N Step 1 Nissan

POLICIES & OPERATIONS MAUNAL (POM)
N-STEP1 POM
SKILL ASSESSMENT
TEXTBOOK
AUTOMOBILE FUNDAMENTALS
GENERALTOOLS AND
3S POLICY
INSTRUCTOR GUIDE
WORKSHEET
TRANSPARENCIES
CORPORATE PHILOSOPHY
Our first commitment is to customer satisfaction. Through diligent efforts to develop new customers
and expand our customer base we are contributing to the ongoing progress and enrichment of society.
CORPORATE PRINCIPLES
1. To create attractive products by capitalizing on the companys innovative and highly reliable
technologies, staying in constant touch with the needs of the global market.
2. To be sensitive to customers needs and offer them maximum satisfaction based on steadfast
sincerity and ceaseless efforts to meet their requirements.
3. To focus on global trends, making the world the stage for our activities, and to nurture a strong
company that will grow with the times.
4. To foster the development of an active and vital group of people who are ready and willing at all
times to take on the challenge of achieving new goals.
NISSAN MOTOR CO., LTD.
Issued: March 2002
FOREWORD
Recently, it has become more difficult to carry out repairs due to the advanced computer controlled
systems and highly sophisticated mechanisms equipped on vehicles. As customers come to have
expectations of their vehicles, technicians need to have a variety of sophisticated technical skills.
It is very important for technicians to improve their technical skills and be familiar with the latest
high-service techniques in order to FIX IT RIGHT THE FIRST TIME and gain CUSTOMER SATISFACTION.
To meet these requirements, we have established the Nissan Service Technician Education Program, or N-STEP.
N-STEP provides systematic training for you and your technicians that aims at providing highly
skilled and highly motivated professionals. Professionalism can only be enhanced by actually honing skills in the service shop. N-STEP, therefore, is an educational program that ensure the highest
skill level and that Fix it right the first time will be consistently achieved.
Edition: March 2002

Printing: March 2002
Publication No. NS2E-NPOMG1
2002
Issued: March 2002
Application of the manual

Purpose of this manual
The purpose of this Policies and Operations Manual is to provide a guide on how to use NSTEP and to explain the following:
- the N-STEP concept
- the introduction process
- the implementation process
This manual should be used not only before implementing N-STEP, but also during or after the
implementation stage, as an active guide for the effective application of the N-STEP system.
For whom
This manual should be used by:
- Training Managers and Service Managers responsible for technical training (as a guide to
make their original N-STEP manual modified depending on their specific conditions.)
- Technical instructors as a guide how to use the N-STEP material and how to assemble
courses.
Issued: March 2002
Definition of terms
The terms used in this N-STEP Policies and Operations Manual are defined as follows.
(1)
Service jobs include pre-delivery inspection, maintenance, parts installation, trouble diagnosis, repair work and regular inspection in the service shop.
(2)
Technicians are mechanics or specialists actually working on service jobs.
(3)
Service shop means a NSCs (National Sales Company) own service shop, a dealers
shop, or a private service shop authorized by the NSC.
(4)
Rank refers to a certified title which is given to a technician who has fulfilled the technical
qualifications of appropriate rank.
(5)
N-STEP training refers to the training conducted by the NSCs under N-STEP to develop
the skills and abilities of service shop technicians.
(6)
STEP indicates the level of the training objectives required.
(7)
Technical qualifications refer to the essential skills and knowledge required so that technicians can carry out their service jobs properly in the service shop.
(8)
Instructor refers to the person in a NSC implementing the N-STEP training for the technicians.
(9)
Topics refer to the modules which the training course consists of.
(10)
Course refers to a training segment consisting of a combination of topics. The training

course curriculum should include the designated topics that cover vehicle specifications in
each market.
(11)
Skill assessment refers to the evaluation of technicians by a person authorized by a NSC to

verify whether technicians satisfy the technical requirements.
(12)
Screening refers to the evaluation to the technicians who have already achieved that level.
Issued: March 2002
Contents
I
II
N-STEP Basic Policies

I-1
N-STEP outline
I-2
Benefits
Training policies
II-1
Skill Matrix
II-1-1
II-1-2
II-1-3
II-2
Performance Based Learning
II-3
Training material package

II-3-1
II-3-2
II-3-3
II-3-4
II-3-5
III
IV
Master Skill Matrix

Active Skill Matrix
Training course description
Package contents
Use of the training material package
Up-date of training material
Materials supply
Training period
Skill assessment
III-1
Aim of skill assessment
III-2
Skill assessor
III-3
Skill assessment timing
III-4
Skill assessment materials
III-5
Skill assessment flow
Ranking policies
IV-1
Aim of ranking
IV-2
Definition of rank
IV-3
Technical qualification for each rank

IV-3-1
IV-3-2
IV-3-3
IV-3-4
IV-4
TECHNICIAN rank
SPECIALIST rank
SENIOR SPECIALIST rank
MASTER TECHNICIAN rank
Necessary conditions for each rank

IV-4-1
IV-4-2
IV-4-3
IV-4-4
To become TECHNICIAN
To become SPECIALIST
To become SENIOR SPECIALIST
To become MASTER TECHNICIAN
Issued: March 2002
IV-5
Necessary conditions for keeping each rank

IV-5-1
IV-5-2
IV-5-3
IV-5-4
TECHNICIAN rank
SPECIALIST rank
SENIOR SPECIALIST rank
MASTER TECHNICIAN rank
Screening
V-1
Aim of screening
V-2
Screening procedure
VI
Certification
VII
Training and certification record
VIII
N-STEP Operations
VIII-1
Preparation for implementation of N-STEP
VIII-2
Implementation procedure
Attachment
Attachment 1
The topics for STEP 1, 2 and 3
Attachment 2
Sample of training materials
Attachment 3
Sample of assessment sheets
Issued: March 2002
Section I
N-STEP Policies & Operations Manual
I N-STEP Basic Policies

I-1 N-STEP outline
The N-STEP (Nissan Service Technician Education Program) has been established
to systematize training and to set a ranking structure for service shop technicians. It
provides the following features:
1. Professional development of service shop technicians is possible through education and experience in N-STEP.
2. Technicians can receive individual recognition depending on their achievements.
3. Service shops can establish efficient organizations by assigning more appropriate technicians to their jobs.
4. NSCs can easily set up their own training courses using N-STEP training materials as the N-STEP training curriculum is composed of small, easy to customize
modules.
These are the ranks of technician achievement within N-STEP:
STEP
Rank
MASTER TECHNICIAN
SENIOR ENGINE SPECIALIST
STEP3
SENIOR CHASSIS SPECIALIST
ENGINE SPECIALIST
STEP2
CHASSIS SPECIALIST
ELECTRICAL SPECIALIST
STEP1
TECHNICIAN
Technicians in service shop can progress to each level upon successful completion
of each level of training courses and evaluation of work experience. As a result, technicians will receive certification for each rank.
The experienced, educated Nissan technicians can increase service profits at dealer,
reduce repeat repair jobs and customer dissatisfaction, and consequently enhance
customer retention and repeat vehicle sales.
N-STEP directly supports FIX IT RIGHT THE FIRST TIME and gaining CUSTOMER SATISFACTION.
Issued: March 2002
Section I
Skill requirement
for each step
STEP 1
STEP 2
STEP 3
The training presented at this

level will enable the trainees to
acquire
- fundamental knowledge of the
specifications and features of
the Nissan vehicles.
- perform pre-delivery inspection and periodic maintenance.
The training presented at this level will enable the

trainees to acquire
- the functions and operations of each mechanism.
- to inspect, tune.
- to diagnose and carry out simple repairs using
CONSULT and necessary equipments.
- to overhaul.
The training presented at this level will enable the trainees to acquire
- to diagnose and fix difficult incidents of
driveability.
- to diagnose and fix difficult incidents of
noise and vibration.
- to diagnose and carry out other difficult
repairs.
STEP 3
STEP 2
2 years
STEP
STEP
STEP 11
3 years
Expected period required for

trainees to obtain certificate
0-2 years
TECHNICIAN
Affected trainees
New employees and apprentices
Technical categories
1.
2.
3.
4.
Fundamentals
Tool
Maintenance
Express Service
Contents of training course
ENGINE
ELECTRICAL
CHASSIS
1. Gasoline Engine
Management
System
2. Gasoline Engine
Mechanical Repair
3. Carburetor Engine
Management
System
4. Diesel Engine
Management
System
5. Diesel Engine
Mechanical Repair
6. Engine Electrical
7. CONSULT
Advanced
1. Electronics
2. Electrical
Troubleshooting
3. Body Electrical
4. Engine Electrical
5. CONSULT Advanced
6. Heater & Air
Conditioner Operation
1. Suspension
Diagnosis and Repair
2. Steering Diagnosis
and Repair
3. Brake Diagnosis and
Repair
4. Manual Transmission
Fundamentals and
Diagnosis
5. Manual Transmission
Repair
6. Automatic Transmission Fundamentals
and Diagnosis
7. Automatic Transmission Repair
8. CVT Diagnosis
9. CVT Repair
10. Final Drive and Drive
Line
Skill assessment
Evaluation
Skill assessment
Skill assessment
Skill assessment
ENGINE
SPECIALIST
Name of ranking &
certification
ENGINE and
ELECTRICAL
SPECIALIST
ELECTRICAL
SPECIALIST
CHASSIS
SPECIALIST
CHASSIS and
ELECTRICAL
SPECIALIST
ENGINE
CHASSIS
1. Gasoline Engine
Diagnosis and
Repair
2. Diesel Engine
Diagnosis and
Repair
3. Carburetor
Engine Diagnosis
and Repair
4. Vibration and
Noise Fundamentals
5. Vibration and
Noise Engine
Diagnosis
1. Automatic Transmission Diagnosis

and Repair
2. Suspension
Diagnosis and
Repair
3. Electrical System
Diagnosis and
Repair
4. Vibration and
Noise Fundamentals
5. Vibration and
Noise Chassis
Diagnosis
6. Heater & Air
Conditioner
Diagnosis and
Repair
Skill
assessment
Skill
assessment
SENIOR
SENIOR
ENGINE
CHASSIS
SPECIALIST SPECIALIST
SENIOR ENGINE and

CHASSIS SPECIALIST
MASTER
TECHNICIAN
TECHNICIAN
Issued: March 2002
Section I
I-2 Benefits
Training
N-STEP makes it possible
for NSC to:
- standardize and implement a high quality training course.
- reduce manpower to develop training course and reduce training and course
preparation time.
- plan effective and flexible training by using course modules.
- implement effective training by using new training materials.
- measure the achievement level of technicians using the objectives of each
course.
for dealers to:
- decide who should be suitable to receive training.
- steadily raise their overall skill level.
for technicians to:
- understand the training objectives.
Ranking
N-STEP makes it possible
for NSC to:
- support the creation of a practical and efficient service shop organization.
- understand dealers overall skill level.
for dealers to:
- evaluate each technicians skills.
- more effectively and appropriately assign service jobs to technicians.
for technicians to:
- receive motivation and encouragement.
- receive accurate appraisal of their skill level
- easily recognize their current skill level.
Issued: March 2002
Section II
II Training policies
II-1 Skill Matrix
II-1-1 Master Skill Matrix
The N-STEP training concept is based on the formation of a set of skills required for
the technician. This set of skills is laid down in a so called the Master Skill Matrix.
The Master Skill Matrix describes all skills with which a technician can perform service and repair of the complete Nissan model line-up.
The Master Skill Matrix consists of a set of topics that each describe a certain skill.
In the Master Skill Matrix, the topics are grouped into course titles. The course titles
are grouped into 3 different levels. Within some levels, Training programs can be
recognized, that are composed of a set of courses. The Master Skill Matrix will be
updated by means of New Model Training. For each New Model release that requires
training, the material will be defined by new topics, that may replace existing ones.
In this way the Master Skill Matrix will be kept updated constantly.
Master Skill Matrix for each steps are shown in attachment 1.
Topics: All skills within the Master Skill Matrix are presented using a combination of a service manual designator and a numeric designator, in most
cases with the following set up:
For example
EC T
1 001 A
Introduction to ECCS
Update level
Topic numerator
STEP
Nissan
Technical
Engine Control system
This description is called a TOPIC.
In case the content of a topic should be revised and the technicians are
required to take it again, then the topic numerator must be changed
accordingly.
In the case of minimal revision to the content and no necessity for technicians to take it again, then the topic numerator need not to be
changed but the level letter should be changed to the updated version,
such as A to B (see example).
Issued: March 2002
Section II
II-1-2 Active Skill Matrix

As the model line-up and also specifications differ from country to country, and as different repair philosophies exist in different countries, the Master Skill Matrix can be
modified in line with the above national requirements, to form the Active Skill Matrix
that is specific depending on each country.
Based upon the Master Skill Matrix each NSC has to define the Active Skill Matrix.
To define the Active Skill Matrix for each country mainly depends on the model mix.
For example: ABC country
GA engine, CVT and Multi-Link suspensions are not introduced in ABC country. In this case, remove the following topics and courses.
STEP 2
ENGINE
EMTN2011A (GA Engine Timing Chain Replacement)

EMTN2012A (GA Engine Valve Shim Adjustment)
(in Gasoline Engine Mechanical Repair course)
CHASSIS
FATN2003A/WS1 (Multi-Link Suspension/Front)

FATN2003A/WS2 (Multi-Link Suspension/Rear)
(in Suspension Diagnosis and Repair course)
Continuously Variable Transmission Repair course
Continuously Variable Transmission Diagnosis course
Then, the NSC defines the active skill matrix by combining the remaining topics.
Issued: March 2002
Section II
II-1-3 Training course description
STEP 1 training program

1. Fundamental skills course
- Fundamental of Engine and Chassis.
Usage of Service Manual and Special Service Tools.
2. Maintenance skill course
- be able to perform Pre-delivery Inspection and Periodic Maintenance.
3. Usage of Tools course
- Usage of general tools, measuring tools and CONSULT-II.
4. Express service course
- be able to perform Express service for improving NSCs profitability.
Issued: March 2002
Section II
STEP 2 engine training program

1. Gasoline engine management system course
- diagnosis and repair of ECCS engine. Major emphasis on actual trouble shooting of test cases. Performance diagnosis. Fuel quality analysis.
2. Gasoline engine mechanical repair course
- repair and overhaul of the mechanical aspects of volume gasoline engines
(GA/SR/QR/VQ series). Includes cooling and lubricating system diagnosis and
mechanical repair.
3. Carburetor engine management system course
- diagnosis and repair of carburetor engine.
4. Diesel engine management system course
- fundamentals of VE injection pump, diesel fuel system. Testing of injector and
pump. Diagnosis and repair of diesel fuel system and pump related incidents.
Emphasis on actual troubleshooting of test cases.
5. Diesel engine mechanical repair course
- repair and overhaul of the mechanical aspects of volume diesel engines (TD/
BD/ZD series).
6. Engine electrical course
- theory, and diagnosis of the battery, charging and starting system, and ignition
systems.
7. CONSULT advanced course
- review of basic CONSULT-II functions and use. Voltage and Pulse measurement. Field test. Recording and graphing functions.
Issued: March 2002
Section II
STEP 2 electrical training program

1. Electronics course
- further theory of electric components and their role/behavior in circuits.
2. Electrical troubleshooting course
- includes diagnosis of open, short and crossover circuits, and poor grounds.
Heavy emphasis is placed on ECM type circuits, the correct use of test equipment (including lab type oscilloscope) and hands-on problem diagnosis.
3. Body electrical course
- theory, diagnosis and repair of body electrical components, including the combination switch, ECM pin tests, Super Multiple Junction, wiring harness and
connectors, multiplex wiring. Includes air bag systems.
- theory, and diagnosis of the battery, charging and starting system, and ignition
systems.
- review of basic CONSULT-II functions and use. Voltage and Pulse measurement. Field test. Recording and graphing functions.
6. Heater & air conditioner operation course
- diagnosis and repair of heater and manual air conditioner, including refrigeration, R12 vs R134a, service equipment.
Issued: March 2002
Section II
STEP 2 chassis training program

1. Suspension diagnosis & repair course
- includes : symptom based diagnosis for common suspension related customer
complaints such as: Tire Wear, Vibration & Noise, Fluid Leaks, Ride Quality.
2. Steering diagnosis & repair course
- includes : symptom based diagnosis for common steering related customer
complaints such as: Vehicle Pull, Steering Wheel Off Center.
3. Brake diagnosis & repair course
- brake systems theory and diagnosis.
4. Manual transmission fundamentals & diagnosis course
- preliminary disassembly of RS5F31/32A and FS5W71C in order to enable
diagnosis and establish a repair method. Diagnosis of clutch related noise, slipping, wear and judder.
5. Manual transmission repair course
- repair and overhaul of RS5F31/32A series and FS5W71C series. Symptom
based diagnosis for common manual transmission related customer complaints. Diagnosis of transmission symptoms such as hard shifting, gear grinding, noise and wear in both front and rear wheel drive vehicles.
6. Automatic transmission fundamentals & diagnosis course
- covers the fundamentals of automatic transmissions operation and in car service and diagnosis includes electronic controlled types.
7. Automatic transmission repair course
- automatic transmission/transaxle unit repair.
8. Final drive & drive line course
- diagnosis and repair of differentials, propeller shaft, locking hubs and transfer.
9. Continuously variable transmission repair course
- repair of Nissan Continuously Variable Transmission.
10. Continuously variable transmission diagnosis course
- service and diagnosis of Nissan Continuously Variable Transmission.
Issued: March 2002
Section II
STEP 3 engine training program

1. Gasoline engine diagnosis and repair
- includes troubleshooting techniques, use of diagnostic equipment as lab-type
oscilloscope and CONSULT-II oscilloscope. Actual troubleshooting of driveability problems with an interrelation of various systems.
2. Diesel engine diagnosis and repair course
- includes troubleshooting techniques of engine control system.
3. Carburetor engine diagnosis and repair course
- includes troubleshooting techniques of carburetor engine, especially Air-Fuel
ratio incidents.
4. Vibration & noise fundamentals course
- fundamentals of vibration and including recognizing noises and vibrations and
describing them. Diagnosis with simple equipment. Repair methods.
5. Vibration and noise engine diagnosis course
- includes troubleshooting techniques of engine noise and vibration.
Issued: March 2002
Section II
STEP 3 chassis training program

1. Electrical system diagnosis and repair course
- covers information on diagnosis and repair of vehicle electrical systems.
2. Heater & air conditioner diagnosis & repair course
- covers information on diagnosis and repair of automatic temperature control
heating and air-conditioning systems.
3. Electronic automatic transmission diagnosis and repair course
- covers information on diagnosis and repair of automatic transmission, includes
electronic controlled automatic transmission.
4. Suspension advanced course
- for suspension related electronic control systems (such as HICAS); function
and operation, self-diagnosis, CONSULT-II use and circuit testing.
5. Vibration & noise fundamentals course
- fundamentals of vibration and including recognizing noises and vibrations and
describing them. Diagnosis with simple equipment. Repair methods.
6. Vibration and noise chassis diagnosis course
- covers information on diagnosis and repair of chassis noise and vibration.
Issued: March 2002
Section II
II-2 Performance Based Learning

It is necessary for instructors to confirm that the technicians skill is acceptably
upgraded during training. This cannot be realized using traditional training methods
only. Therefore, N-STEP is focusing on learning based upon practice in addition to
information delivered. It is called Performance Based Learning.
A. OBJECTIVES
B. LEARNING ACTIVITIES
LEARNING PROCESS
C. PRACTICE
Definition of the Performance Based Learning
A. Objectives
An objective is a statement of what the technician is expected to be able to do
after learning. It is stated in terms of the expected function or performance and
the criteria that are acceptable for the performance.
B. Learning activities
Learning activities contribute to the objective. These are guided, hands-on activities that make up tasks that are part of the performance described by the objective.
The resources include:
- Worksheets
- Discussion with instructor
- Demonstration
The emphasis is on doing or working through the activity using a similar process
as in the dealership situation.
C. Practice
Practice is simulating the task or operation being learned in a controlled training
environment.
Issued: March 2002
Section II
10
Issued: March 2002
Section II
11
II-3 Training material package

II-3-1 Package contents
All N-STEP course material, according to the Master Skill Matrix, will be supplied by
Nissan. All material is designed according to the Performance Based Learning
Model. In practice this means that the actual learning process is mainly covered by
actual hands-on practice exercises.
The training material package consists of the following materials:
Training Guide (This is a hand-out material for trainees)
* Text material
This material contains a technical explanation of the theory for trainees.
* Worksheet
The worksheet belonging to one topic may have various chapters.
The worksheet will allow guided practice, while theory is integrated into the
practice activities.
Instructor Guide (This is a handout for instructors)
Each course has an Instructor Guide. It explains how to conduct the course,
the key points to be taught and how to use the Training Guide and Training
Aids.
Training Aids
Instructors in a NSC may use the following materials when conducting the
courses:
Transparencies, etc.
The sample materials are shown on attachment 2.
Issued: March 2002
Section II
12
II-3-2 Use of the training material package

The actual N-STEP training is conducted by instructors in NSC.
To ensure the correct use of the material, Nissan organizes training for the instructor
sessions.
II-3-3 Up-date of training material
Besides the adding of a new TOPIC CODE, the current TOPIC may change or be
deleted from the Master Skill Matrix.
New TOPICS or changes of TOPICS may occur in the following cases:
- New technology (New model or product change)
- Procedures change
- Technician needs are identified (Systematic troubleshooting problems)
II-3-4 Materials supply
The cost of the training materials for each step shall be paid by NSCs. Each NSC is
required to order materials from Nissan.
Nissan will bill the NSC for the actual cost of packing and shipping.
We will inform you in defail of the prices and the ordering procedure in the N-STEP
publication news.
Issued: March 2002
Section II
13
II-3-5 Training period

In order to identify the required amount of training time per topic, the following guideline can be used. This describes the required training time per course title as defined
in the Master Skill Matrix.
Each NSC can calculate the actual expected time per course, taking his own Active
Skill Matrix into account.
STEP
Category
ENGINE
Duration
(day)
Course
Fundamental
Tool
Maintenance
Express Service
3
2
2
1
Gasoline Engine Management System

Gasoline Engine Mechanical Repair
CONSULT Advanced
Diesel Engine Management System
Diesel Engine Mechanical Repair
Carburetor Engine Management System
Engine Electrical
5
3
1
2
1
1
1
ELECTRICAL Basic Electronics

Electrical Troubleshooting
Body Electrical
Engine Electrical
CONSULT Advanced
Heater & Air Conditioner
1
2
2
1
1
2
CHASSIS
Suspension Diagnosis and Repair

Steering Diagnosis and Repair
Brake Diagnosis and Repair
Manual Transmission/axle Fundamentals
Manual Transmission/axle Repair
Automatic Transmission/axle Fundamentals
Automatic Transmission/axle Repair
Final Drive and Drive Line
Continuously Variable Transmission Repair
Continuously Variable Transmission Diagnosis
1
1
1
1
2
3
3
2
1
1
ENGINE
Gasoline Engine Diagnosis and Repair

Diesel Engine Diagnosis and Repair
Carburetor Engine Diagnosis and Repair
Vibration and Noise Fundamentals
Vibration and Noise Engine Diagnosis
4
2
1
2
1
Issued: March 2002
Section II
14
STEP
Category
Course
Duration
(day)
CHASSIS
Electrical Diagnosis and Repair

Heater and Air Conditioner Diagnosis and Repair
Automatic Transmission Diagnosis and Repair
Suspension Diagnosis and Repair
Vibration and Noise Fundamentals
Vibration and Noise Chassis Diagnosis
2
1
1
2
2
2
Issued: March 2002
Section III
III Skill assessment

III-1 Aim of skill assessment
The purpose of this assessment is to check if a technician has achieved an acceptable level of skill through training and his/her jobs at a service shop. A dealer makes
it clear what level of skill the technician has/hasnt achieved. The result of this
assessment is utilized as a tool for educating the technician as well.
III-2 Skill assessor

Skill assessor for N-STEP 1 and 2 is a person who is authorized by the NSC.
Skill assessor for N-STEP 3 is a person who is authorized by Nissan.
III-3 Skill assessment timing

Assessment is to be conducted after several months of practical experience following
the completion of all the courses for each rank.
III-4 Skill assessment materials

- Skill assessment sheets (for technician)
This is the answer sheet provided to the technician. The technicians should fill in the
answers for the tasks.
- Skill assessment sheets (for assessor)
This is the evaluation sheet which describes the criteria for tasks. The assessor
should fill out the results of the technicians skill on this sheet.
- Assessor guide
This is the guide book for the assessment procedure.
III-5 Skill assessment flow

Assessment is to be conducted in accordance with Assessment sheet provided by
Nissan. Equipment necessary for assessment is described in the Assessors guid.
When the technician has satisfied all the technical qualifications of each rank, the
rank can be given to the technician by the NSC.
Issued: March 2002
Section IV
IV Ranking policies
IV-1 Aim of ranking
The ranking contributes to the following:
- providing a career path for technician and thereby enhancing motivation, leading to decreased turn-over.
- easier overview of current ranking status by identifying rank levels within a service shop.
- easier setting up of training standards by defining required rank distribution
within a service shop.
IV-2 Definition of rank

Ranks are defined in accordance with the level of technical qualifications as follows:
STEP
Rank
MASTER TECHNICIAN
STEP3
SENIOR CHASSIS SPECIALIST
ENGINE SPECIALIST
STEP2
CHASSIS SPECIALIST
STEP1
TECHNICIAN
Issued: March 2002
Section IV
IV-3 Technical qualification for each rank

IV-3-1 TECHNICIAN rank
Technical qualifications
- Possesses fundamental knowledge of the specifications and features
of the Nissan vehicles in the market.
- Understands the functions of the major components and fundamental
engine, electrical and chassis theory.
- Able to perform pre-delivery inspection and periodic maintenance.
- Able to perform fundamental CONSULT-II operations.
- Understands the contents of the service manual.
IV-3-2 SPECIALIST rank
ENGINE SPECIALIST rank
- Understands the functions and operations of engines.
- Able to inspect and tune engines.
- Able to diagnose and carry out simple engine-related repairs and
overhaul engines using CONSULT-II and necessary equipment.
ELECTRICAL SPECIALIST rank
- Understands the functions and operations of electrical and electronic
systems.
- Able to inspect and adjust electrical and electronic systems.
- Able to diagnose and carry out electrical-related repairs and overhaul
electrical and electronic systems using CONSULT-II and necessary
equipment.
CHASSIS SPECIALIST rank
- Understands the functions and operations of chassis.
- Able to inspect and adjust chassis.
- Able to diagnose and carry out simple chassis-related repairs and
overhaul chassis using CONSULT-II and necessary equipment.
Issued: March 2002
Section IV
IV-3-3 SENIOR SPECIALIST rank

SENIOR ENGINE SPECIALIST rank
- Able to diagnose and fix difficult engine-related incidents of noise
and vibration.
- Able to diagnose and carry out difficult engine-related repairs of
driveability.
- Able to diagnose and carry out other difficult engine-related repairs.
SENIOR CHASSIS SPECIALIST rank
- Able to diagnose and fix difficult chassis-related incidents of noise
and vibration.
- Able to diagnose and carry out difficult chassis-related repairs of
driveability.
- Able to diagnose and carry out other difficult chassis-related repairs.
IV-3-4 MASTER TECHNICIAN rank
- Fully meets all the technical requirements through the STEP 3 level.
Issued: March 2002
Section IV
IV-4 Necessary conditions for each rank

IV-4-1 To become TECHNICIAN
- Completion of the following courses
1. Fundamental course
2. Tool course
3. Maintenance course
4. Express service course
- Pass the skill assessment for TECHNICIAN rank.
A technician with no rank
Apply for STEP 1

training course
STEP 1 training course
Technician skill
assessment for the rank of
TECHNICIAN
fail
pass
Application for rank
Approval of rank
Certification for the rank

of TECHNICIAN
Issued: March 2002
Section IV
IV-4-2 To become SPECIALIST

To become ENGINE SPECIALIST rank
- Possession of TECHNICIAN rank
1. Gasoline engine management system course
2. Gasoline engine mechanical repair course
3. Carburetor engine management system course
4. Diesel engine management system course
5. Diesel engine mechanical repair course
- Pass the skill assessment for ENGINE SPECIALIST rank
A technician with the rank
of TECHNICIAN
Apply for STEP 2

engine training course
STEP 2 engine
training course
Technician skill
ENGINE SPECIALIST
fail
pass
Approval of rank
Certification for
the rank of
ENGINE SPECIALIST
Issued: March 2002
Section IV
To become ELECTRICAL SPECIALIST

1. Electronics course
2. Electrical troubleshooting course
3. Body electrical course
6. Heater & air conditioner operation course
- Pass the skill assessment for ELECTRICAL SPECIALIST rank
of TECHNICIAN
Apply for STEP 2

electrical training course
STEP 2 electrical
training course
Technician skill
ELECTRICAL
SPECIALIST
fail
pass
Approval of rank

of ELECTRICAL
SPECIALIST
Issued: March 2002
Section IV
To become CHASSIS SPECIALIST

1. Suspension diagnosis & repair course
2. Steering diagnosis & repair course
3. Brake diagnosis & repair course
4. Manual transmission fundamentals & diagnosis course
5. Manual transmission repair course
6. Automatic transmission fundamentals and diagnosis course
7. Automatic transmission repair course
8. CVT diagnosis course
9. CVT repair course
10. Final drive & drive line course
- Pass the skill assessment for CHASSIS SPECIALIST rank
of TECHNICIAN
Apply for STEP 2 chassis

training course
STEP 2 chassis
training course
Technician skill
CHASSIS SPECIALIST
fail
pass
Approval of rank
Certification for
the rank of
CHASSIS SPECIALIST
Issued: March 2002
Section IV
IV-4-3 To become SENIOR SPECIALIST

To become SENIOR ENGINE SPECIALIST
- Possession of ENGINE SPECIALIST and ELECTRICAL SPECIALIST rank
1. Gasoline engine diagnosis and repair course
2. Diesel engine diagnosis and repair course
3. Carburetor engine diagnosis and repair course
4. Vibration and noise fundamentals course
5. Vibration and noise engine diagnosis course
6. Heater & Air conditioner diagnosis and repair course
- Pass the skill assessment for SENIOR ENGINE SPECIALIST rank
of ENGINE SPECIALIST and ELECTRICAL
SPECIALIST
Apply for STEP 3

engine training course
STEP 3 engine
training course
Technician skill
SENIOR ENGINE
SPECIALIST
fail
pass
Approval of rank

of SENIOR ENGINE
SPECIALIST
Issued: March 2002
Section IV
To become SENIOR CHASSIS SPECIALIST

- Possession of CHASSIS SPECIALIST and ELECTRICAL SPECIALIST rank
1. Automatic transmission diagnosis and repair course
2. Suspension diagnosis and repair course
3. Electrical system diagnosis and repair course
4. Vibration & Noise fundamentals course
5. Vibration and noise chassis diagnosis course
6. Heater & air conditioner diagnosis & repair course
- Pass the skill assessment for SENIOR CHASSIS SPECIALIST rank
of ELECTRICAL
SPECIALIST and
CHASSIS SPECIALIST
Apply for STEP 3 chassis

training course
STEP 3 chassis
training course
Technician skill
SENIOR CHASSIS
SPECIALIST
fail
pass
Approval of rank

of SENIOR CHASSIS
SPECIALIST
Issued: March 2002
Section IV
10
IV-4-4 To become MASTER TECHNICIAN

- Possession of SENIOR CHASSIS SPECIALIST and SENIOR ENGINE SPECIALIST.
A technician with the rank of
SENIOR CHASSIS SPECIALIST and
Application to Nissan for rank
Approval of rank
Certification for the rank of

MASTER TECHNICIAN
Issued: March 2002
Section IV
11
IV-5 Necessary conditions for keeping each rank

IV-5-1 TECHNICIAN rank
The rank can be kept without any conditions.
IV-5-2 SPECIALIST rank
The rank must be maintained by completion of all newly added topics within the
achieved levels.
Normally these topics would be offered with new model training.
IV-5-3 SENIOR SPECIALIST rank
The rank must be maintained by completion of all newly added topics within the
achieved levels.
Normally these topics would be offered with new model training.
Issued: March 2002
Section V
V Screening
V-1 Aim of screening
When introducing N-STEP the wide range of levels that technicians already have
must be considered. Some of the skills required for a rank at N-STEP may already be
in place. As such it would be unnecessary to make all technicians complete all training courses at these levels of training. Thus a screening process that is capable of
integrating technicians at the relevant rank is essential for the successful adoption of
an implementation procedure.
V-2 Screening procedure

What training can technician be exempted from?
Exemption is possible for:
- STEP 1 training complete
- STEP 2 training engine complete
- STEP 2 training electrical complete
- STEP 2 training chassis complete
Exemption is not possible for STEP 3 training complete. Screening procedure is
shown in the following figuration.
Issued: March 2002
Section V
Screening Procedure
Technician skill assessment

for
TECHNICIAN
No rank
fail
pass
Determinig whether
technician skill assessment for
SPECIALIST
No
Yes
Technicians may try to take one or two or all of the categories below.
Te ch n ic ia n sk ill a s se s sm e n t
fo r
E N G IN E S P E C IA L IS T
pass
Approval of TECHNICIAN and

ENGINE SPECIALIST rank
fail
Application for approval of

TECHNICIAN rank
Technician skill assessment

for
fail
pass

TECHNICIAN rank

ELECTRICAL SPECIALIST rank
Te c h n icia n s kill a ss e ss m e n t
fo r
C H A S S IS S P E C IA L IS T
pass
fail

TECHNICIAN rank

TECHNICIAN rank

CHASSIS SPECIALIST rank
Approval of TECHNICIAN rank
Issued: March 2002
Section VI
VI Certification
For technicians efforts, they must receive the certificate and uniform emblem as the
recognition at each rank. It can also provide them with a kind of incentive.
NSC provides them with the certification and uniform emblem for each rank.
Certification
Issued: March 2002
Section VI
Uniform emblem
Issued: March 2002
Section VII
VII Training and certification record

For NSC and dealer
In order to assess how N-STEP training is proceeding and how many technicians have taken which rank, the training/certificate record should be made
and maintained at dealers/NSCs.
For technician
The passport will be given to all technicians. The passport is designed to indicate clearly the subjects that have been studied and to be studied.
It will also stand as a record of the technicians achievements within N-STEP
training system.
How to use the passport
Each technician should keep the passport and use it as explained below.
1. This is his own identification and record.
Whenever he participates in training course and skill assessment, etc., his
personal record and/or certification record should be updated on his passport accordingly.
2. His passport certifies his progress in the training process.
It is necessary for technicians to have instructors certify that he has
attended training and fill in the appropriate item.
Issued: March 2002
Section VII
Passport
Issued: March 2002
Section VIII
VIII N-STEP Operations

This section describes the outline of N-STEP operations and their flow.
Please refer to these operations and flow for your implementation of N-STEP.
VIII-1 Preparation for implementation of N-STEP

1) Plan for introducing N-STEP
The NSC makes a plan for implementing N-STEP.
2) Guidance for introducing of N-STEP to dealers
The NSC provides dealers with its own version of policies and operating procedures based upon this manual.
3) Analysis of the workshops
For planning the training by NSC, it is necessary to analyze the current technician level and workshop operation in general by a screening process implementing.
4) Creating annual training plans, and informing dealers about training courses
The NSC plans the training for dealers in accordance with dealers needs and
technical level.
5) Making technician training plans
A new employee begins with the STEP 1 training course. However an experienced new technician is placed at the appropriate rank through screening. Dealers plan the technician training plans in accordance with the national plan made
by the NSC.
Issued: March 2002
Section VIII
Nissan
NSC
Dealer
1) Plan for introducing

N-STEP
2) Guidance for introducing

N-STEP to dealers
3) Analysis of the workshops

4) Making annual training
plans, and informing
dealers about training
courses
5) Making technicians
training plan
Issued: March 2002
Section VIII
VIII-2 Implementation procedure

6) Application for training courses
Dealers must submit annual training application forms to the NSC.
7) Coordination with dealers
Appropriate courses are offered in accordance with the application forms submitted by dealers.
8) Training preparations
The NSC orders the materials needed for the training from Nissan.
9) Training
Training is carried out using the training material package supplied by Nissan.
The Instructor Guide explains how to implement training courses.
The NSC signs a passport of completion for technicians completing each training course.
10) Record of training results
The NSC keeps records on the training results of technicians.
11) Skill assessment of technicians
Technicians are evaluated by using the assessment sheet and checking off
items, indicating whether the technicians satisfy the technical qualifications.
12) Application for rank
Dealers submit the successful completion of the skill assessment of technical
qualifications by sending an application form to the NSC.
13) Approval of rank
The NSC approves the application form for certification.
14) Certification
The NSC sends the certificates and uniform emblem to the dealers.
15) Record of technician achievement
The NSC keeps records on achievements of certificate holders.
Issued: March 2002
Section VIII
Nissan
Dealer
NSC
7) Coordination with
dealers
6) Application for training

course
8) Training preparations
Ordering of training
materials and passports
9) N-STEP training
Participation by
technicians
10) Record of training

results
11) Skill assessment of technicians
Submission
12) Application for rank
13) Approval of rank
14) Certification
15) Record of technician

achievements
Report
Issued: March 2002
Attachment 1
Attachment 1
The topics for STEP 1, 2 and 3
Issued: March 2002
Attachment 1
STEP 1
MASTER SKILL MATRIX
Course
STEP
FUND
Fundamental
Skills
1
MATN
Maintenance
Skills
Usage of Tools
1
Express
Service
1
Topic code
Descriptions
GITN1001B
Usage of Service Manual
GITN1002A
Usage of Special Service Tools
GITN1003B
General Model Introduction
GITN1005A
Outline of Engine
GITN1006A
Outline of Chassis
ECTN1001B
ELTN1001B
Basic Electrical Concept
ATTN1001A
External Adjustment of A/T
ATTN1002A
External Adjustment of E-A/T
BTTN1001B
Body & Trim
CLTN1001A
Clutch Pedal Adjustment
ELTN1003B
Handling of Battery
EMTN1001B
Engine ldle Adjustment
LCTN1001B
Cooling System Inspection
MATN1001B
Periodic Maintenance
MATN1002B
Pre-Delivery Inspection
MTTN1001A
External Adjustment of M/T
ELTN1002B
Usage of Digital Multimeter
GITN1004B
Usage of Measuring Tools
GITN1007B
Usage of General Tools
ECTN1002A
Usage of CONSULT
ECTN1003B
Usage of CONSULT-II
EXTN1001B
Express Lub. 30
EXTN1002B
Engine Tune-up Service
EXTN1003B
Cooling System Service
EXTN1004B
Tire replacement & Brake System
EXTN1005B
A/C Performance Check
Issued: March 2002
Attachment 1
STEP 2
ENGINE TRAINING MASTER SKILL MATRIX
Course
STEP
GEMS
Gasoline
Engine
Management
System
2
GEMR
Gasoline
Engine
Mechanical
Repair
CEMS
Carburetor
Engine
Management
System
DEMS
Diesel
Engine
Management
System
Topic code
Descriptions
ECTN2021A
Fuel Pressure System Inspection
ECTN2022A
Fuel Injection System Inspection
ECTN2023A
Ignition System Inspection
ECTN2024A
Nissan Direct Ignition System (NDIS) Inspection
ECTN2025A
ECCS Electrical Component Inspection
ECTN2026A
ECM Signal Inspection
ECTN2027A
EVAP & EGR System Inspection
ECTN2028A
Engine Diagnosis Techniques
ECTN2029A
Valve Timing Control System Inspection
ECTN2030A
Variable Induction Air System Inspection
EMTN2011A
GA Engine Timing Chain Replacement
EMTN2012A
GA Engine Valve Shim Adjustment
EMTN2013A
SR Engine Timing Chain Replacement
EMTN2014A
SR Engine Valve Shim Adjustment
EMTN2015A
VG30E Engine Timing Belt Replacement
EMTN2016A
VG30DE Engine Timing Belt Replacement
EMTN2017A
VQ Engine Timing Chain Replacement
EMTN2018A
VQ Engine Valve Shim Adjustment
EMTN2019A
Cylinder Head & Valve Inspection
EMTN2020A
Camshaft Inspection
EMTN2021A
Hydraulic Lash Adjuster Air Bleeding
EMTN2022A
Cylinder Block Inspection
EMTN2023A
Crankshaft Inspection
EMTN2024A
Main Bearing Inspection
EMTN2025A
Connecting Rod Bearing Inspection
EMTN2026A
Engine Compression Diagnosis
ECTN2051A
Carburetor Overhaul
ECTN2052A
Carburetor System Inspection
ECTN2053A
Carburetor System Diagnosis
ECTN2054A
Distributor Overhaul
ECTN2041A
TD, BD Engine VE Type Injection Pump Adjustment
ECTN2042A
TD, BD Engine In-line Type Injection Pump Adjustment
ECTN2043A
CD Engine VE Type Injection Pump Adjustment
ECTN2044A
Injection Nozzle Inspection
ECTN2045A
Glow Plug System Inspection
ECTN2046A
Diesel Engine Diagnosis
Issued: March 2002
Attachment 1
Course
STEP
DEMR
Diesel
Engine
Mechanical
Repair
ELEN
Engine
Electrical
2
COAV
CONSULT
advanced
Topic code
Descriptions
EMTN2031A
TD, BD Engine Valve Clearance Adjustment
EMTN2032A
CD Engine Timing Belt Replacement
EMTN2033A/WS1
TD, BD Engine Cylinder Head & Valve Inspection
EMTN2033A/WS2
CD Engine Cylinder Head & Valve Inspection
EMTN2034A
Camshaft Inspection
EMTN2035A/WS1
TD, BD Engine Cylinder Head Gasket Selection
EMTN2035A/WS2
CD Engine Cylinder Head Gasket Selection
EMTN2036A/WS1
TD, BD Engine Cylinder Block Inspection
EMTN2036A/WS2
TD, BD Engine Cylinder Liner Replacement
EMTN2036A/WS3
CD Engine Cylinder Block Inspection
EMTN2037A
Crankshaft Inspection
EMTN2038A/WS1
TD, BD Engine Main Bearing Inspection
EMTN2038A/WS2
CD Engine Main Bearing Inspection
EMTN2039A/WS1
TD, BD Engine Connecting Rod Bearing Inspection
EMTN2039A/WS2
CD Engine Connecting Rod Bearing Inspection
EMTN2040A
Engine Compression Inspection
ELTN2020A/WS1
Ignition Systems/Primary
ELTN2020A/WS2
Ignition Systems/Secondary
ELTN2020A/WS3
Ignition Systems/Dwell Measurement
ELTN2020A/WS4
Ignition Systems/Ignition Check With Engine Tester
ELTN2021A
Starting System
ELTN2022A
Charging System
ELTN2023A
NDIS Primary System Check
ECTN2010A
Review of CONSULT
ECTN2011A
CONSULT Data Monitor
ECTN2012A
CONSULT Active Test
ECTN2013A
CONSULT Voltage and Pulse Measurement
ECTN2014A
CONSULT Field Test and Support Functions
ECTN2015A
Review of CONSULT-II
ECTN2016A
CONSULT-II Data Monitor
ECTN2017A
CONSULT-II Active Test
ECTN2018A
CONSULT-II Oscilloscope
ECTN2019B
CONSULT-II Function Test
Issued: March 2002
Attachment 1
STEP 2
ELECTRICAL TRAINING MASTER SKILL MATRIX
Course
STEP
ELEC
Electronics
2
ELTS
Electrical
Troubleshooting
2
ELBO
Body
Electrical
ELEN
Engine
Electrical
2
Topic code
Descriptions
ELTN2005A/WS1
Basic Electronics/NTC Resistance
ELTN2005A/WS2
Basic Electronics/Condenser in DC Circuit
ELTN2005A/WS3
Basic Electronics/Diode & Transistor
ELTN2005A/WS4
Basic Electronics/Duty Cycle
ELTN2005A/WS5
Basic Electronics/Voltage Divider
ELTN2005A/WS6
Basic Electronics/Zener Diode
RSTN2010A/WS1
Air Bag System/Introduction
RSTN2010A/WS2
Air Bag System/Self-diagnosis
RSTN2010A/WS3
Air Bag System/Pre-tensioner
ELTN2027A/WS1
Hands-on Diagnosis/Troubleshooting-1
ELTN2027A/WS2
ELTN2027A/WS3
ELTN2027A/WS4
ELTN2027A/WS5
ELTN2010A
Combination Switch
ELTN2011A/WS1
Power Window
ELTN2011A/WS2
Power Window/with Smart Entrance
ELTN2011A/WS3
Power Window/with Amplifier
ELTN2013A
Automatic Speed Control Device
ELTN2014A/WS1
Multiplex Wiring/Power Window
ELTN2014A/WS2
Multiplex Wiring/Power Window - IVMS (LAN)
ELTN2015A/WS1
Power Door Lock System
ELTN2015A/WS2
Power Door Lock/with Smart Entrance
ELTN2016A
Nissan Anti Theft System (NATS)
ELTN2017B
CAN system introduction
ELTN2018B
NATS system introduction
ELTN2019B
IPDM system introduction
ELTN2020A/WS1
Ignition System/Primary
ELTN2020A/WS2
Ignition System/Secondary
ELTN2020A/WS3
Ignition System/Dwell Measurement
ELTN2020A/WS4
Ignition System/Ignition Check with Engine Tester
ELTN2021A
Starting System
ELTN2022A
Charging System
ELTN2023A
NDIS Primary System Check
Issued: March 2002
Attachment 1
Course
STEP
COAV
CONSULT
Advanced
HAOP
Heater & Air
Conditioner
Diagnosis
and Repair
Topic code
Descriptions
ECTN2010A
Review of CONSULT
ECTN2011A
CONSULT Data Monitor
ECTN2012A
CONSULT Active Test
ECTN2013A
CONSULT Voltage and Pulse Measurement
ECTN2014A
CONSULT Field Test and Support Functions
ECTN2015A
Review of CONSULT-II
ECTN2016A
CONSULT-II DATA MONITOR
ECTN2017A
CONSULT-II ACTIVE TEST
ECTN2018A
CONSULT-II OSCILLOSCOPE
ECTN2019B
CONSULT-II Function Test
HATN2001A
HEATER OPERATION
HATN2007A
REFRIGERANT GAS
HATN2008A
Use of Service Manual
HATN2009A
Manual A/C System Operation Check
Issued: March 2002
Attachment 1
STEP 2
CHASSIS TRAINING MASTER SKILL MATRIX
Course
STEP
SUDR
Suspension
Diagnosis
and Repair
STDR
Steering
Diagnosis
and Repair
Topic code
Descriptions
FATN2001A/WS1
SUSPENSION FUNDAMENTALS/STRUT REPAIR
FATN2001A/WS2
SUSPENSION FUNDAMENTALS/WHEEL BEARING
FATN2002A/WS1
SHEEL AND TIRE/FUNDAMENTALS
FATN2002A/WS2
WHEEL AND TIRE/DIAGNOSIS
FATN2002A/WS3
WHEEL AND TIRE/OFF THE CAR BALANCER
FATN2003A/WS1
MULTI-LINK SUSPENSION/FRONT
FATN2003A/WS2
MULTI-LINK SUSPENSION/REAR
FATN2004A
ALIGNMENT GEOMETRY
FATN2005A/WS1
ALIGNMENT PROCEDURES/PRELIMINARY INSPECTION
FATN2005A/WS2
ALIGNMENT PROCEDURES/EXCEPT DOUBLE WISHBONE
FATN2005A/WS3
ALIGNMENT PROCEDURES/FOUR WHEEL ALIGNMENT TESTER
FATN2005A/WS4
ALIGNMENT PROCEDURES/DOUBLE WISHBONE
FATN2006A
Active Damper Suspension Fundamentals
FATN2007A/WS1
Preliminary Check
FATN2007A/WS2
Self-diagnosis with CONSULT
FATN2007A/WS3
Self-diagnosis without CONSULT
FATN2011A
Full-active Suspension Fundamentals
FATN2012A/WS1
Self-diagnosis with CONSULT
FATN2012A/WS2
Self-diagnosis without CONSULT
FATN2013A
On-vehicle Service for Full-active Suspension
STTN2001A
Manual Steering Repair
STTN2002A/WS1 Power Steering Repair/R&B Type

2
STTN2002A/WS2 Power Steering Repair/R&P Type

STTN2002A/WS3 Power Steering Repair/Oil Pump
STTN2003A
Power Steering Diagnosis
STTN2004A
Electronic Controlled Power Steering Fundamentals
Issued: March 2002
Attachment 1
Course
STEP
BRDR
Brake
Diagnosis
and Repair
Topic code
BRTN2001A
Descriptions
BRAKE SYSTEM FUNDAMENTALS
BRTN2002A/WS1 BRAKE SYSTEM OVERHAUL/MASTER CYLINDER

BRTN2002A/WS2 BRAKE SYSTEM OVERHAUL/DISC BRAKE
BRTN2002A/WS3 BRAKE SYSTEM OVERHAUL/DRUM BRAKE
BRTN2002A/WS4 BRAKE SYSTEM OVERHAUL/BRAKE BOOSTER
BRTN2003A/WS1 BRAKE SYSTEM OPERATION CHECK/BRAKE BOOSTER
BRTN2003A/WS2 BRAKE SYSTEM OPERATION CHECK/PROPORTIONING VALVE
2
BRTN2003A/WS3 BRAKE SYSTEM OPERATION CHECK/LOAD SENSING VALVE

BRTN2004A/WS1 BRAKE JUDDER
BRTN2004A/WS2 ON-CAR DISC BRAKE ROTOR RESURFACING
BRTN2005A
ABS System Fundamentals
BRTN2006A
Preliminary Check
BRTN2007A/WS1 Self-diagnosis with CONSULT

BRTN2007A/WS2 Self-diagnosis without CONSULT
BRTN2007A/WS3 Self-diagnosis for G sensor with CONSULT-II
BRTN2008A
MTFD
Manual
Transmission
Fundamentals
MTRP
Manual
Transmission
Repair
2
ATFD
Automatic
Transmission
Fundamentals
Component Removal and Installation
MTTN2005A
MANUAL TRANSMISSION FUNDAMENTALS
MTTN2006A
ON-VEHICLE DIAGNOSIS MANUAL TRANSMISSION
MTTN2007A
PRELIMINARY DISASSEMBLY FOR FS5W71C
MTTN2008A
PRELIMINARY DISASSEMBLY FOR RS5F31A
MTTN2015A
GEAR SET DISASSEMBLY FOR FS5W71C
MTTN2016A
GEAR/SHIFT COMPONENT INSPECTION FOR FS5W71C
MTTN2017A
SYNCHRONIZER ASSEMBLY AND INSPECTION
MTTN2018A
REASSEMBLY FOR FS5W71C
MTTN2019A
FINAL ASSEMBLY FOR FS5W71C
MTTN2020A
GEAR SET DISASSEMBLY FOR RS5F31A
MTTN2021A
GEAR/SHIFT COMPONENT INSPECTION FOR RS5F31A
MTTN2022A
REASSEMBLY FOR RS5F31A
MTTN2023A
BEARING PRE-ROAD ADJUSTMENT FOR RS5F31A
MTTN2024A
FINAL ASSEMBLY FOR RS5F31A
ATTN2021A/WS1 CONSTRUCTION OF AUTOMATIC TRANSMISSION/AXLE

ATTN2021A/WS2 OPERATION OF TORQUE CONVERTER
ATTN2021A/WS3 PRINCIPLE OF PLANETARY GEARS
ATTN2021A/WS4 OPERATION OF OIL PUMP, CLUTCHES AND BRAKES
2
ATTN2022A
HYDRAULIC CONTROL SYSTEM
ATTN2023A
ELECTRONIC CONTROL SYSTEM
ATTN2024A/WS1 PRELIMINARY CHECK

ATTN2024A/WS2 STALL TEST AND PRESSURE TEST
ATTN2024A/WS3 ELECTRICAL COMPONENT INSPECTION FOR E-A/T
ATTN2025A
SELF-DIAGNOSIS FOR E-A/T
ATTN2026A
CONSULT DATA MONITOR FOR E-A/T
Issued: March 2002
Attachment 1
Course
ATRP FR
Automatic
Transmission
Repair
ATRP FF
Automatic
Transmission
Repair
STEP
FDDL
Final Drive
and Drive Line
Topic code
Descriptions
ATTN2031A
DISASSEMBLY AND INSPECTION OF RE4R01A
ATTN2032A
OIL PUMP OVERHAUL
ATTN2033A
CLUTCHES OVERHAUL
ATTN2034A
OTHER COMONENTS OVERHAUL
ATTN2035A
ASSEMBLY AND ADJUSTMENT OF RE4R01A
ATTN2041A
Disassembly & Inspection of RE4F04A
ATTN2042A
Oil Pump Overhaul
ATTN2043A
Clutches Overhaul
ATTN2044A
Other Components Overhaul
ATTN2045A
Assembly and Adjustment of RE4F04A
TFTN2001A/WS1
TRANSFER/OUTLINE OF 4WD SYSTEM
TFTN2001A/WS2
TRANSFER/DISASSEMBLY AND INSPECTION FOR PART-TIME 4WD
TFTN2001A/WS3
TRANSFER/ASSEMBLY AND ADJUSTMENT FOR PART-TIME 4WD
TFTN2001A/WS4
TRANSFER/DISASSEMBLY AND INSPECTION FOR FULL-TIME 4WD
TFTN2001A/WS5
TRANSFER/ASSEMBLY AND ADJUSTMENT FOR FULL-TIME 4WD
TFTN2001A/WS6
TRANSFER/DISASSEMBLY AND INSPECTION FOR FULL-TIME 4WD
TFTN2001A/WS7
TRANSFER/ASSEMBLY AND ADJUSTMENT FOR FULL-TIME 4WD
TFTN2001A/WS8
All Mode 4WD Basic Inspection (J/R50)
TFTN2001A/WS9
All Mode 4WD Basic Inspection (T30)
TFTN2001A/WS10 All Mode 4WD Self Diagnosis with CONSULT-II (J/R50)

TFTN2001A/WS11 All Mode 4WD Self Diagnosis without CONSULT-II (J/R50)
2
TFTN2001A/WS12 All Mode 4WD Self Diagnosis with CONSULT-II (T30)

TFTN2001A/WS13 All Mode 4WD Trouble Diagnosis (J/R50)
TFTN2001A/WS14 All Mode 4WD Trouble Diagnosis (T30)
FATN2010A
AUTO-LOCK FREE-RUNNING HUB
PDTN2001A/WS1 PROPELLER SHAFT AND DRIVE SHAFT FUNDAMENTAL

PDTN2001A/WS2 HOOK JOINT INSPECTION AND OVERHAUL
PDTN2001A/WS3 DRIVE SHAFT INSPECTION AND OVERHAUL
PDTN2002A/WS1 DIFFERENTIALS/FUNDAMENTALS
PDTN2002A/WS2 DIFFERENTIALS/REMOVAL AND INSTALLATION
PDTN2002A/WS3 DIFFERENTIALS/OVERHAUL
PDTN2002A/WS4 DIFFERENTIALS/LSD OVERHAUL
PDTN2002A/WS5 DIFFERENTIALS/DIFFERENTIAL LOCK OVERHAUL
CVTR
Continuously
Variable
Transmission
Repair
ATTN2060A
Disassembly of N-CVT
ATTN2061A/WS1 Component Inspection/Pulleys

ATTN2061A/WS2 Component Inspection/Oil Pump
2
ATTN2061A/WS3 Component Inspection/Main Drive Shaft

ATTN2061A/WS4 Component Inspection/Drive Pinion Shaft
ATTN2062A
Pulley Alignment and Primary End Play
ATTN2063A
Assembly of N-CVT
Issued: March 2002
Attachment 1 10
Course
STEP
CVTD
Continuously
Variable
Transmission
Diagnosis
Topic code
Descriptions
ATTN2070A/WS1 Theory of N-CVT/Construction and Components

ATTN2070A/WS2 Theory of N-CVT/Hydraulic Operation System
ATTN2070A/WS3 Theory of N-CVT/Operation Mechanism
ATTN2071A/WS1 Control Valve Assembly Replacement
ATTN2071A/WS2 Brush Holder Inspection
ATTN2071A/WS3 Pressure Test and Stall Test
2
ATTN2072A
Component Inspection
ATTN2073A
Diagnosis Procedure
ATTN2074A
Electromagnetic Clutch Inspection
ATTN2075A
Signal Inspection
ATTN2081A
Theory of H-CVT/Construction and components
ATTN2082A
Basic Inspection
ATTN2083A
Diagnosis Procedure
ATTN2084A
Signal and Component Inspection
Issued: March 2002
Attachment 1 11
STEP 3
ENGINE TRAINING MASTER SKILL MATRIX
Course
STEP
GEDR
Gasoline
Engine
Diagnosis
and Repair
DEDR
Diesel
Engine
Diagnosis
and Repair
3
Topic code
Descriptions
ECTN3001A
No Crank
ECTN3002A
Impossible to Start Anytime (1)
ECTN3003A
Impossible to Start Anytime (2)
ECTN3004A
Impossible to Start Anytime (3) (New EGI)
ECTN3005A
Hard to Start
ECTN3006A
Rough Idle (1)
ECTN3007A
Rough Idle (2)
ECTN3008A
Rough Idle (3)
ECTN3009A
Unstable Idle (1)
ECTN3010A
Unstable Idle (2) (New EGI)
ECTN3011A
Unstable Idle (3)
ECTN3012A
High Idle (1)
ECTN3013A
High Idle (2)
ECTN3014A
Lack of Power (1)
ECTN3015A
Lack of Power (2)
ECTN3016A
Lack of Power (3)
ECTN3017A
Lack of Power (4)
ECTN3018A
Lack of Power (5)
ECTN3019A
Lack of Power (6) Turbocharger
ECTN3020A
Engine Stall
ECTN3021A
Misfire
ECTN3022A
Excessive Fuel Consumption
ECTN3023A
Trouble Diagnosis Technique
ECTN3024A
Basic Inspection
ECTN3025A
Self-diagnosis & Fail-safe System
ECTN3026A
CONSULT Data Analysis
ECTN3027A
Air Fuel Ratio Analysis
ECTN3041A
On Board Diagnostic System
ECTN3042A
No Crank
ECTN3043A
Impossible to Start (1)
ECTN3044A
Hard to Start
ECTN3045A
Impossible to Start (2)
ECTN3046A
High Idle
ECTN3047A
Hunting
ECTN3048A
Lack of Power
ECTN3049A
Black Smoke
ECTN3050A
White Smoke
ECTN3051A
Diesel Engine Smoke Testing
Issued: March 2002
Attachment 1 12
Course
CEDR
Carburetor
Engine
Diagnosis and
Repair
VNFN
Vibration and
Noise
Fundamental
VNED
Vibration and
Noise Engine
Diagnosis
STEP
Topic code
Descriptions
ECTN3071A
Unstable Idle (1)
ECTN3072A
Unstable Idle (2)
ECTN3073A
Engine Stall
ECTN3074A
Lack of Power
ECTN3075A
Excessive Fuel Consumption
VNTN3001A/WS1
Sound Characteristics Theory
VNTN3001A/WS2
Sound Characteristics Practice
VNTN3002A/WS1
Vibration Characteristics Theory
VNTN3002A/WS2
Vibration Characteristics Practice
VNTN3011A
Engine Idling Vibration
VNTN3012A
Noise from Valve Mechanism
VNTN3013A
Noise from Rotating Parts
VNTN3014A
Noise from Belts
VNTN3015A
Noise from Turbocharger
Issued: March 2002
Attachment 1 13
STEP 3
CHASSIS TRAINING MASTER SKILL MATRIX
Course
STEP
ELDR
Electrical
System
Diagnosis
and Repair
HADR
Heater and Air
Conditioner
Diagnosis
and Repair
ATDR
Automatic
Transmission
Diagnosis
and Repair
SUDR
Suspension
Diagnosis
and Repair
3
Topic code
Descriptions
ELTN3001A
Fuel Gauge Diagnosis
ELTN3002A/WS1
Fuel Warning Lamp Diagnosis-1
ELTN3002A/WS2
Fuel Warning Lamp Diagnosis-2
ELTN3003A
Speedometer Diagnosis
ELTN3004A
Radio Noise Diagnosis
ELTN3005A/WS1
CD Player Diagnosis (1)
ELTN3005A/WS2
CD Player Diagnosis (2)
ELTN3006A/WS1
Cassette Player Diagnosis (1)
ELTN3006A/WS2
ELTN3006A/WS3
ELTN3006A/WS4
ELTN3006A/WS5
ELTN3007A/WS1
Audio General Diagnosis (1)
ELTN3007A/WS2
ELTN3007A/WS3
ELTN3007A/WS4
ELTN3007A/WS5
ELTN3008A/WS1
Multi-Remote Control System Diagnosis (1)
ELTN3008A/WS2
Multi-Remote Control System Diagnosis (2)
HATN3001A
Insufficient Cooling (1)
HATN3002A
HATN3003A
Uncontrollable Temperature
HATN3004A
ATTN3001A
Excessive Shift Shock
ATTN3002A
Abnormal Shift Schedule
ATTN3003A
Slipping
ATTN3004A
Vehicle Runs Forward in N Position
ATTN3005A
Impossible to Shift D1 to D2
FATN3001A
Trigonometric Function
FATN3002A
Suspension Parts Inspection
FATN3003A
Pull to One Side While Braking
FATN3004A
Wander
FATN3005A
Steering Wheel Off Center
FATN3006A
Pull to One Side
FATN3007A
Tire One Side Wear
Issued: March 2002
Attachment 1 14
Course
VNFN
Vibration and
Noise
Fundamental
STEP
VNCD
Vibration and
Noise
Chassis
Diagnosis
Topic code
Descriptions
VNTN3001A/WS1
Sound Characteristic Theory
VNTN3001A/WS2
Sound Characteristic Practice
VNTN3002A/WS1
Vibration Characteristic Theory
VNTN3002A/WS2
Vibration Characteristic Practice
VNTN3022A
Steering Shimmy
VNTN3023A
Body Vibration
VNTN3024A
Booming Noise
VNTN3025A/WS1
Automatic Transmission Noise RE4F04A
VNTN3025A/WS2
Automatic Transmission Noise RL4F03A
VNTN3026A/WS1
Air Conditioner Noise (1)
VNTN3026A/WS2
VNTN3026A/WS3
VNTN3026A/WS4
VNTN3027A/WS1
Squeak and Rattle (1)
VNTN3027A/WS2
VNTN3027A/WS3
VNTN3027A/WS4
VNTN3027A/WS5
VNTN3027A/WS6
VNTN3028A/WS1
Wind Noise (1)
VNTN3028A/WS2
Wind Noise (2)
VNTN3029A
Usage of Chassis EAR
Issued: March 2002
Attachment 2
Attachment 2
Sample of training materials
Issued: March 2002
LE
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Shop Activity
Technical Fundamental
LE
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INTRODUCTION TO ECCS
1.
WHAT IS ECCS ENGINE?

ECCS engine is a real improvement for reduction of each exhaust gas emission
while maintaining driveability by controlling fuel injection, idle engine-speed, fuel
pump control by one microcomputer according to every driving condition, to
always most suitable condition including improvement of fuel consumption.
Control of ECCS engine pre-programs the control module to the most suitable
control value in every driving condition beforehand. It detects the state of the
engine by sensors and selects the most suitable value among the pre-programed data that a control module memorizes by an input signal from sensors.
It also sends an output signal to the actuator and controls it.
2.
PURPOSE OF ECCS DEVELOPMENT

1) Improved engine performance
2) Improved fuel consumption
3) Reduced air pollution
4) Improved driveability
5) Improved starting in cold weather
3.
ECCS FLOW SYSTEM

Although particular components vary from model to model, basically the ECCS
monitors and controls these 3 primary systems to maintain maximum engine
performance.
* FUEL FLOW SYSTEM
* AIR FLOW SYSTEM
* ELECTRONIC FLOW (IGNITION) SYSTEM
Constant adjustments are made to maintain a specified relationship between
these systems. Understanding this relationship will allow you to more easily
break down the overall engine operations into smaller segments. In doing so,
you can more systematically target and/or eliminate them as part of the trouble
cause. Brief descriptions of each system are found on the following pages.
To maintain the operational relationship described above, the ECCS uses three
basic types of components;
* SENSORS
* A CONTROLLER
* ACTUATORS
These components work in relation to each other as shown below:
SENSORS
CONTROLLER (ECM)
Precisely monitor engine conditions, then send input signals to

the control module (ECM).
Processes sensor input signals

relative to stored data, sending
control signals to engine components.
ACTUATORS
Perform various engine functions, based on control signals
received from control module.
LE
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4.
FUNCTIONS OF ECCS
SYSTEM CONFIGURATION
ECCS FUNCTION
The ECCS is capable of controlling a number of functions. It is also capable of
providing more delicate and more sophisticated control. The functions that can
be controlled by ECCS are:
4-1. Fuel Injection Control

Based on the quantity of intake air (air mass), this fuel injection control system
determines the fuel injection quantity corresponding to engine conditions. For
example, optimum fuel injection quantity is determined by the coolant temperature at the time when the engine is started. After idling, the air-fuel ratio is
properly controlled by a learning function.
4-2. Ignition Timing Control
Reads data from the memory in ECM, and determines optimum ignition timing
based on engine rpm and intake air quantity.
4-3. Fuel Pump Control
Controls source voltage to the fuel pump according to engine rpm and condition, thereby reducing pump noise and power consumption.
4-4. Idle Speed Control
Receives signals from various sensors, and adjusts the engine to optimum
idling speed corresponding to the engine condition.
4-5. Pressure Regulator Control
Increases the fuel pressure temporarily when starting the engine with high
coolant temperature.
4-6. Fail-Safe System
In the case of the malfunction of the above system, the fail-safe system keeps
engine operable and it is possible to start the engine.
4-7. On-Board Diagnosis System (Self-Diagnosis)
Checks the input and output signals of control module for any signal trouble in
actuators. (This is done when short- or open-circuit should occur.)
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5.
THREE FLOW SYSTEMS
5-1. Fuel Flow System

All ECCS models have the same basic fuel flow system, as shown in the schematic below. A fuel pump pulls fuel from fuel tank, moves it through the fuel
lines (including a fuel filter) and eventually supplies it to the engine through the
fuel injectors. A pressure device maintains specified fuel pressure throughout
the system.
Typical fuel flow system
Fuel Tank
Fuel Pump
Pressure
Regulator
Fuel Filter
Intake
Manifold
Fuel Injector
5-2. Air Flow System

As with the fuel flow system, ECCS Air Flow Systems are basically the same
from model to model. Since the quantity of air mixed with fuel (Mixture ratio) is
key to engine performance, the control of intake air is extremely important.
Typical air flow system
Air Filter
Mass Air Flow

Sensor
Throttle Chamber
Collector
IACV-AAC valve
IACV-Air Regulator
Intake Manifold
5-3. Electrical Flow System

The 3rd Nissan ECCS flow system is for electrical current. In this system, signals are input to the ECM, primarily from the Camshaft Position Sensor (indicating engine speed and piston position) and the Mass Air Flow Sensor
(indicating mass air intake). The ECM then processes these signals and send
the resulting signals to the injectors and power transistor to control engine
operation.
Typical electrical flow system
SIGNAL SOURCES
Camshaft Position Sensor

Mass Air Flow Sensor
Engine Coolant Temp. Sensor
Throttle Valve Position Sensor
Knock Sensor
Oxygen Sensor
Ignition Switch
Neutral Switch
Air Conditioner Switch
Vehicle Speed Sensor
Battery Voltage
ACTUATORS
Inputs
Outputs
Control Module (ECM)
Injectors
Power Transistor
Fuel Pump
IACV-AAC valve
Others
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6.
FUNCTIONS OF COMPONENT PARTS
6-1. Camshaft Position Sensor (Crank Angle Sensor)

A key component of the ECCS. The CPS monitors engine speed and piston
position by reading light signals passing through 2 sets of slits cut in a rotor
plate. (Except the New EGI system). The set of 1 deg slits read engine speed
and the set of 120 deg (6 cylinder)/180 deg (4 cylinder) slits read piston position. A pulse input signal is then sent to the ECM to control:
*
*
*
*
*
Fuel injection timing

Fuel-cut control
Ignition timing
Basic fuel injection quantity
Various enrichment corrections
NOTE: REF signal Reference signal

POS signal Position signal
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6-2. Mass Air Flow Sensor (Air Flow Meter)

A key component for basic fuel injection control that measures intake air flow
rate and density, then sends these signals to the ECM. These signals vary,
based on the amount of heat emitting from the hot film place in the intake air
stream.
Three kinds of Mass Air Flow Sensors

have been used in Nissan vehicles:
* Flat type
* Hot wire type
* Hot film type
6-3. Throttle Position Switch (Throttle Valve

Switch)
Throttle position switch detects full open or
full close position. It is input for idle
engine-speed control and fuel injection
control.
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6-4. Throttle Position Sensor (Throttle Sensor)

The throttle position sensor detects opening of throttle valve and rate of opening
and it provides input for aditional fuel
injection at acceleration. The throttle position sensor also incorporates the throttle
position switch function.
6-5. Engine Coolant Temperature Sensor
(Water Temperature Sensor)
It detects the cooling water temperature
and it senses to compensate fuel injection
quantity to meet cooling water temperature condition. It also senses an input signal to set the idle engine speed in relation
to the cooling water temperature.
6-6. Oxygen Sensor (Exhaust Gas Sensor)
The oxygen sensor detects oxygen density in exhaust gas and it detects airfuel ratio.
Zirconia:
generates a voltage signal to the
ECM. Some zirconia sensors use a
heater to activate the sensor.
Titania:
senses changes to its internal resistance to provide varying voltage signal.
6-7. Knock Sensor

It detects engine knocking and it delays
ignition timing when knocking occurred.
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6-8. IACV-AAC Valve (AAC Valve)

In relation between actual engine idle
speed and the programed value, the
IACV-AAC valve receives a signal from
the ECM to adjust the air quantity in the
bypass gallery.
As shown, air flows through the AAC

valve. This solenoid valve is repeatedly
energized at a frequency of 160 Hz. The
quantity of air passing through the AAC
valve is adjusted by changing the ratio of
energizing period.
The idle adjusting screw must not be
turned unless required If it is turned excessively, idle speed feedback control may
not function.
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ECCS CONTROL MODULE

The control module is sometimes called ECM, or simply computer.
The control module receives signals from various sensors and switches, performs
computations, and compares the results with data stored in the memory, and outputs
optimum signals to the actuators. This module is the core of the ECCS system.
Sensors & Switches
Camshaft position sensor

Engine coolant temperature sensor
Vehicle speed sensor
Knock sensor
Ignition switch
Air conditioner switch
Throttle position sensor
Mass air flow sensor
Battery voltage
ECCS CONTROL MODULE
I/O port for input & output
CPU
(Central Processing Unit)
Memory
(ROM & RAM)
Actuator
Fuel injector
Fuel pump
Ignition timing
AAC valve
NS048
CAUTION
Disassembly of the control module is not allowed for the following reasons.
Disassembly allows dirt to enter the control module, resulting in poor contact of
connections or rust formation on parts.

Static electric charge in the human body may damage the electronic parts such
as the IC (Integrated Circuit) or LSI (Large Scale Integrated Circuit), etc.
Condition of electronic parts cannot be judged from their appearance.
Internal wiring may be damaged.
When connecting or disconnecting the harness connector to or from the control
module, be sure to turn the power OFF. Otherwise, the control module may be
damaged by a spark discharge, shortcircuit, or generation of surge voltage, etc.
caused by such operation.
Do not allow the control module to get wet as this may cause shortcircuit or leakage and result in damage to the control module.
Do not drop the control module. This may cause the PC (printed circuit) board to
crack, resulting in malfunction of the control module.
Store the control module in a place that is clean and dry and where ambient temperatures are somewhat low and do not change drastically.
LE
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Shop Activity
Technical Fundamental
LE
Worksheet for Introduction to ECCS (ECTN1001A/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
At the end of this session, you will understand name, location

and function of ECCS component parts.
Appropriate Vehicle or Units
RESOURCES:
Appropriate Service Manual

Worksheet
Text
INSTRUCTIONS:
These instructions will outline the tasks that you will need to
complete in order to meet the objective for this worksheet. The
following symbols are used throughout the worksheet to help
clarify these instructions.
Use the Service Manual or other service literature.
Write your answer to the question.
Perform the operation or task.
Key point or service tip.
Obtain instructors initials before continuing.
Continue with worksheet.
End of worksheet.
When you have finished all the activities, have the instructor check your work and
initial this worksheet. Also, have your instructor initial your sign-off sheet so you can
keep track of your overall course progress.
LE
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ECTN1001A/WS1
Name and location of ECCS component parts

Using the Service Manual found at your Worksheet and the vehicle, answer the following questions and fill out the blanks.
1. What is the vehicle model and engine unit?

Model:
Engine unit:
2. Find the EC (EF & EC) section tab and go to that section.
3. On what page does ENGINE AND EMISSION CONTROL OVERALL

SYSTEM information begin for the above model?
4. On what page does System Diagram information?
5. On what page does ENGINE AND EMISSION CONTROL PARTS

DESCRIPTION Information begin?
6. Turn to the ECCS component parts location section.
LE
ECTN1001A/WS1
7. What are the following parts located?

1) Mass Air Flow Sensor _____
2)Power Transistor
3) Fuel Injector_____________
4)Camshaft Position Sensor
5) Fuel Pressure
Regulator _______________
6)Throttle Position Sensor
7) Air Regulator ____________
8)Engine Coolant
Temperature Sensor
LE
S
ECTN1001A/WS1
8. Check the correct part in each rectangle below.

Air flow system:
Air cleaner
Mass air flow sensor/AAC Valve
Throttle chamber
Air duct
FICD Valve/Collector
AAC Valve/Intake Valve

Air Regulator/Pressure Regulator
Intake manifold
Fuel flow system:

Fuel tank
Fuel pump/Fuel sensor
Fuel filter/Damper
Fuel line (Pipe)
Pressure gauge/
Pressure Regulator
Fuel gallery
Fuel Tank/Crank case
Fuel injector
NS087
9. What are the purposes of ECCS?
10. What are the three majors functions of ECCS?

control
control
control
Example of other functions.

Fail-safe system
Fuel pump control
On-board diagnosis system
Pressure regulator control
LE
ECTN1001A/WS1
11. There are two types of component parts: SENSORS and ACTUATORS.
Fill in the name of major sensors and actuators below.
SENSORS
ACTUATORS
12. Match the component to its function and draw a line in-between them.
Engine knocking
Intake air quantity
Throttle valve angle
Density of oxygen
Knock sensor
Crankshaft position
Oxygen sensor
Water temperature
13. Which type of Mass air flow sensor is used on the vehicle provided?
Hot wire type/Hot film type
14. Remove distributor cap and camshaft position sensor cover.
LE
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ECTN1001A/WS1
15. How many reference signal slits are there?
16. What are they used for?
If available
17. Check the Oxygen sensor on your vehicle.
18. Which type of Oxygen sensor is used?

Zirconia type/Titania type
19. Why is a heater needed for the oxygen sensor?
Upon completion, have your instructor sign-off this worksheet and move on to the
next one. If you have any questions, feel free to ask him before starting the next
exercise.
INSTRUCTOR SIGN-OFF
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Attachment 3
Attachment 3
Sample of assessment sheets
Issued: March 2002
E
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ASSESSMENT SHEET (STEP 1)

(FOR ASSESSOR)
ASSESSOR NAME:
DATE:
APPLICANT NAME:
I : He can do with assessors advice.
L : He can do by himself.
SUBJECT
1. Identification information
ASSESSMENT ITEMS
SKILL LEVEL
REMARKS
Vehicle model type matches

with service manual of
assigned vehicle.
(No. 1 through 4)
Unit type matches with service
manual of the assigned
vehicle. (No. 5 through 10)
1. How to read service

manual.
Described pages match with

service manual.
2. Meaning of symbols
Meaning of each symbol

matches with service manual.
1. Selection of SST
Name and No. of SST for each

operation match with the service manual of the assigned
vehicle.
1. Check of Brake system
Judgement of the assessor

matches with that of the
technician.
1-1. Measurement of
Brake Pad
Measuring method and the

measured value are correct.
1-2. Judgement of Brake

Pad
The judgement was made after

checking wear limit in service
manual and deformation or
cracks.
Issued: March 2002
SA
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I : He can do with assessors advice.

L : He can do by himself.
SUBJECT
1. ECCS self-diagnosis
ASSESSMENT ITEMS
SKILL LEVEL
REMARKS
Can read code No. and knows

its meaning.
Checking & judgement were
made after warming up the
Engine.
2. Checking and adjustment of idling rpm & igni Adjustment was made accordtion timing
ing to the procedures shown in
service manual.
1. Measurement of resistance of ignition wire
Can use tester properly and

can read resistance value correctly.
Judgement on OK/NG is made
according to the value shown in
service manual.
Can identify power supply terminal No. of Relay by referring
to service manual.
2. Check of Harness
Can tell colors of the color

codes of Harness.
Can tell parts locations for the
relevant vehicle by referring to
service manual.
Can use tester properly and
can read voltage correctly.
Issued: March 2002
E
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(FOR TECHNICIAN)
Periodic maintenance
DATE:
APPLICANT NAME:
DEALER NAME:
1. Check the following items.

Check all brake fluid lines.
(1)
Bends
Good ____________
No good
_______________
(2)
Twists
Good ____________
No good
_______________
(3)
Abrasion
Good ____________
No good
_______________
(4)
Deterioration
Good ____________
No good
_______________
(5)
Cracks
Good ____________
No good
_______________
(6)
Corrosion
Good ____________
No good
_______________
(7)
Leaks
Good ____________
No good
_______________
2. What is the thickness of each pad on the specified side?

Specified side
Inner
Thickness
mm
Judgement
Outer
Thickness
Judgement
mm
Issued: March 2002
E
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SA

(FOR TECHNICIAN)
DATE:
APPLICANT NAME:
DEALER NAME:
1. Carry out self-diagnosis under on-board condition, and enter the results.
Code No.
Detected items
2. Check the following items, judge whether adjustment is necessary or not, and
adjust it if necessary.
Check results
Judgement
1)
Idling rpm
rpm
Good
No Good
2)
Ignition timing BTDC
deg.
Good
No Good
Issued: March 2002
Contents
I
Policies & operations

I-1 Basic policies
I-2 Training policies
I-3 Skill assessor
I-4 Validity of certification
I-5 Reporting certified technicians to Nissan
I-6 Master technician
I-7 Training and certification record
II
Training package
II-1 Relation between Operation and Materials
II-2 Training Materials for Technician
II-3 Instructor Guide
II-4 Skill Assessment Manual
II-5 Certificate and Uniform Emblem
II-6 Passport
Attachment
Price list
How to order
N-STEP 1 Operations Manual
Section I
I Policies & Operations
I-1 Basic policies

This N-STEP 1 Operation Manual describes only the specified policies and operations on
this course which are different from N-STEP Policies and Operations Manual.
Therefore for the basic operations which are not described here, refer to the N-STEP Policies and Operations Manual.
I-2 Training policies

N-STEP 1 Master and Active Skill Matrix
As the model line-up and, also, specifications differ from country to country, and as different
repair philosophies exist in different countries, the Master Skill Matrix can be modified in
line with the above national requirements, to form the Active Skill Matrix that is specific
depending on each country.
Based upon the Master Skill Matrix each distributor has to define the Active Skill Matrix.
To define the Active Skill Matrix for each country mainly depends on the model mix. Refer
to next page.
Issued: March 2002
Section I
N-STEP 1 Master Skill Matrix

Course
FUND
Fundamental
Skills
MANT
Maintenance
Skills
TOOL
Usage of Tools
EXSE
Express
Service
Topic Code
Descriptions
GITN1001B
GITN1002A
GITN1003B
GITN1005A
Outline of Engine
GITN1006A
Outline of Chassis
ECTN1001B
ELTN1001B
ATTN1001A
ATTN1002A
BTTN1001B
Body & Trim
CLTN1001B
ELTN1003B
Handling of Battery
EMTN1001B
Engine Idle Adjustment
LCTN1001B
MATN1001B
MATN1002B
MTTN1001A
ELTN1002B
GITN1004B
GITN1007B
ECTN1002A
Usage of CONSULT
ECTN1003B
Usage of CONSULT-II
EXTN1001B
Express Lub. Service
EXTN1002B
EXTN1003B
EXTN1004B
Tire Replacement & Brake System
EXTN1005B
Issued: March 2002
Section I
I-3 Skill assessor

Assessor of Nissan or a person who is authorized by Nissan. Assessor authorization is
designated as below:
(1) Assessor for an assessor
Assessor of NSC
(2) Assessment method
A person who has passed the final test after completion of the N-Step 1 Instructorcourse organized by Nissan. The authorized assessor is given an authorization certificate by Nissan.
(3) Validity of authorization
There is a limited period of validity of 5 years for authorization as an assessor. In order
to renew the authorization, the assessor should attend a refresher training course
organized by Nissan and should pass the final test after the course.
I-4 Validity of certification

There is a limited period of validity of 5 years for certification as Senior Specialist. In order
to renew the certification, the technician should attend a refresher training course and
should pass the final test after the course.
Duration of refresher training course is half a day, followed by half-day assessment (written examination).
Refresher training course should be organized by each distributor, based on update
information provided by an assessor of Nissan, by means of N-Step supplement manuals, which have been issued during the 5 years since the applicants were last.
I-5 Reporting certified technicians to Nissan

After assessment, the NSC will send passports of qualified technicians to Nissan. Nissan
will then confirm qualification of each technician and apply a stamp of Certified as Technician on the passport. Passports are then sent back to the NSC along with the emblem and
an authorization certificate issued by NSC.
Certified technicians are recorded on a database at NSC. When the designated time limit
of certification validity approaches, Nissan will notify the corresponding NSC as a reminder
for refresher courses and assessment.
Issued: March 2002
Section I
I-6 Master technician

When a technician is certified as both Engine Senior Specialist and Chassis Senior Specialist, he is automatically certified as Master Technician.
The distributor will send passports of qualified technicians to Nissan. Nissan will then confirm qualification of each technician and apply a Certified as Master Technician stamp on
the passport. Passports are then sent back to the Distributor along with the emblem and
an authorization certificate issued by Nissan. Certified technicians are recorded on a database at Nissan.
I-7 Training and certification record

For distributor/dealer
In order to grasp how N-STEP1 training is proceeding and how many technicians
have achieved the rank, the training/certificate record should be made and maintained by distributor/dealer.
Each distributor is requested to provide Nissan with a periodical status report twice
a year, in April and October, using the form shown on the next page.
For technician
The passport given to all technicians is designed to indicate clearly the subjects that
have been studied and to be studied.
It will also stand as a record of the technicians achievements within N-STEP training system.
Issued: March 2002
Section I
Issued: March 2002
Section II
II Training package
II-1 Relation between Operation and Materials
N-STEP 1 OPERATION FLOW
MATERIALS PACKAGE FOR N-STEP 1
Issued: March 2002
Section II
II-2 Training Materials for Technician

STEP 1 training materials are used by specialist before, during or after training.
It contains the following materials:
(1) TEXTBOOK
This contains a technical explanation of the theory. The textbook assists technicians
understanding during worksheet performance.
(2) SUPPLEMENTAL TEXT BOOK
Provides basic knowledge about automobiles.
GENERAL TOOLS & 3S POLICIES
Explains correct usage of general tools and what technicians must do in their workshop.
Issued: March 2002
Section II
(3) WORKSHEETS
Technicians perform the training activities according to the worksheets. N-STEP 1 training
has 4 courses.
Issued: March 2002
Section II
STEP1 TRAINING MATERIALS

TEXTBOOK
WORKSHEETS
Issued: March 2002
Section II
SUPPLEMENTAL TEXTBOOK
GENERAL TOOLS & 3S POLICEIS
Issued: March 2002
Section II
II-3 Instructor Guide

STEP 1 Instructor Guide is used by the instructor before or during training. It contains the
following materials:
(1) INSTRUCTOR GUIDE
The instructor guide explains how to conduct the course, the key points to be taught and
how to use the training materials.
(2) WORKSHEET ANSWERS
The Worksheet Answer book describes each correct answer. It is used by the instructor to
respond quickly with technician.
Issued: March 2002
Section II
INSTRUCTOR GUIDE
WORKSHEET ANSWERS
Issued: March 2002
Section II
II-4 Skill Assessment Manual

STEP 1 skill assessment manual is used by the assessor when the technician is screened
or assessed for the judgement of certification. It contains details on how to conduct the skill
assessment, assessment tasks and assessment criteria.
SKILL ASSESSMENT MANUAL
Issued: March 2002
Section II
II-5 Certificate and Uniform Emblem

The certificate and uniform emblem are given to the technician as proof of a skill assessment pass. These will contribute to their motivation. A sample is shown as follows.
CERTIFICATE
UNIFORM EMBLEM
Issued: March 2002
Section II
10
II-6 Passport
The passport is used for the technicians record. It shows the technicians progress. A sample is shown as follows.
Issued: March 2002
Attachment 1
PRICE LIST FOR STEP 1 MATERIALS

CD-ROM TYPE
Item
Language Publication Unit
Publication No.
Price
CD-ROM FrameMaker
English
1 Piece
NS1E-IFMKG1
130,000
CD-ROM PDF
English
1 Piece
NS1E-IPDFG1
60,000
Publication No.
Price
FORMER TYPE ONLY

Item
Language Publication Unit
STEP 1 TEXTBOOK
English
1 Set
NS1E-TXTFG1
1,500
MASTER COPY OF STEP 1

TEXTBOOK
English
1 Set (High
Quality Copy)
NS1E-MTTFG1
50,000
STEP 1 WORKSHEET
English
1 Set
NS1E-WSTFG1
1,500
MASTER COPY OF STEP 1

WORKSHEET
English
1 Set (High
Quality Copy)
NS1E-MWTFG1
50,000
STEP 1 INSTRUCTOR GUIDE
English
1 Set
NS1E-IGTFG1
8,000
STEP 1 OPERATIONS MANUAL
English
Without binder
NS1E-NPOMG1
800
English
1 Volume
NS5E-NFUNG0
500
GENERAL TOOL & 3S POLICIES
English
1 Volume
NS5E-FGENG0
500
STEP 1 SKILL ASSESSMENT

MANUAL
English
1 Set
NS1E-ASTFG1
2,000
CERTIFICATE
English
1 Set (10 Sheets)
NS5E-CRTFG0
1,000
UNIFORM EMBLEM
English
1 Piece
NS5E-EMTFG0
1,000
PASSPORT
English
1 Set (10 Books)
NS5E-PASSG1
3,000
BINDER COVER FOR STEP 1

TRAINING MATERIALS
English
10 Pieces
NS8E-CTTFG0
2,000

INSTRUCTOR GUIDE
English
1 Piece
NS8E-CITFG0
200

SKILL ASSESSMENT MANUAL
English
1 Piece
NS5E-CATFG0
200
Issued: March 2002
Attachment 2
HOW TO ORDER
1. To order N-STEP materials, please use the Service Publication Order Form referring
to the explanation on the next page.
2. Send Copy No. 2 of the completed Order Form to the following address:
Maruboshi Co., Ltd.
2-1-7 Higashi Shinagawa, Shinagawa-ku
Tokyo 140-0002
Japan
Facsimile No.: 81-03-3450-5142
3. a) In the event that a Letter of Credit (L/C), Documents against Payment (D/P) or Documents against Acceptance is used for purchasing service parts, the FOB total price
and freight charge will be withdrawn from each payment term.
b) If the above payment terms are not used, remit the calculated amount shown on the
Pro-forma Invoice sent to you by Nissan Tokyo after receiving your order.
4. After T/T remittance has been deposited or the bank draft cashed, the service publications requested will be sent to you.
Notes:
a. Personal checks will not be accepted.
b. Do not send a Bank draft together with the Order Form.
Issued: March 2002
Attachment 3
ORDER FORM
Fill in a specifically prepared Order Form as shown in the following sample. If you require
additional Order Forms, please inform us of the quantity needed and we will supply them
free of charge.
Completing the Order Form

1.
2.
3.
4.
Date
Enter the date on which the Order Form
is completed.
Order No.
Write in the Order No. which is composed of five (5) letters or numbers.
The Order No. will be used as a Reference No. for the pro-forma invoice, shipping advice or a request for shipping
information.
Item No.
Enter the number for each item included
in the order.
Description
Enter the name of the publication being
requested.
5.
6.
7.
8.
Publication No.
Enter the correct Publication No. shown
in this catalog.
If no Publication number is given in this
column, it will be difficult for us to select
the appropriate publication.
Quantity
Enter the number of copies required.
Terms of Payment
Put an X mark on the applicable terms of
payment. *1 In the case of L/C, also
enter the L/C No.
Method of Shipment
Put an X mark on the applicable method
of shipment.
9.
Distributor Name & Country

Enter the name of your company and
country. Write the shipping address if
necessary.
10. Name
Write the name of the orderer.
11. Signature
Write in the signature of the orderer.
*1: L/C: Letter of Credit
D/P: Documents against Payment
D/A: Documents against Acceptance
Issued: March 2002
Edition: March 2002

Publication No. NS2E-NPOMG1
FOREWORD
This skill assessment is for the SCREENING procedure, which is
carried out before the N-STEP 1 training course, and for the CERTIFICATION procedure after the training.
The establishment of the skill assessment tasks and the execution
methods are decided based on an average Nissan service shop.
However, in accordance to the particular needs of different markets,
the contents of the skill assessment can be modified to a certain
extent.
Nissan Motor Co., LTD. hopes you continuously study this skill
assessment program to make it suitable for your market.
CONTENTS
I
Skill assessment policies

I-1 Objectives
I-2 Skill assessment tasks
I-3 Skill assessment conducting timing
I-4 Place for skill assessment
I-5 Skill assessor
I-6 Skill assessment applicants
II
Skill assessment procedure

II-1 Execution method
II-2 Selection of skill assessment tasks
II-3 Operation flow
III Skill assessment materials

Task No. 1-1
Task No. 1-2
Task No. 1-3
Task No. 1-4
Task No. 1-5
Task No. 1-6
Task No. 1-7
Task No. 1-8
Task No. 1-9
Task No. 1-10
Task No. 1-11
Task No. 1-12
Task No. 1-13
Note:
Task No. 1-14
Task No. 1-15
Task No. 1-16
Each of the above Task has the same structure, composed of the same materials as
below.
* Assessor guide
* Equipment preparation table
* Task sheet
* Criteria sheet
* Check sheet
N-STEP 1 Skill assessment manual
Section I
I Skill assessment policies
I-1 Objectives
The purpose of the Skill Assessment is to determine the right subject, right time, and right
way to train a certain technician by using the result of the skill assessment.
This skill assessment is a tool to accurately check if a technician satisfies the technical
qualification of the *1TECHNICIAN rank at a service shop.
*1 Technical qualifications for TECHNICIAN rank are as follows:
- Prossesses fundamental knowledge of the specifications and features of
Nissan vehicles in the market.
- Understands the function of the major components and fundamental engine,
electrical and chassis theory.
- Able to perform Pre-Delivery Inspection and Periodic Maintenance.
- Able to perform fundamental CONSULT operations.
- Understands the contents of the Service Manual.
I-2 Skill assessment tasks

The tasks of this skill assessment are designed to cover all the topics for N-STEP 1.
However, the skill assessment task table does not include some specific task codes related
to GITN1005A (Outline of engine) and GITN1006A (Outline of chassis) which are background knowledge and can be evaluated in other assessment tasks.
In addition, similar topics are grouped as one skill assessment task. (Ex., task codes 1-10
& 1-12)
Refer to next page.
Issued: March 2002
Section I
Relationship: N-STEP 1 topics vs skill

assessment tasks
Master skill matrix table
Course
FUND
Fundamental
Skills
MATN
Maintenance
Skills
Usage of Tools
Express
Service
Topic Code
Descriptions
Skill assessment
task table
Task
code
Descriptions
GITN1001B
1-1
GITN1002A
1-2
GITN1003B
1-3
GITN1005A
Outline of Engine
GITN1006A
Outline of Chassis
ECTN1001B
1-4
ELTN1001B
1-5
ATTN1001A

1-10
ATTN1002A
BTTN1001B
Body & Trim
1-9
Body & Trim
CLTN1001A
1-8
ELTN1003B
Handling of Battery
EMTN1001B
1-7
LCTN1001B
1-6
MATN1001B
1-12
MATN1002B
MTTN1001A
1-14
ELTN1002B
1-15
GITN1004B
1-13
GITN1007B
ECTN1002A
Usage of CONSULT
Usage of CONSULT
1-11
ECTN1003B
Usage of CONSULT-II
EXTN1001B
Express Lub. 30
Express Lub. 30
EXTN1002B
EXTN1003B
EXTN1004B
EXTN1005B
1-16
Usage of CONSULT-II
Issued: March 2002
Section I
I-3 Skill assessment conducting timing

For SCREENING:
Skill assessment is to be conducted before the N-STEP 1 training.
For CERTIFICATION:
Skill assessment is to be conducted after several months of practical experience following
the completion of the final course of the N-STEP 1 training.
I-4 Place for skill assessment

The skill assessment is to be conducted at places determined in accordance with the
actual situations of each NSC or service shop.
I-5 Skill assessor

Assessor of Nissan or a person who is authorized by Nissan.
I-6 Skill assessment applicants

For SCREENING:
All technicians in Nissan dealership.
For CERTIFICATION:
Technicians who have completed all the N-STEP 1 training courses and want to obtain the
rank.
Issued: March 2002
Section II
II Skill assessment procedure
II-1 Execution method

The following two methods are possible.
Method 1): Assessor evaluates the specialists skill level using the *1 criteria sheet with the
*2
task style skill assessment.
Method 2): Checking skill assessment tasks through daily work by using a *3 check sheet.
However, for those skill assessment task(s) which cannot be judged through
daily work and the skill assessment task(s) on which the check results were
unsatisfactory, use the task style skill assessment method for confirmation.
Note: As a basic rule, the skill assessment through daily work can only be used in a situation where the task style skill assessment cannot be executed due to some local difficulty.
Descriptions
*1 Criteria sheet: The judging criteria are described in relation to tasks.
*2 Task style skill assessment: The tasks on the task sheets which are distributed to technicians are carried out, and their skill level is evaluated using the criteria sheet.
*3 Check sheet: The judging criteria are described for the skill assessment through daily
work.
Reference
Usage of skill assessment materials.
Skill assessment method
Method 1)
Task style
Method 2)
Through daily work
Assessor
Criteria sheet
Check sheet
Applicants
Task sheet
User
Issued: March 2002
Section II
II-2 Selection of skill assessment tasks

It is absolutely necessay that the eight essential tasks specified by Nissan (out of a total of
16) be assessed as a minimum requirement. (See skill assessment task selection table on
next page.)
For more accurate evaluation and encouragement of growth of technicians skill levels,
Nissan suggests the other tasks are executed, too.
Note: The selection of the Nissan-specified essential tasks is based on the importance
(effect on other tasks or subsequent steps, or necessity in daily work) and the difficulty (topic which is difficult to become familiar with thoroughly after only a one-time
experience on the worksheet or in daily work) of the tasks.
Selection Flow Chart

*1
*1 Number of skill assessment tasks = 16
*2
*2 Delete skill assessment task(s) which are irrelevant to

the models in the market.
E xam ple : F o r m a rket w he re A /T m od els a re n ot sold,
d elete ta sk code 1 - 10 (AT T N 1 001 A an d AT T N 10 02A ).
*3
*3 The distributor decides on the adoption of tasks in

addition to the essential tasks.
Note: The decision should be based on the effect on
daily work and the difficulty.
Start
Model Mix
Selection of skill
assessment tasks
other than the nine
essential tasks
Decision
* NISSAN recommends the skill assessment task selection table be utilized for selection.
(See next page)
Issued: March 2002
Section II
Task selection table

: Task not to be executed
X : Selected Task
(Essential Task)
Task Code
Topic Code
Descriptions
Essential
Your selection
Standard time
(min)
1-1
GITN1001B
20
1-2
GITN1002A
20
1-3
GITN1003B
15
1-4
ECTN1001B
30
1-5
ELTN1001B
30
1-6
LCTN1001B
40
1-7
EMTN1001B
20
1-8
CLTN1001A
15
1-9
BTTN1001B
Body & Trim
20
1 - 10
ATTN1001A
20
ATTN1002A
ECTN1002A
Usage of CONSULT
ECTN1003B
Usage of CONSULT-II
MATN1001B
GITN1004B
1 - 13
MATN1002B
1 - 14
MTTN1001A
10
1 - 15
ELTN1002B
10
1 - 16
EXTN1001B
Express Lub. 30
EXTN1002B
EXTN1003B
20
EXTN1004B
EXTN1005B
1 - 11
1 - 12
X
X
40
30
20
Issued: March 2002
Section II
II-3 Operation flow

SCREENING assessment flow
Method 1)
<By task style skill assessment>
Issued: March 2002
Section II
Method 2)
<Through daily work & task style skill assessment>
Issued: March 2002
Section II
CERTIFICATION assessment flow

Method 1)
<By task style skill assessment>
Issued: March 2002
Section II
Method 2)
<Through daily work & task style skill assessment>
Issued: March 2002
TASK CODE: 1-1

Section III
III
Assessors preparation
III-1 Assessor guide
Task
code
1 -1
Topic code
GITN1001B
Prior to assessment
Make the technician fill out the assessment sheets according to the Service
Manual. Before starting, you must do as follows:
Check and note the answers for the vehicle model beforehand.
1. Fill in the prefix and suffix designations on the task sheet.
Ex) BAYARFFB14EWA
Select 3 items from each section of the Service Data Specification.
Ex.: On what page is the Service data specification of the valve clearance?
On what page is the self-diagnosis?
On what page is the valve clearance of GA16DE?
2. Select five symbols from the attached sheet and write corresponding
number on the task sheet.
Issued: March 2002
Section III
III-2
Task
code
1 -1
Equipment preparation table

Topic code
GITN1001B
Vehicles/units
Any Nissan vehicle
Preparation items
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 -1
APPLICANT NAME:
Description: Usage of Service Manual
DEALER NAME:
1. Enter page No(s). of the Service Manual where the designated items in the following sections can be
found.
Prefix and suffix designations:
Section
Designated Item
2. Explain the meaning of the designated symbols.
1/2
Page No.
STEP 1 TASK SHEET

Symbols
Attached sheet for task code 1-1
DATE:
APPLICANT NAME:
DEALER NAME:
2/2
STEP 1 CRITERIA SHEET

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1-1
Topic code
(Description)
GITN1001B
(Usage of Service
Manual)
Judgement
Subject
Assessment items
1. How to use the

Service Manual.
Described pages match the Service Manual.
2. Meaning of symbol
Meaning of each symbol matches

the Service Manual.
Satisfied
Unsatisfied
Remarks
Issued: March 2002
STEP 1 CHECK SHEET [Judge by daily work]

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1 -1
Topic code
GITN1001B
Subject
Check point
1.Usage of Service Manual
Technician can find the necessary information in the Service Manual.
2.Usage of Service Manual
Technician can confirm the meaning of the symbol marks using

Service Manual.
Details
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-2

Section III
III
Task
code
1 -2
Topic code
(Descriptions)
GITN1002A
(Usage of Special
Service Tools)
Prior to assessment
Fill in the prefix and suffix designations beforehand.
Ex) BAYARFFB14EWA
Check and note the answer for the vehicle model beforehand.
Issued: March 2002
Section III
III-2
Task
code
1-2

Topic code
GITN1002A
Vehicles/units
Any Nissan vehicle
Preparation items
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 -2
APPLICANT NAME:
Description: Usage of Special Service Tools
DEALER NAME:
1. Write the SST (Special Service Tool) names and number of the items below.
Prefix and suffix designations:
Operation Name
Number
1) Oil filter replacement

2) Installing engine on engine stand
3) Installing brake hose
4) Removing steering linkage
5) Measuring engine oil pressure
6) Installing piston into cylinder
7) Removing steering wheel
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1-2
Topic code
(Description)
GITN1002A
(Usage of Special
Service Tools)
Judgement
Subject
Assessment items
Satisfied
Unsatisfied
Remarks
1. Find out the SST Be able to give the correct No. of

number.
the SST.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1-2
Topic code
GITN1002A
Subject
1.Usage of Special Service
Tools
Check point
Technician can use the special service tools in daily job.
Details
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-3

Section III
III
Task
code
1 -3
Topic code
(Descriptions)
GITN1003B
(General Model
Introduction)
Prior to assessment
Assign the vehicle to the technician.
Check and note the answers for the vehicle model beforehand.
Issued: March 2002
Section III
III-2
Task
code
1-3

Topic code
GITN1003B
Vehicles/units
Any Nissan vehicle
Preparation items
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 -3
APPLICANT NAME:
Description: General Model Introduction
DEALER NAME:
1. Enter the following items for the assigned vehicle.
1) Destination:
2) Vehicle name:
3) Vehicle body type:
4) Grade:
5) Engine type:
6) Transmission type:
7) Front brake type:
8) Rear brake type:
9) Steering gear type:
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1-3
Topic code
(Description)
GITN1003B
(General Model
Introduction)
Judgement
Subject
1. Identification
Information
Assessment items
Satisfied
Unsatisfied
Remarks
Vehicle model type matches the

Service Manual of assigned vehicle. No. 1) through 4).
Unit type matches the Service
Manual of the assigned vehicle.
No. 5) through 9).
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1-3
Topic code
GITN1003B
Subject
General Model
Introduction
Check point
Technician can confirm the specified vehicle type.
Technician can confirm the unit type of the specified vehicle using
Service Manual.
Details
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-4

Section III
III
Task
code
1-4
Topic code
(Descriptions)
ECTN1001B
(Introduction to
ECCS)
Prior to assessment
Assign the vehicle with ECCS to the technician.
1. Check whether the mode is in mode 2 or mode 5 beforehand.
2. For QG engine: Disconnect the engine coolant temperature sensor harness.
Increase or decrease engine idle speed (rpm) to out of specifications
beforehand.
Issued: March 2002
III-2
Task
code
1-4
Section III

Topic code
ECTN1001B
Vehicles/units
Nissan vehicle with ECCS
Preparation items
General Tools
Engine tuner
Timing light
Adapter harness for engine tuner
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 -4
APPLICANT NAME:
Description: Introduction to ECCS
DEALER NAME:
1. Locate the position of the following component parts of QG engine on the assigned vehicle.
IACV-AAC Valve
EGR Valve
PHASE Sensor
POS Sensor
Fuel Pressure Regulator
Ignition Coil
Engine knocking
Intake air quantity
Throttle valve angle
Density of oxygen
Knock sensor
Crankshaft position
Oxygen sensor
Water temperature
3. Perform self-diagnosis and note the result below.

