engine NISSAN TERRANO 2002 Service Repair Manual

Introduction
The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control system,
etc. The ECM accepts input signals from sensors and instantly
drives electronic fuel injection pump. It is essential that both input
and output signals are correct and stable. It is also important that
there are no problems such as vacuum leaks, with the engine.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
caused by poor electric connections or faulty wiring. In this case,
careful checking of suspected circuits may help prevent the unnec-
essary replacement of good parts.
A visual check may not be sufficient to determine the cause of the
problems. An active road test with CONSULT-II or a circuit tester
connected should be performed. Follow the ªWork Flowº on the
next page.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus-
tomer can supply important information about such problems,
especially intermittent ones. Find out what symptoms are present
and under what conditions they occur. A ªDiagnostic Worksheetº
like the example on the next page should be used.
Start your diagnosis by looking for ªconventionalº problems first.
This will help troubleshoot driveability problems on a vehicle with
an electronically controlled engine.
SEF858S
SEF233G
SEF234G
TROUBLE DIAGNOSESTD27Ti
EC-334

Diagnostic Worksheet
There are many operating conditions that lead to the malfunction
of engine components. A good understanding of such conditions
can make troubleshooting easier and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
WORKSHEET SAMPLE
Customer name MR/MS Model & Year VIN
Engine # Trans. Mileage
Incident Date Manuf. Date In Service Date
SymptomslStartabilitylImpossible to startlNo combustionlPartial combustion
lPartial combustion when warming-up engine
lPartial combustion when cooling down engine
lPossible but hard to startlOthers [ ]
lIdlinglNo fast idlelUnstablelHigh idlelLow idle
lOthers [ ]
lDriveabilitylStumblelSurgelKnocklLack of power
lOthers [ ]
lEngine stalllAt the time of startlWhile idling
lWhile acceleratinglWhile decelerating
lJust after stoppinglWhile loading
Incident occurrencelJust after deliverylRecently
lIn the morninglAt nightlIn the daytime
FrequencylAll the timelUnder certain conditionslSometimes
Weather conditionslNot affected
WeatherlFinelRaininglSnowinglOthers [ ]
TemperaturelHotlWarmlCoollColdlHumid ÉF
Engine conditionslColdlDuring warm-uplAfter warm-up
Engine speed
0 2,000 4,000 6,000 8,000 rpm
Road conditionslIn townlIn suburbslHighwaylOff road (up/down)
Driving conditionslNot affected
lAt startinglWhile idlinglAt racing
lWhile acceleratinglWhile cruising
lWhile deceleratinglWhile turning (RH/LH)
Vehicle speed
0 102030 405060708090100mph
Malfunction indicator lamplTurned onlNot turned on
SEF907L
TROUBLE DIAGNOSESTD27Ti
EC-335

Description for Work Flow
STEP DESCRIPTION
STEP IGet detailed information about the conditions and the environment when the incident/symptom occurred using the
ªDIAGNOSTIC WORKSHEETº as shown on the next page.
STEP IIBefore confirming the concern, check and write down (print out using CONSULT-II) the Diagnostic Trouble Code
(DTC), then erase the code. (Refer to EC-321). The DTC can be used when duplicating the incident at STEP III &
IV.
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
ªSymptom Matrix Chartº will be useful. Refer to EC-340.)
STEP IIITry to confirm the symptom and under what conditions the incident occurs.
The ªDIAGNOSTIC WORK SHEETº is useful to verify the incident. Connect CONSULT-II to the vehicle in DATA
MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IVTry to detect the Diagnostic Trouble Code (DTC) by driving in (or performing) the ªDTC CONFIRMATION PROCE-
DUREº. Check and read the DTC by using CONSULT-II.
During the DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode
and check real time diagnosis results.
In case the ªDTC CONFIRMATION PROCEDUREº is not available, perform the ªOVERALL FUNCTION CHECKº
instead. The DTC cannot be displayed by this check, however, this simplified ªcheckº is an effective alternative.
The ªNGº result of the ªOVERALL FUNCTION CHECKº is the same as the DTC detection.
STEP VTake the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC.
If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-338. Then perform inspections
according to the Symptom Matrix Chart. Refer to EC-340.
STEP VIIdentify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect
the system for mechanical binding, loose connectors or wiring damage using (tracing) ªHarness Layoutsº.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in ªDATA MONITOR
(AUTO TRIG)º mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CON-
SULT-II. Refer to EC-346.
The ªDIAGNOSTIC PROCEDUREº in EC section contains a description based on open circuit inspection. A short
circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE.
Repair or replace the malfunctioning parts.
STEP VIIOnce you have repaired the circuit or replaced a component, you need to run the engine in the same conditions
and circumstances which resulted in the customer's initial complaint.
Perform the ªDTC CONFIRMATION PROCEDUREº and confirm the normal code (Diagnostic trouble code No. 55)
is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the
previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM. (Refer
to EC-321.)
TROUBLE DIAGNOSESTD27Ti
EC-337

Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
IHeadlamp switch is OFF,
IAir conditioner switch is OFF,
IRear defogger switch is OFF,
ISteering wheel is in the straight-ahead position, etc.
BEFORE STARTING
1. Check service records for any recent
repairs that may indicate a related
problem, or the current need for
scheduled maintenance.
2. Open engine hood and check the fol-
lowing:
IHarness connectors for improper con-
nections
IVacuum hoses for splits, kinks, or
improper connections
IWiring for improper connections,
pinches, or cuts
3.Using priming pump, bleed air from fuel
system. Refer to ªFuel Filter Checkº in
MA section.
CONNECT CONSULT-II TO THE
VEHICLE.
Connect ªCONSULT-IIº to the data link
connector for CONSULT-II and select
ªENGINEº from the menu.
DOES ENGINE START?
Ye s
ENo
Turn ignition switch to
ªLOCKº position, wait 5
seconds and then start
engine. If engine fails to
start, check diagnostic
trouble code (DTC).
Run engine for 10 minutes.
CHECK IDLE SPEED.
Read engine idle speed in ªDATA
MONITORº mode with CONSULT-II.
725 rpm   50 (in N position)
------------------------------------------------------------------------------------------------------------------------------------OR------------------------------------------------------------------------------------------------------------------------------------
Check idle speed using tachometer
tester.
725 rpm   50 (in N position)
(Go toqAon next page.)
SEF142I
NEF463
YEC237A
NEF464
SEF817Y
H
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TROUBLE DIAGNOSESTD27Ti
EC-338

qA
CHECK INJECTION TIMING.
1. Set No. 1 piston at TDC on its com-
pression stroke.
2. Remove injection tubes and air bleeder
on the back of injection pump.
3. Set dial gauge so its indicator points to
somewhere between 1.0 and 2.0 mm
(0.039 and 0.079 in) on the scale.
4. Turn crankshaft two turns clockwise
and check that dial gauge indicates the
same value again.
5. Turn crankshaft counterclockwise about
100 degrees, then turn crankshaft
clockwise slowly, and set dial gauge
indicator to 0 mm at the position it
stops.
6. Turn crankshaft clockwise and set it at
TDC using the mark on the crankshaft
pulley.
7. Read plunger lift.
Plunger lift:
0.36   0.02 mm (0.0142   0.0008
in) at TDC
IWhen repeating the checking, start
with step 5.
NG
EOK
Bleed air from fuel system.
After this inspection,
unnecessary diagnostic
trouble code No. might be
displayed.
Erase the stored memory
in ECM.
Refer to ªHOW TO ERASE
DTCº (EC-321).
OK
INSPECTION END
Adjusting
1. If plunger lift is not within the specified
value, adjust by turning injection pump.
IIf indication is smaller than the
specified value, turn pump body
away from engine.
IIf indication is larger than the speci-
fied value, turn pump body towards
engine.
2. Tighten injection pump securing bolts
and nuts.
Nut:
: 20-25N×m
(2.0 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt:
: 32-42N×m
(3.3 - 4.3 kg-m, 24 - 31 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 20-25N×m
(2.0 - 2.5 kg-m, 14 - 18 ft-lb)
5. Bleed air from fuel system.
Refer to ªDRAINING SYSTEMº of
ªENGINE MAINTENANCEº in MA sec-
tion.
EGo to.
NEF468
NEF465
NEF466
EEF160A
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TROUBLE DIAGNOSESTD27Ti
Basic Inspection (Cont'd)
EC-339

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 lamp 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
IIqIqqIqEC-338
Retardedqq
IIqIqqIqEC-338
Electric injection
pump mainframe
IIIIqqqqqIqqqIIqqIq qqqÐ*1
Injection nozzleqqqqqqq
Iqq qII IEC-313 *2
Glow systemqq
II I IEC-389
Engine body
qq
IIqqqIqq qIIqqqIEM-
section*3
EGR system
II IEC-431
Air cleaner and
ducts
II IqMA-
section*4
I; 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 DIAGNOSESTD27Ti
EC-340

SYSTEM Ð Engine control system Malfunction
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 lamp 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 HA
Mass air flow sensor circuit open, ground shortqqq q
EC-356
shortqqq
Engine coolant temperature sensor
circuit open, shortqqq qqq qqEC-361Compensation according to
engine coolant temperature does
not function.
Vehicle speed sensor circuit open, shortqqEC-397
Control sleeve position sensor circuit open, shortqqqqqqEC-414
Injection timing control valve circuit
open, shortqqq
EC-380Injection timing cannot be con-
trolled.
ground shortqq
Accelerator switch (F/C) circuit open, shortqqq
EC-365
ground shortqq
Needle lift sensor circuit open, shortqqqEC-427
Fuel cut solenoid valve circuit open, ground shortq qqqq
EC-376
shortqqqEngine runs on after turning igni-
tion switch OFF.
Fuel temperature sensor circuit
open, shortqq qq qq qq q qEC-372Compensation for amount of fuel
injected according to fuel tem-
perature does not function.
Accelerator position sensor circuit open, shortqqq qqEC-365
Crankshaft position sensor (TDC) cir-
cuitopen, shortqq qq
EC-385
noiseqqqqq
TROUBLE DIAGNOSESTD27Ti
Symptom Matrix Chart (Cont'd)
EC-341

