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diesel engine trouble diagnosis

1. d 5 E Gu L o 5 5 E 2338 oe P E 28a j 2 oO Pea 99 F S l E E q Z 5 E E f s NC 340 e T e 0 rg Zh 0 ose St 0 oer ei 0 Zz l 0 A widioo1X oes ed vu1900 1X Seid 42 LOW 21 60 00 00 1NTIIANI dWfid 00 Wd3 SdM5 LIA 4 92 LYS 24 60 00 00 GIM CNL NIYIN 24 60 00 00 TVNOIS LYVLS 24 60 00 00 Z2 60 00 00 24 60 00 00 9z l 0 9 zt 0 AVOX days 3S 14 99 SYN ANOD TOA 3193 L AMMAN MA YA MALA E va Ze 0 dejs A NO2 TOA 3193 92 AVOX 3s 14 alv SYN 24 60 00 00 e wes e 24 60 00 00 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 ENGINE HOT START CRANKING TEST R51 YD25 A T Engine Normal With Ign ON Record touched on CONSULT II then engine cranked started amp allowed to idle then engine is switched OFF 330 peuoyws si euiBu3 P yz Se 0 gd 3S S34d W LNI 88 11 00 00 JJO E Payoyms s eubuy d 4 a x z E D Kal o x D o uL LL o TVN5IS LYVLS 92 11 00 00 Cn E S E m Dm oe o p e ER d T 3 E E C S gt
2. ENGINE TROUBLE DIAGNOSIS August 2009 NISSAN Learning Academy Foreword The information in this Training Manual should not be interpreted as a basis for warranty or goodwill claims against Nissan Motor Co Australia Pty Ltd NMA unless so designated This Technical Training Manual is intended for use by NMA amp Nissan Dealership Technical Personnel It is not designed for the use by press or for customer distribution Before quoting any specifications be sure to check the relevant Service Manual and Technical Bulletins Right for alteration to data and specifications at any time is reserved Any such alterations will be advised by Nissan through Technical and Sales Bulletins 2009 Nissan Motor Company Australia Pty Ltd Inc Victoria Ref Technical Training Department NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 PETROL ENGINE TROUBLE DIAGNOSIS STEP 1 Check In STEP 2 STEP 2a Verify on the vehicle what the incident is amp compare ks to what is described by the Customer Sera inepti Are there any Fault Codes DTC s STEP 4a STEP 5a No The fault is basic FUEL AIR SPARK POWER GROUND Yes STEP 5b STEP 4b 1 Refer to page in SM that is 1 Refer to Symptoms Matrix Chart in relevant to the DTC the SM in conjunction with the 2 Inform TechLine of the fault and information on the following pages the actions that YOU have so far 2 Inform Tec
3. m H ay U o g q a o ke a Pe 9z i 0 AVOX 3S 14 alvy SYN os LL 00 00 ei 0 0 A LOA 192 LYS 9 11 00 00 EGR valve is closed amp opened after shut for self test ioo 0005 DOS 0 AU NaS SOd A 493 Eq Je 38 S3Hd X3 40 S dWAl NV 1009 ee 0 oe 08 ep 9H os ep OF Off ep OF Jo Js SidNLalv 4 3 NAS dWal r Js Je NAS dAL X3 4d N3S dl Xa dd 95 14 00 00 GI 00 00 Eubh 00 00 96 11 00 00 9 11 00 00 Eubh 00 00 98441 00 00 Engine Idling r9 ZE 0 wicligg L Y 20 Wd3l SdM2 9 b 00 00 close amp re open cycle AFTER engine has performs self test come to a stop I hrottle Valve SE 97 l 0 0005 one 0 AVOX Aur NJS SOd 1599V N3S 1LHH L 9 11 00 00 95 11 00 00 o a Y A to 3 o D eae D i a E D CL C i e 1 a j L ae L m e S RR LL L 0 992 ez 0 ose cel 0 0006 005Z 0 Vwooolx Pdi ET Aul LINZ dANd XSS3d YI LIY QIM CNI NIVIN LNS 4 Eubh 00 00 9 11 00 00 9 bb 00 00 96 11 00 00 39 CONSULT II Software used AEDO6G 00 00 10 63 00700 10 63 00 00 10 63 goog 10 ez 00700 10763 00 00 10 63 PUMP CURRENT ACT CR PRESS VHCL SPEED SE MAIN INJ WID 00700 10 63
4. 207kPa peak 205 kPa peak
5. tyres are fitted to the vehicle in question Increased rolling resistance will cause poor fuel consumption Additional parts on the exterior of a vehicle such as roof racks and spoilers or having the window open increases fuel consumption in some cases by over 20 Air Intake System Ensure that the correct type of air filter his installed amp that it is relatively clean Poorly designed snorkels etc also will cause poor fuel consumption issues Tyre Pressures Driven in Auto Lock mode 4WD AWD Incorrect Handbrake Adjustment Ideally the vehicle should be driven in 2WD at all times unless the road surface conditions are unstable Ensure that the free wheeling hubs are NOT LOCKED D22 amp Y61 Ensure that the tyres are set to the correct specification amp MAKE SURE the handbrake has NOT been over adjusted Driveline Friction Ensure the driveline is properly serviced Transmission Transfer Final drive oils the correct type amp are they set to the correct level Ensure the brakes are not dragging Driving Style Driving Pattern Carefully question the customer on their driving styles patterns Short stop start trips only Aggressive driving style vs gentle 24 NISSAN Learning Academy Engine Trouble Diagnosis EFFECTS ON DIESEL ENGINE FUEL ECONOMY Incorrectly Coded Injectors YD25 8 ZD30 CRD Ensure that the codes printed on top of the injectors match the codes in the memory of the ECM ACTIVE
6. 00 00 10 63 00 00 10 63 00 00 10 63 00700 10 63 00 00 10 63 00700 10763 CKPS RPM TDC ACCEL POS SEN MAS AIR FL SE DF EX PRES SE INT M PRES SE RR EX TMP SEN FREXTMP SEN EGRIV ANGLE AIF SEN x 100 rpm x0 1W MPa Xx1000mA mic AAA kPa kPa mv 32500 52 0 39 125 250 0 0 123 530 50 245 530 40 lt a 9000 0 2485 1 I L Pa NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DRIVE TEST R51 YD25 A T Recorded over a period of 10 seconds 180MPa Peak Pressure Approximately 88 deg C N T aen unir aia pna b AAA a Vi V z Engine already idling amp gear lever is already in D Record touched on CONSULT Il then driven under maximum acceleration until vehicle speed reached 70km h NOTE Engine was already at operating temperature CONSULT II Software used AEDO6G TOKM H Max Speed 8 ad Zus bei EGR Valve shut under acceleration AR CG KA Ma I Iw Vum wl HH LA ei The Higher the Differential Exhaust Pressure reading the higher the E level of PM in the DPF causing a blockage in the DPF Na Temperatures of 600 deg C are shown this would indicate that a a Regeneration is being carried out automatically 40 NISSAN Learning Academy Engine Trouble Diagnosis D Nissan Australia August 2009 Accel Pedal repeatedly pus
7. BATTERY VOLT ECM INPUT SIGNALS BENG SPEED ACCEL SEN 1 MAIN SIGNALS BIFUEL SCHDL T P SEN 1 Clear Monitor Item COOLAN TEMPE TURBO BST SEN 1 u sen Gen START SIGNAL beerwme Ser iii Touch the Setting tab circled right ad BCE iv Ideally the Sampling Rate should be slowed down from every 10ms to every 20ms This can be done by selecting the drop down icon small circle There maybe cases where the recording time needs to be extended Otherwise leave set to 30 seconds so as not to make the graphs too large le v Adjust the trigger point Move it to 80 post amp 20 e cn pre large circle arrow gt o vi Touch OK on the bottom right of the screen amp then touch Start once the screen returns to the SELECT MONITOR ITEM SCREEN Total Response Size 11 Byte TResponce Sampling Rate TT Recording Time 30sec Recording File 2FILI Pre Trigger 80 Ead Cancel OK The 2n0 setting tab accesses the recording trigger condition settings Un select the DTC box if the ECM has a permanent DTC in it Otherwise the recording will automatically start as a DIC is detected DATA MONITOR Trigger Condition j bn DATA MONITOR SELECT MONITOR ITEM ECM CHI Recording Condon ECM l Rate 10 sec d 3 Monitor Menu Item 3 ECM INPUT SIGNALS lm MAN SIGNALS Rec Time30 sec 80 X CE Monitor tem Name Trigger Logi Y Trigger Group FFAA sl Rec Files 2
8. During cranking the l injectors open for just over 10ms ANTT ACCEL N PEDAL WAS PRESSED ages X N A GRAPH G Shows voltage output from MAFS as it increase of airflow a q rm GRAPH H Shows actual ignition timing activity GRAPH I Shows actual inlet camshaft timing GRAPH J Coolant temperature remains stable throughout entire period END OF RECORDING After 6 seconds has lapsed From when RECORD was jet touched NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 CONSULT Ill DATA MONITOR RECORD 1 Touch the word Select against the desired vehicle System DTC Reading Store Print DTG is detected g may be rocuir No OTC is detected urthar testing ma 2 ouch the Data Monitor Icon on the left of the screen 3 Highlight ENGINE amp then touch Select Monitor Item TRANSMISSION T AIR BAG IMETER M amp A Select Monitor item NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 CONSULT Ill DATA MONITOR RECORD 4 i Clear the pre selected Main Signals items by touching Clear Monitor Item 11 Highlight the desired items from the list on the screen These are examples ECM cH1 ENG SPEED Monitor Menu her