Results
DTC code:
Trouble part
ECM memory
Erased / Not erased
1/2
STEP 1 TASK SHEET

4. Check and judge the following items.
If not in specified range, adjust it.
Check results
Judgement
1) Idling speed
rpm
Good
No good
2) Ignition timing
deg.
Good
No good
2/2

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1-4
Topic code
(Description)
ECTN1001B
(Introduction to
ECCS)
Judgement
Subject
Assessment items
Satisfied
Unsatisfied
Remarks
1. Component parts Be able to identify ECCS compolocation

nent parts location.
2. Function of sensors
Components and functions

matched.
3. ECCS self-diagnosis
Be able to change mode.

Be able to determine the malfunctioning part from the code No.
Be able to erase DTC code from
ECM memory.
4. Checking and
adjustment of
idling speed &
ignition timing
After warming up engine, be able

to check idle speed and ignition
timing.
Under no-load conditions, be able
timing.
Be able to adjust idle speed and
ignition timing to within specification.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1-4
Topic code
ECTN1001B
Subject
Introduction to
ECCS
Check point
Details
1. Technician understands the ECCS component parts location.

2. Technician understands the names and functions of the ECCS
sensors.
3. Technician can select the self-diagnosis mode, read the malfunc- Be able to change mode.
tion code No. and understand the meaning.
Be able to erase DTC code.
4. Technician can check and adjust the engine idle speed, and igni- After warming up engine,
tion timing.
and under no-load conditions.
Adjustment is made to
within specification.
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-5

Section III
III
Task
code
Topic code
(Descriptions)
1-5
ELTN1001B
(Basic Electrical
Concept)
Prior to assessment
1. Assign the high tension wire and write its number on the task sheet
beforehand.
2. Assign a relay to the technician and write its name on the task sheet
beforehand.
Check and note the answer for the vehicle model specification.
Issued: March 2002
III-2
Task
code
1-5
Section III

Topic code
ELTN1001B
Vehicles/units
Preparation items
General Tools
Multimeter (Digital or Analog type)
Issued: March 2002
STEP 1 TASK SHEET
TASK CODE:1-5
DATE:
Description: Basic Electrical Concept
APPLICANT NAME:
Adjustment (Gasoline & Diesel)
DEALER NAME:
1.
What is resistance of the designated wire on your vehicle?

High tension wire
Resistance
Judgement
Good/No good
2.
With regard to the assigned relay, answer the following questions.

Relay:
(1) To which terminal does the battery voltage come?
(Check using the Service Manual)
Terminal No.
(2) Which color is the wire for that terminal?
(Check using the Service Manual)
Color No.
(3)Measure the battery voltage at that terminal.
V
3.
Circle the correct underlined words in the following sentences.

In a circuit with corrosion at one of the wire connetions, increased
resistance will increase/decrease the current flow.
And, if voltage stays constant and circuit resistance decreases,
current flow will increase/decrease.
4.
In the result of measuring the continuity between inhibitor 1 and inhibitor

2 on the attached wiring diagram, answer the following questions.
1) Does the starter motor rotate? YES / NO
2) If NO, write your conclusion.
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1-5
Topic code
(Description)
ELTN1001B
(Basic Electrical
Concept)
Judgement
Subject
1. Measurement of
resistance and
voltage
Assessment items
Satisfied
Unsatisfied
Remarks
The ZERO point is adjusted

before measurement. (for analog
type multimeter)
Measured value is correct.
Judgement is made according to
the value in the Service Manual.
2. Checking of harness
Be able to identify power supply

terminal number of the relay with
the Service Manual.
Be able to answer the harness
color correctly.
Be able to find the relays location
for the relevant vehicle with the
Service Manual.
The ZERO point is adjusted
before measurement. (for analog
type multimeter)
The measured value is correct.
3. Ohms Law
Technician fully understands

Ohms Law.
4. Inspection of har- Be able to read wiring diagram.

ness
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1-5
Topic code
ELTN1001B
Subject
Basic Electrical
Concept
Check point
1. Technician can measure the resistance using a multimeter.
2. Technician can confirm the terminal number and wire colors of

the connector using Service Manual.
3. Technician understands the Ohms Law.
Details
(1) ZERO point is adjusted.
(2) T he m ea surem ent ra nge
is corre ctly sele cte d and read .
(for analog type)
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-6

Section III
III
Task
code
Topic code
(Descriptions)
1-6
LCTN1001B
(Cooling System
Inspection)
Prior to assessment
Use a cold engine if possible.
Issued: March 2002
Section III
III-2
Task
code
1-6

Topic code
LCTN1001B
Vehicles/units
Nissan vehicle
Preparation items
General Tools
Radiator cap tester
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 -6
Description: Cooling System Inspection
APPLICANT NAME:
DEALER NAME:
1. Check the radiator cap with a radiator cap tester.

Radiator cap relief pressure:
bar / kg/cm2 / psi
JUdgement
Good
No good
2. Check the cooling system leakage with radiator cap tester.

JUdgement
Good
No good
3. Check the engine cooling mixture ratio.
JUdgement
Good
No good
4. Where are the air bleeders located?
Show the assessor the locations of the air bleeders.
5.Why should the heater control lever be turned to the position HOT
when bleeding air from the cooling system?
Explain the reason to the assessor.
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1-6
Topic code
(Description)
LCTN1001B
(Cooling System
Inspection)
Judgement
Subject
Assessment items
Satisfied
Unsatisfied
Remarks
1. Radiator cap test The measured value of the relief

pressure is correct.
Judgement is correct.
2. Cooling system
leakage test
The test is made at the specified

pressure.
The test is made for 1 minute with
the specified pressure applied.
Judgement is correct.
3. Air bleeding loca- Be able to point out all the air

tion
bleeders.
4. Explanation of
reason
Be able to explain the reason correctly.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1-6
Topic code
LCTN1001B
Subject
Cooling System
Inspection
Check point
1. Technician can check radiator cap using a radiator cap tester.
Details
Technician confirms the relief
pressure using Service Manual.
2. Technician can check the cooling system leakage using a radia- Technician checks for about
tor cap tester.
1 minute.
3. Technician can change the coolant. (including air bleeding)
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-7

Section III
III
Task
code
1-7
Topic code
(Descriptions)
EMTN1001B
(Engine Idle
Adjustment)
Prior to assessment
Set the engine idle speed to out of the specified value beforehand.
Assign the CO meter if available.
Decide whether or not use CO meter beforehand.
Issued: March 2002
III-2
Task
code
1-7
Section III

Topic code
EMTN1001B
Vehicles/units
Nissan vehicle with carburetor
engine and/or diesel engine
Preparation items
General Tools
Engine tuner (For gasoline & Diesel engine)
Adapter harness for engine tuner
CO meter if available
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 -7
Description: Engine Idle Adjustment
1.
1-1
APPLICANT NAME:
DEALER NAME:
<For Carburetor Engine>

Inspect the below items.
Engine idle speed:
Ignition timing:
CO %:
1-2
Adjust if necessary.
2.
2-1
<For QG, CG Engine>

rpm
%
Engine idle speed:

IACV-AAC Valve
Idle volume learning
3.
3-1
rpm
Judgement
Good
No good
Good
No good
Good
No good
Judgement
Good
No good
Good
No good
Good
No good
<For Diesel engine>

Inspect the idling conditions.
Engine speed(FICD OFF):
Engine speed(FICD ON):
rpm
rpm
3-2
Adjust if necessary.
4.
4-1
<For YD, QD, ZD, Diesel engine>

Engine idle speed:
Accelerator position sensor
Memory for idle position
rpm
1/1
Judgement
Good
No good
Good
No good
Judgement
Good
No good
Good
No good
Good
No good

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1-7
Topic code
(Description)
Judgement
Subject
EMTN1001A
1. Carburetor
(Engine Idle Adjustengine
ment)
Checking and
adjustment of idle
speed, ignition
timing and CO.
Assessment items
Satisfied
Unsatisfied
Remarks
After warm-up engine, be able to

check idle speed and ignition timing.
Under no-load conditions, be able
timing.
The measured results and their
judgement are correct.
The idle speed is adjusted with
specification.
When the CO meter is not used,
the idle adjusting screw is turned
about 2 turns counterclockwise
from the fully closed position.
2. Diesel engine
After warm-up engine, be able to
Checking and
check idle speed.
adjustment of idle
Be able to check idle speed under
speed.
no-load conditions.
The measured results and their
judgement are correct.
The fuel injection pipe clamp is
removed and engine revolution
meter pickup is installed.
The idle speed is adjusted to
within specification.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1-7
Topic code
EMTN1001A
Subject
Check point
Details
Engine Idle
Adjustment for
Gasoline engine
Technician can adjust the idle speed, ignition timing and CO density When CO meter is not used,
within specifications.
adjustment is made by turning the idle adjusting screw
about 2 turns counterclockwise from the fully closed
position.
Engine Idle
Adjustment for
Diesel engine
Technician can adjust the idle speed to within specifications.
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-8

Section III
III
Task
code
1-8
Topic code
(Descriptions)
CLTN1001A
(Clutch Pedal
Adjustment)
Prior to assessment
Set the clutch pedal free play to out of the specified value beforehand.
Issued: March 2002
Section III
III-2
Task
code
1-8

Topic code
CLTN1001A
Vehicles/units
Nissan vehicle with manual
transmission/axle
Preparation items
General Tools
Ruler
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 -8
APPLICANT NAME:
Description: Clutch Pedal Adjustment
DEALER NAME:
1. Measure the pedal free play (free travel) of the clutch pedal and then write it down.
Result
Pedal free play:
Judgement
mm
Good
2. If not good, adjust the pedal free play (free travel).
1/1
No good

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1 -8
Topic code
(Description)
CLTN1001A
(Clutch Pedal
Adjustment)
Judgement
Subject
Assessment items
Satisfied
Unsatisfied
Remarks
1. Measurement of The measured result and judgethe free play (free ment are correct.
travel) of the
clutch pedal.
2. Adjusting free
play (free travel)
Adjusting method and the

adjusted value are correct.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1-8
Topic code
CLTN1001A
Subject
Clutch Pedal
Adjustment
Check point
Technician can adjust the clutch pedal free play (free travel) to
within specifications.
Details
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-9

Body & Trim
Section III
III
Task
code
1-9
Topic code
(Descriptions)
BTTN1001B
(Body & Trim)
Prior to assessment
1. Check and note the answer for the vehicle model beforehand.
2. Prepare and use the Clip & Fastener training board if possible.
(Refer to Instructor Guide)
If you do not have one, assign the Clip and Fastener to the technician
beforehand.
Issued: March 2002
III-2
Task
code
1-9
Section III

Topic code
BTTN1001B
Vehicles/units
Nissan vehicle
Preparation items
General Tools
Clip & Fastener (If available)
Training board (Refer to the Instructor Guide)
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 -9
APPLICANT NAME:
Description: Body & Trim
DEALER NAME:
1-1. Measure the stepping at the front of the hood and compare your result to the specified value.
Result
Judgement
mm
Good
No good
1-2. Where do you adjust the stepping at the front of the hood?
1) Bumper rubber
2) Hood opener handle
3) Opener cable
2. Remove the clip(s) and/or fastener(s) specified by assessor.
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1-9
Topic code
(Description)
BTTN1001B
(Body & Trim)
Judgement
Subject
Assessment items
1-1. Measurement
of the stepping
Be able to measure the stepping.
Satisfied
Unsatisfied
Remarks
Be able to judge correctly.

1-2. Adjustment of
the stepping
Technician knows to adjust stepping using the bumper rubber.
2. Removal of Clips Be able to remove them without

and Fasteners
damage.
Be able to remove trim parts without damage.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1-9
Topic code
BTTN1001B
Subject
Body
Check point
Technician can judge the stepping of the body outer panel.
Technician can adjust the stepping.
Trim
Technician can replace clips and fasteners without damage them.
Details
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-10

External Adjustment of A/T & E-A/T
Section III
III
Task
code
1 - 10
Topic code
(Descriptions)
Prior to assessment
ATTN1001A
Assign the vehicle with A/T to the technician.
ATTN1002A
(External Adjust- It is not necessary to cause trouble in the inhibitor switch.
ment of A/T, E-A/
T)
Issued: March 2002
Section III
III-2
Task
code
1 - 10

Topic code
ATTN1001A
ATTN1002A
Vehicles/units
Nissan vehicle with A/T and EA/T
Preparation items
General Tools
Multimeter
Car lift
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 10
APPLICANT NAME:
Description: External Adjustment of A/T and E-A/T
DEALER NAME:
1. Check circuit continuity of the inhibitor switch and enter the results.
[Model with indicator lamp]
Lever position
Terminal number
Result
3 and 4
Open / Closed
3 and 7
Open / Closed
Lever position
Terminal number
Result
1 and 2
Open / Closed
1 and 2
Open / Closed
3 and 4
Open / Closed
[Model without indicator lamp]
2. Check the function of the inhibitor switch.

Lever position
Result
Start
No start
Start
No start
Start
No start
Start
No start
Start
No start
Start
No start
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1 - 10
Topic code
(Description)
Judgement
Subject
Assessment items
ATTN1001A
(External adjustment of A/T)
1. Checking of elec- The ZERO point of the multimeter

trical continuity of is adjusted. (if using analog type
inhibitor switch
meter)
ATTN1002A
(External adjustment of E-A/T)
Circuit continuity is checked by

relating lever position to the terminal No. according to the Service
Manual.
Satisfied
Unsatisfied
Remarks
2. Checking the
Judgement is made after checkfunction of inhibi- ing that the engine does not run at
tor switch
position other than P and N.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1 - 10
Topic code
Subject
ATTN1001A
ATTN1002A
Check point
Technician can inspect the circuit of the inhibitor switch using a
multimeter.
Details
The ZERO point of the
multimeter is adjusted. (if
using analog type meter)
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-11

Usage of CONSULT
Section III
III
Task
code
Topic code
(Descriptions)
1 - 11
ECTN1002A
(Usage of CONSULT)
ECTN1003B
(Usage of CONSULT-II)
Prior to assessment
Assign the vehicle with ECCS engine to the technician.
1. Cause a problem in self-diagnosis memory.
Ex) The primary ignition circuit or the like.
2. Cause of problem in the position of the throttle position sensor or engine
speed or ignition timing.
Issued: March 2002
III-2
Task
code
1 - 11
Section III

Topic code
ECTN1002A
ECTN1003B
Vehicles/units
Preparation items
CONSULT or CONSULT-II
General Tools
Timing light
Engine tuner with adapter harness
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 11
APPLICANT NAME:
Description: Usage of CONSULT
DEALER NAME:
1. Perform self-diagnosis with CONSULT/CONSULT-II then answer the following questions.

(1) What is indicated on the screen?
2. Check the following items using the work support function of CONSULT/CONSULT-II.
If not good, adjust them.
Judgement
1) Throttle position sensor
Good
No good
2) Ignition timing
Good
No good
3) Idle speed
Good
No good
4) Enter the adjusted value for items above.

1. Throttle position sensor
2. Ignition timing
BTDC
3. Idle speed
rpm
1/1
(output voltage)

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1 - 11
Topic code
(Description)
ECTN1002A
(Usage of CONSULT)
ECTN1003B
(Usage of CONSULT-II)
Judgement
Subject
Assessment items
Satisfied
Unsatisfied
Remarks
1. Self-diagnosis by Be able to select the self-diagnoCONSULT

sis mode.
2-1. Checking and The throttle position sensor is
adjustment of
adjusted to within specifications.
throttle position
sensor
2-2. Checking and
adjustment of
ignition timing
After warming up engine, idle

position ON is confirmed under
no-load conditions and ignition
timing is adjusted to within specifications.
2-3. Checking and

adjustment of
idle speed
After warming up engine, idle

position ON is confirmed under
no-load conditions and idle speed
is adjusted to within specifications.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1 - 11
Topic code
Subject
Check point
ECTN1002A
1. Self-diagnosis
Technician can perform self-diagnosis using CONSULT.
ECTN1003B
2. Work support
2-1. Technician can adjust throttle position sensor to the specified

value using the CONSULT WORK SUPPORT mode.
2-2. Technician can adjust the ignition timing to within specifications.
2-3. Technician can adjust the idle speed to within specifications.
Details
Check and adjustment is

made under no-load conditions after warming up
engine.
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-12

&
Section III
III
Task
code
Topic code
(Descriptions)
1 - 12
MATN1001B
(Periodic Maintenance)
GITN1004B
(Usage of Measuring Tools)
Prior to assessment
Assign the vehicle and designate front brake be measured by the technician.
Check that the micrometer and vernier caliper are at ZERO.
Issued: March 2002
Section III
III-2
Task
code
1 - 12

Topic code
Vehicles/units
Preparation items
MATN1001B
Nissan vehicle

General Tools
Inspection light (Electrical torch)
Engine tuner with adapter harness
Car lift or the like
GITN1004B
Nissan vehicle
Vernier caliper
Micrometer (0 - 25 mm)
Dial indicator with stand
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 12
APPLICANT NAME:
Description: Periodic Maintenance
DEALER NAME:
Usage of Measureing Tools
1. Check and judge the following items.

Judgement
(1) Brake pipe bends
Good
No good
(2) Brake fluid leakage
Good
No good
(3) Engine oil level
Good
No good
(4) Engine oil leakage
Good
No good
(5) Battery fluid level
Good
No good
2. Check and judge the following items on the assigned brake.

1) Check the thickness of the brake pad using vernier caliper.
Judgement
Measurement:
mm
Specification:
mm
Good
No good
2) Check the runout of the brake rotor using dial indicator.

Judgement
Measurement:
mm
Specification:
mm
Good
No good
3) Check the thickness of the brake rotor using micrometer.

Judgement
Measurement:
mm
Specification:
1/1
mm
Good
No good

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1 - 12
Topic code
(Description)
MATN1001B
GITN1004B
Judgement
Subject
Assessment items
1-1. Check brake

pipe bends.
Assessors judgement coincides

with technicians.
1-2. Check brake

fluid leak.
The throttle position sensor is

adjusted to within specifications.
1-3. Check engine

oil level.
Oil level is checked with the

engine OFF after cleaning the oil
level gauge.
Satisfied
Unsatisfied
Remarks
The judgement for the check

results is correct.
1-4. Check engine
oil leakage.
The relevant areas are checked

for oil leakage.
results is correct.
1-5. Check battery

fluid level.
All cells are checked.

results is correct.
2-1. Check the

thickness of the
brake pad.
Before measurement, the ZERO

point of vernier caliper is confirmed.
The portion to be measured is
cleaned.
Measurement is made by attaching the vernier caliper perpendicular to the measured part.
Several points are measured.
Be able to read value correctly.
Judgement of the
brake pad
Judgement is made by comparing

the minimum measured value with
the specified value.
2-2. Check the

runout of the brake
rotor.

point of dial indicator is adjusted.
cleaned.
Installing the
removed parts
The pad and caliper are installed

in their original position.
Bolts are tighten to the specified
torque.
Judgement of the
runout

the measured value with the specified value.
The judgement is correct.
1/2
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1 - 12
Topic code
(Description)
MATN1001B
GITN1004B
Judgement
Subject
Assessment items
Satisfied
Unsatisfied
Remarks
2-3. Check the

thickness of the point of micrometer is confirmed.
brake rotor.
cleaned.
Several points are measured.
The measured value is correctly
read by attaching a stopper to the
micrometer adjusting knob.
Judgement of the
rotor thickness

the measured value with the specified value.
2/2
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1 - 12
Topic code
MATN1001B
GITN1004B
Subject
1. Periodic maintenance
Check point
Details
1-1. Technician can check the entire brake system for brake pipe
bending.
Technicians check results

coincide with assessors.
1-2. Technician can check the entire brake system for oil leakage.
Technicians check results

1-3. Technician can clean the level gauge before checking the
engine oil level.
Check is made with engine

turned off.
1-4. Technician can check the entire engine for engine oil leakage. Technicians check results
1-5. Technician can check the battery fluid level in all cells.
2. Usage of Mea- 2-1. Technician can measure the thickness using vernier caliper.
suring tools
2-2. Technician can measure the runout using a dial gauge (dial
indicator).
2-3. Technician can measure the thickness using a micrometer.
(1) Before measurement, the

ZERO point of the measuring instrument is
adjusted.
(2) The portion to be measured is cleaned.
(3) Several points are measured.
(4) The measured values are
correctly read.
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-13

Section III
III
Task
code
1 - 13
Topic code
(Descriptions)
MATN1002B
(Pre-Delivery
Inspection)
Prior to assessment
Assign the vehicle with the following problems to the technician.
1. Tire pressure that is above or below the specification.
2. Turn signal lamp or the fuses which have malfunction.
Issued: March 2002
III-2
Task
code
1 - 13
Section III

Topic code
MATN1002B
Vehicles/units
Nissan vehicle
Preparation items
General Tools
Inspection light (Electrical torch)
Tire pressure gauge
Car lift or the like
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 13
APPLICANT NAME:
Description: Pre-Delivery Inspection
DEALER NAME:
1. Check and judge each items.
Judgement
No.
Items
Good
1.
Engine hood operation
2.
Doors and door locks operation
3.
Seat belt operation
4.
Tire pressure
5.
Turn signal lamps
1/1
No good

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1 - 13
Topic code
(Description)
MATN1002B
(Pre-Delivery
Inspection)
Judgement
Subject
1. Engine hood
operation
Assessment items
Satisfied
Unsatisfied
Remarks
Secondary lock is checked and

found to be effective.
Installation of the hood and alignment of lock are checked.
2. Door and door

lock operation
All doors are checked for installation, sliding and locking conditions.
3. Seat belt operation
All seat belts are checked for

proper operation.
4. Tire pressure
5. Turn signal lamp
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1 - 13
Topic code
MATN1002B
Subject
Pre-Delivery
Inspection
Check point
Technician can check the hood for proper installation, alignment
and secondary lock and judge whether or not they are OK.
Technician can check doors for opening, closing and door lock
functions and judge whether or not they are OK.
Technician can check seat belts for locks and locking functions and
judge whether or not they are OK.
Technician can check tire pressure, and judge whether or not they
are OK.
Technician can check turn signal lamps for function and judge
whether or not they are OK.
Details
Technician refers to PDI
Operation Manual
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-14

External Adjustment of Manual Transmission
Section III
III
Task
code
Topic code
(Descriptions)
1 - 14
MTTN1001A
(External Adjustment of M/T)
Prior to assessment
Assign the vehicle (C23 with M/T) to the technician.
Issued: March 2002
Section III
III-2
Task
code
1 - 14

Topic code
MTTN1001A
Vehicles/units
C23 with Manual Transmission
Preparation items
General Tools
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 14
APPLICANT NAME:
Description: External Adjustment of Manual
DEALER NAME:
Transmission
1. Check and judge each items.

1) When control lever is pushed to the right/left and released, does it
return to the center position?
YES
NO
2) Does the control lever move smoothly?
YES
NO
3) Is there any abnormal noise or sticking when the control lever is shifted?
YES
NO
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1 - 14
Topic code
(Description)
MTTN1001A
(External Adjustment of M/T)
Judgement
Subject
Assessment items
Satisfied
Unsatisfied
Remarks
1. Checking of Con- Be able to judge YES or NO by

trol Lever opera- checking if the Control Lever
tion
shifts smoothly to each position.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1 - 14
Topic code
MTTN1001A
Subject
External Adjustment of Manual
Transmission
Check point
Technician can check the control lever for proper operation.
Details
The control lever returns to
the neutral position after
being pushed to the right
and left.
There should be no abnormal noise while operating.
The control lever slides
smoothly.
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-15

Section III
III
Task
code
Topic code
(Descriptions)
1 - 15
ELTN1002B
(Usage of Digital
Multimeter)
Prior to assessment
1. Measure the horn resistance.
2. Measure the fuel injector power supply voltage.
Issued: March 2002
Section III
III-2
Task
code
1 - 15

Topic code
ELTN1002B
Vehicles/units
Vehicle with ECCS
Preparation items
Digital Multimeter
General Tools
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 15
APPLICANT NAME:
Description: Usage of Digital Multimeter
DEALER NAME:
1. Measure the resistance of horn on the assigned vehicle.
2. Measure the power supply voltage of #1 fuel injector on the assigned vehicle.
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
1 - 15
Topic code
(Description)
ELTN1002B
(Usage of Digital
Multimeter)
Judgement
Subject
1. Measure resistance and voltage.
Assessment items
Satisfied
Unsatisfied
Remarks
Be able to measure resistance

and voltage by using Digital
Multimeter.
Issued: March 2002

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Judgement
Task code
1 - 15
Topic code
ELTN1002B
Subject
Usage of Digital
Multimeter
Check point
Technician can use digital Multimeter.
Details
Measure resistance correctly.
Measure voltage correctly.
Satisfied
Unsatisfied
Impossible
Remarks
Issued: March 2002
TASK CODE: 1-16

Express Lub. 30
Section III
III
Task
code
Topic code
(Descriptions)
Prior to assessment
1 - 16 -1 ESTN1001B
Assign a vehicle to the technician.
(Express Lub. 30) Check and note the correct answer beforehand.
Issued: March 2002
Section III
III-2
Task
code
1 - 16 -1

Topic code
ESTN1001B
Vehicles/units
Nissan vehicle
Preparation items
S/M
Vehicle hoist
Working light
Oil filter wrench
Oil drain pan
Drain plug wrench
New engine oil
Torque wrench
New drain plug washer
Lint free shop towel
Seat cover
Fender cover
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 16 - 1
APPLICANT NAME:
Description: Express Lub. 30
DEALER NAME:
1. Drain engine oil and install drain plug.

2. Replace engine oil filter.
3. Refill engine oil.
4. Check drive belt.
1)
belt
OK / NG
2)
belt
OK / NG
3)
belt
OK / NG
If NG, write the reason.
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
Topic code
(Description)
1 - 16 - 1 ESTN1001B
(Express Lub. 30)
Score
Subject
1. Installing drain
plug
Assessment items
Be able to replace drain plug
washer with new one and tighten
drain plug to the specified torque.
Max.
Actual
Remarks
25
2. Changing oil filter Be able to change oil filter according to procedures.
25
3. Refilling engine
oil
Be able to refill engine oil to the

specified level.
25
4. Inspecting drive
belt
Be able to inspect drive belt by

pushing midway between pulleys.
25
Issued: March 2002
Section III
III
Task
code
Topic code
(Descriptions)
1 - 16 - 2 ESTN1002B
(Engine Tune-up
Service)
Prior to assessment
Asign a vehicle to the technician.
Check and note the correct answer beforehand.
Remove a spark plug and reinstall it without regard for specifications.
Issued: March 2002
Section III
III-2
Task
code
1 - 16 - 2

Topic code
ESTN1002B
Vehicles/units
Nissan vehicle
Preparation items
S/M
Spark plug socket
Torque wrench
General tools
(CONSULT-II)
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 16 - 2
APPLICANT NAME:
Description: Engine Tune-up Service
DEALER NAME:
1. Remove spark plugs, inspect and install them. If NG, write reasons in the form below and repair them.
No.
Judgement
Reason (when judgement is NG)
Repair
#1
OK / NG
OK
#2
OK / NG
OK
#3
OK / NG
OK
#4
OK / NG
OK
(#5)
OK / NG
OK
(#6)
OK / NG
OK
2. Inspect engine idle speed. If NG, adjust it.

Engine idle speed
Specification
Measurement
rpm
Judgement
rpm
1/1
OK / NG

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
Topic code
(Description)
1 - 16 - 2 ESTN1002B
(Engine Tune-up
Service)
Score
Subject
1. Changing spark
plugs
2. Adjusting engine
idle speed
Assessment items
Max.
Be able to adjust spark plug gap

to the specifications.
20
Be able to tighten spark plug to

the specifications.
20
Be able to inspect engine speed

using WORK SUPPORT mode
of CONSULT-II or removing the
TPS.
20
Be able to inspect engine speed

using DATA MONITOR mode of
CONSULT-II or connecting the
TPS.
20
Be able to judge correctly whether

the inspection results are OK or
NG.
20
Actual
Remarks
Issued: March 2002
Section III
III
Task
code
Topic code
(Descriptions)
1 - 16 -3 ESTN1003B
(Cooling System
Service)
Prior to assessment
Issued: March 2002
Section III
III-2
Task
code
1 - 16 - 3

Topic code
ESTN1003B
Vehicles/units
Nissan vehicle
Preparation items
S/M
Vehicle hoist
Engine coolant
Radiator cap tester & adapter
Coolant drain pan
Air relief plug washer
General tool
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 16 - 3
APPLICANT NAME:
Description: Cooling System Service
DEALER NAME:
1. Perform pressure tests for cooling system and radiator cap.

Cooling system: OK / NG
Radiator cap: OK / NG.
2. Replace engine coolant.
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
Topic code
(Description)
1 - 16 - 3 ESTN1003B
(Cooling System
Service)
Score
Subject
1. Pressure test
Assessment items
Max.
Be able to inspect whether cooling

system pressure and radiator cap
are within specifications.
40
2. Changing engine Be able to change coolant in rescoolant

ervoir tank.
15
Be able to change air relief plug

gasket.
15
Be able to hear engine coolant

flowing.
15
Be able to check coolant level of

radiator and reservoir tank.
15
Actual
Remarks
Issued: March 2002
Section III
III
Task
code
Topic code
(Descriptions)
Prior to assessment
1 - 16 - 4 ESTN1004B
(Tire Rotation &
Brake Inspection)
Issued: March 2002
Section III
III-2
Task
code
1 - 16 - 4

Topic code
ESTN1004B
(Cooling System
Service)
Vehicles/units
Nissan vehicle
Preparation items
S/M
Vehicle hoist
Engine coolant
Tire pressure gauge
Torque wrench
Working light
Impact wrench
A/T paper towel
Lint free shop towel
Scale
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 16 - 4
APPLICANT NAME:
Description: Tire Rotation & Brake Inspection
DEALER NAME:
1. Check tire condition by wear indicator.

Front
Rear
Left
OK / NG
OK / NG
Right
OK / NG
OK / NG
2. Check front brake RH or LH.

Brake cleaning
OK / NG
Pad wear
OK / NG
Brake fluid leakage
OK / NG
Disc thickness, runout
OK / NG
3. Check drive belt.

1)
belt
OK / NG
2)
belt
OK / NG
3)
belt
OK / NG
4. Inspect automatic transmission fluid at idle.

Judgement
Fluid level
Color of A/T fluid
OK / NG
Normal / Dark brown / Dark
black / Milky / Pink
1/1

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
Topic code
(Description)
1 - 16 - 4 ESTN1004B
(Tire Rotation &
Brake Inspection)
Score
Subject
Assessment items
Max.
1. Checking tire
Be able to check tire condition by
condition by wear wear indicator.
indicator
20
2. Checking brake
Be able to check front brake RH

or LH (4-items).
35
3. Inspecting drive
belt
Be able to inspect drive belt by

pushing midway between pulleys.
25
4. Checking
A/T fluid
Be able to check fluid level and

color.
20
Actual
Remarks
Issued: March 2002
Section III
III
II-1 Assessor guide
Task
code
Topic code
(Descriptions)
1 - 16 - 5 ESTN1005B
(A/C Performance Check)
Prior to assessment
Issued: March 2002
Section III
III-2
Task
code
1 - 16 - 5

Topic code
ESTN1005B
Vehicles/units
Nissan vehicle
Preparation items
S/M
Vehicle(equipped A/C)
Working light
Electrical leak detector or fluorescent dye leak
detector
General tools
Fender cover
Steering cover
Seat cover
Floor paper
Issued: March 2002
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 16 - 5
APPLICANT NAME:
Description: A/C Performance Check
DEALER NAME:
1. Check charge air of AUTO A/C and record the results in the form below by percentage.
ES5-23
2. Check discharge air in AUTO mode and judge whether the result is OK or NG.
OK / NG
3. Perform leakage test using an electrical leak detector and judge whether the result is OK or NG.
1/1
STEP 1 TASK SHEET

DATE:
TASK CODE: 1 - 16 - 5
APPLICANT NAME:
Description: A/C Performance Check
DEALER NAME:
OK / NG
OK / NG
OK / NG
OK / NG
OK / NG
ES5-24
OK / NG
4. Check drive belt for A/C and judge whether the result is OK or NG.
Inspection
Judgement
Cracks
OK / NG
Fraying
OK / NG
Wear and oil
OK / NG
Deflection
OK / NG
Tension
OK / NG
2/2

APPLICANT NAME:
DATE:
DEALER NAME:
ASSESSOR NAME:
Task code
Topic code
(Description)
1 - 16 - 5 ESTN1005B
(A/C Performance
Check)
Score
Subject
Assessment items
Max.
1. Checking discharge air of

AUTO A/C
Be able to fill out the form with the

results percentage.
25
2. Checking discharge air in

AUTO mode
Be able to check the indicator

while pushing the AUTO switch,
and hear the compressor rotating
and the clutch connecting.
20
3. Checking by leak Be able to check all the check

Detector
points shown in the figure and
judge whether the results are OK
or NG.
30
4. Inspecting drive
belt
25
Be able to inspect drive belt pushing midway between drive belts.
Actual
Remarks
Issued: March 2002
Edition: March 2002

Publication No. NS2E-ASTFG1
Textbook
TXC001
Fundamental Skill & Technical
FOUR STEP REPAIR TECHNIQUE

Use the information below to help you plan and carry out effective repairs to electrical problems. Try to follow a logical, systematic procedure during your diagnosis and repair. This process is summarized as follows.
VERIFY
Check to confirm the complaint is occurring.
Is the condition described abnormal? (Use the owners manual or another
vehicle for verification)
What else is not working? (Related circuits)
What is working?
ISOLATE
Locate schematic and wiring diagrams for the YEAR and MODEL vehicle you
are repairing.
Is the circuit controlled by:
A switch?
A relay?
An ECM?
Are components in the same parallel circuit operating correctly or not?
Are components in series operating or not?
Choose test points that:
Can be quickly and easily accessed
Follow a logical process leading to a decision
Separate the relay circuits and individually test the field coil and contact point
circuits.
Bench test components - supply power and ground to cheek their operation
Remember circuit essentials:
POWER source with sufficient voltage
LOAD operating properly in good condition
GROUND with sufficient current capacity
REPAIR
Fix the harness
Clean the connections
Replace the malfunctioning component and repair the cause of the failure
RECHECK
Make sure the complaint has been resolved
Be sure no other problem was caused during the repair
Clean the vehicle so it is customer ready
GLOSSARY OF ELECTRICAL TERMS

AMMETER-An electrical test meter that measures the amount of current flow in a
circuit.
AMPERE-A unit of measurement for the flow of current. Sometimes referred to
as AMPS.
CONBINATION CIRCUIT-A circuit which combines series and parallel circuits.
CONDUCTOR-A material that will easily carry current flow.
CONNECTOR-The plastic that holds wires and wire terminals in position.
CONTINUITY-A complete path for current flow. In the service manual, current
flow does NOT mean V ohms resistance.
CROSSED CIRCUIT-Current flow from a switch operates a LOAD from, or
SHORT CIRCUITS a different, unrelated circuit.
CURRENT FLOW-The movement of electrons in a circuit. Also called amperage
or electricity.
DIODE-An electrical one-way cheek valve that permits current flow in one direction, but stops it from flowing in the other direction.
ECM-An Electronic Control Module that has the logic for the operation of electronically controlled circuits.
GROUNDED CIRCUIT-A circuit in which there is an unwanted contact between a
conductor and ground. On the POWER side of a circuit, this will cause the fuse to
blow. On the ground side of the circuit, the LOAD may be on all the time.
INSULATOR-A material that will not allow current flow. Plastic, rubber and air are
common electrical insulators.
MULTIMETER-A electrical test meter that includes voltmeter, ammeter and ohmmeter scales.
OHM-A unit of measurement for resistance, or opposition to the flow of electrons.
OHMMETER-An electrical test meter that measures the amount of resistance in
a circuit or component.
OHMS LAW-A basic statement that shows the relationship between volts, amps
and ohms in an electrical circuit.
OPEN CIRCUIT-An incomplete circuit in which current can not flow from POWER
to LOAD to GROUND because of a disconnection, broken wire, blown fuse or
other interruption.
PARALLEL CIRCUIT-A circuit ill which there is a separate path for current flow
for each LOAD. If one of the Loads becomes open circuited. the other loads will
continue to operate.
POTENTIOMETER-A variable resistor that is mechanically operated.
POWER-A supply of voltage to operate a circuit. This includes the source of the
power, the wires, and all other components that provide voltage to the circuit
LOAD.
RELAY-An electrically operated switch that uses low current flow in the COIL
CONTROL CIRCUIT to activate high current flow in the CONTACT POINT CIRCUIT.
SERIES CIRCUIT-A circuit in which there is only a single path for current flow. If
one of the components or LOADS in the circuit becomes open, the circuit will no
longer operate.
SHORTED CIRCUIT-A circuit in which current flow takes a shorter path (less
resistance) between POWER and GROUND, bypassing part or all of the circuit
LOAD. Short circuits increase current flow and can cause blown fuses.
TERMINAL-Metal part at the end of a wire. Terminals fit into wire connectors.
THERMISTOR-An electronic component that changes its resistance as its temperature changes.
VARIABLE RESISTOR-A component whose resistance value can be changed to
change the operation of a LOAD in the circuit.
VOLT-A measurement unit of electrical pressure.
VOLTMETER-An electrical test meter that measures the amount of voltage, or
electrical pressure in a circuit.
VOLTAGE DROP-The amount of voltage consumed by a LOAD during circuit
operation. The total of all voltage drops in a circuit, is equal to available voltage.
Voltage drop is the measurement of the voltage loss in one section of a circuit.
WIRE GAUGE-Diameter of a wire. Smaller gauge wire (larger number) carries
less current.
1. TROUBLESHOOTING GUIDES
DIAGNOSIS POINTS
STEP 1. For circuits that you are not familiar with, it might help to start with the
schematic diagram. This will give you an over view of the circuit. The schematic
diagram will show circuit components, and the way in which they are wired.
Always locate the circuit LOAD first, then trace the wires to locate the POWER
and GROUND.
STEP 2. Use the wiring diagram for a more complete picture of the circuit. The
wiring diagram is your best source of guidance for logically tracing the circuit
because it includes information such as wire colors, connector numbers, and
relay box layout. Use your knowledge of POWER, LOAD and GROUND along
with the wiring diagram to guide you in isolating the circuit for test purposes.
STEP 3. The harness layout section of the service manual will give you specific
harness and connector locations on the vehicle. By using the harness layout diagram, you can find the exact locations on the vehicle for performing your diagnosis.
STEP 4. Finally, locate the actual components and the most accessible test
points by using the Location of Electrical Units section of the Service Manual.
When you make electrical tests remember to use test points that:
Are the quickest to locate and test
Are easiest to locate and test at
Will tell you the most information about the circuit
DONT REMOVE THE DASHBOARD BEFORE CHECKING THE FUSE!
TROUBLESHOOTING TIP #5
After tracing a circuit with the
wiring diagram, use the Location of
Electrical Units section to locate
test points that are easy to find and
will help isolate the problem.
CIRCUIT COLOURING
The wires used for automotive wiring are colored for efficient identification and
service.
Color classification
Name of circuit
Starting/ignition circuit
Charging circuit
Lighting circuit
Signal circuit
Instrument circuit
Other circuit
Grounding circuit
Standard color
B
W (Y)
R
G (LG, B R)
Y
L (BR)
B
Supplementary color
(color of stripe)
W. Y. R. G.
B. R. L.
B. W. G. L. Y.
B. W. R. L. Y.
B. W. R. G. L.
B. W. R.
B: black, W: white, R: red, G: green, Y: yellow, L: blue, BR: brown, LR: light green
Wire colors are classified as follows:

Main systems: Standard colors
Detailed circuit: Supplementary colors
Standard and supplementary colors are indicated as follows:
R, W, B, ... Oneletter symbols, representing standard colors only R/W.G/Y ...
Two-letter symbols, with the first letter standing for a standard color and the second letter representing a supplementary color
Example:
Supplementary color (Color of stripe)

Standard color (Color of ground)
TGI001
CIRCUIT CLASSIFICATION
Starting/ignition circuits
Circuit for ignition switch, ignition coil, distributor, starter motor, diesel glow plug,
etc.
Charging circuit
Circuit for alternator, voltage regulator, ammeter or charge warning lamp, etc.
Lighting circuits
Circuit for headlamps, fog lamps and backup lamps, meter illumination lamps,
room lamps, personal lamps, etc.
Signal circuits
Circuit for sparking, turn signal, 4-way flashers, stop, tail, clearance and license
lamps, and for devices that indicate the drivers intent, such as the horn.
In addition, the troubleshooting guide flow chart use symbol explanations to indicate whether a test should be performed with the connector connected or disconnected, as well as many other testing conditions that must be met.
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSIS

Key to symbols signifying measurements or procedures
TGI002
Since electrical diagrams include a lot of information on a single page, accurate

tracing of a single circuit is not always easy. When you use the diagrams, important points to remember are:
Open
Close
TGI003
The two halves of a connector are folded together like a book.

Wires sometimes change colors from one side of a wire connector to the other
side.
TGI004
All connector symbols in wiring diagrams are viewed from the terminal side.
Connector guides for male terminals are shown in black and female terminals
in white in wiring diagrams.
TGI005
TGI006
The number of wires, type of connector and whether it is male of female can be
determined by reading a Nissan wiring diagram. This information is outlined in
the chart below.
SYMBOL
ACTUAL CONNECTOR
Number of terminals available
Male connector (terminal)
Female connector (terminal)
Pin-type connector (bullet)
Plain-type connector (spade)
Number of meshes
Black print
White (not blacked) print
Chamfered corner
Right-angled corner
Example:
An X in a wiring diagram wire
Connector means that is NO
terminal in that connector hole.
Service Manuals include troubleshooting guides for a number of Nissan vehicle

systems. Troubleshooting guide flow charts use a number of symbols to describe
the steps that need to be taken during diagnosis.
DIRECTION MARK
A direction mark is included in the troubleshooting guides of the Service Manual
to differentiate between the harness side of the connector and the terminal side
of the connector. These direction marks indicate which side of a wire connector is
being viewed, and which side of the connector tests should be made from.
View from terminal side
Connector symbol
Signal line
Connector
Direction mark
: T.S. means view and test
from terminal side
Connector symbol
View from harness side
Double line
Connector
Direction mark
: H.S. means view and test
from harness side
TGI007
All connector symbols shown from the terminal side are enclosed by a single
line, and connector symbols shown from the harness side are enclosed by double lines.
Each connector symbol also includes a guide for the connectors.
IF THE GUIDE IS HOLLOW, THE WIRE TERMINALS ARE FEMALE.
IF THE GUIDE IS BLACK, THE WIRE TERMINALS ARE MALE.
All harness connectors have been modified to prevent accidental loosing or disconnection. Pushing or lifting the locking section can disconnect them.
Terminal retainer
PUSH
PUSH
Packing
(Water-proof type)
Terminal retainer
LIFT
PUSH
PUSH
PUSH
PUSH
PUSH
(For combination meter)
(For relay)
TGI008
EXTRACTION OF TERMINAL FROM A CONNECTOR

1. Remove the terminal retainer.
0.8 mm (0.031 in)
2. With a small screwdriver or suitable tool, tilt

the lock tongue and, at the same time, push
out the terminal.
1.8 mm (0.07 in)

Push
Note: Some have a different design and care

must be taken so that the connector is not
damaged.
Screwdriver
Terminal
Lock
tongue
TGI009
10
1) HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSE

INSPECTION START
CHECK POWER SUPPLY

1) Turn ignition switch ON.
2) Check voltage between terminal b and ground.
Battery voltage should exist.
CHECK GROUND CIRCUIT

1) Turn ignition switch OFF.
2) Disconnect crank angle sensor harness connector.
3) Check resistance between
terminal d and ground.
Check the following items.

1) Harness continuty between
crank angle sensor and battery.
2) ECCS relay-1 (See page EF
& EC-106.)
3) BR fusible link
4) Power source for ECU
(See page EF & EC-104)
5) Ignition switch
Check the following items.
1) Harness continuty between
crank angle sensor and
ground.
2) Ground circuit for ECU.
(See page EF & EC-104)
Resistance:
Approximatery 0
TGI010
3. Work and diagnostic procedure

Start to diagnose a problem using procedures indicated in enclosed blocks,
as shown in the following example.
Check item being performed.
CHECK POWER SUPPLY

1) Turn ignition switch ON.
2) Check voltage between terminal
Procedure, steps or measurement results
and ground.
Battery voltage should exist.
O.K.
4. Measurement results
Required results are indicated in bold type in the corresponding block, as
shown below:
These have the following meanings:
Battery voltage ~ 11 - 14V or approximately 12V
Voltage: Approximately 0V ~ Less than 1V
11
5. Cross reference of work symbols in the text and illustration.

Illustrations are provided as visual aids for work procedures. For example,
symbol indicated in the left upper portion of each illustration corresponds
with the symbol in the flowchart for easy identification. More precisely, the
procedure under CHECK POWER SUPPLY outlined previously is indicated
by an illustration .
6. Symbols used in illustrations
Symbols included in illustrations refer to measurement or procedures. Before
diagnosing a problem, familiarize yourself with each symbol.
2) USAGE OF WIRING DIAGRAM

There are two types of diagrams used in the Service Manual to perform trouble
diagnosis.
* Schematic Diagrams
* Wiring Diagrams
Schematic diagrams
The SCHEMATIC DIAGRAM is a simplified electrical diagram.
In this example of a Automatic transmission circuit, all the main components of
the circuit are shown from the POWER source to GROUND.
However, not shown are important repair details such as connector numbers,
wire color codes and location, so the example at the next page indicates the
schematic diagrams.
12
To tachometer
TGI011
13
Wiring diagrams
WIRING DIAGRAMS provide a road map of the electrical system and contain
more detail than SCHEMATIC DIAGRAMS.
The advantages of wiring diagrams are:
* Connector type
* Wire color
* Connector location
* Fuse valves
* Wire connection
Reading WIRING DIAGRAMS
WIRING DIAGRAMS contain many important abbreviations and symbols. These
important features are described in the following examples.
Wire color
Page crossing
Current flow arrow
Fuse 15A
Non detectable line for DTC
Detectable line for DTC
Common connector
Terminal
number
Ground
Optional splice
LHD Model
RHD Model
Component box
in wave line
TGI012
14
Relay
1. The roles of relays
1-1. The roles of relays are as follows.
A large electric circuit that protects a switch, an electric wire, and electrical
systems which use a moderate amount of the electronic current.
Simplification for the electric wiring for a large electric circuit.
Automation for operation of electrical systems.
Remote operation for each system.
1-2. Various kinds of Relays and terminal Symbols
1 M
2
MAKE
(Contacted when
coil is ON)
Normally open (NO)
Number of
contact point
1
TGI013
1M*1B
BRAKE
(Braked when
coil is ON.)
Normally closed(NC)
Same as
above
2
1T
TGI014
Transfer
Number of
contact point
15
TGI015
On the top of the relay is a small diagram that shows the terminal numbers for both the coil control circuit
and the contact point circuit.
TGI016
On the bottom side of the relay, next

each electrical terminal, is the terminal number.
TGI017
For example, an IM relay (one-make relay) with wire terminals #1 and #2, and a
low current magnetic coil: COIL CONTROL CIRCUIT.
This high current CONTACT POINT CIRCUIT operates the circuit LOAD.
The following indicates kinds of relay used for the Nissans vehicles.
TGI018
16
3) FOLDOUT CIRCUIT DIAGRAMS

The foldout circuit diagrams at the back of the Service Manual are schematic diagrams of the entire vehicle, drawn in levels to spread out the circuits. This helps
to eliminate the clutter of wires, components and connectors. This type of diagram separates the electrical system into three levels. Each level is designed
with POWER voltage at the top, circuit LOAD in the middle, and GROUND at the
bottom.
The foldout diagrams have important application during circuit diagnosis.
Because the wiring diagrams only show wiring for a single system, there may be
times when the problem in the system is caused by components that are part of
another system, but interconnected to the system. You can use the foldout circuit
diagram to find out what components of other circuits interconnect with the circuit
you are tracing. This sample foldout diagram is an example of what you'll find in
the service manual. Here's a brief description of some of the symbols found on
the layout diagrams.
TGI019
17
Symbol 1 shows branch circuits, depending on equipment variations. These

symbols are identified on the diagram, and are the same as used on wiring diagrams.
Symbol 2 shows three horizontal columns. Each column represents one of the
three diagram levels. The letters and numbers in the horizontal columns align
with and match the connection numbers in the diagram. For example, the arrow
is pointing to number (4), which is found in the middle column. Following straight
up to the middle diagram level, number (4) is found to indicate a connection.
CIRCUIT DIAGRAM
TGI020
18
Symbol 3 shows how the different levels are connected. The dotted line connects
the circled numbers (4). Notice that the arrows point to each other. The dotted
line does NOT appear on the foldout diagram. Use a straight edge to follow the
arrows on the diagram. To follow this wiring, use the bottom of the diagram.
There are two circled as shown. Each is on a different level, indicating the level
on which each connection is made. By moving straight up from each of the circled numbers, youll find the connection points. Symbol 4 shows wires crossing
each other. Only the wires with dots at the intersections indicate wire connections. These symbols are the same as those found on wiring diagrams. Symbol 5
shows wires crossing over each other (with NO dots). These are NOT connections.
CIRCUIT DIAGRAM
TGI021
19
4) HOW TO USE CIRCUIT TESTER

MEASURING DC VOLTAGE
AS A VOLTMETER
1. Set the selector switch to the DCV position.
2. Connect the test lead (red) to the positive
side of the circuit.
Voltmeter
Load
Battery
3. Connect the test lead (black) to the negative side of the circuit.
Parallel connection
TGI022
HOW TO READ THE NEEDLE INDICATION

Range
3[V]
12 [ V ]
30 [ V ]
Approx. 1.3 [ V ]
Approx. 9.5 [ V ]
Approx. 13 [ V ]
Needle
indication
Reading
MEASURING DC CURRENT
AS AN AMMETER
Connect the test leads as shown in the figure,
Unlike voltage measurement, an ammeter must
be connected in series with the load in the circuit. In general, the DC [A] range of the circuit
tester is small, and it cannot be used for measuring relatively large electric currents, such as
those in the head light circuit and the charging
circuit. (The circuit tester introduced here can
measure up to 0.3 [A] = 300 [mA])
Ammeter
Load
Battery
Series connection
TGI024
20
MEASURING RESISTANCE AND TESTING CONTINUITY AS AN OHMMETER

When measuring resistance or checking for continuity, be sure to disconnect the
vehicle battery negative (-) terminal so no external voltage will be applied to the
circuit being measured.
Connect the test leads to the resistor in the
same way as for voltage measurement.
Set the selector switch to the RXI position.
Short out red and black test leads firmly
together.
Turn the zero-ohm adjuster until the needle
aligns with the zero-ohms position.
Connect the test probes to the circuit in which
the continuity or resistance is to be measured.
Polarity is not important when applying the test
probes to the measuring points.
Read the meter indication.
TGI025
(1) MEASURING RESISTANCE

Selector switch RX1:
The meter directly indicates resistance value.
[Ex: Meter reading: 7 ... Resistance 7 ohms]
Selector switch RX100:
Multiply the meter: reading by 100
[Ex: Meter reading: 9 ... 9 x 100 = 900 ohms]
(2) TESTING CONTINUITY
TGI026
Meter reading: 0 ohm
Continuity exists
Meter reading: Infinity
No continuity
(Open circuit)
TGI027
21
PRECAUTIONS FOR USING THE CIRCUIT TESTER

Before use, cheek to see if the meter needle is set at the zero position. if necessary, zero-adjust the meter by turning the needle zero adjuster.
When reading the meter indication, always view the needle from directly
above. A reading error will result if it is not read in this way.
When measuring high resistance, be careful not to touch the test probe. This
will result in a major error in measurement.
When measuring an unknown voltage, first set the meter to the maximum voltage range to know its approximate value, then set the selector switch to a suitable range for accurate measurement.
When changing the selector switch position, be sure to disconnect one of the
test probes from the measuring point. This precaution is especially essential
when using the tester as an ammeter.
Set the selector switch to a blank or volt position when the tester is not in
use.
The battery must be replaced with a new one if On adjustment cannot be
made.
Q: Is the polarity of this diode wrong?

I checked the polarity of a diode connecting a circuit tester
as shown in the figure at right, but the needle did not
deflect. Is the polarity mark of the diode wrong?
TGI028
A: The polarity of the diode is correct.

A battery is included in the resistance measuring circuit of a circuit tester as shown in Figure 1. Accordingly, the polarity of the circuit tester output voltage is the opposite of that used
for measuring voltage and current.
TGI029
22
CIRCUIT TESTER
Scale panel
Needle pointer
Needle zero
adjuster
Needle
pointer
Test lead terminal
(for high voltage)
Range
selector
Test lead terminal

(Positive)
Test lead terminal

(Negative)
TGI030
DC / AC Voltage [ V ]
DC Current [ A ] [ mA ]
Resistance [ ] [ k ]
Continuity
23
ELECRICAL TEST EQUIPMENT

The most common meter for automotive testing actually functions as three
meters all in one. It is called a DIGITAL VOLT OHMMETER or DIGITAL MULTIMETER.
The three meters of a multimeter are:
Ohmmeter
Voltmeter
Ammeter
There are two types of test meters available for automotive electrical testing,
Analog and Digital.
This section will provide you with an introduction to the DIGITAL MULTIMETER.
DIGITAL METERS
Digital meters provide an electronic digital display of the measurement being
made. This display shows actual numbers.
DETAIL OF DISPLAY
Replace Battery
Measurement Value
Measurement Units
Manual Range / Touch Hold
Bar Graph
OverLoad
TGI031
24
DIGITAL MULTIMETER
Display
VDC
1 2. 1 0
AC Voltage
OFF
DC Voltage
V
300mV
Rotary Switch
Max. 300mV
Voltage
Resistance
Diode and
Continuity
AC Current
DC Current
Max. 10A
Current
10A
Jack
300mA
COM
Max. 300mA
Current
TGI032
25
MEASURING RESISTANCE
An ohmmeter has two important functions:
Measure circuit or component resistance
Check for continuity in a circuit or component
Never use an ohmmeter on a circuit with power. Doing so will damage the meter.
To use an ohmmeter:
Step 1: Connect test lead wire to:
Red test lead:
Jack
TGI033
Black test lead:
Jack
TGI034
Step 2: Turn rotary switch to

Note: Before measuring the resistance, turn off power to
the circuit, and then discharge all capacitors.
TGI035
Step 3: Touch the test lead to the circuit.

Note: Be sure you have a good contact
between the probes and the circuit. Dirt, oil, solder, or other foreign matter seriously affects the
resistance. Never touch the circuit
with your finger.
TGI036
26
Step 4: Read out the resistance from the display.

Note: The number varies in accordance with the selected unit on some
meters.
For example:
250.0
2.500k
0.250k
0.250M
250
2.5k
250
250k
2500
250.000
1 k = 1,000
1 M = 1,000 k
TGI037
27
MEASURING DC VOLTAGE
A voltmeter is used for almost all automotive electrical tests.
A voltmeter has two functions:
Measure circuit voltage
Measure voltage drops
This section will provide you with an introduction to measuring circuit voltage.
To measure voltage:
Red test lead:
Jack
TGI033
Black test lead:
Jack
TGI034
Step 2: Turn rotary switch to V

TGI039
Note: For DC voltage below 300 mV, use the mV

function to get the best resolution.
TGI038
Step 3: Connect the voltage probes in parallel across the circuit or part of the
circuit being measured.
Note: Be sure polarity of the circuit.
Red probe should be positive.
Black probe should be negative.
TGI040
Step 4: Read out voltage from display.
TGI041
28
MEASURING DC AMMETER
An ammeter is used for measuring the current flow in a circuit.
To use the ammeter:
Red test lead:
10A or 300mA Jack
Black test lead:
Jack
TGI034
Note: To avoid blowing an input face, use the

10A Jack until you are sure that the current is less than 300mA.
Step 2: Turn rotary switch to A
TGI042
TGI043
Step 3: Connect an ammeter in series with the circuit.

Note: Be sure the positive probe of the ammeter is inserted into the PLUS (+)
terminal and the negative probe into the ground or negative () side of
the circuit.
Step 4: Read out Amperage from display.
Note: 1) Specification for amperage is usually
not available in the Service Manual.
2) Measuring with an inductive current
probe is also possible. (See the next
illustration.)
TGI044
29
CONTINUITY TEST
Continuity testing is very important for inspecting circuit continuity.
To check continuity:
Red test lead:
Jack
TGI033
Black test lead:
Jack
TGI034

TGI045
Step 3: Touch probes connected to circuit.

If continuity exists, a buzzer sounds continuously.
Step 4: Check the sounds of the buzzer. If the buzzer
sounds, the continuity is judged to be OK.
30
TGI046
CHECKING POLARITY OF DIODE

Diodes are used in the alternator and other circuits.
Inspecting diodes is an important aspect of diagnosis.
To check diodo:
Step1: Connect test lead wire to:
Red test lead:
Jack
TGI033
Black test lead:
Jack
TGI034

TGI045
Step 3: Touch probe to diode as follows.

Normal function:
TGI046
Buzzer sounds exist.

TGI047
TGI034
TGI033
No buzzer sounds.
TGI047
TGI033
TGI034
Abnormal function is not indicated above.
31
5) USAGE OF SERVICE MANUAL

1. A QUICK REFERENCE INDEX
A black tab (e.g. BR) is provided on the first page. You can quickly find the
first page of each section by mating it to the sections black tab.
Example:
GENERAL INFORMATION
GI
MAINTENANCE
MA
ENGINE MECHANICAL
EM
ENGINE LUBRICATION & COOLING SYSTEMS
LC
2. CONTENTS
The contents are listed on the first page of each section.
Example:
CONTENTS
PRECAUTIONS .................................................................................... 2
Precautions for EFI. or ECCS Engine ............................................. 3
Precautions for Catalyst ................................................................... 4
Precautions for Fuel ............................................................................... 4
HOW TO USE THIS MANUAL ............................................................... 5
HOW TO READ WIRING DIAGRAM ..................................................... 7
3. TITLE
The title is indicated on the upper portion of each page and shows the part or
system.
Example:
TGI048
4. PAGE NUMBER
The page number of each section consists of two letters which designate the particular section and a number (e.g BR-5)
32
5. LARGE ILLUSTRATIONS
The large illustrations are exploded views and contain tightening torques, lubrication points 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.
Example:
Tighten
Lock bolt
Adjusting bolt
Loosen
Adjusting bolt
Loosen
16 -22
(1.6 - 2.2,
12 - 16)
Tighten
Loosen
Lock bolt
16 - 22 (1.6 - 2.2, 12 - 16)
Water pump
Water pump
Alternator
Alternator
Power
steering
pump
Power steering
pump
Crankshaft
pulley
Crankshaft
pulley
Compressor
N m (kg-m, ft-bl)
Check point
Without air conditioner
With air conditioner
TGI049
6. SMALL ILLUSTRATIONS
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.
Example:
Timing chain guide
TGI050
33
TGI051
7. SYMBOLS & ABBREVIATIONS

Refer to the Service Manual.
8. UNITS
The units given in this manual are primarily expressed in the SI-UNIT (International System of Unit), and alternatively expressed in the metric system and in
the yard/pond system.
Example:
Tightening torque: 59 - 78 N-m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
The yard/pond system
The metric system
The SI unit
Example:
(6.0 - 8.0 kg-m, 43 - 58 ft-Ib, 53 - 689 in-Ib)
Tightening torque: 59 - 78 N-m (6.0 - 8.0 kg-m, 43 - 58 ft-Ib)

The yard/pond system
The metric system
The SI unit
9. TROUBLE DIAGNOSES
Trouble diagnoses are included in sections dealing with complicated components.
10. S.D.S.
Service data and specifications are included at the end of each section for quick
reference of data.
11. WARNING AND CAUTION
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.
1) Warning indicates the possibility of personal injury if instructions are not followed.
2) Caution indicates the possibility of components damages if instructions are not
followed.
3) Bold typed statements except warning/caution give you helpful information.
34
6) ELECTRONIC SERVICE MANUAL (ESM)

This consists of same contents as the book type Service Manual except for new
information. An ESM provides you with full technical service information through
electronic media.
TGI052
35
Items
How to use... / Details
1. Setting up
1) All programs need to be closed before setup.
(When acro- 2) Insert ESM CD.
bat Reader is
not installed) 3) Click on My Computer icon.
4) Click on CD-ROM icon.
5) Enter the folder titled acroread and click on the file titled
ar32e301.exe. (Acrobat Reader will be installed.)
It is necessary to change your computer display settings;
2. Before
- Display area: 1024 X 768 (Control Panel > Display > Settings tab >
opening
ESM. . .
Display area)
3. Viewing
Opening ESM
1) Insert ESM CD.
2) Click on start.pdf. (Start screen will be displayed.)
3) Click on START button. (Quick Reference Index will be displayed.)
4) Select a section from the Quick Reference Index.
[You can go to the top of the section (Table of Contents).]
5) Select the item you want from the Table of Contents.
(The manual page will be displayed.)
4. Reference
Pages
(Hyper Links)
5. Printing
Screen Layout
Bookmark (Index): Left side
All items link to the appropriate page.
The contents will be displayed if you click on the
icon.
Manual page: Right side
Manual pages are displayed and can be moved forward and
backward using the icons on the tool bar at the top of your
screen or the scroll bar on the right side of your screen.
1) Click on the indication outlined in green. (You can move to reference page.)
2) To return to previous view, use the Previous View icon on

the tool bar.
1) Select Print. (Menu Bar > File > Print)
2) Select printing range: (Refer to the back page.)
- All pages: All pages in the section will be printed.
- Current page: The page you are viewing will be printed.
- Pages: A range of pages you type in will be printed
CAUTION: If you do not select a printing range, all pages
in the section will be printed.
3) Click on OK to print.
36
Items
How to use... / Details
6. Alphabetical Not all items in the Alphabetical Index are linked to an appropriIndex
ate page.
To go to the item you want using the Alphabetical Index:
1) Confirm the page number of the item in the Alphabetical
Index.
2) Select the section from the Bookmark index.
3) Go to the page using the Menu Bar > View > Go To Page...
sequence or the Page Count button at the bottom of your
screen.
7. Finding
CAUTION: The Find Dialog function is only available in
Dialogs
each section. If you do not know which section
you should go to, you can try the Find Dialog
(Key Words)
function in the Alphabetical Index.
1) Select the Find Dialog icon on the tool bar at the top of your
screen.
2) Input the dialog (key word) such as the name of a component,
the name of a system, a diagnostic code, etc.
3) The dialog (key word) can be found by reviewing all pages in
the section.
4) Use the Ctrl + G operation on your keyboard for continuous
retrieval.
8. Zooming in 1) Select the Zoom in icon on the tool bar at the top of your
screen.
2) Drag the area you want to zoom in on, or just click at the
point.
3) If you press the Ctrl key, Zoom in icon switches to Zoom
out icon.
4) To return to previous view, use the Previous View icon on
the tool bar.
37
7) HOW TO READ ABBREVIATIONS

1. Abbreviation for model code
B
Number of model change

1: Passenger car, 4 cylinder engine (less than 2 litter engine)
2: Commercial vehicle or truck
3: Passenger car, 6 cylinder engine (more than 2 liter engine)
5: Passenger car, 8 cylinder engine (more than 3 liter engines)
Individual code for each vehicle
2. Abbreviation for engine

S
S: Carburetor engine, E: ECCS engine or New EGI

Non: Single camshaft
Engine displacement (Capacity of engine) 2.0 liter
Individual code for each engine series
38
3. Abbreviation for manual transmission

New code
Former code
R
31
71
Model symbol (L, A, B)
Design change
Distance between mainshaft

and countershaft
Classification
Drive system
F: Front drive
R: Rear drive
Type of synchromesh
W: Warner type
Number of forward speeds

Number of forward speeds
Additional function
S: With overdrive
N: None
Type of control position
F: Floor direct shift
R: Remote control shift
Additional function
S: With overdrive
None: Without overdrive
4. Abbreviation for automatic transmission

New code
R
01
71
Model symbol (B)
Design change
Diameter of pitch circle for

planetary gear
Classification
Drive system
F: Front drive
R: Rear drive
Nissan
Number of forward speed
Number of forward speed

Additional function
L: Lock-up
E: Electronic control
N: None


39
5. Abbreviation for manual transmissions

P
56 S
Design change
Maker name
S: Nissan Yoshiwara
T: Unisia JECS
P: Nippon Power Steering
J: JKC
N: NSK
K: Koyo
Basic 2-digit figure (Unit: mm)

RB type: Center-to-center distance of sector shaft and worm/stub shaft
RP type: Rack diameter
Gear type
B: Recirculating Ball type
R: Rack and Pinion type
V: Variable gear ratio
None: Constant gear ratio
P: Power steering
None: Manual steering
6. Abbreviation for brake

Drum type
Disk type
LT
CL
23
Design change
*Supplementation
X: Bendix Co.
28
Design change
*Supplementation
X: Made by Bendix Co.
G: Made by Girling Co.
Inside diameter of drum (cm)
V: Ventilation type
H: With parking brake
Type of model
LT: Leading Trailing
DS: Duo Servo
2L: Two Leading
Cylinder section area (cm2)

Type of brake
CL: Collet type
AD: Collet type (Made by Akebono)
OPZ: Opposite type for aluminum
OPF: Opposite type for iron
40
HOW TO READ VIN

VIN (Vehicle Identification Number) indicates manufacturer, body type (Sedan,
Hardtop, Station Wagon, and Cab), Engine type, 2WD or 4WD, Model code, destination, Chassis number.
VIN depends on kind of vehicle, so refer to GI (General Information) section in
the Service Manual for more information.
TGI053
41
Except for the Middle East, Brazil and Venezuela

JN1
A33
XXXXX
Vehicle serial number
0: Stopgap (no meaning)
Model
Destination
A: Australia and New Zealand
U: Europe
Z: Except for the Middle East, Europe,
Australia, New Zealand, Brazil and
Venezuela
U: 2-wheel drive
Engine type
A: VQ20DE engine, C: VQ30DE engine
Body type
C: 4-door Sedan
Manufacturer
JN1: Nissan, Passenger vehicle
For the Middle East

JN1
XXXXX

Manufacturing plant
T: Oppama
Model year
Y: 2000 model year
Check (0 to 9 or X)
The code for the check digit is determined
mathematically
Restraint system
A: Driver and front passenger SRS air bag and
SRS side air bags
C: Driver SRS air bag
D: Driver and front passenger SRS air bag
S: Without SRS air bag
Body type
1: 4-door Sedan
Model change (0 to 9)
Vehicle line
A: Nissan MAXIMA
Engine type
C: VQ30DE
Manufacturer
JN1: Nissan, passenger vehicle
42
For Brazil, Venezuela

JN1
A33
XXXXX
Manufacturing plant
T: Oppama
Model year
Y: 2000 model year, 1: 2001
Model
U: 2-wheel drive
Engine type A: VQ20DE engine, C: VQ30DE engine
Body type
C: 4-door Sedan
Manufacturer
JN1
D22
XXXXX
0: Stopgap (no meaning)

Z: Except for Australia and Brazil
A: Standard wheelbase (2WD)
G: Long wheelbase (2WD)
U: Long wheelbase (4WD)
B: Z24S engine C: KA24E engine E: NA20S engine
H: TD27 engine J: QD32 engine
A: Single Cab C: Double Cab
Manufacturer
43
Vehicle
identificationplate
Front
Frame
Vehicle identification
number
TGI054
44
ELECTRICAL SYMBOLS
variable resistor
single filament bulb
thermistor
dual filament bulb
reed switch
fuse
circuit breaker
fusible link
condenser
(old symbols)
switch
(normally open)
diode
light emitting diode (LED)
switch
(normally closed)
ground
motor
no connection
between wires
connection
between wires
transistor
resistor
branch circuit
coil
battery
(each set of line = 1 cell)
TEL001
45
TEL002
INTRODUCTION TO ELECTRICITY
Nissan vehicle use electricity to control and operate many standard features such as
headlights, windshield wipers and rear window defoggers. More recently, Nissans
Anti-lock Braking System (ABS) and Sonar Suspension have been possible
because of advances in electronic technology. While these represent some of the
more sophisticated uses of electricity and electronics on vehicles today, the troubleshooting and repair techniques are relatively simple.
You will need to be able to troubleshoot and repair electrical and electronic circuits
used on Nissan Diesel vehicles. You do not need to know how to design the systems! This course will provide you with the skills necessary to:
Verify symptoms by attempting to operate circuits, and find out what is working and
what is not working.
Isolate causes of problems by
tracing current flow paths using Wiring Diagrams.
locating harness connectors using Harness Layout Diagrams.
testing electrical circuits using a multimeter.
Repair electrical problems by
fixing broken wires and poor connections.
replacing broken components
adjusting a switch or sensor.
Recheck that the symptom has been fixed, and duplicating the conditions that
caused the problem to be sure no new problems have been caused.
46
1. BASIC ELECTRICAL
1) OHMS LAW
The electrical properties described thus far, voltage,
current, and resistance, have the following relationship. This relationship was discovered by the German physicist Ohm, and is therefore called Ohms
Law. It describes one of the most fundamental relationship in the field of electricity.
A current of 1A
(ampere) flow
Current
Ohms Law
The current which flows in an electric circuit is proportional to amount of applied voltage and inversely
Battery 1V
proportional to the resistance.
In other words, the amount of current flowing in a
circuit is doubled if the applied voltage is doubled,
and cut in half if the resistance is doubled.
If, in the circuit in figure at right, the current is
expressed as 1 (A), voltage as E (V), and resistance
R (), then Ohm's Law is given by the following equation:
I = V / R [A]
R = V / I []
V = I x R [V]
Where: I --- Current

V --- Voltage
R --- Resistance
47
Resistor
1 Ohm
TEL003
AN IDEA HELPFUL IN MEMORIZING OHMS LAW

Just picture a circle which is divided into three. The positions of V.1.R. are important. V actually represents "Volt" but why not think of it as Victory as it is above 1
and R.
TEL004
In the 1800s, a German physicist named George Ohm worked out a relationship
between voltage, resistance and amperage in a circuit. The key to this relationship can be summarized in the following statements:
IF VOLTAGE (VOLTS) STAYS CONSTANT AND CIRCUIT RESISTANCE
(OHMS) INCREASES, CURRENT FLOW (AMPS) WILL DECREASE.
OHMS
(Resistance)
AMPS
(Current flow)
12 V
(Constant)
TEL005
For example, in a circuit with corrosion at one of the wire connections,

INCREASED resistance will DECREASE the current flow. High resistance will
result in light bulbs that are dim, relays that do not engage, and motors that turn
too slowly.
48
Secondly, Ohm's Law states:

IF VOLTAGE STAYS CONSTANT AND CIRCUIT RESISTANCE DECREASES,
CURRENT FLOW WILL INCREASE.
AMPS
(Current flow)
OHMS
(Resistance)
12 V
(Constant)
TEL006
This means. for example, that if the insulation on the POWER wire is nicked or
cut and the wire makes a SHORT circuit to ground, the resistance built into the
circuit is bypassed. As a result, current flow in the circuit increases, and the fuse
will blow. In an unprotected circuit, the wire will get hot and melt the insulation!
In summary:
IF RESISTANCE (OHMS) IN A CIRCUIT GO UP, CURRENT FLOW (AMPS) GO
DOWN DIM BULB
IF RESISTANCE (OHMS) IN A CIRCUIT GO DOWN, CURRENT FLOW (AMPS)
GO UP BLOWN FUSE
49
2) CIRCUIT REQUIREMENTS
The basis for discussing electricity in Nissan vehicles is the CIRCUIT. A circuit is
a complete path for electricity to flow. Electrical circuits consist of wires, wire connectors, switches, relays or other electrical and, electronic components.
Battery
Wire
Load
Wire
Regardless of the complexity of the circuit, or the number of parts in the circuit,
there are three essential elements that ALL CIRCUITS must have in order to
operate. They are:
POWER (SOURCE) The battery AND the electrical path from the battery to the
load. This is the positive (+) side of the circuit.
LOAD Any electrical component that lights, heats or produces motion in a circuit.
GROUND The electrical path from the LOAD back to the battery. This is the
negative (-) side of the circuit.
Ground
Switch
Power
Load
Battery
Ground
TEL007
50
3) VOLTAGE, AMPERAGE AND RESISTANCE

In addition to the requirement that a circuit have a POWER source, a LOAD for
the electrons to pass through, and a GROUND or way for the current to return to
the POWER source, there are three other factors that determine the operation of
the circuit. They are:
VOLTAGE The electrical force in a circuit that pushes electrons through the conductors
AMPERAGE The amount of electrons moving in a circuit
RESISTANCE Opposition to the flow of electrons
VOLTAGE
Electrons will flow through a circuit if they are pushed. Voltage is the amount of
electrical pressure that is available to push electrons through a circuit. Nissan
vehicles all use 12 VOLT batteries, but when the alternator is charging, circuit
voltage will increase to approx. 14 volts.
Voltage (volts)
Electrical pressure
Battery
TEL008
AMPERAGE
The measurement of current flow, or electricity in a circuit is called amperage.
This represents the flow of electrons through the wires as the circuit operates.
There have been many theories written about electricity (current flow). Research
in chemistry and physics has established the electron theory to help explain what
electricity is and how it is used.
RESISTANCE
Resistance is an essential part of electrical LOADs. Circuits are designed with a
specific amount of resistance. Resistance opposes electron flow in a circuit and
is measured in OHMS. OHMS are represented by the symbol .
Resistance (Ohms)
Battery
Resistance
TEL009
51
Sometimes components called RESISTORS are used to oppose current flow in a

circuit. There are two types of resistors used in automotive circuits. A fixed value
resistor is used to establish a set resistance in a circuit. A second type of resistor
can vary its resistance to control the movement of electrons in a circuit. In the
example, a variable resistor is used in the illumination circuit to dim a light bulb.
The fixed resistor in the motor circuit will change the speed of the motor.
Switch
Switch
Motor
Lamp
Battery
Battery
Fixed value resistor
Variable resistor
TEL010
Earlier, we spoke of a circuit's requirements for POWER, LOAD and GROUND.

The LOAD is the resistance in the circuit that provides beat, light, or motion.
When the resistance of the circuit LOAD is at the correct value, and when
POWER and GROUND are correct, the circuit operates as it should. Problems
occur when resistance in a circuit increases or decreases.
Increased circuit resistance can be caused by such things as loose connections,
corroded wire connectors, or dirty switch contacts. These conditions create
UNWANTED resistance. Unwanted resistance opposes the flow of electrons in a
circuit, causing bulbs to be dim and motors to turn slowly. These unwanted resistance are the things you are called on to fix!
While high resistance can keep a circuit from working, there are also serious
consequences when circuit resistance decreases. A decrease in circuit resistance, caused for example by a partially shorted LOAD, increase the current flow
in a circuit. The result is a blown fuse, or even burned wires and connectors.
We'll talk more about ways to isolate and repair these unwanted resistances
later. For now, look at the following chart for a summary of the elements that
determine the operation of a circuit.
TERM
Voltage
Amperage
Resistance
DEFINITION
Electrical Pressure
Current Flow
Opposition to Current Flow
52
UNIT OF MEASUREMENT
Volt
Amp
Ohm
SYMBOL
V
A
UNITS
The units generally used in DC (direct current) electrical circuits are the Ampere
[A], Ohm
[Q], Volt [M, etc. The following auxiliary units are used depending on the magnitude of the values.
Value
Unit
x 10-6
x 10-3
x1
x 103
x 106
General electric
power
[V]
Volt
V
(Micro-)
mV
(Milli-)
kV
(Kiro-)
Electric current
[A]
Ampere
A
(Micro-)
mA
(Milli-)
Electric resistor
[]
Ohm
k
(Kiro-)
M
(Mega-)
1018
--- Quarts glass
1016
--- Polyethylene
--- Ordinary glass
1014
1012
1010
SEMICONDUCTOR
Semiconductors are widely used in today's electronic devices such as diodes, transistor, -and
other elements. Their superior electrical capabilities result from the following characteristics.
cm
INSULATOR
SEMICONDUCTORS
WHAT IS A SEMICONDUCTORS
Some substances have many electrons that
move freely (= free electrons), while others do
not. The former are called conductors, suitable
for carrying electricity. The latter are called insulators and do not allow electricity to flow.
The graph on the right shows the specific resistance of various materials. Germanium, silicon,
etc., having a specific resistance between that of
a conductor and an insulator, are called semiconductors.
--- Mica Diamond

--- Bakelite
--- Marble
108
106
104
102
10
--- Selenium
--- Cuprous oxide
--- Silicon
--- Germanium
--- Iron pyrite
10-2
10-4
--- Indium
--- Nicrom wire
--- Carbon
--- Tin lead
--- Platinum, Silver
---Copper
CONDUCTOR
Although a pure substance does not conduct

electricity well, substantial electricity can be con10-6
ducted if a small amount of an impurity is added.
The change in electrical resistance of semiconductors with respect to a change in temperature
is the opposite of that of metals. For metals, the
resistance becomes larger as temperature rises but resistance of semiconductors becomes smaller. (There are some materials which have the reverse characteristic.)
53
INSULATORS
There is another Category of materials such as wood, glass, rubber and plastic
which are made of atoms whose electrons are very tightly bound to the nucleus.
The electrons of these materials can not easily move to other atoms. Such materials are called insulators. Insulators are important because in vehicle wiring harnesses, where the wires for many circuits travel together, electrons have to be
prevented from moving from one another
CONDUCTORS
Certain materials conduct electricity much better than others. As we said, copper
and steel are good conductors because they have large numbers of free electrons that will move from atom to atom. Metals such as gold and silver are even
better conductors because they have even more orbiting electrons. Since gold
and silver are quite expensive, they are only used' in a few, special applications
on Nissan products.
54
4) CIRCUIT TYPES
All circuits must have POWER, LOAD and GROUND to operate properly. On
Nissan vehicles, these elements are arranged in two different ways:
SERIES CIRCUITS
PARALLEL CIRCUITS
SERIES CIRCUITS
In a series circuit, the POWER, LOAD and GROUND are arranged so that current can take only one path through the circuit. Consequently, current flow
(amps) will be the same no matter where it is measured in the circuit. Voltage in a
series circuit, however, will gradually decrease because each load uses part of
the total voltage available in the circuit.
An open at any point in a
series circuit will prevent the
entire circuit from operating.
A series circuit will operate provided there are no opens in the circuit. In the circuit shown, for example, if the switch fails, creating an open circuit, no current will
flow, and neither of the bulbs will light.
Load #1
Load #2
Switch
Power
Battery
Ground
Ground
TEL011
55
PARALLEL CIRCUITS
In a parallel circuit there are two or more paths for current to flow. Tail light circuits on Nissan vehicles are examples of parallel circuits. If one of the bulbs in a
parallel circuit burns out, current will continue to flow through the other paths in
the circuit, and the other bulbs will still light.
An open in a parallel circuit
prevent only the load in the
open push from operating.
In the example below, if one of the bulbs in the parallel circuit burns out, current
will continue to flow through the other paths in the circuit, and the other bulbs will
still light.
Load #1
Power
Switch
Load #2
Battery
Ground
Ground
TEL012
56
In a parallel circuit, if the resistance of each bulb is the same, current flow will be
the same. If resistance changes in any of the paths, current flow through that
path will also change. A bad connection at one of the bulbs will change the resistance for only that one bulb. It will be dim, but the other bulbs will not be affected.
Load #1
Power
Switch
Load #2
Battery
Ground
Connection with
high
Ground
TEL013
Nissan vehicles generally use parallel circuits when more than one LOAD
receives POWER from a common point, such as in the case of a taillight circuit.
When diagnosing a parallel circuit, if neither LOAD operates, look for an open circuit before the circuit splits. If one or both LOADs are dim, look for high circuit
resistance.
If both LOADs in a parallel
circuit are not operating, look
for the problem to be BEFORE
the circuits split.
In addition to series and parallel circuits, there are SERIES /PARALLEL circuits
on Nissan vehicles. A series/parallel circuit is a combination of the two types.
The parallel part of the series /parallel circuit can be diagnosed as a parallel circuit, while the series part of the circuit is diagnosed the same way as a series circuit.
57
INTRODUCTION TO ECCS
1. What is ECCS engine?
ECCS engine is a real improvement for reduction of each exhaust gas emission
while maintaining driveability by controlling fuel injection, idle engine-speed, fuel
pump control by one microcomputer according to every driving condition, to
always most suitable condition including improvement of fuel consumption. Control of ECCS engine pre-programs the control module to the most suitable control
value in every driving condition beforehand. It detects the state of the engine by
sensors and selects the most suitable value among the pre-programmed data
that a control module memorizes by an input signal from sensors. It also sends
an output signal to the actuator and controls it.
2. Purpose of ECCS development

1)
2)
3)
4)
5)
Improved engine performance

Improved fuel consumption
Reduced air pollution
Improved driveability
Improved starting in cold weather
3. ECCS Flow System

Although particular components vary from model to model, basically the ECCS
monitors and controls these 3 primary systems to maintain maximum engine performance.
* FUEL FLOW SYSTEM
* AIR FLOW SYSTEM
* ELECTRONIC FLOW (IGNITION) SYSTEM
Constant adjustments are made to maintain a specified relationship between
these systems. Understanding this relationship will allow you to more easily
break down the overall engine operations into smaller segments. In doing so, you
can more systematically target and/or eliminate them as part of the trouble
cause. Brief descriptions of each system are found on the following pages. To
maintain the operational relationship described above, the ECCS uses three
basic types of components;
*SENSORS
*CONTROLLER
*ACTUATORS
These components work in relation to each other as shown below:
SENSORS
Precisely monitor current
engine conditions, then
send input signals to the
control module (ECM).
CONTROLLER(ECM)
Processes sensor input
signals relative to stored
data, sends control signals to the actuators.
58
ACTUATORS
Perform various engine
functins, based on control
signals received from control module.
4. Function of ECCS
SYSTEM CONFIGURATION
ECCS FUNCTION
The ECCS is capable of controlling a number of functions. It is also capable of
providing more delicate and more sophisticated control. The functions that can
be controlled by ECCS are:
1) FUEL INJECTION CONTROL
Based on the quantity of intake air (air mass), this fuel injection control system
determines the fuel injection quantity corresponding to engine conditions. For
example, optimum fuel injection quantity is determined by the coolant temperature at the time when the engine is started. After idling, the air-fuel ratio is properly controlled by a learning function.
2) IGNITION TIMING CONTROL
Reads data from the memory in ECM, and determines optimum ignition timing
based on engine rpm and intake air quantity.
3) FUEL PUMP CONTROL
Controls source voltage to the fuel pump according to engine rpm and condition,
thereby reducing pump noise and power consumption.
4) IDLE SPEED CONTROL
Receives signals from various sensors, and adjusts the engine to optimum idling
speed corresponding to the engine condition.
5) PRESSURE REGULATOR CONTROL
Increases the fuel pressure temporarily when starting the engine with high coolant temperature.
6) FAIL-SAFE SYSTEM
When a malfunction occurs in some important sensors, the ECM is able to control the engine in a limited manner so the vehicle may be driven. The ECM itself
has such a back up program if it fails to function correctly.
7) ON-BOARD DIAGNOSIS SYSTEM
The ECM is able to monitor major sensor and some actuators, for incorrect signals. If a malfunction occurs due to missing, open or short circuits, the ECM self
diagnosis system will record a code which can be retrieved by a service technician at a later.
59
5. Three major flow

1) FUEL FLOW SYSTEM
All ECCS models have the same basic fuel flow system, as shown in the schematic below. A fuel pump pulls fuel from fuel tank, moves it through the fuel lines
(including a fuel filter) and eventually supplies it to the engine through the fuel
injectors. A pressure device maintains specified fuel pressure throughout the
system.
Typical fuel flow system
Fuel Tank
Fuel Pump
Pressure
Regulator
Fuel Filter
Fuel Injector
Intake
Manifold
2) AIR FLOW SYSTEM

As with the fuel flow system, ECCS Air Flow Systems are basically the same
from model to model. Since the quantity of air mixed with fuel (Mixture ratio) is
key to engine performance, the control of intake air is extremely important.
Typical air flow system
Air Filter
Mass Air Flow

Sensor
Throttle Chamber
Collector
IACV-AAC valve
IACV-Air Regulator
Intake Manifold
3) ELECTRICAL FLOW SYSTEM

The 3rd Nissan ECCS flow system is for electrical current. In this system, signals
are input to the ECM, primarily from the Camshaft Position Sensor (indicating
engine speed and piston position) and the Mass Air Flow Sensor (indicating
mass air intake). The ECM then processes these signals and send the resulting
signals to the injectors and power transistor to control engine operation.
Typical electrical flow
SIGNAL SOURCES

Engine Coolant Temp. Sensor
Throttle Valve Position Sensor
Knock Sensor
Oxygen Sensor
Ignition Switch
Neutral Switch
Air Conditioner Switch
Vehicle Speed Sensor
Battery Voltage
ACTUATOR
Input
Control Module(ECM)
60
Output
Injector
Power Transistor
Fuel Pump
IACV-AAC valve
Others
6. Function of component parts

1) Camshaft Position Sensor (Crank Angle Sensor)
This is a key component of the ECCS. The CPS monitors engine speed and piston position by reading light signals passing through 2 sets of slits cut in a rotor
plate. (Except the New EGI system) The set of 1 degree slits read engine speed
and the set of 120 degree (6 cylinder)/ 180 degree (4 cylinder) slits read piston
position. A pulse input signal is then sent to the ECM to control:
*
*
*
*
*
Fuel injection timing

Fuel-cut control
Ignition timing
Basic fuel injection quantity
Various enrichment corrections
Cover
Light emitting
diode
Rotor plate
Photo diode
Wave forming
circuit
TEC001
Rotor plate
TEC002
180 degree signal for No. 1 cylinder

(REF signal slit)
1 degree signal slit
(POS signal)
120 degree signal slit for

No. 1 cylinder
180 degree signal

slit (REF signal)
1 degree signal
slit (POS signal)

(REF signal)
TEC003
Note: REF signal

POS signal
TEC004
Reference signal
Position signal
61
2) Mass Air Flow Sensor (Air Flow Meter)

A key component for basic fuel injection control that measures intake air flow rate
and density, then sends these signals to the ECM. These signals vary, based on
the amount of heat emitting from the hot film place in the intake air stream.
TEC005
TEC006
By-pass flow type
Full flow type
Three kinds of Mass Air Flow Sensors

have been used in Nissan vehicles:
* Flap type
* Hot wire type
* Hot film type
Platinum
wire lead
Hook
Hot wire type
Hot film
Adhesive
Lead
Aluminum bobbin
Platinum
coat
Hot film type
TEC007
3) Throttle Position Switch

(Throttle Valve Switch)
Throttle position switch detects full
open or full closed position. This is the
input signal for the idle engine-speed,
idle mixture, idle ignition controls to
start operating.
Idle contact
point
Full contact
point
TEC008
Throttle Position Switch
62
4) Throttle Position Sensor (Throttle Sensor)

The throttle position sensor detects opening
of throttle valve and rate of opening and it
provides input for additional fuel injection at
acceleration. The throttle position sensor
also incorporates the throttle position function.
TEC009
Throttle Position Sensor
5) Engine Coolant Temperature Sensor

(Water Temperature Sensor)
It detects the cooling water temperature and
it senses to compensate fuel injection quantity to meet cooling water temperature condition. It also senses an input signal to set the
idle engine speed in relation to the cooling
water temperature.
Thermistor
6) Oxygen Sensor (Exhaust Gas Sensor)

The oxygen sensor detects oxygen density in
exhaust gas and it detects air-fuel ratio.
Louver
Zirconia
TEC010
Louver
Sensor element (Titania)
Lead terminal
Holder
Holder
Connector
Isolation bushing
Contact plate
Glass seal
TEC011
ZIRCONIA TYPE
Rubber
seal
TEC012
TITANIA TYPE
7) Knock Sensor
It detects engine knocking and it delays
ignition timing when knocking occurred.
Terminal
Weight
Piezoelectric element
TEC013
63
8) IACV-AAC Valve (AAC Valve)

In relation to the actual engine idle speed
and the programmed value, the IACV-AAC
valve receives a signal from the ECM to
adjust the air quantity in the bypass gallery.
Idle adjusting screw

FICD solenoid valve
AAC valve
TEC014
As shown, air flows through the AAC

valve. This solenoid valve is repeatedly
energized at a frequency of 160Hz. The
quantity of air passing through the AAC
valve is adjusted by changing the ratio of
energizing periperiod.
The idle adjusting screw must not be
turned unless required. If it is turned
excessively, idle speed feedback control
may not function.
9) Fuel Injector
Fuel injectors are installed for each cylinder. The fuel injector is a small, elaborate
solenoid valve. As the ECM sends injection signals to the injector, the coil in the
injector pulls the needle valve back and
fuel is released into the intake port through
the nozzle. The injected fuel is controlled
by the ECM in terms of injection pulse
duration.
Vacuum control
valve
To intake manifold
Idle
adjusting
screw
FICD
solenoid
valve
AAC valve
TEC015
Top feed type

Terminal
Nozzle
Fuel flow
Needle
valve
Magnet coil
Filter
TEC016
Side feed type
Nozzle
Needle
valve
O ring
Terminal
Magnet coil
Filter
TEC017
64
GENERAL DESCRIPTION OF NEW EGI ENGINES

FEATURES OF NEW-EGI ENGINES
In contrast to the conventional ECCS, the multi-functional throttle chamber has
been adopted by integrating the mass air flow sensor, IACV-FICD, IACV-AAC
valve and FIX (First Idle cam Wax type).
The mass air flow sensor is installed in the throttle chamber to reduce the distance to the combustion chamber, thereby improving engine response and startability.
SYSTEM COMPONENTS
1. Camshaft Position Sensor
The camshaft position sensor has been
changed from the conventional dual signal
system with V signal (crank angle detection) and 180' signal (cylinder identification) to the single signal system, that is,
the time control system. The cylinder identification signal uses the position signal of
No. 1 cylinder only, and the crankshaft
position (angle) signal is detected according to the slit passage time.
No. 1 cylinder at TDC

on compression stroke
Cylinder
identification
slit
TEC018
For NEW EGI Engine

180 degree signal slit for No. 1 cylinder
TDC signal slit for

No. 1 cylinder
Crankshaft
position
signal
Rotor plate
(rotates counterclockwise)
Rotor plate
(rotates clockwise)
TEC019
65
TEC020
2. Throttle Body
As mentioned above, the mass air flow sensor, IACV-FICD, IACV-AAC valve,
throttle sensor and IACV-FIC are integrated into a single unit forming the
multi-functional throttle body. The mass air flow sensor uses a bypass type hot
wire. The wax type FIC is used to adjust the auxiliary air quantity when the
engine coolant temperature is low.
IACV-AAC valve
Mass air flow

sensor
Idle air
adjusting
screw
Throttle
position
sensor
Thermo
wax FIC
TEC021
TEC022
3. IACV-AAC Valve
The AAC valve of a rotary solenoid type is used. This rotary solenoid has a rotary
magnet which rotates a slider to open or close the flow control hole provided in
the slider housing, thus controlling the flow rate of air.
Rotary solenoid
Auxiliary air passage
Slider
TEC023
66
4. Fuel Injector
The side feed type injector is used. The nozzle uses
a plate orifice type to improve atomization and to prevent deposit.
Connector
Coil
Fuel out
Flat
valve
Orifice
TEC024
Fuel
Injected fuel
Injector
Plate orifice
Intake port
Fuel flows strike
each other.
Intake valve
Fuel is injected without
wetting intake port
TEC025
TEC026
67
ECCS CONTROL MODULE

The control module is sometimes called ECM, or simply computer. The control module receives signals from various sensors and switches, performs computations, and compares the results with data stored in the memory, and outputs
optimum signals to the actuators. This module is the core of the ECCS system.
Sensors & Switches

Vehicle speed sensor
Knock sensor
Ignition switch
Air conditioner switch
Battery voltage
ECCS CONTROL MODULE

I/O port
for input & output
CPU
(Central Processing Unit)
Fuel injector
Fuel pump
Ignition timing
AAC valve
Memory
(ROM & RAM)
TEC027
CAUTION
Disassembly of the control module is not allowed for the following reasons.
Disassembly allows dirt to enter the control module, resulting in poor contact of connections or rust formation on parts.
Static electric charge in the human body may damage the electronic parts
such as the IC (Integrated Circuit) or LSI (Large Scale Integrated Circuit),
etc.
Condition of electronic parts cannot be judged from their appearance.
Internal wiring may be damaged.
When connecting or disconnecting the harness connector to or from the control module, be sure to turn the power OFF. Otherwise, the control module may
be damaged by a spark discharge, short-circuit, or generation of surge voltage, etc. caused by such operation.
Do not allow the control module to get wet as this may cause short-circuit or
leakage and result in damage to the control module.
Do not drop the control module. This may cause the PC (printed circuit) board
to crack, resulting in malfunction of the control module.
Store the control module in a place that is clean and dry and where ambient
temperatures are somewhat low and do not change drastically.
68
NEW ECCS COMPONENT PARTS

1. HALL IC (ELEMENT) TYPE CRANKSHAFT ANGLE SENSOR
Hall IC (element) type crankshaft angle sensor consists of two sensors, POS
(position) sensor and PHASE sensor. The combination of these two sensors
is generally called crankshaft angle sensor.
The POS sensor is used for detecting crankshaft position and obtains the
POS signals by means of a signal plate installed on the No. 6 counterweight
of the crankshaft. The PHASE sensor is used for detecting camshaft position
and obtains the PHASE signal by means of projections provided on the
exhaust cam sprocket.
Basically, these two sensors function in the same manner as the conventional
photoelectric crankshaft angle sensor.
Reference: Hall IC (element) means a semi-conductor element which detects
magnetic field by utilizing Hall effects.
Hall IC (element) type crankshaft angle sensor applies the principle of Hall
effect. This element is provided with excellent features including less susceptibility to magnetic field than magnetic type crankshaft angle sensor and is
capable of high precision ignition timing control.
Functions of each sensor and schematic diagram of the signals are as follows.
Sensor name
Function
POS
Detection of crankshaft
Engine speed and start
Hall IC (element) type sensor angle
positions of each cylinder
crankshaft angle
are detected by two signals.
PHASE
sensor
(start points of injection and
Identification of cylinders
sensor
ignition timings)
Identification of cylinders
and detection of datum
REF
positions (start point of
(Reference) Photosignal
Engine speed detection difinjection and ignition timelectric crankshaft
fers with engine.
ings)
angle sensor
POS
1signal (crankshaft angle)
detection
signal
69
POS signal
(crankshaft)
TEC028
Procedure for detecting datum position of each cylinder

The datum position of each cylinder is calculated based on PHASE signal and
POS signal. (BTDC 50 )
Ignition procedure (example of No. 1 cylinder)
POS signals are counted by using BTDC 50 of No. 1 cylinder as the basic
datum. Then, ignition is carried out at the position where the advance angle
indicated by ignition timing control is obtained. Here, 10 intervals of POS signals and the angle of skipped pulses are compensated by time measurement.
70
1) ECCS CONTROL UNIT

Small-sized ECCS control unit is adopted.
The connector shape is new SMJ81pins,
lever-type.
The mounting position is in the right-hand
side of engine room on the back of dash
panel.
TEC029
2) POS (POSITION) SENSOR

POS sensor of hall IC (element) type is adopted.
POS sensor detects crankshaft angle by signalplate mounted to No. 6 counteweight of crankshaft for setting ignition timing and injection timing.
Engine speed is detected by two signals from POS and PHASE sensors.
The mounting position is at the rear right-hand side of cylinder block.
TEC030
TEC031
3) Mass AIR FLOW SENSOR

Hot-wire type air flow sensor is
adopted.
Accuracy in intake air flow measurement after starting is improved in
comparison with the conventional
type.
The case is resin-made and signals
of output voltage corresponding to
intake air flow are issued.
TEC032
71
4) COOLANT TEMPERATURE SENSOR

Thermister-type sensor is adopted.
The higher coolant temperature
rises, the lower thermister resistance value becomes and so the
output voltage is.
The mounting position is at the front
left-hand side of cylinder head.
TEC033
5) O2 SENSOR
Water-proof zirconia O2 sensor with
heater is adopted.
The mounting position is at exhaust
manifold.
TEC034
6) KNOCK SENSOR
Small-sized piezoelectric knock
sensor is adopted.
The mounting position is at the
right-hand side of cylinder block
(No.2 cylinder).
TEC035
72
7) POWER STEERING OIL PRESSURE SW

This is mounted on power steering oil
piping and turned OFF while power
steering is not operated and turned ON
while it is operated.
The mounting position is at the rear
lower side of intake manifold.
TEC036
73
8) THROTTLE SENSOR AND THROTTLE VALVE SW

Throttle sensor detects signals according to throttle opening to perform idle
judgment through the software, and setting of fuel injection quantity for acceleration/deceleration.
Throttle valve SW is used as a fail-safe device for the electronically controlled
A/T by detecting idling and full-throttle signals. It is also used for idle judgment in the event of failure of both throttle sensor and air flow sensor.
Function of soft idle SW
This function memorizes the minimum value of throttle sensor output in operation as the learned value (learned as idling range) to determine engine condition as idle or not by comparing the throttle sensor output while operating
with said learned value.
Here, it is necessary to rewrite the learned value when idle judgment is not
turned ON at idling when (and after) adjusting the throttle sensor output.
Soft Idle
Idle Switch
TEC037
74
9) IACV-AAC VALVE
IACV-AAC valve with built-in air cut valve is provided in the auxiliary air passage which bypasses throttle valve.
IACV-AAC valve of step-motor type opens/closes the bypass passage to
control auxiliary air flow at the optimum by rotating by the number of steps
corresponding to driving signals from ECCS control unit.
It is necessary to perform rapid TAS learning at detaching/attaching or
replacement of IACV-AAC valve.
Air cut valve is of spring-type and bimetal type and operates according to
cooling coolant temperature. The valve closes when coolant temperature
rises high and rotates to the open side when coolant temperature drops to
restrict auxiliary air from IACV-AAC valve by air cut valve.
TEC038
10)THROTTLE OPENER
Throttle opener is provided to
improve engine startability.
This returns throttle valve to the
close position by intake manifold
vacuum after engine start.
TEC039
75
ON BOARD DIAGNOSTIC
2. DIAGNOSIS SYSTEM
1) OUTLINE
Self-diagnosis system is adopted and measures to conform with COSULT are
taken to facilitate failure diagnosis.
2) SELF-DIAGNOSIS
When an abnormality occurs in an important sensor system among sensors
necessary for ECCS control and conditions for detecting abnormalities by
self-diagnosis are satisfied, this system makes the control unit memorize the
affected sensor system to facilitate troubleshooting.
There are two ways to indicate self-diagnostic results. One uses the malfunction indicator lamp and the other uses CONSULT.
The following table shows how to indicate the results with the malfunction
indicator lamp.
Diagnostic mode
Mode selection
Indication
Malfunction indicator lamp
is lighted when a failure
Failure alarm
To be performed by diagno- alarm is issued. (Refer to
the previous page for
sis connector provided at
the lower part of instrument details.)
Self-diagnosis (when key lower driver panel at
SW is ON)
driver's seat.
To be judged by flickering of
malfunction indicator lamp.
O2 sensor monitor (while
engine is in operation)
TEC040
76
3) HOW TO OPERATE SELF-DIAGNOSIS (MODE II SELF-DIAGNOSIS)

Turn the key SW to ON (Do not start engine), connect CHK and IGN terminals of Data link connector with a suitable harness, wait at least 2 seconds, and then disconnect them.
Make a self-diagnosis with the key SW on.
If the engine is started during a self-diagnosis, Mode II will change to the
O2 sensor monitor. (O2 sensor monitor of Mode II)
When the key SW is turned off, the Mode II will automatically return to Test
Mode I (Normal condition).
Turn the key SW
to ON (Do not start
engine)
TEC041
Mode I-MALFUNCTION
INDICATOR LAMP CHECK
MIL should come on.
Start engine
Diagnostic Test Mode I

- MALFUNCTION WARNING
TEC043
Data link
connector
Connect CHK and IGN terminals
with a suitable harness.
MIL should turn off.
TEC042
Mode II-Self Diagnosis

-Self-diagnostic results.
Start engine
Diagnostic Test Model

-FRONT HEATED O2 SENSOR
MONITOR
TEC043
(ERASING ECM MEMORY)

Data link
connector
Connect CHK and IGN terminals
with a suitable harness.
MIL should turn off.
TEC042
When the key SW is turned off during

diagnosis, the diagnosis will automatically
return to Diagnostic Test Mode I.
77
4) ALPHABETICAL INDEX FOR DTC

Items
(CONSULT-II screen terms)
A/T COMM LINE
CMPS/CIRC (PHASE)
COOLANT T SEN/CIRC
CKPS/CIRC (POS)
ENG OVER TEMP
FRONT O2 SENSOR-B1
IGN SIGNAL-PRIMARY
KNOCK SEN/CIRC-B1
MAF SEN/CIRCUIT
NATS MALFUNCTION
NO DTC IS DETECTED. FURTHER
TESTING MAY BE REQUIRED
NO DTC IS DETECTED. FURTHER
TESTING MAY BE REQUIRED
THRTL POS SEN/CIRC
VEH SPEED SEN/CIRC
DTC
CONSULTS-II
ECM*1
MIL Illumination
P0600
P0340
P0115
P0335
P1217
P0130
P1320
P0325
P0100
P1610-P1615
0600
0340
0115
0335
1217
0190
1320
0325
0100
1610-1615
X
X
X
X
X
X
X
X
0000
Flashing*2
P0120
P0500
0120
0500
X
X
1: In Diagnostic Test Mode II (Self-diagnostic results).

