2001 NISSAN ALMERA N16 engine overheat

SYSTEM Ð ENGINE CONTROL system
Malfunction
SYMPTOM
Reference page
Feature of symptom, Check pointROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator illuminates.
Can be detected by CONSULT-II?BLACK SMOKE
WHITE SMOKEWarranty symptom code AG AH AJ AK AL AM AP HA
ENGINE CONTROL
Start signal circuit *a, *b EC-693 *3
Accelerator position switch (Idle) circuit*a, *c
EC-577
*b 1 1 *4
Ignition switch circuit*a
EC-560
*b*5
Power supply for ECM circuit*a
1 1 EC-560
*b
1 - 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*3: Start control does not function.
*4: Accelerator position sensor NG signal is output.
*5: Engine does not stop.
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONYD
Symptom Matrix Chart (Cont'd)
EC-548

SYSTEM Ð ENGINE CONTROL system
Malfunction
SYMPTOM
Reference page
Feature of symptom, Check pointROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator illuminates.
Can be detected by CONSULT-II?BLACK SMOKE
WHITE SMOKEWarranty symptom code AG AH AJ AK AL AM AP HA
ENGINE CONTROL
EGR volume control valve circuit*a, *b
EC-686
*c 1 *6
Glow relay circuit*a 1
EC-677*7
*b*8
ECM relay (Self-shutoff) circuit*a
EC-666
*b*9
ECM, Connector circuit *a, *b22222222222EC-664,
604
Air conditioner relay circuit*a
EC-700*10
*b*11
Air conditioner switch circuit*a, *c
EC-700*11
*b*12
1 - 5: The numbers refer to the order of inspection.
*a: Open
*b: Short
*c: Ground short
*d: Noise
*6: Does not stop operating.
*7: Glow lamp does not turn on.
*8: Glow lamp does not turn off.
*9: Ground short makes engine unable to stop.
*10: Air conditioner does not operate.
*11: Air conditioner does not stop operating.
*12: Air conditioner does not work.
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONYD
Symptom Matrix Chart (Cont'd)
EC-550

TERMI-
NAL
NO.WIRE
COLORITEM CONDITION DATA(DC Voltage)
221 LG/B Cooling fan relay (High)[Engine is running]
+Cooling fans are not operating
+Cooling fans are operating at low speedBATTERY VOLTAGE
(11 - 14V)
[Engine is running]
+Cooling fans are operating at high speedApproximately 0.1V
On Board Diagnosis LogicNJEC0663This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
DTC Malfunction is detected when ... Check Items (Possible Cause)
P1217
0208+Cooling fan does not operate properly (Overheat).
+Cooling fan system does not operate properly
(Overheat).
+Engine coolant was not added to the system using
the proper filling method.+Harness or connectors
(The cooling fan circuit is open or shorted.)
+Cooling fan
+Radiator hose
+Radiator
+Radiator cap
+Water pump
+Thermostat
+Engine coolant temperature sensor
For more information, refer to ªMAIN 12 CAUSES OF
OVERHEATINGº, EC-633.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the LC-43,
ªChanging Engine Coolantº. Also, replace the engine oil.
1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure
to use coolant with the proper mixture ratio. Refer to MA-22, ªEngine Coolant Mixture Ratioº.
2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.
DTC P1217 OVER HEATYD
ECM Terminals and Reference Value (Cont'd)
EC-619

