ENGINE CONTROL SYSTEM SECTIONEC CONTENTS

Transcription

1 EINE CONTROL SYSTEM SECTIONEC DIAGNOSTIC TROUBLE CODE INDEX1 Alphabetial & Numerial Index for DTC 1 PRECAUTIONS AND PREPARATION2 Speial Servie Tools 2 Commerial Servie Tool3 Supplemental Restraint System (SRS) AIR BAG and SEAT BELT PRE-TENSIONER 4 PRECAUTIONS AND PREPARATION5 Engine Fuel & Emission Control System 5 Preautions6 EINE AND EMISSION CONTROL OVERALL SYSTEM8 ECCS-D Component Parts Loation8 Ciruit Diagram 11 System Diagram 12 Vauum Hose Drawing 13 System Chart 14 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION15 Fuel Injetion System 15 Fuel Injetion Timing System 18 Air Conditioning Cut Control19 Fuel Cut Control (at no load & high engine speed) 20 CRANKCASE VENTILATION SYSTEM21 Desription 21 Inspetion21 INJECTION NOZZLE22 Removal and Installation 22 Disassembly (No 2-4 nozzles) 22 Inspetion (No 2-4 nozzles) 23 Cleaning (No 2-4 nozzles) 23 Assembly (No 2-4 nozzles) 24 Test and Adjustment 25 ELECTRONIC FUEL INJECTION PUMP27 Removal27 Installation28 Disassembly and Assembly29 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION30 DTC and MIL Detetion Logi 30 Diagnosti Trouble Code (DTC) 30 CONTENTS Malfuntion Indiator Lamp (MIL)31 CONSULT 36 TROUBLE DIAGNOSIS Introdution42 Introdution 42 Diagnosti Worksheet43 TROUBLE DIAGNOSIS Work Flow 44 Work Flow44 Desription for Work Flow 45 TROUBLE DIAGNOSIS Basi Inspetion46 Basi Inspetion46 TROUBLE DIAGNOSIS General Desription 48 Symptom Matrix Chart48 CONSULT Referene Value in Data Monitor Mode51 Major Sensor Referene Graph in Data Monitor Mode53 ECM Terminals and Referene Value 54 TROUBLE DIAGNOSIS FOR POWER SUPPLY63 Main Power Supply and Ground Ciruit63 TROUBLE DIAGNOSIS FOR CAM POS SEN (PUMP) (DTC 11)69 Camshaft Position Sensor (CMPS) (PUMP)69 TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN (DTC 12)74 Mass Air Flow Sensor (MAFS)74 TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN (DTC 13)79 Engine Coolant Temperature (ECT) Sensor 79 TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN (DTC 14)83 Vehile Speed Sensor (VSS)83 TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN (DTC 15)87 Control Sleeve Position Sensor (CSPS)87 TROUBLE DIAGNOSIS FOR ADJUST RESISTOR (DTC 17)92 Adjustment Resistor92 TROUBLE DIAGNOSIS FOR F/INJ F/B 2 (DTC 18), F/INJ F/B (DTC 22), ELECTRIC GOV (DTC 25)96 Eletri Governor96 EC

2 TROUBLE DIAGNOSIS FOR F/INJ TIMG F/B (DTC 21)101 Injetion Timing Control Valve101 TROUBLE DIAGNOSIS FOR ACCEL POS SW (F/C) (DTC 23)106 Aelerator Swith (F/C)106 TROUBLE DIAGNOSIS FOR ECM 1 (DTC 27), ECM 2 (DTC 31)111 Engine Control Module (ECM)-ECCS-D Control Module111 TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)113 Cooling Fan (Overheat)113 TROUBLE DIAGNOSIS FOR I/C INT/A TEMP SEN (DTC 33)122 Charge Air Temperature Sensor122 TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN (DTC 34)126 Needle Lift Sensor (NLS)126 TROUBLE DIAGNOSIS FOR FUEL CUT S/V 1 (DTC 36), FCV SHORT (DTC 37), FUEL CUT S/V 2 (DTC 38)130 Fuel Cut Solenoid Valve130 TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR (DTC 42)135 Fuel Temperature Sensor (FTS)135 TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR (DTC 43)139 Aelerator Position Sensor139 TROUBLE DIAGNOSIS FOR CRANK POS SEN (TDC) (DTC 47)144 Crankshaft Position Sensor (TDC)144 TROUBLE DIAGNOSIS FOR GOV CUT CIRCUIT (DTC 48)149 Governor Cut Ciruit149 TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS151 Glow Control System151 EGRC-Solenoid Valve A, Band Throttle Control Solenoid Valve156 Start Signal163 Aelerator Position Swith165 Park/Neutral Position Swith170 A/T Control175 Charge Air Cooler Fan Control178 Heat Up Swith183 Air Conditioner Control187 MIL &Data Link Connetors188 SERVICE DATAAND SPECIFICATIONS (SDS)189 General Speifiations189 Injetion Nozzle189 Inspetion and Adjustment189 When you read wiring diagrams: + Read GI setion, HOW TO READ WIRI DIAGRAMS + See EL setion, POWER SUPPLY ROUTI for power distribution iruit When you perform trouble diagnoses, read GI setion, HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES and HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

3 DIAGNOSTIC TROUBLE CODE INDEX ALPHABETICAL INDEX FOR DTC Alphabetial & Numerial Index for DTC NUMERICAL INDEX FOR DTC Items (CONSULT sreen terms) DTC MIL illumination X: Appliable : Not appliable Referene page ACCEL POS SENSOR 43 X EC-139 ACCEL POS SW (F/C) 23 X EC-106 ADJUST RESISTOR 17 EC-92 CAM POS SEN (PUMP) 11 X EC-69 CONT SLEEV POS SEN 15 X EC-87 COOLANT TEMP SEN 13 X EC-79 CRANK POS SEN (TDC) 47 X EC-144 ECM 1 27 X EC-111 ECM 2 31 X EC-111 ELECTRIC GOV 25 X EC-96 FCV SHORT 37 X EC-130 FUEL CUT S/V 1 36 X EC-130 FUEL CUT S/V 2 38 X EC-130 FUEL TEMP SENSOR 42 EC-135 F/INJ F/B 22 X EC-96 F/INJ F/B 2 18 X EC-96 F/INJ TIMG F/B 21 EC-101 GOV CUT CIRCUIT 48 X EC-149 I/C INT/A TEMP SEN 33 *1 EC-122 MAS AIR FLOW SEN 12 EC-74 NATS MALFUNCTION X EL setion* NEEDLE LIFT SEN 34 EC-126 NO SELF DIAGNOSTIC FAILURE INDICATED 55 OVER HEAT 28 X EC-113 VEHICLE SPEED SEN 14 EC-83 DTC MIL illumination Items (CONSULT sreen terms) X: Appliable : Not appliable Referene page 11 X CAM POS SEN (PUMP) EC MAS AIR FLOW SEN EC X COOLANT TEMP SEN EC VEHICLE SPEED SEN EC X CONT SLEEV POS SEN EC ADJUST RESISTOR EC X F/INJ F/B 2 EC F/INJ TIMG F/B EC X F/INJ F/B EC X ACCEL POS SW (F/C) EC X ELECTRIC GOV EC X ECM 1 EC X OVER HEAT EC X ECM 2 EC *1 I/C INT/A TEMP SEN EC NEEDLE LIFT SEN EC X FUEL CUT S/V 1 EC X FCV SHORT EC X FUEL CUT S/V 2 EC FUEL TEMP SENSOR EC X ACCEL POS SENSOR EC X CRANK POS SEN (TDC) EC X GOV CUT CIRCUIT EC NO SELF DIAGNOSTIC FAILURE INDICATED X NATS MALFUNCTION EL setion*2 *1: When nothing is displayed or the meaningless symbol is displayed in the Self-diag result mode with CONSULT, perform Diagnosti Test Mode II (Self-diagnosti results) with ECM Refer to EC-32 *2: Refer to NATS (Nissan Anti-Theft System) in EL setion EC-1

