infiniti g37-09-coupe4

BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

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SECTION GWA

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GLASS & WINDOW SYSTEM

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CONTENTS

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SYMPTOM DIAGNOSIS ............................... 2

SQUEAK AND RATTLE TROUBLE DIAG-NOSES ................................................................ 2

Work Flow .................................................................2Inspection Procedure ................................................4Diagnostic Worksheet ...............................................6

PRECAUTION ............................................... 8

PRECAUTIONS ................................................... 8Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" ...................................................................8Precaution for Procedure without Cowl Top Cover ......8Precaution for Battery Service ..................................8Handling for Adhesive and Primer ............................8

PREPARATION ...........................................10

PREPARATION ..................................................10Special Service Tools ............................................10Commercial Service Tools .....................................10

REMOVAL AND INSTALLATION ...............11

WINDSHIELD GLASS .......................................11Exploded View .........................................................11Removal and Installation .........................................11Inspection ................................................................13

SIDE WINDOW GLASS ....................................14Exploded View .........................................................14Removal and Installation .........................................14Inspection ................................................................15

REAR WINDOW GLASS ..................................16Exploded View .........................................................16Removal and Installation .........................................16Inspection ................................................................17

DOOR GLASS ...................................................18Exploded View .........................................................18Removal and Installation .........................................18Inspection and Adjustment ......................................19

DOOR REGULATOR ........................................21Exploded View .........................................................21Removal and Installation .........................................21Disassembly and Assembly .....................................21Inspection and Installation .......................................22

GW-1Revision: 2009 October 2009 G37 Coupe

SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSISSQUEAK AND RATTLE TROUBLE DIAGNOSES

Work Flow INFOID:0000000004676909

CUSTOMER INTERVIEWInterview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-nostic Worksheet during the interview to document the facts and conditions when the noise occurs and anycustomer comments. Refer to GW-6, "Diagnostic Worksheet". This information is necessary to duplicate theconditions that exist when the noise occurs.• The customer may not be able to provide a detailed description or the location of the noise. Attempt to obtain

all the facts and conditions that exist when the noise occurs (or does not occur).• If there is more than one noise in the vehicle, perform a diagnosis and repair the noise that the customer is

concerned about. This can be accomplished by performing a test drive with the customer.• After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics

are provided so that the customer, service adviser, and technician use the same language when describingthe noise.

• Squeak – (Like tennis shoes on a clean floor)Squeak characteristics include the light contact / fast movement / brought on by road conditions / hard sur-faces = high-pitched noise / softer surfaces = low-pitched noises / edge to surface = chirping

• Creak – (Like walking on an old wooden floor)Creak characteristics include firm contact / slow movement/twisting with a rotational movement / pitchdependent on materials / often brought on by activity.

• Rattle – (Like shaking a baby rattle)Rattle characteristics include fast repeated contact / vibration or similar movement / loose parts/missing clipor fastener / incorrect clearance.

• Knock – (Like a knock on a door)Knock characteristics include hollow sounds / sometimes repeating / often brought on by driver action.

• Tick – (Like a clock second hand)Tick characteristics include gentle contacting of light materials / loose components / can be caused by driveraction or road conditions.

• Thump – (Heavy, muffled knock noise)Thump characteristics include softer knock / dull sounds often brought on by activity.

• Buzz – (Like a bumblebee)Buzz characteristics include high frequency rattle / firm contact.

• Often the degree of acceptable noise level varies depending upon the person. A noise that a technician mayjudge as acceptable may be very irritating to a customer.

• Weather conditions, especially humidity and temperature, may have a great effect on noise level.

DUPLICATE THE NOISE AND TEST DRIVE

SBT842



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If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information onthe Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used toduplicate the same conditions when the repair is reconfirmed.If the noise can be duplicated easily during the test drive, do the following with the vehicle stopped to helpidentify the source of the noise.1) Close a door.2) Tap or push/pull around the area where the noise appears to be coming from.3) Rev the engine.4) Use a floor jack to recreate vehicle “twist”.5) At idle, apply engine load (electrical load, half-clutch on M/T models, drive position on A/T models).6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.• Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.• If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the

vehicle body.

CHECK RELATED SERVICE BULLETINSAfter verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) relatedto the concern or symptom.If a TSB relates to the symptom, follow the procedure to repair the noise.

LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool

(Chassis ear: J-39570, engine ear, and mechanics stethoscope).2. Narrow down the noise to a more specific area and identify the cause of the noise by:• Removing the component(s) in the area(s) that is / are suspected to be the cause of the noise.

Do not use too much force when removing clips and fasteners, otherwise clips and fasteners can be brokenor lost during the repair, creating a new noise.

• Tapping or pushing/pulling the component(s) that is / are suspected to be the cause of the noise.Do not tap or push/pull the component(s) with excessive force, otherwise the noise is eliminated only tempo-rarily.

• Feeling for a vibration by hand by touching the component(s) that is / are suspected to be the cause of thenoise.

• Placing a piece of paper between components that are suspected to be the cause of the noise.• Looking for loose components and contact marks.

Refer to GW-4, "Inspection Procedure".

REPAIR THE CAUSE• If the cause is a loose component, tighten the component securely.• If the cause is insufficient clearance between components:- Separate components by repositioning or loosening and retightening the components, if possible.- Insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape, or ure-

thane tape. A NISSAN Squeak and Rattle Kit (J-43980) is available through the authorized NISSAN PartsDepartment.

CAUTION:Never use excessive force as many components are constructed of plastic and may be damaged.NOTE:Always check with the Parts Department for the latest parts information.The following materials are contained in the NISSAN Squeak and Rattle Kit (J-43980). Each item can beordered separately as needed.URETHANE PADS [1.5 mm (0.059 in) thick]Insulates connectors, harness, etc.• 76268-9E005: 100 × 135 mm (3.937 × 5.315 in)• 76884-71L01: 60 × 85 mm (2.362 × 3.346 in)• 76884-71L02: 15 × 25 mm (0.591 × 0.984 in)INSULATOR (Foam blocks)Insulates components from contact. Can be used to fill space behind a panel.• 73982-9E000: 45 mm (1.772 in) thick, 50 × 50 mm (1.969 × 1.969 in)• 73982-50Y00: 10 mm (0.394 in) thick, 50 × 50 mm (1.969 × 1.969 in)INSULATOR (Light foam block)80845-71L00: 30 mm (1.18 in) thick, 30 × 50 mm (1.181 × 1.969in)FELT CLOTHTAPE


< SYMPTOM DIAGNOSIS >Used to insulate where movement does not occur. Ideal for instrument panel applications.• 68370-4B000: 15 × 25 mm (0.591 × 0.984 in) pad• 68239-13E00: 5 mm (0.197 in) wide tape rollThe following materials, not found in the kit, can also be used to repair squeaks and rattles.UHMW (TEFLON) TAPEInsulates where slight movement is present. Ideal for instrument panel applications.SILICONE GREASEUsed in place of UHMW tape that is visible or does not fit. Only lasts a few months.SILICONE SPRAYUsed when grease cannot be applied.DUCT TAPEUsed to eliminate movement.
CONFIRM THE REPAIRAfter repair is complete, test drive the vehicle to confirm that the cause of noise is repaired by test driving thevehicle. Operate the vehicle under the same conditions as when the noise originally occurred. Refer to thenotes on the Diagnostic Worksheet.

Inspection Procedure INFOID:0000000004676910

Refer to Table of Contents for specific component removal and installation information.

INSTRUMENT PANELMost incidents are caused by contact and movement between:1. The cluster lid A and instrument panel2. Acrylic lens and combination meter housing3. Instrument panel to front pillar garnish4. Instrument panel to windshield5. Instrument panel mounting pins6. Wiring harnesses behind the combination meter7. A/C defroster duct and duct joint

These incidents can usually be located by tapping or moving the components to duplicate the noise or bypressing on the components while driving to stop the noise. Most of these incidents can be repaired byapplying felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulatewiring harness.CAUTION:Never use silicone spray to isolate a squeak or rattle. If the area is saturated with silicone, therecheck of repair becomes impossible.

CENTER CONSOLEComponents to check include:1. Shifter assembly cover to finisher2. A/C control unit and cluster lid C3. Wiring harnesses behind audio and A/C control unitThe instrument panel repair and isolation procedures also apply to the center console.

DOORSCheck the following items:1. Finisher and inner panel making a slapping noise2. Inside handle escutcheon connection to door finisher3. Wiring harnesses tapping4. Door striker out of alignment causing a popping noise on starts and stopsTapping, moving the components, or pressing on them while driving to duplicate the conditions can isolatemany of these incidents. The areas can usually be insulated with felt cloth tape or insulator foam blocks fromthe NISSAN Squeak and Rattle Kit (J-43980) to repair the noise.

TRUNKTrunk noises are often caused by a loose jack or loose items put into the trunk by the customer.In addition check for the following items:



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1. Trunk lid dumpers out of adjustment2. Trunk lid striker out of adjustment3. Trunk lid torsion bars knocking together4. A loose license plate or bracketMost of these incidents can be repaired by adjusting, securing, or insulating the item(s) or component(s) caus-ing the noise.

SUNROOF/HEADLININGNoises in the sunroof / headlining area can often be traced to one of the following items:1. Sunroof lid, rail, linkage, or seals making a rattle or light knocking noise2. Sunvisor shaft shaking in the holder3. Front or rear windshield touching headlining and squeakingAgain, pressing on the components to stop the noise while duplicating the conditions can isolate most of theseincidents. Repairs usually consist of insulating with felt cloth tape.

SEATSWhen isolating seat noise it is important to note the position the seat is in and the load placed on the seatwhen the noise occurs. These conditions should be duplicated when verifying and isolating the cause of thenoise.Causes of seat noise include:1. Headrest rods and holder2. A squeak between the seat pad cushion and frame3. The rear seatback lock and bracketThese noises can be isolated by moving or pressing on the suspected components while duplicating the con-ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the componentor applying urethane tape to the contact area.

UNDERHOODSome interior noise may be caused by components under the hood or on the engine wall. The noise is thentransmitted into the passenger compartment.Causes of transmitted underhood noise include:1. Any component mounted to the engine wall2. Components that pass through the engine wall3. Engine wall mounts and connectors4. Loose radiator mounting pins5. Hood bumpers out of adjustment6. Hood striker out of adjustmentThese noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The bestmethod is to secure, move, or insulate one component at a time and test drive the vehicle. Also, engine RPMor load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, orinsulating the component causing the noise.


Diagnostic Worksheet INFOID:0000000004676911

PIIB8741E



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PIIB8742E


PRECAUTIONS
< PRECAUTION >
PRECAUTIONPRECAUTIONS

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" INFOID:0000000004249710

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used alongwith a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certaintypes of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRSsystem uses the seat belt switches to determine the front air bag deployment, and may only deploy one frontair bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of thisService Manual.WARNING:• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in

the event of a collision which would result in air bag inflation, all maintenance must be performed byan authorized NISSAN/INFINITI dealer.

• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personalinjury caused by unintentional activation of the system. For removal of Spiral Cable and Air BagModule, see the “SRS AIR BAG”.

• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in thisService Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-ness connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERSWARNING:• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the

ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possiblycausing serious injury.

• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect thebattery, and wait at least 3 minutes before performing any service.

Precaution for Procedure without Cowl Top Cover INFOID:0000000004249711

When performing the procedure after removing cowl top cover, coverthe lower end of windshield with urethane, etc.

Precaution for Battery Service INFOID:0000000004688908

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-ence between the window edge and the vehicle when the door is opened/closed. During normal operation, thewindow slightly raises and lowers automatically to prevent any window to vehicle interference. The automaticwindow function will not work with the battery disconnected.

Handling for Adhesive and Primer INFOID:0000000004249712

• Do not use an adhesive which is past its usable date. Shelf life of this product is limited to six months afterthe date of manufacture. Carefully adhere to the expiration or manufacture date printed on the box.

• Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator.• Open the seal of the primer and adhesive just before application. Discard the remainder.

PIIB3706J


PRECAUTIONS

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< PRECAUTION >

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• Before application, be sure to shake the primer container to stir the contents. If any floating material is found,do not use it.

• If any primer or adhesive contacts the skin, wipe it off with gasoline or equivalent and wash the skin withsoap.

• When using primer and adhesive, always observe the precautions in the instruction manual.


PREPARATION
< PREPARATION >
PREPARATIONPREPARATION

Special Service Tools INFOID:0000000004636319

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Commercial Service Tools INFOID:0000000004636320

Tool number(Kent-Moore No.)Tool name

Description

(J-39570)Chassis ear

Locates the noise

(J-43980)NISSAN Squeak and Rat-tle Kit

Repairs the cause of noise

SIIA0993E

SIIA0994E

Tool name Description

Engine ear Locates the noise

Suction lifter Holds the door glass

Remover tools Removes the clips, pawls and metal clips

SIIA0995E

PIIB1805J

JMKIA3050ZZ


WINDSHIELD GLASS

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< REMOVAL AND INSTALLATION >

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REMOVAL AND INSTALLATIONWINDSHIELD GLASS

Exploded View INFOID:0000000004498888

Removal and Installation INFOID:0000000004498889

REMOVAL1. Remove the front pillar garnish (LH/RH). Refer to INT-14, "Removal and Installation".

1. Windshield molding 2. Spacer 3. Windshield glass

4. Dam rubber (upper, lower) 5. Mirror base 6. Insulator

7. Roof panel 8. Primer 9. Front pillar finisher

10. Dash upper cross member 11. Cowl top cover 12. Adhesive

13. Front pillar outer upper 14. Front pillar garnish

Refer to GI-4, "Components" for symbols in the figure.

JMKIA3460GB


WINDSHIELD GLASS
< REMOVAL AND INSTALLATION >2. Remove partially the headlining (front edge). Refer to the following.
• For normal roof. Refer to INT-22, "NORMAL ROOF : Removal and Installation".• For sunroof. Refer to INT-24, "SUNROOF : Removal and Installation".

3. Remove the front wiper arm and blade. Refer to WW-93, "Removal and Installation".4. Remove the roof side molding (LH/RH). Refer to EXT-31, "Removal and Installation".5. Remove the cowl top cover. Refer to EXT-21, "Removal and Installation".6. Apply protective tape around the windshield glass to protect the painted surface from damage.7. Remove glass using piano wire or power cutting tool (A) and an inflatable pump bag (B) after removing

moldings.

NOTE:Mark the body and the glass with matching marks if the windshield glass is reused.WARNING:Always wear safety glasses and heavy gloves to help prevent glass splinters from entering youreyes or cutting your hands when cutting the glass from the vehicle.CAUTION:• Never use a cutting knife or power cutting tool when the windshield glass is reused.• Be careful not to scratch the glass when removing.• Never set or stand the glass on its edge. Small chips may develop into cracks.

INSTALLATION• The dam rubber should be installed in position.• Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished

with it.• Open a door window while the urethane adhesive is curing. This prevents the glass from being forced out by

passenger room air pressure when all door windows are closed.• The molding must be installed securely so that it is in position and leaves no clearance.• Inform the customer that the vehicle should remain stationary until the urethane adhesive is completely

cured (approximately 24 hours). Curing time varies with temperature and humidity.WARNING:• Keep heat and open flames away as primers and adhesive are flammable.• The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Never let

them come in contact with the skin and eyes.• Use in an open, well ventilated location. Never breathe the vapors. They may be harmful if inhaled.

Move immediately to an area with fresh air if affected by vapor inhalation.• Driving the vehicle before the urethane adhesive is completely cured may affect the performance of

the windshield in case of an accident.CAUTION:• Perform adjustment of front wiper arms stop location. Refer to WW-93, "Adjustment".• Never use an adhesive which is past its usable term. Shelf life of this product is limited to six months

after the date of manufacture. Adhere carefully to the expiration or manufacture date printed on thebox.

• Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator.• Never leave primers or adhesive cartridge unattended with their caps open or off.• The vehicle should not be driven for at least 24 hours or until the urethane adhesive is completely

cured. Curing time varies depending on temperature and humidity. The curing time increases underlower temperature and lower humidity.

PIIB5779E


WINDSHIELD GLASS

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Inspection INFOID:0000000004498890

REPAIRING WATER LEAKAGE FOR WINDSHIELD GLASSLeakage can be repaired without removing glass.Determine the extent of leakage if water is leaking between the urethane adhesive material and body or glass.This can be done by applying water to the windshield glass area while pushing glass outward.Apply primer (if necessary) and then urethane adhesive to the leakage point to stop the leakage.


SIDE WINDOW GLASS
SIDE WINDOW GLASS



REMOVAL1. Remove the rear pillar finisher. Refer to INT-14, "Removal and Installation".2. Remove the headlining. Refer to the following.

• For normal roof. Refer to INT-22, "NORMAL ROOF : Removal and Installation".• For sunroof. Refer to INT-24, "SUNROOF : Removal and Installation".

3. Apply protective tape around the side window to protect the painted surface from damage.

1. Side window glass 2. Spacer 3. Adhesive

4. Primer 5. Rear pillar finisher 6. Rear fender

7. Weatherstrip body side


JMKIA1196GB


SIDE WINDOW GLASS

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4. Remove the side window glass using piano wire or power cutting tool and an inflatable pump bag.WARNING:Always wear safety glasses and heavy gloves to help prevent glass splinters from entering youreyes or cutting your hands when cutting the glass from the vehicle.CAUTION:• Be careful not to scratch the glass when removing.• Never set or stand the glass on its edge. Small chips may develop into cracks.

INSTALLATION• Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished


passenger room air pressure when all door windows are closed.• The molding must be installed securely so that it is in position and leaves no clearance.• Inform the customer that the vehicle should remain stationary until the urethane adhesive is completely

cured (approximately 24 hours). Curing time varies with temperature and humidity.WARNING:• Keep heat and open flames away as primers and adhesive are flammable.• The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Never let

them come in contact with the skin and eyes.• Use in an open, well ventilated location. Never breathe the vapors. They may be harmful if inhaled.

Move immediately to an area with fresh air if affected by vapor inhalation.• Driving the vehicle before the urethane adhesive is completely cured may affect the performance of

the side window in case of an accident.CAUTION:• Never use an adhesive which is past its usable term. Shelf life of this product is limited to six months

after the date of manufacture. Adhere carefully to the expiration or manufacture date printed on thebox.


cured. Curing time varies depending on temperature and humidity. The curing time will increaseunder lower temperature and lower humidity.


REPAIRING WATER LEAKAGE FOR SIDE WINDOW GLASSLeakage can be repaired without removing glass.Determine the extent of leakage if water is leaking between the urethane adhesive material and body or glass.This can be done by applying water to the side window glass area while pushing glass outward.Apply primer (if necessary) and then urethane adhesive to the leakage point to stop the leakage.


REAR WINDOW GLASS
REAR WINDOW GLASS



REMOVAL1. Remove the trunk lid finisher inner. Refer to INT-29, "Removal and Installation".2. Remove the connectors and grounds for the rear window defogger.

1. Rear window glass 2. Dam rubber 3. Spacer

4. Roof panel 5. Primer 6. Adhesive

7. Body side outer panel 8. Waist rear 9. Headlining


JMKIA1197GB


REAR WINDOW GLASS

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3. Remove glass using piano wire or power cutting tool (A) and an inflatable pump bag (B) after removingmolding using pliers.

NOTE:Mark the body and the glass with matching marks if a rear window glass is reused.WARNING:Always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyesor cutting your hands when cutting the glass from the vehicle.CAUTION:• Never use a cutting knife or power cutting tool when the rear window glass is reused. • Be careful not to scratch the glass when removing.• Never set or stand the glass on its edge. Small chips may develop into cracks.

INSTALLATION• The dam rubber should be installed in position.• Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished


passenger compartment air pressure when all door windows are closed.• The molding must be installed securely so that it is in position and leaves no clearance.• Inform the customer that the vehicle should remain stationary until the urethane adhesive is completely

cured (approximately 24 hours). Curing time varies with temperature and humidity.WARNING:• Keep heat and open flames away as primers and adhesive are flammable.• The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Never

let them come in contact with the skin and eyes.• Use in an open, well ventilated location. Never breathe the vapors. They may be harmful if inhaled.

Move immediately to an area with fresh air if affected by vapor inhalation.• Driving the vehicle before the urethane adhesive is completely cured may affect the performance

of the rear window in case of an accident.CAUTION:• Never use an adhesive which is past its usable term. Shelf life of this product is limited to six

months after the date of manufacture. Adhere carefully to the expiration or manufacture dateprinted on the box.


cured. Curing time varies depending on temperature and humidity. The curing time increasesunder lower temperature and lower humidity.


REPAIRING WATER LEAKAGE FOR REAR WINDOW GLASSLeakage can be repaired without removing the glass.Determine the extent of leakage if water is leaking between the urethane adhesive material and body or glass.This can be done by applying water to the rear window glass area while pushing glass outward.Apply primer (if necessary) and then urethane adhesive to the leakage point to stop the leakage.

PIIB5779E


DOOR GLASS
DOOR GLASS



REMOVAL1. Remove the door finisher. Refer to INT-11, "Removal and Installation".2. Disconnect the door speaker harness connector.3. Operate the power window main switch to raise or lower the

door window until the glass mounting bolts can be seen.4. Remove the glass mounting bolts (A) and loosen slightly the bolt

(B).

1. Door glass assembly 2. Power window motor 3. Module assembly

4. Corner piece assembly

JMKIA3043ZZ

JMKIA3045ZZ


DOOR GLASS

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5. Hold securely the door glass and pull it out of the sash toremove the door glass.NOTE:Do not raise the glass at the top upper of the door after the doorglass is removed.

6. Remove the door mirror assembly. Refer to MIR-18, "DOOR MIRROR ASSEMBLY : Removal and Instal-lation".

7. Remove the door inside seal. 8. Remove the door glass run.9. Remove the front lower sash nuts, and then remove the front lower sash.10. Remove the corner piece bolts, and then remove the corner piece.

INSTALLATIONInstall in the reverse order of removal.

Inspection and Adjustment INFOID:0000000004498899

SYSTEM INITIALIZATIONInitialize the system if any of the following work has been done.• Electric power supply to power window switch or motor is interrupted by blown fuse or disconnecting battery

cable, etc.• Removal and installation of the regulator assembly.• Removal and installation of the motor from the regulator assembly.• Removal and installation of the harness connector of the power window switch.• Operation of the regulator assembly as a unit.• Removal and installation of the door glass.• Removal and installation of the body side weather-strip and door weather-strip.• Disconnection and connection of the minus terminal of battery.

InitializationFollow the steps below after installing each component to the vehicle.1. Disconnect the minus terminal of battery or disconnect power window switch harness connector tempo-

rarily. Then reconnect after at least 1 minute.2. Close the door.3. Turn ignition switch ON.4. Operate power window switch to make over a half of the window open area.5. Press the power window switch in the up direction (auto close position) and hold. Continue holding the

switch even when window is completely closed and then release after 3 seconds.6. Inspect the anti-pinch system function.

NOTE:Initialization may be cancelled with continuous opening and closing operation. In this case, initialize thesystem.

INSPECT THE FUNCTION OF THE ANTI-PINCH SYSTEM1. Open fully the door glass.2. Place a wooden piece (wooden hammer handle, etc.) at near fully closed position.3. Perform fully closing operation with auto up switch.• Check that the glass reverses without pinching the wooden piece, is lowered approximately 150 mm (5.906

in) or for 2 seconds and then stops.• The glass should not be raised with power window main switch operated while it is reversing or lowering.CAUTION:

JMKIA1200ZZ


DOOR GLASS
< REMOVAL AND INSTALLATION >• Be careful not to be pinched.• Check that the auto up function is normal before the inspection following the system initialization.
FITTING INSPECTION• Check that the glass is fit securely into the sash groove.• Lower the glass slightly [approximately 10 to 20 mm (0.394 to 0.787 in)] and check that the clearance to the

body side weather-strip is parallel. Loosen the regulator mounting bolts, guide rail mounting bolts, and glassand guide rail mounting bolts to correct the glass position if the clearance between the glass and body sideweather-strip is not parallel.

• Raise the glass fully and adjust the glass top end and body side welt fitting with the adjusting bolt (B), (C), or(D) as shown in the figure below.

NOTE:• Always start at adjusting bolt (B). If the desired angle is not achieved, then proceed to adjusting bolt (C) and

(D) respectively.• Turn the adjusting bolt clockwise to move the door glass upper end outward.• Turn the adjusting bolt anticlockwise to move the door glass upper end inward.• Adjustment process with adjusting bolt (D) is the inverse of adjusting bolt (B) and (C).• When adjusting with adjusting bolt (D), turn the adjusting bolt clockwise to move the door glass upper end

inward, then anticlockwise to move the door glass upper end outward.

JMKIA3044ZZ


DOOR REGULATOR

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DOOR REGULATOR



REMOVAL1. Remove the door glass. Refer to GW-18, "Removal and Installation".2. Disconnect power window motor harness connector.3. Remove the module assembly mounting bolts shown by the

arrows, both seals (B) and then remove the nuts under theseals.

4. Remove the module assembly from the door panel.


Disassembly and Assembly INFOID:0000000004498902

DISASSEMBLY

1. Door glass assembly 2. Power window motor 3. Module assembly

4. Corner piece assembly

JMKIA3043ZZ

JMKIA1202ZZ


DOOR REGULATOR
< REMOVAL AND INSTALLATION >Remove the power window motor from the module assembly.
ASSEMBLYAssemble in the reverse order of disassembly.

Inspection and Installation INFOID:0000000004498903

Inspection after RemovalCheck the regulator assembly for the following items. Replace orgrease it if a malfunction is detected.• Wire wear• Regulator deformation

SYSTEM INITIALIZATIONInitialize the system if any of the following work has been done.• Electric power supply to power window switch or motor is interrupted by blown fuse or disconnecting battery

cable, etc.• Removal and installation of the regulator assembly.• Removal and installation of the motor from the regulator assembly.• Removal and installation of the harness connector of the power window switch.• Operation of the regulator assembly as a unit.• Removal and installation of the door glass.• Removal and installation of the body side weather-strip and door weather-strip.• Disconnection and connection of the minus terminal of battery.

InitializationFollow the steps below after installing each component to the vehicle.1. Disconnect the minus terminal of battery or disconnect power window switch harness connector tempo-

rarily. Then reconnect after at least 1 minute.2. Close the door.3. Turn ignition switch ON.4. Operate power window switch to make over a half of the window open area.5. Draw fully the power window switch in the up direction (auto close position) and hold. Continue holding

the switch even when window is completely closed and then release after 3 seconds.6. Inspect the anti-pinch system function.

NOTE:Initialization may be cancelled with continuous opening and closing operation. In this case, initialize thesystem.

INSPECT THE FUNCTION OF THE ANTI-PINCH SYSTEM1. Fully open the door glass.2. Place a wooden piece (wooden hammer handle, etc.) at near fully closed position.3. Perform fully closing operation with auto up switch.• Check that the glass reverses without pinching the wooden piece, is lowered approximately 150 mm (5.906

in) or for 2 seconds and then stops.• The glass should not be raised with power window main switch operated while it is reversing or lowering.CAUTION:• Be careful not to be pinched.• Check that the auto up function is normal before the inspection following the system initialization.

FITTING INSPECTION• Check that the glass is fit securely into the sash groove.

JMKIA1203ZZ


DOOR REGULATOR

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• Lower slightly the glass [approximately 10 to 20 mm (0.394 to 0.787 in)] and check that the clearance to thebody side weather-strip is parallel. Loosen the regulator mounting bolts, guide rail mounting bolts, and glassand guide rail mounting bolts to correct the glass position if the clearance between the glass and body sideweather-strip is not parallel.

• Raise the glass fully and adjust the glass top end and body side welt fitting with the adjusting bolt (B), (C), or(D) as shown in the figure below.

NOTE:• Always start at adjusting bolt (B). If the desired angle is not achieved, then proceed to adjusting bolt (C) and

(D) respectively.• Turn the adjusting bolt clockwise to move the door glass upper end outward.• Turn the adjusting bolt anticlockwise to move the door glass upper end inward.• Adjustment process with adjusting bolt (D) is the inverse of adjusting bolt (B) and (C)• When adjusting with adjusting bolt (D), turn the adjusting bolt clockwise to move the door glass upper end

inward, then anticlockwise to move the door glass upper end outward.

JMKIA3044ZZ


VENTILATION, HEATER & AIR CONDITIONER

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HEATER & AIR CONDITIONING SYSTEM

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CONTENTS

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BASIC INSPECTION .................................... 3

DIAGNOSIS AND REPAIR WORKFLOW .......... 3Work Flow .................................................................3

SYSTEM DESCRIPTION .............................. 4

REFRIGERATION SYSTEM ............................... 4System Diagram ........................................................4System Description ...................................................4Component Parts Location ........................................5Component Description .............................................6


REFRIGERATION SYSTEM SYMPTOMS .......... 7Trouble Diagnosis For Unusual Pressure .................7Symptom Table .........................................................7

COMPRESSOR SYSTEM SYMPTOMS .............10Symptom Table .......................................................10

PRECAUTION ..............................................11

PRECAUTIONS ..................................................11Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" .................................................................11Precaution Necessary for Steering Wheel Rota-tion after Battery Disconnect ...................................11Precaution for Battery Service ................................12Precaution for Procedure without Cowl Top Cover ....12Precautions For Xenon Headlamp Service .............12Working with HFC-134a (R-134a) ...........................12General Refrigerant Precaution ..............................13Refrigerant Connection ...........................................13Service Equipment ..................................................17

COMPRESSOR ..................................................20General Precautions ...............................................20

LEAK DETECTION DYE ....................................21

General Precautions ................................................21

PREPARATION ...........................................22

PREPARATION .................................................22Special Service Tool ................................................22Commercial Service Tool ........................................25Sealant or/and Lubricant .........................................25

PERIODIC MAINTENANCE ........................26

REFRIGERANT .................................................26Collection and Charge .............................................26

LUBRICANT ......................................................30Description ...............................................................30Adjustment ...............................................................30Lubricant Adjusting Procedure for Components Replacement Except Compressor ...........................30Lubricant Adjusting Procedure for Compressor Replacement ...........................................................31

REFRIGERATION SYSTEM .............................33Inspection ................................................................33Performance Chart ..................................................33Refrigerant Leakages ..............................................34

FLUORESCENT LEAK DETECTOR ................35Inspection ................................................................35

ELECTRICAL LEAK DETECTOR ....................36Inspection ................................................................36


COMPRESSOR .................................................39Exploded View .........................................................39Removal and Installation .........................................39Inspection ................................................................40

COOLER PIPE AND HOSE ..............................41Exploded View .........................................................41

HA-1Revision: 2009 October 2009 G37 Coupe

LOW-PRESSURE FLEXIBLE HOSE AND PIPE 2 ... 41LOW-PRESSURE FLEXIBLE HOSE AND PIPE 2 : Removal and Installation ...................................... 41

HIGH-PRESSURE FLEXIBLE HOSE ....................... 42HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation ....................................................... 43

HIGH-PRESSURE PIPE 1 ......................................... 43HIGH-PRESSURE PIPE 1 : Removal and Installa-tion .......................................................................... 43

LOW-PRESSURE PIPE 1 AND HIGH-PRESSURE PIPE 2 ........................................................................ 45

LOW-PRESSURE PIPE 1 AND HIGH-PRES-SURE PIPE 2 : Removal and Installation ............... 45

CONDENSER .................................................... 47Exploded View ........................................................ 47

CONDENSER ............................................................ 47CONDENSER : Removal and Installation .............. 47

CONDENSER PIPE ASSEMBLY .............................. 47CONDENSER PIPE ASSEMBLY : Removal and Installation .............................................................. 47

LIQUID TANK ............................................................ 48LIQUID TANK : Removal and Installation ............... 48

REFRIGERANT PRESSURE SENSOR .................... 49REFRIGERANT PRESSURE SENSOR : Remov-al and Installation .................................................... 49

HEATER & COOLING UNIT ASSEMBLY ......... 50Exploded View ........................................................ 50

HEATER & COOLING UNIT ASSEMBLY ................ 52HEATER & COOLING UNIT ASSEMBLY : Re-moval and Installation ............................................. 52

HEATER CORE ......................................................... 53HEATER CORE : Removal and Installation ............ 53

EVAPORATOR .......................................................... 54EVAPORATOR : Removal and Installation ............. 54

EXPANSION VALVE ................................................. 55EXPANSION VALVE : Removal and Installation .... 55

SERVICE DATA AND SPECIFICATIONS (SDS) .......................................................... 56

SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................. 56

Compressor ............................................................ 56Lubricant ................................................................. 56Refrigerant .............................................................. 56Engine Idling Speed ................................................ 56Belt Tension ............................................................ 56


DIAGNOSIS AND REPAIR WORKFLOW

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< BASIC INSPECTION >

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BASIC INSPECTIONDIAGNOSIS AND REPAIR WORKFLOW


DETAILED FLOW

1.LISTEN TO CUSTOMER COMPLAINT

Listen to customer complaint. (Get detailed information about the conditions and environment when the symp-tom occurs.)

>> GO TO 2.

2.VERIFY THE SYMPTOM WITH OPERATIONAL CHECK

Verify the symptom with operational check. Refer to HAC-5, "Description & Inspection".

>> GO TO 3.

3.GO TO APPROPRIATE TROUBLE DIAGNOSIS

Go to appropriate trouble diagnosis (Refer to HAC-102, "Diagnosis Chart By Symptom" below).

>> GO TO 4.

4.REPAIR OR REPLACE

Repair or replace the specific parts.

>> GO TO 5.

5.FINAL CHECK

Final check.Is the inspection result normal?YES >> INSPECTION ENDNO >> GO TO 3.


REFRIGERATION SYSTEM
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTIONREFRIGERATION SYSTEM

System Diagram INFOID:0000000004651656

System Description INFOID:0000000004651657

REFRIGERANT CYCLE

Refrigerant FlowThe refrigerant flows from the compressor, through the condenser with liquid tank, through the evaporator, andback to the compressor. The refrigerant evaporation in the evaporator is controlled by an externally equalizedexpansion valve, located inside the evaporator case.

Freeze ProtectionTo prevent evaporator from freezing up, the evaporator air temperature is monitored, and the voltage signal tothe unified meter and A/C amp. makes the A/C relay go OFF and stop the compressor.

REFRIGERANT SYSTEM PROTECTION

Refrigerant Pressure SensorThe refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure sen-sor, located on the liquid tank. The refrigerant pressure sensor detects the pressure inside the refrigerant lineand sends the voltage signal to the ECM if the system pressure rises above, or falls below the specifications.ECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure sidedetected by refrigerant pressure sensor is over approximately 3,119 kPa (31.8 kg/cm2, 452 psi), or belowapproximately 118 kPa (1.2 kg/cm2, 17 psi).

Pressure Relief ValveThe refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.The release port on the pressure relief valve automatically opens and releases refrigerant into the atmospherewhen the pressure of refrigerant in the system increases to an unusual level [more than 3,800 kPa (38.8 kg/cm2, 551 psi)].

JPIIA1366GB



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Component Parts Location INFOID:0000000004494905

ENGINE COMPERTMET

PASSENGER COMPERTMENT

1. Compressor 2. Condenser 3. Refrigerant pressure sensor

4. Liquid tank

JSIIA1435ZZ


Component Description INFOID:0000000004494906

1. Expansion valve 2. Evaporator 3. Blower motor

JSIIA1436ZZ

Component Description

Compressor Intakes, compresses, and discharges refrigerant, to circulate refrigerant inside the refrigerant cycle.

Condenser Cools refrigerant discharged from compressor, and transforms it to liquid refrigerant.

Liquid tank Eliminates foreign matter in refrigerant, and stores temporarily liquid refrigerant.

Refrigerant pressure sensor Refer to EC-520, "Description".

Expansion valveTransforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by drawing function.

EvaporatorThe mist form liquid refrigerant transforms to gas by evaporation by the air conveyed from blower motor. The air is cooled by the heat by evaporation.

Blower motorTakes in air in the vehicle or fresh outside air, provides it forcedly to the air conditioner, and conveys it inside the vehicle.


REFRIGERATION SYSTEM SYMPTOMS

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SYMPTOM DIAGNOSISREFRIGERATION SYSTEM SYMPTOMS

Trouble Diagnosis For Unusual Pressure INFOID:0000000004651861

Diagnose using a manifold gauge whenever system’s high and/or low side pressure(s) is/are unusual. Themarker above the gauge scale in the following tables indicates the standard (usual) pressure range. Refer toabove table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, how-ever, differs from vehicle to vehicle.

Symptom Table INFOID:0000000004651862

Gauge indication Refrigerant cycle Probable cause Corrective action

Both high- and low-pressure sides are too high.

The pressure returns to nor-mal is reduced soon after wa-ter is splashed on condenser.

Excessive refrigerant charge in refrigeration cycle.

Reduce refrigerant until speci-fied pressure is obtained.

Air suction by cooling fan is in-sufficient.

Insufficient condenser cooling performance.↓1. Condenser fins are

clogged.2. Improper fan rotation of

cooling fan.

• Clean condenser.• Check and repair cooling fan

if necessary.

• Low-pressure pipe is not cold.

• When compressor is stopped, high-pressure reading quickly drops by approximately 196 kPa (2

kg/cm2, 28 psi). It then de-creases gradually thereaf-ter.

Poor heat exchange in con-denser(After compressor operation stops, high-pressure decreas-es too slowly).↓Air in refrigeration cycle.

Evacuate repeatedly and re-charge system.

Engine tends to overheat.Engine cooling systems mal-function.

Check and repair each engine cooling system.

• An area of the low-pressure pipe is colder than areas near the evaporator outlet.

• Low-pressure pipe is some-times covered with frost.

• Excessive liquid refrigerant on low-pressure side.

• Excessive refrigerant dis-charge flow.

• Expansion valve is open a lit-tle compared with the speci-fication.

↓Improper expansion valve ad-justment.

Replace expansion valve.

High-pressure side is too high and low-pressure side is too low.

Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot.

High-pressure tube or parts lo-cated between compressor and condenser are clogged or crushed.

• Check and repair or replace malfunctioning parts.

• Check lubricant for contami-nation.

AC359A

AC360A


High-pressure side is too low and low-pressure side is too high. High- and low-pressure sides

become equal soon after compressor operation stops.

Compressor pressure opera-tion is improper.↓Damaged inside compressor packings.

Replace compressor.

No temperature difference be-tween high- and low-pressure sides.

Compressor pressure opera-tion is improper.↓Damaged inside compressor packings.

Replace compressor.

Both high- and low-pressure sides are too low.

• There is a big temperature difference between liquid tank outlet and inlet. Outlet temperature is extremely low.

• Liquid tank inlet and expan-sion valve are frosted.

Liquid tank inside is slightly clogged.

• Replace liquid tank.• Check lubricant for contami-

nation.

• Expansion valve inlet tem-perature is extremely low as compared with areas near liquid tank.

• Expansion valve inlet is frosted.

• Temperature difference oc-curs somewhere in high-pressure side.

High-pressure pipe located be-tween liquid tank and expan-sion valve is clogged.

• Check and repair malfunc-tioning parts.


Expansion valve and liquid tank are warm or slightly cool when touched.

Low refrigerant charge.↓Leaking fittings or components.

Check refrigerant for leakages. Refer to HA-34, "Refrigerant Leakages".

There is a big temperature dif-ference between expansion valve inlet and outlet while the valve itself is frosted.

Expansion valve closes a little compared with the specifica-tion.↓1. Improper expansion

valve adjustment.2. Malfunctioning expansion

valve.3. Outlet and inlet may be

clogged.

• Remove foreign particles by using compressed air.

• Replace expansion valve.• Check lubricant for contami-

nation.

An area of the low-pressure pipe is colder than areas near the evaporator outlet.

Low-pressure pipe is clogged or crushed.

• Check and repair malfunc-tioning parts.


Air flow volume is not enough or is too low.

Evaporator is frozen.

• Check intake sensor circuit.Refer to HAC-73, "Diagnosis Procedure".

• Replace compressor.• Repair evaporator fins.• Replace evaporator.• Check blower motor circuit.

Refer to HAC-57, "Diagnosis Procedure".


AC356A

AC353A



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Low-pressure side sometimes be-comes negative. • Air conditioning system

does not function and does not cyclically cool the com-partment air.

• The system constantly functions for a period of time after compressor is stopped and restarted.

Refrigerant does not discharge cyclically.↓Moisture is frozen at expansion valve outlet and inlet.↓Water is mixed with refrigerant.

• Drain water from refrigerant or replace refrigerant.

• Replace liquid tank.

Low-pressure side becomes nega-tive.

Liquid tank or front/rear side of expansion valve’s pipe is frosted or wet with dew.

High-pressure side is closed and refrigerant does not flow.↓Expansion valve or liquid tank is frosted.

Leave the system at rest until no frost is present. Start it again to check whether or not the mal-function is caused by water or foreign particles.• Cooling is initially okay if wa-

ter is the cause. Then the wa-ter freezes causing a blockage. Drain water from refrigerant or replace refriger-ant.

• Remove expansion valve and remove the particles with dry and compressed air (not shop air) if due to foreign particles.

• Replace expansion valve if either of the above methods cannot correct the malfunc-tion.

• Replace liquid tank.• Check lubricant for contami-

nation.


AC354A

AC362A


COMPRESSOR SYSTEM SYMPTOMS
COMPRESSOR SYSTEM SYMPTOMS

Symptom Table INFOID:0000000004651863

Follow the next table and perform trouble diagnosis if there is a compressor unit malfunction (internal noise,insufficient cooling).

*1: First conduct inspection according to trouble diagnosis for each malfunction. Refer to HAC-103, "Inspec-tion procedure".*2: Applicable to variable capacity compressor only.

Symptom Inspection method Check list Result Action

Noise from compressor unit When A/C is ON.(rattling or rolling sound)

Cooker system in-ternal pressure

Check with manifold gauge

Both high- and low-pressure sides are

high.*2

Recharge with proper amount of refrigerant.

High/low-pressures

hunt.*2Replace compressor only.

Check compressor oil condition.

Sample compressor oil and judge.

Refer to the criteria shown in compressor lubricant.

Diagnostic result 1: Replace compressor only.

Diagnostic result 2: Replace compressor and liquid tank.

Insufficient cooling*1

Compressor bodyCheck rotation of compressor. If sized or stuck, sample com-pressor oil and judge.

Cooler system inter-nal pressure

Check with a manifold gauge. Sample compressor oil and judge if the difference between high-pressure and low-pres-sure is small or if they are al-most the same.

Outlet air temperature rises

temporarily while driving.*2— — —

Replace compressor only.

JSIIA0927GB


PRECAUTIONS

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Precaution Necessary for Steering Wheel Rotation after Battery DisconnectINFOID:0000000004703538

NOTE:• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-

tion, then disconnect both battery cables.• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both

battery cables.• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.

If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock andcannot be turned.If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-cedure below before starting the repair operation.

OPERATION PROCEDURE1. Connect both battery cables.

NOTE:Supply power using jumper cables if battery is discharged.

2. Turn the push-button ignition switch to ACC position.(At this time, the steering lock will be released.)

3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-nected and the steering wheel can be turned.

4. Perform the necessary repair operation.


PRECAUTIONS
< PRECAUTION >5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steeringwheel will lock when the push-button ignition switch is turned to LOCK position.)

6. Perform self-diagnosis check of all control units using CONSULT-III.





Precautions For Xenon Headlamp Service INFOID:0000000004703552

WARNING:Comply with the following warnings to prevent any serious accident.• Disconnect the battery cable (negative terminal) or the power supply fuse before installing, remov-

ing, or touching the xenon headlamp (bulb included). The xenon headlamp contains high-voltagegenerated parts.

• Never work with wet hands.• Check the xenon headlamp ON-OFF status after assembling it to the vehicle. Never turn the xenon

headlamp ON in other conditions. Connect the power supply to the vehicle-side connector.(Turning it ON outside the lamp case may cause fire or visual impairments.)

• Never touch the bulb glass immediately after turning it OFF. It is extremely hot. CAUTION:Comply with the following cautions to prevent any error and malfunction.• Install the xenon bulb securely. (Insufficient bulb socket installation may melt the bulb, the connec-

tor, the housing, etc. by high-voltage leakage or corona discharge.)• Never perform HID circuit inspection with a tester.• Never touch the xenon bulb glass with hands. Never put oil and grease on it.• Dispose of the used xenon bulb after packing it in thick vinyl without breaking it. • Never wipe out dirt and contamination with organic solvent (thinner, gasoline, etc.).

Working with HFC-134a (R-134a) INFOID:0000000004653049

CAUTION:• CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. Compressor mal-

function is likely to occur if the refrigerants are mixed, refer to “CONTAMINATED REFRIGERANT”below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refriger-ant recovery/recycling recharging equipment and Refrigerant Identifier.

• Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-nents. Compressor malfunction is likely to occur if lubricant other than that specified is used.

• The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-lowing handling precautions must be observed:

- Cap (seal) immediately the component to minimize the entry of moisture from the atmosphere whenremoving refrigerant components from a vehicle.

PIIB3706J


PRECAUTIONS

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< PRECAUTION >

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- Never remove the caps (unseal) until just before connecting the components when installing refrig-erant components to a vehicle. Connect all refrigerant loop components as quickly as possible tominimize the entry of moisture into system.

- Use only the specified lubricant from a sealed container. Reseal immediately containers of lubricant.Lubricant becomes moisture saturated and should not be used without proper sealing.

- Never allow lubricant (NISSAN A/C System Oil Type S) to come in contact with styrene foam parts.Damage may result.

CONTAMINATED REFRIGERANTTake appropriate steps shown below if a refrigerant other than pure HFC-134a (R-134a) is identified ina vehicle:• Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into

the atmosphere.• Explain that recovery of the contaminated refrigerant could damage service equipment and refrigerant sup-

ply.• Suggest the customer return the vehicle to the location of previous service where the contamination may

have occurred.• In case of repairing, recover the refrigerant using only dedicated equipment and containers. Never

recover contaminated refrigerant into the existing service equipment. Contact a local refrigerant prod-uct retailer for available service if the facility does not have dedicated recovery equipment. This refrigerantmust be disposed of in accordance with all federal and local regulations. In addition, replacement of allrefrigerant system components on the vehicle is recommended.

• The air conditioner warranty is void if the vehicle is within the warranty period. Please contact Nissan Cus-tomer Affairs for further assistance.

General Refrigerant Precaution INFOID:0000000004653050

WARNING:• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and

throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meetingrequirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment], or J-2209 [HFC-134a (R-134a)recovery equipment]. Ventilate work area before resuming service if accidental system dischargeoccurs. Additional health and safety information may be obtained from refrigerant and lubricantmanufacturers.

• Never release refrigerant into the air. Use approved recovery/recycling recharging equipment to cap-ture the refrigerant each time an air conditioning system is discharged.

• Wear always eye and hand protection (goggles and gloves) when working with any refrigerant or airconditioning system.

• Never store or heat refrigerant containers above 52°C (126°F).• Never heat a refrigerant container with an open flame; Place the bottom of the container in a warm

pail of water if container warming is required.• Never intentionally drop, puncture, or incinerate refrigerant containers.• Keep refrigerant away from open flames: poisonous gas is produced if refrigerant burns.• Refrigerant displaces oxygen, therefore be certain to work in well ventilated areas to prevent suffo-

cation.• Never pressure test or leakage test HFC-134a (R-134a) service equipment and/or vehicle air condi-

tioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a)have been shown to be combustible at elevated pressures. These mixtures, if ignited, may causeinjury or property damage. Additional health and safety information may be obtained from refriger-ant manufacturers.

Refrigerant Connection INFOID:0000000004653080

A new type refrigerant connection has been introduced to all refrigerant lines except the following location.• Expansion valve to evaporator• Refrigerant pressure sensor to liquid tank

ABOUT ONE-TOUCH JOINT

Description• One-touch joints are pipe joints which do not require tools during piping connection.• Unlike conventional connection methods using union nuts and flanges, controlling tightening torque at con-

nection point is not necessary.


PRECAUTIONS
< PRECAUTION >• Use a disconnector when removing a pipe joint.
Component Parts

Functions Of Component Parts

NOTE:

• Garter spring cannot be removed from cage of male-side piping.

• Indicator ring remains near piping connection point, however, this is not a malfunction. (This is to check piping connection during fac-tory assembly.)

Removal

1. Clean piping connection point, and set a disconnector.2. Slide disconnector in axial direction of piping, and stretch garter spring with tapered point of disconnector.

RJIA4383J

1 Pipe (Male-side)• Retains O-rings.• Retains garter spring in cage (A).

2 Garter spring Anchors female-side piping.

3 Indicator ringWhen connection is made properly, this is ejected from male-side piping. (This part is no longer nec-essary after connection.)

4 O-ring Seals connection point. (Not reusable)

5 Pipe (Female-side)• Seals connection by compressing O-rings.• Anchors piping connection using flare (B) and garter spring.

SJIA0106E


PRECAUTIONS

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< PRECAUTION >

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3. Slide disconnector farther so that inside diameter of garter spring becomes larger than outside diameter offemale-side piping flare. Then male-side piping can be disconnected.

Installation

1. Clean piping connection points, and insert male-side piping into female-side piping.2. Push inserted male-side piping harder so that female-side piping flare stretches garter spring.3. Garter spring seats on flare if inside diameter of garter spring becomes larger than outside diameter of

female-side piping flare. Then, it fits in between male-side piping cage and female-side piping flare toanchor piping connection point.NOTE:When garter spring seats on flare, and fits in between male-side piping cage and female-side piping flare,it clicks.CAUTION:• Female-side piping connection point is thin and easy to deform. Slowly insert the male-side pip-

ing straight in axial direction.• Insert piping securely until a click is heard.• After piping connection is completed, pull male-side piping by hand to make sure that connec-

tion does not come loose.

O-RING AND REFRIGERANT CONNECTION

SJIA0107E


PRECAUTIONS
< PRECAUTION >
CAUTION:The new and former refrigerant connections use different O-ring configurations. Never confuse O-rings since they are not interchangeable. Refrigerant may leak at the connection if a wrong O-ring isinstalled.

O-Ring Part Numbers and Specifications

F. Former type refrigerant connection N. New type refrigerant connection O. One-touch joint

: O-ring size

JSIIA0004ZZ

Connection type Piping connection point Part number QTY O-ring size

One-touch joint

Low-pressure pipe 1 to low-pressure pipe 2 92473 N8221 2 φ16

Low-pressure flexible hose to low-pressure pipe 2 92473 N8221 2 φ16

High-pressure pipe 1 to high-pressure pipe 2 92471 N8221 2 φ8

Condenser pipe assembly to high-pressure flexible hose 92472 N8221 2 φ12

Condenser pipe assembly to high-pressure pipe 1 92471 N8221 2 φ8

New

Condenser to condenser pipe assemblyInlet 92472 N8210 1 φ12

Outlet 92471 N8210 1 φ8

Low-pressure pipe 1 to expansion valve 92473 N8210 1 φ16

High-pressure pipe 2 to expansion valve 92471 N8210 1 φ8

Compressor to low-pressure flexible hose 92474 N8210 1 φ19

Compressor to high-pressure flexible hose 92472 N8210 1 φ12

Liquid tank to CondenserInlet

92471 N82101

φ8Outlet 1

Former

Refrigerant pressure sensor to liquid tank J2476 89956 1 φ10

Expansion valve to evaporatorInlet 92475 71L00 1 φ12

Outlet 92475 72L00 1 φ16


PRECAUTIONS

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WARNING:Check that all refrigerant is discharged into the recycling equipment and the pressure in the system isless than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.CAUTION:Observe the following when replacing or cleaning refrigerant cycle components.• Store it in the same way at it is when mounted on the car when the compressor is removed. Failure

to do so will cause lubricant to enter the low-pressure chamber.• Use always a torque wrench and a back-up wrench when connecting tubes.• Plug immediately all openings to prevent entry of dust and moisture after disconnecting tubes.• Connect the pipes at the final stage of the operation when installing an air conditioner in the vehicle.

Never remove the seal caps of pipes and other components until just before required for connection.• Allow components stored in cool areas to warm to working area temperature before removing seal

caps. This prevents condensation from forming inside A/C components.• Remove thoroughly moisture from the refrigeration system before charging the refrigerant.• Replace always used O-rings.• Apply lubricant to circle of the O-rings shown in illustration when connecting tube. Be careful not to

apply lubricant to threaded portion.

• O-ring must be closely attached to the groove portion of tube.• Be careful not to damage O-ring and tube when replacing the O-ring.• Connect tube until a click can be heard. Then tighten the nut or bolt by hand. Check that the O-ring is

installed to tube correctly.• Perform leakage test and make sure that there is no leakage from connections after connecting line.

Disconnect that line and replace the O-ring when the refrigerant leaking point is found. Then tightenconnections of seal seat to the specified torque.

Service Equipment INFOID:0000000004653051

RECOVERY/RECYCLING RECHARGING EQUIPMENTBe certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Neverintroduce any refrigerant other than that specified into the machine.

ELECTRICAL LEAK DETECTORBe certain to follow the manufacturer’s instructions for tester operation and tester maintenance.

VACUUM PUMP

Name : NISSAN A/C System Oil Type S

RHA861F


PRECAUTIONS
< PRECAUTION >The lubricant contained inside the vacuum pump is not compatiblewith the specified lubricant for HFC-134a (R-134a) A/C systems.The vent side of the vacuum pump is exposed to atmospheric pres-sure. So the vacuum pump lubricant may migrate out of the pumpinto the service hose. This is possible when the pump is switchedOFF after evacuation (vacuuming) and hose is connected to it.To prevent this migration, use a manual valve placed near the hose-to-pump connection, as per the following.• Vacuum pumps usually have a manual isolator valve as part of the
pump. Close this valve to isolate the service hose from the pump.• Use a hose equipped with a manual shut-off valve near the pump

end for pumps without an isolator. Close the valve to isolate thehose from the pump.

• Disconnect the hose from the pump if the hose has an automaticshut-off valve. As long as the hose is connected, the valve is openand lubricating oil may migrate.

Some one-way valves open when vacuum is applied and closeunder no vacuum condition. Such valves may restrict the pump’sability to pull a deep vacuum and are not recommended.

MANIFOLD GAUGE SETBe certain that the gauge face indicates HFC-134a or R-134a. Besure the gauge set has 1/2″-16 ACME threaded connections for ser-vice hoses. Confirm the set has been used only with refrigerantHFC-134a (R-134a) and specified lubricants.

SERVICE HOSESBe certain that the service hoses display the markings described(colored hose with black stripe). All hoses must equip positive shut-off devices (either manual or automatic) near the end of the hosesopposite to the manifold gauge.

SERVICE COUPLERS

RHA270DA

SHA533D

RHA272D


PRECAUTIONS

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Never attempt to connect HFC-134a (R-134a) service couplers tothe CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplersdo not properly connect to the CFC-12 (R-12) system. However, if animproper connection is attempted, discharging and contaminationmay occur.

REFRIGERANT WEIGHT SCALEVerify that no refrigerant other than HFC-134a (R-134a) and speci-fied lubricants have been used with the scale. The hose fitting mustbe 1/2″-16 ACME if the scale controls refrigerant flow electronically.

CHARGING CYLINDERUsing a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valvewhen filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of anelectronic scale or of quality recycle/recharge equipment.

Shut-off valve rotation A/C service valve

Clockwise Open

Counterclockwise Close

RHA273D

RHA274D


COMPRESSOR
< PRECAUTION >
COMPRESSOR

General Precautions INFOID:0000000004653085

CAUTION:• Plug all openings to prevent moisture and foreign matter from entering.• Store it in the same way at it is when mounted on the car when the compressor is removed.• Follow “Maintenance of Lubricant Quantity in Compressor” exactly when replacing or repairing

compressor. Refer to HA-30, "Description".• Keep friction surfaces between clutch and pulley clean. Wipe it off by using a clean waste cloth

moistened with thinner if the surface is contaminated with lubricant.• Turn the compressor shaft by hand more than five turns in both directions after compressor service

operation. This distributes equally lubricant inside the compressor. Let the engine idle and operatethe compressor for one hour after the compressor is installed.

• Apply voltage to the new one and check for normal operation after replacing the compressor magnetclutch.


LEAK DETECTION DYE

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LEAK DETECTION DYE


CAUTION:• The A/C system contains a fluorescent leak detection dye used for locating refrigerant leakages. An

ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leakages.• Wear always fluorescence enhancing UV safety goggles to protect eyes and enhance the visibility of

the fluorescent dye.• The fluorescent dye leak detector is not a replacement for an electrical leak detector (SST: J-41995).

The fluorescent dye leak detector should be used in conjunction with an electrical leak detector(SST: J-41995) to pin-point refrigerant leakages.

• Read and follow all manufacture’s operating instructions and precautions prior to performing thework for the purpose of safety and customer’s satisfaction.

• A compressor shaft seal should not necessarily be repaired because of dye seepage. The compres-sor shaft seal should only be repaired after confirming the leakage with an electrical leak detector(SST: J-41995).

• Remove always any remaining dye from the leakage area after repairs are completed to avoid a mis-diagnosis during a future service.

• Never allow dye to come into contact with painted body panels or interior components. Clean imme-diately with the approved dye cleaner if dye is spilled. Fluorescent dye left on a surface for anextended period of time cannot be removed.

• Never spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).• Never use more than one refrigerant dye bottle [1/4 ounce (7.4 cc)] per A/C system.• Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use

HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system, or CFC-12 (R-12) leak detectiondye in HFC-134a (R-134a) A/C system, or A/C system damage may result.

