Nissan NAVARA D40 USER Manual

GENERAL INFORMATION

CONTENTS

PRECAUTIONS .........................................................1

Precautions for Supplemental Restraint

System (SRS) ‘‘AIR BAG’’ (4WD models).............1

Precautions for Supplemental Restraint

System (SRS) ‘‘AIR BAG’’ (2WD models).............1

Precautions for NATS............................................2

General Precautions..............................................2

Precautions for Multiport Fuel Injection System

or ECCS Engine ....................................................4

Precautions for Three Way Catalyst

(If so equipped)......................................................4

Precautions for Engine Oils...................................4

Precautions for Fuel...............................................5

Precautions for Air Conditioning............................6

HOW TO USE THIS MANUAL..................................7

HOW TO READ WIRING DIAGRAMS......................9

Sample/Wiring Diagram - EXAMPL - ....................9

Description...........................................................11

HOW TO CHECK TERMINAL.................................18

How to Probe Connectors ...................................18

How to Check Enlarged Contact Spring of

Terminal...............................................................19

Waterproof Connector Inspection........................20

Terminal Lock Inspection.....................................20

HOW TO PERFORM EFFICIENT DIAGNOSIS

FOR AN ELECTRICAL INCIDENT .........................21

Work Flow............................................................21

SECTION

HOW TO PERFORM EFFICIENT DIAGNOSIS......22

Incident Simulation Tests.....................................22

Circuit Inspection .................................................25

HOW TO FOLLOW FLOW CHART IN

TROUBLE DIAGNOSES .........................................31

How to Follow This Flow Chart ...........................32

CONSULT CHECKING SYSTEM............................34

Function and System Application........................34

Lithium Battery Replacement...............................34

Checking Equipment............................................35

Loading Procedure...............................................36

CONSULT Data Link Connector (DLC) Circuit ...36

IDENTIFICATION INFORMATION..........................37

Model Variation....................................................37

Identification Number...........................................40

Dimensions ..........................................................44

Wheels and Tires.................................................46

LIFTING POINTS AND TOW TRUCK TOWING.....47

Pantograph Jack..................................................47

Screw Jack...........................................................48

Garage Jack and Safety Stand ...........................49

2-pole Lift.............................................................50

Tow Truck Towing ...............................................51

Towing Point........................................................53

TIGHTENING TORQUE OF STANDARD BOLTS..54

SAE J1930 TERMINOLOGY LIST..........................55

SAE J1930 Terminology List...............................55

SGI646

PRECAUTIONS

Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.

Precautions for Supplemental Restraint System (SRS) ‘‘AIR BAG’’ (4WD models)

The Supplemental RestraintSystem ‘‘AIR BAG’’, used along with a seat belt, helps to reduce the risk or severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag module (located in the center of the steering wheel), a diagnosissensor unit, warning lamp,wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING:

● 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 must be performed by an authorized NISSAN dealer.

● Improper maintenance, including incorrect removal and

installation of the SRS, can lead to personal injury caused by unintentional activation of the system.

● Do not use electrical test equipment on any circuit

related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the harness connectors or for the complete harness, for easy identification.

Precautions for Supplemental Restraint System (SRS) ‘‘AIR BAG’’ (2WD models)

The Supplemental RestraintSystem ‘‘AIR BAG’’, used along with a seat belt, helps to reduce the risk or severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING:

● 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 must be performed by an authorized NISSAN dealer.

● Improper maintenance, including incorrect removal and

installation of the SRS, can lead to personal injury caused by unintentional activation of the system.

● Do not use electrical test equipment on any circuit

related to the SRS.

GI-1

SGI916

PRECAUTIONS

Precautions for NATS

NATS (Nissan Anti-Theft System)

NATS will immobilize the engine if someone tries to start it without the registered key of NATS. All of the originally supplied ignition key IDs have been NATS registered. The NATS security indicator is located on the instrument panel. The indicator blinks when the ignition switch is in ‘‘OFF’’ or ‘‘ACC’’ position. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.

