engine overheat NISSAN PRIMERA 1999 Electronic Repair Manual

CVT Fluid CheckNCAT0025FLUID LEAKAGE CHECKNCAT0025S011. Clean area suspected of leaking. Ð for example, mating sur-
face of converter housing and transmission case.
2. Start engine, apply foot brake, place selector lever in ªDº posi-
tion and wait a few minutes.
3. Stop engine.
4. Check for fluid leakage.
FLUID CONDITION CHECKNCAT0025S02
Fluid color Suspected problem
Dark or black with burned odor Wear of frictional material
Milky pink Water contamination Ð Road water
entering through filler tube or breather
Varnished fluid, light to dark brown and
tackyOxidation Ð Over or under filling, Ð
Overheating
FLUID LEVEL CHECKNCAT0025S03Refer to MA section (ªChecking CVT Fluidº, ªCHASSIS AND BODY
MAINTENANCEº).
Stall TestNCAT0026STALL TEST PROCEDURENCAT0026S011. Check CVT fluid and engine oil levels. If necessary, add.
2. Drive vehicle for approx. 10 minutes or until engine oil and CVT
fluid reach operating temperature.
CVT fluid operating temperature:
50 - 80ÉC (122 - 176ÉF)
SAT767B
SAT288G Fluid leakage
SAT638A
SAT647B
TROUBLE DIAGNOSIS Ð BASIC INSPECTION
CVT Fluid Check
AT-34

Injection Timing Control Valve ................................. 82
TROUBLE DIAGNOSIS 7............................................ 86
Engine Control Module (ECM) ................................ 86
TROUBLE DIAGNOSIS 8............................................ 87
Cooling Fan (Overheat) ........................................... 87
TROUBLE DIAGNOSIS 9............................................ 97
Needle Lift Sensor (NLS) ........................................ 97
TROUBLE DIAGNOSIS 10........................................ 100
Fuel Cut Solenoid Valve ........................................ 100
TROUBLE DIAGNOSIS 11........................................ 104
Fuel Temperature Sensor (FTS)............................ 104
TROUBLE DIAGNOSIS 12........................................ 108
Accelerator Position Sensor & Switch ................... 108
TROUBLE DIAGNOSIS 13......................................... 114
Crankshaft Position Sensor (TDC) ......................... 114
TROUBLE DIAGNOSES 14....................................... 118
Glow Control System .............................................. 118TROUBLE DIAGNOSES 15...................................... 126
Air Conditioner Cut Control ................................... 126
TROUBLE DIAGNOSES 16...................................... 129
EGRC-Solenoid Valve ........................................... 129
TROUBLE DIAGNOSES 17...................................... 136
Brake Switch .......................................................... 136
TROUBLE DIAGNOSES 18...................................... 140
ECM Relay............................................................. 140
TROUBLE DIAGNOSES 19...................................... 141
MI & Data Link Connectors ................................... 141
TROUBLE DIAGNOSES 20...................................... 145
Start Signal ............................................................ 145
SERVICE DATA AND SPECIFICATIONS (SDS)...... 147
General Specifications ........................................... 147
Injection Nozzle ..................................................... 147
Inspection and Adjustment .................................... 147
When you read wiring diagrams:
lRead GI section, ªHOW TO READ WIRING DIAGRAMSº.
lSee EL section, ªPOWER SUPPLY ROUTINGº for power distribution circuit.
lSee EL section for NATS information and wiring diagram.
When you perform trouble diagnoses, read GI section, ªHOW TO FOLLOW FLOW CHART
IN TROUBLE DIAGNOSESº and ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN
ELECTRICAL INCIDENTº.
For clarification of system component abbreviations and terminology read GI section
ªSAE J1930 TERMINOLOGY LISTº.
EC-2