• The fluorescent properties of the dye remains for three or more years unless a compressor malfunc-tion occurs.

IDENTIFICATIONNOTE:Vehicles with factory installed fluorescent dye have a green label.Vehicles without factory installed fluorescent dye have a blue label.

IDENTIFICATION LABEL FOR VEHICLEVehicles with factory installed fluorescent dye have the identification label on the front side of hood.


PREPARATION
< PREPARATION >

Special Service Tool INFOID:0000000004653092


HFC-134a (R-134a) Service Tool and Equipment• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/

or its lubricant.• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/

lubricant.• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles

refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoidmixed use of the refrigerants/lubricant.

• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs andcompressor malfunction may result.

Tool number(Kent-Moore No.)

Tool nameDescription

(J-45815)Disconnector tool set

Disconnect one-touch joint connection

(ACR2005-NI)ACR5 A/C Service Center

Function: Refrigerant recovery, recycling and recharging

(J-41995)Electrical leak detector

Power supply:DC 12 V (Battery terminal)

RJIA0391J

WJIA0293E

AHA281A


PREPARATION

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(J-43926)Refrigerant dye leak detection kitKit includes:(J-42220)UV lamp and UV safety goggles(J-41459)HFC-134a (R-134a) dye injectorUse with J-41447, 1/4 ounce bottle(J-41447)HFC-134a (R-134a) fluorescent leak detection dye(Box of 24, 1/4 ounce bottles)(J-43872) Refrigerant dye cleaner

Power supply:DC 12 V (Battery terminal)

(J-42220) UV lamp and UV safety goggles

Power supply:DC 12 V (Battery terminal)For checking refrigerant leakage when flu-orescent dye is equipped in A/C systemIncludes:UV lamp and UV safety goggles

(J-41447)HFC-134a (R-134a) fluorescent leak detection dye(Box of 24, 1/4 ounce bottles)

Application:For HFC-134a (R-134a) PAG oilContainer:1/4 ounce (7.4 cc) bottle(Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.)

(J-41459)HFC-134a (R-134a) dye injectorUse with J-41447, 1/4 ounce bottle

For injecting 1/4 ounce of fluorescent leak detection dye into A/C system

(J-43872)Refrigerant dye cleaner

For cleaning dye spills



ZHA200H

SHA438F

SHA439F

SHA440F

SHA441F


PREPARATION
< PREPARATION >
(J-39183)Manifold gauge set (with hoses and couplers)

Identification:• The gauge face indicates HFC-134a (R-

134a).Fitting size: Thread size

• 1/2″-16 ACME

Service hoses• High-pressure side hose

(J-39501-72)• Low-pressure side hose

(J-39502-72)• Utility hose

(J-39476-72)

Hose color:• Low-pressure side hose: Blue with black

stripe• High-pressure side hose: Red with black

stripe• Utility hose: Yellow with black stripe or

green with black stripeHose fitting to gauge:

• 1/2″-16 ACME

Service couplers• High-pressure side coupler

(J-39500-20)• Low-pressure side coupler

(J-39500-24)

Hose fitting to service hose:M14 x 1.5 fitting is optional or permanently attached.

(J-39650)Refrigerant weight scale

For measuring of refrigerantFitting size: Thread size

1/2″-16 ACME

(J-39649)Vacuum pump(Including the isolator valve)

Capacity:• Air displacement: 4 CFM• Micron rating: 20 microns• Oil capacity: 482 g (17 oz.)Fitting size: Thread size

• 1/2″-16 ACME



RJIA0196E

S-NT201

S-NT202

S-NT200

S-NT203


PREPARATION

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Commercial Service Tool INFOID:0000000004653093

Sealant or/and Lubricant INFOID:0000000004653094

HFC-134a (R-134a) Service Tool and Equipment• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/

or its lubricant.• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/

lubricant.• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles

refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoidmixed use of the refrigerants/lubricant.

• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs andcompressor malfunction may result.


Refrigerant identifier equipmentChecking for refrigerant purity and system contamination

Power tool For loosening bolts and nuts

RJIA0197E

PBIC0190E


HFC-134a (R-134a) refrigerant

Container color: Light blueContainer marking: HFC-134a (R-134a)Fitting size: Thread size

• Large container 1/2″-16 ACME

NISSAN A/C System Oil Type S (DH-PS)

Type: Polyalkylene glycol oil (PAG), type S (DH-PS)Application:HFC-134a (R-134a) swash plate com-pressors (NISSAN only)

Capacity: 40 m (1.4 US fl oz., 1.4 Imp fl oz.)

S-NT196

S-NT197


REFRIGERANT
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCEREFRIGERANT

Collection and Charge INFOID:0000000004653096

SETTING OF SERVICE TOOLS AND EQUIPMENT

Discharging Refrigerant

Evacuating System and Charging Refrigerant

Procedure

1. Shut-off valve 2. A/C service valve 3. Recovery/recycling recharging equipment

JSIIA0238ZZ

1. Shut-off valve 2. A/C service valve 3. Recovery/recycling recharging equipment

4. Refrigerant container (HFC-134a) 5. Weight scale (J-39650) 6. Vacuum pump (J-39649)

7. Manifold gauge set (J-39183)

A. Preferred (best) method B. Alternative method C. For charging

JSIIA0239ZZ


REFRIGERANT

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WARNING:Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirementsof SAE J-2210 [HFC-134a (R-134a) recycling equipment] or J-2209 [HFC-134a (R-134a) recovery equip-ment]. Ventilate work area before resuming service if accidental system discharge occurs. Additionalhealth and safety information may be obtained from refrigerant and lubricant manufacturers.

1.CHECK A/C SYSTEM

1. Check that A/C system operates normally. Refer to HAC-5, "Description & Inspection".2. Check if there is a large amount of leakage of refrigerant or lubricant.

CAUTION:Never perform the lubricant return operation if a large amount of leakage of lubricant is detected.

Is the inspection result normal?YES >> GO TO 2.NO-1 >> Check for refrigerant leakage. Refer to HA-35, "Inspection".NO-2 >> If using electrical leak detector (SST: J-41995). Refer to HA-36, "Inspection".

2.LUBRICANT RETURN OPERATION

1. Start the engine and run it as follows. - Engine speed: Idle – 1,200 rpm- A/C switch: ON- Fan speed: Maximum position- Set temperature: Full hot- Intake position: Recirculation (REC)2. Perform lubricant return operation for approximately 10 minutes. 3. Stop the engine.

>> GO TO 3.

3.CHECK RECOVERY/RECYCLING RECHARGING EQUIPMENT

1. Operate recovery/recycling recharging equipment. CAUTION:• Follow the instructions of the manufacturer for the handling or maintenance of the equipment. • Never fill the equipment with undesignated refrigerant.

2. Check the gauge pressure of recovery/recycling recharging equipment. Is there pressure?YES >> GO TO 4.NO >> GO TO 5.

4.DISCHARGE REFRIGERANT INSIDE PIPES

Discharge the refrigerant from the high-pressure hose and low-pressure hose of recovery/recycling rechargingequipment.

>> GO TO 5.

5.CONNECT RECOVERY/RECYCLING RECHARGING EQUIPMENT

1. Remove the service valve caps from the vehicle. 2. Connect recovery/recycling recharging equipment to the service valves.

>> GO TO 6.

6.DISCHARGE REFRIGERANT FROM THE VEHICLE

Operate recovery/recycling recharging equipment to discharge the refrigerant from the vehicle.

>> GO TO 7.

7.REMOVE ANY REMAINING REFRIGERANT


REFRIGERANT
< PERIODIC MAINTENANCE >Evacuate air for approximately 10 minutes or more to remove any remaining refrigerant integrated to the com-pressor oil, etc.
>> GO TO 8.

8.REPLACE OR REPAIR REFRIGERANT SYSTEM PARTS

1. Replace or repair the malfunctioning part. CAUTION:• Always use a new O-ring for the parts that the cooler system was removed. • Apply compressor oil to the O-rings of piping when installing the piping. However, never apply it

to the threads. 2. Adjust the compressor oil amount according to the replaced parts. Refer to HA-30, "Description".

>> GO TO 9.

9.EVACUATE AIR FROM THE REFRIGERANT SYSTEM

Evacuate air from the refrigerant system for approximately 25 minutes or more. CAUTION:Evacuate air for at least approximately 15 minutes or more if the parts are replaced.

>> GO TO 10.

10.CHECK AIRTIGHTNESS OF REFRIGERANT SYSTEM

Check the airtightness of the refrigerant system for approximately 25 minutes or more. CAUTION:Check the airtightness for at least approximately 15 minutes or more if the parts are replaced. Does the pressure decrease?YES >> GO TO 11.NO >> GO TO 8.

11.CHECK REFRIGERANT LEAKAGE

1. Connect refrigerant recovery/recycling recharging equipment or manifold gauge set (SST: J-39183). 2. Charge the refrigerant of approximately 200 g (7.05 oz) to the refrigerant system. 3. Check for refrigerant leakage. Refer to HA-35, "Inspection".

NOTE:When using electrical leak detector (SST: J-41995). Refer to HA-36, "Inspection".

Is the inspection result normal?YES >> GO TO 12.NO >> Repair or replace parts according to the inspection results.

12.CHARGE REFRIGERANT

1. Connect recovery/recycling recharging equipment or manifold gauge set (SST: J-39183). 2. Evacuate air again. 3. Charge the specified amount of refrigerant to the refrigerant system.

>> GO TO 13.

13.CHECK REFRIGERANT LEAKAGE

Check for refrigerant leakage again. Refer to HA-35, "Inspection".NOTE:When using electrical leak detector (SST: J-41995). Refer to HA-36, "Inspection".Is the inspection result normal?YES >> GO TO 14.NO >> GO TO 6.

14.CHECK OPERATION

Check the A/C system for normal operation. Refer to HA-33, "Inspection".


REFRIGERANT

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Is the inspection result normal?YES >> GO TO 15.NO >> Repair or replace parts according to the inspection results.

15.CHECK RECOVERY/RECYCLING RECHARGING EQUIPMENT

1. Disconnect recovery/recycling recharging equipment or manifold gauge set (SST: J-39183). 2. Discharge the refrigerant from the high-pressure hose and low-pressure hose of the recovery/recycling

recharging equipment. 3. Install the service valve caps.

>> INSPECTION END


LUBRICANT
LUBRICANT

Description INFOID:0000000004653097

MAINTENANCE OF LUBRICANT QUANTITYThe lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres-sor when replacing any component or after a large refrigerant leakage occurred. It is important to maintain thespecified amount.The following malfunctions may result if lubricant quantity is not maintained normally:• Lack of lubricant: May lead to a seized compressor.• Excessive lubricant: Inadequate cooling (thermal exchange interference)

LUBRICANT

Adjustment INFOID:0000000004653098

LUBRICANT RETURN OPERATIONAdjust the lubricant quantity according to the test group shown below.

1.CHECK A/C SYSTEM

1. Check that A/C system operates normally. Refer to HAC-5, "Description & Inspection".2. Check if there is a large amount of leakage of refrigerant or lubricant.

CAUTION:Never perform the lubricant return operation if a large amount of leakage of lubricant is detected.

Is the inspection result normal?YES >> GO TO 2.NO-1 >> Check for refrigerant leakage. Refer to HA-35, "Inspection".NO-2 >> If using electrical leak detector (SST: J-41995). Refer to HA-36, "Inspection".

2.PERFORM LUBRICANT RETURN OPERATION

1. Start the engine, and run it as following.- Engine speed: Idle – 1,200 rpm- A/C switch: ON- Fan speed: Maximum position- Set temperature: Full hot- Intake position: Recirculation (REC)2. Perform lubricant return operation for approximately 10 minutes.3. Stop the engine.

>> GO TO 3.

3.REPAIR OR REPLACE MALFUNCTIONING PART

1. Repair or replace the malfunctioning part.2. Perform the lubricant adjustment depending on the replaced part.

Except compressor >>Refer to HA-30, "Lubricant Adjusting Procedure for Components Replacement ExceptCompressor".

Compressor >>Refer to HA-31, "Lubricant Adjusting Procedure for Compressor Replacement".

Lubricant Adjusting Procedure for Components Replacement Except CompressorINFOID:0000000004653099

Add the correct amount of lubricant to the system after replacing any of the following major components.Amount of lubricant to be added:

Name : NISSAN A/C System Oil Type S


LUBRICANT

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*1: No addition of lubricant is needed if the refrigerant leakage is small.

Lubricant Adjusting Procedure for Compressor Replacement INFOID:0000000004653100

1. Check recovery/recycling recharging equipment gauges before connecting recovery/recycling rechargingequipment to vehicle. No refrigerant pressure should be displayed. Recover refrigerant from equipmentlines if NG.

2. Connect recovery/recycling recharging equipment to vehicle. Confirm refrigerant purity in supply tankusing recovery/recycling recharging equipment and refrigerant identifier. Refer to HA-12, "Working withHFC-134a (R-134a)" if NG.

3. Confirm refrigerant purity in vehicle A/C system using recovery/recycling recharging equipment and refrig-erant identifier. If NG, refer to HA-12, "Working with HFC-134a (R-134a)".

4. Discharge refrigerant into the recovery/recycling recharging equipment. Measure lubricant discharged intothe recovery/recycling recharging equipment.

5. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amountof lubricant drained.

6. Drain the lubricant from the new compressor into a separate. Then clean container.7. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this

lubricant to new compressor through the suction port opening.8. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant

to new compressor through the suction port opening.9. Add another 5 m (0.2 US fl oz., 0.2 Imp fl oz.) of lubricant at this time if the liquid tank also needs to be

replaced.

Replaced part

Lubricant to be added to system

RemarksAmount of lubricant

m (US fl oz., Imp fl oz.)

Evaporator 75 (2.5, 2.6) —

Condenser 35 (1.2, 1.2) —

Liquid tank 10 (0.3, 0.4) —

In case of refrigerant leakage30 (1.0, 1.1) Large leakage

— Small leakage *1


LUBRICANT
Do not add this 5 m (0.2 US fl oz., 0.2 Imp fl oz.) of lubricant when replacing the compressor only.

RJIA3578E



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1.CHECK BLOWER MOTOR OPERATION

Check blower motor operation. Refer to HAC-56, "Component Function Check".Is the inspection result normal?YES >> GO TO 2.NO >> Repair or replace the parts according to the inspection results.

2.CHECK COMPRESSOR OPERATION

Check compressor operation. Refer to HAC-60, "Component Function Check".Is the inspection result normal?YES >> GO TO 3.NO >> Repair or replace the parts according to the inspection results.

3.CHECK REFRIGERANT CYCLE PRESSURE

Connect recovery/recycling recharging equipment to the vehicle and perform the diagnosis with the gaugepressure. Refer to HA-7, "Trouble Diagnosis For Unusual Pressure".Is the inspection result normal?YES >> Perform the performance test. Refer to HA-33, "Performance Chart".NO >> Repair or replace the parts according to the inspection results.

Performance Chart INFOID:0000000004653102

TEST CONDITION

Testing must be performed as per the following:

TEST READING

Recirculating-to-discharge Air Temperature Table

Vehicle condition Indoors or in the shade (in a well-ventilated place)

Doors Closed

Door windows Open

Hood Open

Set temperature Full cold

Mode switch (Ventilation) set

Intake switch (Recirculation) set

Fan speed Maximum speed set

Engine speed Idle speed

Operate the air conditioning system for 10 minutes before taking measurements.

Inside air (Recirculating air) at blower assembly inletDischarge air temperature at center ventilator

°C (°F)Relative humidity%

Air temperature°C (°F)

50 – 60

20 (68) 6.3 – 7.9 (43 – 46)

25 (77) 10.6 – 12.8 (51 – 55)

30 (86) 14.8 – 17.6 (59 – 64)

35 (95) 19.0 – 22.3 (66 – 72)

60 – 70

20 (68) 7.9 – 9.4 (46 – 49)

25 (77) 12.8 – 14.9 (55 – 59)

30 (86) 17.6 – 20.3 (64 – 69)

35 (95) 22.3 – 25.7 (72 – 78)


< PERIODIC MAINTENANCE >Ambient Air Temperature-to-operating Pressure Table
Refrigerant Leakages INFOID:0000000004653103

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricantleakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allowextra inspection time in these areas when using either an electrical leak detector or fluorescent dye leakdetector [refrigerant dye leak detection kit (SST: J-43926)].Confirm the leakage with an electrical leak detector if dye is observed. It is possible a prior leakage wasrepaired and not properly cleaned.Do not stop when one leakage is found but continue checking for additional leakages at all system compo-nents and connections when searching for leakages.Move the probe along the suspected leakage area at 1 to 2 inches per second and no further than 1/4 inchfrom the component when searching for refrigerant leakages using an electrical leak detector.CAUTION:Moving the electrical leak detector probe slower and closer to the suspected leakage area improvesthe chances of finding a leakage.

Ambient airHigh-pressure (Discharge side)

kPa (kg/cm2, psi)

Low-pressure (Suction side)

kPa (kg/cm2, psi)Relative humidity%

Air temperature°C (°F)

50 – 70

20 (68)768 – 940

(7.8 – 9.6, 111.4 – 136.3)180 – 220

(1.8 – 2.2, 26.1 – 31.9)

25 (77)925 – 1,131

(9.4 – 11.5, 134.1 – 164.0)218 – 267

(2.2 – 2.7, 31.6 – 38.7)

30 (86)1,082 – 1,322

(11.0 – 13.5, 156.9 – 191.7)258 – 314

(2.6 – 3.2, 37.4 – 45.5)

35 (95)1,238 – 1,513

(12.6 – 15.4, 179.5 – 219.4)296 – 362

(3.0 – 3.7, 42.9 – 52.5)

40 (104)1,395 – 1,704

(14.2 – 17.4, 202.3 – 247.1)335 – 408

(3.4 – 4.2, 48.6 – 59.2)


FLUORESCENT LEAK DETECTOR

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FLUORESCENT LEAK DETECTOR


CHECKING SYSTEM FOR LEAKAGES USING THE FLUORESCENT LEAK DETECTOR1. Check A/C system for leakages using the UV lamp and safety goggles (SST: J-42220) in a low sunlight

area (area without windows preferable). Illuminate all components, fittings and lines. The dye appears asa bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open-ing indicates an evaporator core assembly (tubes, core or expansion valve) leakage.

2. Use an adjustable mirror or wipe the area with a clean shop rag or cloth, with the UV lamp for dye residueif the suspected area is difficult to see.

3. Remove any residual dye using dye cleaner (SST: J-43872) to prevent future misdiagnosis after the leak-age is repaired.

4. Perform a system performance check and verify the leakage repair with an approved electrical leak detec-tor.

NOTE:Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshieldwasher fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to bechecked are clean.Clean with a dry cloth or blow off with shop air.Do not allow the sensor tip of the detector to contact with any substance. This may also cause false readingsand may damage the detector.

DYE INJECTION(This procedure is only necessary when recharging the system or when the compressor has seized and wasreplaced.)

1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm2, 50 psi).2. Pour one bottle [1/4 ounce (7.4 cc)] of the A/C refrigerant dye into the injector tool (SST: J-41459).3. Connect the injector tool to the A/C low-pressure side service valve.4. Start the engine. Then A/C switch ON.5. Inject one bottle [1/4 ounce (7.4 cc)] of fluorescent dye through the low-pressure service valve using dye

injector tool (SST: J-41459) (refer to the manufacture’s operating instructions) when the A/C operating(compressor running).

6. Disconnect the injector tool from the service valve with the engine still running.CAUTION:Be careful when replacing the A/C system or a component, pour the dye directly into the open sys-tem connection and proceed with the service procedures.

7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on theleakage size, operating conditions and location of the leakage, it may take from minutes to days for thedye to penetrate a leakage and become visible.

8. Attach a blue label if necessary.


ELECTRICAL LEAK DETECTOR


PRECAUTIONS FOR HANDLING LEAK DETECTORUse an electrical leak detector (SST: J-41995) or equivalent whenperforming a refrigerant leakage check. Ensure that the instrument iscalibrated and set properly per the operating instructions.The leak detector is a delicate device. Read the operating instruc-tions and perform any specified maintenance for using the leakdetector properly.

1. Position probe approximately 3 mm (0.12 in) away from point tobe checked.

2. Circle each fitting completely with probe when testing.

3. Move probe along component approximately 25 to 50 mm (1 to2 in)/sec.

CHECKING PROCEDURECheck that there is no refrigerant vapor, shop chemicals, or cigarette smoke in the vicinity of the vehicle to pre-vent inaccurate or false readings. Perform the leakage test in calm area (low air/wind movement) so that theleaking refrigerant is not dispersed.1. Stop the engine.

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2. Connect a suitable A/C manifold gauge set (SST: J-39183) to the A/C service valves.

3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2, 50 psi) above 16°C(61°F). Recover/evacuate and recharge the system with the specified amount of refrigerant if less thanspecification.NOTE:Leakages may not be detected since the system may not reach 345 kPa (3.45 bar, 3.52 kg/cm2, 50 psi) attemperatures below 16°C (61°F).

4. Perform the leakage test in the numerical as shown in the figure. [high-pressure side (compressor dis-charge “a” to evaporator inlet “j”) to low-pressure side (evaporator drain hose “k” to shaft seal “p”)]Clean the component to be checked and move the leakage detected probe completely around the con-nection/component.

NOTE:Check the following carefully.

Service valves• Check all around the service valves. Ensure service valve caps are secured on the service valves (to

prevent leakages).• Wipe any residue from valves to prevent any false readings by leak detector after removing manifold

gauge set (SST: J-39183) from service valves.Cooling unit (Evaporator)

• Turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unitwith engine OFF.

• Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended procedurefor actual wait time) before inserting the leak detector probe into the drain hose.

• Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with wateror dirt that may be in the drain hose.

5. Verify at least once by blowing compressed air into area of suspected leakage, then repeat check as out-lined above if a leak detector detects a leakage.

6. If a leakage is found, but continue checking for additional leakages at all system components.When leakages are not found, go to next step.

7. Start the engine.8. Set the A/C control as per the following:a. A/C switch: ONb. Air flow: VENT (Ventilation)

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< PERIODIC MAINTENANCE >c. Intake door position: Recirculationd. Temperature setting: Full colde. Fan speed: Maximum speed set9. Run engine at 1,500 rpm for at least 2 minutes.10. Stop the engine and perform leakage check again, steps 4 – 6.
Refrigerant leakages should be checked immediately after stop-ping the engine. Begin with the leak detector at the compressor.The pressure on the high-pressure side drops gradually afterrefrigerant circulation stops and pressure on the low-pressureside rises gradually, as shown in the graph. Some leakages aremore easily detected when pressure is high.

11. Check recovery/recycling recharging equipment gauges before connecting recovery/recycling rechargingequipment to vehicle. No refrigerant pressure should be displayed. Recover refrigerant from equipmentlines if pressure is displayed, and then refrigerant purity.

12. Confirm refrigerant purity in supply tank using recovery/recycling recharging equipment and refrigerantidentifier.

13. Confirm refrigerant purity in vehicle A/C system using recovery/recycling recharging equipment and refrig-erant identifier.

14. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-ponent if necessary.

15. Evacuate and recharge A/C system and perform the leakage test to confirm no refrigerant leakages.16. Perform A/C performance test to ensure system works normally.

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COMPRESSOR

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REMOVAL AND INSTALLATIONCOMPRESSOR



REMOVAL1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.2. Remove air cleaner case (LH) and air duct (LH). Refer to EM-27, "Exploded View".3. Remove engine undercover, using power tools.4. Drain engine coolant from radiator. Refer to CO-7, "Draining".5. Remove cooling fan assembly. Refer to CO-16, "Exploded View".6. Remove drive belt. Refer to EM-13, "Exploded View".7. Remove radiator hose (lower). Refer to CO-13, "Exploded View".8. Remove mounting nuts (A) from low-pressure flexible hose (1)

and high-pressure flexible hose (2).CAUTION:Cap or wrap the joint of the A/C piping and compressor withsuitable material such as vinyl tape to avoid the entry of air.

1. Compressor


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COMPRESSOR
< REMOVAL AND INSTALLATION >9. Disconnect compressor (ECV) connector (A).10. Disconnect compressor (magnet clutch) connector (B).
11. Remove mounting bolts (A) from compressor (1), using powertools.

12. Remove the compressor from top of the vehicle.

INSTALLATIONInstallation is basically the reverse order of removal.CAUTION:• Replace O-rings with new ones. Then apply compressor oil to them when installing.• Check for leakages when recharging refrigerant.• Check tension of the drive belt after installing compressor. Refer to EM-13, "Checking".


CHECK DISC TO PULLEY CLEARANCECheck the clearance (B) between pulley assembly (1) and clutchdisc (2) along the entire periphery with a feeler gauge (A).

Replace compressor if specified clearance is not obtained.

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Standard : Refer to HA-56, "Compressor".

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Refer to HA-13, "Refrigerant Connection".

LOW-PRESSURE FLEXIBLE HOSE AND PIPE 2

LOW-PRESSURE FLEXIBLE HOSE AND PIPE 2 : Removal and InstallationINFOID:0000000004648418

REMOVAL1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.2. Remove engine cover. Refer to EM-25, "Exploded View".3. Remove air cleaner case (LH) and air duct (LH). Refer to EM-27, "Exploded View".4. Remove cowl top cover. Refer to EXT-21, "Exploded View".

1. Blower unit 2. O-ring 3. Low-pressure pipe 2

4. Low-pressure flexible hose 5. Compressor 6. Radiator & condenser assembly

7. High-pressure flexible hose 8. High-pressure pipe 1 9. Heater & cooling unit assembly

10. Expansion valve 11. Evaporator 12. High-pressure pipe 2

13. Low-pressure pipe 1


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< REMOVAL AND INSTALLATION >5. Remove mounting bolt (A) from low-pressure flexible hose
bracket (1).

6. Disconnect one-touch joint between low-pressure pipe 1 (1) andlow-pressure pipe 2 (2) with disconnector (A) (SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

7. Disconnect one-touch joint between low-pressure pipe 2 (1) andlow-pressure flexible hose (2) with disconnector (A) (SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

8. Remove low-pressure pipe 2 clip (B).9. Remove low-pressure pipe 2.

10. Remove mounting nut (A) from low-pressure flexible hose (1).CAUTION:Cap or wrap the joint of the A/C piping and compressor withsuitable material such as vinyl tape to avoid the entry of air.

11. Remove low-pressure flexible hose.

INSTALLATIONInstallation is basically the reverse order of removal.CAUTION:• Replace O-rings with new ones. Then apply compressor oil to them when installing.• Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping

straight in axial direction.• Insert piping securely until a click is heard.• After piping connection is completed, pull male-side piping by hand to check that connection does

not come loose.• Check for leakages when recharging refrigerant.HIGH-PRESSURE FLEXIBLE HOSE

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HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000004649269

REMOVAL1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.2. Remove engine cover. Refer to EM-25, "Exploded View".3. Remove air cleaner case (LH) and air duct (LH). Refer to EM-27, "Exploded View".4. Remove mounting bolt (A) from high-pressure flexible hose

bracket (1).

5. Disconnect one-touch joint between high-pressure flexible hose(1) and condenser pipe assembly (2) with disconnector (A)(SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

6. Remove mounting nut (A) from high-pressure flexible hose (1),and then remove high-pressure flexible hose.CAUTION:Cap or wrap the joint of the A/C piping and compressor withsuitable material such as vinyl tape to avoid the entry of air.



not come loose.• Check for leakages when recharging refrigerant.HIGH-PRESSURE PIPE 1

HIGH-PRESSURE PIPE 1 : Removal and Installation INFOID:0000000004649270

REMOVAL1. Remove low-pressure flexible hose and pipe 2. Refer to HA-41, "Exploded View".

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< REMOVAL AND INSTALLATION >2. Remove mounting bolt (A) from high-pressure flexible hose
bracket (1).

3. Remove high-pressure pipe 1 (1) from vehicle clips (A).

4. Disconnect one-touch joint between high-pressure pipe 1 (1)and high-pressure pipe 2 (2) with disconnector (A) (SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

5. Disconnect one-touch joint between high-pressure pipe 1 andcondenser pipe assembly with disconnector (A) (SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

6. Remove vacuum hose. Refer to BR-37, "Exploded View".7. Remove high-pressure pipe 1.



not come loose.

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• Check for leakages when recharging refrigerant.LOW-PRESSURE PIPE 1 AND HIGH-PRESSURE PIPE 2

LOW-PRESSURE PIPE 1 AND HIGH-PRESSURE PIPE 2 : Removal and InstallationINFOID:0000000004649271

REMOVAL1. Set the temperature at 18.0°C (60°F).

CAUTION:The angle may be out, when installing the air mix door motor to the air mix door, unless the aboveprocedure is performed.

2. Disconnect the battery cable from the negative terminal.3. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.4. Remove cowl top cover. Refer to EXT-21, "Exploded View".5. Disconnect one-touch joint between low-pressure pipe 1 (1) and

low-pressure pipe 2 (2) with disconnector (A) (SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

6. Disconnect one-touch joints between high-pressure pipe 1 (3)and high-pressure pipe 2 (4) with disconnector (SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

7. Remove foot grille (right). Refer to VTL-10, "Exploded View".8. Remove blower unit. Refer to VTL-16, "Exploded View".9. Remove air mix door motor (passenger side). Refer to HAC-120, "Exploded View".10. Remove mode door motor. Refer to HAC-120, "Exploded View".11. Remove main link (right) and max. cool door link (right). Refer to HAC-120, "Exploded View".12. Remove mounting screws (A), and then remove evaporator

cover (1).

13. Remove mounting bolt (A), and then remove low-pressure pipe1 (1) and high-pressure pipe 2 (2).CAUTION:Cap or wrap the joint of the A/C piping and expansion valvewith suitable material such as vinyl tape to avoid the entryof air.

INSTALLATIONInstallation is basically the reverse order of removal.

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< REMOVAL AND INSTALLATION >CAUTION:• Replace O-rings with new ones. Then apply compressor oil to them when installing.• Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping

not come loose.• Check for leakages when recharging refrigerant.


CONDENSER

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CONDENSER


CONDENSER

CONDENSER : Removal and Installation INFOID:0000000004649330

REMOVAL1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.2. Remove radiator & condenser assembly. Refer to CO-13, "Exploded View".CAUTION:Be careful not to damage core surface of radiator & condenser assembly/



not come loose.• Check for leakages when recharging refrigerant.CONDENSER PIPE ASSEMBLY

CONDENSER PIPE ASSEMBLY : Removal and Installation INFOID:0000000004649331

REMOVAL1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.2. Remove bumper fascia assembly. EXT-12, "Exploded View".3. Remove air cleaner case (LH) and air duct (LH). Refer to EM-27, "Exploded View".

1. Refrigerant pressure sensor 2. O-ring 3. Liquid tank bracket

4. Liquid tank 5. Bracket 6. Condenser pipe assembly

7. Radiator & condenser assembly


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< REMOVAL AND INSTALLATION >4. Disconnect one-touch joint between high-pressure flexible hose
(1) and condenser pipe assembly (2) with disconnector (A)(SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

5. Disconnect one-touch joints between high-pressure pipe 1 (3)and condenser pipe assembly with disconnector (A) (SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

6. Remove mounting bolt (A) from condenser pipe assembly (1).

7. Remove mounting bolt (A) from condenser pipe assembly (1).8. Remove condenser pipe assembly.



not come loose.• Check for leakages when recharging refrigerant.LIQUID TANK

LIQUID TANK : Removal and Installation INFOID:0000000004649332

REMOVAL1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.2. Remove front grille. Refer to EXT-19, "Exploded View".3. Clean liquid tank and its surrounding area. Then remove dust and rust from liquid tank.

CAUTION:Be sure to clean carefully.

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CONDENSER

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4. Remove mounting bolts (A) from liquid tank (1).5. Remove liquid tank.

INSTALLATION Install liquid tank, and then install liquid tank bracket on condenser. CAUTION:• Check that liquid tank bracket is securely installed at protrusion of condenser. (Check that liquid

tank bracket does not move to a position below center of liquid tank.)• Replace O-rings of the A/C piping with new ones. Then apply compressor oil to them when installing.• Check for leakages when recharging refrigerant.REFRIGERANT PRESSURE SENSOR

REFRIGERANT PRESSURE SENSOR : Removal and Installation INFOID:0000000004649333

REMOVAL1. Remove liquid tank. Refer to HA-47, "Exploded View".2. Fix the liquid tank (1) with a vise (A). Remove the refrigerant

pressure sensor (2) with a wrench (B).CAUTION:Be careful not to damage liquid tank.

INSTALLATIONInstallation is basically the reverse order of removal.CAUTION:• Apply compressor oil to O-ring of refrigerant pressure sensor when installing.• Check for leakages when recharging refrigerant.

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HEATER & COOLING UNIT ASSEMBLY


REMOVAL

DISASSEMBLY

1. Blower unit 2. Heater & cooling unit assembly 3. Steering member

4. Instrument stay (left) 5. Instrument panel assembly 6. Instrument stay (right)


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1. Ventilator seal 2. Ventilator door 3. Defroster seal

4. Defroster door (right) 5. Packing 6. Foot duct (right)

7. Ventilator door spring 8. Ventilator door lever 9. Foot door lever

10. Foot door link 11. Main link sub 12. Ventilator door link

13. Main link 14. Mode door motor bracket 15. Mode door motor

16. Evaporator cover 17. Low-pressure pipe 1 18. Cooler pipe grommet

19. High-pressure pipe 2 20. O-ring 21. Expansion valve

22. Evaporator 23. Insulator 24. Drain hose

25. Evaporator cover adapter 26. Heater pipe bracket 27. Heater pipe grommet

28. Heater core 29. Heater pipe cover 30. Packing

31. Case packing 32. Heater & cooling unit case (left) 33. Air mix door adapter

34. Air mix door motor (driver side) 35. J-nut 36. Front heater duct

37. Aspirator hose 38. Aspirator 39. Foot duct (left)

40. Defroster door (left) 41. Packing 42. Center case

43. Foot door (left) 44. Rear ventilator door 45. Foot door (right)

46. J-nut 47. Max. cool door lever 48. Defroster door lever

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HEATER & COOLING UNIT ASSEMBLY : Removal and Installation INFOID:0000000004649614

REMOVAL1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.2. Drain engine coolant from cooling system. Refer to CO-7, "Draining".3. Remove cowl top cover. Refer to EXT-21, "Exploded View".4. Disconnect one-touch joint between low-pressure pipe 1 (1) and

low-pressure pipe 2 (2) with disconnector (A) (SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

5. Disconnect one-touch joint between high-pressure pipe 1 (3)and high-pressure pipe 2 (4) with disconnector (SST: J-45815).CAUTION:Cap or wrap the joint of the A/C piping with suitable mate-rial such as vinyl tape to avoid the entry of air.

6. Remove clamp (A), and then disconnect heater hoses (1).

7. Remove instrument panel assembly. Refer to IP-11, "Exploded View".8. Remove blower unit. Refer to VTL-16, "Exploded View".9. Remove clips of vehicle harness from steering member.10. Remove instrument stay.11. Remove drain hose.12. Remove mounting bolts (A) from heater & cooling unit assembly

(1).

13. Remove front defroster nozzle, side defroster nozzles and ventilator duct. Refer to VTL-10, "ExplodedView".

49. Defroster door link 50. Max. cool door link 51. Intake sensor

52. Intake sensor bracket 53. Air mix door motor (passenger side) 54. Air mix door adapter

55. Heater & cooling unit case (right) 56. Max. cool door (right) 57. Max. cool door (left)

58. Air mix door (Slide door)


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14. Remove steering column mounting bolts (A) and nuts (B). Refer to ST-18, "WITHOUT ELECTRICMOTOR : Exploded View" (WITHOUT ELECTRIC MOTOR) or ST-21, "WITH ELECTRIC MOTOR :Exploded View" (WITH ELECTRIC MOTOR).

15. Remove steering member mounting bolts (C).16. Remove steering member (1).17. Remove heater & cooling unit assembly.


straight in axial direction.• Insert piping securely until a clicks is heard.• After piping connection is completed, pull male-side piping by hand to make sure that connection

does not come loose.• Check for leakages when recharging refrigerant.NOTE:• Perform 4WAS front actuator adjustment (WITH 4WAS). Refer to STC-28, "4WAS FRONT ACTUATOR

NEUTRAL POSITION ADJUSTMENT : Description".• Refer to CO-8, "Refilling" when filling radiator with engine coolant.• Recharge the refrigerant.HEATER CORE

HEATER CORE : Removal and Installation INFOID:0000000004649615

REMOVAL1. Remove heater & cooling unit assembly. Refer to HA-50, "Exploded View".

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< REMOVAL AND INSTALLATION >2. Remove mounting screws (A), and then remove heater pipe
cover (1).3. Remove mounting screws (B), and then remove foot duct (left)

(2).4. Slide heater core (3) to leftward (as shown in the figure).

INSTALLATIONInstallation is basically the reverse order of removal.NOTE:Refer to CO-8, "Refilling" when filling radiator with engine coolant.EVAPORATOR

EVAPORATOR : Removal and Installation INFOID:0000000004649815

REMOVAL1. Remove low-pressure pipe 1 and high-pressure pipe 2. Refer to HA-41, "Exploded View".

CAUTION:Cap or wrap the joint of the A/C piping and expansion valve with suitable material such as vinyltape to avoid the entry of air.

2. Slide evaporator (1) from heater & cooling unit assembly.3. Remove intake sensor (2) from evaporator, and then remove

evaporator.

4. Remove mounting bolts (A), and then remove expansion valve(1).CAUTION:Cap or wrap the joint of evaporator and expansion valvewith suitable material such as vinyl tape to avoid the entryof air.



not come loose.

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• O-rings differ from low-pressure flexible hose (high-pressure pipe 1) and low-pressure pipe 1 (high-pressure pipe 2).

• Mark the mounting position of intake sensor bracket prior to removal so that the reinstalled sensorcan be located in the same position.

• Check for leakages when recharging refrigerant.EXPANSION VALVE

EXPANSION VALVE : Removal and Installation INFOID:0000000004649816

REMOVAL1. Remove low-pressure pipe 1 and high-pressure pipe 2. Refer to HA-41, "Exploded View".2. Remove mounting bolts (A), and then remove expansion valve

(1).CAUTION:Cap or wrap the joint of evaporator and expansion valvewith suitable material such as vinyl tape to avoid the entryof air.

INSTALLATIONInstallation is basically the reverse order of removal.CAUTION:• Replace O-rings with new ones. Then apply compressor oil to them when installing.• O-rings are different from low-pressure pipe 1 (high-pressure pipe 1) and low-pressure pipe 2 (high-

pressure pipe 2).• Check for leakages when recharging refrigerant.

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SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)SERVICE DATA AND SPECIFICATIONS (SDS)

Compressor INFOID:0000000004655508

Lubricant INFOID:0000000004655509

Refrigerant INFOID:0000000004655510

Engine Idling Speed INFOID:0000000004655511

Refer to EC-619, "Idle Speed".

Belt Tension INFOID:0000000004655512

Refer to EM-148, "Drive Belt".

ModelCALSONIC KANSEI make

CSE-617

Type Variable displacement swash plate

Displacement

cm3 (cu in)/revMax. 170 (10.4)

Number of cylinders 6

Cylinder bore × stroke (Max.)mm (in.)

34.8 (1.37) × 29.8 (1.17)

Direction of rotation Clockwise (viewed from clutch)

Drive belt Poly V

Disc to pulley clearancemm (in.)

Standard 0.3 – 0.6 (0.012 – 0.024)

Name NISSAN A/C System Oil Type S (DH-PS)

Capacity

m (US fl oz., lmp fl oz.)

Total in system 150 (5.07, 5.3)

Compressor (service part) charging amount

150 (5.07, 5.3)

Type HFC-134a (R-134a)

Capacitykg (lb)

0.55 (1.21)


VENTILATION, HEATER & AIR CONDITIONER

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HEATER & AIR CONDITIONING CONTROL SYSTEM

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CONTENTS

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AUTOMATIC AIR CONDITIONER

BASIC INSPECTION .................................... 4

DIAGNOSIS AND REPAIR WORKFLOW .......... 4Work Flow .................................................................4

INSPECTION AND ADJUSTMENT ..................... 5Description & Inspection ...........................................5Temperature Setting Trimmer ...................................7Foot Position Setting Trimmer ...................................9Inlet Port Memory Function .....................................10

SYSTEM DESCRIPTION .............................11

COMPRESSOR CONTROL FUNCTION ............11Description ..............................................................11Fail-safe ..................................................................11Component Part Location .......................................12Component Description ...........................................15

AUTOMATIC AIR CONDITIONER SYSTEM .....16System Diagram ......................................................16System Description .................................................17Component Part Location .......................................25Component Description ...........................................28

CAN COMMUNICATION SYSTEM ....................29System Description .................................................29

MODE DOOR CONTROL SYSTEM ...................30System Diagram ......................................................30System Description .................................................30

AIR MIX DOOR CONTROL SYSTEM ................32System Diagram ......................................................32System Description .................................................32

INTAKE DOOR CONTROL SYSTEM ................34System Diagram ......................................................34System Description .................................................34

BLOWER MOTOR CONTROL SYSTEM ...........36

System Diagram ......................................................36System Description ..................................................36

MAGNET CLUTCH CONTROL SYSTEM .........38System Diagram ......................................................38System Description ..................................................38

DIAGNOSIS SYSTEM (UNIFIED METER & A/C AMP.) .............................................................40

Diagnosis Description ..............................................40

DTC/CIRCUIT DIAGNOSIS .........................46

POWER SUPPLY AND GROUND CIRCUIT ....46

UNIFIED METER AND A/C AMP. ..............................46UNIFIED METER AND A/C AMP. : Diagnosis Pro-cedure ......................................................................46

UNIFIED METER AND A/C AMP. .....................47Description ...............................................................47Component Function Check ....................................47Diagnosis Procedure ...............................................47

MODE DOOR MOTOR ......................................48Description ...............................................................48Component Function Check ..................................48Diagnosis Procedure ...............................................48

AIR MIX DOOR MOTOR ...................................50

WITHOUT LEFT AND RIGHT VENTILATION TEM-PERATURE SEPARATELY CONTROL SYSTEM ....50

WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description .............................................50WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Component Function Check .................50WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure .............................50

HAC-1Revision: 2009 October 2009 G37 Coupe

WITH LEFT AND RIGHT VENTILATION TEMPER-ATURE SEPARATELY CONTROL SYSTEM ........... 51

WITH LEFT AND RIGHT VENTILATION TEM-PERATURE SEPARATELY CONTROL SYSTEM : Description ............................................................ 51WITH LEFT AND RIGHT VENTILATION TEM-PERATURE SEPARATELY CONTROL SYSTEM : Component Function Check ............................... 52WITH LEFT AND RIGHT VENTILATION TEM-PERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure ............................................ 52

INTAKE DOOR MOTOR .................................... 54Description .............................................................. 54Component Function Check ................................. 54Diagnosis Procedure .............................................. 54

BLOWER MOTOR ............................................. 56Description .............................................................. 56Component Function Check ................................. 56Diagnosis Procedure .............................................. 57Component Inspection ............................................ 59

MAGNET CLUTCH ............................................ 60Description .............................................................. 60Component Function Check ................................... 60Diagnosis Procedure .............................................. 60

ECV (ELECTRICAL CONTROL VALVE) .......... 62Description .............................................................. 62Diagnosis Procedure .............................................. 62

AMBIENT SENSOR ........................................... 64Description .............................................................. 64Component Function Check ................................. 64Diagnosis Procedure .............................................. 64Component Inspection ............................................ 65

IN-VEHICLE SENSOR ....................................... 67Description .............................................................. 67Component Function Check ................................. 67Diagnosis Procedure .............................................. 68Component Inspection ............................................ 69

SUNLOAD SENSOR ......................................... 70Description .............................................................. 70Component Function Check ................................. 70Diagnosis Procedure .............................................. 70Component Inspection ............................................ 71

INTAKE SENSOR .............................................. 73Description .............................................................. 73Component Function Check ................................. 73Diagnosis Procedure .............................................. 73Component Inspection ............................................ 74

ECU DIAGNOSIS INFORMATION .............. 76

ECM ................................................................... 76Reference Value ..................................................... 76

UNIFIED METER AND A/C AMP. ..................... 92Reference Value ..................................................... 92Wiring Diagram - AIR CONDITIONER CONTROL SYSTEM - ............................................................... 94Fail-safe ................................................................ 100

SYMPTOM DIAGNOSIS ...........................102

AIR CONDITIONER CONTROL .......................102Diagnosis Chart By Symptom ............................... 102

INSUFFICIENT COOLING ................................103Description ............................................................ 103Inspection procedure ............................................ 103

INSUFFICIENT HEATING ................................105Description ............................................................ 105Inspection procedure ............................................ 105

NOISE ...............................................................107Description ............................................................ 107Inspection procedure ............................................ 107

SELF-DIAGNOSIS CANNOT BE PER-FORMED ...........................................................109

Description ............................................................ 109Inspection procedure ............................................ 109

MEMORY FUNCTION DOES NOT OPERATE ..110Description ............................................................ 110Inspection procedure ............................................ 110

PRECAUTION ...........................................111

PRECAUTIONS ................................................111Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" ............................................................... 111Precaution Necessary for Steering Wheel Rota-tion after Battery Disconnect ................................. 111Precaution for Battery Service .............................. 112

REMOVAL AND INSTALLATION .............113

PRESET SWITCH .............................................113Exploded View ...................................................... 113Removal and Installation ....................................... 113

UNIFIED METER AND A/C AMP. ....................114Exploded View ...................................................... 114Removal and Installation ....................................... 114

AMBIENT SENSOR ..........................................115Exploded View ...................................................... 115Removal and Installation ....................................... 115

IN-VEHICLE SENSOR ......................................116Exploded View ...................................................... 116Removal and Installation ....................................... 116

SUNLOAD SENSOR ........................................117Exploded View ...................................................... 117


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Removal and Installation ....................................... 117

INTAKE SENSOR ............................................ 118Exploded View ...................................................... 118Removal and Installation ....................................... 118

REFRIGERANT PRESSURE SENSOR ........... 119Exploded View ...................................................... 119Removal and Installation ....................................... 119

DOOR MOTOR ................................................. 120Exploded View ...................................................... 120

MODE DOOR MOTOR .............................................120MODE DOOR MOTOR : Removal and Installation ..120

AIR MIX DOOR MOTOR ..........................................120AIR MIX DOOR MOTOR : Removal and Installa-tion .........................................................................121

INTAKE DOOR MOTOR ..........................................121INTAKE DOOR MOTOR : Removal and Installa-tion .........................................................................121


[AUTOMATIC AIR CONDITIONER]DIAGNOSIS AND REPAIR WORKFLOW


BASIC INSPECTIONDIAGNOSIS AND REPAIR WORKFLOW


DETAILED FLOW

1.LISTEN TO CUSTOMER COMPLAINT

Listen to customer complaint. (Get detailed information about the conditions and environment when the symp-tom occurs.)

>> GO TO 2.

2.VERIFY THE SYMPTOM WITH OPERATIONAL CHECK

Verify the symptom with operational check. Refer to HAC-5, "Description & Inspection".

>> GO TO 3.

3.GO TO APPROPRIATE TROUBLE DIAGNOSIS

Go to appropriate trouble diagnosis. Refer to HAC-102, "Diagnosis Chart By Symptom".

>> GO TO 4.

4.REPAIR OR REPLACE

Repair or replace the specific parts.

>> GO TO 5.

5.FINAL CHECK

Final check.Is the inspection result normal?YES >> INSPECTION ENDNO >> GO TO 3.


INSPECTION AND ADJUSTMENT[AUTOMATIC AIR CONDITIONER]

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INSPECTION AND ADJUSTMENT

Description & Inspection INFOID:0000000004536435

DESCRIPTIONThe purpose of the operational check is to check that the individual system operates normally.

INSPECTION PROCEDURE

1.CHECK MEMORY FUNCTION

1. Start the engine.2. Turn temperature control dial (driver side) clockwise until 32.0°C (90°F) is displayed.3. Press the OFF switch.4. Turn the ignition switch OFF.5. Turn the ignition switch ON.6. Press the AUTO switch.7. Check that the temperature setting before turning the ignition switch OFF is stored. Is the inspection result normal?YES >> GO TO 2NO >> Memory function malfunction: HAC-110, "Inspection procedure".

2.CHECK BLOWER MOTOR SPEED

1. Start the engine.2. Press fan (UP: +) switch*1 (turn fan control dial clockwise*2). Check that the fan speed is changed. Check

the operation for all fan speeds.NOTE:*1: With left and right ventilation temperature separately system.*2: Without left and right ventilation temperature separately system.

3. Set the fan speed to max speed.Is the inspection result normal?YES >> GO TO 3NO >> Blower motor system malfunction: HAC-57, "Diagnosis Procedure".

3.CHECK DISCHARGE AIR

1. Press the MODE switch and the DEF switch.2. Each position indicator should change shape. 3. Confirm that discharge air comes out according to the air distribution table as follows:

Without left and right ventilation temperature separately control system

Conditions : Engine running at normal operating temperature

Discharge air flow

Mode position indication

Air outlet/distribution

VENTFOOT

DEFFront Rear

100% — — —

53% 29% 18% —

11% 39% 24% 26%

9% 33% 21% 37%

16% — — 84%


[AUTOMATIC AIR CONDITIONER]INSPECTION AND ADJUSTMENT

< BASIC INSPECTION >With left and right ventilation temperature separately control system

NOTE:Confirm that the compressor clutch is engaged (sound or visual inspection) and the intake door position is atFRE when D/F or DEF is selected.Is the inspection result normal?YES >> GO TO 4NO >> Mode door system malfunction: HAC-48, "Diagnosis Procedure".

4.CHECK INTAKE AIR

1. Press intake switch. REC indicator turns ON.2. Press intake switch again. FRE indicator turns ON.3. Listen for intake door position change. (Slight change of blower sound can be heard.)NOTE:Confirm that the compressor clutch is engaged (sound or visual inspection) and the intake door position is atFRE when D/F or DEF is selected.Is the inspection result normal?YES >> GO TO 5NO >> Intake door system malfunction: HAC-54, "Diagnosis Procedure".

5.CHECK A/C SWITCH

1. Press the A/C switch.2. A/C switch indicator turns ON.

Confirm that the compressor clutch engages (sound or visual inspection).Is the inspection result normal?YES >> GO TO 6NO >> Magnet clutch system malfunction: HAC-60, "Diagnosis Procedure".

6.CHECK WITH TEMPERATURE SETTING LOWERED

1. Turn temperature control dial (driver side) counterclockwise until 18°C (64°F) is displayed.2. Check that the cool air blows from the outlets. Is the inspection result normal?YES >> GO TO 7NO >> Insufficient cooling: HAC-103, "Inspection procedure".

7.CHECK WITH TEMPERATURE SETTING RAISED

1. Turn temperature control dial (driver side) clockwise until 32°C (90°F) is displayed.2. Check that the warm air blows from the outlets.Is the inspection result normal?YES-1 >> With left and right ventilation temperature separately system. GO TO 8YES-2 >> Without left and right ventilation temperature separately system. GO TO 9NO >> Insufficient heating: HAC-105, "Inspection procedure".

8.CHECK LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM FUNC-TION

1. Press the DUAL switch, and then check that “DUAL” is shown on the display.

Discharge air flow

Mode position indication Condition


VENTFOOT

DEFFront Rear

DUAL switch: OFF 100% — — —

53% 29% 18% —

11% 39% 24% 26%

9% 33% 21% 37%

16% — — 84%



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2. Operate temperature control dial (driver side). Check that the discharge air temperature (driver side)changes.

3. Operate the temperature control dial (passenger side). Check that the discharge air temperature (passen-ger side) changes.

4. Press the DUAL switch, and then check that the temperature setting (LH/RH) is unified to the driver sidetemperature setting.

Is the inspection result normal?YES >> GO TO 9.NO >> Refer to HAC-102, "Diagnosis Chart By Symptom" and perform the appropriate diagnosis.

9.CHECK AUTO MODE

1. Press the AUTO switch, and then check that “AUTO” is shown on the display. 2. Check that the discharge air and fan speed depend on ambient temperature, in-vehicle temperature and

temperature setting.Is the inspection result normal?YES >> INSPECTION ENDNO >> Refer to HAC-102, "Diagnosis Chart By Symptom" and perform the appropriate diagnosis.

Temperature Setting Trimmer INFOID:0000000004536436

DESCRIPTIONThe trimmer compensates for differences in range of ±3°C (±6°F) between temperature setting (displayed dig-itally) and temperature felt by customer.

Operating procedures for this trimmer are as per the following:1. Begin self-diagnosis STEP-5 mode. Refer to HAC-40, "Diagnosis Description".2. Press fan (UP: +) switch*1 (turn fan control dial clockwise*2) to set system in auxiliary mode.

NOTE:*1: With left and right ventilation temperature separately system.*2: Without left and right ventilation temperature separately system.

3. Display shows “61” in auxiliary mechanism. It takes approximately 3 seconds to enable setting operation.4. Turn temperature control dial (driver side) as desired. Temperature will change at a rate of 0.5°C (1.0°F)

each time a dial is turned.CAUTION:A decimal point is not indicated on the display.



< BASIC INSPECTION >Without left and right ventilation temperrature separately system

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With left and right ventilation temperature separately system

NOTE:When battery cable is disconnected or battery voltage is below 10 V, trimmer operation is canceled. Tempera-ture set becomes that of initial condition, i.e. 0°C (0°F).

Foot Position Setting Trimmer INFOID:0000000004536437

DESCRIPTIONWind distribution ratio in FOOT mode can be set.

Operating procedures for this trimmer are as per the following:1. Begin self-diagnosis STEP-5 mode. Refer to HAC-40, "Diagnosis Description".2. Press fan (UP: +) switch*1 (turn fancontrol dial clockwise*2) to set system in auxiliary mode.


JSIIA1057GB



< BASIC INSPECTION >3. Press mode switch as desired.

NOTE:When battery cable is disconnected or battery voltage is below 10 V, trimmer operation is canceled. Air distri-bution ratio set becomes that of initial condition.

Inlet Port Memory Function INFOID:0000000004536438

DESCRIPTIONWhen ignition switch is turned from OFF to ON, inlet port can be set to AUTO or manual.

Operating procedures for this trimmer are as per the following:1. Begin self-diagnosis STEP-5 mode. Refer to HAC-40, "Diagnosis Description".2. Press fan (UP: +) switch*1 (turn fan control dial clockwise*2) to set system in auxiliary mode.


3. Press intake switch as desired.

NOTE:When battery cable is disconnected or battery voltage is below 10 V, memory function is canceled. Memoryfunction set becomes that of initial condition.

JSIIA0864GB

FRE indicator REC indicatorSetting status Setting changeover

methodFRE REC

OFF ON AUTO control (Initial setting)Manual REC status is memorized. (Initial setting)

Intake switch: ONON ON Manual FRE status is memorized. Manual REC status is memorized.

ON OFF Manual FRE status is memorized. AUTO control

OFF OFF AUTO control AUTO control


COMPRESSOR CONTROL FUNCTION[AUTOMATIC AIR CONDITIONER]

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SYSTEM DESCRIPTIONCOMPRESSOR CONTROL FUNCTION


PRINCIPLE OF OPERATIONCompressor is not activated.

Functional Circuit Diagram

Functional Initial Inspection Chart×: Applicable

Fail-safe INFOID:0000000004536440

FAIL-SAFE FUNCTION• If a communication error exists between the unified meter and A/C amp., and the AV control unit and preset

switch for 30 seconds or longer, air conditioner is controlled under the following conditions:

CAN(1) : A/C switch signal: Blower fan motor switch signal

CAN(2) : A/C compressor request signal

JSIIA0918GB

Control unit Diagnosis ItemLocation

A B C D

Unified meter and A/C amp. Self-diagnosis function × – – –

ECM “ENGINE”

Self-diagnosis(CAN system diagnosis)

– – × –

Data monitor × × × –

IPDM E/R“IPDM E/R”

Self-diagnosis(CAN system diagnosis)

– – – ×

Data monitor – – × –

Auto active test – – – ×


[AUTOMATIC AIR CONDITIONER]COMPRESSOR CONTROL FUNCTION


Component Part Location INFOID:0000000004536441

ENGINE COMPARTMENT

Compressor : ONAir outlet : AUTOAir inlet : FRE (Fresh)Fan speed : AUTOSet temperature : Setting before communication error occurs



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PASSENGER COMPARTMENT

1. Refrigerant pressure sensor 2. Ambient sensor 3. Compressor (magnet clutch)

4. Compressor (ECV)

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[AUTOMATIC AIR CONDITIONER]COMPRESSOR CONTROL FUNCTION


*: With left and right ventilation temperature separately control system.

1. Intake door motor 2. Mode door motor 3. Air mix door motor (passenger side)

4. Air mix door motor (driver side)* 5. Sunload sensor 6. In-vehicle sensor

7. Unified meter and A/C amp. 8. Intake sensor 9. Blower motor

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*1: Without left and right ventilation temperature separately control system.

*2: With left and right ventilation temperature separately control system.