4 FOR DIESEL EINE INJECTION PUMP PRECAUTIONS AND PREPARATION Speial Servie Tools Tool number Tool name Desription KV Measuring devie V 1 KV Holder V 2 KV Nut V 3 KV Pin V 4 KV Dial gauge Measuring plunger lift NT570 KV Pulley puller Removing injetion pump sproket NT647 FOR DIESEL EINE INJECTION NOZZLE Tool number Tool name Desription KV Nozzle leaning kit V 1 KV Box V 2 KV Brush V 3 KV Nozzle oil sump sraper V 4 KV Nozzle needle tip V 5 KV Nozzle seat sraper V 6 KV Nozzle holder V 7 KV Nozzle hole leaning needle NT296 EC-2

5 PRECAUTIONS AND PREPARATION Speial Servie Tools (Cont d) Tool number Tool name Desription KV Nozzle entering devie NT293 KV Nozzle holder soket (For No 2-4 injetion nozzles) NT563 KV119E0010 No 1 injetion nozzle holder soket NT648 Commerial Servie Tool Tool name Fuel filler ap adapter Desription Cheking fuel tank vauum relief valve opening pressure NT653 EC-3

6 PRECAUTIONS AND PREPARATION Supplemental Restraint System (SRS) AIR BAG and SEAT BELT PRE-TENSIONER The Supplemental Restraint System suh as AIR BAG and SEAT BELT PRE-TENSIONER used along with a seat belt, helps to redue the risk or severity of injury to the driver and front passenger in a frontal ollision The SRS system omposition whih is available to NISSAN MODEL Y61 is as follows (The omposition varies aording to the destination): Driver air bag module (loated in the enter of the steering wheel), front passenger air bag module (loated on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp, wiring harness and spiral able Information neessary to servie the system safely is inluded in the RS setion of this Servie Manual WARNI: + To avoid rendering the SRS inoperative, whih ould inrease the risk of personal injury or death in the event of a ollision whih would result in air bag inflation, all maintenane must be performed by an authorized NISSAN dealer + Improper maintenane, inluding inorret removal and installation of the SRS, an lead to personal injury aused by unintentional ativation of the system For removal of Spiral Cable and Air Bag Module, see the RS setion + Do not use eletrial test equipment on any iruit related to the SRS unless instruted to in this Servie Manual Spiral able and wiring harnesses overed with yellow insulation either just before the harness onnetors or for the omplete harness are related to the SRS EC-4

7 PRECAUTIONS AND PREPARATION Engine Fuel & Emission Control System EC-5 SEF656V

8 PRECAUTIONS AND PREPARATION Preautions + Before onneting or disonneting the ECM harness onnetor, turn ignition swith OFF and disonnet negative battery terminal Failure to do so may damage the ECM beause battery voltage is applied to ECM even if ignition swith is turned off SEF289H + When onneting ECM harness onnetor, tighten seuring bolt until the gap between orange indiators disappears : Nzm (03-05 kg-m, in-lb) SEF308Q + When onneting or disonneting pin onnetors into or from ECM, take are not to damage pin terminals (bend or break) Make sure that there are not any bends or breaks on ECM pin terminal, when onneting pin onnetors SEF291H + Before replaing ECM, perform Terminals and Referene Value inspetion and make sure ECM funtions properly Refer to EC-54 MEF040D SEF051P + If MIL illuminates or blinks irregularly when engine is running, water may have aumulated in fuel filter Drain water from fuel filter If this does not orret the problem, perform speified trouble diagnosti proedures + After performing eah TROUBLE DIAGNOSIS, perform OVERALL FUNCTION CHECK or DTC (Diagnosti Trouble Code) CONFIRMATION PROCEDURE The DTC should not be displayed in the DTC CONFIRMA- TION PROCEDURE if the repair is ompleted The OVER- ALL FUNCTION CHECK should be a good result if the repair is ompleted EC-6

9 PRECAUTIONS AND PREPARATION Preautions (Cont d) + When measuring ECM signals with a iruit tester, never allow the two tester probes to ontat Aidental ontat of probes will ause a short iruit and damage the ECM power transistor SEF348N EC-7

10 EINE AND EMISSION CONTROL OVERALL SYSTEM ECCS-D Component Parts Loation EC-8 SEF657V

11 EINE AND EMISSION CONTROL OVERALL SYSTEM ECCS-D Component Parts Loation (Cont d) EC-9 SEF658V

12 EINE AND EMISSION CONTROL OVERALL SYSTEM ECCS-D Component Parts Loation (Cont d) EC-10 SEF659V

13 EINE AND EMISSION CONTROL OVERALL SYSTEM Ciruit Diagram EC-11 TEC420

14 EINE AND EMISSION CONTROL OVERALL SYSTEM System Diagram EC-12 SEF660V

15 EINE AND EMISSION CONTROL OVERALL SYSTEM Vauum Hose Drawing SEF661V V 1 V 2 V 3 V 4 Charge air ooler to vauum gallery Throttle ontrol valve to throttle ontrol solenoid valve Vauum pump to 3-way onnetor Vauum gallery to wastegate valve atuator V 5 V 6 V 7 3-way onnetor to throttle ontrol solenoid valve 3-way onnetor to EGRC-solenoid valve A 3-way onnetor to EGRC-solenoid valve A V 8 V 9 3-way onnetor to EGRC-solenoid valve B EGR valve and 3-way onnetor Refer to System Diagram, EC-12 for vauum ontrol system EC-13

