NISSAN TERRANO 2004 Service Repair Manual

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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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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CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
198
ECM Terminals and Reference Value .....................198
On Board Diagnosis Logic.......................................198
DTC Confirmation Procedure ..................................199
Wiring Diagram ........................................................200
Diagnostic Procedure ..............................................202
DTC 0802 ECM 10.......................................................205 Description ...............................................................205
On Board Diagnosis Logic.......................................205
DTC Confirmation Procedure ..................................205
Diagnostic Procedure ..............................................206
DTC 0804 ECM 11 .......................................................207
Description ...............................................................207
On Board Diagnosis Logic.......................................207
DTC Confirmation Procedure ..................................207
Diagnostic Procedure ..............................................208
DTC 0807 ECM 14.......................................................209 Description ...............................................................209
ECM Terminals and Reference Value .....................209
On Board Diagnosis Logic.......................................209
DTC Confirmation Procedure ..................................209
Wiring Diagram ........................................................210
Diagnostic Procedure .............................................. 211
DTC 0902 ECM RLY ....................................................214
ECM Terminals and Reference Value .....................214
On Board Diagnosis Logic.......................................214
DTC Confirmation Procedure ..................................214
Wiring Diagram ........................................................215
Diagnostic Procedure ..............................................216
DTC 0903 ECM 15.......................................................218 Description ...............................................................218
On Board Diagnosis Logic.......................................218
DTC Confirmation Procedure ..................................218
Diagnostic Procedure ..............................................219
DTC 0905 TURBO PRESSURE ..................................220
Component Description ...........................................220
ECM Terminals and Reference Value .....................220
On Board Diagnosis Logic.......................................220
DTC Confirmation Procedure ..................................221
Wiring Diagram ........................................................222
Diagnostic Procedure ..............................................224
DTC 1003 EGR VOLUME CONT/V .............................227
Description ...............................................................227
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
228
ECM Terminals and Reference Value .....................228
On Board Diagnosis Logic.......................................228
DTC Confirmation Procedure ..................................229
Wiring Diagram ........................................................230
Diagnostic Procedure ..............................................232
DTC 1004 FUEL CUT SYSTEM1 ................................237Description ...............................................................237
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
238
ECM Terminals and Reference Value .....................238
On Board Diagnosis Logic.......................................238
DTC Confirmation Procedure ..................................239
Wiring Diagram ........................................................240
Diagnostic Procedure ..............................................242
GLOW CONTROL SYSTEM .......................................244
Description ...............................................................244
ECM Terminals and Reference Value .....................245
Wiring Diagram ........................................................246
Diagnostic Procedure ..............................................247
START SIGNAL ...........................................................253
Wiring Diagram ........................................................253
Diagnostic Procedure ..............................................254
PARK/NEUTRAL POSITION (PNP) SWITCH .............256
Description ...............................................................256
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
256
ECM Terminals and Reference Value .....................256
Wiring Diagram ........................................................257
Diagnostic Procedure ..............................................258
HEAT UP SWITCH ......................................................265
Component Description ...........................................265
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
265
ECM Terminals and Reference Value .....................265
Wiring Diagram ........................................................266
Diagnostic Procedure ..............................................267
SWIRL CONTROL VALVE CONTROL SOLENOID
VA LV E ........................................................................\
..271
Description ...............................................................271
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
272
ECM Terminals and Reference Value .....................272
Wiring Diagram ........................................................273
Diagnostic Procedure ..............................................274
INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE ......................................................281
Description ...............................................................281
Operation .................................................................281
ECM Terminals and Reference Value .....................281
Wiring Diagram ........................................................282
Diagnostic Procedure ..............................................283
VARIABLE NOZZLE TURBOCHARGER
CONTROL SOLENOID VALVE ...................................289
Description ...............................................................289
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................\
289
ECM Terminals and Reference Value .....................290
Wiring Diagram ........................................................291
CONTENTS(Cont'd)
EC-3
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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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On Board Diagnosis Logic.......................................395
