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  #1  
Old 10-07-2007, 09:18 AM
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Arrow GU Patrol Reference # The Bible # Newbies Start Here for ZD30 Info #

Hello all, Version 2.5 is now up. Enjoy.

-----------------------------------------------------------------------------------------
NOTE* Go to Post *29 for latest links to versions in B&W and Colour
----------------------------------------------------------------------------------------
5-10-12 - 2.5
* Added Rim Offsets
* Added LED Indicator Lights for Bullbar Section
* Added LED Parking Light Bulbs Section
* Amended Fanbelt Section
* Added Recommended Fluids And Lubricants Section
* Added Vehicle Identification Number (VIN) How To Read Section

24-5-11 – 2.4
* Update bubbling dash section.
* Added Oil Filter section
* Added Air Filter section

8-4-11 – 2.3
* Added replacing Nissan steel bullbar indicator and park lights.
* Added section on belt tensioner.
* Added section on drive belt.
* Added section on alternator.
* Updated electronic speedo correction section.
* Updated VNT section.
* Update bubbling dash section.
* Updated trims - silver plastic on doors and dash section.

23-10-09 – 2.2
* Some word changes here and there
* Pollen filter kit
* Plastic door trims – wear
* Cracked Rear Chassis

22-05-09 - 2.1
* Added tip After/During an Engine Rebuild.
* Wheel Terminology formula re-write - just didn’t make sense, does now.
* Earthing Issues
* Speedo Correction
* Cleaned up some text to make more sense in some paragraphs

04-05-08 - 2.0
* Added Tyre terminology
* Added Wheel terminology
* Bubbling Dash
* Winch Considerations
* 5th Gear Failure GU
* Flat Mirror on GU4 (non convex)
* Free Wheeling Hub Diagrams - Manual
* Keyless Remote - Reprogramming
* Trailer Wiring Diagrams
* Mass Airflow Sensor (MAF)

26-11-07 – 1.9
* Restructured to find info easier
* Added section on oil pressure switches
* Added PCV Valve section
* Oil Pressure Sender install
* Oil Catch Can – How To Make Your Own and Install
* Removed the advanced and Expert Turbo 102 & 103 sections

25-9-07 – 1.8
* Added other tyre wear factors
* Added maintaining your tyres
* Updated air filter sections
* Updated thermal fan section
* Added stereo wiring diagrams section
* Added sway bar extension bracket section

3-9-07 - 1.7
* ZD Engine Protection – Oil Catch Can section - Updated
* How To Test If Your Vehicle Is Affected By Over Boost – Updated with new findings
* Why Synthetic Oils are Superior
* GU Drivers Seat Movement
* Steering Castor Correction – After Lift (added technical explanation)
* Intercoolers
* Air Filter Test Report - Spicers Iso 5011 Duramax
* Credit given to those who supplied info, well those I could remember or find

13-8-07 - 1.6
* Additions to Brake Proportioning Valve and EGR.

9-8-07 - 1.5
* Some major additions and changes to the PDF including a big section on Diesel Performance chips.
__________________
2005 GU4 ST 3.0 TD - Lots of Stuff, Genuine Dents and Scratches...

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  #2  
Old 26-12-2007, 12:33 PM
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Quote:
Originally Posted by big red
thanks to tuffgu&gq for this ...

Displaying the ECU fault codes. (ZD30) 3.0ltr TDi

1.Ensure that the battery is fully charged and that the engine is at normal operating temperature.

2.Ensure all accessories are switched off.

3.Switch the ignition On but do not start the engine.

4.Bridge terminals 8 (IGN) and 1 (CHK) on the diagnosis connector. The engine waring lamp should extinguish.

Connector diagram (looking front on) it looks like a wiring plug rectangle shape.

Top row
16,15,14,13,12,11,10,9
8,7,6,5,4,3,2,1
Bottom row

Bridging 8 (IGN) and 1 (CHK) with piece of wire (just push it into the slot)

5.Wait at least 2 seconds and then remove the wire bridging the terminals of the diagnosis connector. Any stored fault codes should now be able to be read.