● Gasoline engine:

When NATS detects trouble, the malfunction indicator lamp (MIL) blinks. This blinking indicates that the anti-theft is not functioning, so prompt service is required.

● Diesel engine:

When NATS detects trouble while engine is running or ignition switch in ‘‘ON’’ position, the NATS security indicator comes on. This indicates that the anti-theft is not functioning, so prompt service is required.

● When servicing NATS (trouble diagnoses, system initialisa-

tion and additional registration of other NATS ignition key IDs), CONSULT hardware and CONSULT NATS software is necessary. Regarding the procedures of NATS initialisation and NATS ignition key ID registration, refer to CONSULT operation manual, NATS.

Therefore, CONSULT NATS software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function.

● When servicing NATS (trouble diagnoses, system initialisa-

tion and additional registration of other NATS ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to receive all keys from vehicle owner. A maximum of four key IDs can be registered into NATS.

SGI285

General Precautions

● 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.

GI-2

SGI231

PRECAUTIONS

General Precautions (Cont’d)

● 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 them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.

● Before starting repairs which do not require battery power:

Turn off ignition switch. Disconnect the negative battery terminal.

SEF289H

SGI233

SGI234

● To prevent serious burns:

Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot.

● Before servicing the vehicle:

Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint.

● Clean all disassembled parts in the designated liquid or sol-

vent prior to inspection or assembly.

● Replace oil seals, gaskets, packings, O-rings, locking

washers, cotter pins, self-locking nuts, etc. with new ones.

● Replace inner and outer races of tapered roller bearings and

needle bearings as a set.

● Arrange the disassembled parts in accordance with their

assembled locations and sequence.

● Do not touch the terminals of electrical components which

use microcomputers (such as ECMs). Static electricity may damage internal electronic components.

GI-3

PRECAUTIONS

General Precautions (Cont’d)

● After disconnecting vacuum or air hoses, attach a tag to

indicate the proper connection.

● Use only the fluids and lubricants specified in this manual.

● Use approved bonding agent, sealants or their equivalents

when required.

● Use tools and recommended special tools where specified

for safe and efficient service repairs.

● When repairing the fuel, oil, water, vacuum or exhaust

systems, check all affected lines for leaks.

● Dispose of drained oil or the solvent used for cleaning parts

in an appropriate manner.

WARNING: To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the ECCS 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.

SGI787

Precautions for Multiport Fuel Injection System or ECCS Engine

● Before connecting or disconnecting any harness connector

for the multiport fuel injection system or ECM (Engine Control Module): 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.

Precautions for Three Way Catalyst (If so equipped)

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:

● Use unleaded gasoline only. Leaded gasoline will seriously

damage the three way catalyst.

● When checking for ignition spark or measuring engine

compression, make tests quickly and only when necessary.

● 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 Engine Oils

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

GI-4

PRECAUTIONS

Precautions for Engine Oils (Cont’d)

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

HEALTH PROTECTION PRECAUTIONS

● 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, kerosine, 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

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 on to the ground, down sewers or drains, or into water courses.

The regulations concerning the pollution of the environment will vary from country to country.

Precautions for Fuel

GASOLINE ENGINE:

Three way catalyst equipped models ... unleaded gasoline of at least 91 octane (RON)

CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst.

Except for the above models ... unleaded or leaded gasoline of above 88 octane (RON) Use unleaded fuel if instructed on the fuel filler lid.

GI-5

PRECAUTIONS

Precautions for Fuel (Cont’d)

DIESEL ENGINE*:

For Europe: diesel fuel of above 50 cetane * If two types of diesel fuel are available, use summer or win-

ter fuel properly according to the following temperature conditions.

● Above −7°C (20°F) ... Summer type diesel fuel.

● Below −7°C (20°F) ... Winter type diesel fuel.

CAUTION:

● Do not use home heating oil, gasoline, or other alternate

fuels in your diesel engine. The use of those can cause engine damage.

● Do not use summer fuel at temperature below −7°C

(20°F). The cold temperature will cause wax to form in the fuel. As a result, it may prevent the engine from running smoothly.

● Do not add gasoline or other alternate fuels to diesel

fuel.