Ð: Not applicable
Check Items
(Possible Cause)*1
Confirmation
Procedure
Quick Ref.*2
Overall
Function
CheckMI
IlluminationReference
Page
lHarness or connectors
(The cooling fan circuit is open or shorted.)
lCooling fan
lRadiator hose
lRadiator
lRadiator cap
lWater pump
lThermostat
lFan belt
lEngine coolant temperature sensor
For more information, refer to ª12 MAIN CAUSES OF
OVERHEATINGº. (EC-CD-95)ÐIGN: ON
(RUNNING)Lighting up EC-CD-78
lECM
IGN: ON Ð Lighting up EC-CD-86
lHarness or connectors
(The sensor circuit is open or shorted.)
lNeedle lift sensor
lAir in fuel line
lClogging No. 1 injection nozzleRUNNING Ð Lighting up EC-CD-97
lHarness or connectors
(The solenoid valve circuit is open or shorted.)
lFuel cut solenoid valveRUNNING Ð Lighting up EC-CD-100
lHarness or connectors
(The sensor circuit is open or shorted.)
lFuel temperature sensorIGN: ON Ð Ð EC-CD-104
lHarness or connectors
(The sensor circuit is open or shorted.)
lAccelerator position sensor
lAccelerator position switchIGN: ON Ð Lighting up EC-CD-108
lHarness or connectors
(The sensor circuit is open or shorted.)
lCrankshaft position sensor (TDC)RUNNING Ð Lighting up EC-CD-114
lNo failure
Ð ÐÐÐ
*1:lThis is Quick Reference of ªDIAGNOSTIC TROUBLE CONFIRMATION PROCEDUREº.
Details are described in each specific TROUBLE DIAGNOSIS.
*2:
lThe ªOVERALL FUNCTION CHECKº is a simplified and effective way to inspect a component or circuit.
In some cases, the ªOVERALL FUNCTION CHECKº is used rather than a ªDIAGNOSTIC TROUBLE CONFIRMATION PRO-
CEDUREº.
When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available, the ªNGº result of the OVERALL FUNCTION
CHECK can be considered to mean the same as a malfunction item detection.
lDuring an ªNGº OVERALL FUNCTION CHECK, the malfunction item might not be confirmed.lThis is Quick Reference of ªOVERALL FUNCTION CHECKº.
Details are described in each specific TROUBLE DIAGNOSIS.
TROUBLE DIAGNOSIS Ð General DescriptionCD20T
Diagnostic Trouble Chart (Cont'd)
EC-42

Symptom Matrix Chart
SYSTEM
Ð Basic engine
control systemSYMPTOM
Reference page
Feature of symptom, Check pointHARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator illuminates.
Can be detected by CONSULT-II?
Fuel cutNO START (with first firing)
NO START (without first firing)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATING
BLACK SMOKE
WHITE SMOKENew CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Injec-
tion
timingAdvancedqq
llqlqqlqEC-CD-38
Retardedqq
llqlqqlqEC-CD-38
Electric injection
pump mainframe
llllqqqqqlqqqllqqlq qqqÐ*1
Injection nozzleqqqqqqq
lqq qll lEC-CD-22 *2
Glow systemqq
ll l lEC-CD-118
Engine bodyqq
llqqqlqq qllqqqlEM-
section*3
EGR system
ll lEC-CD-129
Air cleaner and
ducts
ll lqMA-
section*4
l; High Possibility Item
q; Low Possibility Item
*1: Insufficient or excess amount. Governor malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
TROUBLE DIAGNOSIS Ð General DescriptionCD20T
EC-47

SYSTEM Ð Engine control module systemMalfunction
SYMPTOM
Reference page Feature of symptom
Check point
HARD/NO START/
RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE) Malfunction indicator illuminates.
Can be detected by CONSULT-II?
Fuel cut
NO START (with first firing) NO START (without first firing)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGBLACK SMOKE WHITE SMOKE
New CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HAEngine control moduleMass air flow sensor circuitopen, ground shortqqq q
EC-CD-62
shortqqq
Engine coolant temperature sensor
circuitopen, shortqqq qqq qqEC-CD-66Compensation according to
engine coolant temperature
does not function.
Vehicle speed sensor circuit or ABS
actuator and electric unit (control
unit) circuitopen, shortqqEC-CD-70
Control sleeve position sensor cir-
cuitopen, shortqqq qqqEC-CD-74
Electric governor circuitopen, ground shortq qqq qqq
EC-CD-78
shortqq
Injection timing control valve circuitopen, shortqqqq
EC-CD-82Injection timing cannot be
controlled.
ground shortqqq
Needle lift sensor circuit open, shortqqqqEC-CD-97
Fuel cut solenoid valve circuitopen, ground shortq qqq qqq
EC-CD-100
shortqqqEngine runs on after turning
ignition switch OFF.
Fuel temperature sensor circuit open, shortqq qq qq q qq qEC-CD-104Compensation for amount
of fuel injected according
to fuel temperature does
not function.
Accelerator position sensor circuit open, shortqqq qqEC-CD-108
Crankshaft position sensor (TDC)
circuitopen, shortqq qq
EC-CD-114
noiseqqq qq
TROUBLE DIAGNOSIS Ð General DescriptionCD20T
Symptom Matrix Chart (Cont'd)
EC-48