6.Read the codes by counting the number of flashes of the Check Engine warning lamp. The code numbers are displayed as sets of separated by a 2.1 second pause. Each set comprises a series of 0.6 second flashes, a 0.9 second pause and a further series of 0.3 second flashes. The first set represents the first 2 digits of the code and the second set represents the last 2 digits.

Example 1. Code 0102 (Air Flow sensor) would be shown as one 0.6 second flash, a 0.9 second pause and two 0.3 second flashes.

Example 2. Code 1004 (Injection Pump fuel cut out system) would be shown as ten 0.6 second flashes, a 0.9 second pause and four 0.3 second flashes.

Note: To cease retrieving codes or to read codes again, turn the ignition Off and wait at least ten seconds before restarting the above procedure if necessary.
-----------------------------------------------------
Clearing Fault Codes:

1.After reading the fault codes as described, reconnect the wire bridging terminals 8 (IGN) and 1 (CHK) while the ignition is still On.

2.Wait at least two seconds and then remove the wire bridging the terminals. Any stored codes should now be erased.

Note: Fault codes are also erased if the battery is disconnected for more than 24 hours.

3.Road test the vehicle and check that there are no fault codes stored.

Fault codes
0102 Air Flow Sensor
0103 Coolant temp sender
0104 Vehicle speed sensor
0203 Throttle pedal switch
0208 Cooling Fan control
0301 Engine ECU
0402 Fuel temperature sensor
0403 Throttle pedal position sensor
0406* Intake air volume VNC system
0407 Crankshaft position sensor
0502* Battery voltage
0504 Auto Trans communication line
0701 Injection Pump –cam ring position sensor
0702 Injection Pump –TDC pulse sensor
0703 Injection Pump communication line
0704 Injection Pump –spill valve
0705 Injection Pump –ECU
0706 Injection Pump –spill valve
0707 Injection Pump injection timing control
0802 Engine ECU
0804* Engine ECU
0807 Stop lamp switch
0901 Engine ECU
0902 Engine ECU relay
0903* Engine ECU
0905 Intake air pressure sensor
1003 EGR volume control valve
1004 Injection Pump –fuel cut out system

* These codes do not illuminate the Check Engine warning lamp.

--Andrew
Bit more info on the fault codes complements of mikegq

Quote:
Originally Posted by mikegq
Infomation Courtesey of Repco Autotech Encyclopedia 2006

Fault Code Table

Code # Circuit and Status

0102 Mass Air Flow Sensor
Circuit, Sensor or ECM failure

0103 Engine Coolant Temperature Sensor
(excessively high or low voltage at ECM)
Circuit, Sensor or ECM failure

0104 Vehicle Speed Sensor
(signal not sent when vehicle is in motion)
Circuit, Sensor or ECM failure

0203 Accelerator Position Switch (incorrect signal sent to ECM)

Accelerator Position Switch fault or ECM failure


0208 Overheating Fault
Cooling Fan system failure, Engine coolant re-filling procedure not followed,
Cooling system faulty, Engine lubrication problem

0301 ECM 2, failure (calculation function is malfunctioning)
Internal IC failure

0402 Fuel Temperature Sensor
(incorrect signal for fuel temperature received)
Refer to Injection Pump Control Unit
Circuit, Sensor or ECM failure

0403 Accelerator Position Sensor
(out of range signal received from sensor or switch assembly)

Circuit malfunction, Accelerator Position Sensor failure,
Accelerator Pedal Dual Contact Position Switch failure, ECM failure

0406 INT/AIR volume (excessively high signal from Mass Air Flow Sensor)
Air Duct, Charge Air cooler, Variable Nozzle Turbo Charger Control System,
Variable Nozzle Turbo Charger, Mass Air Flow Sensor failure, Circuit malfunction

0407 Crankshaft Position Sensor
Circuit, Sensor or ECM failure

0502 Battery voltage (excessively high voltage sent to battery)
Incorrect jump starting, Battery, Alternator, ECM

0504 Automatic Transmission Communication Line

(ECM receives incorrect voltage from Transmission ECM)
Circuit malfunction, Automatic Transmission ECM

