engine NISSAN TERRANO 2004 Service Repair Manual

Cooling Circuit
NLC011
ENGINE COOLING SYSTEMTD27Ti
LC-27
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System Inspection
CHECKING HOSES
Check hoses for proper attachment, leaks, cracks, damage, loose
connections, chafing and deterioration.
CHECKING RADIATOR CAP
To check radiator cap, apply pressure to the cap with a cap tester.Radiator cap relief pressure:78-98kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2, 11 - 14 psi)
CHECKING COOLING SYSTEM FOR LEAKS
Appear pressure to the cooling system by means of a tester to
check for leakage. Testing pressure:157 kPa (1.57 bar, 1.6 kg/cm
2, 23 psi)
CAUTION:
Higher than the specified pressure may cause radiator dam-
age.
SLC613
SMA990A
ENGINE COOLING SYSTEMTD27Ti
LC-28
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Water Pump
REMOVAL AND INSTALLATION
Drain coolant from drain plugs on cylinder block and radiator.Cylinder block drain plug:
(Use proper sealant)
:20-29N ×m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)
CAUTION:
I When removing water pump assembly, be careful not to
spill coolant on drive belt.
I Water pump cannot be disassembled and should be
replaced as a unit.
I Always replace with new gasket.
I After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
NLC012
NLC058
ENGINE COOLING SYSTEMTD27Ti
LC-29
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INSPECTION
1. Check for badly rusted or corroded body assembly and vane.
2. Check the water pump bushing for excessive end play andirregular movement.
3. Check fan coupling for rough operation, oil leakage or bent bimetal.
The water pump and fan coupling cannot be disassembled and
should be replaced as a unit.
SLC979
SLC244
SLC245
ENGINE COOLING SYSTEMTD27Ti
Water Pump (Cont'd)
LC-30
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Thermostat
q1Water outlet
q
2Thermostat with jiggle valve
q
3Rubber seal q
4Water connector
q
5Thermostat housing q
6Engine coolant temperature sen-
sor
q
7Thermal transmitter
CAUTION:
I After installation, run engine for a few minutes, and check
for leaks.
I Be careful not to spill coolant over engine compartment.
Place a rag to absorb coolant.
INSPECTION
1. Check for valve seating condition at ordinary temperatures. It
should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Valve opening temperature ÉC (ÉF) 88 (190)
Max. valve lift mm/ÉC (in/ÉF)8/100
(0.315/212)
3. Then check if valve closes at 5ÉC (9ÉF) below valve opening temperature.
NLC059
SLC343
ENGINE COOLING SYSTEMTD27Ti
LC-31
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Radiator
CAUTION:
When filling radiator with coolant, refer to MA section.
NLC082
ENGINE COOLING SYSTEMTD27Ti
LC-32
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Cooling Fan
DISASSEMBLY AND ASSEMBLY
IProper alignment of components is essential.
Improper alignment will cause them to wobble and may even-
tually cause the fan to separate from the water pump causing
extensive damage.
I If front mark q
Fis present, install fan so that side marked qF
faces the front.
INSPECTION
Check fan coupling for irregular operation, oil leakage or bent
bimetal.