Precautions for Air Conditioning

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

GI-6

HOW TO USE THIS MANUAL

● 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 mating 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, lubri-

cation 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.

SBR364AC

● 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.

GI-7

HOW TO USE THIS MANUAL

● The following SYMBOLS AND ABBREVIATIONS are used:

, : Tightening torque

: Should be lubricated with grease.

Unless otherwise indicated, use recommended multi-purpose

grease. : Should be lubricated with oil. : Sealing point : Checking point : Always replace after every disas-

sembly.

: Apply petroleum jelly.

: Apply ATF.

. : Select with proper thickness. > : Adjustment is required.

SDS : Service Data and Specifications LH, RH : Left-Hand, Right-Hand FR, RR : Front, Rear M/T : Manual Transaxle/Transmission A/T : Automatic Transaxle/Transmission

4WD : 4-Wheel Drive 2WD : 2-Wheel Drive A/C : Air Conditioner P/S : Power Steering SST : Special Service Tools SAE : Society of Automotive Engineers,

ATF : Automatic Transmission Fluid D

OD : Overdrive 2

Inc.

: Drive range 1st gear : Drive range 2nd gear : Drive range 3rd gear : Drive range 4th gear

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

● 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.

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

of data.

● 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.

GI-8

HOW TO READ WIRING DIAGRAMS

● For Description, refer to GI-11.

Sample/Wiring Diagram — EXAMPL —

GI-9

YGI001

HOW TO READ WIRING DIAGRAMS

Sample/Wiring Diagram — EXAMPL — (Cont’d)

OPTIONAL SPLICE

SGI942

GI-10

HOW TO READ WIRING DIAGRAMS

Description

Number Item Description

Power condition

Fusible link

Fusible link/fuse location

Fuse

Current rating ● This shows the current rating of the fusible link or fuse.

Connectors

Optional splice ● The open circle shows that the splice is optional depending on vehicle application. Splice ● The shaded circle shows that the splice is always on the vehicle.

Page crossing

Common connector

Option abbreviation ● This shows that the circuit is optional depending on vehicle application.

Relay

Connectors

Wire color

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

Switch

Assembly parts

Cell code

● This shows the condition when the system receives battery positive voltage (can

be operated).

● The double line shows that this is a fusible link.

● The open circle shows current flow in, and the shaded circle shows current flow

out.

● This shows the location of the fusible link or fuse in the fusible link or fuse box.

For arrangement, refer to EL section (‘‘POWER SUPPLY ROUTING’’).

● The single line shows that this is a fuse.

● The open circle shows current flow in, and the shaded circle shows current flow

out.

● This shows that connector

● The G/R wire is located in the 1A terminal of both connectors.

● Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is

SMJ connector. Refer to GI-17.

● This arrow shows that the circuit continues to an adjacent page.

● The A will match with the A on the preceding or next page.

● The dotted lines between terminals show that these terminals are part of the same

connector.

● This shows an internal representation of the relay. For details, refer to EL section

(‘‘STANDARDIZED RELAY’’).

● This shows that the connector is connected to the body or a terminal with bolt or

nut.

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

B = Black BR = Brown W = White OR = Orange R = Red P = Pink G = Green PU = Purple L = Blue GY = Gray Y = Yellow SB = Sky Blue LG = Light Green CH = Dark Brown

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

● 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.

● Connector terminal in component shows that it is a harness incorporated assem-

bly.

● This identifies each page of the wiring diagram by section, system and wiring dia-

gram page number.

is female and connector

DG = Dark Green

is male.

GI-11

HOW TO READ WIRING DIAGRAMS

Description (Cont’d)

Number Item Description

● Arrow indicates electric current flow, especially where the direction of standard

Current flow arrow

System branch

Page crossing

Shielded line ● The line enclosed by broken line circle shows shield wire. Component box in wave

line Component name ● This shows the name of a component.

Connector number

Ground (GND)

Ground (GND) ● This shows the ground connection.

Connector views

Common component

Connector color

Fusible link and fuse box

Reference area

flow (vertically downward or horizontally from left to right) is difficult to follow.