SYSTEM Ð Engine control 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 lamp 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 HA
Start signal circuit open, shortqqEC-449 Start control does not function.
Air conditioner switch circuit
open, ground short
EC-440Air Conditioner does not stop
operating.
shortAir Conditioner does not work.
Ignition switch circuit openq qqq
EC-449
shortEngine does not stop.
Power supply for ECM circuit openqqq
EC-352
shortqq
Throttle control solenoid valve circuit open, short
EC-435Does not operate.
ground shortqq qDoes not stop operating.
EGRC-solenoid valve A, B circuit open, short
EC-431
ground shortqDoes not stop operating.
Glow relay circuit openqqqqq
EC-389Glow lamp does not turn on.
shortGlow lamp does not turn off.
ECM relay (Self-shut off) circuit openqqqq
EC-446
shortqqGround short makes engine
unable to stop.
Air conditioner relay circuit open
EC-440Air conditioner does not operate.
shortAir conditioner does not stop
operating.
ECM, Connector circuit open, shortqqqqqqqqqqqqqq qqqqqqqqqqqEC-346, 452
TROUBLE DIAGNOSESTD27Ti
Symptom Matrix Chart (Cont'd)
EC-342

CONSULT-II Reference Value in Data Monitor
Mode
Remarks:
ISpecification data are reference values.
ISpecification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
MONITOR ITEM CONDITION SPECIFICATION
CKPS×RPM (TDC)
ITachometer: Connect
IRun engine and compare tachometer indication with the CONSULT-II value.Almost the same speed as the CON-
SULT-II value. CKPS×RPM (REF)
CMPS×RPM-PUMP
COOLAN TEMP/SIEngine: After warming up More than 70ÉC (158ÉF)
VHCL SPEED SEITurn drive wheels and compare speedometer indication with the CONSULT-II
valueAlmost the same speed as
the CONSULT-II value
FUEL TEMP SENIEngine: After warming up More than 40ÉC (104ÉF)
ACCEL POS SENIIgnition switch: ON
(Engine stopped)Accelerator pedal: release 0.40 - 0.60V
Accelerator pedal: depress Approx. 4.0V
FULL ACCEL SWIIgnition switch: ON
(Engine stopped)Accelerator pedal: depress ON
Except above OFF
ACCEL SW (FC)IIgnition switch: ON
(Engine stopped)Accelerator pedal: release CLOSE
Accelerator pedal: slightly open OPEN
OFF ACCEL SWIIgnition switch: ON
(Engine stopped)Accelerator pedal: release ON
Accelerator pedal: slightly open OFF
C/SLEEV POS/SIEngine: After warming up, idle the engine 1.0 - 3.5V
BATTERY VOLTIIgnition switch: ON (Engine stopped) 11 - 14V
P/N POSI SWIIgnition switch: ONShift lever: Neutral ON
Except above OFF
START SIGNALIIgnition switch: ON,START,ON OFF,ON,OFF
AIR COND SIGIEngine: After warming up, idle the
engineAir Conditioner switch: ªOFFº OFF
Air Conditioner switch: ªONº
(Compressor operates.)ON
IGN SWIIgnition switch: ON,OFF ON,OFF
MAS AIR/FL SEIEngine: After warming up
IAir Conditioner switch: ªOFFº
IShift lever: ªNº
INo-loadIdle 1.5 - 2.1V
2,000 rpm 2.3 - 2.9V
ACT INJ TIMGIEngine: After warming up
IAir Conditioner switch: ªOFFº
IShift lever: ªNº
INo-loadIdle þ5.0É to þ9.0É
2,000 rpm þ5.0É to þ18.0É
DECELER F/CUTIEngine: After warming upIdle OFF
When accelerator pedal is released
quickly with engine speed at 3,000 rpm
or more.ON
FUEL CUT S/VIIgnition switch: ON,OFF ON,OFF
AIR COND RLYIAir Conditioner switch: OFF,ON OFF,ON
GLOW RLYIRefer to EC-389.
TROUBLE DIAGNOSESTD27Ti
EC-343

MONITOR ITEM CONDITION SPECIFICATION
EGRC SOL/V AIEngine: After warming up
IAir Conditioner switch: ªOFFº
IShift lever: ªNº
INo-loadIdle ON
3,200 rpm OFF
EGRC SOL/V BIEngine: After warming up
IAir Conditioner switch: ªOFFº
IShift lever: ªNº
INo-loadIdle ON
3,000 rpm OFF
THROT RLYIEngine: After warming up
IAir Conditioner switch: ªOFFº
IShift lever: ªNº
INo-loadIdle ON
3,000 rpm OFF
TROUBLE DIAGNOSESTD27Ti
CONSULT-II Reference Value in Data Monitor
Mode (Cont'd)
EC-344