NISSAN TERRANO 2004 Service Repair Manual

CAUTION:
IDo not disassemble No. 1 nozzle (with needle lift sensor).
Entrust disassembly or adjustment to BOSCH service
shop.
Plug flare nut with a cap or rag so that no dust enters the
nozzle. Cover nozzle tip for protection of needle.
Removal and Installation
1. Remove fuel injection tube and spill tube.
2. Remove injection nozzle assembly.
Also remove washers from nozzle end.
3. Install injection nozzle in the reverse order of removal. Injection nozzle to engine:
:54-64N ×m (5.5 - 6.5 kg-m, 40 - 47 ft-lb)
Injection nozzle to tube:
:20-25N ×m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
a. Always clean the nozzle holes.
b. Always use new injection nozzle gasket.
c. Note that small washer should be installed in specified direction.
d. Bleed air from fuel system.
Disassembly (No.2-4nozzle)
1. Loosen nozzle nut while preventing nozzle top from turning.
2. Arrange all disassembled parts in the order shown at left.
SEM621B
NEM244
NEF459
SEF785
MEC996D
INJECTION NOZZLETD27Ti
EC-336
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Inspection (No.2-4nozzle)
Thoroughly clean all disassembled parts with fresh kerosene or
solvent.
IIf nozzle needle is damaged or fused, replace nozzle assem-
bly with a new one.
I If end of nozzle needle is seized or excessively discolored,
replace nozzle assembly.
I Check nozzle body and distance piece for proper contact. If
excessively worn or damaged, replace nozzle assembly or dis-
tance piece.
I Check nozzle spring for excessive wear or damage. If exces-
sively worn or damaged, replace it with a new spring.
I Check distance piece and nozzle holder for proper contact. If
excessively worn or damaged, replace nozzle holder assembly.
Cleaning (No.2-4nozzle)
a. Do not touch the nozzle mating surface with your fingers.
b. To wash the nozzles, use a wooden stick and brass brush
with clean diesel fuel.
1. Remove any carbon from exterior of nozzle body (except wrap- ping angle portion) by using Tool.
2. Clean oil sump of nozzle body using Tool.
3. Clean nozzle seat by using Tool.
Take extra precautions when performing this job, since nozzle
efficiency depends greatly on a good nozzle seat.
SEF830
YEC231A
SEF832
INJECTION NOZZLETD27Ti
EC-337
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4. Clean spray hole of nozzle body by using Tool.
To prevent spray hole from canting, always clean it by start-
ing with inner side and working towards the outside.
5. Decarbonate nozzle needle tip by using Tool.
6. Check needle sink.
(1) Pull needle about halfway out from body and then release it.
(2) Needle should sink into body very smoothly from just its ownweight.
(3) Repeat this test and rotate needle slightly each time.
If needle fails to sink smoothly from any position, replace both
needle and body as a unit.
Assembly (No.2-4nozzle)
Assembly is in the reverse order of disassembly. Holder to nozzle nut:
:29-49N ×m (3.0 - 5.0 kg-m, 22 - 36 ft-lb)
SEF833
SEF834
SEF835
SEF967
INJECTION NOZZLETD27Ti
Cleaning (No.2-4nozzle) (Cont'd)
EC-338
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Test and Adjustment
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and make
sure your eyes are properly protected with goggles.
INJECTION PRESSURE TEST
1. Install nozzle to injection nozzle tester and bleed air from flarenut.
2. Pump the tester handle slowly (once per second) and watch the pressure gauge.
3. Read the pressure gauge when the injection pressure just starts dropping.Initial injection pressure: Used12,259 - 12,749 kPa (122.6 - 127.5 bar,
120 - 130 kg/cm
2, 1,706 - 1,849 psi)
New 12,749 - 13,730 kPa (127.5 - 137.3 bar,
130 - 140 kg/cm
2, 1,849 - 1,991 psi)
Always check initial injection pressure using a new nozzle.
4. To adjust injection pressure, change adjusting shims. (No. 2 - 4 nozzle)
a. Increasing the thickness of adjusting shims increases ini- tial injection pressure. Decreasing thickness reduces ini-
tial pressure.
b. A shim thickness of 0.04 mm (0.0016 in) corresponds approximately to a difference of 471 kPa (4.71 bar, 4.8
kg/cm
2, 68 psi) in initial injection pressure.
Refer to SDS for adjusting shim.
EF791A
SEF672A
SEF427F
INJECTION NOZZLETD27Ti
EC-339
http://vnx.su/

