injector pump NISSAN PICK-UP 1998 Repair Manual

TROUBLE DIAGNOSIS FOR POWER SUPPLY.... 75
Main Power Supply and Ground Circuit .............. 75
TROUBLE DIAGNOSIS FOR ``CAMSHAFT
POSI SEN'' (DTC 11).............................................. 82
Camshaft Position Sensor (CMPS) ..................... 82
TROUBLE DIAGNOSIS FOR ``MASS AIR
FLOW SEN'' (DTC 12)............................................ 89
Mass Air Flow Sensor (MAFS) ............................ 89
TROUBLE DIAGNOSIS FOR ``COOLANT TEMP
SEN'' (DTC 13)........................................................ 95
Engine Coolant Temperature Sensor (ECTS) ..... 95
TROUBLE DIAGNOSIS FOR ``IGN SIGNAL-
PRIMARY'' (DTC 21)............................................... 99
Ignition Signal ...................................................... 99
TROUBLE DIAGNOSIS FOR ``OVER HEAT''
(DTC 28)................................................................. 106
Overheat ............................................................ 106
TROUBLE DIAGNOSIS FOR ``INT AIR TEMP
SEN'' (DTC 41)...................................................... 109
Intake Air Temperature Sensor ......................... 109
TROUBLE DIAGNOSIS FOR ``THROTTLE POSI
SEN'' (DTC 43)...................................................... 113
Throttle Position Sensor .................................... 113
TROUBLE DIAGNOSIS FOR
NON-DETECTABLE ITEMS.................................. 118
Vehicle Speed Sensor (VSS) ............................ 118
Heated Oxygen Sensor (HO2S)
- LHD Models - .................................................. 123
Heated Oxygen Sensor Heater
- LHD Models - .................................................. 127
Idle Air Control Valve (IACV) - Auxiliary Air
Control (AAC) Valve .......................................... 131
Neutral Position Switch ...................................... 136
EVAP Canister Purge Control Solenoid Valve .. 140
Injector ............................................................... 144
Start Signal ........................................................ 149
Fuel Pump.......................................................... 151
Power Steering Oil Pressure Switch ................. 157
Swirl Control Valve Control Solenoid Valve ...... 161
IACV-FICD Solenoid Valve ................................ 168
MIL & Data Link Connectors ............................. 173
TD
INJECTION SYSTEM............................................ 176
Fuel System ....................................................... 176
INJECTION PUMP................................................. 178
Inspection ........................................................... 178
Removal ............................................................. 178
Installation and Adjustment................................ 180
Disassembly ....................................................... 183
Load Timer Adjustment...................................... 183
Start Q Adjustment Lever .................................. 184
INJECTION NOZZLE............................................. 186Removal and Installation ................................... 186
Disassembly ....................................................... 186
Inspection ........................................................... 187
Cleaning ............................................................. 187
Assembly............................................................ 189
Test and Adjustment .......................................... 189
FUEL SYSTEM CHECK........................................ 191
Bleeding Fuel System ........................................ 191
Bleeding Fuel Filter ............................................ 192
Checking Priming Pump .................................... 192
Checking Fuel Filter Switch ............................... 192
POSITIVE CRANKCASE VENTILATION.............. 193
Description ......................................................... 193
Inspection ........................................................... 193
QUICK-GLOW SYSTEM........................................ 194
Component Parts Location ................................ 194
Circuit Diagram .................................................. 195
Description ......................................................... 196
Wiring Diagram .................................................. 197
Glow Control Unit Circuit Inspection (For Cold
Areas)................................................................. 203
Glow Control Unit Circuit Inspection (Except
for Cold Areas)................................................... 206
Component Inspection ....................................... 208
