NEW GU REFERENCE DOCUMENT
Posted: 19 May 2009 20:01
Hi to all, especially GU 3.0D owners. Look on Aussie web site they just updated the latest ref. doc. for the Patrol. Load it off , its on PDF format. I regard it as the Patrol Bible. Very very informative and excellent info.
Koos
Hello all, Version 2.0 is now up. Enjoy.
Download links are back up and running again.
-----------------------------------------------------------------------------------------
Download black and white version (11 MB) here: ZD30 Y61 Reference Document BW.
http://www.video2000.com.au/zd30/ZD30%2 ... -%20BW.pdf
(JohnBoy ge-Fix) :idea:
Download colour version (15 MB) here: ZD30 Y61 Reference Document Colour.
http://www.video2000.com.au/zd30/ZD30%2 ... Colour.pdf
(JohnBoy ge-Fix) :idea:
Thank you Koos! I'm adding the TOC below and making this pots a sticky.
CONTENTS
INTRODUCTION..................................................................................... 5
ZD 30 SPECIFIC (Mostly) .......................................................................... 6
Engine Protection............................................................................................ 6
Spares ...................................................................................................... 8
After/During an Engine Rebuild........................................................................ 9
Reliability ....................................................................................................10
Test If Your Vehicle Is Affected By Over Boost – How To ............................................12
How I Tested My Own Vehicle.........................................................................12
In Summary...............................................................................................13
ELECTRICALS ......................................................................................15
Air Bag(s) System - Disabling..............................................................................15
ECU Fault Codes - GU ......................................................................................16
Manual Extraction.......................................................................................16
Fault Code Table ........................................................................................16
Clearing Fault Codes....................................................................................18
Key in ignition alarm.......................................................................................19
Spot Light Wiring Diagram.................................................................................20
Stereo Wiring Diagrams ....................................................................................21
MAINTENANCE.....................................................................................22
Maintaining Your Tyres.....................................................................................22
Tyre Inflation ............................................................................................22
Checking Tyre Tread....................................................................................22
Wear On Both Edges: UNDER INFLATION ............................................................22
Wear In Centre: OVER INFLATION ....................................................................22
Cups or Dips in the tread: WORN PARTS.............................................................22
Sawtooth edges: MISALIGNMENT......................................................................22
Tyre Balancing...........................................................................................23
Vehicle Alignment .......................................................................................23
Tyre Rotation ............................................................................................23
Repairing Tyres ..........................................................................................23
MECHANICAL.......................................................................................24
5th Gear Failure GU ........................................................................................24
Belt Tensioners ZD30.......................................................................................25
Exhaust Gas Reticulation System (EGR).................................................................26
EGR Blocking – How To.....................................................................................28
Principle ..................................................................................................28
Tools.......................................................................................................28
Disassembling ............................................................................................29
To reassemble ...........................................................................................29
EGR Technical Diagram....................................................................................30
Earthing Issues...............................................................................................31
Flat Mirror on GU4 (non convex) .........................................................................32
Free Wheeling Hub Diagrams- Manual...................................................................33
Keyless Remote - Reprogramming .......................................................................34
Oil Catch Can – How To Make Your Own and Install...................................................35
How to do it..............................................................................................35
Bits required and costs.................................................................................41
Installation ...............................................................................................41
Oil Pressure Gauge Sendor Install ........................................................................44
Introduction..............................................................................................44
What you will need .....................................................................................45
Nissan Patrol Reference Document
Page 3 of 120
How to do it..............................................................................................45
Rear Brake Force Less Due To Lift Kit – Brake Proportioning Valve ................................48
What Is It – A Technical Explanation.................................................................48
What Is It – A Plain English Explanation .............................................................48
Putting The Above Technical Jargon Simply........................................................49
How To Do And Examples ..............................................................................49
Cracked Rear Chassis.......................................................................................52
Speedo Correction..........................................................................................53
Introduction..............................................................................................53
How Do You Fix Your Speedo Being Out?............................................................53
Steering Castor Correction – After Lift ..................................................................57
Which Kit .................................................................................................57
Technical Explanation..................................................................................57
Other Tyre Wear– Simple Explanations ..............................................................58
Sway Bar Extension Bracket Kit – After Lift ............................................................59
VNT Screw Adjustment.....................................................................................61
TRIMS, MOULDINGS ETC..........................................................................63
Bubbling Dash................................................................................................63
Drivers Seat Movement - GU ..............................................................................64
Pollen Filter Kit .............................................................................................65