9. MT e CO K co Cal e ca ex Ms en amp e C ER gt Sz d c x e LA c gt D Xx S e bm m gt o s 3 gs E LLI ei B gt D d Ce e e 4 O Cl rums Lu a e Y 8 7 A amp gt o j E ke a cC 8 _ T E w no D a y Coolant temp H stable at 16 deg C pom ee cei at EN ces a s 3 2 8 N CO CONSULT II Software used AEDO6G NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 ENGINE HOT START CRANKING TEST Y61 ZD30 CRD M T Engine Normal With Ign ON Record touched on CONSULT Il then engine cranked started amp allowed to idle then amp engine raced twice e em cea 2 2 Z Pedal 9 A fully pressed d iu and released 2 E gt E a K v twice S E E UE t5 o CES s e Ss QS B E HL S 0 clt e gt CA s aum c 2 3 E gt o 3 2 co en T gt S E 5 2 FE 2 LU e E S 3 00 00 30744 TURBO BST SEN 3 F cy ba G EE EE LE gt 4225 rpm c S FER peak CR D e L S d d w 8 L 2 QQ gt AAA SE ae 3 S a 2 E E e 2 L Z x z gt b m d D DZ ev 20 n D o e gt Sa gt e Lu 0 o RR RE SI a d SG 150MPa S gt Ae i pad 1 ME NS A lt 4MPa Z S c c gt 0 E cy gt aq MES A 32 34 at idle CONSULT II Software used AED
10. amp Tight All engine bay GROUND connections in INLET MANIFOLD Y61 or D22 general are OK 1 Disconnect Battery Negative 15 Positive last 2 Unbolt Disconnect at each location shown above Inspect for corrosion or poor contact Ensure that ALL crimped connections are OK no corrosion amp crimped tightly Rectify as necessary Reconnect confirming that connection is clean amp tight 3 Reconnect Battery Positive 1 Negative Last 21 Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 R51 D40 YD25 GROUND CONNECTION POINTS Main Grounds 1 Battery Negative amp Main Body Ensure that the BOTH of the connections circled in the diagram are Clean amp Tight Remove inspect amp refit securely once cleaned to be sure 2 Engine Block Ensure that the connection circled in the diagram is Clean amp Tight Remove inspect amp refit securely once cleaned to be sure 3 Alternator Bracket Ensure that the connection circled in the diagram is Clean amp Tight Remove inspect amp refit securely once cleaned to be sure 28 Timing Chain Cover NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 R51 D40 YD25 GROUND CONNECTION POINTS Engine Control System Grounds Ensure that ALL of the Ground connections shown right are in GOOD CONDITION Ensure they are Clean amp Tight 1 ECM Ground E21 This Ground is located adjacent to the ECM in the
11. crank shaft is properly secured Remove the CKPS amp check for movement of the plate with a screw driver The plate should have 3 tangs on it for the 120 deg signal Typical symptoms include an erratic idle amp the timing reading ACT INJ TIMG in CONSULT DATA MONITOR reads very erratically This plate maybe loose 10 Inspection for Fuel Aeration A quick amp simple inspection of the fuel entering the fuel pump should also be made part of a Diesel Engine trouble diagnosis activity If there is air entering the fuel numerous engine running problems will result Procedure Install a piece of clear hose between the fuel filter amp the fuel pump inlet After the installation of the hose check for air bubbles in the fuel with the engine running at idle and then at 3500rpm It is normal and acceptable to have small intermittent 1mm diameter bubbles in the feed hose at idle amp less frequent but larger bubbles at 3500rpm If the amount of air bubbles seen in the hose exceed the described amount there is an issue of air leakage into the Fuel system Begin with inspecting all the hose fittings for looseness amp the sealing of the sender unit in the tank Contact TechLine for further information Note 1 The check should be made after a settling period of approximately 2 minutes Note 2 Use a 9mm internal diameter clear hose which is fuel compatible 21 NISSAN Learning Academy Engine Trouble Diagnosis Nissan
12. e o 2 gt W x e x p 7 4 03V Peak 5 X el L a o d 4294rpm Peak E 2 A TT ONERE TE ERES UE eel RO USOS UNUS Eu e A seen d nc TE 80km h Peak 3 oq gt 22 RI MENU 2 JE 0 89V UT gt o 8 ss ee et z d S t E 2nd 3rd shift oi DS st 2nd shift o ck e Ee SUE 2 8 1289mA lt el Lx l E 182MPa Peak E o ES e 8 1 34 S A rd Brd shift B E PA a t E u SC auia 2nd shift e 71mg Test 1 Slight rollling start R51 YD25DDTi 5 E A T 232kPa ODO 110km s approx S i Ki Weg a 128 00700 08 93 INT M PRES SE 242kPa Peak 3 N N Learning Academy A NISS Engine Trouble Diagnosis Nissan Australia August 2009 j Poe E 3 EL 3 EE E E 3 ooo _ E Bu i Ne e S E e O e Be geg IST Og aD 3 e E E Oo Leer E 980 8 d EELER o 08 l Lock i L oL Dd i u NO 440 SI D S 0 LO El 0 US SC D 952 gC L 0 A Wdi00 LY 95 LU Edi YUWUO0 LX TVNOIS LYVLS LIOA Ad3llv8 20 Wd3I SdM2 IM CNI NIYIN SS3 ud 49 LOW INSJANI dANdA JE E o S E 2 i xm EE q
13. held in the CRANK position ECM 1 38 E 52 BATTERY VOLT V 20 00 15 00 10 00 Battery Voltage should stay close to 10V when being cranked sum If it is below 9V there is an issue with the battery ECM 1 36 6 62 CKPS RPM TDC rom 3200 The engine should crank over at a MINIMUM of 160 rpm ECM 1 36 6 62 INTAS WOLUME mast 4000 Airis being sucked into the engine reading taken from the MAFS ECM 1 35 6 62 ACT CR PRESS MPa ACT CR PRESS Actual Common Rail Pressure Fuel Pressure in the Rail should increase as cranking speed increases Known Good ZD30 CRD engine being cranked Engine started normally amp allowed to idle 42 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 ENGINE COLD START CRANKING TEST Y61 ZD30 CRD M T Engine Normal With Ign ON Record touched on CONSULT Il then engine cranked engine then stalled so it was re cranked engine started amp allowed to idle then amp engine raced twice En Mme nm Y e e 7 lt Engine cranked twice Y ta aJ E due to stall ac E L uN nz a Ss E e a o m z e et C 2 4 o Yi 5 N R a l P 3 D x e 3 Su 0 mE i c 3 unu 7 5 L e o Cal O Cw gt 7 E gt e c ul gt E Ax gt C T od E gt T T en Z S 3 o pa Z a o OG DK 2 a es NNNM SE co P wo gt gt S 5 5 750rpm ide N y ew m
14. on the top of the assembly amp there is a facility to drain water on the base of the unit Once water in the base of the filter reaches a certain level a float will rise and close a switch circuit This in turn will illuminate a light on the dash See pictures right for the various Water in Fuel warning light possibilities When draining the base look for signs of contamination in the fuel If in doubt remove the filter empty contents into a CLEAN SEALABLE container amp keep it for future reference Light 1 Typically this warning light is found in NON Electronic Control Engine Models However it is now utilised on Y61 8 D22 with CRD engines the T31 X TRAIL M9R Light 2 Typically this warning light is found in Electronic Control Engine Models It is a dual purpose light If the light illuminates intermittently or permanently yet there are NO DTOC s then check for water in the base of the Fuel Filter or a faulty switch If there are DTC s stored follow normal diagnosis procedures to repair fault HOWEVER ensure the base of the filter is checked amp drained regardless E g Y61 RD28ETi Y61 amp D22 ZD380DDTi Y61 TD42ETi Light 3 Currently this light in the RED MIL format is unique to R51 D40 YD25DDTi variants It is a separate light to the ORANGE MIL on the instrument cluster NOTE Some early production R51models will not have a sedimentor unit at all amp there is no Water in Fuel switch instal