EGR SYSTEM........................................................ 210
Component Parts Location ................................ 210
Description ......................................................... 211
Operation ........................................................... 212
Wiring Diagram .................................................. 213
System Inspection.............................................. 217
Component Inspection ....................................... 218
SOLENOID TIMER................................................ 220
Description ......................................................... 220
Operation ........................................................... 220
Wiring Diagram .................................................. 222
Inspection ........................................................... 224
FUEL CUT SYSTEM.............................................. 225
Wiring Diagram .................................................. 225
FUEL HEATER SYSTEM...................................... 226
Description ......................................................... 226
Wiring Diagram .................................................. 227
System Inspection.............................................. 228
Component Inspection ....................................... 228
FAST IDLE CONTROL CIRCUIT.......................... 230
Wiring Diagram .................................................. 230
Electrical Components Inspection ..................... 231
KA
SERVICE DATA AND SPECIFICATIONS (SDS). 232
General Specifications ....................................... 232
Inspection and Adjustment ................................ 232

System Chart
Camshaft position sensorc
ECM
(ECCS
control
module)
Mass air flow sensorc
Engine coolant temperature sensorc
Heated oxygen sensor*c
Ignition switchc
Throttle position sensorc
Neutral position switchc
Vehicle speed sensorc
Air conditioner switchc
Battery voltagec
Power steering oil pressure switchc
Intake air temperature sensorc
*: LHD models
Fuel injection &
mixture ratio controlcInjectors
Distributor ignition systemcPower transistor
Idle air control systemcIACV-AAC valve
IACV-FICD solenoid valve
Swirl control valve controlcSwirl control valve control
solenoid valve
EVAP canister controlcEVAP canister purge control
solenoid valve
Fuel pump controlcFuel pump relay
Heated oxygen sensor moni-
tor & on board diagnostic
systemcMalfunction indicator lamp
(On the instrument panel)
Acceleration cut controlcAir conditioner relay
Heated oxygen sensor
heater control*cHeated oxygen sensor
heater
ENGINE AND EMISSION CONTROL OVERALL SYSTEMKA
EC-13

ECCS COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
ItemDIAGNOSTIC TEST MODE
WORK
SUPPORTSELF-DIAG-
NOSTIC
RESULTSDATA
MONITORACTIVE
TESTFUNCTION
TEST
ECCS COMPONENT PARTS
INPUT
Camshaft position sensor X X
Mass air flow sensor X X
Engine coolant temperature
sensorXXX
Heated oxygen sensor X
Vehicle speed sensor X X
Throttle position sensor X X X X
Intake air temperature sensor X X
Ignition switch (start signal) X X
Closed throttle position switch X X
Air conditioner switch X
Neutral position switch X X
Power steering oil pressure
switchXX
Battery voltage X
OUTPUT
Injectors X X X
Power transistor (Ignition timing) XX (Ignition
signal)XXX
IACV-AAC valve X X X X
Air conditioner relay X
Fuel pump relay X X X X
Swirl control valve control
solenoid valveXXX
EVAP canister purge control
solenoid valve*XXX
X: Applicable
* : This item is indicated as ``EGRC SOL/V'' on the CONSULT screen.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONKA
CONSULT (Cont'd)
EC-47

ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
FUEL INJECTION
lEngine: Return to the original trouble
condition
lChange the amount of fuel injection
using CONSULT.If trouble symptom disappears, see
CHECK ITEM.
lHarness and connectorlFuel injectorslHeated oxygen sensor
IACV-AAC/V
OPENING
lEngine: After warming up, idle the
engine.
lChange the IACV-AAC valve opening
percent using CONSULT.Engine speed changes according to the
opening percent.lHarness and connectorlIACV-AAC valve
ENG COOLANT
TEMP
lEngine: Return to the original trouble
condition
lChange the engine coolant
temperature using CONSULT.If trouble symptom disappears, see
CHECK ITEM.
lHarness and connectorlEngine coolant temperature sensorlFuel injectors
IGNITION TIMING
lEngine: Return to the original trouble
condition
lTiming light: SetlRetard the ignition timing using
CONSULT.If trouble symptom disappears, see
CHECK ITEM.
lAdjust ignition timing (by moving
camshaft position sensor)
POWER BALANCE
lEngine: After warming up, idle the
engine.
