mass air flow NISSAN TERRANO 2002 Service Repair Manual

ENGINE CONTROL SYSTEM
SECTION
EC
CONTENTS
ZD30DDTi
TROUBLE DIAGNOSIS - INDEX....................................7
Alphabetical & Numerical Index for DTC ....................7
PRECAUTIONS...............................................................9
Precautions ..................................................................9
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM.........................................................................12
Engine Control Component Parts Location ...............12
Circuit Diagram ..........................................................16
System Diagram ........................................................17
Vacuum Hose Drawing ..............................................18
System Chart .............................................................19
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION...............................................20
Fuel Injection Control System ...................................20
Fuel Injection Timing Control System........................22
Air Conditioning Cut Control ......................................22
Fuel Cut Control (at no load & high engine
speed) ........................................................................22
Crankcase Ventilation System ...................................23
BASIC SERVICE PROCEDURE...................................24
Injection Tube and Injection Nozzle ..........................24
Electronic Control Fuel Injection Pump .....................27
Air Bleeding ...............................................................32
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION...............................................................33
DTC and MI Detection Logic .....................................33
Diagnostic Trouble Code (DTC) ................................33
Malfunction Indicator (MI) ..........................................34
CONSULT-II ...............................................................39
TROUBLE DIAGNOSIS - INTRODUCTION..................46
Introduction ................................................................46
Work Flow ..................................................................48
TROUBLE DIAGNOSIS - BASIC INSPECTION...........50
Basic Inspection.........................................................50
TROUBLE DIAGNOSIS - GENERAL
DESCRIPTION...............................................................56
Symptom Matrix Chart ...............................................56CONSULT-II Reference Value in Data Monitor
Mode ..........................................................................66
Major Sensor Reference Graph in Data Monitor
Mode ..........................................................................68
ECM Terminals and Reference Value .......................69
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT.......................................................................78
Description .................................................................78
Diagnostic Procedure ................................................78
TROUBLE DIAGNOSIS FOR POWER SUPPLY..........79
Main Power Supply and Ground Circuit ....................79
DTC 0102 MASS AIR FLOW SEN................................88
Component Description .............................................88
CONSULT-II Reference Value in Data Monitor
Mode ..........................................................................88
ECM Terminals and Reference Value .......................88
On Board Diagnosis Logic.........................................88
DTC Confirmation Procedure ....................................89
Wiring Diagram ..........................................................90
Diagnostic Procedure ................................................92
DTC 0103 COOLANT TEMP SEN................................95
Description .................................................................95
On Board Diagnosis Logic.........................................95
DTC Confirmation Procedure ....................................95
Wiring Diagram ..........................................................96
Diagnostic Procedure ................................................97
DTC 0104 VEHICLE SPEED SEN................................99
Description .................................................................99
ECM Terminals and Reference Value .......................99
On Board Diagnosis Logic.........................................99
Overall Function Check ...........................................100
Wiring Diagram ........................................................101
Diagnostic Procedure ..............................................103
DTC 0203 ACCEL POS SW (F/C)..............................104
Description ...............................................................104
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................104
ECM Terminals and Reference Value .....................104
On Board Diagnosis Logic.......................................104