0505 No faults detected
Monitored circuits are operating normally

0701 Camshaft Position Sensor
(incorrect signal from the Injection Pump Control Unit)
Refer to Injection Pump Control Unit
Circuit malfunction, Injection Pump Control Unit

0702 Top Dead Centre Pulse Signal
(incorrect signal from the Injection Pump Control Unit)

Refer to Injection Pump Control Unit
Circuit malfunction, Injection Pump Control Unit

0703 Pump Communication Line
(incorrect signal from the Injection Pump Control Unit)
Refer to Injection Pump Control Unit
Circuit malfunction, Injection Pump Control Unit

0704 Spill Valve Circuit
Circuit malfunction, Injection Pump Control Unit

0705 Pump Control Module
Circuit malfunction, Injection Pump Control Unit failure

0706 Spill Valve

Circuit malfunction, Spill Valve, Injection Pump Control Unit

0707 Fuel Injection Timing Control System
Circuit malfunction, Injection Pump Control Unit failure, Poor fuel quality

0802 Barometric Pressure Sensor (built into the ECM)
Internal circuit malfunction, ECM failure

0804 ECM internal input signal processing function malfunctioning
ECM failure

0807 Brake Light Switch
Circuit malfunction, Switch failure


0901 ECM Failure (calculation function is malfunctioning)
Internal IC failure

0902 ECM Relay (incorrect voltage received by the ECM from the relay)
Main Relay malfunction, Circuit malfunction

0903 ECM Internal input signal processing function malfunctioning
ECM failure

0905 Turbo Pressure
Circuit malfunction, Charge Air Pressure Sensor failure

1003 EGR Volume Control Valve
Circuit malfunction, EGR Volume Control Valve failure

1004 Fuel Cut System
Circuit malfunction, Injection Pump Control Unit failure, ECM failure

1401 to
1408 Nissan Anti Theft System

Refer to Anti Theft system information
Cheers,
Whitie
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  #3  
Old 14-09-2009, 11:09 AM
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Hi to all who have put this document together.
Great stuff and very usefull for a new gu owner.

Afterdoing the vnt adjustment what seemed to be a hundred times.........
i found that the adjusting screw actually has a 2.5mm hex key head which makes it so much easier to adjust and hold when tightening the lock nut.

Just thought i would share this with everyone.....

cheers.
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  #4  
Old 17-11-2009, 11:31 AM
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Post Clean your MAF BEFORE replacing it.

Hello all GU series 3 DI ZD30 owners. I discovered you can remove the MAF sensor & spray Electronic Circuit Board cleaner into the air inlet of the sensor. Gently blow dry & re-install. Clear your fault codes as discussed above & your problem is fixed with power restored. Cost of the cleaner about $15 dollars. It worked for me!
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  #5  
Old 31-12-2009, 03:33 PM
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Default MAF sensor voltages for the 3ltr disels

Here are the pinouts and voltages to test the MAF:

Looking at the back of the connector with it connected to the MAF, the very left hand side is pin 1 which is normally empty and the very right hand side is pin six.

1 - empty
2 - battery
3 - ground (do not use this as the ground of the multi-meter)
4 - Voltage sent from MAF to the ECU (Di - idle to about 4000rpm - 1.5-1.9 to 4v), (CRD - idle to about 4000rpm - 1.6-2.3 to 3.4v) There should be a linear voltage rise as the rpm increase, also, the idle voltages stated are with the EGR in place, expect higher idle voltages if the EGR has been blocked.

For the CRDs
5 - intake air temperature sensor (5v)
6 - intake air temperature ground

On the earlier Di 5 pin models, pin 5 is empty which is on the far right hand side. The MAF output is on pin 1, pin 2 is 5v and pin 3 is ground.

Cheers,
Whitie
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  #6  
Old 21-01-2010, 09:33 PM
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Default MAF Cleaning

First post of the MAF Cleaning thread:

Hi all, it has been a 20k since I blocked the EGR and 13k since I installed the catch can on the truck so I thought I would post an update on the state of the MAF.