AEC640
SEF111X
SEC163BA
MEC475B
Overall Function CheckNJEC0664Use this procedure to check the overall function of the cooling fan.
During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
WITH CONSULT-IINJEC0664S011) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-622.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-622.
3) Turn ignition switch ªONº.
4) Perform ªCOOLING FANº in ªACTIVE TESTº mode with CON-
SULT-II and make sure that cooling fans operate when touch-
ing ªHIGHº or ªLOWº.
If NG, go to ªDiagnostic Procedureº, EC-622.
WITHOUT CONSULT-IINJEC0664S021) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-622.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-622.
3) Start engine.
Be careful not to overheat engine.
4) Set temperature control lever to full cold position.
5) Turn air conditioner switch ªONº.
6) Turn blower fan switch ªONº.
7) Run engine at idle for a few minutes with air conditioner oper-
ating.
Be careful not to overheat engine.
8) Make sure that cooling fans operate at low speed.
9) Turn ignition switch ªOFFº.
10) Turn air conditioner switch and blower fan switch ªOFFº.
11) Disconnect engine coolant temperature sensor harness con-
nector.
12) Connect 150Wresistor to engine coolant temperature sensor
harness connector.
13) Start engine and make sure that cooling fans operate at higher
speed than low speed.
Be careful not to overheat engine.
14) If NG, go to ªDiagnostic Procedureº, EC-622.
DTC P1217 OVER HEATYD
On Board Diagnosis Logic (Cont'd)
EC-620

10 CHECK ENGINE COOLANT TEMPERATURE SENSOR
1. Remove engine coolant temperature sensor.
2. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure.
SEF304X
OK or NG
OK©GO TO 11.
NG©Replace engine coolant temperature sensor.
11 CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to ªMAIN 12 CAUSES OF OVERHEATINGº, EC-633.
©INSPECTION END
PROCEDURE ANJEC0666S05
1 CHECK COOLING FAN POWER SUPPLY CIRCUIT
1. Turn ignition switch ªOFFº.
2. Disconnect cooling fan relay-1.
3. Turn ignition switch ªONº.
4. Check voltage between cooling fan relay-1 terminals 2, 3 and ground with CONSULT-II or tester.
SEF899Y
OK or NG
OK©GO TO 3.
NG©GO TO 2.
DTC P1217 OVER HEATYD
Diagnostic Procedure (Cont'd)
EC-627

9 CHECK INTERMITTENT INCIDENT
1. Perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-559.
©INSPECTION END
Main 12 Causes of OverheatingNJEC0667
Engine Step Inspection item Equipment Condition Reference page
OFF 1+Blocked radiator
+Blocked radiator grille
+Blocked bumper+Visual No blocking Ð
2+Coolant mixture+Coolant tester 50 - 50% coolant mixture See MA-20, ªRECOM-
MENDED FLUIDS AND
LUBRICANTSº.
3+Coolant level+Visual Coolant up to MAX level
in reservoir tank and
radiator filler neckSee LC-17, ªChanging
Engine Coolantº.
4+Radiator cap+Pressure tester 78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0
kg/cm
2, 11 - 14 psi)See LC-37, ªSystem
Checkº.
ON*
25+Coolant leaks+Visual No leaks See LC-37, ªSystem
Checkº.
ON*
26+Thermostat+Touch the upper and
lower radiator hosesBoth hoses should be
hotSee LC-40, ªThermostatº
and ªRadiatorº.
ON*
17+Cooling fan+CONSULT-II Operating See Trouble Diagnosis
for DTC P1217, EC-618.
OFF 8+Combustion gas leak+Color checker chemi-
cal tester 4 Gas ana-
lyzerNegative Ð
ON*
39+Coolant temperature
gauge+Visual Gauge less than 3/4
when drivingÐ
+Coolant overflow to
reservoir tank+Visual No overflow during driv-
ing and idlingSee LC-43, ªChanging
Engine Coolantº.
OFF*
410+Coolant return from
reservoir tank to radia-
tor+Visual Should be initial level in
reservoir tankSee LC-43, ªREFILLING
ENGINE COOLANTº.
OFF 11+Cylinder head+Straight gauge feeler
gauge0.1mm (0.004 in) Maxi-
mum distortion (warping)See EM-121, ªInspec-
tionº.
12+Cylinder block and
pistons+Visual No scuffing on cylinder
walls or pistonSee EM-143, ªInspec-
tionº.
*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to LC-46, ªOVERHEATING CAUSE ANALYSISº.
DTC P1217 OVER HEATYD
Diagnostic Procedure (Cont'd)
EC-633