2: While engine is running, front heated oxygen sensor monitoring status shown
by blinks.
78
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

Diagnostic Test Mode I - Bulb Check
MIL should stay ON with the key SW on (Do not
start engine), then turn OFF after starting engine.
Diagnostic Test Mode I - Malfunction Warning
If the following malfunction is detected, the MIL
should stay ON to warn the driver.
Malfunction in air flow meter system
Malfunction in engine coolant temperature in sensor system
Malfunction in throttle sensor
Malfunction in Oxygen sensor
Malfunction in POS sensor
Malfunction in PHASE sensor
Malfunction in the vehicle speed sensor
Malfunction in over heat
Malfunction in ignition signal
TEC044
Diagnostic Test Mode II

- Self-diagnostic results
In this mode, trouble code can be identified by
the number of four-digit numeral flashes. The
DTC 0000 refers to no malfunction.
TEC045
Diagnostic Test Mode II

-Front Heated Oxygen Sensor Monitor
ON
In this mode, the MIL displays the condition of
(lean)
the fuel mixture (lean or rich) which is monitored by the front heated oxygen sensor. When
A B
ON
running engine at about 2,000 rpm for about 2
(rich)
minutes under no-load conditions after warmDuty ratio per 1 cycle
ing engine up, check that the MIL comes ON Lean: A/ (A + B) x 100
{
more than 5 times within 10 seconds. (the con- Rich: B/ (A + B) x 100
dition of the fuel gets controlled during idling)
MIL
Fuel mixture condition in the exhaust gas
Air feedbac control condition
ON
Lean
Closed loop system
OFF
Rich
Remains ON or OFF
Any condition
79
Open loop system
NISSAN
CONSULT
HANDLING MANUAL
CONTENTS
Overview (Part Names)
1. Precautions................................................................................... 82
2. Getting started.............................................................................. 82
3. Charging the NiCd battery........................................................... 82
4. Replacing the NiCd battery ......................................................... 84
5. Printer and roll paper ................................................................... 85
6. Loading programs........................................................................ 87
7. Cables............................................................................................ 89
8. Thermal paper handling precautions ......................................... 90
9. Reference ...................................................................................... 90
80
OVERVIEW
Part Names
Power OFF switch
Power ON switch
Touch panel
Function key plate slot
Connector cover
Contrast control dial
TCO001
TCO002
81
1. PRECAUTIONS
CONSULT employs precaution electronic components (such as LS1s) which
should not be used where there are sudden changes in temperature, high temperatures or excessive humidity, dust and dirt. Also, do not leave CONSULT
where it might be exposed to direct sunlight.
Moisture may condense on the surface of CONSULT if it is brought into a
warm room from the cold. If this happens, do not use CONSULT until all moisture has been removed or dries.
Always attach the covers to the terminals when the cables are not in use.
Never use volatile substances such as thinner or damp cloths to clean the
CONSULT unit. Use the display cleaner provided to clean the touch panel.
Several magnets are used in the printer section so do not leave your CONSULT unit in place where there are metal particles. Do not allow metal objects
such as paper clips to fall inside.
Do not operate the printer without paper.
2. GETTING STARTED
Before using CONSULT, install the NiCd battery. The battery may grow weak if
considerable time has passed since your CONSULT was shipped from the factory. When using CONSULT for the first time, charge the battery.
3. CHARGING THE NiCd BATTERY
CONSULT uses a NiCd (rechargeable) battery as the power supply. Charge the
battery when using a CONSULT unit for the first time or when the voltage drops.
[Low NiCd batt volt!] is displayed when the NiCd battery drops during use.
(1) Press the power OFF switch.
(2) Plug the CH-85 charger power plug

into an outlet. Then plug the charger
output -- plug into the CONSULT charging connector.
Power ON switch
Power OFF switch
TCO004
TCO003
Before charging the battery, be sure to press the power OFF switch and plug in
the charger output plug.
Insert the charger output plug straight in. Pushing sideways can damage the
connector.
82
(3) The charger lamp will light brightly while charging. Charging will be completed
in approximately eight hours at the first time. Check to make sure the charger
lamp lights brightly after plugging in the output plug. If the lamp does not light
brightly, insert the output plug into the connector again.
(4) When charging is completed, the charger lamp will go out. Remove the plug.
The NiCd battery can be charged by connecting the diagnostic data link cable
to a vehicle and turning the vehicle ignition key to ON. However, using both
the printer and back-light increases current consumption and causes the battery voltage to drop.
Because of this, charging the battery is recommended at the end of each
day's work. Also do not use the printer and back-light unnecessary. Recharge
immediately when the battery voltage warning appears. Do not operate the
CONSULT unit with the battery charger connected.
When the CONSULT unit is not used over a prolonged period, the battery
voltage may drop due to natural discharge. Recharge the battery at least
once a week. The NiCd battery temperature rating is 0C (32F) to 40C
(104F). Always recharge within this temperature range.
83
4. REPLACING THE NiCd BATTERY

The NiCd battery will weaken after being recharged approximately 500 times.
When this happens, [Low NiCd batt volt!] will appear on the display soon after
recharging and the NiCd battery must be replaced. Use the following procedure
of replace the NiCd battery.
(2) Press A mark on top of the battery pack in the

direction of the arrow.
TCO005
(3) Insert the new battery pack as shown in the

illustration.
TCO006
*Do not crush the old battery pack or throw it into a fire.
84
5. PRINTER AND ROLL PAPER

The CONSULT unit is equipped with a thermal dot printer. Use only the specified
roll paper for printing. The hard case also serves as the paper holder. Use the following procedure to load the paper.
1) Move the paper release lever in the direction of the arrow as shown in the illustration.
This lifts the printer head and allows the
paper to enter.
2) If the end of the paper is not straight, cut if

square with scissors. Then insert the end of
paper as far as possible into the paper lot.
3) Turn the paper feed knob while pushing the

roll paper in by hand until the end of the
paper appears above the printer cover.
4) Insert the roll paper shaft into the hole in the

center of the roll of paper.
TCO007
85
5) Fit the ends of the shaft firmly into slots in

the hard case. Then mount CONSULT in the
hard case.
6) Remove any excess slack in the paper.

Then move the paper release lever in the
direction of the arrow as shown in the illustration. This places the printer hard in contact with the paper.
TCO008
The CONSULT printer uses thermal (heat sensitive) paper. It cannot use ordinary paper. Use only the specified thermal paper.
Use of wet paper can result in a paper jam or malfunction and should be
avoided.
If the paper jams, use the paper feed knob whenever possible to remove the
paper. The paper feed knob can also be turned in reverse. Use of excessive
force can damage the printer head. Always use the paper release lever to lift
the printer head from the paper before attempting to remove a paper jam.
To advance the roll paper while CONSULT is mounted in the hard case, pull
lightly on the end of the paper.
86
6. LOADING PROGRAMS
When using a CONSULT unit for the first time, use the following procedure to
load the program card into the main memory.
(1) Hold down the key in the upper left and
right corner of the touch panel and press
the power ON switch as shown in the illustration. If the keys in the upper left and
right corner are not pressed correctly when
the power ON switch is pressed, an alarm
will sound and the power will not turn on.
Press at the same time
TCO009
(2) The following message will appear on the display.

[Initialize by card]
Insert card, OK?
The failure of this display to appear indicates that the keys were not correctly
pressed. If this happens, press the power OFF switch and repeat the above
operation.
87
(3) Insert the program card into the program card reader.
* Removal program card

TCO010
(4) Press Y on the touch panel.
[Initialize by card]
Insert card, OK?
* The power will be turned off if any other key

than Y is pressed..
TCO011
(5) The program will start to load. Then four English alphabets and a blinking
square will appear. After that, the following message will appear.
[Initialize end]
The program can now executed.

An error will be displayed if the program card is not correctly loaded or if a defective card is loaded. If this happens, press the power OFF switch.
88
7. CABLES
Use the following procedures to connect the cables to the CONSULT.
Connecting the diagnostic data link cable
(2) Open and remove the connector cover marked DDL (on the extreme left).
TCO012
(3) Plug the diagnostic data link cable (black) into the CONSULT connector.
Diagnostic connector
for CONSULT
TCO013
TCO014
Always press the power OFF switch before plugging in the connector.
Always hold the connector when disconnecting cables. Never pull the cable
itself.
Store the connector cover to prevent loss.
For other cables, perform the same procedure.
89
8. THERMAL PAPER HANDLING PRECAUTIONS

1) Observe the following precautions to avoid discoloration or fading of the thermal paper. Improper storage conditions can also result in loss of printed data.
2) High temperatures of 50C (122F) or higher and atmospheres containing
thinner, alcohol, benzine or ammonia can cause the paper to turn black.
Prolonged exposure to ultraviolet rays or contact with polyvinyl products,
tape, glue containing thinner, etc., can cause fading of the printing.
9. REFERENCE
1) What is the CONSULT?
Computerized ON-board System Universal Tester
CONSULT represents a significant advance in the technology for diagnostic
troubleshooting in electronic control system. Starting with some 1990
Nissan models, the vehicles are designed with CONSULT in mind.
2) Program number
This number indicated publication year and specifications.
Ex.
E
92
0
0: First version 1: 2nd version 2: 3rd version
Publication year (1992)
Language
E: English F: French G: German S: Spanish
Adoption area
U: USA and Canada

E: General (except above)
A: Australia (from 1995)
This program card can be used on compatible vehicles produced between

1990 and 1992 model years.
Updating of card is responds to new technology.
3) Data of TIME indicated as below:
This indicates how many times the engine started after the last detection of a
failure. If the failure is being detected currently, the time data will be 0.
4) Function of ERASE
When touched, the self-diagnostic results stored in the ECM are erased. You
have to perform self-diagnosis again when you finish repairs.
5) Function of PRINT
When touched, the self-diagnostic results are printed out. (with system, date
and ECM part number).
90
MEASURING TOOLS
1. VERNIER CALIPERS
(Function)
You can measure length, outer diameter, inner diameter and depth easily with
vernier calipers. When you do the maintenance work on trucks, you use these
vernier calipers mainly for measuring the outer diameter of a shaft, the inner
diameter of a bushing, the height of a valve spring and the like.
Inside measuring jaws
Datum surface of the depth measuring end

Stopper screw
Main scale
Depth rod
TTL001
Outside measuring jaws
(Scale reading)
Examples of the minimum scales you can read with vernier calipers are l/ 10,
1/20, and 1150 min. Lets take as an example the vernier calipers which provide a minimum reading of 1/20 min. As the illustration shows, the main scale
is scaled in millimeters. In the vernier, 19 scales of the main scale are equally
divided into 20. This means that one scale of the vernier is 19/20 mm (0.95
mm) and the difference of one scale between the main scale and the vernier is
1 min - 19/20 (0.95 mm) = 1/20 (0.05 mm). By using this principle, you can
read 1/20 min.
When a work is measured, the scale reads as is shown in the illustration. In
this case, the value by the unit of millimeters is read by the main scale, and the
fraction is read by the vernier where the main scale and the vernier meet. In
the illustration, the reading on the main scale is 46, and the scale 4 of the vernier meets a scale on the main scale. Here, the value 4 of the vernier means
0.4 mm. So the total reading is 46 mm + 0.4 mm = 46.4 nun. If the vernier is
divided into 20, the fraction can be found by multiplying 0.05 to the value of the
vernier where both scales meet.
You must read the scale in a right angle
Main scale
against the vernier calipers. If you read
from the wrong angle, an error will arise
due to the thickness of the vernier.
Vernier
TTL002
91
(Important points)
The measuring surfaces of vernier calipers and the measured surfaces of a
work must be always kept clean to obtain a correct value with vernier calipers.
Before using, check that the vernier calipers move smoothly, that the zero lines
of both the main scale and the vernier exactly meet, and that the outer diameter measuring surfaces and the inner diameter measuring surfaces contact
respectively in parallel without any gap. Existence of a gap between the measuring surfaces causes errors. Correct use of vernier calipers prevents such
distortion. Misuse or negligence of maintenance leads to earlier occurrence of
distortion, resulting in incorrect measurements. Application of unnecessarily
large measuring force must be avoided.
Measuring surfaces can be protected if the vernier calipers are kept after use
with both of the measuring surfaces locked with a clearance gap between
them.
TTL003
(Measuring of outer diameter)

Basic way of holding vernier calipers
Let the measuring surface of the jaw of the main scale contact the work, set
your thumb on the knob of the vernier, and hold the work with measuring surface of the jaw of the vernier.
TTL004
92
Use the roots of the jaws for measurement.

Use of the tips of the jaws will bend the vernier as shown in the illustration,
casing incorrect measurements. Application of an unnecessarily large measuring force also causes such bending even if the work is measured at the roots
of the jaws. So, the measuring force (the force applied by your thumb) is
another important factor.
Not recommended
Correct
TTL005
Vernier callipers and work are to be in a right angle.

This is the basic for measuring. If the work is not placed in right angle, rocking
the callipers slightly in the horizontal direction with your thumb and pressing
the vernier lightly will advance the vernier slightly, making the measuring surfaces contact (in right angle) closely to the work.
Jaw of main scale
Work to be measured
Jaw of vernier
TTL006
How to measure a large work

A large work is measured at its end surface, and the trick to this is to make the
main scale contact the end surface of the work. In this way, bending of the vernier calipers is avoided and correct measurement can be obtained.
Make the main scale contact the end surface
of the work
TTL007
93
(Measuring of inner diameter)

Insert the bills of the vernier calipers into the work, and make the measuring
surfaces contact the inside of the work by the pulling the vernier slightly with
your thumb set on the knob of the vernier.
Correct way of applying the bills
Insert the bills as deeply as possible, but not deeper than the relief of the bills.
Moving the calipers slightly in longitudinal and lateral directions by pulling the
vernier lightly with your thumb set on the knob of the vernier will open the vernier slightly, enabling the work to contact the measuring surfaces closely.
Relief of the bill
TTL008
If the bills are inserted too shallowly, the whole body of the vernier callipers
tends to fall as shown in the illustration. Application of unnecessarily large
measuring force is likely to cause distortion to the vernier.
TTL009
How to measure a round hole

A round hole (inner diameter) is to be measured at the largest diameter. The
largest diameter can be found easily by pulling the vernier slightly and moving
the calipers slightly as shown by the arrows.
The largest diameter
Bill
Bill
TTL010
94
How to measure a s
A square hole is a be measured, contrary to a round hole, at the shortest distance or the place where the largest reaction is felt. The shortest distance can
be found using the following procedure. Let the measuring surface of the bill
the main scale contact the measuring surface of the square hole lightly, and
then stop it. Then, set your thumb on the knob of the vernier, and move the bill
of the vernier slightly while pulling it lightly as shown by arrows. The trick is to
narrow down the width to move the bill gradually.
Bill of the main scale
The shortest distance
Bill of the vernier

TTL011
(How to measure depth)

Apply the datum surface of the depth measuring end closely to the datum surface of the depth (length) of the work and slide the vernier till the tip of the
depth bar contacts the bottom. Application of an unnecessarily large measuring force causes the floating of the main scale or the distortion of the datum
surface, and in the case of a deep hole, the depth bar may be deflected as
shown in the illustration, making correct measurement impossible.
If an unnecessarily large measuring
force is applied, ....
Deflection
TTL012
In case the depth can not be measured directly. If the depth bar can not be
applied directly due to the taper provided at the inner surface of the work, use a
square object such as a square bar which can be used as a datum, and then
subtract the thickness of the square object from the actually measured value.
Square bar or the like
TTL013
95
How to measure a small hole

The datum surface of the depth measuring end is to be bridged across the hole.
It is important to make both datum surfaces contact closely. Correct value can
not be obtained if one side is floating.
Wrong
Correct
Main scale
Work to be measured
Depth bar
TTL014
How to measure a large hole

The trick is to contact the depth bar tightly to the inner surface of the work to be
measured as shown in (a) and (b). After it is machined, the R (curvature) will
remain more or less at the corner. Correct value can not be obtained by the
method shown in (c) since the corner of the depth bar contacts the R. It is important to make the relief of the depth bar face the R as shown in (b). A slanted
datum surface shown in (d) will cause the error of at least 0.1 mm to 0.2 nun.
Correct (a)
Correct (b)
Wrong (c)
Avoid R of the work
Wrong (d)
If R is provided on the corner.

TTL015
96
1. MICROMETER
(Function)
A micrometer is used mainly for measuring outer diameter or length. The minimum reading of an ordinary one is 0.01 mm.
A standard gauge is used to inspect the scale error.
Thimble
Anvil
Spindle
Lock clamp
Ratchet stopper
Outer sleeve
TTL016
(Prior inspection)
1) Loosen the clamp.
2) Wipe the hole body with a waste cloth. Pay
attention so that the measuring surface are
free from dust and the like.
3) Check the turning condition of the spindle
by holding and turning the ratchet stopper.
4) Close the space between the measuring
surface until the ratchet stopper turns idly
(ticketing sound) and confirm the zero
point.
TTL017
(Hold a work)
1) Put the work in a stable position.
2) Hold the frame with your left hand and turn
the thimble to open the measuring space a
little wider than the work.
3) Place the work in the space between the
measuring surfaces, turn the ratchet stopper with the thumb and the point finger of
your right hand and hold the work between
TTL018
the anvil and the spindle.
4) Press the work until the ratchet stopper turns idly (ticking sound) two or three
times.
97
(How to read the scale)

1) The scale is to be read with the work held.
2) In order to measure the work which is located at a place where the scale is
hard to read, clamp and fix the spindle, and remove the micrometer gently
from the work to read the scale.
3) Read the scale on the sleeve at the end of the thimble for the valve of the
unit of 0.5mm. Then, read the scale on the circumference of the thimble
for the valve of the unit of 0.01mm at the point where the circumference
scale on the thimble meets the horizontal line of the sleeve.
[Example]
Horizontal line
TTL019
The reading on the sleeve at the end of the thimble = 7.5 mm

The reading on the circumference of the thimble = 0.24 mm
Measured value = 7.5 mm + 0.24 mm = 7.74 mm
(Maintenance after use)

Lock this micrometer with the clamp with the anvil and spindle kept apart
a little, and keep it in the case. That way, deviation of the scale, which may
occur due to thermal expansion by a temperature rise, etc. if the anvil and the
spindle are kept in close contact, can be avoided.
Keep apart a little
TTL020
98
1. DIAL INDICATOR
(Function)
A dial indicator is used to measure a bend or a runout of a shaft, parallelism or
surface roughness.
A dial indicator is so constructed that axial movement of a spindle (probe) is
converted into rotary motion of the pointer by means of gears.
A dial indicator is scaled in 1/100 mm. Movement of 1 mm of the spindle
causes one revolution of the pointer.
Outer ring
Pointer
Revolution counter
Stem
Body
Scale
Spindle
TTL021
Probe
The magnetic base of the dial indicator can be fixed to a surface plate by
means of a magnet.
Supporting rod
Gauge beam lock
Dial gauge
Adjusting lever
Spindle
Magnetic stand
TTL022
99
(Important hints)
(When measuring a flat plane, the spindle is to be set in right angle against
that plane.)
The spindle is to be set in a right In right angle
As short as possible
angle against the work surface when
seen from either the front or the side
as shown in (a). The beam of the
stand is to be as short as possible.
The beam of the stand is to be as
short as possible. The angle between
the beam and the dial indicator is to
be as close as possible to 90'.
(a) Correct
(b) Wrong
If the spindle is inclined as shown in
(b), the spindle will not move in the
Too long
Too long
axial direction precisely, but if pulled
sideways, this will cause the unstableness of the pointer, resulting in
incorrect measuring.
As scale as 90deg.
Even if the spindle is in a right angle
against the work, and if the beam is
too long as shown in (c) or (d), the
(c) Wrong
(d) Wrong
dial indicator is liable to vibrate, which
TTL023
causes incorrect measuring.
Scale is to be read from the very front
of the dial indicator. Reading from a
wrong angle causes incorrect reading.
After the dial indicator is set to the
work, the pointer is to be set to zero
by turning the outer ring. Then, hold
the spindle with your fingers, and
move it lightly several times to check
that the pointer always returns to zero
of the scale.
TTL024
A dial indicator is a precision machine
like a watch. Handle one with care so
as not to drop it or give it a shock.
The area between the spindle and the
stem is to be kept free from oil or
grease. Oil or dust between them
causes rough movement of the spindle.
100
(How to measure)
Example: To measure a runout of a crankshaft
Place V blocks on the surface plate as shown in the illustration and set the
shaft on the V blocks.
Crankshaft
Dial gauge
V block
Surface plate
TTL025
Set the dial indicator fixed to the stand with caution so that the spindle will contact the uppermost surface of the journal and fix the stand to the surface plate
by applying the magnet. Fix the dial indicator at the height where the dial indicator is pushed to about half Of the full stroke of the spindle. Use caution so
that the spindle will be in a right angle against the journal surface.
Turn the crankshaft slowly and find the surface where the pointer points to the
smallest reading. Then turn the outer ring to set the zero point to the pointer.
Turn the crankshaft slowly and read the gauge pointer to find the runout.
101
USAGE OF MEASURING TOOLS

1. TORQUE WRENCH
Function
A torque wrench is used to tighten a bolt or a nut to a specified torque. This
wrench is to be used with a socket.
1) Plate-spring-type
2) Bar-spring-type
3) Auto-limit-type
TTL026
The arm of a plate-spring-type torque wrench is made of one sheet of plate

spring. While tightening a bolt or a nut, this plate spring deflects. By using this
deflection, the tightening torque is directly indicated at the place close to the
handle of this wrench.
An auto-limit-type torque wrench is so designed that predetermined torque can
be set by turning a sleeve at the end of the handle to the desired scale. Then,
the completion of tightening at the predetermined torque can be easily known
by a sound and hand feeling.
1) PLATE-SPRING-TYPE
How to use the torque wrench properly.
(1) Check on zero point.
Check that the pointer clearly indicates zero before using a plate-springtype torque wrench.
TTL027
102
(2) Select a socket

Select a socket which just fits to the bolt or a nut and engage them. When
using a torque wrench, hold the socket joint with one hand so that the
socket and the torque wrench are not separated.
(3) How to apply force
Be sure that the pivot handle and the plate spring will not contact each
other when you measure the torque with a torque wrench. If they contact,
you can not measure the torque correctly.
TTL028
(4) How to operate

Hold the handle of the torque wrench and pull it toward you to apply force.
Pull the handle in the right direction against the arm.
1) AUTO-LIMIT-TYPE
Tightening torque depends on where the tool is used.
The completion of tightening can be easily known by a sound, click.
103
How to use the torque wrench properly.

(1) Set a torque
a) Turn the locker to the left to unlock the Supplementary Graduation.
b) Turn the Supplementary Graduation to set a torque (combination of
valves on the Main and Supplementary Graduation).
c) Turn the locker to the right to lock the Supplementary Graduation (Reposition the pin if it contacts the locker).
(2) Insert the squared drive into the socket.
(3) Apply the socket on to a bolt head nut.
(4) Turn the torque wrench clockwise to fasten the bolt.
(5) Stop pulling the wrench when you hear a click.
TTL029
Example: To set torque at 36 N-m

1. While reading Main Graduation, turn Supplementary Graduation until 36N-m
on Main Graduation comes close to Graduation Datum Line and then, align 0
on Supplementary Graduation with the Supplementary Graduation Window.
Now, torque set is 36N-m.
2. While reading Supplementary Graduation, turn clockwise until 6 on Supplementary Graduation is aligned with the Supplementary Graduation Window.
Torque is set at 36N-m.
TTL030
TTL031
104
1)
(1)
(2)
(3)
(4)
Precaution for use

Use the wrench within the scale range.
Do not set torque below minimum scale torque.
Make sure the torque wrench is set correctly before using.
Confirm that the torque is set according of the correct unit of measure
before using (kgf.cm, kgf, N.m., etc.).
(5) Do not lock Sup. Graduation with pliers. The lock mechanism will be
damaged and will not maintain torque accuracy.
(6) Measurement precision is affected by the grip position.
A line is provided on the knurled surface to indicate effective length.
(7) Stop tightening when you feel a click.
Applying more torque beyond the click will lead to overtightening.
(8) Loading direction.
The loading direction must be at right angles to the torque wrench (tolerance: +/-15 degrees). This tolerance applies to both horizontal and
vertical deviations.
(9) Remove any dirt such as dust, mud, oil and water, etc. after each use
and before storing torque wrench.
(10) When storing the torque wrench for a long time, set at the minimum
torque, apply rust proof oil, and keep in a dry place.
If improperly stored, the accuracy and durability will decrease rapidly.
TTEL032
105
HANDLING OF STUD BOLT

If stud bolt is damaged or deformed, which may be the cause of a drop in
engine power, replace or repair it.
REPLACEMENT PROCEDURE FOR STUD BOLT
(1) with use of stud bolt remover
1. Install stud bolt remover to stud bolt.
2. Be sure to insert the stopper of which circumference is a screw shape
into stud bolt.
3. Put spinner handle into socket, then
loosen stud bolt.
* It is impossible to reuse stud bolt.
TTL033
(2) without use of stud bolt remover

1. Prepare nut with a proper pitch for cracked or damaged stud bolt.
2. Fix double nut to stud bolt.
3. Rotate the inside of nut to the left, then loosen it.
* Rotate the outside of nut to the right, then tighten it.
TTL034
TTL035
106
USAGE OF TAPS & DIES

TAPS
Function
The tap is a tool used for cutting a female screw in a hole of a work. Usually, the
following three types of taps are provided as a set.
First hand tap ---------- for rough shaping
Second hand tap ----- for mid shaping
Third hand tap --------- for final shaping
TTL036
A female screw is to be cut gradually by using the first hand tap, the second hand
tap and the third hand tap in this order.
These three taps are equal in diameter, but different in length of the chamfer.
107
REPAIR FLOW
Repair tips as follows.
1. Confirm a bolt hole has damaged threads (and not a broken bolt).
2. Measure the outer diameter of bolt with a vernier caliper.
3. Measure bolt pitch with a pitch gauge.
4. Select a tap which fits the outer pitch diameter.
5. Insert selected tap, turn it once or twice, then fix the tap handle.
6. Use each tap from step 1 to final step one by one to complete the
bolt.
7. Blow out cuttings with compressed air.
8. Put in the bolt, and check if it rotates.
Explanation for the points of flow chart

Step 1: Selecting an inappropriate tap may cause making a female hole too
large, so be careful when selecting the tap.
Step 2: Measure the outer diameter with a vernier caliper to obtain standard
size for selection.
Step 3: Measure the pitch of bolt with a pitch gauge, then select the tap of the
same pitch as the bolt.
Step 4: Refer to the size which is indicated on the tap for tap selection.
M8 x 1.25
TTL037
108
Step 5 : Select a tap handle to fit the size of the tap.

The use of the tapping wrench makes the tapping operation easier
because this wrench helps you apply a uniform turning force to the
tap.
Step 6 : Generally, the female screw should be cut carefully by advancing the
tap for one turn, and then reversing for a half turn to release the chips
without applying an unreasonably strong force to the tap.
Cutting oil should be applied the tap with a brush or an oiler while the
tapping operation is being carried out. This will lower high temperature during tapping work, protect the tap, and make the tapping operation easier.
TTL038
109
How to Deal With Broken Tap

The best way is to be careful not to break taps, however, taps which are very
hard and brittle can be easily broken with even a little carelessness. Confirm
what caused the breakage in order to prevent its reoccurrence. Main causes
which should be preventable are as follows.
1. Cutting oil is not used or even if the cutting oil is used, the amount is not sufficient.
2. The pilot hole is too small.
3. Neither tap maintenance nor work maintenance is perfect.
4. The tap is clogged with chips or other foreign particles.
5. The tap handle is too large to match the size of the tap.
6. The tap is turned too forcefully.
In any of the above cases, do not apply unnatural force on the tap.
How To Remove Broken Taps
When removing a broken tap from the hole, be careful of the chips. Remove
chips clogging the taps groove before the tap is taken out of the hole. To remove
chips, use a wire or a thin chisel. If the hole is deep, blow compressed air through
the hole to clean the tap.
The best way to remove a broken tap is to confirm the cause of the breakage.
For example, if a pilot hole is too small, the tap will bite into the material, then be
damaged. In most cases the part near the entrance of the hole may be easily
broken. Do not remove the tap by knocking it in the loose direction. Select the
most appropriate way according to the size of the broken tap and the quality of
the material.
110
Recommended ways are as follow:

1. If the broken part is comparatively shallow,
place a punch or chisel on the tap and hit it
with a hammer. Then turn the tap in the loosening direction and carefully remove it so as
not to damage the screw thread at the
entrance of the hole.
TTL039
2. If the broken part of the tap is out of the hole,

grip the tap with pliers, and remove it by turning it in the loosening direction.
TTL040
3. For a large tap, use a three-footed or fourfooted tool for taking out taps according to
the number of tap grooves, apply the feel to
the grooves and turn the tap carefully.
TTL041
4. Weld a handle or round bar to the broken part and remove the tap by turning
it.
5. Pile up padding by welding on the broken part. Then remove the tap by turning the padded part with a pipe wrench.
6. If the above methods are no effective, slowly heat the cylindrical surface of
the hole with a gas burner or torch lamp, then try to remove it. In most cases,
this method will be effective.
111
Examples of other applications

A broken bolt remaining in a screw hole or a bolt of which head is rounded due
to crushed screw thread are hard to remove. Such bolts can be removed by
drilling a hole in the bolt and applying a reverse tap designed exclusively for
bolt removal.
Crushed screw thread of a female screw can be repaired by tapping.
How To Remove Broken Bolt
The way to remove broken bolts depends on the broken conditions of the bolt.
1. If the bolt is broken with 2 or 3 mm outside of the surface:
a) Pull the bolt by turning it with pliers.
TTL042
b) If impossible in the above way, try step 2.

2.
a)
b)
c)
d)
If the bolt is broken below the surface (use of reverse tap):

Make a hole at the center of bolt with a center punch.
Select the drill of the same size as the reverse tap.
Make a hole in the broken bolt with a drill.
Pull out the bolt with the reverse tap.
TTL044
TTL043
In the case of no reverse tap

Make a big hole in the bolt with a drill as indicated below, insert the bolt of the
same size as the hole or other tool into the hole, and then pull it out.
Use a drill of smaller size than the broken bolt.
Caution: Be sure to make a hole at the center of bolt, if not, the screw may be
easily broken.
Broken bolt at the outside.
Drill one size smaller than bolt.

TTL045
112
DIES
Function
A die is a tool used to cut male screw around a round bar or a pipe.
The most widely used dies are called round open dies.
A round open die is shown below. The round split die has a chamfer which is
larger in diameter than the root so that die can easily bite into the material.
TTL046
TTL047
How to use
Screw threads of the round open die are cut off in a tapered form for 2 to 2.5
threads at its starting end so that die can easily start the screw cutting. The die
should be inserted into a die holder with the starting taper of the die facing
downward.
The open die is adjustable in diameter and is widely used for cutting ordinary
external threads.
113
REPAIR FLOW
Repair bolts as follows.
1. Insert a nut into a bolt, then check the hardness.
2. Measure the outer diameter of the bolt with a vernier caliper.
3. Measure the pitch with a bolt pitch gauge.
4. Select dies which fit the outer diameter.
5. Repair the bolt.
6. Clean cuttings with a brush.
7. Put the nut into the bolt, then confirm the bolt rotates.
114
Explanation for the points of flow chart

Step 1 : Measure outer diameter with vernier caliper to select the standard
size.
Step 2 : Measure the bolt pitch with a pitch gauge. Select a die with a pitch
that fits the outer diameter.
Step 3 : Die indication code
Example
6M 1
Pitch 1mm
6mm
(Inner diameter)
TTL048
Step 4: There is a screw hole on the side of the die for installing a handle.
Insert the setscrew of the die handle into the hole to prevent the die
from turning unnecessarily.
TTL049
Step 5 : When turning the die holder handle, apply uniform force to the right
and left of the handle. Generally, the screw should be cut carefully by
advancing the die for one turn, and then reversing for a half turn to
release the chips without applying an unreasonably strong force to
the die.
Cutting oil should be applied to the die with a brush or an oiler while
the screw cutting work with the die is being carried out. This will
reduce the high temperature generated during the screw cutting work
protect the die, make the screw cutting operation easier, and provide
a clean finish of the screw.
115
Examples of other applications

Bolts which are frequently used and are hard to turn when being tightened can
be repaired by cutting the screw with a die again.
TTL050
APPLICATION OF TAP AND DIE

Tap
If the handle of die is hard to use, replace the bolt.
Pitch gauge
If there is no pitch gauge, set the bolt in use as size of tap or dies. If the bolt
can be inserted into a screw thread with no trouble, the pitch is regarded as
the same size.
116
BODY AND TRIM

SERVICING BODY INTERIOR
REMOVAL OF CLIPS
The clips shown in the illustration are widely used in fastening interior trim
pieces. When these clips are forced out with a screwdriver, the trim, the body
panel, or the clip may be damaged.
Trim
Body panel
TBT001
Tool in this illustration ca be easily made, and will come in handy.
Rag
Clip
Old screwdriver
Smoothness out of the edges so
as not to scratch the trims.
TBT002
When pulling out the rivet-type clips with a screwdriver, the screwdriver made
scratch the trim. A tool such as the one described here, which can be easily
made, will come in handy.
TBT003
If the trip or panel may be scratched, apply a

rag underneath the fulcrum point of the tool.
When removing the clip, carefully insert the tip of the tool between the clip and
the trip, and pry it with a lever action.
If there is a danger of scratching the trip or panel, place a rag underneath the
fulcrum point of the tool.
Replace any clips and / or fasteners which are damaged during removal or
installation.
Clips and fasteners in Service Manuals correspond to the following numbers
and symbols.
Replace any clips and / or fasteners which are damaged during removal or
installation.
117
ENGINE FUNDAMENTALS
1. AUTOMOBILE ENGINES
Automobile engines are classified into the following types according to the type
of fuel used:
(1) GASOLINE ENGINE
These engines use gasoline for fuel. Smallsized, high speed, high powered,
and light weight, they are widely used in passenger cars, commercial vehicles
and small trucks.
(2) DIESEL ENGINE
Diesel engines use light oil for fuel. Because they consume less fuel than gasoline engines, and light oil is cheaper than gasoline, diesel engines are often used
in buses and large trucks where fuel economy becomes more important. Smaller
diesel engines are used in some passenger cars, but they are inferior to gasoline
engines in such aspects as maximum speed, output, weight, and noise/vibration
levels.
(3) LPG ENGINE
LPG engines use LPG (Liquefied Petroleum Gas) or natural gas for fuel.
Although output is lower than gasoline engines, they are widely used in taxicabs
due to their superior fuel economy.
118
2. OPERATING PRINCIPLES OF DIESEL ENGINE

2-1. DESCRIPTION
The basic components of gasoline engine are the cylinder, in which an air-fuel
mixture is sealed and combusted, and the piston, connecting rod, and crankshaft, which act together to convert the energy created by the explosive combustion of the air-fuel mixture into rotational movement.
Intake valve 7
Piston
Camshaft 10
Carburetor 11
Connecting
rod
Cylinder head 2
Exhaust valve 8
Crankshaft
Intake
manifold 12
Piston 3
Cylinder 1
Engine rotation
TEM001
Spark plug 9
Connecting rod 5
Crankshaft 4
Flywheel 6
TEM002
Basic component of the engine
The top of the cylinder 1 is sealed to the cylinder head 2 and the piston 3 is
allowed to move freely up and down inside the cylinder. The connecting rod 5
connects the piston to the crankshaft 4 so that the crankshaft will rotate when the
piston moves up / down. At the end of the crankshaft, the flywheel 6 is attached
to make the rotation smooth and even.
On the cylinder head are attached the intake valve 7 and exhaust valve 8 to bring
in, discharge, and seal the air-fuel mixture, and the spark plug 9 to ignite the mixture. As the piston moves downward, air passes through the carburetor 11, creating a gasoline-air mixture, which is sucked into the cylinder through the intake
manifold 12.
When the air-fuel mixture is combusted inside the sealed combustion chamber
above the piston, the pressure inside rapidly increases. This forces the piston
down and rotates the crankshaft through the connecting rod. The piston which
has completed its downward movement is pushed back up again by the connecting rod due to the momentum of the flywheel.
119
In this manner, the reciprocating engine, which uses gasoline for fuel, converts
the reciprocating movement of the pistons, caused by the explosive combustion
of the air-fuel mixture, to the rotation movement of the crankshaft for use as its
motive power.
2-2. OPERATING 4-STROKE ENGINE
To keep the engine running continuously, it is
necessary to perform the steps involved in the
combustion process repeatedly. After the air is
sucked into the cylinder, it is compressed first
and made to explode (combustion) after diesel
injection to generate motive power. Then the
gas resulting from the combustion is ejected
from the combustion chamber. These four
steps - intake, compression, combustion and
exhaust - make up one cycle and they are
repeated over and over. In the 4-cycle engine,
the piston goes through 4 strokes (while the
crankshaft rotates twice) to complete one
cycle.
Intake
Compression
Exhaust
Combustion
TEM003
The engine cycle
(1) INTAKE STROKE

The intake valve is open while the piston moves down and the air-fuel mixture is
sucked into the cylinder (combustion chamber).
(2) COMPRESSION STROKE
As the piston begin to move up, the intake valve closes to seal the combustion
chamber and the air-fuel mixture is compressed. The air-fuel mixture is compressed to one-seventh to one-tenth of its original volume, and its pressure and
temperature increase.
Intake
Intake stroke
Exhaust
Compression
stroke
Combustion
Stroke engine
120
Exhaust stroke
TEM004
(3) COMBUSTION STROKE

Right before the compression stroke is completed, Diesel is injected. The high
temperature generated by the compressed air producing rapid combustion
ignites the air-diesel fuel mixture. The temperature and pressure of the gas mixture within the cylinder rise rapidly, causing the gas to expand and this pushes
the piston down and rotates the crankshaft.
(4) EXHAUST STROKE
Just before the piston completes its downward stroke, the exhaust valve opens
to let the combustion gas escape by its own pressure. The returning piston ejects
the remaining gas. When the piston almost completes its upward stroke, the next
intake stroke begins.
[Reference]
The topmost point inside the cylinder where the piston reaches is called the top
dead center, and the bottommost point is called the bottom dead center. The distance, which the piston travels between the top dead center and bottom dead
center, is called the stroke. The volume of space created above the piston when
at the top dead center is called the combustion chamber.
The injection timing is designed to inject before top dead center. The standard
value is expressed as BTDC 10 degrees (Before Top Dead Center).
Combustion chamber
Top dead center
Stroke
Bottom dead
center
TEM005
Top dead center and bottom dead center
121
3. ENGINE PERFORMANCE
Catalogues or brochures describe the following characteristics which are used to
measure an engines performance: piston displacement, compression ratio,
power output, torque and fuel consumption.
3-1. PISTON DISPLACEMENT
Piston displacement is the volume discharged
when the piston moves from bottom dead center to top dead center. Total piston displacement [expressed in cubic centimeters (CM3)]
is that volume multiplied by the number of cylinders.
Top dead center
Bottom dead
center
TEM006
Piston displacement
3-2. COMPRESSION RATIO

Compression ratio is the ratio of the volume
above the piston when the piston is at bottom
dead center to the volume above the piston
when it is at top dead center.
The volume above the piston when it is at top
dead center is called combustion chamber volume. Thus, the volume above the piston when
it is at bottom dead center equals the piston
displacement plus the combustion chamber
volume.
Top dead center
Bottom dead
center
TEM007
TEM007
Compression ratio
Assuming the compression ratio is P, piston displacement is V (cc) and combustion chamber volume is v (cc), the equation for the compression ratio is as follows:
V + v
* 1 cm3 = 1 cc
Compression ratio P =
v
122
3-3. TORQUE AND HORSEPOWER

Torque is the ability to cause something to
rotate, i.e., the turning force. When a bolt is
tightened with a spanner, the longer the length
of the spanner, the less the tightening force
required. The amount of torque is obtained
from the length of the spanner multiplied by the
tightening force.
Torque (Turning force)
Torque (Turning force)
F (Force)
Torque (T) - Force x Distance = F (kg) x r (m)

1 horsepower (PS)
Torque is represented by the symbol kgm.

This has been changed to N.m, conforming to
the international system of units. 1 kgm = 9.8
Nm
Output is the work volume and speed required
to do the work, i.e., it is the work volume in a
unit of time. For an engine that unit is
expressed as horsepower. One (1) horsepower is the rate of work to do a work for moving one (1) meter in one (1) second with the
force of 75 kg. This has been changed to kW,
conforming to the international system of units.
1 PS = 0.7355 kw.
3-4. ENGINE PERFORMANCE CURVES
Engine performance curves show the shaft
horsepower (PS), shaft torque (kgm) and rate
of fuel consumption (g/PS.h) at respective
numbers of revolution during full throttle acceleration operations. In the engine performance
curves diagram, the horizontal axis shows the
number of revolutions per minute r/min of the
crankshaft and the vertical axis shows the shaft
output, shaft torque and rate of fuel consumption
1 second
TEM008
Torque and horsepower
Total load
Shaft
output
Shaft
torque
Engine speed
TEM009
How to read engine performance curves diagram
123
4. ENGINE COMBUSTION
4-1. DESCRIPTION
(1) AIR -FUEL RATIO
The air and fuel mixture rate necessary for combustion is called air-fuel ratio (mixture ratio) and
is represented by weight percentage, not volume
percentage.
Complete
combustion
Air
14.7 g
(0.518 oz)
Fuel
1 g (0.04 oz)
Air Fuel ratio =
Air volume (g)

TEM010
Fuel (g)
Ideal airfuel ratio
In order to completely burn 1 gram (0.04 oz.) of

gasoline, theoretically 14.7 grams (0.518 oz.) of
air is necessary. Air-fuel ratio in this case is
called ideal air-fuel ratio.
Ecconomical
Airfuel ratio
Output airfuel
ratio
TEM011
Economical airfuel ratio and

output airfuel ratio
(2) IGNITABILITY AND INFLAMMABILITY

When fuel is heated in air, it ignites at a certain
temperature without an open fire or electric
spark. This characteristic is called ignitability
(combustibility) and the temperature at that time
is called the ignition point or fire point. When diesel fuel and gasoline are dropped on a heated
iron plate, diesel fuel ignites quickly but gasoline
does not, because the ignition point of diesel fuel
is approximately 350C (662F) and that of gasoline is approximately 550C (1,022F).
Gasoline
Diesel fuel
Diesel
engine
Heated iron plate

TEM012
Ignitability and inflammability
This lower ignition point of diesel fuel is important in relation to diesel fuel combustion. When fuel is heated in air, hot vapor is generated, and if an open fire or
electric spark is brought close to the vapor, the vapor ignites and begins to burn.
This characteristic is called inflammability, and the minimum temperature at
which fuel catches fire is called flash point. Flash point of gasoline is -40C or
less and that of diesel fuel is 50C or more. For this reason. gasoline is easily
inflamed under normal temperatures.
124
(3) KNOCKING
When an excessive load is applied to a gasoline
engine (for instance when an automobile accelerates suddenly or is driven up a steep slope),
the engine sometimes produce a rapping noise
that sounds as if someone is tapping on the cylinder wall with a hammer. This phenomenon is
called knocking. Knocking means that before
the flame completes its spread after ignition, the
mixture charge remaining at the end of the combustion chamber is compressed and ignites
spontaneously and burning rapidly under high
temperature and pressure. Consequently, the
pressure wave knocks against the cylinder wall
or piston head resulting in a metallic noise
being produced. If knocking occurs rapidly, and
the pressure and temperature increase quickly,
the effect is hazardous to the piston head, gasket, valve, etc. General measures to prevent
this phenomenon include the following:
TEM013
Lower the compression ratio

Use a gasoline with a high octane rating.
Adjust (delay) the ignition timing.
Octane rating represents the anti-knocking quality of gasoline, and the higher
the rate the less knocking.
125
5. DIESEL ENGINE
5-1. DESCRIPTION
The diesel engine, featuring high thermal efficiency, was invented in 1892 by
Rudolf Diesel and uses fuels heavier than gasoline. It provides such advantages
as safe of fuel handling, low fuel consumption, and long durability. A large number of diesel engines are used in trucks, buses, ships and other applications.
5-2. OPERATION OF 4-STROKE DIESEL ENGINE
Compared with the operation of the gasoline engine, the diesel engine differs in
the intake stroke and combustion stroke, as shown below.
Injection nozzle
Intake ( air only)
Compression
Combustion
Exhaust
TEM014
(1) INTAKE STROKE

The gasoline engine draws a mixture of air and fuel into the cylinder. But in diesel
engine, air alone enters the cylinder.
(2) COMPRESSION STROKE
In the diesel engine, fuel is ignited by the heat of the compressed air, so the air
must be compressed in such a way that its temperature reaches the ignition temperature of the fuel. Generally, this temperature is 400 to 500C. In the diesel
engine, the compression ratio is two or three times as high as in the gasoline
engine.
(3) COMBUSTION STROKE
The ignition method of the diesel engine is different from that of the gasoline
engine. The gasoline engine uses spark plugs to electrically ignite the air-fuel
mixture. In the diesel engine, however, the fuel is injected from the injection nozzle at the end of the compression stroke. The injected fuel is spontaneously
ignited by the high temperature of the compressed air.
126
(4) EXHAUST STROKE

The burned fuel, or gas is then discharged through the exhaust valve in the same
manner as in the gasoline engine. So, it is very important that the proper amount
of fuel is injected into the cylinder at the proper time. This was very difficult in the
early days of development of the diesel engine. This problem was solved by the
injection pump invented in 1927, and since then the diesel engine has come into
wide use.
5-3. COMPARISON OF DIESEL ENGINE WITH GASOLINE ENGINE

ITEM
Fuel
Intake gas
Fueling device
Control of output
Ignition
Compression ratio
Compression pressure
Combustion pressure
Startability
Response
Engine construction
Weight of engine
Noise
DIESEL ENGINE
Light oil
Air only
Injection pump
GASOLINE ENGINE
Gasoline engine
Gasoline
Carburettor (or fuel injector)
By changing the amount

of fuel injected
Self-ignition
High (15 - 23)
High [1,961 - 2, 942 kPa
(19.6 - 29.4 bar, 20-30 kg/cm2,
284-427psi)]
High [4,904 - 8,826 kPa
(49.0 - 88.3 bar,50-90 kg/cm2,
711-1280psi)]
Good (Needs some time)
Poor
Mechanical strength is large
Heavier than gasoline engine
Greater than gasoline engine
By changing the amount

of air-fuel mixture
Ignition by electrical spark
Low (7 - 10)
Low [981 - 1,471 kPa
(9.8 - 14.7 bar, 10-15kg/cm2,
142-213psi)]
127
Low [2,942 - 4,904 kPa

(29.4 - 49.0 bar,30-50 kg/cm2,
427-711psi)]
Good
Good
Mechanical strength is small
Small
Quiet
ENGINE STRUCTURE
1. DESCRIPTION
The engine proper is the main part of
an engine. Its appearance varies
according to engine type (four cycle
or two cycle), arrangement of cylinders, type of cooling (water or air),
etc., but the basic structures are similar.
The left figure is an example of a four
cycle, water cooled, four cylinders inline, overhead camshaft (OHC)
engine.
The engine proper is composed of
the cylinder head, cylinder block, piston, connecting rod, crankshaft, camshaft, flywheel, etc.
Additionally, the engine proper contains lubricating oils, cooling water,
intake and exhaust passages, etc.
and is the base on which respective
auxiliary equipment are mounted.
Intake valve
Camshaft
Cylinder
head
Exhaust
port
Cylinder
Cylinder
block
Piston
Flywheel
Connecting rod
Crankshaft
Oil pan
TEM015
Engine proper
2. CYLINDER & CYLINDER BLOCK

A cylinder consists of a combustion chamber together with a cylinder head and
piston, and a cylindrical case in which the piston reciprocates. Power is produced
inside the cylinder by the reciprocating motion of the piston which is subject to
pressure and heat from ignited gases. The part of the, engine containing cooling
water passages, lubricating oil Passages and crankshaft bearings is called the
cylinder block.
2-1. CYLINDER
(1) CLASSIFICATION BY LINERS
Cylinders are classified into two types, a cylinder
block in which a cylindrical liner is press-fitted, and
a cylinder block in which the cylinder is machined.
Single piece type
Liner type
TEM016
128
(2) CLASSIFICATION BY CYLINDER ARRANGEMENT
Inline type
Engine width is small
Vtype
Compact even with
many cylinders
Flat opposition type

Short but wide
TEM017
Arrangement of cylinders and features
1) In-line type
The most common type of cylinders are placed in a row, making the engine
narrow. Total engine length increases as the number of cylinders is
increased. (SR, RB series engines)
2) V-type
Cylinders are arranged in a V-shape. Compared with the in-line type, the Vtype engine can be compact even if the number of cylinders is increased.
With fewer crankshaft bearings, friction loss in this engine is less.(VG and VQ
series engines)
3) Flat opposition type
Cylinders are arranged in two rows opposing each other centering on the
crankshaft. In this type, engine height can be reduced but width is increased.
This type of engine allows for less vibration.
2-2. CYLINDER BLOCK
Names and function of respective parts of the cylinder block are as follows:
Water jacket-Passages of engine coolant that cool down heat generated with a
engine.
Oil gallery-Passages through which lubricating oil that has been sucked up by
pump is distributed.
Screw hole for cylinder head bolt
Oil gallery
Cylinder bore
Cooling water
passage
Water pump
mount
Reinforcement rib
Crankshaft bearing
TEM018
Cylinder block
129
(1) DEEP SKIRT TYPE

The deep skirt type has the advantage of
greater strength in the longitudinal direction,
and is used in many engines.
(2) HALF SKIRT TYPE
The half skirt type has the advantage of being
light weight. (VG and VQ series engines)
Deep skirt type
Half skirt type

TEM019
Type of cylinder block
3. CYLINDER HEAD
The cylinder head is mounted on the upper surface of the cylinder block and,
together with the piston forms the combustion chamber. Located on the cylinder
head are mounting holes for the water jacket which cools the combustion chamber and surrounding areas, suction and exhaust ports, the intake manifold,
exhaust manifold, and lubricating oil passages: The cylinder head structure varies depending on the shape of the combustion chamber, camshaft location, valve
mechanism, etc. Cylinder heads are made of cast iron and aluminum cast. Many
cylinder heads are made of aluminum cast which has high thermal conductivity.
(Gasoline engines).
3-1. STRUCTURE
(1) INTAKE PORT (passage of intake gas)
This is the intake air passage that connects the intake manifold and combustion
chamber. It is shaped so that the resistance of the passing will be minimized.
(2) EXHAUST PORT (passage of exhaust gas)
This is the exhaust gas passage that connects the combustion chamber and
exhaust manifold in which the combustion gas flows while expanding.
Rocker shaft
Rocker arm
Hydraulic valve lifter
Valve lifter
guide
Camshaft
Intake valve
Exhaust valve
TEM020
130
(3) VALVE GUIDE

The valve guide, in which the valve stem
slides, is made from an iron group sintered
alloy and pressfitted to the cylinder head.
Valve collet
Valve stem
Valve stem end

Valve spring retainer
Valve spring
(outer)
Valve spring
(inner)
Oil seal
Water
jacket
Valve guide
Valve seat
TEM021
4. PISTON
For good intake, compression, combustion
and exhaust operations, it is necessary to
maintain a good seal between the piston and
cylinder. It is also necessary that the pistons
have the structure and strength to resist thermal expansion under exposure to high temperatures and pressures. Further, the piston
must be of a light weight material and be
shaped to reduce inertia loads for high speed
reciprocating motion.
Light,
strong
and less
thermal
expansion
Oh no!
Seizing
up.
TEM022
4-1. STRUCTURE
Ring land
Piston
Ring grove
Piston
Rib
Piston pin
Oil returning
slot
Piston ring
Skirt
Pin boss
TEM024
Structure of piston
TEM023
Installation of piston
131
(1) RING GROOVE

Ring groove is the place in which the piston ring is inserted. In many cases, three
ring grooves are provided.
(2) OIL RETURN SLOT
The oil return slot is located on the oil ring groove. Oil scraped off by the ring
flows through this slot and into the oil pan.
(3) SKIRT
The lower part of the piston from the center of the pin is called a skirt.
4-2. PISTON-TO-CYLINDER CLEARANCE

The assembled piston needs to have a specific
clearance [about 0.03 to 0.10 mm] between the
cylinder wall. If the clearance is insufficient, the
piston could possibly seize due to thermal expansion. On the other hand, if clearance is excessive,
it will result in compression failure, increased oil
consumption, or piston slapping noise. To eliminate these problems, a piston must be selected
with outside diameter, which properly fits the finished dimension of the cylinder bore.
Piston clearance,
0.03 to 0.06 mm
(0.0012 to 0.0024 in)
TEM025
Piston to cylinder clearance
5. PISTON RING
5-1. DESCRIPTION
There is a slight clearance between the piston and
cylinder wall to allow for thermal expansion during
operation. Because of this clearance, compression rings are required to prevent compressed
airfuel mixture and/or high pressure burned gas
from leaking from the combustion chamber into
the lower part of the cylinder block. Oil rings serve
to control lubricating oil (thickness of oil film) on
the cylinder wall. Another important function for
these piston rings is to cool the piston by conducting heat to the cylinder wall. Accordingly, the piston rings need to fit closely with the cylinder wall
and are, therefore, designed to expand outward
(tensile force).
132
Top ring
Second
ring
Compression
rings
Oil ring
TEM026
Roles of piston
6. CONNECTING ROD AND PISTON PIN

6-1. DESCRIPTION
Connecting rod connects the piston with the crankshaft. It converts the reciprocating motion of the piston to the rotary motion of the crankshaft. The connecting
rod needs to be light weight, and of sufficient strength to withstand strong compression and tension (vigorous motion similar to that of piston) during engine
operation.
6-2. STRUCTURE
As shown at the right figure, a connecting rod is composed of the
small end which is connected to the
piston with the piston pin, the large
end which is divided into the upper
and lower portions and is connected
with the crank pin of the crankshaft.
Piston
Small end
Rod
Bearing Connecting
rod cap
Reamer bolt
Nut
Piston pin
Large end
TEM027
Connecting rod structure
7. CRANKSHAFT
The crankshaft receives combustion
pressure via the piston and the connecting rod, which converts the reciprocating motion of the piston to a rotary
motion.
In a four cycle engine, the crankshaft
rotates two times in completing one
cycle (intake, compression, combustion and exhaust). In a four cylinder
engine, combustion takes place once
per cylinder while the crankshaft
rotates two times (720 degrees). In
other words, combustion takes place
once every 180 degrees crankshaft
rotation.
Crank arm
Crank journal
Crank pin
Balance weight
TEM028
Crankshaft (4 cylinder)
Crankshaft center
As shown at the right figure, the cylinders are numbered front to back No.1,
No.2, No.3 and No.4 and the firing
order is either 1-3-4-2 (in Nissan vehicles) or 1-2-4-3. In either case, the pistons No.1 and No.4 and No.2 and No.3
are set in motion in pair.
133
Front
TEM029
Example of cylinder inline engine
VALVE MECHANISM
1. DESCRIPTION
1-1. VALVE TIMING MECHANISM
The following figure shows an example of a valve
opening and closing mechanism of an OHC
(overhead camshaft) type engine. Part of the
combustion chamber valve is mushroom shaped
and firmly fits in the intake and exhaust ports by
means of a spring.
The camshaft is a shaft which has a number of
cams grouped in numbers equaling the number
of valves per each cylinder, and is driven by the
crankshaft via the timing chain. The rotary motion
of the camshaft is converted to a reciprocating
motion, which is transmitted to the rocker arm,
which then pushes the valve open, overcoming
the tension of the valve spring.
Rocker arm
Camshaft
sprocket
Rocker shaft
Valve spring
Intake valve
Timing
chain
Exhaust valve
Piston
Tensioner
Crankshaft
sprocket
Crankshaft
TEM030
Structure of the valve opening and

closing mechanism
In four cycle engines, the valve is opened only for intake and exhaust strokes
during each cycle (intake, compression, combustion and exhaust). The cams for
the intake valve and exhaust valve respectively work once during each cycle.
That is, the camshaft rotates once. Therefore, the camshaft rotates once per
two rotations of the crankshaft.
1-2. VALVE ARRANGEMENT TYPES
(1) OVERHEAD VALVE (OHV)
The intake and exhaust valves are located above
the piston, the camshaft is in the cylinder block
and it pushes up the rocker arm on the cylinder
head via the valve lifter and push rod which are
connected with the camshaft. At the same time,
the other end of the rocker arm moves downward
pivoting on the rocker shaft and pushing the valve
open.
Rocker shaft
Rocker shaft
Valve
Push rod
Cylinder
head
Valve lifter
Camshaft
TEM031
OHV type
134
(2) OVERHEAD CAMSHAFT (OHC).

An improvement over the OHV type, the OHC has a reduced number of intermediate parts between the camshaft and valve, and the camshaft is located above
the cylinder head. Because intermediate parts such as push rods, etc. are eliminated, this type is more suitable for higher speed operations than the OHV type.
The OHC is now the major type used in gasoline engines. (MA, GA, SR, RB and
VG series engine, etc.)
Rocker shaft
Rockerarm
Rocker arm
Hydraulic valve
lifter
Camshaft
Camshaft
Rocker arm
Valve lifter
guide
Camshaft
Intake valve
Exhaust
valve
TEM032
OHC type
(3) DOUBLE OVERHEAD CAMSHAFT (OHC)

This type has two camshafts, one
used exclusive for the operation of Intake camshaft
intake valves and the other for
exhaust valves. Generally, this type
has no rocker arms as the cam
pushes directly on the valve. The
valve mechanism is light weight.
This type is therefore, the most suitable for the high speed operations.
Some engines use rocker arms
because a large valve stroke can be
obtained. This type also has two
camshafts, and can utilize four
valves (two intake and two exhaust
valves per cylinder). Thus, the area
of the intake and exhaust ports is
large and intake efficiency is improved.
Hydraulic
valve
lifter
Exhaust
valve
Intake valve
Twin cam engines mean DOHC type engines.
135
Exhaust
camshaft
TEM033
DOHC type
2. CAMSHAFT
2-1. DESCRIPTION
The camshaft cams open and close the intake
and exhaust valves at the most optimal time, corresponding to the up and down motion of the piston. Even if the piston displacement, shape of the
combustion chamber, shape and size of the
intake and exhaust ports have been determined,
the performance and characteristics of an engine
can be changed depending upon the relative
position and shape of the cam. Thus, the cam is
a critical element having great influence on
engine performance.
Cam is
a critical
element of
the valve
mechanism.
TEM034
TEM034
Camshaft
(1) CAMSHAFT DRIVE

Chain guide A
Alignment mark
Dowel pin hole
Cam pulley
Timing belt
Chain guide B
Chain guide C
Chain
Tensioner A
Chain
tensioner B
Belt tensioner
Key groove
Crank timing pulley
Alignment mark
TEM035
Camshaft drive (timing chain type)
TEM036
Camshaft drive (Cog belt type)
There are several methods of camshaft drive and a representative one is the
chain drive. As timing chains tend to swell outward due to centrifugal force, chain
guides and chain tensions are used.
In order to operate the camshaft with the specified valve timing, when an overhaul is conducted, it is important to correctly position the crankshaft and camshaft during reinforced with synthetic fiber cord) are used.
136
3. VALVE LIFTER
Offset of valve lifter
TEM037
The valve lifter (also called tappet) converts the rotary motion of the cam into a
reciprocating motion, and opens and closes the valve via the push rod and
rocker arm. The valve lifter is made of special cast iron and its cam contact surface is hardened. The central axes of the cam is slightly offset from that of the
valve lifter which rotates the valve lifter up and down, thus uneven wear of the
contact surface is prevented.
3-1. VALVE CLEARANCE
Proper clearance [approx. 0.2 to 0.5 min (0.008
to 0.020 in)] between the rocker arm and cam is
provided so that the valve is not prevented from
achieving a close fit in the valve scat due to a lifting action by the cam as a result of the expansion, contraction or wear of valve related parts.
This clearance is called valve clearance.
Rocker arm
Camshaft
Valve clearance
[0.20.5 mm
(0.0080.02 in)]
If the valve clearance is too large or too small,

the valve timing will be changed, resulting in
engine performance being adversely affected. If
TEM038
the valve clearance is too small, the valve fails to
Valve clearance
correctly fit in the valve seat, which results in
defective compression. If the clearance is too
large, when the valve is opened its end face is strongly tapped, which causes a
noise (called rocker or tappet noise). Valve clearance becomes enlarged
because the whole engine expands when the engine temperature rises.
137
3-2. HYDRAULIC VALVE LIFTER

Hydraulic valve lifters, which are used in some engines, always maintain valve
clearance at zero through hydraulic pressure. If the hydraulic valve lifters are
used, valve clearance adjustment is unnecessary. With zero clearance, noise
can be reduced.
Hydraulic valve
lifter
Rocker shaft
Rocker arm
Lifter guide
Body
Plunger
Camshaft
Exhaust valve
Intake valve
TEM039
Installation position of hydraulic valve lifter
138
Check ball
Relief spring
High pressure
chamber
Return spring
TEM040
Structure of hydraulic valve lifter
COOLING SYSTEM
1. DESCRIPTION
While an engine is running, combustion in the
combustion chamber takes place at 2,000C
(3,632F) or more, thereby heating various
engine parts. If allowed to continue, the cylinder
walls, pistons and valves would overheat, causing engine malfunction.
Accordingly, the engine must be constantly
cooled by the cooling system, which maintains
acceptable temperatures.
Automobile engine cooling systems are classified into two types according to their cooling
method: air-cooled or water-cooled. Generally,
water-cooled systems are more commonly used.
TLC001
TLC002
139
In a water-cooled engine, heat generated in the engine is cooled by engine coolant (cooling water) and the radiator dissipates the heat. A forced circulation system for circulating engine coolant is driven by the water pump. The radiator
dissipates heat by means of air that is sucked from outside the vehicle via a radiator fan or through natural air flow while the vehicle is moving.
When an engine is started cold, to expedite warm up, a thermostat closes the
water passage to the radiator and engine coolant is, therefore, circulated only
within the engine. As the engine warms up, the thermostat opens and it the
engine coolant is permitted to flow into the radiator and is cooled as described
above. It is recirculated through the engine by means of a water pump.
The engine coolant is used to warm the inside of the passenger compartment by
circulating it through the heater core.
2. RADIATOR, RADIATOR CAP
2-1. RADIATOR
TLC003
As shown above, the radiator consists of the upper tank, lower tank, drain cock,
radiator cap, etc.
140
2-2. RADIATOR CAP

Cooling water boils at 100C (212F) under 1
atm. (atmospheric pressure at sea level) and
then vaporizes. The radiator cap raises the
boiling point of the cooling water, by increasing pressure inside the radiator, thereby
increasing its temperature range and improving its cooling efficiency.
If the engine coolant boils, heat is not
exchanged (heat transfer) from the engine to
the atmosphere, therefore, the engine continues to heat up. This phenomenon is called
overheating.
TLC004
OPERATION OF PRESSURE VALVE
When overheating occurs, the difference between tile temperatures of the inside
of the radiator and atmospheric temperature is restricted and, consequently, the
radiators performance is decreased.
If the engine coolant temperature falls, pressure inside the radiator drops. If
allowed to drop below atmospheric pressure, the radiator will collapse due to the
pressure. To prevent this from occurring. a vacuum control device is provided.
The pressure valve attached to the radiators upper tank is closed by a pressure
spring. If the internal pressure rises due to an increase in temperature of the
engine coolant and it is allowed to rise above that of the pressure spring [approximately 88 kPa (0.88 bar, 0.9 kg/cm2, 13 psi)], then the pressure valve is opened
and the excess pressure is released.
TTLC005
OPERATION OF VACUUM VALVE
141
If the engine coolant temperature falls

and a negative pressure is created
inside the cooling system, the vacuum
valve is opened and air is sucked in
thus deformation of the radiator is prevented.
If the radiator cap is removed while the
engine is warm, hot fluid will erupt from
the radiator due to the internal pressure. Be sure to remove the cap after
the engine has cooled.
TLC006
Some radiators are equipped with a reservoir tank of engine coolant. Heated
and, therefore, expanded cooling water opens the pressure valve of the radiator
cap, flowing into the reservoir, and is returned to the radiator after being cooled in
the tank.
With the use of a reservoir tank, it is unnecessary to frequently check the engine
coolant level in the radiator.
With radiators that do not have a reservoir tank, if the radiator is fully filled with
engine coolant, the coolant may be vented from the radiator cap. The level of
engine coolant in the radiator needs to be maintained at the specified level during cold conditions.
142
3. WATER PUMP
Fan
TLC007
This pump forces engine coolant to circulate uniformly throughout the complex
water jacket of each cylinder, and is
rotated by the crank pulley with a speed
of 0.8 to 1.5 times that of the engine.
The impeller rotated by a belt, sucks the
engine coolant and then forces it into
the water jacket of the cylinder block
through the discharge port.
TLC008
CIRCULATION IN WATER PUMP
143
WAX PELLET TYPE THEMOSTAT

4. THERMOSTAT
4-1. DESCRIPTION
The thermostat is placed either in the
engine coolant outlet or inlet and automatically maintains the cooling water at a certain temperature level. The ideal engine
coolant temperature for obtaining maximum engine performance is 80 to 90C
(176 to 194F) it must not be outside this
temperature range. For this reason, and in
order to maintain a proper temperature,
TLC009
when the engine coolant temperature is
low, is it not circulated in the radiator in order to quickly warm up the engine. Only
when the engine coolant temperature elevates, it is circulated in the radiator.
The thermostat maintains engine coolant at its proper temperature by changing
the water volume circulating in the radiator.
4-2. OPERATION OF THERMOSTAT
To control the circulation of engine coolant in the radiator, two methods are
employed: the thermostat is placed either in the engine coolant outlet of the
engine or in the engine coolant inlet. Some engines today employ bottom bypass
type thermostats which control not only the engine coolant flowing in and out the
engine, but also the engine coolant circulation in the engine. The thermostat is
generally placed in the engine coolant outlet, but the bottom bypass type is
placed either in the engine coolant outlet or inlet.
(1) THERMOSTAT WITHOUT A BYPASS VALVE
An example of thermostat placed
in the engine coolant outlet is
explained here. The following figure shows the operation of the
wax pellet thermostat. A solid
wax, rubber and spindle piston in
the center are assembled in the
container (pellet), and one end of
the spindle piston is fixed to the
outer case.
144
TLC010
A valve, which controls the coolant flow volume, is attached

outside the pellet, and it stops
the passage of engine coolant
when it is not operated. With an
increase in cooling water temperature, the wax is melted and
its volume expands. The resulting pressure generated pushes
TLC011
the spindle piston. As the spinFLOW OF COOLING WATER
dle piston is fixed to the case,
the pressure overcomes the
loaded spring force and the pellet moves downward opening the valve.
When engine coolant that has been cooled while passing through the radiator
core circulates back to the thermostat, the valve closes. The thermostat repeats
this operation and controls the flow volume to maintain the proper temperature.
Illustration at right shows the flow of engine coolant. When the engine coolant
temperature is low, the thermostat is closed and the engine coolant is not sent to
the radiator, but circulates within the engine. On the other hand, when the engine
coolant temperature rises, the thermostat is opened and the engine coolant circulates in the radiator as well.
(2) BOTTOM BYPASS
TYPE THERMOSTAT
An example of the thermostat
placed in the engine coolant inlet
of the engine is explained here.
The following figure shows the
operation of the bottom bypass
type thermostat. This thermostat
is shaped like a conventional
thermostat the bottom of which a
bypass valve is also attached.
The bypass valve controls the
circulation of engine coolant in
the engine.
TLC012
SIGNATURE AND OPERATION OF BOTTOM

BYPASS TYPE THERMOSTAT
145
When engine coolant temperature is low, the valve on the radiator side is closed and the
bypass valve is opened, whereby
the engine coolant is not circulated in the radiator. At this time,
as the bypass valve begins to
close, circulation in the engine is
controlled.
When the thermostat without the
bottom bypass valve is fully
opened, engine coolant circulates in the engine and radiator
at the same time.
TLC013
FLOW OF COOLING WATER
However, the bottom bypass type thermostat stops engine coolant circulation in
the engine and circulates it only in the radiator, thereby improving cooling efficiency.
Further, the bottom bypass type functions to control circulation in the engine by
permitting the circulation passage to be widened and, compared with conventional types, when the engine is cold, coolant flow resistance is reduced. Accordingly, the load on the water pump is minimized, thereby reducing any loss of
engine power output. Foreboding bypass type thermostats, in some cases if the
thermostat is removed because of poor cooling performance, the cooling efficiency may be reduced.
4-3. JIGGLE VALVE
When engine coolant is removed from the radiator for replacement, air is introduced into the
engines cooling system.
When the engine is refilled with engine coolant,
air inside the system must be purged.
The jiggle valve secures the passages from air. It
is designed so that, when the engine stops, the
passage is opened by its own weight and when
the engine operates, the valve is closed by water
(coolant) pressure from the water pump.
For engines with the thermostat installed perpendicularly to the mounting surface, it is necessary to install the jiggle valve on the top side.
146
TLC014
TLC015
Modern engines are equipped with an air vent plug. The mounting position of the
radiator is lower than the engine for reduction of the air resistance and vehicle
styling. The plug is provided for easy air venting.
RELATIONSHIP OF POSITION BETWEEN RADIATOR AND ENGINE
TLC016
The condition of radiator, engine inlet and outlet hoses and heater hoses should
be checked to confirm the integrity. Heated water causes the rubber material to
deteriorate from the inside out. Squeeze the hose, it should be firm. If the hose
feels mushy or soft in any way, it should be replaced. Check to be sure there is
no evidence of damage such as cracked rubber or obvious breakdown of the
material.
The cooling system must maintain an optimum temperature under all driving conditions and does so by circulating a coolant-to-water solution through the engine.
This solution is responsible for maintaining engine temperature within certain
parameters. It provides for heat removal by absorbing heat as it moves through
the engine, prevents damage to the engine when temperatures drop below the
freezing point, and it also contains inhibitors to prevent corrosion of the cooling
system.
THE COOLANT SOLUTION
Understanding the temperature regulating function of the coolant solution is critical to the efficient operation of the cooling system.
As indicated, the coolant solution must efficiently remove heat from the engine
under both very cold and very hot conditions. Water is the best liquid for heat
removal. However. water freezes at 0C (32F). To prevent freezing of the circulating solution, ethylene glycol (antifreeze) is added to the water. This mixture of
antifreeze-to-water may then operate within a certain range of temperature, preventing freezing of the solution as well as boiling and vaporization of the solution.
147
ANTIFREEZE
Antifreeze is classified into types: Alcohol base or Etylene glycol base. Generally,
Ethylene glycol base is more commonly used because the effect of Alcohol base
lasts only short period (one season). The effect of Ethylene glycol base can last a
longer period so it is called Long Life Coolant (LLC).
LONG LIFE COOLANT (LLC)
The purpose of using LLC for the engine coolant is, in addition to freeze prevention, to prevent the inside of the radiator or engine block (cooling bypass) from
rusting, lubricate in the water pump, raise the boiling point of cooling water, etc.
The effect of LLC varies in accordance with mileage, period of use, engine type
etc., so refer to the Service Manual regarding inspection and maintenance interval.
When using either Nissan genuine coolant or a similar product, inspection and
maintenance intervals vary.
If neglecting inspection or replacement of LLC, the radiator or the inside of the
cylinder would be rusted and then the water pump of the radiator would be
clogged, causing overheat. Also cooling water with poor efficiency due to dirt
would cause some trouble in the water pump.
O
Excellent
Good
X
Failure
Comparative Table of Engine Coolant
Cooling
Antifreezing
Performance
Preventing
Corrosion
Preventing
Foam
Lubricating
Efficiency
Raising
boiling point
Alcohol base
Soft water
Ethylene
glycol base
* In the case of using Nissan genuine coolant

MAXIMIZING THE TEMPERATURE RANGE OF THE COOLANT SOLUTION
There are ways to maximize (extend) the coolant solutions range on both ends
(i.e. the freezing point and the boiling point). One is to increase the amount of
antifreeze in the solution and the other is to increase the pressure of the solution
INCREASING THE AMOUNT OF ANTIFREEZE
Increasing the amount of antifreeze in the solution will increase the boiling point
as well as extend the range of the freezing point (by lowering the temperature at
which the solution will freeze). However, the addition of more antifreeze reduces
the heat removing efficiency of the solution.
148
The coolant to water ratio must be maintained at a maximum of 50% ethylene

glycol (antifreeze) to 50% water to provide the heat removing qualities of the
water in the solution while still maintaining adequate protection against freezing.
It is essential to test the coolant specific gravity with a hydrometer to confirm the
coolant to water ratio, at each service inspection.
INSPECTION FOR COOLING WATER
Inspection of the engine coolant is necessary to confirm if LLC is performing well.
There are several ways of inspecting the engine coolant. Mileage or period may
be inspected after using new coolant. The mixture ratio of engine coolant may be
inspected. To inspect the mixture ratio, a hydrometer or a battery coolant tester
should be used.
Outside temperature
down to
C
Composition
Engine coolant
(concentrated)
15
30%
35
30
50%
Coolant temperature ratio

Specific gravity
Demineralized
water
15 (59)
distilled water
1.046
70%
I
1.050
1.076
50%
I
1.080
25 (77) 35 (95) 45 (113)

1.042
I
1.046
1.070
I
1.076
1.038
I
1.042
1.065
I
1.071
1.033
I
1.038
1.059
I
1.065
Relation of Freezing temperature / mixture ratio of cooling water
* In the case of using Nissan genune coolant

Q: Is LLC quality confirmed by a standard such as API (American Petrolatum
Institute), which is the standard for engine oil or gear oil?
A: LLC is set by JIS, standing for Japan Industrial Standard, not API.
Q: Why LLC is colored?
A: LLC is colored green or red in order to distinguish it from water. The difference of color has nothing to do with operation efficiency. The color of Nissan
genune coolant is green.
149
INCREASING THE PRESSURE OF THE SOLUTION

Increasing the pressure of the antifreeze solution will serve to raise the cooling
systems boiling point, however it will do nothing for the lower end of the temperature range (the point at which the solution will freeze). If the solution will normally boil at 212F (100C), increasing the pressure on the solution will cause
the boiling point to increase as well. This is one of the advantages of a closed
pressurized system. An increase in pressure of 1 pound will increase the temperature 3 degrees. The radiator cap functions to maintain pressure in the cooling
system. A defective radiator cap may cause low pressure. A pressure tester is a
hand held pump with an attached gauge, which indicates applied pressure. It
may be used to substantiate the integrity of the radiator cap as well as to pressure test the cooling system for small and internal leaks, which are not detected
during visual inspection.
TLC017
OTHER METHODS TO DETECT INTERNAL LEAKS

Internal leaks may be detected in several manners.
Air leaks from the water pump or exhaust leaks from the cylinder head gasket
may be detected using chemical combustion leak detectors. Exhaust leaks may
also be detected using an after market leak tester or an exhaust gas analyzer.
150
You may check for exhaust leaks using an after market tester as described
below:
Run the engine to normal operating conditions
Use caution when removing the radiator cap
Install a scaling ring in the filler neck
Attach the pressure tester to the radiator and open the relief valve.
Close the relief valve and observe the gauge
Caution: Do not pressurize the system above maximum specifications
Pressure increase indicates an exhaust leak into the system
A steady gauge reading indicates that the system is OK
Pressure decrease or a fluctuating gauge reading indicates an exhaust leak
A decreased fluctuation will result when the leaking cylinder is shorted out
You may check for exhaust leaks using exhaust gas analyzer as described
below:
Caution: Do not immerse the exhaust gas analyzer probe in the coolant
Run the engine to normal operating conditions
Carefully remove the radiator cap
Hold the analyzer probe at the top of the filler neck (do not immerse the probe
in the coolant)
Accelerate to 2,000 rpm, then return to idle
Observe the analyzer for an increase in HC and CO
151
LUBRICATION SYSTEM
1. DESCRIPTION
There are many moving parts in an engine, and when two pieces of metal rub
against each other, heat and scratches are produced by friction on the contact
surfaces and eventually the metal seizes up. For this reason, a lubrication system is needed to form an oil film on the sliding surface of the metal.
TLC018
Return
Oil tube
Feed
Camshaft
Hydraulic lash adjuster
Relief valve
Oil filter
Oil filter bracket
Oil pump
Oil pan
Oil strainer
TLC019
LUBRICATION SYSTEM (SR ENGINE)

[Relief valve built in type]
152
TLC020
LUBRICATION FLOW (SR ENGINE)
1-1. LUBRICATION CIRCUIT

There are several types of lubricating oil circulation and the full flow filtering pressure-feeding type is the most widely used.
The lubricating oil in the oil pan is drawn up by the oil pump (drive through the oil
strainer to filter large-sized foreign particles and then through the oil cooler oil filter to filter small-sized foreign particles, and sent to the main bearings and valve
mechanism passing through the oil gallery. The oil is sent to lubricate the main
bearings then sent to the crank pin passing through the crankshaft to lubricate
the connecting rods. The oil is injected from the oil jets located at the bottom of
cylinder sleeve and squirts and blows against the of the pistons, piston pins and
cylinder walls to lubricate and cool.
Oil sent from the oil gallery to the valve mechanism passes through the inside of
the rocker shaft and camshaft and lubricates the bushings of the rocker arm, the
cam shaft journal, the contact face of the cam and rocker arm, and then drops
down into the oil pan. The gears are lubricated with oil injected from the oil jet
from the oil gallery.
153
Generally, the oil gallery is equipped with an

oil pressure switch or oil pressure sensor, and
the oil pressure warning lamp and pressure
gauge to inform the driver if oil pressure is
indicating the specified value or not.
TLC021
OIL PRESSURE WARNING LAMP
2. OIL LEVEL GAUGE

The oil level gauge (attached to the side of the
cylinder block) is a stick shaped gauge used
to cheek the oil level in the oil pan. The gauge
is marked with High (H) and lower (L) limits for
optimal oil volume, the difference of which is
approximately 1l (1-1/8 US qt, 7/8 Imp qt).
TLC022
OIL LEVEL GAUGE
3. OIL PUMP
There are several types of oil pumps, with gear and trochoid types generally
used,
3-1. INNER GEAR OIL PUMP
An inner gear and an outer gear are eccentrically assembled, and a crescent is
placed in the space between these gears. When the inner gear is driven, it
causes the outer gear to rotate and lubricating oil is drawn into the space
between the outer gear, inner gear and crescent from the inlet port and forced
out through the outlet port. The driving method of this pump is simple, and
because the inner gear is directly driven by the crankshaft.
This type is used for the automatic transmission oil pump rather than the engine.
(GA, SR, RB and VG series engines, etc.)
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3-2. TROCHOID TYPE OIL PUMP

This type is called a rotary type.
An inner rotor has four lobes, and is driven by the camshaft or crankshaft drive
gear. An outer rotor has five dents to mesh with the inner rotor and is eccentrically assembled in the housing. When the inner rotor rotates, lubricating oil is
drawn into the space between the inner and outer rotors and squeezed out
through the outlet port. The trochoid type oil pump is widely used. (MA and E
series engines, etc.)
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155
To inlet port
of oil pump
4. OIL PRESSURE REGULATOR

Lubricating oil is sent under pressure, and
the higher the engine speed the higher the
oil pressure. Each part to be lubricated is
under high pressure, and requires a large
quantity of oil. However, an excessive rise
in oil pressure causes an excessive load
on the pump and excessive oil consumption, which results in loss of engine power.
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For this reason, a pressure regulator is
installed in the oil pump to properly adjust
OIL PRESSURE REGULATOR
the oil pressure.
The figure shows the cross section view of an oil pressure regulator. If the oil
pressure exceeds the spring force, the relief valve moves to open the bypass
hole to allow some oil to return to the inlet port, thus adjusting the pressure.
5. OIL FILTER
As the engine operates, dust and metal particles may contaminate the lubricating oil. To
prevent seizure and excessive wear, these
foreign particles must be completely removed.
The oil filter is used for this purpose.
Oil filter
Main gallery
Regulator valve
Oil
pump
Relief valve
Oil strainer
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LUBRICATING OIL FLOW
Many types of filters are available, and

recently cartridge type oil strainers are used
on smaller diesel engines because of their
easy maintenance. However, on bigger diesel
engines a replaceable internal element is still
used. The relief valve is designed to allow oil
to pass when the element is clogged. When
replacing the oil filter, be sure to use genuine
Nissan Diesel parts. Some after market oil filters may be sold at a low price, but their element tends to be of low quality. They will
cause malfunction.
Element (filtering material)
From pump
Relief
valve
Main gallery
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OIL FILTER (CARTRIDGE TYPE)
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OIL FILTER (CARTRIDGE TYPE)
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6. ENGINE OIL SPECIFICATION

Engine oil is classified into three types: engine oil for gasoline engine, diesel
engine, and two cycle engine. The type depends on the difference of additives in
order to make good use of characteristics of each engine.
(Some oil makers use gasoline engine and diesel engine together.)
Engine oil base
Engine oil base is classified into four kinds: 100% chemical synthetic based oil,
semi synthetic based oil, part synthetic oil, and mineral oil.
Each engine has differential response and durability, except for engine power.
Compared with mineral oil, 100% chemical sythetic based oil is much more
expensive.
100% chemical synthetic based oil ................... Poly alpha olefin
Semi synthetic based oil.................................... It is also called Semi synthetic
Part synthetic oil ................................................ 20-30% chemical synthetic oil
70-80% mineral oil
Standard
The quality and grade are shared and established by the organization which prepares tests and establishes the standard.
Registration for engine test.
CMA
EOLCS
API
SAE
Confirmation for efficiency of API indicated

oil
API
Registration and issue for a certificate mark.
ASTM
Establishment for test preparation and

standard.
MVMA
ILSAC
JAMA
ACEA
Proposal for Procedure for test and

standard
Europe standard which is an equivalent to API.
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Classification
1. Viscosity (SAE standard)
Viscosity is classified into 11 kinds which range from SAE OW to SAE 60 according to SAE standard.
Example: OW, 5W, 20, 30
In the case of indicating the viscosity with only a number, it indicates the characteristic in high temperature. In the case of indicating the viscosity with number
accompanied with W, it indicates characteristic in low temperature.
Engine oil for the use varies in districts and use conditions. For example, in a
condition to drive with only low speed or middle speed at the outside temperature
ranging from 0 degrees to 20 degrees (from 32 Fahrenheit to 68 Fahrenheit) the
single grade, SAE 30 is used. In the case of indicating characteristics of low temperature to high temperature the multi-grade, 10 W - 30 is used to be easy to
classify the viscosity. Regarding the temperature characteristic of oil, larger number indicates that the efficiency to keep oil film is high in high temperature
(60,40,30...). On the other hands, smaller number preceding W indicates that
the fluid of oil is high even if the temperature is low (0 W,5 W...).
Quality standard (API standard)
API standard establishes quality of applicable oil to engine increasing efficiency.
The quality is classified by deposit, oxidation stability, friction resisting, corrosion
protection, consumption of oil, improvement in fuel mileage, etc.
Alphabet and number gives indication of classification.
Indication of S used in the first letter means gasoline. Indication of C used in the
first letter means diesel gasoline.
example: Gasoline engine ........ SH, SJ
Diesel engine............. CD, CF, CF4
By the U.S. diesel engine emission control regulations to reduce PM, the temperature of the piston portion is required to increase. In order to cope with this circumstance, the specifications to increase the quantity of Dispersants and
decrease the quantity of Detergents (or Ash) for engine oil are required. The
change of the specifications may make it difficult for the oil filter to catch soot and
sludge. The resistance of these oil types is weak to wear the valve mechanism.
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INTAKE & EXHAUST SYSTEM

1. DESCRIPTION
Muffler
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The structure of intake and exhaust system is shown in illustration above. After
dust is removed by the air cleaner, air enters the carburetor, mixed with gasoline,
and is then sucked into the cylinder via the intake manifold. After combustion
takes place in the cylinder, exhaust gas passes through the exhaust manifold
and exhaust pipe and is discharged in the atmosphere after passing through the
muffler.
159
2. AIR CLEANER
The air cleaner is attached to the air inlet of the
carburetor. It removes dust and particles from
air sucked into the engine.
Dust suspended in the air contains substances
which, if allowed to enter the cylinder, would
cause wear to both the cylinder and piston
rings. When mixed in with lubricating oil dust
contributes to the wear of respective engine
parts.
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Foreign matter shortens engine life. Air cleaners

which are currently used are classified according to filter elements of the air cleaner into paper
(dry filter paper type) and viscous (wet filter
paper type) types. The viscous type is most
widely used.
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2-1. PAPER TYPE (DRY TYPE) AIR CLEANER

This type consists of an element (filter) and a
body which contains the element. Foreign matter in the intake air is absorbed by the elements
[dust is trapped or cannot pass through the elements minute holes (10 micron)].
The element is made of filter paper containing
various materials including cotton, rayon, etc.,
and is folded in a circular fashion and supported
around a reinforcing plate. It requires periodic
cleaning.
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2-2. VISCOUS TYPE (WET TYPE) AIR CLEANER

This type is identical in structure to the paper type air cleaner, but the surface of
the element is coated with special viscous oil that collects dust. Compared with
the dry type, the drop in the engine performance is less because dusts are collected by virtue of an adhesion property of the special oil. Cleaning of this type filter is unnecessary, but it should be periodically replaced.
(1) AXIAL-FLOW TYPE AIR CLEANER ELEMENT
This air cleaner element is like an umbrella which allows its height to be lowered,
thereby widening the filtering area.
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(2) SEPARATE TYPE AIR CLEANER ELEMENT

The elements shape is largely modified to incorporate the ECCS device. This
type of cleaner element is attached to the hood ledge side. The element is
square in shape. Recently, this type of element has been used with LPG vehicles. It contributes to easy maintenance.
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3. INTAKE MANIFOLD
This is also called the suction manifold and
is a set of branch tubes that branch from
the carburetor uniformly carrying the airfuel mixture to each engine cylinder.
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4. EXHAUST MANIFOLD
The exhaust manifold collects
exhaust gases from each cylinder
and passes them to the exhaust
pipe with minimal resistance. The
exhaust manifold needs be
designed so that the exhaust
gases from each cylinder do not
interfere with one another.
Restricted exhaust gas flow
causes combustion gas to remain
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in the cylinders resulting in insufficient air-fuel mixture intake for the following intake stroke, which results in reduction in power output.
5. EXHAUST TUBE, MUFFLER

If hot combustion gas under pressure were
released directly from the cylinder into the
air, it would rapidly expand causing a deep
explosive sound. To prevent this, a muffler is
installed so that it arrests noise by gradually
allowing the gas to expand and cool down.
A tube through which the combustion gases
pass, from the exhaust manifold to the muffler and into the air is called the exhaust
tube.
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FUEL SYSTEM
1. DESCRIPTION
The fuel system is a series of systems to supply fuel to the engine. There are
separate systems for carburetor, EGI (Electronic Gasoline Injection), LPG (Liquefied Petroleum Gas) and diesel fuel specifications.
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2. CARBURETOR
The carburetor measures fuel corresponding to the air volume drawn into the
engine and produces a mixture in the necessary air-fuel ratio for the respective
operating condition. It controls the engine power output by adjusting the quantity
of air-fuel mixture required in the cylinder.
2-1. PRINCIPLE
Many types of carburetors are available,
but the basic principle is that fuel is converted into fine particles of fluid (in mist
form) by applying a spraying principle.
When air is blown from one end of the
sprayer, the velocity of the blown air
increases as it passes through the tapered
pipe.
When the velocity of the air increases, the
ambient pressure at the end of the pipe
(point A) is reduced in proportion to the air
velocity (vacuum pressure lower than the
ambient pressure). Therefore, fluid is
drawn from B due to the pressure difference between the ambient pressure in portion C and pressure in portion A, and the
fluid is atomized by the stream of air.
When fluid (or air) flows in the narrow tube
as shown in Fig. 104, the velocity of the
fluid passing through the narrow section
(venturi tube) is higher than that of the fluid
passing through the wide section. Because
fluid has the property that when its velocity
increases the pressure decreases, the
pressure at the venturi section becomes
lower than other sections.
As shown below a pipe is provided in the
narrow section, gasoline is drawn up and
blown out in a mist, similar to the principle
of a sprayer.
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The volume of the air-fuel mixture is controlled by the throttle valve linked with
the accelerator. When the piston moves downward, the air-fuel mixture is drawn
up while being vaporized into the cylinder.
INTAKE OF AIR-FUEL MIXTURE
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2-2. STRUCTURE
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The carburetor is used in an automobile, it requires many auxiliary systems.

