2002 NISSAN TERRANO g sensor

AUTOMATIC TRANSMISSION
SECTION
AT
CONTENTS
PREPARATION AND PRECAUTIONS............................3
Special Service Tools ..................................................3
Supplemental Restraint System (SRS)²AIR
BAG²and²SEAT BELT PRE-TENSIONER²...............4
Precautions ..................................................................4
Service Notice or Precautions .....................................5
OVERALL SYSTEM........................................................6
A/T Electrical Parts Location .......................................6
Wiring Diagram - A/T -.................................................7
Cross-sectional View ...................................................8
Hydraulic Control Circuits ............................................9
Shift Mechanism ........................................................10
Control System ..........................................................12
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION...............................................................14
Self-diagnosis ............................................................14
Diagnosis by CONSULT-II .........................................20
TROUBLE DIAGNOSIS - Introduction........................22
Introduction ................................................................22
Diagnostic Worksheet ................................................23
Work Flow ..................................................................26
TROUBLE DIAGNOSIS - Basic Inspection................27
A/T Fluid Check .........................................................27
Stall Test ....................................................................27
Line Pressure Test .....................................................30
Road Test...................................................................32
TROUBLE DIAGNOSIS - General Description...........43
Symptom Chart ..........................................................43
TCM Terminals and Reference Value........................46
TROUBLE DIAGNOSIS FOR VHCL SPEED
SEN×A/T.........................................................................49
Wiring Diagram - AT - VSSA/T ..................................49
Vehicle Speed Sensor×A/T (Revolution sensor) ........50
TROUBLE DIAGNOSIS FOR VHCL SPEED
SEN×MTR.......................................................................52
Wiring Diagram - AT - VSSMTR ................................52
Vehicle Speed Sensor×MTR ......................................54TROUBLE DIAGNOSIS FOR THROTTLE POSI
SEN................................................................................56
Wiring Diagram - AT - TPS ........................................56
Throttle (Accelerator) Position Sensor ......................60
TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V
A.....................................................................................62
Wiring Diagram - AT - SSV/A ....................................62
Shift Solenoid Valve A ...............................................63
TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V
B.....................................................................................65
Wiring Diagram - AT - SSV/B ....................................65
Shift Solenoid Valve B ...............................................66
TROUBLE DIAGNOSIS FOR OVERRUN CLUTCH
S/V..................................................................................68
Wiring Diagram - AT - OVRCSV................................68
Overrun Clutch Solenoid Valve .................................69
TROUBLE DIAGNOSIS FOR T/C CLUTCH SOL/V.....71
Wiring Diagram - AT - TCV........................................71
Torque Converter Clutch Solenoid Valve ..................72
TROUBLE DIAGNOSIS FOR BATT/FLUID TEMP
SEN................................................................................75
Wiring Diagram - AT - BA/FTS ..................................75
A/T Fluid Temperature Sensor and TCM Power
Source........................................................................76
TROUBLE DIAGNOSIS FOR ENGINE SPEED SIG....79
Wiring Diagram - AT - ENGSS ..................................79
Engine Speed Signal .................................................80
TROUBLE DIAGNOSIS FOR LINE PRESSURE
S/V..................................................................................82
Wiring Diagram - AT - LPSV......................................82
Line Pressure Solenoid Valve ...................................84
TROUBLE DIAGNOSIS FOR NON-DETECTABLE
ITEMS.............................................................................87
Wiring Diagram - AT - PNP/SW.................................87
Park/neutral Position, Overdrive Control or
Throttle (Accelerator) Position Switches ...................88
DIAGNOSTIC PROCEDURES FOR SYMPTOMS........94

