2002 NISSAN TERRANO Service Repair Manual

INSTALLATION
IInsert Tool into clutch disc hub when installing clutch cover and
disc.
ITighten bolts in numerical order.
IBe careful not to allow grease to contaminate clutch fac-
ing.
YCL026
CLUTCH DISC AND CLUTCH COVER
Clutch Cover and Flywheel (Cont'd)
CL-13

General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch control Hydraulic
CLUTCH MASTER CYLINDER
Inner diameter mm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in)
LHD 17.46 (11/16)
RHD 19.05 (3/4)
CLUTCH DISC
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Model 250 260
Facing size
(Outer dia. x inner dia. x
thickness)250 x 160 x 3.7
(9.84 x 6.30 x 0.1457)
Thickness of disc assembly
under load7.9 - 8.3 (0.311 - 0.327)
Under a load of 5,884 N
(600 kg, 1,323 lb)
CLUTCH COVER
Engine TD27Ti ZD30DDTi
Model 250 260
Full load N (kg, lb) 5,884 (600, 1,323) 6,760 (689, 1,520)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Handle LHD RHD
Pedal height*227 - 237
(8.94 - 9.33)210 - 220
(8.27 - 8.66)
Pedal stroke 155 - 160 (6.10 - 6.30)
Pedal free play
(Backlash at clevis)1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of melt sheet to surface of pedal
pad
CLUTCH DISC
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Disc model 250 260
Rear limit of facing
surface to rivet head0.3 (0.012)
Runout limit of facing 1 (0.04)
Distance of runout
check point (from the
hub center)120 (4.72)
Maximum of spline
backlash of spline (at
outer edge of disc)1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Engine TD27Ti ZD30DDTi
Cover model 250 260
Diaphragm spring height 36.5 - 38.5 (1.437 - 1.516)
Uneven limit of dia-
phragm spring toe height
ªAº0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14

ENGINE CONTROL SYSTEM
SECTION
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 ...............................................56CONSULT-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

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, DTC 0901 ECM 12.......................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 ........................................................................130
ECM Terminals and Reference Value .....................131
On Board Diagnosis Logic.......................................131
DTC Confirmation Procedure ..................................132
Wiring Diagram ........................................................133
Diagnostic Procedure ..............................................135
DTC 0406 INT AIR VOL..............................................143
On Board Diagnosis Logic.......................................143
DTC Confirmation Procedure ..................................143
Diagnostic Procedure ..............................................144
DTC 0407 CRANK POS SEN (TDC)..........................145
Description ...............................................................145
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................145
ECM Terminals and Reference Value .....................145
On Board Diagnosis Logic.......................................146
DTC Confirmation Procedure ..................................146
Wiring Diagram ........................................................147
Diagnostic Procedure ..............................................149
DTC 0502 BATTERY VOLTAGE.................................153
On Board Diagnosis Logic.......................................153
DTC Confirmation Procedure ..................................153Diagnostic Procedure ..............................................153
DTC 0504 A/T COMM LINE........................................155
System Description ..................................................155
ECM Terminals and Reference Value .....................155
On Board Diagnosis Logic.......................................155
DTC Confirmation Procedure ..................................156
Overall Function Check ...........................................156
Wiring Diagram ........................................................157
Diagnostic Procedure ..............................................159
DTC 0701 P1×CAM POS SEN.....................................161
Description ...............................................................161
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................162
ECM Terminals and Reference Value .....................162
On Board Diagnosis Logic.......................................162
DTC Confirmation Procedure ..................................163
Wiring Diagram ........................................................164
Diagnostic Procedure ..............................................166
DTC 0702 P2×TDC PULSE SIG..................................168
Description ...............................................................168
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................169
ECM Terminals and Reference Value .....................169
On Board Diagnosis Logic.......................................169
DTC Confirmation Procedure ..................................170
Wiring Diagram ........................................................171
Diagnostic Procedure ..............................................173
DTC 0703 P3×PUMP COMM LINE..............................175
Description ...............................................................175
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................176
ECM Terminals and Reference Value .....................176
On Board Diagnosis Logic.......................................176
DTC Confirmation Procedure ..................................177
Wiring Diagram ........................................................178
Diagnostic Procedure ..............................................180
DTC 0704 P4×SPILL/V CIRC, DTC 0706 P6×SPILL
VA LV E..........................................................................182
Description ...............................................................182
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................183
ECM Terminals and Reference Value .....................183
On Board Diagnosis Logic.......................................183
DTC Confirmation Procedure ..................................184
Wiring Diagram ........................................................185
Diagnostic Procedure ..............................................187
DTC 0705 P5×PUMP C/MODULE................................189
Description ...............................................................189
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................190
ECM Terminals and Reference Value .....................190
On Board Diagnosis Logic.......................................190
CONTENTS(Cont'd)
EC-2