Component Reference

Air mix door motor*1HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEMPER-ATURE SEPARATELY CONTROL SYSTEM : Description"

Air mix door motor (driver side)*2 HAC-51, "WITH LEFT AND RIGHT VENTILATION TEMPERA-TURE SEPARATELY CONTROL SYSTEM : Description"Air mix door motor (passenger side)*2

Ambient sensor HAC-64, "Description"

Blower motor HAC-56, "Description"

Compressor HAC-60, "Description"

Intake door motor HAC-54, "Description"

Intake sensor HAC-73, "Description"

In-vehicle sensor HAC-67, "Description"

Mode door motor HAC-48, "Description"

Refrigerant pressure sensor EC-520, "Description"

Sunload sensor HAC-70, "Description"

Unified meter and A/C amp. HAC-47, "Description"


[AUTOMATIC AIR CONDITIONER]AUTOMATIC AIR CONDITIONER SYSTEM


AUTOMATIC AIR CONDITIONER SYSTEM


CONTROL SYSTEMThe control system consists of input sensors, switches, unified meter and A/C amp. (microcomputer) and out-puts. The relationship of these components is as shown in the figure below:


JPIIA1458GB


AUTOMATIC AIR CONDITIONER SYSTEM[AUTOMATIC AIR CONDITIONER]

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With left and right ventilation temperature separately control system


CONTROL OPERATION

Display ScreenThe operation status of the system is displayed on the screen.



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< SYSTEM DESCRIPTION >Preset Switch



MODE SwitchThe air discharge outlets is controlled with this switch.

Temperature Control Dial (Potentio Temperature Control) (Driver Side) The set temperature is increased or decreased with this dial.

Temperature Control Dial (Potentio Temperature Control) (Passenger Side)*1 • The set temperature is increased or decreased with this dial.• When the temperature control dial is turned, DUAL switch indicator turns ON.

AUTO Switch • The compressor, intake doors, air mix doors, mode doors and fan speed are automatically controlled so that

the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator.• When pressing AUTO switch, air inlet, air outlet, fan speed, and discharge air temperature are automatically

controlled.

Defroster (DEF) SwitchMode doors are set to the defrost position with this switch. Also, intake doors are set to the outside air position,and compressor turns ON.

A/C SwitchCompressor is ON or OFF with this switch.

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(Pressing the A/C switch when the A/C switch is ON turns OFF the A/C switch and compressor.)

FAN Switches*1

The fan speed is manually controlled with this switch. Seven speeds are available for manual control (asshown on the display screen).

FAN Control Dial*2 The fan speed is manually controlled with this switch. Seven speeds are available for manual control (asshown on the display screen).

OFF SwitchCompressor and blower are OFF, air inlet is set to FRE, and mode position is set to foot position.

Rear Window Defogger SwitchWhen indicator is ON, rear window is defogged.

Intake Switch• When intake switch is ON, FRE indicator turns ON, and air inlet is fixed to FRE.• When intake switch is pressed again, REC indicator turns ON, and air inlet is fixed to REC.• When intake switch is pressed for approximately 1.5 seconds or longer, FRE and REC indicators blink twice.

Then, automatic control mode is entered. Inlet status is displayed by indicator even during automatic con-trolled.

• When FRE indicator is turned ON, shifting mode position to D/F or DEF, or when compressor is turned fromON to OFF, intake switch is automatically turned OFF (fixed to FRE mode). REC mode can be re-entered bypressing intake switch again, and then compressor is turned ON. (Except D/F or DEF position)

DUAL Switch*1

• When the DUAL switch indicator is ON, the driver side and passenger side, temperature can each be setindependently.

• When the DUAL switch indicator is OFF, the driver side outlet and setting temperature is applied to bothsides.

NOTE:*1: With left and right ventilation temperature separately control system.*2: Without left and right ventilation temperature separately control system.




DISCHARGE AIR FLOW

SWITCHES AND THEIR CONTROL FUNCTION

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Without Left and right Ventilation Temperature Separately Control System

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< SYSTEM DESCRIPTION >With Left and right Ventilation Temperature Separately Control System

AIR CONDITIONER LAN CONTROL SYSTEMThe LAN (Local Area Network) system consists of unified meter and A/C amp., mode door motor, air mix doormotors and intake door motor.

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A configuration of these components is as shown in the figure below.

SYSTEM CONSTRUCTIONA small network is constructed between the unified meter and A/C amp., mode door motor, air mix doormotors and intake door motor. The unified meter and A/C amp. and motors are connected by data transmis-sion lines and motor power supply lines. The LAN network is built through the ground circuits of each doormotor.Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmittedthrough the data transmission lines connecting the unified meter and A/C amp. and each door motor.The following functions are contained in LCUs built into the mode door motor, the air mix door motors and theintake door motor.• Address• Motor opening angle signals• Data transmission• Motor stop and drive decision• Opening angle sensor (PBR function)• Comparison• Decision (Unified meter and A/C amp. indicated value and motor opening angle comparison)



OperationThe unified meter and A/C amp. receives data from each of the sensors. The unified meter and A/C amp.sends mode door, air mix door and intake door opening angle data to the mode door motor LCU, air mix doormotor LCUs and intake door motor LCU.The mode door motor, air mix door motors and intake door motor read their respective signals according to theaddress signal. Opening angle indication signals received from the unified meter and A/C amp. and each ofthe motor position sensors is compared by the LCUs in each door motor with the existing decision and open-

JSIIA0769GB

JSIIA0116GB

RJIA1747E



< SYSTEM DESCRIPTION >ing angles. Subsequently, HOT/COLD, DEF/VENT and FRE/REC operation is selected. The new selectiondata is returned to the unified meter and A/C amp.



Transmission Data and Transmission OrderUnified meter and A/C amp. data is transmitted consecutively to each of the doors motor following the form asshown in the figure below.

START:• Initial compulsory signal is sent to each of the door motors.

ADDRESS:• Data sent from the unified meter and A/C amp. are selected according to data-based decisions made by the

mode door motor, air mix door motors and intake door motor.• If the addresses are identical, the opening angle data and error check signals are received by the door motor

LCUs. The LCUs then make the appropriate error decision. If the opening angle data have no error, doorcontrol begins.

• If an error exists, the received data are rejected and corrected data received. Finally, door control is basedupon the corrected opening angle data.

OPENING ANGLE:• Data that shows the indicated door opening angle of each door motor.

ERROR CHECK:• In this procedure, transmitted and received data is checked for errors. Error data are then compiled. The

error check prevents corrupted data from being used by the mode door motor, the air mix door motors andthe intake door motor. Error data can be related to the following symptoms.

- Malfunction of electrical frequency- Poor electrical connections- Signal leakage from transmission lines- Signal level fluctuation

STOP SIGNAL:• At the end of each transmission, a stop operation, in-operation, or internal malfunction message is delivered

to the unified meter and A/C amp. This completes one data transmission and control cycle.

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RJIA1748E



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Component Part Location INFOID:0000000004578905

ENGINE COMPARTMENT

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RJIA1749E




PASSENGER COMPARTMENT

1. Refrigerant pressure sensor 2. Ambient sensor 3. Compressor (magnet clutch)

4. Compressor (ECV)

JSIIA0746ZZ



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1. Intake door motor 2. Mode door motor 3. Air mix door motor (passenger side)

4. Air mix door motor (driver side)* 5. Sunload sensor 6. In-vehicle sensor

7. Unified meter and A/C amp. 8. Intake sensor 9. Blower motor

JSIIA1415ZZ







Component Reference

Air mix door motor*1HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEMPER-ATURE SEPARATELY CONTROL SYSTEM : Description"

Air mix door motor (driver side)*2 HAC-51, "WITH LEFT AND RIGHT VENTILATION TEMPERA-TURE SEPARATELY CONTROL SYSTEM : Description"Air mix door motor (passenger side)*2

Ambient sensor HAC-64, "Description"

Blower motor HAC-56, "Description"

Compressor HAC-60, "Description"

Intake door motor HAC-54, "Description"

Intake sensor HAC-73, "Description"

In-vehicle sensor HAC-67, "Description"

Mode door motor HAC-48, "Description"

Refrigerant pressure sensor EC-520, "Description"

Sunload sensor HAC-70, "Description"

Unified meter and A/C amp. HAC-47, "Description"


CAN COMMUNICATION SYSTEM[AUTOMATIC AIR CONDITIONER]

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CAN COMMUNICATION SYSTEM


CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-tiplex communication line with high data communication speed and excellent error detection ability. Many elec-tronic control units are equipped onto a vehicle, and each control unit shares information and links with othercontrol units during operation (not independent). In CAN communication, control units are connected with 2communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.Each control unit transmits/receives data but selectively reads required data only. For details, refer to LAN-27,"CAN System Specification Chart".


[AUTOMATIC AIR CONDITIONER]MODE DOOR CONTROL SYSTEM


MODE DOOR CONTROL SYSTEM



The mode door is automatically controlled by the temperature setting, ambient temperature, in-vehicle temper-ature, intake temperature and amount of sunload.

SYSTEM OPERATION• The unified meter and A/C amp. receives data from each of the sensors.• The unified meter and A/C amp. sends air mix door, mode door and intake door opening angle data to the air

mix door motor LCUs, mode door motor LCU and intake door motor LCU.• The air mix door motors, mode door motor and intake door motor read their respective signals according to

the address signal. Opening angle indication signals received from the unified meter and A/C amp. and eachof the motor position sensors are compared by the LCUs in each door motor with the existing decision andopening angles.

• Subsequently, HOT/COLD, DEF/VENT and FRE/REC operation is selected. The new selection data arereturned to the unified meter and A/C amp.

Door Motor Circuit


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MODE DOOR CONTROL SYSTEM[AUTOMATIC AIR CONDITIONER]

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Mode Door Control SpecificationMode position can be selected manually by pressing MODE switchor DEF switch of the preset switch. This enables to fix a mode posi-tion. Automatic control by unified meter and A/C amp. PressingAUTO switch allows automatic control by unified meter and A/Camp. During the automatic control of mode position, a mode doorposition (VENT, B/L, FOOT, or D/F) is selected based on a target airmix door opening angle and sunload depending on a temperaturecalculated by unified meter and A/C amp. In addition, D/F is selectedto prevent windshield fogging only when ambient temperature isextremely low with mode position FOOT.

JSIIA0880GB

RJIA1778E


[AUTOMATIC AIR CONDITIONER]AIR MIX DOOR CONTROL SYSTEM


AIR MIX DOOR CONTROL SYSTEM


WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTORL SYSTEM


The air mix doors are automatically controlled so that in-vehicle temperature is maintained at a predeterminedvalue by the temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.

SYSTEM OPERATION• The unified meter and A/C amp. receives data from each of the sensors. The unified meter and A/C amp.

sends air mix doors, mode door and intake door opening angle data to the air mix door motor LCUs, modedoor motor LCU and intake door motor LCU.

• The air mix door motors, mode door motor and intake door motor read their respective signals according tothe address signal. Opening angle indication signals received from the unified meter and A/C amp. and eachof the motor position sensors are compared by the LCUs in each door motor with the existing decision andopening angles. Subsequently, HOT/COLD, DEF/VENT and FRE/REC operation is selected. The newselection data are returned to the unified meter and A/C amp.

Door Motor Circuit

JPIIA1474GB

JPIIA1478GB


AIR MIX DOOR CONTROL SYSTEM[AUTOMATIC AIR CONDITIONER]

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Air Mix Door Control SpecificationWhen ignition switch is ON, unified meter and A/C amp. continuouslyand automatically controls temperatures regardless of air conditioneroperational condition. When setting a target temperature with tem-perature control dial, unified meter and A/C amp. corrects the settemperature and decides a target air mix door opening angle. Unifiedmeter and A/C amp. controls air mix door according to the target airmix door opening angle and current air mix door opening angle forkeeping an optimum air mix door opening angle. When a tempera-ture is set at 18°C (64°F), air mix door is fixed at full cold, and whena temperature is set at 32°C (90°F), it is set at full hot.

JSIIA0775GB

JSIIA0880GB

RJIA1782E


[AUTOMATIC AIR CONDITIONER]INTAKE DOOR CONTROL SYSTEM


INTAKE DOOR CONTROL SYSTEM



The intake door is automatically controlled by the temperature setting, ambient temperature, in-vehicle tem-perature, intake temperature, amount of sunload and ON/OFF operation of the compressor.

SYSTEM OPERATIONThe intake door control judges intake door position based on the ambient temperature, the intake air tempera-ture and the in-vehicle temperature. When shifting mode position D/F, when the DEF or OFF switches arepressed, or when A/C switch is OFF, the unified meter and A/C amp. sets the intake door at the FRE position.

Door Motor Circuit


JPIIA1475GB

JSIIA0775GB


INTAKE DOOR CONTROL SYSTEM[AUTOMATIC AIR CONDITIONER]

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Intake Door Control Specification• Intake door position is basically fixed at FRE when FRE indicator

of intake switch is ON or DEF switch is ON.• Intake door position is basically fixed at REC when REC indicator

of intake switch is ON.• Intake door automatic control selects FRE, 20 - 80% FRE, or REC

depending on a target air mix door opening angle, based on in-vehicle temperature, ambient temperature, and sunload.

JSIIA0880GB

RJIA4067E


[AUTOMATIC AIR CONDITIONER]BLOWER MOTOR CONTROL SYSTEM


BLOWER MOTOR CONTROL SYSTEM



Fan speed is automatically controlled by the temperature setting, ambient temperature, in-vehicle tempera-ture, intake temperature, amount of sunload and air mix door position.With pressing AUTO switch, the blower motor starts to gradually increase air flow volume.When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flow-ing.

SYSTEM OPERATION

Automatic ModeIn the automatic mode, the blower motor speed is calculated by the unified meter and A/C amp. based on theinput from the PBR, in-vehicle sensor, sunload sensor, intake sensor and ambient sensor.When the air flow is increased, the duty ratio of the blower motor control signal is changed at 4%/sec. to pre-vent a sudden increase in air flow.In addition to manual air flow control and the usual automatic air flow control, starting air flow control, lowwater temperature starting control and high passenger compartment temperature starting control are avail-able.

Starting Fan Speed ControlStart up from COLD SOAK Condition (Automatic mode)In a cold start up condition where the engine coolant temperature is below 56°C (133°F), the blower does notoperate for a short period of time (up to 150 seconds). The exact start delay time varies depending on theambient and engine coolant temperature.In the most extreme case (very low ambient) the blower start delay is 150 seconds as described above. Afterthis delay, the blower will operate at low speed until the engine coolant temperature rises above 56°C (133°F),and then the fan speed increases to the objective speed.Start up from usual or HOT SOAK Condition (Automatic mode)The blower will begin operation momentarily after the AUTO switch is pressed. The fan speed rises graduallyto the objective speed over a time period of 3 seconds or less (actual time depends on the objective fanspeed).

Fan speed CompensationSunloadWhen the in-vehicle temperature and the set temperature are very close, the blower operates at low speed.The low speed varies depending on the sunload. During conditions of low or no sunload, the fan speed is atduty ratio 25%. During high sunload conditions, the unified meter and A/C amp. raise the fan speed (duty ratio49%).

JPIIA1477GB


BLOWER MOTOR CONTROL SYSTEM[AUTOMATIC AIR CONDITIONER]

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Fan Speed Control Specification

JPIIA0635GB


[AUTOMATIC AIR CONDITIONER]MAGNET CLUTCH CONTROL SYSTEM


MAGNET CLUTCH CONTROL SYSTEM



Unified meter and A/C amp. controls compressor operation by ambient temperature, intake air temperatureand signal from ECM.

SYSTEM OPERATIONWhen A/C switch, AUTO switch, DEF switch is pressed or when shifting mode position D/F, unified meter andA/C amp. transmits A/C switch signal and blower fan motor switch signal to ECM, via CAN communication.ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant-pressure sen-sor signal, throttle angle, etc.). If it judges compressor can be turned ON, it sends A/C compressor request sig-nal to IPDM E/R, via CAN communication.Upon receipt of A/C compressor request signal from ECM, IPDM E/R turns A/C relay ON to operate compres-sor.When sending A/C compressor request signal to IPDM E/R via CAN communication line, ECM simultaneouslysends A/C compressor feedback signal to unified meter and A/C amp. via CAN communication line.ECM sends A/C compressor feedback signal to unified meter and A/C amp., then, uses input A/C compressorfeedback signal to control air inlet.

Compressor Protection ControlECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure sidedetected by refrigerant pressure sensor is over approximately 3,119 kPa (31.8 kg/cm2, 452 psi), or belowapproximately 118 kPa (1.2 kg/cm2, 17 psi).

Low Temperature Protection ControlUnified meter and A/C amp. turns compressor ON or OFF as judged by a signal detected by ambient sensorand intake sensor.When ambient temperature is higher than −2°C (28°F), the compres-sor turns ON. The compressor turns OFF when ambient temperatureis lower than −5°C (23°F).

JPIIA1476GB

RHA094GB


MAGNET CLUTCH CONTROL SYSTEM[AUTOMATIC AIR CONDITIONER]

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When intake air temperature is higher than 1°C (34°F), the compres-sor turns ON. The compressor turns OFF when intake air tempera-ture is lower than −5°C (23°F).

SJIA0267E


[AUTOMATIC AIR CONDITIONER]DIAGNOSIS SYSTEM (UNIFIED METER & A/C AMP.)


DIAGNOSIS SYSTEM (UNIFIED METER & A/C AMP.)

Diagnosis Description INFOID:0000000004536458

SELF-DIAGNOSIS SYSTEMThe self-diagnosis system is built into the unified meter and A/C amp. to quickly locate the cause of malfunc-tions. The self-diagnosis system diagnoses sensors, door motors, blower motor, etc. by system line. Refer toapplicable sections (items) for details.

OPERATION PROCEDURE1. Start the engine (turn ignition switch ON).

NOTE:When checking the procedure except step-4, it is possible to perform in the state of ignition switch ON.

2. Press the OFF switch at 5 seconds or more (within 10 seconds after ignition switch is turned ON).3. Unified meter and A/C amp. self diagnosis mode starts.4. “Test item” are changed by the following operation.

*1: Engine must be running for compressor to operate.



5. Self-diagnosis mode is canceled by either pressing AUTO switch or turning the ignition switch OFF.

CONFORMATION METHOD

1.SET IN SELF-DIAGNOSIS MODE

1. Turn ignition switch ON.2. Set in self-diagnosis mode as per the following. Press OFF switch for at least 5 seconds Within 10 sec-

onds after starting engine (ignition switch is turned ON).NOTE:

Test item Operation

STEP-1Indicator and display screen are checked.

Former STEP-1 does not exist in this self-diagnosis function.

STEP-2Input signals from each sen-sor are checked.

Turn temperature control dial (driver side) clockwise

⇒ STEP-3

STEP-3Mode and intake door motor positions are checked.


⇒ STEP-4

Turn temperature control dial (driver side) counterclockwise

⇒ STEP-2

STEP-4*1 Motors are checked.


⇒ STEP-5 (1)


⇒ STEP-3

STEP-5 (1)Temperature detected by each sensor is checked.


⇒ STEP-4

Press intake switch ⇒ STEP-5 (2)

Press fan (UP:+) switch*2

Turn fan control dial clockwise*3⇒ AUXILIARY MECHANISM

STEP-5 (2) Communication error.


⇒ STEP-4

Press intake switch ⇒ STEP-5 (1)

Press fan (UP:+) switch*2

Turn fan control dial clockwise*3⇒ AUXILIARY MECHANISM

AUXILIARY MECHANISM

Temperature setting trimmer.Press fan (DOWN:−) switch*2

Turn fan control dial counterclockwise*3⇒ STEP-5 (1)Foot position setting trimmer.

Inlet port memory function.


DIAGNOSIS SYSTEM (UNIFIED METER & A/C AMP.)[AUTOMATIC AIR CONDITIONER]

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• If battery voltage drops below 12 V during diagnosis STEP-3, door motor speed becomes slower and as aresult, the system may generate an error even when operation is normal. Start engine before performing thisdiagnosis to avoid this.

• Former STEP-1 (indicators and display screen are checked) does not exist in this self-diagnosis function.• OFF switch may not be recognized according to the timing of pressing it. Operate OFF switch after the

intake switch indicators are turned ON.

>> GO TO 2.

2.STEP-2: SENSOR AND DOOR MOTOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT

Does code No. 20 appear on the display?YES >> GO TO 3.NO >> GO TO 11.

3.STEP-3: MODE DOOR AND INTAKE DOOR POSITIONS ARE CHECKED

Turn temperature control dial (driver side) clockwise.Does code No. 30 appear on the display?YES >> GO TO 4.NO >> GO TO 12.

4.STEP-4: OPERATION OF EACH DOOR MOTOR IS CHECKED

1. Turn temperature control dial (driver side) clockwise.2. Press DEF ( ) switch. Code No. of each door motor test is

indicated on the display.

>> GO TO 5.

5.CHECK MOTORS

Refer to the following chart and check discharge air flow, air temperature, blower motor duty ratio and com-pressor operation.

SJIA1778E

SJIA1779E

SJIA1780E

Code No. 41 42 43 44 45 46

Mode door position VENT B/L 1 B/L 2 FOOT* D/F DEF

Intake door position REC REC 20% FRE FRE FRE FRE

Air mix door position FULL COLD FULL COLD FULL HOT FULL HOT FULL HOT FULL HOT

Blower motor duty ratio 37% 91% 65% 65% 65% 91%




*:Mode door position is in a condition of FOOT mode setting trimmer (automatic control).

Checks must be made visually, by listening the sound, or by touching air outlets with hand, etc. for improperoperation.



Is this inspection result normal?YES >> GO TO 6.NO-1 >> Air outlet does not change. Refer to HAC-48, "Diagnosis Procedure".NO-2 >> Intake door does not change. Refer to HAC-54, "Diagnosis Procedure".NO-3 >> • Discharge air temperature does not change.*1 Refer to HAC-50, "WITHOUT LEFT AND RIGHT

VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure".• Discharge air temperature (driver side) does not change.*2 Refer to HAC-52, "WITH LEFT AND

RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Proce-dure".

• Discharge air temperature (passenger side) does not change.*2 Refer to HAC-52, "WITH LEFTAND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : DiagnosisProcedure".NOTE:*1: Without left and right ventilation temperature separately control system.*2: With left and right ventilation temperature separately control system.

NO-5 >> Blower motor operation is malfunctioning. Refer to HAC-57, "Diagnosis Procedure".NO-6 >> Magnet clutch does not engage. Refer to HAC-60, "Diagnosis Procedure".

6.STEP-5: TEMPERATURE OF EACH SENSOR IS CHECKED

1. Turn temperature control dial (driver side) clockwise.

Compressor (Magnet clutch)

ON ON OFF OFF ON ON

Electronic control valve (ECV) duty ratio

100% 100% 0% 0% 50% 100%

Code No. 41 42 43 44 45 46

Mode door position VENT B/L 1 B/L 2 FOOT* D/F DEF

Discharge air flow

Mode position indication


VENTFOOT

DEFFront Rear

100% — — —

53% 29% 18% —

11% 39% 24% 26%

9% 33% 21% 37%

16% — — 84%

Discharge air flow

Mode position indication Condition


VENTFOOT

DEFFront Rear

DUAL switch: OFF

100% — — —

53% 29% 18% —

11% 39% 24% 26%

9% 33% 21% 37%

16% — — 84%



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2. Code No. 51 appears on the display.

>> GO TO 7.

7.CHECK AMBIENT SENSOR

Press DEF ( ) switch one time. Temperature detected by ambientsensor is indicated on the display.NOTE:Check sensor circuit first if the temperature indicated on the displaygreatly differs from the actual temperature, and then check sensor.Is this inspection result normal?YES >> GO TO 8.NO >> Go to Ambient Sensor Circuit. Refer to HAC-64, "Diag-

nosis Procedure".

8.CHECK IN-VEHICLE SENSOR

Press DEF ( ) switch for the second time. Temperature detectedby in-vehicle sensor is indicated on the display.NOTE:Check sensor circuit first if the temperature indicated on the displaygreatly differs from the actual temperature, and then check sensor.Is this inspection result normal?YES >> GO TO 9.NO >> Go to In-vehicle Sensor Circuit. Refer to HAC-68, "Diag-

nosis Procedure".

9.CHECK INTAKE SENSOR

Press DEF ( ) switch for the third time. Temperature detected byintake sensor is indicated on the display.NOTE:Check sensor circuit first if the temperature indicated on the displaygreatly differs from the actual temperature, and then check sensor.Is this inspection result normal?YES >> GO TO 10.NO >> Go to Intake Sensor Circuit. Refer to HAC-73, "Diagno-

sis Procedure".

10.CHECK CAN COMMUNICATION ERROR

1. Press intake switch.2. CAN communication error between each unit that uses the uni-

fied meter and A/C amp. can be detected as self-diagnosisresults. (The display of each error will blink twice for 0.5 secondintervals if plural errors occur.)

Is the inspection result normal?YES >> INSPECTION ENDNO >> Go to CAN communication (Unified meter and A/C amp.

- AV control unit). Refer to MWI-41,"Diagnosis Procedure".

11.CHECK MALFUNCTIONING SENSOR AND DOOR MOTOR

Refer to the following chart for malfunctioning code No.(Corresponding code Nos. indicates 1 second each if two or more sensors and door motors malfunction.)

PJIA0151E

PJIA0152E

PJIA0153E

JPIIA1360GB



< SYSTEM DESCRIPTION >(Corresponding code Nos. indicates 0.5 second each if two door motors malfunction.)

*1: Perform self-diagnosis STEP-2 under sunshine.



When performing indoors, aim a light (more than 60 W) at sunload sensor, otherwise code No. 25 indicatesdespite that sunload sensor is functioning normally.

>> INSPECTION END

12.CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH

Mode and/or intake door motor PBR (s) is/are malfunctioning.

(Corresponding code Nos. indicates 1 second each if two or more mode or intake door motor malfunction.)*1: The following display pattern will appear if mode door motor harness connector is disconnected.31→32→Return to 31*2: The following display pattern will appear if intake door motor harness connector is disconnected.

Code No. Malfunctioning sensor and door motor (Including circuits) Reference

21 / −21 Ambient sensor HAC-64, "Diagnosis Procedure"

22 / −22 In-vehicle sensor HAC-68, "Diagnosis Procedure"

24 / −24 Intake sensor HAC-73, "Diagnosis Procedure"

25 / −25 Sunload sensor *1 HAC-70, "Diagnosis Procedure"

26 / −26

Air mix door motor PBR*2HAC-50, "WITHOUT LEFT AND RIGHT VEN-

TILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure"

Air mix door motor PBR (driver side)*3HAC-52, "WITH LEFT AND RIGHT VENTILA-TION TEMPERATURE SEPARATELY CON-

TROL SYSTEM : Diagnosis Procedure"

27 / −27 Air mix door motor PBR (passenger side)*3HAC-52, "WITH LEFT AND RIGHT VENTILA-TION TEMPERATURE SEPARATELY CON-

TROL SYSTEM : Diagnosis Procedure"

SJIA1781E

Code No. *1 *2 Mode or intake door position Reference

31 VENTMode door motor HAC-48, "Diagnosis Procedure"

32 DEF

37 FRE

Intake door motor HAC-54, "Diagnosis Procedure"38 20% FRE

39 REC



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37→38→39→Return to 37

>> INSPECTION END

SJIA1782E


[AUTOMATIC AIR CONDITIONER]POWER SUPPLY AND GROUND CIRCUIT

< DTC/CIRCUIT DIAGNOSIS >

DTC/CIRCUIT DIAGNOSISPOWER SUPPLY AND GROUND CIRCUITUNIFIED METER AND A/C AMP.

UNIFIED METER AND A/C AMP. : Diagnosis Procedure INFOID:0000000004536459

1.CHECK FUSE

Check 10A fuses [Nos. 3, 11 and 19, located in the fuse block (J/B)].NOTE:Refer to PG-94, "Fuse, Connector and Terminal Arrangement".Is the inspection result normal?YES >> GO TO 2.NO >> Check harness for short circuit and replace fuse.

2.CHECK POWER SUPPLY CIRCUIT FOR UNIFIED METER AND A/C AMP.

1. Disconnect unified meter and A/C amp. connector.2. Check voltage between unified meter and A/C amp. harness connector and ground.

Is the inspection result normal?YES >> GO TO 3.NO >> Repair harness or connector.

3.CHECK GROUND CIRCUIT FOR UNIFIED METER AND A/C AMP.

1. Turn ignition switch OFF.2. Check continuity between unified meter and A/C amp. harness connector and ground.

Is the inspection result normal?YES >> INSPECTION ENDNO >> Repair harness or connector.

(+) (−) Voltage

Unified meter and A/C amp.—

Ignition switch position

Connector Terminal OFF ACC ON

M67

41

Ground

Approx. 0 V Battery voltage Battery voltage

53 Approx. 0 V Approx. 0 V Battery voltage

54 Battery voltage Battery voltage Battery voltage

Unified meter and A/C amp.— Continuity

Connector Terminal

M6755

Ground Existed71


UNIFIED METER AND A/C AMP.[AUTOMATIC AIR CONDITIONER]

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UNIFIED METER AND A/C AMP.


COMPONENT DESCRIPTION

Unified Meter and A/C Amp. (Automatic Amplifier)The unified meter and A/C amp. (1) has a built-in microcomputerwhich processes information sent from various sensors needed forair conditioner operation. The air mix door motors, mode door motor,intake door motor, blower motor and compressor are then controlled.When the various switches and temperature control dial are oper-ated, data is input to the unified meter and A/C amp. from the AVcontrol unit using CAN communication.Self-diagnosis functions are also built into unified meter and A/Camp. to provide quick check of malfunctions in the auto air condi-tioner system.

Component Function Check INFOID:0000000004536461

1.CONFIRM SYMPTOM BY PERFORMING THE FOLLOWING OPERATIONAL CHECK

1. Press AUTO switch.2. Display should indicate AUTO. Confirm that the compressor clutch engages (sound or visual inspection).

(Discharge air and fan speed depend on ambient, in-vehicle and set temperatures.)Does magnet clutch engaged?YES >> INSPECTION ENDNO >> Go to Diagnosis Procedure. Refer to HAC-47, "Diagnosis Procedure".

Diagnosis Procedure INFOID:0000000004536462

1.INSPECTION BY FAIL-SAFE FUNCTION

1. Turn the ignition switch ON.2. After approximately 30 seconds, check that the air conditioner is operated by the fail-safe function (the

operation display of air conditioner is not performed). Refer to HAC-100, "Fail-safe".Is the fail-safe function operated? YES >> GO TO 3.NO >> GO TO 2.

2.CHECK UNIFIED METER AND A/C AMP. POWER SUPPLY CIRCUIT AND GROUND

Check unified meter and A/C amp. power supply circuit and ground circuit. Refer to HAC-46, "UNIFIEDMETER AND A/C AMP. : Diagnosis Procedure".Is the inspection result normal?YES >> GO TO 3.NO >> Repair or replace parts according to the inspection results.

3.CHECK PRESET SWITCH

Check preset switch. Refer to AV-104, "Symptom Table" (BASE AUDIO WITHOUT NAVIGATION), AV-339,"Symptom Table" (BOSE AUDIO WITHOUT NAVIGATION) or AV-603, "Symptom Table" (BOSE AUDIO WITHNAVIGATION).Is the inspection result normal?YES >> Replace unified meter and A/C amp.NO >> Repair or replace malfunctioning part.

JSIIA1072ZZ


[AUTOMATIC AIR CONDITIONER]MODE DOOR MOTOR


MODE DOOR MOTOR



Mode Door MotorThe mode door motor (1) is attached to the heater & cooling unitassembly. It rotates so that air is discharged from the outlet set bythe unified meter and A/C amp. Motor rotation is conveyed to a linkwhich activates the mode door.



1. Press MODE switch and DEF switch.2. Each position indicator should change shape.3. Confirm that discharge air comes out according to the air distribution table. Refer to VTL-5, "System

Description".NOTE:Confirm that the compressor clutch is engaged (Sound or visual inspection) and intake door position is at FREwhen D/F or DEF is selected.Is the inspection result normal?YES >> INSPECTION ENDNO >> Go to diagnosis procedure. Refer to HAC-48, "Diagnosis Procedure".


1.PERFORM SELF-DIAGNOSIS

Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description".Is the inspection result normal?YES >> GO TO 5.NO >> GO TO 2.

2.CHECK POWER SUPPLY FOR MODE DOOR MOTOR

Check voltage between mode door motor harness connector and ground.


3.CHECK SIGNAL FOR MODE DOOR MOTOR

Confirm A/C LAN signal between mode door motor harness connector and ground using an oscilloscope.

: Vehicle front

JSIIA1389ZZ

(+) (−)Voltage

(Approx.)Mode door motor

—Connector Terminal

M253 1 Ground 12 V


MODE DOOR MOTOR[AUTOMATIC AIR CONDITIONER]

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4.CHECK MODE DOOR MOTOR GROUND CIRCUIT

1. Turn ignition switch OFF.2. Disconnect mode door motor connector.3. Check continuity between mode door motor harness connector and ground.

Is the inspection result normal?YES >> Replace mode door motor.NO >> Repair harness or connector.

5.CHECK MODE DOOR CONTROL LINKAGE

Check mode door control linkage is properly installed. Refer to HAC-120, "Exploded View".Is it installed normally?YES >> INSPECTION ENDNO >> Repair or adjust control linkage.

(+) (−)

VoltageMode door motor—

Connector Terminal

M253 3 Ground

SJIA1453J

Mode door motor— Continuity

Connector Terminal

M253 2 Ground Existed


[AUTOMATIC AIR CONDITIONER]AIR MIX DOOR MOTOR


AIR MIX DOOR MOTORWITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELYCONTROL SYSTEM

WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CON-TROL SYSTEM : Description INFOID:0000000004560518


Air Mix Door MotorThe air mix door motor (1) is attached to the heater & cooling unitassembly. It rotates so that the air mix door is opened or closed to aposition set by the unified meter and A/C amp. Motor rotation is thenconveyed through a shaft and the air mix door position feedback isthen sent to the unified meter and A/C amp. by PBR built-in air mixdoor motors.

WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CON-TROL SYSTEM : Component Function Check INFOID:0000000004560519


1. Turn temperature control dial clockwise until 32°C (90°F) is displayed.2. Check for warm air at discharge air outlets.3. Turn temperature control dial counterclockwise until 18°C (64°F) is displayed.4. Check for cool air at discharge air outlets.Is the inspection result normal?YES >> INSPECTION ENDNO >> Go to diagnosis procedure. Refer to HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEM-

PERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure".

WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CON-TROL SYSTEM : Diagnosis Procedure INFOID:0000000004560520



2.CHECK POWER SUPPLY FOR AIR MIX DOOR MOTOR

Check voltage between air mix door motor harness connector and ground.


: Vehicle front

JSIIA1391ZZ

(+) (−)Voltage

(Approx.)Air mix door motor


M255 1 Ground 12 V


AIR MIX DOOR MOTOR[AUTOMATIC AIR CONDITIONER]

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3.CHECK SIGNAL FOR AIR MIX DOOR MOTOR

Confirm A/C LAN signal between air mix door motor harness connector and ground using an oscilloscope.


4.CHECK AIR MIX DOOR MOTOR GROUND CIRCUIT

1. Turn ignition switch OFF.2. Disconnect air mix door motor connector.3. Check continuity between air mix door motor harness connector and ground.

Is the inspection result normal?YES >> Replace air mix door motor.NO >> Repair harness or connector.

5.CHECK INSTALLATION OF AIR MIX DOOR MOTOR

Check air mix door motor is properly installed. Refer to HAC-120, "Exploded View".Is it installed normally?YES >> INSPECTION ENDNO >> Repair or replace air mix door motor.

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CON-TROL SYSTEM

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description INFOID:0000000004536469


Air Mix Door MotorThe air mix door motor (1) is attached to the heater & cooling unit assembly. It rotates so that the air mix dooris opened or closed to a position set by the unified meter and A/C amp. Motor rotation is then conveyedthrough a shaft and the air mix door position feedback is then sent to the unified meter and A/C amp. by PBRbuilt-in air mix door motors.

(+) (−)

VoltageAir mix door motor—

Connector Terminal

M255 3 Ground

SJIA1453J

Air mix door motor— Continuity

Connector Terminal


: Vehicle front


[AUTOMATIC AIR CONDITIONER]AIR MIX DOOR MOTOR

< DTC/CIRCUIT DIAGNOSIS >Driver side (LH)

Passenger side (RH)

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Component Function Check INFOID:0000000004536470

DRIVER SIDE


1. Turn temperature control dial (driver side) clockwise until 32°C (90°F) is displayed.2. Check for warm air at discharge air outlets.3. Turn temperature control dial (driver side) counterclockwise until 18°C (64°F) is displayed.4. Check for cool air at discharge air outlets.Is the inspection result normal?YES >> INSPECTION ENDNO >> Go to diagnosis procedure. Refer to HAC-52, "WITH LEFT AND RIGHT VENTILATION TEMPER-

ATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure".

PASSENGER SIDE


1. Turn temperature control dial (passenger side) clockwise until 32°C (90°F) is displayed.2. Check for warm air at discharge air outlets.3. Turn temperature control dial (passenger side) counterclockwise until 18°C (64°F) is displayed.4. Check for cool air at discharge air outlets.Is the inspection result normal?YES >> INSPECTION ENDNO >> Go to diagnosis procedure. Refer to HAC-52, "WITH LEFT AND RIGHT VENTILATION TEMPER-

ATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure".

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure INFOID:0000000004536471


Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description".

JSIIA1390ZZ

JSIIA1391ZZ


AIR MIX DOOR MOTOR[AUTOMATIC AIR CONDITIONER]

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Is the inspection result normal?YES >> GO TO 5.NO >> GO TO 2.

2.CHECK POWER SUPPLY FOR AIR MIX DOOR MOTOR

Check voltage between air mix door motor harness connector and ground.


3.CHECK SIGNAL FOR AIR MIX DOOR MOTOR

Confirm A/C LAN signal between air mix door motor harness connector and ground using an oscilloscope.


4.CHECK AIR MIX DOOR MOTOR GROUND CIRCUIT

1. Turn ignition switch OFF.2. Disconnect air mix door motor connector.3. Check continuity between air mix door motor harness connector and ground.

Is the inspection result normal?YES >> Replace air mix door motor.NO >> Repair harness or connector.

5.CHECK INSTALLATION OF AIR MIX DOOR MOTOR

Check air mix door motor is properly installed. Refer to HAC-120, "Exploded View".Is it installed normally?YES >> INSPECTION ENDNO >> Repair or replace air mix door motor.

(+) (−)Voltage

(Approx.)Air mix door motor


M255 (RH)M252 (LH)

1 Ground 12 V

(+) (−)

VoltageAir mix door motor—

Connector Terminal

M255 (RH)M252 (LH)

3 Ground

SJIA1453J

Air mix door motor— Continuity

Connector Terminal

M255 (RH)M252 (LH)

2 Ground Existed


[AUTOMATIC AIR CONDITIONER]INTAKE DOOR MOTOR


INTAKE DOOR MOTOR



Intake Door MotorThe intake door motor (1) is attached to the blower unit. It rotates sothat air is drawn from inlets set by the unified meter and A/C amp.Motor rotation is conveyed to a lever which activates the intake door.



1. Press intake switch.2. REC indicator turns ON.3. Listen for intake door position change (Slight change of blower sound can be heard.).4. Press intake switch again.5. FRE indicator turns ON.Is the inspection result normal?YES >> INSPECTION ENDNO >> Go to diagnosis procedure. Refer to HAC-54, "Diagnosis Procedure".




2.CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR

Check voltage between intake door motor harness connector and ground.


3.CHECK SIGNAL FOR INTAKE DOOR MOTOR

Confirm A/C LAN signal between intake door motor harness connector and ground using an oscilloscope.

: Vehicle front

JSIIA1413ZZ

(+) (−)Voltage

(Approx.)Intake door motor


M254 1 Ground 12 V


INTAKE DOOR MOTOR[AUTOMATIC AIR CONDITIONER]

C

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4.CHECK INTAKE DOOR MOTOR GROUND CIRCUIT

1. Turn ignition switch OFF.2. Disconnect intake door motor connector.3. Check continuity between intake door motor harness connector and ground.

Is the inspection result normal?YES >> Replace intake door motor.NO >> Repair harness or connector.

5.CHECK INTAKE DOOR CONTROL LINKAGE

Check intake door control linkage is properly installed. Refer to HAC-120, "Exploded View".Is it installed normally?YES >> INSPECTION ENDNO >> Repair or adjust control linkage.

(+) (−)

VoltageIntake door motor—

Connector Terminal

M254 3 Ground

SJIA1453J

Intake door motor— Continuity

Connector Terminal



[AUTOMATIC AIR CONDITIONER]BLOWER MOTOR


BLOWER MOTOR



Brush-less MotorThe blower motor utilizes a brush-less motor with a rotating magnet.Quietness is improved over previous motors where the brush wasthe point of contact and the coil rotated.

Blower Motor Circuit



1. Press fan (UP: +) switch*1 (turn fan control dial clockwise*2). Blower should operate on low speed.NOTE:*1: With left and right ventilation temperature separately control system.*2: Without left and right ventilation temperature separately control system.

2. Press fan (UP: +) switch*1 (turn control dial clockwise*2), and continue checking fan speed and fan symboluntil all speeds checked.NOTE:*1: With left and right ventilation temperature separately control system.*2: Without left and right ventilation temperature separately control system.

Is the inspection result normal?YES >> INSPECTION ENDNO >> Go to diagnosis procedure. Refer to HAC-57, "Diagnosis Procedure".

RJIA2467J

ZHA152H

RJIA4071E


BLOWER MOTOR[AUTOMATIC AIR CONDITIONER]

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1.PERFORM SELF-DIAGNOSIS STEP-4

Perform self-diagnosis STEP-4. Refer to HAC-40, "Diagnosis Description", see Nos. 1 to 5.

Does blower motor speed change according to each code No.?YES >> INSPECTION ENDNO >> GO TO 2.

2.CHECK POWER SUPPLY FOR BLOWER MOTOR

1. Disconnect blower motor connector.2. Turn ignition switch ON.3. Check voltage between blower motor harness connector and ground.


3.CHECK BLOWER MOTOR GROUND CIRCUIT

1. Turn ignition switch OFF.2. Check continuity between blower motor harness connector and ground.


4.CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND UNIFIED METER AND A/C AMP.

1. Disconnect unified meter and A/C amp. connector.2. Check continuity between blower motor harness connector and unified meter and A/C amp. harness con-

nector.

3. Check continuity between blower motor harness connector and ground.


Code No. 41 42 43 44 45 46

Blower motor duty ratio 37% 91% 65% 65% 65% 91%

(+) (−)

VoltageBlower motor—

Connector Terminal

M109 1 Ground Battery voltage

Blower motor— Continuity

Connector Terminal


Blower motor Unified meter and A/C amp.Continuity

Connector Terminal Connector Terminal

M109 2 M66 38 Existed

Blower motor— Continuity

Connector Terminal

M109 2 ground Not existed


[AUTOMATIC AIR CONDITIONER]BLOWER MOTOR


5.CHECK UNIFIED METER AND A/C AMP. OUTPUT SIGNAL

1. Reconnect blower motor connector and unified meter and A/C amp. connector.2. Turn ignition switch ON.3. Set MODE switch to VENT position.4. Change fan speed from Lo to Hi, and check duty ratios between blower motor harness connector and

ground by using an oscilloscope.NOTE:Calculate the drive signal duty ratio as shown in the figure.T2 = 1.6 ms

Is the inspection result normal?YES >> Replace blower motor after confirming the fan air flow does not change.NO >> Replace unified meter and A/C amp.

6.CHECK POWER VOLTAGE OF BLOWER RELAY

1. Turn ignition switch OFF.2. Remove blower relay. Refer to PG-94, "Fuse, Connector and Terminal Arrangement".3. Turn ignition switch ON.4. Check the voltage between blower relay fuse block terminals and ground. Refer to PG-92, "Description"

for relay terminal assignment.

Is the inspection result normal?YES >> GO TO 7.NO >> Check ignition power supply circuit. Refer to PG-51, "Wiring Diagram - IGNITION POWER SUP-

PLY -".

7.CHECK BLOWER RELAY

1. Turn ignition switch OFF.2. Install blower relay. Refer to PG-94, "Fuse, Connector and Terminal Arrangement".3. Check operation sound of the blower relay after switching ignition switch ON.Is the inspection result normal?YES >> GO TO 8.NO >> Replace blower relay.

8.CHECK FUSE

Check fuse 15A [Nos 21 and 22, located in the fuse block (J/B). Refer to PG-94, "Fuse, Connector and Termi-nal Arrangement".Is the inspection result normal?

Blower motor ConditionDuty ratio(Approx.)Connector Terminal

• fan speed: manual• Vent mode

M109 2

1st 25 %

2nd 33 %

3rd 41 %

4th 51 %

5th 61 %

6th 71 %

7th 83 %

JPLIA1210GB

(+) (−)Voltage

Blower relay —

1Ground Battery voltage

3


BLOWER MOTOR[AUTOMATIC AIR CONDITIONER]

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YES >> Repair harness or connector.NO >> Be sure to eliminate cause of malfunction before installing new fuse.

Component Inspection INFOID:0000000004536478

1.CHECK BLOWER MOTOR

1. Remove blower motor. Refer to VTL-16, "Exploded View".2. Confirm smooth rotation of the blower motor.Is the inspection result normal?YES >> INSPECTION ENDNO >> Replace blower motor.


[AUTOMATIC AIR CONDITIONER]MAGNET CLUTCH


MAGNET CLUTCH


Magnet clutch drives a compressor, by a signal of IPDM E/R.



1. Press AUTO switch.2. Display should indicate AUTO. Confirm that the magnet clutch engages (sound or visual inspection). (Dis-

charge air and fan speed depend on ambient, in-vehicle and set temperatures.)Does the magnet clutch operate?YES >> INSPECTION ENDNO >> Go to Diagnosis Procedure. Refer to HAC-60, "Diagnosis Procedure".



Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description".Is the inspection result normal?YES >> INSPECTION ENDNO >> GO TO 2.

2.PERFORM IPDM E/R AUTO ACTIVE TEST

Perform IPDM E/R auto active test. Refer to PCS-9, "Diagnosis Description".Does the magnet clutch operate?YES-1 >> WITH CONSULT-III: GO TO 6.YES-2 >> WITHOUT CONSULT-III: GO TO 5.NO >> Check 10A fuse (No. 49, located in IPDM E/R), and GO TO 3.

3.CHECK CIRCUIT CONTINUITY BETWEEN IPDM E/R AND COMPRESSOR

1. Turn ignition switch OFF.2. Disconnect IPDM E/R connector and compressor connector.3. Check continuity between IPDM E/R harness connector and compressor harness connector.


4.CHECK MAGNET CLUTCH CIRCUIT

Check for operation sound when applying battery voltage direct current to terminal.Is the inspection result normal?YES >> Replace IPDM E/R.NO >> Replace compressor.

5.CHECK REFRIGERANT PRESSURE SENSOR (WITHOUT CONSULT-III)

1. Start the engine.2. Check voltage between ECM harness connector and ground.

IPDM E/R CompressorContinuity


E7 48 F43 1 Existed


MAGNET CLUTCH[AUTOMATIC AIR CONDITIONER]

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Is the inspection result normal?YES >> Repair harness or connector.NO >> Refer to EC-520, "Diagnosis Procedure".

6.CHECK ECM INPUT SIGNAL-1

Check A/C switch signal in “Data monitor”. Refer to EC-525, "Reference Value".


7.CHECK REFRIGERANT PRESSURE SENSOR (WITH CONSULT-III)

1. Start the engine.2. Check voltage of refrigerant pressure sensor in “Data monitor”. Refer to EC-525, "Reference Value".Is the inspection result normal?YES >> GO TO 8.NO >> Refer to EC-520, "Diagnosis Procedure".

8.CHECK ECM INPUT SIGNAL-2

Check blower fan motor switch signal in “Data monitor”. Refer to EC-525, "Reference Value".


9.CHECK CAN COMMUNICATION

Check CAN communication. Refer to LAN-18, "Trouble Diagnosis Flow Chart".• ECM – IPDM E/R• ECM – Unified meter and A/C amp.Is the inspection result normal?YES >> Replace ECM.NO >> Repair or replace malfunctioning part.

(+) (−)

ConditionVoltage

(Approx.)ECM

— connector Terminal

M107 105 GroundA/C switch: ON

(Blower motor operates.)1.0 - 4.0 V

Monitor item Condition Status

AIR COND SIG A/C switch: OFF Off

A/C switch: ON On

Monitor item Condition Status

HEATER FAN SW Fan switch: OFF Off

Fan switch: ON On


[AUTOMATIC AIR CONDITIONER]ECV (ELECTRICAL CONTROL VALVE)


ECV (ELECTRICAL CONTROL VALVE)


The ECV (electrical control valve) is installed in the compressor and controls it for emitting appropriate amountof refrigerant when necessary.


1.CHECK POWER SUPPLY FOR ECV (ELECTRIC CONTROL VALVE)

1. Disconnect compressor (ECV) connector.2. Turn ignition switch ON.3. Check voltage between compressor (ECV) harness connector and ground.

Is the inspection result normal?YES >> GO TO 3NO >> GO TO 2

2.CHECK FUSE

Check power supply circuit and 10A fuse [No. 3, located in the fuse block (J/B)]. Refer to PG-94, "Fuse, Con-nector and Terminal Arrangement".Is the inspection result normal?YES >> Check harness for open circuit. Repair or replace if necessary.NO >> Replace fuse and check harness for short circuit. Repair or replace if necessary.

3.CHECK ECV CONTROL SIGNAL

1. Turn ignition switch OFF.2. Reconnect compressor (ECV) connector.3. Perform self-diagnosis. Refer to HAC-40, "Diagnosis Description".4. Set in self-diagnosis STEP-4 (Code No. 45).5. Confirm ECV control signal between unified meter and A/C amp

harness connector M67 terminal 65 and ground using an oscillo-scope.

Is the inspection result normal?YES >> Replace compressor.NO >> GO TO 4

4.CHECK CIRCUIT CONTINUITY BETWEEN ECV AND UNIFIED METER AND A/C AMP.

1. Turn ignition switch OFF.2. Disconnect compressor (ECV) connector and unified meter and A/C amp. connector.3. Check continuity between compressor (ECV) harness connector and unified meter and A/C amp harness

connector.

Is the inspection result normal?

(+) (−)

VoltageCompressor (ECV)—

Connector Terminal

F44 2 Ground Battery voltage

SJIA1765E

Compressor (ECV) Unified meter and A/C amp.Continuity


F44 3 M67 65 Existed


ECV (ELECTRICAL CONTROL VALVE)[AUTOMATIC AIR CONDITIONER]

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YES >> GO TO 5NO >> Repair the harnesses or connectors.

5.CHECK ECV

Check continuity between compressor (ECV) connector.

Is the inspection result normal?YES >> Replace the unified meter and A/C amp.NO >> Replace the compressor.

Compressor (ECV)Continuity


F44 2 F44 3 Existed


[AUTOMATIC AIR CONDITIONER]AMBIENT SENSOR


AMBIENT SENSOR



Ambient SensorThe ambient sensor (1) is attached on hood lock stay assembly. Itdetects ambient temperature and converts it into a resistance valuewhich is then input into the unified meter and A/C amp.

Ambient Sensor Circuit

AMBIENT TEMPERATURE INPUT PROCESSThe unified meter and A/C amp. equips a processing circuit for the ambient sensor input. However, when thetemperature detected by the ambient sensor increases quickly, the processing circuit retards the unified meterand A/C amp. function. It only allows the unified meter and A/C amp. to recognize an ambient temperatureincrease of 0.33°C (0.6°F) per 100 seconds.As an example, consider stopping for a few minutes after high speed driving. Although the actual ambient tem-perature has not changed, the temperature detected by the ambient sensor increases. This is because theheat from the engine compartment can radiate to the front bumper area, location of the ambient sensor.



Perform self-diagnosis function STEP-2. Refer to HAC-40, "Diagnosis Description".21 or −21 is displayed.YES >> Go to Diagnosis Procedure. Refer to HAC-64, "Diagnosis Procedure".NO >> INSPECTION END


1.CHECK VOLTAGE BETWEEN AMBIENT SENSOR AND GROUND

1. Disconnect ambient sensor connector.2. Turn ignition switch ON.3. Check voltage between ambient sensor harness connector and ground.

JSIIA0658ZZ

RJIA4088E


AMBIENT SENSOR[AUTOMATIC AIR CONDITIONER]

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2.CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND UNIFIED METER AND A/C AMP.

1. Turn ignition switch OFF.2. Disconnect unified meter and A/C amp. connector.3. Check continuity between ambient sensor harness connector and unified meter and A/C amp. harness

connector.



Check ambient sensor. Refer to HAC-65, "Component Inspection".Is the inspection result normal?YES >> Replace unified meter and A/C amp.NO >> Replace ambient sensor.

4.CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND UNIFIED METER AND A/C AMP.

1. Turn ignition switch OFF.2. Disconnect unified meter and A/C amp. connector.3. Check continuity between ambient sensor harness connector and unified meter and A/C amp. harness

connector.

4. Check continuity between ambient sensor harness connector and ground.

Is the inspection result normal?YES >> Replace unified meter and A/C amp.NO >> Repair harness or connector.



1. Turn ignition switch OFF.2. Disconnect ambient sensor connector. Refer to HAC-115, "Exploded View".3. Check resistance between ambient sensor terminals.

(+) (−)Voltage

(Approx.)Ambient sensor


E76 1 Ground 5 V

Ambient sensor Unified meter and A/C amp.Continuity


E76 2 M67 61 Existed

Ambient sensor Unified meter and A/C amp.Continuity


E76 1 M67 45 Existed

Ambient sensor— Continuity

Connector Terminal

E76 1 Ground Not existed


[AUTOMATIC AIR CONDITIONER]AMBIENT SENSOR


Is the inspection result normal?YES >> INSPECTION ENDNO >> Replace ambient sensor.

TerminalCondition

Resistance kΩTemperature °C (°F)

1 2

−15 (5) 12.73

−10 (14) 9.92

−5 (23) 7.80

0 (32) 6.19

5 (41) 4.95

10 (50) 3.99

15 (59) 3.24

20 (68) 2.65

25 (77) 2.19

30 (86) 1.81

35 (95) 1.51

40 (104) 1.27

45 (113) 1.07


IN-VEHICLE SENSOR[AUTOMATIC AIR CONDITIONER]

C

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IN-VEHICLE SENSOR



In-vehicle SensorThe in-vehicle sensor (1) is located on instrument driver lower panel.It converts variations in compartment air temperature drawn from theaspirator into a resistance value. It is then input into the unified meterand A/C amp.

In-vehicle Sensor Circuit

AspiratorThe aspirator (1) is located on driver’s side of heater & cooling unitassembly. It produces vacuum pressure due to air discharged fromthe heater & cooling unit assembly, continuously taking compartmentair in the aspirator.



JSIIA0048ZZ

RJIA4094E

: Vehicle front

JSIIA1341ZZ

RJIA1804E


[AUTOMATIC AIR CONDITIONER]IN-VEHICLE SENSOR

< DTC/CIRCUIT DIAGNOSIS >Perform self-diagnosis function STEP-2. Refer to HAC-40, "Diagnosis Description".22 or –22 is displayed.YES >> Go to Diagnosis Procedure. Refer to HAC-68, "Diagnosis Procedure".NO >> INSPECTION END


1.CHECK VOLTAGE BETWEEN IN-VEHICLE SENSOR AND GROUND

1. Disconnect in-vehicle sensor connector.2. Turn ignition switch ON.3. Check voltage between in-vehicle sensor harness connector and ground.


2.CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND UNIFIED METER AND A/C AMP.

1. Turn ignition switch OFF.2. Disconnect unified meter and A/C amp. connector.3. Check continuity between in-vehicle sensor harness connector and unified meter and A/C amp. harness

connector.



Check in-vehicle sensor. Refer to HAC-69, "Component Inspection".Is the inspection result normal?YES >> Replace unified meter and A/C amp.NO >> Replace in-vehicle sensor.

4.CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND UNIFIED METER AND A/C AMP.

1. Turn ignition switch OFF.2. Disconnect unified meter and A/C amp. connector.3. Check continuity between in-vehicle sensor harness connector and unified meter and A/C amp. harness

connector.

4. Check continuity between in-vehicle sensor harness connector and ground.

(+) (−)Voltage

(Approx.)In-vehicle sensor


M61 1 Ground 5 V

In-vehicle sensor Unified meter and A/C amp.Continuity



In-vehicle sensor Unified meter and A/C amp.Continuity



In-vehicle sensor— Continuity

Connector Terminal

M61 1 Ground Not existed


IN-VEHICLE SENSOR[AUTOMATIC AIR CONDITIONER]

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1. Turn ignition switch OFF.2. Disconnect in-vehicle sensor connector. Refer to HAC-116, "Exploded View".3. Check resistance between in-vehicle sensor terminals.

Is the inspection result normal?YES >> INSPECTION ENDNO >> Replace in-vehicle sensor.

TerminalCondition


1 2

−15 (5) 12.73

−10 (14) 9.92

−5 (23) 7.80

0 (32) 6.19

5 (41) 4.95

10 (50) 3.99

15 (59) 3.24

20 (68) 2.65

25 (77) 2.19

30 (86) 1.81

35 (95) 1.51

40 (104) 1.27

45 (113) 1.07


[AUTOMATIC AIR CONDITIONER]SUNLOAD SENSOR


SUNLOAD SENSOR



Sunload SensorThe sunload sensor (1) is located on the front defroster grille LH. Itdetects sunload entering through windshield by means of a photodiode. The sensor converts the sunload into a current value which isthen input into the unified meter and A/C amp.