CONSULT-II Reference Value in Data Monitor
Mode ........................................................................281
ECM Terminals and Reference Value .....................282
Wiring Diagram ........................................................283
Diagnostic Procedure ..............................................284
AIR CONDITIONER CONTROL..................................289
Wiring Diagram ........................................................289
MI (MIL) & DATA LINK CONNECTORS.....................291
Wiring Diagram ........................................................291
SERVICE DATA AND SPECIFICATIONS (SDS)........292
General Specifications .............................................292
Injection Pump Numbers .........................................292
Injection Nozzle .......................................................292
Engine Coolant Temperature Sensor ......................292
Crankshaft Position Sensor (TDC) ..........................292
Glow Plug ................................................................292
Accelerator Position Sensor ....................................292
EGR Volume Control Valve .....................................292
TD27Ti
TROUBLE DIAGNOSIS - INDEX................................293
Alphabetical & Numerical Index for DTC ................293
PRECAUTIONS AND PREPARATION........................295
Special Service Tools ..............................................295
Engine Fuel & Emission Control System ................297
Precautions ..............................................................298
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM.......................................................................300
Engine Control Component Parts Location .............300
Circuit Diagram ........................................................302
System Diagram ......................................................303
Vacuum Hose Drawing ............................................304
System Chart ...........................................................305
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION.............................................306
Fuel Injection System ..............................................306
Fuel Injection Timing System ..................................309
Air Conditioning Cut Control .................................... 311
Fuel Cut Control (at high engine speed) ................. 311
Glow Control ............................................................ 311
CRANKCASE VENTILATION SYSTEM......................312
Description ...............................................................312
Blow-by Control Valve .............................................312
Ventilation Hose .......................................................312
INJECTION NOZZLE...................................................313
Removal and Installation .........................................313
Disassembly (No.2-4nozzle) ...............................313
Inspection (No.2-4nozzle) ...................................314
Cleaning (No.2-4nozzle) .....................................314
Assembly (No.2-4nozzle) ....................................315
Test and Adjustment ................................................316
ELECTRONIC FUEL INJECTION PUMP....................318Removal ...................................................................318
Installation ................................................................319
Disassembly and Assembly .....................................320
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION.............................................................321
DTC and MI Detection Logic ...................................321
Diagnostic Trouble Code (DTC) ..............................321
Malfunction Indicator (MI) ........................................322
CONSULT-II .............................................................327
TROUBLE DIAGNOSES.............................................334
Introduction ..............................................................334
Diagnostic Worksheet ..............................................335
Work Flow ................................................................336
Description for Work Flow .......................................337
Basic Inspection.......................................................338
Symptom Matrix Chart .............................................340
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................343
Major Sensor Reference Graph in Data Monitor
Mode ........................................................................345
ECM Terminals and Reference Value .....................346
TROUBLE DIAGNOSIS FOR POWER SUPPLY........352
Wiring Diagram ........................................................352
Diagnostic Procedure ..............................................353
DTC P0100 MASS AIR FLOW SEN...........................356
Component Description ...........................................356
On Board Diagnosis Logic.......................................356
DTC Confirmation Procedure ..................................356
Wiring Diagram ........................................................357
Diagnostic Procedure ..............................................359
Component Inspection .............................................360
DTC P0115 COOLANT TEMP SEN............................361
Component Description ...........................................361
On Board Diagnosis Logic.......................................361
DTC Confirmation Procedure ..................................361
Wiring Diagram ........................................................362
Diagnostic Procedure ..............................................363
Component Inspection .............................................364
DTC P0120 ACCEL POS SENSOR............................365
Component Description ...........................................365
On Board Diagnosis Logic.......................................365
DTC Confirmation Procedure A (For General
Plausibility) ...............................................................365
DTC Confirmation Procedure B (For Accelerator
Sticking) ...................................................................366
Wiring Diagram ........................................................367
Diagnostic Procedure ..............................................368
Component Inspection .............................................371
DTC P0180 FUEL TEMP SENSOR............................372
Component Description ...........................................372
On Board Diagnosis Logic.......................................372
DTC Confirmation Procedure ..................................372
CONTENTS(Cont'd)
EC-4

Alphabetical & Numerical Index for DTC
ALPHABETICAL INDEX FOR DTC
X: Applicable Ð: Not applicable
Items
(CONSULT-II screen terms)DTC MI (MIL) illumination Reference page
ACCEL POS SENSOR 0403 X EC-130
ACCEL POS SW (F/C) 0203 X EC-104
A/T COMM LINE 0504 Ð EC-155
BATTERY VOLTAGE 0502 Ð EC-153
COOLANT TEMP SEN 0103 X EC-95
CRANK POS SEN (TDC) 0407 X EC-145
ECM 2 0301 X EC-121
ECM 10 0802 X EC-200
ECM 11 0804 Ð EC-202
ECM 12 0901 X EC-121
ECM 14 0807 X EC-204
ECM 15 0903 Ð EC-213
ECM RLY 0902 X EC-209
EGR VOLUME CONT/V 1003 X EC-222
FUEL CUT SYSTEM1 1004 X EC-232
INT/AIR VOLUME 0406 Ð EC-143
MASS AIR FLOW SEN 0102 X EC-88
NATS MALFUNCTION 1401 - 1408 Ð EL section
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.0505 Ð Ð
OVER HEAT 0208 X EC-109
P1×CAM POS SEN 0701 X EC-161
P2×TDC PULSE SIG 0702 X EC-168
P3×PUMP COMM LINE 0703 X EC-175
P4×SPILL/V CIRC 0704 X EC-182
P5×PUMP C/MODULE 0705 X EC-189
P6×SPILL VALVE 0706 X EC-182
P7×F/INJ TIMG FB 0707 X EC-192
P9×FUEL TEMP SEN 0402 X EC-123
TURBO PRESSURE 0905 X EC-215
VEHICLE SPEED SEN 0104 X EC-99
TROUBLE DIAGNOSIS Ð INDEXZD30DDTi
EC-7