DTC Confirmation Procedure ..................................191
Diagnostic Procedure ..............................................191
DTC 0707 P7×F/INJ TIMG FB.....................................192
Description ...............................................................192
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................193
ECM Terminals and Reference Value .....................193
On Board Diagnosis Logic.......................................193
DTC Confirmation Procedure ..................................194
Wiring Diagram ........................................................195
Diagnostic Procedure ..............................................197
DTC 0802 ECM 10.......................................................200
Description ...............................................................200
On Board Diagnosis Logic.......................................200
DTC Confirmation Procedure ..................................200
Diagnostic Procedure ..............................................201
DTC 0804 ECM 11.......................................................202
Description ...............................................................202
On Board Diagnosis Logic.......................................202
DTC Confirmation Procedure ..................................202
Diagnostic Procedure ..............................................203
DTC 0807 ECM 14.......................................................204
Description ...............................................................204
ECM Terminals and Reference Value .....................204
On Board Diagnosis Logic.......................................204
DTC Confirmation Procedure ..................................204
Wiring Diagram ........................................................205
Diagnostic Procedure ..............................................206
DTC 0902 ECM RLY....................................................209
ECM Terminals and Reference Value .....................209
On Board Diagnosis Logic.......................................209
DTC Confirmation Procedure ..................................209
Wiring Diagram ........................................................210
Diagnostic Procedure .............................................. 211
DTC 0903 ECM 15.......................................................213
Description ...............................................................213
On Board Diagnosis Logic.......................................213
DTC Confirmation Procedure ..................................213
Diagnostic Procedure ..............................................214
DTC 0905 TURBO PRESSURE..................................215
Component Description ...........................................215
ECM Terminals and Reference Value .....................215
On Board Diagnosis Logic.......................................215
DTC Confirmation Procedure ..................................216
Wiring Diagram ........................................................217
Diagnostic Procedure ..............................................219
DTC 1003 EGR VOLUME CONT/V.............................222
Description ...............................................................222
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................223
ECM Terminals and Reference Value .....................223
On Board Diagnosis Logic.......................................223DTC Confirmation Procedure ..................................224
Wiring Diagram ........................................................225
Diagnostic Procedure ..............................................227
DTC 1004 FUEL CUT SYSTEM1................................232
Description ...............................................................232
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................233
ECM Terminals and Reference Value .....................233
On Board Diagnosis Logic.......................................233
DTC Confirmation Procedure ..................................234
Wiring Diagram ........................................................235
Diagnostic Procedure ..............................................237
GLOW CONTROL SYSTEM.......................................239
Description ...............................................................239
ECM Terminals and Reference Value .....................240
Wiring Diagram ........................................................241
Diagnostic Procedure ..............................................242
START SIGNAL...........................................................248
Wiring Diagram ........................................................248
Diagnostic Procedure ..............................................249
PARK/NEUTRAL POSITION (PNP) SWITCH.............251
Description ...............................................................251
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................251
ECM Terminals and Reference Value .....................251
Wiring Diagram ........................................................252
Diagnostic Procedure ..............................................253
HEAT UP SWITCH......................................................258
Component Description ...........................................258
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................258
ECM Terminals and Reference Value .....................258
Wiring Diagram ........................................................259
Diagnostic Procedure ..............................................260
SWIRL CONTROL VALVE CONTROL SOLENOID
VA LV E..........................................................................263
Description ...............................................................263
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................264
ECM Terminals and Reference Value .....................264
Wiring Diagram ........................................................265
Diagnostic Procedure ..............................................266
INTAKE AIR CONTROL VALVE CONTROL
SOLENOID VALVE......................................................273
Description ...............................................................273
Operation .................................................................273
ECM Terminals and Reference Value .....................273
Wiring Diagram ........................................................274
Diagnostic Procedure ..............................................275
VARIABLE NOZZLE TURBOCHARGER
CONTROL SOLENOID VALVE...................................281
Description ...............................................................281
CONTENTS(Cont'd)
EC-3