Trims - Silver Plastic on Doors and Dash................................................................66
WHITE PAPERS, BULLETINS AND PRODUCT TESTING........................................67
Air Filter Test Report - Spicers ISO 5011 Duramax ....................................................67
Scope......................................................................................................67
ISO 5011 Test ............................................................................................67
Capacity and Efficiency ................................................................................67
Flow Restriction.........................................................................................67
Filter Efficiency .........................................................................................68
Accumulative Capacity.................................................................................68
Accumulative Gain......................................................................................69
Initial Restriction........................................................................................69
Dirt Passed Versus Total Test Time ..................................................................70
Dust Loading .............................................................................................70
Restriction to Flow......................................................................................71
Test Data Tables ........................................................................................71
The Story Behind The Test.............................................................................75
Chip Tuning or Performance Modules or Electronic Tuning Devices................................77
What Are They...........................................................................................77
Diesel Tuning Devices ..................................................................................77
Chips And Computers - How Do They Go About Improving Performance? .....................78
Basic Basic Basic Universal Fuel Increase Units....and Cheap To Manufacture ...............78
Basic Basic....Multi Point Fuel Adjustment .........................................................79
Desirable Fuel Mapping.................................................................................79
Independent Injection Timing.........................................................................80
Engine Durability ........................................................................................81
Programming, Numbers, Data - The Stuff That Goes Into a Computer.........................82
Conclusions...............................................................................................83
Differentials (Diffs).........................................................................................84
What Are They...........................................................................................84
A Standard (Open) Differential .......................................................................84
Traction-Adding Devices ...............................................................................84
Whats A Locking Differential Or Locker .............................................................85
Intercoolers..................................................................................................87
What Are They...........................................................................................87
Air To Air Intercoolers..................................................................................87
Nissan Patrol Reference Document
Page 4 of 120
Front Mounting An Intercooler? .......................................................................88
Air-To-Liquid Intercoolers .............................................................................88
Mass Airflow Sensor (MAF).................................................................................89
What Is It .................................................................................................89
Hot Wire Sensor .........................................................................................89
How To Remove .........................................................................................90
Nissan Bulletin On ZD30 Engine Oil – Sept 2004........................................................91
PCV Valve ....................................................................................................92
Explanation...............................................................................................92
History ....................................................................................................92
PCV System...............................................................................................93
Operation.................................................................................................93
Trailer Wiring Diagrams....................................................................................95
Turbo Tech 101 ( Basic ) By Garrett .....................................................................96
Tyre Terminology ......................................................................................... 102
All Terrain Tires ....................................................................................... 102
Mud Terrain Tyres..................................................................................... 102
Bias-Ply Tyres and Radial Tyres..................................................................... 102
Radial ................................................................................................... 103
Reading a Tire ......................................................................................... 104
Light Truck Sidewall Designations.................................................................. 106
Tire Components ...................................................................................... 106
Winch Considerations .................................................................................... 109
Major Considerations ................................................................................. 109
Other Considerations ................................................................................. 110
Winch Components.................................................................................... 110
Winch Solenoid ........................................................................................ 112
Wheel Terminology ....................................................................................... 113
A few terms ............................................................................................ 113
Why Synthetic Oils Are Superior........................................................................ 115
Engine Oil Basics ...................................................................................... 115
What Is Lubricating Oil? .............................................................................. 115
There Are Four Different Types of Motor Oil Base Stocks ...................................... 115
And There Are a Variety of Additives .............................................................. 115
Let's Look at Conventional (Mineral) Oil........................................................... 116
Hydroprocessed Oil ................................................................................... 116
Severe Hydroprocessed Oil .......................................................................... 116
Semi-Synthetics........................................................................................ 116
Synthetics .............................................................................................. 116
Base Oils Summary.................................................................................... 117
So What Does This All Mean? ........................................................................ 117
There Is a Clear Difference in Motor Oil Protection and Performance....................... 118
GLOSSARY ........................................................................................ 119
Koos
Hello all, Version 2.0 is now up. Enjoy.