1. SPORT Indicator Lamp Does Not Come On ........94
2. SPORT or SNOW Indicator Lamp Does Not
Come On...................................................................95
3. O/D OFF Indicator Lamp Does Not Come On......95
4. SPORT Indicator Lamp Does Not Come On ........96
5. Engine Cannot Be Started In²P²and²N²
Position......................................................................97
6. In²P²Position, Vehicle Moves Forward Or
Backward When Pushed...........................................97
7. In²N²Position, Vehicle Moves .............................98
8. Large Shock.²N²->²R²Position .........................99
9. Vehicle Does Not Creep Backward In²R²
Position....................................................................100
10. Vehicle Does Not Creep Forward In²D²,²2²
Or²1²Position.........................................................101
11. Vehicle Cannot Be Started From D
1.................102
12. A/T Does Not Shift: D
1-> D2Or Does Not
Kickdown: D
4-> D2..................................................103
13. A/T Does Not Shift: D
2-> D3............................104
14. A/T Does Not Shift: D
3-> D4.............................105
15. A/T Does Not Perform Lock-up .........................106
16. A/T Does Not Hold Lock-up Condition ..............107
17. Lock-up Is Not Released ...................................107
18. Engine Speed Does Not Return To Idle (Light
Braking D
4-> D3) .....................................................108
19. Vehicle Does Not Start From D
1.......................109
20. A/T Does Not Shift: D
2-> D1When
Depressing Accelerator Pedal................................. 110
21. A/T Does Not Shift: D
4-> D3, When
Overdrive Control Switch²ON²->²OFF²............... 111
22. A/T Does Not Shift: D
3-> 22, When Selector
Lever²D²->²2²Position......................................... 111
23. A/T Does Not Shift: 2
2-> 11, When Selector
Lever²2²->²1²Position ......................................... 112
24. Vehicle Does Not Decelerate By Engine
Brake........................................................................ 112
ON-VEHICLE SERVICE.............................................. 113Control Valve Assembly and Accumulators ............. 113
Revolution Sensor Replacement ............................. 114
Rear Oil Seal Replacement ..................................... 114
Parking Components Inspection.............................. 114
Park/neutral Position Switch Adjustment ................. 114
Manual Control Linkage Adjustment........................ 115
REMOVAL AND INSTALLATION................................ 116
Removal ................................................................... 116
Installation ................................................................ 117
MAJOR OVERHAUL................................................... 119
Oil Channel ..............................................................121
Locations of Needle Bearings, Thrust Washers
and Snap Rings .......................................................122
DISASSEMBLY............................................................123
Disassembly.............................................................123
REPAIR FOR COMPONENT PARTS..........................134
Oil Pump ..................................................................134
Control Valve Assembly ...........................................138
Control Valve Upper Body .......................................144
Control Valve Lower Body .......................................149
Reverse Clutch ........................................................151
High Clutch ..............................................................155
Forward and Overrun Clutches ...............................157
Low & Reverse Brake..............................................161
Forward Clutch Drum Assembly ..............................165
Rear Internal Gear and Forward Clutch Hub ..........168
Band Servo Piston Assembly ..................................171
Parking Pawl Components ......................................175
ASSEMBLY..................................................................177
Assembly (1) ............................................................177
Adjustment ...............................................................185
Assembly (2) ............................................................188
A/T FLUID COOLER SYSTEM...................................195
A/T Fluid Cooler.......................................................195
SERVICE DATA AND SPECIFICATIONS (SDS)........196
General Specifications .............................................196
Specifications and Adjustment.................................196
When you read wiring diagrams:
IRead GI section, ªHOW TO READ WIRING DIAGRAMSº.
ISee EL section, ªPOWER SUPPLY ROUTINGº for power distribution circuit.
When you perform trouble diagnoses, read GI section, ªHOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSESº and ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRI-
CAL INCIDENTº.
CONTENTS(Cont'd)
AT- 2

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 in a frontal collision.
The SRS system composition which is available to NISSAN MODEL R20 is as follows (The composition var-
ies according to the destination.):
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 pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
Information necessary to service the system safely is included in theRS sectionof 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 must be performed
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 either just before
the harness connectors or for the complete harness are related to the SRS.
Precautions
IBefore proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to
prevent the internal parts from becoming contaminated by dirt or other foreign matter.
IDisassembly should be done in a clean work area.
IUse lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could inter-
fere with the operation of the transmission.
IPlace disassembled parts in order for easier and proper assembly.
IAll parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
IGaskets, seals and O-rings should be replaced any time the transmission is disassembled.
IIt is very important to perform functional tests whenever they are indicated.
IThe valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place removed parts in a parts rack in order to replace them in correct positions and sequences. Care will
also prevent springs and small parts from becoming scattered or lost.
IProperly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
IBefore assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, and to hold bearings and washers in place during assembly. Do not use grease.
IExtreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
IAfter overhaul, refill the transmission with new ATF.
IWhen the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque
converter and ATF cooling system.
Always follow the procedures under ªChanging A/T Fluidº in the MA section when changing A/T fluid.
PREPARATION AND PRECAUTIONS
AT- 4