Sunload Sensor Circuit

SUNLOAD INPUT PROCESSThe unified meter and A/C amp. also equips a processing circuit which averages the variations in detectedsunload over a period of time. This prevents drastic swings in the air temperature control system operationdue to small or quick variations in detected sunload.For example, consider driving along a road bordered by an occasional group of large trees. The sunloaddetected by the sunload sensor varies whenever the trees obstruct the sunlight. The processing circuit aver-ages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarilyobstructing the sunlight does not cause any change in the air temperature control system operation. On theother hand, shortly after entering a long tunnel, the system recognizes the change in sunload, and the systemreacts accordingly.





1.CHECK VOLTAGE BETWEEN SUNLOAD SENSOR AND GROUND

1. Disconnect sunload sensor connector.2. Turn ignition switch ON.3. Check voltage between sunload sensor harness connector and ground.

JSIIA1422ZZ

RJIA4099E


SUNLOAD SENSOR[AUTOMATIC AIR CONDITIONER]

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2.CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND UNIFIED METER AND A/C AMP.

1. Turn ignition switch OFF.2. Disconnect unified meter and A/C amp. connector.3. Check continuity between sunload sensor harness connector and unified meter and A/C amp. harness

connector.


3.CHECK SUNLOAD SENSOR

1. Reconnect sunload sensor connector and unified meter and A/C amp. connector.2. Check sunload sensor. Refer to HAC-71, "Component Inspection".Is the inspection result normal?YES >> Replace unified meter and A/C amp.NO >> Replace sunload sensor.

4.CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND UNIFIED METER AND A/C AMP.

1. Turn ignition switch OFF.2. Disconnect unified meter and A/C amp. connector.3. Check continuity between sunload sensor harness connector and unified meter and A/C amp. harness

connector.

4. Check continuity between sunload sensor harness connector and ground.



1.CHECK SUNLOAD SENSOR

1. Turn ignition switch ON.2. Check voltage between unified meter and A/C amp. harness connector and ground.

(+) (−)Voltage

(Approx.)Sunload sensor


M46 1 Ground 5 V

Sunload sensor Unified meter and A/C amp.Continuity



Sunload sensor Unified meter and A/C amp.Continuity



Sunload sensor— Continuity

Connector Terminal



[AUTOMATIC AIR CONDITIONER]SUNLOAD SENSOR


NOTE:Select a place where sunshine directly on it when checking sunload sensor.

Is the inspection result normal?YES >> INSPECTION ENDNO >> Replace sunload sensor.

(+) (−)

Unified meter and A/C amp.—

Connector Terminal

M67 46 Ground

SHA930E


INTAKE SENSOR[AUTOMATIC AIR CONDITIONER]

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INTAKE SENSOR



Intake SensorThe intake sensor (1) is located on the evaporator. It converts airtemperature after it passes through the evaporator (2) into a resis-tance value which is then input to the unified meter and A/C amp.

Intake Sensor Circuit





1.CHECK VOLTAGE BETWEEN INTAKE SENSOR AND GROUND

1. Disconnect intake sensor connector.2. Turn ignition switch ON.3. Check voltage between intake sensor harness connector and ground.


2.CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND UNIFIED METER AND A/C AMP.

JSIIA1423ZZ

RJIA4104E

(+) (−)Voltage

(Approx.)Intake sensor


M77 1 Ground 5 V


[AUTOMATIC AIR CONDITIONER]INTAKE SENSOR

< DTC/CIRCUIT DIAGNOSIS >1. Turn ignition switch OFF.2. Disconnect unified meter and A/C amp. connector.3. Check continuity between intake sensor harness connector and unified meter and A/C amp. harness con-

nector.



Check intake sensor. Refer to HAC-74, "Component Inspection".Is the inspection result normal?YES >> Replace unified meter and A/C amp.NO >> Replace intake sensor.

4.CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND UNIFIED METER AND A/C AMP.

1. Turn ignition switch OFF.2. Disconnect unified meter and A/C amp. connector.3. Check continuity between intake sensor harness connector and unified meter and A/C amp. harness con-

nector.

4. Check continuity between intake sensor harness connector and ground.




1. Turn ignition switch OFF.2. Disconnect intake sensor connector.3. Check resistance between intake sensor terminals.

Intake sensor Unified meter and A/C amp.Continuity



Intake sensor Unified meter and A/C amp.Continuity



Intake sensor— Continuity

Connector Terminal



INTAKE SENSOR[AUTOMATIC AIR CONDITIONER]

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Is the inspection result normal?YES >> INSPECTION ENDNO >> Replace intake sensor.

TerminalCondition


1 2

−15 (5) 12.28

−10 (14) 9.58

−5 (23) 7.55

0 (32) 6.00

5 (41) 4.81

10 (50) 3.88

15 (59) 3.16

20 (68) 2.59

25 (77) 2.14

30 (86) 1.77

35 (95) 1.48

40 (104) 1.24

45 (113) 1.05


[AUTOMATIC AIR CONDITIONER]ECM

< ECU DIAGNOSIS INFORMATION >

ECU DIAGNOSIS INFORMATIONECM

Reference Value INFOID:0000000004554978

VALUES ON THE DIAGNOSIS TOOLNOTE:• Specification data are reference values.• Specification data are output/input values which are detected or supplied by the ECM at the connector.

* Specification data may not be directly related to their components signals/values/operations.i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may showthe specification data in spite of the ignition timing not being adjusted to the specification data. This IGN TIM-ING monitors the data calculated by the ECM according to the signals input from the camshaft position sen-sor and other ignition timing related sensors.

CONSULT-III MONITOR ITEM

Monitor Item Condition Values/Status

ENG SPEED • Run engine and compare CONSULT-III value with the tachometer indication.Almost the same speed as the tachometer indication

MAS A/F SE-B1 See EC-137, "Description".

MAS A/F SE-B2 See EC-137, "Description".

B/FUEL SCHDL See EC-137, "Description".

A/F ALPHA-B1 See EC-137, "Description".

A/F ALPHA-B2 See EC-137, "Description".

COOLAN TEMP/S • Ignition switch: ONIndicates engine coolant temperature

A/F SEN1 (B1) • Engine: After warming up Maintaining engine speed at 2,000 rpm Fluctuates around 2.2 V

A/F SEN1 (B2) • Engine: After warming up Maintaining engine speed at 2,000 rpm Fluctuates around 2.2 V

HO2S2 (B1)

• Revving engine from idle up to 3,000 rpm quickly after the following conditions are met.

- Engine: After warming up- After keeping engine speed between 3,500 and 4,000 rpm for 1 minute and at

idle for 1 minute under no load

0 - 0.3 V ←→ Approx. 0.6 - 1.0 V

HO2S2 (B2)




0 - 0.3 V ←→ Approx. 0.6 - 1.0 V

HO2S2 MNTR (B1)




LEAN ←→ RICH

HO2S2 MNTR (B2)




LEAN ←→ RICH

VHCL SPEED SE• Turn drive wheels and compare CONSULT-III value with the speedometer indi-

cation.Almost the same speed as speedometer indication

BATTERY VOLT • Ignition switch: ON (Engine stopped) 11 - 14 V

ACCEL SEN 1• Ignition switch: ON

(Engine stopped)

Accelerator pedal: Fully released 0.45 - 1.00 V

Accelerator pedal: Fully depressed 4.4 - 4.8 V

ACCEL SEN 2*1 • Ignition switch: ON(Engine stopped)

Accelerator pedal: Fully released 0.45 - 1.00 V

Accelerator pedal: Fully depressed 4.3 - 4.8 V


ECM[AUTOMATIC AIR CONDITIONER]

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TP SEN 1-B1• Ignition switch: ON

(Engine stopped)• Selector lever: D (A/T) or 1st (M/T)

Accelerator pedal: Fully released More than 0.36 V

Accelerator pedal: Fully depressed Less than 4.75 V

TP SEN 2-B1*1• Ignition switch: ON




FUEL T/TMP SE • Ignition switch: ONIndicates fuel tank tempera-ture

INT/A TEMP SE • Ignition switch: ONIndicates intake air temper-ature

EVAP SYS PRES • Ignition switch: ON Approx. 1.8 - 4.8 V

FUEL LEVEL SE • Ignition switch: ONDepending on fuel level of fuel tank

START SIGNAL • Ignition switch: ON → START → ON OFF → ON → OFF

CLSD THL POS• Ignition switch: ON

(Engine stopped)

Accelerator pedal: Fully released ON

Accelerator pedal: Slightly depressed OFF

AIR COND SIG• Engine: After warming up, idle the

engine

Air conditioner switch: OFF OFF

Air conditioner switch: ON(Compressor operates.)

ON

P/N POSI SW • Ignition switch: ONSelector lever: P or N (A/T), Neutral (M/T) ON

Selector lever: Except above OFF

PW/ST SIGNAL• Engine: After warming up, idle the

engine

Steering wheel: Not being turned OFF

Steering wheel: Being turned ON

LOAD SIGNAL • Ignition switch: ON

Rear window defogger switch: ONand/orLighting switch: 2nd position

ON

Rear window defogger switch and lighting switch: OFF

OFF

IGNITION SW • Ignition switch: ON → OFF → ON ON → OFF → ON

HEATER FAN SW• Engine: After warming up, idle the

engine

Heater fan switch: ON ON

Heater fan switch: OFF OFF

BRAKE SW • Ignition switch: ONBrake pedal: Fully released OFF

Brake pedal: Slightly depressed ON

INJ PULSE-B1

• Engine: After warming up• Selector lever: P or N (A/T), Neu-

tral (M/T)• Air conditioner switch: OFF• No load

Idle 2.0 - 3.0 msec

2,000 rpm 1.9 - 2.9 msec

INJ PULSE-B2



Idle 2.0 - 3.0 msec

2,000 rpm 1.9 - 2.9 msec

IGN TIMING



Idle 7° BTDC

2,000 rpm 25° - 45° BTDC

CAL/LD VALUE



Idle 5% - 35%

2,500 rpm 5% - 35%





MASS AIRFLOW



Idle 2.0 - 6.0 g·m/s

2,500 rpm 7.0 - 20.0 g·m/s

PURG VOL C/V



Idle(Accelerator pedal: Not depressed even slightly, after engine starting.)

0%

2,000 rpm —

INT/V TIM (B1)



Idle − 5 - 5°CA

2,000 rpm Approx. 0 - 30°CA

INT/V TIM (B2)



Idle − 5 - 5°CA

2,000 rpm Approx. 0 - 30°CA

INT/V SOL (B1)



Idle 0 - 2%

2,000 rpm Approx. 0 - 50%

INT/V SOL (B2)



Idle 0 - 2%

2,000 rpm Approx. 0 - 50%

TP SEN 1-B2• Ignition switch: ON




TP SEN 2-B2*1• Ignition switch: ON




AIR COND RLY• Engine: After warming up, idle the

engine

Air conditioner switch: OFF OFF

Air conditioner switch: ON(Compressor operates)

ON

FUEL PUMP RLY

• For 1 second after turning ignition switch: ON• Engine running or cranking

ON

• Except above OFF

VENT CONT/V • Ignition switch: ON OFF

THRTL RELAY • Ignition switch: ON ON

HO2S2 HTR (B1)

• Engine speed: Below 3,600 rpm after the following conditions are met.- Engine: After warming up- Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at


ON

• Engine speed: Above 3,600 rpm OFF

HO2S2 HTR (B2)

• Engine speed: Below 3,600 rpm after the following conditions are met.- Engine: After warming up- Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at


ON

• Engine speed: Above 3,600 rpm OFF

I/P PULLY SPD • Vehicle speed: More than 20 km/h (12 MPH)Almost the same speed as the tachometer indication




C

D

E

F

G

H

J

K

L

M

A

B

AC

N

O

P


H

VEHICLE SPEED• Turn drive wheels and compare CONSULT-III value with the speedometer indi-

cation.Almost the same speed as the speedometer indication

IDL A/V LEARN • Engine: Running

Idle air volume learning has not been per-formed yet.

YET

Idle air volume learning has already been performed successfully.

CMPLT

SNOW MODE SW • Ignition switch: ONSnow mode switch: Pressed ON

Snow mode switch: Released OFF

ENG OIL TEMP • Engine: After warming up More than 70°C (158°F)

TRVL AFTER MIL • Ignition switch: ONVehicle has traveled after MIL has illumi-nated.

0 - 65,535 km(0 - 40,723 miles)

A/F S1 HTR (B1)• Engine: After warming up, idle the engine

(More than 140 seconds after starting engine)4 - 100%

A/F S1 HTR (B2)• Engine: After warming up, idle the engine

(More than 140 seconds after starting engine)4 - 100%

AC PRESS SEN• Engine: Idle• Both A/C switch and blower fan switch: ON (Compressor operates)

1.0 - 4.0 V

VHCL SPEED SE• Turn drive wheels and compare CONSULT-III value with the speedometer indi-

cation.Almost the same speed as the speedometer indication

SET VHCL SPD • Engine: Running ASCD: OperatingThe preset vehicle speed is displayed

MAIN SW • Ignition switch: ONMAIN switch: Pressed ON

MAIN switch: Released OFF

CANCEL SW • Ignition switch: ONCANCEL switch: Pressed ON

CANCEL switch: Released OFF

RESUME/ACC SW • Ignition switch: ON

RESUME/ACCELERATE switch: Pressed

ON

RESUME/ACCELERATE switch: Re-leased

OFF

SET SW • Ignition switch: ONSET/COAST switch: Pressed ON

SET/COAST switch: Released OFF

BRAKE SW1(ICC/ASCD brake switch)

• Ignition switch: ONBrake pedal: Fully released ON

Brake pedal: Slightly depressed OFF

BRAKE SW2(Stop lamp switch)

• Ignition switch: ONBrake pedal: Fully released OFF

Brake pedal: Slightly depressed ON

DIST SW • Ignition switch: ONDISTANCE switch: Pressed ON

DISTANCE switch: Released OFF

CRUISE LAMP • Ignition switch: ONMAIN switch: Pressed at the 1st time → at the 2nd time

ON → OFF

BAT CUR SEN

• Engine speed: Idle

• Battery: Fully charged*2

• Selector lever: P or N (A/T), Neutral (M/T)• Air conditioner switch: OFF• No load

Approx. 2,600 - 3,500 mV

ALT DUTY • Engine: Idle 0 - 80%

ATOM PRES SEN • This item is displayed but is not applicable to this model.

BRAKE BST PRES SE

• This item is displayed but is not applicable to this model.





*1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differfrom ECM terminals voltage signal.

*2: Before measuring the terminal voltage, confirm that the battery is fully charged. Refer to PG-3, "How to Handle Battery".

TERMINAL LAYOUT

PHYSICAL VALUES

NOTE:• ECM is located behind the instrument assist lower panel. For this inspection, remove passenger side instru-

ment lower panel.• Specification data are reference values and are measured between each terminal and ground.• Pulse signal is measured by CONSULT-III.

VVEL POSITION SEN-B1



Idle Approx. 0.25 - 1.40 V

When revving engine up to 2,000 rpm quickly

Approx. 0.25 - 4.75 V

VVEL POSITION SEN-B2



Idle Approx. 0.25 - 1.40 V


Approx. 0.25 - 4.75 V

VVEL TIM-B1



Idle Approx. 0 - 20 deg


Approx. 0 - 90 deg

VVEL TIM-B2



Idle Approx. 0 - 20 deg


Approx. 0 - 90 deg

VVEL LEARN• Ignition switch: OFF → ON

(After warming up)

VVEL learning has not been performed yet.

YET

VVEL learning has already been per-formed successfully.

DONE

VVEL SEN LEARN-B1

• VVEL learning has already been performed successfully Approx. 0.30 - 0.80 V

VVEL SEN LEARN-B2

• VVEL learning has already been performed successfully Approx. 0.30 - 0.80 V

A/F ADJ-B1 • Engine: Running −0.330 - 0.330

A/F ADJ-B2 • Engine: Running −0.330 - 0.330

FAN DUTY • Engine: Running 0 - 100%

ALT DUTY SIG• Power generation voltage variable control: Operating ON

• Power generation voltage variable control: Not operating OFF


JMBIA0070ZZ



C

D

E

F

G

H

J

K

L

M

A

B

AC

N

O

P


H

Terminal No.(Wire color)

Description

ConditionValue

(Approx.)+ -– Signal name

Input/Output

1(W)

128(B)

A/F sensor 1 heater(bank 1)

Output

[Engine is running]• Warm-up condition• Idle speed

(More than 140 seconds after starting engine)

2.9 - 8.8 V

2(G)

128(B)

Throttle control motor (Open) (bank 1)

Output

[Ignition switch: ON]• Engine stopped• Selector lever: D (A/T) or 1st (M/T)• Accelerator pedal: Fully depressed

0 - 14 V

[Ignition switch: ON]• Engine stopped• Selector lever: D (A/T) or 1st (M/T)• Accelerator pedal: Fully released

0 - 14 V

3(R)

128(B)

Throttle control motor power supply (bank 1)

Input [Ignition switch: ON]BATTERY VOLTAGE(11 - 14 V)

4(BR)

128(B)

Throttle control motor (Close) (bank 1)

Output

[Ignition switch: ON]• Engine stopped• Selector lever: D (A/T) or 1st (M/T)• Accelerator pedal: In the middle of re-

leasing operation

0 - 14 V

5(GR)

128(B)

A/F sensor 1 heater(bank 2)

Output


(More than 140 seconds after starting engine)

2.9 - 8.8 V

8(B)

— ECM ground — — —

JMBIA0030GB

JMBIA0031GB

JMBIA0032GB

JMBIA0033GB

JMBIA0030GB




11(GR)

128(B)

Ignition signal No. 4

Output


NOTE:The pulse cycle changes depending on rpm at idle

0 - 0.2 V

12(L)


15(V)


16(G)


[Engine is running]• Warm-up condition• Engine speed: 2,000 rpm

0.1 - 0.4 V

19(SB)


20(Y)


17(P)

128(B)

Heated oxygen sensor 2 heater (bank 1)

Output

[Engine is running]• Engine speed: Below 3,600 rpm after

the following conditions are met- Engine: after warming up- Keeping the engine speed between

3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load

10 V

[Ignition switch: ON]• Engine stopped[Engine is running]• Engine speed: Above 3,600 rpm

BATTERY VOLTAGE(11 - 14 V)

18(W)

128(B)

Intake valve timing con-trol solenoid valve (bank 1)

Output



[Engine is running]• Warm-up condition• Engine speed: 2,000rpm

7 - 12 V


Description

ConditionValue


Input/Output

JMBIA0035GB

JMBIA0036GB

JMBIA0037GB

JMBIA0038GB



C

D

E

F

G

H

J

K

L

M

A

B

AC

N

O

P


H

21(GR)

128(B)

EVAP canister purge vol-ume control solenoid valve

Output

[Engine is running]• Idle speed• Accelerator pedal: Not depressed even

slightly, after engine starting

BATTERY VOLTAGE

(11 - 14 V)

[Engine is running]• Engine speed: About 2,000 rpm (More

than 100 seconds after starting engine)

BATTERY VOLTAGE

(11 - 14 V)

22(R)

128(B)

Fuel pump relay Output

[Ignition switch: ON]• For 1 second after turning ignition switch

ON[Engine is running]

0 - 1.5 V

[Ignition switch: ON]• More than 1 second after turning ignition

switch ON


24(P)

128(B)

ECM relay(Self shut-off)

Output

[Engine is running][Ignition switch: OFF]• A few seconds after turning ignition

switch OFF

0 - 1.5 V

[Ignition switch: OFF]• More than a few seconds after turning

ignition switch OFF


25(O)

128(B)

Throttle control motor re-lay

Output[Ignition switch: ON → OFF]

0 - 1.0 V ↓BATTERY VOLTAGE (11 - 14 V) ↓0 V

[Ignition switch: ON] 0 - 1.0 V

28(BR)

128(B)

VVEL actuator motor re-lay abort signal[VVEL control module]

Output[Engine is running]• Warm-up condition• Idle speed

0 V

29(G)

128(B)

Intake valve timing con-trol solenoid valve (bank 2)

Output



[Engine is running]• Warm-up condition• Engine speed: 2,000rpm

7 - 12 V


Description

ConditionValue


Input/Output

JMBIA0039GB

JMBIA0040GB

JMBIA0038GB




30(Y)

40(R)

Throttle position sensor 1 (bank 1)

Input


More than 0.36 V


Less than 4.75 V

31(R)

48(B)


Input


More than 0.36 V


Less than 4.75 V

33(SB)

128(B)

Heated oxygen sensor 2 heater (bank 2)

Output

[Engine is running]• Engine speed: Below 3,600 rpm after

the following conditions are met- Engine: after warming up- Keeping the engine speed between


10 V

[Ignition switch: ON]• Engine stopped[Engine is running]• Engine speed: Above 3,600 rpm


34(B)

40(R)


Input


Less than 4.75 V


More than 0.36 V

35(W)

48(B)


Input


Less than 4.75 V


More than 0.36 V

36(O)

—Sensor ground[Brake booster pressure sensor]

— — —


Description

ConditionValue


Input/Output

JMBIA0037GB



C

D

E

F

G

H

J

K

L

M

A

B

AC

N

O

P


H

37(W)

128(B)

Crankshaft position sen-sor (POS)

Input



4.0 - 5.0 V

[Engine is running]• Engine speed: 2,000 rpm

4.0 - 5.0 V

38(O)

96(P)

Manifold absolute pres-sure (MAP) sensor

Input


1.2 V


1.5 V

39(P)

36(O)

Brake booster pressure sensor

Input

[Engine is running]• Warm-up condition• Idle speed• Brake pedal: Fully released

1.2 V

[Engine is running]• Warm-up condition• Idle speed• Brake pedal: Fully depressed

3.0 V

40(R)

—Sensor ground[Throttle position sensor (bank 1)]

— — —

43(G)

48(B)

Sensor power supply[Throttle position sensor (bank 2)]

— [Ignition switch: ON] 5 V

44(L)

40(R)

Sensor power supply[Throttle position sensor (bank 1)]


45(LG)

36(O)

Sensor power supply[Brake booster pressure sensor]


46(R)

128(B)

Sensor power supply[Crankshaft position sensor (POS)]


47(Y)

—Sensor ground[Crankshaft position sensor (POS)]

— — —

48(B)

—Sensor ground[Throttle position sensor (bank 2)]

— — —


Description

ConditionValue


Input/Output

JMBIA0041GB

JMBIA0042GB




49(GR)

128(B)

Throttle control motor (Close) (bank 2)

Output

[Ignition switch: ON]• Engine stopped• Selector lever: D (A/T) or 1st (M/T)• Accelerator pedal: In the middle of re-

leasing operation

0 - 14 V

50(V)

128(B)

Throttle control motor (Open) (bank 2)

Output


0 - 14 V


0 - 14 V

52(R)

128(B)

Throttle control motor power supply (bank 2)

Input [Ignition switch: ON]BATTERY VOLTAGE(11 - 14 V)

53(W)

128(B)

Ignition switch Input

[Ignition switch: OFF] 0 V

[Ignition switch: ON]BATTERY VOLTAGE(11 - 14 V)

54(Y)

—CAN communication line[VVEL control module]

Input/output

— —

55(LG)

—CAN communication line[VVEL control module]

Input/output

— —

57(L)

128(B)

A/F sensor 1 (bank 1) Input [Ignition switch: ON] 2.2 V

59(O)

128(B)

Camshaft position sen-sor (PHASE) (bank 1)

Input



3.0 - 5.0 V


3.0 - 5.0 V


Description

ConditionValue


Input/Output

JMBIA0033GB

JMBIA0031GB

JMBIA0032GB

JMBIA0045GB

JMBIA0046GB



C

D

E

F

G

H

J

K

L

M

A

B

AC

N

O

P


H

60(G)

128(B)

Sensor power supply[Camshaft position sen-sor (PHASE) (bank 1), Manifold absolute pres-sure (MAP) sensor, Pow-er steering pressure sensor]


61(R)

128(B)

A/F sensor 1 (bank 1) Input[Engine is running]• Warm-up condition• Engine speed: 2,000 rpm

1.8 VOutput voltage varies with air fuel ratio.

63(L)

128(B)

Camshaft position sen-sor (PHASE) (bank 2)

Input



3.0 - 5.0 V


3.0 - 5.0 V

64(SB)

128(B)

Sensor power supply[Camshaft position sen-sor (PHASE) (bank 2), Battery current sensor]


65(LG)

128(B)

A/F sensor 1 (bank 2) Input [Ignition switch: ON] 2.2 V

66(V)

128(B)

A/F sensor 1 (bank 2) Input[Engine is running]• Warm-up condition• Engine speed: 2,000 rpm

1.8 VOutput voltage varies with air fuel ratio.

67(P)

128(B)

Intake air temperature sensor

Input [Engine is running]0 - 4.8 VOutput voltage varies with intake air temperature.

68(LG)

—

Sensor ground[Mass air flow sensor (bank 1), Intake air tem-perature sensor]

— — —

69(W)

128(B)

Knock sensor (bank 2) Input[Engine is running]• Idle speed 2.5 V*1

71(Y)

128(B)

Engine coolant tempera-ture sensor

Input [Engine is running]0 - 4.8 VOutput voltage varies with engine coolant temperature.

72(—)

—Sensor ground(Knock sensor)

— — —

73(W)

128(B)

Knock sensor (bank 1) Input[Engine is running]• Idle speed 2.5 V*1


Description

ConditionValue


Input/Output

JMBIA0045GB

JMBIA0046GB




76(W)

128(B)

Heated oxygen sensor 2 (bank 1)

Input

[Engine is running]• Revving engine from idle to 3,000 rpm

quickly after the following conditions are met

- Engine: after warming up- Keeping the engine speed between


0 - 1.0 V

77(SB)

68(LG)

Mass air flow sensor (bank 1)

Input


0.7 - 1.2 V


1.3 - 1.7 V

78(G)

84(B)

Engine oil temperature sensor

Input [Engine is running]0 - 4.8 VOutput voltage varies with engine oil temperature.

79(BR)

94(Y)

Mass air flow sensor (bank 2)

Input


0.7 - 1.2 V


1.3 - 1.7 V

80(O)

128(B)

Heated oxygen sensor 2 (bank 2)

Input

[Engine is running]• Revving engine from idle to 3,000 rpm

quickly after the following conditions are met

- Engine: after warming up- Keeping the engine speed between


0 - 1.0 V

81(R)

128(B)

Fuel injector No. 3

Output



BATTERY VOLTAGE

(11 - 14 V)

82(V)

Fuel injector No. 6

85(BR)

Fuel injector No. 2

86(W)

Fuel injector No. 5


BATTERY VOLTAGE

(11 - 14 V)

89(GR)

Fuel injector No. 1

90(O)

Fuel injector No. 4

84(B)

—

Sensor ground(Heated oxygen sensor 2, Engine coolant tem-perature sensor, Engine oil temperature sensor)

— — —


Description

ConditionValue


Input/Output

JMBIA0047GB

JMBIA0048GB



C

D

E

F

G

H

J

K

L

M

A

B

AC

N

O

P


H

87(Y)

96(P)

Power steering pressure sensor

Output

[Engine is running]• Steering wheel: Being turned

0.5 - 4.5 V

[Engine is running]• Steering wheel: Not being turned

0.4 - 0.8 V

91(SB)

95(G)

Battery current sensor Input[Engine is running]

• Battery: Fully charged*2

• Idle speed2.6 - 3.5 V

92(G)

—Sensor ground[Camshaft position sen-sor (PHASE) (bank 2)]

— — —

93(P)

128(B)

Power supply for ECM (Back-up)

Input [Ignition switch: OFF]BATTERY VOLTAGE(11 - 14 V)

94(Y)

—Sensor ground[Mass air flow sensor (bank 2)]

— — —

95(G)

—Sensor ground(Battery current sensor)

— — —

96(P)

—

Sensor ground[Camshaft position sen-sor (PHASE) (bank 1),Manifold absolute pressure (MAP) sensor, Power steering pressure sensor]

— — —

97(R)

100(W)

Accelerator pedal posi-tion sensor 1

Input

[Ignition switch: ON]• Engine stopped• Accelerator pedal: Fully released

0.45 - 1.00 V

[Ignition switch: ON]• Engine stopped• Accelerator pedal: Fully depressed

4.2 - 4.8 V

98(P)

104(GR)

Accelerator pedal posi-tion sensor 2

Input

[Ignition switch: ON]• Engine stopped• Accelerator pedal: Fully released

0.22 - 0.50 V

[Ignition switch: ON]• Engine stopped• Accelerator pedal: Fully depressed

2.1 - 2.5 V

99(L)

100(W)

Sensor power supply(Accelerator pedal posi-tion sensor 1)


100(W)

—Sensor ground(Accelerator pedal posi-tion sensor 1)

— — —


Description

ConditionValue


Input/Output




101(SB)

108(Y)

ICC steering switch(models with ICC sys-tem)

Input

[Ignition switch: ON]• ICC steering switch: OFF

4.3 V

[Ignition switch: ON]• MAIN switch: Pressed

0 V

[Ignition switch: ON]• CANCEL switch: Pressed

1.3 V

[Ignition switch: ON]• RESUME/ACCELERATE switch:

Pressed3.7 V

[Ignition switch: ON]• SET/COAST switch: Pressed

3 V

[Ignition switch: ON]• DISTANCE switch: Pressed

2.2 V

101(SB)

108(Y)

ASCD steering switch(models with ASCD sys-tem)

Input

[Ignition switch: ON]• ASCD steering switch: OFF

4 V

[Ignition switch: ON]• MAIN switch: Pressed

0 V

[Ignition switch: ON]• CANCEL switch: Pressed

1 V

[Ignition switch: ON]• RESUME/ACCELERATE switch:

Pressed3 V

[Ignition switch: ON]• SET/COAST switch: Pressed

2 V

102(GR)

112(SB)

EVAP control system pressure sensor

Input [Ignition switch: ON] 1.8 - 4.8 V

103(G)

104(GR)

Sensor power supply(Accelerator pedal posi-tion sensor 2)


104(GR)

—Sensor ground(Accelerator pedal posi-tion sensor 2)

— — —

105(L)

116(P)

Refrigerant pressure sensor

Input

[Engine is running]• Warm-up condition• Both A/C switch and blower fan motor

switch: ON (Compressor operates)

1.0 - 4.0 V

106(W)

128(B)

Fuel tank temperature sensor

Input [Engine is running]0 - 4.8 VOutput voltage varies with fuel tank temperature.

107(BR)

112(SB)

Sensor power supply(EVAP control system pressure sensor,Refrig-erant pressure sensor)


108(Y)

—Sensor ground(ASCD/ICC steering switch)

— — —

109(G)

128(B)

PNP signal Input

[Ignition switch: ON]• Selector lever: P or N (A/T), Neutral (M/

T)


[Ignition switch: ON]• Selector lever: Except above

0 V


Description

ConditionValue


Input/Output



C

D

E

F

G

H

J

K

L

M

A

B

AC

N

O

P


H

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

*1: This may vary depending on internal resistance of the tester.

**2: Before measuring the terminal voltage, confirm that the battery is fully charged. Refer to PG-3, "How to Handle Battery".

110(R)

128(B)

Engine speed output sig-nal

Output



1 V

[Engine is running]• Engine speed is 2,000 rpm

1 V

112(SB)

—

Sensor ground(EVAP control system pressure sensor, Refrig-erant pressure sensor)

— — —

113(P)

— CAN communication lineInput/Output

— —

114(L)

— CAN communication lineInput/Output

— —

117(V)

128(B)

Data link connectorInput/Output

— —

121(LG)

128(B)

EVAP canister vent con-trol valve

Output [Ignition switch: ON]BATTERY VOLTAGE(11 - 14 V)

122(P)

128(B)

Stop lamp switch Input

[Ignition switch: OFF]• Brake pedal: Fully released

0 V

[Ignition switch: OFF]• Brake pedal: Slightly depressed


123(B)124(B)


125(R)

128(B)

Power supply for ECM Input [Ignition switch: ON]BATTERY VOLTAGE(11 - 14 V)

126(BR)

128(B)

ICC brake switch (mod-els with ICC system)ASCD brake switch (models with ASCD sys-tem)

Input

[Ignition switch: ON]• Brake pedal: Slightly depressed

0 V

[Ignition switch: ON]• Brake pedal: Fully released


127(B)128(B)



Description

ConditionValue


Input/Output

JMBIA0076GB

JMBIA0077GB


[AUTOMATIC AIR CONDITIONER]UNIFIED METER AND A/C AMP.



Reference Value INFOID:0000000004536499

TERMINAL LAYOUT

PHYSICAL VALUES

JSIIA0097ZZ


Description

ConditionValue

(Approx.)+ − Signal name

Input/Output

38(P)

Ground Blower motor control signal Output• Ignition switch ON• Fan speed: 1st speed (man-

ual)

41(L)

Ground ACC power supply — Ignition switch ACC Battery voltage

43(R)

Ground Intake sensor signal Input Ignition switch ON0 – 4.8 V

Output voltage varies with intake temperature.

44(LG)

Ground In-vehicle sensor signal Input Ignition switch ON0 – 4.8 V


45(V)

Ground Ambient sensor signal Input Ignition switch ON0 – 4.8 V


46(O)

Ground Sunload sensor signal Input Ignition switch ON0 – 4.8 V


53(W)

Ground Ignition power supply — Ignition switch ON Battery voltage

54(Y)

Ground Battery power supply — Ignition switch OFF Battery voltage

55(B)

Ground Ground — Ignition switch ON 0 V

56(L)

Ground CAN-H — — —

59(Y)

Ground Intake sensor ground — — 0 V

60(L)

Ground In-vehicle sensor ground — Ignition switch ON 0 V

JSIIA0096ZZ



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61(R)

Ground Ambient sensor ground — Ignition switch ON 0 V

62(SB)

Ground Sunload sensor ground — Ignition switch ON 0 V

65(O)

GroundECV (Electrical Control Valve) signal

Output• Ignition switch ON• Self-diagnosis. STEP-4

(Code No. 45)

69(L)

Ground A/C LAN signalInput/Output

Ignition switch ON

70(R)

GroundEach door motor power sup-ply

Output Ignition switch ON 12 V

71(GR)

Ground Ground — Ignition switch ON 0 V

72(P)

Ground CAN-L — — —


Description

ConditionValue

(Approx.)+ − Signal name

Input/Output

SJIA1607E

SJIA1453J




Wiring Diagram - AIR CONDITIONER CONTROL SYSTEM - INFOID:0000000004536500

JCIWM0351GB



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JCIWM0352GB




JCIWM0353GB



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JCIWM0354GB




JCIWM0355GB



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JCIWM0356GB




Fail-safe INFOID:0000000004536501

FAIL-SAFE FUNCTION• If a communication error exists between the unified meter and A/C amp., and the AV control unit and preset

switch for 30 seconds or longer, air conditioner is controlled under the following conditions:

JCIWM0357GB



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Compressor : ONAir outlet : AUTOAir inlet : FRE (Fresh)Fan speed : AUTOSet temperature : Setting before communication error occurs


[AUTOMATIC AIR CONDITIONER]AIR CONDITIONER CONTROL


SYMPTOM DIAGNOSISAIR CONDITIONER CONTROL

Diagnosis Chart By Symptom INFOID:0000000004536502



Symptom Reference

A/C system does not activate. Go to Trouble Diagnosis Procedure for A/C System. HAC-47, "Diagnosis Procedure"

A/C system cannot be controlled. Go to Preset Switch System.

AV-104, "Symptom Table" (BASE AUDIO WITHOUT NAVIGATION), AV-339, "Symptom Table" (BOSE AUDIO WITHOUT NAVIGATION)

or AV-603, "Symptom Table" (BOSE AUDIO WITH NAVIGA-

TION)

Air outlet does not change.Go to Trouble Diagnosis Procedure for Mode Door Motor. (LAN)

HAC-48, "Diagnosis Procedure"Mode door motor does not operate normally.

Discharge air temperature does not

change.*1 Go to Trouble Diagnosis Procedure for Air Mix Door Motor. (LAN)

HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERA-TURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure"

Air mix door motor does not operate

normally.*1

Discharge air temperature (driver

side) does not change.*2 Go to Trouble Diagnosis Procedure for Air Mix Door Motor (driver side). (LAN)

HAC-52, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYS-

TEM : Diagnosis Procedure"

Air mix door motor (driver side)

does not operate normally.*2

Discharge air temperature (passen-

ger side) does not change.*2 Go to Trouble Diagnosis Procedure for Air Mix Door Motor (passenger side). (LAN)Air mix door motor (passenger side)

does not operate normally.*2

Intake door does not change.Go to Trouble Diagnosis Procedure for Intake Door Motor. (LAN)

HAC-54, "Diagnosis Procedure"Intake door motor does not operate normally.

Blower motor operation is malfunc-tioning.

Go to Trouble Diagnosis Procedure for Blower Motor. HAC-57, "Diagnosis Procedure"

Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch. HAC-60, "Diagnosis Procedure"

Insufficient cooling

Go to Trouble Diagnosis Procedure for Insufficient Cooling. HAC-103, "Inspection procedure"No cool air comes out.(Air flow volume is normal.)

Insufficient heating

Go to Trouble Diagnosis Procedure for Insufficient Heating. HAC-105, "Inspection procedure"No warm air comes out.(Air flow volume is normal.)

Noise Go to Trouble Diagnosis Procedure for Noise. HAC-107, "Inspection procedure"

Self-diagnosis function cannot be performed normally.

Go to Trouble Diagnosis Procedure for Self-diagnosis. HAC-109, "Inspection procedure"

Memory function does not operate normally.

Go to Trouble Diagnosis Procedure for Memory Function. HAC-110, "Inspection procedure"


INSUFFICIENT COOLING[AUTOMATIC AIR CONDITIONER]

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INSUFFICIENT COOLING


Symptom• Insufficient cooling• No cool air comes out. (Air flow volume is normal.)

Inspection procedure INFOID:0000000004536504

1.CHECK WITH A GAUGE OF RECOVERY/RECYCLING RECHARGING EQUIPMENT

Connect the recovery/recycling recharging equipment to the vehicle and perform the pressure inspection withthe gauge.Is there refrigerant?YES >> GO TO 2.NO-1 >> Check for refrigerant leakages with the refrigerant leakage detecting fluorescent leak detector.

Refer to HA-35, "Inspection".NO-2 >> GO TO 2 after repairing or replacing the parts according to the inspection results.

2.CHECK CHARGED REFRIGERANT AMOUNT

1. Connect recovery/recycling recharging equipment to the vehicle and discharge the refrigerant. Refer toHA-26, "Collection and Charge".

2. Recharge with the proper amount of refrigerant. Refer to HA-26, "Collection and Charge".3. Perform the inspection with the refrigerant leakage detecting fluorescent leak detector. Refer to HA-35,

"Inspection".Is the inspection result normal?YES >> GO TO 3.NO >> Refill the refrigerant and repair or replace the parts according to the inspection results.

3.PERFORM THE PERFORMANCE TEST

Connect recovery/recycling recharging equipment to the vehicle and perform the performance test. Refer toHA-33, "Performance Chart".Is the inspection result normal?YES >> GO TO 4.NO >> Perform the diagnosis with the gauge pressure. Refer to HA-7, "Trouble Diagnosis For Unusual

Pressure".

4.CHECK SETTING OF TEMPERATURE SETTING TRIMMER

Check the setting of temperature setting trimmer. Refer to HAC-7, "Temperature Setting Trimmer".1. Check that the temperature setting trimmer is set to “+ direction”.

NOTE:The control temperature can be set with the setting of temperature setting trimmer.

2. Set temperature control dial to “0”.Are the symptoms solved?YES >> INSPECTION ENDNO >> GO TO 5.


Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description".Is the inspection result normal?YES >> GO TO 6.NO >> Repair or replace parts according to the inspection results.

6.CHECK DRIVE BELT

Check tension of the drive belt. Refer to EM-13, "Checking".Is the inspection result normal?YES >> GO TO 7.


[AUTOMATIC AIR CONDITIONER]INSUFFICIENT COOLING

< SYMPTOM DIAGNOSIS >NO >> Adjust or replace drive belt.

7.CHECK AIR LEAKAGE FROM DUCT

Check duct and nozzle, etc. of A/C system for air leakage.Is the inspection result normal?YES >> GO TO 8.NO >> Repair or replace parts according to the inspection results.

8.CHECK ECV

Perform the ECV diagnosis procedure. Refer to HAC-62, "Diagnosis Procedure".Is the inspection result normal?YES >> Replace the unified meter and A/C amp.NO >> Replace the compressor.


INSUFFICIENT HEATING[AUTOMATIC AIR CONDITIONER]

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INSUFFICIENT HEATING


Symptom• Insufficient heating• No warm air comes out. (Air flow volume is normal.)


1.CHECK COOLING SYSTEM

1. Check engine coolant level and check for leakage. Refer to CO-7, "Inspection".2. Check radiator cap. Refer to CO-11, "RADIATOR CAP : Inspection".3. Check water flow sounds of engine coolant. Refer to CO-8, "Refilling".Is the inspection result normal?YES >> GO TO 2.NO >> Refill the engine coolant and repair or replace the parts according to the inspection results.

2.CHECK SETTING OF TEMPERATURE SETTING TRIMMER

1. Check the setting of temperature setting trimmer. Refer to HAC-7, "Temperature Setting Trimmer".2. Check that the temperature setting trimmer is set to “− direction”.

NOTE:The control temperature can be set with the setting of temperature setting trimmer.

3. Set temperature control dial to “0”.Are the symptoms solved?YES >> INSPECTION ENDNO >> GO TO 3.

3.CHECK OPERATION

1. Turn temperature dial (driver side) and raise temperature setting to 32°C (90°F) after warming up theengine.

2. Check that warm air blows from outlets.Is the inspection result normal?YES >> INSPECTION ENDNO >> GO TO 4.


Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description".Is the inspection result normal?YES >> GO TO 5.NO >> Repair or replace parts according to the inspection results.

5.CHECK AIR LEAKAGE FROM DUCT

Check duct and nozzle, etc. of A/C system for air leakage.Is the inspection result normal?YES >> GO TO 6.NO >> Repair or replace parts according to the inspection results.

6.CHECK HEATER HOSE INSTALLATION CONDITION

Check the heater hose installation condition visually (for twist, crush, etc.).Is the inspection result normal?YES >> GO TO 7.NO >> Repair or replace parts according to the inspection results.

7.CHECK TEMPERATURE OF HEATER HOSE

1. Check the temperature of inlet hose and outlet hose of heater core.


[AUTOMATIC AIR CONDITIONER]INSUFFICIENT HEATING

< SYMPTOM DIAGNOSIS >2. Check that the inlet side of heater core is hot and the outlet side is slightly lower than/almost equal to the

inlet side.CAUTION:The temperature inspection should be performed in a short time because the engine coolant tem-perature is too hot.

Is the inspection result normal?YES >> GO TO 8.NO >> Replace the heater core after performing the procedures after the cooling system inspection

again. GO TO 1.

8.REPLACE HEATER CORE

Replace the heater core. Refer to heater core. Refer to HA-50, "Exploded View".Are the symptoms solved?YES >> INSPECTION ENDNO >> Perform the procedures after the cooling system inspection again. GO TO 1.


NOISE[AUTOMATIC AIR CONDITIONER]

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NOISE


Symptom• Noise• Noise is heard when the A/C system operates.


1.CHECK OPERATION

1. Operate the A/C system and check the operation. Refer to HAC-5, "Description & Inspection".2. Check the parts where noise is occurring.Can the parts where noise is occurring be checked?YES-1 >> Noise from blower motor: GO TO 2.YES-2 >> Noise from compressor: GO TO 3.YES-3 >> Noise from expansion valve: GO TO 4.YES-4 >> Noise from A/C piping (pipe, flexible hose): GO TO 6.YES-5 >> Noise from drive belt: GO TO 7.NO >> INSPECTION END

2.CHECK BLOWER MOTOR

1. Remove blower motor.2. Remove in-cabin microfilter.3. Remove foreign materials that are in the blower unit.4. Check the noise from blower motor again.Is the inspection result normal?YES >> INSPECTION ENDNO >> Replace blower motor.

3.REPLACE COMPRESSOR

1. Correct the refrigerant with recovery/recycling recharging equipment.2. Recharge with the proper amount of the collected refrigerant after recycling or new refrigerant.3. Check for the noise from compressor again.Is the inspection result normal?YES >> INSPECTION ENDNO >> Replace compressor.

4.CHECK WITH GAUGE PRESSURE

Perform the diagnosis with the gauge pressure. Refer to HA-7, "Trouble Diagnosis For Unusual Pressure".Is the inspection result normal?YES >> GO TO 5.NO >> Repair or replace malfunctioning part.

5.REPLACE EXPANSION VALVE

1. Correct the refrigerant with recovery/recycling recharging equipment.2. Recharge with the proper amount of the collected refrigerant after recycling or new refrigerant.3. Check for the noise from expansion valve again.Are the symptoms solved?YES >> INSPECTION ENDNO >> Replace expansion valve.

6.CHECK A/C PIPING (PIPE, FLEXIBLE HOSE)

1. Check A/C piping (pipe, flexible hose) (for deformation and damage, etc.).2. Check the installation condition of clips and brackets, etc. of A/C piping (pipe, flexible hose).Is the inspection result normal?YES >> Fix the line with rubber or come vibration absorbing material.


[AUTOMATIC AIR CONDITIONER]NOISE

< SYMPTOM DIAGNOSIS >NO >> Repair or replace parts according to the inspection results.

7.CHECK DRIVE BELT

Check tension of the drive belt. Refer to EM-13, "Checking".Is the inspection result normal?YES >> Check the noise from compressor: GO TO 3.NO >> Adjust or replace drive belt according to the inspection results.


SELF-DIAGNOSIS CANNOT BE PERFORMED[AUTOMATIC AIR CONDITIONER]

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SELF-DIAGNOSIS CANNOT BE PERFORMED


Symptom: Self-diagnosis function does not operate normally.


1.CHECK SELF-DIAGNOSIS FUNCTION

1. Turn ignition switch ON.2. Set in self-diagnosis mode as per the following. Within 10 seconds after starting engine (ignition switch is

turned ON.), press OFF switch for at least 5 seconds.NOTE:• If battery voltage drops below 12 V during diagnosis STEP-3, door motor speed becomes slower and as a

result, the system may generate an error even when operation is normal. Start engine before performing thisdiagnosis to avoid this.

• Former STEP-1 (indicators and display screen are checked) does not exist in this self-diagnosis function.• OFF switch may not be recognized according to the timing of pressing it. Operate OFF switch after the

intake switch indicators are turned ON.Does self-diagnosis function operate?YES >> INSPECTION ENDNO >> GO TO 2.

2.CHECK POWER SUPPLY AND GROUND CIRCUIT OF UNIFIED METER AND A/C AMP.

Check power supply and ground circuit of unified meter and A/C amp. Refer to HAC-46, "UNIFIED METERAND A/C AMP. : Diagnosis Procedure".Is the inspection result normal?YES >> Replace unified meter and A/C amp.NO >> Repair or replace malfunctioning part.


[AUTOMATIC AIR CONDITIONER]MEMORY FUNCTION DOES NOT OPERATE


MEMORY FUNCTION DOES NOT OPERATE


Symptom• Memory function does not operate normally.• The setting is not maintained. (It returns to the initial condition.)


1.CHECK OPERATION

1. Set temperature control dial to 32°C (90°F).2. Press OFF switch.3. Turn ignition switch OFF.4. Turn ignition switch ON.5. Press AUTO switch.6. Check that the set temperature is maintained.Is the inspection result normal?YES >> INSPECTION ENDNO >> GO TO 2.

2.CHECK POWER SUPPLY AND GROUND CIRCUIT OF UNIFIED METER AND A/C AMP

Check power supply and ground circuit of unified meter and A/C amp. Refer to HAC-46, "UNIFIED METERAND A/C AMP. : Diagnosis Procedure". Is the inspection result normal?YES >> Replace unified meter and A/C amp.NO >> Repair or replace malfunctioning part.


PRECAUTIONS[AUTOMATIC AIR CONDITIONER]

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< PRECAUTION >

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[AUTOMATIC AIR CONDITIONER]PRECAUTIONS







PRESET SWITCH[AUTOMATIC AIR CONDITIONER]

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REMOVAL AND INSTALLATIONPRESET SWITCH



REMOVALRefer to AV-120, "Exploded View" (BASE AUDIO WITHOUT NAVIGATION), AV-362, "Exploded View" (BOSEAUDIO WITHOUT NAVIGATION) or AV-629, "Exploded View" (BOSE AUDIO WITH NAVIGATION).


1. Clock 2. Cluster lid C 3. Preset switch

JSNIA0107ZZ







REMOVAL1. Remove audio unit. Refer to AV-111, "Exploded View" (BASE AUDIO WITHOUT NAVIGATION), AV-348,

"Exploded View" (BOSE AUDIO WITHOUT NAVIGATION) or AV-616, "Exploded View" (BOSE AUDIOWITH NAVIGATION).

2. Remove mounting screws, and then remove unified meter and A/C amp.

INSTALLATIONInstallation is basically the reverse order of removal.CAUTION:Since unified meter and A/C amp. connector and AV control unit connector have the same form, becareful not to insert them wrongly.

1. Unified meter and A/C amp. 2. Bracket (LH) 3. Audio unit

4. Bracket (RH)

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AMBIENT SENSOR[AUTOMATIC AIR CONDITIONER]

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AMBIENT SENSOR



REMOVAL1. Remove front grille. Refer to EXT-19, "Exploded View".2. Disconnect ambient sensor connector, and then remove ambient sensor.


1. Ambient sensor

JPIIA1479ZZ


[AUTOMATIC AIR CONDITIONER]IN-VEHICLE SENSOR


IN-VEHICLE SENSOR



REMOVAL1. Remove instrument lower panel LH. Refer to IP-11, "Exploded View".2. Remove mounting screw, and then remove in-vehicle sensor.


1. Instrument lower panel LH 2. In-vehicle sensor

JPIIA0645ZZ


SUNLOAD SENSOR[AUTOMATIC AIR CONDITIONER]

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SUNLOAD SENSOR



REMOVAL1. Remove front defroster grille LH. Refer to VTL-10, "Exploded View".2. Disconnect sunload sensor connector, and then remove sunload sensor.


1. Front defroster grille LH

2. Sunload sensor

JPIIA0648ZZ


[AUTOMATIC AIR CONDITIONER]INTAKE SENSOR


INTAKE SENSOR



REMOVAL1. Remove low-pressure pipe 1 and high-pressure pipe 2. Refer to HA-41, "Exploded View".

CAUTION:Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entryof air.

2. Slide evaporator to passenger side, and then remove intake sensor.

INSTALLATIONInstallation is basically the reverse order of removal.CAUTION:• Replace O-rings with new ones. Then apply compressor oil to them when installing.• Mark the mounting position of intake sensor bracket prior to removal so that the reinstalled sensor

can be located in the same position.• Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping

straight in axial direction.• Insert piping securely until a click is heard.• After piping connection is completed, pull male-side piping by hand to make sure that connection

does not come loose.• Check for leakages when recharging refrigerant.

1. Heater & cooling unit assembly 2. Intake sensor bracket 3. Intake sensor

4. Evaporator assembly 5. Evaporator cover

JSIIA1424ZZ


REFRIGERANT PRESSURE SENSOR[AUTOMATIC AIR CONDITIONER]

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REFRIGERANT PRESSURE SENSOR



REMOVAL1. Remove liquid tank. Refer to HA-47, "Exploded View".2. Fix the liquid tank (1) with a vise (A). Remove the refrigerant

pressure sensor (2) with a wrench (B).CAUTION:Be careful not to damage liquid tank.

INSTALLATIONInstallation is basically the reverse order of removal.CAUTION:• Replace O-ring with new one. Then apply compressor oil to them when installing.• Check for leakages when recharging refrigerant.

1. Refrigerant pressure sensor 2. O-ring 3. Liquid tank bracket

4. Liquid tank 5. Bracket 6. Condenser pipe assembly

7. Radiator & condenser assembly


JSIIA0012GB

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[AUTOMATIC AIR CONDITIONER]DOOR MOTOR


DOOR MOTOR



MODE DOOR MOTOR

MODE DOOR MOTOR : Removal and Installation INFOID:0000000004536545

REMOVAL1. Remove blower unit. Refer to VTL-16, "Exploded View".2. Remove mounting screws, and then remove mode door motor.3. Disconnect mode door motor connector.

INSTALLATIONinstallation is basically the reverse order of removal.AIR MIX DOOR MOTOR

1. Air mix door motor (driver side)* 2. Air mix door motor adapter 3. Heater & cooling unit assembly

4. Ventilator door lever 5. Foot door lever 6. Foot door link

7. Air mix door motor adapter 8. Air mix door motor (passenger side) 9. Ventilator door link

10. Blower unit 11. Intake door lever 2 12. Intake door motor

13. Intake door link 14. Intake door lever 1 15. Mode door motor

16. Mode door motor bracket 17. Main link 18. Main link sub

19. Max.cool door link 20. Defroster door link 21. Max.cool door lever

22. Defroster door lever

JSIIA1425ZZ


DOOR MOTOR[AUTOMATIC AIR CONDITIONER]

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AIR MIX DOOR MOTOR : Removal and Installation INFOID:0000000004536547

REMOVAL


1. Set the temperature at 18°C (64°F).CAUTION:The angle may be out, when installing the air mix door motor to the air mix door, unless the aboveprocedure is performed.

2. Disconnect the battery cable from the negative terminal.3. Remove blower unit. Refer to VTL-16, "Exploded View".4. Remove mounting screws, and then remove air mix door motor.5. Disconnect air mix door motor connector.

With left and right ventilation temperature separately control systemDriver side1. Set the temperature (driver side) at 18°C (64°F).


2. Disconnect the battery cable from the negative terminal.3. Remove Instrument driver lower panel. Refer to IP-11, "Exploded View".4. Remove Accelerator pedal bracket and lever assembly. Refer to ACC-3, "Exploded View".5. Remove mounting screws, and then remove air mix door motor (driver side).6. Disconnect air mix door motor connector.

Passenger side1. Set the temperature (passenger side) at 18°C (64°F).


2. Disconnect the battery cable from the negative terminal.3. Remove blower unit. Refer to VTL-16, "Exploded View".4. Remove mounting screws, and then remove air mix door motor (passenger side).5. Disconnect air mix door motor connector.

INSTALLATIONInstallation is basically the reverse order of removal.INTAKE DOOR MOTOR

INTAKE DOOR MOTOR : Removal and Installation INFOID:0000000004536549

REMOVAL1. Remove ECM and power steering control unit with bracket attached. Refer to VTL-17, "BLOWER UNIT :

Removal and Installation".2. Remove mounting screws, and then remove intake door motor from blower unit.3. Disconnect intake door motor connector.



DRIVER CONTROLS

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SECTION HRNA

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HORN

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CONTENTS

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DTC/CIRCUIT DIAGNOSIS .......................... 2

HORN .................................................................. 2Wiring Diagram - HORN - .........................................2

PRECAUTION ............................................... 5

PRECAUTIONS ................................................... 5

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" .................................................................. 5Precaution for Battery Service .................................. 5

REMOVAL AND INSTALLATION ................ 6

HORN ................................................................. 6Exploded View .......................................................... 6Removal and Installation .......................................... 6

HRN-1Revision: 2009 October 2009 G37 Coupe

HORN
DTC/CIRCUIT DIAGNOSISHORN

Wiring Diagram - HORN - INFOID:0000000004249148

JCLWM2731GB


HORN

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JCLWM2732GB


HORN
JCLWM2733GB


PRECAUTIONS

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HORN
REMOVAL AND INSTALLATIONHORN



REMOVAL

Horn (LOW)

1. Remove radiator core support ornament. Refer to DLK-212, "Exploded View".2. Disconnect the horn (LOW) connector.3. Remove the horn mounting nut, and remove the horn (LOW) from the vehicle.

Horn (HIGH)

1. Remove fender protector (LH). Refer to EXT-24, "FENDER PROTECTOR : Exploded View".2. Disconnect the horn (HIGH) connector.3. Remove the horn mounting bolt, and remove the horn (HIGH) from the vehicle.