YLC041
SLC072
ENGINE COOLING SYSTEMTD27Ti
LC-33
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Engine Lubrication System
Oil pressure check
Engine rpmApproximate discharge pressure
kPa (bar, kg/cm2, psi)
Idle speed More than 78 (0.78, 0.8, 11)
3,000 294 - 392 (2.94 - 3.92, 3.0 - 4.0, 43 - 57)
Oil pump
Unit: mm (in)
Gear side clearance Less than 0.13 (0.0051)
Gear backlash Less than 0.43 (0.0169)
Oil pump bushing clearance Less than 0.15 (0.0059)
Oil pump bushing inside diameter 13.012 - 13.098
(0.5123 - 0.5157)
Drive gear shaft outside diameter 12.974 - 12.992
(0.5108 - 0.5115)
Engine Cooling System
Thermostat
Valve opening temperature ÉC (ÉF)88 (190)
Max. Valve lift mm/ÉC (in/ÉF) 8/100
(0.315/212)
Radiator
Unit: kPa (bar, kg/cm2, psi)
Cap relief pressure 78-98
(0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Leakage test pressure 157 (1.57, 1.6, 23)
SERVICE DATA AND SPECIFICATIONS (SDS)TD27Ti
LC-34
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ENGINE CONTROL SYSTEMSECTION
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 ...............................................56 CONSULT-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
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Diagnostic Procedure ..............................................292
ENGINE OIL PRESSURE SWITCH ............................297
Component Description ...........................................297
System Description ..................................................297
ECM Terminals and Reference Value .....................298
Wiring Diagram ........................................................299
Diagnostic Procedure ..............................................301
AIR CONDITIONER CONTROL ..................................308
Wiring Diagram ........................................................308
MI (MIL) & DATA LINK CONNECTORS .....................310
Wiring Diagram ........................................................310
SERVICE DATA AND SPECIFICATIONS (SDS) ........312
General Specifications .............................................312
Injection Pump Numbers .........................................312
Injection Nozzle .......................................................312
Engine Coolant Temperature Sensor ......................312
Crankshaft Position Sensor (TDC) ..........................312
Glow Plug ................................................................312
Accelerator Position Sensor ....................................312
EGR Volume Control Valve .....................................312
TD27Ti
TROUBLE DIAGNOSIS - INDEX ................................313
Alphabetical & Numerical Index for DTC ................313
PRECAUTIONS AND PREPARATION ........................315
Precautions ..............................................................315
Special Service Tools ..............................................318
Engine Fuel & Emission Control System ................320
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM .......................................................................323
Engine Control Component Parts Location .............323
Circuit Diagram ........................................................325
System Diagram ......................................................326
Vacuum Hose Drawing ............................................327
System Chart ...........................................................328
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION .............................................329
Fuel Injection System ..............................................329
Fuel Injection Timing System ..................................332
Air Conditioning Cut Control ....................................334
Fuel Cut Control (at high engine speed) .................334
Glow Control ............................................................334
CRANKCASE VENTILATION SYSTEM ......................335
Description ...............................................................335
Blow-by Control Valve .............................................335
Ventilation Hose .......................................................335
INJECTION NOZZLE ...................................................336
Removal and Installation .........................................336
Disassembly (No.2-4 nozzle) ...............................336
Inspection (No.2-4 nozzle) ...................................337
Cleaning (No.2-4 nozzle) .....................................337
Assembly (No.2-4 nozzle) ....................................338 Test and Adjustment ................................................339
ELECTRONIC FUEL INJECTION PUMP ....................341
Removal ...................................................................341
Installation ................................................................342
Disassembly and Assembly .....................................343
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION .............................................................344
DTC and MI Detection Logic ...................................344
Diagnostic Trouble Code (DTC) ..............................344
Malfunction Indicator (MI) ........................................345
CONSULT-II .............................................................350
TROUBLE DIAGNOSES .............................................357
Introduction ..............................................................357
Diagnostic Worksheet ..............................................358
Work Flow ................................................................359
Description for Work Flow .......................................360
Basic Inspection.......................................................361
Symptom Matrix Chart .............................................363
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
366
Major Sensor Reference Graph in Data Monitor
Mode ........................................................................\
368
ECM Terminals and Reference Value .....................369
TROUBLE DIAGNOSIS FOR POWER SUPPLY ........375
Wiring Diagram ........................................................375
Diagnostic Procedure ..............................................376
DTC P0100 MASS AIR FLOW SEN ...........................379
Component Description ...........................................379
On Board Diagnosis Logic.......................................379
DTC Confirmation Procedure ..................................379
Wiring Diagram ........................................................380
Diagnostic Procedure ..............................................382
Component Inspection .............................................383
DTC P0115 COOLANT TEMP SEN ............................384
Component Description ...........................................384
On Board Diagnosis Logic.......................................384
DTC Confirmation Procedure ..................................384
Wiring Diagram ........................................................385
Diagnostic Procedure ..............................................386
Component Inspection .............................................387
DTC P0120 ACCEL POS SENSOR ............................388
Component Description ...........................................388
On Board Diagnosis Logic.......................................388
DTC Confirmation Procedure A (For General
Plausibility) ...............................................................388
DTC Confirmation Procedure B (For Accelerator
Sticking) ...................................................................389
Wiring Diagram ........................................................390
Diagnostic Procedure ..............................................391
Component Inspection .............................................394
DTC P0180 FUEL TEMP SENSOR ............................395
Component Description ...........................................395
CONTENTS(Cont'd)
EC-4
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