lA/C switch ``OFF''lShift lever ``N''lCut off each injector signal one at a
time using CONSULT.Engine runs rough or dies.
lHarness and connectorlCompressionlInjectorslIgnition coil with power transistorlSpark plugs
FUEL PUMP RELAY
lIgnition switch: ON (Engine stopped)lTurn the fuel pump relay ``ON'' and
``OFF'' using CONSULT and listen to
operating sound.Fuel pump relay makes the operating
sound.lHarness and connectorlFuel pump relay
EGRC SOLENOID
VALVE
(EVAP canister
purge control
solenoid valve)
lIgnition switch: ONlTurn solenoid valve ``ON'' and ``OFF''
with CONSULT and listen to
operating sound.Solenoid valve makes an operating
sound.lHarness and connectorlEVAP canister purge control solenoid
valve
SWIRL CONT SOL
VALVE
lIgnition switch: ON (Engine stopped)lTurn solenoid valve ``ON'' and ``OFF''
with CONSULT and listen to
operating sound.Solenoid valve makes an operating
sound.lHarness and connectorlSwirl control valve control solenoid
valve
SELF-LEARNING
CONT
lIn this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by touching ``CLEAR'' on the
screen.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONKA
CONSULT (Cont'd)
EC-50

FUNCTION TEST
ITEMCONDITION JUDGEMENT CHECK ITEM (REMEDY)
PW/ST SIGNAL
CIRCUIT
lIgnition switch: ON
(Engine running)
lPower steering oil pressure switch
circuit is tested when steering
wheel is rotated fully and then set
to a straight line running position.Locked position ONlHarness and connector
lPower steering oil pressure switch
lPower steering oil pump
Neutral position OFF
SWRL CONT S/V
CIRCUIT
lIgnition switch: ON
(Engine stopped)
lSwirl control valve control sole-
noid valve circuit is tested by
checking solenoid valve operating
sound.The solenoid valve makes an
operating sound every 3 sec-
onds.
lHarness and connector
lSolenoid valve
lSwirl control valve
lVacuum hose
VEHICLE SPEED
SEN CKT
lVehicle speed sensor circuit is
tested when vehicle is running at
a speed of 10 km/h (6 MPH) or
higher.Vehicle speed sensor input
signal is greater than 4 km/h
(2 MPH).lHarness and connector
lVehicle speed sensor
lSpeedometer
IGN TIMING ADJ
lAfter warming up, idle the engine.
lIgnition timing is checked by read-
ing ignition timing with a timing
light and checking whether it
agrees with specifications.The timing light indicates the
same value on the screen.
lAdjust ignition timing (by moving
camshaft position sensor or
distributor)
lCamshaft position sensor drive
mechanism
MIXTURE RATIO
TEST
lAir-fuel ratio feedback circuit
(injection system, ignition system,
vacuum system, etc.) is tested by
examining the heated oxygen
sensor output at 2,000 rpm under
non-loaded state.Heated oxygen sensor
COUNT: More than 5 times
during 10 seconds
lINJECTION SYS (Injector, fuel
pressure regulator, harness or
connector)
lIGNITION SYS (Spark plug,
ignition coil, power transistor
harness or connector)
lVACUUM SYS (Intake air leaks)
lHeated oxygen sensor circuit
lHeated oxygen sensor operation
lFuel pressure high or low
lMass air flow sensor
POWER BALANCE
lAfter warming up, idle the engine.
lInjector operation of each cylinder
is stopped one after another, and
resultant change in engine rota-
tion is examined to evaluate com-
bustion of each cylinder. (This is
only displayed for models where a
sequential multiport fuel injection
system is used.)Difference in engine speed is
greater than 25 rpm before
and after cutting off the injec-
tor of each cylinder.lInjector circuit (Injector, harness
or connector)
lIgnition circuit (Spark plug, igni-
tion coil, power transistor harness
or connector)
lCompression
lValve timing
IACV-AAC/V
SYSTEM
lAfter warming up, idle the engine.