15. replaced n e Complaints of excessive fuel consumption smoke emission Use this in conjunction with a thorough engine driveline vehicle inspection SPECIAL PUMP LEANT CLEAR PROCEDURE 1 With engine idling touch CLEAR on CONSULT amp pa wait until CMPLT appears Active Test 2 Touch BACK or back out of the screen to the Active L test menu 3 Switch off ignition stop engine for 15seconds 4 Restart engine amp idle 5 Once again access the Pump Leant Clear in CONSULT D 6 With engine idling touch CLEAR on CONSULT amp For C Ill Select Engine gt Active Test gt Pump wait until CMPLT appears Leant Clear 7 Continually repeat these steps Ensure the ignition OFF condition step 3 is always carried out TechLine may advise to try this up to 10 times 8 Re evaluate engine operation 22 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS Diesel Basic Service 2 Injector Adjustment Value Registration All CRD engines Each Injector will tend to have very slight differences between them with the amount of Fuel they deliver when an electrical current is applied to them If the ECM was to apply exactly the same current to all 4 x injectors on the Engine there will tend to be slight differences in the amount of Fuel each Injector delivers Therefore once the Injector has been manufactur
16. the Driveplate Flywheel Remove the starter motor or inspection plate to check inside the bell housing Foreign object material has damaged obstructed the camshaft signal plate sensor dle Air Volume Learn IAVL hasn t Completed CMPLT e Target Ignition Timing Adj located in WORK SUPPORT in CONSULT is incorrectly set G C i E QX Z7 NOTE Y61 TB48 engines require inspection adjustment of the ignition timing every 20 000km s NISSAN Learning Academy Engine Trouble Diagnosis PETROL ENGINE TROUBLE DIAGNOSIS Basic Service 3 Accel r Pedal Released Pos n Learning amp Throttle Valve Closed Pos n Learning 1 Voltage value s output from Throttle Position Sensor TPS amp Accelerator Position Sensor APPS are seen by the ECM The ECM must continually see the same voltage reading EACH time Confirm this by making your own observations in DATA MONITOR on CONSULT II Ign SW ON About 5 sec About 5 sec About 5 sec About 5 sec About 5 sec Ign SW OFF 10 sec 10 sec 10 sec 10 sec 10 sec THIS TIMING IS CRITICAL 2 Listen for the sound of the Throttle Valve being opened amp closed on the Engine each time the ignition is turned OFF Once it rests it must rest in the same position it rested previously If it rests in a different position the TPS voltage output will be different each time the ignition is turned on again THIS SIMPLE OPERATION IS CRITICA
17. then followed by a WET compression check Refer to section EM of the Service Manual for procedure b Air intake system Are their any air leaks oil cap dip stick throttle body gasket amp bypass hoses vacuum hoses fitted correctly c Air intake system Blockage or air flow interference d Air outlet system Exhaust Blockage Leaking manifold gaskets or cracked exhaust manifold e EGR amp crankcase ventilations systems operating OK 5 ENGINE MECHANICAL TIMING INDICATION SYSTEM a CKPS amp CMPS signal plates functioning OK Serviceable Sensors mounted correctly Flywheel has been fitted in the correct place oe Crankshaft timed correctly Variable camshaft timing mechanism amp timing chain condition 6 ENGINE OIL COOLANT amp PREVIOUS WORK HISTORY HAS THE VEHICLE GOT A DECENT SERVICE HISTORY a Oil level is correct Is it over under full Due for changing Is it the correct grade viscosity for the engine Coolant level amp condition is OK Genuine coolant used Cooling system is functioning OK b c d Have you got records of other PREVIOUS WORK HISTORY Nissan dealer or Non Nissan Dealer FITMENT OF NON GENUINE PARTS amp AFTER MARKET ACCESSORIES NISSAN Learning Academy Engine Trouble Diagnosis PETROL ENGINE TROUBLE DIAGNOSIS Checklist Continued 7 NATS All keys start the car OK Remove keys from key ring set amp retry Ensure there are no other electronic devices that i
18. too high e Engine Oil is overdue for changing High viscosity Excessive external drive belt tension Mechanical fault with engine High engine load required to turn engine Mechanical fault in Transmission High engine load required to drive transmission Insufficient Combustion e Valve clearances incorrect e Valve Timing incorrect Correlation between camshaft amp crankshaft is incorrect e Intake Valve Timing Control mechanism fault Valve timing advance retard unit could be jammed Other e Interference with the airflow through the air intake Possible blockage or modified air intake system Try a known good MAFS NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 ADR 81 01 FUEL CONSUMPTION TEST PROCEDURE FUEL CONSUMPTION Comparative fuel consumption Litres per 100 km THIS LABEL IS FITTED SO THAT THE CUSTOMER CAN COMPARE THE FUEL CONSUMPTION OF DIFFERENT VEHICLE MODELS IT DOES NOT SUGGEST THE ACTUAL FUEL CONSUMPTION OF THE VEHICLE ACTUAL FUEL CONSUMPTION OF THE ENGINE UNDER EVERYDAY DRIVING CONDITIONS IS TYPICALLY 15 34 HIGHER THAN THE FIGURE QUOTED ON THE LABEL The ADR 81 01 Test Cycle sourced directly from www greenhouse gov au fuelguide The test cycle simulates an 11 km trip with an average speed of 33 6 km h Approximately two thirds of the test time simulates urban stop go driving where the average speed is 18 8 km h with the fin
19. 00 06 11 gt START SIGNAL UJ BATTERY VOLT O ENG SPEED O m THRTL SEN X0 1V 26 ON 20 OFF oem 15 el o o 3 39 13 d START OF RECORDING 0 Seconds RECORD was touched NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 CREATING GRAPHS WITH CONSULT Il Cut the print out into sections amp lay out on sheet of paper Attach with cello tape etc Each graph section shows time from 0 seconds through until just over 6 seconds GRAPH A Shows when IGN SW is turned from ON to CRANK Ensure base line of graph is aligned with all others A This shows the time from when RECORD was S touched 3 GRAPHB NEN i Show s Battery Voltage status during F ENGINE CRANKING S GRAPH C Engine RPM throughout RECORD TIME RECORD was touched prior to engine being f Ew cranked gt E FS x 2 2 GRAPHD After engine was started the accelerator pressed briefly GRAPH E The Electrically controlled throttle valve reacts to the movement of the accel pedal ON iiy L vv uuj 1 vo COOLAN TEMP S 31 msec wi Lu vi a e e ix un G ea ec D gt oil a HI ue ei LL e d o LA D E D ON E H 9 INT V TIM B1 c F DURING CRANKING reacts to the GRAPH F Shows injection pulse width
20. Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS CONSULT Il or lll Basic Service ACTIVE TEST 1 Fuel Pump Learning Value Clearing PUMP LEANT CLEAR CMPLT All YD25 The ECM has the capability to learn how to control the Fuel pressure in the Rail in order to match each Fuel Pumps unique characteristics This is achieved via the y control of the suction valve on the Fuel Pump after Ensure CMPLT appears shortly monitoring the Fuel Pressure sensor in the Fuel Rail after touching CLEAR However it maybe necessary to clear this learnt value from the memory of the ECM after working on the Fuel system This principle of learning the ideal Fuel Pressure amp maintaining a unique setting for each engine is very much like the principle of Petrol engines learning amp maintaining a unique A F Alpha This CLEAR function in CONSULT II can be found in ACTIVE TEST Follow the directions outlined in section B EC of the Service Manual A typical scenario that will require the CLEAR operation to be performed is after the repairs have been carried out This screen in CONSULT II is located by 15 A new Fuel Filter has been fitted in any case SE En EC AS LE e Rectification of the following DTC s l P0088 P0089 P0093 P1272 P1273 P1274 P1275 After rectification of a fuel blockage issue e After rectification of a fuel aeration issue e After the HP Fuel Pump has been replaced ren e After Injectors amp or Fuel Rail has been