These systems are; a float system that stores a fixed quantity of fuel delivered
from the fuel pump to obtain a proper air-fuel ratio; a slow fuel system that supplies fuel during engine idling and low speeds; a main fuel system that supplies
fuel during middle and high engine speeds; a power fuel system that operates
during high engine power output; an acceleration fuel system that operates during rapid acceleration; a start-up fuel system that supplies more fuel than usual
at start-up; and a throttle valve which is linked to the acceleration pedal which is
operated by the driver.
(1) FLOAT SYSTEM
The float system stores a fixed quantity of fuel to be
ready to supply fuel as the engine needs it and
maintains fuel at the specified level in the storage
chamber (float chamber) at all times.
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(2) SLOW FUEL SYSTEM
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The slow fuel system consists of a slow jet, slow air bleed, slow port, idle port,
idle adjustment screw, etc. Fuel is measured at the slow jet and compensated at
the slow air bleed and, simultaneously, mixed with air in the foam state at the
slow air bleed, where atomizing of the fuel is enhanced.
The slow port is positioned slightly above the throttle valve as it fully closes.
When the throttle valve begins to open, i.e., the engine is running at a low speed,
fuel is supplied from the slow port together with the idle port that is positioned
below the throttle valve until sufficient fuel is drawn out from the main nozzle. The
idle port supplies fuel when the engine is idling with the throttle valve fully closed.
The fuel flow volume (air-fuel ratio) can be adjusted with the idle adjustment
screw.
Run-on preventive mechanism of fuel-cut system:
To prevent the *run-on phenomenon, i.e.,
even if the ignition switch is turned off the
engine continues to run, this mechanism
shuts off fuel in the slow fuel system simultaneously when the ignition switch is turned
off. As indicated in the illustration, the fuel
passage in the slow fuel system is opened
by a solenoid valve when the ignition switch
is turned on and it is shut off when the ignition switch is turned off.
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*Run-on: This refers to the phenomenon in which the engine may continue to run
after the ignition key is turned OFF by mixture gases ignited by the hot spots in
the combustion chamber.
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(3) MAIN FUEL SYSTEM

The main fuel system supplies fuel during normal
engine operation. The main jet which is attached
to the lower part of the float chamber meters and
regulates fuel.
The main air bleed consists of a jet and an emulsion tube with several holes on its perimeter. As
indicated in Fig. below, fuel in the main fuel system is metered and compensated by the main air
bleed, and at the same time, mixed with air in the
emulsion tube, and thus the atomizing of the fuel
is enhance
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(4) START-UP FUEL SYSTEM

This is a mechanism to facilitate
start-up of a cold engine. When the
engine is cold, the fuel in the air-fuel
mixture is not well vaporized and it is
difficult to start up the engine. Thus,
a richer than normal air-fuel mixture
is required.
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To improve start-up and operation of the cold engine, a choke mechanism is provided. The choke mechanism has, as indicated in Figure above, a choke valve to
restrict intake air in the intake air inlet of the carburetor. It also produces a large
vacuum pressure below the valve by closing the choke valve and allows as much
fuel as possible to flow from the main fuel system and slow fuel system in order
to obtain a richer than normal air-fuel mixture.
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(5) DASH POT

During quick deceleration, the negative pressure in the intake manifold increases
due to rapid closing of the throttle valve. The mixture becomes over rich temporarily and harmful incomplete combustion gases will be emitted. To prevent this,
the dash pot is designed to close the throttle valve slowly so that this over rich situation can be avoided.
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(6) F1 POT
The FI pot has both functions of the dash pot described above and FICD*.
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*FICD
The FICD stands for Fast Idle Control Device. When the air conditioner compressor operates, engine load increases resulting in rough idling. To prevent this, this
device forcibly opens the throttle valve a little to increase the engine speed.
169
3. FUEL PUMP
3-1. MECHANICAL FUEL PUMP
The fuel pump supplies fuel from the fuel tank to the float chamber of carburetor
under a fixed pressure. There are two types, i.e., mechanical and electromagnetic, and generally the mechanical pump flitted to carbureted engines is commonly used.
TFE023
The operation of a mechanical fuel pump is

made by an eccentric cam driven by the
camshaft of the engine. The rocker arm is
pushed by the motion of the cam, and the
diaphragm is pulled up and down. When the
diaphragm is pushed downward, the inlet
check valve is opened and fuel is drawn into
the pump chamber; when the diaphragm is
pushed back to its original position by spring
force, the inlet check valve is closed and the
outlet check valve is opened, allowing feeding of fuel under pressure to the float chamber of the carburetor.
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3-2. ELECTRICAL FUEL PUMP

Generally fuel pump is mounted with inside fuel
tank. Motor turns in fuel, because fuel goes
through the inside of motor of fuel pump. Opening pressure of relief valve is approximately 343
to 441 (3.43 to 4.41 bar, 3.5 to 4.5 kg/ cm2, 50 to
65 psi). And it has a check valve to improve startability of engine and to protect from vapor lock by
remaining a suitable residual pressure inside the
fuel system.
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4. FUEL STRAINER
The fuel strainer is also called a fuel filter, and is generally provided between the
fuel tank and fuel pump in a carburetor system. ECCS uses a metal type fuel
strainer and is generally provided between the fuel pump and fuel pressure regulator.
Fuel contains dust, gum substances and water. Since dust and gum substances
may clog the narrow passages in the carburetor, and water and rust may cause
freezing, these must be removed. Fuel strainers require replacement as they are
a non-serviceable part.
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ENGINE ELECTRICAL SYSTEM

1. IGNITION SYSTEM
IGNITION SYSTEM COMPONENTS
Illustration shows a typical 4 cycle engine ignition system. Each component is
briefly described below.
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(1) IGNITION COIL

An ignition coil is actually a pulse-type transformer that transfers 12 volt battery
voltage into a high voltage necessary for ignition. The secondary high voltage is
generated by intermittent interruption of the primary current in the coil by opening
and closing the breaker points inside the distributor.
(2) DISTRIBUTOR
In order to respond to various engine operating conditions, the distributor is
designed to provide ignition sparks at the correct time to the spark plugs. It contains breaker points that intermittently open and close to send the current flow to
the primary winding side of the ignition coil. It is also designed to. distribute secondary high voltage to each spark plug according to the firing order and to control
spark advance in response to valve opening and engine rpm.
(3) SPARK PLUG
A spark plug ignites the gas mixture by the use of two electrodes from the secondary high voltage which is supplied from the ignition coil and the distributor.
(4) HIGH TENSION CABLE
A cable designed to transmit secondary high voltage from the ignition coil to the
spark plug.
172
2. STARTER SYSTEM
STARTER SYSTEM FUNCTION
In order to start the engine through a cycle of gas mixture intake, compression,
ignition, and exhaust, it must be cranked by an outside force. For this, a DC
motor (called a starter) is connected to a battery.
Illustration shows a schematic diagram of a starter. The starter is mounted on the
flywheel housing and operates a pinion gear that can be meshed with a large ring
gear (which is installed on the flywheel.). The pinion gear can be moved forward
and backward on the shaft. In other words, during starts, the pinion gear moves
out and engages the ring gear. After the engine starts, the pinion gear disengages and returns to the original position and stops.
STARTER SCHEMATIC LAYOUT
TEL015
Thus, the main components of the starter are composed of a motor section that
generates torque and the pinion gear structure that engages and disengages
with the ring gear.
SCHEMATIC DRAWING OF STARTER MOTOR
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3. CHARGING SYSTEM
3-1. DESCRIPTION
The electrical charging system is part of the automobile electrical power system,
and its output varies according to each operating condition. The electrical power
output from an alternator is low at relatively slow engine rpm, and when electrical
demand exceeds that of the alternator output, the power is supplemented from
the battery. At middle to high engine speed, the output power from the alternator
is increased to a sufficient level that excess electricity is stored back to the battery.
3-2. EACH COMPONENT FUNCTION
The charging system consists of an alternator, voltage regulator, and warning
lamp.
(1) ALTERNATOR
The alternator is driven by the engine via a belt attached to the crank pulley. It is
a generator that converts engine rotation (mechanical energy) into electrical
energy.
(2) VOLTAGE REGULATOR
A voltage regulator controls voltage generated from the alternator to maintain a
constant value. There are two types of voltage regulators: contact type and
non-contact type. In recent years, almost all automobiles are equipped with IC
regulators inside the alternators, a non-contact type.
(3) CHARGE WARNING LAMP
A charge warning lamp illuminates when the alternator belt becomes loose, or
when the alternator itself becomes inoperative and does not generate electricity.
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SCHEMATIC OF GENERATOR
174
GENERAL INFORMATION
1. UNITS MAKING UP THE CHASSIS
Normally, a chassis is defined as the part of a vehicle excluding the body which
carries passengers or objects; the chassis frame and all units needed for selfpropelling that are mounted on the chassis frame are collectively referred to as
the chassis.
Recently, however, with the adoption of the monocled body (a reinforced body
that incorporates the functions of a chassis frame), many vehicles no longer use
a chassis frame. Moreover, there is also an increasing trend for the engine and
the engine electrical equipment to be classified in a separate category from the
chassis.
CHASSIS CONFIGURATION
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175
Clutch
Transmission
Transmission
Propeller shaft and universal joint

Drive shaft
Final drive and differential gears
Chassis
Suspension unit
Axles and suspension

wheels and tires
Brake system
Brake
Parking brake
Steering system
Steering
2. CHASSIS SPECIFICATIONS
2-1. WEIGHT
(1) CURB WEIGHT (C.W.)
The weight of an empty vehicle without payload or driver but including maximum
amounts of fuel, radiator coolant, engine oil, spare tires, jack, hand tools and
mats in designated position.
(2) GROSS VEHICLE WEIGHT (G.V.W.)
The maximum permissible total weight of the vehicle that may not be exceeded,
as designed by the manufacturer, taking into account all legal requirements and
material stresses.
(3) SPRUNG WEIGHT
Refers to the weight of the section supported by the chassis springs.
(4) UNSPRUNG WEIGHT
Refers to the weight of areas not supported by the chassis springs (for example,
wheels and axles). Some parts that fall into both the sprung and unsprung weight
categories (for example, propeller shafts, suspension arms and steering rings)
are classified in the sprung weight category.
2-2. DIMENSIONS
(1) OVERALL LENGTH
Indicates the maximum vehicle length
including accessories (bumpers, tail
lights and so on) when measured parallel
to the centre plane and ground plane of
the vehicle.
DIMENSIONS OF AN AUTOMOBILE
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(2) OVERALL WIDTH

Refers to the total width of the vehicle, including accessories, when measured at
right angles to the centre plane.
176
(3) OVERALL HEIGHT

Indicates the height of the vehicle from the ground surface to the highest point on
the vehicle.
(4) WHEELBASE
This is the horizontal distance between front and
rear axles. As shown in Fig. 126, in the case of a
3-axle vehicle the distance a between the front
axle and the middle axle is axle length 1, while the
distance a between the middle and rear axles is
axle length 2. Also, in some cases this indicates
the distance between the front axle and the center
of the multiple axles.
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(5) TREAD
Indicates the distance between the left and right
tires in the center of the ground plane. In the case
of multiple wheels, this value refers to the distance between lines drawn through the center of
each set of wheels, as shown by b' in the figure.
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(6) MAXIMUM STABLE ANGLE

When an empty vehicle is tilted, this value indicates the angle, formed by the ground and horizontal surface, at which both wheels on the upper
side of the tilt leave the around. In the case of a
vehicle with the same wheel distance (tread), the
lower the center of gravity, the greater this value
will be.
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177
(7) FRONT OVERHANG

Indicates the horizontal distance from (a) the vertical plane passing through the from most axle to
(b) the from most part of the vehicle, including
bumpers, hooks and all other parts fastened to
the vehicle. There are sometimes two values for
front overhang, one for the body overhang and
another for the frame overhang. In the figure at
right, value b indicates the front body overhang,
while value a indicates the front frame overhang.
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(8) REAR OVERHANG

Indicates the horizontal distance from (a) the vertical plane passing through the
center of the rearmost axle to (b) the rearmost part of the vehicle, including tow
hooks and other parts fastened to the vehicle. This value may be differentiated
between frame and body, as in the case of the front overhang discussed above.
(9) MINIMUM TURN RADIUS
This indicates the radius traveled by the outer
wheels of the vehicle (on the center of the ground
plane) when the vehicle is turned at low speed
with the steering wheel turned as far as possible
to one side.
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2-3. PERFORMANCE
(1) MAXIMUM SPEED
Maximum speed is established by testing the loaded vehicle on a level road The
distance that the vehicle travels in one hour is expressed by km/h.
(2) FUEL EFFICIENCY
The distance that can be traveled on 1 liter of diesel is expressed by km/l. Fuel
efficiency is a comparison of 1 kw to the gasoline consumed and is expressed by
g/kw-h.
(3) MAXIMUM GRADEABILITY
Maximum gradeability is the ability of a vehicle to
go up an incline and is measured by the maximum incline that the vehicle is capable of climbing. Maximum gradeability is expressed in most
diagrams by b/ a = sin 0; b/c x 100%) is also used.
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3. BODY TYPES AND CONSTRUCTION

3-1. BODY TYPES-1
SEDAN
A vehicle with two rows of seats in the
front and the rear. The most basic type
for the passenger car.
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COUPE
A sporty passenger car with two doors.
The basic form is a 2-seater accommodating only two passengers. Normally,
compared with a sedan, the roof is
smaller and the height of the vehicle is
lower.
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WAGON
This is a vehicle formed by extending
the interior space of the sedan. The
rear part can be used as a baggage
space. Originally, it was called the station wagon, which is a reminder of the
era of horse-drawn wagons.
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CONVERTIBLE
The 2-door vehicle with a folding roof.
Cabriolet is the German name.
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HARDTOP
A vehicle with no center pillar and no
door sash (window frame). This vehicle
offers a wide view, and the image of
design is nimble. The style with center
pillars but with no sash is called the pillared hardtop.
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VAN
This is a commercial car with a box-type
baggage compartment at the rear of the
cab.
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HATCHBACK
The vehicle whose rear door can be lifted
up like a hatch of a ship. This style can
be seen in many 2-box cars.
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BODY TYPES-2
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ONE-BOX TYPE
THREE-BOX TYPE
TWO-BOX TYPE
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3-2. BODY CONSTRUCTION

1. FRAME CONSTRUCTION
In the frame construction, the body is
mounted on a ladder like frame. Because
this construction is strong but heavy, this
construction is suitable mainly for the
truck body.
2. MONOCOQUE CONSTRUCTION
A flat plate is easily bent by an outside
force. However, by making the plate into
a shape of the letter L or by processing it
into the shape of a box, the strength is
significantly improved. This principle is
used for this construction.
Light in weight because no frame is
provided.
An engine and suspension system are
mounted to the body directly.
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DRIVE TRAIN
1. OUTLINE OF THE DRIVE TRAIN
1-1. DESCRIPTION
The drive train transmits torque to rotate the wheels. The drive train consists of
the following.
CLUTCH ... Transmits or cuts engine torque to the transmission.
TRANSMISSION ... Depending upon driving conditions, the transmission
changes the gear ratio, the amount of torque from the engine, and the forward
or reverse direction of the vehicle.
PROPELLER SHAFT & UNIVERSAL JOINT ... Transmits engine torque from
the transmission to the final drive (FR vehicles). Universal joints are generally
connected to both ends of the propeller shaft. These joints ensure smooth
movement even when the transmission and final drive are at the greatest or
smallest distance from each other.
FINAL GEAR ... At the same time that torque from the propeller shaft (or
transmission) is being transferred to the axle shaft (or drive shaft), the final
drive enables final speed reduction and increases tractability.
DIFFERENTIAL CARRIER (FINAL DRIVE) ... Creates rotation variation
between the left and right wheels to allow for smooth travel on rough roads or
when making turns.
DRIVE SHAFT ... Transmits torque from the final drive to the wheels. Has the
same function as the propeller shaft. (All FF vehicles have drive shafts. Only
FR vehicles with independent suspension have drive shafts.)
1-2. OUTLINE OF DRIVE TRAIN
(1) FRONT ENGINE REAR DRIVE
(FR = Front Engine, Rear Drive)
The engine, clutch, and transmission, and other parts are placed as
an integrated unit in the front of the
vehicle while other parts such as the
differential carrier are placed in the
rear. The front and rear units are
connected by a propeller shaft.
(2) FRONT ENGINE FRONT DRIVE
(FF = Front Engine, Front Drive)
The engine, clutch, transmission,
final drive and other parts are placed
as an integrated unit in the front of
the vehicle making the propeller
shaft unnecessary.
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(3) FRONT ENGINE 4-WHEEL DRIVE (4WD = Wheel Drive)

As shown in the figure, drive torque is distributed to each of the wheels. A transfer assembly is used to distribute the torque. There are both full-time 4WD) vehicles and part-time 4WD) vehicles.
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(a) Part-time 4WD

This allows the driver to use the 2WD mode or the 4WD mode as desired. On FF
vehicles, for example, moving between 2WD and 4WD can be accomplished by
transferring the engine torque through the clutch, converter, transmission, and
final gear to the transfer. Most vehicle use an electric (switch operated) system.
(b) Full-time 4WD (Permanent 4WD)
With this type, the 4WD mode operates at all times. A viscous coupling is
installed behind the transfer which allows flexible transfer of torque so that when
the load over the front wheels suddenly decreases, torque will be continually provided tot he rear wheels preventing the front t wheels from loosing traction.
(4) REAR ENGINE REAR DRIVE (RR = Rear Engine, Rear Drive)
The engine is placed behind the rear wheels, and drives the rear wheels.
(5) MIDSHIP (MR)
The engine is placed between the front and rear wheels, and drives the rear
wheels.
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2. CLUTCH
2-1. FUNCTION OF THE CLUTCH
TCL001
A clutch used in vehicles transmits the torque from the engine to the transmission/ axle. Its purpose is to disconnect the engine from the transmission when
starting the engine, or when shifting gears, and to reconnect the engine to the
transmission for driving the vehicle. This reconnection or engagement of the
engine and drive line must be done smoothly to ensure smooth starting and driving of the vehicle. To achieve these objectives, the clutch must satisfy the following requirements:
In the engaged state, the clutch must transmit engine power to the transmission without slipping.
At the beginning of engagement, the clutch must have a proper amount of slip
so that the vehicle can start off without jerking.
The engaging and disengaging of power must be done quickly when shifting
gears.
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3. TRANSMISSION (FR models) /TRANSAXLE (FF models)

3-1. FUNCTION OF THE TRANSMISSION
An automobile requires a great amount of driving force for starting, accelerating,
climbing hills, or carrying heavy load: however, when running on a highway at
high speed, it needs fast rotation of the wheels rather than a large driving force.
Also requires such a device should be able to reverse the direction of rotation so
that the vehicle can also be operated in reverse. This device is called the transmission. Multiplication of torque is performed by reducing the rotating speed.
This is attained by changing the engagement pattern of gears in the transmission.
(1) TRANSMISSION GEAR RATIO AND TORQUE CHANGING
The transmission consists of several gears which can mesh in various ways to
adjust torque and speed.
Power transmission line
gear a _ gear b gear c gear d.
Torque, gear ratio and transmission gear
ratio
When starting to accelerating or climbing up,
the first gear (the smallest drive gear in the
transmission) or the second gear is used.
Torque is increased by smaller gear rotating
larger gear (the reason described later),
though, the rotation of the output shaft is
TRANSMISSION OPERATION
slowed and speed is decreased. The torque
PRINCIPLE
change relates to gear ratio. The calculation of
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gear ratio is as follows.
Gear ratio =
Number of teeth of driven gear

Number of teeth of drive gear
Transmission has several different number of teeth gears. Transmission gear

ratio can be changed due to the combination of gears. Transmission torque
relates transmission gear ratio. The calculation of transmission gear ratio is as
follows.
Transmission gear ratio =
Number of teeth of driven gear b

Number of teeth of drive gear a
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gear d
gear c
The relation among transmission gear

ratio, torque and speed is as follows.
When transmission gear ratio is 3, the
output torque comes to 3 times of input
torque, and output shaft speed comes to
one third. In a gear system ' a reduction of
speed means an increase in the torque
transmitted.
PRINCIPLE OF TORQUE INCREASE

TMT002
(2) IDLER GEAR AND REVERSE

The gear system shown in the figure is
similar in structure to the previous figure
with the exception that an idler gear E,
has been added between C and D. Movement occurs in the order of. input - A -B C - E - D - output. As the figure shows,
the rotation direction of the output shaft is
different. In other words, the idler gear is
used to reverse the direction of the shaft.
As shown below, the gear ratio with idler
gear is the same as that of without idler
gear, it can be seen that the idle gear has
no effect on the transmission gear ratio.
Combination of gear teeth (reverse)
[With idle gear]

B teeth (25)
E teeth (7)
A teeth (15)
C teeth (10)
D teeth (30)
=5
E teeth (7)
[Without idle gear]

B teeth (25)
D teeth (30)
=5
A teeth (15)
C teeth (10)
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TMT003
3-2. TRANSMISSION TYPES

Transmissions can be broadly divided into the categories shown below, but the
major types in use today are the synchromesh type in the parallel shaft gear category and the planetary gear type. The parallel shaft gear type has two shafts
with several groups of gears which change position as required. In most such
gear types, forward motion is generated by a combination of four or five gears
while reverse is usually generated by one gear. The planetary gear type is often
used in automatic transmissions because it allows for easy control of automatic
shifting.
Sliding mesh type
Parallel shaft gear type
Gear type
Constant mesh type

Synchro mesh type
Planetary gear type
Currently, most manual transmissions use the parallel shaft gear type. Most automatic transmissions use the planetary gear type with a torque converter.
3-3. AUTOMATIC TRANSMISSION
(1) DESCRIPTION
The major parts of the automatic transmission include the cases and housings,
torque converter which transmits power, hydraulic control mechanisms, shift control mechanisms and auxiliary devices. The hydraulic devices, which include control valves, drive the power train and the power train includes the torque
converter, clutch & brake, planetary gear, output shaft, final drive, etc.
The shift control mechanisms work by sending instructions to the hydraulic control mechanisms.
Automatic transmission
Transmission (Gear box assembly)
Torque converter
Speed changing
mechanism
(Power train)
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Final drive
(Transaxle)
Hydraulic control
mechanism
(Control valve,
oil pump)
The torque converter transmits the revolving power of the engine to the output
shaft by means of hydraulic oil called automatic transmission fluid (role of the
fluid coupling). Also, the torque converter works to enhance the torque transmitted to the output shaft depending on the driving conditions in a stepless manner
from 1:1 to 1:2 (role of the stepless transmission up to a gear ratio of 1:2).
Planetary gears are used for the speed changing mechanism and they change
the rotation transmitted from the torque converter to preset gear ratios. The
hydraulic control mechanism directs the hydraulic pressure generated in the oil
pump to each hydraulic cylinder (clutch and servo) based on vehicle speed and
load. Also, it automatically fixes or releases each gear of the planetary gear to
perform automatic speed changes.
As described above, the torque converter itself functions to enhance torque and
change speeds. Nevertheless, a transmission is needed. This is because sufficient driving performance is requested for a vehicle and there is also a need to
rotate the power train in reverse. Recently, the transmission has become increasingly multi-staged and complicated.
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4. PROPELLER SHAFT & DRIVE SHAFT

4-1. PROPELLER SHAFT
(1) DESCRIPTION
On FR vehicles, a shaft is needed to transmit power from the transmission to the final
drive. This is called the propeller shaft.
When the vehicle is being driven on uneven
roads, the transmission and final drive are
always changing positions either vertically or
laterally in relation to each other. Because of
this continual change, the transmission and
final drive cannot be one fixed length or fixed
angle.
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SLEEVE YOKE AND SPLINE
TPD002
*This journal is commonly called either a cross shaft or spider

This is why the propeller shaft is connected with a universal joint and a sleeve
yoke so that rotation torque can always be transmitted smoothly from the transmission to the final drive. The universal joint allows for vertical angle changes.
The sleeve yoke with spline makes it possible for the shaft to expand or shrink.
The propeller shaft is generally light, with strong turning torque. A hollow steel
pipe with strong flexural rigidity is used.
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The propeller shaft rotates at high speeds when travelling fast. To prevent vibration and loud noise, the propeller shaft must be in complete balance.
On most vehicles, the wheel base is quite short requiring a 2-piece propeller
shaft. The use of shafts that are held by a central bearing are becoming more
common. The reason a 2-shaft propeller is used is to improve ride comfort at
high speeds and to prevent the shaft from being damaged by hard twisting and
turning.
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CENTRE BEARING
4-2. UNIVERSAL JOINT

(1) DESCRIPTION
A universal joint is general connected to the ends of the propeller shaft. It allows
for torque to be transmitted smoothly even when there is a large gap between the
transmission and the final gear.
A spline on the propeller shaft allows for the propeller shaft to adjust length without any damage when the wheels move up or down.
TPD004
UNIVERSAL JOINT
190
5. FINAL DRIVE
The torque from the engine moves
through the transmission and propeller shaft to the final drive. The final
drive consists mainly of the final gear
assembly (reduction gear) and the differential.
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The final gear ultimately reduces the engine speed and delivers increased traction to the wheels. The differential permits both left and right wheels to rotate at
different speeds when the vehicle rounds a curve.
5-1. FINAL GEAR
The final gear reduces the engine speed and increases the rotation power for
increased torque to the drive shaft. The final gear receives its name because
engine power is not reduced any more after the final gear assembly. On FR vehicles, the final gear serves to align the direction of the transmitted torque at right
angles. The reduction ratio that the final gear creates differs with each vehicle.
The appropriate ratio is determined by a composite of factors which include running resistance. engine output, rotation range, effective tyre radius for maximum
speed, acceleration performance, climbing power, and fuel consumption.
Final gear ratio =
Number of driven ring gear teeth

Number of drive pinion teeth
(Example:
35
9
= 3.889)
FR VEHICLE FINAL DRIVE ASSEMBLY
TPD006
191
As shown in the figure, on front-engine drive

vehicles, the transaxle, final gear, and differential are one unit that operate as the transaxle.
TPD007
5-2. DIFFERENTIAL GEAR

(1) DESCRIPTION
The differential helps torque to be smoothly transferred from the final gear to the
wheels. When the vehicle rounds a curve or when travelling straight on rough
roads, the rotation length of the left and right wheels will vary. If the rotation of
both sides is the same (both sides rotating on the same shaft), the wheel with the
shorter length will slip making driving difficult. So that the wheels do not slip and
can rotate smoothly, the differential allows for left and right wheels to rotate at different speeds.
(2) BASIC STRUCTURE AND OPERATION OF THE DIFFERENTIAL
As shown in the figure, the differential pinion
inside the differential case is meshed with
side gears.
A spline in the centre of the side gears is
connected to the axle drive shaft.
TPD008
Because the differential case is an integrated

part of the ring gear, torque can be transmitted from propeller shaft _ drive pinion ring
gear differential case differential pinion
side gear axle (drive) shaft.
BASIC STRUCTURE
OF THE DIFFERENTIAL
Differential operation
When the vehicle is travelling straight, the differential allows the wheels on both
side to rotate together; when travelling around a corner, the differential allows for
variation between wheels while transmitting smooth drive torque.
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SUSPENSION SYSTEM
1. AXLE
1-1. AXLE TYPES
There are basically two types
of axles. The driven wheel axle
which simply holds up the
weight of the body and the
drive wheel axle which, in addition to holding the load of the
vehicle, transmits traction.
TAX001
The axle can be further classified by structure into the rigid axle type that is a single shaft connecting the right and left wheels and the independent suspension
type axle that allows wheels to move independent of each other.
1-2. FRONT AXLE
The front axle supports the front wheel load and is used to control driving direction. There are two types: the rigid axle type and the independent type.
(1) RIGID AXLE (DRIVEN WHEEL TYPE)
The rigid axle type connects
right and left wheels on a single
axle. It is strong and large in
structure.
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193
This type is simple and reliable and is used for larger commercial vehicles. The
body tips very slightly on turns, but because the axle is heavy, the ride can be
uncomfortable when one wheel passes over a bump.
(2) INDEPENDENT SUSPENSION (DRIVE WHEEL TYPE)
This type is used for the front axle on
FF and FR-4WD vehicles and is usually similar to the structure shown in
the illustration. (The front axle in the
illustration is the double wishbone
type)
TAX003
1-3. REAR AXLE

The outer part of the rear axle shaft supports the weight of the frame and the
body. There are two types: full-floating and semi-floating.
(1) FULL FLOATING TYPE
On this type, the wheel hub is connected
by two bearings on the end of a free floating axle case. This means that the entire
weight of the body is on the axle case and
that torque power is transmitted exclusively by the torque shaft. Because the
axle shaft and the case that supports the
body weight are separate, this type is used
often on large and medium size trucks and
buses.
194
TAX004
(2) SEM FLOATING TYPE

On the semi-floating axle, there is a bearing
between the rear axle shaft and the axle
case. The rear axle shaft not only transmits
torque, it also supports the weight of the
vehicle. Because of the simple and lightweight structure of this type, it is often used
in small trucks.
TAX005
(3) INDEPENDENT SUSPENSION REAR AXLE

This type does not require an axle case. Most are similar to the structure shown
in the illustration. On FF vehicles, it is not necessary for the rear axle to transmit
torque. Most axles of this type will be part of an integrated unit with the strut similar to the front axle on FR vehicles.
TAX006
195
2. SUSPENSION
2-1. DESCRIPTION
The suspension connects the axle to the body. Along with the tires, it improves
ride and protects the body and load by absorbing road vibration and bumps that
would otherwise be transmitted directly to the body. The suspensions basic functions are to insure smooth vertical movement and correct side and lateral positioning over the wheels.
2-2. SUSPENSION STRUCTURE AND FUNCTION
The main parts of the suspension systems are spring, shock absorber, stabilizer
and link.
Spring ... Supports the weight of the body and absorbs shock from the road
Shock absorber.... Controls vertical movement of the body
Stabilizer Reduces body roll
LinkDetermines body positions and transmits motion and braking to the body.
Through changing the layout of these basic parts, many types of suspension systems have been designed.
2-3. SUSPENSION TYPES
(1) AXLE SUSPENSION
On axle type suspensions, the left
and right wheels are connected
by one axle. The body is connected to the axle by springs.
Because of the strength and simple structure of this type, it is often
used in large trucks and buses.
TSU001
Leaf springs are the most commonly used

spring type suspension. Depending on the layout, parallel spring or leaf spring types may be
used. The parallel spring type is the most common.
TSU002
AXLE TYPE
(Even when the body and axle move vertically in relation to each other, the tread
camber does not change)
196
(2) INDEPENDENT SUSPENSION

When passing over a bump, the angle of the wheel changes with the up and
down movement. This movement also effects the wheel on the other side on flat
ground.
This is excess movement that is undesirable from the viewpoint of both safety
and comfort. In order to eliminate this, a system called independent suspension
was developed to allow the left and right wheels to respond independently without affecting the other side.
Independent suspension adds much to comfort by reducing weight below the
spring and preventing one wheel from affecting another. Type of independent
suspension and functions.
TSU003
TSU004
RIGID AXLE TYPE SUSPENSION WITH

ONE WHEEL RAISED
(The angle of both wheels is affected)
INDEPENDENT SUSPENSION WITH

ONE WHEEL RAISED
(The angle of the wheels to the ground has
not changed)
197
2-4. FRONT SUSPENSION

(1) FRONT SUSPENSION TYPES
(a) Strut types
Characteristics
This type usually uses shock absorbers called suspension struts that are heavyduty and highly rigid. Strut suspension and McPherson strut are other names
also used. The structure is simple with few parts. Besides being light, it does not
occupy much space. The bilateral force on the wheels is received by the transverse link. The fore and aft force is received by the tension rod.
TSU005
198
(b) Double wishbone (lateral leaf spring) type

Characteristics
The structure in the figure is similar to the old coil spring type wishbone suspensions except that the coil spring has been replaced by a leaf spring (placed sideways). The vertical movement is controlled by the leaf spring and shock absorber
while lateral and side movement is controlled by the upper and lower link. When
compared with the strut type, this is more complicated, but the vertically operated
link has greater rigidity.
TSU006
199
(c) Double wishbone (torsion bar spring) type

Characteristics
On this type, when the upper arm shakes, the torsion bar connected by serrations (joint where boss and shaft connect together is serrated) twists to soften the
shock.
TSU007
(d) Multi link type

Characteristics
The multi link type uses the double wishbone suspension as a base with an
added third link. This allows the kingpin shaft to be free from the upper link unlike
on the former type.
In other words, the kingpin shaft can be set in the most ideal position regardless
of the upper link position. The upper link and kingpin shaft are connected
together by this third link. This makes it possible to set alignment at any position.
Also, because this third link only works during vertical movement and is not
affected by drive turning, the spring and shock absorber system can be installed
on the same shaft. With this arrangement, the wheel stroke and the shock
absorber stroke work efficiently to reduce shock on a 1:1 ratio.
200
TSU008
2-5. REAR SUSPENSION

(1) REAR SUSPENSION TYPES
(a) Parallel link type
Characteristics
As shown in the figure, because two
parallel links of the same length are
used, there is very little tire alignment
change resulting in high stability. With
the parallel link type, when high
reverse load is added on the tires,
when stopping for example, or during
bound and rebound, the toe change
can be controlled against the change
of the floor height in order to maintain
stability.
TSU009
When turning corners, the lateral force on the tire is located slightly to the rear of
center; but by moving this lateral force close to the elastic center of the rear parallel link, toe change will be small and stability can be maintained.
201
(2) Multi link type

A double upper link (front upper link and rear upper link) is installed on the upper
part and the lower arm. It consists of an A arm placed on a slant and the lateral
link behind it. The lower arm is arranged on the lower part. This facilitates the
most ideal movement of the tires to absorb the force from fore and aft, lateral and
vertical directions.
TSU010
202
(a) Semi trailing arm type

In structure, the semi trailing arm is somewhere between the trailing arm and the
swing axle type. The trailing arm pivot shafts slant towards the center of the
body. This type is most often used on FR vehicles. The defining characteristic is
the semi trailing arms ability to change pivot shaft angle to control the camber
and horizontal angle of the wheels.
TSU011
(b) 4-link coil spring type

On 4-link suspension systems the link
determines the axle position of the
vehicle. The ride comfort is improved
because the spring can be used
exclusively to absorb much of the
vibration. There are two ways of supporting the lateral weight: an upper
link shaped like a reverse V (4-link
type) and also a specialized support
rod (5-link type).
Upper link
bushing
Lower link bushing
TSU012
203
(c) 5-link coil spring type

The roll center is lower and bilateral rigidity is higher on the 5-link coil spring than
on the 4-link coil spring type. Because of this, there is less lateral movement
which makes travelling on rough roads more comfortable.
*The panhard rod gets its name from a French engineer named Panhard. This
support rod restricts lateral movement. Recently it is also being called a lateral
rod.
TSU013
204
(d) Rigid leaf spring type

The rigid leaf spring is installed parallel to the vehicle. Besides absorbing road
shock, it also holds the axle in position.
All of the wheel traction, brake force, and lateral force from turning is transmitted
through the spring to the body.
TSU014
205
(e) Multi-link beam suspension

This system has the newly developed multi-link beam type suspension.
Designed on the basis of the torsion beam type suspension, the multi-link suspension system now has an additional structure of a lateral link and a control rod.
MULTI-LINK BEAM
TSU015
TORSION BEAM
TSU016
206
WHEEL ALIGNMENT
1. DESCRIPTION
Wheel alignment usually refers to the front wheels but in effect it means that all
the wheels on a vehicle should be aligned. Incorrect wheel alignment may cause
uneven tyre wear or the steering to be effected by wheel jerking. When the
wheels on a vehicle are aligned- there is balance between the points shown in
the figure. In the following description, we will assume that front and rear alignment is correct and focus on front wheel alignment.
RELATIVE POSITION OF FRONT AND REAR WHEELS
TSU017
2. FRONT WHEEL ALIGNMENT

The front wheels determine the direction of travel. When coming out of a turn, the
front wheels should return smoothly to a straight position. This requires that parts
such as the front axle and kingpin work smoothly together. This is what is meant
by front wheel alignment. Front wheel alignment is affected by the following factors.
Camber
Caster
Kingpin inclination
Toe in
These factors work together for the following functions.

Make steering wheel easy to handle
Maintain steering wheel in stable forward position
Give steering wheel return power
Reduce tyre wear
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2-1. CAMBER
When looking at the front of the front wheel as shown
in the figure, the wheel appears to be leaning outward. The angle between the surface and the centre
line of the wheel is called the camber. Camber varies
from model to model, but generally the camber angle
is between 0.5 and 2 degrees. The wheel in the figure which is leaning outwards is said to have a positive camber; wheels that lean in have a negative
camber.
TSU018
CAMBER
2-2. KINGPIN INCLINATION

When looking at the front wheel from the front, the upper part of the kingpin
appears to be on an inward angle. The perpendicular line of the kingpin with the
ground is called the kingpin inclination.
TSU019
The kingpin inclination varies between models.

It is generally in the range of 6 to 9 degrees.
TSU020
RETURN TO POSITION OF STEERING

WHEEL BY KINGPIN INCLINATION
208
2-3. TOE-IN
The figure, a view from above, shows that
the distance between the front of the
wheels is shorter than the distance
between the rear of the wheels. This is
what is meant by toe-in. Toe-in is the difference between the tread centre on the front
of the wheels and the centre of the tread in
the rear of the wheels. The toe-in is generally in the range between 2 and 8 mm
(0.08 and 0.31 in). If the front of the
wheels is wider than the rear of the
wheels, this is called toe-out. Toe-in keeps
the wheels straight when driving.
2-4. CASTER
When looking at the vehicle from the
side, most kingpins will be set at an
angle as shown in the figure. This
angle is called the caster and is generally in the range of 0.5 to 4 degrees.
The B point where the kingpin centre
line intersects with the road surface is
farther ahead than the centre contact
point A. Thus, the wheel running resistance will pull the contact point A back
which prevents side run-out. This also
tends to return the steering wheel back
into the straight forward position. This
so called caster effect stabilizes the
direction of travel and helps the steering wheel return to position.
209
TSU021
TSU022
CASTER ANGLE
STEERING
1. DESCRIPTION
The steering system determines the direction the vehicle moves. The system is
responsible for the smooth, stable and, most importantly, the safe steering of the
vehicle. It must be sturdy and completely reliable.
The steering system is made up of the
following three structures.
Steering
The parts that the driver turns to steer
the vehicle include the steering wheel,
steering shaft, and column.
Gear
Along with reducing the rotation speed
of the steering shaft, the gears, transmit the rotation of the steering shaft to
the link. The steering gear structure is
TST001
connected directly to the frame.
Linkage
Along with transmitting the gear structure movement to the front wheels, the link
structure maintains the correct relationship between the left and right wheels.
The structure includes the Pitman arm, drag link, knuckle arm and tie rod.
2. STEERING GEAR
(1) RECIRCULATING BALL TYPE (RB type)
As shown in the figure, on the RB type
steering gear there are several balls
between the worm shaft and the nut.
When the steering wheel is turned, the
worm shaft turns the balls, which
moves the nut and finally turns the sector.
Because there is very little friction with
this system, it is endurable and it helps
to make steering lighter.
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TST002
(2) RACK AND PINION TYPE (R & P TYPE)

On this type, a pinion will be connected
to the tip of the column shaft that
meshes with a rack and changes the
direction of the wheels. Because the
rack, which acts as tie rod, is moved
directly by the column shaft, the steering is very responsive. The structure of
this type is also relatively simple.
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211
BRAKE
1. DESCRIPTION
Along with slowing or stopping the vehicle, the brake system is also used to hold
the vehicle in a stopped position. The brake system does this by converting the
movement energy, which generally uses friction, into heat energy. The friction
type brake is able to perform its functions by releasing this heat energy. The
brake system must include the following features.
Operation must be completely effective.
The system must be of superior reliability and durability.
Inspection and adjustment must be easy.
There are many different types of brake systems, but the basic system includes
links and hydraulic devices to improve reliability of the structure to transfer braking power, and the braking device that reacts when this power is received.
Types of brakes are the main brake (foot brake) used when the vehicle is in
motion and the parking brake used to hold the vehicle in one position. The main
brake is operated by the foot and the parking brake (hand brake) is operated by
the hand. Two types of brake systems are mechanical systems which uses rods
and wires and hydraulic systems which uses hydraulic devices. The foot brake is
generally hydraulic and the parking brake is generally mechanical.
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212
2. BRAKE TYPES and FUNCTIONS OF COMPONENTS

Brake
Foot brake --- hydraulic type

Parking brake (hand brake) --- mechanical type
2-1. FOOT BRAKE

With the foot brake, a brake drum or brake disc is installed on the interior side of
the wheel and has friction material packed into it. Friction is used to stop the
vehicle. Braking power is applied at all four wheels form the brake pedal. The
actual braking device can be either the drum brake type or the disc brake type.
TBR002
FOOT BRAKE
213
(1) DRUM BRAKE

As shown in the illustration, the general
structure for the actual braking device of
the hydraulic drum type brake includes
the brake shoe (hereafter referred to as
shoe) which expands inside the brake
drum (hereafter referred to as drum).
When the brake pedal is depressed, the
piston inside the master cylinder is activated to increase the pressure of the
brake fluid.
The pressure travels through the brake
pipe and brake hose to the wheel cylinder. The wheel cylinder uses this hydraulic pressure to push on both sides (or
one side) of the piston to force the shoe
to press against the drum and create
braking force. When the brake pedal is
released, the pressure inside the master
cylinder is lowered which lowers the
pressure inside the wheel cylinder. A
return spring pulls the shoe back and
braking ceases.
As shown in the figure, the basic structure of the brake itself includes the wheel
cylinder, the shoe and back plate and
used for installation of the drum.
Depending on how the shoe and wheel
cylinders are installed, drum-type brakes
can be divided into the following classifications.
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GENERAL STRUCTURE FOR

HYDRAULIC DRUM BRAKE
TBR004
DRUM TYPE HYDRAULIC BRAKE
Leading-Trailing type (used often for the rear wheel)

Drum brake
Two-Leading type (double acting type is used on the front wheels of large trucks and buses)
Uni-Servo brake (used for the front wheel brake, but being replaced by disc brakes)
Duo-Servo brake (used for the rear wheel brake on some small trucks and passenger cars)
214
(2) DISC BRAKE

As the figure shows, the disc hydraulic brake
(hereafter referred to as disc brake) applies
braking power by the use of two strong pads
around a disc that rotates with the wheels.
On this type, because the disc is exposed as it
rotates, it is heat resistant, shows little performance deterioration during repeated use at
high speeds, and provides stable braking
power.
1) Types of disc brakes
As shown in the figure, types of disc brakes
TBR005
include the anchored caliper (also called
opposed piston) type with a cylinder that squeezes on both sides of the disc and
the floating caliper type (one or two pistons) with a cylinder only on one side.
Disc brake
Anchored caliper type (opposed piston)
(2 pistons)
(4 pistons)
* Used for sports car specifications
Floating-caliper type
Single-piston - type
* Used on general type vehicles
Double-piston type
*Used for small passenger cars
TBR006
TYPES OF DISC BRAKES
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(a) Anchored calliper type

As shown in the illustration, on the
anchored calliper, a calliper
anchored to the disc rotates with
the wheel. There are cylinders on
both sides of the calliper. Pistons or
self-adjusting devices are installed
inside the cylinder to receive the
pressure from the master cylinder
and in turn squeeze the pads on
both sides of the disc to deliver
braking power.
The disc is installed on the hub and
rotates with the wheel. As shown in
the illustration, when the brake is
applied, the friction heat in some
types of discs (sometimes called
ventilated discs) is easily released
through openings.
TBR007
ANCHORED CALLIPER TYPE
TBR008
VENTILATED DISC
216
2-2. PARKING BRAKE

(1) REAR-WIHEEL BRAKE TYPE
The rear wheel parking brake functions by a mechanical to the foot brake shoe.
The general structure is usually similar to that shown in figure below.
1) Brake unit
The brake unit uses the existing structure of the foot brake as shown in the brake
shoe. There are also brake systems where the parking brake is attached to the
wheel cylinder. The figure shows a rear disc brake. On this type, along with the
disc brake for the foot brake, there is also a drum and brake shoe which function
as the parking brake. On the brake drum. the hat part of the brake disc is used.
The brake shoe can be expanded by using the same structure as that shown in
the figure below.
TBR009
TBR010
WHEEL BRAKE TYPE HAND BRAKE

STRUCTURE
ONE EXAMPLE OF A DISC BRAKE

PARKING BRAKE
217
WHEELS & TIRES

1. WHEEL
As shown in the figure, the wheel
includes the rim to secure the tyre and
a disc area used to install the wheel to
the hub. The shape and size of the
wheel is regulated by RS. The various
curvatures and structural parts of the
tyre must meet various performance
and endurance standards depending
upon use.
The rim diameter, rim width, flange
shape and other dimensions must also
meet international standards. As
shown below, the wheel size displayed
includes the rim size, shape and type.
TWL001
(1) EXPLANATION OF CODE

Example:
5 1/2
Rim width
(inch)
JJ
Flange shape
13
Rim diameter
(inch)
(2) FLANGE SHAPE AND NUMBERING SYSTEM (Reference)

The shape of the flange is identified by a letter of the alphabet. A general rule is
that the higher the letters (A, B, ...J, K, L ... T,V), the higher the flange, as shown
below. Please refer to table 7-1 for standard passenger car heights.
SHAPE OF FLANGE
TWL002
218
(3) PCD (Unit: mm)

PCD refers to Pitch Circle Diameter. Nissan uses 100 nun and 114.3 mm (3.94
and 4.50 in).
(4) OFFSET
Offset is the distance between the rim central line and the surface of the hub
install hole. Offset is related to prevention of interference with the brake and
wheel alignment.
TWL003
If the offset is large, the center of the tire will lean inwards; if offset is small, the
center of the tire will lean outwards. The offset for FR vehicle is approximately
between 15 and 40 mm (0.59 and 1.57 in), 35 to 55 mm(1.38 to 2.17 in) for FF
vehicles.
2. TIRES
The automobiles of today travel at high speeds. With the demand for higher performance, the tire plays a more important role than ever.
2-1. FUNCTIONS, TYPES, AND STRUCTURE
(1) TIRE FUNCTIONS
Support the weight of the vehicle.
Transmit rotation and braking torque to the road.
Absorb vibration from the road surface.
Maintain change direction when in motion
219
(2) TYPES OF TYRES

1) Bias tyre
On the bias tyre, carcass plies are laid alternately around the carcass of the tyre on a slant
(bias) in the direction of forward rotation. This
gives circumferential and radial support to the
carcass. This structure is efficient at absorbing
road vibration and provides a comfortable ride
as the tires deform with the road surface. But
because of extra movement against the road
surface, it is not as durable as the radial tyre.
TWL004
2) Radial tyre
On the radial tyre, the carcass plies are laid at
right angles with the direction of forward direction. This gives strong radial support, however, it
is necessary for a reinforcing belt to be wrapped
around the carcass for circumferential support.
The strength of this band allows for little friction
with the road meaning that the tread will last
longer and have a higher critical speed.
TWL005
220
(3) ASPECT RATIO

185/70 HR 14 As shown in the figure, aspect ratio
is a comparison of the tires height and the tires
width. Aspect ratio = H/W
Aspect percentage = H/W x 100 (%)
W: The width of the tyre (min)
H: The height of the tyre (mm)
* Aspect ratio is usually expressed by percentage.
TWL006
(4) LOAD CARRYING CAPACITY (load index)

195/60R15 86 H
Load carrying capacity: The heaviest load that the tyre can support expressed by
the speed symbol (code) for use in standard conditions. The larger the index, the
heavier the load carrying capacity.
(5) SPEED SYMB0L
Under normal conditions (correct tyre pressure, etc.), the appropriate speed for
the load capacity represented by the speed symbol is shown in the example
chart below. The chart is for 185/70 HR 14, 195/60R15 86H.
Speed symbol
(code)
Speed
Km/h (MPH)
Speed symbol
(code)
Speed
Km/h (MPH)
150 (93)
190 (190)
160 (99)
210 (110)
170 (106)
240 (140)
180 (112)
Over 240 (over 149)
TYRE PROBLEMS
Standing wave
Standing wave is a visible wave phenomenon. In ordinary tires it occurs at vehicle speeds over 150 km/h (93 MPH). Once it occurs, excessive tire surface bending can cause the tyre to burst.
While a tyre is rolling, it changes its shape at the portion where it contacts the
road. The tyre then tries to regain its original shape at the point at which it leaves
the road. In other words, changes to and recovery of its shape accompany the
rolling of the tyre, which are constantly repeated.
221
As the tyre rolls at high speed, the deformed portion of tyre, caused by contact
with the road, will not have time to fully recover before the next revolution. This
continuous phenomenon is called a standing wave.
The speed of the car at which this standing wave first occurs is called the boundary speed. Boundary speed will decrease as the tyre inflation pressure decrease
and it will vary with the sectional construction of the tyre. In radial tires, the
boundary speed is approximately 190 to 200 km /h (118 to 124 MPH).
TWL007
STANDING WAVE
Hydroplaning
As the car moves along a wet road at high speed, the resistance produced by the
water causes the tires to float and slide over the water film. This effect is called
hydroplaning and employs the same principle as water-skiing. When it occurs,
car stability and controllability are adversely affected. The boundary speed,
beyond which hydroplaning occurs, is influenced by various factors. Careful
attention should be paid to car speed, tyre inflation pressure, road conditions,
and tyre wear. The problems indicated below may result from hydroplaning:
Ineffective braking.
Insufficient or no traction.
Ineffective or unreliable steering.
Side slipping as a result of side winds.
222
For safety in high speed driving as in preventing standing waves, tires should be
inflated somewhat higher than the specified pressure.
TWL008
HYDROPLANNING
223
STEP 1
Contents
1. Outline of Automobile
1 - 1 Classification of Vehicles by the Location of Engine and Driving Wheels . . . . . . . . . . . . . . . . . 2
1 - 2 Construction of Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Mechanism of Engine
2 - 1 Principle of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 - 2 Construction of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 - 3 Characteristics of Engine <Part-1>
Bore/Strokes/Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 - 4 Characteristics of Engine <Part-2>
Shapes of Combustion Chamber/Number of
Cylinders/Arrangement/Valve Driving Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 - 5 Accessories <Part-1>
Mechanism of Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mechanism of Intake/Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mechanism of Battery/Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mechanism of Start-up/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mechanism of Cooling/Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. Mechanism of Chassis
3 - 1 Principle and Functions of Clutch/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 2 Principle and Functions of Propeller Shaft/
Final Drive/Automatic Transmission (AT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 3 Mechanism of Suspension System <Part-1>
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 4 Mechanism of Suspension System <Part-2>
Front Suspension/Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 5 Wheel Alignment and Mechanism of Tires/Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 6 Mechanism of Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 7 Mechanism of Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
26
31
34
36
39
42
4. Mechanism of Body, Electrical Systems, and Air Conditioning System

4 - 1 Name, Type and Construction of Each Part of Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 2 Name of Each Part of Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 3 Designing Points, Adjustment Functions and
Classification of Seats/Mechanism of Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 4 Mechanism of Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 5 Mechanism of Lighting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 6 Mechanism of Audio Equipment and Other
Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 7 Mechanism of Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
55
5. Practical Knowledge
5 - 1 About Safety Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 2 Handle A Customer's Car with Great Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 3 Hand Tools and Their Usages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 4 Knowledge of Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
62
63
68
45
48
49
51
53
Edition: MARCH 2002

Printing: MARCH 2002
Publication No.: SA2E-AFUNG1
QUICK REFERENCE INDEX

GENERAL TOOLS
MEASURING TOOLS
3S POLICY
STEP 1
GENERAL TOOLS
AND 3S POLICY
1994
Not to be reproduced in whole or in part without the prior written permission of Nissan Motor Company Ltd., Tokyo, Japan.
FOREWORD
This booklet has been published to provide information on
the proper use of general tools (hand tools). NISSAN plants
are equipped not only with ordinary general tools but also
with other tools designed for highly specific purposes.
What have been selected to explain herein are those
ordinary general tools with which you should be especially
familiar.
By learning the proper use of such tools, you will be able to
perform your work more safely and quickly, and at the
same time increase the service life of the tools. Moreover, if
you should see another mechanic using a tool the wrong
way, you will be able to show him how to use it properly.
This booklet includes illustrations where appropriate to
help you better understand the written information
presented.
CONTENTS
GENERAL TOOLS
1:
2:
3:
4:
5:
6:
7:
8:
9:
10 :
11 :
12 :
13 :
14 :
15 :
16 :
17 :
18 :
19 :
20 :
21 :
22 :
Wrench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Box-end wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable wrench (monkey wrench) . . . . . . . . . . . . . . . . . .
Socket wrench set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hex nut wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torx wrench (Torx socket wrench) . . . . . . . . . . . . . . . . . . . .
Sliding hammer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chisel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scraper (Gasket scraper) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Garage jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rigid rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire stopper (scotch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1- 1
1- 2
1- 3
1- 4
1- 6
1- 7
1 - 10
1 - 10
1 - 10
1 - 11
1 - 11
1 - 11
1 - 12
1 - 13
1 - 14
1 - 14
1 - 15
1 - 15
1 - 15
1 - 16
1 - 17
1 - 17
MEASURING TOOLS
23 :
24 :
25 :
26 :
27 :
28 :
29 :
30 :
31 :
Torque wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vernier calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bore gauge (cylinder gauge) . . . . . . . . . . . . . . . . . . . . . . . . .
Plasti-gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thickness gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surface plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2- 1
2- 2
2- 6
2- 8
2 - 10
2 - 11
2 - 13
2 - 13
2 - 14
3S POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
N-STEP Introduction: Tools & Devices for Maintenance

Hand tools
We use various types of hand tools for maintenance of automobiles. Hand tools serve as a
mechanic's right-hand man. How to handle these hand tools will affect not only the result but also the
efficiency of our work. It often occurs that when we are about to get to work, we cannot see the tool
we are going to use, so we look around for it, and, finally, since we cannot find it, we have to borrow
it from our co-worker. What we have most while we are at work is that we do not have the necessary
tools at hand. I advise you to have all the necessary hand tools well arranged at all times and
replace quickly the damaged tools, if any.
Management of hand tools

Management of hand tools is every mechanic's business, not some-body else's. Put the hand tools
in order for each task before starting the next task. If the tools are kept in order for each task, you
can never leave the tools behind in your customer's car by mistake. Also, at the end of your day's
work, clean the tools and check them for damage. Replace damaged tools and supplement lost tools
as soon as possible after reporting to your foreman. In order to keep your tools properly you need to
make clear where the tools are to be placed in the tool box or the caddie cart to make the checking
easier. Always keep the tool box in neat order and don's keep unnecessary things in the box.
Hand tools and how to use them

However good your tools may be, improper use of them may not only reduce the effect of such tools
but also cause you unexpected injury. You must learn how to use the tools properly beforehand to do
your work safely and properly.
What you have to pay attention to most when you use hand tools are:
to use tools with guaranteed quality which you can rely on,
to use tools properly which fit your purpose,
to check the damage and operating condition of tools before use, and
to be sure to clean and keep the tools in neat order after every use so that you can always use
them at will. Always keep the above in your mind and use the tools with great care.
The function, use, and the cautionary measures for the use of hand tools are as follows.
GENERAL TOOLS
1 : Wrench
(Function)
Wrenches are used to tighten or loosen a bolt or a nut. Single-ended, double-ended and bothended wrenches are widely used.
The open end of a wrench is generally inclined by 15 against its handle to make it easier for you
to turn a bolt or a nut even in a tight space by reversing the direction of the wrench. Wrench size is
indicated by the width across flats of the bolt or the nut which fits to the wrench.
(Important hints)
Select the wrench which fits the bolt or the nut and engage them properly.
When you use a wrench, always pull it. It is safer that way. If you push it, you may stumble
forward, or your hand may touch another part and you may get hurt when the wrench slips off the
bolt or the nut. Further, if you hold the area where the wrench and the bolt or the nut are engaged
with the other hand, the work will be safer and more secure. When you have to push it forward for
some reason or other, do it with your palm open. That way, if the tool slips, your injury will be less
serious. (This warning applies to the use of similar tools or socket wrenches.)
Be careful since the opening of a wrench may open and become loose if you tighten/loosen a nut
or a bolt suddenly with a large force even if the wrench is securely engaged with the nut or the
bolt.
1-1
GENERAL TOOLS
The length of a wrench handle is determined according to the size of the open end so that it can
tighten a bolt or a nut with a torque suitable for the size of the bolt or the nut. So, don't combine
two wrenches, don't cover the wrench handle with a pipe to make the handle longer, and don't hit
the wrench with a hammer instead of pushing it with your hand. (If you use a wrench that way, the
torque will become larger, which will lead not only to the breakage of a bolt and damage to the
wrench but even to a serious accident. So, never use a wrench that way.)
When you have to apply a large torque, use a box-end wrench or a socket wrench.
2 : Box-end wrench
(Function)
A box-end wrench is easier to use than the ordinary wrenches since it holds the head of a bolt or a
nut all around. Also, we can apply a larger torque since the handle is longer than that of an
ordinary wrench.
A flare-nut wrench is provided with a cut off at the head and is used to tighten the nuts of the
connecting pipes of the carburetor, fuel pump, brake, and the like.
(Important hints)
We cannot do the work with a box-end wrench as fast as we do with an ordinary wrench, but it is
more useful when it is used at the beginning of loosening or at the end of tightening a bolt or a nut.
Fix the box-end wrench of a proper size securely to a bolt or a nut so that the box end area is
parallel to the head of a bolt or a nut, and pull the handle.
Don't hit the wrench handle with a hammer and the like or connect a pipe even when the bolt is not
loosened. These actions will cause the breakage of the bolt or damage to the tool. If you hit the
bolt or the nut lightly with the hammer several times to give a shock, it will help loosen it.
1-2
GENERAL TOOLS
3 : Screwdriver
(Function)
A screwdriver is used to tighten or loosen screws.
Screwdrivers with various types of tips are available so that you can find the one that fits to the
groove on the screw head.
(Important hints)
The tip of a screwdriver and the groove of a screw must match.
The tip must engage securely with the screw groove.
Don't turn a large screw with a small screwdriver. Use of a screwdriver of an improper size will
damage the screw groove or the tip of the screwdriver.
A screwdriver is to be used only to loosen or tighten a screw. If you use a screwdriver in place of a
lever or hold a screwdriver with pliers and turn it forcefully, the tip of the screwdriver will be
damaged. Don't hit a screwdriver even if a screw is too tight to be loosened. The use of a
screwdriver whose joint to the handle is hexagonal to be turned by a wrench, or the use of a
specially designed shock screwdriver will make it easier to loosen the screw.
1-3
GENERAL TOOLS
4 : Pliers
(Function)
There are two types of pliers, general and special. General type pliers are used for holding,
bending, twisting, and cutting things, or for other uses, while special type pliers are for attaching/
detaching piston rings or snap rings.
(Important hints)
4 - 1 Combination pliers
Combination pliers are what are called pliers in general and can be applied to both larger and
smaller works since the mouth opening can be adjusted in two ways, large and small. Also, wire
and the like can be cut at the roots of the jaws.
Don't use pliers for loosening/tightening a bolt or a nut. If you use them this way, the corners of the
bolt or the nut may be crushed.
4 - 2 Nose pliers
The tips of nose pliers are made long and narrow. Nose pliers are used for the place too tight for
combination pliers or for holding a pin or the like in a hole.
4 - 3 Nippers
Nippers are used to cut a thin wire, to remove the insulation of an electric wire, and to pull out a
cotter pin and the like.
Don't cut hard material so as not to damage the cutting edges.
1-4
GENERAL TOOLS
4 - 4 Cutting pliers
Cutting pliers can be used for various purposes such as cutting rather thick wire and the like,
holding and bending things.
When cutting a thick wire with cutting pliers, don't hit the pliers with a hammer so as not to damage
the cutting edges.
4 - 5 Water pump pliers

The opening is adjustable in several steps. So, water pump pliers are suitable for holding works of
various sizes ranging from small ones to large ones which cannot be held firmly by ordinary
combination pliers.
4 - 6 Vice grip pliers

Vice grip pliers are used when a strong grip is needed. These pliers are handy to remove a
damaged bolt or a seized nut.
4 - 7 Snap ring pliers

Snap ring pliers are used to detach/attach a snap ring. There are two types, the one whose tips
are open and the other whose tips are closed.
1-5
GENERAL TOOLS
5 : Adjustable wrench (monkey wrench)
(Function)
Opening width of an adjustable wrench can be widened or narrowed according to the size of a bolt
or a nut by turning the adjusting screw to move the adjustable jaw.
An adjustable wrench is used for a bolt or a nut not of a standard size such as those used for joints
of an air conditioner piping to which a standard wrench does not fit.
(Important hints)
Use this adjustable wrench after adjusting the opening width to fit to a bolt or a nut perfectly. If you
use this adjustable wrench with the grip too loose, the corners of the bolt or the nut will be crushed
or the adjusting screw will become loose.
An adjustable wrench is so constructed that the fixed jaw can withstand the larger force and hold a
work more securely than the adjustable jaw, so pull this adjustable wrench with the fixed jaw
placed on the upper side. If you use an adjustable wrench with the adjustable jaw placed on the
upper side, a bolt or a nut tends to slip from the adjustable wrench and the corners of the bolt or
the nut will be crushed.
1-6
GENERAL TOOLS
6 : Socket wrench set
(Function)
A socket wrench can be used for nuts of various sizes by combining this with various types of
handles or extension bars, and can be used safely and quickly even for the hard-to-reach nuts.
There are two types of sockets, a shallow type and a deep type. In general, a shallow type is used.
The socket of a deep type is two or three times as deep as that of the ordinary one.
A wrench with the width (across flats) of 9.5mm (3/8 inches) or 12.7mm (1/2 inch) is generally
used. Two types of box shapes for hexagon and dodecagon are available. A dodecagon type is
more widely used.
(Important hints)
6 - 1 Socket
Use the socket wrenches of proper size by fitting them securely to the bolts and nuts, and you will
be able to work safely without crushing the corners of the heads of the bolts and nuts and without
deforming the sockets.
When connecting the adaptor, universal joint, extension bar, handle, etc. to the socket, make sure
to connect each of them securely. Insecure connections may cause disengagement during
operation and an unexpected injury to you.
If you use a general-purpose socket in conjunction with an impact wrench, the crests of the socket
hole may be easily damaged by the impact. So, in this case, use a socket specially designed for
this purpose.
1-7
GENERAL TOOLS
6 - 2 Extension bar and universal joint
When the socket cannot be set on a nut because the nut is situated in a deep recess, the addition
of an extension bar of an appropriate length will make this operation possible. Extension bars of
different lengths are available. So, select and use the one suitable for your work.
The use of a universal joint will make it possible to operate in the area where straight insertion of
the extension bar is impossible.
Be careful when you work using a combination of the extension bar and the universal joint
because the socket tends to disengage from the nut. Furthermore, be careful that accurate torque
cannot be applied when the extension bar is inclined.
6 - 3 T-type slide handle

This is a combination of a socket and a cross bar. Fastening at a various torque is made possible
by changing the relative position of the two.
6 - 4 Ratchet handle
The ratchet handle enables you to turn the bolt or nut rapidly only in one direction with the socket
kept on the bolt or nut. The turning direction can be reversed by flipping the ratchet lock lever. Do
not apply an unnecessarily large force to the handle, or you may damage the ratchet. Use the
spinner handle when a large force is needed.
1-8
GENERAL TOOLS
6 - 5 Spinner handle (Hinged handle)
A universal joint is provided between the socket and the handle. Bend the lever at a right angle to
apply a large force to loosen a tight bolt or a nut. Once the bolt or the nut is loosened, then
straighten the handle or tilt the handle to an angle you like to turn the bolt or the nut more rapidly.
6 - 6 Speeder handle
You can loosen or tighten a bolt or a nut rapidly by holding the top of this handle with one hand
and turning the U-shaped crank with the other hand.
This handle is very convenient for work on transmissions and engine oil pans where a lot of the
same bolts or nuts are used.
6 - 7 Spark plug wrench

The spark plug wrench is specially designed for installing and removing spark plugs. A built-in
magnet holds the spark plug firmly to make your work easy.
A hand-to-reach spark plug can be easily installed or removed by adding an extension bar of a
suitable length and a ratchet handle to this wrench.
Use the spark plug wrench exactly in line with the spark plug. Inclined use of this wrench may
damage the plug insulator.
1-9
GENERAL TOOLS
7 : Hammer
Generally, about six types of hammers are used for automobile servicing. Rubber hammers,
plastic tip hammers, wooden hammers and copper hammers are used for the parts whose
surfaces can be easily damaged or for the parts on which no damage is allowed.
Test hammers are used for detecting loose bolts or nuts and for other inspections.
Before using a hammer, make sure that the head of the hammer is securely fixed to the handle.
Use of a hammer with a loose head is very dangerous because the head may fly away.
8 : Hex nut wrench

This is a L-shaped, hexagonal-section bar and is used to turn hex nuts.
The size of the wrench is indicated by the width across the flats of the hexagon. The wrenches of
about 5 to 30mm in this size are available, generally as a set of about 5 pieces.
A hexagonal wrench, a combination of a box and a hexagonal bar, is used to turn hex nuts by
adding an extension bar or a ratchet handle in the same way as the hex nut wrench.
When loosening or tightening a hex nut, do not add a pipe to the hex nut wrench or hit it with a
hammer even if the nut is too tight. This may bend or break the wrench.
9 : Torx wrench (Torx socket wrench)

The contact face between the Torx wrench and a bolt is made vertical to the bolt head. So, even
when the applied pushing force (thrust) is small, the wrench and the bolt will not tend to be
disengaged.
This reduces the turning force and makes the life of this tool longer. The Torx fixing system has
been employed widely for the recent automobile parts.
1 - 10
GENERAL TOOLS
10 : Sliding hammer
This is a tool used to extract gears, pulleys, rear axle shafts and so on by giving an impact with a
shock hammer.
Since there are a variety of types of the sliding hammers, such as the hook type tip and various
types of puller tip, use the one suitable for the purpose of your work.
Use the sliding hammer by setting it straight to the extracting direction. Inclined extraction will not
only make the extraction difficult but also damage the parts.
11 : Chisel
(Function)
This tool is used for cutting and chipping metals. Flat chisels and crosscut chisels are used to chip
the flat surface or to cut ribets, bolts, thin steel sheets and so on.
(How to use)
As a practical example, when the crushed corners of the bolts and nuts do not allow you to use a
spanner, you can loosen them by applying the chisel and by giving an impact with a hammer.
12 : Vice
(Function)
The vice is used to hold a work securely.
(How to use)
When holding a work by the vice, fasten the work by turning the vice handle gently with your
hands. It is dangerous to hit the handle with a hammer.
When holding a slippery round bar or a work which may be easily damaged, use attachments
made of wood pieces, copper, aluminum, and brass or the like to make the fixing easier and to
avoid damages to the work.
1 - 11
GENERAL TOOLS
13 : File
(Function)
The file is used to finish the surface of a work. There are three types of file-edges, a coarse file for
rough finishing, a second cut file for semifinishing, and a smooth cut file for final finishing.
The types of files are as shown below.
Flat file for flat face finishing
Half-round file for curved face finishing
Round filefor finishing the inner surface of a round hole
Square file
for finishing holes or recessed corners
Triangle file
* Set files A set of the above files for filing comparatively small areas
(How to use)
When using a file other than the set files, be sure to use it by attaching a handle. The use of the
file without a handle is dangerous and may cause injury.
When the teeth of the file gets clogged with filings during filing, remove the filings using a wire
brush along the teeth of the file. A file clogged with filings is poor in filing efficiency and may
scratch the work.
1 - 12
GENERAL TOOLS
14 : Taps
(Function)
The tap is a tool used for cutting a female screw in a hole of a work. Usually, the following three
types of taps are provided as a set.
A female screw is to be cut gradually by using the first hand tap, the second hand tap and the third
hand tap in this order.
(How to use)
For tapping, always use a specially designed tapping wrench except for an unavoidable case
where the use of the tapping wrench is impossible due to restriction in available space. The use of
the tapping wrench makes the tapping operation easier because this wrench helps you to apply a
uniform turning force to the tap. The tap should be inserted straight into a hole. Generally, the
female screw should be cut carefully by advancing the tap for one turn, and then, reversing for a
half turn to release the chips without applying an unreasonably strong force to the tap.
Cutting oil should be applied to the tap by a brush or an oiler while the tapping operation is being
carried out. This will reduce the high temperature generated during the tapping work, protect the
tap, make the tapping operation easier, and provide a clean finish of the screw.
(Examples of other applications)

A broken bolt remaining in a screw hole or a bolt whose head is rounded due to crushed screw
thread are difficult to remove. Such bolts can be removed by drilling a previous hole on the bolt
and applying a reverse tap designed exclusively for bolt removal in this hole.
A crushed screw thread of a female screw on a part can be repaired by tapping.
1 - 13
GENERAL TOOLS
15 : Dies
(Function)
A die is a tool used to cut a male screw around a round bar or a pipe.
The most widely used dies are called round open dies.
(How to use)
Screw threads of the round open die are cut off in a tapered form for 2 to 2.5 threads at its starting
end so that the die can easily start the screw cutting. So, the die should be inserted into a die
holder with the starting taper of the die facing downward.
When turning the die holder handle, apply uniform forces to the right and left of the handle.
Generally, the male screw should be cut carefully by advancing the die for one turn, and then,
reversing for a half turn to release the chips without applying an unreasonably strong force to the
die.
Cutting oil should be applied to the die by a brush or an oiler while the screw cutting work with the
die is being carried out. This will reduce the high temperature generated during the screw cutting
work, protect the die, make the screw cutting operation easier, and provide a clean finish of the
screw.
(Examples of other applications)
Bolts which are frequently used and are hard to turn when being tightened can be repaired by
cutting the screw with a die again.
16 : Reamers
(Function)
The reamers are used to finish the drilled holes more precisely or to finish the inner surface of the
bushes.
(How to use)
Pay attention to align the reamer with the center of a hole. Be sure to turn the reamer in a cutting
direction, that is, clockwise when inserting and removing the reamer.
A counterclockwise turn may cause the catching of chips and damage the cutting edge of the
reamer or finish of the hole.
While finishing with the reamer, apply cutting oil using a brush or an oiler. The oil will wash away
the chips to give a fine finish.
1 - 14
GENERAL TOOLS
17 : Center punch
(Function)
The center punch is used for positioning a drill for drilling operation, reassembling the similarly
shaped parts, and marking the matchmarks to show original positions.
The angle of the tip of the center punch is 60 to the punch center.
(How to use) Important Hints

When drilling a hole, mark the drilling position by this punch. This facilitates positioning of a drill
and avoids drill wandering.
When positioning the punch at a working position, slant the punch to make the position easily
visible.
After setting the punch, raise the punch normal to the working surface and then hit it with a
hammer. Do not avert your eyes from the top of the punch while hitting it with the hammer, thus
avoiding dislocation of the punched mark.
18 : Pin punch
(Function)
This is used to remove rivets or pins by hitting.
There are several pin punches of different size. Select and use the one suitable for the purpose of
your work.
19 : Scraper (Gasket scraper)

(Function)
This is used to remove old gaskets and clean the surface after removing them.
Scrape such soft materials as aluminum with special care to avoid causing scratches.
1 - 15
GENERAL TOOLS
20 : Garage jack (Trolley jack)
A garage jack is a device to jack up a car for chassis-related repair and so forth. Several kinds of
jacks are available. In terms of power source, two types, the hydraulic type and the combined
hydro-pneumatic type are available. Jacks of several lifting capacities (for 1 ton, 2 tons, 3 tons,
etc.) are available, so use the one which best suits the purpose.
The illustration shows an example of a hydraulic type jack, which consists of a manual handle, a
foot pedal, a relief handle, an arm and the like. The device jacks up a car by means of pumping
the foot pedal or the arm. Some types are powered by compressed air. The relief handle is used to
lower down the jacked-up car.
Jacking up or lowering down cars must be conducted on a flat floor, and be sure to provide the tire
with chocks for safety. For example, when you jack up the front side of a car, you must provide
chocks on both the front and rear sides of either one of rear tires.
After jacking up a car, be sure to support and fix the car with a rigid rack before working on the car.
The car jacked up only with the garage jack is unstable, and it is dangerous to work on the car.
When you work on the jack, pay
attention to the safety of yourself and the
people working around you. Particularly
when you are going to lower down the
car, lower it slowly and gradually, not in a
hurry.
Jack-up points differ among models, so,
never fail to refer to the service manual
of the model concerned.
When you jack up a whole car, jack up
the side with the lighter axle load first
since the car is more stable that way.
When you remove the tire while you are
working on the jacked up car, place that
tire between the garage floor and under
the floor of the car. That way, even if the
car slips down, your hands or feet can
be protected.
1 - 16
GENERAL TOOLS
21 : Rigid rack (Axle stand)
A rigid rack is used as an auxiliary support when
performing chassis-related works. Its height adjusts
to several levels. When you support the car with rigid
racks at 4 places, adjust the height of them by using
spacers and the like so that the car weight is
distributed evenly among these 4 racks. Never use
the rigid racks to support your hands or feet while you
are doing the chassis-related works.
22 : Tire stopper (scotch)

Tire stoppers are used to prevent the car from moving while you are replacing the tire or working
on the jacked up car.
There are several types such as one plate type and folding type. Be sure to use chocks for safety.
1 - 17
MEASURING TOOLS
23 : Torque wrench
(Function)
A torque wrench is used to tighten a bolt or a nut with a specified torque. This wrench is to be used
with a socket (box) on.
1) The arm of a plate-spring-type torque wrench is made of one sheet of plate spring. While
tightening a bolt or a nut, this plate spring deflects. By using this deflection, the tightening torque
is directly indicated at the place close to the handle of this wrench.
2) A bar-spring-type torque wrench has a square bar which is inserted into a socket (box). While
tightening a bolt or a nut, this square bar is twisted. The twist is magnified and moves a gauge
pointer to indicate the tightening torque.
3) An auto-limit-type torque wrench is so designed that a predetermined torque can be set by
turning a sleeve at the end of the handle to the desired scale. Then, the completion of tightening
at the predetermined torque can be easily known by a sound and hand feeling.
(Important hints)
Tighten a bolt or a nut provisionally with another wrench before final tightening with a torque
wrench.
Check that the pointer clearly indicates zero before using a plate-spring-type or a bar spring-type
torque wrench.
Select a socket which just fits to the bolt or a nut and engage them. When using a torque wrench,
hold the socket joint with one hand so that the socket and the torque wrench are not separated.
Hold the handle of the torque wrench and pull it toward you to apply force.
Pull the handle in the right direction against the arm of a wrench.
Be sure that the pivot handle and the plate spring will not contact each other when you measure
the torque with a torque wrench. If they contact, you cannot measure the torque correctly.
2-1
MEASURING TOOLS
24 : Vernier calipers
(Function)
You can measure length, outer diameter, inner diameter and depth easily with vernier calipers.
When you do the maintenance work of automobiles, you use these vernier calipers mainly for
measuring the outer diameter of shaft, the inner diameter of a bush, the height of a valve spring
and the like.
(Scale reading)
Examples of the minimum scales you can read with vernier calipers are 1/10, 1/20, and 1/50 mm.
Let's take as an example the vernier calipers which provide a minimum reading of 1/20mm. As the
illustration shows, the main scale is scaled in millimeters. In the vernier, 19 scales of the main
scale are equally divided into 20. This means that one scale of the vernier is 19/20mm (0.95mm)
and the difference of one scale between the main scale and the vernier is 1mm - 19/20 (0.95mm)
= 1/20 (0.05mm). By using this principle, you can read 1/20mm.
When a work is measured, the scale reads as is shown in the illustration. In this case, the value by
the unit of millimeters is read by the main scale, and the fraction is read by the vernier where the
main scale and the vernier meet. In the illustration, the reading on the main scale is 46, and the
scale 4 of the vernier meets a scale on the main scale. Here, the value 4 of the vernier means
0.4mm. So the total reading is 46mm + 0.4mm = 46.4mm. If the vernier is divided into 20, the
fraction can be found by multiplying 0.05 to the value of the vernier where both scales meet.
You must read the scale in a right angle against the vernier calipers. If you read from the wrong
angle, an error will arise due to the thickness of the vernier.
2-2
MEASURING TOOLS
(Important points)
The measuring surfaces of vernier calipers and the measured surfaces of a work must be always
kept clean to obtain a correct value with vernier calipers.
Before using, check that the vernier calipers move smoothly, that the zero lines of both the main
scale and the vernier exactly meet, and that the outer diameter measuring surfaces and the inner
diameter measuring surfaces contact respectively in parallel without any gap. Existence of a gap
between the measuring surfaces causes errors. Correct use of vernier calipers prevents such
distortion. Misuse or neglegence of maintenance leads to earlier occurrence of distortion, resulting
in incorrect measuring. Application of unnecessarily large measuring force must be avoided.
Measuring surfaces can be protected if the vernier calipers are kept after use with both of the
measuring surfaces locked with a gap clearance between them.
(Measuring of outer diameter)

*Basic way of holding vernier calipers
Let the measuring surface of the jaw of the main scale contact the work, set your thumb on the
knob of the vernier, and hold the work with measuring surface of the jaw of the vernier.
*Use the roots of the jaws for measurement.

Use of the tips of the jaws will bend the vernier as shown in the illustration, causing incorrect
measuring. Application of an unnecessarily large measuring force also causes such bending even
if the work is measured at the roots of the jaws. So, the measuring force (the force applied by your
thumb) is another important factor.
*Vernier calipers and work are to be in a right angle.

This is the basic for measuring. If the work is not placed in right angle, rocking the calipers slightly
in the horizontal direction with your thumb and pressing the vernier lightly will advance the vernier
slightly, making the measuring surfaces contact (in right angle) closely to the work.
2-3
MEASURING TOOLS
*How to measure a large work

A large work is measured at its end surface, and the trick to this is to make the main scale contact
the end surface of the work. In this way, bending of the vernier calipers is avoided and correct
measurement can be obtained.
(Measuring of inner diameter)

Insert the bills of the vernier calipers into the work, and make the measuring surfaces contact the
inside of the work by pulling the vernier slightly with your thumb set on the knob of the vernier.
*Correct way of applying the bills
Insert the bills as deeply as possible, but not deeper than the relief of the bills. Moving the calipers
slightly in longitudinal and lateral directions by pulling the vernier lightly with your thumb set on the
knob of the vernier will open the vernier slightly, enabling the work to contact the measuring
surfaces closely.
If the bills are inserted too shallowly, the whole body of the vernier calipers tends to fall as shown
in the illustration. Application of unnecessarily large measuring force is likely to cause distortion to
the vernier.
2-4
MEASURING TOOLS
*How to measure a round hole
A round hole (inner diameter) is to be measured at the largest diameter. The largest diameter can
be found easily by pulling the vernier slightly and moving the calipers slightly as shown by the
arrows.
*How to measure a square hole

A square hole is to be measured, contrary to a round hole, at the shortest distance or the place
where the largest reaction is felt. The shortest distance can be found using the following
procedure. Let the measuring surface of the bill of the main scale contact the measuring surface of
the square hole lightly, and then stop it. Then, set your thumb on the knob of the vernier, and move
the bill of the vernier slightly while pulling it lightly as shown by the arrows. The trick is to narrow
down the width to move the bill gradually.
(How to measure depth)

Apply the datum surface of the depth measuring end closely to the datum surface of the depth
(length) of the work and slide the vernier till the tip of the depth bar contacts the bottom.
Application of an unnecessarily large measuring force causes the floating of the main scale or the
distortion of the datum surface, and in the case of a deep hole, the depth bar may be deflected as
shown in the illustration, making correct measurement impossible.
In case the depth cannot be measured directly. If the depth bar cannot be applied directly due to
the taper provided at the inner surface of the work, use a square object such as a square bar
which can be used as a datum, and then subtract the thickness of the square object from the
actually measured value.
2-5
MEASURING TOOLS
*How to measure a small hole
The datum surface of the depth measuring end is to be bridged across the hole. It is important to
make both datum surfaces contact closely. Correct value cannot be obtained if one side is floating.
*How to measure a large hole

The trick is to contact the depth bar tightly to the inner surface of the work to be measured as
shown in (a) and (b). After it is machined, the R (curvature) will remain more or less at the corner.
Correct value cannot be obtained by the method shown in (c) since the corner of the depth bar
contacts the R. It is important to make the relief of the depth bar face the R as shown in (b). A
slanted datum surface shown in (d) will cause the error of at least 0.1mm to 0.2mm.
25 : Micrometer
(Function)
A micrometer is used mainly for measuring outer diameter or length. The minimum reading of an
ordinary one is 0.01mm.
A standard gauge is used to inspect the scale error.
2-6
MEASURING TOOLS
(Prior inspection)
1) Loosen the clamp.
2) Wipe the whole body with a waste cloth. Pay special attention
so that the measuring surfaces are free from dust and the like.
3) Check the turning condition of the spindle by holding and
turning the ratchet stopper.
4) Close the space between the measuring surfaces until the
ratchet stopper turns idly (ticking sound) and confirm the zero
point.
(Hold a work.)
1) Put the work in a stable position.
2) Hold the frame with your left hand and turn the thimble to open
the measuring space a little wider than the work.
3) Place the work in the space between the measuring surfaces,
turn the ratchet stopper with the thumb and the point finger of
your right hand and hold the work between the anvil and the
spindle.
4) Press the work until the ratchet stopper turns idly (ticking
sound) two or three times.
(How to read the scale)
1) The scale is to be read with the work held.
2) In order to measure the work which is located at a place where the scale is hard to read, clamp
and fix the spindle, and remove the micrometer gently from the work to read the scale.
3) Read the scale on the sleeve at the end of the thimble for the value of the unit of 0.5mm. Then,
read the scale on the circumference of the thimble for the value of the unit of 0.01mm at the point
where the circumference scale on the thimble meets the horizontal line of the sleeve.
[Example]
The reading on the sleeve at the end of the thimble = 7.5mm

The reading on the circumference of the thimble = 0.24mm
Measured value = 7.5mm + 0.24mm = 7.74mm
(Maintenance after use)
Lock this micrometer with the clamp with the anvil and spindle kept apart a little, and keep it in the
case. That way, deviation of the scale, which may occur due to thermal expansion by a
temperature rise, etc. if the anvil and the spindle are kept in close contact, can be avoided.
2-7
MEASURING TOOLS
26 : Dial gauge
(Function)
A dial gauge is used to measure a bend or a runout of a shaft, parallelism or surface roughness.
A dial gauge is so constructed that the axial movement of a spindle (probe) is converted into rotary
motion of the pointer by means of gears.
A dial gauge is scaled in 1/100mm. Movement of 1mm of the spindle causes one revolution of the
pointer.
The magnetic base of the dial gauge can be fixed to a surface plate by means of a magnet.
2-8
MEASURING TOOLS
(Important hints)
(When measuring a flat plane, the spindle is to be set in right angle against that plane.)
The spindle is to be set in a right angle against
the work surface when seen from either the
front or the side as shown in (a). The beam of
the stand is to be as short as possible. The
angle between the beam and the dial gauge is
to be as close as possible to 90.
If the spindle is inclined as shown in (b), the
spindle will not move in the axial direction
precisely, but if pulled sideways, this will cause
the unstableness of the pointer, resulting in
incorrect measuring.
Even if the spindle is in a right angle against the
work, and if the beam is too long as shown in (c)
or (d), the dial gauge is liable to vibrate, which
causes incorrect measuring.
Scale is to be read from the very front of the dial
gauge. Reading from a wrong angle causes
incorrect reading.
After the dial gauge is set to the work, the
pointer is to be set to zero by turning the outer
ring. Then, hold the spindle with your fingers,
and move it lightly several times to check that
the pointer always returns to zero of the scale.
A dial gauge is a precision machine like a
watch. Handle one with care so as not to drop it
or give it a shock.
The area between the spindle and the stem is to
be kept free from oil or grease. Oil or dust
between them causes rough movement of the
spindle.
2-9
MEASURING TOOLS
(How to measure)
* Example: To measure a runout of a crankshaft
Place V blocks on the surface plate as shown in the illustration and set the shaft on the V blocks.
Set the dial gauge fixed to the stand with caution so that the spindle will contact the uppermost
surface of the journal and fix the stand to the surface plate by applying the magnet. Fix the dial
gauge at the height where the dial gauge is pushed to about half of the full stroke of the spindle.
Use caution so that the spindle will be in a right angle against the journal surface.
Turn the crankshaft slowly and find the surface where the pointer points to the smallest reading.
Then turn the outer ring to set the zero point to the pointer.
Turn the crankshaft slowly and read the gauge pointer to find the runout.
27 : Bore gauge (cylinder gauge)

A cylinder gauge is used, combined with a dial gauge, to
measure the exact inner diameter of a part such as the inner
diameter of a cylinder bore.
When you install the dial gauge into the cylinder gauge
proper, loosen the fixing screw and set them in the state with
the spindle pushed at least 0.3mm (0.012inches) to avoid
the incorrect measuring caused by the backlash of the dial
gauge, and fix them securely with a fixing screw. About one
turn (1mm) of the pointer of the dial gauge is the
approximate target of the ordinary pushing of the spindle.
The spindle can be moved freely and the full stroke of the
spindle is about 2mm.
The nominal dimension of the cylinder gauge is shown by
the length from the tip of the anvil to the tip where the spindle
is pushed for measurement.
The dial gauge is to be set vertically, and the dial surface of
the gauge is to be parallel with the spindle.
Setting up (Establishment of dimension)
Measure the inner diameter of the work with vernier calipers
beforehand.
Select a replacement rod and a replacement washer
according to the specified dimension and install them
securely to the main body.
Use the replacement rod for the major change and the
replacement washer for the minor change of the range to be
measured. In order to prevent measuring error, the minimum
number of replacement washers and rods attached to every
bore gauge are to be used. For example, to establish a
dimension of 3mm by the replacement washers, use one
replacement washer of 3mm and avoid combined use of
replacement washers of 2mm and 1mm.
2 - 10
MEASURING TOOLS
(How to measure)
Be sure to conduct zero adjustment before measurement.
Be sure to conduct zero adjustment when the range to be
measured is changed by changing a washer and so forth.
1) Measure the inner diameter of the work with vernier
calipers. In accordance with the measured value, select a
replacement rod and a replacement washer properly and
install them to the cylinder gauge. If the diameter is 73mm,
install the replacement rod of 70mm and the replacement
washer of 3mm.
2) Set the micrometer at 73mm and set the replacement rod
and the spindle of the cylinder gauge to the micrometer.
Turn the outer ring to set the zero point.
3) Insert the cylinder gauge into the work in a diagonal
direction. Fix the measuring point side to prevent shaking
and move the alternative rod side in every direction to find
out the smallest reading of the dial gauge. If the reading of
the dial gauge is 0.03mm, it means that the diameter is
0.03mm shorter than 73mm, which was set on the
micrometer. So, the inner diameter of the work is 72.97mm.
(73.00 - 0.03mm)
28 : Plasti-gauge
A plasti-gauge is generally used to measure the oil clearance between crank pin and bearing.
A plasti-gauge is made of plastic. It is shaped like a filament with uniform thickness and is kept in
a paper envelope.
2 - 11
MEASURING TOOLS
(How to measure)
The measuring of oil clearance between the crank pin and the connecting rod bearing by means of
plasti-gauge is to be conducted as follows.
1) Wipe off oil and dust on the surface of your hands, each crank pin and bearing.
2) Cut and open the corner of the paper envelope of the plasti-gauge, take out the plasti-gauge with
care, cut it a little shorter than the width of the bearing and place it in the axial direction of the
crankshaft, avoiding the oil hole.
3) Set the bearing cap with the plasti-gauge left as it is and tighten the cap with a specified torque.
Note : Never turn the crankshaft after the plasti-gauge is set.
4) Remove the bearing cap and measure the width of the flattened plasti-gauge with the scale
provided on the plasti-gauge envelope. If the width of the plasti-gauge is not even, measure the
widest area.
(Matter of importance)
The measurable range of clearance is indicated on the plasti-gauge envelope. Select the plastigauge of the proper size in reference to the indication together with the values specified in the
service manual.
2 - 12
MEASURING TOOLS
29 : Thickness gauge
A thickness gauge is widely known as a feeler gauge and is used to measure the clearance
between two parts. It consists of thin steel sheets of various thickness with the accuracy of 1/100
(0.01)mm. The thickness normally range from 0.03 to 1.0mm, and the sheet thickness dimension
is indicated on each sheet.
Wipe cleanly the gauge and the part to be measured before measuring. Attachment of oil or dust
causes measuring error.
The thickness of the thickness gauge is not necessarily increased at the increment of 0.01mm. If
one sheet is not enough for measuring, a combination of two or more sheets is required. Here,
adjust the combination so that the minimum number of sheets is selected to minimize the
measuring error.
Pay attention not to bend or cause damage to the tip of the sheet when the thickness gauge is
inserted into the clearance between two parts.
(How to measure)
Insert the gauge carefully into the clearance between two parts. If the gauge can be easily pulled
out, select a thicker gauge (or combination of plural gauges) until you feel a resistance for pulling
it (or them) out. The thickness of gauge (or gauges) is the same as the dimension of the
clearance.
30 : Surface plate
(Function)
The surface plates are divided into the box type surface plate which is made of cast iron and is
used for inspecting the existence of warpage or distortion of the work, and the sheet metal working
surface plate which is used for sheet metal work. The figure shows an example of the box type
surface plate made of cast iron. The surface of this surface plate is precisely finished by a fitting
process after machining. This is used for the centering of works, precise inspection of distortion,
warpage, etc. of works, and fitting, etc.
2 - 13
MEASURING TOOLS
(How to use the box type surface plate)
It is important that the surface of the surface plate is precisely planed and free from flaws,
distortion and rust. When using the surface plate, pay attention not to damage the surface, and
use it only after cleaning.
On the surface plate, never do such wrong works as to use a center punch on the sheet metal, or
to use the surface plate in place of an anvil, etc. Also, it is necessary to keep the surface plate
from rust by applying oil after use.
31 : V block
(Function)
The V blocks are used in combination with the surface plate. A set of two blocks of the same size,
in general, are used to hold a work, keep the vertical state of a work, hold a cylindrical work
horizontally, and so on.
Most of the V blocks are made of cast iron with a 90-angled groove on the upper side of them.
The bottom surface, side surfaces and groove of the V block are precisely finished. The corners
are also finished precisely. Therefore, use the V blocks with care. It is necessary to apply oil after
use to avoid the generation of rust.
(How to use)
The V blocks are essential for measuring roundness as shown in (a) and for measuring
straightness as shown in (b), and enable you to measure bend and runout of a shaft in the
condition shown in (c).
2 - 14
3S POLICY
3S
Three steps to shape up the shop floor
First, let me ask you three questions.
Q1. On your shop floor, are all the tools kept at a fixed place close to you? If the place is not fixed,
you have to look for them or ask somebody the whereabouts of tools every time you want to use
them. It's troublesome, isn't it? You can't do your job effectively, can you? If you can't do your job
effectively, this means that you cannot make much money. What shall we do? Isn't there
something we can do to correct this problem? Let's think about it.
Q2. Even if the place is fixed on your shop floor, everything may be mixed up there, the tools you
always use, those you seldom use, those you don't need any longer and the like, right? If so,
what is the situation like?
It's troublesome to take out the necessary tool, isn't it? Sometimes, the tool you need may be
placed behind unnecessary tools, and then, you have to look for it.
Or, you may hit it against an unnecessary tool and break it. It's disgusting, isn't it?
If unnecessary articles are kept with necessary articles, they may take up the space needed for
necessary articles. What shall we do? Let's think about it together.
3-1
3S POLICY
Q3. Don't you sometimes stare at your face reflected on a mirror? If you look grouchy, you will be
depressed. If it's dirty, what would you do? Your shop floor is the same as your face reflected on
the mirror. What do you think we ought to do? Let's think about it. Together with your pals.
The guidance for them is 3S.
What is 3S?
This is the 3S program.
Step - 1 SEIRI -----
Clearing up
Step - 2 SEITON ---- Organizing

Step - 3 SEISO ----- Cleaning
Here, the S is the initial letter of 3 S's or Step - 1, 2 and 3, and at the same time, that of Japanese SEIRI
(Clearing up), SEITON (Organizing) and SEISO (Cleaning). Now, let's study together how to introduce
this 3S into your precious shopfloor where you earn your money. There are many activities you can
carry out willingly all by yourself in this 3S program. If you can't do it alone, consult your co - workers or
your boss about it. By doing so, you can do your job safely, willingly and effectively, your customers will
be satisfied with your good job, and you will have a bright future.
3-2
3S POLICY
STEP - 1
CLEARING UP
[What can we get rid of?]
Clearing up means to group articles into necessary ones and unnecessary ones. This grouping is kind
of complicated. We tend to think that some day we may need those articles we grouped as unnecessary.
So, first of all, we have to group the articles according to the frequency of use. Here's the suggestion.
First, let's group the articles roughly into four groups.
The suggestion of the proper clearing up
Articles you don't need
Articles you never use
Articles you use once or so in a period

ranging from half a year to one year
Articles you seldom use
Articles you don't use even once a year
Articles you use once or more in a month

Articles you use once or so in a period
ranging from two months to half a year
Articles you sometimes use
Articles you always use

Articles you use once every day
Articles you often use
Articles you use once a week

* If you apply every article with a specific mark, it would help you do your job more smoothly.
3-3
3S POLICY
Now, let me give you a concrete example of how to find unnecessary articles
and so forth.
* Tool boxes, drawers and lockers
If the tools such as hammers, wrenches and cutting
tools which somebody brought are kept.
If the measuring tools such as micrometers, vernier
calipers and dial gauges are left broken.
If the consumables such as dirty waste cloth, cotton
gloves and oil exist among the tools.
If the space is occupies with personal belongings
such as magazines.
If defective tools exist.
* Floor
If equipment, large jigs, dollies and the like which
you don't use or which cannot be used are placed.
If replacement parts are piled up, trash is scattered
or oil is splashed.
If empty boxes of parts or unnecessary tools are left
in a mess.
If parts or devices are left in a mess in the corners or
by the walls of the shop floor or the room.
If oil or gasoline is left.
* Parts warehouse and materials warehouse
If parts or materials which have not been used for
the past several years are left. (These articles can be identified by their extent of dirtiness.)
If there is a heap of replaced parts which are being stored just for future possible convenience. As
the result of this, if the storage is so messed up that nobody knows what articles are stored where.
* Outdoors
If parts or raw materials which have not been used for the past several years are left as they are.
(These articles can be identified by the extent of rust on them.)
If dollies, pallets and containers are left as they are.
* Offices and a resting room
If unnecessary documents are kept in the cabinet and the locker, or on the rack and the like.
3-4
3S POLICY
STEP - 2
ORGANIZING
[Functional storage]
After selecting necessary tools by clearing up determine the layout to show where to place the correct
number of tools. This is "organizing". The trick for doing this is shown below.
The suggestion of the proper organizing

Articles you never use
to be discarded.
Articles you seldom use
to be placed at a distant place.
Articles you sometimes use
to be placed together at one place on

the shop floor.
Articles you often use
to be placed within the working area

or to be kept by operators.
After determining the proper placement of tools, the next important matter is to know how quickly you
can fetch the necessary things. By determining this, the quantity of things to be kept will also be
determined.
Things to be fetched quickly
Only a necessary minimum of them are to be kept.
Things which take time to fetch Excess number of them are to be kept.
In order to organize your workshop in good order, it is important, at first, to mark the aisle lines and
demarcation lines distinctly. As a rule, articles are to be placed on the floor in a straight line, at a right
angle, vertically or in parallel. Of course, all the articles are primarily to be so arranged as to enhance
workability. A variety of efforts is required to make clear the visual whereabouts of articles. Tool racks
and tool benches must be so designed that the tools are easily taken out from and stored in. At the
same time, various types of identification must be clearly indicated.
3-5
3S POLICY
Now, let us see some actual examples of the ways we can organize our shop
floor neatly.
1. Remove unneeded articles.
2. Reorganize the storage area.

Rearrange the surplus space, racks and cabinets. This can be done by discarding unneeded articles.
If necessary, add a few racks or the like to rearrange the storage area.
3. Assign the storage space.

Determine the most convenient and most practical rules.
Have a meeting with everybody involved. Never try to determine the rules by yourself.
Place the frequently used tools close to you, at a
height between your shoulder and elbow.
Place those which are seldom used in the back
of a rack or in a different place.
Place heavy tools on the lowest tier of a rack.
4. Indication of the storage area

Assign indication codes to each storage area so that everybody can understand what is stored in
a certain area.
For example, you may be confused if no
room numbers are given to rooms in a hotel.
So, provide indication codes such as 1, 2, 3,
--- or A, B, C, --- to the storage areas.
Next, indicate the names of all articles to be
stored. For example, indicate the names of
the articles on the rack so that everybody can
understand what is to be placed there. Thus,
even when a tool used by a person is to be
returned to a rack by another person, the
latter person can easily find the right storing
place.
3-6
3S POLICY
5. Indication on an article itself
In short, a name tag is to be attached to each article.
By doing this, even a newly hired person, who is not familiar with the shop floor yet, can surely
return a tool to the exact spot by comparing the name tag and the indication on the rack, etc.
6. Other ideas
Use marks and classifications by coloring so that the state of "organizing" is noticed at a glance.
* Clearly distinguish the aisle from the working area.
Demarcation of the aisle, working area and

storage area
The principles for demarcation lines are also "in parallel" and "in right angle".
* The farther you can look out across the shop floor, the better!
3-7
3S POLICY
Determination of the storage area
* Place the most frequently used tools close to you at the height of your elbow!
* Place those which are seldom used in a distant place and control them collectively!
* Tools:
Before use "Tools can be taken out quickly whenever necessary" as a matter of course.
After use Importance is the fact that "tools can be returned quickly to the fixed position"
* The principles for placing articles on the floor are "in parallel" and "at a right angle"!
3-8
3S POLICY
* Indication of the parts storage area (Combined use of parts identification is desirable.)
* Storage of tools and instruments
Let's look into the inside of the locker, document cabinet, and desk.
* Aren't the papers of several years ago still piled up?
* Aren't there still two or more copies of the same
document?
* Discard the papers which you have not looked at for several months.
* Discard the documents whose storage period is expired.
3-9
3S POLICY
Proper arrangement of files
* Arrange the files of work sheets, drawings, service manuals, and so on in good order by
classifying them with coloring and serial numbers.
Display of check lists and formats

* Provide the check lists such as that for start-up inspection close to the machine.
3 - 10
3S POLICY
STEP - 3
CLEANING
[Creating a Spotless Workshop]
In the army, the guns are always polished so that they are available whenever necessary. In the same
way, if you always clean your shop floor thoroughly, there will be less failure of the precious machines or
tools. This will especially eliminate the failures in the control system, so that you can use it any time you
want to. That is, cleaning means not to just clean the articles but to also clean and maintain by your own
hands, the most important tools of the trade.
By doing this, you will be able to avoid accidents, defects, breakdowns, and so on, caused by
contamination, foreign matters, and so forth.
The best of it is that you yourself can enjoy your life (work) in such a clean, neat and wonderful working
environment.
For the sake of this, you must keep yourself clean. And then the final thing is to practice it. Please repeat
the practice until you acquire it as your habit. Once you make this your habit, it will cause no pain to you
any more. You will be able to practice this easily and even enjoy practicing it.
Cleaning procedures are shown below by dividing them into several items.
* Environmental cleaning-up of shop floor
Demarcation lines of the aisles
Indication of the dolly and parts storage places,
area where placement of articles is prohibited,
and so forth on the floor surface.
Floor markings which indicate the specified
positions of small equipment such as trash
boxes, ashtrays, extinguishers.
Provision of a mat for rubbing off dirt at the
entrance.
* Thorough cleaning
The stepped area on the floor, wall and side
surfaces
The upper surface, inner area and lower side of
machines, equipment, etc.
The upper surfaces of the ceiling, angle bars of
the ceiling, piping, etc.
The upper surfaces of the illuminating lamps and
lamp shades.
The upper and lower surfaces of the racks and
workbenches
Thus, you can detect oil leakage from the
machines and water leakage from the tanks and
pipes, which are overlooked in your daily work
routine.
3 - 11
3S POLICY
* Daily cleaning
Clean the floor surface.
If the floor is always kept clean, even a small part dropped on the floor will be located quite easily. If
the floor becomes clean and shiny, everybody will try to keep the floor clean. You can also with your
customers' confidence.
New idea for efficient cleaning.
Even though cleaning is an important thing to do, cleaning too often and for too long can cause
problems. Think of the most efficient way of cleaning your shop floor, together with your co-workers.
Afterword
I hope you were able to understand well what you have learned regarding the importance of 3S. Please
try the 3S activity, honestly, and step by step, starting with your own working area on your shop floor.
You will be surprised at the effect of this 3S activity. It will renew your shop floor, thus giving it a different
atmosphere. You will surely notice that the waste of looking for something you need and your wasteful
movements are eliminated and that you can do your work more easily, rapidly, precisely, and safely.
Thus, your bright future will be assured.
Please do your best!
3 - 12
Instructor Guide
N-STEP 1
FUND & MATN & TOOL
& EXSE Courses
NISSAN MOTOR CO., LTD
&
tECHNICAL sKILL
Technical Fundamentals
COURSE OUTLINE
Course Name:
Course Duration:
* FUND: Technical Fundamentals

* MATN: Maintenance Skill
* TOOL: Usage of Tools
* EXSE: Express Service
8 days (Depending on the situation of each market)
Type of Training:
* Discussion
* Hands-on workshop activities utilizing training vehicle and
measuring tools.
Tools and Equipment:
General tools, Micrometer, Dial indicator and Vernier caliper

CONSULT or CONSULT-II with latest program software
Multi-meter and Electrical Board set
Timing light and Engine tuner for Gasoline and Diesel
engines)
Flash light, Special Service Tools
OHP (Over Head Projector)
Training Aids:
Worksheet, Textbook and Service Manual

Camshafts, Pistons, Bolts, Clips, Fasteners and Brake pads
Training Vehicles:
Nissan vehicles
* with carburetor engine
* with ECCS engine
* with diesel engine
* with RS5W71C manual transmission
* with automatic transmission
* with electronic controlled automatic transmission
TRAINING COURSE OBJECTIVE

GITN1001B
GITN1002A
GITN1003B
GITN1004B
GITN1005A
GITN1006A
GITN1007B
ECTN1001B
ECTN1002A
ECTN1003B
ELTN1001B
ELTN1002B
ELTN1003B
EMTN1001B
LCTN1001B
BTTN1001B
CLTN1001A
MTTN1001A
ATTN1001/2A
MATN1001B
MATN1002B
ESTN1001B
ESTN1002B
ESTN1003B
ESTN1004B
ESTN1005B
be able to locate necessary information to read wiring diagram in the

Service Manual.
be able to efficiently use the Special Service Tools.
be able to access vehicle specifications, model code and related information in the Service Manual.
be able to use Micro-meter, Dial indicator and Vernier caliper.
understand Engine structure and Component parts names.
understand Drive train structure and Component parts names.
be able to use general tools for sub-work.
understand ECCS component part names and function.
be able to operate CONSULT Self-diagnosis, Work-support and Function test.
be able to operate CONSULT-II overview, Self-diagnosis, Work-support
and Function test.
understand electrical concepts related to Ohms law.
be able to measure voltage and resistance with digital multimeter.
be able to inspect and maintain the battery as an automobile power
source.
be able to adjust Idle speed for Gasoline and Diesel engines.
be able to inspect cooling system.
be able to adjust Hood and Trunk lid alignment.
be able to remove and install Clips and Fasteners.
be able to adjust Clutch pedal height and pedal free play for Manual
transmission/transaxle.
be able to perform external adjustment for RS5W71C.
be able to perform external adjustment of the automatic transaxle/transmission.
be able to perform Periodic maintenance inspection and adjustments
according to the Service Manual.
be able to perform Pre-Delivery Inspection.
be able to change oil, filter and 14-point inspection.
be able to inspect spark plug, engine rpm, adjust ignition timing and
perform 14-point inspection.
be able to inspect cooling system and perform 14-point inspection.
be able to replace tires and inspect brakes.
be able to inspect A/C system.
ESTIMATED TIME
1. GITN1001B/WS1
2. GITN1001B/WS2
3. GITN1001B/WS3
4. GITN1002A
5. GITN1003B/WS1
6. GITN1003A/WS2
7. GITN1005A
F
U
N
D
M
A
T
N
8. GITN1006A
9. ELTN1001A/WS1
10. ELTN1001A/WS2
11. ELTN1001B/WS3
12. ECTN1001A/WS1
13. ECTN1001A/WS2
14. ECTN1001A/WS3
15. ECTN1001B/WS4
16. ECTN1001B/WS5
17. ATTN1001A
18. ATTN1002A
19. BTTN1001A/WS1
20. BTTN1001B/WS2
21. CLTN1001A
22. ELTN1003B
23. EMTN1001A/WS1
24. EMTN1001A/WS2
25. EMTN1001B/WS3
26. EMTN1001B/WS4
27. LCTN1001B
28. MATN1001B
29. MATN1002B
30. MTTN1001A
40 min.
40 min.
40 min.
30 min.
40 min.
20 min.
90 min.
110
min.
45 min.
60 min.
90 min.
60 min.
40 min.
45 min.
30 min.
30 min.
70 min.
70 min.
40 min.
40 min.
50 min.
30 min.
60 min.
60 min.
20 min.
20 min.
60 min.
60 min.
T
O
O
L
E
X
S
E
# These estimated times are not standard time.
31. ELTN1002B
32. GITN1004A/WS1
33. GITN1004A/WS2
34. GITN1004A/WS3
35. GITN1004B/WS4
36. GITN1007B
37. ECTN1002A/WS1
38. ECTN1002A/WS2
39. ECTN1002A/WS3
40. ECTN1002A/WS4
41. ECTN1003B/WS1
42. ECTN1003B/WS2
43. ECTN1003B/WS3
44. ECTN1003B/WS4
45. ESTN1001B
46. ESTN1002B
47. ESTN1003B
48. ESTN1004B
49. ESTN1005B
20 min.
50 min.
60 min.
75 min.
20 min.
30 min.
20 min.
40 min.
60 min.
60 min.
30 min.
30 min.
30 min.
50 min.
30 min.
60 min.
60 min.
60 min.
60 min.
START
GITN1001B
Usage of
Service
Manual
GITN1005A
Outline of
Engine
GITN1002A
Usage of
Special
Service
Tools
GITN1004B
Usage of
Measuring
Tools
GITN1006A
Outline of
Chassis
GITN1003B
General
Model
Introduction
ELTN1002B
Usage of
Digital
Multimeter
ELTN1003B
Handling of
Battery
ECTN1001B
Introduction to
ECCS
ECTN1002A
ECTN1003B
Usage of
CONSULT
& CONSULT-II
CLTN1001A
Clutch
Pedal
Adjustment
MTTN1001A
External
Adjustment
of M/T
ATTN1001A
External
Adjustment
of A/T
ATTN1002A
External
Adjustment
of E-A/T
MATN1001A
Engine Idle
Adjustment
LCTN1001B
Cooling
System
Inspection
BTTN1001B
Body and
Trim
COURSE MAP
ELTN1001B
Basic
Electrical
Concept
MATN1001B
Periodic
Maintenance
MATN1002B
Pre-Delivery
Inspection
ESTN1001BESTN1005B
Express
Service
END
OPENING ACTIVITIES
* Orientation
Ex. Introduce yourself and get trainees to introduce themselves.
Introduce Training Center Policies (If necessary)
* Give the Worksheets and other training materials to the participants.
* Introduce the course
Technical Fundamental and Technical Skill Course
This is an 8 days course (depending on regional situations)
* Review Training Schedule
* Have trainees refer to Worksheets for course procedure. Briefly review the layout/
structure of the Worksheets. The objective is the knowledge that the technician will
gain by completing the Worksheets. Discuss the icons that are used in the Worksheets. The icons are included as guidance for the technicians through the Worksheet activities.
* Course Objectives
Review the course objectives by using OHT (Over Head Transparency)
Have the trainees refer to the objective list in the Worksheet.
n instructor sign-off is required at the end of each Worksheet.
For some Worksheets, there are additional sign-off required at various points during
the carrying out of the Worksheet.
The instructor will sign each technicians Worksheet and course sign-off sheet as a
record of work completed
* Assign groups and Worksheet performance schedule. (Set of Worksheets for each
group.)
* Assign the vehicles or equipment and work station for each Worksheet.
* Start practice
WORKSHOP PREPARATION AND INSTRUCTION POINTS

Listed next are guidelines for setting up the workshop prior to the beginning of training.
Included are vehicles and supplies and additional comments regarding the Worksheets.
You should read these instruction points and preparations before starting the training.
REFERENCES USED IN CONDUCTING TRAINING
Training schedule
FUND, MATN, TOOL and EXSE courses have 54 Worksheets in 27 topics.
Its very difficult to conduct the training course, therefore you have to make Worksheet
sets for efficient training. We would like to suggest to you one example of a Worksheet
set.
Situation: 8 persons/course (2 persons/group x 4 groups)
* GITN1001A Usage of Service Manual
Assign the vehicle. (You can assign one vehicle to each group or just tell them the
vehicle specification.)
All participants can work at the same time.
You should prepare 4 Service Manuals and give one to each group.
* Once the present Worksheet is completed, the next one should be assigned.
Example:
Day 1
Group A
Group B
Group C
Group D
GITN1001A
GITN1001A
GITN1001A
GITN1001A
GITN1005A
GITN1003A
GITN1002A
GITN1006A
GITN1006A
GITN1002A
GITN1003A
GITN1005A
End
6
Example (contd)
Day 2
Group A
Group B
Group C
Group D
GITN1004A
GITN1005A
GITN1005A
GITN1004A
GITN1002A
GITN1006A
GITN1006A
GITN1002A
GITN1003A
GITN1004A
GITN1004A
GITN1003A
End
Thus you do not need prepare many training materials at one time.
You should draw up a set of the Worksheets like the example mentioned above for reference.
Reference:
Work station number plate
Worksheet progress control sheet

Day 1
WORK STATION No.1
Group A
Group B
Group C
Group D
GITN1001A
GITN1001A
GITN1001A
GITN1001A
GITN1005A
GITN1003A
GITN1002A
GITN1005A
GITN1006A
GITN1002A
GITN1003A
GITN1006A
Day 2
GITN1003A
Group A
Group B
Group C
Group D
GITN1004A
GITN1005A
GITN1006A
GITN1004A
GITN1002A
GITN1006A
GITN1005A
GITN1002A
GITN1003A
GITN1004A
GITN1003A
GITN1003A
GITN1001B
Usage of the Service Manual (GITN1001B)
Introduction
These worksheets mainly use new technical terms.
Briefly review the layout of the Service Manual with demonstrations included.
PREPARATION CHECK SHEET
Nissan Vehicle
Applied model Service Manual
Textbook (Already sent?)
Worksheet
Instructor Guide with all the answers
Worksheet number label for the training vehicles
Safety tools, fender covers, seat covers and the like.
HAVE YOU DONE THE FOLLOWING?