1. Horn (LOW) 2. Horn (HIGH)

JPLIA0569ZZ


ENGINE

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SECTION EMA

EM

ENGINE MECHANICAL

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CONTENTS


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................. 3

NVH Troubleshooting - Engine Noise ....................3Use the Chart Below to Help You Find the Cause of the Symptom ..............................................3

PRECAUTION ............................................... 5

PRECAUTIONS ................................................... 5Precaution for Procedure without Cowl Top Cover ......5Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" ...................................................................5Precaution Necessary for Steering Wheel Rota-tion after Battery Disconnect .....................................5Precaution for Battery Service ..................................6Draining Engine Coolant ..........................................6Disconnecting Fuel Piping .......................................6Removal and Disassembly ......................................6Inspection, Repair and Replacement ......................6Assembly and Installation ........................................6Parts Requiring Angle Tightening ...........................7Liquid Gasket ...........................................................7Definitions of Bank Names ........................................8

PREPARATION ............................................ 9

PREPARATION ................................................... 9Special Service Tools ..............................................9Commercial Service Tools .....................................10

PERIODIC MAINTENANCE .........................13

DRIVE BELT .......................................................13Exploded View ........................................................13Checking .................................................................13Tension Adjustment ................................................13Removal and Installation .........................................13Inspection ................................................................14

AIR CLEANER FILTER .....................................15Removal and Installation .........................................15

SPARK PLUG ...................................................16Exploded View .........................................................16Removal and Installation .........................................16Inspection ................................................................17

CAMSHAFT VALVE CLEARANCE ..................18Inspection and Adjustment ......................................18

COMPRESSION PRESSURE ...........................23Inspection ................................................................23


ENGINE COVER ...............................................25Exploded View .........................................................25Removal and Installation .........................................25

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY .............................................................26

Exploded View .........................................................26Removal and Installation .........................................26

AIR CLEANER AND AIR DUCT .......................27Exploded View .........................................................27Removal and Installation .........................................27Inspection ................................................................28

INTAKE MANIFOLD COLLECTOR ..................29Exploded View .........................................................29Removal and Installation .........................................29

INTAKE MANIFOLD .........................................32Exploded View .........................................................32Removal and Installation .........................................32Inspection ................................................................33

EXHAUST MANIFOLD ......................................34Exploded View .........................................................34Removal and Installation .........................................34Inspection ................................................................36

EM-1Revision: 2009 October 2009 G37 Coupe

FUEL INJECTOR AND FUEL TUBE ................. 37Exploded View ........................................................ 37Removal and Installation ........................................ 37Inspection ............................................................... 42

OIL PAN (LOWER) ............................................ 43Exploded View (2WD) ............................................ 43Exploded View (AWD) ............................................ 44Removal and Installation ........................................ 44Inspection ............................................................... 46

IGNITION COIL, SPARK PLUG AND ROCK-ER COVER ......................................................... 47

Exploded View ........................................................ 47Removal and Installation ........................................ 47

TIMING CHAIN .................................................. 50Exploded View ........................................................ 50Removal and Installation ........................................ 51Inspection ............................................................... 65

OIL SEAL ........................................................... 67

FRONT OIL SEAL ..................................................... 67FRONT OIL SEAL : Removal and Installation ........ 67

REAR OIL SEAL ....................................................... 67REAR OIL SEAL : Removal and Installation .......... 67

UNIT REMOVAL AND INSTALLATION ..... 69

ENGINE ASSEMBLY ......................................... 69

2WD ........................................................................... 692WD : Exploded View ............................................. 692WD : Removal and Installation ............................. 692WD : Inspection .................................................... 72

AWD .......................................................................... 73AWD : Exploded View ............................................ 73AWD : Removal and Installation ............................. 74AWD : Inspection .................................................... 77

UNIT DISASSEMBLY AND ASSEMBLY .... 79

ENGINE STAND SETTING ................................ 79Setting .................................................................... 79

ENGINE UNIT .................................................... 81Disassembly ........................................................... 81Assembly ................................................................ 81

OIL PAN (UPPER) AND OIL STRAINER .......... 82

2WD ........................................................................... 822WD : Exploded View ............................................. 822WD : Disassembly and Assembly ......................... 822WD : Inspection ..................................................... 84

AWD .......................................................................... 84AWD : Exploded View ............................................. 85AWD : Disassembly and Assembly ......................... 85AWD : Inspection .................................................... 88

REAR TIMING CHAIN CASE ............................ 89Exploded View ........................................................ 89Disassembly and Assembly .................................... 90

CAMSHAFT ....................................................... 94Exploded View ........................................................ 94Disassembly and Assembly .................................... 95Inspection .............................................................. 104

CYLINDER HEAD .............................................111Exploded View ...................................................... 111Disassembly and Assembly .................................. 112Inspection .............................................................. 117

CYLINDER BLOCK ..........................................121Exploded View ...................................................... 121Disassembly and Assembly .................................. 122Inspection .............................................................. 131

HOW TO SELECT PISTON AND BEARING ...142Description ............................................................ 142Piston .................................................................... 142Connecting Rod Bearing ..................................... 143Main Bearing ........................................................ 146

SERVICE DATA AND SPECIFICATIONS (SDS) .........................................................148

SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................148

General Specification ........................................... 148Drive Belt .............................................................. 148Spark Plug ............................................................ 148Intake Manifold ...................................................... 149Exhaust Manifold .................................................. 149Camshaft ............................................................... 149Cylinder Head ...................................................... 151Cylinder Block ...................................................... 153Main Bearing ........................................................ 157Connecting Rod Bearing ..................................... 158


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

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SYMPTOM DIAGNOSISNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting - Engine Noise INFOID:0000000004250451

Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000004250452

1. Locate the area where noise occurs.

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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >2. Confirm the type of noise.3. Specify the operating condition of the engine.4. Check specified noise source.If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not related

Location of noise

Type of noise

Operating condition of engine

Source of noise

Check itemRefer-

ence pageBefore warm-

up

After warm-

up

When start-ing

When idling

When racing

While driving

Top of en-gineRocker coverCylinder head

Ticking or clicking

C A — A B —Tappet noise

Valve clearance EM-18

Rattle C A — A B CCamshaft bearing noise

Camshaft runoutCamshaft journal oil clearance

EM-149

Crank-shaft pul-leyCylinder block (Side of engine)Oil pan

Slap or knock

— A — B B —Piston pin noise

Piston to piston pin oil clearanceConnecting rod bushing oil clearance

EM-153

Slap or rap

A — — B B APiston slap noise

Piston to cylinder bore clearancePiston ring side clear-ancePiston ring end gapConnecting rod bend and torsion

EM-153

Knock A B C B B B

Connect-ing rod bearing noise

Connecting rod bushing oil clearanceConnecting rod bearing oil clearance

EM-153

EM-158

Knock A B — A B CMain bear-ing noise

Main bearing oil clear-anceCrankshaft runout

EM-157

EM-153

Front of engineTiming chain case

Tapping or ticking

A A — B B B

Timing chain and timing chain ten-sioner noise

Timing chain cracks and wearTiming chain tensioner operation

EM-65

EM-51

Front of engine

Squeak-ing or fizz-ing

A B — B — C

Drive belt (Sticking or slip-ping)

Drive belt deflection

EM-13

Creaking A B A B A BDrive belt (Slipping)

Idler pulley bearing op-eration

SquallCreak

A B — B A BWater pump noise

Water pump operationCO-18,

"Exploded View"


PRECAUTIONS

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If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock andcannot be turned.

PIIB3706J


PRECAUTIONS
< PRECAUTION >If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-cedure below before starting the repair operation.




4. Perform the necessary repair operation.5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn





Draining Engine Coolant INFOID:0000000004250455

Drain engine coolant and engine oil when the engine is cooled.

Disconnecting Fuel Piping INFOID:0000000004250456

• Before starting work, make sure that no fire or spark producing items are in the work area. • Release fuel pressure before disconnecting and disassembly.• After disconnecting pipes, plug openings to stop fuel leakage.

Removal and Disassembly INFOID:0000000004250457

• When instructed to use SST, use the specified tools. Always be careful to work safely, and avoid forceful oruninstructed operations.

• Exercise maximum care to avoid damage to mating or sliding surfaces.• Dowel pins are used for the alignment of several parts. When replacing and reassembling parts with dowel

pins, make sure that dowel pins are installed in the original position.• Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials.• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally

opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be usedin the step.

Inspection, Repair and Replacement INFOID:0000000004250458

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, andreplace if necessary.

Assembly and Installation INFOID:0000000004250459

• Use torque wrench to tighten bolts or nuts to specification.• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the

ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,do exactly as specified.

• Replace with new gasket, packing, oil seal or O-ring.• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for

any restriction and blockage.


PRECAUTIONS

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• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.Before assembly, oil sliding surfaces well.

• Release air within route when refilling after draining engine coolant. • After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and

exhaust gases for leakage.

Parts Requiring Angle Tightening INFOID:0000000004250460

• Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts: - Cylinder head bolts- Lower cylinder block bolts- Connecting rod cap bolts• Do not use a torque value for final tightening. • The torque value for these parts are for a preliminary step.• Ensure thread and seat surfaces are clean and coated with engine oil.

Liquid Gasket INFOID:0000000004250461

REMOVAL OF LIQUID GASKET SEALING• After removing mounting nuts and bolts, separate the mating sur-

face using the seal cutter [SST: KV10111100 (J-37228)] (A) andremove old liquid gasket sealing.CAUTION:Be careful not to damage the mating surfaces.

• Tap the seal cutter [SST: KV10111100 (J-37228)] to insert it (B),and then slide it (C) by tapping on the side as shown in the figure.

• In areas where the seal cutter [SST: KV10111100 (J-37228)] is dif-ficult to use, lightly tap the parts using a plastic hammer to removeit.CAUTION:If for some unavoidable reason a tool such as a screwdriver isused, be careful not to damage the mating surfaces.

LIQUID GASKET APPLICATION PROCEDURE1. Using a scraper (A), remove old liquid gasket adhering to the liq-

uid gasket application surface and the mating surface.• Remove liquid gasket completely from the groove of the liquid

gasket application surface, mounting bolts and bolt holes.2. Wipe the liquid gasket application surface and the mating sur-

face with white gasoline (lighting and heating use) to removeadhering moisture, grease and foreign materials.

3. Attach liquid gasket tube to the tube presser (commercial ser-vice tool).Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".

4. Apply liquid gasket without gaps to the specified location accord-ing to the specified dimensions.• If there is a groove for liquid gasket application, apply liquid

gasket to the groove.

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EMA0622D


PRECAUTIONS
< PRECAUTION >
• As for bolt holes (B), normally apply liquid gasket inside theholes. Occasionally, it should be applied outside the holes.Make sure to read the text of this manual.

• Within five minutes of liquid gasket application, install the mat-ing component.

• If liquid gasket protrudes, wipe it off immediately.• Do not retighten mounting bolts or nuts after the installation.• After 30 minutes or more have passed from the installation, fill

engine oil and engine coolant.CAUTION:If there are specific instructions in this manual, observe them.

Definitions of Bank Names INFOID:0000000004250462

• In this manual, each bank name is defined as follows:

• For cylinder numbers and bank layout, refer to the illustration.

A : Groove

: Inside

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A : Bank 1 (The conventional right bank)

B : Bank 2 (The conventional left bank)

: Engine front

Bank 1 : The bank side including cylinder No. 1 (odd-numbered cylinder side)

Bank 2 : The other bank side of the above (even-numbered cylinder side)

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PREPARATION

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Description

KV10116200(J-26336-A)Valve spring compressor1. KV10115900(J-26336-20)Attachment2.KV10109220( — )Adapter

Disassembling valve mechanismPart (1) is a component of KV10116200 (J-26336-A), but Part (2) is not so.

KV10107902(J-38959)Valve oil seal puller

Replacing valve oil seal

KV10115600(J-38958)Valve oil seal drift

Installing valve oil sealUse side A (G).a: 20 (0.79) dia. d: 8 (0.31) dia.b: 13 (0.51) dia. e: 10.7 (0.421)c: 10.3 (0.406) dia. f: 5 (0.20)H: side B Unit: mm (in)

EM03470000(J-8037)Piston ring compressor

Installing piston assembly into cylinder bore

ST16610001(J-23907)Pilot bushing puller

Removing pilot converter

KV10111100(J-37228)Seal cutter

Removing oil pan (lower and upper), front and rear timing chain case, etc.

PBIC1650E

NT011

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NT044

NT045

NT046


PREPARATION
< PREPARATION >

KV10112100(BT8653-A)Angle wrench

Tightening bolts for connecting rod bearing cap, cylinder head, etc. at an angle

KV10114400(J-38365)Heated oxygen sensor wrench

Loosening or tightening air fuel ratio sensor 1a: 22 mm (0.87 in)

KV10118600(J-48641)Ring gear stopper

Removing and installing crankshaft pulley


Description

NT014

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JPBIA0409ZZ

(Kent-Moore No.)Tool name

Description

( — )Tube presser

Pressing the tube of liquid gasket

( — )Power tool

Loosening nuts and bolts

( — )TORX socket

Removing and installing drive plate

NT052

PBIC0190E

PBIC1113E


PREPARATION

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( — )Manual lift table caddy

Removing and installing engine

(J-24239-01)Cylinder head bolt wrench

Loosening and tightening cylinder head bolt, and used with the angle wrench [SST: KV10112100 (BT8653-A)]a: 13 (0.51) dia.b: 12 (0.47)c: 10 (0.39)Unit: mm (in)

( — )1.Compression gauge2.Adapter

Checking compression pressure

( — )Spark plug wrench

Removing and installing spark pluga: 14 mm (0.55 in)

( — )Valve seat cutter set

Finishing valve seat (EXH) dimensions

( — )Piston ring expander

Removing and installing piston ring

( — )Valve guide drift

Removing and installing valve guide (EXH)Exhaust:a: 9.5 mm (0.374 in) dia.b: 5.5 mm (0.217 in) dia.


Description

ZZA1210D

JPBIA0398ZZ

ZZA0008D

JPBIA0399ZZ

NT048

NT030

JPBIA0400ZZ


PREPARATION
< PREPARATION >
( — )Valve guide reamer

A: Reaming valve guide (EXH) inner holeB: Reaming hole for oversize valve guide (EXH)Exhaust:c: 6.0 mm (0.236 in) dia.d: 10.2 mm (0.402 in) dia.

(J-43897-18)(J-43897-12)Oxygen sensor thread cleaner

Reconditioning the exhaust system threads before installing a new air fuel ratio sensor and heated oxygen sensor (Use with anti-seize lu-bricant shown below.)A: J-43897-18 [18 mm (0.71 in) dia.] for zir-conia heated oxygen sensor and air fuel ratio sensorB: J-43897-12 [12 mm (0.47 in) dia.] for tita-nia heated oxygen sensorC: Mating surface shave cylinderD: Flutes

( — )Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specifica-tion MIL-A-907)

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

( — )Feeler gauge

Inspection valve clearance (Use a curved-tip gauge)


Description

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AEM489

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DRIVE BELT

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PERIODIC MAINTENANCEDRIVE BELT


Checking INFOID:0000000004250466

WARNING:Be sure to perform the this step when engine is stopped.• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range

(A).NOTE:• Check the drive belt auto-tensioner indication when the engine is cold.• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the fig-

ure.• Visually check the entire drive belt for wear, damage or crack.• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.

Tension Adjustment INFOID:0000000004250467

Refer to EM-148, "Drive Belt".


REMOVAL1. Remove engine undercover with power tool.

JPBIA1060ZZ

1. Power steering oil pump 2. Alternator 3. Drive belt auto-tensioner

4. Idler pulley 5. Crankshaft pulley 6. A/C compressor

7. Idler pulley 8. Drive belt 9. Idler pulley

A. Possible use range B. Range when new drive belt is installed C. Indicator

D. View D


DRIVE BELT
< PERIODIC MAINTENANCE >2. While securely holding the square hole (A) in pulley center of
auto tensioner (1) with a spinner handle, move spinner handle inthe direction of arrow (loosening direction of drive belt). CAUTION:Never place hand in a location where pinching may occur ifthe holding tool accidentally comes off.

3. Under the above condition, insert a metallic bar of approximately6 mm (0.24 in) in diameter [hexagonal wrench (C) shown asexample in the figure] through the holding boss (B) to lock auto-tensioner pulley arm.

4. Remove drive belt.

INSTALLATIONNote the following, and install in the reverse order of removal.CAUTION:• Check drive belt is securely installed around all pulleys.• Check drive belt is correctly engaged with the pulley groove.• Check for engine oil and engine coolant are not adhered drive belt and pulley groove.


INSPECTION AFTER INSTALLATION• Turn crankshaft pulley clockwise several times to equalize tension between each pulley, and then confirm

tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to EM-13,"Exploded View".

: Loosening direction of drive belt

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AIR CLEANER FILTER

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AIR CLEANER FILTER


REMOVAL1. Unhook clips (A).

2. Remove holder (3) from air cleaner case (2), and then removeair cleaner filter (1) from holder.

INSTALLATIONNote the following, and install in the reverse order of removal.• Install the air cleaner filter by aligning the seal with the notch of air cleaner case.

1 : Holder

2 : Air cleaner case

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SPARK PLUG
SPARK PLUG



REMOVAL1. Remove engine cover with power tool. Refer to EM-25, "Exploded View".2. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View".3. Remove electric throttle control actuator. Refer to EM-29, "Exploded View".4. Remove ignition coil. Refer to EM-47, "Removal and Installation".

1. PCV hose 2. Clamp 3. PCV valve

4. O-ring 5. Clamp 6. PCV hose

7. Ignition coil 8. Spark plug 9. Rocker cover (bank 1)

10. Oil filler cap 11. Rocker cover gasket (bank 1) 12. Clamp

13. PCV hose 14. PCV hose 15. Rocker cover gasket (bank 2)

16. Rocker cover (bank 2)

A. To intake manifold collector B. To air duct C. VVEL ladder assembly side

D. Refer to EM-47


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SPARK PLUG

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5. Remove spark plug with a spark plug wrench (commercial ser-vice tool).

INSTALLATIONInstallation is the reverse order of removal.


INSPECTION AFTER REMOVALUse the standard type spark plug for normal condition.

CAUTION:• Never drop or shock spark plug.• Never use a wire brush for cleaning.• If plug tip is covered with carbon, use spark plug cleaner to

clean.

• Check and adjustment of plug gap is not required betweenchange intervals.

a : 14 mm (0.55 in)

JPBIA0030ZZ

Spark plug (Standard type) : Refer to EM-148, "Spark Plug".

Cleaner air pressure

: Less than 588 kPa (6 kg/cm2, 85 psi)Cleaning time

: Less than 20 secondsSMA773C

JPBIA0031ZZ


CAMSHAFT VALVE CLEARANCE

Inspection and Adjustment INFOID:0000000004250474

INSPECTION

Check valve clearance if applicable to the following cases:

Intake side:• At the removal and installation of VVEL ladder assembly or valve-related parts, or at the occurrence of mal-

function (poor starting, idle malfunction, unusual noise) due to aged deterioration in valve clearance.CAUTION:Valve clearance check on the intake side is not required after replacing the VVEL ladder assembly andcylinder head assembly with a new one. (Install new VVEL ladder assembly and cylinder head assem-bly in factory-shipped condition because it is factory-adjusted and inspected.)NOTE:VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinderhead assembly.

Exhaust side:• At the removal, installation, and replacement of camshaft (EXH) or valve-related parts, or at the occurrence

of malfunction (poor starting, idle malfunction, unusual noise) due to aged deterioration in valve clearance.

1. Remove rocker covers (bank 1 and bank 2). Refer to EM-47, "Removal and Installation".2. Measure the valve clearance as follows:

• Use the feeler gauge (commercial service tool) of curved-tip. This allows the feeler gauge to access theclearance between camshaft and valve lifter with ease.

NOTE:Be sure to note the following points when measuring valve clearance on the intake side.• Before measuring, check that the position of drive shaft nose

is within the angle shown in the figure.

• Refer to the illustration for the insertion direction of the feelergauge since the direction depends on the bank.

a. Set No. 1 cylinder at TDC of its compression stroke.

Valve clearance : Refer to EM-149, "Camshaft".

A : Bank 1

B : Feeler gauge (commercial service tool)

D : View D

c : 45 degrees (drive shaft nose angle)

: Insertion direction of feeler gauge on the bank 1

: Insertion direction of feeler gauge on the bank 2

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• Rotate crankshaft pulley clockwise to align timing mark(grooved line without color) with timing indicator.

• Check that exhaust cam nose on No. 1 cylinder (engine frontside of bank 1) is located as shown in the figure.

• If not, turn crankshaft one revolution (360 degrees) and alignas shown in the figure.

• By referring to the figure, measure the valve clearances atlocations marked “×” as shown in the table below (locationsindicated in the figure).

• No. 1 cylinder at compression TDC

b. Rotate crankshaft 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at TDCits compression stroke.NOTE:

: Timing mark (grooved line without color)

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1 : Camshaft (EXH) (bank 1)

: Engine front

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: Engine front

Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL.

No. 1 cylinder at com-pression TDC

EXH × (C)

INT × (D)

Measuring position [bank 2 (B)] No. 2 CYL. No. 4 CYL. No. 6 CYL.


INT × (E)

EXH × (F)

JPBIA1334ZZ


Mark a position 240 degrees (b) from a corner of the hexagonalpart of crankshaft pulley mounting bolt as shown in the figure.Use the hexagonal part as a guide.



c. Rotate crankshaft 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at TDCof compression stroke.NOTE:Mark a position 240 degrees (b) from a corner of the hexagonalpart of crankshaft pulley mounting bolt as shown in the figure.Use the hexagonal part as a guide.

1 : Crankshaft pulley

A : Paint mark

JPBIA0166ZZ

: Engine front



EXH × (C)

INT × (D)



INT × (E)

EXH × (F)

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A : Paint mark

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3. Perform adjustment or replacement if the measured value is out of the standard. • If a valve clearance on the exhaust side is out of specification, adjust the valve clearance.• If a valve clearance on the intake side is out of specification, replace VVEL ladder assembly and cylin-

der head assembly. Refer to EM-94, "Exploded View".CAUTION:Never adjust valve clearance on the intake side.NOTE:Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder headassembly replacement are required.

CAMSHAFT (EXH) VALVE CLEARANCE ADJUSTMENT• Perform adjustment depending on selected head thickness of valve lifter (EXH).1. Measure the valve clearance. Refer to “INSPECTION”.2. Remove VVEL ladder assembly and camshaft (EXH). Refer to EM-95, "Disassembly and Assembly".

CAUTION:Never loosen adjusting bolts and mounting bolts (black color) of VVEL ladder assembly.

3. Remove valve lifter (EXH) at the locations that are out of the standard.4. Measure the center thickness of the removed valve lifters (EXH)

with a micrometer (A).

5. Use the equation below to calculate valve lifter (EXH) thickness for replacement.

: Engine front


No. 5 cylinder at compression TDC

EXH × (C)

INT × (D)


No. 5 cylinder at compression TDC

INT × (E)

EXH × (F)

JPBIA1336ZZ

JPBIA0169ZZ

Valve lifter (EXH) thickness calculation: t = t1 + (C1 – C2)t = Valve lifter (EXH) thickness to be replacedt1 = Removed valve lifter (EXH) thickness


• Thickness of new valve lifter (EXH) can be identified by stampmarks on the reverse side (inside the cylinder).Stamp mark 788 indicates 7.88 mm (0.3102 in) in thickness.

Available thickness of valve lifter (EXH): 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) insteps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-149, "Camshaft".

6. Install selected valve lifter (EXH).7. Install VVEL ladder assembly and camshaft (EXH). Refer to EM-95, "Disassembly and Assembly".8. Manually turn crankshaft pulley a few turns. 9. Check that the valve clearances for cold engine are within the specifications by referring to the specified

values. Refer to EM-18, "Inspection and Adjustment".10. Install all removed parts in the reverse order of removal. 11. Warm up the engine, and check for unusual noise and vibration.

C1 = Measured valve clearanceC2 = Standard valve clearance:

Exhaust : 0.33 mm (0.013 in)

A : Stamp

B : Thickness of valve lifter (EXH)

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COMPRESSION PRESSURE

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1. Warm up engine thoroughly. Then, stop it.2. Release fuel pressure. Refer to EC-614, "Inspection".3. Disconnect fuel pump fuse (1) from IPDM E/R (2) to avoid fuel

injection during measurement.

4. Remove engine cover with power tool. Refer to EM-25, "Exploded View".5. Remove ignition coil and spark plug from each cylinder. Refer to EM-47, "Exploded View".6. Connect engine tachometer (not required in use of CONSULT-III).7. Install compression gauge with an adapter (commercial service

tool) onto spark plug hole.

• Use the adapter whose picking up end inserted to spark plughole is smaller than 20 mm (0.79 in) in diameter. Otherwise, itmay be caught by cylinder head during removal.

8. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gaugepointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check eachcylinder.

CAUTION:• Measure a six-cylinder under the same conditions since a measurement depends on measure-

ment conditions (engine water temperature, etc.).• Always use a fully changed battery to obtain the specified engine speed.• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the

engine speed again with normal battery gravity.

JMBIA0021ZZ

PBIC0900E

a : 20 mm (0.79 in)

JPBIA0171ZZ

Compression pressure : Refer to EM-148, "General Specification".


• If compression pressure is below the minimum value, check valve clearances and parts associated withcombustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder headgasket). After checking, measure compression pressure again.

• If a cylinder has low compression pressure, pour a small amount of engine oil into the spark plug hole ofthe cylinder to recheck it for compression.

- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-ton rings and replace if necessary.

- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-functioning. Check valves for damage. Replace valve or valve seat accordingly.

• If two adjacent cylinders have respectively low compression pressure and their compression remainslow even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-inder head gaskets.

9. After inspection is completed, install removed parts.10. Start the engine, and check that the engine runs smoothly.11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-137, "Description".


ENGINE COVER

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REMOVAL AND INSTALLATIONENGINE COVER



REMOVALLoosen mounting bolts and nuts in the reverse order as shown in thefigure, and then remove engine cover.CAUTION:Never damage or scratch engine cover when installing orremoving.

INSTALLATIONInstall engine cover, and then tighten mounting bolts and nuts innumerical order as shown in the figure.CAUTION:Never damage or scratch engine cover when installing orremoving.

1 : Engine cover


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DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
DRIVE BELT AUTO TENSIONER AND IDLER PULLEY



REMOVAL1. Remove drive belt. Refer to EM-13, "Exploded View".

• Keep auto-tensioner pulley arm locked after drive belt is removed.2. Remove auto-tensioner and idler pulley.

• Keep auto-tensioner pulley arm locked to install or remove auto-tensioner.

INSTALLATIONInstallation is the reverse order of removal.CAUTION:If there is damage greater than peeled paint, replace drive belt auto-tensioner.

1. Front timing chain case 2. Idler pulley 3. Drive belt auto-tensioner

4. Idler pulley 5. Idler pulley


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AIR CLEANER AND AIR DUCT

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REMOVALNOTE:Mass air flow sensor is removable under the car-mounted condition.1. Disconnect mass air flow sensor harness connector.2. Disconnect PCV hose.3. Remove air cleaner case & mass air flow sensor assembly and air duct & air hose by disconnecting their

joints.• Add marks if necessary for easier installation.

4. Remove mass air flow sensor from air cleaner case, if necessary.CAUTION:Handle mass air flow sensor according to the following instructions.• Never shock the mass air flow sensor.• Never disassemble the mass air flow sensor.

1. Mass air flow sensor (bank 1) 2. Air cleaner filter 3. Holder

4. Bracket 5. Air dust side duct (bank 1) 6. Resonator (RH)

7. Bracket 8. Grommet 9. Clamp

10. PCV hose 11. Grommet 12. Air cleaner case (RH)

13. Clamp 14. Air duct (RH) 15. Air duct (LH)

16. Clamp 17. PCV hose 18. Air cleaner case (LH)

19. Air dust side duct (bank 2) 20. Bracket 21. Resonator (LH)

22. Bracket 23. Mass air flow sensor (bank 2)

A. To electric throttle control actuator B. To rocker cover (bank 1) C. To rocker cover (bank 2)


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• Never touch the sensor of the mass air flow sensor.

INSTALLATIONNote the following, and install in the reverse order of removal.• Align marks. Attach each joint. Screw clamps firmly.


INSPECTION AFTER REMOVALInspect air duct and resonator assembly for crack or tear.• If anything is found, replace air duct and resonator assembly


INTAKE MANIFOLD COLLECTOR

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REMOVALWARNING:Never drain engine coolant when the engine is hot to avoid the danger of being scalded.1. Remove engine cover with power tool. Refer to EM-25, "Exploded View".2. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View".3. Remove electric throttle control actuator as follows:a. Drain engine coolant. When water hoses are disconnected, attach plug to prevent engine coolant leak-

age.

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1.EVAP canister purge control solenoid valve

2. Clamp 3. EVAP hose

4. EVAP hose 5. Clamp 6. Water hose

7. Water hose 8. Electric throttle control actuator (bank 1) 9. Gasket

10. PCV hose 11. Clamp 12. PCV hose

13. Intake manifold collector 14. Gasket 15. Water hose

16. Water hose 17. Electric throttle control actuator (bank 2) 18. EVAP hose

19.Manifold absolute Pressure (MAP) sen-sor

20. EVAP tube assembly 21. EVAP hose

A. To vacuum pipe B. To brake booster C. To water outlet (rear)

D. To PCV valve E. To heater pipe



CAUTION:• Perform this step when engine is cold.• Never spill engine coolant on drive belt.

b. Disconnect water hoses from electric throttle control actuator. When engine coolant is not drained fromradiator, attach plug to water hoses to prevent engine coolant leakage.

c. Disconnect harness connector.d. Loosen mounting bolts in reverse order as shown in the figure.

NOTE:• When removing only intake manifold collector, move electric

throttle control actuator without disconnecting the water hose.• The figure shows the electric throttle control actuator (bank 1)

viewed from the air duct side.• Viewed from the air duct side, the order of loosening mounting

bolts of electric throttle control actuator (bank 2) is the sameas that of the electric throttle control actuator (bank 1).

CAUTION:Handle carefully to avoid any shock to electric throttle con-trol actuator.

4. Disconnect vacuum hose, PCV hose and EVAP hose from intake manifold collector.5. Remove EVAP canister purge volume control solenoid valve and EVAP tube assembly from intake mani-

fold collector.6. Loosen mounting bolts and nuts with power tool in the reverse

order as shown in the figure to remove intake manifold collector.

INSTALLATIONNote the following, and install in the reverse order of removal.

INTAKE MANIFOLD COLLECTOR • If stud bolts were removed, install them and tighten to the torque specified below.

• Tighten mounting bolts and nuts in numerical order as shown in thefigure.

WATER HOSE• Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.• Clamp hose at location of 3 to 7 mm (0.12 to 0.28 in) from hose end.

ELECTRIC THROTTLE CONTROL ACTUATOR (BANK 1 AND BANK 2)

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: Engine front

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: 10.8 N·m (1.1 kg-m, 8 ft-lb)

: Engine front

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• Tighten in numerical order as shown in the figure.NOTE:• The figure shows the electric throttle control actuator (bank 1)

viewed from the air duct side.• Viewed from the air duct side, the order of tightening mounting

bolts of electric throttle control actuator (bank 2) is the same asthat of the electric throttle control actuator (bank 1).

• Perform the “Throttle Valve Closed Position Learning” when har-ness connector of electric throttle control actuator is disconnected.Refer to EC-18, "THROTTLE VALVE CLOSED POSITIONLEARNING : Description".

• Perform the “Idle Air Volume Learning” and “Throttle Valve ClosedPosition Learning” when electric throttle control actuator is replaced. Refer to EC-19, "IDLE AIR VOLUMELEARNING : Description" and EC-18, "THROTTLE VALVE CLOSED POSITION LEARNING : Description".

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INTAKE MANIFOLD
INTAKE MANIFOLD



REMOVAL1. Release fuel pressure. Refer to EC-614, "Inspection".2. Remove intake manifold collector. Refer to EM-29, "Exploded View".3. Remove fuel tube and fuel injector assembly. Refer to EM-37, "Exploded View".4. Loosen mounting bolts in reverse order as shown in the figure to

remove intake manifold with power tool.

CAUTION:• Cover engine openings to avoid entry of foreign materi-

als.• Put a mark on the intake manifold and the cylinder head

with paint before removal because they need to beinstalled in the specified direction.

5. Remove gaskets.


INTAKE MANIFOLD• If stud bolts were removed, install them and tighten to the torque specified below.

1. Intake manifold 2. Gasket

A. Refer to EM-32


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: Engine front

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: 10.8 N·m (1.1 kg-m, 8 ft-lb)


INTAKE MANIFOLD

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• Tighten all mounting bolts to the specified torque in two or moresteps in numerical order as shown in the figure.

CAUTION:• Install intake manifold with the marks (put on the intake

manifold and the cylinder head before removal) aligned.


INSPECTION AFTER REMOVAL

Surface Distortion• Check the surface distortion of the intake manifold mating surface

with a straightedge (A) and a feeler gauge (B).

• If it exceeds the limit, replace intake manifold.

: Engine front

1st step:

: 7.4 N·m (0.75 kg-m, 5 ft-lb)

2nd step and after:: 25.5 N·m (2.6 kg-m, 19 ft-lb)

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Limit : Refer to EM-149, "Intake Manifold".

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EXHAUST MANIFOLD
EXHAUST MANIFOLD



REMOVALWARNING:Perform the work when the exhaust and cooling system have completely cooled down.NOTE:When removing bank 1 side parts only, steps 1, 4 and 7 are unnecessary.1. Drain engine coolant. Refer to CO-7, "Draining".2. Remove engine cover with power tool. Refer to EM-25, "Exploded View".3. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View".4. Remove water pipe and water hose. Refer to CO-23, "Exploded View".5. Remove engine undercover with power tool.6. Remove exhaust front tube and three way catalysts (bank 1 and bank 2). Refer to EX-5, "Exploded View".7. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.

1. Heated oxygen sensor 2 (bank 1) 2. Air fuel ratio sensor 1 (bank 1) 3. Exhaust manifold cover (upper)

4. Exhaust manifold (bank 1) 5. Exhaust manifold cover (lower) 6. Gasket

7. Ring gasket 8. Three way catalyst (bank 1) 9. Gasket

10. Heated oxygen sensor 2 (bank 2) 11. Gasket 12. Three way catalyst (bank 2)

13. Ring gasket 14. Exhaust manifold (bank 2) 15. Exhaust manifold cover (lower)

16. Gasket 17. Air fuel ratio sensor 1 (bank 2) 18. Exhaust manifold cover (upper)


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EXHAUST MANIFOLD

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8. Disconnect air fuel ratio sensor 1 (bank 1 and bank 2) harness connectors and remove harness clip.9. Using the heated oxygen sensor wrench [SST: KV10114400 (J-

38365)] (C), remove air fuel ratio sensor 1 (bank 1 and bank 2).

CAUTION:• Be careful not to damage air fuel ratio sensor 1.• Discard any air fuel ratio sensor 1 that has been dropped

onto a hard surface such as a concrete floor. Replace witha new sensor.

10. Remove exhaust manifold cover (upper) (bank 1 and bank 2).11. Loosen mounting nuts in the reverse order as shown in the fig-

ure to remove exhaust manifold.

NOTE:Disregard the numerical order No. 7 and 8 in removal.

12. Remove gaskets.CAUTION:Cover engine openings to avoid entry of foreign materials.


EXHAUST MANIFOLD GASKET• Install exhaust manifold gasket in direction shown in the figure.

(Follow the same procedure for both banks.)

EXHAUST MANIFOLD• If stud bolts were removed, install them and tighten to the torque specified below.

A : Bank 1

B : Bank 2

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A : Bank 1

B : Bank 2

: Engine front

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A : Bank 1

B : Triangle press

C : Bank 2

: Engine front

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EXHAUST MANIFOLD
• Install exhaust manifold and tighten mounting bolts in numericalorder as shown in the figure.

NOTE:Tighten nuts the No. 1 and 2 in two steps. The numerical order No.7 and 8 shows the second step.

AIR FUEL RATIO SENSOR 1CAUTION:• Before installing a new air fuel ratio sensor 1, clean exhaust system threads using heated oxygen

sensor thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply anti-seizelubricant.

• Never apply excessive torque to air fuel ratio sensor 1. Doing so may cause damage to air fuel ratiosensor 1, resulting in the “MIL” illuminating.



Surface Distortion• Check the surface distortion of the exhaust manifold mating sur-

face with a straightedge (A) and a feeler gauge (B).

• If it exceeds the limit, replace exhaust manifold.

Tightening torque : Refer to EM-34, "Exploded View".

A : Bank 1

B : Bank 2

: Engine front

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Limit : Refer to EM-149, "Exhaust Manifold".

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FUEL INJECTOR AND FUEL TUBE

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CAUTION:Never remove or disassemble parts unless instructed as shown in the figure.


REMOVALWARNING:• Put a “CAUTION: FLAMMABLE” sign in the workshop.• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.• Never drain engine coolant when the engine is hot to avoid the danger of being scalded.1. Release fuel pressure. Refer to EC-614, "Inspection".2. Disconnect battery cable from the negative terminal. Refer to PG-99, "Exploded View".3. Remove engine cover with power tool. Refer to EM-25, "Exploded View".4. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View".5. Remove intake manifold collector. Refer to EM-29, "Exploded View".

1. Quick connector cap 2. Fuel feed hose (with damper) 3. O-ring

4. Fuel sub tube 5. O-ring 6. Clip

7. Fuel damper 8. O-ring 9. Fuel tube

10. O-ring (black) 11. Fuel injector 12. Clip

13. O-ring (green)

A. Refer to EM-37


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< REMOVAL AND INSTALLATION >6. Remove fuel feed hose (with damper) (1) from fuel sub-tube (2)
and remove harness bracket (3).

NOTE:There is no fuel return route.CAUTION:• While hoses are disconnected, plug them to prevent fuel

from draining.• Never separate damper and hose.

7. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnectquick connector as follows:

a. Remove quick connector cap (2) from quick connector connec-tion on right member side.

b. Disconnect fuel feed hose (with damper) (1) from bracket hoseclamp.

c. Push in retainer tabs (2).d. Draw and pull out quick connector (1) straight from centralized

under-floor piping (3).CAUTION:• Pull quick connector holding (A) position as shown in the

figure.• Never pull with lateral force applied. O-ring inside quick

connector may be damaged.• Prepare container and cloth beforehand because fuel will

leak out.• Avoid fire and sparks.• Keep parts away from heat source. Especially, be careful

when welding is performed around them.• Never expose parts to battery electrolyte or other acids.• Never bend or twist connection between quick connector and fuel feed hose (with damper) dur-

ing installation/removal.• To keep the connecting portion clean and to avoid dam-

age and foreign materials, cover them completely withplastic bags, etc. (A) or a similar item.

8. Remove fuel sub tube mounting bolt.9. Disconnect harness connector from fuel injector.

: Engine front

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10. Loosen mounting bolts in reverse order as shown in the figure,and remove fuel tube and fuel injector assembly.

CAUTION:Never tilt it, or remaining fuel in pipes may flow out frompipes.

11. Remove fuel injector (2) from fuel tube (4) as follows:

a. Open and remove clip (1).b. Remove fuel injector from fuel tube by pulling straight.

CAUTION:• Be careful with remaining fuel that may go out from fuel

tube.• Be careful not to damage injector nozzles during removal.• Never bump or drop fuel injector.• Never disassemble fuel injector.

12. Remove fuel sub-tube and fuel damper, if necessary.

INSTALLATION1. Install fuel damper (4) as follows:

a. Install new O-ring (1) to fuel tube as shown. When handling newO-ring, pay attention to the following caution items:CAUTION:• Handle O-ring with bare hands. Never wear gloves.• Lubricate O-ring with new engine oil.• Never clean O-ring with solvent.• Check that O-ring and its mating part are free of foreign

material.• When installing O-ring, be careful not to scratch it with

tool or fingernails. Also be careful not to twist or stretchO-ring. If O-ring was stretched while it was beingattached, do not insert it quickly into fuel tube.

• Insert new O-ring straight into fuel tube. Never twist it.b. Install spacer (3) to fuel damper.c. Insert fuel damper straight into fuel tube.

CAUTION:• Insert straight, checking that the axis is lined up.• Never pressure-fit with excessive force.

• Insert fuel damper until (A) is touching (B) of fuel tube.

: Engine front

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3 : O-ring

A : Installed condition

B : Clip mounting groove

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2 : Cup

5 : Clip

C : Cut-out

Reference value : 130 N (13.3 kg, 29.2 lb)

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< REMOVAL AND INSTALLATION >d. Install the cut-out (A) of the clip (2) to the projection (B), which
ensures that the fuel tube does not move or rotate.

e. Unlock the clip after making sure that the rib of the cup and thebrim of the fuel damper are mated each other and positioned inthe holes (C) of the clip.

f. Check that the opening (B) and the slit (C) of the clip are posi-tioned and fixed properly so it does not rotate or pull out.

2. Install fuel sub-tube.• When handling new O-rings, be careful of the following caution items:

CAUTION:• Handle O-ring with bare hands. Never wear gloves.• Lubricate O-ring with new engine oil.• Never clean O-ring with solvent.• Check that O-ring and its mating part are free of foreign material.• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not

to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert itquickly into fuel tube.

• Insert new O-ring straight into fuel tube. Never decenter or twist it.• Insert fuel sub-tube straight into fuel tube.• Tighten mounting bolts evenly in turn.• After tightening mounting bolts, Check that there is no gap between flange and fuel tube.

3. Install new O-rings to fuel injector, paying attention to the following items.CAUTION:• Upper and lower O-ring are different. Be careful not to confuse them.

• Handle O-ring with bare hands. Never wear gloves.• Lubricate O-ring with new engine oil.• Never clean O-ring with solvent.• Check that O-ring and its mating part are free of foreign material.• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to

twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quicklyinto fuel tube.

• Insert O-ring straight into fuel injector. Never decenter or twist it.

1 : Fuel tube

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A : Under view

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Fuel tube side : BlackNozzle side : Green



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4. Install fuel injector to fuel tube as follows:

a. Insert clip (3) into clip mounting groove (F) on fuel injector (5).CAUTION:• Never reuse clip. Replace it with a new one.• Be careful to keep clip from interfering with O-ring. If

interference occurs, replace O-ring.• Insert clip so that protrusion (E) of fuel injector matches

cut-out (C) of clip.b. Insert fuel injector into fuel tube (1) with clip attached.

• Insert it while matching it to the axial center.• Insert fuel injector so that protrusion (A) of fuel tube matches

cutout (B) of clip.• Check that fuel tube flange (G) is securely fixed in flange fixing

groove (D) on clip.c. Check that installation is complete by checking that fuel injector

does not rotate or come off.• Check that protrusions of fuel injectors and fuel tube are

aligned with cutouts of clips after installation.

5. Install fuel tube and fuel injector assembly to intake manifold.CAUTION:Be careful not to let tip of injector nozzle come in contact with other parts.• Tighten mounting bolts in two steps in numerical order as

shown in the figure.

6. Connect injector sub-harness.7. Install fuel sub tube mounting bolt.8. Connect fuel feed hose (with damper).

• Handling procedure of O-ring is the same as that of fuel damper and fuel sub-tube.• Insert fuel damper straight into fuel sub-tube.• Tighten mounting bolts evenly in turn.• After tightening mounting bolts, check that there is no gap between flange and fuel sub-tube.

9. Connect quick connector between fuel feed hose (with damper) and centralized under-floor piping con-nection as follows:

a. Check that no foreign substances are deposited in and around centralized under-floor piping and quickconnector, and that there is no damage to them.

b. Thinly apply new engine oil around centralized under-floor piping from tip end to spool end.c. Align center to insert quick connector straightly into centralized under-floor piping.

• Insert quick connector to centralized under-floor piping until top spool is completely inside quick connec-tor and 2nd level spool exposes right below quick connector.

CAUTION:• Hold align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.• Insert until you hear a “click” sound and actually feel the engagement.• To avoid misidentification of engagement with a similar sound, be sure to perform the next step.

2 : O-ring (Black)

4 : O-ring (Green)

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: Engine front

1st step: 10.1 N·m (1.0 kg-m, 7 ft-lb)

2nd step: 23.6 N·m (2.4 kg-m, 17 ft-lb)

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< REMOVAL AND INSTALLATION >d. Pull quick connector by hand holding position (A). Check it is
completely engaged (connected) so that it does not come outfrom centralized under-floor piping (1).

e. Install quick connector cap (3) to quick connector connection.

• Install quick connector cap with arrow (A) on surface facing indirection of quick connector (fuel feed hose side).

CAUTION:If quick connector cap cannot be installed smoothly, quickconnector may have not been installed correctly. Check theconnection again.

10. Install in the reverse order of removal after this step.


INSPECTION AFTER INSTALLATION

Check for Fuel Leakage

1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check thatthere is no fuel leakage at connection points.NOTE:Use mirrors for checking at points out of clear sight.

2. Start the engine. With engine speed increased, check that again that there is no fuel leakage at connec-tion points.CAUTION:Never touch the engine immediately after it is stopped because the engine is extremely hot.

PBIC3795E

1 : Centralized under-floor piping

2 : Fuel feed hose

B : Under view

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OIL PAN (LOWER)

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OIL PAN (LOWER)

Exploded View (2WD) INFOID:0000000004496180

1. Oil level gauge 2. Oil level gauge guide 3. O-ring

4. O-ring 5. Connector bolt 6. Oil filter

7. Relief valve 8. Oil pressure switch 9. Oil strainer

10. Oil temperature sensor 11. Washer 12. Oil pan (upper)

13. Drain plug 14. Drain plug washer 15. Oil pan (lower)

16. Rear plate cover 17. Rear cover plate (M/T models)

A. Refer to LU-9 B. To oil pump C. Oil pan side


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OIL PAN (LOWER)
Exploded View (AWD) INFOID:0000000004496181


REMOVALCAUTION:Never drain engine oil when the engine is hot to avoid the danger of being scalded.1. Remove engine undercover with power tool.2. Remove oil pan (lower) as follows:


4. O-ring 5. Gasket 6. Oil strainer


10. Baffle plate 11. O-ring (small) 12. Axle pipe

13. O-ring (large) 14. Rear plate cover 15 Oil pan (upper)



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OIL PAN (LOWER)

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a. Loosen mounting bolts in reverse order as shown in the figure toremove.

b. Insert the seal cutter [SST: KV10111100 (J-37228)] (A) betweenoil pan (upper) and oil pan (lower).CAUTION:• Be careful not to damage the mating surfaces.• Never insert a screwdriver. This damages the mating sur-

faces.c. Slide the seal cutter by tapping on the side of tool with a ham-

mer. Remove oil pan (lower).

INSTALLATION1. Install oil pan (lower) as follows:a. Use scraper (A) to remove old liquid gasket from mating sur-

faces.• Remove old liquid gasket from the bolt holes and thread.CAUTION:Never scratch or damage the mating surfaces when clean-ing off old liquid gasket.

b. Apply a continuous bead of liquid gasket with the tube presser(commercial service tool) to the oil pan (lower) as shown in thefigure.

Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".CAUTION:Attaching should be done within 5 minutes after coating.

c. Install oil pan (lower).

: Engine front

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a : φ4.0 - 5.0 mm (0.157 - 0.197 in)

: Engine front

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OIL PAN (LOWER)
• Tighten mounting bolts in numerical order as shown in the fig-ure.

2. Install oil pan drain plug.• Refer to the figure of the components of on the prior page for installation direction of drain plug washer.

Refer to EM-43, "Exploded View (2WD)".3. Install in the reverse order of removal after this step.

NOTE:Wait at least 30 minutes after oil pan is installed before pouring engine oil.


INSPECTION AFTER REMOVALClean oil strainer if any object is attached.

INSPECTION AFTER INSTALLATION1. Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection".2. Start engine, and check there is no leakage of engine oil.3. Stop engine and wait for 10 minutes.4. Check the engine oil level again. Refer to LU-6, "Inspection".

: Engine front

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IGNITION COIL, SPARK PLUG AND ROCKER COVER

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REMOVAL1. Remove the following parts:

• Engine cover: Refer to EM-25, "Exploded View".• Air cleaner case and air duct (RH and LH): Refer to EM-27, "Exploded View".• Intake manifold collector: Refer to EM-29, "Exploded View".

2. Disconnect PCV hose from rocker cover.3. Remove PCV valve and O-ring from rocker cover, if necessary.4. Remove oil filler cap from rocker cover, if necessary. 5. Remove ignition coil.

CAUTION:Never shock ignition coil.

6. Remove harness clips on the rocker cover.

1. PCV hose 2. Clamp 3. PCV valve

4. O-ring 5. Clamp 6. PCV hose

7. Ignition coil 8. Spark plug 9. Rocker cover (bank 1)

10. Oil filler cap 11. Rocker cover gasket (bank 1) 12. Clamp

13. PCV hose 14. PCV hose 15. Rocker cover gasket (bank 2)

16. Rocker cover (bank 2)

A. To intake manifold collector B. To air duct C. VVEL ladder assembly side

D. Refer to EM-47


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< REMOVAL AND INSTALLATION >7. Loosen mounting bolts with power tool in reverse order as

8. Remove rocker cover gasket from rocker cover.9. Use scraper to remove all traces of liquid gasket from cylinder head and VVEL ladder assembly.

CAUTION:Never scratch or damage the mating surface when cleaning off old liquid gasket.

INSTALLATION1. Apply liquid gasket to the position shown in the figure with the

following procedure:

a. Refer to figure (E) to apply liquid gasket to joint part of VVEL lad-der assembly (1) and cylinder head.

b. Refer to figure (H) to apply liquid gasket in 90 degrees to figure.Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".

2. Install rocker cover gasket to rocker cover.3. Install rocker cover.

• Check that rocker cover gasket does not drop from the installation groove of rocker cover.

A : Bank 1

B : Bank 2

: Engine front

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2 : Actuator bracket (rear)

3 : VVEL actuator sub assembly

A : Liquid gasket application point

F : View F

I : End surface of VVEL ladder assembly

b : 4 mm (0.16 in)

c : φ2.5 - 3.5 mm (0.098 - 0.138 in)

d : 5 mm (0.20 in)

g : 10 mm (0.39 in)

: Engine front

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4. Tighten bolts in two steps separately in numerical order asshown in the figure.


A : Bank 1

B : Bank 2

: Engine front

1st step: 2.0 N·m (0.2 kg-m, 18 in-lb)

2nd step: 8.3 N·m (0.85 kg-m, 73 in-lb)

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TIMING CHAIN
TIMING CHAIN


1. Timing chain (secondary) 2. Camshaft sprocket (EXH) 3. O-ring

4. Timing chain (secondary) 5. Camshaft sprocket (EXH) 6. Internal chain guide

7. Timing chain (primary) 8. Camshaft sprocket (INT) (bank 1) 9. Timing chain tensioner (primary)

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TIMING CHAIN

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REMOVAL1. Release the fuel pressure. Refer to EC-614, "Inspection".2. Disconnect the battery cable from the negative terminal.3. Remove engine cover with power tool. Refer to EM-25, "Exploded View".4. Remove radiator reservoir tank. Refer to CO-13, "Exploded View".5. Remove air duct and air cleaner case assembly (RH and LH). Refer to EM-27, "Exploded View".6. Remove engine undercover with power tool.7. Drain engine coolant from radiator. Refer to CO-7, "Draining".

CAUTION:• Perform this step when the engine is cold.• Never spill engine coolant on drive belt.

8. Remove radiator hose (upper and lower). Refer to CO-13, "Exploded View".9. Drain engine oil. Refer to LU-8, "Draining".

CAUTION:Perform this step when the engine is cold.

10. Remove radiator cooling fan assembly. Refer to CO-13, "Exploded View".11. Remove drive belt. Refer to EM-13, "Removal and Installation".12. Separate engine harnesses by removing their brackets from front timing chain case.13. Remove intake manifold collector. Refer to EM-29, "Exploded View".14. Remove fuel sub tube mounting bolt. Refer to EM-37, "Exploded View".15. Remove oil level gauge and oil level gauge guide.16. Remove A/C compressor from bracket with piping connected, and temporarily secure it aside. Refer to

HA-39, "Exploded View".17. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.

Refer to ST-48, "FOR MODELS WITHOUT 4WAS AND MODELS EXCEPT SPORT MODELS : ExplodedView" or ST-53, "FOR MODELS WITH 4WAS AND SPORT MODELS : Exploded View".

18. Remove power steering oil pump bracket.19. Remove idler pulley, drive belt auto-tensioner and bracket. Refer to EM-26, "Exploded View".20. Remove alternator and alternator bracket. Refer to CHG-25, "2WD : Exploded View" (2WD models) or

CHG-27, "AWD : Exploded View" (AWD models).21. Remove water pipe. Refer to CO-23, "Exploded View".

10. Slack guide 11. Crankshaft sprocket 12. Camshaft sprocket (INT) (bank 2)

13. Tension guide 14.Intake valve timing control cover gasket (bank 1)

15. Seal ring

16.Intake valve timing control cover (bank 1)

17. O-ring 18.Camshaft position sensor (PHASE) (bank 1)


22.Intake valve timing control solenoid valve (bank 2)


24.Camshaft position sensor (PHASE) (bank 2)

25.Intake valve timing control cover gasket (bank 2)

26. Front oil seal 27. Crankshaft pulley

28. Crankshaft pulley bolt 29.Intake valve timing control solenoid valve (bank 1)

30. Power steering oil pump bracket

31. Idler pulley bracket 32. Alternator bracket 33. Water outlet (front)

34. Front timing chain case 35. Rear timing chain case 36. O-ring

37. O-ring 38. O-ring

A. Refer to EM-51 B. Refer to EM-90 C. Oil filter

Refer to GI-4, "Components" for symbol marks in the figure.


TIMING CHAIN
< REMOVAL AND INSTALLATION >22. Remove camshaft position sensor (PHASE).
CAUTION:• Handle carefully to avoid dropping and shocks.• Never disassemble.• Never allow metal powder to adhere to magnetic part at

sensor tip.• Never place sensors in a location where they are exposed

to magnetism.

23. Remove intake valve timing control covers and gasket as follows:a. Disconnect intake valve timing control solenoid valve harness connector.b. Loosen mounting bolts in reverse order as shown in the figure.

CAUTION:Shaft is internally jointed with camshaft sprocket (INT) cen-ter hole. When removing, keep it horizontal until it is com-pletely disconnected.

c. Shaft is engaged with camshaft sprocket (INT) center hole on inside. Pull straight out so that it does not tiltuntil the joint is disengaged.

24. Remove intake valve timing control solenoid valve, if necessary.CAUTION:Intake valve timing control solenoid valve is nonreusable. Never remove it unless required.

25. Remove rocker covers (bank 1 and bank 2). Refer to EM-47, "Exploded View".26. Obtain No.1 cylinder at TDC of its compression stroke as follows:a. Rotate crankshaft pulley clockwise to align timing mark (grooved

line without color) with timing indicator.

b. Check that exhaust cam noses on No.1 cylinder (engine frontside of bank 1) is located as shown in the figure.

• If not, turn crankshaft one revolution (360 degrees) and alignas shown in the figure.

27. Remove crankshaft pulley as follows:

A : Keep free from magnetic materials

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A : Bank 1

B : Bank 2

C : Dowel pin hole

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: Timing mark (grooved line without color)

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: Engine front

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TIMING CHAIN

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a. Remove rear cover plate and set the ring gear stopper [SST:KV10118600 (J-48641)] (A) as shown in the figure.

b. Loosen crankshaft pulley bolt and rotate bolt seating surface at10 mm (0.39 in) from its original position.

CAUTION:Never remove crankshaft pulley bolt because it is used as asupporting point for suitable puller.

c. Place suitable puller tab on holes of crankshaft pulley, and pullcrankshaft pulley through.CAUTION:Never put suitable puller tab on crankshaft pulley periphery,because this damages internal damper.

28. Remove oil pan (lower). Refer to EM-43, "Exploded View (2WD)" (2WD models) or EM-44, "ExplodedView (AWD)" (AWD models).

29. Loosen two mounting bolts in front of oil pan (upper) with powertool in reverse order as shown in the figure.

30. Remove front timing chain case as follows:

1 : Oil pan (upper)

2 : Flywheel (M/T models) or drive plate (A/T models)

: Vehicle front

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: Engine front

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TIMING CHAIN
< REMOVAL AND INSTALLATION >a. Loosen mounting bolts in reverse order as shown in the figure.
b. Insert a suitable tool (A) into the notch at the top of front timingchain case as shown.

c. Pry off case by moving the suitable tool as shown.• Use the seal cutter [SST: KV10111100 (J-37228)] to cut liquid

gasket for removal. CAUTION:• Never use a screwdriver or a similar item. • After removal, handle front timing chain case carefully so

it does not tilt, cant, or warp under a load.

31. Remove front oil seal from front timing chain case using a suit-able tool.• Use a screwdriver for removal.CAUTION:Be careful not to damage front timing chain case.

32. Remove O-ring (1) from rear timing chain case.

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A : Bank 1

B : Bank 2

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TIMING CHAIN

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33. Remove timing chain tensioner (primary) (1) as follows:a. Remove lower mounting bolt (A).b. Loosen upper mounting bolt (B) slowly, and then turn timing

chain tensioner (primary) on the upper mounting bolt so thatplunger (C) is fully expanded.NOTE:Even if plunger is fully expanded, it does not drop from the bodyof timing chain tensioner (primary).

c. Remove upper mounting bolt, and then remove timing chain ten-sioner (primary).

34. Remove internal chain guide (1), slack guide (2) and tensionguide (3).

35. Remove timing chain (primary) and crankshaft sprocket.CAUTION:After removing timing chain (primary), never turn crankshaft and camshaft separately, or valvesstrike the piston heads.

36. Remove timing chain (secondary) and camshaft sprockets as follows:a. Attach suitable stopper pin (C) to the timing chain tensioners

(secondary) (1), (2).

NOTE:• Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a

stopper pin.• For removal of timing chain tensioners (secondary), refer to

EM-94, "Exploded View". (Removing VVEL ladder assembly isrequired.)

b. Remove camshaft sprocket (EXH) mounting bolt.• Secure the hexagonal portion of camshaft (EXH) using a wrench to loosen mounting bolt.

CAUTION:Never loosen the mounting bolt by securing anything other than the camshaft (EXH) hexagonalportion or with tensioning the timing chain.

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A : Bank 1

B : Bank 2

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TIMING CHAIN
< REMOVAL AND INSTALLATION >c. Remove camshaft sprocket (INT) mounting bolt.
• Secure the hexagonal portion (located in between journal No.1 and journal No. 2) of drive shaft (A) using a wrench to loosenmounting bolt.