21. FILES E a Trigger Group ENG SPEED ENG SPEED unused Se ing BF UEL SCH DL Trigger Condrbon MAS AE SE B1 unused T DIE Sw i 72 AVF ALPHA B1 Engine Stall Come BATTERY VOLT unused COOLAM TEMPIS ES Clear Monitor Item a Setting Plural e OR AND HO281 B1 DISPLAY Weit Conditions Hum Hal Kg ITT HO2S2 B1 ac A Load E Pile Diflerential 7 Harn Centinuae ending En e ds ET T HO2S2 MNTR B1 pier date AA i E SPEC EN Eum 2 sel Formula sec Cancel I Engine Stall OK Default lvHCL SPEED SE NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 CONSULT Ill DATA MONITOR RECORD 5 Once prepared touch RECORD on the bottom x Se en right of the screen to capture the activity of the engine Watch the recording time bar graph circled right Recording stops at 100 A MONITOR ENGINE The example recording activity is basically as follows S Tu e srev i Touch record za ii In less than a second start Engine amp allow to idle for a 2 ma oss 1 second KENIS a A PS Ing Num Plural 8 l l l l l ge are listed on the screen m lil Race engine twice amp allow to idle again until the end SC of recording m Pile The above must be carried out as quickly as possible in order to maximise the recorded data on the graphs 6 Once the recording has stopped touch the back arrow top le
22. L Ensure the time frame suggested above for each key position is observed 10 sec means 10 actual seconds on an accurate watch or stop watch NOT 10 mini seconds or 10 that ll be right seconds This 2 in 1 learning operation is an EXTREMELY important operation that MUST be carried out for any of the following reasons e After the Reprogramming of an ECM BUT BEFORE THE ENGINE IS STARTED A new or substitute ECM is installed in the vehicle Along with reprogramming ALL of the NATS ignition keys Make sure you get ALL THE KEYS from the owner driver A new or substitute Throttle Body Unit is installed on the vehicle e The existing throttle body unit is cleaned e Battery power has been lost for a long period of time e Prior to carrying the Idle Air Volume Learn IAVL operation NISSAN Learning Academy Engine Trouble Diagnosis PETROL ENGINE TROUBLE DIAGNOSIS Basic Service AO ez SC 4 Idle Air Volume Learn IAVL 9 YEZ The completion of this operation in around 15 20 seconds is a good indication that the engine operation is OK Reasons why the IAVL will not CMPLT Both Target settings found in WORK SUPPORT on CONSULT are not set to 0 ELT Engine is not at operating temperature Even though the Engine may feel hot make sure this temperature is indicated in DATA MONITOR on CONSULT Engine is too hot above 90 deg C Poor Power Supply to ECM Bad Ground Connect
23. L NOTE D22 ZD30 Orange MIL check engine light is also the WIF warning NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS Diesel Basic Service amp Inspection 1 b Fuel Filter Bleeding amp Water Drain For ALL DIESEL ENGINE VEHICLES Ensure that the fuel filter is drained EVERY 10 000KM S If water collects in the base of the filter the Water in Fuel warning light will illuminate to warn the driver of the water in fuel condition There will be no DTC s recorded in the ECM however DTC s will eventually be logged if the water in fuel condition is not quickly rectified 2 Air Filter amp Inspection of Air Intake Ensure the Air Filter is serviceable If it is lightly dusted it can be cleaned with compressed air as the element is a dry paper type Other wise it should be replaced Ensure the remainder of the air intake system such as the intercooler behind the bumper is free from Blockage e Leakage e Damage Especially considering the Intercooler that is mounted behind the front bumper 3 DTC Inspection Using CONSULT check for any DTC s in ENGINE as well as any other system PRINT OFF ANY DTC s RECORDED IMMEDIATELY prior to taking any further action Refer to the ESM for information about the codes Refer to the list of Possible Causes to determine the MOST LIKELY cause of the fault REMEMBER THE CODE COULD BE RELATED TO THE BASICS Do
24. NOT immediately blame expensive components 19 Fuel Filter Water in Fuel Sensor included in base VVhen the MIL above the TEMP GAUGE illuminates RED drain water from the base of the Fuel Filter IMMEDIATELY Air Filter mu Element NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS Condition e CKPS RPM 2000rpm Diesel Basic Service amp Inspection DF EX PRES SE kPa 4 DPF Pressure Difference Inspection e FR EX TMP SEN 150 200 C 302 392 F Less than 6 7 Ensure that the DPF IS not restricted excessively Use e RR EX TMP SEN 150 200 C 302 392 F CONSULT in ENGINE DATA MONITOR to view the DIFF EXH PRES with the engine running as per the DPF engines only conditions outlined in the chart shown right Refer to the DPF Training Manual for more detail 5 Battery Alternator GROUNDS Given the engines high reliance on ELECTRICAL POWER ensure that the source of this is in perfect order Clean tight battery terminals Battery can pass a load test e Alternator is charging properly WHEN IT IS UNDER LOAD e Engine ground connections E21 E41 E61 F7 REFER TO PAGES 70 74 OF THIS MANUAL FOR MORE DETAIL 6 Fuel Pressure Use CONSULT in ENGINE DATA MONITOR ACT CR PRESS to determine the amount of fuel pressure in IDATA MONITOR ENGINE the rail Do NOT loosen a fuel line at the injector or rail
25. O6G 44 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DRIVE TEST Y61 ZD30 CRD M T Recorded over a period of 1 minute Engine already idling amp already in 15 gear Record touched on CONSULT Il then driven changing through all gears from 151 then 24 3 amp finally 41 until vehicle speed reached 62km h Then slowed down changing back gears amp eventually brought to a stop NOTE Engine was already at operating temperature Approximately 88 deg C X100rpm 64 3800rpm peaks 00 00 60 13 CKPS RPM TDC 3 i X0 1V 00 00 60 13 ACCEL POS SEN MPa PIN POSI SW ACT CR PRESS 00 00 60 13 00 00 60 13 00 00 60 13 VHCL SPEED SE 00 00 60 13 OIL PRESS SEN 1 0 326 50 163 25 00 00 60 13 TRG INJ QTY mag 0 CONSULT II Software used AEDO6G i Gears being changed M T model lli tested LL O 2 945V peak 5 BAR Eng Oil Pressure U Vlo A AA AR 0000 60 13 00 00 60 13 00 00 60 13 00 00 60 13 00 00 60 13 I O1 TC V N CONT V INT A VOLUME 203 kPa peak in 1st gear in 2nd gear in 3rd gear a m E PN ne t e J en la o S 5 S Full graph not shown due to software error eir AA a U z lt N 2 O Lu o 5 o e O o a LL o 5 X100mg 10 gt BE gt wa ee rere
26. OLUME CONTROL SYSTEM check in section B EC of the Service Manual c Check that Exhaust System is not blocked d Check the Turbo Unit Refer to TC BOOST CONTROL SOLENOID VALVE check in section B EC of the Service Manual Ensure there is a sufficient vacuum supply coming from the engine driven vacuum pump Also refer to TURBO CHARGER checks in section EM of the Service Manual e Check the Engine COMPRESSION with a KNOWN GOOD compression gauge WRITE down the figures you measured Follow the directions in section B EM of the Service Manual f Check that the Crankcase Ventilation System as per the information in section B EC ENGINE CONTROL SYSTEM of the Service Manual 3 POWER SUPPLY amp GROUND CONNECTIONS a Check the Battery Is it serviceable Does the condition improve with a jumper battery connected b Confirm the cranking speed if no start The engine should crank at a speed of at LEAST 160rpm Use DATA MONITOR amp view the CKPS in CONSULT to verify the Engine Cranking Speed c Check ALL of the ground connections battery terminals fuses amp fusible links that relate to the ENGINE SYSTEM Carry out the POWER SUPPLY AND GROUND CIRCUIT checks in section B EC of the Service Manual d Ensure the ECM relay is serviceable Especially for D22 ZD30 Y61 TD42Ti 4 ENGINE OIL COOLANT amp PREVIOUS WORK HISTORY HAS THE VEHICLE GOT A DECENT SERVICE HISTORY a Oil level is co
27. REFER TO PAGE 15 amp 30 OF THIS MANUAL FOR MORE DETAIL ECM ACT CR PRESS ECM MAS AIR FL SE 7 Turbo Boost Pressure Mass Air Flow 2 00 32 MPa RANGF Scroll Down Up 1 43 V RANGE Use CONSULT III in ENGINE DATA MONITOR A a 2 Down Up INTAKE M PRES SE amp MAS AIR FL SE to determine the kPa amount of air pressure turbo boost amp airflow in the um intake when the engine is starting raced under load REFER TO PAGE 53 OF THIS MANUAL FOR MORE DETAIL 256 00 192 00 14 00 D Z 8 Engine Compression Ensure that there is suitable compression Follow the directions outlined in section EM of the ESM 20 RANGE 128 00 AV NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS Diesel Basic Service amp Inspection 9 Pump Timing Inspection L TD RD amp QD Engines only m PST The static pump timing setting is critical for the above y v y stated engines Once set in the correct position the OF D electronically controlled pump timing mechanism can ES accurately control injection timing Procedure Refer to Basic Service in section EC of the appropriate Service Manual SST number E7149 Injection Pump Plunger Dial Gauge will be required for this operation Special Note for Y61 RD28ETi Ensure the thin metal plate that is attached to the rear of the timing belt pulley on the front of the
