Nissan Truck/Pathfinder D21 1989 Service Manual (P/N SM9E-0D21U0)

Nissan factory service manual P/N SM9E-0D21U0, July 1988 edition for 1989 Truck and Pathfinder D21-series models. Covers Z24i and VG30i engines, 2WD and 4WD configurations, and the listed U.S. and Canadian builds.

PDF Bookmarks and Wiring Detail

Search and diagram navigation: Text search is not available. Embedded bookmarks open the main sections. Small wire-color codes and terminal labels on the checked diagrams are readable when enlarged; the overall circuit diagram requires substantial zooming.

One printable, English-language PDF with 1,370 pages: 1,355 numbered section pages, including seven notes pages; two opening pages; ten blank pages; and three closing reference pages—the overall circuit diagram, conversion table, and Quick Reference Chart.

Powertrain Repair and Vehicle-System Diagnosis

The selected coverage highlights below are a preview; additional topics include tire rotation and seat-belt inspection.

• Engine repair: Step-by-step engine removal, cylinder-head service, oil-pan work, timing-belt or timing-chain procedures, compression testing, and internal overhaul.

• Fuel and emissions: E.C.C.S. self-diagnosis, symptom charts, intermittent-problem simulation, ECU input/output checks, and fuel- and emission-control component tests.

• Clutch and transmissions: Hydraulic clutch service, manual-transmission overhaul, automatic-transmission road and pressure tests, valve-body repair, and lock-up diagnosis.

• Transfer and final drives: TX10 overhaul, propeller-shaft service, differential adjustment, and H233B limited-slip inspection and repair.

• Chassis repair: Free-running hubs, drive shafts, wheel bearings, suspension, wheel alignment, disc and drum brakes, and steering-gear and pump overhaul.

• Body and climate control: Doors, glass, power accessories, heater controls, refrigerant service, A/C performance testing, and DKV-14C compressor work.

• Electrical diagnosis: Starting and charging tests, system-specific wiring diagrams, connector identification, harness layouts, and Super Multiple Junction terminal arrangements.

Suited to professional technicians, independent repair shops, and experienced DIY owners comfortable with electrical testing, precision measurement, and the specified special service tools.

Matching the Vehicle and Drivetrain

The identification tables connect engines, transmissions, differential carriers, body styles, wheelbases, grades, and destination codes; diagrams show the vehicle, engine, transmission, and transfer serial-number locations.

They distinguish Regular Cab, King Cab, and Heavy Duty trucks from Pathfinder Wagon and Van configurations, with STD, E, XE, and SE grades. Matching these identifiers helps select the appropriate repair procedures and service data for the vehicle.

Two-wheel-drive trucks use H190A or H233B rear carriers. Four-wheel-drive builds pair R180A or R200A front carriers with C200 or H233B rear units. Differential coverage includes bearing preload, backlash, and tooth-contact adjustment; TX10 material also addresses control linkage and oil-seal replacement.

Engine Internals, Lubrication, and Cooling

Internal inspection: Factory measurement methods and limits cover heads, valves, guides, camshafts, pistons, rings, connecting rods, crankshafts, bearings, cylinder bores, and flywheels. Maintenance coverage includes drive-belt and ignition checks, fuel-line inspection, and normal- and severe-service schedules.

Timing and sealing: The VG30i uses a timing belt; the Z24i uses a timing chain. The VG30i procedures distinguish left- and right-hand camshaft sprockets and warn that rotating the crankshaft and camshafts independently can cause valve-to-piston contact.

The oil-pan procedure specifies a seal cutter and explains how improper separation can damage the pan flange or the aluminum mating face at the oil pump or rear seal retainer.

Lubrication and cooling: The Lubrication Circuit accompanies oil-pressure testing and oil-pump inspection. Cooling coverage includes radiator-cap and leakage tests, thermostat checks, and water-pump removal and installation. The VG30i water pump is replaced as a complete assembly.

E.C.C.S. Fault Diagnosis

The Engine and Emission Control System Chart, fuel- and air-flow descriptions, and E.C.C.S. Wiring Diagram explain the system relationships. The diagnostic worksheet records operating conditions before symptom tables address no-start, hard-start, idle, stall, and driveability complaints.

Component checks distinguish crank-angle and temperature sensors, air-flow and throttle inputs, injectors, relays, and ECU power and grounds. EGR, evaporative-emission, crankcase-emission, and air-injection inspections are also covered.

Transmission Inspection and Overhaul

F4W71C, FS5W71C, and FS5R30A manual-transmission chapters include synchronizer and gear inspection, disassembly, and reassembly. Automatic coverage separates the 71B family—L4N71B and E4N71B—from the RE4R01A, with shift-schedule charts, stall and line-pressure tests, internal component repair, and RE4R01A self-diagnosis.

The valve-body service notes emphasize keeping precision parts and springs in their original positions and sequence to preserve correct hydraulic-control operation after reassembly.

Axles, Suspension, Brakes, and Steering

Axles and suspension: Separate procedures address manual- and auto-lock hubs, hub and rotor assemblies, knuckle spindles, front drive shafts, and rear axle shafts. Rear-axle disassembly is labeled for single-tire models.

Leaf-spring and 5-link rear suspension are distinguished; adjustable-shock diagnosis includes the Adjustable Shock Absorber Wiring Diagram.

Brake variants: CL28VA/CL28VD front discs, DS22/DS25B/DS25C/LT26B rear drums, AD14VB rear discs, and the DS19HB parking drum have their own service information.

Steering: B56S manual steering is treated separately from PB56S and PB48S power steering, with gear and pump overhaul procedures.

Body, HVAC, and Electrical Systems

Body service: Door and lock mechanisms, power windows and door locks, weatherstrips, interior trim, instrument panel, center console, windshield and window glass, mirrors, and body-alignment dimensions are covered.

HVAC: Heater controls and electrical circuits accompany refrigerant discharging, evacuation, charging, checking, and compressor service.

Electrical reference: Power Supply Routing, Harness Layout, and Super Multiple Junction (S.M.J.) terminal arrangements support circuit tracing. The EL section also covers lighting, meters and gauges, warning lamps and chime, wipers and washers, rear defogger, audio, A.S.C.D., relay logic, and electrical-unit locations.

Factory Tools and Service Precautions

Tool tables identify the ST10120000 cylinder-head bolt wrench, KV40105400 wheel-bearing lock-nut wrench, and GG94310000 flare-nut torque wrench. Transmission equipment includes the ST07870000 case stand and KV319K0010 lock-up diagnostic sub-harness.

Reference tables provide component torque values, lubricant capacities and viscosity guidance, wear limits, and electrical test specifications.

Before under-vehicle or heavy repair work, support the vehicle at the specified lifting points with rated safety stands and wheel chocks. Fuel, brake, and refrigerant work should follow the pressure-release, fluid-handling, and system-isolation precautions in the manual.

Selected Valve-Clearance and Compression Data

For the warm Z24i engine with the engine stopped, the maintenance section specifies 0.30 mm (0.012 in) intake and exhaust valve clearance.

VG30i compression-test data lists a standard pressure of 1,196 kPa (173 psi) and a minimum of 883 kPa (128 psi) at 300 rpm with the engine warm.