As I do an oil change every 10k, I had also decided to take out the MAF for an inspection at the same time as the oil change ever since my MAF failed 20k ago.

This is the first real inspection since I installed the catch can and I am happy to post that the MAF looked very clean compared to the state my previous one was in when it failed which was black everywhere (I believe due to blowby)!

This time I could see both the metal bar and the metal plate that the MAF uses for sensing and calibrating and both looked pretty clean. Since the motor is running sweet, I was tossing up if there was any merit in giving the MAF a clean anyway since it was out.

Well I did clean it thinking that this would be a good test anyway as I did not touch anything else on the motor and when I took it for a drive today - to my surprise, there was a difference! The motor seemed to be crisper as it revved through the range?

I have now decided to clean the MAF at 5k intervals with CRC contact cleaner (purchased from an electronic store), I just spray it onto the metal bar at the end of the MAF and the metal plate just before that bar and let the CRC evaporate. I do not physically touch anything and the spray leaves no residue.

Disclaimer:- I do not believe that the MAF can be damaged by cleaning this way as the electronics seem to be sealed and I am using electronic contact cleaner anyway - having said that, the old saying "if it ain't broke - don't fix it" comes to mind so if you do want to clean the MAF - be aware that we are all responsible for what we choose to do to our motors so it is done at our own risk


All the best and hope you all had a great Fathers Day

Whitie


Update: For those of us that have not played with a MAF yet, here are some pics..





I Find it easier to remove when I pull up the air filter cover.



After you remove the two screws, you need to wedge a small screwdriver between the MAF and it's housing - pry it open evenly from the top, middle and the bottom.



Spray the metal plate and the metal bar (which you can see better on the picture below) with electronic contact cleaner that leaves no residue.



I also clean the plate at the bottom of the MAF - I do not know it this achieves anything but it gives me a warm and fuzzy feeling to know that it is clean

Happy cleaning,
Whitie
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  #7  
Old 23-02-2010, 11:31 AM
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Quote:
Originally Posted by darrell View Post
Can any body tell me were the air pressure sensor located I have a 0905 and a 0707 code coming up could these codes be related somehow any help would be great I have a 2002 DDTI ZD30 nissan patrol

Darrell,

The sensor is located at the bottom right side of the intercooler nearest the oil filler cap.

My initial though is I don't think that they are related, but with the way the ECU is setup, it could be.

Here is a copy out of my manual on the error code 0905. There are pictures, but not shown here.

Hope it helps,
Smiley69

DTC 0905 TURBO PRESSURE ZD30DDTi

Component Description
The charge air pressure sensor detects pressure in the exit side of the charge air cooler. The sensor output voltage to the ECM increases as pressure increases. The charge air pressure sensor is not used to control the engine system under normal conditions.

ECM Terminals and Reference Value
Specification data are reference values, and are measured between each terminal and ground.


CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the ECM’s transistor. Use a ground other than ECM terminals, such as the ground.

TERMINAL NO.__WIRE COLOR________ITEM____________CONDITION DATA__(DC Voltage)
_____46____________L________Charge air pressure sensor_ Engine is running.____Approximately 2.0V
_________________________________________________W arm-up condition
_________________________________________________I dle speed

Diagnostic Procedure

On Board Diagnosis Logic
Malfunction is detected when ... Check Items (Possible Cause)
+ An excessively high or low voltage from the sensor is sent to ECM.
+ Harness or connectors (The sensor circuit is open or shorted.)
+ Charge air pressure sensor