16 EINE AND EMISSION CONTROL OVERALL SYSTEM System Chart Camshaft position sensor (PUMP) Fuel injetion ontrol Eletri governor Crankshaft position sensor (TDC) Control sleeve position sensor Fuel injetion timing ontrol Injetion timing ontrol valve Fuel temperature sensor Engine oolant temperature sensor Fuel ut ontrol Fuel ut solenoid valve Needle lift sensor Aelerator position sensor Glow ontrol system Glow relay & glow lamp Aelerator position swith Aelerator swith (F/C) ECM (ECCS-D ontrol module) On board diagnosti system Malfuntion indiator lamp (On the instrument panel) Neutral position swith Ignition swith EGR valve & throttle ontrol valve ontrol EGRC-solenoid valve A, B & throttle ontrol solenoid valve Battery voltage Vehile speed sensor Cooling fan ontrol Cooling fan relay Air onditioner swith Mass air flow sensor Air onditioning ut ontrol Air onditioner relay Charge air temperature sensor Heat up swith Charge air ooler fan ontrol Charge air ooler fan relay EC-14

17 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injetion System SYSTEM DESCRIPTION Three types of fuel injetion ontrol are provided to aommodate engine operating onditions; normal ontrol, idle ontrol and start ontrol The ECM determines the appropriate fuel injetion ontrol Under eah ontrol, the amount of fuel injeted is ompensated to improve engine performane The ECM performs duty ontrol on the eletri governor (built into the fuel injetion pump) aording to sensor signals to ompensate the amount of fuel injeted to the preset value START CONTROL Input/output signal line Engine oolant temperature sensor Engine oolant temperature Crankshaft position sensor (TDC) Ignition swith Engine speed Start signal ECM Eletri governor Control sleeve position sensor Control sleeve position When the ECM reeives a start signal from the ignition swith, the ECM adapts the fuel injetion system for the start ontrol The amount of fuel injeted at engine starting is a preset program value in the ECM The program is determined by the engine speed and engine oolant temperature For better startability under ool engine onditions, the lower the oolant temperature beomes, the greater the amount of fuel injeted The ECM ends the start ontrol when the engine speed reahes 400 rpm (for M/T models), 600 rpm (for A/T models) and shifts the ontrol to the normal or idle ontrol SEF648S EC-15

18 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injetion System (Cont d) IDLE CONTROL Input/output signal line Engine oolant temperature sensor Engine oolant temperature Crankshaft position sensor (TDC) Engine speed Neutral position swith Gear position Battery Battery voltage Control sleeve position sensor Control sleeve position ECM Eletri governor Aelerator position swith Idle position Vehile speed sensor Vehile speed Air onditioner swith Air onditioner signal Heat up swith Heat up swith signal When the ECM determines that the engine speed is at idle, the fuel injetion system is adapted for the idle ontrol The ECM regulates the amount of fuel injeted orresponding to hanges in load applied to the engine to keep engine speed onstant The ECM also provides the system with a fast idle ontrol in response to the engine oolant temperature and heat up swith signal NORMAL CONTROL Input/output signal line Crankshaft position sensor (TDC) Engine speed Control sleeve position sensor Aelerator position sensor Control sleeve position Aelerator position ECM Eletri governor Vehile speed sensor Vehile speed The amount of fuel injeted under normal driving onditions is determined aording to sensor signals The rankshaft position sensor (TDC) detets engine speed and the aelerator position sensor detets aelerator position These sensors send signals to the ECM The fuel injetion data, predetermined by orrelation between various engine speeds and aelerator positions, are stored in the ECM memory, forming a map The ECM determines the optimal amount of fuel to be injeted using the sensor signals in omparison with the map SEF649S EC-16

19 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injetion System (Cont d) FUEL TEMPERATURE COMPENSATION Input/output signal line Fuel temperature sensor Fuel temperature Crankshaft position sensor (TDC) Engine speed ECM Eletri governor Control sleeve position sensor Control sleeve position The amount of fuel leaking at or around high-pressure parts inside fuel injetion pump varies with fuel temperature and engine speed This will result in a differene between the target amount of fuel injeted and the atual amount The ECM ompensates for the atual amount depending on the signal from the fuel temperature sensor whih detets fuel temperature DECELERATION CONTROL Input/output signal line Aelerator swith (F/C) Camshaft position sensor (PUMP) Aelerator position Engine speed ECM Eletri governor The ECM uts power supply delivery to the eletri governor during deeleration for better fuel effiieny The ECM determines the time of deeleration aording to signals from the aelerator swith (F/C) and amshaft position sensor (PUMP) EC-17

20 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injetion Timing System SYSTEM DESCRIPTION The fuel injetion timing system provides the optimal fuel injetion timing for the target amount of fuel injeted aording to engine speed The timing is ompensated when the vehile is being driven or when starting depending on the engine oolant temperature The ECM performs duty ontrol on the timing ontrol valve, allowing the valve to provide optimal fuel injetion timing The ECM also performs feedbak ontrol on the timing ontrol valve using the signal from the needle lift sensor whih detets the atual fuel injetion timing BASIC CONTROL Input/output signal line Crankshaft position sensor (TDC) Needle lift sensor Engine speed Injetion timing ECM Injetion timing ontrol valve The optimal fuel injetion timing data, predetermined in proportion to engine speeds and amount of fuel injeted, are stored in the ECM memory The ECM uses the data to ontrol the fuel injetion timing SEF650S EINE COOLANT TEMPERATURE COMPENSATION (When starting) Input/output signal line Crankshaft position sensor (TDC) Engine speed Engine oolant temperature sensor Needle lift sensor Engine oolant temperature Ignition timing ECM Injetion timing ontrol valve Ignition swith Start signal For better startability under ool engine onditions, the fuel injetion timing is ompensated aording to the engine oolant temperature Fuel injetion timing ompensation Engine oolant temperature Engine rpm SEF651S EC-18

21 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injetion Timing System (Cont d) EINE COOLANT TEMPERATURE COMPENSATION (During driving) Input/output signal line Crankshaft position sensor (TDC) Engine speed Engine oolant temperature sensor Engine oolant temperature ECM Injetion timing ontrol valve Needle lift sensor Injetion timing For better exhaust effiieny under ool engine onditions, the fuel injetion timing is ontrolled within a ompensation range depending on the engine speed, engine oolant temperature and amount of fuel injeted SEF652S Air Conditioning Cut Control INPUT/OUTPUT SIGNAL LINE Air onditioner swith Air onditioner ON signal Aelerator position sensor Vehile speed sensor Aelerator valve opening angle Vehile speed ECM Air onditioner relay Engine oolant temperature sensor Engine oolant temperature SYSTEM DESCRIPTION This system improves aeleration when the air onditioner is used When the aelerator pedal is fully depressed, the air onditioner is turned off for a few seonds When engine oolant temperature beomes exessively high, the air onditioner is turned off This ontinues until the oolant temperature returns to normal EC-19

