fuel pump NISSAN TERRANO 2004 Service User Guide

Removal
1. Set No. 1 cylinder at TDC on its compression stroke.
2. Drain engine coolant from drain plugs on cylinder block andradiator.
3. Remove air cleaner and intercooler components.
4. Remove the following parts: Ð Water temperature connectors
Ð Throttle chamber vacuum hoses
Ð EGR valve vacuum hose
Ð Connectors located on the intake manifold
Ð Connector located on the thermostat housing
Ð Heater tubes
Ð Connectors of the injection pump
5. Remove alternator adjusting bolt.
6. Disconnect exhaust manifold from front exhaust tube.
7. Remove turbocharger oil and water tubes.
8. Remove turbocharger bracket bolts.
9. Disconnect radiator outlet hose and thermostat housing water inlet hose.
10. Remove fuel injection tube assembly and spill tube.
11. Remove injection nozzle holder from first cylinder with a spe- cial tool (KV119E0030). Remove injection nozzles from cylin-
ders 2, 3 and 4 using a deep socket wrench.
12. Remove thermostat housing bolts shown at left.
13. Remove rocker cover and ventilation hose.
14. Remove rocker shaft with rocker arms.
15. Remove push rods.
16. Remove cylinder head bolts in numerical order and remove cylinder head.
Head warpage or cracking could result from removing in incor-
rect order.
EEM092
SEM621B
EEM103
SEM623B
CYLINDER HEADTD27Ti
EM-105
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2. Install pistons with connecting rods.
(1) Install them into corresponding cylinder using Tool.
IBe careful not to scratch cylinder wall with connecting rod.
I Apply engine oil to cylinder wall, piston and bearing.
I The leaf type combustion chamber on piston head must be
facing toward the fuel pump side.
(2) Install connecting rod bearing caps.
3. Measure connecting rod side clearance. Connecting rod side clearance:Standard0.10 - 0.32 mm (0.0039 - 0.0126 in)
Limit 0.32 mm (0.0126 in)
If beyond the limit, replace connecting rod and/or crankshaft.
4. Install oil strainer and oil pan.
5. Install all removed parts.
GEAR TRAIN
1. Set No. 1 piston at its Top Dead Center.
2. Align each gear mark and install gears.
EEM108
SEM678B
SEM488
NEM177
ENGINE OVERHAULTD27Ti
Assembly (Cont'd)
EM-140
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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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DTC Confirmation Procedure ..................................105
Wiring Diagram ........................................................106
Diagnostic Procedure ..............................................107
DTC 0208 OVER HEAT ...............................................109
Description ...............................................................109
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
109
ECM Terminals and Reference Value ..................... 110
On Board Diagnosis Logic....................................... 110
Overall Function Check ........................................... 111
Wiring Diagram ........................................................ 112
Diagnostic Procedure .............................................. 114
Main 12 Causes of Overheating..............................120
DTC 0301 ECM 2.........................................................121 Description ...............................................................121
On Board Diagnosis Logic.......................................121
DTC Confirmation Procedure ..................................121
Diagnostic Procedure ..............................................122
DTC 0402 P9×FUEL TEMP SEN .................................123
Description ...............................................................123
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
124
ECM Terminals and Reference Value .....................124
On Board Diagnosis Logic.......................................124
DTC Confirmation Procedure ..................................125
Wiring Diagram ........................................................126
Diagnostic Procedure ..............................................128
DTC 0403 ACCEL POS SENSOR ..............................130
Description ...............................................................130
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
131
ECM Terminals and Reference Value .....................131
On Board Diagnosis Logic.......................................132
DTC Confirmation Procedure ..................................132
Wiring Diagram ........................................................133
Diagnostic Procedure ..............................................137
DTC 0406 INT AIR VOL ..............................................150
On Board Diagnosis Logic.......................................150
DTC Confirmation Procedure ..................................150
Diagnostic Procedure ..............................................151
DTC 0407 CRANK POS SEN (TDC) ..........................152
Description ...............................................................152
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
152
ECM Terminals and Reference Value .....................152
On Board Diagnosis Logic.......................................153
DTC Confirmation Procedure ..................................153
Wiring Diagram ........................................................154
Diagnostic Procedure ..............................................156
DTC 0504 A/T COMM LINE ........................................160
System Description ..................................................160
ECM Terminals and Reference Value .....................160 On Board Diagnosis Logic.......................................160
DTC Confirmation Procedure ..................................161
Overall Function Check ...........................................161
Wiring Diagram ........................................................162
Diagnostic Procedure ..............................................164
DTC 0701 P1×CAM POS SEN .....................................166
Description ...............................................................166
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
167
ECM Terminals and Reference Value .....................167
On Board Diagnosis Logic.......................................167
DTC Confirmation Procedure ..................................168
Wiring Diagram ........................................................169
Diagnostic Procedure ..............................................171
DTC 0702 P2×TDC PULSE SIG ..................................173
Description ...............................................................173
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
174
ECM Terminals and Reference Value .....................174
On Board Diagnosis Logic.......................................174
DTC Confirmation Procedure ..................................175
Wiring Diagram ........................................................176
Diagnostic Procedure ..............................................178
DTC 0703 P3×PUMP COMM LINE ..............................180
Description ...............................................................180
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
181
ECM Terminals and Reference Value .....................181
On Board Diagnosis Logic.......................................181
DTC Confirmation Procedure ..................................182
Wiring Diagram ........................................................183
Diagnostic Procedure ..............................................185
DTC 0704 P4×SPILL/V CIRC, DTC 0706 P6×SPILL
VA LV E ........................................................................\
..187
Description ...............................................................187
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
188
ECM Terminals and Reference Value .....................188
On Board Diagnosis Logic.......................................188
DTC Confirmation Procedure ..................................189
Wiring Diagram ........................................................190
Diagnostic Procedure ..............................................192
DTC 0705 P5×PUMP C/MODULE ................................194
Description ...............................................................194
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
195
ECM Terminals and Reference Value .....................195
On Board Diagnosis Logic.......................................195
DTC Confirmation Procedure ..................................196
Diagnostic Procedure ..............................................196
DTC 0707 P7×F/INJ TIMG FB .....................................197
Description ...............................................................197
CONTENTS(Cont'd)
EC-2
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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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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 Ð*1 or X*2 EC-130