Download links are back up and running again.
-----------------------------------------------------------------------------------------
Download black and white version (11 MB) here: ZD30 Y61 Reference Document BW.
http://www.video2000.com.au/zd30/ZD30%2 ... -%20BW.pdf
(JohnBoy ge-Fix) :idea:
Download colour version (15 MB) here: ZD30 Y61 Reference Document Colour.
http://www.video2000.com.au/zd30/ZD30%2 ... Colour.pdf
(JohnBoy ge-Fix) :idea:
Thank you Koos! I'm adding the TOC below and making this pots a sticky.
CONTENTS
INTRODUCTION..................................................................................... 5
ZD 30 SPECIFIC (Mostly) .......................................................................... 6
Engine Protection............................................................................................ 6
Spares ...................................................................................................... 8
After/During an Engine Rebuild........................................................................ 9
Reliability ....................................................................................................10
Test If Your Vehicle Is Affected By Over Boost – How To ............................................12
How I Tested My Own Vehicle.........................................................................12
In Summary...............................................................................................13
ELECTRICALS ......................................................................................15
Air Bag(s) System - Disabling..............................................................................15
ECU Fault Codes - GU ......................................................................................16
Manual Extraction.......................................................................................16
Fault Code Table ........................................................................................16
Clearing Fault Codes....................................................................................18
Key in ignition alarm.......................................................................................19
Spot Light Wiring Diagram.................................................................................20
Stereo Wiring Diagrams ....................................................................................21
MAINTENANCE.....................................................................................22
Maintaining Your Tyres.....................................................................................22
Tyre Inflation ............................................................................................22
Checking Tyre Tread....................................................................................22
Wear On Both Edges: UNDER INFLATION ............................................................22
Wear In Centre: OVER INFLATION ....................................................................22
Cups or Dips in the tread: WORN PARTS.............................................................22
Sawtooth edges: MISALIGNMENT......................................................................22
Tyre Balancing...........................................................................................23
Vehicle Alignment .......................................................................................23
Tyre Rotation ............................................................................................23
Repairing Tyres ..........................................................................................23
MECHANICAL.......................................................................................24
5th Gear Failure GU ........................................................................................24
Belt Tensioners ZD30.......................................................................................25
Exhaust Gas Reticulation System (EGR).................................................................26
EGR Blocking – How To.....................................................................................28
Principle ..................................................................................................28
Tools.......................................................................................................28
Disassembling ............................................................................................29
To reassemble ...........................................................................................29
EGR Technical Diagram....................................................................................30
Earthing Issues...............................................................................................31
Flat Mirror on GU4 (non convex) .........................................................................32
Free Wheeling Hub Diagrams- Manual...................................................................33
Keyless Remote - Reprogramming .......................................................................34
Oil Catch Can – How To Make Your Own and Install...................................................35
How to do it..............................................................................................35
Bits required and costs.................................................................................41
Installation ...............................................................................................41
Oil Pressure Gauge Sendor Install ........................................................................44
Introduction..............................................................................................44
What you will need .....................................................................................45
Nissan Patrol Reference Document
Page 3 of 120
How to do it..............................................................................................45
Rear Brake Force Less Due To Lift Kit – Brake Proportioning Valve ................................48
What Is It – A Technical Explanation.................................................................48
What Is It – A Plain English Explanation .............................................................48
Putting The Above Technical Jargon Simply........................................................49
How To Do And Examples ..............................................................................49
Cracked Rear Chassis.......................................................................................52
Speedo Correction..........................................................................................53
Introduction..............................................................................................53
How Do You Fix Your Speedo Being Out?............................................................53
Steering Castor Correction – After Lift ..................................................................57
Which Kit .................................................................................................57
Technical Explanation..................................................................................57
Other Tyre Wear– Simple Explanations ..............................................................58
Sway Bar Extension Bracket Kit – After Lift ............................................................59
VNT Screw Adjustment.....................................................................................61
TRIMS, MOULDINGS ETC..........................................................................63
Bubbling Dash................................................................................................63
Drivers Seat Movement - GU ..............................................................................64
Pollen Filter Kit .............................................................................................65
Trims - Silver Plastic on Doors and Dash................................................................66
