warning NISSAN PICK-UP 2001 Repair Manual

Special Service Tool (YD25DDTi)
Tool number
Tool nameDescription
KV111060S0
Removal/Installation tool kit for
fuel injection pump
NT814
Supplemental Restraint System (SRS) ªAIR
BAGº
The Supplemental Restraint System such as ªAIR BAGº used along with a seat belt, helps to reduce the risk
or severity of injury to the driver and front passenger for certain types of collision. The SRS system composi-
tion which is available to NISSAN MODEL D22 is as follows (The composition varies according to the desti-
nation and optional equipment.):
Driver air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
Information necessary to service the system safely is included in theRS sectionof D22 Service Manual
Supplement VI.
WARNING:
+To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the
event of a collision which would result in air bag inflation, all maintenance should be performed by an
authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury
caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see
the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service
Manual. SRS wiring harnesses can be identified by yellow harness connector.
PRECAUTIONS AND PREPARATION
Special Service Tool (YD25DDTi)
EC-3008

Supplemental Restraint System (SRS) ªAIR
BAGº and ªSEAT BELT PRE-TENSIONERº
NEEC0002The Supplemental Restraint System such as ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS system composition which is available to NISSAN MODEL D22 is as follows (The composition var-
ies according to the destination and optional equipment.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable.
Information necessary to service the system safely is included in theRS sectionof this Service Manual.
WARNING:
+To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
+Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
+Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
Precautions for On Board Diagnostic (OBD)
System of Engine
NEEC0003The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver
of a malfunction causing emission deterioration.
CAUTION:
+Be sure to turn the ignition switch OFF and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc.
will cause the MI to light up.
+Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
+Certain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector.
For description and how to disconnect, refer to EL section, ªHARNESS CONNECTORº.
+Be sure to route and secure the harnesses properly after work. The interference of the harness with
a bracket, etc. may cause the MI to light up due to the short circuit.
+Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of the fuel injection system, etc.
+Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before
returning the vehicle to the customer.
PRECAUTIONSKA24DE (EURO OBD)
Supplemental Restraint System (SRS) ªAIR BAGº and ªSEAT BELT PRE-TENSIONERº
EC-3012

Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but
all of the data listed above, are cleared from the ECM memory during work procedures.
NVIS (Nissan Vehicle Immobilizer System Ð
NATS)
NEEC1601
SEF515Y
+If the security indicator lights up with the ignition switch in the ªONº position or ªNATS MALFUNC-
TIONº is displayed on ªSELF-DIAG RESULTSº screen, perform self-diagnostic results mode with
CONSULT-II using NATS program card. Refer to ªNVIS (Nissan Vehicle Immobilizer System Ð
NATS)º in EL section.
+Confirm no self-diagnostic results of NVIS (NATS) is displayed before touching ªERASEº in ªSELF-
DIAG RESULTSº mode with CONSULT-II.
+When replacing ECM, initialization of NVIS (NATS) system and registration of all NVIS (NATS) igni-
tion key IDs must be carried out with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner. Regarding the procedures of NVIS (NATS)
initialization and NVIS (NATS) ignition key ID registration, refer to CONSULT-II operation manual,
IVIS/NVIS.
Malfunction Indicator (MI)
DESCRIPTIONNEEC0032
SAT652J
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without the engine running. This is a bulb check.
+If the MI does not light up, refer to EL section, ªWARNING LAMPSº or see EC-3396.
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has detected an engine system malfunction.
On Board Diagnostic System FunctionNEEC0032S07The on board diagnostic system has the following four functions.
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION
KA24DE (EURO OBD)
Emission-related Diagnostic Information
EC-3061