Service Notice or Precautions
FAIL-SAFE
The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major
electrical input/output device circuit is damaged.
Under Fail-Safe, the vehicle always runs in third gear even with a shift lever position of ª1º, ª2º or ªDº. Cus-
tomer may complain of ªsluggish or poor accelerationº.
When the Fail-Safe operation occurs the next time the key is turned to the ªONº position, the SPORT indica-
tor lamp will blink for about 8 seconds. (For diagnosis, refer to AT-33.)
Fail-Safe may activate without electrical circuit damages if the vehicle is driven under extreme conditions (such
as excessive wheel spins and emergency braking immediately afterwards). In this case, turn the ignition key
ªOFFº for 5 seconds and then ªONº to recover normal shift pattern.
The blinking of the SPORT indicator lamp for about 8 seconds will appear only once and be cleared. The cus-
tomer may resume normal driving conditions by chance.
Always follow the ªWORK FLOWº (Refer to AT-26).
The SELF-DIAGNOSIS results will be as follows:
The first SELF-DIAGNOSIS will indicate the damage of the vehicle speed sensor or the revolution sensor.
During the next SELF-DIAGNOSIS performed after checking the sensor, no damages will be indicated.
PREPARATION AND PRECAUTIONS
AT- 5

Control System
OUTLINE
The automatic transmission senses vehicle operating conditions through various sensors. It always controls
the optimum shaft position and reduces shifting and lock-up shocks.
SENSORSTCMACTUATORS
Park/neutral position switch
Throttle (accelerator) position
sensor
Closed throttle position switch
Wide open throttle position
switch
Engine speed signal
A/T fluid temperature sensor
Revolution sensor
Vehicle speed sensor
Overdrive control switch
A/T mode switch
E
Shift control
Line pressure control
Lock-up control
Overrun clutch control
Timing control
Fail-safe control
Self-diagnosis
Duet-EU control
CONSULT-II communication line
control
E
Shift solenoid valve A
Shift solenoid valve B
Overrun clutch solenoid valve
Torque converter clutch
solenoid valve
Line pressure solenoid valve
O/D OFF or SPORT indicator
lamp
CONTROL SYSTEM
NAT230
OVERALL SYSTEM
AT-12

TCM FUNCTION
The function of the TCM is to:
IReceive input signals sent from various switches and sensors.
IDetermine required line pressure, shifting point, lock-up operation, and engine brake operation.
ISend required output signals to the respective solenoids.
INPUT/OUTPUT SIGNAL OF TCM
Sensors and solenoid valves Function
InputPark/neutral position switch Detects select lever position and sends a signal to TCM.
Throttle (accelerator) position sensor Detects throttle valve position and sends a signal to TCM.
Closed throttle position switch Detects throttle valve's fully-closed position and sends a signal to TCM.
Wide open throttle position switchDetects a throttle valve position of greater than 1/2 of full throttle and sends a
signal to TCM.
Engine speed signal From ECM.
A/T fluid temperature sensor Detects transmission fluid temperature and sends a signal to TCM.
Revolution sensor Detects output shaft rpm and sends a signal to TCM.
Vehicle speed sensorUsed as an auxiliary vehicle speed sensor. Sends a signal when revolution sen-
sor (installed on transmission) malfunctions.
Overdrive control switch
A/T mode switchSends a signal, which prohibits a shift to ªD
4º (overdrive) position, to the TCM.
OutputShift solenoid valve A/BSelects shifting point suited to driving conditions in relation to a signal sent from
TCM.
Line pressure solenoid valveRegulates (or decreases) line pressure suited to driving conditions in relation to
a signal sent from TCM.
Torque converter clutch solenoid valveRegulates (or decreases) lock-up pressure suited to driving conditions in relation
to a signal sent from TCM.
Overrun clutch solenoid valveControls an ªengine brakeº effect suited to driving conditions in relation to a sig-
nal sent from TCM.
O/D OFF indicator lamp
SPORT indicator lampShows TCM malfunctions, when A/T control components malfunction.
OVERALL SYSTEM
Control System (Cont'd)
AT-13