lIACV-AAC valve system is tested
by detecting change in engine
speed when IACV-AAC valve
opening is changed to 0%, 20%
and 80%.Difference in engine speed is
greater than 150 rpm between
when valve opening is at 80%
and at 20%.
lHarness and connector
lIACV-AAC valve
lAir passage restriction between
air inlet and IACV-AAC valve
lIAS (Idle adjusting screw) adjust-
ment
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONKA
CONSULT (Cont'd)
EC-52

Symptom Matrix Chart
SYMPTOM
Reference page
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER/POOR ACCELERATION
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
OVERCOOLS
OVERCHARGING
Warranty Symptom Code AA AB AC AD AE AF AG AH AJ AK AL AM HA 1P 1X
Basic engine control system
Fuel Fuel pump circuitllljlljjjEC-151
Fuel pressure regulator system
llljljlljlEC-22
Injector circuit
llljlll lEC-144
Evaporative emission systemjjjj
ljjjj jEC-19
Air Positive crankcase ventilation systemjjjj
ljjjj jjEC-21
Incorrect idle speed adjustmentjj jjjj jEC-25
Swirl control valve circuitjj
lEC-161
IACV-AAC valve circuit
llljllllljjEC-131
IACV-FICD solenoid valve circuitjjjjjjjjj jEC-168
Ignition Incorrect ignition timing adjustmentjj
lll ll lEC-25
Ignition circuit
lllll ll lEC-99
EVAP EVAP canister purge control solenoid
valve circuit
ljjjj j jEC-140
Main power supply and ground circuit
llljj jj jj jEC-75
Air conditioner circuitjjjjjjjjj j jHA section
ECCS system
ECCS Camshaft position sensor circuitllllljj jEC-82
Mass air flow sensor circuit
lllll ljjEC-89
Heated oxygen sensor circuit
lljlljlEC-123, 127
Engine coolant temperature sensor circuit
llljllljjlEC-95
Throttle position sensor circuit
ll lllll lEC-113
Incorrect throttle position sensor adjust-
ment
ljjljjljEC-58
Vehicle speed sensor circuitjj j jEC-118
ECMjjjjjjjjjjjEC-61
Start signal circuitjEC-149
Neutral position switch circuitjjjj jEC-136
Power steering oil pressure switch circuitjjjEC-157
l; High Possibility Item
j; Low Possibility Item(continued on next page)
TROUBLE DIAGNOSIS Ð General DescriptionKA
EC-62

TERMINAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC voltage)
101
103
110
112W/B
W/R
W/L
W/GInjector No. 1
Injector No. 3
Injector No. 2
Injector No. 4Engine is running.
(Warm-up condition)
Idle speedBATTERY VOLTAGE
(11 - 14V)
SEF069U
Engine is running.
Engine speed is 2,000 rpm.BATTERY VOLTAGE
(11 - 14V)
SEF070U
104 W/R Fuel pump relayIgnition switch ``ON''
For 5 seconds after turning ignition switch
``ON''
Engine is running.Approximately 1V
Ignition switch ``ON''
5 seconds after turning ignition switch ``ON''BATTERY VOLTAGE
(11 - 14V)
105 W/LEVAP canister
purge control
solenoid valveEngine is running.
(Warm-up condition)
Idle speedBATTERY VOLTAGE
(11 - 14V)
Engine is running.
(Warm-up condition)
Engine is above 3,800 rpm.Approximately 1V
107
108B/P ECCS groundEngine is running.
Idle speedEngine ground
109 B/W Current returnEngine is running.
Idle speedBATTERY VOLTAGE
(11 - 14V)
113 W/G IACV-AAC valveEngine is running.
Idle speed10 - 13V
Engine is running.
Steering wheel is being turned.Air conditioner is operating.Rear window defogger switch is ``ON''.Lighting switch is ``ON''.5 - 10V
114 RHeated oxygen
sensor heaterEngine is running.