1 CHECK CHARGE AIR PRESSURE SENSOR POWER SUPPLY CIRCUIT
1. Stop engine.
2. Disconnect charge air pressure sensor harness connector.
3. Turn ignition switch “ON”.
4. Check voltage between charge air pressure sensor terminal 1 and ground with CONSULT-II or tester.
OK or NG
OK c GO TO 2.
NG c Repair harness or connectors.
2 CHECK CHARGE AIR PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch “OFF”.
2. Check harness continuity between charge air pressure sensor terminal 3 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK c GO TO 4.
NG c GO TO 3.
3 DETECT MALFUNCTIONING PART
Check the following.
+ Harness connectors F6, M51 (A/T models)
+ Harness connectors M88, E106 (A/T models)
+ Harness for open or short between ECM and charge air pressure sensor
+ Harness for open or short between TCM (Transmission control module) and charge air pressure sensor
c Repair open circuit or short to ground or short to power in harness or connectors.
4 CHECK CHARGE AIR PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 46 and charge air pressure sensor terminal 2. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK c GO TO 5.
NG c Repair open circuit or short to ground or short to power in harness or connectors.
5 CHECK CHARGE AIR PRESSURE SENSOR
1. Remove charge air pressure sensor with its harness connector connected.
2. Turn ignition switch “ON”.
3. Use pump to apply pressure to charge air pressure sensor as shown in the figure.
CAUTION:
+ Always calibrate the pressure pump gauge when using it.
+ Inspection should be done at room temperature [10 - 30°C (50 - 86°F)].
4. Check the output voltage between charge air pressure sensor terminal 2 and engine ground.
OK or NG
OK c GO TO 6.
NG c Replace charge air pressure sensor.
6 CHECK INTERMITTENT INCIDENT
Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.
c INSPECTION END
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  #8  
Old 20-10-2010, 09:54 PM
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Quote:
Originally Posted by XQZME View Post
Hi Whitie,

I noticed you have a K&N air filter... I have heard about the oil in the filters giving fault to the MAF... have you experienced any problems?

Have you experienced increased in performance?

Cheers!
You have heard correctly, the way I get around it is after I oil the filter, let it set and install it, I go for a spin down the highway for 10 minutes or so then take the MAF out and give it a clean.

I have not had a problem using that process after I oil the K&N, bear in mind that I only use it for blacktop stuff, in the scrub, I change over to the Nissan filter.

As for any increase in performance, no, you do not really notice it on a turbo diesel, a NA diesel or petrol would be a different story. It does however minimise the vacuum between the filter and the turbo which means less is sucked out of the PCV system (same as when the factory filter is clean).

The main benefit to me is the cost saving because I change the air filter every 10k, with the K&N I just clean it instead.

Cheers,
Whitie
__________________

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Old 18-08-2011, 03:00 PM
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Hi Aksniss, I have experienced a problem similar to yuor described overboost protection. I have a 2006 GU 3.0 TDI. No modifications at all. I was driving at approx 80km per hr and had only been doing so for about half a km. I put foot on excellerator to pick up and nothing happened except the check engine light came on. No picky upy speedy. Kept on putting foot down and still no picky upy speedy. Get to end of road, approx 5 km had to slow down to turn corner. Go around corner and pick up speed okay now to 110km per hr. Engine light stayed on until I turned off ingnition and then when turned back on no check engine light.

Is this the same or similar problem to that you describe.

Many thanks,

Whitie, could you give an opinion on the posssible cause please?
Ta, Mark
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Last edited by Mark Davies; 24-08-2011 at 10:34 AM. Reason: See if Whitie may be able to advise
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Old 30-08-2011, 07:53 AM
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Quote:
Originally Posted by Mark Davies View Post
Hi Aksniss, I have experienced a problem similar to yuor described overboost protection. I have a 2006 GU 3.0 TDI. No modifications at all. I was driving at approx 80km per hr and had only been doing so for about half a km. I put foot on excellerator to pick up and nothing happened except the check engine light came on. No picky upy speedy. Kept on putting foot down and still no picky upy speedy. Get to end of road, approx 5 km had to slow down to turn corner. Go around corner and pick up speed okay now to 110km per hr. Engine light stayed on until I turned off ingnition and then when turned back on no check engine light.

Is this the same or similar problem to that you describe.