LEAKAGE TEST
1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure.
2. Check that there is no dripping from the nozzle tip or around the body.
3. If there is leakage, replace nozzle assembly.
SPRAY PATTERN TEST
1. Check spray pattern by pumping tester handle one full stroke per second.
a. If main spray angle is within 30 degrees as shown, injec- tion nozzle is good.
b. It is still normal even if a thin stream of spray deviates from the main spray (pattern B).
2. If the spray pattern is not correct, disassemble and clean nozzle.
3. Test again and if spray pattern is not corrected, replace nozzle.
SEF674A
SEF079S
INJECTION NOZZLETD27Ti
Test and Adjustment (Cont'd)
EC-340
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q1Electric fuel injection pump
q
2Key
q
3Bracket q
4Injection pump drive gear
q
5Dust cover
q
6Bracket q
7Gasket
q
8Gasket
Removal
1. Remove battery. Disconnect electronic injection pump harness connectors.
2. Set No. 1 piston at TDC on its compression stroke.
3. Remove fuel hoses (supply, return and spill) and injection tubes.
NEF460
EEF181
ELECTRONIC FUEL INJECTION PUMPTD27Ti
EC-341
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4. Remove dust cover and injection pump gear.Refer to EM section.
5. Remove fixing nuts and bolts. Then remove injection pump.
Installation
Install injection pump assembly in the reverse order of removal,
observing the following:
1. Confirm that No. 1 cylinder is set at TDC on its compression stroke.
2. Install injection pump (Refer to EM section).
(1) Temporarily set injection pump so that the flange of the pump is aligned with aligning mark on front cover.
(2) Install injection pump gear.
:59-69N ×m (6 - 7 kg-m, 43 - 51 ft-lb)
Make sure that the key does not fall into the front cover.
Make sure that ªZº marks are aligned.
(3) Apply liquid gasket to mating surface of injection pump gear cover and install it.
3. Adjust injection timing. Refer to ªBasic Inspectionº, EC-361.
4. Install all parts removed.
SEM653B
EEF160
EEF181
SEF337F
ELECTRONIC FUEL INJECTION PUMPTD27Ti
Removal (Cont'd)
EC-342
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Disassembly and Assembly
CAUTION:
IDo not disassemble the parts not shown in the illustration
above.
I Before installing injection timing control valve, smear a
coat of diesel fuel to O-ring and its mating area. Insert
injection timing control valve straight into bore in fuel
pump body. After positioning the injection timing control
valve correctly, visually check that the fuel does not leak.
I After re-assembling the parts, erase Diagnostic Trouble
Code (DTC), and perform DTC CONFIRMATION PROCE-
DURE (or OVERALL FUNCTION CHECK).
YEC236A
ELECTRONIC FUEL INJECTION PUMPTD27Ti
EC-343
http://vnx.su/

DTC and MI Detection Logic
When a malfunction is detected for the first time, the malfunction (DTC) is stored in the ECM memory.
The MI will light up each time the ECM detects a malfunction. However, if the same malfunction is experienced
in two consecutive driving patterns and the engine is still running, the MI will stay lit up. For a description of
diagnostic items causing the MI to light up, refer to ªTROUBLE DIAGNOSIS Ð INDEXº, EC-313.
Diagnostic Trouble Code (DTC)
HOW TO READ DTC
The DTC can be read by the following methods.
Without CONSULT-II
ECM displays the DTC by a set of four digit numbers with MI illumination in the diagnostic test mode II (Self-
diagnostic results). Example: 0102, 0103, 0104, etc.
With CONSULT-II
CONSULT-II displays the DTC in ªSELF-DIAG RESULTSº mode. Examples: P0100, P0115, P0500, etc.
These DTCs are prescribed by ISO15031-6.
(CONSULT-II also displays the malfunctioning component or system.)
IOutput of the trouble code means that the indicated circuit has a malfunction. However, in the Mode
II it does not indicate whether the malfunction is still occurring or occurred in the past and returned
to normal.
CONSULT-II can identify them. Therefore, using CONSULT-II (if available) is recommended.
HOW TO ERASE DTC
How to Erase DTC (
With CONSULT-II)
1. If the ignition switch stays ªONº after repair work, be sure to turn ignition switch ªOFFº once. Wait at least
5 seconds and then turn it ªONº (engine stopped) again.
2. Touch ªENGINEº.
3. Touch ªSELF-DIAG RESULTSº.
4. Touch ªERASEº. (The DTC in the ECM will be erased.)
The emission related diagnostic information in the ECM can be erased by selecting ªERASEº in the ªSELF-
DIAG RESULTSº mode with CONSULT-II.
SEF246Z
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONTD27Ti
EC-344
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How to Erase DTC (Without CONSULT-II)
1. If the ignition switch stays ªONº after repair work, be sure to turn ignition switch ªOFFº once. Wait at least5 seconds and then turn it ªONº (engine stopped) again.
2. Change the diagnostic test mode from Mode II to Mode I by using the data link connector. (See EC-346.)
The emission related diagnostic information in the ECM can be erased by changing the diagnostic test mode.
I If the battery is disconnected, the emission-related diagnostic information will be lost after approx.
24 hours.
I Erasing the emission-related diagnostic information using CONSULT-II is easier and quicker than
switching the diagnostic test mode using the data link connector.
Malfunction Indicator (MI)
1. The malfunction indicator will light up when the ignition switch
is turned ON without the engine running. This is a bulb check.
I If the malfunction indicator does not light up, refer to EL sec-
tion (ªWARNING LAMPS/WIRING DIAGRAMº) or see MI &
DATA LINK CONNECTORS.
2. When the engine is started, the malfunction indicator should go off.
If the lamp remains on, the on board diagnostic system has
detected an engine system malfunction.
If MI illuminates or flashes irregularly after starting engine,
water may have accumulated in fuel filter. Drain water from
fuel filter.
ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The on board diagnostic system has the following three functions.
Diagnostic
Test Mode KEY and ENG.
Status Function Explanation of Function
Mode I Ignition switch in
ON position
Engine stoppedBULB CHECK
This function checks the MI bulb for damage (blown, open
circuit, etc.).
If the MI does not come on, check MI circuit. (See EC-475.)
Engine running
MALFUNCTION
WARNING This is a usual driving condition. When ECM detects a
malfunction, the MI will light up to inform the driver that a mal-
function has been detected.
Mode II Ignition switch in
ON position
Engine stopped
SELF-DIAGNOSTIC
RESULTS
This function allows DTCs to be read.
SAT652J
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONTD27Ti
Diagnostic Trouble Code (DTC) (Cont'd)
EC-345
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