*Check and note the correct answer for each question.
Have you labeled worksheet number on the training vehicle?
Classroom layout and work area layout
* You should check and note the correct answer to each question.
Some answers may differ to the vehicle specifications.
Your memo
GITN1001B
INSTRUCTION POINTS AND REFERENCES

This number corresponds to the worksheet task numbers.
GITN1001B/WS1
2. EC (EF&EC)
Some section names of Service Manual change in the new Service Manual.
EX. B14, S14, A32.
Former
New
EF&EC
EC
BF
BT
Body & Trim
None
RS
Restraint System (Air-bag)
10. According to the specification of each vehicle, change the question to the others.
Ex. Fuel Pressure Release, Fuel Pressure Check, etc.
15. Fill in the Engine type, Transmission/axle, type and Final gear ratio which correspond to the assigned vehicle.
18. If the trainees do not know the technical terms changed as shown below, explain
them.
Former
New
Camshaft Position Sensor Crank Angle Sensor
Throttle Sensor
Knock Sensor
Detonation Sensor
Oxygen Sensor
Exhaust Gas Sensor

GITN1001B/WS2
2. EC (EF&EC)
Some section names of Service Manual change in the new Service Manual.
EX. B14, S14, A32.
Former
New
EF&EC
EC
BF
BT
Body & Trim
None
RS
Restraint System (Air-bag)
8. On the Service Manual of B14 & S14, Structure of some sections differs from the
other models. Therefore, this question is not much for these models.
10. According to the specification of each vehicle, change the question to the others.
Ex. Fuel Pressure Release, Fuel Pressure Check, etc.
18. If the trainees do not know the technical terms changed as shown below, explain
them.
Former
Knock Sensor
Oxygen Sensor
New
Crank Angle Sensor
Throttle Sensor
Detonation Sensor
Exhaust Gas Sensor
10
GITN1001B/WS2

GITN1001B/WS3
6. [Reference]
To open this software,Acrobat Reader, is required to be installed in PC.
13-17.
Instruct usage of each toools for screen size change, page zooming, and page
scrolling.
11
GITN1002A
Usage of Special Service Tools (GITN1002A)
Nissan Vehicle
Worksheet

Have you labeled worksheet number on the training vehicle?
Worksheet number for the training vehicle
Your memo
12
GITN1002A
Reference:
7. Several types of engine attachments are used for Nissan vehicle engines. Some
engines require both attachment and sub-attachment, some engines require only
sub-attachment.
If you do not use NISSAN ALTIA (NISSALCO) type engine stand, you can skip this
question.
8. Some engines do not require the SST. (Use socket wrench)
9. Some engines do not require the seal cutter. You can skip this question when you
are assigned that.
13. This question is to ask what job is required.
Example of answers
1) Removing and installing 1st gear bushing.
2) Removing main drive gear bearing.
3) Measuring wear of baulk rings.
17. It is necessary to securely tighten brake connections as it is dangerous if brake fluid
leaks. (For safety reasons. a Special Service Tool (SST) specifically for this purpose
is adopted so that customers can not carry out servicing.)
13
GITN1003B
General Model Introduction (GITN1003B)
Nissan Vehicle
Worksheet
Flash light (Electric torch)

Your memo
14
GITN1003B
GITN1003B/WS1
3. Note the difference between Vehicle Identification Number and Model Variation
Number. Refer to the Service Manual and Identification Plate.
5. Example of answers
SR series engine, 2 liter, Double Over Head Camshaft and ECCS engine.
4. - 6.
If you do not handle these units, you can answer the questions with Textbook.
GITN1003A/WS2
2. Removing the positive terminal first may read to a short circuit between tools and
the body.
3. This answer will vary depending on your actual workshop job.
7. 11.
Towing speed and distance for 4WD vehicle are the same as those for automatic
transmission/axle vehicle.
15
GITN1005A
Outline of Engine (GITN1005A)

Nissan vehicle
Worksheet
Engine cut-way model (If available)
Disassembled carburetor
Variation of air elements (Viscous type and Dry paper type), if available
Safety tools, fender covers, seat covers and the like

Prepare the disassembled carburetor.
Worksheet number label for the training vehicle
Your memo
16
GITN1005A
1. Show trainees the engine cut-way model, if available. (Display it in the classroom.)
2-C.
The piston is moved in a reciprocating motion within the cylinder by combustion
energy. Then, this motion converts to a rotational motion to the crankshaft via the
connecting rod.
3. Give them a question
Which stroke is the better position for adjusting valve clearance?
Answer: Top Dead Center --- Compression stroke.
(Exhaust and Intake valves must be fully closed.)
11. Show them the real air filter. (Display it in the classroom.)
Give them a question
Which element can be cleaned up with compressed air?
Answer: Dry paper type
12. Give them a question
What is the ideal air-fuel ratio?
Answer: 15 (14.7) : 1
Reference: CO gas density is 0.5 to 1.0% at the ideal air-fuel ratio.
14. Show them a disassembled carburetor for identification of component parts.
Throttle adjusting screw, Idle adjusting screw, Float Air float, Main jet, Acceleration
pump and the like.
16. Reference:
Layout of valves
OHV type gasoline engine
OHC type gasoline engine
Name of engine series

A, J, P, Y and TB
L, CA, Z, KA, MA, E, GA, VG, RB and NA
CA, CG, GA, QG, SR, KA, VG, RB, VH, VQ, QG
DOHC type gasoline engine
and QR
OHV type diesel engine
BD, SD, ED, FD and TD
OHC type diesel engine
CD, LD, and RD
DOHC type diesel engine
YD and ZD
17
GITN1006A
Outline of Chassis (GITN1006A)
Nissan vehicle
Worksheet
Disassembled differential gear carrier

Your memo
18
GITN1006A
3. Reference:
* Engine power flow (FR type with Manual transmission)
Engine --- Clutch --- Transmission --- Propeller shaft --- Differential gear --- Drive
shaft --- Tire
* Engine power flow (FF type with Manual transaxle)
Engine --- Clutch --- Transaxle --- Differential gear --- Drive shaft --- Tire
8. Show trainees disassembled differential gear carrier.
Side gear, Pinion mate gear, Ring gear and the like.
19
ELTN1001B
Basic Electrical Concept (ELTN1001B)
Nissan vehicle
Worksheet
Multi-meter (Analog type)
Electric circuit board or the like (including voltmeter and Ammeter)

Your memo
20
ELTN1001B
Classroom activity
Explain to trainees the following
1) Ohms law V = I x R
* If voltage stays constant and circuit resistance increases, current flow will
decrease.
(Refer to the Textbook)
2) Total resistance of Series connected and Parallel connected circuit.
Series connected:
R1 + R2 = R3
10 + 10 = 20
Parallel connected: 1/(1/R1 + 1/R2) = R3 1/(1/10 + 1/10) = 1/(1/5) = 5
* R means resistance
3) Electric Units
Voltage = V
Current = A
Resistance =
1kV = 1,000V, 1V = 1,000mV

1kA = 1,000A, 1A = 1,000mA
1M = 1,000k, 1k = 1,000
4) Diode: Direction of current flow

5) Precautions for Multimeter handling
Refer to the Textbook
ELTN1001A/WS1
5. The over 15-volts range should be selected for testing vehicle electrical system.
ELTN1001A/WS2
* The main goal of this Worksheet is for Trainees to learn Ohms Law
ELTN1001B/WS3
* This Worksheet is explanation for the new type Service Manual.
21
ECTN1001B
Introduction to ECCS (ECTN1001B)
Nissan vehicle with ECCS WS4.5 (QG Engine)
ECCS component parts (Mass Air Flow Sensor, Hot wire type and Hot film
type)
General tools, Timing light and Engine tuner
Worksheet
Transparency sheets

Adjust the engine idle speed over 1,000 rpm
Adjust the ignition timing so it is out of specification
Put on the number label on each component parts. (for task No.7)
Familiarize yourself with ECCS in case an explanation is required.
Your memo
22
ECTN1001B
INSTRUCTION POINTS AND REFEENCES
Classroom activity
* Explain to trainees the three major flows
Air flow: Air cleaner --- Mass air flow sensor --- Throttle position switch --- AAC
valve (includes FICD solenoid) --- Air regulator
Fuel flow: Fuel pump --- Fuel damper --- Fuel filter --- Fuel pressure regulator --Fuel injector
Electrical flow: engine coolant temperature sensor, Camshaft position sensor, Oxygen sensor, Knock sensor (If available)
* Briefly explain to them the function of component parts.
* Explain to them the difference between Sensor and Actuator.
* Explain to them the difference between REF and POS signal.
* Show them changed technical terms.
ECTN1001A/WS1
7. You can delete 7) Air regulator when you use vehicle with new EGI.
Generally the Air regulator is not visible. You should number the Air regulator with a
label on a string.
13. Show them Hot wire type and Hot film type of Mass air flow sensors
14. - 15.
You can delete these tasks when you see vehicle without distributor type Camshaft
position sensor.
ECTN1001A/WS2
* Demonstrate to them how to perform on-board diagnostic test by using CONSULT
data link connector. (Also how to switch modes when they take too much time.)
* You should remove some connectors. Ex. Engine coolant temperature
ECTN1001A/WS3
* This worksheet is used to adjust the idle speed and the ignition timing without CONSULT.
* Demonstrate to them how to adjust the idle speed and the ignition timing when they
take too much time.
ECTN1001B/WS4
* Make your trainees ensure the location of each component parts by using actual
vehicle.
ECTN1001B/WS5
* Male your trainees understand the reading and meaning of DTC code.
* Make your trainees understand how to erase DTC code.
CAUTION:
* Stop engine when you remove the Camshaft position sensor fixing bolts or
nuts.
23
ATTN1001A
External Adjustment of A/T (ATTN1001A)
Nissan vehicle with FF type automatic transaxle
General tools and insert pin (4 mm diameter)
Grease
Disassembled differential gear carrier
Worksheet number label for training vehicle

Introduce some problems in inhibitor switch adjustment and control cable
adjustment
Introduce a problem in throttle wire adjustment
Have you labeled station number on the vehicle?
Your memo
24
ATTN1001A
1. See if the correct page is open.
Check the correct answers beforehand for followings;
No. 5, 6, 8, 10, 13, 19, 20, 22, 26, 28, 29, 30, 31 and 32.
15. and 18.
See if the correct page is open. If not, advise them.
25
ATTN1002A
Nissan vehicle with FR type automatic transaxle
General tools and insert pin (4 mm diameter)

Introduce some problems in inhibitor switch adjustment.
Introduce a problem in manual control linkage adjustment
Your memo
26
ATTN1002A
Check the correct answers beforehand for followings;
No. 5, 6, 14 and 22.
2, 9 and 17.
See if the correct page is open. If not, advise them.
27
BTTN1001A/WS1
Body & Trim Adjustment (BTTN1001A/WS1)
Nissan vehicle
General tools
Worksheet

Introduce stepping (Hood and Fender)
Introduce stepping (Trunk lid and Rear fenders)
Your memo
28
BTTN1001A/WS1
Tell them how to find the page if necessary.
3. 3 through 9, observe the participant and advise them not to damage the body paint
and the like.
29
BTTN1001B/WS2
Body & Trim Adjustment (BTTN1001B/WS2)
Nissan vehicle
General tools
Worksheet
Some clips, fasteners and practice board

Prepare flash light (Electric torch)
Your memo
30
BTTN1001B/WS2
Reference:
Advise them if necessary.
3. to 5. Check the correct answer beforehand
8. Check correct answer beforehand
13. Check the correct answer beforehand
20.and 21. Check the correct answer beforehand
23. Some illustration in the Service Manual are not indicate clip and fastener location
for all.
* Check and fill in the correct answer beforehand.
* Never scratch parts when you remove clip and/or fastener. You should use suitable tool
with cloth.
31
CLTN1001A
Clutch Adjustment (CLTN1001A)
Nissan vehicle with manual transmission / axle
Ruler
General tools

Change the clutch pedal height
Change the withdrawal lever play.
Your memo
32
CLTN1001A
4. Check the correct answer beforehand.
7. See if they are on the right course to No. 7 or No.12.
Check the correct answer beforehand.
12.See if they are on the right course to No. 7 or No.12.
Check the correct answer beforehand.
[REFERENCE]
Sometimes abnormal wear of release bearing or clutch cable sticking causes problems with withdrawal lever play and clutch pedal free travel distance even though
they have been correctly adjusted.
33
ELTN1003B

Nissan vehicle
Safety glasses
Safety glove
Hydrometer
Timing light

Check and note the correct answer for each question.
Have you labeled worksheet number on the trainining vehicle?
Classroom layout and work area layout.
Your memo
34
ELTN1003B
Reference:
1. Normal battery requires battery fluid check. Do not add additional fluid to maintenance-free battery.
2. Battery fluid is highly corrosive. If it adheres to body, clothes, or vehicle body, thoroughly flush with water.
3. Battery service life is normally about 2 to 4 years. It differs greatly depending on
operating conditions.
4. Battery fluid specific gravity shall be measured accurately with fluid temperature
being 20C as the reference. If liquid temperature is higher than 20C, add 0.0007
every 1C. If it is lower, subtract 0.0007 every 1C.
5. Battery standard value
Specific gravity (at 20C) Normal: 1.22 to 1.29
Charge needed: 1.22 or less
Difference of each cell: Within 0.03
35
EMTN1001A/WS1
Engine idle adjustment (EMTN1001B/WS1)
Nissan vehicle with carburetor engine without catalyzer.
Engine tuner
CO meter (if available)
General tools
Timing light

Set the idle speed more than 1,000 rpm with idle adjusting screw and throttle
adjusting screw after warm-up.
Set ignition timing out of specification.
Your memo
36
EMTN1001B/WS1
Advise them when they are taking too much time to find the correct page.
2. See if the engine tune meter is attached correctly.
Must warm trainees when engine
Check if the water temperature is adequate after warming up the engine.
3. Check on their performance.
6. Check idle ignition timing specification beforehand.
8. See if the vacuum hose is disconnected before adjusting.
9. Confirm the answers written on the worksheet to ascertain their understanding.
Use the carburetor on the assigned vehicle if necessary.
10. Check idle speed specification beforehand.
Before number 15
Check idle CO specification and warm up CO meter beforehand.
Ask them if they know how to use the CO meter.
Explain or demonstrate it if they do not know how to use the CO meter.
18. See if the idle compensator vacuum hose is disconnected.
21. Point to the CAUTION written in the Service Manual.
CAUTION
Do not attempt to screw the idle adjusting screw down completely. Doing so could
cause damage to tip, which in turn will tend to cause malfunctions.
23. REFERENCE
Turning the idle adjusting screw clockwise and counterclockwise cause engine
speed to increase and decrease. This is because as the air-fuel mixture becomes
too rich or too lean, stoichiometric efficiency (optimum air-fuel mixture for combustion) is reduce and engine speed drops.
37
EMTN1001A/WS2
Engine idle adjustment (EMTN1001B/WS2)
Nissan vehicle with diesel engine (preferably without cold start devise)
Tachometer for diesel engine
General tools

Set the idle speed to out of specification.
Your memo
38
EMTN1001B/WS2
Advise them when they are taking too much time to find the correct page.
2. and 4.
[Reference]
No clearance cause unstable idle due to the vibration of engine within itself even
though it is only small vibration. (One of the reasons.)
5. Check engine idle speed specification beforehand.
6. Check all the clamps removed.
[Reference]
Tachometer for diesel engine should detect the pulsation of No. 1 fuel tube without
interference from the other.
7. See if the tachometer is attached correctly.
Must warn when it is specifically install in a danger.
9. See if the water temperature is adequate after warming up the engine.
39
LCTN1001B
Engine idle adjustment (LCTN1001B)
Nissan vehicle
General tools
Radiator cap tester
New radiator cap (for demonstrate)
Engine coolant (if necessary)
Temperature gauge, Electrical heater or appropriate equipment

Your memo
40
LCTN1001B
Part 1
Advise them when they are taking too much time to find it.
Book type Service Manual indicated in MA section. Electronic Service Manual indicated in LC section.
Ask the reason. If they do not know, explain reason.
5. Check the coolant capacity beforehand.
Part 2
2. Check the specification of radiator cap relief pressure beforehand.
3. Ask them if they know how to use the radiator cap tester.
If they do not know, explain or demonstrate it with another radiator cap.
5. Check the testing pressure required for cooling system leakage beforehand.
6. Have them read the key points.
Sometimes compressed air escape from the connection of radiator cap tester, so
sure to check it when indicating a leak.
Part 3
* Explain how to read coolant mixture ratio chart to trainees in the crassroom before
excerise.
41
MATN1001B
Periodic Maintenance (MATN1001B)
Nissan vehicle
General tools
Worksheet

Your memo
42
MATN1001B
Reference: You should refer to the Service Manual procedure for all item inspections.
2. See if the correct page is open, if necessary.
3.These answers are for under normal conditions. Refer to the MA section in the Service Manual. The maintenance schedule should be adapted to your own workshop
maintenance schedule.
Engine components:
6. Ask trainees if they know how to use a radiator cap tester. If they do not know,
show them how to use it.
9.You should tell them Nissan vehicle must be used genuine LLC, specially aluminum radiator type engine.
16. 1) Slipping noise will occur when tension force is too low or high.
2) The operation of Water pump/Alternator/Power steering and the like is are
reduced.
20. Pay attention to scale range of multi-meter if you use analog type multi-meter.
30. 1) Unfiltered oil can go through the relief valve into the engine and engine can be
driven though, finally leads to a serious problem.
2) Too much oil will be come aerated by crankshaft rotation and lead to less cooling/lubricating effect.
3) Excessive oil restricts and reduces engine power.
4) Excessive oil pumps up into the combustion chamber.
Under body
34. Task number from 34 to 38. Its better to inspect at same time.
62. The Service Manual says that fluid level should be checked by using HOT and
COLD level, but it is difficult, in this training, to cool down and fluid temperature
every time because each trainee uses the same vehicle. So, in this training, we
use HOT range with engine idling.
43
MATN1002B
Pre-Delivery Inspection (MATN1002B)
Nissan vehicle
General tools
Engine tuner and Timing light
Torque wrench
Tire pressure gauge
Gas leak tester (If available for R12 and R134a)
Appropriate Owners Manual
New Vehicle Handling Manual-G PDI (NV3E-0PDIG0)
Worksheet

Your memo
44
MATN1002B
NOTE: All operations should follow the procedures in the PDI Manual or Service Manual.
Reference:
* Check own PDI checklist, if applicable before hand. Give trainees PDI checklist.
45
MTTN1001A
Manual Transmission (MTTN1001A)
Nissan vehicle, C23 with manual transmission (RS5W71C)
General tools

Change the length of shift cable.
Change the length of select cable.
Your memo
46
MTTN1001A
If not, advise them.
5. Check correct answer beforehand.
9. Note the difference among shift lever, select lever and control lever.
12. [REFERENCE]
If it is hard to shift the control lever to each select position correctly, it normally indicates that the gear control adjustment is wrong.
47
ELTN1002B
Usage of Digital Multimeter (ELTN1002B)
Nissan vehicle with ECCS Engine
Digital Multimeter
Worksheet

Your memo
48
ELTN1002B

Explain to trainees the following.
Generally, switches for vehicle service are as follows.
1) Direct voltage
2) Resistance
3) Continuity
By understanding the three functions above the troubleshooting and repair techniques would be relatively simple.
10. Do not touch the edge part in the lead wire of the Multimeter when measuring the
resistance because human body has a certain amount of resistance, so it would
be impossible to measure the correct resistance if touching the measurement
part with hands.
49
GITN1004B
Usage of Measuring Tools (GITN1004B)
Worksheet
Vernier caliper, Dial indicator and Micrometer set
Pistons, Camshafts, Brake pads, Bolts and some parts to measure the inner
diameter
Surface plate and paper towel

Familiarize yourself with measuring tools in case demonstration is required.
Measure the value of assigned parts size (Diameter, runty, thickness, etc.)
by yourself.
Adjust the zero point to 0.02 mm beforehand.
Your memo
50
GITN1004B
GITN1004A/WS1
8. Demonstrate to trainees when they do not understand how to read the scale.
12. Use the depth rod when measuring Brake pad thickness. (Not standard measuring
procedure --- for use in training only)
14. Prepare a suitable part to measure the inner diameter of;
EX. Bearing, Washer, Pipe or the like.
GITN1003A/WS2
3. Advise trainees when they do not know the terminology.
10. 18.
Demonstrate them how to measure the runout when they take too much time or do
not know how to do it.
15. 16.
Check runout twice.
GITN1004A/WS3
6. 10.
Advise trainees when they can not read scale.
13. Distance a is provided in the Service Manual.
Camshaft journal
Diameter
Camshaft A
Camshaft B
Camshaft C
Camshaft D
Runout
Piston Diameter
Inner Diameter
Diameter
GITN1004B/WS3
* Advice trainees how to read scale and how to adjust torque for limit type torque
wrench.
51
GITN1007B/WS1
Usage of Taps & Dies (GITN1007B/WS1)
Worksheet
Taps and Dies set
Pitch gauge
Oiler

Your memo
52
GITN1007B/WS1
Part 1: Suppliment
1) Demonstrate how to use taps and dies to trainees before practice.
2) The tap should be inserted straight into a hole, otherwise the female hole may
become at a slant which causes malfunction of equipments.
53
ECTN1002A
Usage of CONSULT (ECTN1002A)
CONSULT with appropriate program card and fully charged battery
General tools
Timing light
CONSULT operation manual (ENGINE)

Set the idle speed over 1,000 rpm.
Set ignition timing out of specification.
Your memo
54
ECTN1002A
ECTN1002A/WS1
Check often whether they are performing task correctly.
Provide advice or demonstrate if necessary.
1. Depending on the vehicle specification.
ECTN1002A/WS2
ECTN1002A/WS3
22. Misleading
[Reference]
ECM has MAP and Table. When the throttle position sensor is in the OFF position, it reads the Ignition timing based on the MAP (for normal running conditions).
When the throttle position sensor is in ON position, it reads the ignition timing
based on the Table (for idle ignition timing). That is the reason why we must set to
the ON position.
ECTN1002A/WS4
55
ECTN1003B
Usage of CONSULT-II (ECTN1003B)
CONSULT-II with appropriate program card and fully charged battery
General tools
Timing light
CONSULT-II operation manual (ENGINE)

Set the idle speed over 1,000 rpm.
Set ignition timing out of specification. (If available)
Your memo
56
ECTN1003B
ECTN1003B/WS1
6. and 7. Demonstrate them for prevent damage to battery connector and wire if necessary.
8. Take care of paper up-side down.
ECTN1003B/WS2
ECTN1003B/WS3
ECTN1003B/WS4
57
ESTN1001B
EXPRESS LUB. 30 (ESTN1001B)
Vehicle
Textbook
Worksheet
Safety tools, fender cover, seat cover and the like
Vehicle hoist
Oil filter wrench
Oil drain pan
Drain plug wrench
Tire pressure gauge

Have you labeled worksheet number on the training vehicles?
Your memo
58
ESTN1001B
First, explain safety.
8. Tire pressure may be different depending on tire size, or in front/rear tires. Provide
accurate instruction on how to read the tire pressure label correctly.
15. When installing oil filter, apply oil to sealing rubber and tighten by hand. Otherwise,
sealing rubber may become deformed or damaged and oil seal leak may result.
20.
Do not remove radiator cap rapidly when engine is hot. Oil may spill out.
If oil is mixed with engine coolant, there may be damaged cylinder head gasket.
23. When checking exterior lights by one person, use a mirror or see reflection on wall.
26. When checking engine oil leak, check the following: drain plug, around oil filter, oil
pan mounting area, and around cylinder block
28. When checking A/T fluid level, observe the following: When oil temperature is
between 30C and 50C, adjust fluid level within "COLD" range on oil level gauge.
After that, warm up fluid to 50 - 80C, then check fluid level is within "HOT" range.
29. Show actual viscous and dry paper type to confirm the difference.
31. Variation in brake fluid level indirectly indicates the following conditions: presence
of oil leak or wear condition of brake pad
35.
To check drive belt, check the following 2 aspects: deflection (push) and tension
(pull)
Generally, check belt with cold engine or approximately 30 minutes or more
after engine is stopped.
If tension is low, belt will slip. If high, bearings (water pump or alternator) may be
damaged.
59
ESTN1002B
ENGINE TUNE-UP SERVICE (ESTN1002B)
Vehicle
Worksheet
CONSULT-II
Torque wrench
Spark plug socket
General tool
Battery hydrometer
Timing light

Your memo
60
ESTN1002B
3. When the work support or TPS are removed, adjust the engine idle speed to 50 rpm
lower than the normal value.
13. Visual inspection of spark plugs.
(1) When it is light brown, the engine is in good condition and heat range is proper.
(2) When it is white, the engine is overheating, heat range is too low, or mixing ratio
is too lean.
(3) When it is black and dry, the mixing ratio is too rich or heat range is too high.
(4) When it is black and wet, oil is infiltrating into combustion chamber, or plug is
misfiring.
14. Do not use wire brushes to clean a platinum-chip spark plug. It will damage the platinum chip.
16. Tightening the spark plug with an excessive tightening torque will damage the
screw thread. In the worst case, the cylinder head must be replaced.
18. Check the difference between viscous and dry paper types with the actual parts.
19.
Drive belt inspection includes two inspections: inspection by deflection (push)

and inspection by tension (pull).
As a rule, it shall be measured when the engine is cold or at least with 30 minutes after the engine stops.
Low belt tension may cause a skid. High belt tension may damage the water
pump or alternator bearing.
21. Inspect the ignition timing and idle speed with no electrical load applied.
22. Battery life can be judged by the following condition.
(1) The specific gravity does not increase even though it is recharged.
(2) Dispersion in specific gravity among cells is large.
(3) Fluid decreases rapidly.
61
ESTN1002B
23.
When measuring the battery specific gravity, pay attention to fluid temperature,
and convert into 20C for judgement. When the temperature rises by 1C, the
specific gravity decreases by 0.0007. When the temperature decreases by 1C,
it increases by 0.0007.
Read point A for specific gravity.
How to charge batteries.

(1) Normal charging
Charge with a current of 1/10 of battery capacity. This method is most advisable
(Example, 60 AH: charging current 6A)
(2) Quick charging
Charge with a current of 1/2 of battery capacity for approximately 30 minutes.
(Example, 60 AH: charging current 30A)
(3) During charging, be careful not to raise fluid temperature over 45C. It will
deform the battery cells and damage the plates, resulting in short battery life.
Since battery fluid is highly corrosive, never allow it to splash on your body,
clothes, or automobile body. If it splashes, rinse completely with water.
62
ESTN1003B
COOLING SYSTEM SERVICE (ESTN1003B)
Vehicle
Vehicle hoist
Worksheet
Coolant drain pan
Coolant tester
Tire pressure gauge
Drain plug wrench
Torque wrench

Your memo
63
ESTN1003B
First, explain safety.
14. Do not remove radiator cap rapidly when engine is hot. Oil may spill out.
16. (1) When using radiator cap tester, be sure to connect adapter.
Otherwise, filler neck may be damaged.
(2) Do not apply excessive pressure. Otherwise, radiator, heater core and hose,
etc. may be damaged.
24.
(pull)
damaged.
26. Observe correct procedure to refill engine coolant. Otherwise air mixes with cooling system and can cause overheating.
28. When checking exterior lights by one person, use a mirror or see reflection on wall.
64
ESTN1004B
Tire Rotation and Brake Inspection (ESTN1004B)
Vehicle
Worksheet

Your memo
65
ESTN1004B
2. When setting the lift arm, do not allow the arm to contact the brake tubes, brake
cable, fuel lines and sill spoiler.
5. Instruct position and purpose of tire wear indicator.
41.
(pull)
damaged.
66
ESTN1005B
A/C Performance Check (ESTN1005B)
Vehicle
Worksheet

Your memo
67
ESTN1005B
If NG, go to trouble diagnosis procedures for each item. Refer to HA section.
14. Explain air outlet/distribution for AUTO A/C using the table below.
33. Explain air outlet/distribution for MANUAL A/C using the table below.
68
Worksheet Answer
FUND Course
Worksheet #
Worksheet tasks
GITN1001B
GITN1001B/WS3
Usage of Electronic Service

Manual
GITN1002A
Usage of SST
GITN1003B
GITN1005A
Outline of Engine
GITN1006A
Outline of Chassis
ELTN1001B
ECTN1001B
Fundamental Skills
Remarks
Worksheet
GITN1001B
GI01B000
Fundamental Skills
Usage of Service Manual (GITN1001B/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to use the Service
Manual to locate information, by using this worksheet.
Nissan Vehicle
Service Manual (white face page version)
Worksheet
INSTRUCTIONS: These instructions will outline the tasks that you will need to

End of worksheet.
GITN1001B/WS1
Using the Service Manual found at your workshop, complete the following exercises.
If you have any questions or problems while working with this material, ask your
instructor for assistance.
1.
Locate the Quick Reference Index at the front of the Service Manual.
2.
What is the meaning of the abbreviations shown below?

EC (EF & EC): Engine Control System
HA: Heater & Air Conditioner
RS: Restraint System

EL: Electrical System
3.
Turn to the EM section.
4.
On what page does following information begin?

. (Ask your instructor)
Assigned engine is
1) Engine removal:
2) Cylinder head:
_____________________________
_____________________________
3) Outer component parts: ______________________________
5.
On what page can you find the tightening torque of the crank pulley bolt?
6.
What is the tightening torque of the crank pulley bolt?

(N-m / kg-m / ft-lb)
7.
Turn to the "EC (EF & EC)" section.
8.
On what page does the "TROUBLE DIAGNOSES" begin?
GITN1001B/WS1
9.
*
Turn to that page.

You can see the "How to perform trouble diagnoses for quick and accurate
repair" section. It's very helpful for your trouble shooting.
10. On what page do trouble diagnoses for Throttle position sensor begin?
__________________
11.
Turn to that page.
12. What is the terminal number of the signal line on ECM connector?
__________________
*
13.
You can find the terminal number and wire color of each signal line.
Turn to the MT section.
14. On what page does Service Data and Specification (SDS) begin?
__________________
15. Turn to that page.
16. What is the final gear ratio?

Engine:
Transmission:
Gear ratio:
17. Locate Trouble Diagnoses in EC (EF& EC) section.
18. On what page can you find it?

__________________
GITN1001B/WS1
19. Go to that page and use the Trouble Diagnosis in the contents to answer the
following questions:
20. On what page is the following information found?
TROUBLE DIAGNOSIS ITEM
PAGE LOCATION
Electrical Components Inspection
Hunting Diagnostic Procedure

(Crank Angle Sensor) Diagnostic Procedure
Basic Inspection Information
Throttle Position Sensor Diagnostic Procedure
Injector Diagnostic Procedure
Unstable Idle Diagnostic Procedure
Knock Sensor Diagnostic Procedure

(If available)
Surge Diagnostic Procedure
Mode II [Self-Diagnostic Results]
Fuel Pump Diagnostic Procedure
GITN1001B/WS1
21.
To answer the following questions, use the Service Manual GI section.
22. Draw lines to match the symbol to description.
a. Disconnect battery negative

cable.
b. Voltage should be measured
with a voltmeter.
c. A/C switch is OFF.
d. Depress brake pedal.
e. Release accelerator pedal.
f. Apply parking brake.
g. Procedure without CONSULT
h. Check after disconnecting the
connector to be measured.
i. Turn ignition switch from OFF to
ON position.
j. Release brake pedal.
k. Turn ignition switch from ON to
OFF position.
l. Procedure with CONSULT
m. Do not start engine, or check
with engine stopped.
Gl01B001
GITN1001B/WS1
TROUBLE DIAGNOSIS FLOW CHART
Gl01B002
23. While measuring, the harness should be:

Connected / Disconnected
24. The ignition switch should be:

OFF / ON / START
25. The engine should be:

Running / Stop
26.
What electrical test must be done?

Amperage / Resistance / Voltage
27. Which connector terminal must be checked?
28. Which side of the connector must be checked?

Terminal / Harness
GITN1001B/WS1
29.
Locate How to use this manual in GI section.
30. Answer the following questions with large sample illustration in the Service
Manual.
1) How many parts must be replaced when overhauling this unit?

__________________
2) How many parts must be lubricated with grease?

__________________
3) What is the difference between two symbols of torque (if available)?

__________________
The UNITS given in this Manual are primarily expressed as SI UNITS (International System of Unit), and expressed in the metric system or alternatively
the yeard / pond system.
Example: xx - xx N-m (yy - yy kg-m, zz-zz ft-lb)
xx - xx N-m (yy - yy kg-m, zz-zz in-lb)
Unit conversion
1 N-m = 0.1017 kg-m 1N-m = 0.7495 ft-Ib 1 N-m = 8.827 in-Ib
1 kg-m =9.806 N-m
1 ft-Ib =1.334 N-m 1 in-Ib = 0.1133 N-m
Review the objective of this worksheet. If you are not clear on any part of the
objective, ask your instructor for assistance. When you are satisfied that you have
met the objective, have your instructor check your work and initial your worksheet.
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
Nissan Vehicle
Service Manual
(Red color face page version excluding B14 & S14)
Worksheet

End of worksheet.
GITN1001B/WS2
1. Locate the Quick Reference Index at the front of the Service Manual.
2.

EC (EF & EC): Engine Control System
RS: Restraint System
HA: Heater & Air Conditioner EL: Electrical System
3.
4.

Assigned engine is
1) Engine removal:
2) Cylinder head:
_____________________________
_____________________________

5.
__________________
6.
What is the correct tightening torque of the crank pulley bolt for your
vehicle's engine?
7.
8.
On what page does the General Description of TROUBLE DIAGNOSIS

begin?
__________________
GITN1001B/WS2
9.
Turn to that page.
10. On what page does Idle Speed Adjustment or Check in BASIC SERVICE
PROCEDURE begin?
__________________
11.
Turn to that page.
12. What is the specification of base idle speed?

rpm
13.
Turn to the AT section.
__________________
16. What is the 1st gear ratio?

Engine:
Transmission:
Gear ratio :
GITN1001B/WS2
18. On what page is the following information found:
PAGE LOCATION
Basic Inspection
Fail-Safe Chart
Engine Coolant Temperature Sensor
Symptom Matrix Chart
Oxygen Sensor
Knock Sensor
(If available)
Diagnostic Trouble Code (DTC)
On-board Diagnostic System Description
GITN1001B/WS2
19.

cable.
with a voltmeter.
ON position.
OFF position.
Gl01B001
GITN1001B/WS2
Gl01B002


OFF / ON / START

Running / Stop
24.


Terminal / Harness
GITN1001B/WS2
27.
28. Answer the following questions with large sample illustration in the
Service Manual.

__________________

__________________
Conversion Unit ( to kg-m, ft-lb or kg-m, in-lb )
The UNITS given in this Manual are primarily expressed as SI UNITS (International System of Unit), and expressed in the metric system or
alternatively the yard / pond system.
Example: xx - xx N-m (yy - yy kg-m, zz - zz ft-lb)
xx - xx N-m (yy - yy kg-m, zz -zz in-lb)
Unit conversion
1 N-m = 0.1017 kg-m 1 N-m = 0.7495 ft-Ib 1 N-m = 8.827 in-Ib
1 kg-m =9.806 N-m 1 ft-Ib =1.334 N-m 1 in-Ib = 0.1133 N-m
INSTRUCTOR SIGN-OFF
Usage of Electronic Service Manual (GITN1001B/WS3)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
Nissan Vehicle
Electronic Service Manual
Worksheet

End of worksheet.
When you have finished all the activities, have the instructor check your work and initial this
worksheet. Also, have your instructor initial your sign-off sheet so you can keep track of
your overall course progress.
GITN1001B/WS3
Using the Electronic Service Manual found at your workshop, complete the following
exercises. If you have any questions or problems while working with this material,
ask your instructor for assistance.
1.
Turn ON your Personal Computer (PC).
2.
Is the operating system of your PC Microsoft Windows 95/98 or later model?

YES / NO If NO, find Windows 95/98 PC or later.
3.
Is the CPU of your PC i486DX-66MHz or higher?

YES / NO If NO, find the applicable PC.
* Your CPU should have pentium 166 MHz or higher and at least 32 MB memory.
* At least 16 bit colors monitor and 8-speed CD-ROM drive are recommended.
4.
Insert CD-ROM of ESM to CD drive on your PC.
5.
Is Acrobat Reader installed into your PC?

YES / NO
If YES, go to step11.
6.
Double-click on the CD icon.
7.
Double-click on the folder titled acroread icon inside the CD icon.
8.
Double-click on ar32e301(.exe) inside the acroread icon.
9.
Install Adobe Acrobat Reader according to the instruction of the installation

program.
GITN1001B/WS3
10.
Open CD contents folder.
11. Double-click on the [start (.pdf)] inside CD icon.
12. Click START button on the opening screen. You can see QUICK REFERENCE INDEX.
13. Click Zoom control box in tool box on the bottom of screen to change the
screen size according to your needs.
14. Choose Fit width from the menu box, then click OK.
15. Click Select zoom-in tool box on tool bar on the top of screen.
Be sure pointer should change to
mark.
16. Click any place on the Service Manual page to make the screen size double
every click.
17. What percentage can the screen size be enlarged at the maximum?
800
18. Click or drag scroll bar at the right end of screen to move screen.
The screen can be moved by a triangle mark at the top of screen.
GITN1001B/WS3
19.
Click EC section tab on the QUICK REFERENCE INDEX at the right

side of screen to see EC section of contents page.
20
Click QUICK REFERENCE INDEX book mark at the left side screen.
By clicking name of section at the right or left screen can be moved according to your needs.
21. What is the meaning of the abbreviations shown below?
EC:
Engine Control System
RS:
Restraint System
HA:
Heater & Air Conditioner
EL:
Electrical System
22. Click EM section book mark on the screen.
GITN1001B/WS3
23.
On what page does the following information begin?

Assigned engine is
24.
N16 QG18DE
Ask your instructor.
1)
Outer component parts:
EM-11 (N16)
2)
Cylinder block
EM-53 (N16)
3)
Service Data and Specification
EM-66 (N16)
On what page can you find the tightening torque of camshaft bracket bolts?
EM-47 (N16)
25. What is the tightening torque of camshaft bracket bolts?
9.0 - 11.8
(N-m / kg-m / in-lb)
(0.91 - 1.20 kg-m, 79 - 104 in-lb)
26. Click QUICK REFERENCE INDEX book mark at the left side of screen.
27. Click EC book mark at the left side of screen.
28. Click triangle mark for suitable choice, or engine type, if required.
You can move any pages which you want to see detail of contents by both
right (scroll bar) and left (book mark) screen.
29. On what page does the General Description of TROUBLE DIAGNOSIS

begin?
EC-73 (N16)
30. Go to the page of Fail-safe Chart.
31. What does the detected code, DTC No- P0120, mean?
GITN1001B/WS3
32. On what page does CONSULT-II Reference Value in Data Monitor Mode in
IDLE AIR CONTROL VALVE (IACV) begin?
EC-194 (N16)
33. Go to the page.
34. What is the specification of IACV-AAC/V operation at engine idling?
5 - 30 (N16 QG engine)
steps
35. Back to QUICK REFERENCE INDEX with the left side of screen.
36. Click AT section.
AT-330 (N16)
38. Go to that page.
39. What is 1st gear ratio?

Assigned Engine & Transmission are:
(Ask your instructor)
Engine:
QG18DE
Gear ratio:
Transmission:
2.861
40. Back to Trouble Diagnoses in EC section.
RE4F03B
GITN1001B/WS3
41.
On what page is the following information found?
for N16 QG18DE

PAGE LOCATION

Basic Inspection
EC-58
Fail-Safe Chart
EC-73
EC-132
EC-107
EC-112
EC-74
Oxygen Sensor
EC-119
Knock Sensor (If available)
EC-128
Diagnosis Trouble Code (DTC)
EC-38
Circuit Diagram
EC-17
EC-38
GITN1001B/WS3
42.
43.
Draw lines to match the symbol to the description.

a. Disconnect battery negative cable.
b. Voltage should be measured with a
voltmeter.
h. Check after disconnecting the connector to be measured.
ON position.
OFF position.
m. Do not start engine, or check with
engine stopped.
GI01B001
GITN1001B/WS3
GI01B002


OFF / ON / START

Running / Stop
47.


Terminal / Harness
GITN1001B/WS3
50.
Go to How to use this Manual in GI section.
51. Answer the following questions with sample illustration in the Service Manual. (Brake caliper)
_________1________

__________4________
3) What is the difference between two symbols of torque?
Conversion Unit (to kg-m, ft-lb or kg-m, in-lb)
Example: xx - xx N-m (yy-yy kg-m, zz - zz ft-lb)
xx - xx N-m (yy-yy kg-m, zz -zz in-lb)
Unit conversion
1 N-m = 0.1017 kg-m 1 N-m = 0.7495 ft-Ib
1 kg-m = 9.806 N-m 1 ft-Ib = 1.334 N-m
1 N-m = 8.827 in-lb

1 in-Ib = 0.1133 N-m
INSTRUCTOR SIGN-OFF
10
Worksheet
GITN1002A
GI02A000
Fundamental Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to select the correct
Special Service Tools (SST) for each job, by using this worksheet.
None
Service Manual
Worksheet

End of worksheet.
GITN1002A
1.
2.
Find the MA section and go to that page.
3.
On what page does Special Service Tools (SST) in the preparation section
begin?
4.
What is the SST number of the oil filter wrench for your engine?
Nissan has three kinds of wrenches.
1) 65 mm (2.56 in) diameter ............for SR and CG

2) 80 mm (3.15 in) diameter ...............for A, E, CA, GA, RB, VG, VH and CD
3) 93 mm (3.64 in) diameter ................. for Z, L and TD42
5.
Find the EM section and go to that page.
6.
On what page does SST in the preparation section begin?
7.
What are the SST numbers for engine attachments for your engine?
Attachment
and / or Sub-attachment
Sub-attachments are different in size among different engine models.

You have to check the correct SST number.
GITN1002A
8.
What is the SST number of the cylinder head bolt wrench for your engine?
(If available)
This wrench is used for GA, SR, L, RB, VG, VH, CD and LD series engine.
9.
Enter the correct SST number of the following tools used for your engine:
1) Piston ring compressor

2) Valve oil seal drift
3) Seal cutter
10. Are these SST commonly used for all engine?
YES / NO
Piston ring compressor only
11. Find the MT section and go to that page.
12.
On what page does Special Service Tools in the preparation section begin?
13.
What is serviceable with the SST numbered ST30031000?
See Instructor Guide.
Various types of puller are available for the manual transaxle. You have to
choose and use a suitable puller for each job.
14. What will happen to a bearing when a different size puller is used?
Hard to remove or broken bearing.
GITN1002A
15.
Find the BR section and go to that page.
16.
17.
For what would you use a flare nut torque wrench?
To securely tighten the flare nuts without damaging them.

Upon completion, have your instructor sign-off this worksheet. If you have any
question, feel free to ask him.
INSTRUCTOR SIGN-OFF
Worksheet
GITN1003B
GI03B000
Fundamental Skills
General Model Introduction (GITN1003B/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand Nissan Vehicles

Handling precautions, by using this Worksheet.
Nissan Vehicle
Worksheet

End of worksheet.
GITN1003B/WS1
Vehicle Identification Number (VIN)
1.
Using Service Manual found at your Workshop, answer the following questions and fill out the blanks.
Refer to the Identification information of GI section in the Service Manual.
2.
On what page does Model variation information begin in GI section?
GI-35 (A32)
3.
What is the model code of your vehicle?
4.
What is the Vehicle Identification Number (chassis number) of your vehicle?
5.
Enter the type of the following items.

Body type:
Sedan / Coupe / Hatch-back / Wagon / Van
Engine type:
Grade:
Transaxle type:
Destination:
6.
Draw lines to match the abbreviation to description.

FF
FR
RR
MR
RHD
LHD
Midship engine, rear drive

Right hand drive
Front engine, front drive
Front engine, rear drive
Left hand drive
Rear engine, rear drive
GITN1003B/WS1
*
Refer to the Textbook.
7.
What is the code of the engine?
Ex. VQ30DE
This code indicates: Ex. VQ series, 3 liter capacity, Double Overhead
Camshaft, with ECCS engine.

Transmission code number
* Refer to the Textbook.
8.
Relate the code to the statements:
RS5F50A
1) Type of control position:
2) Additional function:
Remote control shift

With overdrive
3) Number of forward speeds:

4) Drive system:
Front engine front

drive
Refer to the Textbook and Service Manual.
9.
What type of brake is used on your vehicle?

Front brake code:
This code indicates:
Rear brake code:

RL4F03A
Remote control shift
Lock-up
4
Front engine front drive
GITN1003B/WS1
*
10.

What is the steering type on your vehicle?
Code:
11. Which engines use the ECCS system?

Mark the common ones:
GA16DS
NA20S
SR20DE
VQ20DE
VG33E
KA24E
Z24S
QG15DE
12. Which transmissions are for front-wheel drive vehicles?

Mark each type of transmission
RS5W71C
RL4F03A
RE4R03A
FS5W71C
FS5R30A
RS5F31A
13. Which engines use carburetors?

Mark each type of engine
VG33E
NA20S
TB45E
VH45DE
VQ30DE
GA14DS
QG13DE
Z24S
INSTRUCTORS SIGN-OFF
General Model Introduction (GITN1003A/WS2)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand Nissan vehicles

handling precautions, by using this Worksheet.
Nissan Vehicle
Service Manual
Worksheet

End of worksheet.
GITN1003A/WS2
1.
On what page does Precautions information begin in GI section?
2.
Which battery terminal should you remove before servicing an electrical

component?
Positive / Negative
3.
What areas of the vehicle should be covered with protective mats or covers?
Fenders / Roof / Tire / Steering wheel / Seats / Mirror / Headlamp
(Mark the correct ones)
4.
Can any type of fuel be used on vehicles fitted with catalytic converters?
YES / NO
Leaded fuel will damage the catalytic converter and some engine part.
5.
On what page does Tow Truck Towing information begin in GI section?
6.
What is the jack point for your vehicle?

Side sill / Sill spoiler / Bumper / Axle case / Stabilizer bar / CTR Member
GITN1003A/WS2
7.
What is the maximum towing speed for an A/T vehicles with 4 wheels on
ground?
Below 50 km/h (30 MPH)

8.
What is the maximum towing distance for A/T vehicle with 4 wheels on
ground?
Less than 65 km (40 miles)
9.
If you have to tow a vehicle equipped with an automatic transmission / axle a

long distance, what precautions should you take?
Vehicle be towed with the driving wheels off the ground.

or Vehicle be towed with the 4 wheels off the ground
Upon comlpletion, have your instructor sign-off this worksheet. If you have any
INSTRUCTOR SIGN-OFF
Worksheet
Outline of Engine
GITN1005A
GI05A000
Fundamental Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand engine structure

and component part names, by using this worksheet.
Nissan Vehicle
General tools
Service Manual
Textbook
Worksheet

End of worksheet.
GITN1005A
Answer the following questions after reading the textbook.
1.
Major engine parts names are written below.

Choose the number from 1 through 12, and fill its number in the matched
blank box.
1) Radiator
2) Drive shaft
3) Camshaft
4) Piston
5) Ignition coil
6) Connecting rod
7) Crankshaft
8) Flywheel
9) Injector
10) Intake manifold
11) Exhaust manifold
12) Cylinder head
GI05A001
2. Mark the best answer to each question.

A. In general, automotive engines are classified into two groups.
What are they? (Mark the correct answer.)
Diesel / Coal / Gasoline / Charcoal / Oil
B. What is carburetor mixed with gasoline?
Oil / Air / Water / Paper
C. What is the power flow for a gasoline combustion engine?
Combustion gas
Piston / Exhaust valve / Cylinder head

Push rod / Connecting rod / Cylinder head
Camshaft / Drive shaft / Crankshaft
Flywheel
GITN1005A
3.
What stroke engine is illustrated below?

8 stroke engine / 4 stroke engine / 2 stroke engine
GI05A002
4.
Which stroke does each description correspond to?
A. The intake valve is open while the piston moves down and the
air-fuel mixture is sucked into the cylinder.
Exhaust stroke / Combustion stroke / Intake stroke / Compression stroke
B. As the piston begins to move up, the intake valve closes to seal the
combustion chamber and the air-fuel mixture is compressed.
C. The air-fuel mixture is ignited by an electric spark (spark plug).
D. The exhaust valve opens to let the combustion gas discharge.
5.
There are 3 illustrations of cylinder arrangements below.

Mark the correct answer.
GI05A003
In-line
In-line
In-line
V-type
V-type
V-type
Flat opposition
Flat opposition
Flat opposition
GITN1005A
*
Refer to the S.D.S. section of EM in the Service Manual.
6.
What is the cylinder arrangement of assigned vehicle engine?

* Cylinder arrangement:
In-line / V-type / Flat opposition
* Number of cylinders:_______________________________
*Total displacement:
7.
cm
Answer the questions corresponding to the parts in the illustration.
GI05A004
* What is the A part in the illustration? Mark one.

Bottom Dead Center / Top Dead Center / Middle Dead Center
* What is the B part in the illustration?
* What is the C part in the illustration?
Combustion chamber / Float chamber / Throttle chamber
8.
What is the compression ratio of gasoline engine generally?

14 : 1 / 8 - 10 : 1 / 16 - 20 : 1
9.
What is the compression ratio of your assigned one?
GITN1005A
10. The illustrations below show automotive parts with attached numbers.
Write the number corresponding to the part shown in the illustration
next to the part name in the list.
Part name
Fuel pump
Fuel pipe
Fuel filter
Fuel tank
Carburetor
Number in
illustration
3
5
4
1
2
GI05A005
Part name
Air cleaner
Air element
Main muffler
Exhaust manifold
Intake manifold
GI05A006
Sub muffler
Exhaust pipe
GI05A007
11. What type of air element is used in your vehicle?

Viscous / Dry paper
Number in
illustration
7
12
10
8
6
9
11
GITN1005A
12. Below are some incomplete sentences about the carburetor. Some
words are given in each sentence. Choose and mark the word which
best completes the sentences.
* The carburetor controls the volume of (Oil / Fuel / Water) and (Air / Gas/
Solid) entering the engine cylinder.
* It provides the proper (Air-fuel mixture / Liquid mixture / Blow-by gas) for
the existing driving conditions.
13. Below are some descriptions about carburetor fuel systems. Some
system names are given beneath each sentence. Choose and mark
the best system name.
A. Operates when high power output is required.
Slow fuel system / Main fuel system / Power fuel system
B. Supplies fuel to the engine during idling periods and at low speeds.
Acceleration fuel system / Main fuel system / Slow fuel system
C. Operates during rapid acceleration.
Acceleration fuel system / Main fuel system / Power fuel system
D. Supplies fuel to the engine during intermediate and high-speed.
GITN1005A
14. The illustration shown below is a typical carburetor. Some words, marked 1
to 6 are given below. Find the parts name and write the number in the blank
boxes in the illustration.
GI05A008
1) Float chamber
3) Main nozzle
5) Primary throttle valve
2) Float
4) Acceleration pump
6) Idle adjusting screw
15. The illustration shown below is cooling system structure. Some part
names, marked 1 to 4 are given beneath illustration. Find the best part
name and write the number in the blank boxes in the illustration.
GI05A009
1) Radiator
3) Thermostat
2) Water pump
4) Cooling fan
GITN1005A
16. The illustrations shown below are variety of valve mechanism systems. Three system names are given beneath each illustration.
Choose and mark the best answer.
OHV / OHC / DOHC
OHV / OHC / DOHC
OHV / OHC / DOHC
GI05A010
met the objective, have your instructor check your work and initial for your worksheet.
INSTRUCTOR SIGN-OFF
Worksheet
Outline of Chassis
GITN1006A
GI06A000
Fundamental Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand chassis structure

Nissan Vehicle
General tools
Service Manual
Worksheet
Textbook

End of worksheet.
GITN1006A
VEHICLE CONSTRUCTION
1. The illustration below shows typical vehicle drive systems.

FF (Front Engine Front Drive)

FR (Front Engine Rear Drive)
4WD (Four Wheel Drive)


GI06A001
2.
Listed below are 4 sentences which describe the operation of various chassis
systems. Choose and mark the best answer.
A. This system is to change the vehicle direction during operation.
Drive train / Suspension / Steering / Brake
B. This system controls vehicle speed and stops the vehicle.
C. This system transfers the power generated by the engine to the

wheels.
D. This system improves the riding comfort by easing shocks from the road
surface.
GITN1006A
3.
The illustration below shows a typical automobile. The names of parts,

marked 1 through 5 are listed underneath. Select the correct term, which
identifies the various components in the drive train. Write the associated
number in the blank box.
GI06A002
1) Transmission
2) Drive shaft
4) Clutch
5) Propeller shaft
3) Final drive
CLUTCH
4. Below are some descriptions about the clutch. Choose and mark the best
answer.
A. When the clutch is engaged, is the engine power transmitted to the transmission?
YES / NO
B. When the clutch pedal is depressed, is the clutch engaged or disengaged?
Engaged / Disengaged
5.
What is the relationship between clutch pedal and clutch operation?

A. What happens to clutch operation when clutch pedal free play increases?
Causes difficult disengagement / a slip
B. What happens to clutch operation when clutch pedal free play decreases?
GITN1006A
TRANSMISSION / AXLE
6. Below are some incomplete sentences about transmission/axle. Some
words are given in each sentence. Choose and mark the word which best
completes the sentence.
1) [ ? ] within the transmission/axle change position relative to each other
(engage or disengage) in response to vehicle conditions.
Gears / Forward / Engine speed
2) The engine torque is delivered to the [ ? ]
Suspension / Vehicle drive shaft / Steering wheel
3) The transmission/axle permits the vehicle to move in the forward and the
[ ? ]direction.
Upper / Reverse / Left
7.
The illustration below shows an example of gear flow. Use the formula
beneath the illustration to determine the ratio of the input speed to the output
speed.
GI06A003
Formula:
A
C
X
= Output speed ratio
B
D
2 ( 20 X 30 = 1 X 2 = 2)
20
15
GITN1006A
FINAL DRIVE
8.
The illustration below shows typical differential (final drive assembly).

Choose the number from (1) to (4), and fill its number in the corresponding
blank box in the illustration.
1) Ring gear
2) Differential case
3) Side gear
4) Pinion mate gear
GI06A004
9.
Below are some incomplete sentences about the final drive assembly. Some
1) The final drive assembly consists of the final gear assembly and the [ ? ]
Differential assembly / Drive shaft / Suspension
2) The final gear mechanism provides the final [ ? ] of the engine's high rotation speed.
Exception / Reduction / Suspension
3) The differential allows for adjustment of individual drive wheel [ ? ]

during vehicle turning.
Running distance / Direction / Height
GITN1006A
10. The illustration shows the rear wheels of a vehicle that are driving straight
ahead and turning to the left. Choose and mark the best description of wheel
and tire motion from the boxes below.
GI06A005
(1) Vehicle driving straight ahead
(2) Vehicle turning to the left.
1) The right-hand tire is rotating

faster than the left-hand tire.

2) Both tires are rotating at the

same speed.

same speed.
3) The left-hand tire is rotating

faster than the right-hand tire.

SUSPENSION
11. Below are some descriptions about function of suspension components.
Choose and mark the best component name for each description.
1) Reduces body roll.
Spring / Shock absorber / Stabilizer / Link
2) Determines body position and transmits motion and braking to the body.
3) Supports the weight of the body and absorbs shock from the road.
4) Controls vertical movement of the body.
GITN1006A
12. The illustrations below show typical front suspension. Choose and mark the
appropriate suspension type.
1) Multi-link type
2) Strut type
3) Double wishbone
GI06A006
1) Multi-link type
2) Strut type
3) Double wishbone
GI06A007
1) Multi-link type
2) Strut type
3) Double wishbone
GI06A008
GITN1006A
13. The illustrations below show typical rear suspension. Choose and mark the
1) Parallel-link type
2) Multi-link bean type
3) 5-link type
GI06A009
3) 5-link type
G I06A 010
3) 5-link type
G I06A 011
GITN1006A
14. Below are some incomplete sentences about the steering system.
Some words are given in each sentence. Choose and mark the word
which the best completes the sentence.
1) The wheels must turn [ ? ] with minimal resistance in the proper direction.
Lightly / Heavily
2) After turning a corner, the wheels must [ ? ] position.
Continue in direction of turn / Return smoothly to the straight-ahead
3) For above operations, [ ? ] need to be checked.
Wheel alignment / Fuel properties
15. What are the four primary factors to be considered in wheel alignment?
CAMBER / RUNOUT / TOE-IN / FREE PLAY

CASTER / SIDE-SLIP / KINGPIN INCLINATION
The above factors work together to carry out the following functions.
*Make operation of steering wheel easy.

*Maintain steering in straight-ahead direction.
*Give steering self-centering qualities.
*Reduce tire wear
GITN1006A
16. The illustrations show important wheel alignment areas.
Choose and write the name of appropriate wheel alignment area number in
the corresponding blank space in the illustrations.
CASTER [
CAMBER [
TOE-IN [
KINGPIN INCLINATION [
GI06A012
GI06A013
GI06A014
10
GITN1006A
STEERING
17. The illustrations below show a typical steering system.
GI06A015
Rack and pinion type / Recirculating ball / Push rod type
GI06A016
11
GITN1006A
BRAKE
18. The illustrations shows a typical brake system. The name of the parts,
marked 1 through 6, are given in the list. Choose the best number to each
blank box and fill in the blank.
GI06A017
1) Brake pedal
2) Booster
3) Master cylinder
4) Disc brake type
5) Drum brake type
6) Parking brake lever
WHEEL & TIRE

19. Tire and wheel classification are indicated by alphanumeric symbols.
Write the number that corresponds to the alphanumeric symbols in the box
provided.
195
60
14
89
1) Rim diameter
2) Tire width
3) Speed symbol
4) Load carrying capacity
5) Aspect percent
6) Radial
6 - 1/2
14
1) Wheel rim diameter
2) Tire width
3) Wheel rim width
4) Flange shape
12
GITN1006A
PRACTICE
Go to your assigned vehicle and answer the following questions.
1.
What is the vehicle model?
2.
What type of drive train does the vehicle have?

Front engine Front drive / Front engine Rear drive / 4-Wheel Drive
3.
What type of transmission/axle is fitted to the vehicle?

Manual / Automatic / CVT (Continuously Variable Transmission)
4.
What type of clutch operation does the vehicle have?

(To be answered only if the vehicle is equipped with a manual transmission/
axle.)
Mechanical type / Hydraulic
5.
What type of front suspension does the vehicle have?
6.
What type of rear suspension does the vehicle have?
7.
What type of front brakes does the vehicle have?

Disc type / Drum type
8.
What type of rear brakes does the vehicle have?

13
GITN1006A
9.
What is the front tire size?

1. Tire code_______________________________________
2. Tire width______________________________________
3. Aspect percent or ply rating (for bias tire)_____________
10. What is the front road wheel rim size?

1. Rim size code__________________________________
2. Rim diameter___________________________________
3. Rim width______________________________________
4. Offset_________________________________________
11. What type of steering does the vehicle have?

Recirculating ball type / Rack and pinion type
INSTRUCTOR SIGN-OFF
14
Worksheet
ELTN1001B
V=IR
I=
V
R
R=
V
I
EL01B000
Fundamental Skills
Basic Electrical Concept (ELTN1001B/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to use an analog type
Multi-meter (circuit tester), by using this worksheet.
Analog type Multi-meter

Vehicle or appropriate units
Worksheet
Textbook

End of worksheet.
ELTN1001A/WS1
Using this worksheet and the Multi-meter, answer the following questions.
Voltage measurement
1. What does the scale read below?
EL01A001
EL01A002
3. Adjust meter to 0 by the needle zero adjuster.

4. Select highest voltage range by using range selector.
ELTN1001A/WS1
5.
Connect Red test lead wire to the Positive side of battery and Black
test lead to negative side of battery or body ground.
* Voltmeter must be connected in parallel in the circuit.
6.
Measure the battery voltage.

V
7.
Change to the lower range, which indicates more than half on the scale.
8.

V
When measuring a voltage, use the reading where the needle deflects
beyond half on the scale. Because there is resolution correspond to the each
range.
Resistance measurement
9.
Select range selector to x10k position.
10. Short out Red and Black test leads firmly together while checking.
* When reading the meter indication, aways view the needle from directly
above.
* A reading error will result if it is not read in this way.

* Some Multi-meters have a mirror for this reason.
ELTN1001A/WS1
11. Check the zero ohm position. If necessary, adjust zero. Turn the zero-ohm
adjuster until the needle aligns with zero-ohm position.
12. Select range selector to x1k position.

13. Check the ohm zero position.
14. What happens to the meter indication?
Needle indicated (Same / Different)
* When measuring a resistance, use the reading where the needle deflects
beyond half on the scale. Because there is resolution correspond to the
each range.
15. If necessary, adjust zero. Turn the zero-ohm adjuster until the needle aligns
with zero-ohm position.
16. Measure the resistance of the high tension cable.
* Polarity is not important when applying the test leads to the measuring
points.
* Never make any continuity or resistance test with the power connected to
the circuit being tested as it will damage the circuitry of the Multi-meter.
17. Change range selector to x10k .
ELTN1001A/WS1
19.
Measure the resistance of high tension cable again.
20.
What is the resistance?
21. Is this reading within the specification?

YES / NO
Testing continuity
22. Change range selector to x1k.

24. Measure the continuity of assigned circuit A and B.

25. If the meter indicates zero ohm, it means an (open / closed) circuit, and infinity means an (open / closed) circuit.
INSTRUCTOR SIGN-OFF
Basic Electrical Concept (ELTN1001A/WS2)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand the principle of

Ohms Law, by using this worksheet.
Multi-meter
Circuit block set (appropriate kit)
Worksheet
Textbook

End of worksheet.
ELTN1001A/WS2
Ohms Law
Ohms Law describes one of the most fundamental relationships in the

field of electricity.
1.

increased resistance will increase / decrease the current flow.
And, if voltage stays constant and circuit resistance decreases, current
flow will increase /decrease.
2.
Calculate the current in below circuit:
V
Current =
R
12
=
6
=2
(A)
V
Current =
R
12
=
12
EL01A003
=1
CIRCUIT TYPES
Using Circuit Block Kit, answer the following questions.
(A)
ELTN1001A/WS2
SERIES CONNECTION AND PARALLEL CONNECTION
PURPOSE:
Resistance can be connected in two different ways; series connection and parallel
connection. Each of these connections is examined using the blocks and circuit
tester.
SERIES CONNECTION
PROCEDURE
1. Connect the blocks as shown below.
EL01A004
2. After completing connection, turn ON the switch and measure the following items.
Voltage (V)
Current (mA)
Resistance()
(1)
12 V
60
(mA)
200 x one
(2)
12 V
30
(mA)
200 x one
(3)
12 V
60
(mA)
400 x one
Resistance( ) 200 x two

Voltage (V)
A to B
12 V
B to C
(V)
A to C
(V)
12
(V)
ELTN1001A/WS2
SUMMARY
* The same current is measured in (1) and (2). This means that when 100
and 200 resistors are connected in series, the resistance values can be
added.
From Ohms law, we can calculate as follows:
(1) I = V / R
(2) I = V / R
I = 9V /(100 + 200) = 30 mA
I = 9V / 300 = 30 mA
PARALLEL CONNECTION
PROCEDURE
3. Connect the blocks shown below.
EL01A005
4.
After completing connection, turn ON the switch and measure the following items.
Voltage (V)
Current (mA)
Resistance ()
(1) 9 V
15
mA
600 x one
(2) 9 V
30
mA
600 x two
ELTN1001A/WS2
* SUMMARY
The measured current in test (2) where 2 x 600 resistors are connected in
parallel is larger than measured in test (1) where only 1 x 600 resistor is
used. The current flows may be calculated as follows:
Test (1) I = V / R = 9 / 600 = 15 mA
However, with a parallel circuit, the current flow increases as the current
can flow through both circuits simultaneously.
When we calculate the total resistance for a parallel circuit we should use
the Test (2).
Total resistance =
1
1 + 1
R1
R1
=
1
=
1
= 300
1 + 1
2
600
600
600
Using Ohms law the current can be calculated as follows:
I = V / R = 9 / 300 = 30 mA
NOTE: This is twice the current flow of test (1).
met the objective, have your instructor check your work and initial for your
worksheet and move on to the next one.
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to locate and interpret
Service Manual information, by using this worksheet.
Nissan Vehicle
Multi tester
Service Manual
Worksheet
Textbook

End of worksheet.
ELTN1001B/WS3
To answer the following questions, use the Service Manual.
GENERAL INFORMATION SECTION
1. Turn to the General Information section in the Service Manual.
2. On what page does How to read wiring diagram start?
GI-9 (A32)
3. TURN TO THAT PAGE. This page explains symbols used to read wiring diagram, and how to interpret switch position.
4. The illustration at right explains the position

in which the system can be operated.
IGNITION SWITCH
ACC or ON
YES / NO
5. On what page is the explanation of Connector Symbols?

GI-13 (A32)
6. Which of the following connectors are male connectors?

CIRCLE EACH MALE CONNECTOR.
EL01B001
7. On what page is the explanation for How to follow flow chart in trouble
diagnoses?
GI-30 (A32)
ELTN1001B/WS3
8.
Turn to that page and read the notes on how to follow flow charts.
ELECTRICAL SYSTEM SECTION

9.
Turn to the contents of Electrical System section in the Service Manual.
10. On what page does the explanation for Standardized Relays begin?
EL-6 (A32)
TURN TO THAT PAGE.
11. What color is the 2 M relay?

BROWN
12. On what page does Power Supply Routing begin?

EL-7 (A32)
13. Find the Location of Electrical Units and TURN TO THAT PAGE.
14. Where is the relay box located? (L.H.D.model)
Engine compartment / Under instrument panel / Under drivers seat
15. Turn to the Harness layout in the Service Manual. Locate the Engine
room harness layout.
ELTN1001B/WS3
* The E means this connector is in the engine room harness.
* The following is a list of wiring harness and the letters that indicate the
harnessess names:
M
Main
Room (Interior Lamp)
Engine
Sunroof
Instrument
Door
EFI
Alternator
Body
16. What is the page number for the Super Multiple Junction (S.M.J)?
Foldout (A32)
TURN TO THAT PAGE.
* This diagram shows the S.M.J harness terminal locations.

- Refer to this diagram if it is necessary to make electrical checks at the
S.M.J. during diagnosing of electrical problem.
- Terminal side or harness side explains how the connector is viewed.
17. Turn to the table of contents for the EC(EF& EC) section and read through.
* Notice the arrangement of information:
- The EC (EF & EC) overall system includes the system circuit wiring diagram.
Also the EC (EF & EC) parts description and the EC (EF& EC) system
description are included here.
- Trouble diagnoses.
NOTE: Some Service Manuals will call this section diagnostic procedure.
18. What is the DIAGNOSTIC TOUBLE CODE (DTC) number (Code No.) for the
Engine Coolant Temperature Sensor?
13
ELTN1001B/WS3
CRITERION TEST
1. On what page will you find wire color coding? (In GI section)
GI-12 (A32)
2. On what page will you find the explanation of Super Multiple Junction in GI
section?
GI-16 (A32)
3.
What is the page number for the explanation of the symbols shown below?
GI-32 (A32)
EL01B002
ELECTRICAL SECTION
4. What type of relay has a gray colored case?
IM & IB
5.
Where is the location of the ECCS control module(ECM)?

6.
Locate the power supply routing wiring diagram. Turn to that page.
What amperage fuse is used to control the fuel pump?
15
ELTN1001B/WS3
7.
What wire color code and wire color carries power to the fuel pump?
code
8.
B/W
color Black with white stripe
On what page will you find location information for the engine room
harness layout?
TURN TO THAT PAGE.
EL-308 (A32)
9.
What is a number of the connector to LH headlamp?

E21 (A32)
10. Turn to the Engine Control harness layout section. What is the connector number for the Throttle Position Sensor?
F7 (A32)
CONNECTORS
11. The numbers in this connector represent terminal numbers.
What is the terminal number for the W wire?
1
What is the terminal number for the G/R?
EL01B003
ELTN1001B/WS3
(Super Multiple Junction)
12. What does the letter and the number in the ovals above the connector represent?
( ) Component location
( ) Terminal number
( ) Connector number
EL01B004
13. What does the 1B and 2D represent in this illustration?

( ) Connector location
( ) Super multiple junction terminal
location
( ) Multiple switch terminal location

EL01B005
WIRING DIAGRAM
* The dot in this illustration represents a splice on a harness wire.
A splice is used to distribute battery
voltage to more than one load in a circuit.
EL01B006
Splices are also used for circuit

grounds.
By using a splice, one wire can be separated into two or more grounds.
* The circle in this illustration represents a branch circuit, a variation in
model, system, or market.
For example, one starting system wiring
diagram may be used for both manual
and automatic transmissions. An A in
a circle or oval, or an M in a circle or
oval is a clue that wiring is shown for
both systems. The wiring diagram has a
EL01B007
key that explains and letters that are in
circles or ovals.
ELTN1001B/WS3
EL01B008
14. How many connectors are used in this check?

2
15. What type of connectors are they?

MALE / FEMALE
16. What type of check must be done?

Voltage / Resistance / Amperage
17. Which is the ignition switch position?

ON / OFF
18. What two terminals must be checked?

27
and
19. On which side must the C/Module connector be checked?

Terminal side / Harness side
ELTN1001B/WS3
EL01B009
Answer the following questions taken from the illustration shown above.

21. Which pedal is being depressed?

BRAKE / ACCELERATOR
22. What color is the wire checked?

Sky Blue
23. Is this check done with the connector disconnected?

YES / NO
24. What does the
M107 represent?
Connector number
25. On what side of the connector must this check be done?

ELTN1001B/WS3
How to read the Service Manual
Despite the complexity of the circuit or the number of parts in the circuit,
there are three essential elements ALL CIRCUITS must have for operation:
* POWER * LOAD *GROUND
EL01B010
26. Turn to the EL section.

27. On what page does the Stop Lamp / Wiring Diagram section for your
vehicles begin?
EL-62 (A32)

29. What are the wire color code and the wire color between fuse block and stop
lamp switch?
Color code: R/Y
Color: Red with Yellow stripe
30. Turn to LOCATION OF ELECTRICAL UNITS SECTION in the Service Manual.
31. Where is the fuse box location? Inform your instructor.
10
ELTN1001B/WS3
32. Answer the following questions referring to Stop lamp / wiring diagram
attached on page 13.
Vehicle specification : LHD MODEL GENERAL AREA
: without rear air spoiler
: with high-mounted stop lamp on the rear parcel shelf.
1) Which terminal number of the stop lamp switch is connected when

depressing the pedal?
1 and 2
2) Fill out the electric current ranging from the battery to the GND on Stop
lamp/wiring diagram attached on page 13 when depressing the pedal.
33. The figure below is the function of the combination switch. In the case of
turning the lighting switch to B and 1 positions, which terminal number is
contacted?
5-7
8-10
11-12
EL01B011
11
ELTN1001B/WS3
34. Turn to Front wiper and washer / wiring diagram in the Service Manual.
Where is the connector number
E14 location?
Inform your instructor.
35. On what page does the Cooling fan / Wiring Diagram in the EC section of
Service Manual begin?
EC-204 (A32)

37. What is the color of the power supply harness at the coil side of the cooling
fan relay 1?
Color code:
G/Y
Name of the color: Green with Yellow stripe
Review the objective for this worksheet. If you are not clear on any part of
the objective, ask your instructor for assistance. When you are satisfied that
you have met the objective, have your instructor initial your worksheet.
INSTRUCTOR SIGN-OFF
12
ELTN1001B/WS3
EL01B012
13
Worksheet
ECTN1001B
EC01A000
Fundamental Skills
Introduction to ECCS (ECTN1001A/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand name, location

and function of ECCS component parts, by using this worksheet.
Nissan Vehicle with ECCS engine

Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001A/WS1
Using the Service Manual found at your workshop, and the vehicle, answer
the following questions and fill out the blanks.
Model: ________________Engine unit:_______________

4. On what page does System Diagram information begin?

DESCRIPTION information begin?
ECTN1001A/WS1
7.
Go to assigned vehicle and name the labeled components with help of Service Manual.
1) Mass Air Flow Sensor

2) Power Transistor
3) Fuel Injector
4) Camshaft Position Sensor
5) Fuel Pressure Regulator
6) Throttle Position Sensor
7) Air Regulator
ECTN1001A/WS1
MAJOR FLOW SYSTEM
8. Mark the correct flow system part in each rectangle below.

Air flow system
Mass air flow sensor /AAC valve
Air cleaner
Throttle
chamber
Air duct
FICD Valve / collector

AAC valve / Intake valve
Intake
manifold
Air regulator / Pressure regulator

Fuel flow system
Fuel tank
Fuel pump / Fuel sensor
Fuel gallery
Pressure gauge /
Pressure regulator
Fuel tank / Crank case
Fuel injector
Fuel filter / Damper
9.
Fuel line (Pipe)
What are the four major purpose of ECCS?
Improved engine performance

Reduced air pollution
Improved fuel consumption

Improved driveability
or Improved starting in cold weather
10. What are the three major functions of ECCS?

Fuel injection control
Ignition timing control
Idle speed control

Fail-safe system
Fuel pump control
On-board diagnosis system
Pressure regulator control
ECTN1001A/WS1
11. There are two types of component parts: SENSORS and ACTUATORS. Fill
in the name of five sensors and four actuators below.
SENSORS
ACTUATORS
Injector
Power transistor
Engine coolant temp. sensor
Fuel pump
IACV-AAC valve
Knock sensor or the like
Engine coolant temperature

sensor
* Engine knocking
* Intake air quantity
* Throttle valve angle
* Density of oxygen
* Crankshaft position
* Water temperature

Knock sensor
Oxygen sensor
Hot wire type / Hot film type
ECTN1001A/WS1
14. Remove the distributor cap and camshaft position sensor cover.

They are used to detect top dead center for each cylinder and to control the ignition timing.
18. Which is a heater needed for the oxygen sensor?

Zirconia type / Titania type

Because the heater makes the oxygen sensor react quicker.
worksheet.
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform self-diagnosis without CONSULT, by using this worksheet.

Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001A/WS2
On-board [II Modes] Self-diagnosis by ECM diagnostic mode selector
1. Go to EC (EF & EC) table of contents and locate Trouble Diagnoses. Go to

that page and locate Self-diagnosis information. Use this material to answer
the following questions.
2. How can on-board Self-Diagnosis be read on your vehicle?
3. Where is ECM (ECCS Control Module) located on your vehicle?

Center console / Dash side / Under seat
4. To access the Malfunction Warning codes in Mode II self-diagnosis, the

engine must be:
(Standard/ stopped) and IGN key (ON/OFF).
5. Which mode are you used to:

Engine running with Mode II
* monitor the oxygen sensor?
Engine stopped with Mode II
* obtain self-diagnosis result?
6. On what page can the Display code table be found in the Service Manual?
ECTN1001A/WS2
7. Go to that page and fill out the blanks with correct Code No. or Detected
Items.
Code No.
Detected Items
43
Throttle position sensor circuit
55
No malfunction in these circuits
11
Camshaft position sensor circuit
13
Engine coolant temperature sensor circuit
12
Mass air flow sensor circuit
21
Ignition signal circuit
* In Mode II self-diagnosis, some models have more component/circuit codes.

[depending on the vehicle engine specification]
8. Access Mode II self-diagnosis on your vehicle and check for codes.

9. What Display code appear?
10. What does it designate?
11. How do you erase stored self-diagnosis codes?

The diagnostic mode is changed from Mode II to Mode I.
or The battery terminal is disconnected within 24 hours.
ECTN1001A/WS2
12. Erase any codes that appeared during your check.
13. Disconnect the harness for one of the self-diagnosis items listed in the Service Manual, other than the one found earlier in this worksheet.
14. Access Mode II self-diagnosis and check for code.

15. List which Display code appeared and its designation.
16. Does this correspond with the designation in the Service Manual?
YES / NO
17. Erase this code. Reconnect the component harness connector, then
recheck Mode II self-diagnosis to make sure that the code was erased.
exercise.
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to complete the Idle
speed/Ignition timing inspection procedure. Compare the check
results with Service Manual specifications and determine what
adjustments are necessary, by using this worksheet.

Multi-meter
Timing light
Engine tuner
Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001A/WS3
1.
Locate the Idle speed / Ignition timing inspection procedure in Service Manual.
On what page is it located?
2.
Go to that page and review the procedure.
3.
Perform the visual check.
4.
Were any problems found during visual check?

YES / NO
5.
If yes, note them below and repair it.
6.
What are the specifications for ignition timing?

BTDC
The throttle position sensor should be disconnected prior to setting the ignition timing, and the engine must be warmed up before setting idle speed and
ignition timing.
7.
Check the ignition timing with timing light.

Sample marks for BTDC17 setting
Ignition timing marks [see the figure]

vary from model to model. Refer to
your Service manual for applicable timing mark information, or Technical Bulletins for additional information.
EC01A001
ECTN1001A/WS3
8.
Is the ignition timing within specification?

YES / NO
9.
If not, correctly set the timing.
10. What do you need to disconnect to adjust the timing?

Throttle position sensor connector
11. Why do you need to disconnect it?

To fix Soft idle control (Ignition timing control for idle stability.)
12. Recheck ignition timing after tightening distributor body lock bolt/nuts.
13. Is ignition timing within Service manual specification?
YES / NO
14.
Check the idle speed. Note the result below:

rpm
15. Is idle speed within Service manual specification?

YES / NO
16. What do you need to disconnect to adjust idle speed?

Throttle position sensor connector
ECTN1001A/WS3
17. If not, adjust the idle speed.
18. Is idle speed now within Service manual specification?
YES / NO
19. What is controlled when the idle speed adjusting screw is turned?
Quantity of bypass air controlled
20. Explain what will occur if you do not disconnect to adjust idle rpm.
Cannot adjust the idle speed accurately.
* Idle speed is controlled by the ECM, based on sensor input. Compare actual
value and ECM data.
* Ignition timing should be set prior to setting idle speed.

met the objective, have your instructor check your worksheet, then initial your
worksheet.
INSTRUCTOR SIGN-OFF
Introduction to ECCS (QG ENGINE) (ECTN1001B/WS4)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand name and location
of QG Engine component parts, by using this worksheet.
Nissan Vehicle with QG Engine
Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001B/WS4
Name and location of QG Engine component parts
Using the Service Manual found at your workshop and the vehicle, answer the following questions and fill out the blanks.
1. Turn to the Engine control component parts location section in the Service
Manual.
2. The following figures indicate QG engine.

Fill the square box with a suitable component name chosen from those in the
box below.
D
EC01B001
EC01B002
A: Mass Air Flow Sensor B: IACV-AAC Valve C: Throttle Position Sensor & Switch
D: EGR Valve
E: Oxygen Sensor
F: EVAP Canister Purge Volume Control Solenoid Valve
G: Fuel Injector
H: Position Sensor I: Camshaft Position (Phase) sensor
J: Fuel Pressure Regulator
ECTN1001B/WS4
EC01B003
I
EC01B004
D: EGR Valve
E: Oxygen Sensor
G: Fuel Injector
ECTN1001B/WS4
3.
Which type of AAC valve is used for this QG engine?

STEP MOTOR TYPE
DUTY CONTROL TYPE
4.
Choose the input signals into ECM.

Mass Air Flow
VTC
PHASE
Throttle Position
A/C Compressor
Power transistor
IACV-AAC
Air Conditioner SW
Knock Sensor
Oxygen sensor
Inhibitor SW
Fuel injector
Vehicle speed
POS
Fuel Pump relay
Power Steering SW
Cooling fan relay
EGRC solenoid valve
Engine Coolant temp.
5.
Locate each position of sensor and actuator answered at the step 4, and
then inform your instructor.
6.
Locate the position of both ignition coil and power transistor, and then inform
your instructor.
7.
What is such ignition SW called?
NDIS (Nissan Direct Ignition System)
ECTN1001B/WS4
8.
Find the oxygen sensor on your vehicle if available.
9.
Which type of oxygen sensor is used?

10. What is the main operation of oxygen sensor?

Monitor density of oxygen in a exhaust gas.
Upon completion, have your instructor sign off this worksheet and move on the
next one. If you have any question, feel free to ask him before starting the next
exercise.
Self-diagnosis without CONSULT (ECTN1001B/WS5)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform self-diagnosis without CONSULT.

Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001B/WS5
On-board (Mode II) Self-diagnosis
Using the Service Manual found at your workshop and the vehicle, answer the following question and fill out the blanks.
1. Turn to the ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION in
EC section.
2. What is the function of On-Board Diagnostic System at engine stopped (Ignition switch ON)?
Mode I : BULB CHECK
Mode II: SELF-DIAGNOSTIC RESULTS

engine must be:
(Started / Stopped) and IGN key (ON / OFF)
4. Fill out how to change to Mode II on your vehicle.

1)
2)
Turn the IGN SW to ON.

Make a short circuit between IGN and CHK on CONSULT DDL2
connector more than 2 seconds.
3)
Release it.
5. On what page does the DTC code information begin in the Service Manual?
EC-45 (N16)
ECTN1001B/WS5
6.
Fill out the blanks with the correct DTC number.

Code No.
0600
0340
0115
0335
1217
0130
0325
0100
0000
0120
0500
7.
Detected items
A/T COMM LINE
CPMS / CIRCUIT (PHASE)
COOLANT TEMP. SENSOR CIRCUIT
CKPS/CIRCUIT (POS)
ENGINE OVER HEAT
Front O2 SENSOR CIRCUIT
KNOCK SENSOR CIRCUIT
MASS AIR FLOW SENSOR CIRCUIT
NO DTC is DETECTED
THROTTLE POS. SENSOR CIRCUIT
VEHICLE SPEED SENSOR CIRCUIT
The following figure indicates DTC of Mode II Self-diagnosis.

Fill out the DTC number.
1320
0100
EC01B005
8.
Access Mode II Self-diagnosis on your vehicle and record DTC numbers.

DTC:
ECTN1001B/WS5
9.
What does it mean?
10. Fill out how to erase the stored Self-diagnosis codes in ECM.
The diagnosis mode is changed from Mode II to Mode I, or the battery

terminal is left disconnected for 24 hours.
11.
Disconnect the harness for Engine Coolant Temperature Sensor and PHASE
SENSOR connector and crank 3 seconds.
12. Access Mode II Self-diagnostic Results and check for DTC.

DTC:
DTC:
13. Fill out the detected parts location which DTC appeared.
1.
2.
14. Does it correspond with the designation in the Service Manual?

YES / NO
15. Reconnect the engine coolant temperature sensor and phase sensor.
16. Erase DTC from ECM, and then recheck Mode II to make sure that the DTC
was erased.
ECTN1001B/WS5
17. Change Self-diagnosis function to Mode I.
exercise.
Worksheet Answer
MATN Course
Worksheet #
Worksheet tasks
ATTN1001A
ATTN1002A
BTTN1001B
Body & Trim
CLTN1001A
ELTN1003B
Handling of Battery
EMTN1001B
LCTN1001B
MATN1001B
MATN1002B
MTTN1001A
Maintenance Skills
Remarks
Worksheet
ATTN1001A
AT01A000
Maintenance Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform A/T external adjustment for RL4F03A type A/T, by using this worksheet.
Vehicle with FF type automatic transaxle
General tools
Worksheet

End of worksheet.
ATTN1001A
Using the Service manual found, complete the following questions and exercises.
1.
Find the GENERAL INFORMATION (GI) section.
2.
Using the table of contents in the GI section, locate IDENTIFICATION

INFORMATION, and turn to that page.
The IDENTIFICATION INFORMATION portion of the GI section contains

information which will assist you to identify the Transmission/Transaxle
installed in the vehicle.
3.
Find the illustration in this section which shows the location of the Vehicle
Identification Plate.
4.
Locate the illustration of the vehicles transmission model which is indicated

on the plate.
5.
Using the Service manual, find the location of the Vehicle Identification Plate
and Transaxle number. Write this below.
The AT section of the Service manual identifies repair information and specifications based on the Transmission model number. Because more than
one engine or transmission may be installed in a particular vehicle model, it
is important to apply the correct specification and procedures to the vehicle
that you are servicing.
6.
What is the transmission model and unit number?

Vehicle model:
Transmission model code:
Transmission number:
ATTN1001A
7.
Locate the AT section in the Service manual.
8.
On what page does the ON-VEHICLE SERVICE information begin?
Inhibitor switch adjustment:

It is important to correctly adjust the inhibitor switch. When it is incorrectly
*
adjusted, the engine may be started with the shift lever in D, 2, 1 or R range
which may cause dangerous situations.
9.
Remove Control cable end from the manual shaft of A/T assembly.
10. In which position should the manual shaft be set?

P/R/N/D
11. Loosen Inhibitor switch fixing bolts.

12. Insert a pin into adjustment holes in both inhibitor switch and manual shaft of
A/T assembly.
The Pin locks the inhibitor switch to the selector lever (manual shaft) thus fixing the position of the inhibitor switch.
13. What is the diameter of the pin to be inserted into the adjustment hole?
14. Remove pin from the adjustment hoes after adjusting the inhibitor switch.
15. Check continuity of the Inhibitor switch according to the procedure for Electrical components in the TROUBLE DIAGNOSIS in AT section.
Models with indicator lamp
Models without indicator lamp
Lever position "P" between 3 and 4 is open / close.

Lever position "R" between 3 and 5 is open / close.
Lever position "N" between 1 and 2 is open / close.
Lever position "D" between 3 and 7 is open / close.

ATTN1001A
16. Re-install any part that has been removed.
17. Check eachitem shown belows.
Move selector lever from P range to 1 range.

Does the selector lever move smoothly without
Any abnormal noise?
YES / NO
Does reverse lamp turn ON in R range?
YES / NO
Does the engine start only in the N and P positions?
YES / NO
Can the engine be started in positions other than N or P?
YES / NO
Control Cable Adjustment:
When control cable is incorrectly adjusted, the engine may be started in D, 2,

1 or R range which may cause dangerous situations.
18. Loosen control cable lock nut.
19. Set select lever and manual shaft.

In which position should the select lever and manual shaft be set?
20. Pull control cable in the direction of the arrow shown in the illustration using
specified force. How much is the specified force?
0.7 kg
21. Return control cable 1.0 mm in the opposite direction of the arrow.
ATTN1001A
22.
Tighten Control cable lock nut.

What is the correct tightening torque?
1.2 - 1.5
kg-m
Make sure that the positions of the manual control linkage and the rod do not
change when tightening the lock nut.
23. Move selector lever from "P" range to "1" and make sure that selector lever
moves smoothly and without any noise. Apply grease to contacting areas of
selector lever and control cable.
24. Apply grease to contacting areas of selector lever and control cable.
Throttle wire adjustment:
A throttle wire is used on a conventional hydraulically controlled transmission

to report engine load, while a throttle position sensor is used in an electrically
controlled transmission. Throttle wire adjustment affects throttle pressure
and line pressure in the transmission, which affects shift timing and quality.
Correct adjustment of the throttle wire is critical to assure the proper shift
characteristics of the vehicle. Maladjustment can have a dramatic effect on
the shift pattern exhibited and the performance of the vehicle.
25. Use the Service Manual at your workshop to refer to the On-Vehicle Service section.
*
*
When the throttle wire is adjusted too tight, throttle pressure will become too
high, causing the transmission to shift late.
When the throttle wire is adjusted too loose, throttle pressure will become too
low, causing the transmission to shift early.
26. Locate the Throttle Wire adjustment procedure in the On-Vehicle Service
section.
ATTN1001A
*
This procedure requires you to measure the throttle wire stroke (measurement "L"). This measurement is made by placing marks on the throttle wire
to facilitate measuring the wire stroke.
27. If the vehicle at your workshop requires an adjustment of the Throttle Wire,
perform the adjustment according to Service manual procedures. Then,
answer the following questions.
28. Should the ignition switch be turned off when the Throttle Wire adjustment is
performed?
YES / NO
29. Should the throttle wire stroke be adjusted when the throttle wire or accelerator wire is installed?
YES / NO
30. How long was the throttle wire stroke in millimeters in your measurement?
mm
31. Should the throttle wire stroke be adjusted when the accelerator pedal stroke
is checked?
YES / NO
32. If the throttle wire had been set too loose, will kickdown occur?
YES / NO
questions, feel free to ask him.
Worksheet
ATTN1002A
AT02A000
Maintenance Skills
External Adjustment of E-A/T (ATTN1002A)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform A/T external adjustment for FR type A/T, by using this worksheet.
Vehicle with FR type transmission
General Tools and insert pin
Worksheet

End of worksheet.
ATTN1002A
[REFERENCE]
MODEL NO. AND ITS IDENTIFICATION
Model No.
01
A
Modification
Classification
Drive (R: rear-wheel drive)
No. of forward speed ranges
E: Electronic-controlled with lock-up
Control type (R: remote control)
AT62A001
Unit No.
On the RE4R01A automatic transmission, unit No. and assembly No. are indicated on the
label attached to the rear extension.
0035
Production serial number
1-9: January-September
Month manufactured
X: October
Y: November
Z: December
Last digit Year manufactured
(8: 1988)
41X2
Last five digits of assembly parts No.
ATTN1002A
Using the Service Manual found, complete the following questions and exercises.
1. Find the GENERAL INFORMATION (GI) section.
2. Use the table of contents in the GI section, locate IDENTIFICATION INFORMATION, and turn to that page.
* The IDENTIFICATION INFORMATION portion of the GI section contains

information which will assist you to identify the Transmission installed in the
vehicles.
3. Find the illustration in this section which shows the location of the Vehicle
4. Locate the indication of the vehicles transmission model indicated on the

plate.
5. Using the Service Manual, find the location of the Vehicle Identification Plate
and Transmission number. Write this below.
The AT section of the Service Manual identifies repair information and specifications based on the Transmission model number. Because more than one
engine or transmission may be installed in a particular vehicle model, it is
important to apply the correct specification and procedures to the vehicle that
you are servicing.
6.

Vehicle model:
ATTN1002A
7. Locate the AT section in the Service Manual.
8. On what page does ON-VEHICLE SERVICE information begin?
9. Locate Inhibitor Switch Adjustment.

*

10. Remove manual control linkage from the manual shaft of A/T assembly.
This inhibitor switch can only be adjusted with the manual shaft set in the N
position.
A/T assembly.
ATTN1002A
15.
Remove pin from the adjustment holes after adjusting the inhibitor switch.
16.
Check continuity of Inhibitor switch according to the procedure for Electrical

components in the TROUBLE DIAGNOSES section.

Lever position P between 1 and 2 is
open / close
open / close
Lever position R between 3 and 5 is
open / close
Lever position N between 1 and 2 is
open / close
open / close
Lever position D between 3 and 7 is
open / close
Lever position 2 between 3 and 8 is
open / close
open / close

open / close
open / close
open / close
17.
Re-install any part that has been removed.
18.
Locate Manual Control Linkage Adjustment in ON-VEHICLE SERVICE.

Go to that page.
ATTN1002A
Manual Control Linkage Adjustment
*
*
When manual control linkage is maladjusted, the engine may be started in

D, 2, 1 or R range which may cause dangerous situations.
Refer to the Service manual for adjustment procedure. Follow this procedure
to set the manual control linkage.
19. In which position should the select lever be set?
20. Loosen control linkage lock nut.
AT02A002
21. Does the lever marker align with the P mark on the position indicator in the P
position?
YES / NO
If not, adjust.
22. Tighten lock nut.
Make sure the positions of the manual control linkage and the rod do not
23. What is the correct tightening torque?

N-m / kgm / ft-lb
ATTN1002A
24.
Move selector lever from P range to 1 and make sure that selector lever
moves smoothly without any noise.
25.
Apply grease to contacting areas of selector lever and manual control linkage.
26.
Check each item shown below:
* Does the select lever move smoothly?
YES / NO
* Is there any abnormal noise or shift sticking

when selector lever is shifted?
YES / NO
* Does the reverse lamp turn ON in R range?
YES / NO
* Does the engine start in N and P position?
YES / NO
* Can the engine be started in any positions

other than N or P?
YES / NO
Review the objective for this worksheet. If you are not clear on any part of the
met the objective, have your instructor initial your worksheet.
Worksheet
Body & Trim
BTTN1001B
BT01A000
Maintenance Skills
Body and Trim Adjustment (BTTN1001B/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to adjust the Hood lock
and Trunk lid lock by using this worksheet.
Nissan Vehicle
General tools
Service Manual
Textbook
Worksheet

End of worksheet.
BTTN1001B/WS1
Introduction
It is important to adjust hood lock correctly for safety and comfortable driving to avoid
hood opening, and making noise while driving. And also check and readjust the gaps
between the hood and the fenders, trunk lid, and so forth to get a good shape.
1. Locate the BT(BF) section in the Service Manual.

2. On what page does the BODY END information begin?
3. Is the gap between the hood and the fenders equal on both sides?
BT01A001
YES / NO
If not, adjust the gaps with hood adjustment A in the BF (BT) section of the
Service Manual.
Hood adjusting mechanism
BT01A002
BTTN1001B/WS1
4.
Is there any stepping between the hood and fenders?
BT01A003
YES / NO
If yes, adjust the steps according to the hood lock and adjustment procedure
in the Service Manual.
Be sure to check the bumper rubbers are in the fully down position or
remove them all before adjusting the hood primary lock.
5.
Does the hood opener operate smoothly?

YES / NO
If not, check and adjust the linkage and the brackets.
6.
On what page does the Body Rear End and Opener information begin?
7.
Does the trunk opener operate smoothly?

YES / NO
If not, check and adjust the linkage and brackets.
BTTN1001B/WS1
8.
Is it possible to close the trunk lid smoothly?

YES / NO
If not, check and adjust the striker according to the Service Manual.
9.
Is there any stepping between the trunk lid and fenders?

YES / NO
If yes, check and adjust the striker according to the Service Manual.
The striker is designed to lock at its lowest position when the trunk is forcefully closed. Adjust the striker so that it locks at minimum closing pressure.

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to remove and install
clips/fasteners, by using this worksheet.

General tools
Applied Model Service Manual
Worksheet

End of worksheet.
BTTN1001B/WS2
Put seat covers and floor mats on your vehicle before starting this worksheet.
* When removing as well as installing various parts, place metal pad and/or
cloth onto the vehicle body to prevent scratches.
1.
Locate the BT (BF) section.
2.
On what page does CLIP and FASTENER information begin?

Turn that page.
BT-3 (N16)
3.
How many kind of clips and fasteners are used for your assigned vehicle?
9 (N16)
4.
Pieces
On what page does INSTRUMENT PANEL ASSEMBLY information begin?
BT-21 (N16)
5.
Turn to that page.
6.
Review the procedure of Audio & A/C control panel removal.
7.
Which parts must be removed first?

Cluster lid C / Center ventilator assembly / A/T or M/T finisher
8.
9.
Check the location of clips and/or fasteners on parts which are chosen above
with the Service Manual.
Remove the parts according to the procedure of audio removal.
BTTN1001B/WS2
10.
Check the location of screws for audio unit assembly with the Service Manual, then remove them.
11. Review the procedure of Center console box removal.

12. Which parts must be removed first?
Ashtray
(N16)
13. Check the location of clips and/or fasteners on the parts which is chosen
above with the Service Manual.
14. Remove them.