28. TEST FUEL PUMP LEANT CLEAR YD25 Denso CRD R51 D40 amp D22 Perform this action with CONSULT after every fuel filter replacement or as part of an excessive fuel consumption smoke emission diagnosis Poor Ground connections amp Power supply Always ensure that the ground connections are clean amp tight Especially for R51 amp D40 YD25 25 Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 1 POWER CONNECTION CHECKS BATTERY POSITIVE TERMINAL FUSIBLE LINK COMPARTMENT Check for corroded contacts P Clean amp Tight Crimping OK Corrosion 3 c ea FUSIBLE LINK x E COMPARTMENT Main Power connections are free from corrosion CHECK AT THESE 2 LOCATIONS FOR Loc amp CORROSION STARTER mu Clean amp Tight MOTOR STARTER MOTOR 1 Disconnect Battery Negative 18 Positive last 2 Unbolt Disconnect at each location shown above Inspect for corrosion or poor contact Ensure that ALL crimped connections are OK no corrosion amp crimped tightly Rectify as necessary Reconnect confirming that connection is clean amp tight 3 Reconnect Battery Positive 1 Negative Last 26 Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 2 GROUND CONNECTION CHECKS Clean amp Batt NEG to Body GROUND 1 Tight Inner Guard of D22 Clean amp Clean amp Tight Battery NEG cable to Ground connection All connections are Clean
29. aintaining the pressure correctly Cylinder miss fire due to bad spark Worn non genuine spark plug faulty coil coil connection coil ground connection Cylinder miss fire due to bad no injector operation injector dribbling fuel not spraying e Interference with the airflow through the air intake Possible blockage or modified air intake system Try a known good Mass Air Flow Sensor NISSAN Learning Academy Engine Trouble Diagnosis PETROL ENGINE TROUBLE DIAGNOSIS 7 B FUEL SCHDL Inspection Base Fuel Schedule DATA MONITOR SPEC 0 1600 3200 4800 6400 Fuel Delivery Decrease gt Fuel Delivery Increase Procedure 1 Road Test vehicle briskly for 10 km s Engine amp Transmission should be at operating temperature 2 Confirm that the lAVL can be successfully completed 3 Ideally the vehicle should have more than 5000km s on it Vehicle has been properly run in 4 Ensure that the engine has been properly serviced Ensure the correct grade type of oil is in the engine amp the level is correct Ensure components such as spark plugs air filter s etc are serviceable genuine parts Ensure that the correct Part Numbered components have been installed 5 Ideally the barometric pressure should be 98 3 104 3 kPa 6 Ideally the atmospheric temperature is between 20 30 deg C 7 Engine speed is idling The IAVL must have achieved a CMPLT 8 With CONSULT select options
30. al third of the test drive time being similar to driving on a highway with the vehicle driven to over 100 km h The vehicle used in the test exactly matches the vehicle as it appears in the new vehicle brochure LE NO ACCESSORIES ARE FITTED 12 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 EFFECTS ON PETROL ENGINE FUEL ECONOMY Increased purchasing cost of Fuel Rising fuel costs are giving the customer the belief that the vehicle is at fault Especially if the customer adds fuel to the vehicle in set amounts of dollars every week etc Towing Roof Racks Bars Even though many Nissan vehicles have remarkable towing capacities the fuel consumption will be greatly affected as a result of towing Especially if the vehicle is towing something on or close to the maximum towing capacity If roof racks or bars are fitted with or without contents this will greatly effect fuel consumption Wrong Engine Oil Poor Service History Modern engines are extremely sensitive to Engine Oil viscosity Ensure that only Nissan 7 5W 30 engine is used Irregular servicing will easily cause poor fuel consumption concerns as well Incorrect Wheels Tyres Vehicle is Overweight amp or Modified Aftermarket accessories Ensure that the original soec wheels amp tyres are fitted to the vehicle in question Increased rolling resistance will cause poor fuel consumption Additional parts on the exterior of a vehicle
31. dication iii Does it move out of the hashed area above 100 If so see next page for LEAN trouble indication NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 PETROL ENGINE TROUBLE DIAGNOSIS A F ALPHA Indicates RICH Well below 100 Check the following Items Engine Oil is contaminated with excessive fuel or it is the wrong viscosity or overdue for changing Change engine oil amp filter if in doubt e Air Flow through the air intake is restricted check for interference of airflow e Fault with EVAP system fuel is being drawn directly from fuel tank breathing system amp entering inlet manifold Leaking injectors Excessively high fuel pressure Fuel Pressure regulator is leaking fuel Fuel entering combustion chamber via the vacuum hose connected to it This applies to engines with a return type fuel system only e Try a known good Mass Air Flow Sensor A F ALPHA Indicates LEAN Well above 100 Check the following Items Air Leaks before amp after the throttle or in the Inlet Manifold Gaskets seals hoses cracks etc Air Leaks in the Engine Gaskets seals rocker cover oil cap dip stick rear main oil seal etc Air Leaks in Exhaust Manifold gaskets flange gaskets cracks etc e Engine is lacking Fuel Fuel pressure is too low pump output is poor fuel filter tank pick up is blocked hoses kinked blocked or the pressure regulator not m
32. dition b c d Fuses they are in the correct place amp OK There are typically 3 x different locations where fuses are located CHECK ALL LOCATIONS HAS THE VEHICLE GOT DECENT POWER SUPPLY amp GROUND CONNECTIONS 2 FUEL a Is there Fuel in the tank Who was the last to put Fuel in the tank What kind of Fuel went into the tank Run engine on known good fresh fuel if in doubt b Fuel Pressure 1 Measure it with a known good FP gauge amp write the figures on the R O Measure the FP at idle amp again under FULL LOAD Ensure the tank pick up pump filter return system if applicable is OK Refer to section EC Basic Service in the Service Manual c Fuel Pressure 2 Can the system maintain a residual pressure with the Engine OFF If the pressure drops away over 20min where is it going Back to the tank Through leaking injectors or fuel pressure regulator diaphragm Leaking injectors or F P regulator will contribute to hard start amp black smoke emission 3 IGNITION SYSTEM a The CORRECT type of spark plugs for the engine are fitted Spark plugs are worn due for replacement Ignition leads distributor cap is in good condition Ignition coil unit coil power supply is coil ground connection OK A poor coil ground can cause premature coil failures b C d 4 COMPRESSION Air a Measure with a known good compression gauge amp write the figures on the R O Do both a DRY amp
33. e s Static Timing OK Valve timing etc Timing Chains amp associated drive components amp CKPS CMPS indication devices OK Excessive or Insufficient Valve Clearances Also refer to Check Item 2 on the previous page SPECIAL NOTE FOR MANUAL TRANSMISSION R51 D40 YD25 ENGINES Ensure the Dual Mass flywheel is serviceable If it has excessive backlash it will trigger CKPS related faults 8 NATS Are all of the Keys working Is there a foreign Electronic device on the Key Ring Set Are the keys genuine parts The RED Key Car symbol in the Combination Meter will illuminate if there is a NATS related issue however this is NOT always the case 9 PRE PROGRAMMED ECM FAILSAFE OPERATIONS a Ensure the customer does NOT drive with the brake pedal applied Specifically on Yet ZD30 CRD b Ensure that the brake pedal amp brake pedal switches Stop Lamp amp ASCD cut are correctly adjusted Ensure the clutch pedal ASCD cut switch is correctly adjusted where fitted 16 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS Diesel Basic Service amp Inspection 1 a Fuel Filter Bleeding amp Water Drain In the event of trouble diagnosis on a diesel engine a blocked fuel filter is the 1st item that must be checked for The Fuel Filter design amp construction is typically the same on ALL diesel engine models There is a primer pump which is operated by hand
