2002 NISSAN TERRANO check engine

REMOVAL
1. Remove the following:
IEngine coolant draining
ICharge air cooler
IAir inlet pipe
IThrottle body
IRocker cover
IOil level gauge guide
IEGR cooler
IEGR guide tube
IEGR volume control solenoid valve
IFuel hose
IInjection tube
IRadiator upper hose
IRadiator shroud
ICooling fan
IDrive belt
IVacuum pipe
IVacuum pump
2. Move the power steering pump.
3. Remove the harness connector from the fuel injection pump.
IAfter pulling the connector stopper all the way back, remove the
connector.
IWhen the stopper is pulled all the way back, the interlocked-
connector will come off.
As for installation, when the connector is pushed all the way
forward until the stopper locks, the interlocked-connector is
inserted.
4. Remove the fuel injection pump rear bracket.
5. Remove the chain cover.
IRemove the installation bolts A, B, and C shown in the figure
(left).
CAUTION:
During chain cover removal, seal the opening to prevent for-
eign objects from getting into the engine.
6. Fix the internal mechanism of the idler gear (scissors gear
structure).
a. Remove the plug on the front side of the gear case.
b. While turning the crankshaft pulley clockwise, check the tight-
ening bolt hole of the idler gear internal mechanism through the
plug hole.
IConduct the visual check using a mirror.
IWhen checking, note that there are 2 other holes (with no
thread) beside the tightening bolt hole on the idler gear.
JEF260Z
JEF261Z
JEF262Z
BASIC SERVICE PROCEDUREZD30DDTi
Electronic Control Fuel Injection Pump (Cont'd)
EC-28

13. Make the mating marks on the fuel injection pump flange and
front plate with paint.
14. Remove installation bolts first, and then fuel injection pump
toward the rear side of the engine.
IWhen the fuel injection pump is stationary, it can still be
retained by the dowel without all bolts.
CAUTION:
Do not disassemble or adjust the fuel injection pump.
INSTALLATION
IThe injection timing adjustment to correct the installation angle
deviation is not necessary. Install the pump in the proper posi-
tion according to the dowel and installation bolts.
1. Install the fuel injection pump from the rear side of the engine.
IMatch the dowel of the spacer to the dowel hole of the pump
side for installation.
IReplace the seal washer of the installation bolt with a new one.
2. Align the mating marks of the fuel injection pump flange and
front plate, and then adjust the approximate flange position.
IEach hole [6 mm (0.24 in) dia.] is used as a reference point for
the fuel injection pump flange, fuel injection pump gear, and fuel
injection pump sprocket.
IOnly during removal/installation at No. 1 cylinder compression
top dead center, can the hole [6 mm (0.24 in) dia.] of the pump
body be aligned.
3. Install the fuel injection pump sprocket and gear as an assem-
bly.
IAlign the mating marks of the idler gear and fuel injection pump
gear properly.
4. Tighten the installation bolt of the fuel injection pump sprocket.
IFix the fuel injection pump gear with the pulley holder (SST),
and tighten the installation bolt.
CAUTION:
Before tightening the installation bolt, check again that the
mating marks of the idler gear and fuel injection pump gear are
aligned.
JEF268Z
JEF269Z
JEF270Z
JEF271Z
JEF267Z
BASIC SERVICE PROCEDUREZD30DDTi
Electronic Control Fuel Injection Pump (Cont'd)
EC-30

IIf the battery is disconnected, the emission-related diagnostic information will be lost after approx.
24 hours.
IErasing the emission-related diagnostic information using CONSULT-II is easier and quicker than
switching the diagnostic test mode using the data link connector.
NATS (Nissan Anti-Theft System)
IIf the security indicator lights up with the ignition switch in
the ªONº position or ªNATS MALFUNCTIONº is displayed
on ªSELF-DIAG RESULTSº screen, perform self-diagnostic
results mode with CONSULT-II using NATS program card.
Refer to ªNATS (Nissan Anti-Theft System)º in EL section.
IConfirm no self-diagnostic results of NATS is displayed
before touching ªERASEº in ªSELF-DIAG RESULTSº mode
with CONSULT-II.
IWhen replacing ECM, initialization of NATS system and
registration of all NATS ignition key IDs must be carried out
with CONSULT-II using NATS program card.
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedures of NATS initialization and NATS
ignition key ID registration, refer to CONSULT-II operation
manual, NATS.
Malfunction Indicator (MI)
DESCRIPTION
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON with-
out the engine running. This is a bulb check.
IIf the MI does not light up, refer to EL section (ªWARNING
LAMPS AND CHIMEº) or see EC-291.
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has
detected an engine system malfunction.
If MI illuminates or blinks irregularly after starting engine,
water may have accumulated in fuel filter. Drain water from
fuel filter. Refer to MA section.
SEF252Z
SAT652J
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
Diagnostic Trouble Code (DTC) (Cont'd)
EC-34

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 stopped
BULB 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-291.)
Engine running
MALFUNCTION
WARNINGThis is a usual driving condition. When ECM
detects a malfunction, the MI will light up to
inform the driver that a malfunction has been
detected.
Mode II Ignition switch in ON
position
Engine stopped
SELF-DIAGNOSTIC RESULTS This function allows DTCs to be read.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
Malfunction Indicator (MI) (Cont'd)
EC-35

ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
COOLING FANIIgnition switch: ON
IOperate the cooling fan at
ªLOWº, ªHIº speed and turn
ªOFFº using CONSULT-II.Cooling fan moves at ªLOWº, ªHIº
speed and stops.IHarness and connector
ICooling fan motor
ICooling fan relay
OFF ACCEL PO
SIGIClears the self-learning fully closed accelerator position, detected by accelerator position sensor, from the
ECM.
GLOW RLYIIgnition switch: ON (Engine
stopped)
ITurn the glow relay ªONº and
ªOFFº using CONSULT-II and
listen to operating sound.Glow relay makes the operating
sound.IHarness and connector
IGlow relay
INJ TIMING*IEngine: Return to the original
trouble condition
IRetard the injection timing using
CONSULT-II.If trouble symptom disappears, see
CHECK ITEM.IElectronic control fuel injection
pump
SWIRL CONT S/V1IIgnition switch: ON
ITurn solenoid valve ªONº and
ªOFFº with the CONSULT-II and
listen to operating sound.Solenoid valve makes an operating
sound.IHarness and connector
ISolenoid valve
EGR VOL CONT/VIIgnition switch: ON
IChange EGR volume control
valve opening step using CON-
SULT-II.EGR volume control valve makes
an operating sound.IHarness and connector
IEGR volume control valve
*: When using this item, DTC 0707 ªP7×F/INJ TIMG FBº may be detected. If so, erase it because it is not a malfunction.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
CONSULT-II (Cont'd)
EC-43

Introduction
The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control system,
etc. The ECM accepts input signals from sensors and instantly
drives electronic control fuel injection pump. It is essential that both
input and output signals are proper and stable. At the same time,
it is important that there are no problems such as vacuum leaks,
or other problems with the engine.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT-II or a circuit tester connected should be per-
formed. Follow the ªWork Flowº, EC-48.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus-
tomer can supply good information about such problems, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A ªDiagnostic Worksheetº like the
example on next page should be used.
Start your diagnosis by looking for ªconventionalº problems first.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.
DIAGNOSTIC WORKSHEET
There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can make
troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
SEF858S
SEF233G
SEF234G
SEF907L
TROUBLE DIAGNOSIS Ð INTRODUCTIONZD30DDTi
EC-46

Work Flow
*1 Refer to MA section (ªChecking
and Replacing Fuel Filter and
Draining Waterº, ªENGINE MAIN-
TENANCEº).
*2 If time data of ªSELF-DIAG
RESULTSº is other than ª0º, per-
form ªTROUBLE DIAGNOSIS
FOR INTERMITTENT INCIDENTº,
EC-78.*3 If the incident cannot be verified,
perform ªTROUBLE DIAGNOSIS
FOR INTERMITTENT INCIDENTº,
EC-78.
*4 If the on board diagnostic system
cannot be performed, check main
power supply and ground circuit.
Refer to ªTROUBLE DIAGNOSIS
FOR POWER SUPPLYº, EC-79.*5 If malfunctioning part cannot be
detected, perform ªTROUBLE
DIAGNOSIS FOR INTERMIT-
TENT INCIDENTº, EC-78.
YEC253A
TROUBLE DIAGNOSIS Ð INTRODUCTIONZD30DDTi
EC-48

DESCRIPTION FOR WORK FLOW
STEP DESCRIPTION
STEP IGet detailed information about the conditions and the environment when the incident/symptom occurred using
the ªDIAGNOSTIC WORKSHEETº, EC-46.
STEP IIBefore confirming the concern, check and write down (print out using CONSULT-II) the DTC, then erase the
DTC. Refer to EC-33.
If the incident cannot be verified, perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
ªSymptom Matrix Chartº will be useful. Refer to EC-56.) Also check related service bulletins for information.
STEP IIITry to confirm the symptom and under what conditions the incident occurs.
The ªDIAGNOSTIC WORK SHEETº is useful to verify the incident. Connect CONSULT-II to the vehicle in DATA
MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IVTry to detect the DTC by driving in (or performing) the ªDTC Confirmation Procedureº. Check and read the DTC
by using CONSULT-II.
During the DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG)
mode and check real time diagnosis results.
If the incident cannot be verified, perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
In case the ªDTC Confirmation Procedureº is not available, perform the ªOverall Function Checkº instead. The
DTC cannot be displayed by this check, however, this simplified ªcheckº is an effective alternative.
The ªNGº result of the ªOverall Function Checkº is the same as the DTC detection.
STEP VTake the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC XXXX.
If the normal code is indicated, proceed to the Basic Inspection, EC-50. Then perform inspections according to
the Symptom Matrix Chart. Refer to EC-56.
STEP VIIdentify where to begin diagnosis based on the relationship study between symptom and possible causes.
Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) ªHarness Layoutsº.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in ªDATA MONITOR
(AUTO TRIG)º mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CON-
SULT-II. Refer to EC-69 or EC-66.
The ªDiagnostic Procedureº in EC section contains a description based on open circuit inspection. A short circuit
inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to GI section (ªCir-
cuit Inspectionº, ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENTº).
Repair or replace the malfunction parts.
If the malfunctioning part cannot be detected, perform ªTROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENTº, EC-78.
STEP VIIOnce you have repaired the circuit or replaced a component, you need to run the engine in the same conditions
and circumstances which resulted in the customer's initial complaint.
Perform the ªDTC Confirmation Procedureº and confirm the normal code (DTC No. 0505) is detected. If the inci-
dent is still detected in the final check, perform STEP VI by using a different method from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM.
(Refer to EC-33.)
TROUBLE DIAGNOSIS Ð INTRODUCTIONZD30DDTi
Work Flow (Cont'd)
EC-49