SYSTEM Ð Engine control module systemMalfunction
SYMPTOM
Reference page Feature of symptom
Check point
HARD/NO START/
RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE) Malfunction indicator illuminates.
Can be detected by CONSULT-II?
Fuel cut
NO START (with first firing) NO START (without first firing)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGBLACK SMOKE WHITE SMOKE
New CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HAEngine control moduleStart signal circuit open, shortqqEC-CD-145 Start control does not function.
Air conditioner switch circuitopen, ground short
EC-CD-126Air conditioner does not stop
operating.
shortAir conditioner does not work.
Accelerator position switch (Idle)
circuitopen, ground shortqq q qq
EC-CD-108
shortqqq qqAccelerator position sensor NG
signal is output.
Ignition switch circuit (ON signal)openq qqq
EC-CD-59
shortEngine does not stop.
Power supply for ECM circuitopenqqq
EC-CD-59
shortqq
EGRC-solenoid valve circuitopen, shortqq
EC-CD-129
ground shortqqqDoes not stop operating.
Glow relay circuitopenqqqq q qq
EC-CD-118Glow lamp does not turn on.
shortqqGlow lamp does not turn off.
Engine control module relay (Self-
shutoff) circuitopenqqqq
EC-CD-59
shortqq qGround short makes engine
unable to stop.
Air conditioner relay circuitopen
EC-CD-126Air conditioner does not oper-
ate.
shortqqAir conditioner does not stop
operating.
Brake switch circuitsopenq
EC-CD-136
shortq
ECM, Connector circuit open, shortqqqqqqqqqqqqq qqqqqqqqqqqqEC-CD-86
TROUBLE DIAGNOSIS Ð General DescriptionCD20T
Symptom Matrix Chart (Cont'd)
EC-49

Cooling Fan (Overheat)
SYSTEM DESCRIPTION
Vehicle speed sensorEVehicle speed
ECM
ECooling
fan
relay(s)Engine coolant temperature sensorEEngine coolant temperature
Air conditioner switch
EAir conditioner ªONº signal
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air con-
ditioner system pressure and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/
OFF]. This system indirectly relates to diagnostic trouble code 28 (Overheat).
Operation
ON-BOARD DIAGNOSIS LOGIC
This diagnosis continuously monitors the engine coolant temperature.
If 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.
Malfunction is detected when ...Check Items
(Possible Cause)
lAn excessive high engine coolant temperature sensor sig-
nal is detected by the ECM. (Overheat)lHarness or connectors
(The cooling fan circuit is open or shorted.)
lCooling fan
lRadiator hose
lRadiator
lRadiator cap
lWater pump
lThermostat
lFan belt
lEngine coolant temperature sensor
For more information, refer to ª12 MAIN CAUSES OF
OVERHEATINGº, EC-CD-95.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (ªChanging Engine Coolantº, ªENGINE MAINTENANCEº). Also, replace the engine oil.
a. 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, ªRECOMMENDED FLUIDS AND LUBRICANTSº).
b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
NEF772
Engine coolant
temperature ÉC (ÉF)
Air conditioner is OFF
.102 (216)
.96 (205)
.20
(12).80
(50)
Vehicle speed km/h (mph)
Cooling fans do not operateCooling fans operate at high speed
Engine coolant
temperature ÉC (ÉF)
Vehicle speed km/h (mph)
.20
(12).80
(50)
.102 (216)
.96 (205)Air conditioner is ON
Cooling fans operate at low speed
TROUBLE DIAGNOSIS 8CD20T
EC-87

OVERALL FUNCTION CHECK
Use this procedure to check the overall function of the cooling
fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Seri-
ous burns could be caused by high pressure fluid escaping
from the radiator.
Wrap a thick cloth around the 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
ªDIAGNOSTIC PROCEDUREº, EC-CD-90.
2) Confirm whether customer filled the coolant or not. If cus-
tomer filled the coolant, skip the following steps and go to
ªDIAGNOSTIC PROCEDUREº, EC-CD-90.
3) Turn ignition switch to ªONº position.
4) Perform ªCOOLING FANº in ªACTIVE TESTº mode
with CONSULT-II (LOW speed and HI speed).
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------OR--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
3) Start engine.
Be careful not to overheat engine.
4) Set temperature control switch to full cold position.
5) Push Air Conditioner switch to ªONº position.
6) Turn blower fan switch to ªONº position.
7) Run engine at idle for a few minutes with Air Con-
ditioner operating.
Be careful not to overheat engine.
8) Make sure that both cooling fans operate at low
speed.
9) Turn ignition switch to ªLOCKº position.
10) Push Air Conditioner switch and blower fan switch
to ªOFFº position.
11) Disconnect engine coolant temperature sensor
harness connector.
12) Connect 150Wresistor to engine coolant tempera-
ture sensor harness connector.
13) Restart engine and make sure that both cooling
fans operate at higher speed than low speed.
Be careful not to overheat engine.
AEC640 MAX.
MIN.OK
SEF111X
SEC163BA
MEC475B Cooling fan
Engine coolant
temperature sensor
harness connector
150Wresistor
TROUBLE DIAGNOSIS 8CD20T
Cooling Fan (Overheat) (Cont'd)
EC-88