22 EINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION INPUT/OUTPUT SIGNAL LINE Fuel Cut Control (at no load & high engine speed) Vehile speed sensor Vehile speed Neutral position swith Neutral position Aelerator position swith or Aelerator swith (F/C) Aelerator position ECM Eletri governor Engine oolant temperature sensor Engine oolant temperature Crankshaft position sensor (TDC) Engine speed If the engine speed is above 3,000 rpm with no load (for example, in neutral and engine speed over 3,000 rpm) fuel will be ut off after some time The exat time when the fuel is ut off varies based on engine speed Fuel ut will operate until the engine speed reahes 1,500 rpm, then fuel ut is anelled NOTE: This funtion is different from deeleration ontrol and fuel ut solenoid valve ontrol listed under Fuel Injetion System, EC-15 and TROUBLE DIAGNOSIS FOR DTC 36, 37, 38, EC-130 EC-20

23 CRANKCASE VENTILATION SYSTEM Desription In this system, blow-by gas is suked into the air inlet pipe through the ontrol valve after oil separation by oil separator in the roker over Blow-by ontrol valve SEF456HA Inspetion BLOW-BY CONTROL VALVE Chek ontrol valve for logging and abnormalities Intake manifold Roker over SEC586B VENTILATION HOSE 1 Chek hoses and hose onnetions for leaks 2 Disonnet all hoses and lean with ompressed air If any hose annot be freed of obstrutions, replae SEC692 EC-21

24 INJECTION NOZZLE CAUTION: + Do not disassemble No 1 nozzle (with needle lift sensor built-in) If, replae No 1 injetion nozzle + Plug flare nut with a ap or rag so that no dust enters the nozzle Cover nozzle tip for protetion of needle Nozzle side Combustion hamber side SEF939S Removal and Installation 1 Remove fuel injetion tube and spill tube 2 Remove injetion nozzle assembly Also remove gasket from nozzle end 3 Install injetion nozzle in the reverse order of removal Injetion nozzle to engine: : 59-69Nzm (60-70 kg-m, ft-lb) Injetion nozzle to tube: : 22-25Nzm (22-25 kg-m, ft-lb) Spill tube: : 39-49Nzm (40-50 kg-m, ft-lb) a Always lean the nozzle holes b Always use new injetion nozzle gasket Note that small washer should be installed in speified diretion d Bleed air from fuel system SEF662V Disassembly (No 2-4 nozzles) Do not disassemble No 1 nozzle (with needle lift sensor) 1 Loosen nozzle nut while preventing nozzle top from turning Holder Adjusting shim Nozzle spring Push rod Distane piee SEF669A 2 Arrange all disassembled parts in the order shown at left Nozzle needle Nozzle body Nozzle nut SEF670A EC-22

25 INJECTION NOZZLE Inspetion (No 2-4 nozzles) Thoroughly lean all disassembled parts with fresh kerosene or solvent + If nozzle needle is damaged or fused, replae nozzle assembly with a new one + If end of nozzle needle is seized or exessively disolored, replae nozzle assembly + Chek nozzle body and distane piee for proper ontat If exessively worn or damaged, replae nozzle assembly or distane piee + Chek distane piee and nozzle holder for proper ontat If exessively worn or damaged, replae distane piee or nozzle holder + Chek nozzle spring for exessive wear or damage If exessively worn or damaged, replae it with a new spring Cleaning (No 2-4 nozzles) a Do not touh the nozzle mating surfae with your fingers b To wash the nozzles, use a wooden stik and brass brush with lean diesel fuel 1 Remove any arbon from exterior of nozzle body (exept wrapping angle portion) by using Tool SEF830 2 Clean oil sump of nozzle body using Tool SEF831 3 Clean nozzle seat by using Tool This job should be performed with extra preautions, sine effiieny of nozzle depends greatly on a good nozzle seat SEF832 EC-23

26 INJECTION NOZZLE Cleaning (No 2-4nozzles) (Cont d) 4 Clean spray hole of nozzle body by using Tool To prevent spray hole from anting, always lean it by starting with inner side and working towards outside SEF833 5 Dearbonate nozzle needle tip by using Tool SEF834 6 Chek needle sinking (1) Pull needle about halfway out from body and then release it (2) Needle should sink into body very smoothly from just its own weight (3) Repeat this test and rotate needle slightly eah time If needle fails to sink smoothly from any position, replae both needle and body as a unit SEF835 Assembly (No 2-4 nozzles) Assemble in the reverse order of disassembly, observing the following SEF671A If nozzle body is not installed properly, Tool annot be removed and nozzle body may be damaged Holder to nozzle nut: : 78-98Nzm ( kg-m, ft-lb) EC-24

27 INJECTION NOZZLE Test and Adjustment WARNI: When using nozzle tester, be areful not to allow diesel fuel sprayed from nozzle to ontat your hands or body, and make sure your eyes are properly proteted with goggles INJECTION PRESSURE TEST 1 Install nozzle to injetion nozzle tester and bleed air from flare nut Adjusting shim EF791A SEF672A 2 Pump the tester handle slowly (one time per seond) and wath the pressure gauge 3 Read the pressure gauge when the injetion pressure just starts dropping Initial injetion pressure: Used 14,220 kpa (1422 bar, 145 kg/m 2, 2,062 psi) New 14,711-15,495 kpa ( bar, kg/m 2, 2,133-2,247 psi) Always hek initial injetion pressure using a new nozzle 4 To adjust injetion pressure, hange adjusting shims (No 2-4 nozzles) a Inreasing the thikness of adjusting shims inreases initial injetion pressure Dereasing thikness redues initial pressure b A shim thikness of 004 mm (00016 in) orresponds approximately to a differene of 471 kpa (471 bar, 48 kg/m 2, 68 psi) in initial injetion pressure Refer to SDS for adjusting shim (EC-189) SEF673A LEAKAGE TEST 1 Maintain the pressure at about 981 to 1,961 kpa (98 to 196 bar, 10 to 20 kg/m 2, 142 to 284 psi) below initial injetion pressure 2 Chek that there is no dripping from the nozzle tip or around the body SEF674A EC-25

28 INJECTION NOZZLE Test and Adjustment (Cont d) 3 If there is leakage, lean, overhaul or replae nozzle SPRAY PATTERN TEST 1 Chek spray pattern by pumping tester handle one full stroke per seond + If main spray angle is within 30 degrees as shown, injetion nozzle is good + 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 orret, disassemble and lean nozzle 3 Test again and if spray pattern is not orreted, replae nozzle SEF079S EC-26