Many thanks,

Whitie, could you give an opinion on the posssible cause please?
Ta, Mark
Hi.
What to do when that happens!
Stop the vehicle and the engine off, waiting at least 1 minute.
Then reconnect it and check engine light has faded and the acceleration of the vehicle responds.
If yes, ok.
If not, or if you happen to come back more often, consider changing the MAF sensor. And problem solved.
Bye
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  #11  
Old 14-09-2011, 12:25 AM
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If anyone needs it, PM me with an email address and I'll send my copy (if your email is up to it, it's a big file). I think I updated my version about two months ago.
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Old 20-09-2011, 11:39 AM
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Right click on the link, go to "Save link as...", save it onto your computer where ever you like.
I tried to open in a webpage and it didn't work, saved onto the computer and opened it no worries.
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steel bar, IPF's, snorkel, rear bar, dual-wheel carrier + more to come hopefully
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  #13  
Old 24-09-2011, 02:52 PM
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Default Maf

Hey Guys I am new to this forum. Like a lot of feeds i read over and over about over boost and MAF sensors playing havoc with the 3 ltr patrols. I can tell you now you can eliminate your over boost forever and run 20psi +. I have been so frustrated with so much talk about how to fix this problem. Well after some research and extensive discussion with Monster Performance Mackay i agreed to let them convince me they could remedy my problem . Well more power the turbo does not drop out on steep climbs running close to 20psi Boost with no side afects at all boy am i impressed. If my story about over boost and lack of power is the same as your 3 ltr patrol then give these guys a ring. By the way these guys can get any diesel hauling so give them a call. You can see the dyno charts and i was in the booth when the dyno was run so no BS.
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  #14  
Old 16-11-2011, 02:22 PM
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For anyone that is interested.

I stumbled accross this website that has a full service maul of all Nissans inc all Patrol Models.

For example http://nissan4u.com/parts/patrol_gr/er_y61/2000_6/ is the link for my 2000 GU.

Thanks
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4.2T 2000 GU II ST
35" MTZ
SS 3" Flexy's, Locked & Accessories
Lunacy Unanimous Club #3 (Elmo)
Contact: 0433 708 376
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Old 18-11-2011, 02:25 PM
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http://static.nissan4u.com/epc_img/25542011287811.png
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Deccers
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  #16  
Old 22-12-2011, 10:13 AM
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Quote:
Originally Posted by Border patrol View Post
Just went to get crc contact cleaner and found crc maf sensor cleaning spray. Was $25 and worked really well maf sensor looked brand new after only a couple of sprays! Sounds expensive for a can of spray but way cheaper then an engine rebuild
It's good stuff, just make sure you spray it from the correct distance and allow it to evaporate completely before reinstalling and powering up, otherwise you will be up for a new MAF

Cheers,
Craig
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Old 11-01-2012, 09:53 AM
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Originally Posted by Philldemb View Post
Hi guys, just reading all of this info and it's confusing but some of it is relevant to what I have done. I have a 2008 Patrol 3 litre manual and it has started going into limp mode for the past 2 weeks. Today was the worst trying to go to the Gold Coast with nothing short of 20 or more limp modes from Cleveland to Helensvale. Has anyone got any ideas as to what is going on. I have already removed and cleaned the MAF (last week) but no change just getting worse.
Read the section starting on page 12 of the reference document "Test If Your Vehicle Is Affected By Over Boost – How To".

AKSNISS
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  #18  
Old 11-01-2012, 10:13 AM
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Cleaning the MAF will not always work, you may need to replace it.
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  #19  
Old 05-03-2012, 11:42 AM
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Default New Alernator, still no charge to battery

I'm a newbie to the Nissan Patrol...
Just got a 2002 GU3 with the ZD30.....and starting to do it up.....awesome 4x4
I had sub tank, park brake and battery light come on....changed the alternator...problem went away for about 300km, but then came back. Not getting any charge to battery.... alternater is pumping out charge(tested the terminals there)....Is there a relay or fuse that could be blown..... had a quick look at fuses in engine bay near battery, but all looked ok...
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Old 23-05-2012, 12:34 AM
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Hi, in my 2002 ZD30 Patrol data port I have terminals 1,3,4,5,8 9,12,13,16 populated, if terminal 8 is (IGN) and 1 is (CHK) on the diagnosis connector what are others terminals for?? wich one is ground, wich are others?? thanks.
Julioenr
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