34. ed a special resistance measurement is taken of the Injector This measurement is converted into a special code amp then printed on the top of the Injector This code is entered into the ECM at the factory via a special scan tool However if during service 1 or more than 1 of the injectors are replaced the code of the failed injector needs to be erased from the ECM amp the code of the newly installed injector will need to be entered into the ECM This operation is can be carried out easily using CONSULT If the ECM is replaced the codes of the already existent Injectors need to be entered into the ECM 1 IGN ON Engine STOPPED ENTER INJCTR CALIB DATA ENTER INJCTR CALIB DATA SETVALUE 1 CH A 15 2 1 AOE CYL a IGNITION ON AND ENGINE STOPPED CYLS DODSECCOFCECEEOU i Ghia 7 DODSFAFIFAESEADO CYLa DODDCCOCOODOE d Select which cylinder needs Select ENGINE amp then WORK SUPPORT the Injector Adjustment Value Registration KEYBOARD ENTER INJCTR CALIB DATA ENTER INJCTR CAUB DATA 00021933140E00000000000000CA Kl CMND FINISHED D D z1AEBCLDEFEBTZ34 UOUCUOOOCOUOUU EE Ma E ATA a AA RRP 23 CaOUSECGOFUC ECE EO CPD T DOD5F3F1F3EgEAC O COODER ECFE EE A 5 Repeat steps 4 5 until all the 7 When COMMAND FINISHED is of the Injector the 1 that matches the cylinder Injector value are entered into displayed ensure that all the numbers selected amp type it in the ECs printed on the injector matc
35. efore RECORD was touched Use the small slider tab on the screen to do so small circle 35 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 CONSULT Ill DATA MONITOR RECORD 11 i Touch All items button under the PRINT title on the RHS of the screen A small window will then appear as shown right ii Touch the Save button on the field that next appears followed by OK otherwise select print to actually print the graphs onto paper 12 Once Save has been selected the graphs are converted into images which can be easily viewed on any PC The image files are sent to a specific folder in the C drive of the PC as follows Print Images folder C Consult lll ApplicationData Print Images a Locate this folder on the CONSULT Ill amp create a shortcut to the folder on the desktop 13 THESE FILES CAN BE EASILY ATTACHED TO THE TECHLINE CONTACT THERE IS NO NEED TO FAX GRAPHS TO TECHLINE ANY LONGER The graphs show that once the engine was started the accelerator pedal was press twice amp then the engine returned to idle amp then the recording finished ECH STE PAN 36 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 u 3rd 3rd Shift S fo 5 00 00 08 93 00 00 08 93 00 00 08 93 00 00 08 93 Er aa d A SS 7 Bo T 9V A gt B e
36. en START for general items DATA MONITOR l ENG SPEED 0 rpm MAS A F SE B1 0 33 V COOLAN TEMPIS 86 C BATTERY VOLT 12 3 V ACCEL SEN 1 0 T6 V THRTL SEN 1 0 81 V START SIGNAL OFF INJ PULSE B41 9 2 maec IGN TIMING 110 BTOC BENIN RECORD wer sack er 6 Touch RECORD at the desired moment T The timer begins count down to 0 from 100 not shown in pic DATA MONITOR ECM INPUT SIGNALS i SELECTION FROM MENU ondaa Display e m e or BACK LIGHT Once count down to 0 is complete above screen is displayed 8 Touch DISPLAY If a situation arises where a known COOLA TEMP SEN S amp 5 Le e 3 a 1163 EA 1175 133 06 04 LES pies 9 Touch until Print Graph is displayed 10 Touch items that require graphing 11 Touch double arrow to reveal other recorded items 12 Touch Print Printer will output graphs as shown over page SET RECORDING CONDITION AUTO TRIG DTC will automatically trigger AUTO 2 RECORD the machine can be set for MANUAL RECORD regardless of DTC or not 1 Touch SETTING 2 Touch MANU TRIG 3 ONLY if required Touch the double arrows to slow down the time the recording Is taken 30 Le MANU TRIG TRIGGER POINT g 206 40 6004 00 1005 00 00 064 Ne 00 00 06 11 0O 00 06711 VU VU UN 11 ACCEL SEN 1 00
37. engine bay Remember The ECM outputs an EXTREMELY HIGH CURRENT to operate the Injectors Therefore a GOOD GROUND connection is very important for reliable engine operation 2 ECM Ground E41 This Ground is located under battery carrier It can be accessed by the removal of the grill in many cases Otherwise the battery needs to be removed 3 ECM Ground E61 This Ground is located under Air Cleaner Housing 4 TCM amp A F Ratio Sensor Heater Ground F7 or F59 This single Ground connection is the ONLY Ground connection for the Automatic Transmission For DPF equipped vehicles the A F Ratio Sensor heater also shares the same Ground connection 29 COOLANT TANK BATTERY 1 Touch DATA M 7 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 CREATING GRAPHS WITH CONSULT Il DATA MONITOR ECM INPUT SIGNALS MAIN SIGNALS SELECTION FROM MENU E SETTING Ez E DAIA MONITOR B FUEL SCHDL A F ALPHA B1 W CZ SETTING Numerical Display 3 Touch the items you would like to view record 4 Touch PAGE DOWN to see other items for selection DA T KNONITUR ENG SPEED MAS AIF SE B1 AJF ALPHA B4 AIF ALPHA B2 e e ee I SETTING Numero START Display Each selected item is highlighted 5 Then touch START 2 Touch ONITOR SELECTION FROM MENU Otherwise touch MAIN SIGNALS and th
38. ft of screen once A message appears on the screen circled right Touch Yes vi BH 100 DISPLAY STYLI Num Hum Plural Bar Line 7 i Add any text after the model code to make the file name unique circled right ii Highlight the desired data amp then touch Upload A B di zon iii 55 Selected Files 1 2 Data i Gand DATE TIME iwi MI EC 2008 02 11 11 41 10 625 2008 02 11 11 40 54 210 E a vi BH 100 DISPLAY STYL Bar Line CANCEL Upload Data Upload All Data 34 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 CONSULT Ill DATA MONITOR RECORD 8 i Touch Sub The main Sub Mode screen will appear over the Data Monitor screen ii Touch the Data Control Icon 9 i Highlight the saved file touch the text area with the unique name previously given to the file il Touch Display in the bottom right of the screen Select Recording File Vehicle Type Ve hic le Type 10 i Once the next screen appears select Line This will change the recorded data from Numerical to Line graph ii Ensure that the desired data is displayed In this T Sa SS ae example the START SIGNAL switching from OFF to 3 Selected ito ON is clearly seen large circle This shows when the corna nic engine was cranked over d E 111 It s possible to slide the data back in time to catch activity well b
39. h the numbers on the CONSULT Il screen Ensure the codes on CONSULT II screen match the code printed on top of each Injector NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 EFFECTS ON DIESEL ENGINE FUEL ECONOMY Increased purchasing cost of Fuel Rising fuel costs are giving the customer the belief that the vehicle is at fault Especially if the customer adds fuel to the vehicle in set amounts of dollars every week etc Towing Roof Racks Bars Even though many Nissan vehicles have remarkable towing capacities the fuel consumption will be greatly affected as a result of towing Especially if the vehicle is towing something on or close to the maximum towing capacity If roof racks or bars are fitted with or without contents this will greatly effect fuel consumption Wrong Engine Oil Poor Service History Modern engines are extremely sensitive to Engine Oil viscosity Ensure that only Nissan 10W 40 ACEA B3 Engine Oil is used ZD30 amp non DPF YD25 Irregular servicing will easily cause poor fuel consumption concerns as well DPF equipped engines YD25 in R51 D40 must use 5W 30 ACEA C3 Low Ash type engine oil Poor Quality Fuel Modern Common Rail Diesel engines DEMAND to be ran on good quality diesel fuel Bio Diesel is NOT good quality fuel Incorrect Wheels Tyres Vehicle is overweight Modified body Aftermarket accessories Ensure that the original spec wheels amp