● A double arrow ‘‘b

on circuit operation.

● This shows that the system branches to another system identified by cell code

(section and system).

● This arrow shows that the circuit continues to another page identified by cell code.

● The C will match with the C on another page within the system other than the next

or preceding pages.

● This shows that another part of the component is also shown on another page

(indicated by wave line) within the system.

● This shows the connector number.

● The letter shows which harness the connector is located in.

Example: M: main harness. For detail and to locate the connector, refer to EL section (‘‘Main Harness’’, ‘‘HARNESS LAYOUT’’). A coordinate grid is included for complex harnesses to aid in locating connectors.

● The line spliced and grounded under wire color shows that ground line is spliced

at the grounded connector.

● This area shows the connector faces of the components in the wiring diagram on

the page.

● Connectors enclosed in broken line show that these connectors belong to the

same component.

● This shows a code for the color of the connector. For code meaning, refer to wire

color codes, Number

● This shows the arrangement of fusible link(s) and fuse(s), used for connector

views of ‘‘POWER SUPPLY ROUTING’’ in EL section. The open square shows current flow in, and the shaded square shows current flow out.

● This shows that more information on the Super Multiple Junction (SMJ) and Joint

Connectors (J/C) exists on the foldout page. Refer to GI-17 for details.

—

c’’ shows that current can flow in either direction depending

of this chart.

GI-12

HOW TO READ WIRING DIAGRAMS

Description (Cont’d)

CONNECTOR SYMBOLS

Most of connector symbols in wiring diagrams are shown from the terminal side.

● Connector symbols shown from the terminal side are

enclosed by a single line and followed by the direction mark

● Connector symbols shown from the harness side are

enclosed by a double line and followed by the direction mark

SGI364

SGI363

● Male and female terminals

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

GI-13

HOW TO READ WIRING DIAGRAMS

Description (Cont’d)

Harness indication

● Letter designations next to test meter probe indicate harness

(connector) wire color.

● Connector numbers in a single circle

connectors.

Component indication

● Connector numbers in a double circle F211 indicate compo-

nent connectors.

M33

indicate harness

AGI070

SGI860

SWITCH POSITIONS

Switches are shown in wiring diagrams as if the vehicle is in the ‘‘normal’’ condition. A vehicle is in the ‘‘normal’’ condition when:

● ignition switch is ‘‘OFF’’,

● doors, hood and trunk lid/back door are closed,

● pedals are not depressed, and

● parking brake is released.

GI-14

HOW TO READ WIRING DIAGRAMS

Description (Cont’d)

DETECTABLE LINES AND NON-DETECTABLE LINES

In some wiring diagrams, two kinds of lines, representing wires, with different weight are used.

● A line with regular weight (wider line) represents a ‘‘detect-

able line for DTC (Diagnostic Trouble Code)’’. A ‘‘detectable line for DTC’’ is a circuit in which ECM (Engine Control Module) can detect its malfunctions with the on board diagnostic system.

● A line with less weight (thinner line) represents a ‘‘non-de-

tectable 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.

SGI862-A

GI-15

HOW TO READ WIRING DIAGRAMS

Description (Cont’d)

MULTIPLE SWITCH

The continuity of multiple switch is described in two ways as shown below.

● The switch chart is used in schematic diagrams.

● The switch diagram is used in wiring diagrams.

GI-16

SGI875

HOW TO READ WIRING DIAGRAMS

Description (Cont’d)

FOLDOUT PAGE

The foldout page should be opened when reading wiring diagram.

Super multiple junction (SMJ)

In wiring diagram,connectors consisting ofterminals having terminalnumbers with analphabet (1B, 0D, etc.) are SMJ connectors. If connector numbers are shown in Reference Area, these connector symbols are not shown in Connector Area. For terminal arrangement of these connectors, refer to the foldout page at the end of this manual.

Joint connector

Joint connector symbols are shown in Connector Area in the wiring diagram concerned. Foldout page also carries inside wiring layout together with such joint connector symbols.

GI-17

SGI943

+ 41 hidden pages