DTC Confirmation Procedure ..................................395
Wiring Diagram ........................................................396
Diagnostic Procedure ..............................................397
Component Inspection .............................................398
DTC P0215 FUEL CUT S/V 1 .....................................399
Component Description ...........................................399
On Board Diagnosis Logic.......................................399
DTC Confirmation Procedure ..................................399
Wiring Diagram ........................................................400
Diagnostic Procedure ..............................................401
Component Inspection .............................................402
DTC P0216 INJ TIMING CONT/V, DTC P1246 F/
INJ TIMG F/B ...............................................................403
Component Description ...........................................403
On Board Diagnosis Logic.......................................403
DTC P0216 Confirmation Procedure.......................403
DTC P1246 Confirmation Procedure.......................404
Wiring Diagram ........................................................405
Diagnostic Procedure ..............................................406
Component Inspection .............................................407
DTC P0335 CRANK POS SEN (TDC) ........................408
Component Description ...........................................408
On Board Diagnosis Logic.......................................408
DTC Confirmation Procedure ..................................408
Wiring Diagram ........................................................409
Diagnostic Procedure ..............................................410
Component Inspection ............................................. 411
DTC P0380 GLOW RELAY, DTC P0381 GLOW
LAMP ........................................................................\
...412
System Description ..................................................412
Component Description ...........................................413
On Board Diagnosis Logic.......................................413
DTC Confirmation Procedure ..................................413
Wiring Diagram ........................................................414
Diagnostic Procedure ..............................................416
System Operation Check.........................................418
Component Inspection .............................................419
DTC P0500 VEHICLE SPEED SEN ............................420
Component Description ...........................................420
On Board Diagnosis Logic.......................................420
Overall Function Check ...........................................420
Wiring Diagram ........................................................421
Diagnostic Procedure ..............................................422
DTC P0571 BRAKE SW ..............................................423
Component Description ...........................................423
On Board Diagnosis Logic.......................................423
DTC Confirmation Procedure ..................................423
Wiring Diagram ........................................................424
Diagnostic Procedure ..............................................425
Component Inspection .............................................426
DTC P0650 MI .............................................................427 Component Description ...........................................427
On Board Diagnosis Logic.......................................427
DTC Confirmation Procedure ..................................427
Wiring Diagram ........................................................428
Diagnostic Procedure ..............................................429
DTC P1107 ECM 10 ....................................................430
Description ...............................................................430
On Board Diagnosis Logic.......................................430
DTC Confirmation Procedure ..................................430
Diagnostic Procedure ..............................................431
DTC P1206 F/INJ F/B 2 ..............................................432
Component Description ...........................................432
On Board Diagnosis Logic.......................................432
DTC Confirmation Procedure ..................................433
Wiring Diagram ........................................................434
Diagnostic Procedure ..............................................435
Component Inspection .............................................436
DTC P1207 CONT SLEEV POS SEN .........................437
Component Description ...........................................437
On Board Diagnosis Logic.......................................437
DTC Confirmation Procedure ..................................437
Wiring Diagram ........................................................438
Diagnostic Procedure ..............................................439
Component Inspection .............................................440
DTC P1217 OVER HEAT ............................................441
Description ...............................................................441
On Board Diagnosis Logic.......................................441
Overall Function Check ...........................................442
Wiring Diagram ........................................................443
Diagnostic Procedure ..............................................444
Main 12 Causes of Overheating..............................448
Component Inspection .............................................449
DTC P1240 NEEDLE LIFT SEN, DTC P1242
NEEDLE LIFT SE (RPM) .............................................450
Component Description ...........................................450
On Board Diagnosis Logic.......................................450
DTC Confirmation Procedure ..................................450
Wiring Diagram ........................................................451
Diagnostic Procedure ..............................................452
Component Inspection .............................................453
DTC P1404 EGR SOL/V A, DTC P1405 EGR SOL/
V B/P1407 THROTTLE SOLENOID VALVE ...............454
System Description ..................................................454
Component Description ...........................................454
On Board Diagnosis Logic.......................................455
DTC Confirmation Procedure ..................................455
Wiring Diagram ........................................................456
Diagnostic Procedure ..............................................459
Component Inspection .............................................462
DTC P1530 AIR CONDITIONER RLY .........................463
Component Description ...........................................463
On Board Diagnosis Logic.......................................463
CONTENTS(Cont'd)
EC-5
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