CAUTION:• Never loosen the mounting bolt by securing anything

other than the drive shaft hexagonal portion or with ten-sioning the timing chain.

• When holding the hexagonal part of drive shaft on theintake side with a wrench, be careful not to allow the wrench to cause interference with otherparts.

• Never disassemble camshaft sprocket (INT). [Neverloosen bolts (A) as shown in the figure.]

d. Remove timing chain (secondary) together with camshaft sprockets.37. Use a scraper to remove all traces of old liquid gasket from front

and rear timing chain cases and oil pan (upper), and liquid gas-ket mating surfaces.CAUTION:Be careful not to allow gasket fragments to enter oil pan.

38. Remove old liquid gasket from bolt hole and thread.

INSTALLATIONNOTE:The figure below shows the relationship between the matching mark on each timing chain and that on the cor-responding sprocket with the components installed.


: Engine front

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A : Remove old liquid gasket that is stuck

B : Bolt hole

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TIMING CHAIN

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1. Check that dowel pin (A) and crankshaft key (1) are located asshown in the figure. (No. 1 cylinder at compression TDC)NOTE:Though camshaft does not stop at the position as shown in thefigure, for the placement of cam noses, it is generally acceptedthat camshaft is placed in the same direction as that of the fig-ure.

2. Install timing chains (secondary) and camshaft sprockets as follows:CAUTION:Matching marks between timing chain and sprockets slip easily. Confirm all matching mark posi-tions repeatedly during the installation process.

1. Internal chain guide 2. Camshaft sprocket (INT) 3. Timing chain (secondary)

4. Camshaft sprocket (EXH) 5. Timing chain tensioner (primary) 6. Slack guide

7. Timing chain (primary) 8. Crankshaft sprocket 9. Water pump

10. Tension guide 11.Timing chain tensioner (secondary) (bank 2)

12.Timing chain tensioner (secondary) (bank 1)

A. Matching mark [punched (back side)] B. Matching mark (yellow link) C. Matching mark (punched)

D. Matching mark (orange link) E. Matching mark (notched) F. Crankshaft key

G. Matching mark [punched]

Camshaft dowel pin: At cylinder head upper face side in each bank.

Crankshaft key: At cylinder head side of bank 1.

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TIMING CHAIN
< REMOVAL AND INSTALLATION >a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with a stopper pin (A).

b. Install timing chains (secondary) and camshaft sprockets.NOTE:Figure shows bank 1 (rear view).

• Align the matching marks on timing chain (secondary) (orangelink) with the ones on intake and exhaust camshaft sprockets(punched), and install them.NOTE:• Matching marks for camshaft sprockets (INT) are on the

back side of camshaft sprockets (secondary).• There are two types of matching marks, the circle and oval

types. They should be used for the bank 1 and bank 2,respectively.

• Shape (orientation of signal plate) of camshaft sprocket (INT)varies depending on the bank position. See the right figure toinstall.

• Align dowel pin camshafts with the pin groove on sprockets, and install them.• In case that positions of each matching mark and each dowel pin do not fit with matching parts, make

fine adjustment to the position holding the hexagonal portion on camshaft (EXH) or drive shaft withwrench or equivalent tool.

• Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand issufficient to prevent the dislocation of dowel pins.

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A : Camshaft sprocket (INT) back face

B : Orange link

C : Dowel groove

D : Matching mark (oval)

E : Matching mark (2 oval: on front face)

F : Matching mark (circle)

G : Camshaft sprocket (EXH) back face

H : Matching mark (2 circle: on front face)

I : Timing chain (secondary)

Bank 1 : Use circle typeBank 2 : Use oval type

A : Bank 1

B : Bank 2

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TIMING CHAIN

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• It may be difficult to visually check the dislocation of matchingmarks during and after installation. To make the matching eas-ier, make a matching mark on the top of sprocket teeth and itsextended line in advance with paint.

c. Tighten camshaft sprocket (EXH) mounting bolt.• Secure camshaft (EXH) using a wrench at the hexagonal portion to tighten mounting bolt.

d. After confirming the matching marks are aligned, tighten camshaft sprocket (INT) mounting bolt.• Secure the hexagonal portion (located in between journal No.

1 and journal No. 2) of drive shaft (A) using a wrench to tightenmounting bolt.

CAUTION:When holding the hexagonal part of drive shaft on theintake side with a wrench, be careful not to allow thewrench to cause interference with other parts.

e. Pull stopper pins (C) out from timing chain tensioners (second-ary) (1), (2).

3. Install timing chain (primary) as follows:a. Install crankshaft sprocket (1).

• Check that the matching marks on crankshaft sprocket facethe front of the engine.

b. Install timing chain (primary).

A : Matching mark (painted)

B : Matching mark (orange link)

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: Engine front

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A : Bank 1

B : Bank 2

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A : Matching mark (front side)

: Engine front

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TIMING CHAIN
• Install timing chain (primary) so that the matching mark(punched) (B) on camshaft sprocket (INT) (1) is aligned withthe yellow link (A) on timing chain, while the matching mark(notched) (C) on crankshaft sprocket (2) is aligned with theorange link (D) one on timing chain, as shown in the figure.

• When it is difficult to align matching marks of timing chain (pri-mary) with each sprocket, gradually turn drive shaft usingwrench on the hexagonal portion to align it with the matchingmarks.

4. Install internal chain guide (1), slack guide (2), and tension guide(3).

CAUTION:

3 : Water pump

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Never overtighten slack guide mounting bolt (2). It is nor-mal for a gap (A) to exist under the bolt seats when mount-ing bolt are tightened to the specification.

5. Install the timing chain tensioner (primary) with the following procedure:a. Pull plunger stopper tab (A) up (or turn lever downward) so as to

remove plunger stopper tab from the ratchet of plunger (D).NOTE:Plunger stopper tab and lever (C) are synchronized.

b. Push plunger into the inside of tensioner body.c. Hold plunger in the fully compressed position by engaging

plunger stopper tab with the tip of ratchet.d. To secure lever, insert stopper pin (E) through hole of lever into

tensioner body hole (B).• The lever parts and the plunger stopper tab are synchronized.

Therefore, the plunger is secured under this condition.NOTE:Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.

e. Install timing chain tensioner (primary) (1).• Remove any dirt and foreign materials completely from the

back and the mounting surfaces of timing chain tensioner (pri-mary).

f. Pull out stopper pin (A) after installing, and then release plunger.

6. Check again that the matching marks on sprockets and timing chain have not slipped out of alignment.7. Install new O-rings (1) on rear timing chain case.

1 : Slack guide

3 : Cylinder block

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A : Bank 1

B : Bank 2

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TIMING CHAIN
< REMOVAL AND INSTALLATION >8. Install new front oil seal on front timing chain case.
• Apply new engine oil to both oil seal lip (A) and dust seal lip(B).

• Install it so that each seal lip is oriented as shown in the figure.

• Using a suitable drift [outer diameter: 60 mm (2.36 in)] (A),press-fit oil seal until it becomes flush with front timing chaincase end face.

• Check that the garter spring is in position and seal lip is notinverted.

9. Install front timing chain case as follows:• Check that O-rings stay in place during installation to rear timing chain case.

a. Apply a continuous bead of liquid gasket with the tube presser(commercial service tool) to front timing chain case back side asshown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".

: Engine inside

: Engine outside

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B : Protrusion

c : φ3.4 - 4.4 mm (0.134 - 0.173 in)

d : φ2.6 - 3.6 mm (0.102 - 0.142 in)

e : 4.0 - 5.6 mm (0.157 - 0.220 in)

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TIMING CHAIN

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b. Apply liquid gasket to top surface of oil pan (upper) as shown inthe figure.

Use Genuine RTV Silicone Sealant or equivalent. RefertoGI-17, "Recommended Chemical Products and Sealants".

c. Assemble front timing chain case.

CAUTION:• Be careful not to damage front oil seal by interference

with front end of crankshaft.• Attaching should be done within 5 minutes after liquid

gasket application.d. Install front timing chain case fitting its dowel pin hole together with dowel pin on rear timing chain case.e. Tighten mounting bolts to the specified torque in numerical order

as shown in the figure.• There are two types of mounting bolts. Refer to the following

for locating bolts.

f. After all bolts are tightened, retighten them to the specifiedtorque in numerical order shown in the figure.CAUTION:Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).

g. Install two mounting bolts in front of oil pan (upper) in numericalorder shown in the figure.

10. Install intake valve timing control covers as follows:

A : φ4.0 - 5.0 mm (0.157 - 0.197 in)

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1 : Front timing chain case

2 : Oil pan (upper)

3 : Cylinder block

: Engine front

M10 bolts : 1, 2, 3, 4, 5, 6, 7

: 55.0 N·m (5.6 kg-m, 41 ft-lb)M6 bolts : Except the above

: 12.7 N·m (1.3 kg-m, 9 ft-lb)

: Engine front

Tightening torque : Refer to EM-82, "2WD : Exploded View".

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TIMING CHAIN
< REMOVAL AND INSTALLATION >a. Install new seal rings (1) in shaft grooves.
CAUTION:When replacing seal ring, replace all rings with new ones.NOTE:The figure shows an example of bank 2.

b. Install intake valve timing control cover with new gasket to front timing chain case.CAUTION:• Align the center of both shaft holes of the shaft and the intake side camshaft sprocket, and then

insert them.• Be careful not to drop the seal ring from the shaft groove.

c. Being careful not to move seal ring from the installation groove,align dowel pins on front timing chain case with dowel pin holes(C) to install intake valve timing control covers.

d. Tighten mounting bolts in numerical order as shown in the fig-ure.• After all bolts are tightened, tighten No.1 bolt to the specified

torque again.

11. Install oil pan (lower). Refer to EM-43, "Exploded View (2WD)" (2WD models) or EM-44, "Exploded View(AWD)" (AWD models).

12. Install rocker covers (bank 1 and bank 2). Refer to EM-47, "Exploded View".13. Install crankshaft pulley as follows:a. Fix crankshaft using the ring gear stopper [SST: KV10118600 (J-48641)].b. Install crankshaft pulley, taking care not to damage front oil seal.

• When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).c. Tighten crankshaft pulley bolt.

d. Tighten the bolt 90 degrees (one mark) (b).• Place a matching mark (A) on crankshaft pulley (2) aligning

with the matching (C) of crankshaft pulley bolt (1).

e. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turnssmoothly.

14. Install power steering oil pump bracket and idler pulley bracket as follows:

A : Bank 2

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A : Bank 1

B : Bank 2

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: 44.1 N·m (4.5 kg-m, 33 ft-lb)

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TIMING CHAIN

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a. Tighten mounting bolts in numerical order as shown in the fig-ure. (temporarily)

b. Tighten mounting bolts to specified torque in numerical order asshown in the figure.

15. For the following operations, perform steps in the reverse order of removal.



Timing ChainCheck for cracks and any excessive wear at link plates and rollerlinks of timing chain. Replace timing chain if necessary.


Inspection for Leakage

The following are procedures for checking fluid leakage, lubricant leakage.• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the

required quantity, fill them to the specified level. Refer to MA-10, "Fluids and Lubricants".• Follow the procedure below to check for fuel leakage.- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping,

check for fuel leakage at connection points.- Start engine. With engine speed increased, check again for fuel leakage at connection points.• Run engine to check for unusual noise and vibration.

NOTE:If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate apounding noise during and just after the engine start. However, this does not indicate a malfunction. Thenoise will stop after hydraulic pressure rises.

• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil andengine coolant.

• Bleed air from lines and hoses of applicable lines, such as in cooling system.

1 : Idler pulley bracket

2 : Power steering oil pump bracket


A : Engine front side

B : Engine right side

: Engine front

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A : Crack

B : Wear

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TIMING CHAIN
< REMOVAL AND INSTALLATION >• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.

Summary of the inspection items:

*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

Items Before starting engine Engine running After engine stopped

Engine coolant Level Leakage Level

Engine oil Level Leakage Level

Other oils and fluids* Level Leakage Level

Fuel Leakage Leakage Leakage


OIL SEAL

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OIL SEALFRONT OIL SEAL

FRONT OIL SEAL : Removal and Installation INFOID:0000000004250502

REMOVAL1. Remove the following parts:

• Engine undercover with power tool.• Drive belt: Refer to EM-13, "Exploded View".• Crankshaft pulley: Refer to EM-50, "Exploded View".

2. Remove front oil seal using a suitable tool.CAUTION:Be careful not to damage front timing chain case and crank-shaft.

INSTALLATION1. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal.2. Install front oil seal.

• Install front oil seal so that each seal lip is oriented as shown inthe figure.

• Using a suitable drift, press-fit until the height of front oil seal islevel with the mounting surface.

- Suitable drift: outer diameter 60 mm (2.36 in), inner diameter50 mm (1.97 in).

• Check that the garter spring is in position and seal lips are notinverted.

CAUTION:• Be careful not to damage front timing chain case and

crankshaft.• Press-fit straight and avoid causing burrs or tilting oil

seal.3. Install in the reverse order of removal after this step.

REAR OIL SEAL

REAR OIL SEAL : Removal and Installation INFOID:0000000004250503

REMOVAL1. Remove transmission assembly. Refer to TM-26, "Exploded View" (M/T models), TM-294, "2WD :

Exploded View" (2WD A/T models) or TM-297, "AWD : Exploded View" (AWD A/T models).

PBIC2931E

A : Oil seal lip

B : Dust seal lip

: Engine inside

: Engine outside

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PBIC2931E


OIL SEAL
< REMOVAL AND INSTALLATION >2. Remove drive plate (A/T models) or fly wheel (M/T models). Refer to EM-121, "Exploded View".3. Remove rear oil seal with a suitable tool.
CAUTION:Be careful not to damage crankshaft and cylinder block.

INSTALLATION1. Install rear oil seal.

• Install rear oil seal so that each seal lip is oriented as shown inthe figure.

• Press in rear oil seal (1) to the position as shown in the figure.

• Using a suitable drift (A), press-fit until the height of rear oil seal islevel with the mounting surface.

- Suitable drift: outer diameter 100 mm (3.94 in), inner diameter 85mm (3.35 in).CAUTION:• Be careful not to damage crankshaft and cylinder block.• Press-fit straight and avoid causing burrs or tilting oil seal.


PBIC2932E

A : Oil seal lip

B : Dust seal lip

: Engine inside

: Engine outside

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B : Cylinder block rear end face

a : 0 - 0.5 mm (0 - 0.020 in)

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ENGINE ASSEMBLY

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E

UNIT REMOVAL AND INSTALLATIONENGINE ASSEMBLY2WD

2WD : Exploded View INFOID:0000000004496182

2WD : Removal and Installation INFOID:0000000004496183

WARNING:• Situate the vehicle on a flat and solid surface.• Place chocks at the front and back of rear wheels.• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS

CATALOG.CAUTION:• Always be careful to work safely, and avoid forceful or uninstructed operations.• Never start working until exhaust system and engine coolant are cool enough.• If items or work required are not covered by the engine section, refer to the applicable sections.• Always use the support point specified for lifting.• Use either 2-pole lift type or separate type lift as much as possible. If board-on type is used for

unavoidable reasons, support at rear axle jacking point with transmission jack or similar tool beforestarting work, in preparation for the backward shift of the center of gravity.

• For supporting points for lifting and jacking point at rear axle, refer to GI-32, "Garage Jack andSafety Stand and 2-Pole Lift".

REMOVAL

Outline

1. Engine mounting bracket (RH) 2. Engine mounting insulator (RH) 3. Engine mounting bracket (LH)

4. Engine mounting insulator (LH) 5. Rear engine mounting member 6. Engine mounting insulator (rear)

7. Dynamic damper (M/T models) 8. Dynamic damper (A/T models)

A. Front mark

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ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >At first, remove the engine and the transmission assembly with front suspension member facing downward.Then separate the engine from transmission.
Preparation

1. Release fuel pressure. Refer to EC-614, "Inspection".2. Disconnect both battery cables. Refer to PG-99, "Exploded View".3. Drain engine coolant from radiator. Refer to CO-7, "Draining".

CAUTION:• Perform this step when engine is cold.• Never spill engine coolant on drive belt.

4. Remove the following parts:• Radiator reservoir tank: Refer to CO-13, "Exploded View".• Engine cover: Refer to EM-25, "Exploded View".• Front road wheel and tires (power tool)• Engine undercover (power tool)• Cowl top cover: Refer to EXT-21, "Exploded View".• Air duct and air cleaner case assembly (RH and LH): Refer to EM-27, "Exploded View".• Cooling fan assembly: Refer to CO-13, "Exploded View".

5. Discharge refrigerant from A/C circuit. Refer to HA-26, "Collection and Charge".6. Remove radiator hoses (upper and lower). Refer to CO-13, "Exploded View".

Engine Room LH

1. Disconnect heater hose at vehicle side, and fit a plug onto hose end to prevent engine coolant leakage.2. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to HA-

41, "Exploded View".3. Disconnect brake booster vacuum hose.4. Disconnect ground cable.

Engine Room RH

1. Disconnect battery positive cable at vehicle side and temporarily fasten it on engine. 2. Disconnect all clips and connectors of the engine room harness from engine back side.3. Disconnect fuel feed hose (with damper) and EVAP hose. Refer to EM-37, "Exploded View".

CAUTION:Fit plugs onto disconnected hoses to prevent fuel leakage.

4. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure themon engine. Refer to ST-59, "2WD : Exploded View".CAUTION:When temporarily securing, keep the reservoir tank upright to avoid fluid leakage.

Vehicle InsideFollow the procedure below to disconnect engine room harness connectors at passenger room side, and tem-porarily secure them on engine.1. Remove passenger-side kicking plate and dash side finisher. Refer to INT-14, "Exploded View".2. Disconnect engine room harness connectors at unit sides TCM, ECM and other locations.3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily

secure them on engine.CAUTION:• When pulling out harnesses, take care not to damage harnesses and connectors.• After temporarily securing, cover connectors with vinyl or similar material to protect against

adhesion of foreign materials.

Vehicle Underbody

1. Remove A/T fluid cooler hoses (A/T models) and power steering oil pump oil cooler hoses.• Install plug to avoid leakage of A/T fluid and power steering fluid.

2. Disconnect heated oxygen sensor 2 harness. Refer to EX-5, "Exploded View".3. Remove three way catalyst and exhaust front tube. Refer to EX-5, "Exploded View".


ENGINE ASSEMBLY

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4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.Refer to ST-24, "WITHOUT 4WAS : Exploded View" (without 4WAS models) or ST-25, "WITH 4WAS :Exploded View" (with 4WAS models).

5. Remove rear propeller shaft. Refer to DLN-90, "Exploded View" (M/T models) or DLN-97, "ExplodedView" (A/T models).

6. Disengage shift lever and remove clutch tube (M/T models). Refer to TM-18, "Exploded View".7. Disengage A/T control rod at A/T shift selector side. Then, temporarily secure it on the transmission

assembly, so that it does not sag (A/T models). Refer to TM-281, "Exploded View". 8. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter (A/

T models). Refer to EM-43, "Exploded View (2WD)".9. Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Refer to EM-82, "2WD :

Exploded View".10. Remove front stabilizer connecting rod from transverse link. Refer to FSU-9, "Exploded View".11. Remove lower ends of left and right steering knuckle from transverse link. Refer to FAX-6, "Exploded

View". 12. Separate steering outer sockets from steering knuckle. Refer to ST-30, "2WD : Exploded View". 13. Remove transverse links mounting bolts at suspension member side. Refer to FSU-14, "Exploded View".

Removal Work

1. Use a manual lift table caddy (commercial service tool) or equiv-alently rigid tool such as a transmission jack. Securely supportbottom of suspension member and the transmission assembly.CAUTION:Use a piece of wood or a similar item as the supporting sur-face to secure a completely stable condition.

2. Remove rear engine mounting member bolts.3. Remove front suspension member mounting bolts and nuts. Refer to FSU-21, "Exploded View". 4. Carefully lower jack, or raise lift, to remove the engine, the transmission assembly and front suspension

member. When performing work, observe the following caution items:CAUTION:• Confirm there is no interference with the vehicle.• Check that all connection points have been disconnected.• Keep in mind that the center of gravity of the vehicle changes. If necessary, use jack(s) to sup-

port the vehicle at rear jacking point(s) to prevent it from falling off the lift.

Separation Work

1. Install engine slingers into front of cylinder head (bank 1) andrear of cylinder head (bank 2).

2. Remove power steering oil pump from engine side. Refer to ST-48, "FOR MODELS WITHOUT 4WASAND MODELS EXCEPT SPORT MODELS : Exploded View".

PBIC0804E

1 : Engine front slinger

2 : Engine rear slinger

A : Bank 1

B : Bank 2

: Engine front

Slinger bolts:

: 28.0 N·m (2.9 kg-m, 21 ft-lb)

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ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >3. Remove engine mounting insulators (RH and LH) under side nuts with power tool.4. Lift with hoist and separate the engine and the transmission assembly from front suspension member.
CAUTION:• Before and during this lifting, always check that any harnesses are left connected.• Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine

mounting insulator.5. Remove alternator. Refer to CHG-25, "2WD : Exploded View".6. Remove starter motor. Refer to STR-15, "Exploded View".7. Separate the engine from the transmission assembly. Refer to TM-26, "Exploded View" (M/T models) or

TM-294, "2WD : Exploded View" (A/T models).8. Remove each engine mounting insulator and each engine mounting bracket from the engine with power

tool.

INSTALLATIONNote the following, and install in the reverse order of removal.• Do not damage engine mounting insulator and do not spill oil on it.• For a location with a positioning pin, insert it securely into hole of mating part.• For a part with a specified installation orientation, refer to component figure in EM-69, "2WD : Exploded

View".• When installing engine mounting bracket (RH and LH) on cylinder

block, tighten two upper bolts [shown as (B) in the figure] first.Then tighten two lower bolts [shown as (C) in the figure].

• Check that all engine mounting insulators are seated properly, then tighten mounting nuts.• Tighten rear engine mounting member bolts in numerical order as


2WD : Inspection INFOID:0000000004496184






NOTE:

A : Example Left

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: Vehicle front

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ENGINE ASSEMBLY

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If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate apounding noise during and just after the engine start. However, this does not indicate a malfunction. Thenoise will stop after hydraulic pressure rises.


• Bleed air from lines and hoses of applicable lines, such as in cooling system.• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to




AWD

AWD : Exploded View INFOID:0000000004496185






Exhaust gases — Leakage —

1. Engine mounting bracket (RH) 2.Engine mounting bracket (RH) (low-er)

3. Dynamic damper

4. Washer 5. Engine mounting insulator (RH) 6. Engine mounting bracket (LH)

7. Engine mounting insulator (LH) 8. Heat insulator 9. Rear engine mounting member

10. Engine mounting insulator (rear) 11. Dynamic damper

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ENGINE ASSEMBLY
AWD : Removal and Installation INFOID:0000000004496186

WARNING:• Situate the vehicle on a flat and solid surface.• Place chocks at front and back of rear wheels.• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS

CATALOG.CAUTION:• Always be careful to work safely, avoid forceful or uninstructed operations.• Never start working until exhaust system and engine coolant are cool enough.• If items or work required are not covered by the engine section, refer to the applicable sections.• Always use the support point specified for lifting.• Use either 2-pole lift type or separate type lift as much as possible. If board-on type is used for

unavoidable reasons, support at rear axle jacking point with transmission jack or similar tool beforestarting work, in preparation for the backward shift of center of gravity.

• For supporting points for lifting and jacking point at rear axle, refer to GI-32, "Garage Jack andSafety Stand and 2-Pole Lift".

REMOVAL

OutlineAt first, remove the engine, the transmission assembly, the transfer assembly and the front final drive assem-bly with front suspension member downward. Then separate the engine, the transmission assembly, the trans-fer and the front final drive assembly.

Preparation

1. Release fuel pressure. Refer to EC-614, "Inspection".2. Drain engine coolant from radiator. Refer to CO-7, "Draining".

CAUTION:• Perform this step when engine is cold.• Never spill engine coolant on drive belts.

3. Disconnect both battery terminals. Refer to PG-99, "Exploded View".4. Remove the following parts:

• Radiator reservoir tank: Refer to CO-13, "Exploded View".• Engine cover: Refer to EM-25, "Exploded View".• Front road wheel and tires (power tool)• Engine undercover (power tool)• Front cross bar: Refer to FSU-43, "Exploded View".• Cowl top cover: Refer to EXT-21, "Exploded View".• Air duct and air cleaner case assembly (RH and LH): Refer to EM-27, "Exploded View".• Cooling fan assembly: Refer to CO-16, "Exploded View".

5. Discharge refrigerant from A/C circuit. Refer to HA-26, "Collection and Charge".6. Remove radiator hoses (upper and lower). Refer to CO-13, "Exploded View".

Engine Room LH

1. Disconnect heater hose from vehicle side, and fit a plug onto hose end to prevent engine coolant leak.2. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to HA-

41, "Exploded View".3. Disconnect brake booster vacuum hose.4. Disconnect ground cables.

Engine Room RH

1. Disconnect battery positive cable vehicle side and temporarily fasten it on engine. 2. Disconnect all clips and connectors of the engine room harness from engine back side.3. Disconnect fuel feed hose (with damper) and EVAP hose. Refer to EM-37, "Exploded View".

CAUTION:

A. Front mark



ENGINE ASSEMBLY

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Fit plugs onto disconnected hoses to prevent fuel leakage.4. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure them

on engine. Refer to ST-48, "FOR MODELS WITHOUT 4WAS AND MODELS EXCEPT SPORT MODELS: Exploded View" (EXCEPT FOR SPORT MODELS) or ST-53, "FOR MODELS WITH 4WAS AND SPORTMODELS : Exploded View" (SPORT MODELS).CAUTION:When temporarily securing, keep the reservoir tank upright to avoid a fluid leakage.

Vehicle InsideFollow procedure below to disconnect engine room harness connectors at passenger room side, and tempo-rarily secure them on engine.1. Remove passenger-side kicking plate and dash side finisher. Refer to INT-14, "Exploded View".2. Disconnect engine room harness connectors at unit sides TCM, ECM and other.3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily

secure them on engine.CAUTION:• When pulling out harnesses, take care not to damage harnesses and connectors.• After temporarily securing, cover connectors with vinyl or similar material to protect against

adhesion of foreign materials.

Vehicle Underbody

1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses.• Install plug to avoid leakage of A/T fluid and power steering fluid.

2. Disconnect heated oxygen sensor 2 harness. Refer to EX-5, "Exploded View".3. Remove three way catalyst and exhaust front tube. Refer to EX-5, "Exploded View".4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.

Refer to ST-24, "WITHOUT 4WAS : Exploded View" (without 4WAS models) or ST-25, "WITH 4WAS :Exploded View" (with 4WAS models).

5. Remove rear propeller shaft. Refer to DLN-105, "Exploded View".6. Remove front drive shaft (both side). Refer to FAX-22, "Exploded View".7. Disconnect harness connector from transmission assembly and transfer assembly.8. Disengage A/T control rod at A/T shift selector side. Then, temporarily secure it on the transmission

assembly, so that it does not sag. Refer to TM-281, "Exploded View".9. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter.

Refer to EM-85, "AWD : Exploded View".10. Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Refer to EM-44, "Exploded

View (AWD)".11. Remove front stabilizer connecting rod from transverse link. Refer to FSU-41, "Exploded View".12. Remove lower ends of left and right steering knuckle from transverse link. Refer to FSU-31, "Exploded

View".13. Separate steering outer sockets from steering knuckle. Refer to ST-37, "AWD : Exploded View".14. Remove transverse links mounting bolts at suspension member side. Refer to FSU-36, "Exploded View".

Removal Work

1. Use a manual lift table caddy (commercial service tool) or equiv-alently rigid tool such as a transmission jack. Securely supportbottom of suspension member and the transmission assembly.CAUTION:Use a piece of wood or a similar item as the supporting sur-face to secure a completely stable condition.

2. Remove rear engine mounting member bolts.

PBIC0804E


ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >3. Remove front suspension member mounting bolts and nuts. Refer to FSU-43, "Exploded View".4. Carefully lower jack, or raise lift to remove the engine, transmission assembly, transfer, front final drive
assembly and front suspension member. When performing work, observe the following caution:CAUTION:• Confirm there is no interference with the vehicle.• Check that all connection points have been disconnected.• Keep in mind that the center of gravity of the vehicle changes. If necessary, use jack(s) to sup-

port the vehicle at rear jacking point(s) to prevent it from falling it off the lift.

Separation Work

1. Install engine slingers into front of cylinder head (bank 1) andrear of cylinder head (bank 2).

2. Remove power steering oil pump from engine side. Refer to ST-48, "FOR MODELS WITHOUT 4WASAND MODELS EXCEPT SPORT MODELS : Exploded View" (without 4WAS models).

3. Remove engine mounting insulators (RH and LH) under side nuts with power tool.4. Lift with hoist and separate the engine, transmission assembly, transfer, front final drive assembly and

front suspension member.CAUTION:• Before and during this lifting, always check any harnesses are left connected.• Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine

mounting insulator.5. Remove alternator. Refer to CHG-27, "AWD : Exploded View".6. Remove starter motor. Refer toSTR-15, "Exploded View".7. Remove front propeller shaft from the front final drive assembly side. Refer to DLN-83, "Exploded View".8. Separate the engine from the transmission assembly. Refer to TM-297, "AWD : Exploded View".9. Remove the front final drive assembly from oil pan (upper). Refer to DLN-120, "Exploded View".10. Remove each engine mounting insulator and each engine mounting bracket from the engine with power

tool.

INSTALLATIONNote the following, and install in the reverse order of removal.• Do not damage engine mounting insulator and do not spill oil on it.• For a location with a positioning pin, insert it securely into hole of mating part.• For a part with a specified installation orientation, refer to component figure in EM-73, "AWD : Exploded

View".

1 : Engine front slinger

2 : Engine rear slinger

A : Bank 1

B : Bank 2

: Engine front

Slinger bolts:

: 28.0 N·m (2.9 kg-m, 21 ft-lb)

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ENGINE ASSEMBLY

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• When installing engine mounting bracket (RH and LH) on cylinderblock, tighten two upper bolts [shown as (B) in the figure] first.Then tighten two lower bolts [shown as (C) in the figure].

• Install engine mounting bracket (RH) (lower) (2) as follows:- Temporarily tighten mounting bolts [shown as (D), (E) and (F) in

the figure].- Tighten mounting bolts to the specified torque with following

mounting surfaces touched.• Engine mounting bracket (RH) (1) to engine mounting bracket

(RH) (lower) [shown as and in figure].• Front final drive to engine mounting bracket (RH) (lower) [shown

as in figure].• Check all engine mounting insulators are seated properly, then

tighten mounting nuts.

• Tighten rear engine mounting member bolts in numerical order asshown in the figure.

AWD : Inspection INFOID:0000000004496187


Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the

required quantity, fill to the specified level. Refer to MA-10, "Fluids and Lubricants".• Follow the procedure below to check for fuel leakage.- Turn ignition switch to the “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for

fuel leakage at connection points.- Start engine. With engine speed increased, check again for fuel leakage at connection points.• Run engine to check for unusual noise and vibration.





3 : Engine mounting bracket (LH)

A : Right side

G : Left side

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: Vehicle front

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ENGINE ASSEMBLY





Other oils and fluid* Level Leakage Level


Exhaust gases — Leakage —


ENGINE STAND SETTING

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E

UNIT DISASSEMBLY AND ASSEMBLYENGINE STAND SETTING

Setting INFOID:0000000004250507

NOTE:Explained here is how to disassemble with engine stand supporting transmission surface. When using a differ-ent type of engine stand, note the difference in the steps, etc.1. Remove the engine assembly from the vehicle. Refer to EM-69, "2WD : Exploded View" (2WD models) or

EM-73, "AWD : Exploded View" (AWD models).2. Remove the parts that may restrict installation of engine to a widely use engine stand.

NOTE:The procedure is described assuming that you use a widely use engine stand holding the surface, towhich transmission is installed.• Remove clutch cover and clutch disc (M/T models). Refer to CL-19, "Exploded View".• Remove drive plate (A/T models) or flywheel (M/T models) with power tool. Fix crankshaft with a ring

gear stopper [SST: KV10118600 (J-48641)], and remove mounting bolts.• Loosen mounting bolts in diagonal order.• Check for deformation or damage of drive plate (A/T models) or flywheel (M/T models).

CAUTION:• Never disassemble drive plate (A/T models) or flywheel (M/T models).• Never place drive plate (A/T models) or flywheel (M/T models) with signal plate facing down.• When handling signal plate, take care not to damage or scratch it. • Handle signal plate in a manner that prevents it from becoming magnetized.

3. Remove pilot converter (A/T models) using the pilot bushingpuller [SST: ST16610001 (J-23907)] (A) if necessary.

4. Lift the engine with hoist to install it onto the widely use engine stand.CAUTION:Use an engine stand that has a load capacity [220 kg (485 lb) or more] large enough for supportingthe engine weight. • If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the

potential risk of overturning the stand.- Remove intake manifold collector. Refer to EM-29, "Exploded View". - Remove intake manifold. Refer to EM-32, "Exploded View".- Remove fuel injector and fuel tube assembly. Refer to EM-37, "Exploded View".- Remove ignition coil. Refer to EM-47, "Exploded View".- Remove rocker cover. Refer to EM-47, "Exploded View".- Remove exhaust manifold. Refer to EM-34, "Exploded View".- Other removable brackets.

NOTE:

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ENGINE STAND SETTING
The figure shows an example of widely use engine stand (A)that can hold mating surface of transmission with drive plate(A/T models) or flywheel (M/T models) removed.CAUTION:Before removing the hanging chains, check the enginestand is stable and there is no risk of overturning.

5. Drain engine oil. Refer to LU-8, "Draining".6. Drain engine coolant by removing water drain plug (1) from both

sides of the cylinder block as shown in the figure.

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2 : Washer

3 : Plug

4 : Drain plug

: Engine front

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ENGINE UNIT

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ENGINE UNIT

Disassembly INFOID:0000000004250508

1. Remove intake manifold collector. Refer to EM-29, "Exploded View".2. Remove intake manifold. Refer to EM-32, "Exploded View".3. Remove exhaust manifold. Refer to EM-34, "Exploded View".4. Remove oil pan (lower). Refer to EM-43, "Exploded View (2WD)" (2WD models) or EM-44, "Exploded

View (AWD)" (AWD models).5. Remove ignition coil, spark plug and rocker cover. Refer to EM-47, "Exploded View".6. Remove fuel injector and fuel tube. Refer to EM-37, "Exploded View".7. Remove timing chain. Refer to EM-50, "Exploded View".8. Remove rear timing chain case. Refer to EM-89, "Exploded View".9. Remove camshaft (EXH) and VVEL ladder assembly. Refer to EM-94, "Exploded View".10. Remove cylinder head. Refer to EM-111, "Exploded View".

Assembly INFOID:0000000004250509

Assemble in the reverse order of disassembly.


OIL PAN (UPPER) AND OIL STRAINER
OIL PAN (UPPER) AND OIL STRAINER2WD

2WD : Exploded View INFOID:0000000004496188

2WD : Disassembly and Assembly INFOID:0000000004496189

REMOVALCAUTION:Never drain engine oil when the engine is hot to avoid the danger of being scalded.1. Remove oil level gauge, oil pressure switch and oil temperature sensor.


4. O-ring 5. Connector bolt 6. Oil filter

7. Relief valve 8. Oil pressure switch 9. Oil strainer

10. Oil temperature sensor 11. Washer 12. Oil pan (upper)


16. Rear plate cover 17. Rear cover plate (M/T models)



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2. Remove oil pan (lower). Refer to EM-43, "Exploded View (2WD)".3. Remove oil strainer.4. Loosen mounting bolts in the reverse order as shown in the fig-

ure with power tool to remove.

• Insert the seal cutter [SST: KV10111100 (J-37228)] betweenoil pan (upper) and lower cylinder block. Slide seal cutter bytapping on the side of tool with a hammer. Remove oil pan(upper).CAUTION:• Be careful not to damage the mating surfaces.• Never insert a screwdriver, because this damages the

mating surfaces.

5. Remove O-rings (2) from bottom of lower cylinder block (1) andoil pump (3).

INSTALLATION1. Install oil pan (upper) as follows:a. Use a scraper (A) to remove old liquid gasket from mating sur-

faces.CAUTION:Never scratch or damage the mating surfaces when clean-ing off old liquid gasket.• Also remove old liquid gasket from mating surface of lower cyl-

inder block.• Remove old liquid gasket from the bolt holes and threads.

b. Install new O-rings (2) on the bottom of lower cylinder block (1)and oil pump (3).

: Engine front

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: Engine front

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: Engine front

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< UNIT DISASSEMBLY AND ASSEMBLY >c. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to the cylinder block mating surface ofoil pan (upper) to a limited portion as shown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".CAUTION:• For bolt holes with marks (7 locations), apply liquid

gasket outside the holes.• Attaching should be done within 5 minutes after coating.

d. Install oil pan (upper).CAUTION:Never misalign both O-rings during installation.• Tighten mounting bolts in numerical order as shown in the fig-

ure.

• There are two types of mounting bolts. Refer to the followingfor locating bolts.

2. Install oil strainer to oil pump.3. Install oil pan (lower). Refer to EM-43, "Exploded View (2WD)".4. Install oil pan drain plug.

• Refer to the figure of components on the prior page for installation direction of drain plug washer. Referto EM-43, "Exploded View (2WD)".

5. Install in the reverse order of removal after this step.NOTE:Wait at least 30 minutes after oil pan is installed before pouring engine oil.

2WD : Inspection INFOID:0000000004496190

INSPECTION AFTER REMOVALClean oil strainer if any object is attached.


AWD

a : φ4.0 - 5.0 mm (0.157 - 0.197 in)

: Engine front

: Engine front

M8 × 90 mm (3.54 in) : 7, 10, 13M8 × 25 mm (0.98 in) : Except the above

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AWD : Exploded View INFOID:0000000004496191

AWD : Disassembly and Assembly INFOID:0000000004496192

REMOVALCAUTION:Never drain engine oil when the engine is hot to avoid the danger of being scalded.1. Remove oil level gauge, oil pressure switch and oil temperature sensor.2. Remove oil filter bracket. Refer to LU-11, "Exploded View".3. Remove oil pan (lower). Refer to EM-44, "Exploded View (AWD)".4. Remove oil strainer.


4. O-ring 5. Gasket 6. Oil strainer


10. Baffle plate 11. O-ring (small) 12. Axle pipe

13. O-ring (large) 14. Rear plate cover 15. Oil pan (upper)



JPBIA2763GB


< UNIT DISASSEMBLY AND ASSEMBLY >5. Loosen mounting bolts in the reverse order as shown in the fig-
ure with power tool to remove.

• Insert the seal cutter [SST: KV10111100 (J-37228)] betweenoil pan (upper) and lower cylinder block. Slide seal cutter bytapping on the side of tool with a hammer. Remove oil pan(upper).CAUTION:• Be careful not to damage the mating surfaces.• Never insert a screwdriver, because this will damage the

mating surfaces.

6. Remove O-rings (2) from bottom of lower cylinder block (1) andoil pump (3).

7. Remove axle pipe, if necessary.• Remove axle pipe from oil pan (upper) using a suitable drift (A)

[outer diameter: 37 mm (1.46 in)].

INSTALLATION1. Install axle pipe (3) to oil pan (upper), if removed.

• Lubricate O-ring groove of axle pipe, O-rings (1), (2), and O-ring joint of oil pan with new engine oil.

Unit: mm (in)

: Engine front

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: Engine front

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Items O-ring inner diameter

Final drive side (right side) 31.4 (1.236)

Axle pipe flange side (left side) 33.6 (1.323)

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• Install axle pipe (1) to oil pan (upper) from axle pipe flangeside (left side) using a suitable drift (A) [outer diameter: 43 to57 mm (1.69 to 2.24 in)].CAUTION:Insert it with care to prevent O-ring from sliding.

2. Install oil pan (upper) as follows:a. Use a scraper (A) to remove old liquid gasket from mating sur-

faces.CAUTION:Never scratch or damage the mating surfaces when clean-ing off old liquid gasket.• Also remove old liquid gasket from mating surface of lower cyl-

inder block.• Remove old liquid gasket from the bolt holes and threads.

b. Install new O-rings (2) on the bottom of lower cylinder block (1)and oil pump (3).

c. Apply a continuous bead of liquid gasket with the tube presser(commercial service tool) to the cylinder block mating surface ofoil pan (upper) to a limited portion as shown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".CAUTION:• For bolt holes with marks (7 locations), apply liquid

gasket outside the holes.• Attaching should be done within 5 minutes after coating.

d. Install oil pan (upper).CAUTION:Never misalign both O-rings during installation.

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: Engine front

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a : φ4.0 - 5.0 mm (0.157 - 0.197 in)

: Engine front

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• Tighten mounting bolts in numerical order as shown in the fig-ure.

• There are three types of mounting bolts. Refer to the followingfor locating bolts.

3. Install oil strainer to oil pump.4. Install oil pan (lower). Refer to EM-44, "Exploded View (AWD)".5. Install oil pan drain plug.

• Refer to the figure of components on the prior page for installation direction of drain plug washer. Referto EM-44, "Exploded View (AWD)".

6. Install in the reverse order of removal after this step.NOTE:Wait at least 30 minutes after oil pan is installed before pouring engine oil.

AWD : Inspection INFOID:0000000004496193

INSPECTION AFTER REMOVALClean oil strainer if any object attached.


: Engine front

M8 × 25 mm (0.98 in) : 3, 6, 8, 9, 11, 12, 14, 15, 16M8 × 50 mm (1.97 in) : 2M8 × 90 mm (3.54 in) : 1, 4, 5, 7, 10, 13 JPBIA0022ZZ


REAR TIMING CHAIN CASE

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1. Timing chain (secondary) 2. Camshaft sprocket (EXH) 3. O-ring

4. Timing chain (secondary) 5. Camshaft sprocket (EXH) 6. Internal chain guide

7. Timing chain (primary) 8. Camshaft sprocket (INT) (bank 1) 9. Timing chain tensioner (primary)

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DISASSEMBLY1. Remove front timing chain case and timing chain. Refer to EM-51, "Removal and Installation".2. Remove water pump. Refer to CO-18, "Exploded View".3. Remove oil pan (upper). Refer to EM-82, "2WD : Exploded View" (2WD models) or EM-85, "AWD :

Exploded View" (AWD models).4. Remove rear timing chain case as follows:a. Loosen mounting bolts in reverse order as shown in the figure.b. Cut liquid gasket using the seal cutter [SST: KV10111100 (J-

37228)] and remove rear timing chain case.

CAUTION:• Never remove plate metal cover (1) of oil passage.• After removal, handle rear timing chain case carefully so

it does not tilt, cant, or warp under a load.

10. Slack guide 11. Crankshaft sprocket 12. Camshaft sprocket (INT) (bank 2)

13. Tension guide 14.Intake valve timing control cover gasket (bank 1)

15. Seal ring


17. O-ring 18.Camshaft position sensor (PHASE) (bank 1)


22.Intake valve timing control solenoid valve (bank 2)


24.Camshaft position sensor (PHASE) (bank 2)

25.Intake valve timing control cover gasket (bank 2)

26. Front oil seal 27. Crankshaft pulley

28. Crankshaft pulley bolt 29.Intake valve timing control solenoid valve (bank 1)

30. Power steering oil pump bracket

31. Idler pulley bracket 32. Alternator bracket 33. Water outlet (front)

34. Front timing chain case 35. Rear timing chain case 36. O-ring

37. O-ring 38. O-ring

A. Refer to EM-51 B. Refer to EM-90 C. Oil filter


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5. Remove O-rings (1) from cylinder block.

6. Use a scraper to remove all traces of liquid gasket from rear timing chain cases and opposite mating sur-faces.

7. Remove old liquid gasket from bolt hole and thread.

ASSEMBLY

1. Install rear timing chain case as follows:a. Install new O-rings (1) onto cylinder block.

b. Apply liquid gasket with the tube presser (commercial service tool) to rear timing chain case back side asshown in the figure.Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Prod-ucts and Sealants".CAUTION:• For in the figure, completely wipe off liquid gasket extended on a portion touching at engine

coolant.• Apply liquid gasket on installation position of water pump and cylinder head completely.

: Engine front

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A : Remove old liquid gasket that is stuck

B : Bolt hole

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: Engine front

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c. Align rear timing chain case with dowel pins (bank 1 and bank 2) on cylinder block and install rear timingchain case.• Check that O-rings stay in place during installation to cylinder block.

d. Tighten mounting bolts in numerical order as shown in the fig-ure.• There are three types of mounting bolts. Refer to the following

for locating bolts.

e. After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure.• If liquid gasket protrudes, wipe it off immediately.

C. Protrusion D. Clearance 1 mm (0.04 in) E. Do not protrude in this area

F. Run along bolt hole inner side G.Protrusions at beginning and end of gasket

h. φ3.4 - 4.4 mm (0.134 - 173 in) i. φ2.6 - 2.8 mm (0.102 - 0.110 in)


Bolt length: Bolt position20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 1016 mm (0.63 in) : 4, 5, 11, 12, 13

: 12.7 N·m (1.3 kg-m, 9 ft-lb)

16 mm (0.63 in) : Except the above

: 15.0 N·m (1.5 kg-m, 11 ft-lb)

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f. After installing rear timing chain case, check the surface heightdifference between the following parts on the oil pan (upper)mounting surface.

• If not within the standard, repeat the installation procedure.2. Install water pump with new O-rings. Refer to CO-18, "Exploded View".3. Install timing chains, camshaft sprockets and front timing chain case. Refer to EM-51, "Removal and

Installation".• After installing front timing chain case, check the surface

height difference between the following parts on the oil pan(upper) mounting surface.

• If not within the standard, repeat the installation procedure.4. Install oil pan (upper). Refer to EM-82, "2WD : Exploded View" (2WD models) or EM-85, "AWD : Exploded

View" (AWD models).5. Install in the reverse order of removal after this step.

1 : Rear timing chain case

2 : Lower cylinder block

StandardRear timing chain case to lower cylinder block:

–0.24 to 0.14 mm (–0.0094 to 0.0055 in)

1 : Front timing chain case

2 : Rear timing chain case

3 : Lower cylinder block

StandardFront timing chain case to rear timing chain case:

–0.14 to 0.14 mm (–0.0055 to 0.0055 in)

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CAMSHAFT
CAMSHAFT


CAUTION:As for replacement of parts on the intake side as shown in the exploded view, replace VVEL ladderassembly and cylinder head assembly. NOTE:

1.VVEL control shaft position sensor (bank 1)

2. VVEL actuator sub assembly (bank 1) 3. Actuator bracket (rear) (bank 1)

4. Washer 5. VVEL ladder assembly (bank 1) 6. Washer


8. Camshaft (EXH) (bank 1) 9. Valve lifter (EXH)

10. Valve lifter (INT) 11. Oil filter 12. Cylinder head (bank 1)


14. Cylinder head (bank 2) 15. Camshaft (EXH) (bank 2)

16. VVEL ladder assembly (bank 2) 17. VVEL actuator sub assembly (bank 2) 18.VVEL control shaft position sensor (bank 2)

19. Actuator bracket (rear) (bank 2)

A. Refer to EM-95


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CAMSHAFT

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VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinderhead assembly.

VVEL Ladder Assembly and Cylinder Head Assembly Features

NOTE:The figure shows an example of bank 2.


DISASSEMBLY

CAUTION:Never loosen adjusting bolts (A) and mounting bolts (black color) (B) of VVEL ladder assembly. If loos-ened, the stroke of cam lift becomes out of adjustment. In such case, replacement of VVEL ladderassembly and cylinder head assembly is required. NOTE:VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinderhead assembly.1. Remove rocker covers (bank 1 and bank 2). Refer to EM-47, "Exploded View".2. Remove VVEL actuator sub assembly as follows:

CAUTION:

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A. Control shaft B. Drive shaft C.Hexagonal part of drive shaft(for holding)

D.Hexagonal part of camshaft (EXH)(for holding)

E. Stopper of control shaft F.Two flat area of control shaft (for holding)

: Engine front

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CAMSHAFT
VVEL actuator sub assembly and VVEL control shaft position sensor are nonreusable. Neverremove them unless they are required.

a. Remove VVEL control shaft position sensor.b. Turn control shaft to the large lift side and fix it in order to prevent the interference of the stopper surface.

• If control shaft cannot be moved, set crankshaft in position referring to the information below. (To dis-place cam nose)

c. Fix two flat areas (C) of control shaft with a wrench to removemounting bolts of control shaft.

CAUTION:• During the operation, never allow a wrench to interfere

with other parts.• Fix control shaft to prevent the interference of the stopper

surface.

d. Remove VVEL actuator sub assembly.• Loosen mounting bolts in the reverse order as shown in the

figure.

CAUTION:• When removing, prepare wastes because oil spills.• When installing, be careful with VVEL actuator sub

assembly (bank 2) mounting bolt No. 1 because its lengthis different.

e. Remove actuator bracket (rear).• Loosen mounting bolts in the reverse order as shown in the

figure.

Bank 1 : Turn 120 degrees from no.1 cylinder at TDCBank 2 : No.1 cylinder at TDC

A : Bank 1

B : Bank 2

: Engine front

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A : Bank 2

B : Bank 1

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A : Bank 1

B : Bank 2

: Engine front

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CAMSHAFT

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3. Remove front timing chain case, camshaft sprockets, and timing chain. Refer to EM-50, "Exploded View".4. Remove rear timing chain case. Refer to EM-89, "Exploded View".5. Remove VVEL ladder assembly.

• Loosen mounting bolts (gold color) in the reverse order asshown in the figure.

CAUTION:• Never loosen adjusting bolts and mounting bolts (black

color).• When removing VVEL ladder assembly, hold the drive

shaft from below so as not to drop it.

6. Remove camshaft (EXH).7. Remove valve lifter.

• Identify installation positions, and store them without mixing them up.8. Remove timing chain tensioners (secondary) (1) from cylinder

head.

• Remove timing chain tensioners (secondary) with its stopperpin (C) attached.

NOTE:Stopper pin should be attached when timing chain (secondary)is removed.

9. Remove oil filter from cylinder head, if necessary.

ASSEMBLY1. Install timing chain tensioners (secondary) (1) on both sides of

cylinder head.

• Install timing chain tensioner with its stopper pin (C) attached. • Install timing chain tensioner with sliding part facing downward

on cylinder head (bank 1), and with sliding part facing upwardon cylinder head (bank 2).

A : Bank 1

B : Bank 2

: Engine front

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A : Bank 1

B : Bank 2

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A : Bank 1

B : Bank 2

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CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY >2. Install oil filter (1), if removed.
• Do not project from the cylinder head (2) surface.

3. Install valve lifter.• Install it in the original position.

4. Install camshaft (EXH).• Distinction between camshaft (EXH) (bank 1 and bank 2) is

performed with the identification mark.

5. Install VVEL ladder assembly as follows:a. Apply a continuous bead of liquid gasket with tube presser

(commercial service tool) to the cylinder head as shown in thefigure.


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BankPaint marks Identification mark

(F)M1 (C) M2 (D) M3 (E)

Bank 1 (A) No Blue Light blue 1 N

Bank 2 (B) No Blue Light blue 1 P

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A : Bank 1

B : Bank 2

c : φ3.4 - 4.4 mm (0.134 - 0.173 in)

: Engine front

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CAMSHAFT

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b. Tighten mounting bolts in the following step, in numerical orderas shown in the figure.

i. Tighten bolts in numerical order as shown in the figure.

ii. Tighten bolts in numerical order as shown in the figure.

iii. Tighten bolts in numerical order as shown in the figure.

6. Measure difference in levels between front end faces of VVELladder assembly and cylinder head.

• Measure two positions (both intake and exhaust side) for asingle bank.

• If the measured value is out of the standard, re-install VVELladder assembly.

7. Install rear timing chain case. Refer to EM-89, "Exploded View".8. Install camshaft sprockets and timing chains. Refer to EM-50, "Exploded View".9. Install actuator bracket (rear) as follows:a. Apply a continuous bead of liquid gasket with tube presser

(commercial service tool) to the actuator bracket (rear) asshown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".CAUTION:Never apply gasket to the oil passage.

A : Bank 1

B : Bank 2

: Engine front

: 1.96 N·m (0.20 kg-m, 1 ft-lb)

: 5.88 N·m (0.60 kg-m, 4 ft-lb)

: 10.4 N·m (1.1 kg-m, 8 ft-lb)

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Standard : −0.14 to 0.14 mm (−0.0055 to 0.0055 in)

EMQ0044D

A : Bank 1

B : Bank 2

c : φ3.4 - 4.4 mm (0.134 - 0.173 in)

: Engine front

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CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY >b. Tighten mounting bolts in the following steps, in numerical order
as shown in the figure.

i. Tighten bolts in numerical order as shown in the figure.

ii. Tighten bolts in numerical order as shown in the figure.

iii. Tighten bolts in numerical order as shown in the figure.

10. Install new VVEL actuator sub assembly as follows:CAUTION:Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft positionsensor are controlled on a one-on-one basis, replace them as a set.NOTE:• VVEL actuator arm (B) is factory-fixed at 5.5 degrees from the

small lift with a holding jig (A).• The holding jig is supplied in the new VVEL actuator sub

assembly.

CAUTION:• Never disassemble VVEL actuator sub assembly. [Never

loosen actuator motor mounting bolts (A) shown in thefigure]

• Never shock VVEL actuator sub assembly.

a. Move control shaft to the position of small lift stopper.

A : Bank 1

B : Bank 2

: Engine front

: 1.96 N·m (0.20 kg-m, 1 ft-lb)

: 5.88 N·m (0.60 kg-m, 4 ft-lb)

: 31.4 N·m (3.2 kg-m, 23 ft-lb)

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CAMSHAFT

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• The position where a part of the stopper of control shaft con-tacts VVEL ladder bracket.

CAUTION:Be careful not to damage the stopper surface.

• If control shaft cannot be moved, set crankshaft in position referring to the information below. (To dis-place cam nose)

b. Hold two flat areas of control shaft with a wrench, and rotate thecontrol shaft (5.5 degrees from the stopper) to the large lift side.(This is for aligning the bolt hole of control shaft and the hole ofVVEL actuator arm.)

1 : VVEL ladder assembly (bank 2)

2 : VVEL ladder assembly (bank 1)

A : Stopper of control shaft

: Small lift side

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Bank 1 : Turn 120 degrees from No. 1 cylinder at TDCBank 2 : No. 1 cylinder at TDC

1 : VVEL actuator sub assembly (bank 1)

A : Control shaft

b : 5.5 degrees

: Large lift side

JPBIA1132ZZ


CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY >c. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to the VVEL actuator sub assembly asshown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".CAUTION:Never apply gasket to the oil passage.

d. Install new VVEL actuator sub assembly.• Tighten mounting bolts in the following step, in numerical order

as shown.

CAUTION:• When installing, be careful with VVEL actuator sub

assembly (bank 2) mounting bolt No. 1 because its lengthis different.

• Be sure to check that the VVEL actuator sub assembly isin contact with the cylinder head before tightening themounting bolts.

e. Remove holding jig.f. Check that VVEL actuator arm bolt hole is aligned with control shaft tapped hole. If it is not aligned, turn

control shaft for alignment.



a : 4.0 - 5.6 mm (0.157 - 0.220 in)

b : φ3.4 - 4.4 mm (0.134 - 0.173 in)

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A : Bank 2

B : Bank 1

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CAMSHAFT

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g. Fix two flat areas (C) of control shaft with a wrench to installmounting bolts of control shaft.

CAUTION:• During the operation, never allow a wrench to interfere

with other parts.• Fix control shaft to prevent the interference of the stopper

surface.

11. Install new VVEL control shaft position sensor as follows:CAUTION:Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft positionsensor are controlled on a one-on-one basis, replace them as a set.

a. Apply engine oil to O-ring or contact surface of O-ring.b. Align matching marks (B) of VVEL control shaft position sensor

and upper housing.

• Face connector toward matching mark (A).

c. Temporarily tighten bolt.d. Adjust VVEL control shaft position sensor after setting the engine assembly in the vehicle. Refer to EC-21,

"VVEL CONTROL SHAFT POSITION SENSOR ADJUSTMENT : Description".CAUTION:Be sure to adjust VVEL control shaft position sensor.

e. After adjusting VVEL control shaft position sensor, tighten bolts to the specified torque.

A : Bank 1

B : Bank 2

: Engine front

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C : Bank 2

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CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY >12. Inspect the valve clearance. Refer to EM-18, "Inspection and Adjustment".13. Install in the reverse order of removal after this step.

INSPECTION AFTER REMOVAL (EXHAUST SIDE)

Camshaft (EXH) Runout

1. Put V-block on precise flat table, and support No. 2 and 4 jour-nals of camshaft.CAUTION:Never support No. 1 journal (on the side of camshaftsprocket) because it has a different diameter from the otherthree locations.

2. Set a dial indicator vertically to No. 3 journal.3. Turn camshaft (EXH) to one direction with hands, and measure

the camshaft runout on a dial indicator. (Total indicator reading)

4. If it exceeds the limit, replace camshaft (EXH).

Camshaft (EXH) Cam Height• Measure the camshaft (EXH) cam height with a micrometer.

• If wear exceeds the limit, replace camshaft (EXH).

Camshaft (EXH) Journal Oil Clearance

CAMSHAFT (EXH) JOURNAL DIAMETER• Measure the outer diameter of camshaft (EXH) journal with a

micrometer (A).