29 ELECTRONIC FUEL INJECTION PUMP SEF663V Removal 1 Remove battery Disonnet eletroni injetion pump harness onnetors 2 Set No 1 piston at TDC on its ompression stroke TDC: Crankshaft pulley noth without painted mark 3 Remove fuel hoses (supply, return and spill) and injetion tubes 4 Remove air dut and injetion pump timing belt over 5 Remove injetion pump timing belt Refer to EM setion ( Injetion Pump Timing Belt ) SEF664V 6 Remove injetion pump sproket with Tool + Remove key from injetion pump shaft and store safely SEF665V EC-27

30 ELECTRONIC FUEL INJECTION PUMP Removal (Cont d) 7 Remove injetion pump assembly SEF666V Installation 1 Install key on injetion pump shaft, then install injetion pump sproket + Use alignment mark on sproket 2 Install injetion pump timing belt Refer to EM setion ( Injetion Pump Timing Belt ) SEF667V 3 Adjust injetion timing Refer to Basi Inspetion, EC-46 4 Install all parts removed EC-28

31 ELECTRONIC FUEL INJECTION PUMP SEF668V Disassembly and Assembly CAUTION: + Do not disassemble the parts not shown in the illustration above + Before installing injetion timing ontrol valve, liberally apply a oat of diesel fuel to O-ring and its mating area Insert injetion timing ontrol valve straight into bore in fuel pump body After properly positioning injetion timing ontrol valve, visually hek that fuel does not leak + After assembling the parts, erase Diagnosti Trouble Code (DTC), and perform DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK) EC-29

32 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION DTC and MIL Detetion Logi When a malfuntion is deteted for the first time, the malfuntion (DTC) is stored in the ECM memory The MIL will light up eah time the ECM detets malfuntion However, if the same malfuntion is experiened in two onseutive driving patterns and the engine is still running, the MIL will stay lit up For diagnosti items ausing the MIL to light up, refer to DIAGNOSTIC TROUBLE CODE INDEX, EC-1 Diagnosti Trouble Code (DTC) HOW TO READ DTC The diagnosti trouble ode an be read by the following methods 1 The number of blinks of the malfuntion indiator lamp in the Diagnosti Test Mode II (Self-Diagnosti Results) Examples: 11, 13, 14, et These DTCs are ontrolled by NISSAN 2 CONSULT Examples: CAM POS SEN (PUMP), et + Output of the trouble ode means that the indiated iruit has a malfuntion However, in the Mode II it does not indiate whether the malfuntion is still ourring or ourred in the past and returned to normal CONSULT an identify them Therefore, using CONSULT (if available) is reommended HOW TO ERASE DTC The diagnosti trouble ode an be erased by the following methods Seleting ERASE in the SELF-DIAG RESULTS mode with CONSULT Changing the diagnosti test mode from Diagnosti Test Mode II to Mode I (Refer to EC-32) + If the battery terminal is disonneted, the diagnosti trouble ode will be lost within 24 hours + When you erase the DTC, using CONSULT is easier and quiker than swithing the diagnosti test modes HOW TO ERASE DTC (With CONSULT) 1 If the ignition swith stays ON after repair work, be sure to turn ignition swith OFF one Wait at least 5 seonds and then turn it ON (Engine stopped) again 2 Turn CONSULT ON and touh EINE 3 Touh SELF-DIAG RESULTS 4 Touh ERASE (The DTC in the ECM will be erased) SEF691S HOW TO ERASE DTC (No Tools) 1 If the ignition swith stays ON after repair work, be sure to turn ignition swith OFF one Wait at least 5 seonds and then turn it ON again 2 Change the diagnosti test mode from Mode II to Mode I (Refer to EC-32) EC-30

33 ON BOARD DIAGNOSTIC SYSTEM FUNCTION The on board diagnosti system has the following three funtions Malfuntion Indiator Lamp (MIL) 1 The malfuntion indiator lamp will light up when the ignition swith is turned ON without the engine running This is a bulb hek + If the malfuntion indiator lamp does not light up, refer to EL setion ( WARNI LAMPS AND CHIME ) or see EC When the engine is started, the malfuntion indiator lamp should go off If the lamp remains on, the on board diagnosti system has deteted an engine system malfuntion If MIL illuminates or blinks irregularly after starting engine, water may have aumulated in fuel filter Drain water from fuel filter 1 BULB CHECK : This funtion heks the MIL bulb for damage (blown, open iruit, et) 2 MALFUNCTION : This is a usual driving ondition When a malfuntion is deteted, the WARNI MIL will light up to inform the driver that a malfuntion has been 3 SELF-DIAGNOSTIC RESULTS ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION SEF051P deteted : This funtion allows diagnosti trouble odes to be read Refer to HOW TO SWITCH DIAGNOSTIC TEST MODES on next page Ignition swith in ON position Condition Engine stopped Engine running Diagnosti Test Mode I BULB CHECK MALFUNCTION WARNI Diagnosti Test Mode II SELF-DIAGNOSTIC RESULTS EC-31

34 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfuntion Indiator Lamp (MIL) (Cont d) HOW TO SWITCH DIAGNOSTIC TEST MODES Turn ignition swith ON (Do not start engine) Diagnosti Test Mode I BULB CHECK Refer to previous page MIL should ome on b Chek MIL iruit (See EC-188) Repair harness or onnetors G Start engine Diagnosti Test Mode I MALFUNC- TION WARN- I Refer to previous page Chek MIL iruit and data link onnetor for CONSULT iruit (See EC-188) Data link onnetor for CONSULT (Connet CHK and IGN terminals with a suitable harness) MIL should go off Repair harness or onnetors Wait at least 2 seonds b Data link onnetor for CONSULT (Disonnet the suitable harness between CHK and IGN terminals) DIAGNOSTIC TEST MODE II SELF-DIAGNOSTIC RESULTS jb ja EC-32

35 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfuntion Indiator Lamp (MIL) (Cont d) jb m ja Data link onnetor for CONSULT (Connet CHK and IGN terminals with a suitable harness) + Swithing the modes is not possible when the engine is running + When ignition swith is turned off during diagnosis, power to ECM will drop after approx 5 seonds The diagnosis will automatially return to Diagnosti Test Mode I Wait at least 2 seonds Data link onnetor for CONSULT (Disonnet the suitable harness between CHK and IGN terminals) If the suitable harness is disonneted at this time, the diagnosti trouble ode will be erased from the bakup memory in the ECM EC-33