Self-diagnosis
After performing this procedure, place check marks for results on
the ªDIAGNOSTIC WORKSHEETº, AT-24. Reference pages are
provided following the items.
SELF-DIAGNOSTIC PROCEDURE (With CONSULT-II)
1. Turn on CONSULT-II and touch ªA/Tº.
If A/T is not displayed, check TCM power supply and ground
circuit. Refer to AT-46. If result is NG, refer to EL section
(ªPOWER SUPPLY ROUTINGº).
2. Touch ªSELF-DIAG RESULTSº.
Display shows malfunction experienced since the last erasing
operation.
CONSULT-II performs REAL-TIME SELF-DIAGNOSIS.
Also, any malfunction detected while in this mode will be dis-
played at real time.
Item Display Description Remarks
No failure
****NO FAILURE
****INo failure has been detected.
Initial start
*INITIAL START
*IThis is NOT a malfunction message.
Whenever shutting off a power supply to the
TCM, this message appears on the screen.
[]
Vehicle speed
sensor×A/T
(Revolution sensor)VHCL SPEED SEN×A/TINo signal input from vehicle speed sensor×A/T (revolution
sensor) during traveling due to disconnection, or input of
abnormal signal.
Vehicle speed
sensor×MTR (Meter)VHCL SPEED SEN×MTRINo signal input from vehicle speed sensor×MTR during
traveling due to disconnection, or input of abnormal signal.
Throttle (accelerator)
position sensorTHROTTLE POSI SENIThrottle (accelerator) position sensor signal voltage is
abnormally high.
IThrottle (accelerator) position sensor signal voltage is
abnormally low with closed throttle position switch ªOFFº
or wide open throttle position switch ªONº.
Shift solenoid valve A SHIFT SOLENOID/V AISpecified voltage is not applied to solenoid valve due to
disconnection or shortcircuit.
Shift solenoid valve B SHIFT SOLENOID/V BISpecified voltage is not applied to solenoid valve due to
disconnection or shortcircuit.
Overrun clutch
solenoid valveOVERRUN CLUTCH S/VISpecified voltage is not applied to solenoid valve due to
disconnection or shortcircuit.
T/C clutch solenoid
valveT/C CLUTCH SOL/VISpecified voltage is not applied to solenoid valve due to
disconnection or shortcircuit.
A/T fluid temperature
sensor/TCM power
sourceBATT/FLUID TEMP SENISupply voltage to TCM is abnormally low during traveling.
IFluid temperature signal voltage is abnormally high
(fluid temperature is low) during traveling.To be dis-
played in case
of abnormality
and no record-
ing is made Engine speed signal ENGINE SPEED SIGIEngine RPM is abnormally low during traveling.
Line pressure
solenoid valveLINE PRESSURE S/VISpecified voltage is not applied to solenoid valve due to
disconnection or shortcircuit.
TCM (ROM) CONTROL UNIT (ROM)ITCM memory (ROM) is malfunctioning.
TCM (RAM) CONTROL UNIT (RAM)ITCM memory (RAM) is malfunctioning.
SAT014K
SAT987J
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
AT-14

JUDGEMENT OF SELF-DIAGNOSIS CODE
SPORT indicator lamps
All judgement flickers are same.
SAT819H
All circuits that can be confirmed by self-diagnosis are OK.
4th judgement flicker is longer than others.
SAT797H
Shift solenoid valve A circuit is short-circuited or discon-
nected.
Go to SHIFT SOLENOID VALVE A, AT-63.
1st judgement flicker is longer than others.
SAT794H
Revolution sensor circuit is short-circuited or disconnected.
Go to VEHICLE SPEED SENSOR×A/T (REVOLUTION
SENSOR), AT-50.
5th judgement flicker is longer than others.
SAT798H
Shift solenoid valve B circuit is short-circuited or discon-
nected.
Go to SHIFT SOLENOID VALVE B, AT-66.
2nd judgement flicker is longer than others.
SAT795HVehicle speed sensor circuit is short-circuited or discon-
nected.
Go to VEHICLE SPEED SENSOR×MTR, AT-54.
6th judgement flicker is longer than others.
SAT799H
Overrun clutch solenoid valve circuit is short-circuited or dis-
connected.
Go to OVERRUN CLUTCH SOLENOID VALVE, AT-69.
3rd judgement flicker is longer than others.
SAT796H
Throttle (accelerator) position sensor circuit is short-circuited
or disconnected.
Go to THROTTLE (ACCELERATOR) POSITION
SENSOR, AT-60.
7th judgement flicker is longer than others.
SAT800H
Torque converter clutch solenoid valve circuit is short-cir-
cuited or disconnected.
Go to TORQUE CONVERTER CLUTCH SOLENOID
VALVE, AT-72.
t1= 2.5 seconds t2= 2.0 seconds t3= 1.0 second
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Self-diagnosis (Cont'd)
AT-17