Diagnostic Test
ModeKEY and ENG.
StatusFunction Explanation of Function
Mode I Ignition switch in
ªONº position
Engine stopped
BULB CHECK This function checks the MI bulb for damage (blown,
open circuit, etc.).
If the MI does not come on, check MI circuit.
Engine running
MALFUNCTION WARNING This is a usual driving condition. When a malfunction is
detected twice in two consecutive driving cycles (two trip
detection logic), the MI will light up to inform the driver
that a malfunction has been detected. The following mal-
functions will light up or blink the MI in the 1st trip.
+ªMisfire (Possible three way catalyst damage)º
+ªClosed loop controlº
+Fail-safe mode
Mode II Ignition switch in
ªONº position
Engine stopped
SELF-DIAGNOSTIC RESULTS This function allows DTCs and 1st trip DTCs to be read.
Engine running
HEATED OXYGEN SENSOR 1
MONITORThis function allows the fuel mixture condition (lean or
rich), monitored by heated oxygen sensor 1, to be read.
MI Flashing without DTCNEEC0032S0701If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diag-
nostic test mode. How to Switch Diagnostic Test Mode.
How to switch the diagnostic test (function) modes, and details of the above functions are described later. How
to Switch Diagnostic Test Mode.
The following emission-related diagnostic information is cleared when the ECM memory is erased.
1. Diagnostic trouble codes
2. 1st trip diagnostic trouble codes
3. Freeze frame data
4. 1st trip freeze frame data
5. System readiness test (SRT) codes
6. Test values
7. Others
How to Switch Diagnostic Test ModeNEEC0032S08NOTE:
+It is better to count the time accurately with a clock.
+It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit
has a malfunction.
+Always ECM returns to Diagnostic Test Mode I after ignition switch is turned ªOFFº.
How to Set Diagnostic Test Mode II (Self-diagnostic Results)
NEEC0032S08011. Confirm that accelerator pedal is fully released, turn ignition switch ªONº and wait 3 seconds.
2. Repeat the following procedure quickly five times within 5 seconds.
1) Fully depress the accelerator pedal.
2) Fully release the accelerator pedal.
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION
KA24DE (EURO OBD)
Malfunction Indicator (MI)
EC-3062

3. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts
blinking.
4. Fully release the accelerator pedal.
ECM has entered to Diagnostic Test Mode II (Self-diagnostic results).
PBIB0092E
How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor)NEEC0032S08021. Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to How to Set Diagnostic Test Mode
II (Self-diagnostic Results).
2. Start Engine.
ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor).
ECM will start heated oxygen sensor 1 monitoring from the bank 1 sensor.
How to Erase Diagnostic Test Mode II (Self-diagnostic Results)
NEEC0032S08041. Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to How to Set Diagnostic Test Mode
II (Self-diagnostic Results).
2. Fully depress the accelerator pedal and keep it for more than 10 seconds. The emission-related diagnos-
tic information has been erased from the backup memory in the ECM.
3. Fully release the accelerator pedal, and confirm the DTC 0000 is displayed.
Diagnostic Test Mode I Ð Bulb CheckNEEC0032S09In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to
WARNING LAMPS, EC-3396.
Diagnostic Test Mode I Ð Malfunction WarningNEEC0032S10
MI Condition
ON When the malfunction is detected or the ECM's CPU is malfunctioning.
OFF No malfunction.
+These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS)
Diagnostic Test Mode II Ð Self-Diagnostic ResultsNEEC0032S11In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below.
The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode
I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illu-
minates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are
displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These uni-
dentified codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example for how
to read a code.
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION
KA24DE (EURO OBD)
Malfunction Indicator (MI)
EC-3063

TERMI-
NAL
NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
49*1 WCamshaft position sen-
sor (Position signal)[Engine is running]
+Warm-up condition
+Idle speedApproximately 2.5V
SEF195T
[Engine is running]
+Engine speed is 2,000 rpmApproximately 1.0V
SEF196T
49*2
53*2OR
ORCamshaft position sen-
sor (Reference signal)[Engine is running]
+Warm-up condition
+Idle speed0.2 - 0.5VSEF114V
[Engine is running]
+Engine speed is 2,000 rpm0 - 0.5V
SEF200T
50 WHeated oxygen sensor
1[Engine is running]
+After warning up to normal operating tempera-
ture and engine speed is 2,000 rpm.0 - Approximately 1.0V
SEF201T
54 L Mass air flow sensor[Engine is running]
+Warm-up condition
+Idle speed0.9 - 1.8V
[Engine is running]
+Warm-up condition
+Engine speed is 2,500 rpm1.9 - 2.3V
55 PMass air flow sensor
ground[Engine is running]
+Warm-up condition
+Idle speedApproximately 0V
TROUBLE DIAGNOSIS Ð GENERAL
DESCRIPTION
KA24DE (EURO OBD)
ECM Terminals and Reference Value
EC-3116

On Board Diagnosis LogicNEEC1534If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
DTC No. Malfunction is detected when ...Check Items
(Possible Cause)
P1217
1217+Engine coolant temperature reaches an abnormally high
temperature.+Cooling fan (crankshaft driven)
Radiator hose
+Radiator
+Radiator cap
+Water pump
+Thermostat
+Engine coolant temperature sensor
For more information, refer to ªMAIN 11 CAUSES
OF OVERHEATINGº, EC-3348.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer to MA section, ªChanging Engine
Coolantº. Also, replace the engine oil.
1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure
to use coolant with the proper mixture ratio. Refer to MA section, ªAnti-freeze Coolant Mixture
Ratioº.
2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.
SEF621W
Overall Function CheckNEEC1535WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by
turning it a quarter turn to allow built-up pressure to escape.
Then turn the cap all the way off.
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-3345.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-3345.
DTC P1217 ENGINE OVER
TEMPERATURE
KA24DE (EURO OBD)
On Board Diagnosis Logic
EC-3344