36 DIAGNOSTIC TEST MODE I BULB CHECK In this mode, the MALFUNCTION INDICATOR LAMP on the instrument panel should stay ON If it remains OFF, hek the bulb Refer to EL setion ( WARNI LAMPS AND CHIME ) or see EC-188 DIAGNOSTIC TEST MODE I MALFUNCTION WARNI MALFUNCTION INDICATOR LAMP ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfuntion Indiator Lamp (MIL) (Cont d) Condition When the malfuntion is deteted or the ECM s CPU is malfuntioning (Refer to MIL Illumination of the ON DIAGNOSTIC TROUBLE CODE INDEX, EC-1) OFF No malfuntion + These Diagnosti Trouble Code Numbers are larified in Diagnosti Test Mode II (SELF-DIAGNOSTIC RESULTS) DIAGNOSTIC TEST MODE II SELF-DIAGNOSTIC RESULTS In this mode, a diagnosti trouble ode is indiated by the number of blinks of the MALFUNCTION INDICA- TOR LAMP as shown below SEF212NA Long (06 seond) blinking indiates the number of ten digits, and short (03 seond) blinking indiates the number of single digits For example, the malfuntion indiator lamp blinks 4 times for 5 seonds (06 se x 4 times) and then it blinks three times for about 1 seond (03 se x 3 times) This indiates the DTC 43 and refers to the malfuntion of the aelerator position sensor iruit In this way, all the deteted malfuntions are lassified by their diagnosti trouble ode numbers The DTC 55 refers to no malfuntion (See DIAGNOSTIC TROUBLE CODE INDEX, EC-1) HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnosti results) The diagnosti trouble ode an be erased from the bakup memory in the ECM when the diagnosti test mode is hanged from Diagnosti Test Mode II to Diagnosti Test Mode I (Refer to HOW TO SWITCH DIAGNOS- TIC TEST MODES on previous page) + If the battery terminal is disonneted, the diagnosti trouble ode will be lost from the bakup memory within 24 hours + Be areful not to erase the stored memory before starting trouble diagnoses + If the MIL blinks or NATS MALFUNCTION is displayed on SELF-DIAG RESULTS sreen, perform self-diagnosti results mode with CONSULT using NATS program ard (NATS-E940) Refer to EL setion + Confirm no self-diagnosti results of NATS is displayed before touhing ERASE in SELF-DIAG RESULTS mode with CONSULT + When replaing ECM, initialisation of NATS V20 system and registration of all NATS V20 ignition key IDs must be arried out with CONSULT using NATS program ard (NATS-E940) SEF288Q Therefore, be sure to reeive all keys from vehile owner Regarding the proedures of NATS initialisation and NATS ignition key ID registration, refer to CONSULT operation manual, NATS V20 EC-34

37 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfuntion Indiator Lamp (MIL) (Cont d) RELATIONSHIP BETWEEN MIL, DTC, CONSULT AND DRIVI PATTERNS Detetion This driving pattern does not satisfy self-diagnosti ondition This driving pattern satisfies self-diagnosti ondition Driving Pattern Engine (GN) RUN (ON) STOP (OFF) MIL ON OFF ECM Diagnosti trouble ode DISPLAY NO DISPLAY CONSULT SELF- DIAGNOSTIC DTC exists RESULTS SCREEN & DTC does DATA MONITOR not exist (AUTO TRIG) SCREEN SELF- DIAGNOSTIC RESULTS SCREEN COUNTER SEF659S *1: When a malfuntion is deteted, MIL will light up *2: When the same malfuntion is deteted in two onseutive driving patterns, MIL will stay lit up *3: MIL will go off after vehile is driven three times without any malfuntions *4: When a malfuntion is deteted for the first time, the DTC will be stored in ECM *5: The DTC will not be displayed any longer after vehile is driven 40 times without the same malfuntion (The DTC still remain in ECM) *6: Other sreens exept SELF-DIAGNOSTIC RESULTS & DATA MONITOR (AUTO TRIG) annot display the malfuntion DATA MONITOR (AUTO TRIG) an display the malfuntion at the moment it is deteted EC-35

38 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT CONSULT INSPECTION PROCEDURE 1 Turn off ignition swith 2 Connet CONSULT to data link onnetor for CONSULT (Data link onnetor for CONSULT is loated under the hood opener) SEF669V 3 Turn on ignition swith 4 Touh START 5 Touh EINE 6 Perform eah diagnosti test mode aording to eah servie proedure For further information, see the CONSULT Operation Manual SEF895K SEF660S EC-36

39 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT (Cont d) ECCS COMPONENT PARTS/CONTROL SYSTEMS APPLICATION DIAGNOSTIC TEST MODE ECCS COMPONENT PARTS INPUT OUTPUT X: Appliable Item SELF-DIAG- NOSTIC RESULTS DATA MONITOR ACTIVE TEST Camshaft position sensor (PUMP) X X Engine oolant temperature sensor X X Control sleeve position sensor X X Fuel temperature sensor X X Vehile speed sensor X X Aelerator position sensor X X X Aelerator position swith X X Aelerator swith (F/C) X X Crankshaft position sensor (TDC) X X Needle lift sensor X Ignition swith (start signal) X Neutral position swith X Battery voltage X Air onditioner swith X Heat up swith X Mass air flow sensor X X Charge air temperature sensor X Injetion timing ontrol valve X X X Fuel ut solenoid valve X X X Glow relay X X EGRC-solenoid valve A, B & throttle ontrol solenoid valve X X Cooling fan relay X X Charge air ooler fan relay X EC-37

40 SELF-DIAGNOSTIC MODE Regarding items deteted in SELF-DIAG RESULTS mode, refer to DIAGNOSTIC TROUBLE CODE INDEX, EC-1 DATA MONITOR MODE Monitored item [Unit] CKPSzRPM (TDC) [rpm] CKPSzRPM (REF) [rpm] CMPSzRPM - PUMP [rpm] COOLAN TEMP/S [ C] or [ F] VHCL SPEED SE [km/h] or [mph] FUEL TEMP SEN [ C] or [ F] ACCEL POS SEN [V] FULL ACCEL SW [ON/OFF] ACCEL SW (FC) [OPEN/CLOSE] OFF ACCEL SW [ON/OFF] C/SLEEV POS/S [V] BATTERY VOLT [V] P/N POSI SW [ON/OFF] START SIGNAL [ON/OFF] ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT (Cont d) ECM input signals Main signals j j Desription + The engine speed omputed from the rankshaft position sensor (TDC) signal is displayed j j + The engine speed [determined by the time between pulses from the rankshaft position sensor (TDC) signal] is displayed j j j j j j j j j j j j j j j j j j j j j j j j + The engine speed omputed from the amshaft position sensor (PUMP) signal is displayed + The engine oolant temperature (determined by the signal voltage of the engine oolant temperature sensor) is displayed + The vehile speed omputed from the vehile speed sensor signal is displayed + The fuel temperature (determined by the signal voltage of the fuel temperature sensor) is displayed + The aelerator position sensor signal voltage is displayed + Indiates [ON/OFF] ondition from the aelerator position swith signal + Indiates [OPEN/CLOSE] ondition from the aelerator swith (FC) signal + Indiates [ON/OFF] ondition from the aelerator position swith signal + The ontrol sleeve position sensor signal voltage is displayed + The power supply voltage of ECM is displayed + Indiates [ON/OFF] ondition from the park/neutral position swith signal + Indiates [ON/OFF] ondition from the starter signal Remarks + When the engine oolant temperature sensor is open or short-iruited, ECM enters fail-safe mode The engine oolant temperature determined by the ECM is displayed + After starting the engine, [OFF] is displayed regardless of the starter signal NOTE: Any monitored item that does not math the vehile being diagnosed is deleted from the display automatially EC-38