ACCEL POS SW (F/C)*1 0203 Ð EC-104
A/T COMM LINE*1 0504 Ð EC-160
COOLANT TEMP SEN 0103 Ð EC-95
CRANK POS SEN (TDC) 0407 X EC-152
ECM 2 0301 X EC-121
ECM 10 0802 Ð EC-205
ECM 11 0804 Ð EC-207
ECM 14 0807 Ð*1 or X*2 EC-209
ECM 15 0903 X EC-218
ECM RLY 0902 Ð EC-214
EGR VOLUME CONT/V 1003 Ð EC-227
FUEL CUT SYSTEM1 1004 X EC-237
INT/AIR VOLUME 0406 Ð EC-150
MASS AIR FLOW SEN 0102 Ð EC-88
NATS MALFUNCTION 1401 - 1408 Ð EL section
NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED. 0505 Ð Ð
OVER HEAT 0208 Ð EC-109
P1×CAM POS SEN 0701XEC-166
P2×TDC PULSE SIG 0702ÐEC-173
P3×PUMP COMM LINE 0703XEC-180
P4×SPILL/V CIRC 0704XEC-187
P5×PUMP C/MODULE 0705XEC-194
P6×SPILL VALVE 0706XEC-187
P7×F/INJ TIMG FB 0707XEC-197
P9×FUEL TEMP SEN 0402ÐEC-123
TURBO PRESSURE 0905ÐEC-220
VEHICLE SPEED SEN 0104ÐEC-99
*1: For A/T models
*2: For M/T models
TROUBLE DIAGNOSIS Ð INDEXZD30DDTi
EC-7
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NUMERICAL INDEX FOR DTC
X: Applicable Ð: Not applicable
DTCItems
(CONSULT-II screen terms) MI (MIL) illumination Reference page
0102 MASS AIR FLOW SEN Ð EC-88
0103 COOLANT TEMP SEN Ð EC-95
0104 VEHICLE SPEED SEN Ð EC-99
0203*1 ACCEL POS SW (F/C)*1 Ð EC-104 0208 OVER HEAT Ð EC-109
0301 ECM 2 X EC-121
0402 P9×FUEL TEMP SEN ÐEC-123
0403 ACCEL POS SENSOR Ð*1 or X*2EC-130
0406 INT/AIR VOLUME ÐEC-150
0407 CRANK POS SEN (TDC) XEC-152
0504*1 A/T COMM LINE ÐEC-160
0505 NO DTC IS DETECTED.
FURTHER TESTING
MAY BE REQUIRED. ÐÐ
0701 P1×CAM POS SEN XEC-166
0702 P2×TDC PULSE SIG ÐEC-173
0703 P3×PUMP COMM LINE XEC-180
0704 P4×SPILL/V CIRC XEC-187
0705 P5×PUMP C/MODULE XEC-194
0706 P6×SPILL VALVE XEC-187
0707 P7×F/INJ TIMG FB XEC-197
0802 ECM 10 ÐEC-205
0804 ECM 11 ÐEC-207
0807 ECM 14 Ð*1 or X*2EC-209
0902 ECM RLY ÐEC-214
0903 ECM 15 XEC-218
0905 TURBO PRESSURE ÐEC-220
1003 EGR VOLUME CONT/V Ð EC-227
1004 FUEL CUT SYSTEM1 X EC-237
1401 - 1408 NATS MALFUNCTION Ð EL section
*1: For A/T models
*2: For M/T models
TROUBLE DIAGNOSIS Ð INDEXZD30DDTi
Alphabetical & Numerical Index for DTC
(Cont'd)
EC-8
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IDo not disconnect pump harness connector with engine
running.
I Do not disassemble electronic fuel injection pump.
If NG, take proper action.
I Do not disassemble injection nozzle.
If NG, replace injection nozzle.
I Even a slight leak in the air intake system can cause seri-
ous problems.
I Do not shock or jar the crankshaft position sensor (TDC).
I Do not depress accelerator pedal when starting.
I Immediately after starting, do not rev up engine unneces-
sarily.
I Do not rev up engine just prior to shutdown.
I When installing C.B. ham radio or a mobile phone, be sure
to observe the following as it may adversely affect elec-
tronic control systems depending on its installation loca-
tion.
1) Keep the antenna as far as possible away from the ECM.
2) Keep the antenna feeder line more than 20 cm (7.9 in) away from the harness of electronic controls.
Do not let them run parallel for a long distance.
3) Adjust the antenna and feeder line so that the standing- wave ratio can be kept smaller.
4) Be sure to ground the radio to vehicle body.