15. Remove the center console box according to the procedure of the Service
Manual.
16. Install all removed parts.

17. On what page does DOOR TRIM removal and installation information
begin?

19. What kind of clips or fasteners are used for driver side door finisher?
CS101 / CS102 / C101 / C102 / C103 / C203
20. Which part must be removed first?

Door finisher screw / Inside handle escutcheon / Power window switch
BTTN1001B/WS2
21. Confirm the removal procedure of front door finisher.
22. Check the location of clips and/or fastener on front door finisher.
23. How many clips and fasteners are used for door finisher?
Pieces
24. Remove driver side door finisher with the procedure of the Service Manual.
Worksheet
CLTN1001A
CL01A000
Maintenance Skills
Clutch Pedal Adjustment (CLTN1001A)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to adjust the Clutchpedal height and pedal free play (free travel) on a manual transmission/axle vehicle by using this worksheet.
Vehicle with manual transmission/axle

Ruler
General tools
Service Manual
Worksheet

End of worksheet.
CLTN1001A
Introduction
The following operations are required whenever the clutch is replaced or the clutch pedal
free play is adjusted.
1. What is the vehicle specification?

Model:
Engine type:
LHD / RHD
2 Wheel Drive / 4 Wheel Drive
Clutch type: Hydraulic / Mechanical
Some floor configuration and pedal height differ with vehicle specifications.
2. Locate the CL section in the Service Manual.

3. On what page does the Inspection and Adjustment information begin?
Go to that page.
4. What is the specification of the Clutch pedal height?

mm
* It is essential that the floor, carpet and mats are removed before taking the
clutch pedal height measurement.
5. Is the clutch pedal height within the specification?

YES / NO
If not, adjust the clutch pedal height.
Hydraulic type go to Step 6.

Mechanical type go to Step 11.
CLTN1001A
6.
What is the specification of the pedal free play (free travel)?

mm
A = Free play
(Play due to clevis pin and clevis
pin hole in clutch)
Approx. 1 to 3 mm
B = Free travel
(Stroke where hydraulic pressure is just begining.)
Approx. 9 to 16 mm
CL01A001
7.
Measure the pedal free play (free travel) and then write it down.
mm
8.
Is the pedal free play (free travel) within the specification?

YES / NO
If not, adjust the pedal free play (free travel).
* When the clutch pedal free play (free travel) has been adjusted, check to see
the clevis pin rotates smoothly.
9.
Go to Step 15.
10. What is the specification of the items written below?

Pedal free travel
mm
Withdrawal lever play
mm
CLTN1001A
11. Measure the withdrawal lever free play and
then write it down.
mm
CL01A002
CL01A002
12. Is the withdrawal lever play within the specification?

YES / NO
If not, adjust the withdrawal lever play with adjusting nut.
13. Measure pedal free travel and write it down.

mm
14. Is the pedal free travel within the specification?

YES / NO
If not, readjust the withdrawal lever free play. (Go back to Step 12)
* Adjusting the withdrawal lever play to the specified range will generally also
bring the clutch pedal free travel distance to within the specified range. The
clutch pedal free travel distance is proportional to the withdrawal lever play.
Therefore, you can tell if the withdrawal lever play needs to be increased or
decreased by checking pedal free travel distance. Abnormal withdrawal
lever play and clutch pedal free travel may be the result of problems elsewhere in the assembly. Ask your instructor for assistance.
15. Put all the removed parts back.
CLTN1001A
* The clutch pedal free travel distance is proportional to the withdrawal lever
play. Therefore, you can tell if the withdrawal lever play needs to be
increased or decreased by checking pedal free travel distance.
Worksheet
Handling of Battery
ELTN1003B
EL03B000
Maintenance Skills
Handling of Battery (ELTN1003B)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet you will be able to inspect and maintain the Battery as an automobile power source.
Nissan vehicle
Safety glasses
Glove
Rag
Hydrometer

Worksheet

End of worksheet.
ELTN1003B
The BATTERY provides the source of electrical power for the automotive.
For example, when the ignition switch is turned to START, current is
drawn to starter to rotate the engine. And the BATTERY is used for the
power source of headlamp, power window, radio, etc. The BATTERY is
charged by the alternator while an engine is rotating. A properly functioning automotive electrical system requires a battery that is in good
condition and fully charged.
BATTERY construction
The battery consists of a case, plates and separators, etc.
EL03B001
Case
It is basically a container which houses the positive and negative
plates, separators, and electrolyte.
It is made of plastic resin or ebonite, which are not corroded by the
electrolyte. The interior of the case is divided into small compartments
called cells.
Positive and Negative plates
There are used to generate and store electricity by acting chemically
with the electrolyte. There are both positive and negative plates. Each
of them is shaped as a grid and made of an alloy that is prepared by
mixing antimony and lead.
ELTN1003B
At the positive plate lead peroxide (PbO2) is fitted in a grid. This plate
is colored chocolate. At the negative plate sponge lead (Pb) is fitted in
a grid. This plate is colored gray.
In each cell, the positive and negative plates are combined alternately
and the same kind of plates are grouped by plate straps. They are connected by a cell connector.
Separators
Insulation plates which prevent shorts caused by direct contact
between the positive and negative plates are also provided. These
plates are made of plastic resin, reinforced fiber, etc.
Cell Connector
These are used to connect the cells in series. A single cell is 2 volts,
therefore, six cells connected are 12 volts. Plate straps which hold the
positive and negative plates respectively are connected in series so a
cells negative plates are connected to the positive plates of an adjacent cell, and a cells positive plates are connected to the negative
plates of an adjacent cell, etc. They are made of a lead-antimony alloy.
Terminals
The terminals serve as inlet and outlet points for the batterys electricity. The plate straps that are located on the end are equipped with
poles that act as positive and negative terminals.
Vent Plugs
These plugs act as a stoppers for the cells inlet hole. They are made
of syntheric resin. They have small holes to release gas that is produced in the battery.
Whenever checking the battery, be sure to wear safety glasses to protect your eyes, gloves to protect your hands, and a shop coat to protect your body. If battery fluid comes in contact with your eyes, skin, or
clothing, flush immediately with cold water and seek medical attention
if necessary. Do not smoke, cause sparks to occur, or use open flame
near the battery.
When removing battery cables, remove the ground (negative) cable

first.
ELTN1003B
1.
Disconnect the battery cables, negative and positive Terminals.
2.
Check the battery specifications of your work station.

Battery type:
Battery manufacturer:
3.
Is the battery specification correct for assigned vehicle?

YES / NO
Refer to the Service Manual EL (or SDS) section under Battery.
Visual inspection
4.
Check the case for cracks and fluid leaks.

Damage: OK / NG Fluid leaks: OK / NG
If NG, ask your instructor for assistance.
5.
Inspect the cables and terminals for corrosion and cracks.

OK / NG
Check electrolyte level.

6.
Is the fluid level between MAX and MIN?

YES / NO
If NO, add distilled water as follows.
Remove the cell plug using a suitable tool.
Add distilled water up to the MAX level.
Plug the cell plug.
Clean the battery surface.
ELTN1003B
Check specific gravity
*
The specific gravity is the ratio of the sulfate divided by the weight of
an equal amount of water at 20C (68F).
Refer to the Hydrometer temperature correction chart on next page.
Example:
When electrolyte temperature is 35C (95F) and specific
gravity of electrolyte is 1.230, converted specific gravity at
20C (68F) is 1.240.
20C (68F) is 1.196.
EL03B003
ELTN1003B
7.
Wear shop coat, safety glasses and Glove.
8.

Suck up electrolyte.
9.
Read hydrometer and

thermometer indications at eye
level.
Gravity:
Temperature:
EL03B002
10. Convert into specific gravity at 20C (68F) based on the conversion
chart on previous page.
Gravity
11. Install the cell plug using a suitable tool.
Corrected specific gravity is below 1.220, charge the battery.

Corrected specific gravity is above 1.220, perform capacity check.
When you perform charging the battery and performing capacity
check, follow manufacturers instructions.
Review the objective of this worksheet. If you are not clear on any part of
the objective, ask your instructor for assistance. When you are satisfied
that you have met the objective, have your instructor check your work and
initial your worksheet.
Worksheet
EMTN1001B
EM01B000
Maintenance Skills
Engine Idle Adjustment (EMTN1001A/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to adjust the Carburetor Engine idle speed, by using the worksheet.
Vehicle with carburetor engine without catalyzer

Engine tuner (with Tachometer and Vacuum Meter)
General tools
Textbook
Worksheet

End of worksheet.
EMTN1001A/WS1
Answer the following questions by using the Service Manual.
1.
Locate the checking and adjusting idle speed and mixture ratio in the
Service Manual.
And go to that page.
2. Refer to the procedure in the Service Manual for adjusting Mixture

ratio and idle speed. Attach the engine tune meter and warm-up the
engine.
3. Check the following conditions in order to adjust idle speed and mixture ratio.
-Turn off headlamps
-Turn off heater blower
-Turn off rear defogger
-Keep front wheels pointed straight ahead
-Make the check after the cooling fan has stopped
-Gear shift lever in N or P position
4.
Is the idle speed lower than 1,000 rpm?

YES / NO
5.
If not, adjust idle speed less than 1,000 rpm.
The distributor has a mechanical governor system to advance the ignition timing when the engine is at speeds above idle. The engine must
be set at idle before inspecting or adjusting the ignition timing.
6.
What is the specification of basic idle ignition timing?

BTDC
EMTN1001A/WS1
7.
Check the idle ignition timing and write the result of checked value.
BTDC
8.
If idle ignition timing is out of specification, disconnect distributor vacuum hose and then adjust it by turning distributor.
9.
Which is the throttle adjusting screw on the following figure?

A / B
EM01B001
10. What is the idle speed specification?

rpm
11. Check the idle speed and write the result of checked value.
rpm
12. If idle speed is out of specification, adjust it by turning the throttle

adjusting screw.
13. When the throttle adjusting screw is turned clockwise, does idle speed
(increase/decrease)?
EMTN1001A/WS1
14. When the distributor is turned to clockwise (as viewed from above the
distributor cap), does ignition timing (advance / retard)?
Check this condition beforehand.

If you use CO-meter, go to Step 15.
If you do not use CO-meter, go to Step 20.

With CO-meter
15. What is the CO% specification at idle speed?
%
16. What is the CO% at idle speed?

%
17. If the CO is not within specification, adjust it by turning idle adjusting

screw.
Then perform from Step 6 to 15 again.
*
If the idle speed changes to become out of specification after adjusting

the idle mixture, reset the idle speed and recheck the idle mixture.
18. What is the CO% when idle compensator vacuum hose is disconnected and plugged at the intake manifold?
%
CO% should change when idle compensator is operated.

This is caused by air leaking from the vacuum hose when idle compensator is operated.
19. Go to Step 27.
EMTN1001A/WS1
Without CO -meter
20. What is the idle CO specification?

%
21. Unscrew idle adjust screw approximately two turns, starting from fully
closed position. Then, adjust to the specified engine speed by turning
the throttle adjusting screw in.
22. Is idle speed within specification?

YES / NO If not, adjust idle speed.
23. Turn the idle adjusting screw until engine runs smoothly at highest
speed.
* If you could not identify the best point, set the vacuum meter.
You can see the best point by using vacuum meter.
24. Adjust the idle speed again by turning the throttle adjusting screw.
speed.
26. Is idle speed with specification?

YES / NO
If YES, continue next.
If NO, go back to Step 23.
EMTN1001A/WS1
27. Put tools back and clean the work area.

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to adjust the Diesel
Engine idle speed, by using the worksheet.
Nissan vehicles with diesel engine (VE-type injection pump)

General tools
Service Manual
Textbook
Worksheet

End of worksheet.
EMTN1001A/WS2
1.
Locate the Idle Speed Check (VE-TYPE PUMP) procedure in the

Service Manual.
2.
3.
4.
Check the throttle control cable condition as follows.

Procedure:
1. Turn idle control knob fully counterclockwise.
2. Make sure that clearance between idle
control lever pin and fuel injection pump
control lever is within the specified range.
Clearance: 1 - 2 mm (0.04 - 0.08 in)
3. If not within the specified range, adjust with
idle control cable adjusting nut.
4. After adjusting clearance, tighten lock nut.
5.
EM01B002
What is the specification for idle engine speed?

rpm
6.
Remove clamps that secure No. 1 fuel injection tube in order to take an
accurate reading of engine speed.
EMTN1001A/WS2
7.
Attach tachometers pick-up to No.1 fuel injection tube.
EM01B003
8.
Turn off the lights, heater and all other accessories.
9.
Warm up the engine until coolant temperature indicator points to middle of gauge.
10. Perform the idle adjusting procedure according to the Service Manual
provided and use your findings to answer the following questions.
11. What was the engine speed before adjusting?

rpm
12. What is the engine speed after adjusting?

rpm
13. Were any problems found during the visual check?

YES / NO
14. If so, note them below:
EMTN1001A/WS2
(OPTION)
AIR CONDITIONER EQUIPPED MODEL
1.
Make certain that the clearance between the actuator idle control lever pin and the
injection pump control lever is within the specified limits.
2.
Adjust the idle speed to specified rpm without the air conditioner operating.
3.
Then check the idle speed when the air conditioner is operating and make
sure it is correct. If not, adjust it by turning F.I.C.D. actuator stroke adjusting
screw.
EM01B004
Engine Idle Check (EMTN1001B/WS3)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to check the QG

idle speed by using this worksheet.
Nissan vehicles with QG engine

Engine tuner with Tachometer and Vacuum Meter or
CONSULT-II
General tools
Service Manual
Worksheet
Textbook

End of worksheet.
EMTN1001B/WS3
1.
On what page does Basic Inspection information begin in the Service

Manual?
EC-58(N16)
Go to the page.
2.
Refer to the procedure in the Service Manual for idle speed and ignition timing.
Attach the engine tune meter or CONSULT-II and warm up the engine.
3.
In the case of inspecting idle speed, mark (

inspection below.
) on the correct basic
- Headlamp is OFF.
- Headlamp is ON.
- Air conditioner is OFF.
- Air conditioner is ON.
- Rear window defogger is OFF.
- Rear window defogger is ON.
- Steering wheel is in the straight-ahead position.
- During the cooling fan stop.
- During the cooling fan running.
- Gear shift lever in the N or P position.
(If equipped with A/T)
EMTN1001B/WS3
4.
When must you perform IACV-AAC valve initialization before Basic

Inspection?
Engine is cold / Every time before setting / Unstable idle
5.
Fill in the time in the blanks below when you perform IACV-AAC valve
initialization.
a) Stop the engine, then wait for
seconds.
b) Turn the ignition switch to ON, then wait for

c) Turn the ignition switch to OFF, then wait for
1
9
second.
seconds.
6.
Initialize the IACV-AAC valve according to the procedure in the Service

Manual.
7.
On what page does the Idle air volume leaning information begin in
the Service Manual?
With CONSULT-II:
EC-36
Without CONSULT-II:
EC-37
EMTN1001B/WS3
8.
When you perform IDLE AIR VOL LEARN, the following indicates
part of the necessary items at each step. Choose the correct number
below at the each step.
Turn the ignition switch to OFF , then wait for at least
Start the engine, then let the engine idle for at least 28
With CONSULT-II
sec.
sec.
Without CONSULT-II
Select IDLE AIR VOL LEARN

in ACTIVE TEST mode.
Disconnect the throttle

position sensor harness
connector, then reconnect
it within 5 seconds.
Touch START and wait for 20

sec.
5, 6, 7, 8, 9, 10,
20, 21, 22, 23, 24
25, 26, 27, 28, 29, 30
EMTN1001B/WS3
9.
Perform Idle air volume learn of IACV-AAC valve according to the procedure in the Service Manual.
rpm
(N16 QG18DE A/T: 700 +50rpm, M/T: 630 +50rpm)

11.
Check the idle speed.

rpm
12. Is the idle speed within specification?
YES / NO
If NO, check it according to the basic procedure in the Service Manual.
If YES, put tools back and clean the work area.
objective, ask your instructor for assistance. When you are satisfied that you
have met the objective, have your instructor check your work and initial your
worksheet.

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to check the YD or QD

or ZD Engine idle speed by using this worksheet.
Nissan vehicles with YD, QD, ZD engine

Tachometer for diesel engine or CONSULT-II
General tools
Service Manual
Worksheet
Textbook

End of worksheet.
EMTN1001B/WS4
1.

Manual?
Go to the page.
2.
Refer to the procedure in the Service Manual for idle speed.

Attach the diesel tachometer or CONSULT-II, then warm up the
engine.
3.

inspection below.
- Headlamp switch is OFF.

- Headlamp switch is ON.
- Air conditioner switch is OFF.
- Air conditioner switch is ON.
- Rear window defogger switch is OFF.
- Rear window defogger switch is ON.
- A check on the cooling fan after the switch is OFF.
EMTN1001B/WS4
4.
What page does the Reset Accelerator position sensor in the Service
Manual?
With CONSULT-II
Without CONSULT-II
5.
Reset the idle position memory of the accelerator position sensor.
6.
What is the specification of idle speed?

rpm
7.

rpm
8.
Is the idle speed within specification?

YES / NO
If YES, put tools back and clean the workshop.
9.
What is the engine speed after adjusting?

rpm
Judgement: OK / NG
If NG, ask to your instructor for assistance.
worksheet.
Worksheet
LCTN1001B
LC01B000
Maintenance Skills
Cooling System Inspection (LCTN1001B)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to change engine

coolant and perform Cooling system inspection, by using the
worksheet.
Nissan Vehicle
General tools, Radiator cap tester, Coolant hydrometer or
Battery coolant tester
Service Manual
Worksheet
Textbook

End of worksheet.
LCTN1001B
PART I
1.
On what page does the Changing engine coolant information begin in the
Service Manual?
LC-18 (N16)
MA-15 (A32)
2. Review the procedure for changing engine coolant.

3. Did you set the heater temperature control lever/button or temperature setting at maximum?
YES / NO
If NO, move or turn temperature control lever/button.
4.
Where is the location of drain plug?

Bottom of reservoir tank / Upper tank of radiator / Lower tank of radiator
5.
What is the coolant capacity with reservoir on your vehicle?
M/T 6.6, M/T 6.7
(N16)
Liter
6.
Drain the engine coolant according to the Service manual procedure.
7.
Go to your assigned work bench.
8.
Inspect opening temperature of the thermostat.

OK / NG
(If not, replace thermostat on actual job.)
9.
Where is the air relief plug located? (If equipped.)

Located on the:
Cylinder head / Intake manifold / Thermostat housing
/ Water gallery / None fitted
LCTN1001B
10. Fill the radiator with coolant according to the procedure of the Service Manual.
11. Check coolant level and leakage.

Coolant Level: OK / NG
Coolant Leakage: OK / NG
(If not, note them below and repair them.)
PART II
1.
On what page does the Checking Radiator Cap information begin?
2.
What is the specification of radiator cap relief pressure?
78 - 98
(kPa / bar / kg/cm / psi)
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
3.
Test the radiator cap pressure using the radiator cap tester.
4.
Is the radiator cap within the specification pressure?

YES / NO
(If not, replace the radiator cap.)
5.
What is the testing pressure required for cooling system leakage?
157
(kPa / kg / cm / psi)
2
(1.57 bar, 1.6 kg/cm , 23 psi)
6.
Check cooling system leakage with radiator cap tester.
* The test pressure should remain steady for approximately 1 minute.

* If the testing pressure drops, check the radiator tester itself for leakage and
then recheck the pressure.
* Inspect heater and radiator hoses and hose clips for condition and security.
CAUTION:
If excessively high pressure is applied, radiator and hoses may be damaged.
LCTN1001B
7.
Is there any coolant leakage in cooling system?

YES/NO (If not, note them below and repair them.)
PART III-1 Measurement of Coolant Mixture Ratio (The Use of Hydrometer)
1.
On what page does the Coolant Mixture Ratio information begin in the MA
section?
MA-10 (N16)
2. Does the engine coolant in the vehicle exceed regulated milage or

period?
YES / NO
If in excess of both regulated milage and period, replace the coolant with
new one.
If within both regulated milage and period, go to step 3.
3. Measure both temperature and specification of coolant mixture ratio.

Temperature of coolant
15
Mixture ratio:
30
(F)
LCTN1001B
* 1) Measure the coolant which should be below 45C.
2) Never remove the radiator cap when the engine is hot.
Serious burns could be caused by high pressure fluid escaping from the
radiator. Wait until the engine and radiator cool down.
3) Try to avoid direct skin contact with coolant. If skin contact is made, wash
thoroughly in water.
4.
What is the required coolant mixture ratio?
30
5.
Refer to a conversion table in the Service Manual.
6.
What is the coolant mixture ratio of assigned vehicle?

%
7.
Refer to the regulated mixture ratio in the Service Manual.
8.
Is the mixture ratio of this vehicle normal?

YES / NO
If YES, go to the end.
If NO, refill LLC, then go to the end.
PART III-2 Measurement of Coolant Mixture Ratio (The Use of Battery and Coolant
Tester)
1.
section?
MA-10 (N16)
LCTN1001B
period?
YES / NO
new one.
3.
What is the mixture ratio of coolant?

%
* 1) Measure the coolant mixture in normal temperature.

radiator.
Wait until the engine and radiator cool down.
4.
30
5.
6.
Is the mixture ratio of this vehicle within specification?

YES / NO
Worksheet
MATN1001B
MT01B000
Maintenance Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet you will be able to perform

PERIODIC MAINTENANCE, by using this worksheet and
Service Manual.
Nissan Vehicle, General tools

Torque wrench, Tachometer
Tire pressure gauge, Timing light
Radiator cap tester
Worksheet

End of worksheet.
MATN1001B
Refer to the Service Manual for your allocated vehicle, and complete the following
questions and exercise.
1. Find the MA section tab and go to that page.

2. On what page does PERIODIC MAINTENANCE begin?
MA-4 (N16)
3. Referring to the Maintenance schedule table, answer the following questions.

1)
Engine oil replacement

Interval
10,000 km / mile
Requirement of Nissan
Your Company
2)
km / mile
Brake fluid
Interval
40,000 km / mile
Your Company
*
km / mile
Basically the specified months or mileage for maintains should be 20,000km.
Engine Compartment
4. Put seat and fender covers on the vehicle.
Never remove the radiator cap when the engine is hot; serious burns could
be caused by high pressure coolant escaping from radiator. Wrap a thick
cloth around the cap and carefully remove it by turning it quarter turn to allow
built-up pressure to escape and then turn the cap all the way off.
MATN1001B
5.
Check condition of hoses and clamp for leaks and cracks on cooling system.
OK / NG
If NG, replace it.
To avoid the danger of being scalded, never open radiator cap when
engine is hot. Be careful not to allow coolant to contact drive belts.
6.
Perform Radiator cap test.

OK / NG
If NG, refill coolant.
7.
Check Engine coolant level at radiator neck.

OK / NG
8.
Check Engine coolant level at reservoir tank.

OK / NG
9.
What is the function of L.L.C. (Long Life Coolant)?

Mark the answer.
Fuel economy / Prevent rust / Clean air pollution / Anti freeze
10. Check Power steering fluid level and condition if equipped.

Fluid level: OK / NG
Fluid conditions: OK / NG (If NG, replace fluid.)
11. Check condition of hoses for leaks and cracks on power steering system.
OK / NG
MATN1001B
12. Check Brake fluid level and condition at reservoir tank.
When the level of the brake fluid is too low, fluid may be leaking.
Wash off spillage of brake fluid on the paint film with water immidiately, as
the paint may be damaged by the brake system.
13. Check Brake fluid leaks on brake system.

OK / NG
14. Check Clutch fluid level and condition at reservoir tank if applicable.
15. Check Clutch fluid leaks on clutch system if applicable.

OK / NG
16. Check all Drive belts for tension force, crack and wear.
1)
Belt tension
OK / NG
2)
Crack and wear
OK / NG
All Poly V belts tension should be inspected when the engine is cold after the
engine has remained stationary for approximately 30 minutes.
Drive belts cause noise when the tension is too low and too high.
17. Check battery conditions as follows.
1)
Terminal tightness
OK / NG
2)
Damage of positive terminal cover
OK / NG
3)
Electrolyte level
OK / NG
MATN1001B
*
Make sure to check all cells.

When the battery electrolytic temperature increases, the measured gravity
reduces. (The reverse may happen also.)
18. Check Ignition wires for cracks, damage, burned terminals and for poor connection if applicable.
OK / NG
If NG, replace them or ask your instructor.
19. Check Distributor cap for damage and crack if applicable.

OK / NG
20. Measure the resistance of each wire.

Resistance
Judgement
Center
OK / NG
No.1
OK / NG
No.2
OK / NG
No.3
OK / NG
No.4
OK / NG
No.5
OK / NG
No.6
OK / NG
21. Replace Spark plugs if required.
22. What is a specification of spark plug for your vehicle?

1)
Spark plug type
2)
Specification of gap
3)
Tightening torque
BKR5E
0.8 - 0.9
mm
20 - 29 N-m / kg-m
for N16
MATN1001B
23. Remove one spark plug, then check both condition and gap.
OK / NG
If NG, check all plug gap, then adjust their gap.
*
*
*
Brush the spark plug when it is covered with carbon. (Except platinum type
plug)
Install the spark plug by hand temporarily, then tighten it until only four or five
threads slightly by finger force to avoid damaging the threads of hole of cylinder head.
Tighten it with a torque wrench.
24. Check PCV (Positive Crankcase Ventilation) valve and hoses for leaks,
crack and collapse.
OK / NG
25. Check Vacuum hoses for leaks, cracks and connections.
OK / NG
26. Check leakage of coolant (water), oil and fuel in the engine compartment.
1)
Water leaks
OK / NG
2)
Oil leaks
OK / NG
3)
Fuel leaks
OK / NG
27. Replace Fuel filter and Air filter (Element) if required.
28. Check Air filter for clogged or damage.

OK / NG
MATN1001B
29.
Does a viscous type filter need for air blow when paper gets dirty?
YES / NO
Viscous paper type filter does not need air blow for cleaning, but it is necessary to replace it when it gets dirty. Dry paper type filter is necessary to clean
the element or replace it at the recommended intervals, more often under
dusty driving conditions.
30. Check Engine oil level and conditions.

OK / NG
*
The engine may fail or wear out prematurely if the incorrect grade or oil quality classification is used. The viscosity range is determined depending upon
the ambient air temperature expected during the operation period.
31. Remove engine oil filter cap if required to replace engine oil.
32. What is the specification of tire pressure for your assigned vehicle?
Front:
kPa / kg/cm2 / psi
Rear:
kPa / kg/cm2 / psi (If different)
33. Lift vehicle up to middle height (approximately. 1.2m from ground).

34. Inspect Tires pressure and then check for defects, wear and damage at the
same time.
OK / NG
If NG, refill air or advice customer to change their tires.
Rotate tire between the front and the rear if you find uneven wear between
the front and the rear.
MATN1001B
35. Check Wheel bearing axial end play both the front and the rear.
OK / NG
If NG, note them below and ask your instructor for assistance.
36. Check Shock absorber oil leakage on suspension system.

OK / NG
37. What is the specification of brake pad wear limit?

Front:
mm
Rear:
38. Inspect thickness of the Front / rear brake pads.

OK / NG
39. Remove Rear tires, then inspect rear brake lining for wear if applicable.
OK / NG
40. Check Drum inner surface for crack and damage if applicable.
OK / NG
41. Check brake wheel cylinder body for leakage.
OK / NG
Under body
42. Lift vehicle up to high position (maximum height to lift).
43. Drain Engine oil, then replace engine oil filter if required.
mm
MATN1001B
44.
Replace Manual transmission oil if required.
45.
Check Manual transmission oil level if applicable.

OK / NG
46.
Replace Differential gear oil if required.
47.
Check Differential gear oil level if applicable.

OK / NG
48.
Check Clutch fluid leaks from operating cylinder if applicable.

OK / NG
49.
Check Front drive shaft boots for cracks and damage if applicable.
OK / NG
50.
Check Rear drive shaft boots for cracks and damage if applicable.
OK / NG
51.
Check Under body for damage and deformation.

OK / NG
52.
Check Leakage for coolant (water), oil and fuel from underside body.
1)
Water leaks
OK / NG
2)
Oil leaks
OK / NG
3)
Fuel leaks
OK / NG
MATN1001B
53. Check Exhaust system fittings.
OK / NG
54. Check all nuts and bolts of suspension and axle components for tightness.
OK / NG
55.
Check the ball joints for damage and grease leaks.

OK / NG
56. Lower the vehicle until the ground.
57. Refill Engine oil, then check oil level.
58. Start engine, then warm it up.
59. Check following items during engine warm-up.
1)
Parking brake lever stroke
OK / NG
If NG, repair it.
2)
Windshield wiper operation
OK / NG
If NG, repair it.
3)
Headlamps
OK / NG
If NG, repair it.
4)
Turn signal lamps
OK / NG
If NG, repair it.
5)
Hazard lamps
OK / NG
If NG, repair it.
60. Check Clutch pedal height and free travel(play).

OK / NG
10
MATN1001B
61.
62.
63.
64.
Check Idle conditions as follows after engine warm-up.
1)
Ignition timing
OK / NG
If NG, adjust it.
2)
Engine speed
OK / NG
If NG, adjust it.
Check automatic transmission/axle fluid level and conditions.
1)
Fluid level
OK / NG
If NG, adjust it.
2)
Fluid conditions
OK / NG
If NG, replace it.
Check vacuum hose of brake booster for crack and leaks.
1)
Operation check
OK / NG
If NG, adjust it.
2)
Air leaks
OK / NG
If NG, adjust it.
Block the tail pipe temporarily by placing a rubber mat over the exhaust pipe
end. Run the engine, then check for leaks (while idling after warming up the
engine).
Check exhaust system for leaks.

OK / NG If NG, ask your instructor for assistance.
11
Worksheet
MATN1002B
MA02B000
Maintenance Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet you will be able to perform the PDI,
by using this worksheet, PDI Manual and Service Manual.
Nissan Vehicle, General tools,
Tire pressure gauge,
Timing light,
Gas leak detector
Worksheet
New Vehicle Handling Manual-G sec. for PDI (NV3E-0PDIG0)
PDI Checklist (Your own list)

End of worksheet.
MATN1002B
Using the Service Manual found at your work station and the vehicle, answer the
following questions and fill out the blanks. Also fill out inspection results on your
PDI checklist.
Before starting PDI

1. Fill out the following information on your PDI checklist.
1) Vehicle model
2) Vehicle Identification Number
3) Engine number
4) Registered number (License number)
5) Key number
6) Mileage reading
7) Other item if you need
2. Did you park the vehicle on a flat area?
YES / NO
If NO, place the vehicle on a flat area.
3. Check engine hood operation.

OK / NG
4. Open engine hood, then check the position of engine hood lock if applicable.
5. Put fender covers, seat and handle covers on the vehicle.
Under the hood
6. Does the coolant level come up to the top of the radiator?
YES / NO
7. What is the coolant level in the reservoir tank?

OK / NG
If NG, fill in coolant.
MATN1002B
8.
How many drive belts are used in the vehicle?

pieces
9.
What is the applied pushing force for the alternator belt?
10
N / kg / lb
10. Check the tension force of all belts and adjust if necessary.
11. What problem occurs when the tension force of a belt is too tight?
Damage to bearings (Alternator, Water pump, P/S pump)
12. What problem occurs when the tension force of a belt is too loose?
Will make belt slip noise.

1)
Terminal tightness
OK / NG
2)
Damege of positive terminal cover
OK / NG
3)
Electrolyte density
OK / NG
4)
Electrolyte level
OK / NG
* Make sure to check all cells.

14. Check the brake fluid level at brake master cylinder reservoir tank.
OK / NG
If NG, fill in the brake fluid.
* In case the level of the brake fluid is too low, fluid may be leaking.
Wash off spillage of brake fluid on the paint film with water immediately, as
the paint may be damaged by the brake fluid.
MATN1002B
15. Check Clutch fluid level at master cylinder reservoir tank if applicable.
OK / NG
16. Check power steering fluid level if applicable.

OK / NG
17. Check Engine oil level.

OK / NG
18. Check the front and rear window washer fluid tank level.
Front:
OK / NG
Rear: OK / NG (If available)
19. Check fluid, oil and water leaks in the engine compartment.
OK / NG
Underside of vehicle
20. Lift vehicle up to approximately 1.2 m which is middle height.
21. What is the specification of tire pressure?

Front:
kPa / bar / kg/cm2 / psi
Rear:
kPa / bar / kg/cm2 / psi (If applicable)
22. Check Tire pressure for damage, then check suspension conditions at the
same time.
1)
Tire pressure
OK / NG
2)
Tire damage
OK / NG
3)
Shock absorber leak
OK / NG
4)
Suspension spring
OK / NG
MATN1002B
23.
Lift vehicle up to high position.
24. Check following items.

1)
Check underside body damage.
OK / NG
2)
Check free running hub operation if applicable.
OK / NG
3)
Check oil level for differential gear if applicable.
OK / NG
4)
Check for fluid and water leakage.
OK / NG
5)
Check tightness of bolts/nuts on suspension system. OK / NG
6)
Check exhaust system fitting.
OK / NG

Inside vehicle
26. Check operation of doors and door locks, then get into the vehicle.
OK / NG
27. Install fuses that were removed during transport to prevent battery discharge.
* Fuses are usually found in the ashtray.

28. Check operation of seats.
OK / NG
If NG, note the failure part.
* Refer to the Service Manual when power seats are equipped.

29. Check operation of seat belts.
OK / NG
30. Check warning lamps when ignition key is in the ON position.

OK / NG
MATN1002B
31. If the vehicle is equipped with Automatic transmission, check the engine
start conditions.
1)
Shift lever position to N and/or P position
OK / NG
2)
Shift lever position without N and P position
OK / NG
32. Start engine, then warm up it.

33. Check steering wheel lock and position adjustment.
OK / NG
34. Check other items while warming up the engine.

1)
Horn
OK / NG
2)
Dash panel lamp and room lamp
OK / NG
3)
Headlamps and High beam indicator
OK / NG
4)
Headlamps cleaner if applicable
OK / NG
5)
Combination lamps and Turn signal lamps
OK / NG
6)
Hazard lamp
OK / NG
7)
Door courtesy lamps, Vanity mirror lamps
OK / NG
8)
Windshield wipers and washers

(Front and rear if applicable)
OK / NG
9)
Heater and Air conditioner
OK / NG
10)
Rear window defogger
OK / NG
11)
Sunroof and T-bar roof operation if applicable
OK / NG
12)
Window operation
(window lock switch operation if applicable)
OK / NG
13)
Fuel lid and Trunk lid operation
OK / NG
14)
Rearview mirrors
OK / NG
15)
Set clock and radio station preset
OK / NG
MATN1002B
35. Check glove box lid and other interior components according to the PDI Manual.
Glove box lid
OK / NG
Console box lid
OK / NG
Ashtray
OK / NG
36. Check jack, tool installation, and spare tire pressure.

OK / NG
37. Check wheel nut tightening torque.

OK / NG
38. Check operation of all door locks and child safety door locks (if applicable) on
your assigned vehicle.
OK / NG
39. Is the engine warmed up?

YES / NO
* If answer is "NO", raise the engine speed and warm up the engine again.
40. Check automatic transmission select lever operation through each gear position, after checking shift operation to P position.
OK / NG
41. What is the specification of idle engine speed and ignition timing?
rpm
BTDC
MATN1002B
42. Check engine idle speed and ignition timing, then adjust them if necessary.
OK / NG
43. Check Automatic Transmission fluid level.
OK / NG
44. Check air conditioner for refrigerant leakage with gas leak detector if applicable.
Worksheet
MTTN1001A
MT01A000
Maintenance Skills
External Adjustment of M/T (MTTN1001A)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform M/T external adjustment for RS5W71C (C23) by using this worksheet.
Vehicle model: C23
General tools
Service Manual
Worksheet

End of worksheet.
MTTN1001A
1.
2.


3.
4.

on the plate.
5.
Using the Service Manual, find the location of the Vehicle Identification Plate
VIP: On the dash panel in the engine compartment

M/T No.: On the transmission case (Clutch housing side)
The MT section of the Service Manual identifies repair information and specifications based on the Transmission model number. Because more than
that you are servicing. (See worksheet GITN1003A if you cannot understand the meaning of the codes.)
6.

Vehicle model:
MTTN1001A
GEAR CONTROL adjustment:
Using the Service manual, complete the following questions and exercises.
If the control cable is maladjusted, the shift action will become poor.
7.
On what page does GEAR CONTROL information begin?
MT-7
8.
Adjust gear control according to Service manual.
9.
In which position should shift lever be set?
10. In which position should select lever be set?

N
11. What is tightening torque of lock nuts?

Shift cable lock nut: 0.8-1.1 kg-m
Select cable lock nuts: 0.3-0.4 kg-m
12. Does control lever mounting appear secure when control lever is operated?
YES / NO
MTTN1001A
13. Does Control lever move smoothly?
YES / NO
14. Is there any abnormal sound or shift sticking when control lever shifted?
YES / NO
Worksheet Answer
TOOL Course
Worksheet #
Worksheet tasks
ELTN1002B
GITN1004B
GITN1007B
ECTN1002A/WS1
CONSULT Introduction
ECTN1002A/WS2
CONSULT Self-diagnosis
ECTN1002A/WS3
CONSULT Work Support
ECTN1002A/WS4
CONSULT Function Test
ECTN1003B/WS1
CONSULT-II Overview
ECTN1003B/WS2
CONSULT-II Self-diagnosis
ECTN1003B/WS3
CONSULT-II Work support
ECTN1003B/WS4
CONSULT-II
Function Test Mode
Usage of Tools
Remarks
Worksheet
ELTN1002B
EL02B000
Usage of Tools

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to measure voltage,

and resistance with digital multimeter.
Vehicle with ECCS Engine

Digital Multimeter

Worksheet
Textbook

End of worksheet.
ELTN1002B
Measuring Voltage
* A voltmeter measures voltage. You can diagnose many electrical malfunctions by using a voltmeter to measure system voltage.
1. The following figure indicates the Digital multimeter.

Fill the table with a suitable name chosen from those in the box below.
(1)
No. Name
1
b
(3)
2
j
3
d
(4)
(2)
4
c
(5)
5
h
6
i
(6)
7
g
(14)
(7)
8
f
9
g
(8)
10
k
11
m
(9)
12
n
(13)
13
e
(10)
(12)
14
a
EL02B001
a:
c:
e:
g:
i:
k:
l:
m:
n:
(11)
Rotary switch
DC voltage
DC current
Voltage, Resistance, Diode and continuity
Resistance
COMMON TERMINAL
VOLT, ohms, Diode test terminal
Max, 300mA, Current test terminal
Max, 10A, Current test terminal
b:
d:
f:
h:
j:
LCD display
AC voltage
AC current
300 mV DC voltage
OFF
ELTN1002B
2. Switch the voltmeter to measure DC VOLTs (

3.
Connect the meter test leads to the DIGITAL TESTER.

The RED tester lead connects to the V
input jack.
The BLACK test lead connects to the COM
(Common) input jack.
EL02B002
4. Measure the battery voltage.

Connect the RED test lead to
the Battery positive (+) terminal
on the vehicle.
Connect the BLACK voltmeter
test lead to the Battery negative (-) terminal on the vehicle,
and then fill out the results on
the illustration of screen.
EL02B003
ELTN1002B
* Generally, horn circuit is as follows.
Bottom view of the

HORN RELAY
EL02B004
EL02B005
5. Remove the Horn Relay from

assigned vehicle.
EL02B006
ELTN1002B
6.
Measure the Horn Relay power

supply voltage, and then record in
the space provided in the illustration.
EL02B007
EL02B008
* Excessive circuit resistance reduces current flow and results in an accessory

operating incorrectly.
7.
Switch the voltmeter to measure Resistance (), and

then measure Resistance
between the Horn Relay terminal number one to two and
record in the space provided in
the illustration.
EL02B009
* Never use the ohmmeter to make any tests with power connected to
the circuit being tested in ohm range.
* Never touch positive and negative test lead metal portion with your
hand when measuring the resistance.

8.
Disconnect injector harness connector.
EL02B010
ELTN1002B
9.
What is the injector resistance specification?
10. Choose 2 fuel injectors and measure resistance.

Injector
#
#
Resistance Judgement
OK / NG
OK / NG
Checking continuity
* In continuity testing function, the buzzer starts buzzing continuously
below the threshold level.
11. Switch the multimeter to check continuity (
).
EL02B011
12. Contact the red lead wire with the black lead wire.
Does the buzzer ring?
YES / NO
EL02B012
ELTN1002B
13. Connect the BLACK lead wire of the multimeter to negative (-) terminal of the battery, connect the red lead wire of the multimeter to the
body, and then check the continuity.
OK / NG
* To check the continuity of the circuit, change the multimeter to check

continuity
mode, and then check ON or OFF on the Buzzer.
Upon completion, have your instructor sign off this worksheet and move on
the next one. If you have any question, feel free to ask him before starting
the next exercise.
Worksheet
GITN1004B
GI04A000
Usage of Tools
Usage of Measuring Tools (GITN1004A/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to use a Vernier caliper, by using this worksheet.
Vernier caliper
Disc Brake Pad, Bolt, Nut
Worksheet
Textbook

End of worksheet.
GITN1004A/WS1
1.
Read the Textbook and answer the following questions.
2.
Fill out the name of each parts of vernier caliper in the blank boxes.
Select and put the correct answer number in the blank boxes.
1. Depth rod
2. Stop screw
3. Outside measuring jaw
4. Weight scale
5. Inside measuring jaw
GI04A001
3. What can the vernier caliper measure?

Mark the correct ones.
4.
1. Weight
2. Depth
3. Volume
4. Outer diameter
5. Tire pressure
6. Inner diameter
Which is the most accurate measurement method in the following figures?

Mark the correct anwer.
GI04A002
GI04A003
GITN1004A/WS1
5.

GI04A004
GI04A005
GI04A006
GI04A007
GITN1004A/WS1
6.
What is the scale reading below?
GI04A008
7.
GI04A009
8.
If you do not fully understand how to read the vernier caliper scale, ask your
instructor for assistance. Refer to the textbook first.
If OK, go to next.
9.
Check the alignment of jaws and zero point scale.
There should be no clearance when the outside jaws are fully closed.
10. Measure the outside diameter of bolt provided. (one piece)
mm
GI04A010
GITN1004A/WS1
11. Measure the brake pad thickness.
mm
GI04A011
12. Measure the assigned nut inner diameter.

mm
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to use Dial indicator,
by using this worksheet.
Dial indicator and stand

V-block and surface plate
Camshaft
Textbook
Worksheet

End of worksheet.
GITN1004A/WS2
1.
Read the textbook and answer the following questions.
2.
Fill out the name of each parts of Dial indicator in the blank boxes.
1. Spindle
2. Main scale
3. Outer ring
4. Revolution counter
5. Pointer
GI04A012
6. Adjusting needle
3. What can the Dial indicator measure?

4.
1. Runout
2. Weight
3. Axles shaft end play
4. Temperature
5. Volume
6. Valve lift
Which is the correct measurement on the following figure?

Mark the correct anwer. (Refer to the textbook)
GI04A013
GITN1004A/WS2
5.
Which is the correct measurement method on the following figure?

Mark the correct answer. (Refer to the Textbook.)
GI04A014
6.
What is the measuring range of Dial indicator provided?

Minimum
7.
mm / Maximum
mm
When the runout of camshaft is measured, the Dial indicator reads as follows.
GI04A015
8.
What is the runout of camshaft?
0.18
mm
GITN1004A/WS2
9.
When the spindle of Dial indicator is pushed, the pointer moves

clockwise / counterclockwise
10. Measure the camshaft runout in accordance with following procedure.

*
Check Dial indicator condition before measuring.

(Check for spindle play and stroke smoothness)
11. V-blocks are placed on the surface plate, and the camshaft placed in the Vshaped grooves as in the following figure.
GI04A016
Use same height V-blocks to keep horizontal axis.
12. The spindle of the Dial indicatior is set horizontally, directed toward the center of the camshaft as in the following figure.
GI04A017
GITN1004A/WS2
13. Press the spindle against the camshaft, so that pointer makes at least one
rotation. By turning the bezel, bring the zero on the dial face directly under
the pointer.
14. Slowly turning the camshaft one revolution, obtain the maximum reading for
oscillation clockwise and counterclockwise from the indicator.
As shown in the following figure, the bend of the camshaft is indicated by half
the total indicator reading.
Runout
Bend =
GI04A018
15. What is the maximum oscillation clockwise?

mm
16. What is the maximum oscillation counterclockwise?

mm
total indication reading

2
GITN1004A/WS2
17. What is the camshaft runout?
mm
18. What is the camshaft bend?

mm
worksheet.
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to use a Micrometer,

Micrometer
Camshaft and Piston
Textbook
Worksheet

End of worksheet.
GITN1004A/WS3
Part names of a micrometer (Refer to the Textbook.)
1. Select the name of each part of micrometer from below and fill its number in
the boxes.
GI04A019
1. Lock clamp
2. Thimble
3. Spindle
4. Outer sleeve
5. Anvil
6. Ratchet stopper
Checking the zero point of micrometer

To check the zero point, first clean the contact points on the anvil and the
spindle, secure the micrometer using a micrometer stand, and correctly
clamp a standard gauge corresponding to the minimum value between the
anvil and the spindle. Turn the ratchet stopper two or three turns and then
closely read at zero point.
Precautions for measurement

Clean the contact points of the anvil, the spindle and the surfaces to be measured. Correctly fit the object between the anvil and spindle, and take a measurement turning only the ratchet stopper.
Do not turn the thimble. One measurement is not enough, so take measurements several times.
GITN1004A/WS3
2.
lnspect the scale deviation of micrometer (zero point) with the standard gauge
provided.
GI04A020
3.
What is the scale deviation?

mm
4.
Adjust the micrometer if the zero line on the thimble auxiliary scale is not correctly aligned with the base line on the scale.
(Refer to the following key points.)
GITN1004A/WS3
*
Zero Point adjustment

1) If the deviation is 0.02 mm or less
Fix the spindle once with the lock clamp. Insert the edge of the
adjusting wrench (supplied with the micrometer) into the small hole
in the outer sleeve. Then, align the "0" point of the thimble with the
index line of the outer sleeve. After adjustment is completed,
recheck the "0" point to confirm that the micrometer is calibrated
correctly.
GI04A021
2) If the deviation is larger than 0.02 mm
Fix the spindle with the lock clamp, and loosen the ratchet stopper
with the adjusting wrench to free the thimble. Align the "0" point of
the thimble with the index line of the outer sleeve, and retighten the
ratchet stopper with the adjusting wrench. After adjustment is completed, re-check the "0" point to confirm that the micrometer is calibrated correctly.
GI04A022
GITN1004A/WS3
5.
Reading the scales. (Refer to the Textbook - How to read the scale.)
6.
What does the scale below read?
4.00
mm
GI04A023
7.
5.00
mm
GI04A024
8.
4.50
mm
GI04A025
GITN1004A/WS3
9.
4.24
mm
GI04A026
10. What does the scale below read?

4.74
mm
GI04A027
* Feel free to ask your instructors if you do not understand how to read the
scale so far, even though you have already read the Textbook several times.
If OK, go to next step.
* It is essential to get the micrometer to correctly contact the work to be measured. Do not fail to hold the micrometer at right angles to the surfaces
being measured.
GI04A028
GITN1004A/WS3
11. Measure the outside diameter of camshaft journal provided. (one piece)
GI04A029
12. What are the diameters of camshaft journals?

No.
5.
Diameter
mm
mm
mm
mm
mm
Two actual measurement should be taken of camshaft; one at X point and

one at Y point.
GI04A030
13. Measure the piston skirt diameter. (one piece) Check Micrometer zero
position before measuring. Refer to the Service manual for measuring

point "a" on the piston skirt.
GI04A031
GITN1004A/WS3
14. What is the diameter of that?
mm
worksheet.
INSTRUCTOR SIGN-OFF
Usage of Measuring Tools (GITN1004B/WS4)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand Usage of Torque

wrench, by using this Worksheet.
Torque wrench (Plate-spring-type, Auto-limit-type)

General Tools
Nissan Vehicle
Service Manual
Worksheet

End of worksheet.
GITN1004B/WS4
1.
2. Draw lines to match the tool name to the appropriate tool in the photo.
* Auto-limit-type
* Plate-spring-type
GI04B001

1)
26
kgfcm
GI04B002
2)
660
GI04B003
kgfcm
GI04B004
GI04B005
GITN1004B/WS4
4.
Which method of the following figures is used more frequently?

GI04B006
5.
Fill out the name of each part of the torque wrench in the blank box.
1. Needle
2. Main Grad
3. Locker
4. Pin
5. Sup Grad
GI04B007
6.
Which paragraph is suitable for Precaution for use. Mark (

rect answer.
) on the cor-
1. Use the wrench without the scale range.

2. Make sure the torque wrench is set correctly before using.
3.The loading direction must be at right angles to the torque wrench
(tolerance +/- 20 degrees).
4. Stop tightening when you feel a click.
5. Lock Sup. Graduation, by using pliers.
GITN1004B/WS4
7.
What is the tightening torque of wheel nut?

8.
Set tightening torque on torque wrench.
9.
Tighten the wheel nuts for rear wheels.
10.
Put all equipment back to original position.
Worksheet
GITN1007B
GI07B000
Usage of Tools
Usage of Taps and Dies (GITN1007B)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand Usage of Taps and
Dies, by using this Worksheet.
Taps, Dies pitch gauge

Vernier Caliper
Oiler
Worksheet
Textbook

End of worksheet.
GITN1007B
Part1: Taps
1.
2.
What is the use of the tap?

1) Make a hole
2) Cut a male screw
3) Cut a female screw
3.
Which is the most accurate repair method in the following figures?

Choose the correct one.
GI07B001
4.
5.
GI07B002
Put numbers (1-3) in the order of usage priority.
Second hand tap (for semi finishing)
Third hand tap (for final finishing)
First hand tap (for rough finishing)
If the bolt is broken at the inside of the case, choose suitable tool for repairing
it.
1) Pin punch
2) Dies
3) Center Punch
4) Drill
5) Screw extractor
GITN1007B
6.
Measure the outer diameter of bolt.

mm(inch)
7.
Measure the pitch of bolt.

pitch
8.
In the result of measuring at the above, choose the correct tap.
9.
Refer to the flow chart of the tap procedure.
10. Proceed to the work by using the tap.
Part 2: Dies
1.
2.
What is the use of the Dies?

1) Make a hole
2) Cut a male screw
3.
Which of the following measurements should be made when selecting a die?

1) Measure the length of bolt.
2) Measure the outer diameter of bolt.
3) Measure the length of screw threads.
4) Measure the pitch with a pitch gauge.
GITN1007B
4.
Which is the correct way to handle dies?
1) A portion of round open die cannot be adjusted.

2) The inside of die tapers to start to cut easily.
3) It is possible to make a cut all at once in the case of using dies.
4) First turn the die one rotation clockwise, then use the die while turning it a
half rotation counterclockwise (to eject the metal cuttings).
5) Oil must be used when cutting with the die (to allow heat to escape and
make the cut surface smooth).
met the objective, have your instructor check your work and initial for your Worksheet.
Worksheet
Usage of CONSULT
ECTN1002A
EC02A000
Usage of Tools
CONSULT Introduction (ECTN1002A/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to prepare the

CONSULT for diagnosis, by using the worksheet.
Vehicle with ECCS engine

CONSULT
Worksheet
Textbook

End of worksheet.
ECTN1002A/WS1
What is the CONSULT?
Computerized ON-board System UniversaL Tester

The CONSULT diagnostic test tool is used for analyzing and trouble shooting
"on board" electronic control systems.
Using this worksheet and operation manual, answer the following questions
and fill out the blanks.
1. Which systems can be monitored with CONSULT?

ENGINE
AIR BAG
ABS
AUTO A/C
2. Install the NiCd battery to CONSULT.
3. Push the power ON switch.
4. Is the battery charged sufficiently?

YES / NO
* CONSULT will display (Low NiCd batt volt!) when the battery voltage is
too low.
* If loaded sufficiently go to step 9.
5. Press the power OFF switch.
ECTN1002A/WS1
6.
Connect the charger (CH-85) into AC power plug.
7.
Connect the output plug into the CONSULT charging connector.
When using a new battery for the first time, allow 8 to 10 hours for full charging.
8.
Install a fully charged battery and push the power ON switch.
9.
Is program number available for the vehicle?

(Refer to the textbook.)
YES / NO
When program number is not available, load the program using appropriate
program card.
10. Push power OFF switch.

If the program was already installed, go to step 12.
11. Referring to operation manual, load the appropriate program card into main
memory.
12. Referring to operation manual, set the roll paper.
ECTN1002A/WS1
*
This paper has a right side and wrong side.
13. Push power ON switch.
14. Touch SUB MODE
15. Touch CLOCK SETTING
16. Referring to operation manual, set the date and time.
17. Print the screen with new date and time.

* The screen can be printed by touching the blank key on the upper right hand
side of the mode keys.
18. Touch
BACK
19. Touch
CUNIT CONVERSION
20. Referring to operation manual, set the units.
21. Print the screen with set unit.
22. Connect the diagnostic cable into the CONSULT connector.
ECTN1002A/WS1
* CONSULT is now ready for operation on the vehicle.
23. Touch BACK
twice.
25. Put roll paper and so on back.
questions feel free to ask him.
INSTRUCTOR SIGN-OFF
CONSULT Self-diagnosis (ECTN1002A/WS2)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform self-diagnosis with CONSULT, by using this Worksheet and Service Manual.
CONSULT
Worksheet
Textbook

End of worksheet.
ECTN1002A/WS2
1.
On what page is the CONSULT inspection procedure for the ECCS system
located in Service Manual ?
2. Make sure that ignition key is in OFF position.

Find diagnostic connector of vehicle and connect CONSULT to it.
3.
Turn ignition switch ON.
* CONSULT will automatically turn ON.
4.
Does the program number correspond the vehicle? (Refer to the Textbook.)
YES / NO
5.
Touch
The appropriate systems which are equipped on the vehicle will appear.
6.
Touch ENGINE
You can see the function name of the system on the screen.
7.
Touch SELF-DIAG RESULT
8.
Is there any failure?
START
YES / NO
ECTN1002A/WS2
*
When there is no failure, it will be indicated with the following screen.
EC02A001
9.
Push the power OFF switch of CONSULT.
10. Turn the ignition switch to OFF.
Confirmation practice-1
11. Disconnect ENGINE COOLANT TEMPERATURE SENSOR connector.
12. Turn the ignition switch to ON.

*
Power switch of CONSULT will automatically turn ON.
13. Touch
*
START
14. Touch ENGINE

*
15. Touch SELF-DIAG RESULT
ECTN1002A/WS2
16. Does CONSULT indicate a failure of ENGINE TEMPERATURE SENSOR?
YES / NO
17. Touch ERASE
18. Does the failure still appear?

YES / NO
The SELF-DIAG RESULT screen
A:
Any component/circuit (s) failing SelfDiagnosis.
B:
The number of times the vehicle has been

started since the last detected failure. 0
indicates that component failure is being
detected currently.
EC02A002
19. What is the meaning of the number indicated under time on the screen at
the right?
Above key-point B
20. Connect the ENGINE TEMPERATURE SENSOR.
21. Did the screen change?

YES / NO
22. Touch ERASE .

*
When ERASE is touched, Self-diagnosis is carried out once again.
ECTN1002A/WS2
23. Did the screen change to NO FAILURE?
YES / NO
24. If YES, finish the self-diagnosis.

If NO, check the failure part or unit and repair that.
25. Push the power OFF switch and turn ignition switch OFF.
26. Disconnect the Ignition coil connector.
27. Turn the ignition switch ON.

28. Touch START
29. Touch ENGINE
31. Does CONSULT indicate a failure?

YES / NO
32. Turn ignition switch to START for a few seconds.
33. What does the screen indicate?

IGN SIGNAL-PRIMARY 0
ECTN1002A/WS2
34. What is the number of time at above right of the screen?
35. Connect the Ignition coil connector after turning ignition switch OFF.
36. Start the engine.

YES / NO
The number of Time should change.
39. Touch ERASE

YES / NO
41. If YES, finish the self-diagnosis. Completely finish repair.

If NO, check and repair the failure part or unit.
Difference between practice 1 and 2:

Coolant temperature sensor transmits a signal to the ECM when the ignition
key is in the ON position and the engine is running or being started. The
other sensors however do not transmit signal to the ECM when the ignition
key is in the ON position. It's necessary to start or crank the engine for the
signal to the ECM to change.
ECTN1002A/WS2
42.
On what page does Description of Self-Diagnosis information begin?

TURN TO THAT PAGE.
43.
Check in the Service Manual which other systems will be indicated by the
Self-diagnosis mode.
44.
Explain the possible conditions under which a diagnostic item may be

detected.
(Refer to the Service manual.)
1. Shorted circuit
2. Open circuit
3. Abnormal signal (voltage)
45. Push power OFF switch and stop the engine.
46. Put CONSULT back.
next one. If you have any questions feel free to ask him before starting the next
exercise.
INSTRUCTOR SIGN-OFF
CONSULT Work Support (ECTN1002A/WS3)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform work support using CONSULT, by using this worksheet.

CONSULT
Timing light
General tools
Worksheet

End of worksheet.
ECTN1002A/WS3
1. THROTTLE POSITION SENSOR ADJUSTMENT
1. On what page is the CONSULT data monitor mode in Service Manual?
2.
What is the specification value of Throttle position sensor signal voltage

when fully closed?
V
3.
Make sure the ignition key is in the OFF position.

Connect the CONSULT diagnostic cable to the connector.
4.
Perform a visual check and perform self-diagnosis with CONSULT.
Confirm that there is no failure on the system.
5.
Operate the parking brake.
6.
Turn ignition switch to the ON position.
CONSULT will automatically turn ON.
7.
Touch
8.
Touch ENGINE
START
ECTN1002A/WS3
9.
Touch WORK SUPPORT
10. Touch
THRTL POS SEN ADJ
11. Touch
START
12. What is the voltage of the Throttle position sensor signal?
13. Is the output voltage within specification?

YES / NO
14. If not, correctly set the position of the Throttle position sensor body.
*
If the Throttle position sensor requires adjustment, refer to the Service manual for the correct setting procedure.
15. Touch function key of BACK
twice.
2. IGNITION TIMING ADJUSTMENT
16. On what page is the IDLE SPEED/IGNITION TIMING procedure located

in the Service Manual?
17. What is the specification of Ignition timing?

BTDC
18. Start the engine and warm it up until water temperature indicator points to
the middle of gauge.
ECTN1002A/WS3
19. Touch
IGNITION TIMING ADJ
20. Touch
START
21. Is the Throttle position ON?

YES / NO
22. What is the effect on the Ignition timing, if the Throttle position is incorrectly
adjusted with idle position set to OFF?
Cannot adjust the ignition timing correctly. Because ECM doesnt

acknowledge idle position.(ECM contains an idle ignition timing table
which is controlled by throttle position ON.)
23. Check the Ignition timing with timing light.

*
When reading the CONSULT screen while changing timing by rotating the
distributor body, there should be no change in the timing value on the CONSULT screen, because CONSULT always indicates ECM data, not the actual
value.
24. Is Ignition timing within specification?

YES / NO
25. If not, correctly set the timing by rotating the Distributor body or the Camshaft position sensor body.
Engine should be stopped when you loosen the fixing bolts.
ECTN1002A/WS3
27. Is the Ignition timing within specification?
YES / NO
28. If not, correctly set the timing again.

29. Touch function key of
BACK
twice.
3. IACV-AAC VALVE ADJUSTMENT

30. On what page is the IDLE SPEED/IGNITION TIMING procedure in Service
Manual?
31. What is the specification of Idle engine speed?

rpm
32. Touch
33. Touch
IACV-AAC/V ADJ
START
34. Is the THROTTLE VALVE IDLE POSITION ON when the accelerator is

released?
YES / NO
35. If not, correctly adjust the THROTTLE POSITION to ON.

Refer to the Service manual for the correct procedure.
36. Is Idle engine speed within specification?

YES / NO
ECTN1002A/WS3
37. If not, correctly adjust the engine speed with adjusting screw.
*
BACK and then touch
MODE
Now adjust the engine speed again with the adjusting screw.
39. Does the engine speed change to the desired value?

YES / NO
40. Now touch WORK SUPPORT and then touch
IACV-AAC/V ADJ
again.
41. Touch
START
IACV-AAC/V ADJ
When
is selected, the operation of IACV-AAC/V is
fixed while the engine speed is being adjusted by the screw.

(Until
CANCEL is touched.)
42. Perform the adjustment in both situations until you completely understand
the difference. Finally, adjust the idle engine speed correctly.
43. Push power OFF switch and stop engine.

exercise.
INSTRUCTOR SIGN-OFF
CONSULT Function Test (ECTN1002A/WS4)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to access and perform
the CONSULT Function Test (Sequence & Single Modes). Determine if test results for applicable components/circuits are within
specification, and then print out the results of each test.

CONSULT
Timing light
General tools
Worksheet

End of worksheet.
ECTN1002A/WS4
Part 1 - Sequence test mode
Using this worksheet and a CONSULT, perform the following Function test procedures.
Upon completion, place a check next to each Function test section heading.
1.
The Function test is designed with parameters that test within specification
ranges for the tested component/circuit. When an OK appears on the
screen, the individual item has been tested within this range.
Locate the CONSULT check connector and connect the diagnostic cable.
2. Turn the ignition key to the ON position - the CONSULT will automatically
turn itself on. If necessary, adjust the contrast and/or turn the light ON and/or
OFF, as required.
3. Touch START
4. Touch ENGINE
5. Touch
FUNCTION TEST
6. Touch SEQUENCE TEST
7. After SELF-DIAGNOSIS
screen appears, touch
NEXT .
8. Follow the menu-driven instructions through the component/circuit checks on

the following page and note the indicated results.
CONSULT reads components/circuits available on the vehicle. Any item

listed below that did not appear during the Sequence test is not a part of the
vehicle equipment.
ECTN1002A/WS4
COMPONENT/CIRCUIT
-SELF-DIAGNOSIS RESULTS
GIVEN
JUDGEMENT SPECIFICATIONS/
NOTES
OK / NO
-IDLE POSITION
OK / NO
-THROTTLE POSITION
SENSOR CIRCUIT
OK / NO
-NEUTRAL SWITCH
OK / NO
-FUEL PUMP CIRCUIT
OK / NO
-EGR CONTROL S/V CIRCUIT

(If available)
OK / NO
-VALVE TIMING S/V

CIRCUIT (If available)
OK / NO
-COOLING FAN CIRCUIT
OK / NO
-START SIGNAL CIRCUIT
OK / NO
-POWER STEERING SIGNAL

CIRCUIT
OK / NO
-IGNITION TIMING
ADJUSTMENT
OK / NO
-MIXTURE RATIO TEST
OK / NO
-POWER BALANCE TEST
OK / NO
-AAC VALVE CIRCUIT
OK / NO
If it is not possible to drive the vehicle, or a hoist is not available, not this in the
specifications/notes column.
At this point if you require more practice, please return to step 6 and repeat the
Sequence test.
ECTN1002A/WS4
Part 2 -Single test mode
9.
Using this worksheet and a CONSULT, perform the following Function test
single mode checks. Upon completion, place a check next to each function
test section heading.
10. Access the Select test mode and touch SINGLE TEST
11. Touch THROTTLE SENSOR CIRCUIT
12. Perform the test, using the prompt on the CONSULT screen as guides.
13. Touch NEXT , then touch PRINT
to print displayed screen. Keep the
printed result for review by instructor.
14. Touch
15.
BACK TO MENU
to return to Test Item Menu.
Perform the Single Item test procedure (steps 2-4) again on each of the following circuit components:
COOLING FAN CIRCUIT
POWER BALANCE TEST
16. Print the result of each test and keep the results for review by your instructor.
ECTN1002A/WS4
17. Touch BACK
key:
touch BACK
again to return to Test mode screen.
touch BACK
again to go to the Diag. mode screen.
touch BACK
again to go to the Select system screen.
18. Turn CONSULT off.
19. If you require more practice at this point, please return to step 1.
After completing these tests, check that all components are returned to their
original positions.
INSTRUCTOR SIGN-OFF
Worksheet
Usage of CONSULT-II
ECTN1003B
EC03B000
Usage of Tools
CONSULT-II Overview (ECTN1003B/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet you will be able to use

CONSULT-II.
Nissan vehicle equipped with ECCS engine

CONSULT-II set
Worksheet
CONSULT-II Operation Manual
CONSULT-II Operators Manual

End of worksheet.
ECTN1003B/WS1
What is CONSULT-II?
The CONSULT, Computerized ON-board System UniversaL Tester,
diagnostic test tool is used for analyzing and trouble shooting onboard electronic systems. In recent years, automotive electronics
technology is advancing rapidly, and its application is becoming
more complicated and diversified. CONSULT-II is developed to carry
out accurate servicing and trouble diagnosis more speedily. The
CONSULT-II is improvement version of CONSULT.
The CONSULT-II has the following functions.
DIAGNOSTIC MODE
Example: ENGINE
WORK SUPPORT, SELF-DIAG RESULTS, DATA MONITOR,
DATA MONITOR (SPEC), ACTIVE TEST, FUNCTION TEST,
ECM PART NUMBER
SUB MODE
BATTERY CHARGE, MEASUREMENT (Voltage, Resistance,
Frequency, Duty, Pulse width), SIMPLE OSCILLOSCOPE,
RECORD DISPLAY/PRINT, FIELD TEST, SET DATE, SET
TIME, UNIT CONVERSION, CONFIGURE ETHERNET, COMMUNICATIONS TEST, PRINTER TEST, TOUCH SCREEN
TEST, LCD TEST, CONTRAST ADJUST, SELECT SYSTEM
SHORTCUT (From program card AED01A), VERSION.
1. Check the following parts by using Operators Manual.
CONSULT-II, AC/DC Power Supply, DLC Adapter Cable, Test Leads
(Red, Black and Blue), Probe Handles (Red, Black and Blue), Tip set,
Alligator clip, RS232C Cable, DLC Cable, Self Test Adapter, RS232C/
Ethernet Self Test Adapter, Printer Paper, Battery Pack, Program Card.
2. Check the following parts for CONSULT-II by using Operators Manual.
Display and Touch-screen, Test Lead ports, Instrumentation port, DLC
Adapter Cable Port, PC Port, External Power Port, On/Off Switch, Paper
Advance Knob, Paper Release Lever, Printer, DLC-1 Connector, DLC-2
Connector, Program Card Slot (Slot A), Expansion Card Slot (Slot B).
ECTN1003B/WS1
*
If you are not clear the parts, ask your instructor for assistance.
Install the CONSULT-II battery.
Only use a genuine CONSULT-II battery pack supplied by a CONSULT-II distributor in the CONSULT-II. Other types of batteries may
burst causing personal injury and damage to the tester.
3.
Confirm that power supply cable is not connected to CONSULT-II.
4.
Unfasten the velcro strap on the back of the tester and pull the strap
out of its retainer at the bottom of the tester.
5.
Turn the fastener near the top back of the tester 1/4 turn counterclockwise, then lift the back cover away from the tester.
6.
Connect the battery pack wire to the connector in the back of the
tester. Press the connector on firmly.
EC03B001
ECTN1003B/WS1
7.
Route the wires around the batteries, then snap the battery pack into
the plastic clips.
Install paper
8.
Install a paper roll onto the plastic shaft.
9.
Unroll the paper approximately 4 inches. Orient the paper roll so the
unrolled paper side is toward the bottom of the tester. Refer to the illustration.
EC03B002
Damage to the print head may result if the paper is installed with the
wrong side of the paper towards the print head.
10. Insert the end of the paper into the paper slot on the tester until it
passes through the tester (in the direction of the arrow on the plastic)
and projects out the front at least 1 inch.
11. From the front of the tester confirm the paper is projecting through the
paper slot and is aligned straight, then press the lever to its original
position pointing toward the top of the tester. This locks the paper in
place.
ECTN1003B/WS1
12. Press the plastic paper roll shaft into the plastic retainer clips until it
snaps into place.
13. Fit the tab on the bottom end of the back cover into the slot on the back
of the tester, then lower the top of the cover into place.
When closing the back cover, be sure to avoid pinching the battery
pack wire.
14. Turn the fastener 1/4 turn clockwise to lock the cover in place.
Make sure close the cover completely.
Insert a program card.

15. Confirm that the CONSULT-II is turned off.
*
When installing or removing the program card, the CONSULT-II must

be turned off.
16. Open the rubber flap and insert the program card to program card slot
A (Upper slot) carefully.
* A program card is shaped for a 1 way fit. Match it to the CONSULT-II.

Do not try to force the connection.
* CONSULT-II must have a program card inserted at all times.
17. Connect the AC/DC power supply to the lower right side of the tester,
then plug the power supply into a electricity.
ECTN1003B/WS1
18. Turn ON the On/Off switch.
When loading the program, the screen

(shown in the figure on the right) will be
displayed. If there is information
Unable to detect Program Card on the
screen, check insertion condition of the
program card or the card slot.
EC03B003
19. After the screen changed to the start up

screen (shown in the figure on the right),
touch COPY and confirm the printer is
operating correctly.
20. Printer operation: OK / NG
EC03B004
* If NO, ask your instructor for assistance.

* Program card No.
A
01
A: 1st release
B: 1st revised
C: 2nd revised
01: Issue year
D : Diagnosis card, N : NATS card
E : English, G: German, F: French, S : Spanish, I: Italian
N: Finnish, H: Greek
A: For All area (Included North America and European market)
E: For European market
U: For U.S.A. (North America) market
ECTN1003B/WS1
21. Turn the CONSULT-II off.
Review the objective of this worksheet. If you are not clear on any part
of the objective, ask your instructor for assistance. When you are satisfied that you have met the objective, have your instructor check your
work and initial your worksheet.
INSTRUCTOR SIGN-OFF
ECTN1003B/WS1
(Reference)
OPERATING PRECAUTIONS:
When performing any checks with the engine running in an enclosed space such
as a garage, be sure there is proper ventilation. Never inhale exhaust gases; they
contain carbonmonoxide, a colorless, odorless, extremely dangerous gas which
can cause unconsciousness or death.
Never use the Basic Measurement Lead Set to check voltages higher than 32
volts. Doing so will always destroy the CONSULT-II tester. (Dont plug the test
leads into a standard AC wall outlet.) Also, the test leads should be kept away
from high tension secondary ignition wires when the engine is cranking or running.
When measuring resistance, be sure to confirm that voltage is not applied to the
object. Otherwise, the tester may be damaged due to the abnormal current.
Use only the Genuine CONSULT-II battery and AC adapter. The tester may be
damaged if anything else is used.
After replacing the printer paper or Genuine CONSULT-II batteries, always confirm that the back cover is securely locked in place with the fastener. If the back
cover is not locked securely in place, the tester itself, the battery pack, the paperroll or the back cover may fall, resulting in personal injury or damage to the CONSULT-II.
The tester should be used where the operating temperature is between 0 and
50C (32 and 122F).
To reduce risk of injury, charge only Genuine CONSULT-II batteries. Other types
of batteries may burst causing personal injury and damage.
BEFORE USING YOUR NISSAN CONSULT-II TESTER
GENERAL PRECAUTIONS:
CONSULT-II employs precision electronic components which should not be used
where there are sudden changes in temperature, high temperatures or excessive
humidity, dust and dirt. Also, do not leave the CONSULT-II where it might be
exposed to direct sunlight.
ECTN1003B/WS1
Moisture may condense on the surface of the CONSULT-II if it is brought into a
warm room from the cold. If this happens, do not use the CONSULT-II until all
moisture has been removed or has dried.
Several magnets are used in the printer section, so do not leave your CONSULTII unit in places where there are metal particles. Do not allow metal objects such
as paper clips to fall inside.
Be sure to use the needle type of measurement probes carefully. The needle may
cause personal injury or damage.
Do not perform Calibrate Touch Screen if touch screen works correctly.
If calibration is needed, be sure to calibrate correctly. (If you calibrate incorrectly,
tester may go out of control.)
Do not remove or install a program card while power to CONSULT-II is ON. If you
wish to change or add a program card, first turn the tester off by pressing the On/
Off switch.
Do not use sharp objects on the touch screen. Use your finger tip.
Genuine CONSULT-II batteries are recyclable. Under various state and local laws
it may be illegal to dispose of Genuine CONSULT-II batteries in the municipal
waste system. Check with local solid waste officials in your area for recycling
options or proper disposal methods.
If the CONSULT-II, test leads, adapters or cables become dirty, they may be
cleaned by wiping them with a rag lightly coated with a mild detergent or nonabrasive hand soap. Do not immerse the tester, test leads, adapters, or cables in
water. Avoid using harsh solvents such as petroleum based cleaning agents, Acetone, Benzene, Trichloroethylene, or any other volatile substances (such as thinner), etc. Because the tester and accessories are not waterproof, thoroughly dry
them prior to storage.
The touch screen has air vents and is not designed to be water tight. Fluid may
seep in from behind the panel if it is not cleaned properly.
Please connect or disconnect the 26-pin DLC connector carefully and straightly to
or from CONSULT-II. If the connector is slanted, connector terminals will be broken.
ECTN1003B/WS1
The front surface of the touch screen should be kept free of dust, dirt, finger prints
and other abrasive materials that could scratch the front surface and detrimentally
affect its optical properties. For best results, use a clean, damp, nonabrasive cloth
and any commercially available window cleaner to clean the surface on a regular
basis. Always clean the tester screen by wiping vertically, only. Never use a circular motion on clear plastics. The cleaning solution should be applied to the towel
rather than directly to the surface of the touch screen.
Basically, the CONSULT-II communicates with only a PC. CONSULT-II may be
connected to a network, however, you should confirm the Ethernet setting of your
network (LAN or WAN) administrator. If the address of CONSULT-II and the
address of the PC which are connected to the same network are the same, they
will conflict and make it impossible to use the Ethernet and the LAN/WAN.
NOTES:
Turn power off when measurement unit is changed. If CONSULT-II is not turned
off, the measurement unit may not change.
RESISTANCE is not applicable in DATA MONITOR item. This is because measuring the RESISTANCE while providing voltage will cause damage.
The LCD back light will turn off automatically when the ambient temperature is
higher than 40C (104F) to avoid shortening the LCDs life.
If the ignition switch is not turned off, CONSULT-II may not be turned off. (Warning
may be displayed on the screen.) If this happens, first turn off the ignition switch,
then automatically turn off CONSULT-II.
The CONSULT-II must be used with a program card inserted into the card slot A.
CONSULT-II does not require loading (Initialization) procedures as does CONSULT.
In order to charge the Genuine CONSULT-II battery effectively, ambient room
temperature of between 10 and 30C (50 and 86F) is recommended.
10
CONSULT-II Self-diagnosis (ECTN1003B/WS2)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform self-diagnosis of CONSULT-II
Nissan Vehicle equipped with ECCS engine

CONSULT-II
Worksheet

End of worksheet.
ECTN1003B/WS2
1.
On what page is the "CONSULT-II inspection procedure" in ONBOARD DIAGNOSTIC SYSTEM DESCRIPTION section?
EC-50 (A33)
2.
Make sure the ignition key is in "OFF" position.
3.
Connect the CONSULT-II cable to the connector.
The CONSULT-II connector is shaped for a 1-way fit. Match it to the

vehicle connector. Do not try to force the connection.
4.
Turn ignition switch "ON".
CONSULT-II will automatically turn ON.
5.
Does the program number correspond the vehicle?

YES / NO
Refer to the Checking Equipment in GI section of the Service Manual.

If you are not clear the program card, ask your instructor for assistance.
6.
Touch START.
7.
What selections are offered?
ASCD, ENGINE, A/T, AIR BAG, ABS, etc.
The systems able to be checked with CONSULT-II will be displayed.
ECTN1003B/WS2
8.
Touch ENGINE.
9.
Touch SELF-DIAG RESULTS.
10. Is there any failure?

YES / NO If YES, ask your instructor for assistance.
*
When there is no failure, it will be indicated

with the following screen.
EC03B005
11. Touch BACK 3 times.

12. Turn the ignition switch to "OFF".
*
You should turn OFF the ignition switch before power off CONSULTII.
13. Push the power "OFF" switch of CONSULT-II.
ECTN1003B/WS2
Confirmation practice

*
16. Touch START.

17. Touch ENGINE.
18. Touch SELF-DIAG RESULTS.
19. Does CONSULT-II indicate a failure of ENGINE COOLANT TEMPERATURE SENSOR?
YES / NO
20. Touch ERASE, then touch YES.
YES / NO
22. Print the screen and attach the printout
in the space to the right.
23. Touch BACK 3 times
Attach here
ECTN1003B/WS2
25. Connect the ENGINE COOLANT TEMPERATURE SENSOR connector.

27. Touch START.
28. Touch ENGINE.

30. Are there any change on the screen compare with the screen at step
22?
YES / NO
If YES, what is it?
31. Start engine for few seconds, then stop engine.
32. Check self-diagnoses result again.
33. Are there any change on the screen compare with before?
YES / NO
If YES, what is it?
No. of times of data.
ECTN1003B/WS2
34. What is the meaning of the number indicated under time on the
screen?
This indicates how many times the vehicle was driven after the
last detection of a malfunction.
If you are not clear this step, ask your instructor for assistance.
35. Touch ERASE.
When ERASE is touched, self-diagnosis is carried out once again.
36. Did the screen change to NO DTC IS DETECTED. FURTHER TESTING MAY BE REQIRED?
YES / NO If NO, ask your instructor for assistance.
37. Turn the ignition switch OFF and push the power OFF switch of
CONSULT-II .
INSTRUCTOR SIGN-OFF
CONSULT-II Work Support (ECTN1003B/WS3)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session, you will be able to perform work support of CONSULT-II.
CONSULT-II
Worksheet

End of worksheet.
ECTN1003B/WS3
1.
On what page is the CONSULT-II INSPECTION PROCEDURE in the

EC section of the Service Manual?
2.
Make sure that the ignition key is in the OFF position.
3.
Connect the CONSULT-II connector to data link connector.
* The CONSULT-II connector is shaped for a 1-way fit. Match it to the

4.
Perform a visual check and self-diagnosis.

Visual check: OK / NG
Self-diagnosis: OK / NG If NG, repair them.
* Confirm that there is no failure on the system.

5.
Start engine.
6.
Touch START.
7.
Touch ENGINE.
8.
Touch WORK SUPPORT.
9.

TP SW/SEN IDLE POSI ADJ, FUEL PRESSURE RELEASE,
IDLE AIR VOL LEARN, SELF-LEARNING CONT,
TARGET IGN TIM ADJ, TARGET IDLE RPM ADJ
ECTN1003B/WS3
THROTTLE POSITION SENSOR ADJUSTMENT
10.
What is the specification of Throttle Position Sensor output voltage at

idle?
0.15 - 0.85 (A33)
11. Make sure that the engine is warmed up fully.

12. Touch TP SW/TP SEN IDLE POSI ADJ.
13. Touch START.
14. What is the CLSD THL POS and CLSD THL/P SW data on the CONSULT-II?
CLSD THL POS:
ON / OFF
CLSD THL/P SW: ON / OFF
If data are OFF, adjust them by rotating Throttle Position Sensor body.
* If you are not clear, ask your instructor for assistance.
16. Check Throttle position sensor output voltage at idle according to the
procedure as following.
1) Touch DATA MONITOR.
2) Select MAIN SIGNAL, then touch START.
3) Touch PAGE DOWN.
17. What is the THRTL POS SEN signal voltage?

V
ECTN1003B/WS3
18. Is the THRTL POS SEN signal voltage within specification?
YES / NO If NO, adjust it.
19. Touch BACK twice.
IGNITION TIMING ADJUSTMENT

20. What is the specification of ignition timing?
15 (A33)
BTDC
21. Touch TARGET IGN TIM ADJ.
22. Touch START.
23. Check the ignition timing with timing light.

BTDC
* When reading the CONSULT-II ignition timing data while changing
ignition timing by rotating the distributor body, the ignition timing data in
the CONSULT-II does not change. Because CONSULT-II ignition timing data always indicates ECM memorized data, not actual value.
* Engine should be stopped when you loosen the fixing bolts.
* Idle ignition timing cannot be changed for VQ engine.
24. Is ignition timing within specification?

YES / NO
If NO, set the ignition timing by rotating the distributor body or the
camshaft position sensor body.
25.
Touch BACK twice.
ECTN1003B/WS3
IDLE SPEED ADJUSTMENT
26. What is the specification of idle speed?
rpm
27. Touch TARGET IDLE RPM ADJ.

28. Touch START.
YES / NO
If NO, adjust the idle speed with idle adjusting screw.
30. Touch BACK.
31. Does the engine speed change to the desired level?

YES / NO
32. Turn the ignition switch OFF and push power switch of CONSULT-II.
INSTRUCTOR SIGN-OFF
CONSULT-II Function Test Mode (ECTN1003B/WS4)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet, you will be able to perform the

FUNCTION TEST MODE of CONSULT-II.

CONSULT-II (Program card AED01A)
Worksheet

End of worksheet.
ECTN1003B/WS4
FUNCTION TEST OUTLINE
The FUNCTION TEST was developed for the following reasons.
For Customer:
Test RESULT is simply displayed and easily understood with either
OK or NG. NG is displayed when a malfunction is detected.
NOTE: When OK is displayed on the CONSULT & CONSULT-II, it
means NG is not detected. The CONSULT & CONSULT-II may not
be able to detect mechanical malfunctions.
For Technicians:
A) For Basic Technician: The FUNCTION TEST is designed to
diagnose the engine by reading instructions on its comment screen.
B) Specification Test: For some test items in the engine it is possible
to execute detailed specification tests.
NOTE: Technicians do not refer to the result of CAR COMPUTER
DIAG for trouble diagnosis. (The technicians use Self-Diagnosis
Results.)
For Technical Advisor:
The new FUNCTION TEST is designed to provide technical advisors simple explanation of the condition of your customers vehicles.
The self-diagnosis result inside the FUNCTION TEST is displayed
with OK or NG, which is improved to arrange each item and function for easier comprehension by customers.
PDI/Repair confirmation:
The FUNCTION TEST can assure confirmation by checking sensor, switch and actuator during PDI or after repair.
ECTN1003B/WS4
1. Connect the CONSULT-II diagnostic cable to the diagnostic connector.
*
The CONSULT-II power is automatically turned ON.
The right screen is displayed on the

models from 2001 with a program card
AED01A or equivalent version.
If there is no ENGINE menu, ask your
instructor for assistant.
3. Touch ENGINE.
Touch START when you want meet
another systems.
EC03B006
4. Touch ENGINE.
5. Touch FUNCTION TEST.
6. What items are offered?

CAR COMPUTER DIAG / SENSOR/SW TEST / CONFIRMATION TEST
MIXTURE RATIO TEST / POWER BALANCE / IACV-AAC/V SYSTEM
7. Touch CAR COMPUTER DIAG.
8. [If you ERASE the SELF-DIAG RESULTS, this test may display the
false results. This test judge OK when except NG detect condition.] is
displayed.
9. Touch OK.
*
The test is started automatically.
ECTN1003B/WS4
10. Check the RESULT .
OK / NG
If NG is displayed, ask your

Attach here
11. Touch PRINT and attach the

printout in the space to the right.
12. Touch BACK.
13. Touch SENSOR/SW TEST.
14. [STOP engine and TURN IGNITION ON] is displayed.
15. Touch OK.
16. Touch THRTL POS SEN.
If you do not need check P/N POSI SW check, touch PASS.
ECTN1003B/WS4
17. Keep to depress throttle fully few seconds, then release throttle.
18. Confirm that THRTL POS SEN and CLSD THL POS are judged
OK.
19. Touch P/N POSI SW.
20. Shift following operation and keep a few seconds each range.
M/T: Any gear
A/T: P
R
N
N
Any gear
D
P
Slowly move shift lever (Selector lever).
21. Check the result of P/N POSI SW.

22. Touch NEXT twice.
23. Start engine, then touch OK.
24. Touch VHCL SPEED SE.
25. Touch PASS in this time.

If you need to check, perform it.
26. Touch AIR COND SIG.
ECTN1003B/WS4
27. [TURN A/C SW and A/C FAN ON (OFF) to keep a few second, then
TURN A/C SW OFF (ON)] is displayed.
28. Touch PW/ST SIGNAL.
29. [HOLD and keep steering wheel in a full

LOCKED position a few second then
RELEASE in a NEUTRAL position] is displayed.
Follow the instruction.
Attach here
30. Check the result.

31. Touch END.

33. Touch END.
Stand on around an engine room.
34. Touch CONFIRMATION TEST.

This test can check the following systems on most vehicles.
1. FUEL PUMP CIRCUIT
2. EGR CONTROL S/V CIRCUIT
3. PRVR CONT S/V CIRCUIT
4. VALVE TIMING S/V CKT
5. COOLING FAN CIRCUIT
6. VIAS S/V CIRCUIT
7. SWRL CONT S/V CIRCUIT
8. ELEC. CONT ENG. MOUNT
36. Touch OK.
ECTN1003B/WS4
* The test is started automatically.
37. [PINCH fuel feed hose with fingers. Is there any pressure pulsation on
the fuel feed hose or Does the fuel pump RELAY make an operate
SOUND every 3 seconds?] is displayed. Follow the instruction.
38. What is the test result?

YES / NO If yes, touch YES. If no, touch NO.
EGR CONTROL S/V test is started automatically if equipped.
39. Does the EGR Control Solenoid Valve make an operating sound every
3 seconds?
* PRVR CONT S/V CIRCUIT test is started automatically if equipped.
40. Does the PRVR Control Solenoid Valve make an operating sound
every 3 seconds?
* VALVE TIMING S/V CKT test is started automatically.
41. Does the Valve Timing Solenoid Valve make an operating sound every
3 seconds?
ECTN1003B/WS4
* COOLING FAN CIRCUIT test is started automatically.
42. Does the COOLING FAN rotate and STOP every 3 seconds?
* SWRL CONT S/V CIRCUIT test is started automatically if equipped.
43. Does the Swirl Valve Control Solenoid Valve make an operating sound
every 3 seconds?
* ELEC. CONT ENG. MOUNT test is started automatically if equipped.
44. Does the Electrical Control Engine Mount make an operating sound
every 3 seconds?

Attach here
ECTN1003B/WS4
46. Check the results.
If NG is displayed, ask your instructor for assistance.
47. Touch END.

* Function Test mode screen is displayed when the vehicle is not
equipped with an oxygen sensor.
48. Touch MIXTURE RATIO TEST.
50. When the following is displayed, warm up the engine.

[RUN ENGINE UNTIL ENG TEMP IS ABOVE 176 F]
51. [AT FIRST, KEEP (ACCELERATE) ENGINE SPEED TO 2000 rpm

AND HOLD. THEN TOUCH START] is displayed.
52. Touch START.
53. When the test is finished, release the accelerator pedal.

OK / NG If NG is displayed, ask your instructor for assistance.
ECTN1003B/WS4
55.
Touch PRINT and attach the

Attach here
56. Touch END.
57. Touch POWER BALANCE.
58. Let engine idle, then touch START.
59. When the following is displayed,

warm up the engine.
[RUN ENGINE UNTIL ENG
TEMP IS ABOVE 176 F]
60. Wait until the test is finished.


OK / NG
If NG is displayed,
63. Touch END.
10
Attach here
ECTN1003B/WS4
64. Touch IACV-AAC/V SYSTEM.

66. [LET ENGINE IDLE. THEN TOUCH START] and

[A/C SW, LIGHT SW OFF] are displyed.
67. Touch START.
68. If engine stall occur, start engine again or

adjust air by-pass screw then touch OK.
Attach here
* IACV-AAC valve test is started automatically.
69. After finish the test, touch PRINT and

attach the printout in the space to the right.
70. Touch END.
71. Touch BACK.
72. Turn ignition off and power off CONSULT-II.
INSTRUCTOR SIGN-OFF
11
Worksheet Answer
EXSE Course
Worksheet #
Worksheet tasks
ESTN1001B
Express Lub. 30
ESTN1002B
ESTN1003B
ESTN1004B
Tire Rotation & Brake Service
ESTN1005B
Express Service
Remarks
Worksheet
Express Lub. 30
ESTN1001B
ES1-1
Express Service
Express Lub. 30 (ESTN1001B)

OBJECTIVE:
Be able to change the Engine oil and perform 14-point

inspection.
TOOLS AND
EQUIPMENT:
RESOURCES:
Service Manual
INSTRUCTIONS:
These instructions will outline the tasks that you will need
to complete in order to meet the objective for this worksheet. The following symbols are used throughout the
worksheet to help clarify these instructions.
Vehicle hoist
Oil filter wrench
Oil drain pan
Drain plug wrench
General tool
Tire pressure gauge

Seat cover, steering cover,
floor paper
Fender cover
A/T paper towel
Work light

End of worksheet.
When you have finished all the activities, have the instructor check your
work and initial this worksheet. Also, have your instructor initial your signoff sheet so you can keep track of your overall course progress.
ESTN1001B
* If any NG is found in worksheet, repair it or contact to your instructor.
1. Open MA section of Service Manual.
2. For drive belt adjustment fill out table No. 35 on page 11 with specification of used belt deflection.
Limit
Applied pushing force
3. Write refill engine oil capacity with oil filter change on page 5.
4. Referring to MA section of Service Manual, write torque value of
engine oil drain plug in the illustration on page 5.
5. Confirm size of front and rear tires and write the value in the illustration on page 5.
6. Install seat cover, steering cover and floor paper.

7. Confirm the tire pressure label on vehicle and write the indicated
value in the illustration on page 5.
(Fill out the measurement column later.)
ES1-2
8. Set vehicle on a lift (but do not lift it).

2
ESTN1001B
* Lift point information is found in the GI section of the Service Manual.
9. Inspect wiper blade and arm.

Inspection point
Judgement
Tears or cracks in rubber
OK / NG
Hardening of the rubber
OK / NG
Bending of the wiper arm
OK / NG
10. Open hood and install fender protector.
ES1-3
11. Remove engine oil filler cap. Lift up vehicle with hood open until the
bottom is the same height as your head.
* When setting the lift arm, do not allow the arm to contact the brake
tubes, brake cable, fuel lines and sill spoiler.
12. Remove drain plug and drain engine oil.
ESTN1001B
13. Inspect the wear or damage condition of the tire as next procedure.
Front left Rear left Rear right Front right
Record inspection result in the illustration on page 5.
Inspection point
Excessive wear (Tread depth)
ES1-3.5
Flat spot or cutting on the edges of the tread
ES1-5
Damage or cuts on tread or side walls
ES1-4
ESTN1001B
T/M oil level & condition: OK / NG
Engine oil capacity:

Drain plug torque:
OK / NG
Tire Pressure
Tire Pressure
Tire wear
or damage
Spec Measure- Judgement

ment

ment
Fr
RH
Fr
LH
OK / NG
OK / NG
Tire wear
or damage
OK / NG
Fr tire size:
Diff oil level & conditions: OK / NG
Tire Pressure
Tire wear
or damage
OK / NG
Tire Pressure

ment
Rr
RH

ment
Rr
LH
OK / NG
OK / NG
Tire wear
or damage
OK / NG
Rr tire size:
ES1-6
ESTN1001B
14. Referring to tightening torque of drain plug on page 5, install drain
plug.
* Be sure to clean drain plug and install with new washer.
15. Remove oil filter and install new oil filter.
* Clean the oil filter mounting surface on cylinder block.
* Lubricate the seal rubber of the new oil filter with engine oil.
* Tighten by hand 2/3 turn after seal rubber of filter contacts mounting surface of cylinder block.
16. Inspect transmission fluid for oil level and condition, and record
inspection result on page 5. (Manual transmission only)
ES1-7
* Be careful not to burn yourself, when oil temperature is high.

* Insert a finger into plug hole and hook first joint on plug hole edge.
If oil touches the finger, oil level is correct.
ESTN1001B
17. Inspect differential fluid for level and condition, and record inspection result on page 5. (Rear wheel and 4-wheel drive only)
Checking procedure is same as Step 16.
ES1-8
18. Lower the vehicle until tires contact ground.

19. Fill the engine oil and install filler cap.
For amount of oil to fill, refer to the specification on page 5.
20. Inspect the engine coolant.
Inspection point
1
2
3
Coolant level at filler neck

of the radiator
Coolant level between
MAX. and MIN. indicated
on reservoir tank
Contamination
Judgement
OK / NG
OK / NG
OK / NG
ES1-9
* When large amounts of coolant are

lost, the most likely cause is leakage.
* Never remove the radiator cap
when the engine is hot.
ES1-10
ESTN1001B
21. Inspect the engine coolant hoses.
Inspection point
Judgement
Cracking of the rubber
OK / NG
Deformation or deterioration
OK / NG
Loose connection
OK / NG
Leakage
OK / NG
ES1-11

23. Inspect the exterior lamps.
Inspection point
Judgement
Headlamp high and low

beams
OK / NG
Park and side marker lamps
OK / NG
Brake lamps
OK / NG
Flasher lamps RH and LH
OK / NG
Hazard lamps
OK / NG
24. Open trunk lid and inspect spare tire condition.

Inspection point
Judgement
Air pressure
OK / NG
Wear or damage
OK / NG
25. Raise the vehicle until it is same as your height.
ESTN1001B
26. Inspect engine oil for leaks.
Inspection point
Judgement
Around drain plug
OK / NG
Around oil filter
OK / NG
27. Lower the vehicle and remove all lift

arms from vehicle.
ES1-12
28. Inspect the automatic transmission fluid

while engine is at idle.
Inspection point
1
Fluid level between hot and

cold
Color of ATF
Judgement
OK / NG
ES1-13
Normal / Dark brown / Dark / Black / Milky

pink
* Before inspection of automatic transmission fluid, move selector

lever through each gear position.
29. Stop the engine.
30. Inspect the air filter.
Inspection point
Judgement
Damaged filter element
OK / NG
Blockage
OK / NG
* Shine a light through the air filter

from the opposite side. If light can
be seen, condition of air filter is OK.
* Viscous paper type filter does not
need cleaning.
* Dry paper type filter must be cleaned.
9
ES1-14
ESTN1001B
31. Inspect the brake fluid.
Inspection point
1
2
Judgement
Fluid level between MIN.

and MAX.
Leakage around brake
master cyliner
OK / NG
OK / NG
ES1-15
ES1-16
* If fluid level is extremely low, check brake system for leaks.

* When replacing or refilling brake fluid, always use the same kind.
Using the wrong type or mixing types can cause brake malfunction
during high temperature operation (heavy braking).
32. Inspect the clutch fluid.
(Manual transmission only)
Inspection point
1
2

and MAX.
Leakage around clutch
master cylinder
Judgement
OK / NG
OK / NG
ES1-17
* If fluid level is extremely low, check clutch system for leaks.
33. Inspect the windshield washer fluid.

Adequate fluid in the tank:
OK / NG
10
ESTN1001B
34. Inspect the power steering fluid.
Fluid level between MIN. and MAX.:
OK / NG
* If fluid level is extremely low, check power steering system for

leaks.
35. Inspect the drive belts.

Drive belts
Used belt
deflection
Limit
Alternator
Measurement
Judgement Judgement Judgement Judgement

of deflec- of cracking of contami- of worn or
tion
or fraying
nation
glazed
With A/C compressor
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
Without A/C compressor
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
Power steering oil pump

(kg)
ES1-18
36. Inspect the engine oil level.

Between H and L:
OK / NG
ES1-19
* Do not perform inspection of engine oil level immediately after stopping engine. After stopping, leave the engine for a few minutes and
wait until oil level settles.
11
ESTN1001B
37. If any NG is found in worksheet, did you repair it or contact to your
instructor?
YES / NO
38. Lower hood and lock completely.
of the objective, ask your instructor for assistance. When you are satisfied that you have met the objectives, have your instructor check your
work and initial your Worksheet.
INSTRUCTOR SIGN-OFF
12
Worksheet
ESTN1002B
ESTN1002B
ES2-1
Express Service
Engine Tune-up Service (ESTN1002B)

OBJECTIVE:
Be able to inspect spark plug, engine idle speed, ignition

timing and battery.
TOOLS AND
EQUIPMENT:
RESOURCES:
Service Manual
Worksheet
INSTRUCTIONS:
Spark plug socket

Battery hydrometer
Torque wrench
(CONSULT-II)
Timing light
Seat cover
Fender cover
Water temperature gauge
Rag

End of worksheet.
ESTN1002B
1. Referring to the Service Manual MA or EM section, write the spark

plug gap and tightening torque in the specification column on page
3.
2. Referring to the Service Manual EC section, write ignition timing in
the specification column on page 3.
3. Referring to the Service Manual EC section, write the engine idle
rpm in the specification column on page 3.
4. For the drive belt adjustment, write the following specification of
used belts deflection in step 19 on page 7.
Limit
5. Install a seat cover, steering cover and floor paper.

6. Open the hood, and install a fender protector.
ESTN1002B
Go to next page.
Spark plug gap
Specification
Measurement
Judgement
#1
mm
OK / NG
#2
mm
OK / NG
mm
OK / NG
#4
mm
OK / NG
(#5)
mm
OK / NG
(#6)
mm
OK / NG
#3
mm
ES2-2
Tightening torque
Ignition timing
Ignition timing
Specification
Measurement
Judgement
BTDC
BTDC
OK / NG
ES2-3
Idle speed
Specification
Measurement
Judgement
Idle speed
(WORK SUPPORT mode or
disconnected TPS)
rpm
rpm
OK / NG
Idle speed
(DATA MONITOR mode or
connected TPS)
rpm
rpm
OK / NG
ES2-4
ESTN1002B
7. Air-blow the spark plugs, distributor, ignition coil, and ignition wires
for cleaning.
8. When the vehicle is equipped with a distributor, go to step 9.
When it has no distributor, remove the ignition coil from the spark
plugs, then go to step 12.
9. Disconnect the spark plug wires from spark plugs by gently twisting
and pulling the boots, and inspect it.
Spark plug wires
#1
#2
#3
Inspection point
Cracks
Damage
Rubbing
Contact with engine
components
Judgement
OK / NG
OK / NG
OK / NG
#4
OK / NG
(#5)
(OK / NG)
(#6)
(OK / NG)
Ignition wire between coil

and distributor cap
OK / NG
* To prevent damage, do not pull hard on the spark plug wires to

remove them.
10. Remove the distributor cap and the rotor for the following procedure.
1) Remove the distributor cap with spark plug wires and high tension wire from ignition coil.
2) Remove the rotor.
3) Wipe the inside of the distributor cap and rotor.
11. Inspect the distributor cap and the rotor.
Inspection point
Distributor cap
Rotor
Cracks
Carbon tracking
Damage
Judgement
OK / NG
OK / NG
ESTN1002B
12. Remove the spark plugs and place them in cylinder order on the
work bench.
ES2-5
13. Inspect the spark plugs.

Inspection point
Judgement
#1 Oil fouling
Carbon tracking
#2 Other damage
OK / NG
#3
OK / NG
#4
OK / NG
(#5)
OK / NG
(#6)
OK / NG
OK / NG
ES2-6
14. Clean the spark plugs.

* [Platinum-tipped type]
Do not use a wire brush for cleaning.
If plug tip is covered with carbon,
spark plug cleaner may be used.
Checking and adjusting plug gap
is not required between change
intervals (90,000 km or 54,000 miles).
* [Conventional type]
Use a wire brush for cleaning, if
necessary.
* Cleaner air pressure:
Less than 588 kPa (6 kg/cm2, 85
psi)
Cleaning time: Less than 20 seconds
5
ES2-7
ES2-8
ESTN1002B
15. Inspect the spark plug gap and record it on page 3. (Conventional
type only)
16. Install the spark plugs, and tighten with the specified tightening
torque. (Refer to page 3.)
* When installing the spark plugs, follow the procedures below.
1) Install the spark plugs in cylinder order as before.
2) When installing the new spark plugs, confirm the gap before
installation.
3) Secure the spark plugs with suitable spark plug wrench.
17. For the distributor type vehicle, go to step 17-1.