VVEL LADDER ASSEMBLY (EXHAUST SIDE) INNER DIAMETER• Tighten VVEL ladder assembly bolts to the specified torque. Refer to “INSTALLATION” for the tightening

procedure.

Standard and limit: Refer to EM-149, "Camshaft".

PBIC0929E

Standard : Refer to EM-149, "Camshaft".

EMQ0072D


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CAMSHAFT

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• Measure inner diameter (A) of VVEL ladder assembly (Exhaustside) with a bore gauge.

CAMSHAFT (EXH) JOURNAL OIL CLEARANCE• (Oil clearance) = [VVEL ladder assembly (Exhaust side) inner diameter] – [Camshaft (EXH) journal diame-

ter].

• If the calculated value exceeds the limit, replace either or both camshaft (EXH) and VVEL ladder assemblyand cylinder head assembly.NOTE:VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinderhead assembly.

Camshaft (EXH) End Play• Install a dial indicator in thrust direction on front end of camshaft.

Measure the end play of a dial indicator when camshaft (EXH) ismoved forward/backward (in direction of axis).

• Measure the following parts if out of the limit.- Dimension “A” for camshaft (EXH) No. 1 journal

- Dimension “B” for cylinder head No. 1 journal bearing

• Refer to the standards above, and then replace camshaft (EXH)and/or VVEL ladder assembly and cylinder head assembly.NOTE:Cylinder head assembly cannot be replaced as a single part,because it is machined together with VVEL ladder assembly.

Camshaft Sprocket (EXH) Runout

1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft (EXH).CAUTION:Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameterfrom the other three locations.


PBIC1645E

Standard and limit : Refer to EM-149, "Camshaft".


SEM864E

Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in)

Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in)

KBIA2404J


CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY >2. Measure the camshaft sprocket (EXH) runout with a dial indica-
tor. (Total indicator reading)

3. If it exceeds the limit, replace camshaft sprocket (EXH).

Valve Lifter (EXH)• Check if surface of valve lifter has any wear or crack.• If wear or crack is found, replace valve lifter (EXH). Refer to EM-

149, "Camshaft".

Valve Lifter Clearance (EXH)

VALVE LIFTER OUTER DIAMETER• Measure the outer diameter at 1/2 height of valve lifter with a

micrometer (A) since valve lifter is in barrel shape.

VALVE LIFTER HOLE DIAMETER• Measure the inner diameter of valve lifter hole of cylinder head with

an inside micrometer.

VALVE LIFTER CLEARANCE• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)

• If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter andvalve lifter hole diameter, replace either or both valve lifter and VVEL ladder assembly and cylinder headassembly.

Limit : Refer to EM-149, "Camshaft".

PBIC0930E

KBIA0182E


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SEM867E



CAMSHAFT

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NOTE:Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL lad-der assembly.

INSPECTION AFTER REMOVAL (INTAKE SIDE)

Drive Shaft End Play• Install a dial indicator in thrust direction on front end of drive shaft.

Measure the end play of a dial indicator when drive shaft is movedforward/backward (in direction of axis).

• Measure the following parts if out of the limit.- Dimension “A” for drive shaft No. 1 journal

- Dimension “B” for cylinder head No. 1 journal bearing

• If it exceeds the limit, replace VVEL ladder assembly and cylinderhead assembly.NOTE:Cylinder head assembly cannot be replaced as a single part,because it is machined together with VVEL ladder assembly.

Camshaft Sprocket (INT) Runout

1. Put V-block on precise flat table, and support No. 2 and 4 journals of drive shaft.CAUTION:Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameterfrom the other three locations.

2. Measure the camshaft sprocket (INT) runout with a dial indicator. (Total indicator reading)

3. If it exceeds the limit, replace camshaft sprocket (INT).

Valve Lifter (INT)• Check if surface of valve lifter has any wear or crack.• If wear or crack is found, replace VVEL ladder assembly and cylin-

der head assembly. Refer to EM-149, "Camshaft".NOTE:Since the valve lifter (INT) cannot be replaced by the piece, VVELladder assembly and cylinder head assembly replacement arerequired.

Valve Lifter Clearance (INT)

VALVE LIFTER OUTER DIAMETER


JPBIA1337ZZ

Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in)

Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in)

KBIA2404J

Limit : Refer to EM-149, "Camshaft".

KBIA0182E


CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY >• Measure the outer diameter at 1/2 height of valve lifter (INT) with a
micrometer (A) since valve lifter is in barrel shape.

VALVE LIFTER HOLE DIAMETER• Measure the inner diameter of valve lifter hole of cylinder head with

an inside micrometer.

VALVE LIFTER CLEARANCE• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)

• If the calculated value is out of the standard, replace VVEL ladder assembly and cylinder head assembly.NOTE:Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder headassembly replacement are required.

VVEL Ladder Assembly

DRIVE SHAFT OPERATIONAL CHECK• Hold the both ends of the drive shaft (A) and rotate it to check that

it rotates smoothly.CAUTION:Turn VVEL ladder assembly upside down to prevent the driveshaft from dropping off.

CONTROL SHAFT OPERATIONAL CHECK


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SEM867E


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• Move control shaft (A) to the small stopper and large stopper tocheck that the control shaft functions smoothly.CAUTION:Turn VVEL ladder assembly upside down to prevent the driveshaft from dropping off.

RINK CHECK FOR BACK-LASH (BONDING)• Check that the link and the shaft of drive shaft and control shaft are

not fixed. • Check this by moving drive shaft and control shaft in the axial and

rotation directions.

• If there is an unusualness related to the above three, replace VVEL ladder assembly and cylinder headassembly.

NOTE:VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinderhead assembly.


Inspection of Camshaft Sprocket (INT) Oil GrooveCAUTION:• Perform this inspection only when DTC P0011, P0012 is detected in self-diagnostic results of CON-

SULT-III and it is directed according to inspection procedure of EC section. Refer to EC-112, "Diag-nosis Description".

• Check when engine is cold to prevent burns from the splashing engine oil.1. Check engine oil level. Refer to LU-6, "Inspection".2. Perform the following procedure to prevent the engine from being unintentionally started while checking.a. Release the fuel pressure. Refer to EC-614, "Inspection".b. Disconnect ignition coil and injector harness connectors. Refer to EM-47, "Exploded View".3. Remove intake valve timing control solenoid valve. Refer to EM-50, "Exploded View".4. Crank engine, and then check that engine oil comes out from

intake valve timing control solenoid valve hole (A). End crankafter checking.

WARNING:Be careful not to touch rotating parts (drive belt, idler pul-ley, and crankshaft pulley, etc.).CAUTION:• Prevent splashing by using a shop cloth to prevent the

worker from injury from engine oil and to prevent engine oil contamination.

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1 : Intake valve timing control cover (bank 1)

: Engine front

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CAMSHAFT
• Prevent splashing by using a shop cloth to prevent engine oil from being splashed to engine andvehicle. Especially, be careful no to apply engine oil to rubber parts of drive belt, engine mount-ing insulator, etc. Wipe engine oil off immediately if it is splashed.

5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoidvalve oil hole of the cylinder head.• Remove oil filter, and then clean it. Refer to EM-50, "Exploded View".• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-2,

"Engine Lubrication System".6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),

and then check each oil groove for clogging.• Clean oil groove if necessary. Refer to LU-2, "Engine Lubrication System".

7. After inspection, install removed parts in the reverse order.

















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CAUTION:As for replacement of parts on the intake side as shown in the exploded view, replace VVEL ladderassembly and cylinder head assembly. (Only valve oil seals are replaceable as a single part.)NOTE:VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinderhead assembly.

1. Valve lifter (EXH) 2. Valve collet (EXH) 3. Valve spring retainer (EXH)

4. Valve oil seal (EXH) 5. Valve spring (EXH) 6. Valve spring seat (EXH)

7. Valve guide (EXH) 8. Spark plug 9. Valve lifter (INT)

10. Valve collet (INT) 11. Valve spring retainer (INT) 12. Valve oil seal (INT)

13. Valve spring (INT) 14. Valve spring seat (INT) 15. Cylinder head bolt

16. Cylinder head (bank 1) 17. Valve seat (EXH) 18. Valve (EXH)

19. Cylinder head gasket (bank 1) 20. Valve (INT) 21. Cylinder head gasket (bank 2)

22. Cylinder head (bank 2) 23. Engine rear lower slinger

A. Refer to EM-112


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CYLINDER HEAD

DISASSEMBLY1. Remove the following parts:

• Intake manifold collector: Refer to EM-29, "Exploded View".• Rocker cover: Refer to EM-47, "Exploded View".• Fuel tube and fuel injector assembly: Refer to EM-37, "Exploded View".• Intake manifold: Refer to EM-32, "Exploded View".• Exhaust manifold: Refer to EM-34, "Exploded View".• Water inlet and thermostat assembly: Refer to CO-21, "Exploded View".• Water outlet, water pipe and heater pipe: Refer to CO-23, "Exploded View".• Timing chain: Refer to EM-50, "Exploded View".• Rear timing chain case: Refer to EM-89, "Exploded View".• Camshaft (EXH) and VVEL ladder assembly: Refer to EM-94, "Exploded View".

2. Remove cylinder head.• Loosen mounting bolts in reverse order as shown in the figure.

• Use the cylinder head bolt wrench [commercial service tool:— (J-24239-01)] and power tool.

3. Remove cylinder head gaskets.4. Remove spark plug with spark plug wrench (commercial service tool).5. Remove valve lifter.

• Identify installation positions, and store them without mixing them up.6. Remove valve collet.

• Compress valve spring with the valve spring compressor [SST:KV10116200 (J-26336-A)] (A), the attachment [SST:KV10115900 (J-26336-20)] (C) and the adapter [SST:KV10109220 ( — )] (B). Remove valve collet with a magnethand.

CAUTION:When working, take care not to damage valve lifter holes.

7. Remove valve spring retainer, valve spring and valve spring seat.8. Push valve stem to combustion chamber side, and remove valve.

• Identify installation positions, and store them without mixing them up.

A : Bank 1

B : Bank 2

: Engine front

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9. Remove valve oil seal using the valve oil seal puller [SST:KV10107902 (J-38959)] (A).

10. Remove valve seat (EXH), if valve seat (EXH) must be replaced.• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat

recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-151, "Cylinder Head".CAUTION:Prevent to scratch cylinder head by excessive boring.

11. Remove valve guide (EXH), if valve guide (EXH) must be replaced.a. To remove valve guide (EXH), heat cylinder head to 110 to

130°C (230 to 266°F) by soaking in heated oil (A).

b. Drive out valve guide (EXH) with a press [under a 20 kN (2 ton,2.2 US ton, 2.0 lmp ton) pressure] or a hammer and the valveguide drift (commercial service tool).WARNING:Cylinder head contains heat. When working, wear protec-tive equipment to avoid getting burned.

ASSEMBLY1. If valve guide (EXH) is removed in step 11 (DISASSEMBLY), install it.

Replace with oversized [0.2 mm (0.008 in)] valve guide (EXH).a. Using the valve guide reamer (commercial service tool) (A),

ream cylinder head valve guide (EXH) hole.

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SEM931C

Oversize (service) [0.2 mm (0.008 in)]:: Refer to EM-151, "Cylinder Head".

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CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY >b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).

c. Using the valve guide drift (commercial service tool), press valveguide (EXH) from camshaft side to the dimensions as shown inthe figure.

WARNING:Cylinder head contains heat. When working, wear protec-tive equipment to avoid getting burned.

d. Using the valve guide reamer (commercial service tool) (A),apply reamer finish to valve guide (EXH).

2. If valve seat (EXH) is removed in step 10 (DISASSEMBLY), install it. Replace with oversize [0.5 mm (0.020 in)] valve seat (EXH).

a. Ream cylinder head recess diameter (a) for service valve seat(EXH).

• Be sure to ream in circles concentric to valve guide center.This will enable valve to fit correctly.

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Projection (A): Refer to EM-151, "Cylinder Head".

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Standard : Refer to EM-151, "Cylinder Head".

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Oversize (service) [0.5 mm (0.020 in)]:: Refer to EM-151, "Cylinder Head".

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b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking inheated oil (A).

c. Provide valve seats (EXH) cooled well with dry ice. Force fit valve seat (EXH) into cylinder head.WARNING:Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.CAUTION:Avoid directly touching cold valve seats.

d. Using the valve seat cutter set (commercial service tool) or valveseat grinder, finish seat to the specified dimensions. Refer toEM-151, "Cylinder Head".CAUTION:When using the valve seat cutter, firmly grip cutter handlewith both hands. Then, press on the contacting surface allaround the circumference to cut in a single drive. Improperpressure on cutter or cutting many different times mayresult in staged valve seat.

e. Using compound, grind to adjust valve fitting. f. Check again for normal contact. Refer to "VALVE SEAT CONTACT".3. Install new valve oil seals as follows.a. Apply new engine oil on new valve oil seal joint and seal lip.b. Using the valve oil seal drift [SST: KV10115600 (J-38958)] (A),

press fit valve seal to height (b) shown in figure.NOTE:Dimension: Height measured before valve spring seat installa-tion

4. Install valve spring seat.5. Install valve.

NOTE:Larger diameter valves are for intake side.

6. Install new cylinder head gaskets.

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SEM934C

Height (b) : 14.3 - 14.9 mm (0.563 - 0.587 in)

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CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY >7. Turn crankshaft until No. 1 piston is set at TDC.
• Crankshaft key should line up with the cylinder center line(bank 1) as shown in the figure.

8. Install cylinder head, and tighten cylinder head bolts in numeri-cal order as shown in figure as follows:

• Use the cylinder head bolt wrench [commercial service tool:— (J-24239-01)] and power tool.

CAUTION:• If cylinder head bolts are re-used, check their outer diam-

eters before installation. Refer to EM-117, "Inspection".• Before installing cylinder head, inspect cylinder head dis-

tortion. Refer to EM-117, "Inspection".a. Apply new engine oil to threads and seat surfaces of cylinder

head bolts.b. Tighten all cylinder head bolts.

c. Completely loosen all cylinder head bolts.

CAUTION:In step “c”, loosen bolts in the reverse order of that indicated in the figure.

d. Tighten all cylinder head bolts.

e. Turn all cylinder head bolts 95 degrees clockwise (angle tightening).CAUTION:Check the tightening angle using the angle wrench [SST:KV10112100 (BT8653-A)] (A). Never make judgment byvisual inspection.• Check tightening angle indicated on the angle wrench indica-

tor plate.f. Turn all cylinder head bolts 95 degrees clockwise again (angle

tightening).

1 : Crankshaft key

: Bank 1 side

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A : Bank 1

B : Bank 2

: Engine front

: 105 N·m (11 kg-m, 77 ft-lb)

: 0 N·m (0 kg-m, 0 ft-lb)

: 40.0 N·m (4.1 kg-m, 30 ft-lb)

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9. After installing cylinder head, measure distance between frontend faces of cylinder block and cylinder head (bank 1 and bank2).

• If measured value is out of the standard, re-install cylinderhead.

10. Install valve spring (uneven pitch type).• Install narrow pitch (B) end [paint mark (C)] to cylinder head

side (valve spring seat side).

11. Install valve spring retainer.12. Install valve collet.

• Compress valve spring with the valve spring compressor [SST:KV10116200 (J-26336-A)] (A), the attachment [SST:KV10115900 (J-26336-20)] (C) and the adapter [SST:KV10109220 ( — )] (B). Install valve collet with a magnethand.CAUTION:When working, take care not to damage valve lifter holes.

• Tap valve stem edge lightly with plastic hammer after installa-tion to check its installed condition.

13. Install valve lifter.• Install it in the original position.

14. Install spark plug with spark plug wrench (commercial service tool).15. Install in the reverse order of removal after this step.


INSPECTION AFTER DISASSEMBLY

Cylinder Head Bolts Outer Diameter

Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)

EMQ0662D

A : Wide pitch

: Cylinder head side

Paint mark colorIntake : PurpleExhaust : Yellowish green

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CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY >• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between (B) and (A)exceeds the limit, replace them with new one.

• If reduction of outer diameter appears in a position other than (A),use it as (A) point.

Cylinder Head DistortionNOTE:When performing this inspection, cylinder block distortion should be also checked. Refer to EM-131, "Inspec-tion".1. Using a scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.

CAUTION:Never allow gasket fragments to enter engine oil or engine coolant passages.

2. At each of several locations on bottom surface of cylinder head,measure the distortion in six directions (A), (B), (C), (D), (E), and(F).

• If it exceeds the limit, replace VVEL ladder assembly and cylinderhead assembly.NOTE:Cylinder head assembly cannot be replaced as a single part,because it is machined together with VVEL ladder assembly.

Valve Dimensions• Check the dimensions of each valve. For the dimensions, refer to EM-151, "Cylinder Head".• If dimensions are out of the standard. - Replace valve (EXH) and check valve seat contact. Refer to "VALVE SEAT CONTACT". (Exhaust side)- Replace VVEL ladder assembly and cylinder head assembly. Refer to EM-94, "Exploded View". (Intake side)

NOTE:Since the valve (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assemblyreplacement are required.

Valve Guide Clearance

Valve Stem Diameter• Measure the diameter of valve stem with micrometer (A).

Valve Guide Inner Diameter• Measure the inner diameter of valve guide with bore gauge.

Valve Guide Clearance• (Valve guide clearance) = (Valve guide inner diameter) – (Valve

stem diameter)

• If the calculated value exceeds the limit.- Replace valve (EXH) and/or valve guide (EXH). Refer to EM-111, "Exploded View". (Exhaust side)- Replace VVEL ladder assembly and cylinder head assembly. Refer to EM-94, "Exploded View". (Intake side)

NOTE:

c : 48 mm (1.89 in)

d : 11 mm (0.43 in)

Limit [(B) - (A)] : 0.18 mm (0.0071 in)

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Limit : Refer to EM-151, "Cylinder Head".

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Since the valve (INT) and valve guide (INT) cannot be replaced by the piece, VVEL ladder assembly andcylinder head assembly replacement are required.

Valve Seat Contact• After confirming that the dimensions of valve guides and valves are within the specifications, perform this

procedure.• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve

contact on the surface.• Check if the contact area band is continuous all around the circum-

ference.

- If not, grind to adjust valve fitting and check again. If the contactingsurface still has “NG” conditions even after the recheck, replacevalve seat (EXH). Refer to EM-111, "Exploded View". (Exhaustside)

- If not, replace VVEL ladder assembly and cylinder head assembly.Refer to EM-94, "Exploded View". (Intake side)NOTE:Since the valve seat (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder headassembly replacement are required.

Valve Spring Squareness• Set a try square (A) along the side of valve spring and rotate

spring. Measure the maximum clearance between the top of springand try square.

• If it exceeds the limit.- Replace valve spring (EXH). Refer to EM-111, "Exploded View".

(Exhaust side)- Replace VVEL ladder assembly and cylinder head assembly.

Refer to EM-94, "Exploded View". (Intake side)NOTE:Since the valve spring (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder headassembly replacement are required.

Valve Spring Dimensions and Valve Spring Pressure Load• Check the valve spring pressure at specified spring height.

• If the installation load or load with valve open is out of the stan-dard.

- Replace valve spring (EXH). Refer to EM-111, "Exploded View".(Exhaust side)

- Replace VVEL ladder assembly and cylinder head assembly.Refer to EM-94, "Exploded View". (Intake side)NOTE:Since the valve spring (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder headassembly replacement are required.



The following are procedures for checking fluid leakage, lubricant leakage.

A : OK

B : NG

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B : Contact

Limit : Refer to EM-151, "Cylinder Head".

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Standard: Refer to EM-151, "Cylinder Head".

SEM113


CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY >• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the














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1. Sub harness 2. Knock sensor 3. Crankshaft position sensor

4. Cylinder block heater (for Canada) 5. Cylinder block 6. Thrust bearing

7. Main bearing (upper) 8. Crankshaft 9. Crankshaft key

10. Main bearing (lower) 11. O-ring 12. Lower cylinder block bolt

13. Baffle plate 14. Lower cylinder block 15. Pilot bush (M/T models)

16. Pilot converter (A/T models) 17. Reinforcement plate (A/T models) 18. Drive plate (A/T models)

19. Rear oil seal 20. Flywheel (M/T models) 21. Oil jet

22. Top ring 23. Second ring 24. Oil ring

25. Piston 26. Piston pin 27. Snap ring

28. Connecting rod 29. Connecting rod bearing 30. Connecting rod bearing cap

31. Connecting rod bolt

JPBIA1771GB


CYLINDER BLOCK

DISASSEMBLY1. Remove the following parts:

• Oil pans (upper and lower): Refer to EM-43, "Exploded View (2WD)" and EM-82, "2WD : ExplodedView" (2WD models) or EM-44, "Exploded View (AWD)" or EM-85, "AWD : Exploded View" (AWD mod-els).

• Front and rear timing chain case: Refer to EM-50, "Exploded View" and EM-89, "Exploded View".• Cylinder head: Refer to EM-111, "Exploded View".

2. Remove knock sensor.CAUTION:Carefully handle sensor avoiding shocks.

3. Remove baffle plate from lower cylinder block.4. Remove piston and connecting rod assembly with the following procedure:

• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer toEM-131, "Inspection".

CAUTION:Be careful not to drop connecting rod bearing, and to scratch the surface.

a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.b. Remove connecting rod bearing cap.c. Using a hammer handle or similar tool, push piston and connect-

ing rod assembly out to the cylinder head side.CAUTION:Be careful not to damage the cylinder wall and crankshaftpin, resulting from an interference of the connecting rod bigend.

5. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.CAUTION:• Be careful not to drop connecting rod bearing, and to scratch the surface.• Identify installation positions, and store them without mixing them up.

6. Remove piston rings from piston.• Before removing piston rings, check the piston ring side clearance. Refer to EM-131, "Inspection".• Use a piston ring expander (commercial service tool) (A).CAUTION:• When removing piston rings, be careful not to damage

piston.• Be careful not to damage piston rings by expanding them

excessively.

7. Remove piston from connecting rod as follows:

A. Refer to EM-122 B. Chamfered C. Front mark

: Crankshaft side

PBIC2940E

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a. Using snap ring pliers (A), remove snap rings.

b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial usedryer (A) or equivalent.

c. Push out piston pin using a stick than has an outer diameter ofapproximately 20 mm (0.79 in).

8. Remove lower cylinder block bolts.• Before loosening lower cylinder block bolts, measure the crankshaft end play. Refer to EM-131, "Inspec-

tion".• Loosen lower cylinder block bolts in the reverse order shown

in the figure in several different steps.

9. Remove lower cylinder block as follows:

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PBIC0262E

: Engine front

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CYLINDER BLOCK
Screw M8 bolt [pitch: 1.25 mm (0.049 in) length: approximately50 mm (1.97 in)] into bolt holes (A). Then equally tighten eachbolt, and remove lower cylinder block.

CAUTION:• Be careful not to damage the mounting surfaces.• Never tighten bolts excessively.• Never insert screwdriver, this will damage the mating sur-

face.10. Remove crankshaft.11. Pull rear oil seal out from rear end of crankshaft.12. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.

CAUTION:• Be careful not to drop main bearing, and to scratch the surface.• Identify installation positions, and store them without mixing them up.

13. Remove oil jet.

ASSEMBLY1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to

remove any foreign material.CAUTION:Use goggles to protect your eyes.

2. Install each plug to cylinder block as shown in the figure.

• Apply sealant to the thread of water drain plug (1).Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".

• Apply sealant to the thread of plug (4).Use Genuine High Strength Thread Locking Sealant orequivalent. Refer to GI-17, "Recommended ChemicalProducts and Sealants".

• Replace washers (2) with new ones.

• Tighten each plug as specified below.Unit: N·m (kg-m, ft-lb)

3. Install oil jet.

: Engine front

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3 : Plug

: Engine front

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Part Washer Tightening torque

1 No 19.6 (2.0, 14)

3 Yes 78.0 (8.0, 58)

4 Yes 12.3 (1.3, 9)


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• Insert oil jet dowel pin (A) into cylinder block dowel pin hole,and tighten mounting bolts.

4. Install main bearings and thrust bearings as follows:CAUTION:Be careful not to drop main bearing, and to scratch the surface.

a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.b. Install thrust bearings (1) to both sides of the No. 3 journal hous-

ing on cylinder block.

• Install thrust bearings with the oil groove (E) facing crankshaftarm (outside).

c. Install main bearings paying attention to the direction.

• Main bearing with oil hole (B) and groove (C) goes on cylinderblock. The one without them goes on lower cylinder block.

• Before installing main bearings, apply engine oil to the bearingsurface (inside). Do not apply engine oil to the back surface,but thoroughly clean it.

• When installing, align main bearing stopper protrusion to cut-out of cylinder block and lower cylinder block.

• Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.

5. Install crankshaft to cylinder block.• While turning crankshaft by hand, check that it turns smoothly.

6. Install lower cylinder block.NOTE:Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinderblock.

: Engine front

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A : No. 1

B : No. 2

C : No. 3

D : No. 4

F : Thrust bearing installation position

: Engine front

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A : Cylinder block side

D : Lower cylinder block side

: Engine front

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CYLINDER BLOCK
• Apply a continuous bead of liquid gasket with the tube presser(commercial service tool) to lower cylinder block as shown inthe figure.


7. Inspect the outer diameter of lower cylinder block bolt. Refer to EM-131, "Inspection".8. Install lower cylinder block bolts in numerical order as shown in the figure as follows:a. Apply new engine oil to threads and seat surfaces of lower cylinder block bolts.b. Tighten bolts (No. 17 to 26) in numerical order as shown in the

figure.

c. Repeat step b.

d. Tighten bolts (No. 1 to 16) in numerical order as shown in thefigure.

NOTE:Use TORX socket for bolts No.1 to 16.

e. Turn bolts (No. 1 to 16) 90 degrees clockwise (angle tightening).CAUTION:Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) tocheck tightening angle. Never make judgment by visualinspection.

• After installing lower cylinder block bolts, check that crankshaft can be rotated smoothly by hand.• Check the crankshaft end play. Refer to EM-131, "Inspection".

9. Install piston to connecting rod as follows: a. Using snap ring pliers, install new snap ring to the groove of piston rear side.

• Insert it fully into groove to install.

B : Apply to end

a : φ4.0 - 5.0 mm (0.157 - 0.197 in)

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: Engine front

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

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: Engine front

: 35.3 N·m (3.6 kg-m, 26 ft-lb)

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b. Install piston to connecting rod.• Using an industrial use dryer or similar tool, heat piston until piston pin can be pushed in by hand without

excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin intopiston and connecting rod.

• Assemble so that the front mark on the piston head and thecylinder number on connecting rod are positioned as shown inthe figure.

c. Install new snap ring to the groove of the piston front side. • Insert it fully into groove to install.• After installing, check that connecting rod moves smoothly.

10. Using a piston ring expander (commercial service tool) (A),install piston rings.CAUTION:• When installing piston rings, be careful not to damage

piston.• Be careful not to damage piston rings by expending them

excessively.

• If there is stamped mark on ring, mount it with marked side up.

• Position each ring with the gap as shown in the figure referringto the piston front mark (D).

• Check the piston ring side clearance. Refer to EM-131, "Inspection".11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.

A : Example RH

B : Piston grade number

C : Front mark

D : Pin grade number

E : Cylinder number

F : Front mark

: Engine frontJPBIA1213ZZ

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Stamped mark:Top ring (A) : 1 N

Second ring (B) : 2 N

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C : Top ring gap

E : Oil ring upper or lower rail gap (either of them)

F : Second ring and oil ring spacer gap

a : 90 degrees

b : 45 degrees

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CYLINDER BLOCK
CAUTION:Be careful not to drop connecting rod bearing, and to scratch the surface.• Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply

engine oil to the back surface, but thoroughly clean it. • When installing, align connecting rod bearing stopper protru-

sion (B) with cutout (C) of connecting rods and connecting rodbearing caps to install.

• Ensure the oil hole (A) on connecting rod and that on the cor-responding bearing are aligned.

12. Install piston and connecting rod assembly to crankshaft. • Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. • Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.• Match the cylinder position with the cylinder number on connecting rod to install. • Be sure that front mark on piston crown is facing the front of the engine.• Using a piston ring compressor [SST: EM03470000 (J-8037)]

(A) or suitable tool, install piston with the front mark on the pis-ton crown facing the front of the engine.

CAUTION:Be careful not to damage the cylinder wall and crankshaftpin, resulting from an interference of the connecting rod bigend.

13. Install connecting rod bearing cap.• Match the stamped cylinder number marks on connecting rod

with those on connecting rod bearing cap to install.

• Be sure that front mark (H) on connecting rod bearing cap is facing the front of the engine.14. Tighten connecting rod bolt as follows:a. Inspect the outer diameter of connecting rod bolt. Refer to EM-131, "Inspection".b. Apply engine oil to the threads and seats of connecting rod bolts. c. Tighten connecting rod bolts.

d. Completely loosen connecting rod bolts.

e. Tighten connecting rod bolts.

JPBIA0206ZZ

JPBIA0207ZZ

A : Sample codes

B : Bearing stopper groove

C : Small-end diameter grade

D : Big-end diameter grade

E : Weight grade

F : Cylinder No.

G : Management code

I : Management code

: 28.4 N·m (2.9 kg-m, 21 ft-lb)

: 0 N·m (0 kg-m, 0 ft-lb)

JPBIA0208ZZ


CYLINDER BLOCK

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f. Then turn connecting rod bolts 90 degrees clockwise (angle tightening).CAUTION:Always use the angle wrench [SST: KV10112100 (BT8653-A)] (A). Never make judgment by visual inspection.• After tightening connecting rod bolts, check that crankshaft

rotates smoothly.• Check the connecting rod side clearance. Refer to EM-131,

"Inspection".

15. Install baffle plate.16. Install new rear oil seal. Refer to EM-67, "REAR OIL SEAL : Removal and Installation".

• Apply new engine oil to both oil seal lip and dust seal lip.

17. Install pilot converter (A/T models) or pilot bushing (M/T mod-els).• With a drift of the following outer diameter, press-fit as far as it

will go.

• Press-fit pilot converter with its chamfer facing crankshaft asshown in the figure. (A/T models)

• Press-fit pilot bushing (1) as the dimension shown in the fig-ure. (M/T models)

: 24.5 N·m (2.5 kg-m, 18 ft-lb)

JPBIA0209ZZ

Pilot bushing : Approx. 17 mm (0.67 in)Pilot converter : Approx. 33 mm (1.30 in)

PBIC2947E

: Crankshaft side

JPBIA0210ZZ

A : Crankshaft (rear end surface)

b: 10.20 – 10.85 mm (0.402 – 0.427 in)[Target: 10.20 mm (0.402 in)]

JPBIA0415ZZ


CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >18. Install knock sensors.
• Install knock sensor so that connector faces the rear of theengine.

• After installing knock sensor, connect harness connector, andlay it out to rear of the engine.

CAUTION:• Never tighten mounting bolts while holding connector. • If any impact by dropping is applied to knock sensor,

replace it with new one.NOTE:• Check that there is no foreign material on the cylinder block

mating surface and the back surface of knock sensor. • Check that knock sensor does not interfere with other parts.

19. Note the following, assemble in the reverse order of disassembly after this step.

Flywheel (M/T models)• Ensure the dowel pin (1) is installed in the crankshaft.

• When installing flywheel (3) to crankshaft (2), be sure to cor-rectly align crankshaft side dowel pin and flywheel side dowelpin hole (A).

• There is a matching mark (B) on the clutch cover side of fly-wheel (4). Refer it during installation.

Drive plate (A/T models)• When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive

plate side dowel pin hole.CAUTION:If these are not aligned correctly, engine runs roughly and “MIL” illuminates.

A : Bank 1

B : Bank 2

: Engine front

JPBIA0211ZZ

4 : Rear oil seal

JPBIA0322ZZ

1 : Dowel pin

2 : Rear oil seal

3 : Crankshaft

A : Hole

JPBIA0323ZZ


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• Install drive plate (2) and reinforcement plate (3) as shown inthe figure.

• Holding ring gear with the ring gear stopper [SST:KV10118600 (J-48641)].

• Tighten the mounting bolts crosswise over several times.


CRANKSHAFT END PLAY• Measure the clearance between thrust bearings and crankshaft

arm when crankshaft is moved fully forward or backward with a dialindicator.

• If the measured value exceeds the limit, replace thrust bearings,and measure again. If it still exceeds the limit, replace crankshaftalso.

CONNECTING ROD SIDE CLEARANCE• Measure the side clearance between connecting rod and crank-

shaft arm with a feeler gauge.

• If the measured value exceeds the limit, replace connecting rod,and measure again. If it still exceeds the limit, replace crankshaftalso.

PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole DiameterMeasure the inner diameter of piston pin hole with an insidemicrometer (A).

Piston Pin Outer Diameter

1 : Ring gear

4 : Pilot converter

5 : Crankshaft

A : Rounded

: Engine front

JPBIA0212ZZ

Standard and limit : Refer to EM-153, "Cylinder Block".

PBIC2953E


PBIC2954E

Standard : Refer to EM-153, "Cylinder Block".

JPBIA0217ZZ


CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >Measure the outer diameter of piston pin with a micrometer (A).
Piston to Piston Pin Oil Clearance(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

• If the calculated value is out of the standard, replace piston and piston pin assembly.• When replacing piston and piston pin assembly, refer to EM-142, "Description".

NOTE:• Piston is available together with piston pin as assembly.• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no

piston pin grades can be selected. (Only “0” grade is available.)

PISTON RING SIDE CLEARANCE• Measure the side clearance of piston ring (1) and piston ring

groove with a feeler gauge (C).

• If the measured value exceeds the limit, replace piston ring, andmeasure again. If it still exceeds the limit, replace piston also.

PISTON RING END GAP• Check that the cylinder bore inner diameter is within the specification. Refer to EM-122, "Disassembly and

Assembly".• Lubricate with new engine oil to piston (1) and piston ring (2), and

then insert piston ring until middle of cylinder with piston, and mea-sure the piston ring end gap with a feeler gauge (B).

• If the measured value exceeds the limit, replace piston ring, andmeasure again. If it still exceeds the limit, rebore cylinder and useoversize piston and piston rings.

CONNECTING ROD BEND AND TORSION


JPBIA0218ZZ


A : NG

B : OK


JPBIA0219ZZ

A : Press-fit

C : Measuring point


JPBIA0220ZZ


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• Check with a connecting rod aligner.

• If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BIG END DIAMETER• Install connecting rod bearing cap without installing connecting rod

bearing, and tighten connecting rod bolts to the specified torque.Refer to EM-122, "Disassembly and Assembly" for the tighteningprocedure.

• Measure the inner diameter of connecting rod big end with aninside micrometer.

• If out of the standard, replace connecting rod assembly.

CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner DiameterMeasure the inner diameter of connecting rod bushing with an insidemicrometer (A).

Piston Pin Outer Diameter

A : Bend

B : Torsion

C : Feeler gauge

Bend limit: Refer to EM-153, "Cylinder Block".

Torsion limit

JPBIA0221ZZ

1 : Connecting rod

Standard : Refer to EM-153, "Cylinder Block".JPBIA0222ZZ


JPBIA0223ZZ


CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >Measure the outer diameter of piston pin with a micrometer (A).
Connecting Rod Bushing Oil Clearance(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-ter)

• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pinassembly.

• If replacing piston and piston pin assembly, refer to EM-142, "Description".• If replacing connecting rod assembly, refer to EM-143,

"Connecting Rod Bearing" to select the connecting rod bearing.

Factory installed parts grading:• Service parts apply only to grade “0”.

Unit: mm (in)

*: After installing in connecting rod

CYLINDER BLOCK DISTORTION


JPBIA0218ZZ


A : Sample codes



D : Big-end diameter grade

E : Weight grade

F : Cylinder No.

G : Management code

H : Front mark

I : Management code

JPBIA0208ZZ

A : RH

B : LH

C : Piston pin grade number

D : Piston grade number

E : Front mark

F : Identification code

Grade 0 1

Connecting rod bushing inner diameter *

22.000 - 22.006 (0.8661 - 0.8664)

22.006 - 22.012 (0.8664 - 0.8666)

Piston pin hole diameter 21.993 - 21.999 (0.8659 - 0.8661)

21.999 - 22. 005 (0.8661 - 0.8663)

Piston pin outer diameter 21.989 - 21.995 (0.8657 - 0.8659)

21.995 - 22.001 (0.8659 - 0.8662)

JPBIA1212ZZ


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• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, orother contamination. CAUTION:Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.

• Measure the distortion on the cylinder block upper face at somedifferent points in six directions (C), (D), (E), (F), (G), and (H) with astraightedge (A) and a feeler gauge (B).

• If it exceeds the limit, replace cylinder block.

MAIN BEARING HOUSING INNER DIAMETER• Install lower cylinder block (2) without installing main bearings, and

tighten lower cylinder block bolts to the specified torque. Refer toEM-122, "Disassembly and Assembly" for the tightening proce-dure.

• Measure the inner diameter of main bearing housing with a boregauge.

• If out of the standard, replace cylinder block (1) and lower cylinderblock as assembly.NOTE:Cylinder block cannot be replaced as a single part, because it ismachined together with lower cylinder block.

PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore inner Diameter • Using a bore gauge, measure cylinder bore for wear, out-of-round

and taper at six different points on each cylinder. [(A) and (B) direc-tions at (C), (D) and (E)] is in longitudinal direction of engine.

• If the measured value exceeds the limit, or if there are scratchesand/or seizure on the cylinder inner wall, hone or rebore the innerwall.

• Oversize piston is provided. When using oversize piston, reborecylinder so that the clearance of the piston-to-cylinder bore satis-fies the standard.CAUTION:When using oversize piston, use oversize pistons for all cylin-ders with oversize piston rings.

Piston Skirt Diameter

Limit : Refer to EM-153, "Cylinder Block".

JPBIA0224ZZ


JPBIA0225ZZ

f : 10 mm (0.39 in)g : 60 mm (2.36 in)h : 125 mm (4.92 in)

Standard and limit : Refer to EM-153, "Cylinder Block".JPBIA0226ZZ

Oversize (O/S) : 0.2 mm (0.008 in)SEM843E


CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >Measure the outer diameter of piston skirt with a micrometer (A).
Piston-to-Cylinder Bore ClearanceCalculate by piston skirt diameter and cylinder bore inner diameter[direction (B), position (D)].

(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter).

• If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-153,"Cylinder Block".

Reboring Cylinder Bore

1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.

2. Install lower cylinder block, and tighten to the specified torque. Otherwise, cylinder bores may be distortedin final assembly.

3. Cut cylinder bores.NOTE:• When any cylinder needs boring, all other cylinders must also be bored.• Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a

time.4. Hone cylinders to obtain the specified piston to cylinder bore clearance.5. Measure finished cylinder bore for the out-of-round and taper.

NOTE:Perform measurement after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER• Measure the outer diameter of crankshaft main journals with a micrometer.

Measure point : Refer to EM-153, "Cylinder Block".

Standard

JPBIA0227ZZ

A : Direction AC : Position CE : Position Ef : 10 mm (0.39 in)g : 60 mm (2.36 in)h : 125 mm (4.92 in)

JPBIA0226ZZ


Re-bored size calculation: D = A + B – Cwhere,

A: Piston skirt diameter as measuredB: Piston to cylinder bore clearance (standard value)C: Honing allowance 0.02 mm (0.0008 in)D: Bored diameter



CYLINDER BLOCK

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• If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-146, "Main Bearing".

CRANKSHAFT PIN JOURNAL DIAMETER• Measure the outer diameter of crankshaft pin journal with a

micrometer (A).

• If out of the standard, measure the connecting rod bearing oilclearance. Then use undersize bearing. Refer to EM-143,"Connecting Rod Bearing".

CRANKSHAFT OUT-OF-ROUND AND TAPER• Measure the dimensions at four different points as shown in the

figure on each main journal and pin journal with a micrometer. • Out-of-round is indicated by the difference in the dimensions

between (d) and (c) at (a) and (b).• Taper is indicated by the difference in the dimensions between.

• If the measured value exceeds the limit, correct or replace crank-shaft.

• If corrected, measure the bearing oil clearance of the correctedmain journal and/or pin journal. Then select the main bearing and/or connecting rod bearing. Refer to EM-146, "Main Bearing" and/or EM-143, "Connecting Rod Bearing".

CRANKSHAFT RUNOUT • Place V-block on precise flat table, and support the journals on

both ends of crankshaft.• Place a dial indicator straight up on the No. 3 journal.• While rotating crankshaft, read the movement of the pointer on a

dial indicator. (Total indicator reading)

• If it exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation• Install connecting rod bearings (1) to connecting rod (2) and con-

necting rod cap, and tighten connecting rod bolts to the specifiedtorque. Refer to EM-122, "Disassembly and Assembly" for thetightening procedure.

• Measure the inner diameter of connecting rod bearing with an inside micrometer.(Oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter)


JPBIA0228ZZ

Limit : Refer to EM-153, "Cylinder Block".

JPBIA0229ZZ


SEM346D

JPBIA0230ZZ


CYLINDER BLOCK
• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rodbig end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer toEM-142, "Description".

Method of Using Plastigage• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely. • Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil

holes.• Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting

rod bolts to the specified torque. Refer to EM-122, "Disassembly and Assembly" for the tightening proce-dure.CAUTION:Never rotate crankshaft.

• Remove connecting rod bearing cap and bearings, and using thescale on the plastigage bag, measure the plastigage width.NOTE:The procedure when the measured value exceeds the limit is thesame as that described in the “Method by Calculation”.

MAIN BEARING OIL CLEARANCE

Method by Calculation• Install main bearings (3) to cylinder block (1) and lower cylinder

block (2), and tighten lower cylinder block bolts to the specifiedtorque. Refer to EM-122, "Disassembly and Assembly" for thetightening procedure.

• Measure the inner diameter of main bearing with a bore gauge.(Oil clearance) = (Main bearing inner diameter) – (Crankshaft mainjournal diameter)

• If the calculated value exceeds the limit, select proper main bear-ing according to main bearing inner diameter and crankshaft mainjournal diameter to obtain the specified bearing oil clearance.Refer to EM-142, "Description".

Method of Using Plastigage• Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely. • Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil

holes.• Install main bearing to cylinder block and lower cylinder block, and tighten lower cylinder block bolts with

lower cylinder block to the specified torque. Refer to EM-122, "Disassembly and Assembly" for the tighteningprocedure.CAUTION:Never rotate crankshaft.

Standard and limit : Refer to EM-158, "Connecting Rod Bearing".

JPBIA0231ZZ

Standard and limit : Refer to EM-157, "Main Bearing".

JPBIA0232ZZ


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• Remove lower cylinder block and bearings, and using the scale onthe plastigage bag, measure the plastigage width. NOTE:The procedure when the measured value exceeds the limit is thesame as that described in the “Method by Calculation”.

MAIN BEARING CRUSH HEIGHT• When lower cylinder block is removed after being tightened to the

specified torque with main bearings (1) installed, the tip end ofbearing must protrude. Refer to EM-122, "Disassembly andAssembly" for the tightening procedure.

• If the standard is not met, replace main bearings.

CONNECTING ROD BEARING CRUSH HEIGHT• When connecting rod bearing cap is removed after being tightened

to the specified torque with connecting rod bearings (1) installed,the tip end of bearing must protrude. Refer to EM-122, "Disassem-bly and Assembly" for the tightening procedure.

• If the standard is not met, replace connecting rod bearings.

LOWER CYLINDER BLOCK BOLT OUTER DIAMETER• Measure the outer diameters (c), (d) at two positions as shown in

the figure.

• If reduction appears in (a) range, regard it (c).

• If it exceeds the limit (large difference in dimensions), replacelower cylinder block bolt with new one.

CONNECTING ROD BOLT OUTER DIAMETER

JPBIA0231ZZ

A : Crush height

Standard : There must be crush height.

JPBIA0233ZZ

A : Crush height

Standard : There must be crush height.

JPBIA0233ZZ

a : 20 mm (0.79 in)

b : 30 mm (1.18 in)

e : 10 mm (0.39 in)

Limit [(d) – (c)] : 0.11 mm (0.0043 in)

JPBIA0234ZZ


CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >1. Measure the outer diameters [(a), (b) and (c)] at the position

2. Obtain a mean value (d) of (a) and (b).3. Subtract (c) from (d).

4. If it exceeds the limit (large difference in dimensions), replace the bolt with new one.

FLYWHEEL DEFLECTION (M/T models)• Measure the deflection of flywheel contact surface to clutch with a

dial indicator (A).• Measure the deflection at 210 mm (8.27 in) dia.

• If measured value is out of the standard, replace flywheel.

MOVEMENT AMOUNT OF FLYWHEEL (M/T models)CAUTION:Never disassemble double mass flywheel.

Movement Amount in Radial (Rotation) DirectionCheck the movement amount of radial (rotation) direction with the following procedure:1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel

center line.• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.

2. Put a matching mark on circumferences of the two flywheelmasses without applying any load (measurement standardpoints).

3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,and mark the movement amount on the mass on the transaxleside.

4. Measure the dimensions of movement amounts (C) and (D) on circumference of the flywheel on the tran-saxle side.

• If measured value is out of the standard, replace flywheel.

DRIVE PLATE (A/T models)

a : Value at the end of the smaller diameter of the bolt

b : Value at the end of the smaller diameter of the bolt [opposite side of (a)]

c : Value of the smallest diameter of the smaller of the bolt

Limit [(d) – (c)] : 0.09 mm (0.0035 in) JPBIA0262ZZ

Standard : 0.45 mm (0.0177 in) or less.

JPBIA0236ZZ

1 : Clutch cover mounting bolt

2 : Flywheel (transaxle side)

A : Torque wrench

b : 9.8 N·m (1.0 kg-m, 87 in-lb)

Standard: Less than 29.9 mm (1.177 in)

JPBIA0237ZZ


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• Check drive plate and signal plate for deformation or damage.CAUTION:• Never disassemble drive plate.• Never place drive plate with signal plate facing down.• When handling signal plate, take care not to damage or

scratch it. • Handle signal plate in a manner that prevents it from becom-

ing magnetized.• If anything is found, replace drive plate.

OIL JET• Check nozzle for deformation and damage.• Blow compressed air from nozzle, and check for clogs.• If it is not satisfied, clean or replace oil jet.

OIL JET RELIEF VALVE• Using a clean plastic stick, press check valve in oil jet relief valve.

Check that valve moves smoothly with proper reaction force.• If it is not satisfied, replace oil jet relief valve.

JPBIA0192ZZ

EMU0468D


HOW TO SELECT PISTON AND BEARING


*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) Theinformation at the shipment from the plant is described as a reference.

• The identification grade stamped on each part is the grade for the dimension measured in new condition.This grade cannot apply to reused parts.

• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing themeasurement with the values of each selection table.

• For details of the measurement method of each part, the reuse standards and the selection method of theselective fitting parts, refer to the text.

Piston INFOID:0000000004250525

WHEN NEW CYLINDER BLOCK IS USEDCheck the cylinder bore grade (“1”, “2” or “3”) on rear side of cylinderblock, and select piston of the same grade.

NOTE:Piston is available with piston pin as a set for the service part. (Only “0” grade piston pin is available.)

WHEN NEW CYLINDER BLOCK IS REUSED1. Measure the cylinder bore inner diameter. Refer to EM-131, "Inspection".

Selection points Selection parts Selection items Selection methods

Between cylinder block and crankshaft

Main bearingMain bearing grade(bearing thickness)

Determined by match of cylin-der block bearing housing grade (inner diameter of hous-ing) and crankshaft journal grade (outer diameter of jour-nal)

Between crankshaft and con-necting rod

Connecting rod bearingConnecting rod bearing grade (bearing thickness)

Combining service grades for connecting rod big end diame-ter and crankshaft pin outer di-ameter determine connecting rod bearing selection.

Between cylinder block and pis-ton

Piston and piston pin assembly(Piston is available together with piston pin as assembly.)

Piston grade(piston skirt diameter)

Piston grade = cylinder bore grade (inner diameter of bore)

Between piston and connecting rod*

— — —

A : Bearing housing grade No. 1

B : Bearing housing grade No. 2

C : Bearing housing grade No. 3

D : Bearing housing grade No. 4

E : Cylinder bore grade No. 1

F : Cylinder bore grade No. 2

G : Cylinder bore grade No. 3

H : Cylinder bore grade No. 4

I : Cylinder bore grade No. 5

J : Cylinder bore grade No. 6

K : Identification

: Engine front

JPBIA0268ZZ



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2. Determine the bore grade by comparing the measurement withthe values under the cylinder bore inner diameter of the “PIS-TON SELECTION TABLE”.

3. Select piston of the same grade.

PISTON SELECTION TABLEUnit: mm (in)

NOTE:• Piston is available together with piston pin as assembly.• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no pis-

ton pin grades can be selected. (Only “0” grade is available.)• No second grade mark is available on piston.

Connecting Rod Bearing INFOID:0000000004250526

WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED1. Apply connecting rod big end diameter grade stamped (D) on

connecting rod side face to the row in the “CONNECTING RODBEARING SELECTION TABLE”.

A : RH

B : LH

C : Piston pin grade number

D : Piston grade number

E : Front mark

F : Identification code

JPBIA1212ZZ

Grade 1 2 3

Cylinder bore inner diameter95.500 - 95.510

(3.7598 - 3.7602)95.510 - 95.520

(3.7602 - 3.7606)95.520 - 95.530

(3.7606 - 3.7610)

Piston skirt diameter95.480 - 95.490

(3.7590 - 3.7594)95.490 - 95.500

(3.7594 - 3.7598)95.500 - 95.510

(3.7598 - 3.7602)

A : Sample codes



E : Weight grade

F : Cylinder No.

G : Management code

H : Front mark

I : Management code

JPBIA0208ZZ


< UNIT DISASSEMBLY AND ASSEMBLY >2. Apply crankshaft pin journal diameter grade stamped on crank-
shaft front side to the column in the “CONNECTING RODBEARING SELECTION TABLE”

3. Read the symbol at the cross point of selected row and column in the “CONNECTING ROD BEARINGSELECTION TABLE”.

4. Apply the symbol obtained to the “CONNECTING ROD BEARING GRADE TABLE” to select connectingrod bearing.

WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED1. Measure connecting rod big end diameter and crankshaft pin journal diameter. Refer to EM-131, "Inspec-

tion".2. Correspond the measured dimension in “connecting rod big end diameter” row of “CONNECTING ROD

BEARING SELECTION TABLE”.3. Correspond the measured dimension in “crankshaft pin diameter” column of “CONNECTING ROD BEAR-

ING SELECTION TABLE”.4. Follow step 3 and later in “WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED”.

CONNECTING ROD BEARING SELECTION TABLE

A : Journal diameter grade No. 1

B : Journal diameter grade No. 2

C : Journal diameter grade No. 3

D : Journal diameter grade No. 4

E : Pin diameter grade No. 1

F : Pin diameter grade No. 2

G : Pin diameter grade No. 3

H : Pin diameter grade No. 4

I : Pin diameter grade No. 5

J : Pin diameter grade No. 6

K : Identification

JPBIA0269ZZ



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CONNECTING ROD BEARING GRADE TABLE

UNDERSIZE BEARING USAGE GUIDE• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod

bearings, use undersize (US) bearings.• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing

installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. CAUTION:In grinding crankshaft pin to use undersize bearings, keep thefillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].

PBIC5435E

Connecting rod bearing grade table : Refer to EM-158, "Connecting Rod Bearing".

JPBIA0216ZZ


Main Bearing INFOID:0000000004250527

WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED1. “MAIN BEARING SELECTION TABLE” rows correspond to

bearing housing grade on rear side of cylinder block.

2. “MAIN BEARING SELECTION TABLE” columns correspond tojournal diameter grade on front side of crankshaft.

3. Select main bearing grade at the point where selected row and column meet in “MAIN BEARING SELEC-TION TABLE”.

4. Apply sign at crossing in above step 3 to “MAIN BEARING GRADE TABLE”.NOTE:• “MAIN BEARING GRADE TABLE” applies to all journals.• Service parts are available as a set of both upper and lower.

WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer

to EM-131, "Inspection".2. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of

“MAIN BEARING SELECTION TABLE”.3. Correspond the measured dimension in “Crankshaft main journal diameter” column of “MAIN BEARING

SELECTION TABLE”.4. Follow step 3 and later in “When New Cylinder Block and Crankshaft are Used”.

Bearing undersize table : Refer to EM-158, "Connecting Rod Bearing".

A : Bearing housing grade No. 1

B : Bearing housing grade No. 2

C : Bearing housing grade No. 3

D : Bearing housing grade No. 4

E : Cylinder bore grade No. 1

F : Cylinder bore grade No. 2

G : Cylinder bore grade No. 3

H : Cylinder bore grade No. 4

I : Cylinder bore grade No. 5

J : Cylinder bore grade No. 6

K : Identification code

: Engine front

JPBIA0268ZZ

A : Journal diameter grade No. 1

B : Journal diameter grade No. 2

C : Journal diameter grade No. 3

D : Journal diameter grade No. 4

E : Pin diameter grade No. 1

F : Pin diameter grade No. 2

G : Pin diameter grade No. 3

H : Pin diameter grade No. 4

I : Pin diameter grade No. 5

J : Pin diameter grade No. 6

K : Identification code

JPBIA0269ZZ



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MAIN BEARING SELECTION TABLE

MAIN BEARING GRADE TABLE (ALL JOURNALS)

UNDERSIZE BEARING USAGE GUIDE• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-

side (US) bearing.• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and

grind main journal so that the main bearing oil clearance satisfies the standard.CAUTION:In grinding crankshaft main journal to use undersize bearings,keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].

JPBIA0264ZZ

Main bearing grade table (All journals) : Refer to EM-157, "Main Bearing".

Bearing undersize table : Refer to EM-157, "Main Bearing".