SEF437Y
SEF709Y
SEF708Y
PRECAUTIONSZD30DDTi
Precautions (Cont'd)
EC-11
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System Chart
Input (Sensor)ECM FunctionOutput (Actuator)
I Electronic control fuel injection pump
I Crankshaft position sensor (TDC)
I Engine coolant temperature sensor
I Accelerator position sensor
I Accelerator position switch
I Accelerator switch (F/C)
I Park/Neutral position (PNP) switch
I Ignition switch
I Battery voltage
I Vehicle speed sensor
I Air conditioner switch
I Mass air flow sensor
I Stop lamp switch
I Heat up switch
I Charge air pressure sensor*1 Fuel 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 MI (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
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Fuel Injection Control System
DESCRIPTION
System description
Three types of fuel injection control are provided to accommodate engine operating conditions; normal control,
idle control and start control. The ECM determines the appropriate fuel injection control. Under each control,
the amount of fuel injected is compensated to improve engine performance.
Pulse signals are exchanged between ECM and electronic control fuel injection pump (control unit is built-in).
The fuel injection pump control unit performs duty control on the spill valve (built into the fuel injection pump)
according to the input signals to compensate the amount of fuel injected to the preset value.
Start control
Input/output signal chart
SensorInput Signal to ECM ECM Function Actuator
Engine coolant temperature sensor Engine coolant temperature
Fuel injection con-
trol (start control)Electronic control fuel injec-
tion pump
Crankshaft position sensor (TDC)
Engine speed
Ignition switch Start signal
When the ECM receives a start signal from the ignition switch, the
ECM adapts the fuel injection system for the start control. The
amount of fuel injected at engine starting is a preset program value
in the ECM. The program is determined by the engine speed and
engine coolant temperature.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches the specific value, and shifts the control to the normal or
idle control.
Idle control
Input/output signal chart
SensorInput Signal to ECM ECM Function Actuator
Engine coolant temperature sensor Engine coolant temperature
Fuel injection con-
trol (Idle control)Electronic control fuel injec-
tion pump
Crankshaft position sensor (TDC)
Engine speed
Park/Neutral position (PNP) switch Gear position
Battery Battery voltage
Accelerator position switch Idle position
Vehicle speed sensor Vehicle speed
Air conditioner switch Air conditioner signal
Heat up switch Heat up switch signal
When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle
control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine
to keep engine speed constant. The ECM also provides the system with a fast idle control in response to the
engine coolant temperature and heat up switch signal.
SEF648S
ENGINE AND EMISSION BASIC CONTROL SYSTEM
DESCRIPTIONZD30DDTi
EC-20
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