41 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT (Cont d) Monitored item [Unit] AIR COND SIG [ON/OFF] IGN SW [ON/OFF] MAS AIR/FL SE [V] ACT INJ TIMG [ ] INJ TIMG C/V [%] DECELER F/CUT [ON/OFF] FUEL CUT S/V [ON/OFF] GLOW RLY [ON/OFF] COOLI FAN [LOW/HI/OFF] I/C FAN RLY [ON/OFF] EGRC SOL/V A [ON/OFF] EGRC SOL/V B [ON/OFF] THROT RLY [ON/OFF] ECM input signals Main signals j j j j j j Desription + Indiates [ON/OFF] ondition of the air onditioner swith as determined by the air onditioner signal + Indiates [ON/OFF] ondition from ignition swith signal + The signal voltage of the mass air flow sensor is displayed j j + The atual injetion timing angle determined by the ECM (an approximate average angle between injetion start and end from TDC) is displayed j j j j j + Indiates the duty ratio of fuel injetion timing ontrol valve + Indiates [ON/OFF] ondition from deeleration fuel ut signal + The ontrol ondition of the fuel ut solenoid valve (determined by ECM aording to the input signal) is indited + OFF Fuel ut solenoid valve is not operating ON Fuel ut solenoid valve is operating + The glow relay ontrol ondition (determined by ECM aording to the input signal) is displayed + Indiates the ontrol ondition of the ooling fans (determined by ECM aording to the input signal) + LOW Operates at low speed HI Operates at high speed OFF Stopped + Indiates the ontrol ondition of the harge air ooler fan (determined by ECM aording to the input signals) + The ontrol ondition of the EGRC-solenoid valve A (determined by ECM aording to the input signal) is indiated + OFF EGRC-solenoid valve A is not operating ON EGRC-solenoid valve A is operating + The ontrol ondition of the EGRC-solenoid valve B (determined by ECM aording to the input signal) is indiated + OFF EGRC-solenoid valve B is not operating ON EGRC-solenoid valve B is operating + The ontrol ondition of the throttle ontrol solenoid valve (determined by ECM aording to the input signal) is indiated + OFF Throttle ontrol solenoid valve is not operating ON Throttle ontrol solenoid valve is operating Remarks + When the engine is stopped, a ertain value is indiated + When the aelerator pedal is released quikly with engine speed at 3,000 rpm or more, ON is displayed + When the fuel ut solenoid valve is not operating, fuel is not supplied to injetion nozzles EC-39

42 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT (Cont d) ACTIVE TEST MODE TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY) COOLI FAN OFF ACCEL PO SIG FUEL CUT SOL/V EGRC SOL/V A EGRC SOL/V B THROT CONT SOL/V GLOW RLY INJ TIMI + Ignition swith: ON + Operate the ooling fan at LOW, HI speed and turn OFF using CONSULT Cooling fan moves at LOW, HI speed and stops + Harness and onnetor + Cooling fan motor + Clears the self-learning fully losed aelerator position, deteted by aelerator position sensor, from the ECM + Ignition swith: ON + Turn solenoid valve ON and OFF with the CONSULT and listen to operating sound + Ignition swith: ON + Turn solenoid valve ON and OFF with the CONSULT and listen to operating sound + Ignition swith: ON + Turn solenoid valve ON and OFF with the CONSULT and listen to operating sound + Ignition swith: ON + Turn solenoid valve ON and OFF with the CONSULT and listen to operating sound + Ignition swith: ON (Engine stopped) + Turn the glow relay ON and OFF using CONSULT and listen to operating sound + Engine: Return to the original trouble ondition + Retard the injetion timing using CONSULT Solenoid valve makes an operating sound Solenoid valve makes an operating sound Solenoid valve makes an operating sound Solenoid valve makes an operating sound Glow relay makes the operating sound If trouble symptom disappears, see CHECK ITEM + Harness and onnetor + Solenoid valve + Harness and onnetor + Solenoid valve + Harness and onnetor + Solenoid valve + Harness and onnetor + Solenoid valve + Harness and onnetor + Glow relay + Adjust initial injetion timing EC-40

43 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT (Cont d) REAL TIME DIAGNOSIS IN DATA MONITOR MODE CONSULT has two kinds of triggers and they an be seleted by touhing SETTI in DATA MONITOR mode 1 AUTO TRIG (Automati trigger): + The malfuntion will be identified on the CONSULT sreen in real time In other words, the malfuntion item will be displayed at the moment the malfuntion is deteted by ECM DATA MONITOR an be performed ontinuously until a malfuntion is deteted However, DATA MONITOR annot ontinue any longer after the malfuntion detetion 2 MANU TRIG (Manual trigger): + The malfuntion item will not be displayed automatially on CONSULT sreen even though a malfuntion is deteted by ECM DATA MONITOR an be performed ontinuously even though a malfuntion is deteted Use these triggers as follows: 1 AUTO TRIG + While trying to detet the DTC by performing the DTC CONFIRMATION PROCEDURE, be sure to selet to DATA MONITOR (AUTO TRIG) mode You an onfirm the malfuntion at the moment it is deteted + While narrowing down the possible auses, CONSULT should be set in DATA MONITOR (AUTO TRIG) mode, espeially in ase the inident is intermittent Inspet the iruit by gently shaking (or twisting) suspiious onnetors, omponents and harness in the DTC CONFIRMATION PROCEDURE The moment a malfuntion is found the malfuntion item will be displayed (Refer to GI setion, Inident Simulation Tests in HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ) 2 MANU TRIG + If the malfuntion is displayed as soon as DATA MONITOR is seleted, reset CONSULT to MANU TRIG By seleting MANU TRIG you an monitor and store the data The data an be utilized for further diagnosis, suh as a omparison with the value for the normal operating ondition SEF529Q EC-41

44 TROUBLE DIAGNOSIS Introdution SEF858S SEF233G Introdution The engine has an ECM to ontrol major systems suh as fuel injetion ontrol, fuel injetion timing ontrol, glow ontrol system, et The ECM aepts input signals from sensors and instantly drives eletroni fuel injetion 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 suh as vauum leaks, or other problems with the engine It is muh more diffiult to diagnose a problem that ours intermittently rather than ontinuously Most intermittent problems are aused by poor eletri onnetions or improper wiring In this ase, areful heking of suspeted iruits may help prevent the replaement of good parts A visual hek only may not find the ause of the problems A road test with CONSULT or a iruit tester onneted should be performed Follow the Work Flow, EC-44 Before undertaking atual heks, take a few minutes to talk with a ustomer who approahes with a driveability omplaint The ustomer an supply good information about suh problems, espeially intermittent ones Find out what symptoms are present and under what onditions they our A Diagnosti Worksheet like the example on next page should be used Start your diagnosis by looking for onventional problems first This will help troubleshoot driveability problems on an eletronially ontrolled engine vehile SEF234G EC-42