NUMERICAL INDEX FOR DTC
X: Applicable Ð: Not applicable
DTCItems
(CONSULT-II screen terms)MI (MIL) illumination Reference page
0102 MASS AIR FLOW SEN X EC-88
0103 COOLANT TEMP SEN X EC-95
0104 VEHICLE SPEED SEN X EC-99
0203 ACCEL POS SW (F/C) X EC-104
0208 OVER HEAT X EC-109
0301 ECM 2 X EC-121
0402 P9×FUEL TEMP SEN X EC-123
0403 ACCEL POS SENSOR X EC-130
0406 INT/AIR VOLUME Ð EC-143
0407 CRANK POS SEN (TDC) X EC-145
0502 BATTERY VOLTAGE Ð EC-153
0504 A/T COMM LINE Ð EC-155
0505NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED.ÐÐ
0701 P1×CAM POS SEN X EC-161
0702 P2×TDC PULSE SIG X EC-168
0703 P3×PUMP COMM LINE X EC-175
0704 P4×SPILL/V CIRC X EC-182
0705 P5×PUMP C/MODULE X EC-189
0706 P6×SPILL VALVE X EC-182
0707 P7×F/INJ TIMG FB X EC-192
0802 ECM 10 X EC-200
0804 ECM 11 Ð EC-202
0807 ECM 14 X EC-204
0901 ECM 12 X EC-121
0902 ECM RLY X EC-209
0903 ECM 15 Ð EC-213
0905 TURBO PRESSURE X EC-215
1003 EGR VOLUME CONT/V X EC-222
1004 FUEL CUT SYSTEM1 X EC-232
1401 - 1408 NATS MALFUNCTION Ð EL section
TROUBLE DIAGNOSIS Ð INDEXZD30DDTi
Alphabetical & Numerical Index for DTC
(Cont'd)
EC-8

System Chart
Input (Sensor) ECM Function Output (Actuator)
IElectronic control fuel injection pump
ICrankshaft position sensor (TDC)
IEngine coolant temperature sensor
IAccelerator position sensor
IAccelerator position switch
IAccelerator switch (F/C)
IPark/Neutral position (PNP) switch
IIgnition switch
IBattery voltage
IVehicle speed sensor
IAir conditioner switch
IMass air flow sensor
IStop lamp switch
IHeat up switch
ICharge air pressure sensor*1Fuel injection control Electronic control fuel injection pump
Fuel injection timing control Electronic control fuel injection pump
Fuel cut control Electronic control fuel injection pump
Glow control system Glow relay & glow lamp
On board diagnostic system MIL (On the instrument panel)
EGR volume control EGR volume control valve
Cooling fan control Cooling fan relay
Air conditioning cut control Air conditioner relay
Variable nozzle turbocharger control Variable nozzle turbocharger control sole-
noid valve
Swirl control valve control Swirl control valve control solenoid valve
Intake air control valve control Intake air control valve control solenoid
valve
*1: This sensor is not used to control the engine system under normal conditions.
ENGINE AND EMISSION CONTROL OVERALL SYSTEMZD30DDTi
EC-19