Engine speed is below 3,200 rpm.Approximately 0V
Engine is running.
Engine speed is above 3,200 rpm.BATTERY VOLTAGE
(11 - 14V)
TROUBLE DIAGNOSIS Ð General DescriptionKA
ECM Terminals and Reference Value
(Cont'd)
EC-73

General Specifications
PRESSURE REGULATOR
Fuel pressure
kPa (bar, kg/cm2, psi)
At idleApproximately
235 (2.35, 2.4, 34)
A few seconds after ignition
switch is turned OFF to ONApproximately
294 (2.94, 3.0, 43)
Inspection and Adjustment
Idle speed*1 rpm Base idle speed*3 750 25
No-load*2
(in ``N'' position)Target idle speed 800 50
Air conditioner: ON
(in ``N'' position)900 or more
Ignition timing 10É 2É BTDC
Throttle position touch
speed rpm1,000 150
*1: Feedback controlled and needs no adjustments
*2: Under the following conditions:
lAir conditioner switch: OFFlSteering wheel: Kept in straight-ahead positionlElectrical load: OFF (Lights, heater fan & rear window defog-
ger)
*3: Throttle position sensor connector is disconnected.
IGNITION COIL
Primary voltage V Battery voltage (11 - 14)
Primary resistance
[at 25ÉC (77ÉF)]WLess than 1.0
Secondary resistance
[at 25ÉC (77ÉF)] kW7-13
MASS AIR FLOW SENSOR
Supply voltage V Battery voltage (11 - 14)
Output voltage at idle V1.3 - 1.7 at idle*
1.7 - 2.1 at 2,500 rpm*
*: Engine is warmed up sufficiently and running under no-load.
ENGINE COOLANT TEMPERATURE
SENSOR
Temperature ÉC (ÉF) Resistance
20 (68) 2.1 - 2.9 kW
50 (122) 0.68 - 1.00 kW
90 (194) 0.236 - 0.260 kW
FUEL PUMP
Resistance [at 25ÉC (77ÉF)]W0.2 - 5.0
IACV-AAC VALVE
Resistance [at 25ÉC (77ÉF)]WApproximately 10.0
INJECTOR
Resistance [at 25ÉC (77ÉF)]W10-14
RESISTOR
Resistance [at 25ÉC (77ÉF)] kWApproximately 2.2
THROTTLE POSITION SENSOR
Throttle valve conditions Resistance [at 25ÉC (77ÉF)]
Completely closed Approximately 0.6 kW
Partially open 0.6 - 4.0 kW
Completely open Approximately 4.0 kW
HEATED OXYGEN SENSOR HEATER
Resistance [at 25ÉC (77ÉF)]W2.3 - 4.3
INTAKE AIR TEMPERATURE SENSOR
Temperature ÉC (ÉF) Resistance
20 (68) 2.1 - 2.9 kW
80 (176) 0.27 - 0.38 kW
SERVICE DATA AND SPECIFICATIONS (SDS)KA
EC-232

Use the chart below to find out what each wiring diagram code
stands for.
Refer to the wiring diagram code in the alphabetical index to find
the location (page number) of each wiring diagram.
