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Nissan YD22DDTi engine factory workshop and repair manual download

Tools & supplies
- Socket set (8mm, 10mm, sometimes 12mm), ratchet, 3–6" extension
- Phillips and flat-blade screwdrivers
- Torx bits (T20/T25) — some trim screws
- Plastic trim/clip removal tool
- Long-nose pliers
- Gloves (nitrile) and soft clean gloves for halogen bulbs
- Safety glasses
- Dielectric grease or contact cleaner
- Anti-seize (optional) for bolts
- Replacement part(s): correct headlight bulb(s) or full headlight assembly (confirm exact type for your vehicle/year; many Nissan YD22 applications use H4 or H7 halogen bulbs — check the old bulb or manual)
- Clean rag, tape for marking, small container for fasteners
- Torque wrench (optional) for final snugging
- Masking tape and marker (for aiming adjustment)

Safety precautions
- Work on a flat surface, engine off, parking brake on. If battery terminals are corroded, disconnect negative terminal when wiring access is required. For bulb-only replacement you generally don’t need to disconnect battery, but if you will remove the bumper or work around airbags/battery, disconnect negative.
- Allow headlight bulbs to cool before handling.
- Never touch halogen bulb glass with bare fingers — oils cause hot spots and early failure. Use clean gloves or hold by the base.
- If the vehicle has HID/Xenon, do not attempt ballast or bulb replacement unless experienced — high voltage risk. Replace whole assembly or go to a shop if unsure.
- Protect painted surfaces with rags; don’t force plastic clips or tabs (they break easily).

Overview (what you’ll do)
1) Access headlight fasteners (may need to move battery/air cleaner or remove a few trim clips).
2) Remove screws/clips securing headlight.
3) Pull headlight forward slightly and disconnect electrical connectors.
4) Replace bulb or swap complete assembly.
5) Reconnect, test, and aim headlights.

Step-by-step procedure
1. Preparation
- Park with plenty of room in front, set parking brake, open bonnet.
- Put on safety glasses and gloves. Lay out tools and container for fasteners.

2. Remove obstructing components (if needed)
- Many YD22 vehicles have top access bolts visible when the bonnet is open. If battery or airbox blocks access, loosen or remove them:
- Disconnect battery negative only if you will unplug electrical connectors or are uncomfortable working near the battery.
- Remove battery hold-down and slide battery out if necessary (usually 10mm).
- Loosen or remove air intake snorkel or airbox cover (Phillips or 8/10mm) to gain room.
- Use trim tool to pop plastic clips on the upper grille if grille removal makes access easier.

3. Remove headlight assembly (if replacing assembly or to access bulbs easily)
- Locate headlight mounting bolts: typically two top bolts under bonnet and one or two bolts on the inner wing/behind bumper. Sizes commonly 10mm or 12mm.
- Use ratchet + appropriate socket and extension to remove top bolts. Keep bolts in container in order.
- Turn wheel outwards (if necessary) to access inner wing bolt via wheel arch, or unclip a few wheel-arch plastic rivets to reach the lower screws.
- Remove any bumper-to-wing retaining clips if the bumper must be lowered (keep track of clips).
- Gently pull the headlight assembly forward. Don’t yank — check for any hidden screws or wiring tucked behind.

4. Disconnect electrical connectors
- Press the locking tab(s) on the headlight harness and pull straight off. If stuck, use small flat screwdriver to lift the tab and wiggle the connector free.
- For bulbs: remove the rubber dust cap (twist/unsnap), unclip the spring retainer or twist the bulb holder counterclockwise (depending on type), then remove bulb.
- For spring-retained bulbs: use pliers or fingers to unhook the spring clamp (note orientation for reassembly).

5. Install new bulb or assembly
- Bulb only:
- With gloves, insert new bulb without touching glass. Seat it into the reflector properly and secure the spring or twist-lock into place.
- Reinstall rubber dust cap. Apply a small smear of dielectric grease on the connector pins (not on the bulb glass).
- Reconnect wiring harness.
- Full assembly:
- Position new assembly into mounting points, reconnect harness, and loosely install fasteners so you can adjust fit.
- When tightening bolts, snug firmly but do not overtighten plastic mounts — they strip easily. If you have a torque wrench, 6–10 Nm is typical for headlamp mounting bolts — just snug is acceptable for plastic bolts.

6. Test lights before final reassembly
- With ignition on, turn on low beam and high beam. Check indicators/position lights.
- If bulb doesn’t light, recheck connector seating and bulb orientation. For dual-filament bulbs (H4), ensure wiring plug matches base orientation.

7. Reassemble everything
- Reinstall any airbox, battery, grille, bumper clips removed earlier.
- Tighten bolts to seat the assembly. Replace damaged clips with new ones — they’re cheap and save trouble.

8. Aim the headlights (basic method)
- Park vehicle 7–10 m (25–33 ft) from a flat wall on level ground with vehicle perpendicular.
- Mark center lines of each headlamp on wall with tape (use center of lamp and vehicle centerline).
- Adjust vertical and horizontal adjusters (usually screws on top and side of assembly) until beam center lines are slightly below and to the right (or as per local regulation) of the marks. Small turns of the adjuster move the beam noticeably — use a screwdriver or appropriate bit.
- Tighten retaining screws after aiming.

Common pitfalls & how to avoid them
- Touching halogen bulb glass: causes early failure. Use gloves or clean cloth.
- Breaking plastic tabs/clips: use trim tools and lift clips straight; replace any broken clips.
- Corroded/rusty bolts: spray penetrating oil beforehand; use proper socket size and pull straight to avoid rounding heads.
- Forcing the assembly: locate all fasteners first; wobbling could break alignment tabs.
- Poor sealing causing condensation: ensure dust cap is seated and seals are intact. Replace torn rubber caps.
- Incorrect bulb type: verify part number or remove existing bulb to check before buying.
- Miswired connectors or loose grounds: if the bulb doesn’t work, check the connector for bent pins or corrosion and test for voltage at the plug.
- HID dangers: ballast can hold charge — do not open. If HID fails, better to replace the whole unit or have a specialist install.

How specific tools are used
- Ratchet & sockets: use correct socket size; an extension helps reach top-mounted bolts behind the grille. Use steady force to avoid slipping.
- Trim tool: wedges under plastic clips to pry up the center pin then remove the clip without damaging paint.
- Flat screwdriver: used gently to depress small locking tabs on electrical connectors; avoid prying on harness wires.
- Pliers: to manipulate the spring retainer on halogen bulbs. Use long-nose to improve access.
- Dielectric grease: a small dab on connector pins prevents corrosion and eases future removal.

Replacement parts checklist
- Correct bulb(s) (replace in pairs if one side failed, to match light output/age)
- New dust cap(s) if torn
- New mounting clips or screws if broken
- Full headlight assembly if lenses are cracked, seal failed, or reflector is degraded
- HID ballast/bulb only if vehicle is equipped and you’re qualified

Estimated time & difficulty
- Bulb replacement only: 15–45 minutes per side (easy–moderate).
- Full headlight assembly replacement: 45–90 minutes per side depending on bumper/airbox removal (moderate).

Follow-up actions (don’t skip)
- Verify beam aim and brightness on a short night test drive.
- Dispose of old bulbs responsibly — halogen bulbs can go in household waste but many places recycle automotive bulbs; HID bulbs should be recycled due to mercury.

That’s it — follow the steps in order, protect plastic fasteners, don’t touch bulb glass, and aim lights after installation.
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