CONSULT-II Reference Value in Data Monitor
Mode ........................................................................281
ECM Terminals and Reference Value .....................282
Wiring Diagram ........................................................283
Diagnostic Procedure ..............................................284
AIR CONDITIONER CONTROL..................................289
Wiring Diagram ........................................................289
MI (MIL) & DATA LINK CONNECTORS.....................291
Wiring Diagram ........................................................291
SERVICE DATA AND SPECIFICATIONS (SDS)........292
General Specifications .............................................292
Injection Pump Numbers .........................................292
Injection Nozzle .......................................................292
Engine Coolant Temperature Sensor ......................292
Crankshaft Position Sensor (TDC) ..........................292
Glow Plug ................................................................292
Accelerator Position Sensor ....................................292
EGR Volume Control Valve .....................................292
TD27Ti
TROUBLE DIAGNOSIS - INDEX................................293
Alphabetical & Numerical Index for DTC ................293
PRECAUTIONS AND PREPARATION........................295
Special Service Tools ..............................................295
Engine Fuel & Emission Control System ................297
Precautions ..............................................................298
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM.......................................................................300
Engine Control Component Parts Location .............300
Circuit Diagram ........................................................302
System Diagram ......................................................303
Vacuum Hose Drawing ............................................304
System Chart ...........................................................305
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTION.............................................306
Fuel Injection System ..............................................306
Fuel Injection Timing System ..................................309
Air Conditioning Cut Control .................................... 311
Fuel Cut Control (at high engine speed) ................. 311
Glow Control ............................................................ 311
CRANKCASE VENTILATION SYSTEM......................312
Description ...............................................................312
Blow-by Control Valve .............................................312
Ventilation Hose .......................................................312
INJECTION NOZZLE...................................................313
Removal and Installation .........................................313
Disassembly (No.2-4nozzle) ...............................313
Inspection (No.2-4nozzle) ...................................314
Cleaning (No.2-4nozzle) .....................................314
Assembly (No.2-4nozzle) ....................................315
Test and Adjustment ................................................316
ELECTRONIC FUEL INJECTION PUMP....................318Removal ...................................................................318
Installation ................................................................319
Disassembly and Assembly .....................................320
ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION.............................................................321
DTC and MI Detection Logic ...................................321
Diagnostic Trouble Code (DTC) ..............................321
Malfunction Indicator (MI) ........................................322
CONSULT-II .............................................................327
TROUBLE DIAGNOSES.............................................334
Introduction ..............................................................334
Diagnostic Worksheet ..............................................335
Work Flow ................................................................336
Description for Work Flow .......................................337
Basic Inspection.......................................................338
Symptom Matrix Chart .............................................340
CONSULT-II Reference Value in Data Monitor
Mode ........................................................................343
Major Sensor Reference Graph in Data Monitor
Mode ........................................................................345
ECM Terminals and Reference Value .....................346
TROUBLE DIAGNOSIS FOR POWER SUPPLY........352
Wiring Diagram ........................................................352
Diagnostic Procedure ..............................................353
DTC P0100 MASS AIR FLOW SEN...........................356
Component Description ...........................................356
On Board Diagnosis Logic.......................................356
DTC Confirmation Procedure ..................................356
Wiring Diagram ........................................................357
Diagnostic Procedure ..............................................359
Component Inspection .............................................360
DTC P0115 COOLANT TEMP SEN............................361
Component Description ...........................................361
On Board Diagnosis Logic.......................................361
DTC Confirmation Procedure ..................................361
Wiring Diagram ........................................................362
Diagnostic Procedure ..............................................363
Component Inspection .............................................364
DTC P0120 ACCEL POS SENSOR............................365
Component Description ...........................................365
On Board Diagnosis Logic.......................................365
DTC Confirmation Procedure A (For General
Plausibility) ...............................................................365
DTC Confirmation Procedure B (For Accelerator
Sticking) ...................................................................366
Wiring Diagram ........................................................367
Diagnostic Procedure ..............................................368
Component Inspection .............................................371
DTC P0180 FUEL TEMP SENSOR............................372
Component Description ...........................................372
On Board Diagnosis Logic.......................................372
DTC Confirmation Procedure ..................................372
CONTENTS(Cont'd)
EC-4