45 TROUBLE DIAGNOSIS Introdution Diagnosti Worksheet There are many operating onditions that lead to the malfuntion of engine omponents A good grasp of suh onditions an make troubleshooting faster and more aurate In general, eah ustomer feels differently about a problem It is important to fully understand the symptoms or onditions for a ustomer omplaint Utilize a diagnosti worksheet like the one shown below in order to organize all the information for troubleshooting SEF907L WORKSHEET SAMPLE Customer name MR/MS Model & Year VIN Engine # Trans Mileage Inident Date Manuf Date In Servie Date h Startability h Impossible to start h No ombustion h Partial ombustion h Partial ombustion when engine is warm h Partial ombustion when engine is ool h Possible but hard to start h Others [ ] Symptoms h Idling h Driveability h Engine stall h No fast idle h Unstable h High idle h Low idle h Others [ ] h Stumble h Surge h Knok h Lak of power h Others [ ] h At the time of start h While aelerating h Just after stopping h While idling h While deelerating h While loading Inident ourrene h Just after delivery h Reently h In the morning h At night h In the daytime Frequeny h All the time h Under ertain onditions h Sometimes Weather onditions h Not affeted Weather h Fine h Raining h Snowing h Others [ ] Temperature h Hot h Warm h Cool h Cold h Humid F h Cold h During warm-up h After warm-up Engine onditions Engine speed Road onditions h In town h In suburbs h Highway h Off road (up/down) Driving onditions h Not affeted h At starting h While idling h At raing h While aelerating h While ruising h While deelerating h While turning (RH/LH) Vehile speed Malfuntion indiator lamp h Turned on h Not turned on EC-43

46 TROUBLE DIAGNOSIS Work Flow Work Flow CHECK IN CHECK INCIDENT CONDITIONS Listen to ustomer omplaints (Get symptoms) STEP I Chek and PRINT OUT (write down) Diagnosti Trouble Code (DTC) Then lear Also hek related servie bulletins for information STEP II Symptoms olleted Verify the symptom by driving in the ondition the ustomer desribed No symptoms, exept MIL lights up, or Malfuntion Code exists at STEP II *1 STEP III Normal Code (at STEP II) Malfuntion Code (at STEP II) INCIDENT CONFIRMATION Verify the DTC by performing the DTC CONFIRMATION PROCEDURE *1 STEP IV Choose the appropriate ation Malfuntion Code (at STEP II or IV) Normal Code (at both STEP II and IV) *2 STEP V BASIC INSPECTION SYMPTOM BASIS (at STEP I or III) ċ Perform inspetions aording to Symptom Matrix Chart TROUBLE DIAGNOSIS FOR DTC XX STEP VI REPAIR/REPLACE FINAL CHECK Confirm that the inident is ompletely fixed by performing BASIC INSPECTION and DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK) Then, erase the unneessary (already fixed) DTCs in ECM STEP VII CHECK OUT *1: If the inident annot be dupliated, refer to GI setion ( Inident Simulation Tests, HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ) *2: If the on board diagnosti system annot be performed, hek main power supply and ground iruit Refer to TROUBLE DIAGNOSIS FOR POWER SUPPLY, EC-63 EC-44

47 TROUBLE DIAGNOSIS Work Flow Desription for Work Flow STEP STEP I STEP II STEP III STEP IV STEP V STEP VI STEP VII DESCRIPTION Get detailed information about the onditions and the environment when the inident/symptom ourred using the DIAGNOSTIC WORKSHEET as shown on EC-43 Before onfirming the onern, hek and write down (print out using CONSULT) the Diagnosti Trouble Code (DTC), then erase the ode Refer to EC-30 Study the relationship between the ause, speified by DTC, and the symptom desribed by the ustomer (The Symptom Matrix Chart will be useful Refer to EC-48) Try to onfirm the symptom and under what onditions the inident ours The DIAGNOSTIC WORK SHEET is useful to verify the inident Connet CONSULT to the vehile in DATA MONITOR (AUTO TRIG) mode and hek real time diagnosis results If the inident annot be verified, perform INCIDENT SIMULATION TESTS Refer to GI setion If the malfuntion ode is deteted, skip STEP IV and perform STEP V Try to detet the Diagnosti Trouble Code (DTC) by driving in (or performing) the DTC CONFIRMATION PROCE- DURE Chek and read the DTC by using CONSULT During the DTC verifiation, be sure to onnet CONSULT to the vehile in DATA MONITOR (AUTO TRIG) mode and hek real time diagnosis results If the inident annot be verified, perform INCIDENT SIMULATION TESTS Refer to GI setion In ase the DTC CONFIRMATION PROCEDURE is not available, perform the OVERALL FUNCTION CHECK instead The DTC annot be displayed by this hek, however, this simplified hek is an effetive alternative The result of the OVERALL FUNCTION CHECK is the same as the DTC detetion Take the appropriate ation based on the results of STEP I through IV If the malfuntion ode is indiated, proeed to TROUBLE DIAGNOSIS FOR DTC XX If the normal ode is indiated, proeed to the BASIC INSPECTION Refer to EC-46 Then perform inspetions aording to the Symptom Matrix Chart Refer to EC-48 Identify where to begin diagnosis based on the relationship study between symptom and possible auses Inspet the system for mehanial binding, loose onnetors or wiring damage using (traing) Harness Layouts Gently shake the related onnetors, omponents or wiring harness with CONSULT set in DATA MONITOR (AUTO TRIG) mode Chek the voltage of the related ECM terminals or monitor the output data from the related sensors with CON- SULT Refer to EC-54 The DIAGNOSTIC PROCEDURE in EC setion ontains a desription based on open iruit inspetion A short iruit inspetion is also required for the iruit hek in the DIAGNOSTIC PROCEDURE For details, refer to GI setion ( Ciruit Inspetion, HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ) Repair or replae the malfuntion parts One you have repaired the iruit or replaed a omponent, you need to run the engine in the same onditions and irumstanes whih resulted in the ustomer s initial omplaint Perform the DTC CONFIRMATION PROCEDURE and onfirm the normal ode (Diagnosti trouble ode No 55) is deteted If the inident is still deteted in the final hek, perform STEP VI by using a different method from the previous one Before returning the vehile to the ustomer, be sure to erase the unneessary (already fixed) DTC in ECM (Refer to EC-30) EC-45