WHITE PAPERS, BULLETINS AND PRODUCT TESTING........................................67
Air Filter Test Report - Spicers ISO 5011 Duramax ....................................................67
Scope......................................................................................................67
ISO 5011 Test ............................................................................................67
Capacity and Efficiency ................................................................................67
Flow Restriction.........................................................................................67
Filter Efficiency .........................................................................................68
Accumulative Capacity.................................................................................68
Accumulative Gain......................................................................................69
Initial Restriction........................................................................................69
Dirt Passed Versus Total Test Time ..................................................................70
Dust Loading .............................................................................................70
Restriction to Flow......................................................................................71
Test Data Tables ........................................................................................71
The Story Behind The Test.............................................................................75
Chip Tuning or Performance Modules or Electronic Tuning Devices................................77
What Are They...........................................................................................77
Diesel Tuning Devices ..................................................................................77
Chips And Computers - How Do They Go About Improving Performance? .....................78
Basic Basic Basic Universal Fuel Increase Units....and Cheap To Manufacture ...............78
Basic Basic....Multi Point Fuel Adjustment .........................................................79
Desirable Fuel Mapping.................................................................................79
Independent Injection Timing.........................................................................80
Engine Durability ........................................................................................81
Programming, Numbers, Data - The Stuff That Goes Into a Computer.........................82
Conclusions...............................................................................................83
Differentials (Diffs).........................................................................................84
What Are They...........................................................................................84
A Standard (Open) Differential .......................................................................84
Traction-Adding Devices ...............................................................................84
Whats A Locking Differential Or Locker .............................................................85
Intercoolers..................................................................................................87
What Are They...........................................................................................87
Air To Air Intercoolers..................................................................................87
Nissan Patrol Reference Document
Page 4 of 120
Front Mounting An Intercooler? .......................................................................88
Air-To-Liquid Intercoolers .............................................................................88
Mass Airflow Sensor (MAF).................................................................................89
What Is It .................................................................................................89
Hot Wire Sensor .........................................................................................89
How To Remove .........................................................................................90
Nissan Bulletin On ZD30 Engine Oil – Sept 2004........................................................91
PCV Valve ....................................................................................................92
Explanation...............................................................................................92
History ....................................................................................................92
PCV System...............................................................................................93
Operation.................................................................................................93
Trailer Wiring Diagrams....................................................................................95
Turbo Tech 101 ( Basic ) By Garrett .....................................................................96
Tyre Terminology ......................................................................................... 102
All Terrain Tires ....................................................................................... 102
Mud Terrain Tyres..................................................................................... 102
Bias-Ply Tyres and Radial Tyres..................................................................... 102
Radial ................................................................................................... 103
Reading a Tire ......................................................................................... 104
Light Truck Sidewall Designations.................................................................. 106
Tire Components ...................................................................................... 106
Winch Considerations .................................................................................... 109
Major Considerations ................................................................................. 109
Other Considerations ................................................................................. 110
Winch Components.................................................................................... 110
Winch Solenoid ........................................................................................ 112
Wheel Terminology ....................................................................................... 113
A few terms ............................................................................................ 113
Why Synthetic Oils Are Superior........................................................................ 115
Engine Oil Basics ...................................................................................... 115
What Is Lubricating Oil? .............................................................................. 115
There Are Four Different Types of Motor Oil Base Stocks ...................................... 115
And There Are a Variety of Additives .............................................................. 115
Let's Look at Conventional (Mineral) Oil........................................................... 116
Hydroprocessed Oil ................................................................................... 116
Severe Hydroprocessed Oil .......................................................................... 116
Semi-Synthetics........................................................................................ 116
Synthetics .............................................................................................. 116
Base Oils Summary.................................................................................... 117
So What Does This All Mean? ........................................................................ 117
There Is a Clear Difference in Motor Oil Protection and Performance....................... 118
GLOSSARY ........................................................................................ 119