40. hLine of the fault and carried out amp other info gathered if the the actions that YOU have so far problem persists carried out amp other info gathered if the problem persists PRIOR TO COMPLETION OF REPAIR AND HANDING BACK TO THE CUSTOMER 1 Go through the checklist on the following page Consider each item in the list in relation to the problem experienced REGARDLESS if the problem is there or not 2 Carry out the IDLE AIR VOLUME LEARN IAVL operation in WORK SUPPORT Ensure CMPLT is achieved 3 Carry out the A F ALPHA inspection with CONSULT II in DATA MONITOR SPEC 4 Carry out the B FUEL SCHDL inspection with CONSULT II in DATA MONITOR SPEC 5 Take vehicle on a thorough road test re check for any DTC s amp re do IAVL on return from road test For earlier vehicles carry out Base Idle Ignition Timing check adjust amp Mixture Ratio Feedback inspection NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 PETROL ENGINE TROUBLE DIAGNOSIS 1 POWER AND GROUND more detail further on a Battery Is it charged Can it hold a charge Is it being charged Does it pass a load test a o SC Can it cope with high electrical loads Switch on all accessories amp check it s output under oa b Condition of battery terminals Fusible links are in good condition terminals clean amp tight Main ground connections are in good con
41. he Fuel Pressure is too HIGH replace the fuel pressure regulator NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 PETROL ENGINE TROUBLE DIAGNOSIS Basic Service 6 Clearing the Self Learn Select SELF LEARN CONTROL from the work Support menu amp then touch CLEAR This operation clears the LONG TERM A F Alpha values stored in the ECM This should be carried out after a major engine service or after the repair of an engine running fault NOTE e ALPHA reading below 100 e g 75 indicates that the engine is running TOO RICH ALPHA reading above 100 e g 125 indicates that the engine is running TOO LEAN or has a missfire condition not burning O2 S 2 9 un FS e SELF LEARNING CONT see MONITOR TM M C B1 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 PETROL ENGINE TROUBLE DIAGNOSIS Basic Service 6 A F ALPHA Inspection DATA MONITOR SPEC MONITOR NO DTC ENG SPEED XXX rpm 0 1600 3200 4800 6400 A F ALPHA B1 Well above 100 indicates there is an excess of AIR in comparison to fuel is entering the combustion chamber amp is being burned Well below 100 indicates there is an excess of FUEL in comparison to air is entering the combustion chamber amp is being burned RICH LEAN 75 100 0 A F ALPHA B2 6 cylinder engine displayed 2 separate bank
42. hed to max position 8 j az d NE GEES S Su 2 8 B ENGINE RACE TEST R51 YD25 A T Recorded over a period of 10 7 aH mem seconds 8 Engine already idling in neutral Record touched on CONSULT Il ag 3 then accelerator is repeatedly pressed to the maximum position 5B l then released Ca E E A Ki K j f x N sg EZ RT SSES ATA NOTE Engine was already at operating temperature S S ra d ka Approximately 88 deg C e sl CONSULT Il Software used AEDO6G so O X s 2 ZF z DA E n S 3 L V di Rail Pressure reaches190MPa Peak 00700 10762 ACT CR PRESS MPa 0 128 256 0 ML Ld Hn A A J 3 2 T z LLI i L e Ia f IN A S 20 ON SS e 25 e a el 00 00 10 62 MAS AIR FL SE X0 1V um 13 kPa 256 0 INT M PRES SE 50 28 00 90 10 62 00700 10 62 00 00 10 62 DF EX PRES SE kPa 25 1 1 An N A 1 l W f P ei a p d WU VM Le L t d A SE rr AP M had g ul d 4 E e GENE A AL m E IA SEN gt H Di a d e ES 2500 C G C Low 00 00 10 62 AJF SEN1 41 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DATA MONITOR recorded Charr ail items Wien the record button was touched ECM 1 35 B 52 START SIGNAL on Start Signal ON indicates how long the ignition key was
43. in the following order ENGINE DATA MONITOR SPEC SELECTION FROM MENU B FUEL SCHDL START The screen in the graphic above should now appear 9 With the engine under the conditions requested in steps 1 6 what does the black bar indicator do 1 Does it remain stable and central within the hashed area If so this is OK See earlier page for A F ALPHA inspection amp check If A F ALPHA as well as B FUEL SCHDL is OK engine condition is normal ii Does it move out of the hashed area below the indicated value If so see next page for Fuel Delivery Increase inspection iii Does it move out of the hashed area above the indicated value If so see next page for Fuel Delivery Decrease inspection 10 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 PETROL ENGINE TROUBLE DIAGNOSIS B F SCHDL Indicates a Fuel Delivery Decrease Check the following Items Interference with Air Flow through the intake system Restriction of Air Flow e Blocked Air Filter Modified Air Intake System Non standard components in Air Intake system have been fitted e Valve clearances incorrect s Engine Compression is not to spec Try a known good MAFS B F SCHDL Indicates a Fuel Delivery Increase Check the following Items Excessive Engine Friction e High viscosity Engine Oil Use correct grade of engine oil for the engine e Engine Oil Level
44. ine of the fault and carried out amp other info gathered if the the actions that YOU have so far problem persists carried out amp other info gathered if the problem persists PRIOR TO COMPLETION OF REPAIR AND HANDING BACK TO THE CUSTOMER 1 ONCE AGAIN ensure that ALL of the items listed under the heading CHECK LIST amp Diesel Basic Service discussed on the following 5 pages are in PERFECT order 2 Take vehicle on a thorough road test re check for any DTC s on return 3 PLEASE UPDATE the TechLine contact 14 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS Checklist 1 FUEL a Is there sufficient QUANTITY of Fuel being delivered to the pump Blocked Filter or Lines b Is there an acceptable QUALITY of Fuel being delivered to the Pump Drain base of Filter amp check for contaminated Fuel Dirt amp or Water Check for PETROL as well c Is there air leaking into fuel prior to it reaching the pump Refer to further on in this manual for more detail Take a sample of Fuel amp store it in a clean air tight container for future reference 2 AIR a Is there sufficient QUANTITY of Air being delivered to the Engine Blocked Air Filter or Air Intake system Faulty Air Intake Control Valve Air Leaks between MAFS amp Engine b Is there an acceptable QUALITY of Air being delivered to the Engine EGR valve stuck open Refer to EGR V
45. ions for ECM Position Learn procedure An Electrical Load is ON Heater fan lights audio For all other ETC engines carry out the Idle e Switch inputs such as P N Posi Power Steering Air Volume Learn procedure pressure are indicating that the transmission is in Neutral or the Power Steering system is under load e There is a BASIC ENGINE MECHANICAL problem such as an intake system air leak compression issues fuel supply issues or ignition system issues e The Accelerator Pedal Released Position Learning amp Closed Throttle Position Learning has NOT been carried out properly lt may need to be repeated up to 20 times e Throttle valve isn t closed properly Typically excessive carbon is fouling the operation of the throttle unit For T31 QR25 carry out the Closed Throttle 5 Fuel Pressure Check This is for engines that have a Returnless type of fuel aver pressure ches O __ adapter KV10117600AUS y system only 255 or Ensure that there is a CONSTANT PRESSURE OF 350 f M kPa AT ALL TIMES whilst the engine is idling amp under full load The Fuel pressure should never vary Check the following items if the Fuel Pressure is too LOW e Blocked fuel pump pick up filter the fuel filter forms part of the pump assembly e Restricted fuel lines e Faulty fuel pressure regulator The pressure regulator also forms part of the fuel pump assembly Y Ke If t