Normal control
Input/output signal chart
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor (TDC) Engine speed
Fuel injection con-
trol (Normal con-
trol)Electronic control fuel injec-
tion pump Accelerator position sensor Accelerator position
Vehicle speed sensor Vehicle speed
The amount of fuel injected under normal driving conditions is
determined according to sensor signals. The crankshaft position
sensor (TDC) detects engine speed and the accelerator position
sensor detects accelerator position. These sensors send signals to
the ECM.
The fuel injection data, predetermined by correlation between vari-
ous engine speeds and accelerator positions, are stored in the
ECM memory, forming a map. The ECM determines the optimal
amount of fuel to be injected using the sensor signals in compari-
son with the map.
Maximum amount control
Input/output signal chart
Sensor Input Signal to ECM ECM Function Actuator
Mass air flow sensor Amount of intake air
Fuel injection con-
trol (Maximum
amount control)Electronic control fuel injec-
tion pump Engine coolant temperature sensor Engine coolant temperature
Crankshaft position sensor (TDC) Engine speed
Accelerator position sensor Accelerator position
The maximum injection amount is controlled to an optimum by the engine speed, intake air amount, engine
coolant temperature, and accelerator opening in accordance with the driving conditions.
This prevents the oversupply of the injection amount caused by decreased air density at a high altitude or
during a system failure.
Deceleration control
Input/output signal chart
Sensor Input Signal to ECM ECM Function Actuator
Accelerator switch (F/C) Accelerator positionFuel injection con-
trol (Deceleration
control)Electronic control fuel injec-
tion pump
Crankshaft position sensor (TDC) Engine speed
The ECM sends a fuel cut signal to the electronic control fuel injection pump during deceleration for better
fuel efficiency. The ECM determines the time of deceleration according to signals from the accelerator switch
(F/C) and crankshaft position sensor (TDC).
SEF649S
ENGINE AND EMISSION BASIC CONTROL SYSTEM
DESCRIPTIONZD30DDTi
Fuel Injection Control System (Cont'd)
EC-21

ENGINE CONTROL COMPONENT PARTS/CONTROL
SYSTEMS APPLICATION
ItemDIAGNOSTIC TEST MODE
SELF-DIAG
RESULTSDATA MONI-
TORACTIVE
TEST
ENGINE CONTROL COMPONENT PARTS
INPUTEngine coolant temperature sensor X X
Vehicle speed sensor X X
Accelerator position sensor X X X
Accelerator position switch X X
Accelerator switch (F/C) X X
Crankshaft position sensor (TDC) X X
Ignition switch (start signal) X
Park/Neutral position (PNP) switch X
Battery voltage X
Air conditioner switch X
Mass air flow sensor X X
Stop lamp switch X X
Heat up switch X
Charge air pressure sensor X
OUTPUTGlow relayXX
EGR volume control valve X X X
Cooling fan relay X X X
Air conditioner relay X
Variable nozzle turbocharger control solenoid valve X
Swirl control valve control solenoid valve X X
X: Applicable
SELF-DIAGNOSTIC MODE
Regarding items detected in ªSELF-DIAG RESULTSº mode,
refer to ªTROUBLE DIAGNOSIS Ð INDEXº, EC-7.
DATA MONITOR MODE
Monitored item
[Unit]ECM
input
signalsMain
signalsDescription Remarks
CKPS×RPM (TDC)
[rpm]qqIThe engine speed computed from the
crankshaft position sensor (TDC) signal
is displayed.
CMPS×RPM×PUMP
[rpm]qqIThe engine speed computed from the
pulse signal sent from electronic control
fuel injection pump is displayed.
COOLAN TEMP/S
[ÉC] or [ÉF]
qqIThe engine coolant temperature (deter-
mined by the signal voltage of the engine
coolant temperature sensor) is displayed.IWhen the engine coolant temperature
sensor is open or short-circuited, ECM
enters fail-safe mode. The engine cool-
ant temperature determined by the ECM
is displayed.
VHCL SPEED SE
[km/h] or [mph]qqIThe vehicle speed computed from the
vehicle speed sensor signal is displayed.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
CONSULT-II (Cont'd)
EC-40

