Condition
ON When the malfunction is detected or the ECM's CPU is malfunctioning.
OFF No malfunction.
Diagnostic test mode II Ð Self-diagnostic results
In this mode, DTC is indicated by the number of blinks of the MI as shown below.
Long (0.6 second) blinking indicates the two LH digits of number and short (0.3 second) blinking indicates the
two RH digits of number. For example, the MI blinks 10 times for 6 seconds (0.6 sec x 10 times) and then it
blinks three times for about 1 second (0.3 sec x 3 times). This indicates the DTC ª1003º.
In this way, all the detected malfunctions are classified by their DTC numbers. The DTC ª0505º refers to no
malfunction. (See TROUBLE DIAGNOSIS Ð INDEX, EC-7.)
How to erase diagnostic test mode II (Self-diagnostic results)
The DTC can be erased from the backup memory in the ECM when the diagnostic test mode is changed from
Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to ªHow to Switch Diagnostic Test Modesº, EC-36.)
IIf the battery terminal is disconnected, the DTC will be lost from the backup memory within 24
hours.
IBe careful not to erase the stored memory before starting trouble diagnoses.
SEF298QA
SEF162PB
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
Malfunction Indicator (MI) (Cont'd)
EC-37

Overall Function Check
Use this procedure to check the overall function of the cooling fan.
During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
WITH CONSULT-II
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-114.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-114.
3) Turn ignition switch ªONº.
4) Perform ªCOOLING FANº in ªACTIVE TESTº mode with CON-
SULT-II and make sure that cooling fans operate when touch-
ing ªHIGHº or ªLOWº.
If NG, go to ªDiagnostic Procedureº, EC-114.
WITHOUT CONSULT-II
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-114.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-114.
3) Disconnect engine coolant temperature sensor harness con-
nector.
4) Connect 150Wresistor to engine coolant temperature sensor
harness connector.
5) Start engine and make sure that cooling fan operates.
Be careful not to overheat engine.
6) If NG, go to ªDiagnostic Procedureº, EC-114.
AEC640
SEF111X
MEC475B
DTC 0208 OVER HEATZD30DDTi
EC-111

Description
SYSTEM DESCRIPTION
Sensor Input Signal to ECMECM
FunctionActuator
Crankshaft position
sensor (TDC)Engine speed
Glow
controlGlow lamp,
Glow relay
"
Glow plugs Engine coolant tem-
perature sensorEngine coolant tem-
perature
When engine coolant temperature is more than approximately 75ÉC
(167ÉF), the glow relay turns off, inactivating the quick-glow control
until coolant temperature drops below approximately 55ÉC (131ÉF).
When coolant temperature is lower than approximately 75ÉC
(167ÉF):
IIgnition switch ON
After ignition switch has turned to ON, the glow relay turns ON
for a certain period of time in relation to engine coolant
temperature, allowing current to flow through glow plug.
ICranking
The glow relay turns ON, allowing current to flow through glow
plug.
IStarting
After engine has started, current continues to flow through glow
plug (after-glow mode) for a certain period in relation to engine
coolant temperature.
When engine speed exceeds approximately 4,800 rpm, current
flow through glow plug is interrupted.
The glow indicator lamp turns ON for a certain period of time in
relation to engine coolant temperature at the time glow relay is
turned ON.
COMPONENT DESCRIPTION
Glow plug
IThe glow plug is provided with a ceramic heating element to
obtain a high-temperature resistance. It glows in response to a
signal sent from the ECM, allowing current to flow through the
glow plug via the glow relay.
IThis engine uses two types of glow plugs.
Type A has a blue or yellow paint mark.
Type B has no paint mark.
The location of the paint mark is shown in the figure.
WARNING:
Do not use two types of glow plugs at the same time.
SEF376Y
SEF280Z
GLOW CONTROL SYSTEMZD30DDTi
EC-239

Test and Adjustment
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and make
sure your eyes are properly protected with goggles.
INJECTION PRESSURE TEST
1. Install nozzle to injection nozzle tester and bleed air from flare
nut.
2. Pump the tester handle slowly (once per second) and watch the
pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
Used
12,259 - 12,749 kPa (122.6 - 127.5 bar,
120 - 130 kg/cm
2, 1,706 - 1,849 psi)
New
12,749 - 13,730 kPa (127.5 - 137.3 bar,
130 - 140 kg/cm
2, 1,849 - 1,991 psi)
Always check initial injection pressure using a new nozzle.
4. To adjust injection pressure, change adjusting shims. (No. 2 -
4 nozzle)
a. Increasing the thickness of adjusting shims increases ini-
tial injection pressure. Decreasing thickness reduces ini-
tial pressure.
b. A shim thickness of 0.04 mm (0.0016 in) corresponds
approximately to a difference of 471 kPa (4.71 bar, 4.8
kg/cm
2, 68 psi) in initial injection pressure.
Refer to SDS for adjusting shim.
EF791A
SEF672A
SEF427F
INJECTION NOZZLETD27Ti
EC-316