DIAGNOSTIC PROCEDURE
INSPECTION START
CHECK COOLING FAN LOW
SPEED OPERATION.
1. Disconnect cooling fan relay-3.
2. Turn ignition switch to ªONº
position.
3. Perform ªCOOLING FANº
in ªACTIVE TESTº mode
with CONSULT-II.
-------------------------------------------------------------------------------------------------------------------------OR-------------------------------------------------------------------------------------------------------------------------
2. Start engine.
3. Set temperature switch at
full cold position.
4. Turn Air Conditioner switch
to ªONº position.
5. Turn blower fan switch to
ªONº position.
6. Run engine at idle speed
for a few minutes with Air
Conditioner operating.
7. Make sure that both cool-
ing fans operate at low
speed.
OK
ENG
Check cooling fan low
speed control circuit.
(Go to
PROCEDURE A
.)
CHECK COOLING FAN HIGH
SPEED OPERATION.
1. Turn ignition switch to ªLOCKº
position.
2. Reconnect cooling fan relay-3.
3. Disconnect cooling fan relay-1.
4. Turn ignition switch to ªONº
position.
5. Perform ªCOOLING FANº
in ªACTIVE TESTº mode
with CONSULT-II.
-------------------------------------------------------------------------------------------------------------------------OR-------------------------------------------------------------------------------------------------------------------------
4. Turn Air Conditioner switch
and blower fan switch to
ªOFFº position.
5. Disconnect engine coolant
temperature sensor har-
ness connector.
6. Connect 150Wresistor to
engine coolant temperature
sensor harness connector.
7. Restart engine and make
sure that both cooling fans
operate at higher speed
than low speed.
OK
ENG
Check cooling fan high
speed control circuit.
(Go to
PROCEDURE B
.)
pB
(Go to EC-CD-94.)
.Cooling fan relay 2
Cooling fan relay-1Cooling fan relay-3
YEC383
SEF111X
NEF809
Cooling fan
SEF111X
YEC384
Cooling fan
Engine coolant
temperature sensor
harness connector
resistor
H
H
H
TROUBLE DIAGNOSIS 8CD20T
Cooling Fan (Overheat) (Cont'd)
EC-90

pB
CHECK COOLING SYSTEM FOR LEAK.
Apply pressure to the cooling system with a
tester, and check if the pressure drops.
Testing pressure:
157kPa (1.57 bar, 1.6 kg/cm
2, 23 psi)
Pressure should not drop.
CAUTION:
Higher than the specified pressure may
cause radiator damage.
OK
ENG
Check the following
for leaks:
lHoselRadiatorlWater pump
Refer to LC section
(ªWater Pumpº).
CHECK RADIATOR CAP.
Apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78 - 98 kPa (0.78 - 0.98 bar,
0.8 - 1.0 kg/cm
2, 11 - 14 psi)
Limit
59 - 88 kPa (0.59 - 0.88 bar,
0.6 - 0.9 kg/cm
2,9-13psi)
OK
ENG
Replace radiator
cap.
CHECK THERMOSTAT.
1. Check valve seating condition at normal
room temperatures.
It should seat tightly.
2. Check valve opening temperature and
maximum valve lift.
Valve opening temperature:
76.5ÉC (170ÉF) [standard]
Maximum valve lift:
More than 8 mm/90ÉC
(0.31 in/194ÉF)
3. Check if valve is closed at 5ÉC (9ÉF)
below valve opening temperature.
For details, refer to LC section
(ªThermostatº).
OK
ENG
Replace thermostat.
Check engine coolant temperature sensor.
Refer to ªCOMPONENT INSPECTIONº,
EC-69.
OK
ENG
Replace engine cool-
ant temperature sen-
sor.
If the cause can not be isolated, go to ª12
MAIN CAUSES OF OVERHEATINGº on
next page.
INSPECTION END
Perform FINAL CHECK by the following procedure after
repair is completed.
1. Warm up engine. Run the vehicle for at least 20 minutes. Pay
attention to engine coolant temperature gauge on the instru-
ment panel. If the reading shows an abnormally high
temperature, another part may be malfunctioning.
2. Stop vehicle and let engine idle. Check the intake and
exhaust systems for leaks by listening for noise or visually
inspecting the components.
3. Allow engine to cool and visually check for oil and coolant
leaks. Then, perform ªOVERALL FUNCTION CHECKº.
Hose adapter
.SLC754AA
SLC755AA
SLC343
H
H
H
H
H
H
TROUBLE DIAGNOSIS 8CD20T
Cooling Fan (Overheat) (Cont'd)
EC-94