Spill Tube
Removal
Loosen and remove the mounting bolts and flare nuts in the
reverse order of the numbers in the figure.
+When the flare nuts are loosened, hold the head of hexago-
nal retaining bolts (head inside) using a wrench.
Installation
1. Tighten the flare nuts and mounting bolts in the numerical
order shown in the figure.
+When the flare nuts are tightened, hold the head of the hex-
agonal retaining bolts (head inside) using a wrench.
2. To prevent interference with the rocker cover, place the spill
gasket joint within the range shown by the arrow, then tighten
the mounting bolts. (Be especially careful about No. 2 and 4
cylinders.)
+After the spill tube is installed, check the airtightness of
the spill tube.
+After the bolts are tightened, the joint of the spill tube gasket
might be broken. However, this will not affect function.
High Pressure Injection Nozzle Assembly
Removal
1. Remove the nozzle support, then pull out the high-pressure
injection nozzle assembly by turning it clockwise/
counterclockwise.
2. Using a tool such as a flat-head screwdriver, remove the
copper washer inside the cylinder head.
CAUTION:
Do not disassemble the high-pressure injection nozzle.
Installation
1. Insert the nozzle gasket to the cylinder head hole.
2. Attach the O-ring to the mounting groove of the nozzle side,
then insert it in the cylinder head.
TEST AND ADJUSTMENT
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and
make sure your eyes are properly protected with goggles.
JEF344Y
JEF345Y
BASIC SERVICE PROCEDUREYD25DDTi
Injection Tube and Injection Nozzle (Cont'd)
EC-3417

+Erasing the emission-related diagnostic information using CONSULT-II is easier and quicker than
switching the diagnostic test mode using the data link connector.
NATS (Nissan Anti-Theft System)
+If the security indicator lights up with the ignition switch
in the ªONº position or ªNATS MALFUNCTIONº is dis-
played on ªSELF-DIAG RESULTSº screen, perform self-
diagnostic results mode with CONSULT-II using NATS
program card. Refer to ªNATS (Nissan Anti-Theft Sys-
tem)º in EL section.
+Confirm no self-diagnostic results of NATS is displayed
before touching ªERASEº in ªSELF-DIAG RESULTSº
mode with CONSULT-II.
+When replacing ECM, initialization of NATS system and
registration of all NATS ignition key IDs must be carried
out with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle
owner. Regarding the procedures of NATS initialization
and NATS ignition key ID registration, refer to CON-
SULT-II operation manual, NATS.
Malfunction Indicator Lamp (MIL)
DESCRIPTION
The MIL is located on the instrument panel.
1. The MIL will light up when the ignition switch is turned ON
without the engine running. This is a bulb check.
+If the MIL does not light up, refer to EL section (ªWARNING
LAMPS AND CHIMEº) or see EC-3647.
2. When the engine is started, the MIL should go off.
If the MIL remains on, the on board diagnostic system has
detected an engine system malfunction.
Fuel filter switch is equipped except for Europe.
If MIL illuminates or blinks irregularly after starting engine,
water may have accumulated in fuel filter. Drain water from
fuel filter. Refer to EC-3426.
On board diagnostic system function
The on board diagnostic system has the following three func-
tions.
SEF252Z
SAT652J
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONYD25DDTi
Diagnostic Trouble Code (DTC) (Cont'd)
EC-3429

Diagnostic Test Mode KEY and ENG. Status Function Explanation of Function
Mode I Ignition switch in ON
position
Engine stopped
BULB CHECK This function checks the MIL bulb for dam-
age (blown, open circuit, etc.).
If the MIL does not come on, check MIL cir-
cuit. (See EC-3647.)
Engine running
MALFUNCTION
WARNINGThis is a usual driving condition. When ECM
detects a malfunction, the MIL will light up to
inform the driver that a malfunction has been
detected.
Mode II Ignition switch in ON
position
Engine stopped
SELF-DIAGNOSTIC RESULTS This function allows DTCs to be read.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONYD25DDTi
Malfunction Indicator Lamp (MIL) (Cont'd)
EC-3430