46. led in the Fuel Filter Contact TechLine should you have any specific queries relating to this 17 Eng Trouble Orange amp or VVater in Fuel Red Water in Fuel NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS YD25 Fuel Filtration amp Water in Fuel Warning Arrangement Operate to drain water after opening drain tap NO WATER IN FUEL WARNING LIGHT FITTED April June 2005 R51 only Ensure to drain water regularly as there is no Water Switch fitted Fuel Filter Water in Fuel Sensor included in base Diff Lock ON warning light S Operate pump when draining water EN DIDA Primer June 2006 onwards R51 amp Spain D40 Water Sensor included as part of filter assembly If an ORANGE coloured Diff Lock ON light appears on some vehicles late 06 production this indicates Water in Fuel Drain the water amp report the incident to TechLine 18 Air Bleed loosen when draining water Operate to drain water after opening drain tap Fuel Sensor RED R51 Spain D40 June 05 May 06 R51 amp Spain D40 Ensure to drain water from both the Sedimentor amp Fuel Filter Drain tube Water Switch fitted to base of Sedimentor Operate to drain water after opening drain tap M ORANGE e ORANGE 7 Thai D40 D22 m a All Thailand D40 amp D22 Water Switch fitted to base of Filter SPECIA
47. nterfere with NATS keys operation when starting 8 ILLOGICAL INPUTS INTO THE ECM a Whilst being driven as well as stationary ensure that inputs such as P N Posi Sw amp Brake Sw are input correctly For a complete reference list refer to section B EC TROUBLE DIAGNOSIS CONSULT Il Reference Value in Data Monitor Mode of the Service Manual b If possible drive the vehicle fitted with a KNOWN GOOD Mass Air Flow Sensor 9 PRE PROGRAMMED ECM FAILSAFE OPERATIONS a Ensure the customer does NOT drive with the brake pedal applied Specifically on T31 amp Y61 TB48 b Ensure that the brake pedal amp brake pedal switches Stop Lamp amp ASCD cut are correctly adjusted Ensure the clutch pedal ASCD cut switch is correctly adjusted where fitted c Ensure the brake lights globes amp associated circuit is functioning correctly Inspect for open circuit brake light globes amp or wiring connections amp grounds are OK Specifically on N16 Hatch with ETC NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 PETROL ENGINE TROUBLE DIAGNOSIS Sm s TE Basic Service 1 Idle Speed Check With CONSULT select ENGINE amp then DATA MONITOR amp view the idle speed by viewing Engine Speed in Main Signals 2 Ignition Timing Inspection Given that the engine is installed with a CKPS monitoring the movement amp position of the Crankshaft fl
48. rrect Is it over under full Due for changing b Is it the correct grade viscosity for the engine c Coolant level amp condition is OK Genuine coolant used Cooling system is functioning OK d Have you got records of other PREVIOUS WORK HISTORY Nissan dealer or Non Nissan Dealer FITMENT OF NON GENUINE PARTS amp AFTER MARKET ACCESSORIES 15 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS Checklist Continued 5 BASIC SERVICE ITEMS All models a Perform a fuel filter inspection water drain amp bleeding operation b Perform the fuel aeration inspection c For CRD engines check that the Injector Adjustment Value Registration has been correctly entered into the ECM as outlined in section B EC BASIC SERVICE of the Service Manual YD models only d Perform the Fuel Pump Learning Value Clearing as outlined in section B EC BASIC SERVICE of the Service Manual 6 ILLOGICAL INPUTS INTO THE ECM a Whilst being driven as well as stationary ensure that inputs such as P N Posi Sw amp Brake Sw are input correctly For a complete reference list refer to section B EC TROUBLE DIAGNOSIS CONSULT Il Reference Value in Data Monitor Mode of the Service Manual b If possible drive the vehicle fitted with a KNOWN GOOD Mass Air Flow Sensor 7 ENGINE MECHANICAL TIMING INDICATION SYSTEM Is the Engin
49. s of cylinders 4 cylinder has 1 bank Procedure 1 Road Test vehicle briskly for 10 km s Engine amp Transmission should be at operating temperature 2 Confirm that the lAVL can be successfully completed 3 Ideally the vehicle should have more than 5000km s on it Vehicle has been properly run in 4 Ensure that the engine has been properly serviced Ensure the correct grade type of oil is in the engine amp the level is correct Ensure components such as spark plugs air filter s etc are serviceable genuine parts Ensure that the correct Part Numbered components have been installed 5 Ideally the barometric pressure should be 98 3 104 3 kPa 6 Ideally the atmospheric temperature is between 20 30 deg C 7 Engine speed is idling The IAVL must have achieved a CMPLT 8 With CONSULT select options in the following order ENGINE DATA MONITOR SPEC SELECTION FROM MENU A F ALPHA select the 2 of them for a 6 cyl engine There are 2 banks of cylinders that need to be monitored START The screen in the graphic above should now appear 9 With the engine under the conditions requested in steps 1 6 what does the black bar indicator do 1 Does it remain stable amp central within the hashed area If so all is OK See next page for B FUEL SCHEDULE inspection 11 Does it move out of the hashed area below 100 If so see next page for RICH trouble in
50. such as roof racks and spoilers or having the window open increases fuel consumption in some cases by over 20 Tyre Pressures Driven in Auto Lock mode 4WD AWD Incorrect Handbrake Adjustment Ideally the vehicle should be driven in 2WD at all times unless the road surface conditions are unstable Ensure that the tyres are set to the correct specification amp MAKE SURE the handbrake has NOT been over adjusted Driveline Friction Ensure the driveline is properly serviced Transmission Transfer Final drive oils the correct type amp are they set to the correct level Ensure the brakes are not dragging Driving Style Driving Pattern Carefully question the customer on their driving styles patterns Short stop start trips only Aggressive driving style vs gentle 13 NISSAN Learning Academy Engine Trouble Diagnosis Nissan Australia August 2009 DIESEL ENGINE TROUBLE DIAGNOSIS STEP 1 Check In STEP 2 STEP 2a Verify on the vehicle what the incident is amp compare Can t Fault it to what is described by the Customer j Are there any Fault Codes DTC s STEP 4a STEP 5a v NO EZ The fault is basic FUEL AIR POWER GROUND STEP 5b STEP 4b 1 Refer to page in SM that is 1 Refer to Symptoms Matrix Chart in relevant to the DTC the SM in conjunction with the 2 Inform TechLine of the fault and information on the following pages the actions that YOU have so far 2 Inform TechL
51. ywheel amp a CMPS monitoring the movement amp position of the inlet camshaft the ECM has the ability to see where the Crankshaft is in relation to the Camshaft amp adjust the timing by itself accordingly Therefore it is NOT necessary to check the ignition timing at normal service intervals etc HOWEVER it maybe necessary to inspect the ignition timing as part of a Trouble Diagnosis procedure If so desired the actual Ignition Timing can be inspected in the traditional manner to ensure the CKPS amp CMPS systems are operating correctly L A Alsa Vehicle As shown right remove No 1 ignition coil install d f C NN T front Special Service Tool SST E7032 amp check the NU ignition timing The engine must be idling at operating temperature amp ALL accessories OFF Compare the reading seen by the timing light with the Ignition Timing reading in Data Monitor on CONSULT RECORD No 1 ignition coil FA a e el E Timing Cee T Typical Scenario s which may cause the Ignition timing light LE ee to be out of specification e The Driveplate Flywheel has been removed amp re installed in the wrong place 1 bolt hole out etc Only use the Timing Light adapter SST NEVER e The inlet camshaft variable timing mechanism has use the loop wire in the harness jammed in the advanced or retarded position Typically due the engine oil never being changed Foreign object has damaged the sensor pick up ring on

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