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

• Built for experienced DIY owners, independent shops, and professional technicians servicing 1989 Nissan Truck and Pathfinder D21-series models. Coverage includes Z24i and VG30i engines, 2WD and 4WD drivetrains, Regular Cab, King Cab, Heavy Duty, Wagon, and Van bodies, plus STD, E, XE, and SE grades for U.S. and Canadian markets.
• Details engine removal and installation, oil-pan service, compression testing, cylinder-head disassembly and inspection, oil-seal replacement, and internal overhaul. The VG30i chapters cover the timing-belt system; the Z24i chapters cover the timing-chain system.
• Includes clutch service and factory repair coverage for F4W71C, FS5W71C, and FS5R30A manual transmissions; L4N71B, E4N71B, and RE4R01A automatic transmissions; the TX10 transfer case; propeller shafts; and H190A, R180A, R200A, C200, and H233B final drives.
• Covers manual- and auto-lock front hubs, drive shafts, wheel bearings, adjustable shock absorbers, leaf-spring and 5-link rear suspension, wheel alignment, disc and drum brakes, manual and power steering, body hardware, glass, doors, and heating and air-conditioning systems.
• Provides E.C.C.S. fault diagnosis, symptom charts, intermittent-problem simulation, ECU input/output checks, transmission road tests and pressure checks, system-specific wiring diagrams, connector views, harness layouts, exploded assemblies, and Service Data and Specifications tables.
• Nissan factory publication P/N SM9E-0D21U0, first printed in July 1988 for the 1989 model year. The supplied manual is a 1,370-page PDF.

Manual Contents and System Overview

The identification section connects each engine to the applicable transmission, transfer case, differential carrier, body style, wheelbase, grade, and destination code. It also explains model-code prefixes and suffixes, VIN construction, production-start identification numbers, and the locations of vehicle, engine, transmission, and transfer serial numbers. Coverage is limited to the listed 1989 Z24i and VG30i configurations rather than later D21 model years.

Drivetrain combinations are treated as separate factory builds. Two-wheel-drive trucks use H190A or H233B rear carriers, while four-wheel-drive configurations pair R180A or R200A front carriers with C200 or H233B rear units. The H233B chapter includes the limited-slip differential. The TX10 section covers on-vehicle service, removal, control linkage, oil-seal replacement, disassembly, component repair, assembly, and specifications.

Engine, Fuel, and Transmission Repair Depth

The Z24i and VG30i chapters move from maintenance into major repair: drive-belt and ignition checks, fuel-line and cooling service, lubrication and compression testing, engine removal, cylinder-head work, valve-train inspection, timing-system service, and bottom-end overhaul. Inspection sections provide factory measurement methods and limits for heads, valves, guides, camshafts, pistons, rings, connecting rods, crankshafts, bearings, cylinder bores, and flywheels.

Fuel and emission-control coverage includes the Engine and Emission Control System Chart, E.C.C.S. circuit and wiring diagrams, fuel- and air-flow descriptions, a diagnostic worksheet, intermittent-problem simulation, and symptom tables for no-start, hard-start, idle, stall, and driveability complaints. Component tests cover crank-angle and temperature sensors, air-flow and throttle inputs, injectors, relays, ECU power and grounds, EGR, evaporative-emission, crankcase-emission, and air-injection systems.

Manual transmissions receive removal, disassembly, inspection, synchronizer and gear service, reassembly, and major-overhaul procedures. The 71B-type and RE4R01A automatic chapters include fluid-condition checks, road testing, shift-schedule charts, stall and line-pressure testing, lock-up diagnosis, RE4R01A self-diagnosis, removal, valve-body service, and internal component repair.

Chassis, Body, HVAC, and Electrical Coverage

The chassis sections cover 2WD and 4WD wheel-bearing service, hub and rotor work, knuckle and spindle repair, manual- and auto-lock free-running hubs, front drive shafts, rear axle shafts, leaf-spring and 5-link suspension, alignment, and adjustable-shock diagnosis. Brake chapters distinguish CL28VA/CL28VD front discs, DS22/DS25B/DS25C/LT26B rear drums, AD14VB rear discs, and the DS19HB parking drum. Steering coverage separates the B56S manual gear from PB56S and PB48S power-steering systems and includes gear and pump overhaul.

Body and HVAC material includes door and lock mechanisms, power windows and power door locks, weatherstrips, interior trim, instrument panel and center console, windshield and window glass, mirrors, heater controls, refrigerant discharging, evacuation, charging and checking, DKV-14C compressor work, and heater/A/C electrical circuits.

Named diagrams and reference views include the Lubrication Circuit, E.C.C.S. Wiring Diagram, Adjustable Shock Absorber Wiring Diagram, Power Supply Routing, Harness Layout, and Super Multiple Junction (S.M.J.) terminal arrangements. The EL section also covers starting, charging, lighting, meters and gauges, warning lamps and chime, wipers and washers, rear defogger, audio, A.S.C.D., relay logic, electrical-unit locations, and connector identification.

Factory Tools, Specifications, and Repair Notes

Tool tables identify equipment such as the ST10120000 cylinder-head bolt wrench, KV40105400 wheel-bearing lock-nut wrench, GG94310000 flare-nut torque wrench, ST07870000 transmission case stand, and KV319K0010 lock-up diagnostic sub-harness. Reference tables supply component torque values, fluid capacities and viscosity guidance, pressure-test data, clearances, bearing preloads, backlash and tooth-contact settings, wear limits, alignment data, and electrical test values.

The VG30i timing section warns that the left- and right-hand camshaft sprockets are different parts. Incorrect positioning, or rotating the crankshaft and camshafts separately with the belt removed, can cause valve-to-piston contact.

The oil-pan procedure calls for a seal cutter and warns against prying between the block and pan, where the flange or rear oil-seal retainer can be damaged. Automatic-transmission valve-body springs and precision parts must remain in their original order; mixing them can create hydraulic-control and shift faults after reassembly.

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.