parts. Apply petroleum jelly to protect O-rings and seals, or
hold bearings and washers in place during assembly. Do not
use grease.
+Extreme care should be taken to avoid damage to O-rings,
seals and gaskets when assembling.
+After overhaul, refill the transaxle with new ATF.
+When the A/T drain plug is removed, only some of the fluid is
drained. Old A/T fluid will remain in torque converter and ATF
cooling system.
Always follow the procedures under ªChanging A/T Fluidº in the
AT section when changing A/T fluid. Refer to ªChanging A/T
Fluidº, AT-15.
Service Notice or PrecautionsNJAT0247FAIL-SAFENJAT0247S01The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major
electrical input/output device circuit is damaged.
Under Fail-Safe, the vehicle always runs in third gear, even with a shift lever position of ª1º, ª2º or ªDº. The
customer may complain of sluggish or poor acceleration.
When the ignition key is turned ªONº following Fail-Safe operation, O/D OFF indicator lamp blinks for about
8 seconds. (For EXCEPT FOR EURO-OBD; ªSELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-II)º,
refer to AT-42 and for EURO-OBD; ªTCM SELF-DIAGNOSTIC PROCEDURE (No Tools)º, refer to AT-61.)
Fail-Safe may occur without electrical circuit damage if the vehicle is driven under extreme conditions (such
as excessive wheel spin followed by sudden braking). To recover normal shift pattern, turn the ignition key
ªOFFº for 5 seconds, then ªONº.
The blinking of the O/D OFF indicator lamp for about 8 seconds will appear only once and be cleared. The
customer may resume normal driving conditions.
Always follow the ªWORK FLOWº [Refer to AT-71 (Except for Euro-OBD), AT-76 (EURO-OBD).]
The SELF-DIAGNOSIS results will be as follows:
The first SELF-DIAGNOSIS will indicate damage to the vehicle speed sensor or the revolution sensor.
During the next SELF-DIAGNOSIS, performed after checking the sensor, no damages will be indicated.
TORQUE CONVERTER SERVICENJAT0247S02The torque converter should be replaced under any of the following conditions:
+External leaks in the hub weld area.
+Converter hub is scored or damaged.
+Converter pilot is broken, damaged or fits poorly into crankshaft.
+Steel particles are found after flushing the cooler and cooler lines.
+Pump is damaged or steel particles are found in the converter.
+Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses
have been made. (Converter clutch material may be glazed.)
+Converter is contaminated with engine coolant containing antifreeze.
+Internal failure of stator roller clutch.
+Heavy clutch debris due to overheating (blue converter).
+Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are
worn or damaged Ð indicates that lining material came from converter.
The torque converter should not be replaced if:
PRECAUTIONS
Precautions (Cont'd)
AT-9

SAT767B
A/T Fluid CheckNJAT0025FLUID LEAKAGE CHECKNJAT0025S011. Clean area suspected of leaking. Ð for example, mating sur-
face of converter housing and transmission case.
2. Start engine, apply foot brake, place selector lever in ªDº posi-
tion and wait a few minutes.
3. Stop engine.
SAT288G
4. Check for fresh leakage.
SAT638A
FLUID CONDITION CHECKNJAT0025S02
Fluid color Suspected problem
Dark or black with burned odor Wear of frictional material
Milky pink Water contamination Ð Road water
entering through filler tube or breather
Varnished fluid, light to dark brown
and tackyOxidation Ð Over or under filling, Ð
Overheating
FLUID LEVEL CHECKNJAT0025S03Refer to ªChecking A/T Fluidº, AT-15.
SAT647B
Stall TestNJAT0026STALL TEST PROCEDURENJAT0026S011. Check A/T fluid and engine oil levels. If necessary, add.
2. Drive vehicle for approx. 10 minutes or until fluid and oil reach
operating temperature.
ATF operating temperature:
50 - 80ÉC (122 - 176ÉF)
TROUBLE DIAGNOSIS Ð BASIC INSPECTION
A/T Fluid Check
AT-78