Wiring Diagram ........................................................373
Diagnostic Procedure ..............................................374
Component Inspection .............................................375
DTC P0215 FUEL CUT S/V 1.....................................376
Component Description ...........................................376
On Board Diagnosis Logic.......................................376
DTC Confirmation Procedure ..................................376
Wiring Diagram ........................................................377
Diagnostic Procedure ..............................................378
Component Inspection .............................................379
DTC P0216 INJ TIMING CONT/V, DTC P1246 F/
INJ TIMG F/B...............................................................380
Component Description ...........................................380
On Board Diagnosis Logic.......................................380
DTC P0216 Confirmation Procedure.......................380
DTC P1246 Confirmation Procedure.......................381
Wiring Diagram ........................................................382
Diagnostic Procedure ..............................................383
Component Inspection .............................................384
DTC P0335 CRANK POS SEN (TDC)........................385
Component Description ...........................................385
On Board Diagnosis Logic.......................................385
DTC Confirmation Procedure ..................................385
Wiring Diagram ........................................................386
Diagnostic Procedure ..............................................387
Component Inspection .............................................388
DTC P0380 GLOW RELAY, DTC P0381 GLOW
LAMP...........................................................................389
System Description ..................................................389
Component Description ...........................................390
On Board Diagnosis Logic.......................................390
DTC Confirmation Procedure ..................................390
Wiring Diagram ........................................................391
Diagnostic Procedure ..............................................393
System Operation Check.........................................395
Component Inspection .............................................396
DTC P0500 VEHICLE SPEED SEN............................397
Component Description ...........................................397
On Board Diagnosis Logic.......................................397
Overall Function Check ...........................................397
Wiring Diagram ........................................................398
Diagnostic Procedure ..............................................399
DTC P0571 BRAKE SW..............................................400
Component Description ...........................................400
On Board Diagnosis Logic.......................................400
DTC Confirmation Procedure ..................................400
Wiring Diagram ........................................................401
Diagnostic Procedure ..............................................402
Component Inspection .............................................403
DTC P0650 MI.............................................................404
Component Description ...........................................404
On Board Diagnosis Logic.......................................404DTC Confirmation Procedure ..................................404
Wiring Diagram ........................................................405
Diagnostic Procedure ..............................................406
DTC P1107 ECM 10....................................................407
Description ...............................................................407
On Board Diagnosis Logic.......................................407
DTC Confirmation Procedure ..................................407
Diagnostic Procedure ..............................................408
DTC P1206 F/INJ F/B 2..............................................409
Component Description ...........................................409
On Board Diagnosis Logic.......................................409
DTC Confirmation Procedure ..................................410
Wiring Diagram ........................................................ 411
Diagnostic Procedure ..............................................412
Component Inspection .............................................413
DTC P1207 CONT SLEEV POS SEN.........................414
Component Description ...........................................414
On Board Diagnosis Logic.......................................414
DTC Confirmation Procedure ..................................414
Wiring Diagram ........................................................415
Diagnostic Procedure ..............................................416
Component Inspection .............................................417
DTC P1217 OVER HEAT............................................418
Description ...............................................................418
On Board Diagnosis Logic.......................................418
Overall Function Check ...........................................419
Wiring Diagram ........................................................420
Diagnostic Procedure ..............................................421
Main 12 Causes of Overheating..............................425
Component Inspection .............................................426
DTC P1240 NEEDLE LIFT SEN, DTC P1242
NEEDLE LIFT SE (RPM).............................................427
Component Description ...........................................427
On Board Diagnosis Logic.......................................427
DTC Confirmation Procedure ..................................427
Wiring Diagram ........................................................428
Diagnostic Procedure ..............................................429
Component Inspection .............................................430
DTC P1404 EGR SOL/V A, DTC P1405 EGR SOL/
V B/P1407 (THROTTLE SOLENOID VALVE)............431
System Description ..................................................431
Component Description ...........................................431
On Board Diagnosis Logic.......................................432
DTC Confirmation Procedure ..................................432
Wiring Diagram ........................................................433
Diagnostic Procedure ..............................................436
Component Inspection .............................................439
DTC P1530 AIR CONDITIONER RLY.........................440
Component Description ...........................................440
On Board Diagnosis Logic.......................................440
DTC Confirmation Procedure ..................................440
Wiring Diagram ........................................................441
CONTENTS(Cont'd)
EC-5

Diagnostic Procedure ..............................................443
DTC PD1603 ECM 12, DTC P1607 ECM2.................444
Description ...............................................................444
On Board Diagnosis Logic.......................................444
DTC Confirmation Procedure ..................................444
Diagnostic Procedure ..............................................445
DTC P1620 ECM RLY.................................................446
On Board Diagnosis Logic.......................................446
DTC Confirmation Procedure ..................................446
Wiring Diagram ........................................................447
Diagnostic Procedure ..............................................448START SIGNAL...........................................................449
Wiring Diagram ........................................................449
Diagnostic Procedure ..............................................450
OIL PRESSURE SWITCH...........................................451
Wiring Diagram ........................................................451
MI & DATA LINK CONNECTORS...............................452
Wiring Diagram ........................................................452
SERVICE DATA AND SPECIFICATIONS (SDS)........453
General Specifications .............................................453
Injection Nozzle .......................................................453
Inspection and Adjustment ......................................453
CONTENTS(Cont'd)
EC-6