For the direct ignition type vehicle, go to step 17-2.
17-1. [Distributor type]
Install the rotor, distributor cap and spark plug wires with the following procedures.
1) Install rotor.
2) Install distributor cap.
3) Reconnect spark plug wires according to number indication
to spark plug
4) Reconnect high tension wire to ignition coil.
ES2-9
ES2-10
ES2-11
ESTN1002B
17-2. [Direct ignition type]
Install the ignition coil to each spark plug.
Inspection point
Judgement
Damage filter element
OK / NG
Blockage
OK / NG
* Shine a light from the opposite side

of the air filter.
If the light can be seen from your
side, it is judged OK.
need cleaning.
* Dry paper type filter is necessary to
clean.
ES2-29
#1Drive belts
Alternator
#1Judgeme
#1Used belt
#1Judgeme #1Judgeme
#1Judgeme
nt of crackdeflection #1Measure
nt of con- nt of worn
nt of deflecing or frayment
tamination
or glazed
tion
#1Limit
ing
With A/C compressor
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
(kg)
ES2-30
ESTN1002B
20. Inspect engine coolant hoses.
Inspection point
Judgement

deformation
OK / NG
Deterioration
OK / NG
Loose connection
OK / NG
Leakage
OK / NG
ES2-31
21. Inspect ignition timing and idle speed with the following procedures.
[Without CONSULT-II]
INSPECTION START
Start engine and warm it up
to normal operating temperES2-12
Run engine at approx.

2,000 rpm for approx. 2
minutes under no-load.
ES2-13
Rev engine (2,000 to 3,000

rpm) two or three times
under no-load, then run
engine at idle speed for
ES2-4
Turn off engine and disconnect throttle position sensor

harness connector.
A
(Go to next page.)
ES2-15
ESTN1002B
(From previous page)

A
Race engine (2,000 to
3,000 rpm) 2 or 3 times
under no-load and then run
engine at idle speed.
Check ignition timing with a
timing light.
Check idle speed.
Record inspection results
on page 3.
Turn off engine and connect

throttle position sensor harness connector.
Restart engine.
ES2-15

under no-load and run
ES2-4
Inspect engine idle speed

and record inspection result
on page 3, and judge it.
INSPECTION END
ESTN1002B
[With CONSULT-II]
INSPECTION START
Connect CONSULT-II to
DDL terminal.
ES2-16
ES2-17
ES2-12
ES2-18
Start engine, warm it up to

normal operating temperature and touch START on
the CONSULT-II screen.
ES2-13

ES2-4
Touch ENGINE, then

WORK SUPPORT on the
CONSULT-II screen.
ES2-19
ES2-20
ES2-21
ES2-22
Touch IACV-AAC/V ADJ

or IGNITION TIMING ADJ
or TARGET IGN TIM ADJ
on the CONSULT-II screen.
timing light and record inspection result on page 3, and
A
(Go to next page.)
10
ESTN1002B

A
on page 3.
Touch BACK 3 times,
DATA MONITOR and
MAIN SIGNAL on the
CONSULT-II screen.
ES2-24
ES2-25

on page 3.
ES2-26
INSPECTION END
22. By observing the level lines or removing the battery case caps,
visually check that the fluid level in each battery cell is within the
specified range.
OK / NG
ES2-27
11
ESTN1002B
* When the battery life is near the end, the fluid will become empty
soon after replenishment. Periodical checks are important. (Charging voltage is higher than battery generation voltage.) The battery
life lasts generally about 2 to 4 years.
* Enclosed maintenance-free batteries need no check. Do not add
water.
23. Check the battery specific gravity to judge if it needs recharging.
Specific gravity (20C conversion value):
Needs recharging / Needs no recharging
* Standard value (20C):

Normal value 1.22 - 1.29
Limit value 1.22 or less
Difference among cells: 0.03 or less
* The specific gravity of battery fluid changes depending on temperature, but it shall be evaluated at a standard temperature of 20C.
By following the conversion table for electrolyte specific gravity and
temperature, convert the measured specific gravity into the 20C
standard value for judgement.
[EXAMPLE]
Electrolyte temperature: 40C
Measured specific gravity: 1.226
Specific gravity (Converted at 20C):

1.240
Consequently, it can be judged that the
battery needs recharging.
Conversion table for electrolyte specific gravity/temperature

10C 0C 10C 20C 30C 40C 50C
1.321 1.314 1.307 1.300 1.293 1.286 1.279
1.311 1.304 1.297 1.290 1.283 1.276 1.269
1.301 1.294 1.287 1.280 1.273 1.266 1.259
1.291 1.284 1.277 1.270 1.263 1.256 1.249
1.281 1.274 1.267 1.260 1.253 1.246 1.239
1.271 1.264 1.257 1.250 1.243 1.236 1.229
1.261 1.254 1.247 1.240 1.233 1.226 1.219
1.251 1.244 1.237 1.230 1.223 1.216 1.209
1.241 1.234 1.227 1.220 1.213 1.206 1.199
1.231 1.224 1.217 1.210 1.203 1.196 1.189
1.221 1.214 1.207 1.200 1.193 1.186 1.179
(C
12
ESTN1002B
* A battery tester such as one shown
in the photo can automatically judge
OK / NG.
ES2-28
INSTRUCTOR SIGN-OFF
13
Worksheet
ESTN1003B
ES3-1
Express Service
Cooling System Service (ESTN1003B)

OBJECTIVE:
Be able to change the engine coolant and perform 14point inspection.
TOOLS AND
EQUIPMENT:
RESOURCES:
Service Manual
Worksheet
Vehicle hoist
General tool
Coolant drain pan
Fender cover
Coolant tester
Rag
Tire pressure gauge
Torque wrench
Seat cover, steering cover, floor paper
INSTRUCTIONS: These instructions will outline the tasks that you will need
End of worksheet.
ESTN1003B
* If any NG is found in worksheet, repair or contact your instructor.
1. Open MA section of Service Manual and write the limit value of
used belt deflection and applied pushing force on page 10, step 24.
2. Referring to Service Manual, write the limit value of radiator cap

relief pressure on page 5. (Fill out the measurement column later.)
ES3-2
3. Referring to Service Manual, write the applied pressure value when

checking cooling system on page 5. (Fill out the judgement column
later.)
ES3-3
4. Referring to LC section of Service Manual, confirm the position of

air relief plug and write the tightening torque on page 5.
ES3-4
ES3-5
QG engine
SR engine
ESTN1003B
value in the illustration on page 5. (Fill out the measurement column later.)
ES3-6
8. Set vehicle on a lift. (but do not lift it.)

Inspection point
Judgement
OK / NG
OK / NG
OK / NG
ESTN1003B
10. Lift up vehicle until the bottom is the same height as your head.
Inspect the wear or damage condition of the tire as next procedure.

Inspection point
ES3-7
Flat spot or cupping on the edges of the tread
ES3-9
ES3-8
ESTN1003B
Radiator Cap
Limit
Cooling System
Measurement Judgement
Air relief plug tightening torque
Testing Pressure
OK / NG
OK / NG
Front
T/M oil level & condition OK / NG
Air relief plug

T
O
R
Q
U
E
Tire Pressure
Tire Pressure
Tire wear
or damage
OK / NG
Judgement

ment

ment
Fr
RH
Fr
LH
OK / NG
OK / NG
Tire wear
or damage
OK / NG
Fr tire size:
Tire Pressure
Tire wear
or damage
OK / NG
Tire Pressure

ment
Rr
RH

ment
Rr
LH
OK / NG
OK / NG
Tire wear
or damage
OK / NG
Rr tire size:
ES3-10
ESTN1003B
ES3-11

ES3-12
ESTN1003B
14. Raise the hood, install fender protector and remove the radiator
cap.
* Wrap a thick cloth around the cap and carefully remove it by turning
it a quarter turn to allow built up pressure to escape and then take
the cap all the way off.
ES3-13
15. Inspect the radiator cap relief pressure and write the measured value on
page 5.
ES3-14
16. Referring to the value written on page

5, inspect cooling system for leaks
and write the inspection result on
page 5.
ES3-15
* Use caution. If the applied pressure exceeds the limit, the joints of
the radiator, heater core, hoses, and other parts may be damaged.
ESTN1003B
17. Drain the engine coolant with following procedure.
Turn ignition switch
ON and move A/C
control lever to
MAX HOT position.
Wait 10 seconds
and turn ignition
switch OFF.
Remove radiator
drain plug and
drain coolant.
Remove air relief

plug from cylinder
block.
Drain coolant from

reservoir tank.
* Perform following steps, while draining the coolant for express service.

Between H and L:
OK / NG
* Do not perform inspection of engine

oil level immediately after stopping
engine.
After stopping, leave the engine for a
few minutes and wait until oil level
settles.

Inspection point
Judgement
OK / NG
Blockage
OK / NG
NOTE:
Refer to key points on the next page.
ES3-16
ESTN1003B
* Shine a light through the air filter from
the opposite side. If light can be seen,
condition of air filter is OK.
need cleaning.
ES3-17

Inspection point
1
2
Fluid level between

MIN. and MAX.
master cylinder
Judgement
OK / NG
OK / NG
ES3-18
ES3-19

Inspection point
1
2

and MAX.
master cylinder
Judgement
OK / NG
OK / NG
ES3-20
ESTN1003B
OK / NG

OK / NG

leaks.

Used belt
deflection
Drive belts
Limit
Alternator
Measurement

tion
or fraying
nation
glazed
With A/C compressor
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG

(kg)
ES3-21

Judgement
Inspection point
1
OK / NG
OK / NG
Loose connection
OK / NG
Leakage
OK / NG
10
ES3-22
ESTN1003B
26. Refill engine coolant, using following procedure.
START
installing the drain plug, apply
NOTE: When
sealant to thread portion of the plug
Install reservoir tank and

radiator drain plug.
and refer to the value of tightening

torque written on page 5.
Fill radiator slowly with coolant until coolant spills from

the air relief plug, then
install air relief plug.
NOTE: Copper washer of air relief plug must

be replaced with new one.
Fill the coolant with volume of 2 liter/

min (like filling water with a pot).
A
Fill radiator and reservoir
tank with engine coolant.
If the filling coolant is overfilled, or

filled too quickly, it may cause entry
of air.
NOTE: Fill the coolant to the height of radiator filler neck.
Fill the coolant to the MAX line of reservoir tank.
Warm up the engine to normal operating temperature

without radiator cap.
NOTE: Coolant level must be checked.
Install radiator cap and run

the engine with 2,500 rpm
for 10 seconds.
Cool down
the engine until the coolant temNG
perature falls to approx. 50C
and then check coolant
level.
Repair.
OK
NG
Check cooling system for leaks

with engine running.
OK
Go to next page.
11
NOTE: When removing radiator cap,
watch out for sudden spray of hot

engine coolant.
ESTN1003B
Go to A
on previous page
From previous page
Cool down the engine until

the coolant temperature
falls to approx. 50C.
Run engine at 3,000 rpm for

2 minutes and then at idle.
Sound exists
from heater unit
Move the heater control lever

Step by Step from FULL COLD
to FULL HOT.
NOTE:
Close windows, doors and
hood, and switch radio OFF.
No sound from
heater unit
NG
Check engine
coolant level. The level must be;
on filler neck height of radiator
on MAX line of reservoir tank
OK
END
12
NOTE:
When removing radiator cap
watch out for sudden spray
of hot engine coolant.
ESTN1003B
27. Inspect the automatic transmission
fluid while engine is at idle.
Judgement
Inspection point
1
Fluid level between hot

and cold
Color of ATF
OK / NG
ES3-23
Normal / Dark brown / Dark / Black / Milky pink

28. Inspect the exterior lamps while engine is at idle.

Inspection point
Judgement
Headlamp high and low beams
OK / NG
OK / NG
Brake lamps
OK / NG
OK / NG
Hazard lamps
OK / NG

Judgement
Inspection point
1
Air pressure
OK / NG
Wear or damage
OK / NG
INSTRUCTOR SIGN-OFF
13
Worksheet
Tire Rotation & Brake
Service
ESTN1004B
ES4-1
Express Service
Tire Rotation & Brake Service (ESTN1004B)

OBJECTIVE:
Be able to conduct tire rotation and brake inspection with

14-point inspection.
TOOLS AND
EQUIPMENT:
RESOURCES:
Service Manual
Worksheet
INSTRUCTIONS:
Vehicle hoist
Tire pressure gauge
Torque wrench
Work light
Impact wrench
A/T paper towel

Rag
Fender cover
Seat cover
Scale

End of worksheet.
ESTN1004B
Inspection point
Judgement
Wears or cracks in rubber
OK / NG
OK / NG
OK / NG
2. Lift point information is found in the GI section of the Service Manual.
ES4-2
ESTN1004B
3. Raise the vehicle until the wheel center is waist high.
* In the Service Manual two methods of tire rotation (4 and 5 tires)
are explained and 4-tire rotation procedure is as follows.
ES4-3
4. Inspect the tire condition of the left front tire.

Visually check tire for excessive wear or appearance of wear indicator on tire tread.
OK / NG
ES4-4
* When tire tread depth becomes shallow, the water shedding effect
is diminished. As a result, the coefficient of friction is reduced on
wet roads and the distance required for braking increases.
5. Is there flat spot or cupping on the edges of the tread?

OK / NG
ESTN1004B
6. Visually check tire and side wall for cracks, sticking or trapped foreign materials.
OK / NG
ES4-5
7. Remove wheel and tire assemblies in left front.

(Recommend using an impact wrench)
8. Clean each part of brake system with rags or vacuum cleaner.
9. Locate the disc brake pad thickness MA section in the Service

Manual.
10. Inspect the condition of the left front brake.

Visually check brake pad thickness through brake pad inspection
hole or position indicated with arrow in figure.
Use a scale, if necessary.
OK / NG
ES4-6
ESTN1004B
11. Check brake caliper and brake hoses for oil leakage.
OK / NG
ES4-7
12. Check rotor for roughness, cracks or chips.

If necessary, measure thickness and deflection of disc and ensure
that measured value is within specified range.
OK / NG
ES4-8
13. Bring wheel and tire assemblies from left front to the left rear.
14. Inspect the tire condition of the left rear tire.
Visually check tread pattern for unusual wear or wear indicators.
OK / NG
ES4-9
ESTN1004B
15. Is there flat spot or cutting on the edges of the tread?

OK / NG
OK / NG
ES4-10
17. Remove wheel and tire assemblies on left rear. (Recommend using
an impact wrench.)
ESTN1004B
19. Inspect the condition on the left rear brake.
OK / NG
ES4-11
20. Perform visual inspection for fluid leakage from brake caliper or
brake hoses.
OK / NG
ES4-12

OK / NG
ES4-13
ESTN1004B
22. Bring wheel and tire assemblies from left rear to the left front.
* Perform tire rotation and brake inspection for right front and right
rear wheel in same procedure as used for left front and left rear
wheel. Refer to Step 10 to 16.
23. Check the following items and judge the inspection result.
Right front tire
Excessive wear around tire or tire tread indicator
Flat spot or cupping
OK
NG
OK
NG
Crack, sticking or trapped foreign materials
OK
NG
Cleaning of brake system parts
OK
NG
Brake pad wear
OK
NG
Brake fluid leakage
OK
NG
Rotor roughness, cracks or chips
OK
NG
OK
NG
OK
NG
OK
NG
OK
NG
Brake pad wear
OK
NG
Brake fluid leakage
OK
NG
OK
NG
Right rear tire
24. Install wheel and tire assemblies according to the following procedure.
Right Front Right Rear Left Rear Left Front
8
ESTN1004B
26. Inspect transmission fluid for oil level and condition. (Manual transmission only)
OK / NG
ES4-14

If oil touches to the finger, oil level is correct.
27. Inspect differential fluid for level and condition. (Rear wheel and 4wheel drive only)
OK / NG
ES4-15
28. Lower the vehicle until tires contact ground and remove lift arms.
29. Locate the tighten wheel nut MA section in the Service Manual.
ESTN1004B
30. Using torque wrench, tighten wheel nuts to the specified torque.
Tightening torque :
Nm/kg-m
ES4-16
ES4-17

Between H and L:
OK / NG
ES4-18
* Do not perform inspection of engine oil level immediately after stopping engine.
After stopping, leave the engine for a few minutes and wait until oil
level settles.
10
ESTN1004B
Inspection point
1
2
3
Coolant level at filler

neck of radiator
MAX. and MIN. indicated on reservior tank
Contamination
Judgement
OK / NG
ES4-19
OK / NG
OK / NG
ES4-20
* When large amounts of coolant are lost, the most likely cause is
leakage.
* Never remove the radiator cap when the engine is hot.
Inspection point
Judgement
OK / NG
OK / NG
Loose connection
OK / NG
Leakage
OK / NG
ES4-21

Inspection point
Judgement
OK / NG
Blockage
OK / NG
11
ESTN1004B
need cleaning.
* Dry paper type filter must be
cleaned.
ES4-22

Inspection point
1
2
Fluid level between

MIN. and MAX.
master cylinder
Judgement
OK / NG
OK / NG
ES4-23
* If fluid level is extremely low, check

brake system for leaks.
* When replacing or refilling brake
fluid, always use the same kind.
Using the wrong type or mixing
types can cause brake malfunction
during high temperature operation
(heavy braking).
ES4-24
37. Inspect the clutch fluid. (Manual

transmission only)
Inspection point
1
2
Fluid level between

MIN. and MAX.
master cylinder
Judgement
OK / NG
OK / NG
ES4-25

12
ESTN1004B
OK / NG

OK / NG

leaks.

Drive belts
Used belt
deflection
Limit
Alternator
Measurement

tion
or fraying
nation
glazed
With A/C compressor
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG

(kg)
ES4-26
13
ESTN1004B
Start
41. Start the engine and inspect the exterior lamps.

Inspection point
Judgement

beams
OK / NG
OK / NG
Brake lamps
OK / NG
OK / NG
Hazard lamps
OK / NG
42. Inspect the air pressure of all four tires.

OK / NG
* Refer to the tire label attached to
the drivers door lock pillar or etc.
ES4-27
43. Open trunk lid and inspect spare tire

condition.
Inspection point
Judgement
Air pressure
OK / NG
Wear or damage
OK / NG
ES4-28
14
ESTN1004B
44. Inspect the automatic transmission fluid while engine is at idle.
Inspection point
1

and cold
Color of ATF
Judgement
OK / NG
ES4-29
INSTRUCTOR SIGN-OFF
15
Worksheet
ESTN1005B
ES5-1
Express Service

OBJECTIVE:
Be able to complete the A/C performance check.
TOOLS AND
EQUIPMENT:
Leak detector (Electrical leak detector or fluorescent

dye leak detector)
General tools
Fender cover
Seat cover
Rag
RESOURCES:
Service Manual
Worksheet
INSTRUCTIONS:

End of worksheet.
ESTN1005B
* If there is NG in the worksheet, repair it or ask the instructor.
1. Open the Service Manual to the HA section.
2. Install fender cover, seat cover, steering cover and floor paper.
3. Connect an exhaust hose to the vehicles tail pipe.
OPERATIONAL CHECK - AUTO A/C
4. Check blower operation in all speeds to confirm all mode changes.
OK / NG
5. Start the engine and warm it up to normal operating temperature.
OK / NG
6. Check temperature control lever movement from hot to cold, then
back to cold and confirm temperature changes.
OK / NG
ESTN1005B
Check Memory Function
7. Set temperature at 90F or 32C, then press OFF switch.
ES5-2
8. Stop the engine.
9. Start the engine and press the AUTO switch.
10. Confirm that the set temperature remains at previous temperature.

OK / NG
Check Blower
11. Press fan switch (UP side) one time. Check blower should operate
on low speed.
OK / NG
ES5-3
ESTN1005B
12. Press fan switch (UP side) one more time, and continue checking
blow speed and fan symbol until all speeds are checked.
OK / NG
Check Discharge Air
13. Press mode switch four times and DEF button.
ES5-4
14. Each position indicator should change its shape and confirm that
discharge air comes out from the each indicator position.
OK / NG
15. Confirm that the compressor clutch is engaged (Visual inspection)
and intake door position changes to FRESH when the DEF is
selected.
OK / NG
ESTN1005B
Check Recirculation
16. Press REC switch and recirculation
indicator should illuminate.
OK / NG
ES5-5
17. Inpect intake door position change. (You should hear air flow or
door actuator sound change slightly.)
OK / NG
Check Discharge Air Temperature
18. Turn the temperature dial counterclockwise until 18C (60F) is displayed and confirm cold air at discharge air outlets.
OK / NG
ES5-6
19. Turn the temperature dial clockwise until 32C (90F) is displayed
and confirm hot air at discharge air outlets.
OK / NG
ES5-7
ESTN1005B
Check ECON (Economy) Mode
20. Set temperature at 75F or 25C, then press ECON switch.
ES5-8
21. Display should indicate ECON (not AUTO). Confirm that the compressor clutch is not engaged (visual inspection).
OK / NG
* Discharge air and blower speed will depend on ambient, in-vehicle
and set temperatures.
Check AUTO Mode
22. Press AUTO switch
.
ES5-9
23. Display should indicate AUTO (not ECON). Confirm that the compressor clutch is engaged (sound or visual inspection).
OK / NG
ESTN1005B
Check Ambient Display
24. Press AMB switch.
ES5-10
25. Display should show the outside (ambient) temperature for approximately 5 seconds.
OK / NG
OPERATIONAL CHECK - MANUAL A/C
OK / NG
OK / NG
28. Check temperature control movement from hot to cold, then back
to cold and confirm temperature changes.
OK / NG
ESTN1005B
Check Blower
29. Turn fan control dial to 1st speed. Blower should operate on 1st
speed.
ES5-11
30. Turn fan control dial to 2nd speed. Blower should operate on 2nd
speed.
OK / NG
31. Continue checking blower speed until all four speeds are checked.
OK / NG
32. Leave blower on 4th speed.
Check Discharge Air

33. Press each mode switch and confirm discharge air comes out from
each position.
OK / NG
ES5-12
34. Confirm compressor clutch is engaged (visual inspection) and

intake door position is at FRESH when DEF switch is pressed.
OK / NG
ESTN1005B
35. Confirm intake door position is at FRESH when D/F switch is
pressed.
OK / NG
Check Recirculation
36. Press recirculation switch. Recirculation indicator should light.
OK / NG
ES5-13
37. Inspect intake door position change.

(You should hear blower sound change slightly.)
OK / NG
38. Confirm RECIRCULATION (REC) switch is canceled in DEF and D/
F mode.
OK / NG
39. Slide temperature control lever to full cold and confirm cold air at
discharge air outlets.
OK / NG
ES5-14
ESTN1005B
40. Slide temperature control lever to full hot and confirm hot air at discharge air outlets.
OK / NG
ES5-15
Check A/C Switch

41. Push A/C switch to turn ON and confirm indicator lamp comes on
when A/C is ON.
OK / NG
ES5-16
CHECK THE ENTIRE SYSTEM FOR REFRIGERANT LEAKS PRELIMINARY CHECK

* Perform a visual inspection of all refrigeration parts, fitting, hose
and components for signs of A/C lubricant leakage, damage and
corrosion.
* There are two refrigerant leak detectors.
1) Electrical leak detector
2) Fluorescent dye leak detector
* Position probe approximately 5 mm (3/16 in) away from point to be
checked.
ES5-17
10
ES5-18
ESTN1005B
* Move probe along component approximately 25 to 50 mm (1 to 2
in)/sec.
ES5-19
Procedure for Leak Test with Electrical Leak Detector
ES5-20
* Conduct leak test from high side to low side.
43. Clean the component to be checked and move leak detector probe
completely.
OK / NG
11
ESTN1005B
44. Perform a leak test for the following areas, and write the judgement
results.
OK / NG
OK / NG
OK / NG
OK / NG
OK / NG
OK / NG
ES5-21
* If leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat checks as outlined above.
* Do not stop when one leak is found. Continue to check for additional leaks at all system components.
12
ESTN1005B
Procedure for Leak Test with Fluorescent Dye Leak Detector
ES5-22
* Always wear fluorescence enhancing UV safety glasses to protect

your eyes and enhance the visibility of the fluorescent dye.
* Illuminate all components, fittings and lines. The dye will appear as
a bright green/yellow area at the point of leakage.
* If the suspected area is difficult to see, use an adjustable mirror or
wipe the area with a clean shop rag or cloth, then check the cloth
with a UV lamp for dye residue.
13
ESTN1005B
46. Perform a system performance check and verify the leak.
OK / NG
OK / NG
OK / NG
OK / NG
OK / NG
OK / NG
ES5-23
47. Inspect the condenser.

Inspection point
Judgement
Leakage
Leaves & twigs
Mud
Debris
Clean the core.
OK / NG
Rinse the core.
OK / NG
OK / NG
14
ESTN1005B
48. Inspect the drive belt(s).
Inspection point
1
2
Judgement
Cracks
Fraying
Wear and oil
Deflection
Tension
OK / NG
OK / NG
PERFORMANCE TEST FOR A/C

49. Park the vehicle indoors or in a shaded area.
50. Open the hood, start the engine, close all of the doors, and open
the windows.
51. Set temperature control to full cold position.
52. Set mode control to vent (face) position.
53. Turn recirculation switch ON.
54. Set fan speed to max. and turn A/C switch ON.
15
ESTN1005B
55. Run the engine at 1,500 rpm for 10 minutes.
56. Confirm discharge air temperature at center vent is cold.

OK / NG
* Verify that all inspections have been performed.
58. Disconnect proper exhaust ventilation.
59. Lower the hood.
INSTRUCTOR SIGN-OFF
16
Worksheet
FUND Course
Worksheet #
Worksheet tasks
GITN1001B
GITN1001B/WS3
Usage of Electronic Service

Manual
GITN1002A
Usage of SST
GITN1003B
GITN1005A
Outline of Engine
GITN1006A
Outline of Chassis
ELTN1001B
ECTN1001B
Fundamental Skills
Remarks
Worksheet
GITN1001B
GI01B000
Fundamental Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
Nissan Vehicle
Service Manual (white face page version)
Worksheet

End of worksheet.
GITN1001B/WS1
1.
2.

EC (EF & EC):
RS:
HA:
EL:
3.
4.

Assigned engine is
1) Engine removal:
2) Cylinder head:
_____________________________
_____________________________
5.
6.
What is the tightening torque of the crank pulley bolt?

7.
8.
On what page does the "TROUBLE DIAGNOSES" begin?
GITN1001B/WS1
9.
*
Turn to that page.

You can see the "How to perform trouble diagnoses for quick and accurate
repair" section. It's very helpful for your trouble shooting.
10. On what page do trouble diagnoses for Throttle position sensor begin?
__________________
11.
Turn to that page.
12. What is the terminal number of the signal line on ECM connector?
__________________
*
13.
You can find the terminal number and wire color of each signal line.
Turn to the MT section.
__________________
16. What is the final gear ratio?

Engine:
Transmission:
Gear ratio:
18. On what page can you find it?

__________________
GITN1001B/WS1
19. Go to that page and use the Trouble Diagnosis in the contents to answer the
following questions:
20. On what page is the following information found?
PAGE LOCATION
Electrical Components Inspection
Hunting Diagnostic Procedure

(Crank Angle Sensor) Diagnostic Procedure
Basic Inspection Information
Throttle Position Sensor Diagnostic Procedure
Injector Diagnostic Procedure
Unstable Idle Diagnostic Procedure
Knock Sensor Diagnostic Procedure

(If available)
Surge Diagnostic Procedure
Mode II [Self-Diagnostic Results]
Fuel Pump Diagnostic Procedure
GITN1001B/WS1
21.

cable.
with a voltmeter.
ON position.
OFF position.
Gl01B001
GITN1001B/WS1
Gl01B002


OFF / ON / START

Running / Stop
26.


Terminal / Harness
GITN1001B/WS1
29.
30. Answer the following questions with large sample illustration in the Service
Manual.

__________________

__________________

__________________
the yeard / pond system.
Example: xx - xx N-m (yy - yy kg-m, zz-zz ft-lb)
xx - xx N-m (yy - yy kg-m, zz-zz in-lb)
Unit conversion
1 N-m = 0.1017 kg-m 1N-m = 0.7495 ft-Ib 1 N-m = 8.827 in-Ib
1 kg-m =9.806 N-m
1 ft-Ib =1.334 N-m 1 in-Ib = 0.1133 N-m
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
Nissan Vehicle
Service Manual
(Red color face page version excluding B14 & S14)
Worksheet

End of worksheet.
GITN1001B/WS2
1. Locate the Quick Reference Index at the front of the Service Manual.
2.

EC (EF & EC):
RS:
HA:
EL:
3.
4.

Assigned engine is
1) Engine removal:
2) Cylinder head:
_____________________________
_____________________________

5.
__________________
6.
What is the correct tightening torque of the crank pulley bolt for your
vehicle's engine?
7.
8.
On what page does the General Description of TROUBLE DIAGNOSIS

begin?
__________________
GITN1001B/WS2
9.
Turn to that page.
10. On what page does Idle Speed Adjustment or Check in BASIC SERVICE
PROCEDURE begin?
__________________
11.
Turn to that page.
12. What is the specification of base idle speed?

rpm
13.
Turn to the AT section.
__________________
16. What is the 1st gear ratio?

Engine:
Transmission:
Gear ratio :
GITN1001B/WS2
18. On what page is the following information found:
PAGE LOCATION
Basic Inspection
Fail-Safe Chart
Oxygen Sensor
Knock Sensor
(If available)
Diagnostic Trouble Code (DTC)
GITN1001B/WS2
19.

cable.
with a voltmeter.
ON position.
OFF position.
Gl01B001
GITN1001B/WS2
Gl01B002


OFF / ON / START

Running / Stop
24.


Terminal / Harness
GITN1001B/WS2
27.
28. Answer the following questions with large sample illustration in the
Service Manual.

__________________

__________________
The UNITS given in this Manual are primarily expressed as SI UNITS (International System of Unit), and expressed in the metric system or
alternatively the yard / pond system.
Example: xx - xx N-m (yy - yy kg-m, zz - zz ft-lb)
xx - xx N-m (yy - yy kg-m, zz -zz in-lb)
Unit conversion
1 N-m = 0.1017 kg-m 1 N-m = 0.7495 ft-Ib 1 N-m = 8.827 in-Ib
1 kg-m =9.806 N-m 1 ft-Ib =1.334 N-m 1 in-Ib = 0.1133 N-m
INSTRUCTOR SIGN-OFF
Usage of Electronic Service Manual (GITN1001B/WS3)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
Nissan Vehicle
Electronic Service Manual
Worksheet

End of worksheet.
When you have finished all the activities, have the instructor check your work and initial this
worksheet. Also, have your instructor initial your sign-off sheet so you can keep track of
your overall course progress.
GITN1001B/WS3
Using the Electronic Service Manual found at your workshop, complete the following
exercises. If you have any questions or problems while working with this material,
1.
Turn ON your Personal Computer (PC).
2.
Is the operating system of your PC Microsoft Windows 95/98 or later model?

YES / NO If NO, find Windows 95/98 PC or later.
3.
Is the CPU of your PC i486DX-66MHz or higher?

YES / NO If NO, find the applicable PC.
* Your CPU should have pentium 166 MHz or higher and at least 32 MB memory.
* At least 16 bit colors monitor and 8-speed CD-ROM drive are recommended.
4.
Insert CD-ROM of ESM to CD drive on your PC.
5.
Is Acrobat Reader installed into your PC?

YES / NO
If YES, go to step11.
6.
Double-click on the CD icon.
7.
Double-click on the folder titled acroread icon inside the CD icon.
8.
Double-click on ar32e301(.exe) inside the acroread icon.
9.
Install Adobe Acrobat Reader according to the instruction of the installation

program.
GITN1001B/WS3
10.
Open CD contents folder.
11. Double-click on the [start (.pdf)] inside CD icon.
12. Click START button on the opening screen. You can see QUICK REFERENCE INDEX.
13. Click Zoom control box in tool box on the bottom of screen to change the
screen size according to your needs.
14. Choose Fit width from the menu box, then click OK.
15. Click Select zoom-in tool box on tool bar on the top of screen.
Be sure pointer should change to
mark.
16. Click any place on the Service Manual page to make the screen size double
every click.
17. What percentage can the screen size be enlarged at the maximum?
%
18. Click or drag scroll bar at the right end of screen to move screen.
The screen can be moved by a triangle mark at the top of screen.
GITN1001B/WS3
19.
Click EC section tab on the QUICK REFERENCE INDEX at the right

side of screen to see EC section of contents page.
20
Click QUICK REFERENCE INDEX book mark at the left side screen.
By clicking name of section at the right or left screen can be moved according to your needs.
21. What is the meaning of the abbreviations shown below?
EC:
RS:
HA:
EL:
22. Click EM section book mark on the screen.
GITN1001B/WS3
23.
On what page does the following information begin?

Assigned engine is
24.
Ask your instructor.
1)
Outer component parts:
2)
Cylinder block
3)
Service Data and Specification
On what page can you find the tightening torque of camshaft bracket bolts?
25. What is the tightening torque of camshaft bracket bolts?

(N-m / kg-m / in-lb)
26. Click QUICK REFERENCE INDEX book mark at the left side of screen.
27. Click EC book mark at the left side of screen.
28. Click triangle mark for suitable choice, or engine type, if required.
You can move any pages which you want to see detail of contents by both
right (scroll bar) and left (book mark) screen.
29. On what page does the General Description of TROUBLE DIAGNOSIS

begin?
30. Go to the page of Fail-safe Chart.
31. What does the detected code, DTC No- P0120, mean?
GITN1001B/WS3
32. On what page does CONSULT-II Reference Value in Data Monitor Mode in
IDLE AIR CONTROL VALVE (IACV) begin?
33. Go to the page.
34. What is the specification of IACV-AAC/V operation at engine idling?

steps
35. Back to QUICK REFERENCE INDEX with the left side of screen.
36. Click AT section.
39. What is 1st gear ratio?

Assigned Engine & Transmission are:
(Ask your instructor)
Engine:
Transmission:
Gear ratio:
40. Back to Trouble Diagnoses in EC section.
GITN1001B/WS3
41.
On what page is the following information found?
for N16 QG18DE

PAGE LOCATION

Basic Inspection
Fail-Safe Chart
Oxygen Sensor
Knock Sensor (If available)
Diagnosis Trouble Code (DTC)
Circuit Diagram
GITN1001B/WS3
42.
43.
Draw lines to match the symbol to the description.

a. Disconnect battery negative cable.
b. Voltage should be measured with a
voltmeter.
h. Check after disconnecting the connector to be measured.
ON position.
OFF position.
m. Do not start engine, or check with
engine stopped.
GI01B001
GITN1001B/WS3
GI01B002


OFF / ON / START

Running / Stop
47.


Terminal / Harness
GITN1001B/WS3
50.
Go to How to use this Manual in GI section.
51. Answer the following questions with sample illustration in the Service Manual. (Brake caliper)
________________

________________
3) What is the difference between two symbols of torque?
Example: xx - xx N-m (yy-yy kg-m, zz - zz ft-lb)
xx - xx N-m (yy-yy kg-m, zz -zz in-lb)
Unit conversion
1 N-m = 0.1017 kg-m 1 N-m = 0.7495 ft-Ib
1 kg-m = 9.806 N-m 1 ft-Ib = 1.334 N-m
1 N-m = 8.827 in-lb

1 in-Ib = 0.1133 N-m
INSTRUCTOR SIGN-OFF
10
Worksheet
GITN1002A
GI02A000
Fundamental Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to select the correct
Special Service Tools (SST) for each job, by using this worksheet.
None
Service Manual
Worksheet

End of worksheet.
GITN1002A
1.
2.
Find the MA section and go to that page.
3.
On what page does Special Service Tools (SST) in the preparation section
begin?
4.
What is the SST number of the oil filter wrench for your engine?
Nissan has three kinds of wrenches.
1) 65 mm (2.56 in) diameter ............for SR and CG

2) 80 mm (3.15 in) diameter ...............for A, E, CA, GA, RB, VG, VH and CD
3) 93 mm (3.64 in) diameter ................. for Z, L and TD42
5.
Find the EM section and go to that page.
6.
7.
What are the SST numbers for engine attachments for your engine?
Attachment
and / or Sub-attachment
Sub-attachments are different in size among different engine models.

You have to check the correct SST number.
GITN1002A
8.
What is the SST number of the cylinder head bolt wrench for your engine?
(If available)
This wrench is used for GA, SR, L, RB, VG, VH, CD and LD series engine.
9.
Enter the correct SST number of the following tools used for your engine:
1) Piston ring compressor

2) Valve oil seal drift
3) Seal cutter
10. Are these SST commonly used for all engine?
YES / NO
11. Find the MT section and go to that page.
12.
On what page does Special Service Tools in the preparation section begin?
13.
What is serviceable with the SST numbered ST30031000?
Various types of puller are available for the manual transaxle. You have to
choose and use a suitable puller for each job.
14. What will happen to a bearing when a different size puller is used?
GITN1002A
15.
Find the BR section and go to that page.
16.
17.
For what would you use a flare nut torque wrench?
INSTRUCTOR SIGN-OFF
Worksheet
GITN1003B
GI03B000
Fundamental Skills
General Model Introduction (GITN1003B/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand Nissan Vehicles

Handling precautions, by using this Worksheet.
Nissan Vehicle
Worksheet

End of worksheet.
GITN1003B/WS1
Vehicle Identification Number (VIN)
1.
Using Service Manual found at your Workshop, answer the following questions and fill out the blanks.
Refer to the Identification information of GI section in the Service Manual.
2.
On what page does Model variation information begin in GI section?
3.
What is the model code of your vehicle?
4.
What is the Vehicle Identification Number (chassis number) of your vehicle?
5.
Enter the type of the following items.

Body type:
Sedan / Coupe / Hatch-back / Wagon / Van
Engine type:
Grade:
Transaxle type:
Destination:
6.
Draw lines to match the abbreviation to description.

FF
FR
RR
MR
RHD
LHD
Midship engine, rear drive

Right hand drive
Front engine, front drive
Front engine, rear drive
Left hand drive
Rear engine, rear drive
GITN1003B/WS1
*
7.
What is the code of the engine?
Ex. VQ30DE
Transmission code number

* Refer to the Textbook.
8.
Relate the code to the statements:
RS5F50A
1) Type of control position:
2) Additional function:
3) Number of forward speeds:
4) Drive system:
Refer to the Textbook and Service Manual.
9.
What type of brake is used on your vehicle?

Front brake code:
Rear brake code:

RL4F03A
GITN1003B/WS1
*
10.

What is the steering type on your vehicle?
Code:
11. Which engines use the ECCS system?

Mark the common ones:
GA16DS
NA20S
SR20DE
VQ20DE
VG33E
KA24E
Z24S
QG15DE
12. Which transmissions are for front-wheel drive vehicles?

Mark each type of transmission
RS5W71C
RL4F03A
RE4R03A
FS5W71C
FS5R30A
RS5F31A
13. Which engines use carburetors?

Mark each type of engine
VG33E
NA20S
TB45E
VH45DE
VQ30DE
GA14DS
QG13DE
Z24S
General Model Introduction (GITN1003A/WS2)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand Nissan vehicles

handling precautions, by using this Worksheet.
Nissan Vehicle
Service Manual
Worksheet

End of worksheet.
GITN1003A/WS2
1.
On what page does Precautions information begin in GI section?
2.
Which battery terminal should you remove before servicing an electrical

component?
Positive / Negative
3.
What areas of the vehicle should be covered with protective mats or covers?
Fenders / Roof / Tire / Steering wheel / Seats / Mirror / Headlamp
(Mark the correct ones)
4.
Can any type of fuel be used on vehicles fitted with catalytic converters?
YES / NO
Leaded fuel will damage the catalytic converter and some engine part.
5.
On what page does Tow Truck Towing information begin in GI section?
6.
What is the jack point for your vehicle?

Side sill / Sill spoiler / Bumper / Axle case / Stabilizer bar / CTR Member
GITN1003A/WS2
7.
What is the maximum towing speed for an A/T vehicles with 4 wheels on
ground?
8.
What is the maximum towing distance for A/T vehicle with 4 wheels on
ground?
9.
If you have to tow a vehicle equipped with an automatic transmission / axle a

long distance, what precautions should you take?
INSTRUCTOR SIGN-OFF
Worksheet
Outline of Engine
GITN1005A
GI05A000
Fundamental Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand engine structure

Nissan Vehicle
General tools
Service Manual
Textbook
Worksheet

End of worksheet.
GITN1005A
1.
Major engine parts names are written below.

Choose the number from 1 through 12, and fill its number in the matched
blank box.
1) Radiator
2) Drive shaft
3) Camshaft
4) Piston
5) Ignition coil
6) Connecting rod
7) Crankshaft
8) Flywheel
9) Injector
10) Intake manifold
11) Exhaust manifold
12) Cylinder head
GI05A001
2. Mark the best answer to each question.

A. In general, automotive engines are classified into two groups.
What are they? (Mark the correct answer.)
Diesel / Coal / Gasoline / Charcoal / Oil
B. What is carburetor mixed with gasoline?
Oil / Air / Water / Paper
C. What is the power flow for a gasoline combustion engine?
Combustion gas
Piston / Exhaust valve / Cylinder head

Push rod / Connecting rod / Cylinder head
Camshaft / Drive shaft / Crankshaft
Flywheel
GITN1005A
3.
What stroke engine is illustrated below?

8 stroke engine / 4 stroke engine / 2 stroke engine
GI05A002
4.
Which stroke does each description correspond to?
A. The intake valve is open while the piston moves down and the
air-fuel mixture is sucked into the cylinder.
B. As the piston begins to move up, the intake valve closes to seal the
combustion chamber and the air-fuel mixture is compressed.
C. The air-fuel mixture is ignited by an electric spark (spark plug).
D. The exhaust valve opens to let the combustion gas discharge.
5.
There are 3 illustrations of cylinder arrangements below.

GI05A003
In-line
In-line
In-line
V-type
V-type
V-type
Flat opposition
Flat opposition
Flat opposition
GITN1005A
*
Refer to the S.D.S. section of EM in the Service Manual.
6.
What is the cylinder arrangement of assigned vehicle engine?

* Cylinder arrangement:
In-line / V-type / Flat opposition
* Number of cylinders:_______________________________
*Total displacement:
7.
cm
Answer the questions corresponding to the parts in the illustration.
GI05A004
* What is the A part in the illustration? Mark one.

* What is the B part in the illustration?
* What is the C part in the illustration?
Combustion chamber / Float chamber / Throttle chamber
8.
What is the compression ratio of gasoline engine generally?

14 : 1 / 8 - 10 : 1 / 16 - 20 : 1
9.
What is the compression ratio of your assigned one?
GITN1005A
10. The illustrations below show automotive parts with attached numbers.
Write the number corresponding to the part shown in the illustration
next to the part name in the list.
Part name
Number in
illustration
Fuel pump
Fuel pipe
Fuel filter
Fuel tank
Carburetor
GI05A005
Part name
Air cleaner
Air element
Main muffler
Exhaust manifold
Intake manifold
GI05A006
Sub muffler
Exhaust pipe
GI05A007
11. What type of air element is used in your vehicle?

Viscous / Dry paper
Number in
illustration
GITN1005A
12. Below are some incomplete sentences about the carburetor. Some
words are given in each sentence. Choose and mark the word which
best completes the sentences.
* The carburetor controls the volume of (Oil / Fuel / Water) and (Air / Gas/
Solid) entering the engine cylinder.
* It provides the proper (Air-fuel mixture / Liquid mixture / Blow-by gas) for
the existing driving conditions.
13. Below are some descriptions about carburetor fuel systems. Some
system names are given beneath each sentence. Choose and mark
the best system name.
A. Operates when high power output is required.
B. Supplies fuel to the engine during idling periods and at low speeds.
Acceleration fuel system / Main fuel system / Slow fuel system
C. Operates during rapid acceleration.
Acceleration fuel system / Main fuel system / Power fuel system
D. Supplies fuel to the engine during intermediate and high-speed.
GITN1005A
14. The illustration shown below is a typical carburetor. Some words, marked 1
to 6 are given below. Find the parts name and write the number in the blank
boxes in the illustration.
GI05A008
1) Float chamber
3) Main nozzle
5) Primary throttle valve
2) Float
4) Acceleration pump
6) Idle adjusting screw
15. The illustration shown below is cooling system structure. Some part
names, marked 1 to 4 are given beneath illustration. Find the best part
name and write the number in the blank boxes in the illustration.
GI05A009
1) Radiator
3) Thermostat
2) Water pump
4) Cooling fan
GITN1005A
16. The illustrations shown below are variety of valve mechanism systems. Three system names are given beneath each illustration.
OHV / OHC / DOHC
OHV / OHC / DOHC
OHV / OHC / DOHC
GI05A010
INSTRUCTOR SIGN-OFF
Worksheet
Outline of Chassis
GITN1006A
GI06A000
Fundamental Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand chassis structure

Nissan Vehicle
General tools
Service Manual
Worksheet
Textbook

End of worksheet.
GITN1006A
VEHICLE CONSTRUCTION
1. The illustration below shows typical vehicle drive systems.




GI06A001
2.
Listed below are 4 sentences which describe the operation of various chassis
systems. Choose and mark the best answer.
A. This system is to change the vehicle direction during operation.
B. This system controls vehicle speed and stops the vehicle.
C. This system transfers the power generated by the engine to the

wheels.
D. This system improves the riding comfort by easing shocks from the road
surface.
GITN1006A
3.
The illustration below shows a typical automobile. The names of parts,

marked 1 through 5 are listed underneath. Select the correct term, which
identifies the various components in the drive train. Write the associated
number in the blank box.
GI06A002
1) Transmission
2) Drive shaft
4) Clutch
5) Propeller shaft
3) Final drive
CLUTCH
4. Below are some descriptions about the clutch. Choose and mark the best
answer.
A. When the clutch is engaged, is the engine power transmitted to the transmission?
YES / NO
B. When the clutch pedal is depressed, is the clutch engaged or disengaged?
Engaged / Disengaged
5.
What is the relationship between clutch pedal and clutch operation?

A. What happens to clutch operation when clutch pedal free play increases?
B. What happens to clutch operation when clutch pedal free play decreases?
GITN1006A
TRANSMISSION / AXLE
6. Below are some incomplete sentences about transmission/axle. Some
1) [ ? ] within the transmission/axle change position relative to each other
(engage or disengage) in response to vehicle conditions.
Gears / Forward / Engine speed
2) The engine torque is delivered to the [ ? ]
Suspension / Vehicle drive shaft / Steering wheel
3) The transmission/axle permits the vehicle to move in the forward and the
[ ? ]direction.
Upper / Reverse / Left
7.
The illustration below shows an example of gear flow. Use the formula
beneath the illustration to determine the ratio of the input speed to the output
speed.
GI06A003
Formula:
A
C
X
= Output speed ratio
B
D
GITN1006A
FINAL DRIVE
8.
The illustration below shows typical differential (final drive assembly).

Choose the number from (1) to (4), and fill its number in the corresponding
blank box in the illustration.
1) Ring gear
2) Differential case
3) Side gear
4) Pinion mate gear
GI06A004
9.
Below are some incomplete sentences about the final drive assembly. Some
1) The final drive assembly consists of the final gear assembly and the [ ? ]
Differential assembly / Drive shaft / Suspension
2) The final gear mechanism provides the final [ ? ] of the engine's high rotation speed.
Exception / Reduction / Suspension
3) The differential allows for adjustment of individual drive wheel [ ? ]

during vehicle turning.
Running distance / Direction / Height
GITN1006A
10. The illustration shows the rear wheels of a vehicle that are driving straight
ahead and turning to the left. Choose and mark the best description of wheel
and tire motion from the boxes below.
GI06A005
(1) Vehicle driving straight ahead
(2) Vehicle turning to the left.



same speed.

same speed.


SUSPENSION
11. Below are some descriptions about function of suspension components.
Choose and mark the best component name for each description.
1) Reduces body roll.
2) Determines body position and transmits motion and braking to the body.
3) Supports the weight of the body and absorbs shock from the road.
4) Controls vertical movement of the body.
GITN1006A
12. The illustrations below show typical front suspension. Choose and mark the
1) Multi-link type
2) Strut type
3) Double wishbone
GI06A006
1) Multi-link type
2) Strut type
3) Double wishbone
GI06A007
1) Multi-link type
2) Strut type
3) Double wishbone
GI06A008
GITN1006A
13. The illustrations below show typical rear suspension. Choose and mark the
3) 5-link type
GI06A009
3) 5-link type
G I06A 010
3) 5-link type
G I06A 011
GITN1006A
14. Below are some incomplete sentences about the steering system.
Some words are given in each sentence. Choose and mark the word
which the best completes the sentence.
1) The wheels must turn [ ? ] with minimal resistance in the proper direction.
Lightly / Heavily
2) After turning a corner, the wheels must [ ? ] position.
Continue in direction of turn / Return smoothly to the straight-ahead
3) For above operations, [ ? ] need to be checked.
Wheel alignment / Fuel properties
15. What are the four primary factors to be considered in wheel alignment?
CAMBER / RUNOUT / TOE-IN / FREE PLAY

CASTER / SIDE-SLIP / KINGPIN INCLINATION
The above factors work together to carry out the following functions.
*Make operation of steering wheel easy.

*Maintain steering in straight-ahead direction.
*Give steering self-centering qualities.
*Reduce tire wear
GITN1006A
16. The illustrations show important wheel alignment areas.
Choose and write the name of appropriate wheel alignment area number in
the corresponding blank space in the illustrations.
CASTER [
CAMBER [
TOE-IN [
KINGPIN INCLINATION [
GI06A012
GI06A013
GI06A014
10
GITN1006A
STEERING
17. The illustrations below show a typical steering system.
GI06A015
GI06A016
11
GITN1006A
BRAKE
18. The illustrations shows a typical brake system. The name of the parts,
marked 1 through 6, are given in the list. Choose the best number to each
blank box and fill in the blank.
GI06A017
1) Brake pedal
2) Booster
3) Master cylinder
4) Disc brake type
5) Drum brake type
6) Parking brake lever
WHEEL & TIRE

19. Tire and wheel classification are indicated by alphanumeric symbols.
Write the number that corresponds to the alphanumeric symbols in the box
provided.
195
60
14
89
1) Rim diameter
2) Tire width
3) Speed symbol
4) Load carrying capacity
5) Aspect percent
6) Radial
6 - 1/2
14
1) Wheel rim diameter
2) Tire width
3) Wheel rim width
4) Flange shape
12
GITN1006A
PRACTICE
Go to your assigned vehicle and answer the following questions.
1.
What is the vehicle model?
2.
What type of drive train does the vehicle have?

Front engine Front drive / Front engine Rear drive / 4-Wheel Drive
3.
What type of transmission/axle is fitted to the vehicle?

Manual / Automatic / CVT (Continuously Variable Transmission)
4.
What type of clutch operation does the vehicle have?

(To be answered only if the vehicle is equipped with a manual transmission/
axle.)
Mechanical type / Hydraulic
5.
What type of front suspension does the vehicle have?
6.
What type of rear suspension does the vehicle have?
7.
What type of front brakes does the vehicle have?

8.
What type of rear brakes does the vehicle have?

13
GITN1006A
9.
What is the front tire size?

1. Tire code_______________________________________
2. Tire width______________________________________
3. Aspect percent or ply rating (for bias tire)_____________
10. What is the front road wheel rim size?

1. Rim size code__________________________________
2. Rim diameter___________________________________
3. Rim width______________________________________
4. Offset_________________________________________
11. What type of steering does the vehicle have?

Recirculating ball type / Rack and pinion type
INSTRUCTOR SIGN-OFF
14
Worksheet
ELTN1001B
V=IR
I=
V
R
R=
V
I
EL01B000
Fundamental Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to use an analog type
Multi-meter (circuit tester), by using this worksheet.
Analog type Multi-meter

Vehicle or appropriate units
Worksheet
Textbook

End of worksheet.
ELTN1001A/WS1
Using this worksheet and the Multi-meter, answer the following questions.
Voltage measurement
V
EL01A001
V
EL01A002
3. Adjust meter to 0 by the needle zero adjuster.

4. Select highest voltage range by using range selector.
ELTN1001A/WS1
5.
Connect Red test lead wire to the Positive side of battery and Black
test lead to negative side of battery or body ground.
* Voltmeter must be connected in parallel in the circuit.
6.

V
7.
Change to the lower range, which indicates more than half on the scale.
8.

V
When measuring a voltage, use the reading where the needle deflects
beyond half on the scale. Because there is resolution correspond to the each
range.
Resistance measurement
9.
Select range selector to x10k position.
10. Short out Red and Black test leads firmly together while checking.
* When reading the meter indication, aways view the needle from directly
above.
* A reading error will result if it is not read in this way.

* Some Multi-meters have a mirror for this reason.
ELTN1001A/WS1
12. Select range selector to x1k position.

13. Check the ohm zero position.
14. What happens to the meter indication?
Needle indicated (Same / Different)
* When measuring a resistance, use the reading where the needle deflects
beyond half on the scale. Because there is resolution correspond to the
each range.
16. Measure the resistance of the high tension cable.
* Polarity is not important when applying the test leads to the measuring
points.
* Never make any continuity or resistance test with the power connected to
the circuit being tested as it will damage the circuitry of the Multi-meter.
17. Change range selector to x10k .
ELTN1001A/WS1
19.
Measure the resistance of high tension cable again.
20.
What is the resistance?
21. Is this reading within the specification?

YES / NO
Testing continuity
22. Change range selector to x1k.

24. Measure the continuity of assigned circuit A and B.

25. If the meter indicates zero ohm, it means an (open / closed) circuit, and infinity means an (open / closed) circuit.
INSTRUCTOR SIGN-OFF
Basic Electrical Concept (ELTN1001A/WS2)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand the principle of

Ohms Law, by using this worksheet.
Multi-meter
Circuit block set (appropriate kit)
Worksheet
Textbook

End of worksheet.
ELTN1001A/WS2
Ohms Law
Ohms Law describes one of the most fundamental relationships in the

field of electricity.
1.

increased resistance will increase / decrease the current flow.
And, if voltage stays constant and circuit resistance decreases, current
flow will increase /decrease.
2.
Calculate the current in below circuit:
V
Current =
R
12
=
6
=2
(A)
V
Current =
R
12
=
12
EL01A003
=1
CIRCUIT TYPES
Using Circuit Block Kit, answer the following questions.
(A)
ELTN1001A/WS2
SERIES CONNECTION AND PARALLEL CONNECTION
PURPOSE:
Resistance can be connected in two different ways; series connection and parallel
connection. Each of these connections is examined using the blocks and circuit
tester.
SERIES CONNECTION
PROCEDURE
1. Connect the blocks as shown below.
EL01A004
2. After completing connection, turn ON the switch and measure the following items.
Voltage (V)
Current (mA)
Resistance()
(1)
12 V
(mA)
200 x one
(2)
12 V
(mA)
200 x one
(3)
12 V
(mA)
400 x one
Resistance( ) 200 x two

Voltage (V)
12 V
A to B
B to C
(V)
A to C
(V)
(V)
ELTN1001A/WS2
SUMMARY
* The same current is measured in (1) and (2). This means that when 100
and 200 resistors are connected in series, the resistance values can be
added.
From Ohms law, we can calculate as follows:
(1) I = V / R
(2) I = V / R
I = 9V /(100 + 200) = 30 mA
I = 9V / 300 = 30 mA
PARALLEL CONNECTION
PROCEDURE
3. Connect the blocks shown below.
EL01A005
4.
After completing connection, turn ON the switch and measure the following items.
Voltage (V)
Current (mA)
Resistance ()
(1) 9 V
mA
600 x one
(2) 9 V
mA
600 x two
ELTN1001A/WS2
* SUMMARY
The measured current in test (2) where 2 x 600 resistors are connected in
parallel is larger than measured in test (1) where only 1 x 600 resistor is
used. The current flows may be calculated as follows:
Test (1) I = V / R = 9 / 600 = 15 mA
However, with a parallel circuit, the current flow increases as the current
can flow through both circuits simultaneously.
When we calculate the total resistance for a parallel circuit we should use
the Test (2).
Total resistance =
1
1 + 1
R1
R1
=
1
=
1
= 300
1 + 1
2
600
600
600
Using Ohms law the current can be calculated as follows:
I = V / R = 9 / 300 = 30 mA
NOTE: This is twice the current flow of test (1).
worksheet and move on to the next one.
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to locate and interpret
Service Manual information, by using this worksheet.
Nissan Vehicle
Multi tester
Service Manual
Worksheet
Textbook

End of worksheet.
ELTN1001B/WS3
To answer the following questions, use the Service Manual.
1. Turn to the General Information section in the Service Manual.
2. On what page does How to read wiring diagram start?
3. TURN TO THAT PAGE. This page explains symbols used to read wiring diagram, and how to interpret switch position.
4. The illustration at right explains the position

in which the system can be operated.
IGNITION SWITCH
ACC or ON
YES / NO
5. On what page is the explanation of Connector Symbols?
6. Which of the following connectors are male connectors?

CIRCLE EACH MALE CONNECTOR.
EL01B001
7. On what page is the explanation for How to follow flow chart in trouble
diagnoses?
ELTN1001B/WS3
8.
Turn to that page and read the notes on how to follow flow charts.
ELECTRICAL SYSTEM SECTION

9.
Turn to the contents of Electrical System section in the Service Manual.
10. On what page does the explanation for Standardized Relays begin?
TURN TO THAT PAGE.
11. What color is the 2 M relay?
12. On what page does Power Supply Routing begin?
13. Find the Location of Electrical Units and TURN TO THAT PAGE.
14. Where is the relay box located? (L.H.D.model)
15. Turn to the Harness layout in the Service Manual. Locate the Engine
room harness layout.
ELTN1001B/WS3
* The E means this connector is in the engine room harness.
* The following is a list of wiring harness and the letters that indicate the
harnessess names:
M
Main
Room (Interior Lamp)
Engine
Sunroof
Instrument
Door
EFI
Alternator
Body
16. What is the page number for the Super Multiple Junction (S.M.J)?
TURN TO THAT PAGE.
* This diagram shows the S.M.J harness terminal locations.

- Refer to this diagram if it is necessary to make electrical checks at the
S.M.J. during diagnosing of electrical problem.
- Terminal side or harness side explains how the connector is viewed.
17. Turn to the table of contents for the EC(EF& EC) section and read through.
* Notice the arrangement of information:
- The EC (EF & EC) overall system includes the system circuit wiring diagram.
Also the EC (EF & EC) parts description and the EC (EF& EC) system
description are included here.
- Trouble diagnoses.
NOTE: Some Service Manuals will call this section diagnostic procedure.
18. What is the DIAGNOSTIC TOUBLE CODE (DTC) number (Code No.) for the
Engine Coolant Temperature Sensor?
ELTN1001B/WS3
CRITERION TEST
1. On what page will you find wire color coding? (In GI section)
2. On what page will you find the explanation of Super Multiple Junction in GI
section?
3.
What is the page number for the explanation of the symbols shown below?
EL01B002
ELECTRICAL SECTION
4. What type of relay has a gray colored case?
5.
Where is the location of the ECCS control module(ECM)?

6.
Locate the power supply routing wiring diagram. Turn to that page.
What amperage fuse is used to control the fuel pump?
A
ELTN1001B/WS3
7.
What wire color code and wire color carries power to the fuel pump?
color
code
8.
On what page will you find location information for the engine room
harness layout?
TURN TO THAT PAGE.
9.
What is a number of the connector to LH headlamp?
10. Turn to the Engine Control harness layout section. What is the connector number for the Throttle Position Sensor?
CONNECTORS
11. The numbers in this connector represent terminal numbers.
What is the terminal number for the W wire?
What is the terminal number for the G/R?
EL01B003
ELTN1001B/WS3
(Super Multiple Junction)
12. What does the letter and the number in the ovals above the connector represent?
( )
Component location
( )
Terminal number
( )
Connector number
EL01B004
13. What does the 1B and 2D represent in this illustration?

( )
Connector location
( )
Super multiple junction terminal

location
( )
Multiple switch terminal location
EL01B005
WIRING DIAGRAM
* The dot in this illustration represents a splice on a harness wire.
A splice is used to distribute battery
voltage to more than one load in a circuit.
EL01B006
Splices are also used for circuit

grounds.
By using a splice, one wire can be separated into two or more grounds.
* The circle in this illustration represents a branch circuit, a variation in
model, system, or market.
For example, one starting system wiring
diagram may be used for both manual
and automatic transmissions. An A in
a circle or oval, or an M in a circle or
oval is a clue that wiring is shown for
both systems. The wiring diagram has a
key that explains and letters that are in
EL01B007
circles or ovals.
ELTN1001B/WS3
EL01B008
14. How many connectors are used in this check?
15. What type of connectors are they?

MALE / FEMALE

17. Which is the ignition switch position?

ON / OFF
18. What two terminals must be checked?

and
19. On which side must the C/Module connector be checked?

ELTN1001B/WS3
EL01B009
Answer the following questions taken from the illustration shown above.

21. Which pedal is being depressed?

BRAKE / ACCELERATOR
22. What color is the wire checked?
23. Is this check done with the connector disconnected?

YES / NO
24. What does the
M107 represent?
25. On what side of the connector must this check be done?

ELTN1001B/WS3
How to read the Service Manual
Despite the complexity of the circuit or the number of parts in the circuit,
there are three essential elements ALL CIRCUITS must have for operation:
* POWER * LOAD *GROUND
EL01B010
26. Turn to the EL section.

27. On what page does the Stop Lamp / Wiring Diagram section for your
vehicles begin?

29. What are the wire color code and the wire color between fuse block and stop
lamp switch?
Color code:
Color:
30. Turn to LOCATION OF ELECTRICAL UNITS SECTION in the Service Manual.
31. Where is the fuse box location? Inform your instructor.
10
ELTN1001B/WS3
32. Answer the following questions referring to Stop lamp / wiring diagram
attached on page 13.
Vehicle specification : LHD MODEL GENERAL AREA
: without rear air spoiler
: with high-mounted stop lamp on the rear parcel shelf.
1) Which terminal number of the stop lamp switch is connected when

depressing the pedal?
2) Fill out the electric current ranging from the battery to the GND on Stop
lamp/wiring diagram attached on page 13 when depressing the pedal.
33. The figure below is the function of the combination switch. In the case of
turning the lighting switch to B and 1 positions, which terminal number is
contacted?
EL01B011
11
ELTN1001B/WS3
34. Turn to Front wiper and washer / wiring diagram in the Service Manual.
Where is the connector number
location?
E14
Inform your instructor.
35. On what page does the Cooling fan / Wiring Diagram in the EC section of
Service Manual begin?

37. What is the color of the power supply harness at the coil side of the cooling
fan relay 1?
Color code:
Name of the color:
Review the objective for this worksheet. If you are not clear on any part of
the objective, ask your instructor for assistance. When you are satisfied that
you have met the objective, have your instructor initial your worksheet.
INSTRUCTOR SIGN-OFF
12
ELTN1001B/WS3
EL01B012
13
Worksheet
ECTN1001B
EC01A000
Fundamental Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand name, location

and function of ECCS component parts, by using this worksheet.

Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001A/WS1
Using the Service Manual found at your workshop, and the vehicle, answer
the following questions and fill out the blanks.
Model: ________________Engine unit:_______________

4. On what page does System Diagram information begin?

DESCRIPTION information begin?
ECTN1001A/WS1
7.
Go to assigned vehicle and name the labeled components with help of Service Manual.
1) Mass Air Flow Sensor

2) Power Transistor
3) Fuel Injector
4) Camshaft Position Sensor
5) Fuel Pressure Regulator
6) Throttle Position Sensor
7) Air Regulator
ECTN1001A/WS1
MAJOR FLOW SYSTEM
8. Mark the correct flow system part in each rectangle below.

Air flow system
Mass air flow sensor /AAC valve
Air cleaner
Throttle
chamber
Air duct
FICD Valve / collector

AAC valve / Intake valve
Air regulator / Pressure regulator
Intake
manifold
Fuel flow system

Fuel tank
Fuel pump / Fuel sensor
Fuel gallery
Pressure gauge /
Pressure regulator
Fuel tank / Crank case
Fuel injector
Fuel filter / Damper
9.
Fuel line (Pipe)
What are the four major purpose of ECCS?
10. What are the three major functions of ECCS?
ECTN1001A/WS1
11. There are two types of component parts: SENSORS and ACTUATORS. Fill
in the name of five sensors and four actuators below.
SENSORS
ACTUATORS
Engine coolant temperature

sensor
* Engine knocking
* Intake air quantity
* Throttle valve angle
* Density of oxygen
* Crankshaft position
* Water temperature

Knock sensor
Oxygen sensor
Hot wire type / Hot film type
ECTN1001A/WS1
14. Remove the distributor cap and camshaft position sensor cover.
18. Which is a heater needed for the oxygen sensor?

worksheet.
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform self-diagnosis without CONSULT, by using this worksheet.

Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001A/WS2
On-board [II Modes] Self-diagnosis by ECM diagnostic mode selector
1. Go to EC (EF & EC) table of contents and locate Trouble Diagnoses. Go to

that page and locate Self-diagnosis information. Use this material to answer
the following questions.
2. How can on-board Self-Diagnosis be read on your vehicle?
3. Where is ECM (ECCS Control Module) located on your vehicle?

Center console / Dash side / Under seat

engine must be:
(Standard/ stopped) and IGN key (ON/OFF).
5. Which mode are you used to:

* monitor the oxygen sensor?
* obtain self-diagnosis result?
6. On what page can the Display code table be found in the Service Manual?
ECTN1001A/WS2
7. Go to that page and fill out the blanks with correct Code No. or Detected
Items.
Code No.
Detected Items
43
No malfunction in these circuits
11
13
Mass air flow sensor circuit
Ignition signal circuit
* In Mode II self-diagnosis, some models have more component/circuit codes.

[depending on the vehicle engine specification]
8. Access Mode II self-diagnosis on your vehicle and check for codes.

9. What Display code appear?
10. What does it designate?
11. How do you erase stored self-diagnosis codes?
ECTN1001A/WS2
12. Erase any codes that appeared during your check.
13. Disconnect the harness for one of the self-diagnosis items listed in the Service Manual, other than the one found earlier in this worksheet.
14. Access Mode II self-diagnosis and check for code.

15. List which Display code appeared and its designation.
16. Does this correspond with the designation in the Service Manual?
YES / NO
17. Erase this code. Reconnect the component harness connector, then
recheck Mode II self-diagnosis to make sure that the code was erased.
exercise.
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to complete the Idle
speed/Ignition timing inspection procedure. Compare the check
results with Service Manual specifications and determine what
adjustments are necessary, by using this worksheet.

Multi-meter
Timing light
Engine tuner
Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001A/WS3
1.
Locate the Idle speed / Ignition timing inspection procedure in Service Manual.
2.
3.
Perform the visual check.
4.
Were any problems found during visual check?

YES / NO
5.
If yes, note them below and repair it.
6.
What are the specifications for ignition timing?

BTDC
The throttle position sensor should be disconnected prior to setting the ignition timing, and the engine must be warmed up before setting idle speed and
ignition timing.
7.
Check the ignition timing with timing light.

Sample marks for BTDC17 setting
Ignition timing marks [see the figure]

vary from model to model. Refer to
your Service manual for applicable timing mark information, or Technical Bulletins for additional information.
EC01A001
ECTN1001A/WS3
8.
Is the ignition timing within specification?

YES / NO
9.
If not, correctly set the timing.
10. What do you need to disconnect to adjust the timing?
11. Why do you need to disconnect it?
12. Recheck ignition timing after tightening distributor body lock bolt/nuts.
13. Is ignition timing within Service manual specification?
YES / NO
14.
Check the idle speed. Note the result below:

rpm
15. Is idle speed within Service manual specification?

YES / NO
16. What do you need to disconnect to adjust idle speed?
ECTN1001A/WS3
17. If not, adjust the idle speed.
18. Is idle speed now within Service manual specification?
YES / NO
19. What is controlled when the idle speed adjusting screw is turned?
20. Explain what will occur if you do not disconnect to adjust idle rpm.
* Idle speed is controlled by the ECM, based on sensor input. Compare actual
value and ECM data.
* Ignition timing should be set prior to setting idle speed.

met the objective, have your instructor check your worksheet, then initial your
worksheet.
INSTRUCTOR SIGN-OFF
Introduction to ECCS (QG ENGINE) (ECTN1001B/WS4)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand name and location
of QG Engine component parts, by using this worksheet.
Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001B/WS4
Name and location of QG Engine component parts
Using the Service Manual found at your workshop and the vehicle, answer the following questions and fill out the blanks.
1. Turn to the Engine control component parts location section in the Service
Manual.
2. The following figures indicate QG engine.

Fill the square box with a suitable component name chosen from those in the
box below.
EC01B001
EC01B002
D: EGR Valve
E: Oxygen Sensor
G: Fuel Injector
ECTN1001B/WS4
EC01B003
EC01B004
D: EGR Valve
E: Oxygen Sensor
G: Fuel Injector
ECTN1001B/WS4
3.
Which type of AAC valve is used for this QG engine?

STEP MOTOR TYPE
DUTY CONTROL TYPE
4.
Choose the input signals into ECM.

Mass Air Flow
VTC
PHASE
Throttle Position
A/C Compressor
Power transistor
IACV-AAC
Air Conditioner SW
Knock Sensor
Oxygen sensor
Inhibitor SW
Fuel injector
Vehicle speed
POS
Fuel Pump relay
Power Steering SW
Cooling fan relay
EGRC solenoid valve
Engine Coolant temp.
5.
Locate each position of sensor and actuator answered at the step 4, and
then inform your instructor.
6.
Locate the position of both ignition coil and power transistor, and then inform
your instructor
7.
What is such ignition SW called?
ECTN1001B/WS4
8.
Find the oxygen sensor on your vehicle if available.
9.
Which type of oxygen sensor is used?

10. What is the main operation of oxygen sensor?
exercise.
Self-diagnosis without CONSULT (ECTN1001B/WS5)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform self-diagnosis without CONSULT.

Service Manual
Worksheet
Textbook

End of worksheet.
ECTN1001B/WS5
On-board (Mode II) Self-diagnosis
Using the Service Manual found at your workshop and the vehicle, answer the following question and fill out the blanks.
1. Turn to the ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION in
EC section.
2. What is the function of On-Board Diagnostic System at engine stopped (Ignition switch ON)?
Mode I :
Mode II:

engine must be:
(Started / Stopped) and IGN key (ON / OFF)
4. Fill out how to change to Mode II on your vehicle.

1)
2)
3)
5. On what page does the DTC code information begin in the Service Manual?
ECTN1001B/WS5
6.
Fill out the blanks with the correct DTC number.

Code No.
7.
Detected items
A/T COMM LINE
CPMS / CIRCUIT (PHASE)
COOLANT TEMP. SENSOR CIRCUIT
CKPS/CIRCUIT (POS)
ENGINE OVER HEAT
Front O2 SENSOR CIRCUIT
KNOCK SENSOR CIRCUIT
MASS AIR FLOW SENSOR CIRCUIT
NO DTC is DETECTED
THROTTLE POS. SENSOR CIRCUIT
VEHICLE SPEED SENSOR CIRCUIT
The following figure indicates DTC of Mode II Self-diagnosis.

Fill out the DTC number.
EC01B005
8.
Access Mode II Self-diagnosis on your vehicle and record DTC numbers.

DTC:
ECTN1001B/WS5
9.
What does it mean?
10. Fill out how to erase the stored Self-diagnosis codes in ECM.
11.
Disconnect the harness for Engine Coolant Temperature Sensor and PHASE
SENSOR connector and crank 3 seconds.
12. Access Mode II Self-diagnostic Results and check for DTC.

DTC:
DTC:
13. Fill out the detected parts location which DTC appeared.
1.
2.
14. Does it correspond with the designation in the Service Manual?

YES / NO
15. Reconnect the engine coolant temperature sensor and phase sensor.
16. Erase DTC from ECM, and then recheck Mode II to make sure that the DTC
was erased.
ECTN1001B/WS5
17. Change Self-diagnosis function to Mode I.
exercise.
Worksheet
MATN Course
Worksheet #
Worksheet tasks
ATTN1001A
ATTN1002A
BTTN1001B
Body & Trim
CLTN1001A
ELTN1003B
Handling of Battery
EMTN1001B
LCTN1001B
MATN1001B
MATN1002B
MTTN1001A
Maintenance Skills
Remarks
Worksheet
ATTN1001A
AT01A000
Maintenance Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform A/T external adjustment for RL4F03A type A/T, by using this worksheet.
Vehicle with FF type automatic transaxle
General tools
Worksheet

End of worksheet.
ATTN1001A
Using the Service manual found, complete the following questions and exercises.
1.
2.


3.
4.

on the plate.
5.
Using the Service manual, find the location of the Vehicle Identification Plate
The AT section of the Service manual identifies repair information and specifications based on the Transmission model number. Because more than
that you are servicing.
6.

Vehicle model:
ATTN1001A
7.
Locate the AT section in the Service manual.
8.
On what page does the ON-VEHICLE SERVICE information begin?

*
9.
Remove Control cable end from the manual shaft of A/T assembly.

P/R/N/D

A/T assembly.
14. Remove pin from the adjustment hoes after adjusting the inhibitor switch.
15. Check continuity of the Inhibitor switch according to the procedure for Electrical components in the TROUBLE DIAGNOSIS in AT section.

Lever position "D" between 3 and 7 is open / close.

ATTN1001A
16. Re-install any part that has been removed.
17. Check eachitem shown belows.
Move selector lever from P range to 1 range.

Does the selector lever move smoothly without
Any abnormal noise?
YES / NO
Does reverse lamp turn ON in R range?
YES / NO
Does the engine start only in the N and P positions?
YES / NO
Can the engine be started in positions other than N or P?
YES / NO
Control Cable Adjustment:
When control cable is incorrectly adjusted, the engine may be started in D, 2,

1 or R range which may cause dangerous situations.
18. Loosen control cable lock nut.
19. Set select lever and manual shaft.

In which position should the select lever and manual shaft be set?
20. Pull control cable in the direction of the arrow shown in the illustration using
specified force. How much is the specified force?
21. Return control cable 1.0 mm in the opposite direction of the arrow.
ATTN1001A
22.
Tighten Control cable lock nut.

What is the correct tightening torque?
kg-m
Make sure that the positions of the manual control linkage and the rod do not
23. Move selector lever from "P" range to "1" and make sure that selector lever
moves smoothly and without any noise. Apply grease to contacting areas of
selector lever and control cable.
24. Apply grease to contacting areas of selector lever and control cable.
Throttle wire adjustment:
A throttle wire is used on a conventional hydraulically controlled transmission

to report engine load, while a throttle position sensor is used in an electrically
controlled transmission. Throttle wire adjustment affects throttle pressure
and line pressure in the transmission, which affects shift timing and quality.
Correct adjustment of the throttle wire is critical to assure the proper shift
characteristics of the vehicle. Maladjustment can have a dramatic effect on
the shift pattern exhibited and the performance of the vehicle.
25. Use the Service Manual at your workshop to refer to the On-Vehicle Service section.
*
*
When the throttle wire is adjusted too tight, throttle pressure will become too
high, causing the transmission to shift late.
When the throttle wire is adjusted too loose, throttle pressure will become too
low, causing the transmission to shift early.
26. Locate the Throttle Wire adjustment procedure in the On-Vehicle Service
section.
ATTN1001A
*
This procedure requires you to measure the throttle wire stroke (measurement "L"). This measurement is made by placing marks on the throttle wire
to facilitate measuring the wire stroke.
27. If the vehicle at your workshop requires an adjustment of the Throttle Wire,
perform the adjustment according to Service manual procedures. Then,
answer the following questions.
28. Should the ignition switch be turned off when the Throttle Wire adjustment is
performed?
YES / NO
29. Should the throttle wire stroke be adjusted when the throttle wire or accelerator wire is installed?
YES / NO
30. How long was the throttle wire stroke in millimeters in your measurement?
mm
31. Should the throttle wire stroke be adjusted when the accelerator pedal stroke
is checked?
YES / NO
32. If the throttle wire had been set too loose, will kickdown occur?
YES / NO
Worksheet
ATTN1002A
AT02A000
Maintenance Skills
External Adjustment of E-A/T (ATTN1002A)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform A/T external adjustment for FR type A/T, by using this worksheet.
Vehicle with FR type transmission
General Tools and insert pin
Worksheet

End of worksheet.
ATTN1002A
[REFERENCE]
MODEL NO. AND ITS IDENTIFICATION
Model No.
01
A
Modification
Classification
Drive (R: rear-wheel drive)
No. of forward speed ranges
E: Electronic-controlled with lock-up
Control type (R: remote control)
AT62A001
Unit No.
On the RE4R01A automatic transmission, unit No. and assembly No. are indicated on the
label attached to the rear extension.
0035
Production serial number
1-9: January-September
Month manufactured
X: October
Y: November
Z: December
Last digit Year manufactured
(8: 1988)
41X2
Last five digits of assembly parts No.
ATTN1002A
1. Find the GENERAL INFORMATION (GI) section.
2. Use the table of contents in the GI section, locate IDENTIFICATION INFORMATION, and turn to that page.
* The IDENTIFICATION INFORMATION portion of the GI section contains

information which will assist you to identify the Transmission installed in the
vehicles.
3. Find the illustration in this section which shows the location of the Vehicle
4. Locate the indication of the vehicles transmission model indicated on the

plate.
5. Using the Service Manual, find the location of the Vehicle Identification Plate
and Transmission number. Write this below.
The AT section of the Service Manual identifies repair information and specifications based on the Transmission model number. Because more than one
engine or transmission may be installed in a particular vehicle model, it is
important to apply the correct specification and procedures to the vehicle that
you are servicing.
6.

Vehicle model:
ATTN1002A
7. Locate the AT section in the Service Manual.
8. On what page does ON-VEHICLE SERVICE information begin?
9. Locate Inhibitor Switch Adjustment.

*

10. Remove manual control linkage from the manual shaft of A/T assembly.
This inhibitor switch can only be adjusted with the manual shaft set in the N
position.
A/T assembly.
ATTN1002A
15.
Remove pin from the adjustment holes after adjusting the inhibitor switch.
16.
Check continuity of Inhibitor switch according to the procedure for Electrical

components in the TROUBLE DIAGNOSES section.

open / close
open / close
open / close
open / close
open / close
Lever position D between 3 and 7 is
open / close
open / close
open / close

open / close
open / close
open / close
17.
Re-install any part that has been removed.
18.
Locate Manual Control Linkage Adjustment in ON-VEHICLE SERVICE.

Go to that page.
ATTN1002A
Manual Control Linkage Adjustment
*
*
When manual control linkage is maladjusted, the engine may be started in

D, 2, 1 or R range which may cause dangerous situations.
Refer to the Service manual for adjustment procedure. Follow this procedure
to set the manual control linkage.
19. In which position should the select lever be set?
20. Loosen control linkage lock nut.
AT02A002
21. Does the lever marker align with the P mark on the position indicator in the P
position?
YES / NO
If not, adjust.
22. Tighten lock nut.
Make sure the positions of the manual control linkage and the rod do not
23. What is the correct tightening torque?

N-m / kgm / ft-lb
ATTN1002A
24.
Move selector lever from P range to 1 and make sure that selector lever
moves smoothly without any noise.
25.
Apply grease to contacting areas of selector lever and manual control linkage.
26.
Check each item shown below:
* Does the select lever move smoothly?
YES / NO
* Is there any abnormal noise or shift sticking

when selector lever is shifted?
YES / NO
* Does the reverse lamp turn ON in R range?
YES / NO
* Does the engine start in N and P position?
YES / NO
* Can the engine be started in any positions

other than N or P?
YES / NO
Worksheet
Body & Trim
BTTN1001B
BT01A000
Maintenance Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to adjust the Hood lock
and Trunk lid lock by using this worksheet.
Nissan Vehicle
General tools
Service Manual
Textbook
Worksheet

End of worksheet.
BTTN1001B/WS1
Introduction
It is important to adjust hood lock correctly for safety and comfortable driving to avoid
hood opening, and making noise while driving. And also check and readjust the gaps
between the hood and the fenders, trunk lid, and so forth to get a good shape.
1. Locate the BT(BF) section in the Service Manual.

2. On what page does the BODY END information begin?
3. Is the gap between the hood and the fenders equal on both sides?
BT01A001
YES / NO
If not, adjust the gaps with hood adjustment A in the BF (BT) section of the
Service Manual.
Hood adjusting mechanism
BT01A002
BTTN1001B/WS1
4.
Is there any stepping between the hood and fenders?
BT01A003
YES / NO
If yes, adjust the steps according to the hood lock and adjustment procedure
in the Service Manual.
Be sure to check the bumper rubbers are in the fully down position or
remove them all before adjusting the hood primary lock.
5.
Does the hood opener operate smoothly?

YES / NO
If not, check and adjust the linkage and the brackets.
6.
On what page does the Body Rear End and Opener information begin?
7.
Does the trunk opener operate smoothly?

YES / NO
If not, check and adjust the linkage and brackets.
BTTN1001B/WS1
8.
Is it possible to close the trunk lid smoothly?

YES / NO
If not, check and adjust the striker according to the Service Manual.
9.
Is there any stepping between the trunk lid and fenders?

YES / NO
If yes, check and adjust the striker according to the Service Manual.
The striker is designed to lock at its lowest position when the trunk is forcefully closed. Adjust the striker so that it locks at minimum closing pressure.

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to remove and install
clips/fasteners, by using this worksheet.

General tools
Applied Model Service Manual
Worksheet

End of worksheet.
BTTN1001B/WS2
Put seat covers and floor mats on your vehicle before starting this worksheet.
* When removing as well as installing various parts, place metal pad and/or
cloth onto the vehicle body to prevent scratches.
1.
Locate the BT (BF) section.
2.
On what page does CLIP and FASTENER information begin?

Turn that page.
3.
How many kind of clips and fasteners are used for your assigned vehicle?
Pieces
4.
On what page does INSTRUMENT PANEL ASSEMBLY information begin?
5.
Turn to that page.
6.
Review the procedure of Audio & A/C control panel removal.
7.
Which parts must be removed first?

Cluster lid C / Center ventilator assembly / A/T or M/T finisher
8.
9.
Check the location of clips and/or fasteners on parts which are chosen above
with the Service Manual.
Remove the parts according to the procedure of audio removal.
BTTN1001B/WS2
10.
Check the location of screws for audio unit assembly with the Service Manual, then remove them.
11. Review the procedure of Center console box removal.

12. Which parts must be removed first?
13. Check the location of clips and/or fasteners on the parts which is chosen
above with the Service Manual.
14. Remove them.

15. Remove the center console box according to the procedure of the Service
Manual.

17. On what page does DOOR TRIM removal and installation information
begin?

19. What kind of clips or fasteners are used for driver side door finisher?
CS101 / CS102 / C101 / C102 / C103 / C203
20. Which part must be removed first?

Door finisher screw / Inside handle escutcheon / Power window switch
BTTN1001B/WS2
21. Confirm the removal procedure of front door finisher.
22. Check the location of clips and/or fastener on front door finisher.
23. How many clips and fasteners are used for door finisher?
Pieces
24. Remove driver side door finisher with the procedure of the Service Manual.
Worksheet
CLTN1001A
CL01A000
Maintenance Skills
Clutch Pedal Adjustment (CLTN1001A)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to adjust the Clutchpedal height and pedal free play (free travel) on a manual transmission/axle vehicle by using this worksheet.
Vehicle with manual transmission/axle

Ruler
General tools
Service Manual
Worksheet

End of worksheet.
CLTN1001A
Introduction
The following operations are required whenever the clutch is replaced or the clutch pedal
free play is adjusted.
1. What is the vehicle specification?

Model:
Engine type:
LHD / RHD
2 Wheel Drive / 4 Wheel Drive
Clutch type: Hydraulic / Mechanical
Some floor configuration and pedal height differ with vehicle specifications.
2. Locate the CL section in the Service Manual.

3. On what page does the Inspection and Adjustment information begin?
Go to that page.
4. What is the specification of the Clutch pedal height?

mm
* It is essential that the floor, carpet and mats are removed before taking the
clutch pedal height measurement.
5. Is the clutch pedal height within the specification?

YES / NO
If not, adjust the clutch pedal height.
Hydraulic type go to Step 6.

Mechanical type go to Step 11.
CLTN1001A
6.
What is the specification of the pedal free play (free travel)?

mm
A = Free play
(Play due to clevis pin and clevis
pin hole in clutch)
Approx. 1 to 3 mm
B = Free travel
(Stroke where hydraulic pressure is just begining.)
Approx. 9 to 16 mm
CL01A001
7.
Measure the pedal free play (free travel) and then write it down.
mm
8.
Is the pedal free play (free travel) within the specification?

YES / NO
If not, adjust the pedal free play (free travel).
* When the clutch pedal free play (free travel) has been adjusted, check to see
the clevis pin rotates smoothly.
9.
Go to Step 15.
10. What is the specification of the items written below?

Pedal free travel
mm
Withdrawal lever play
mm
CLTN1001A
11. Measure the withdrawal lever free play and
then write it down.
mm
CL01A002
CL01A002
12. Is the withdrawal lever play within the specification?

YES / NO
If not, adjust the withdrawal lever play with adjusting nut.
13. Measure pedal free travel and write it down.

mm
14. Is the pedal free travel within the specification?

YES / NO
If not, readjust the withdrawal lever free play. (Go back to Step 12)
* Adjusting the withdrawal lever play to the specified range will generally also
bring the clutch pedal free travel distance to within the specified range. The
clutch pedal free travel distance is proportional to the withdrawal lever play.
Therefore, you can tell if the withdrawal lever play needs to be increased or
decreased by checking pedal free travel distance. Abnormal withdrawal
lever play and clutch pedal free travel may be the result of problems elsewhere in the assembly. Ask your instructor for assistance.
15. Put all the removed parts back.
CLTN1001A
* The clutch pedal free travel distance is proportional to the withdrawal lever
play. Therefore, you can tell if the withdrawal lever play needs to be
increased or decreased by checking pedal free travel distance.
Worksheet
Handling of Battery
ELTN1003B
EL03B000
Maintenance Skills
Handling of Battery (ELTN1003B)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet you will be able to inspect and maintain the Battery as an automobile power source.
Nissan vehicle
Safety glasses
Glove
Rag
Hydrometer

Worksheet

End of worksheet.
ELTN1003B
The BATTERY provides the source of electrical power for the automotive.
For example, when the ignition switch is turned to START, current is
drawn to starter to rotate the engine. And the BATTERY is used for the
power source of headlamp, power window, radio, etc. The BATTERY is
charged by the alternator while an engine is rotating. A properly functioning automotive electrical system requires a battery that is in good
condition and fully charged.
BATTERY construction
The battery consists of a case, plates and separators, etc.
EL03B001
Case
It is basically a container which houses the positive and negative
plates, separators, and electrolyte.
It is made of plastic resin or ebonite, which are not corroded by the
electrolyte. The interior of the case is divided into small compartments
called cells.
Positive and Negative plates
There are used to generate and store electricity by acting chemically
with the electrolyte. There are both positive and negative plates. Each
of them is shaped as a grid and made of an alloy that is prepared by
mixing antimony and lead.
ELTN1003B
At the positive plate lead peroxide (PbO2) is fitted in a grid. This plate
is colored chocolate. At the negative plate sponge lead (Pb) is fitted in
a grid. This plate is colored gray.
In each cell, the positive and negative plates are combined alternately
and the same kind of plates are grouped by plate straps. They are connected by a cell connector.
Separators
Insulation plates which prevent shorts caused by direct contact
between the positive and negative plates are also provided. These
plates are made of plastic resin, reinforced fiber, etc.
Cell Connector
These are used to connect the cells in series. A single cell is 2 volts,
therefore, six cells connected are 12 volts. Plate straps which hold the
positive and negative plates respectively are connected in series so a
cells negative plates are connected to the positive plates of an adjacent cell, and a cells positive plates are connected to the negative
plates of an adjacent cell, etc. They are made of a lead-antimony alloy.
Terminals
The terminals serve as inlet and outlet points for the batterys electricity. The plate straps that are located on the end are equipped with
poles that act as positive and negative terminals.
Vent Plugs
These plugs act as a stoppers for the cells inlet hole. They are made
of syntheric resin. They have small holes to release gas that is produced in the battery.
Whenever checking the battery, be sure to wear safety glasses to protect your eyes, gloves to protect your hands, and a shop coat to protect your body. If battery fluid comes in contact with your eyes, skin, or
clothing, flush immediately with cold water and seek medical attention
if necessary. Do not smoke, cause sparks to occur, or use open flame
near the battery.
When removing battery cables, remove the ground (negative) cable

first.
ELTN1003B
1.
Disconnect the battery cables, negative and positive Terminals.
2.
Check the battery specifications of your work station.

Battery type:
Battery manufacturer:
3.
Is the battery specification correct for assigned vehicle?

YES / NO
Refer to the Service Manual EL (or SDS) section under Battery.
Visual inspection
4.
Check the case for cracks and fluid leaks.

Damage: OK / NG Fluid leaks: OK / NG
5.
Inspect the cables and terminals for corrosion and cracks.

OK / NG
Check electrolyte level.

6.
Is the fluid level between MAX and MIN?

YES / NO
If NO, add distilled water as follows.
Add distilled water up to the MAX level.
Plug the cell plug.
Clean the battery surface.
ELTN1003B
Check specific gravity
*
The specific gravity is the ratio of the sulfate divided by the weight of
an equal amount of water at 20C (68F).
Refer to the Hydrometer temperature correction chart on next page.

Example:
20C (68F) is 1.240.
20C (68F) is 1.196.
EL03B003
ELTN1003B
7.
Wear shop coat, safety glasses and Glove.
8.

Suck up electrolyte.
9.
Read hydrometer and

thermometer indications at eye
level.
Gravity:
Temperature:
EL03B002
10. Convert into specific gravity at 20C (68F) base on the conversion
chart on previous page.
Gravity
11. Install the cell plug using a suitable tool.
Corrected specific gravity is below 1.220, charge the battery.

Corrected specific gravity is above 1.220, perform capacity check.
When you perform charging the battery and performing capacity
check, follow manufacturers instructions.
Review the objective of this worksheet. If you are not clear on any part of
the objective, ask your instructor for assistance. When you are satisfied
that you have met the objective, have your instructor check your work and
initial your worksheet.
Worksheet
EMTN1001B
EM01B000
Maintenance Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to adjust the Carburetor Engine idle speed, by using the worksheet.
Vehicle with carburetor engine without catalyzer

Engine tuner (with Tachometer and Vacuum Meter)
General tools
Textbook
Worksheet

End of worksheet.
EMTN1001A/WS1
1.
Locate the checking and adjusting idle speed and mixture ratio in the
Service Manual.
And go to that page.
2. Refer to the procedure in the Service Manual for adjusting Mixture

ratio and idle speed. Attach the engine tune meter and warm-up the
engine.
3. Check the following conditions in order to adjust idle speed and mixture ratio.
-Turn off headlamps
-Turn off heater blower
-Turn off rear defogger
-Keep front wheels pointed straight ahead
-Make the check after the cooling fan has stopped
-Gear shift lever in N or P position
4.
Is the idle speed lower than 1,000 rpm?

YES / NO
5.
If not, adjust idle speed less than 1,000 rpm.
The distributor has a mechanical governor system to advance the ignition timing when the engine is at speeds above idle. The engine must
be set at idle before inspecting or adjusting the ignition timing.
6.
What is the specification of basic idle ignition timing?

BTDC
EMTN1001A/WS1
7.
Check the idle ignition timing and write the result of checked value.
BTDC
8.
If idle ignition timing is out of specification, disconnect distributor vacuum hose and then adjust it by turning distributor.
9.
Which is the throttle adjusting screw on the following figure?

A / B
EM01B001

rpm
11. Check the idle speed and write the result of checked value.
rpm
12. If idle speed is out of specification, adjust it by turning the throttle

adjusting screw.
13. When the throttle adjusting screw is turned clockwise, does idle speed
(increase/decrease)?
EMTN1001A/WS1
14. When the distributor is turned to clockwise (as viewed from above the
distributor cap), does ignition timing (advance / retard)?
Check this condition beforehand.

If you use CO-meter, go to Step 15.
If you do not use CO-meter, go to Step 20.

With CO-meter
15. What is the CO% specification at idle speed?
%
16. What is the CO% at idle speed?

%
17. If the CO is not within specification, adjust it by turning idle adjusting

screw.
Then perform from Step 6 to 15 again.
*
If the idle speed changes to become out of specification after adjusting

the idle mixture, reset the idle speed and recheck the idle mixture.
18. What is the CO% when idle compensator vacuum hose is disconnected and plugged at the intake manifold?
%
CO% should change when idle compensator is operated.

This is caused by air leaking from the vacuum hose when idle compensator is operated.
19. Go to Step 27.
EMTN1001A/WS1
Without CO -meter
20. What is the idle CO specification?

%
21. Unscrew idle adjust screw approximately two turns, starting from fully
closed position. Then, adjust to the specified engine speed by turning
the throttle adjusting screw in.

YES / NO If not, adjust idle speed.
speed.
* If you could not identify the best point, set the vacuum meter.
You can see the best point by using vacuum meter.
24. Adjust the idle speed again by turning the throttle adjusting screw.
speed.
26. Is idle speed with specification?

YES / NO
If YES, continue next.
If NO, go back to Step 23.
EMTN1001A/WS1
27. Put tools back and clean the work area.

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to adjust the Diesel
Engine idle speed, by using the worksheet.
Nissan vehicles with diesel engine (VE-type injection pump)

General tools
Service Manual
Textbook
Worksheet

End of worksheet.
EMTN1001A/WS2
1.
Locate the Idle Speed Check (VE-TYPE PUMP) procedure in the

Service Manual.
2.
3.
4.
Check the throttle control cable condition as follows.

Procedure:
1. Turn idle control knob fully counterclockwise.
2. Make sure that clearance between idle
control lever pin and fuel injection pump
control lever is within the specified range.
Clearance: 1 - 2 mm (0.04 - 0.08 in)
3. If not within the specified range, adjust with
idle control cable adjusting nut.
4. After adjusting clearance, tighten lock nut.
5.
EM01B002
What is the specification for idle engine speed?

rpm
6.
Remove clamps that secure No. 1 fuel injection tube in order to take an
accurate reading of engine speed.
EMTN1001A/WS2
7.
Attach tachometers pick-up to No.1 fuel injection tube.
EM01B003
8.
Turn off the lights, heater and all other accessories.
9.
Warm up the engine until coolant temperature indicator points to middle of gauge.
10. Perform the idle adjusting procedure according to the Service Manual
provided and use your findings to answer the following questions.
11. What was the engine speed before adjusting?

rpm
12. What is the engine speed after adjusting?

rpm
13. Were any problems found during the visual check?

YES / NO
14. If so, note them below:
EMTN1001A/WS2
(OPTION)
AIR CONDITIONER EQUIPPED MODEL
1.
Make certain that the clearance between the actuator idle control lever pin and the
injection pump control lever is within the specified limits.
2.
Adjust the idle speed to specified rpm without the air conditioner operating.
3.
Then check the idle speed when the air conditioner is operating and make
sure it is correct. If not, adjust it by turning F.I.C.D. actuator stroke adjusting
screw.
EM01B004

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to check the QG

idle speed by using this worksheet.
Nissan vehicles with QG engine

Engine tuner with Tachometer and Vacuum Meter or
CONSULT-II
General tools
Service Manual
Worksheet
Textbook

End of worksheet.
EMTN1001B/WS3
1.

Manual?
Go to the page.
2.
Refer to the procedure in the Service Manual for idle speed and ignition timing.
Attach the engine tune meter or CONSULT-II and warm up the engine.
3.

inspection below.
- Headlamp is OFF.
- Headlamp is ON.
- Air conditioner is OFF.
- Air conditioner is ON.
- Rear window defogger is OFF.
- Rear window defogger is ON.
- During the cooling fan stop.
- During the cooling fan running.
EMTN1001B/WS3
4.
When must you perform IACV-AAC valve initialization before Basic

Inspection?
Engine is cold / Every time before setting / Unstable idle
5.
Fill in the time in the blanks below when you perform IACV-AAC valve
initialization.
a) Stop the engine, then wait for
seconds.
b) Turn the ignition switch to ON, then wait for

c) Turn the ignition switch to OFF, then wait for
second.
seconds.
6.
Initialize the IACV-AAC valve according to the procedure in the Service

Manual.
7.
On what page does the Idle air volume leaning information begin in
the Service Manual?
With CONSULT-II:
Without CONSULT-II:
EMTN1001B/WS3
8.
when you perform IDLE AIR VOL LEARN, the following indicates
part of the necessary items at each step. Choose the correct number
below at the each step.
Turn the ignition switch to OFF , then wait for at least
Start the engine, then let the engine idle for at least
With CONSULT-II
sec.
sec.
Without CONSULT-II
Select IDLE AIR VOL LEARN

in ACTIVE TEST mode.
Disconnect the throttle

position sensor harness
connector, then reconnect
it within
seconds.
Touch START and wait for

sec.
5, 6, 7, 8, 9, 10,
20, 21, 22, 23, 24
25, 26, 27, 28, 29, 30
EMTN1001B/WS3
9.
Perform Idle air volume learn of IACV-AAC valve according to the procedure in the Service Manual.
rpm
11.

rpm
12. Is the idle speed within specification?
YES / NO
If YES, put tools back and clean the work area.
worksheet.

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to check the YD or QD

or ZD Engine idle speed by using this worksheet.
Nissan vehicles with YD, QD, ZD engine

Tachometer for diesel engine or CONSULT-II
General tools
Service Manual
Worksheet
Textbook

End of worksheet.
EMTN1001B/WS4
1.

Manual?
Go to the page.
2.
Refer to the procedure in the Service Manual for idle speed.

Attach the diesel tachometer or CONSULT-II, then warm up the
engine.
3.

inspection below.
- Headlamp switch is OFF.

- Headlamp switch is ON.
- Air conditioner switch is OFF.
- Air conditioner switch is ON.
- Rear window defogger switch is OFF.
- Rear window defogger switch is ON.
- A check on the cooling fan after the switch is OFF.
EMTN1001B/WS4
4.
What page does the Reset Accelerator position sensor in the Service
Manual?
With CONSULT-II
Without CONSULT-II
5.
Reset the idle position memory of the accelerator position sensor.
6.
What is the specification of idle speed?

rpm
7.

rpm
8.
Is the idle speed within specification?

YES / NO
If YES, put tools back and clean the workshop.
9.
What is the engine speed after adjusting?

Judgement: OK / NG
rpm
If NG, ask to your instructor for assistance.
worksheet.
Worksheet
LCTN1001B
LC01B000
Maintenance Skills
Cooling System Inspection (LCTN1001B)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to change engine

coolant and perform Cooling system inspection, by using the
worksheet.
Nissan Vehicle
General tools, Radiator cap tester, Coolant hydrometer or
Battery coolant tester
Service Manual
Worksheet
Textbook

End of worksheet.
LCTN1001B
PART I
1.
On what page does the Changing engine coolant information begin in the
Service Manual?
2. Review the procedure for changing engine coolant.

3. Did you set the heater temperature control lever/button or temperature setting at maximum?
YES / NO
If NO, move or turn temperature control lever/button.
4.
Where is the location of drain plug?

Bottom of reservoir tank / Upper tank of radiator / Lower tank of radiator
5.
What is the coolant capacity with reservoir on your vehicle?

Liter
6.
Drain the engine coolant according to the Service manual procedure.
7.
Go to your assigned work bench.
8.
Inspect opening temperature of the thermostat.

OK / NG
(If not, replace thermostat on actual job.)
9.
Where is the air relief plug located? (If equipped.)

Located on the:
Cylinder head / Intake manifold / Thermostat housing
/ Water gallery / None fitted
LCTN1001B
10. Fill the radiator with coolant according to the procedure of the Service Manual.
11. Check coolant level and leakage.

Coolant Level: OK / NG
Coolant Leakage: OK / NG
(If not, note them below and repair them.)
PART II
1.
On what page does the Checking Radiator Cap information begin?
2.
What is the specification of radiator cap relief pressure?