Monitored item
[Unit]ECM
input
signalsMain
signalsDescription Remarks
FUEL TEMP SEN
[ÉC] or [ÉF]qqIThe fuel temperature (sent from elec-
tronic control fuel injection pump) is dis-
played.
ACCEL POS SEN [V]
qqIThe accelerator position sensor signal
voltage is displayed.
FULL ACCEL SW
[ON/OFF]qqIIndicates [ON/OFF] condition from the
accelerator position switch signal.
ACCEL SW (FC)
[OPEN/CLOSE]qqIIndicates [OPEN/CLOSE] condition from
the accelerator switch (FC) signal.
OFF ACCEL SW
[ON/OFF]qqIIndicates [ON/OFF] condition from the
accelerator position switch signal.
SPILL/V [ÉCA]
qIThe control position of spill valve (sent
from electronic control fuel injection
pump) is displayed.
BATTERY VOLT [V]
qqIThe power supply voltage of ECM is dis-
played.
P/N POSI SW
[ON/OFF]qqIIndicates [ON/OFF] condition from the
park/neutral position switch signal.
START SIGNAL
[ON/OFF]qqIIndicates [ON/OFF] condition from the
starter signal.IAfter starting the engine, [OFF] is dis-
played regardless of the starter signal.
AIR COND SIG
[ON/OFF]qqIIndicates [ON/OFF] condition of the air
conditioner switch as determined by the
air conditioner signal.
BRAKE SW [ON/OFF]
qqIIndicates [ON/OFF] condition from the
stop lamp switch signal.
IGN SW
[ON/OFF]qqIIndicates [ON/OFF] condition from igni-
tion switch signal.
WARM UP SW
[ON/OFF]qIIndicates [ON/OFF] condition from the
heat up switch signal.
MAS AIR/FL SE [V]
qqIThe signal voltage of the mass air flow
sensor is displayed.IWhen the engine is stopped, a certain
value is indicated.
DECELER F/CUT
[ON/OFF]qIThe [ON/OFF] condition from decelera-
tion fuel cut signal (sent from electronic
control fuel injection pump) is displayed.
INJ TIMG C/V [%]
qIThe duty ratio of fuel injection timing
control valve (sent from electronic control
fuel injection pump) is displayed.
AIR COND RLY
[ON/OFF]qIIndicates the control condition of the air
conditioner relay (determined by ECM
according to the input signals).
GLOW RLY [ON/OFF]
qIThe glow relay control condition (deter-
mined by ECM according to the input
signal) is displayed.
COOLING FAN
[ON/OFF]
qIIndicates the control condition of the
cooling fans (determined by ECM
according to the input signal).
ION ... Operates.
OFF ... Stopped.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
CONSULT-II (Cont'd)
EC-41

3 CHECK IDLE SPEED
With CONSULT-II
1. Select ªCKPS×RPM (TDC)º in ªDATA MONITORº mode with CONSULT-II.
2. Read idle speed.
SEF817Y750 25 rpm
Without CONSULT-II
Check idle speed.
750 25 rpm
OK or NG
OKEINSPECTION END
NGEGO TO 4.
4 CHECK FOR INTAKE AIR LEAK
Listen for an intake air leak after the mass air flow sensor.
OK or NG
OKEGO TO 5.
NGERepair or replace.
5 BLEED AIR FROM FUEL SYSTEM
1. Stop engine.
2. Using priming pump, bleed air from fuel system. Refer to ªAir Bleedingº, EC-32.
EGO TO 6.
TROUBLE DIAGNOSIS Ð BASIC INSPECTIONZD30DDTi
Basic Inspection (Cont'd)
EC-51

SYSTEM Ð ENGINE CONTROL system
Malfunction
SYMPTOM
Reference page
Feature of symptom, Check pointHARD/NO START/RESTART
(EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE 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 DECELERATINGWarranty symptom code AA AB AC AD AE AF
ENGINE CONTROL
Electronic control fuel injection pump
circuit*a, *b 1 1
111111111
Ð
*c, *d
Mass air flow sensor circuit*a, *c
111
EC-88
*b
Engine coolant temperature sensor
circuit*a, *b 1 1 1 1 EC-95 *1
Vehicle speed sensor circuit *a, *b 1 EC-99
1 - 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*1: Compensation according to engine coolant temperature does not function.
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONZD30DDTi
Symptom Matrix Chart (Cont'd)
EC-58