Code Section Wiring Diagram Name
AAC/V EC IACV-AAC Valve
ABS BR Anti-lock Brake System
A/C, M HA Manual Air Conditioner
AUDIO EL Audio
BACK/L EL Back-up Lamp
BUZZER EL Warning Buzzer
CHARGE EL Charging System
CHOKE EC Automatic Choke
CIGAR EL Cigarette Lighter
CLOCK EL Clock
CMPS EC Camshaft Position Sensor
COOL/F LC Cooling Fan Control
DEF EL Rear Window Defogger
DIMDIP ELHeadlamp Ð With Dim-dip Lamp
System
D/LOCK EL Power Door Lock
DTRL ELHeadlamp Ð With Daytime Light
System
ECTS ECEngine Coolant Temperature
Sensor
EGRC/V EC EGRC Ð Solenoid Valve
FCUT EC Fuel Cut Solenoid Valve
F/HEAT EC Fuel Heater System
FICD EC IACV-FICD Solenoid Valve
FIPOT EC ISC-FI Pot
FPCM EC Fuel Pump Control Module
F/PUMP EC Fuel Pump
F/RTN EC Fuel Return Control Solenoid Valve
GLOW EC Quick-glow System
H/AIM EL Headlamp Aiming Control
HEATER HA Heater
H/LAMP EL Headlamp
HLC EL Headlamp Washer
HO2S EC Heated Oxygen Sensor
HORN EL Horn
H/SEAT EL Heated Seat
IATS EC Intake Air Temperature Sensor
IDLE EC IACV-Idle Up ControlCode Section Wiring Diagram Name
IGN EC Ignition System
IGN/SG EC Ignition Signal
ILL EL Illumination
INJECT EC Injector
INT/L EL Interior and Spot Lamps
MAFS EC Mass Air Flow Sensor
MAIN ECMain Power Supply and Ground Cir-
cuit
METER ELSpeedometer, Tachometer, Temp.
and Fuel Gauges
MIL/DL ECMIL and Data Link Connector For
CONSULT
MIRROR EL Power Door Mirror
MULTI EL Multi-remote Control System
NATS EL Nissan Anti-theft System
P/ANT EL Power Antenna
PGC/V ECCanister Purge
Control Solenoid Valve
PLA EC Partial Load Advance Control
PNP/SW EC Park/Neutral Position Switch
POWER EL Power Supply Routing
PST/SW EC Power Steering Oil Pressure Switch
R/FOG EL Rear Fog Lamp
SRS RS Supplemental Restraint System
S/SIG EC Start Signal
START EL Starting System
STOP/L EL Stop Lamp
SWL/V ECSwirl Control Valve Control Solenoid
Valve
TAIL/L EL Parking, License and Tail Lamps
TPS EC Throttle Position Sensor
TURN ELTurn Signal and Hazard Warning
Lamps
VSS EC Vehicle Speed Sensor
WARN EL Warning Lamps
WINDOW EL Power Window
WIPER EL Front Wiper and Washer
WIRING DIAGRAM CODES (CELL CODES)
EL-253

lAfter disconnecting vacuum or air hoses, attach a tag to
indicate the proper connection.
lUse only the fluids and lubricants specified in this manual.
lUse approved bonding agent, sealants or their equivalents
when required.
lUse tools and recommended special tools where specified
for safe and efficient service repairs.
lWhen repairing the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
lDispose of drained oil or the solvent used for cleaning parts
in an appropriate manner.
WARNING:
To prevent ECM from storing the diagnostic trouble codes,
do not carelessly disconnect the harness connectors which
are related to the ECCS system and TCM (Transmission
Control Module) system. The connectors should be discon-
nected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC section.
Precautions for Multiport Fuel Injection
System or ECCS Engine
lBefore connecting or disconnecting any harness connector
for the multiport fuel injection system or ECM (Engine Con-
trol Module):
Turn ignition switch to ``OFF'' position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
lBefore disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
lBe careful not to jar components such as ECM and mass air
flow sensor.
Precautions for Three Way Catalyst
(If so equipped)
If a large amount of unburned fuel flows into the catalyst, the
catalyst temperature will be excessively high. To prevent this,
follow the instructions below:
lUse unleaded gasoline only. Leaded gasoline will seriously
damage the three way catalyst.
lWhen checking for ignition spark or measuring engine
compression, make tests quickly and only when necessary.
lDo not run engine when the fuel tank level is low, otherwise
the engine may misfire causing damage to the catalyst.
Do not place the vehicle on flammable material. Keep flammable
material off the exhaust pipe and the three way catalyst.
Precautions for Engine Oils
Prolonged and repeated contact with used engine oil may cause
skin cancer. Try to avoid direct skin contact with used oil.
SGI787
PRECAUTIONS
General Precautions (Cont'd)
GI-4