(kPa / bar / kg/cm / psi)
3.
Test the radiator cap pressure using the radiator cap tester.
4.
Is the radiator cap within the specification pressure?

YES / NO
(If not, replace the radiator cap.)
5.
What is the testing pressure required for cooling system leakage?

(kPa / kg / cm / psi)
6.
Check cooling system leakage with radiator cap tester.
* The test pressure should remain steady for approximately 1 minute.

* If the testing pressure drops, check the radiator tester itself for leakage and
then recheck the pressure.
* Inspect heater and radiator hoses and hose clips for condition and security.
CAUTION:
If excessively high pressure is applied, radiator and hoses may be damaged.
LCTN1001B
7.
Is there any coolant leakage in cooling system?

YES/NO (If not, note them below and repair them.)
PART III-1 Measurement of Coolant Mixture Ratio (The Use of Hydrometer)
1.
section?

period?
YES / NO
new one.
3. Measure both temperature and specification of coolant mixture ratio.

Temperature of coolant
(F)
Mixture ratio:
LCTN1001B
* 1) Measure the coolant which should be below 45C.
radiator. Wait until the engine and radiator cool down.
4.

%
5.
Refer to a conversion table in the Service Manual.
6.
What is the coolant mixture ratio of assigned vehicle?

%
7.
8.
Is the mixture ratio of this vehicle normal?

YES / NO
PART III-2 Measurement of Coolant Mixture Ratio (The Use of Battery and Coolant
Tester)
1.
section?
LCTN1001B
period?
YES / NO
new one.
3.
What is the mixture ratio of coolant?

%
* 1) Measure the coolant mixture in normal temperature.

radiator.
Wait until the engine and radiator cool down.
4.

%
5.
6.
Is the mixture ratio of this vehicle within specification?

YES / NO
Worksheet
MATN1001B
MT01B000
Maintenance Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet you will be able to perform

PERIODIC MAINTENANCE, by using this worksheet and
Service Manual.
Nissan Vehicle, General tools

Tire pressure gauge, Timing light
Radiator cap tester
Worksheet

End of worksheet.
MATN1001B
Refer to the Service Manual for your allocated vehicle, and complete the following
questions and exercise.
1. Find the MA section tab and go to that page.

2. On what page does PERIODIC MAINTENANCE begin?
3. Referring to the Maintenance schedule table, answer the following questions.

1)
Engine oil replacement

Interval
2)
km / mile
Your Company
km / mile
Brake fluid
Interval
km / mile
Your Company
km / mile
Basically the specified months or mileage for maintains should be 20,000km.
Engine Compartment
4. Put seat and fender covers on the vehicle.
Never remove the radiator cap when the engine is hot; serious burns could
be caused by high pressure coolant escaping from radiator. Wrap a thick
cloth around the cap and carefully remove it by turning it quarter turn to allow
built-up pressure to escape and then turn the cap all the way off.
MATN1001B
5.
Check condition of hoses and clamp for leaks and cracks on cooling system.
OK / NG
If NG, replace it.
To avoid the danger of being scalded, never open radiator cap when
engine is hot. Be careful not to allow coolant to contact drive belts.
6.
Perform Radiator cap test.

OK / NG
7.
Check Engine coolant level at radiator neck.

OK / NG
8.
Check Engine coolant level at reservoir tank.

OK / NG
9.
What is the function of L.L.C. (Long Life Coolant)?

Mark the answer.
Fuel economy / Prevent rust / Clean air pollution / Anti freeze
10. Check Power steering fluid level and condition if equipped.

11. Check condition of hoses for leaks and cracks on power steering system.
OK / NG
MATN1001B
12. Check Brake fluid level and condition at reservoir tank.
When the level of the brake fluid is too low, fluid may be leaking.
Wash off spillage of brake fluid on the paint film with water immidiately, as
the paint may be damaged by the brake system.
13. Check Brake fluid leaks on brake system.

OK / NG
14. Check Clutch fluid level and condition at reservoir tank if applicable.
15. Check Clutch fluid leaks on clutch system if applicable.

OK / NG
16. Check all Drive belts for tension force, crack and wear.
1)
Belt tension
OK / NG
2)
Crack and wear
OK / NG
All Poly V belts tension should be inspected when the engine is cold after the
engine has remained stationary for approximately 30 minutes.
Drive belts cause noise when the tension is too low and too high.
1)
Terminal tightness
OK / NG
2)
Damage of positive terminal cover
OK / NG
3)
Electrolyte level
OK / NG
MATN1001B
*
Make sure to check all cells.

18. Check Ignition wires for cracks, damage, burned terminals and for poor connection if applicable.
OK / NG
19. Check Distributor cap for damage and crack if applicable.

OK / NG
20. Measure the resistance of each wire.

Resistance
Judgement
Center
OK / NG
No.1
OK / NG
No.2
OK / NG
No.3
OK / NG
No.4
OK / NG
No.5
OK / NG
No.6
OK / NG
21. Replace Spark plugs if required.
22. What is a specification of spark plug for your vehicle?

1)
Spark plug type
2)
Specification of gap
3)
Tightening torque
mm
N-m / kg-m
MATN1001B
23. Remove one spark plug, then check both condition and gap.
OK / NG I
f NG, check all plug gap, then adjust their gap.
*
*
*
Brush the spark plug when it is covered with carbon. (Except platinum type
plug)
Install the spark plug by hand temporarily, then tighten it until only four or five
threads slightly by finger force to avoid damaging the threads of hole of cylinder head.
Tighten it with a torque wrench.
24. Check PCV (Positive Crankcase Ventilation) valve and hoses for leaks,
crack and collapse.
OK / NG
25. Check Vacuum hoses for leaks, cracks and connections.
OK / NG
26. Check leakage of coolant (water), oil and fuel in the engine compartment.
1)
Water leaks
OK / NG
2)
Oil leaks
OK / NG
3)
Fuel leaks
OK / NG
27. Replace Fuel filter and Air filter (Element) if required.
28. Check Air filter for clogged or damage.

OK / NG
MATN1001B
29.
Does a viscous type filter need for air blow when paper gets dirty?
YES / NO
Viscous paper type filter does not need air blow for cleaning, but it is necessary to replace it when it gets dirty. Dry paper type filter is necessary to clean
the element or replace it at the recommended intervals, more often under
dusty driving conditions.
30. Check Engine oil level and conditions.

OK / NG
*
The engine may fail or wear out prematurely if the incorrect grade or oil quality classification is used. The viscosity range is determined depending upon
the ambient air temperature expected during the operation period.
31. Remove engine oil filter cap if required to replace engine oil.
32. What is the specification of tire pressure for your assigned vehicle?
Front:
kPa / kg/cm2 / psi
Rear:
kPa / kg/cm2 / psi (If different)
33. Lift vehicle up to middle height (approximately. 1.2m from ground).

34. Inspect Tires pressure and then check for defects, wear and damage at the
same time.
OK / NG
If NG, refill air or advice customer to change their tires.
Rotate tire between the front and the rear if you find uneven wear between
the front and the rear.
MATN1001B
35. Check Wheel bearing axial end play both the front and the rear.
OK / NG
36. Check Shock absorber oil leakage on suspension system.

OK / NG
37. What is the specification of brake pad wear limit?

Front:
mm
Rear:
38. Inspect thickness of the Front / rear brake pads.

OK / NG
39. Remove Rear tires, then inspect rear brake lining for wear if applicable.
40. Check Drum inner surface for crack and damage if applicable.
OK / NG
41. Check brake wheel cylinder body for leakage.
OK / NG
Under body
42. Lift vehicle up to high position (maximum height to lift).
43. Drain Engine oil, then replace engine oil filter if required.
mm
MATN1001B
44.
Replace Manual transmission oil if required.
45.
Check Manual transmission oil level if applicable.

OK / NG
46.
Replace Differential gear oil if required.
47.
Check Differential gear oil level if applicable.

OK / NG
48.
Check Clutch fluid leaks from operating cylinder if applicable.

OK / NG
49.
Check Front drive shaft boots for cracks and damage if applicable.
OK / NG
50.
Check Rear drive shaft boots for cracks and damage if applicable.
OK / NG
51.
Check Under body for damage and deformation.

OK / NG
52.
Check Leakage for coolant (water), oil and fuel from underside body.
1)
Water leaks
OK / NG
2)
Oil leaks
OK / NG
3)
Fuel leaks
OK / NG
MATN1001B
53. Check Exhaust system fittings.
OK / NG
54. Check all nuts and bolts of suspension and axle components for tightness.
OK / NG
55.
Check the ball joints for damage and grease leaks.

OK / NG
57. Refill Engine oil, then check oil level.
58. Start engine, then warm it up.
59. Check following items during engine warm-up.
1)
Parking brake lever stroke
OK / NG
If NG, repair it.
2)
Windshield wiper operation
OK / NG
If NG, repair it.
3)
Headlamps
OK / NG
If NG, repair it.
4)
Turn signal lamps
OK / NG
If NG, repair it.
5)
Hazard lamps
OK / NG
If NG, repair it.
60. Check Clutch pedal height and free travel(play).

OK / NG
10
MATN1001B
61.
62.
63.
64.
Check Idle conditions as follows after engine warm-up.
1)
Ignition timing
OK / NG
If NG, adjust it.
2)
Engine speed
OK / NG
If NG, adjust it.
Check automatic transmission/axle fluid level and conditions.
1)
Fluid level
OK / NG
If NG, adjust it.
2)
Fluid conditions
OK / NG
If NG, replace it.
Check vacuum hose of brake booster for crack and leaks.
1)
Operation check
OK / NG
If NG, adjust it.
2)
Air leaks
OK / NG
If NG, adjust it.
Block the tail pipe temporarily by placing a rubber mat over the exhaust pipe
end. Run the engine, then check for leaks (while idling after warming up the
engine).
Check exhaust system for leaks.

11
Worksheet
MATN1002B
MA02B000
Maintenance Skills

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet you will be able to perform the PDI,
by using this worksheet, PDI Manual and Service Manual.
Nissan Vehicle, General tools,
Tire pressure gauge,
Timing light,
Gas leak detector
Worksheet
New Vehicle Handling Manual-G sec. for PDI (NV3E-0PDIG0)
PDI Checklist (Your own list)

End of worksheet.
MATN1002B
Using the Service Manual found at your work station and the vehicle, answer the
following questions and fill out the blanks. Also fill out inspection results on your
PDI checklist.
Before starting PDI

1. Fill out the following information on your PDI checklist.
1) Vehicle model
2) Vehicle Identification Number
3) Engine number
4) Registered number (License number)
5) Key number
6) Mileage reading
7) Other item if you need
2. Did you park the vehicle on a flat area?
YES / NO
If NO, place the vehicle on a flat area.
3. Check engine hood operation.

OK / NG
4. Open engine hood, then check the position of engine hood lock if applicable.
5. Put fender covers, seat and handle covers on the vehicle.
Under the hood
6. Does the coolant level come up to the top of the radiator?
YES / NO
7. What is the coolant level in the reservoir tank?

OK / NG
If NG, fill in coolant.
MATN1002B
8.
How many drive belts are used in the vehicle?

pieces
9.
What is the applied pushing force for the alternator belt?

N / kg / lb
10. Check the tension force of all belts and adjust if necessary.
11. What problem occurs when the tension force of a belt is too tight?
12. What problem occurs when the tension force of a belt is too loose?

1)
Terminal tightness
OK / NG
2)
Damege of positive terminal cover
OK / NG
3)
Electrolyte density
OK / NG
4)
Electrolyte level
OK / NG
* Make sure to check all cells.

14. Check the brake fluid level at brake master cylinder reservoir tank.
OK / NG
If NG, fill in the brake fluid.
* In case the level of the brake fluid is too low, fluid may be leaking.
Wash off spillage of brake fluid on the paint film with water immediately, as
the paint may be damaged by the brake fluid.
MATN1002B
15. Check Clutch fluid level at master cylinder reservoir tank if applicable.
OK / NG
16. Check power steering fluid level if applicable.

OK / NG
17. Check Engine oil level.

OK / NG
18. Check the front and rear window washer fluid tank level.
Front:
OK / NG
Rear: OK / NG (If available)
19. Check fluid, oil and water leaks in the engine compartment.
OK / NG
Underside of vehicle
20. Lift vehicle up to approximately 1.2 m which is middle height.
21. What is the specification of tire pressure?

Front:
kPa / bar / kg/cm2 / psi
Rear:
kPa / bar / kg/cm2 / psi (If applicable)
22. Check Tire pressure for damage, then check suspension conditions at the
same time.
1)
Tire pressure
OK / NG
2)
Tire damage
OK / NG
3)
Shock absorber leak
OK / NG
4)
Suspension spring
OK / NG
MATN1002B
23.
Lift vehicle up to high position.
24. Check following items.

1)
Check underside body damage.
OK / NG
2)
Check free running hub operation if applicable.
OK / NG
3)
Check oil level for differential gear if applicable.
OK / NG
4)
Check for fluid and water leakage.
OK / NG
5)
Check tightness of bolts/nuts on suspension system. OK / NG
6)
Check exhaust system fitting.
OK / NG

Inside vehicle
26. Check operation of doors and door locks, then get into the vehicle.
OK / NG
27. Install fuses that were removed during transport to prevent battery discharge.
* Fuses are usually found in the ashtray.

28. Check operation of seats.
OK / NG
If NG, note the failure part.
* Refer to the Service Manual when power seats are equipped.
29. Check operation of seat belts.

OK / NG
30. Check warning lamps when ignition key is in the ON position.

OK / NG
MATN1002B
31. If the vehicle is equipped with Automatic transmission, check the engine
start conditions.
1)
Shift lever position to N and/or P position
OK / NG
2)
Shift lever position without N and P position
OK / NG
32. Start engine, then warm up it.

33. Check steering wheel lock and position adjustment.
OK / NG
34. Check other items while warming up the engine.

1)
Horn
OK / NG
2)
Dash panel lamp and room lamp
OK / NG
3)
Headlamps and High beam indicator
OK / NG
4)
Headlamps cleaner if applicable
OK / NG
5)
Combination lamps and Turn signal lamps
OK / NG
6)
Hazard lamp
OK / NG
7)
Door courtesy lamps, Vanity mirror lamps
OK / NG
8)
Windshield wipers and washers

(Front and rear if applicable)
OK / NG
9)
Heater and Air conditioner
OK / NG
10)
Rear window defogger
OK / NG
11)
Sunroof and T-bar roof operation if applicable
OK / NG
12)
Window operation
(window lock switch operation if applicable)
OK / NG
13)
Fuel lid and Trunk lid operation
OK / NG
14)
Rearview mirrors
OK / NG
15)
Set clock and radio station preset
OK / NG
MATN1002B
35. Check glove box lid and other interior components according to the PDI Manual.
Glove box lid
OK / NG
Console box lid
OK / NG
Ashtray
OK / NG
36. Check jack, tool installation, and spare tire pressure.

OK / NG
37. Check wheel nut tightening torque.

OK / NG
38. Check operation of all door locks and child safety door locks (if applicable) on
your assigned vehicle.
OK / NG
39. Is the engine warmed up?

YES / NO
* If answer is "NO", raise the engine speed and warm up the engine again.
40. Check automatic transmission select lever operation through each gear position, after checking shift operation to P position.
OK / NG
41. What is the specification of idle engine speed and ignition timing?
rpm
BTDC
MATN1002B
42. Check engine idle speed and ignition timing, then adjust them if necessary.
OK / NG
43. Check Automatic Transmission fluid level.
OK / NG
44. Check air conditioner for refrigerant leakage with gas leak detector if applicable.
Worksheet
MTTN1001A
MT01A000
Maintenance Skills
External Adjustment of M/T (MTTN1001A)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform M/T external adjustment for RS5W71C (C23) by using this worksheet.
Vehicle model: C23
General tools
Service Manual
Worksheet

End of worksheet.
MTTN1001A
1.
2.


3.
4.

on the plate.
5.
Using the Service Manual, find the location of the Vehicle Identification Plate
VIP:
M/T No.:
The MT section of the Service Manual identifies repair information and specifications based on the Transmission model number. Because more than
that you are servicing. (See worksheet GITN1003A if you cannot understand the meaning of the codes.)
6.

Vehicle model:
MTTN1001A
GEAR CONTROL adjustment:
Using the Service manual, complete the following questions and exercises.
If the control cable is maladjusted, the shift action will become poor.
7.
On what page does GEAR CONTROL information begin?
8.
Adjust gear control according to Service manual.
9.
In which position should shift lever be set?
10. In which position should select lever be set?
11. What is tightening torque of lock nuts?

Shift cable lock nut:
Select cable lock nuts:
12. Does control lever mounting appear secure when control lever is operated?
YES / NO
MTTN1001A
13. Does Control lever move smoothly?
YES / NO
14. Is there any abnormal sound or shift sticking when control lever shifted?
YES / NO
Worksheet
TOOL Course
Worksheet #
Worksheet tasks
ELTN1002B
GITN1004B
GITN1007B
ECTN1002A/WS1
CONSULT Introduction
ECTN1002A/WS2
CONSULT Self-diagnosis
ECTN1002A/WS3
CONSULT Work Support
ECTN1002A/WS4
CONSULT Function Test
ECTN1003B/WS1
CONSULT-II Overview
ECTN1003B/WS2
CONSULT-II Self-diagnosis
ECTN1003B/WS3
CONSULT-II Work support
ECTN1003B/WS4
CONSULT-II
Function Test Mode
Usage of Tools
Remarks
Worksheet
ELTN1002B
EL02B000
Usage of Tools

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to measure voltage,

and resistance with digital multimeter.
Vehicle with ECCS Engine

Digital Multimeter

Worksheet
Textbook

End of worksheet.
ELTN1002B
Measuring Voltage
* A voltmeter measures voltage. You can diagnose many electrical malfunctions by using a voltmeter to measure system voltage.
1. The following figure indicates the Digital multimeter.

Fill the table with a suitable name chosen from those in the box below.
(1)
No. Name
1
(3)
2
3
(4)
(2)
4
(5)
5
6
(6)
7
(14)
(7)
8
9
(8)
10
11
(9)
12
(13)
13
(10)
(12)
14
EL02B001
a:
c:
e:
g:
i:
k:
l:
m:
n:
(11)
Rotary switch
DC voltage
DC current
Voltage, Resistance, Diode and continuity
Resistance
COMMON TERMINAL
VOLT, ohms, Diode test terminal
Max, 300mA, Current test terminal
Max, 10A, Current test terminal
b:
d:
f:
h:
j:
LCD display
AC voltage
AC current
300 mV DC voltage
OFF
ELTN1002B
2. Switch the voltmeter to measure DC VOLTs (

3.
Connect the meter test leads to the DIGITAL TESTER.

The RED tester lead connects to the V
input jack.
The BLACK test lead connects to the COM
(Common) input jack.
EL02B002
4. Measure the battery voltage.

Connect the RED test lead to
the Battery positive (+) terminal
on the vehicle.
Connect the BLACK voltmeter
test lead to the Battery negative (-) terminal on the vehicle,
and then fill out the results on
the illustration of screen.
EL02B003
ELTN1002B
* Generally, horn circuit is as follows.
Bottom view of the

HORN RELAY
EL02B004
EL02B005
5. Remove the Horn Relay

from
assigned vehicle.
EL02B006
ELTN1002B
6.
Measure the Horn Relay power

supply voltage, and then record in
the space provided in the illustration.
EL02B007
EL02B008
* Excessive circuit resistance reduces current flow and results in an accessory

operating incorrectly.
7.
Switch the voltmeter to measure Resistance (), and

then measure Resistance
between the Horn Relay terminal number one to two and
record in the space provided in
the illustration.
EL02B009
* Never use the ohmmeter to make any tests with power connected to
the circuit being tested in ohm range.
* Never touch positive and negative test lead metal portion with your
hand when measuring the resistance.

8.
Disconnect injector harness connector.
EL02B010
ELTN1002B
9.
What is the injector resistance specification?
10. Choose 2 fuel injectors and measure resistance.

Injector
#
#
Resistance Judgement
OK / NG
OK / NG
Checking continuity
* In continuity testing function, the buzzer starts buzzing continuously
below the threshold level.
11. Switch the multimeter to check continuity (
).
EL02B011
12. Contact the red lead wire with the black lead wire.
Does the buzzer ring?
YES / NO
EL02B012
ELTN1002B
13. Connect the BLACK lead wire of the multimeter to negative (-) terminal of the battery, connect the red lead wire of the multimeter to the
body, and then check the continuity.
OK / NG
* To check the continuity of the circuit, change the multimeter to check

continuity
mode, and then check ON or OFF on the Buzzer.
Upon completion, have your instructor sign off this worksheet and move on
the next one. If you have any question, feel free to ask him before starting
the next exercise.
Worksheet
GITN1004B
GI04A000
Usage of Tools

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to use a Vernier caliper, by using this worksheet.
Vernier caliper
Disc Brake Pad, Bolt, Nut
Worksheet
Textbook

End of worksheet.
GITN1004A/WS1
1.
Read the Textbook and answer the following questions.
2.
Fill out the name of each parts of vernier caliper in the blank boxes.
1. Depth rod
2. Stop screw
3. Outside measuring jaw
4. Weight scale
5. Inside measuring jaw
GI04A001
3. What can the vernier caliper measure?

4.
1. Weight
2. Depth
3. Volume
4. Outer diameter
5. Tire pressure
6. Inner diameter

Mark the correct anwer.
GI04A002
GI04A003
GITN1004A/WS1
5.

GI04A004
GI04A005
GI04A006
GI04A007
GITN1004A/WS1
6.
GI04A008
7.
GI04A009
8.
If you do not fully understand how to read the vernier caliper scale, ask your
instructor for assistance. Refer to the textbook first.
If OK, go to next.
9.
Check the alignment of jaws and zero point scale.
There should be no clearance when the outside jaws are fully closed.
10. Measure the outside diameter of bolt provided. (one piece)
mm
GI04A010
GITN1004A/WS1
11. Measure the brake pad thickness.
mm
GI04A011
12. Measure the assigned Nut inner diameter.

mm
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to use Dial indicator,
Dial indicator and stand

V-block and surface plate
Camshaft
Textbook
Worksheet

End of worksheet.
GITN1004A/WS2
1.
2.
Fill out the name of each parts of Dial indicator in the blank boxes.
1. Spindle
2. Main scale
3. Outer ring
4. Revolution counter
5. Pointer
GI04A012
6. Adjusting needle
3. What can the Dial indicator measure?

4.
1. Runout
2. Weight
3. Axles shaft end play
4. Temperature
5. Volume
6. Valve lift
Which is the correct measurement on the following figure?

Mark the correct anwer. (Refer to the textbook)
GI04A013
GITN1004A/WS2
5.
Which is the correct measurement method on the following figure?

Mark the correct answer. (Refer to the Textbook.)
GI04A014
6.
What is the measuring range of Dial indicator provided?

Minimum
7.
mm / Maximum
mm
When the runout of camshaft is measured, the Dial indicator reads as follows.
GI04A015
8.
What is the runout of camshaft?

mm
GITN1004A/WS2
9.
When the spindle of Dial indicator is pushed, the pointer moves

clockwise / counterclockwise
10. Measure the camshaft runout in accordance with following procedure.

*
Check Dial indicator condition before measuring.

(Check for spindle play and stroke smoothness)
11. V-blocks are placed on the surface plate, and the camshaft placed in the Vshaped grooves as in the following figure.
GI04A016
Use same height V-blocks to keep horizontal axis.
12. The spindle of the Dial indicatior is set horizontally, directed toward the center of the camshaft as in the following figure.
GI04A017
GITN1004A/WS2
13. Press the spindle against the camshaft, so that pointer makes at least one
rotation. By turning the bezel, bring the zero on the dial face directly under
the pointer.
14. Slowly turning the camshaft one revolution, obtain the maximum reading for
oscillation clockwise and counterclockwise from the indicator.
As shown in the following figure, the bend of the camshaft is indicated by half
the total indicator reading.
Runout
Bend =
GI04A018
15. What is the maximum oscillation clockwise?

mm
16. What is the maximum oscillation counterclockwise?

mm

2
GITN1004A/WS2
17. What is the camshaft runout?
mm
18. What is the camshaft bend?

mm
worksheet.
INSTRUCTOR SIGN-OFF

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to use a Micrometer,

Micrometer
Camshaft and Piston
Textbook
Worksheet

End of worksheet.
GITN1004A/WS3
Part names of a micrometer (Refer to the Textbook.)
1. Select the name of each part of micrometer from below and fill its number in
the boxes.
GI04A019
1. Lock clamp
2. Thimble
3. Spindle
4. Outer sleeve
5. Anvil
6. Ratchet stopper
Checking the zero point of micrometer

To check the zero point, first clean the contact points on the anvil and the
spindle, secure the micrometer using a micrometer stand, and correctly
clamp a standard gauge corresponding to the minimum value between the
anvil and the spindle. Turn the ratchet stopper two or three turns and then
closely read at zero point.
Precautions for measurement

Clean the contact points of the anvil, the spindle and the surfaces to be measured. Correctly fit the object between the anvil and spindle, and take a measurement turning only the ratchet stopper.
Do not turn the thimble. One measurement is not enough, so take measurements several times.
GITN1004A/WS3
2.
lnspect the scale deviation of micrometer (zero point) with the standard gauge
provided.
GI04A020
3.
What is the scale deviation?

mm
4.
Adjust the micrometer if the zero line on the thimble auxiliary scale is not correctly aligned with the base line on the scale.
(Refer to the following key points.)
GITN1004A/WS3
*
Zero Point adjustment

1) If the deviation is 0.02 mm or less
Fix the spindle once with the lock clamp. Insert the edge of the
adjusting wrench (supplied with the micrometer) into the small hole
in the outer sleeve. Then, align the "0" point of the thimble with the
index line of the outer sleeve. After adjustment is completed,
recheck the "0" point to confirm that the micrometer is calibrated
correctly.
GI04A021
2) If the deviation is larger than 0.02 mm
Fix the spindle with the lock clamp, and loosen the ratchet stopper
with the adjusting wrench to free the thimble. Align the "0" point of
the thimble with the index line of the outer sleeve, and retighten the
ratchet stopper with the adjusting wrench. After adjustment is completed, re-check the "0" point to confirm that the micrometer is calibrated correctly.
GI04A022
GITN1004A/WS3
5.
Reading the scales. (Refer to the Textbook - How to read the scale.)
6.
mm
GI04A023
7.
mm
GI04A024
8.
mm
GI04A025
GITN1004A/WS3
9.

mm
GI04A026

mm
GI04A027
* Feel free to ask your instructors if you do not understand how to read the
scale so far, even though you have already read the Textbook several times.
If OK, go to next step.
* It is essential to get the micrometer to correctly contact the work to be measured. Do not fail to hold the micrometer at right angles to the surfaces
being measured.
GI04A028
GITN1004A/WS3
11. Measure the outside diameter of camshaft journal provided. (one piece)
GI04A029
12. What are the diameters of camshaft journals?

No.
5.
Diameter
mm
mm
mm
mm
mm
Two actual measurement should be taken of camshaft; one at X point and

one at Y point.
GI04A030
13. Measure the piston skirt diameter. (one piece) Check Micrometer zero
position before measuring. Refer to the Service manual for measuring

point "a" on the piston skirt.
GI04A031
GITN1004A/WS3
14. What is the diameter of that?
mm
worksheet.
INSTRUCTOR SIGN-OFF
Usage of Measuring Tools (GITN1004B/WS4)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand Usage of Torque

wrench, by using this Worksheet.
Torque wrench (Plate-spring-type, Auto-limit-type)

General Tools
Nissan Vehicle
Service Manual
Worksheet

End of worksheet.
GITN1004B/WS4
1.
2. Draw lines to match the tool name to the appropriate tool in the photo.
* Auto-limit-type
* Plate-spring-type
GI04B001

1)
kgfcm
GI04B002
2)
GI04B003
kgfcm
GI04B004
GI04B005
GITN1004B/WS4
4.
Which method of the following figures is used more frequently?

GI04B006
5.
Fill out the name of each part of the torque wrench in the blank box.
1. Needle
2. Main Grad
3. Locker
4. Pin
5. Sup Grad
GI04B007A
6.
Which paragraph is suitable for Precaution for use. Mark (

rect answer.
) on the cor-
1. Use the wrench without the scale range.

2. Make sure the torque wrench is set correctly before using.
3.The loading direction must be at right angles to the torque wrench
(tolerance +/- 20 degrees).
4. Stop tightening when you feel a click.
5. Lock Sup. Graduation, by using pliers.
GITN1004B/WS4
7.
What is the tightening torque of wheel nut?

8.
Set tightening torque on torque wrench.
9.
Tighten the wheel nuts for rear wheels.
10.
Put all equipment back to original position.
Worksheet
GITN1007B
GI07B000
Usage of Tools
Usage of Taps and Dies (GITN1007B)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will understand Usage of Taps and
Dies, by using this Worksheet.
Taps, Dies pitch gauge

Vernier Caliper
Oiler
Worksheet
Textbook

End of worksheet.
GITN1007B
Part1: Taps
1.
2.
What is the use of the tap?

1) Make a hole
2) Cut a male screw
3.
Which is the most accurate repair method in the following figures?

Choose the correct one.
GI07B001
4.
GI07B002
Put numbers (1-3) in the order of usage priority.

Second hand tap (for semi finishing)
Third hand tap (for final finishing)
First hand tap (for rough finishing)
5.
If the bolt is broken at the inside of the case, choose suitable tool for repairing
it.
1) Pin punch
2) Dies
3) Center Punch
4) Drill
5) Screw extractor
GITN1007B
6.
Measure the outer diameter of bolt.

mm(inch)
7.
Measure the pitch of bolt.

pitch
8.
In the result of measuring at the above, choose the correct tap.
9.
Refer to the flow chart of the tap procedure.
10. Proceed to the work by using the tap.
Part 2: Dies
1.
2.
What is the use of the Dies?

1) Make a hole
2) Cut a male screw
3.
Which of the following measurements should be made when selecting a die?

1) Measure the length of bolt.
2) Measure the outer diameter of bolt.
3) Measure the length of screw threads.
4) Measure the pitch with a pitch gauge.
GITN1007B
4.
Which is the correct way to handle dies?
1) A portion of round open die cannot be adjusted.

2) The inside of die tapers to start to cut easily.
3) It is possible to make a cut all at once in the case of using dies.
4) . First turn the die one rotation clockwise, then use the die while turning it a
half rotation counterclockwise (to eject the metal cuttings).
5) Oil must be used when cutting with the die (to allow heat to escape and
make the cut surface smooth).
met the objective, have your instructor check your work and initial for your Worksheet.
Worksheet
Usage of CONSULT
ECTN1002A
EC02A000
Usage of Tools
CONSULT Introduction (ECTN1002A/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to prepare the

CONSULT for diagnosis, by using the worksheet.

CONSULT
Worksheet
Textbook

End of worksheet.
ECTN1002A/WS1
What is the CONSULT?
Computerized ON-board System UniversaL Tester

The CONSULT diagnostic test tool is used for analyzing and trouble shooting
"on board" electronic control systems.
Using this worksheet and operation manual, answer the following questions
and fill out the blanks.
1. Which systems can be monitored with CONSULT?
2. Install the NiCd battery to CONSULT.
3. Push the power ON switch.
4. Is the battery charged sufficiently?

YES / NO
* CONSULT will display (Low NiCd batt volt!) when the battery voltage is
too low.
* If loaded sufficiently go to step 9.
5. Press the power OFF switch.
ECTN1002A/WS1
6.
Connect the charger (CH-85) into AC power plug.
7.
Connect the output plug into the CONSULT charging connector.
When using a new battery for the first time, allow 8 to 10 hours for full charging.
8.
Install a fully charged battery and push the power ON switch.
9.
Is program number available for the vehicle?

(Refer to the textbook.)
YES / NO
When program number is not available, load the program using appropriate
program card.

If the program was already installed, go to step 12.
11. Referring to operation manual, load the appropriate program card into main
memory.
12. Referring to operation manual, set the roll paper.
ECTN1002A/WS1
*
This paper has a right side and wrong side.
13. Push power ON switch.
14. Touch SUB MODE
15. Touch CLOCK SETTING
16. Referring to operation manual, set the date and time.
17. Print the screen with new date and time.

* The screen can be printed by touching the blank key on the upper right hand
side of the mode keys.
18. Touch
BACK
19. Touch
CUNIT CONVERSION
20. Referring to operation manual, set the units.
21. Print the screen with set unit.
22. Connect the diagnostic cable into the CONSULT connector.
ECTN1002A/WS1
* CONSULT is now ready for operation on the vehicle.
23. Touch BACK
twice.
25. Put roll paper and so on back.
questions feel free to ask him.
INSTRUCTOR SIGN-OFF
CONSULT Self-diagnosis (ECTN1002A/WS2)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform self-diagnosis with CONSULT, by using this Worksheet and Service Manual.
CONSULT
Worksheet
Textbook

End of worksheet.
ECTN1002A/WS2
1.
On what page is the CONSULT inspection procedure for the ECCS system
located in Service Manual ?
2. Make sure that ignition key is in OFF position.

Find diagnostic connector of vehicle and connect CONSULT to it.
3.
Turn ignition switch ON.
* CONSULT will automatically turn ON.
4.
Does the program number correspond the vehicle? (Refer to the Textbook.)
YES / NO
5.
Touch
6.
Touch ENGINE
7.
Touch SELF-DIAG RESULT
8.
Is there any failure?
START
YES / NO
ECTN1002A/WS2
*
When there is no failure, it will be indicated with the following screen.
EC02A001
9.
Push the power OFF switch of CONSULT.

*
Power switch of CONSULT will automatically turn ON.
13. Touch
*
START
14. Touch ENGINE

*
ECTN1002A/WS2
16. Does CONSULT indicate a failure of ENGINE TEMPERATURE SENSOR?
YES / NO
17. Touch ERASE

YES / NO
The SELF-DIAG RESULT screen
A:
Any component/circuit (s) failing SelfDiagnosis.
B:
The number of times the vehicle has been

started since the last detected failure. 0
indicates that component failure is being
detected currently.
EC02A002
19. What is the meaning of the number indicated under time on the screen at
the right?
20. Connect the ENGINE TEMPERATURE SENSOR.

YES / NO
22. Touch ERASE .

*
When ERASE is touched, Self-diagnosis is carried out once again.
ECTN1002A/WS2
YES / NO
24. If YES, finish the self-diagnosis.

If NO, check the failure part or unit and repair that.
25. Push the power OFF switch and turn ignition switch OFF.
26. Disconnect the Ignition coil connector.
27. Turn the ignition switch ON.

28. Touch START
29. Touch ENGINE
31. Does CONSULT indicate a failure?

YES / NO
32. Turn ignition switch to START for a few seconds.
33. What does the screen indicate?
ECTN1002A/WS2
35. Connect the Ignition coil connector after turning ignition switch OFF.

YES / NO
39. Touch ERASE

YES / NO
41. If YES, finish the self-diagnosis. Completely finish repair.

If NO, check and repair the failure part or unit.
Difference between practice 1 and 2:

Coolant temperature sensor transmits a signal to the ECM when the ignition
key is in the ON position and the engine is running or being started. The
other sensors however do not transmit signal to the ECM when the ignition
key is in the ON position. It's necessary to start or crank the engine for the
signal to the ECM to change.
ECTN1002A/WS2
42.
On what page does Description of Self-Diagnosis information begin?

TURN TO THAT PAGE.
43.
Check in the Service Manual which other systems will be indicated by the
Self-diagnosis mode.
44.
Explain the possible conditions under which a diagnostic item may be

detected.
(Refer to the Service manual.)
1.
2.
3.
45. Push power OFF switch and stop the engine.
exercise.
INSTRUCTOR SIGN-OFF
CONSULT Work Support (ECTN1002A/WS3)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform work support using CONSULT, by using this worksheet.

CONSULT
Timing light
General tools
Worksheet

End of worksheet.
ECTN1002A/WS3
1. THROTTLE POSITION SENSOR ADJUSTMENT
1. On what page is the CONSULT data monitor mode in Service Manual?
2.
What is the specification value of Throttle position sensor signal voltage

when fully closed?
V
3.
Make sure the ignition key is in the OFF position.

Connect the CONSULT diagnostic cable to the connector.
4.
Perform a visual check and perform self-diagnosis with CONSULT.
Confirm that there is no failure on the system.
5.
Operate the parking brake.
6.
Turn ignition switch to the ON position.
CONSULT will automatically turn ON.
7.
Touch
8.
Touch ENGINE
START
ECTN1002A/WS3
9.
Touch WORK SUPPORT
10. Touch
THRTL POS SEN ADJ
11. Touch
START
12. What is the voltage of the Throttle position sensor signal?
13. Is the output voltage within specification?

YES / NO
14. If not, correctly set the position of the Throttle position sensor body.
*
If the Throttle position sensor requires adjustment, refer to the Service manual for the correct setting procedure.
15. Touch function key of BACK
twice.
2. IGNITION TIMING ADJUSTMENT
16. On what page is the IDLE SPEED/IGNITION TIMING procedure located

in the Service Manual?
17. What is the specification of Ignition timing?

BTDC
18. Start the engine and warm it up until water temperature indicator points to
the middle of gauge.
ECTN1002A/WS3
19. Touch
IGNITION TIMING ADJ
20. Touch
START
21. Is the Throttle position ON?

YES / NO
22. What is the effect on the Ignition timing, if the Throttle position is incorrectly
adjusted with idle position set to OFF?

*
When reading the CONSULT screen while changing timing by rotating the
distributor body, there should be no change in the timing value on the CONSULT screen, because CONSULT always indicates ECM data, not the actual
value.
24. Is Ignition timing within specification?

YES / NO
25. If not, correctly set the timing by rotating the Distributor body or the Camshaft position sensor body.
Engine should be stopped when you loosen the fixing bolts.
ECTN1002A/WS3
27. Is the Ignition timing within specification?
YES / NO
28. If not, correctly set the timing again.

BACK
twice.
3. IACV-AAC VALVE ADJUSTMENT

30. On what page is the IDLE SPEED/IGNITION TIMING procedure in Service
Manual?
31. What is the specification of Idle engine speed?

rpm
32. Touch
33. Touch
IACV-AAC/V ADJ
START
34. Is the THROTTLE VALVE IDLE POSITION ON when the accelerator is

released?
YES / NO
35. If not, correctly adjust the THROTTLE POSITION to ON.

Refer to the Service manual for the correct procedure.
36. Is Idle engine speed within specification?

YES / NO
ECTN1002A/WS3
37. If not, correctly adjust the engine speed with adjusting screw.
*
BACK and then touch
MODE
Now adjust the engine speed again with the adjusting screw.
39. Does the engine speed change to the desired value?

YES / NO
40. Now touch WORK SUPPORT and then touch
IACV-AAC/V ADJ
again.
41. Touch
START
IACV-AAC/V ADJ
When
is selected, the operation of IACV-AAC/V is
fixed while the engine speed is being adjusted by the screw.

(Until
CANCEL is touched.)
42. Perform the adjustment in both situations until you completely understand
the difference. Finally, adjust the idle engine speed correctly.
43. Push power OFF switch and stop engine.

exercise.
INSTRUCTOR SIGN-OFF
CONSULT Function Test (ECTN1002A/WS4)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to access and perform
the CONSULT Function Test (Sequence & Single Modes). Determine if test results for applicable components/circuits are within
specification, and then print out the results of each test.

CONSULT
Timing light
General tools
Worksheet

End of worksheet.
ECTN1002A/WS4
Part 1 - Sequence test mode
Using this worksheet and a CONSULT, perform the following Function test procedures.
Upon completion, place a check next to each Function test section heading.
1.
The Function test is designed with parameters that test within specification
ranges for the tested component/circuit. When an OK appears on the
screen, the individual item has been tested within this range.
Locate the CONSULT check connector and connect the diagnostic cable.
2. Turn the ignition key to the ON position - the CONSULT will automatically
turn itself on. If necessary, adjust the contrast and/or turn the light ON and/or
OFF, as required.
3. Touch START
4. Touch ENGINE
5. Touch
FUNCTION TEST
6. Touch SEQUENCE TEST
7. After SELF-DIAGNOSIS
screen appears, touch
NEXT .
8. Follow the menu-driven instructions through the component/circuit checks on

the following page and note the indicated results.
CONSULT reads components/circuits available on the vehicle. Any item

listed below that did not appear during the Sequence test is not a part of the
vehicle equipment.
ECTN1002A/WS4
COMPONENT/CIRCUIT
-SELF-DIAGNOSIS RESULTS
GIVEN
JUDGEMENT SPECIFICATIONS/
NOTES
OK / NO
-IDLE POSITION
OK / NO
-THROTTLE POSITION
SENSOR CIRCUIT
OK / NO
-NEUTRAL SWITCH
OK / NO
-FUEL PUMP CIRCUIT
OK / NO
-EGR CONTROL S/V CIRCUIT

(If available)
OK / NO
-VALVE TIMING S/V

CIRCUIT (If available)
OK / NO
-COOLING FAN CIRCUIT
OK / NO
-START SIGNAL CIRCUIT
OK / NO
-POWER STEERING SIGNAL

CIRCUIT
OK / NO
-IGNITION TIMING
ADJUSTMENT
OK / NO
-MIXTURE RATIO TEST
OK / NO
-POWER BALANCE TEST
OK / NO
-AAC VALVE CIRCUIT
OK / NO
If it is not possible to drive the vehicle, or a hoist is not available, not this in the
specifications/notes column.
At this point if you require more practice, please return to step 6 and repeat the
Sequence test.
ECTN1002A/WS4
Part 2 -Single test mode
9.
Using this worksheet and a CONSULT, perform the following Function test
single mode checks. Upon completion, place a check next to each function
test section heading.
10. Access the Select test mode and touch SINGLE TEST
11. Touch THROTTLE SENSOR CIRCUIT
12. Perform the test, using the prompt on the CONSULT screen as guides.
13. Touch NEXT , then touch PRINT
to print displayed screen. Keep the
printed result for review by instructor.
14. Touch
15.
BACK TO MENU
to return to Test Item Menu.
Perform the Single Item test procedure (steps 2-4) again on each of the following circuit components:
COOLING FAN CIRCUIT
POWER BALANCE TEST
16. Print the result of each test and keep the results for review by your instructor.
ECTN1002A/WS4
17. Touch BACK
key:
touch BACK
again to return to Test mode screen.
touch BACK
again to go to the Diag. mode screen.
touch BACK
again to go to the Select system screen.
18. Turn CONSULT off.
19. If you require more practice at this point, please return to step 1.
After completing these tests, check that all components are returned to their
original positions.
INSTRUCTOR SIGN-OFF
Worksheet
Usage of CONSULT-II
ECTN1003B
EC03B000
Usage of Tools
CONSULT-II Overview (ECTN1003B/WS1)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet you will be able to use

CONSULT-II.

CONSULT-II set
Worksheet
CONSULT-II Operators Manual

End of worksheet.
ECTN1003B/WS1
What is CONSULT-II?
The CONSULT, Computerized ON-board System UniversaL Tester,
diagnostic test tool is used for analyzing and trouble shooting onboard electronic systems. In recent years, automotive electronics
technology is advancing rapidly, and its application is becoming
more complicated and diversified. CONSULT-II is developed to carry
out accurate servicing and trouble diagnosis more speedily. The
CONSULT-II is improvement version of CONSULT.
The CONSULT-II has the following functions.
DIAGNOSTIC MODE
Example: ENGINE
WORK SUPPORT, SELF-DIAG RESULTS, DATA MONITOR,
DATA MONITOR (SPEC), ACTIVE TEST, FUNCTION TEST,
ECM PART NUMBER
SUB MODE
BATTERY CHARGE, MEASUREMENT (Voltage, Resistance,
Frequency, Duty, Pulse width), SIMPLE OSCILLOSCOPE,
RECORD DISPLAY/PRINT, FIELD TEST, SET DATE, SET
TIME, UNIT CONVERSION, CONFIGURE ETHERNET, COMMUNICATIONS TEST, PRINTER TEST, TOUCH SCREEN
TEST, LCD TEST, CONTRAST ADJUST, SELECT SYSTEM
SHORTCUT (From program card AED01A), VERSION.
1. Check the following parts by using Operators Manual.
CONSULT-II, AC/DC Power Supply, DLC Adapter Cable, Test Leads
(Red, Black and Blue), Probe Handles (Red, Black and Blue), Tip set,
Alligator clip, RS232C Cable, DLC Cable, Self Test Adapter, RS232C/
Ethernet Self Test Adapter, Printer Paper, Battery Pack, Program Card.
2. Check the following parts for CONSULT-II by using Operators Manual.
Display and Touch-screen, Test Lead ports, Instrumentation port, DLC
Adapter Cable Port, PC Port, External Power Port, On/Off Switch, Paper
Advance Knob, Paper Release Lever, Printer, DLC-1 Connector, DLC-2
Connector, Program Card Slot (Slot A), Expansion Card Slot (Slot B).
ECTN1003B/WS1
*
If you are not clear the parts, ask your instructor for assistance.
Install the CONSULT-II battery.
Only use a genuine CONSULT-II battery pack supplied by a CONSULT-II distributor in the CONSULT-II. Other types of batteries may
burst causing personal injury and damage to the tester.
3.
Confirm that power supply cable is not connected to CONSULT-II.
4.
Unfasten the velcro strap on the back of the tester and pull the strap
out of its retainer at the bottom of the tester.
5.
Turn the fastener near the top back of the tester 1/4 turn counterclockwise, then lift the back cover away from the tester.
6.
Connect the battery pack wire to the connector in the back of the
tester. Press the connector on firmly.
EC03B001
ECTN1003B/WS1
7.
Route the wires around the batteries, then snap the battery pack into
the plastic clips.
Install paper
8.
Install a paper roll onto the plastic shaft.
9.
Unroll the paper approximately 4 inches. Orient the paper roll so the
unrolled paper side is toward the bottom of the tester. Refer to the illustration.
EC03B002
Damage to the print head may result if the paper is installed with the
wrong side of the paper towards the print head.
10. Insert the end of the paper into the paper slot on the tester until it
passes through the tester (in the direction of the arrow on the plastic)
and projects out the front at least 1 inch.
11. From the front of the tester confirm the paper is projecting through the
paper slot and is aligned straight, then press the lever to its original
position pointing toward the top of the tester. This locks the paper in
place.
ECTN1003B/WS1
12. Press the plastic paper roll shaft into the plastic retainer clips until it
snaps into place.
13. Fit the tab on the bottom end of the back cover into the slot on the back
of the tester, then lower the top of the cover into place.
When closing the back cover, be sure to avoid pinching the battery
pack wire.
14. Turn the fastener 1/4 turn clockwise to lock the cover in place.
Make sure close the cover completely.
Insert a program card.

15. Confirm that the CONSULT-II is turned off.
*
When installing or removing the program card, the CONSULT-II must

be turned off.
16. Open the rubber flap and insert the program card to program card slot
A (Upper slot) carefully.
* A program card is shaped for a 1 way fit. Match it to the CONSULT-II.

Do not try to force the connection.
* CONSULT-II must have a program card inserted at all times.
17. Connect the AC/DC power supply to the lower right side of the tester,
then plug the power supply into a electricity.
ECTN1003B/WS1
18. Turn ON the On/Off switch.
When loading the program, the screen

(shown in the figure on the right) will be
displayed. If there is information
Unable to detect Program Card on the
screen, check insertion condition of the
program card or the card slot.
EC03B003
19. After the screen changed to the start up

screen (shown in the figure on the right),
touch COPY and confirm the printer is
operating correctly.
20. Printer operation: OK / NG
EC03B004
* If NO, ask your instructor for assistance.

* Program card No.
A
01
A: 1st release
B: 1st revised
C: 2nd revised
01: Issue year
D : Diagnosis card, N : NATS card
E : English, G: German, F: French, S : Spanish, I: Italian
N: Finnish, H: Greek
A: For All area (Included North America and European market)
E: For European market
U: For U.S.A. (North America) market
ECTN1003B/WS1
21. Turn the CONSULT-II off.
INSTRUCTOR SIGN-OFF
ECTN1003B/WS1
(Reference)
OPERATING PRECAUTIONS:
When performing any checks with the engine running in an enclosed space such
as a garage, be sure there is proper ventilation. Never inhale exhaust gases; they
contain carbonmonoxide, a colorless, odorless, extremely dangerous gas which
can cause unconsciousness or death.
Never use the Basic Measurement Lead Set to check voltages higher than 32
volts. Doing so will always destroy the CONSULT-II tester. (Dont plug the test
leads into a standard AC wall outlet.) Also, the test leads should be kept away
from high tension secondary ignition wires when the engine is cranking or running.
When measuring resistance, be sure to confirm that voltage is not applied to the
object. Otherwise, the tester may be damaged due to the abnormal current.
Use only the Genuine CONSULT-II battery and AC adapter. The tester may be
damaged if anything else is used.
After replacing the printer paper or Genuine CONSULT-II batteries, always confirm that the back cover is securely locked in place with the fastener. If the back
cover is not locked securely in place, the tester itself, the battery pack, the paperroll or the back cover may fall, resulting in personal injury or damage to the CONSULT-II.
The tester should be used where the operating temperature is between 0 and
50C (32 and 122F).
To reduce risk of injury, charge only Genuine CONSULT-II batteries. Other types
of batteries may burst causing personal injury and damage.
BEFORE USING YOUR NISSAN CONSULT-II TESTER
GENERAL PRECAUTIONS:
CONSULT-II employs precision electronic components which should not be used
where there are sudden changes in temperature, high temperatures or excessive
humidity, dust and dirt. Also, do not leave the CONSULT-II where it might be
exposed to direct sunlight.
ECTN1003B/WS1
Moisture may condense on the surface of the CONSULT-II if it is brought into a
warm room from the cold. If this happens, do not use the CONSULT-II until all
moisture has been removed or has dried.
Several magnets are used in the printer section, so do not leave your CONSULTII unit in places where there are metal particles. Do not allow metal objects such
as paper clips to fall inside.
Be sure to use the needle type of measurement probes carefully. The needle may
cause personal injury or damage.
Do not perform Calibrate Touch Screen if touch screen works correctly.
If calibration is needed, be sure to calibrate correctly. (If you calibrate incorrectly,
tester may go out of control.)
Do not remove or install a program card while power to CONSULT-II is ON. If you
wish to change or add a program card, first turn the tester off by pressing the On/
Off switch.
Do not use sharp objects on the touch screen. Use your finger tip.
Genuine CONSULT-II batteries are recyclable. Under various state and local laws
it may be illegal to dispose of Genuine CONSULT-II batteries in the municipal
waste system. Check with local solid waste officials in your area for recycling
options or proper disposal methods.
If the CONSULT-II, test leads, adapters or cables become dirty, they may be
cleaned by wiping them with a rag lightly coated with a mild detergent or nonabrasive hand soap. Do not immerse the tester, test leads, adapters, or cables in
water. Avoid using harsh solvents such as petroleum based cleaning agents, Acetone, Benzene, Trichloroethylene, or any other volatile substances (such as thinner), etc. Because the tester and accessories are not waterproof, thoroughly dry
them prior to storage.
The touch screen has air vents and is not designed to be water tight. Fluid may
seep in from behind the panel if it is not cleaned properly.
Please connect or disconnect the 26-pin DLC connector carefully and straightly to
or from CONSULT-II. If the connector is slanted, connector terminals will be broken.
ECTN1003B/WS1
The front surface of the touch screen should be kept free of dust, dirt, finger prints
and other abrasive materials that could scratch the front surface and detrimentally
affect its optical properties. For best results, use a clean, damp, nonabrasive cloth
and any commercially available window cleaner to clean the surface on a regular
basis. Always clean the tester screen by wiping vertically, only. Never use a circular motion on clear plastics. The cleaning solution should be applied to the towel
rather than directly to the surface of the touch screen.
Basically, the CONSULT-II communicates with only a PC. CONSULT-II may be
connected to a network, however, you should confirm the Ethernet setting of your
network (LAN or WAN) administrator. If the address of CONSULT-II and the
address of the PC which are connected to the same network are the same, they
will conflict and make it impossible to use the Ethernet and the LAN/WAN.
NOTES:
Turn power off when measurement unit is changed. If CONSULT-II is not turned
off, the measurement unit may not change.
RESISTANCE is not applicable in DATA MONITOR item. This is because measuring the RESISTANCE while providing voltage will cause damage.
The LCD back light will turn off automatically when the ambient temperature is
higher than 40C (104F) to avoid shortening the LCDs life.
If the ignition switch is not turned off, CONSULT-II may not be turned off. (Warning
may be displayed on the screen.) If this happens, first turn off the ignition switch,
then automatically turn off CONSULT-II.
The CONSULT-II must be used with a program card inserted into the card slot A.
CONSULT-II does not require loading (Initialization) procedures as does CONSULT.
In order to charge the Genuine CONSULT-II battery effectively, ambient room
temperature of between 10 and 30C (50 and 86F) is recommended.
10
CONSULT-II Self-diagnosis (ECTN1003B/WS2)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session you will be able to perform self-diagnosis of CONSULT-II
Nissan Vehicle equipped with ECCS engine

CONSULT-II
Worksheet

End of worksheet.
ECTN1003B/WS2
1.
On what page is the "CONSULT-II inspection procedure" in ONBOARD DIAGNOSTIC SYSTEM DESCRIPTION section?
2.
Make sure the ignition key is in "OFF" position.
3.
Connect the CONSULT-II cable to the connector.
The CONSULT-II connector is shaped for a 1-way fit. Match it to the

4.
Turn ignition switch "ON".
5.
Does the program number correspond the vehicle?

YES / NO
Refer to the Checking Equipment in GI section of the Service Manual.

If you are not clear the program card, ask your instructor for assistance.
6.
Touch START.
7.
The systems able to be checked with CONSULT-II will be displayed.
ECTN1003B/WS2
8.
Touch ENGINE.
9.
Touch SELF-DIAG RESULTS.
10. Is there any failure?

YES / NO If YES, ask your instructor for assistance.
*
When there is no failure, it will be indicated

with the following screen.
EC03B005

12. Turn the ignition switch to "OFF".
*
You should turn OFF the ignition switch before power off CONSULTII.
13. Push the power "OFF" switch of CONSULT-II.
ECTN1003B/WS2
Confirmation practice

*
16. Touch START.

17. Touch ENGINE.
19. Does CONSULT-II indicate a failure of ENGINE COOLANT TEMPERATURE SENSOR?
YES / NO
20. Touch ERASE, then touch YES.
YES / NO
22. Print the screen and attach the printout
in the space to the right.
23. Touch BACK 3 times
Attach here
ECTN1003B/WS2
25. Connect the ENGINE COOLANT TEMPERATURE SENSOR connector.

27. Touch START.
28. Touch ENGINE.

30. Are there any change on the screen compare with the screen at step
22?
YES / NO
If YES, what is it?
31. Start engine for few seconds, then stop engine.
32. Check self-diagnoses result again.
33. Are there any change on the screen compare with before?
YES / NO
If YES, what is it?
ECTN1003B/WS2
34. What is the meaning of the number indicated under time on the
screen?
If you are not clear this step, ask your instructor for assistance.
35. Touch ERASE.
When ERASE is touched, self-diagnosis is carried out once again.
36. Did the screen change to NO DTC IS DETECTED. FURTHER TESTING MAY BE REQIRED?
YES / NO If NO, ask your instructor for assistance.
37. Turn the ignition switch OFF and push the power OFF switch of
CONSULT-II .
INSTRUCTOR SIGN-OFF
CONSULT-II Work Support (ECTN1003B/WS3)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this session, you will be able to perform work support of CONSULT-II.
CONSULT-II
Worksheet

End of worksheet.
ECTN1003B/WS3
1.
On what page is the CONSULT-II INSPECTION PROCEDURE in the

EC section of the Service Manual?
2.
Make sure that the ignition key is in the OFF position.
3.
Connect the CONSULT-II connector to data link connector.
* The CONSULT-II connector is shaped for a 1-way fit. Match it to the

4.
Perform a visual check and self-diagnosis.

Visual check: OK / NG
Self-diagnosis: OK / NG If NG, repair them.
* Confirm that there is no failure on the system.

5.
Start engine.
6.
Touch START.
7.
Touch ENGINE.
8.
Touch WORK SUPPORT.
9.
ECTN1003B/WS3
THROTTLE POSITION SENSOR ADJUSTMENT
10.
What is the specification of Throttle Position Sensor output voltage at

idle?
V
11. Make sure that the engine is warmed up fully.

12. Touch TP SW/TP SEN IDLE POSI ADJ.
13. Touch START.
14. What is the CLSD THL POS and CLSD THL/P SW data on the CONSULT-II?
CLSD THL POS:
ON / OFF
CLSD THL/P SW: ON / OFF
If data are OFF, adjust them by rotating Throttle Position Sensor body.
* If you are not clear, ask your instructor for assistance.
16. Check Throttle position sensor output voltage at idle according to the
procedure as following.
1) Touch DATA MONITOR.
2) Select MAIN SIGNAL, then touch START.
3) Touch PAGE DOWN.
17. What is the THRTL POS SEN signal voltage?

V
ECTN1003B/WS3
18. Is the THRTL POS SEN signal voltage within specification?
YES / NO If NO, adjust it.
19. Touch BACK twice.
IGNITION TIMING ADJUSTMENT

20. What is the specification of ignition timing?
BTDC
21. Touch TARGET IGN TIM ADJ.
22. Touch START.
23. Check the ignition timing with timing light.

BTDC
* When reading the CONSULT-II ignition timing data while changing
ignition timing by rotating the distributor body, the ignition timing data in
the CONSULT-II does not change. Because CONSULT-II ignition timing data always indicates ECM memorized data, not actual value.
* Engine should be stopped when you loosen the fixing bolts.
* Idle ignition timing cannot be changed for VQ engine.
24. Is ignition timing within specification?

YES / NO
If NO, set the ignition timing by rotating the distributor body or the
camshaft position sensor body.
25.
Touch BACK twice.
ECTN1003B/WS3
IDLE SPEED ADJUSTMENT
26. What is the specification of idle speed?
rpm
27. Touch TARGET IDLE RPM ADJ.

28. Touch START.
YES / NO
If NO, adjust the idle speed with idle adjusting screw.
30. Touch BACK.
31. Does the engine speed change to the desired level?

YES / NO
32. Turn the ignition switch OFF and push power switch of CONSULT-II.
INSTRUCTOR SIGN-OFF
CONSULT-II Function Test Mode (ECTN1003B/WS4)

OBJECTIVE:
TOOLS AND
EQUIPMENT:
RESOURCES:
At the end of this worksheet, you will be able to perform the

FUNCTION TEST MODE of CONSULT-II.

CONSULT-II (Program card AED01A)
Worksheet

End of worksheet.
ECTN1003B/WS4
FUNCTION TEST OUTLINE
The FUNCTION TEST was developed for the following reasons.
For Customer:
Test RESULT is simply displayed and easily understood with either
OK or NG. NG is displayed when a malfunction is detected.
NOTE: When OK is displayed on the CONSULT & CONSULT-II, it
means NG is not detected. The CONSULT & CONSULT-II may not
be able to detect mechanical malfunctions.
For Technicians:
A) For Basic Technician: The FUNCTION TEST is designed to
diagnose the engine by reading instructions on its comment screen.
B) Specification Test: For some test items in the engine it is possible
to execute detailed specification tests.
NOTE: Technicians do not refer to the result of CAR COMPUTER
DIAG for trouble diagnosis. (The technicians use Self-Diagnosis
Results.)
For Technical Advisor:
The new FUNCTION TEST is designed to provide technical advisors simple explanation of the condition of your customers vehicles.
The self-diagnosis result inside the FUNCTION TEST is displayed
with OK or NG, which is improved to arrange each item and function for easier comprehension by customers.
PDI/Repair confirmation:
The FUNCTION TEST can assure confirmation by checking sensor, switch and actuator during PDI or after repair.
ECTN1003B/WS4
1. Connect the CONSULT-II diagnostic cable to the diagnostic connector.
*
The CONSULT-II power is automatically turned ON.
The right screen is displayed on the

models from 2001 with a program card
AED01A or equivalent version.
If there is no ENGINE menu, ask your
instructor for assistant.
3. Touch ENGINE.
Touch START when you want meet
another systems.
EC03B006
4. Touch ENGINE.
5. Touch FUNCTION TEST.
6. What items are offered?
7. Touch CAR COMPUTER DIAG.
8. [If you ERASE the SELF-DIAG RESULTS, this test may display the
false results. This test judge OK when except NG detect condition.] is
displayed.
9. Touch OK.
*
The test is started automatically.
ECTN1003B/WS4
10. Check the RESULT .
OK / NG
If NG is displayed, ask your

Attach here

12. Touch BACK.
13. Touch SENSOR/SW TEST.
15. Touch OK.
16. Touch THRTL POS SEN.
If you do not need check P/N POSI SW check, touch PASS.
ECTN1003B/WS4
17. Keep to depress throttle fully few seconds, then release throttle.
18. Confirm that THRTL POS SEN and CLSD THL POS are judged
OK.
19. Touch P/N POSI SW.
20. Shift following operation and keep a few seconds each range.
M/T: Any gear
A/T: P
R
N
N
Any gear
D
P
Slowly move shift lever (Selector lever).
21. Check the result of P/N POSI SW.

22. Touch NEXT twice.
24. Touch VHCL SPEED SE.
25. Touch PASS in this time.

If you need to check, perform it.
26. Touch AIR COND SIG.
ECTN1003B/WS4
27. [TURN A/C SW and A/C FAN ON (OFF) to keep a few second, then
TURN A/C SW OFF (ON)] is displayed.
28. Touch PW/ST SIGNAL.
29. [HOLD and keep steering wheel in a full

LOCKED position a few second then
RELEASE in a NEUTRAL position] is displayed.
Attach here
30. Check the result.

31. Touch END.

33. Touch END.
Stand on around an engine room.
34. Touch CONFIRMATION TEST.

This test can check the following systems on most vehicles.
1. FUEL PUMP CIRCUIT
2. EGR CONTROL S/V CIRCUIT
3. PRVR CONT S/V CIRCUIT
4. VALVE TIMING S/V CKT
5. COOLING FAN CIRCUIT
6. VIAS S/V CIRCUIT
7. SWRL CONT S/V CIRCUIT
8. ELEC. CONT ENG. MOUNT
36. Touch OK.
ECTN1003B/WS4
* The test is started automatically.
37. [PINCH fuel feed hose with fingers. Is there any pressure pulsation on
the fuel feed hose or Does the fuel pump RELAY make an operate
SOUND every 3 seconds?] is displayed. Follow the instruction.
38. What is the test result?

EGR CONTROL S/V test is started automatically if equipped.
39. Does the EGR Control Solenoid Valve make an operating sound every
3 seconds?
* PRVR CONT S/V CIRCUIT test is started automatically if equipped.
40. Does the PRVR Control Solenoid Valve make an operating sound
every 3 seconds?
* VALVE TIMING S/V CKT test is started automatically.
41. Does the Valve Timing Solenoid Valve make an operating sound every
3 seconds?
ECTN1003B/WS4
* COOLING FAN CIRCUIT test is started automatically.
42. Does the COOLING FAN rotate and STOP every 3 seconds?
* SWRL CONT S/V CIRCUIT test is started automatically if equipped.
43. Does the Swirl Valve Control Solenoid Valve make an operating sound
every 3 seconds?
* ELEC. CONT ENG. MOUNT test is started automatically if equipped.
44. Does the Electrical Control Engine Mount make an operating sound
every 3 seconds?

Attach here
ECTN1003B/WS4
If NG is displayed, ask your instructor for assistance.
47. Touch END.

* Function Test mode screen is displayed when the vehicle is not
equipped with an oxygen sensor.
48. Touch MIXTURE RATIO TEST.

51. [AT FIRST, KEEP (ACCELERATE) ENGINE SPEED TO 2000 rpm

AND HOLD. THEN TOUCH START] is displayed.
52. Touch START.
53. When the test is finished, release the accelerator pedal.

OK / NG If NG is displayed, ask your instructor for assistance.
ECTN1003B/WS4
55.
Touch PRINT and attach the

Attach here
56. Touch END.
57. Touch POWER BALANCE.
58. Let engine idle, then touch START.
59. When the following is displayed,

warm up the engine.
[RUN ENGINE UNTIL ENG
TEMP IS ABOVE 176 F]
60. Wait until the test is finished.


OK / NG
If NG is displayed,
63. Touch END.
10
Attach here
ECTN1003B/WS4
64. Touch IACV-AAC/V SYSTEM.

66. [LET ENGINE IDLE. THEN TOUCH START] and

[A/C SW, LIGHT SW OFF] are displyed.
67. Touch START.
68. If engine stall occur, start engine again or

adjust air by-pass screw then touch OK.
Attach here
* IACV-AAC valve test is started automatically.
69. After finish the test, touch PRINT and

attach the printout in the space to the right.
70. Touch END.
71. Touch BACK.
72. Turn ignition off and power off CONSULT-II.
INSTRUCTOR SIGN-OFF
11
Worksheet
EXSE Course
Worksheet #
Worksheet tasks
ESTN1001B
Express Lub. 30
ESTN1002B
ESTN1003B
ESTN1004B
ESTN1005B
Express Service
Remarks
Worksheet
Express Lub. 30
ESTN1001B
ES1-1
Express Service
Express Lub. 30 (ESTN1001B)

OBJECTIVE:
Be able to change the Engine oil and perform 14-point

inspection.
TOOLS AND
EQUIPMENT:
RESOURCES:
Service Manual
INSTRUCTIONS:
Vehicle hoist
Oil filter wrench
Oil drain pan
Drain plug wrench
General tool
Tire pressure gauge

Seat cover, steering cover,
floor paper
Fender cover
A/T paper towel
Work light

End of worksheet.
ESTN1001B
1. Open MA section of Service Manual.
2. For drive belt adjustment fill out table No. 35 on page 11 with specification of used belt deflection.
Limit
3. Write refill engine oil capacity with oil filter change on page 5.
4. Referring to MA section of Service Manual, write torque value of
engine oil drain plug in the illustration on page 5.

value in the illustration on page 5.
(Fill out the measurement column later.)
ES1-2
8. Set vehicle on a lift (but do not lift it).

2
ESTN1001B
* Lift point information is found in the GI section of the Service Manual.

Inspection point
Judgement
OK / NG
OK / NG
OK / NG
ES1-3
11. Remove engine oil filler cap. Lift up vehicle with hood open until the
bottom is the same height as your head.
* When setting the lift arm, do not allow the arm to contact the brake
tubes, brake cable, fuel lines and sill spoiler.
12. Remove drain plug and drain engine oil.
ESTN1001B
13. Inspect the wear or damage condition of the tire as next procedure.
Inspection point
ES1-3.5
Flat spot or cutting on the edges of the tread
ES1-5
ES1-4
ESTN1001B
T/M oil level & condition: OK / NG
Engine oil capacity:

Drain plug torque:
OK / NG
Tire Pressure
Tire Pressure
Tire wear
or damage

ment

ment
Fr
RH
Fr
LH
OK / NG
OK / NG
Tire wear
or damage
OK / NG
Fr tire size:
Tire Pressure
Tire wear
or damage
OK / NG
Tire Pressure

ment
Rr
RH

ment
Rr
LH
OK / NG
OK / NG
Tire wear
or damage
OK / NG
Rr tire size:
ES1-6
ESTN1001B
14. Referring to tightening torque of drain plug on page 5, install drain
plug.
* Be sure to clean drain plug and install with new washer.
15. Remove oil filter and install new oil filter.
* Clean the oil filter mounting surface on cylinder block.
* Lubricate the seal rubber of the new oil filter with engine oil.
* Tighten by hand 2/3 turn after seal rubber of filter contacts mounting surface of cylinder block.
ES1-7

ESTN1001B
Checking procedure is same as Step 16.
ES1-8

19. Fill the engine oil and install filler cap.
For amount of oil to fill, refer to the specification on page 5.
Inspection point
1
2
3
Coolant level at filler neck

of the radiator
MAX. and MIN. indicated
on reservoir tank
Contamination
Judgement
OK / NG
OK / NG
OK / NG
ES1-9
* When large amounts of coolant are

lost, the most likely cause is leakage.
* Never remove the radiator cap
when the engine is hot.
ES1-10
ESTN1001B
Inspection point
Judgement
OK / NG
OK / NG
Loose connection
OK / NG
Leakage
OK / NG
ES1-11

23. Inspect the exterior lamps.
Inspection point
Judgement

beams
OK / NG
OK / NG
Brake lamps
OK / NG
OK / NG
Hazard lamps
OK / NG

Inspection point
Judgement
Air pressure
OK / NG
Wear or damage
OK / NG
25. Raise the vehicle until it is same as your height.
ESTN1001B
26. Inspect engine oil for leaks.
Inspection point
Judgement
Around drain plug
OK / NG
Around oil filter
OK / NG
27. Lower the vehicle and remove all lift

arms from vehicle.
ES1-12
28. Inspect the automatic transmission fluid

while engine is at idle.
Inspection point
1
Fluid level between hot and

cold
Color of ATF
Judgement
OK / NG
ES1-13
Normal / Dark brown / Dark / Black / Milky

pink

Inspection point
Judgement
OK / NG
Blockage
OK / NG

need cleaning.
9
ES1-14
ESTN1001B
Inspection point
1
2
Judgement

and MAX.
master cyliner
OK / NG
OK / NG
ES1-15
ES1-16

Inspection point
1
2

and MAX.
master cylinder
Judgement
OK / NG
OK / NG
ES1-17

OK / NG
10
ESTN1001B
OK / NG

leaks.

Drive belts
Used belt
deflection
Limit
Alternator
Measurement

tion
or fraying
nation
glazed
With A/C compressor
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG

(kg)
ES1-18

Between H and L:
OK / NG
ES1-19
* Do not perform inspection of engine oil level immediately after stopping engine. After stopping, leave the engine for a few minutes and
wait until oil level settles.
11
ESTN1001B
37. If any NG is found in worksheet, did you repair it or contact to your
instructor?
YES / NO
38. Lower hood and lock completely.
INSTRUCTOR SIGN-OFF
12
Worksheet
ESTN1002B
ESTN1002B
ES2-1
Express Service
Engine Tune-up Service (ESTN1002B)

OBJECTIVE:
Be able to inspect spark plug, engine idle speed, ignition

timing and battery.
TOOLS AND
EQUIPMENT:
RESOURCES:
Service Manual
Worksheet
INSTRUCTIONS:
Spark plug socket

Battery hydrometer
Torque wrench
(CONSULT-II)
Timing light
Seat cover
Fender cover
Water temperature gauge
Rag

End of worksheet.
ESTN1002B
1. Referring to the Service Manual MA or EM section, write the spark

plug gap and tightening torque in the specification column on page
3.
2. Referring to the Service Manual EC section, write ignition timing in
the specification column on page 3.
3. Referring to the Service Manual EC section, write the engine idle
rpm in the specification column on page 3.
4. For the drive belt adjustment, write the following specification of
used belts deflection in step 19 on page 7.
Limit
5. Install a seat cover, steering cover and floor paper.

6. Open the hood, and install a fender protector.
ESTN1002B
Go to next page.
Spark plug gap
Specification
Measurement
Judgement
#1
mm
OK / NG
#2
mm
OK / NG
mm
OK / NG
#4
mm
OK / NG
(#5)
mm
OK / NG
(#6)
mm
OK / NG
#3
mm
ES2-2
Tightening torque
Ignition timing
Ignition timing
Specification
Measurement
Judgement
BTDC
BTDC
OK / NG
ES2-3
Idle speed
Specification
Measurement
Judgement
Idle speed
(WORK SUPPORT mode or
disconnected TPS)
rpm
rpm
OK / NG
Idle speed
(DATA MONITOR mode or
connected TPS)
rpm
rpm
OK / NG
ES2-4
ESTN1002B
7. Air-blow the spark plugs, distributor, ignition coil, and ignition wires
for cleaning.
8. When the vehicle is equipped with a distributor, go to step 9.
When it has no distributor, remove the ignition coil from the spark
plugs, then go to step 12.
9. Disconnect the spark plug wires from spark plugs by gently twisting
and pulling the boots, and inspect it.
Spark plug wires
#1
#2
#3
Inspection point
Cracks
Damage
Rubbing
Contact with engine
components
Judgement
OK / NG
OK / NG
OK / NG
#4
OK / NG
(#5)
(OK / NG)
(#6)
(OK / NG)
Ignition wire between coil

and distributor cap
OK / NG
* To prevent damage, do not pull hard on the spark plug wires to

remove them.
10. Remove the distributor cap and the rotor for the following procedure.
1) Remove the distributor cap with spark plug wires and high tension wire from ignition coil.
2) Remove the rotor.
3) Wipe the inside of the distributor cap and rotor.
11. Inspect the distributor cap and the rotor.
Inspection point
Distributor cap
Rotor
Cracks
Carbon tracking
Damage
Judgement
OK / NG
OK / NG
ESTN1002B
12. Remove the spark plugs and place them in cylinder order on the
work bench.
ES2-5
13. Inspect the spark plugs.

Inspection point
Judgement
#1 Oil fouling
Carbon tracking
#2 Other damage
OK / NG
#3
OK / NG
#4
OK / NG
(#5)
OK / NG
(#6)
OK / NG
OK / NG
ES2-6
14. Clean the spark plugs.

* [Platinum-tipped type]
Do not use a wire brush for cleaning.
If plug tip is covered with carbon,
spark plug cleaner may be used.
Checking and adjusting plug gap
is not required between change
intervals (90,000 km or 54,000 miles).
* [Conventional type]
Use a wire brush for cleaning, if
necessary.
* Cleaner air pressure:
Less than 588 kPa (6 kg/cm2, 85
psi)
Cleaning time: Less than 20 seconds
5
ES2-7
ES2-8
ESTN1002B
15. Inspect the spark plug gap and record it on page 3. (Conventional
type only)
16. Install the spark plugs, and tighten with the specified tightening
torque. (Refer to page 3.)
* When installing the spark plugs, follow the procedures below.
1) Install the spark plugs in cylinder order as before.
2) When installing the new spark plugs, confirm the gap before
installation.
3) Secure the spark plugs with suitable spark plug wrench.
17. For the distributor type vehicle, go to step 17-1.

For the direct ignition type vehicle, go to step 17-2.
17-1. [Distributor type]
Install the rotor, distributor cap and spark plug wires with the following procedures.
1) Install rotor.
2) Install distributor cap.
3) Reconnect spark plug wires according to number indication
to spark plug
4) Reconnect high tension wire to ignition coil.
ES2-9
ES2-10
ES2-11
ESTN1002B
17-2. [Direct ignition type]
Install the ignition coil to each spark plug.
Inspection point
Judgement
Damage filter element
OK / NG
Blockage
OK / NG
* Shine a light from the opposite side

of the air filter.
If the light can be seen from your
side, it is judged OK.
need cleaning.
* Dry paper type filter is necessary to
clean.
ES2-29
#1Drive belts
Alternator
#1Judgeme
#1Used belt
#1Judgeme #1Judgeme
#1Judgeme
nt of crackdeflection #1Measure
nt of con- nt of worn
nt of deflecing or frayment
tamination
or glazed
tion
#1Limit
ing
With A/C compressor
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
(kg)
ES2-30
ESTN1002B
20. Inspect engine coolant hoses.
Inspection point
Judgement

deformation
OK / NG
Deterioration
OK / NG
Loose connection
OK / NG
Leakage
OK / NG
ES2-31
21. Inspect ignition timing and idle speed with the following procedures.
[Without CONSULT-II]
INSPECTION START
Start engine and warm it up
to normal operating temperES2-12

ES2-13

ES2-4
Turn off engine and disconnect throttle position sensor

harness connector.
A
(Go to next page.)
ES2-15
ESTN1002B

A
under no-load and then run
timing light.
Check idle speed.
Record inspection results
on page 3.
Turn off engine and connect

throttle position sensor harness connector.
Restart engine.
ES2-15

under no-load and run
ES2-4

on page 3, and judge it.
INSPECTION END
ESTN1002B
[With CONSULT-II]
INSPECTION START
Connect CONSULT-II to
DDL terminal.
ES2-16
ES2-17
ES2-12
ES2-18
Start engine, warm it up to

normal operating temperature and touch START on
the CONSULT-II screen.
ES2-13

ES2-4
Touch ENGINE, then

WORK SUPPORT on the
CONSULT-II screen.
ES2-19
ES2-20
ES2-21
ES2-22
Touch IACV-AAC/V ADJ

or IGNITION TIMING ADJ
or TARGET IGN TIM ADJ
on the CONSULT-II screen.
timing light and record inspection result on page 3, and
A
(Go to next page.)
10
ESTN1002B

A
on page 3.
Touch BACK 3 times,
DATA MONITOR and
MAIN SIGNAL on the
CONSULT-II screen.
ES2-24
ES2-25

on page 3.
ES2-26
INSPECTION END
22. By observing the level lines or removing the battery case caps,
visually check that the fluid level in each battery cell is within the
specified range.
OK / NG
ES2-27
11
ESTN1002B
* When the battery life is near the end, the fluid will become empty
soon after replenishment. Periodical checks are important. (Charging voltage is higher than battery generation voltage.) The battery
life lasts generally about 2 to 4 years.
* Enclosed maintenance-free batteries need no check. Do not add
water.
23. Check the battery specific gravity to judge if it needs recharging.
Specific gravity (20C conversion value):
Needs recharging / Needs no recharging
* Standard value (20C):

Normal value 1.22 - 1.29
Limit value 1.22 or less
Difference among cells: 0.03 or less
* The specific gravity of battery fluid changes depending on temperature, but it shall be evaluated at a standard temperature of 20C.
By following the conversion table for electrolyte specific gravity and
temperature, convert the measured specific gravity into the 20C
standard value for judgement.
[EXAMPLE]
Electrolyte temperature: 40C
Measured specific gravity: 1.226
Specific gravity (Converted at 20C):

1.240
Consequently, it can be judged that the
battery needs recharging.
Conversion table for electrolyte specific gravity/temperature

10C 0C 10C 20C 30C 40C 50C
1.321 1.314 1.307 1.300 1.293 1.286 1.279
1.311 1.304 1.297 1.290 1.283 1.276 1.269
1.301 1.294 1.287 1.280 1.273 1.266 1.259
1.291 1.284 1.277 1.270 1.263 1.256 1.249
1.281 1.274 1.267 1.260 1.253 1.246 1.239
1.271 1.264 1.257 1.250 1.243 1.236 1.229
1.261 1.254 1.247 1.240 1.233 1.226 1.219
1.251 1.244 1.237 1.230 1.223 1.216 1.209
1.241 1.234 1.227 1.220 1.213 1.206 1.199
1.231 1.224 1.217 1.210 1.203 1.196 1.189
1.221 1.214 1.207 1.200 1.193 1.186 1.179
(C
12
ESTN1002B
* A battery tester such as one shown
in the photo can automatically judge
OK / NG.
ES2-28
INSTRUCTOR SIGN-OFF
13
Worksheet
ESTN1003B
ES3-1
Express Service
Cooling System Service (ESTN1003B)

OBJECTIVE:
Be able to change the engine coolant and perform 14point inspection.
TOOLS AND
EQUIPMENT:
RESOURCES:
Service Manual
Worksheet
Vehicle hoist
General tool
Coolant drain pan
Fender cover
Coolant tester
Rag
Tire pressure gauge
Torque wrench
Seat cover, steering cover, floor paper
INSTRUCTIONS: These instructions will outline the tasks that you will need
End of worksheet.
ESTN1003B
* If any NG is found in worksheet, repair or contact your instructor.
1. Open MA section of Service Manual and write the limit value of
used belt deflection and applied pushing force on page 10, step 24.
2. Referring to Service Manual, write the limit value of radiator cap

relief pressure on page 5. (Fill out the measurement column later.)
ES3-2
3. Referring to Service Manual, write the applied pressure value when

checking cooling system on page 5. (Fill out the judgement column
later.)
ES3-3
4. Referring to LC section of Service Manual, confirm the position of

air relief plug and write the tightening torque on page 5.
ES3-4
ES3-5
QG engine
SR engine
ESTN1003B
value in the illustration on page 5. (Fill out the measurement column later.)
ES3-6
8. Set vehicle on a lift. (but do not lift it.)

Inspection point
Judgement
OK / NG
OK / NG
OK / NG
ESTN1003B
Inspect the wear or damage condition of the tire as next procedure.

Inspection point
ES3-7
Flat spot or cupping on the edges of the tread
ES3-9
ES3-8
ESTN1003B
Radiator Cap
Limit
Cooling System
Measurement Judgement
Air relief plug tightening torque
Testing Pressure
OK / NG
OK / NG
Front
T/M oil level & condition OK / NG
Air relief plug

T
O
R
Q
U
E
Tire Pressure
Tire Pressure
Tire wear
or damage
OK / NG
Judgement

ment

ment
Fr
RH
Fr
LH
OK / NG
OK / NG
Tire wear
or damage
OK / NG
Fr tire size:
Tire Pressure
Tire wear
or damage
OK / NG
Tire Pressure

ment
Rr
RH

ment
Rr
LH
OK / NG
OK / NG
Tire wear
or damage
OK / NG
Rr tire size:
ES3-10
ESTN1003B
ES3-11

ES3-12
ESTN1003B
14. Raise the hood, install fender protector and remove the radiator
cap.
* Wrap a thick cloth around the cap and carefully remove it by turning
it a quarter turn to allow built up pressure to escape and then take
the cap all the way off.
ES3-13
15. Inspect the radiator cap relief pressure and write the measured value on
page 5.
ES3-14
16. Referring to the value written on page

5, inspect cooling system for leaks
and write the inspection result on
page 5.
ES3-15
* Use caution. If the applied pressure exceeds the limit, the joints of
the radiator, heater core, hoses, and other parts may be damaged.
ESTN1003B
17. Drain the engine coolant with following procedure.
Turn ignition switch
ON and move A/C
control lever to
MAX HOT position.
Wait 10 seconds
and turn ignition
switch OFF.
Remove radiator
drain plug and
drain coolant.
Remove air relief

plug from cylinder
block.
Drain coolant from

reservoir tank.
* Perform following steps, while draining the coolant for express service.

Between H and L:
OK / NG
* Do not perform inspection of engine

oil level immediately after stopping
engine.
After stopping, leave the engine for a
few minutes and wait until oil level
settles.

Inspection point
Judgement
OK / NG
Blockage
OK / NG
NOTE:
Refer to key points on the next page.
ES3-16
ESTN1003B
* Shine a light through the air filter from
the opposite side. If light can be seen,
condition of air filter is OK.
need cleaning.
ES3-17

Inspection point
1
2
Fluid level between

MIN. and MAX.
master cylinder
Judgement
OK / NG
OK / NG
ES3-18
ES3-19

Inspection point
1
2

and MAX.
master cylinder
Judgement
OK / NG
OK / NG
ES3-20
ESTN1003B
OK / NG

OK / NG

leaks.

Used belt
deflection
Drive belts
Limit
Alternator
Measurement

tion
or fraying
nation
glazed
With A/C compressor
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG

(kg)
ES3-21

Judgement
Inspection point
1
OK / NG
OK / NG
Loose connection
OK / NG
Leakage
OK / NG
10
ES3-22
ESTN1003B
26. Refill engine coolant, using following procedure.
START
installing the drain plug, apply
NOTE: When
sealant to thread portion of the plug
Install reservoir tank and

radiator drain plug.
and refer to the value of tightening

torque written on page 5.
Fill radiator slowly with coolant until coolant spills from

the air relief plug, then
install air relief plug.
NOTE: Copper washer of air relief plug must

be replaced with new one.
Fill the coolant with volume of 2 liter/

min (like filling water with a pot).
A
Fill radiator and reservoir
tank with engine coolant.
If the filling coolant is overfilled, or

filled too quickly, it may cause entry
of air.
NOTE: Fill the coolant to the height of radiator filler neck.
Fill the coolant to the MAX line of reservoir tank.
Warm up the engine to normal operating temperature

without radiator cap.
NOTE: Coolant level must be checked.
Install radiator cap and run

the engine with 2,500 rpm
for 10 seconds.
Cool down
the engine until the coolant temNG
perature falls to approx. 50C
and then check coolant
level.
Repair.
OK
NG
Check cooling system for leaks

with engine running.
OK
Go to next page.
11
NOTE: When removing radiator cap,
watch out for sudden spray of hot

engine coolant.
ESTN1003B
Go to A
on previous page
From previous page
Cool down the engine until

the coolant temperature
falls to approx. 50C.
Run engine at 3,000 rpm for

2 minutes and then at idle.
Sound exists
from heater unit
Move the heater control lever

Step by Step from FULL COLD
to FULL HOT.
NOTE:
Close windows, doors and
hood, and switch radio OFF.
No sound from
heater unit
NG
Check engine
coolant level. The level must be;
on filler neck height of radiator
on MAX line of reservoir tank
OK
END
12
NOTE:
When removing radiator cap
watch out for sudden spray
of hot engine coolant.
ESTN1003B
27. Inspect the automatic transmission
fluid while engine is at idle.
Judgement
Inspection point
1

and cold
Color of ATF
OK / NG
ES3-23

28. Inspect the exterior lamps while engine is at idle.

Inspection point
Judgement
Headlamp high and low beams
OK / NG
OK / NG
Brake lamps
OK / NG
OK / NG
Hazard lamps
OK / NG

Judgement
Inspection point
1
Air pressure
OK / NG
Wear or damage
OK / NG
INSTRUCTOR SIGN-OFF
13
Worksheet
Tire Rotation & Brake
Service
ESTN1004B
ES4-1
Express Service
Tire Rotation & Brake Service (ESTN1004B)

OBJECTIVE:
Be able to conduct tire rotation and brake inspection with

14-point inspection.
TOOLS AND
EQUIPMENT:
RESOURCES:
Service Manual
Worksheet
INSTRUCTIONS:
Vehicle hoist
Tire pressure gauge
Torque wrench
Work light
Impact wrench
A/T paper towel

Rag
Fender cover
Seat cover
Scale

End of worksheet.
ESTN1004B
Inspection point
Judgement
Wears or cracks in rubber
OK / NG
OK / NG
OK / NG
2. Lift point information is found in the GI section of the Service Manual.
ES4-2
ESTN1004B
3. Raise the vehicle until the wheel center is waist high.
* In the Service Manual two methods of tire rotation (4 and 5 tires)
are explained and 4-tire rotation procedure is as follows.
ES4-3
4. Inspect the tire condition of the left front tire.

Visually check tire for excessive wear or appearance of wear indicator on tire tread.
OK / NG
ES4-4
5. Is there flat spot or cupping on the edges of the tread?

OK / NG
ESTN1004B
OK / NG
ES4-5
7. Remove wheel and tire assemblies in left front.

(Recommend using an impact wrench)
9. Locate the disc brake pad thickness MA section in the Service

Manual.
10. Inspect the condition of the left front brake.

OK / NG
ES4-6
ESTN1004B
11. Check brake caliper and brake hoses for oil leakage.
OK / NG
ES4-7

OK / NG
ES4-8
13. Bring wheel and tire assemblies from left front to the left rear.
14. Inspect the tire condition of the left rear tire.
Visually check tread pattern for unusual wear or wear indicators.
OK / NG
ES4-9
ESTN1004B
15. Is there flat spot or cutting on the edges of the tread?

OK / NG
OK / NG
ES4-10
17. Remove wheel and tire assemblies on left rear. (Recommend using
an impact wrench.)
ESTN1004B
19. Inspect the condition on the left rear brake.
OK / NG
ES4-11
20. Perform visual inspection for fluid leakage from brake caliper or
brake hoses.
OK / NG
ES4-12

OK / NG
ES4-13
ESTN1004B
22. Bring wheel and tire assemblies from left rear to the left front.
* Perform tire rotation and brake inspection for right front and right
rear wheel in same procedure as used for left front and left rear
wheel. Refer to Step 10 to 16.
23. Check the following items and judge the inspection result.
Right front tire
OK
NG
OK
NG
OK
NG
OK
NG
Brake pad wear
OK
NG
Brake fluid leakage
OK
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
NG
Brake pad wear
OK
NG
Brake fluid leakage
OK
NG
OK
NG
Right rear tire
24. Install wheel and tire assemblies according to the following procedure.
Right Front Right Rear Left Rear Left Front
8
ESTN1004B
26. Inspect transmission fluid for oil level and condition. (Manual transmission only)
OK / NG
ES4-14

If oil touches to the finger, oil level is correct.
27. Inspect differential fluid for level and condition. (Rear wheel and 4wheel drive only)
OK / NG
ES4-15
28. Lower the vehicle until tires contact ground and remove lift arms.
29. Locate the tighten wheel nut MA section in the Service Manual.
ESTN1004B
30. Using torque wrench, tighten wheel nuts to the specified torque.
Tightening torque :
Nm/kg-m
ES4-16
ES4-17

Between H and L:
OK / NG
ES4-18
* Do not perform inspection of engine oil level immediately after stopping engine.
After stopping, leave the engine for a few minutes and wait until oil
level settles.
10
ESTN1004B
Inspection point
1
2
3
Coolant level at filler

neck of radiator
MAX. and MIN. indicated on reservior tank
Contamination
Judgement
OK / NG
ES4-19
OK / NG
OK / NG
ES4-20
* When large amounts of coolant are lost, the most likely cause is
leakage.
* Never remove the radiator cap when the engine is hot.
Inspection point
Judgement
OK / NG
OK / NG
Loose connection
OK / NG
Leakage
OK / NG
ES4-21

Inspection point
Judgement
OK / NG
Blockage
OK / NG
11
ESTN1004B
need cleaning.
* Dry paper type filter must be
cleaned.
ES4-22

Inspection point
1
2
Fluid level between

MIN. and MAX.
master cylinder
Judgement
OK / NG
OK / NG
ES4-23
* If fluid level is extremely low, check

brake system for leaks.
* When replacing or refilling brake
fluid, always use the same kind.
Using the wrong type or mixing
types can cause brake malfunction
during high temperature operation
(heavy braking).
ES4-24
37. Inspect the clutch fluid. (Manual

transmission only)
Inspection point
1
2
Fluid level between

MIN. and MAX.
master cylinder
Judgement
OK / NG
OK / NG
ES4-25

12
ESTN1004B
OK / NG

OK / NG

leaks.

Drive belts
Used belt
deflection
Limit
Alternator
Measurement

tion
or fraying
nation
glazed
With A/C compressor
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG
mm
mm
OK / NG
OK / NG
OK / NG
OK / NG

(kg)
ES4-26
13
ESTN1004B
Start
41. Start the engine and inspect the exterior lamps.

Inspection point
Judgement

beams
OK / NG
OK / NG
Brake lamps
OK / NG
OK / NG
Hazard lamps
OK / NG
42. Inspect the air pressure of all four tires.

OK / NG
* Refer to the tire label attached to
the drivers door lock pillar or etc.
ES4-27
43. Open trunk lid and inspect spare tire

condition.
Inspection point
Judgement
Air pressure
OK / NG
Wear or damage
OK / NG
ES4-28
14
ESTN1004B
44. Inspect the automatic transmission fluid while engine is at idle.
Inspection point
1

and cold
Color of ATF
Judgement
OK / NG
ES4-29
INSTRUCTOR SIGN-OFF
15
Worksheet
ESTN1005B
ES5-1
Express Service

OBJECTIVE:
Be able to complete the A/C performance check.
TOOLS AND
EQUIPMENT:
Leak detector (Electrical leak detector or fluorescent

dye leak detector)
General tools
Fender cover
Seat cover
Rag
RESOURCES:
Service Manual
Worksheet
INSTRUCTIONS:

End of worksheet.
ESTN1005B
* If there is NG in the worksheet, repair it or ask the instructor.
1. Open the Service Manual to the HA section.
2. Install fender cover, seat cover, steering cover and floor paper.
3. Connect an exhaust hose to the vehicles tail pipe.
OPERATIONAL CHECK - AUTO A/C
OK / NG
OK / NG
6. Check temperature control lever movement from hot to cold, then
back to cold and confirm temperature changes.
OK / NG
ESTN1005B
Check Memory Function
7. Set temperature at 90F or 32C, then press OFF switch.
ES5-2
8. Stop the engine.
9. Start the engine and press the AUTO switch.
10. Confirm that the set temperature remains at previous temperature.

OK / NG
Check Blower
11. Press fan switch (UP side) one time. Check blower should operate
on low speed.
OK / NG
ES5-3
ESTN1005B
12. Press fan switch (UP side) one more time, and continue checking
blow speed and fan symbol until all speeds are checked.
OK / NG
Check Discharge Air
13. Press mode switch four times and DEF button.
ES5-4
14. Each position indicator should change its shape and confirm that
discharge air comes out from the each indicator position.
OK / NG
15. Confirm that the compressor clutch is engaged (Visual inspection)
and intake door position changes to FRESH when the DEF is
selected.
OK / NG
ESTN1005B
Check Recirculation
16. Press REC switch and recirculation
indicator should illuminate.
OK / NG
ES5-5
17. Inpect intake door position change. (You should hear air flow or
door actuator sound change slightly.)
OK / NG
18. Turn the temperature dial counterclockwise until 18C (60F) is displayed and confirm cold air at discharge air outlets.
OK / NG
ES5-6
19. Turn the temperature dial clockwise until 32C (90F) is displayed
and confirm hot air at discharge air outlets.
OK / NG
ES5-7
ESTN1005B
Check ECON (Economy) Mode
20. Set temperature at 75F or 25C, then press ECON switch.
ES5-8
21. Display should indicate ECON (not AUTO). Confirm that the compressor clutch is not engaged (visual inspection).
OK / NG
Check AUTO Mode
22. Press AUTO switch
.
ES5-9
23. Display should indicate AUTO (not ECON). Confirm that the compressor clutch is engaged (sound or visual inspection).
OK / NG
ESTN1005B
Check Ambient Display
24. Press AMB switch.
ES5-10
25. Display should show the outside (ambient) temperature for approximately 5 seconds.
OK / NG
OPERATIONAL CHECK - MANUAL A/C
OK / NG
OK / NG
28. Check temperature control movement from hot to cold, then back
to cold and confirm temperature changes.
OK / NG
ESTN1005B
Check Blower
29. Turn fan control dial to 1st speed. Blower should operate on 1st
speed.
ES5-11
30. Turn fan control dial to 2nd speed. Blower should operate on 2nd
speed.
OK / NG
31. Continue checking blower speed until all four speeds are checked.
OK / NG
32. Leave blower on 4th speed.
Check Discharge Air

33. Press each mode switch and confirm discharge air comes out from
each position.
OK / NG
ES5-12
34. Confirm compressor clutch is engaged (visual inspection) and

intake door position is at FRESH when DEF switch is pressed.
OK / NG
ESTN1005B
35. Confirm intake door position is at FRESH when D/F switch is
pressed.
OK / NG
Check Recirculation
36. Press recirculation switch. Recirculation indicator should light.
OK / NG
ES5-13
37. Inspect intake door position change.

(You should hear blower sound change slightly.)
OK / NG
38. Confirm RECIRCULATION (REC) switch is canceled in DEF and D/
F mode.
OK / NG
39. Slide temperature control lever to full cold and confirm cold air at
discharge air outlets.
OK / NG
ES5-14
ESTN1005B
40. Slide temperature control lever to full hot and confirm hot air at discharge air outlets.
OK / NG
ES5-15
Check A/C Switch

41. Push A/C switch to turn ON and confirm indicator lamp comes on
when A/C is ON.
OK / NG
ES5-16
CHECK THE ENTIRE SYSTEM FOR REFRIGERANT LEAKS PRELIMINARY CHECK

* Perform a visual inspection of all refrigeration parts, fitting, hose
and components for signs of A/C lubricant leakage, damage and
corrosion.
* There are two refrigerant leak detectors.
1) Electrical leak detector
2) Fluorescent dye leak detector
* Position probe approximately 5 mm (3/16 in) away from point to be
checked.
ES5-17
10
ES5-18
ESTN1005B
* Move probe along component approximately 25 to 50 mm (1 to 2
in)/sec.
ES5-19
Procedure for Leak Test with Electrical Leak Detector
ES5-20
* Conduct leak test from high side to low side.
43. Clean the component to be checked and move leak detector probe
completely.
OK / NG
11
ESTN1005B
44. Perform a leak test for the following areas, and write the judgement
results.
OK / NG
OK / NG
OK / NG
OK / NG
OK / NG
OK / NG
ES5-21
* If leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat checks as outlined above.
* Do not stop when one leak is found. Continue to check for additional leaks at all system components.
12
ESTN1005B
Procedure for Leak Test with Fluorescent Dye Leak Detector
ES5-22
* Always wear fluorescence enhancing UV safety glasses to protect

your eyes and enhance the visibility of the fluorescent dye.
* Illuminate all components, fittings and lines. The dye will appear as
a bright green/yellow area at the point of leakage.
* If the suspected area is difficult to see, use an adjustable mirror or
wipe the area with a clean shop rag or cloth, then check the cloth
with a UV lamp for dye residue.
13
ESTN1005B
46. Perform a system performance check and verify the leak.
OK / NG
OK / NG
OK / NG
OK / NG
OK / NG
OK / NG
ES5-23
47. Inspect the condenser.

Inspection point
Judgement
Leakage
Leaves & twigs
Mud
Debris
Clean the core.
OK / NG
Rinse the core.
OK / NG
OK / NG
14
ESTN1005B
48. Inspect the drive belt(s).
Inspection point
1
2
Judgement
Cracks
Fraying
Wear and oil
Deflection
Tension
OK / NG
OK / NG
PERFORMANCE TEST FOR A/C

49. Park the vehicle indoors or in a shaded area.
50. Open the hood, start the engine, close all of the doors, and open
the windows.
51. Set temperature control to full cold position.
52. Set mode control to vent (face) position.
53. Turn recirculation switch ON.
54. Set fan speed to max. and turn A/C switch ON.
15
ESTN1005B
55. Run the engine at 1,500 rpm for 10 minutes.
56. Confirm discharge air temperature at center vent is cold.

OK / NG
* Verify that all inspections have been performed.
58. Disconnect proper exhaust ventilation.
59. Lower the hood.
INSTRUCTOR SIGN-OFF
16

N Step 1 Nissan

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POLICIES & OPERATIONS MAUNAL (POM)

NISSAN MOTOR CO., LTD.

Issued: March 2002

Edition: March 2002

Issued: March 2002

Application of the manual

Issued: March 2002

Technicians are mechanics or specialists actually working on service jobs.

STEP indicates the level of the training objectives required.

Course refers to a training segment consisting of a combination of topics. The training

Skill assessment refers to the evaluation of technicians by a person authorized by a NSC to

Issued: March 2002

N-STEP Basic Policies

Performance Based Learning

Training material package

Master Skill Matrix

Aim of skill assessment

Skill assessment timing

Skill assessment materials

Skill assessment flow

Technical qualification for each rank

Necessary conditions for each rank

Necessary conditions for keeping each rank

Training and certification record

Preparation for implementation of N-STEP

The topics for STEP 1, 2 and 3

Sample of training materials

Sample of assessment sheets

Issued: March 2002

N-STEP Policies & Operations Manual

I N-STEP Basic Policies

Issued: March 2002

N-STEP Policies & Operations Manual

The training presented at this

The training presented at this level will enable the

Expected period required for

New employees and apprentices

Contents of training course

1. Automatic Transmission Diagnosis

SENIOR ENGINE and

Issued: March 2002

N-STEP Policies & Operations Manual

Issued: March 2002

N-STEP Policies & Operations Manual

Issued: March 2002

N-STEP Policies & Operations Manual

II-1-2 Active Skill Matrix

EMTN2011A (GA Engine Timing Chain Replacement)

FATN2003A/WS1 (Multi-Link Suspension/Front)

Issued: March 2002

N-STEP Policies & Operations Manual

II-1-3 Training course description

STEP 1 training program

Issued: March 2002

N-STEP Policies & Operations Manual

STEP 2 engine training program

Issued: March 2002

N-STEP Policies & Operations Manual

STEP 2 electrical training program

Issued: March 2002

N-STEP Policies & Operations Manual

STEP 2 chassis training program

Issued: March 2002