JPBIA0216ZZ



General Specification INFOID:0000000004250528

GENERAL SPECIFICATIONS

Drive Belt INFOID:0000000004250529

DRIVE BELT

Spark Plug INFOID:0000000004250530

SPARK PLUGUnit: mm (in)

Cylinder arrangement V-6

Displacement cm3 (cu in) 3,696 (225.53)

Bore and stroke mm (in) 95.5 x 86.0 (3.76 x 3.386)

Valve arrangement DOHC

Firing order 1-2-3-4-5-6

Number of piston ringsCompression 2

Oil 1

Number of main bearings 4

Compression ratio 11

Compression pressure

kPa (kg/cm2, psi)/200 rpm

Standard 1,667 - 2,354 (17 - 24, 242 - 341)

Minimum 1,226 (12.5, 178)

Differential limit between cylinders 98 (1.0, 14)

Cylinder number

Unit: degree

Valve timing

Intake valve open (BTDC) 63 - −64

Intake valve close (ABDC) −73 - 82

Exhaust valve open (BBDC) 64

Exhaust valve close (ATDC) 12

SEM713A

Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Make DENSO

Standard type FXE24HR11

Gap (Nominal) 1.1 (0.043)



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Intake Manifold INFOID:0000000004250531

INTAKE MANIFOLDUnit: mm (in)

Exhaust Manifold INFOID:0000000004250532

EXHAUST MANIFOLDUnit: mm (in)

Camshaft INFOID:0000000004250533

CAMSHAFT (EXH)Unit: mm (in)

*1: Cam wear limit

*2: Total indicator reading

CAMSHAFT (INT)Unit: mm (in)

*1: Total indicator reading

Items Limit

Surface distortion Intake manifold 0.1 (0.004)

Items Limit

Surface distortion Exhaust manifold 0.7 (0.028)

Items Standard Limit

Camshaft (EXH) journal oil clearanceNo. 1 0.045 - 0.086 (0.0018 - 0.0034)

0.150 (0.0059)No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030)

VVEL ladder assembly bracket inner diameter (EXH)No. 1 26.000 - 26.021 (1.0236 - 1.0244) —

No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) —

Camshaft (EXH) journal diameterNo. 1 25.935 - 25.955 (1.0211 - 1.0218) —

No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) —

Camshaft (EXH) end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)

Camshaft (EXH) cam height “A” Bank 1 45.015 - 45.205 (1.7722 - 1.7797)

0.2 (0.008)*1

Bank 2 46.735 - 46.925 (1.8400 - 1.8474)

Camshaft (EXH) runout [TIR*2] Less than 0.02 (0.001) 0.05 (0.002)

Camshaft sprocket (EXH) runout [TIR*2] — 0.15 (0.0059)

SEM671


Drive shaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)

Camshaft sprocket (INT) runout [TIR*1] — 0.15 (0.0059)


VALVE LIFTERUnit: mm (in)

VALVE CLEARANCEUnit: mm (in)

*: Approximately 80°C (176°F)

AVAILABLE VALVE LIFTERUnit: mm (in)

Items Standard

Valve lifter outer diameter 33.980 - 33.990 (1.3378 - 1.3382)

Valve lifter hole diameter 34.000 - 34.016 (1.3386 - 1.3392)

Valve lifter clearance 0.010 - 0.036 (0.0004 - 0.0014)

Items Cold Hot* (reference data)

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)

Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)

Identification (stamped) mark Thickness

788 7.88 (0.3102)

790 7.90 (0.3110)

792 7.92 (0.3118)

794 7.94 (0.3126)

796 7.96 (0.3134)

798 7.98 (0.3142)

800 8.00 (0.3150)

802 8.02 (0.3157)

804 8.04 (0.3165)

806 8.06 (0.3173)

808 8.08 (0.3181)

810 8.10 (0.3189)

812 8.12 (0.3197)

814 8.14 (0.3205)

816 8.16 (0.3213)

818 8.18 (0.3220)

820 8.20 (0.3228)

822 8.22 (0.3236)

824 8.24 (0.3244)

826 8.26 (0.3252)

828 8.28 (0.3260)

830 8.30 (0.3268)

832 8.32 (0.3276)

834 8.34 (0.3283)

836 8.36 (0.3291)

838 8.38 (0.3299)



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Cylinder Head INFOID:0000000004250534

CYLINDER HEADUnit: mm (in)

VALVE DIMENSIONSUnit: mm (in)

840 8.40 (0.3307)

Identification (stamped) mark Thickness

SEM758G


Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)

Normal cylinder head height “H” 126.4 (4.98) —

PBIC0924E

Valve head diameter “D”Intake 36.6 - 36.9 (1.441 - 1.453)

Exhaust 30.2 - 30.5 (1.189 - 1.201)

Valve length “L”Intake 100.11 (3.94)

Exhaust 94.67 (3.7272)

Valve stem diameter “d”Intake 5.965 - 5.980 (0.2348 - 0.2354)

Exhaust 5.962 - 5.970 (0.2347 - 0.2350)

SEM188


VALVE GUIDEUnit: mm (in)

*: Parts settings are for exhaust side only

VALVE SEATUnit: mm (in)

Valve seat angle “α”Intake

45°15′ - 45°45′Exhaust

Valve margin “T”Intake 1.1 (0.043)

Exhaust 1.3 (0.051)

Valve margin “T” limit 0.5 (0.020)

Valve stem end surface grinding limit 0.2 (0.008)

Items Standard Oversize (Service) [0.2 (0.008)]*

Valve guideOuter diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)*

Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)

Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)*

Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)


Valve guide clearanceIntake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.003)

Exhaust 0.030 - 0.056 (0.0012 - 0.0022) 0.09 (0.004)

Projection length “L” 12.6 - 12.8 (0.496 - 0.504)

SEM950E

Items Standard Oversize (Service) [0.5 (0.02)] *4

Cylinder head seat recess diameter “D”Intake 38.000 - 38.016 (1.4961 - 1.4967) —

Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)*4

Valve seat outer diameter “d”Intake 38.097 - 38.113 (1.4999 - 1.5005) —

Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676)*4

PBIC2745E



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*1: Diameter made by intersection point of conic angles “α1” and “α2”

*2: Diameter made by intersection point of conic angles “α2” and “α3”

*3: Machining data

*4: Parts settings are for exhaust side only

VALVE SPRING

Cylinder Block INFOID:0000000004250535

CYLINDER BLOCK

Valve seat interference fitIntake 0.081 - 0.113 (0.0032 - 0.0044)

Exhaust 0.064 - 0.096 (0.0025 - 0.0038)

Diameter “d1”*1Intake 34.6 (1.362)

Exhaust 27.7 (1.091)

Diameter “d2”*2Intake 35.9 - 36.4 (1.413 - 1.433)

Exhaust 29.3 - 29.8 (1.154 - 1.173)

Angle “α1”Intake 60°

Exhaust 60°

Angle “α2”Intake 88°45′ - 90°15′

Exhaust 88°45′ - 90°15′

Angle “α3”Intake 120°

Exhaust 120°

Contacting width “W”*3Intake 1.0 - 1.4 (0.039 - 0.055)

Exhaust 1.2 - 1.6 (0.047 - 0.063)

Height “h”Intake 5.9 - 6.0 (0.232 - 0.236) —

Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)*4

Depth “H” 6.0 (0.236)

ItemsStandard

Intake Exhaust

Free height 45.66 mm (1.7976 in) 43.85 mm (1.7264 in)

Pressure

Installation191.1 - 215.5 N (19.5 - 22 kg, 43 - 48 lb)

at 40.90 mm (1.6102 in) 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)

at 37.00 mm (1.4567 in)

Valve open830.9 - 936.9 N (84.8 - 95.6 kg, 187 - 211 lb)

at 28.07 mm (1.1051 in)502 - 566 N (51.2 - 57.7 kg, 113 - 127 lb)

at 26.80 mm (1.0551 in)

Identification color Purple Yellowish green

ItemsLimit

Intake Exhaust

Out-of-square 2.0 mm (0.079 in) 1.9 mm (0.075 in)


Unit: mm (in)

AVAILABLE PISTON

Surface flatnessStandard Less than 0.03 (0.0012)

Limit 0.1 (0.004)

Main bearing housing inner diameter Standard 69.993 - 70.017 (2.7556 - 2.7566)

Cylinder bore Inner diameterStandard

Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602)

Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606)

Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610)

Wear limit 0.2 (0.008)

Out-of-round Limit

0.015 (0.0006)

Taper 0.010 (0.0004)

Main bearing housing inner diameter grade (Without bearing)

Grade No. AGrade No. BGrade No. CGrade No. DGrade No. EGrade No. FGrade No. GGrade No. HGrade No. JGrade No. KGrade No. LGrade No. MGrade No. NGrade No. PGrade No. RGrade No. SGrade No. TGrade No. UGrade No. VGrade No. WGrade No. XGrade No. YGrade No. 4Grade No. 7

69.993 - 69.994 (2.7556 - 2.7557)69.994 - 69.995 (2.7557 - 2.7557)69.995 - 69.996 (2.7557 - 2.7557)69.996 - 69.997 (2.7557 - 2.7558)69.997 - 69.998 (2.7558 - 2.7558)69.998 - 69.999 (2.7558 - 2.7559)69.999 - 70.000 (2.7559 - 2.7559)70.000 - 70.001 (2.7559 - 2.7559)70.001 - 70.002 (2.7559 - 2.7560)70.002 - 70.003 (2.7560 - 2.7560)70.003 - 70.004 (2.7560 - 2.7561)70.004 - 70.005 (2.7561 - 2.7561)70.005 - 70.006 (2.7561 - 2.7561)70.006 - 70.007 (2.7561 - 2.7562)70.007 - 70.008 (2.7562 - 2.7562)70.008 - 70.009 (2.7562 - 2.7563)70.009 - 70.010 (2.7563 - 2.7563)70.010 - 70.011 (2.7563 - 2.7563)70.011 - 70.012 (2.7563 - 2.7564)70.012 - 70.013 (2.7564 - 2.7564)70.013 - 70.014 (2.7564 - 2.7565)70.014 - 70.015 (2.7565 - 2.7565)70.015 - 70.016 (2.7565 - 2.7565)70.016 - 70.017 (2.7565 - 2.7566)

Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)

JPBIA1050GB



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Unit: mm (in)

PISTON RINGUnit: mm (in)

PISTON PINUnit: mm (in)

CONNECTING RODUnit: mm (in)

Items Standard Oversize (Service) [0.2 (0.008)]

Piston skirt diameter “A”

Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) —

Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) —

Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) —

Service — 95.680 - 95.710 (3.7669 - 3.7681)


“a” dimension 38.8 (1.528) —

Piston pin hole diameterGrade No. 0 21.993 - 21.999 (0.8659 - 0.8661) —

Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) —

Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)

SEM882E


Side clearance

Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043)

2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)

Oil ring 0.055 - 0.155 (0.0022 - 0.0061) 0.19 (0.0075)

End gap

Top 0.23 - 0.33 (0.0091 - 0.0130) 0.42 (0.0169)

2nd 0.23 - 0.33 (0.0091 - 0.0130) 0.57 (0.0224)

Oil (rail ring) 0.17 - 0.47 (0.0067 - 0.0185) 0.63 (0.0248)


Piston pin outer diameterGrade No. 0 21.989 - 21.995 (0.8657 - 0.8659) —

Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662) —

Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —

Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)


Center distance 149.45 - 149.55 (5.88 - 5.89) —

Bend [per 100 (3.94)] — 0.15 (0.0059)

Torsion [per 100 (3.94)] — 0.30 (0.0118)

Connecting rod bushing inner diameter*Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) —

Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) —


*: After installing in connecting rod

CRANKSHAFTUnit: mm (in)

Connecting rod big end diameter (Without bearing)

Grade No. A 57.000 - 57.001 (2.2441 - 2.2441) —

Grade No. B 57.001 - 57.002 (2.2441 - 2.2442) —

Grade No. C 57.002 - 57.003 (2.2442 - 2.2442) —

Grade No. D 57.003 - 57.004 (2.2442 - 2.2442) —

Grade No. E 57.004 - 57.005 (2.2442 - 2.2443) —

Grade No. F 57.005 - 57.006 (2.2443 - 2.2443) —

Grade No. G 57.006 - 57.007 (2.2443 - 2.2444) —

Grade No. H 57.007 - 57.008 (2.2444 - 2.2444) —

Grade No. J 57.008 - 57.009 (2.2444 - 2.2444) —

Grade No. K 57.009 - 57.010 (2.2444 - 2.2445) —

Grade No. L 57.010 - 57.011 (2.2445 - 2.2445) —

Grade No. M 57.011 - 57.012 (2.2445 - 2.2446) —

Grade No. N 57.012 - 57.013 (2.2446 - 2.2446) —


Side clearance 0.20 - 0.35 (0.0079 - 0.0138) 0.40 (0.0157)

Main journal diameter. “Dm” grade Standard

Grade No. AGrade No. BGrade No. CGrade No. DGrade No. EGrade No. FGrade No. GGrade No. HGrade No. JGrade No. KGrade No. LGrade No. MGrade No. NGrade No. PGrade No. RGrade No. SGrade No. TGrade No. UGrade No. VGrade No. WGrade No. XGrade No. YGrade No. 4Grade No. 7

64.975 - 64.974 (2.5581 - 2.5580)64.974 - 64.973 (2.5580 - 2.5580)64.973 - 64.972 (2.5580 - 2.5579)64.972 - 64.971 (2.5579 - 2.5579)64.971 - 64.970 (2.5579 - 2.5579)64.970 - 64.969 (2.5579 - 2.5578)64.969 - 64.968 (2.5578 - 2.5578)64.968 - 64.967 (2.5578 - 2.5578)64.967 - 64.966 (2.5578 - 2.5577)64.966 - 64.965 (2.5577 - 2.5577)64.965 - 64.964 (2.5577 - 2.5576)64.964 - 64.963 (2.5576 - 2.5576)64.963 - 64.962 (2.5576 - 2.5576)64.962 - 64.961 (2.5576 - 2.5575)64.961 - 64.960 (2.5575 - 2.5575)64.960 - 64.959 (2.5575 - 2.5574)64.959 - 64.958 (2.5574 - 2.5574)64.958 - 64.957 (2.5574 - 2.5574)64.957 - 64.956 (2.5574 - 2.5573)64.956 - 64.955 (2.5573 - 2.5573)64.955 - 64.954 (2.5573 - 2.5572)64.954 - 64.953 (2.5572 - 2.5572)64.953 - 64.952 (2.5572 - 2.5572)64.952 - 64.951 (2.5572 - 2.5571)

SEM645 SBIA0535E



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*: Total indicator reading

Main Bearing INFOID:0000000004250536

MAIN BEARINGUnit: mm (in)

Pin journal diameter. “Dp” grade Standard

Grade No. A 53.974 - 53.973 (2.1250 - 2.1249)

Grade No. B 53.973 - 53.972 (2.1249 - 2.1249)

Grade No. C 53.972 - 53.971 (2.1249 - 2.1248)

Grade No. D 53.971 - 53.970 (2.1248 - 2.1248)

Grade No. E 53.970 - 53.969 (2.1248 - 2.1248)

Grade No. F 53.969 - 53.968 (2.1248 - 2.1247)

Grade No. G 53.968 - 53.967 (2.1247 - 2.1247)

Grade No. H 53.967 - 53.966 (2.1247 - 2.1246)

Grade No. J 53.966 - 53.965 (2.1246 - 2.1246)

Grade No. K 53.965 - 53.964 (2.1246 - 2.1246)

Grade No. L 53.964 - 53.963 (2.1246 - 2.1245)

Grade No. M 53.963 - 53.962 (2.1245 - 2.1245)

Grade No. N 53.962 - 53.961 (2.1245 - 2.1244)

Grade No. P 53.961 - 53.960 (2.1244 - 2.1244)

Grade No. R 53.960 - 53.959 (2.1244 - 2.1244)

Grade No. S 53.959 - 53.958 (2.1244 - 2.1243)

Grade No. T 53.958 - 53.957 (2.1243 - 2.1243)

Grade No. U 53.957 - 53.956 (2.1243 - 2.1242)

Center distance “r” 42.96 - 43.04 (1.6913 - 1.6945)

Taper (Difference between “A” and “B”)Limit

0.0025 (0.0001)

Out-of-round (Difference between “X” and “Y”) 0.0025 (0.0001)

Crankshaft runout [TIR*]Standard Less than 0.05 (0.002)

Limit 0.10 (0.0039)

Crankshaft end playStandard 0.10 - 0.25 (0.0039 - 0.0098)

Limit 0.30 (0.0118)

Grade number Thickness Width Identification color Remarks

PBIC2969E


UNDERSIZEUnit: mm (in)

MAIN BEARING OIL CLEARANCEUnit: mm (in)

*: Actual clearance

Connecting Rod Bearing INFOID:0000000004250537

CONNECTING ROD BEARINGUnit: mm (in)

UNDERSIZEUnit: mm (in)

0 2.500 - 2.503 (0.0984 - 0.0985)

19.9 - 20.1(0.783 - 0.791)

Black

Grade is the same for upper and lower bearings.

1 2.503 - 2.506 (0.0985 - 0.0987) Brown

2 2.506 - 2.509 (0.0987 - 0.0988) Green

3 2.509 - 2.512 (0.0988 - 0.0989) Yellow

4 2.512 - 2.515 (0.0989 - 0.0990) Blue

5 2.515 - 2.518 (0.0990 - 0.0991) Pink

6 2.518 - 2.521 (0.0991 - 0.0993) Purple

7 2.521 - 2.524 (0.0993 - 0.0994) White

01UPR 2.503 - 2.506 (0.0985 - 0.0987) Brown

Grade and color are different for upper and lower bearings.

LWR 2.500 - 2.503 (0.0984 - 0.0985) Black

12UPR 2.506 - 2.509 (0.0987 - 0.0988) Green

LWR 2.503 - 2.506 (0.0985 - 0.0987) Brown

23UPR 2.509 - 2.512 (0.0988 - 0.0989) Yellow

LWR 2.506 - 2.509 (0.0987 - 0.0988) Green

34UPR 2.512 - 2.515 (0.0989 - 0.0990) Blue

LWR 2.509 - 2.512 (0.0988 - 0.0989) Yellow

45UPR 2.515 - 2.518 (0.0990 - 0.0991) Pink

LWR 2.512 - 2.515 (0.0989 - 0.0990) Blue

56UPR 2.518 - 2.521 (0.0991 - 0.0993) Purple

LWR 2.515 - 2.518 (0.0990 - 0.0991) Pink

67UPR 2.521 - 2.524 (0.0993 - 0.0994) White

LWR 2.518 - 2.521 (0.0991 - 0.0993) Purple

Items Thickness Main journal diameter

0.25 (0.0098) 2.633 - 2.641 (0.1037 - 0.1040) Grind so that bearing clearance is the specified value.


Main bearing oil clearance 0.035 - 0.045 (0.0014 - 0.0018)* 0.065 (0.0026)

Grade number Thickness Identification color (mark)

0 1.497 - 1.500 (0.0589 - 0.0591) Black

1 1.500 - 1.503 (0.0591 - 0.0592) Brown

2 1.503 - 1.506 (0.0592 - 0.0593) Green

3 1.506 - 1.509 (0.0593 - 0.0594) Yellow

4 1.509 - 1.512 (0.0594 - 0.0595) Blue

Items Thickness Crank pin journal diameter

0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643) Grind so that bearing clearance is the specified value.



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CONNECTING ROD BEARING OIL CLEARANCEUnit: mm (in)

*: Actual clearance


Connecting rod bearing oil clearance 0.040 - 0.053 (0.0016 - 0.0021)* 0.070 (0.0028)


ENGINE

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SECTION EXA

EX

EXHAUST SYSTEM

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CONTENTS

PRECAUTION ............................................... 2

PRECAUTIONS ................................................... 2Removal and Installation ...........................................2

PREPARATION ............................................ 3

PREPARATION ................................................... 3Special Service Tool .................................................3Commercial Service Tool ..........................................3

PERIODIC MAINTENANCE ......................... 4

EXHAUST SYSTEM ........................................... 4Inspection ................................................................. 4


EXHAUST SYSTEM ........................................... 5Exploded View .......................................................... 5Removal and Installation .......................................... 6Inspection ................................................................. 6

EX-1Revision: 2009 October 2009 G37 Coupe

PRECAUTIONS
< PRECAUTION >


CAUTION:• Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat

resistance, corrosion resistance, and shape.• Perform the operation with the exhaust system fully cooled down because the system will be hot

just after engine stops. • Be careful not to cut your hand on the heat insulator edge.


PREPARATION

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Description

KV10114400(J-38365)Heated oxygen sensor wrench

Loosening or tightening heated oxygen sen-sor 2 For 22 mm (0.87 in) (a) width hexagon nut

S-NT636


Description

A: (J-43897-18)B: (J-43897-12)Heated oxygen sensor thread cleaner

Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.)A: J-43897-18 [18 mm (0.71 in) dia.] for zir-conia heated oxygen sensorB: J-43897-12 [12 mm (0.47 in) dia.] for tita-nia heated oxygen sensorC: Mating surface shave cylinderD: Flutes

( — )Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specifica-tion MIL-A-907)

Lubricating heated oxygen sensor thread cleaner when reconditioning exhaust system threads

( — )Power tool

Loosening bolts and nuts

JPBIA0238ZZ

AEM489

PBIC0190E


EXHAUST SYSTEM
PERIODIC MAINTENANCEEXHAUST SYSTEM


Check exhaust pipes, muffler and mounting for improper attachment,leaks, cracks, damage or deterioration.• If anything is found, repair or replace damaged parts.

SMA211A


EXHAUST SYSTEM

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REMOVAL AND INSTALLATIONEXHAUST SYSTEM


1. Mounting bracket 2. Mounting rubber 3. Main muffler

4. Dynamic damper 5. Mounting rubber 6. Gasket

7. Mounting rubber 8. Mounting bracket 9. Center muffler

10. Gasket 11. Three way catalyst (bank 1) 12. Heated oxygen sensor 2 (bank 1)

13. Collar 14. Grommet 15. Exhaust mounting bracket

16. Grommet 17. Heated oxygen sensor 2 (bank 2) 18. Three way catalyst (bank 2)

19. Gasket 20. Dynamic damper 21. Exhaust front tube

22. Gasket


JPBIA1939GB


EXHAUST SYSTEM

REMOVAL• Disconnect each joint and mounting using power tool.• Remove heated oxygen sensor 2 as follows:- Using heated oxygen sensor wrench [SST: KV10114400 (J-

38365)] (C), removal heated oxygen sensor 2.

CAUTION:Be careful not to damage heated oxygen sensor 2.

INSTALLATIONNote the following, and install in the reverse order of removal.• Check for deformation of the grommets (14 and 16 of Components).• Insert the collar (13 of Components) vertically.• Temporarily tighten nuts and bolts when installing exhaust pipe assembly. Tighten them to the specified

torque when connecting the vehicle rear to the vehicle front.CAUTION:• Always replace exhaust tube gaskets with new ones when reassembling.• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a con-

crete floor. Use a new one. • Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxy-

gen sensor thread cleaner (commercial service tool: J-43897-18 or J-43897-12), and apply the anti-seize lubricant (commercial service tool).

• Never over torque heated oxygen sensor 2. Doing so may cause damage to heated oxygen sensor 2,resulting in the “MIL” coming on.

• If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heatinsulator, remove them.

• When installing heat insulator avoid large gaps or interference between heat insulator and eachexhaust pipe.

• Remove deposits from the sealing surface of each connection. Connect them securely to avoidgases leakage.

• Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicleside. Check each part for unusual interference, and then tighten them to the specified torque.

• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/leftdirections.


INSPECTION AFTER INSTALLATION• Check clearance between tail tube and rear bumper is even.• With engine running, check exhaust tube joints for gas leakage and unusual noises.• Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue

stress. Improper installation could result in excessive noise and vibration.

A : Bank 1

B : Bank 2

: Vehicle front

JPBIA2218ZZ


BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

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SECTION EXTA

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EXTERIOR

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CONTENTS

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SQUEAK AND RATTLE TROUBLE DIAG-NOSES ................................................................ 3

Work Flow .................................................................3Inspection Procedure ................................................5Diagnostic Worksheet ...............................................7

PRECAUTION ............................................... 9

PRECAUTIONS ................................................... 9Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" ...................................................................9Precaution Necessary for Steering Wheel Rota-tion after Battery Disconnect .....................................9Precaution for Battery Service ................................10Precaution for Procedure without Cowl Top Cover ....10Precaution for Work ................................................10

PREPARATION ...........................................11

PREPARATION ..................................................11Special Service Tools ..............................................11Commercial Service Tools .....................................11


FRONT BUMPER ...............................................12Exploded View ........................................................12Removal and Installation .........................................13

REAR BUMPER .................................................16Exploded View ........................................................16Removal and Installation .........................................17

FRONT GRILLE .................................................19Exploded View ........................................................19Removal and Installation .........................................19

COWL TOP .........................................................21Exploded View ........................................................21

Removal and Installation .........................................21

FENDER PROTECTOR ....................................24

FENDER PROTECTOR .............................................24FENDER PROTECTOR : Exploded View ...............24FENDER PROTECTOR : Removal and Installa-tion ...........................................................................24

REAR WHEEL HOUSE PROTECTOR ......................25REAR WHEEL HOUSE PROTECTOR : Exploded View .........................................................................25REAR WHEEL HOUSE PROTECTOR : Removal and Installation ........................................................25

CENTER MUD GUARD .....................................27Exploded View .........................................................27Removal and Installation .........................................27

FLOOR SIDE FAIRING .....................................29Exploded View .........................................................29Removal and Installation .........................................29

ROOF SIDE MOLDING .....................................31Exploded View .........................................................31Removal and Installation .........................................31

FRONT PILLAR FINISHER ...............................33Exploded View .........................................................33Removal and Installation .........................................33

DOOR OUTSIDE MOLDING .............................35Exploded View .........................................................35Removal and Installation .........................................35

DOOR PARTING SEAL ....................................36Exploded View .........................................................36Removal and Installation .........................................36

TRUNK LID FINISHER ......................................37

TRUNK LID OUTER FINISHER .................................37TRUNK LID OUTER FINISHER : Exploded View ....37

EXT-1Revision: 2009 October 2009 G37 Coupe

TRUNK LID OUTER FINISHER : Removal and In-stallation ................................................................. 37

TRUNK DRIP COVER ............................................... 38TRUNK DRIP COVER : Exploded View ................. 39

TRUNK DRIP COVER : Removal and Installation ... 39

REAR SPOILER ................................................ 41Exploded View ........................................................ 41Removal and Installation ......................................... 41



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SYMPTOM DIAGNOSISSQUEAK AND RATTLE TROUBLE DIAGNOSES


CUSTOMER INTERVIEWInterview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any ofcustomer's comments; refer to EXT-7, "Diagnostic Worksheet". This information is necessary to duplicate theconditions that exist when the noise occurs.• The customer may not be able to provide a detailed description or the location of the noise. Attempt to obtain

all the facts and conditions that exist when the noise occurs (or does not occur).• If there is more than one noise in the vehicle, perform a diagnosis and repair the noise that the customer is

concerned about. This can be accomplished by performing a cruise test on the vehicle with the customer.• After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics

are provided so the customer, service adviser and technician are all speaking the same language whendefining the noise.

• Squeak – (Like tennis shoes on a clean floor)Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard surfaces= higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping

• Creak – (Like walking on an old wooden floor)Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch depen-dent on materials/often brought on by activity.

• Rattle – (Like shaking a baby rattle)Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missingclip or fastener/incorrect clearance.

• Knock – (Like a knock on a door)Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.

• Tick – (Like a clock second hand)Tick characteristics include gentle contacting of light materials/loose components/can be caused by driveraction or road conditions.

• Thump – (Heavy, muffled knock noise)Thump characteristics include softer knock/dead sound often brought on by activity.

• Buzz – (Like a bumblebee)Buzz characteristics include high frequency rattle/firm contact.

• Often the degree of acceptable noise level will vary depending up on the person. A noise that a technicianmay judge as acceptable may be very irritating to the customer.

• Weather conditions, especially humidity and temperature, may have a great effect on noise level.

DUPLICATE THE NOISE AND TEST DRIVE

SBT842


< SYMPTOM DIAGNOSIS >If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information onthe Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used toduplicate the same conditions when the repair is reconfirmed.If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-cate the noise with the vehicle stopped by doing one or all of the following:1) Close a door.2) Tap or push/pull around the area where the noise appears to be coming from.3) Rev the engine.4) Use a floor jack to recreate vehicle “twist”.5) At idle, apply engine load (electrical load, half-clutch on M/T models, drive position on A/T models).6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.• Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.• If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.

CHECK RELATED SERVICE BULLETINSAfter verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) relatedto that concern or symptom.If a TSB relates to the symptom, follow the procedure to repair the noise.

LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool

(Chassis ear: J-39570, Engine ear and mechanics stethoscope).2. Narrow down the noise to a more specific area and identify the cause of the noise by:• Removing the components in the area that is are suspected to be the cause of the noise.

Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be brokenor lost during the repair, resulting in the creation of new noise.

• Tapping or pushing/pulling the component that is are suspected to be the cause of the noise.Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only tem-porarily.

• Feeling for a vibration by hand by touching the component(s) that is are suspected to be the cause of thenoise.

• Placing a piece of paper between components that are suspected to be the cause of the noise.• Looking for loose components and contact marks.

Refer to EXT-5, "Inspection Procedure".

REPAIR THE CAUSE• If the cause is a loose component, tighten the component securely.• If the cause is insufficient clearance between components:- Separate components by repositioning or loosening and retightening the component, if possible.- Insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-

thane tape. A Nissan Squeak and Rattle Kit (J-43980) is available through the authorized Nissan PartsDepartment.

CAUTION:Never use excessive force as many components are constructed of plastic and may be damaged.NOTE:Always check with the Parts Department for the latest parts information.The following materials are contained in the Nissan Squeak and Rattle Kit (J-43980). Each item can beordered separately as needed.URETHANE PADS [1.5 mm (0.059 in) thick]Insulates connectors, harness, etc.• 76268-9E005: 100 × 135 mm (3.937 × 5.315 in)• 76884-71L01: 60 × 85 mm (2.362 × 3.346 in)• 76884-71L02:15 × 25 mm (0.591 × 0.984 in)INSULATOR (Foam blocks)Insulates components from contact. Can be used to fill space behind a panel.• 73982-9E000: 45 mm (1.772 in) thick, 50 × 50 mm (1.969 × 1.969 in)• 73982-50Y00: 10 mm (0.394 in) thick, 50 × 50 mm (1.969 × 1.969 in)INSULATOR (Light foam block)80845-71L00: 30 mm (1.18 in) thick, 30 × 50 mm (1.181 × 1.969in)FELT CLOTHTAPE



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Used to insulate where movement does not occur. Ideal for instrument panel applications.• 68370-4B000: 15 × 25 mm (0.591 × 0.984 in) pad• 68239-13E00: 5 mm (0.197 in) wide tape rollThe following materials, not found in the kit, can also be used to repair squeaks and rattles.UHMW (TEFLON) TAPEInsulates where slight movement is present. Ideal for instrument panel applications.SILICONE GREASEUsed in place of UHMW tape that is be visible or does not fit. Will only last a few months.SILICONE SPRAYUsed when grease cannot be applied.DUCT TAPEUsed to eliminate movement.

CONFIRM THE REPAIRConfirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the sameconditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.

Inspection Procedure INFOID:0000000004678285

Refer to Table of Contents for specific component removal and installation information.

INSTRUMENT PANELMost incidents are caused by contact and movement between:1. The cluster lid A and instrument panel2. Acrylic lens and combination meter housing3. Instrument panel to front pillar garnish4. Instrument panel to windshield5. Instrument panel mounting pins6. Wiring harnesses behind the combination meter7. A/C defroster duct and duct joint

These incidents can usually be located by tapping or moving the components to duplicate the noise or bypressing on the components while driving to stop the noise. Most of these incidents can be repaired byapplying felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulatewiring harness.CAUTION:Never use silicone spray to isolate a squeak or rattle. If the area is saturated with silicone, therecheck of repair becomes impossible.

CENTER CONSOLEComponents to pay attention to include:1. Shifter assembly cover to finisher2. A/C control unit and cluster lid C3. Wiring harnesses behind audio and A/C control unitThe instrument panel repair and isolation procedures also apply to the center console.

DOORSPay attention to the following:1. Finisher and inner panel making a slapping noise2. Inside handle escutcheon to door finisher3. Wiring harnesses tapping4. Door striker out of alignment causing a popping noise on starts and stopsTapping or moving the components or pressing on them while driving to duplicate the conditions can isolatemany of these incidents. The areas can usually be insulated with felt cloth tape or insulator foam blocks fromthe Nissan Squeak and Rattle Kit (J-43980) to repair the noise.

TRUNKTrunk noises are often caused by a loose jack or loose items put into the trunk by the customer.In addition look for the following:1. Trunk lid dumpers out of adjustment


< SYMPTOM DIAGNOSIS >2. Trunk lid striker out of adjustment3. The trunk lid torsion bars knocking together4. A loose license plate or bracketMost of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-ing the noise.
SUNROOF/HEADLININGNoises in the sunroof/headlining area can often be traced to one of the following:1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise2. Sunvisor shaft shaking in the holder3. Front or rear windshield touching headlining and squeakingAgain, pressing on the components to stop the noise while duplicating the conditions can isolate most of theseincidents. Repairs usually consist of insulating with felt cloth tape.

SEATSWhen isolating seat noise it's important to note the position the seats in and the load placed on the seat whenthe noise occurs. These conditions should be duplicated when verifying and isolating the cause of the noise.Cause of seat noise include:1. Headrest rods and holder2. A squeak between the seat pad cushion and frame3. The rear seatback lock and bracketThese noises can be isolated by moving or pressing on the suspected components while duplicating the con-ditions under which the noise occurs.Most of these incidents can be repaired by repositioning the componentor applying urethane tape to the contact area.

UNDERHOODSome interior noise may be caused by components under the hood or on the engine wall. The noise is thentransmitted into the passenger compartment.Causes of transmitted underhood noise include:1. Any component mounted to the engine wall2. Components that pass through the engine wall3. Engine wall mounts and connectors4. Loose radiator mounting pins5. Hood bumpers out of adjustment6. Hood striker out of adjustmentThese noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The bestmethod is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPMor load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, orinsulating the component causing the noise.



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Diagnostic Worksheet INFOID:0000000004678286

PIIB8741E


PIIB8742E


PRECAUTIONS

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< PRECAUTION >

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PRECAUTIONS






Precaution for Work INFOID:0000000004249856

• After removing and installing the opening/closing parts, be sure to carry out fitting adjustments to check theiroperation.

• Check the lubrication level, damage, and wear of each part. If necessary, grease or replace it.

PIIB3706J


PREPARATION

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< PREPARATION >

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(J-39570)Chassis ear

Locates the noise

(J-43980)NISSAN Squeak and Rattle Kit

Repaires the cause of noise

SIIA0993E

SIIA0994E


Engine ear Locates the noise

Remover tool Removes clips, pawls and metal clips

Power tool

SIIA0995E

JMKIA3050ZZ

PIIB1407E


FRONT BUMPER
REMOVAL AND INSTALLATIONFRONT BUMPER


1. Bumper bracket RH 2. Hood seal assembly (front) 3. Bumper side bracket RH

4. Bumper side stiffener RH 5. Bumper finisher RH 6. License plate bracket

7. Front grille 8. J-nut 9. Bumper side stiffener LH

10. Bumper finisher LH 11. Bumper bracket LH 12. Bumper reinforcement

13. Energy absorber 14. Bumper fascia assembly (normal) 15. Grommet

JMKIA1225ZZ


FRONT BUMPER

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REMOVALCAUTION:Bumper fascia is made of resin. Never apply strong force to it, and be careful to prevent contact withoil.1. Fully open hood assembly.2. Remove clips (A) of front bumper fascia upper side.

3. Remove radiator core support ornament. Refer to DLK-212, "Removal and Installation".4. Remove clips (A) of hood seal assembly (side) (LH/RH) with

remover tool (B), and then remove hood seal assembly locatedfront portion. Refer to DLK-215, "Removal and Installation".

5. Remove bolts (A), and then remove bumper bracket (1) (LH/RH).

16. Bumper side bracket LH 17. Bumper finisher (center) 18. Bumper bracket cover

19. Bumper fascia assembly (sports)

: Clip

: Pawl

JMKIA1226ZZ

JMKIA1227ZZ

JMKIA1228ZZ


FRONT BUMPER
< REMOVAL AND INSTALLATION >6. Remove bolts (A) of fixing engine lower cover and front fender
protector.

7. Remove fender protector (front) mounting bolts and clips, andthen remove screw (A) of fixing bumper fascia left and right side.

8. Pull the bumper fascia side toward the vehicle side to disengagethe fitting of bumper side bracket and bumper fascia side.

9. Remove bumper fascia assembly.CAUTION:When removing bumper fascia, 2 workers are required so as to prevent it from dropping.

10. Remove the following parts after removing bumper fascia.• Front grille • Hood seal assembly (front)• License plate bracket • Front bumper side bracket (LH/RH) • Front bumper side stiffener (LH/RH) • Front bumper finisher

11. Remove bumper energy absorber.12. Remove bumper reinforcement mounting nuts and bolts, and then remove bumper reinforcement with

power tool.

INSTALLATIONInstall in the reverse order of removal.NOTE:After installing, perform fitting adjustment.

JMKIA1229ZZ

JMKIA1230ZZ

JMKIA1231ZZ

Portion Clearance

Front bumper – Hood assembly A – A 2.0 – 4.5 mm (0.079 – 0.177 in)

Front bumper – Front grille B – B 0.2 – 2.8 mm (0.008 – 0.110 in)


FRONT BUMPER

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Front bumper – Headlamp C – C 0.5 – 3.2 mm (0.020 – 0.126 in)

Front bumper – Front fender D – D 0.0 – 0.7 mm (0.000 – 0.028 in)

Front bumper – Headlamp E – E 0.3 – 3.2 mm (0.012 – 0.126 in)

Front bumper – Front fender F – F 0.0 – 0.7 mm (0.000 – 0.028 in)

Front bumper – Front fender G – G 0.0 – 0.8 mm (0.000 – 0.031 in)

Portion Clearance


REAR BUMPER
REAR BUMPER


1. Bumper side bracket RH 2. Bumper stay RH 3. Bumper lower retainer

4. Bumper stay LH 5. Rivet 6. Bumper side bracket LH

7. Bumper energy absorber 8. Bumper fascia assembly 9. Rear license plate bracket

10. Grommet 11. License lamp bracket 12. Bumper reinforcement

: Clip

JMKIA1232ZZ


REAR BUMPER

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REMOVALCAUTION:Bumper fascia is made of resin. Never apply strong force to it, and be careful to prevent contact withoil.1. Fully open trunk lid assembly.2. Remove rear combination lamp (LH/RH). Refer to EXL-203, "Removal and Installation".3. Remove clips (A) located under rear combination lamp (LH/RH).

4. Remove bolts (A) of bumper fascia underside (LH/RH).

5. Remove screws (A) of bumper fascia front end upper (LH/RH).

6. Remove clips of bumper fascia underside, and then pull out bumper fascia toward rear of vehicle.

: Pawl


JMKIA1233ZZ

JMKIA1234ZZ

JMKIA0095GB


REAR BUMPER
< REMOVAL AND INSTALLATION >7. Disconnect license plate lamp connector (A).
8. Pull the bumper fascia side toward the vehicle side to disengagethe fitting of bumper side bracket and bumper fascia side.

9. Remove bumper fascia assembly.CAUTION:When removing bumper fascia, 2 workers are required so as to prevent it from dropping.

10. Remove the following parts after removing bumper fascia.• License plate lamp. Refer to EXL-207, "Removal and Installation". • License lamp bracket.• License plate bracket.• Bumper lower retainer.

11. Remove bumper energy absorber.12. Remove license lamp harness clamps of bumper reinforcement.13. Remove bumper reinforcement mounting nuts and bolts, and then remove bumper reinforcement with

power tool.

INSTALLATIONInstall in the reverse order of removal.NOTE:After installing, perform fitting adjustment.

JMKIA0096GB

JMKIA1235ZZ

Portion Clearance

Rear bumper – Trunk lid A – A 4.0 – 8.0 mm (0.157 – 0.315 in)

Rear bumper – Rear combination lamp B – B 0.0 – 3.0 mm (0.000 – 0.118 in)

Rear bumper – Rear fender C – C 0.0 – 0.8 mm (0.000 – 0.031 in)

Rear bumper – Rear fender D – D 0.0 – 0.8 mm (0.000 – 0.031 in)


FRONT GRILLE

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FRONT GRILLE



REMOVALCAUTION:Apply protection tape around outer circumference of front grille (bumper fascia side).1. Fully open hood assembly.2. Remove reservoir tank. Refer to CO-14, "Removal and Installation". 3. Remove radiator core support ornament. Refer to DLK-212, "Removal and Installation".4. Remove front grille mounting nuts (A).

1. Front grille 2. Front emblem

: Pawl

JMKIA1236ZZ

JMKIA0097GB


FRONT GRILLE
< REMOVAL AND INSTALLATION >5. Disengage pawls (A) of fixing front grille.
6. Pull front grille out toward vehicle front.7. Remove the following parts after removing front grille.

Front emblem


: Pawl

JMKIA0098GB


COWL TOP

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COWL TOP



REMOVAL1. Fully open hood assembly.

1. Front fender cover (RH) 2. Cowl top seal 3. Front fender cover (LH)

4. Cowl top cover (RH) 5. Cowl top cover (LH) 6. Cowl top cover seal (RH)

7. Cowl top cover seal (LH) 8. Battery cover 9. Brake master cylinder cover

10. Hoodledge cover (RH) 11. Hoodledge cover (LH) 12. EPT sealer

: Clip

: Pawl


JMKIA1507ZZ


COWL TOP
< REMOVAL AND INSTALLATION >2. Remove front wiper arm (LH/RH) from vehicle. Refer to WW-93, "Removal and Installation".3. Remove battery cover and brake master cylinder cover.4. Remove hoodledge cover mounting clips and then remove hoodledge cover (LH/RH) and cowl top cover
seal (LH/RH).5. Remove cowl top seal. 6. Remove cowl top cover mounting clips.7. Plastic pawl (A) is pull up and cowl top cover RH (2) is removed

ahead of vehicles.

8. Plastic pawl (B) is push down and cowl top cover LH (1) isremoved ahead of vehicles.

9. Remove the following parts after removing cowl top cover.• Front fender cover (LH/RH).• EPT sealer.

INSTALLATIONNote the following, and install in the reverse order of removal.• Install cowl top cover LH (1) with (C) (pin from front windshield

glass) aligned with concave part.

JMKIA0099GB

JMKIA0100GB

JMKIA0104GB


COWL TOP

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• Slide the pawl while aligning with the concave part of (E).• Engage the joint of plastic pawl of (A) with (D), and then assemble

cowl top covers LH (1) and RH (2).

CAUTION:After installing, perform adjustment of wiper arm. Refer to WW-93, "Adjustment".

JMKIA0105GB


FENDER PROTECTOR
FENDER PROTECTORFENDER PROTECTOR

FENDER PROTECTOR : Exploded View INFOID:0000000004249867

FENDER PROTECTOR : Removal and Installation INFOID:0000000004249868

REMOVAL1. Remove bolt (A) of fender protector (rear) rear end.2. Remove screws (B) of fender protector (rear) located center

mud guard and front fender.

3. Remove clips of fender protector (rear).4. Remove fender clip from wheelhouse arches, and then remove fender protector (rear) from wheel house.

1. Fender protector (front) 2. Fender protector (rear) 3. J-nut

4. Fairing 5. Splash guard 6. Front fender

7. Fender clip 8. Grommet

JMKIA1237ZZ

JMKIA0106GB


FENDER PROTECTOR

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5. Remove bolts (A) of fender protector (front) located engineunder cover and front bumper.

6. Remove fender protector (front) mounting clips.7. Remove fender clip from wheel house arches, and then remove fender protector (front) from wheel house.8. Remove the following parts after removing front fender protector.

• Fairing• Fender clip

INSTALLATIONInstall in the reverse order of removal.REAR WHEEL HOUSE PROTECTOR

REAR WHEEL HOUSE PROTECTOR : Exploded View INFOID:0000000004249869

REAR WHEEL HOUSE PROTECTOR : Removal and Installation INFOID:0000000004249870

REMOVAL

JMKIA0107GB

1. Rear wheel house protector

JMKIA1238ZZ


FENDER PROTECTOR
< REMOVAL AND INSTALLATION >1. Remove bolt (A) of rear wheel house protector rear end.
2. Remove screw (A) of rear wheel house protector located centermud guard.

3. Remove rear wheel house protector mounting nuts and then remove rear wheel house protector.


JMKIA1239ZZ

JMKIA1240ZZ


CENTER MUD GUARD

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CENTER MUD GUARD



REMOVAL1. Remove wind deflector mounting clip (A) and nuts (B), and then

remove wind deflector (1).

1. Body side outer 2. Grommet 3. Wind deflector

4. Center mud guard

JMKIA1241ZZ

JMKIA1242ZZ


CENTER MUD GUARD
< REMOVAL AND INSTALLATION >2. Remove screw (A) and bolt (B) of center mud guard front end.
3. Remove screw (A) of center mud guard rear end.

4. Remove screws of center mud guard underside.5. Fully open front door.6. Remove clips from back of center mud guard using remover tool.7. Remove center mud guard from body side.

INSTALLATIONInstall in the reverse order of removal.CAUTION:When installing center mud guard, chack that clips are securely fitted in panel holes on body, and thenpress them in.

JMKIA0111GB

JMKIA1243ZZ


FLOOR SIDE FAIRING

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FLOOR SIDE FAIRING



REMOVAL

ENGINE LOWER COVER

1. Remove engine lower cover mounting clips.2. Remove engine lower cover mounting bolts with power tool.3. Remove engine lower cover.

FRONT UNDER COVER

1. Remove front under cover mounting clips.2. Remove front under cover mounting bolts with power tool.3. Remove front under cover.

FLOOR UNDER COVER (LH/RH)

1. Remove floor under cover mounting clips.2. Remove floor under cover mounting bolts and nuts with power tool.3. Remove floor under cover.

REAR UNDER COVER (LH/RH)

1. Remove rear under cover mounting bolts.

1. Engine lower cover 2. Front under cover 3. Floor under cover RH

4. Floor under cover LH 5. Rear under cover RH 6. Rear under cover LH

JMKIA1244ZZ


FLOOR SIDE FAIRING
< REMOVAL AND INSTALLATION >2. Remove rear under cover.


ROOF SIDE MOLDING

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ROOF SIDE MOLDING



REMOVALDisengage roof side molding (1) fixing clips with remover tool (A).CAUTION:Wrap the tip of remover tool (A) with a cloth (B).

INSTALLATIONInstall from roof side molding rear end to front end in this order after temporarily holding.

REMOVAL AND INSTALLATION OF ROOF SIDE MOLDING CLIP

Removal

1. Remove roof side molding.

1. Roof side molding 2. Roof side molding clip 3. Body side panel

4. Roof panel

JMKIA1774ZZ

: Clip

JMKIA1246ZZ


ROOF SIDE MOLDING
< REMOVAL AND INSTALLATION >2. Heat adhesive tape interface using a dryer, and then peel roof side molding clips (body side) using long-
nose pliers.CAUTION:Be careful not to damage the body.

Installation

1. Clean tape removed surface with a shop cloth soaked in white gasoline or IPA.2. Use two-part epoxy adhesive.

3. Apply adhesive evenly to clip tape surface.

4. Position applied parts to the proper location, and then sufficiently press-fit until the adhesive protrudes totape side.

5. Tape clips after press fit, and temporarily hold it for specified time based on the following.

6. Install from roof side molding rear end to front end in this order after temporarily holding.CAUTION:• Use double-faced adhesive tape after hardening for clips. • Securely insert molding rear end cap onto roof rear end cutout (installation standard).• When installing roof side molding of windshield portion, check that molding fastener is securely

inserted and then press in.• Never wash the vehicle with in 24 hours so as to keep adhesive.

Adhesive : 3M–weld DP-100 or equivalent

Thickness : Approximately 0.5 mm (0.020 in)

Press-fit limit : 19.6 N × 2 seconds

5 to 10°C (41 to 50°F) : 1 hour or more11 to 23°C (52 to 73°F) : 30 minutes or more24°C or more (75°F or more) : 15 minutes or more


FRONT PILLAR FINISHER

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Removal 1. Remove clip and double faced adhesive tapes of body side weather-strip.2. Remove body side weather-strip.3. Remove body side weather-strip retainer (1) mounting screws

(A) and clip (B), and then remove body side weather-stripretainer (1).

1. Front pillar finisher 2. Body side weather-strip retainer 3. Body side weather-strip

4. Grommet 5. Body side outer

: Clip


JMKIA1509ZZ

JMKIA1248ZZ


< REMOVAL AND INSTALLATION >4. Remove front pillar finisher (1) fixing clips with remover tool (A).
5. Remove front pillar finisher.

InstallationInstall in the reverse order of removal.

: Clip

JMKIA1249ZZ


DOOR OUTSIDE MOLDING

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DOOR OUTSIDE MOLDING



REMOVAL1. Remove door finisher. Refer to INT-11, "Removal and Installation".2. Remove door mirror assembly. Refer to MIR-18, "DOOR MIRROR ASSEMBLY : Removal and Installa-

tion".3. Twists and pull up to upper side, and then remove front door out-

side molding (1).


1. Door outside molding 2. Door panel assembly


JMKIA1250ZZ

JMKIA0116GB


DOOR PARTING SEAL
DOOR PARTING SEAL



REMOVAL1. Fully open door.2. Remove door parting seal mounting plastic clips with remover tool.3. Remove door parting seal.


1. Door parting seal 2. Door panel assembly

: Clip

JMKIA1251ZZ


TRUNK LID FINISHER

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TRUNK LID FINISHERTRUNK LID OUTER FINISHER

TRUNK LID OUTER FINISHER : Exploded View INFOID:0000000004249883

TRUNK LID OUTER FINISHER : Removal and Installation INFOID:0000000004249884

REMOVAL1. Fully open trunk lid.2. Remove trunk lid trim. Refer to INT-29, "Removal and Installation".

1. Trunk lid finisher outer 2. Trunk lid panel assembly 3. Rivet

4. Trunk drip cover RH 5. Trunk drip cover LH 6. Double-faced adhesive tape[t: 4.0 mm (0.157 in)]

7. Double-faced adhesive tape[t: 2.5 mm (0.098 in)]

: Clip

: Metal clip


JMKIA1252ZZ


TRUNK LID FINISHER
< REMOVAL AND INSTALLATION >3. Remove trunk lid finisher outer mounting nuts (A).
4. Apply protection tape (A) around outer circumference of trunk lidfinisher outer (1).

5. Remove trunk lid finisher outer, using remover tool (B).

CAUTION:Be careful not to damage the body.

INSTALLATIONInstall in the reverse order of removal.CAUTION:• Install after cleaning adhesive parts of body side and back of finisher outer.• When installing door finisher, check that clips are securely fitted in panel holes on body, and then-

press them in.TRUNK DRIP COVER

JMKIA1253ZZ

: Clip

JMKIA1254ZZ


TRUNK LID FINISHER

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TRUNK DRIP COVER : Exploded View INFOID:0000000004249885

TRUNK DRIP COVER : Removal and Installation INFOID:0000000004249886

REMOVAL1. Fully open trunk lid.2. Remove double-faced adhesive tape (A) of trunk drip cover (1)

with remover tool (B).

1. Trunk lid finisher outer 2. Trunk lid panel assembly 3. Rivet

4. Trunk drip cover RH 5. Trunk drip cover LH 6. Double-faced adhesive tape[t: 4.0 mm (0.157 in)]

7. Double-faced adhesive tape[t: 2.5 mm (0.098 in)]

: Clip

: Metal clip


JMKIA1252ZZ

JMKIA1258ZZ


TRUNK LID FINISHER
< REMOVAL AND INSTALLATION >3. Disengage trunk drip cover (1) fixing clip using remover tool (A).
4. Disengage trunk drip cover (1) fixing metal clip using removertool (A).

5. Slide forward then remove drip cover (1).

INSTALLATIONInstall in the reverse order of removal.CAUTION:• Double-faced adhesive tape is not reusable, always use new double-faced adhesive tape.• Never wash vehicle with in 24 hours after installation.

: Clip

JMKIA1262ZZ

: Metal clip

JMKIA1263ZZ

JMKIA1264ZZ


REAR SPOILER

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REAR SPOILER



REMOVAL1. Remove trunk lid trim. Refer to INT-29, "Removal and Installation".

1. Rear spoiler assembly 2. Trunk lid panel assembly 3. Grommet

4. Rear view camera assembly 5. High-mounted stop lamp 6. Double-faced adhesive tape[t: 2.0mm (0.079 in)]

: Clip


JMKIA1259ZZ


REAR SPOILER
< REMOVAL AND INSTALLATION >2. Disconnect harness connector (A) of high-mounted stop lamp.3. Disconnect harness connector (B) of rear view camera.4. Remove bolt (C).
5. Remove rear spoiler mounting nuts (A).

6. Release rear spoiler connection between trunk lid panel and rear spoiler, using a remover tool, and takeoff double-faced adhesive tape.

7. Disengage rear spoiler mounting clip, and then disconnect grommets of high-mounted stop lamp harnessand rear view camera harness.

8. Remove rear spoiler.

9. Remove following parts after removing rear spoiler.• High-mounted stop lamp. Refer to EXL-205, "WITH REAR SPOILER : Removal and Installation".• Rear view camera. Refer to AV-638, "Removal and Installation".• Rear spoiler clip and grommet.

INSTALLATIONInstall in the reverse order of removal.CAUTION:• Be careful not to damage the body. • Never let air between contact surfaces when installing.• Never wash vehicle within 24 hours after installation.

JMKIA1261ZZ

JMKIA1260ZZ


TRANSMISSION & DRIVELINE

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FRONT AXLE

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CONTENTS

2WD



NVH Troubleshooting Chart ......................................3

PREPARATION ............................................ 4

PREPARATION ................................................... 4Commercial Service Tool ..........................................4

PERIODIC MAINTENANCE .......................... 5

FRONT WHEEL HUB AND KNUCKLE .............. 5Inspection ..................................................................5


FRONT WHEEL HUB AND KNUCKLE .............. 6Exploded View ..........................................................6Removal and Installation ...........................................6Inspection ..................................................................7

SERVICE DATA AND SPECIFICATIONS (SDS) ............................................................. 8

SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................... 8

Wheel Bearing ...........................................................8AWD




PRECAUTION ..............................................10

PRECAUTIONS ..................................................10

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" .................................................................10Precaution Necessary for Steering Wheel Rota-tion after Battery Disconnect ...................................10Precaution for Procedure without Cowl Top Cover ....11Precautions for Drive Shaft ......................................11

PREPARATION ...........................................12

PREPARATION .................................................12Special Service Tool ................................................12Commercial Service Tool ........................................13

PERIODIC MAINTENANCE ........................14

FRONT WHEEL HUB AND KNUCKLE ............14Inspection ................................................................14

FRONT DRIVE SHAFT .....................................15Inspection ................................................................15


FRONT WHEEL HUB AND KNUCKLE ............16Exploded View .........................................................16Removal and Installation .........................................16Inspection ................................................................17

FRONT DRIVE SHAFT BOOT ..........................18Exploded View .........................................................18Replacement ...........................................................18

FRONT DRIVE SHAFT .....................................22Exploded View .........................................................22Removal and Installation .........................................23Disassembly and Assembly .....................................23Inspection ................................................................26

SERVICE DATA AND SPECIFICATIONS (SDS) ............................................................28

FAX-1Revision: 2009 October 2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) .................................................................. 28

Wheel Bearing ........................................................ 28Drive Shaft .............................................................. 28


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING[2WD]

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NVH Troubleshooting Chart INFOID:0000000004670017

Use chart below to find the cause of the symptom. If necessary, repair or replace these parts.

×: Applicable

Reference page

FAX

-6

—

FAX

-5

NV

H in

FA

X a

nd F

SU

sec

tions

NV

H in

WT

sec

tion

NV

H in

WT

sec

tion

NV

H in

BR

sec

tion

NV

H in

ST

sec

tion

Possible cause and SUSPECTED PARTS

Impr

oper

inst

alla

tion,

loos

enes

s

Par

ts in

terf

eren

ce

Whe

el b

earin

g da

mag

e

FR

ON

T A

XLE

AN

D F

RO

NT

SU

SP

EN

SIO

N

TIR

E

RO

AD

WH

EE

L

BR

AK

E

ST

EE

RIN

G

Symptom FRONT AXLE

Noise × × × × × × × ×

Shake × × × × × × × ×

Vibration × × × × × ×

Shimmy × × × × × × ×

Judder × × × × × ×

Poor quality ride or handling × × × × ×


[2WD]PREPARATION

< PREPARATION >




Power tool Loosening bolts and nuts

PBIC0190E


FRONT WHEEL HUB AND KNUCKLE[2WD]

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PERIODIC MAINTENANCEFRONT WHEEL HUB AND KNUCKLE


MOUNTING INSPECTIONMake sure that the mounting conditions (looseness, backlash) of each component and component conditions(wear, damage) are normal.

WHEEL BEARING INSPECTION• Move wheel hub and bearing assembly in the axial direction by hand. Make sure there is no looseness of

wheel bearing.

• Rotate wheel hub and bearing assembly and make sure that is no unusual noise or other irregular condi-tions. If there is any of irregular conditions, replace wheel hub and bearing assembly.

StandardAxial end play : Refer to FAX-8, "Wheel Bearing".


[2WD]FRONT WHEEL HUB AND KNUCKLE


REMOVAL AND INSTALLATIONFRONT WHEEL HUB AND KNUCKLE



REMOVAL

Wheel Hub and Bearing Assembly

1. Remove tires from vehicle with power tool.2. Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View".

CAUTION:Never pull on wheel sensor harness.

3. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work. Refer toBR-45, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Exploded View" (1 piston type), BR-53,"BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) : Exploded View" (4 piston type).CAUTION:Never depress brake pedal while brake caliper is removed.

4. Remove disc rotor. Refer to BR-46, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Removal andInstallation" (1 piston type), BR-54, "BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) : Removal andInstallation" (4 piston type).

5. Remove wheel hub and bearing assembly mounting bolts, and then remove splash guard and wheel huband bearing assembly from steering knuckle.

Steering Knuckle

1. Remove wheel hub and bearing assembly, and then remove splash guard.2. Remove brake hose bracket. Refer to BR-21, "FRONT : Exploded View".

1. Steering knuckle 2. Ball seat 3. Cotter pin

4. Splash guard 5. Wheel hub and bearing assembly


JPDIF0166GB


FRONT WHEEL HUB AND KNUCKLE[2WD]

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3. Remove cotter pin (1) of steering outer socket, and then loosenthe nut.

4. Remove steering outer socket (2) from steering knuckle (3) soas not to damage ball joint boot (4) using the ball joint remover. CAUTION:Temporarily tighten the nut to prevent damage to threadsand to prevent the ball joint remover from suddenly comingoff.

5. Remove cotter pin of transverse link and steering knuckle, andthen loosen nut.

6. Separate upper link from steering knuckle.7. Separate transverse link from steering knuckle so as not to damage ball joint boot using the ball joint

remover.CAUTION:Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint removerfrom suddenly coming off.

8. Remove steering knuckle form vehicle.

INSTALLATIONNote the following, and install in the reverse order of the removal.• Perform the final tightening of each of parts under conditions, which were removed when removing wheel

hub and bearing assembly and steering knuckle.• Never reuse cotter pin.


INSPECTION AFTER REMOVALCheck components for deformation, cracks, and other damage. Replace if necessary.

Ball Joint InspectionCheck boots of transverse link and steering outer socket ball joint for breakage, axial play, and torque. Refer toFSU-7, "Inspection" and ST-36, "2WD : Inspection".

INSPECTION AFTER INSTALLATION• Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View".• Check wheel alignment. Refer to FSU-8, "Inspection".• Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE

SENSOR NEUTRAL POSITION : Special Repair Requirement".

SGIA1183E


[2WD]SERVICE DATA AND SPECIFICATIONS (SDS)



Wheel Bearing INFOID:0000000004670023

Item Standard

Axial end play 0.05 mm (0.002 in) or less


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING[AWD]

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×: Applicable

Reference page —

FAX

-26

—

FAX

-16

—

FAX

-14

NV

H in

FA

X a

nd F

SU

sec

tions

Ref

er to

Fro

nt a

xle

in th

is c

hart

.

NV

H in

WT

sec

tion

NV

H in

WT

sec

tion

Ref

er to

DR

IVE

SH

AF

T in

this

cha

rt.

NV

H in

BR

sec

tion

NV

H in

ST

sec

tion


Exc

essi

ve jo

int a

ngle

Join

t slid

ing

resi

stan

ce

Imba

lanc

e

Impr

oper

inst

alla

tion,

loos

enes

s

Par

ts in

terf

eren

ce

Whe

el b

earin

g da

mag

e

FR

ON

T A

XLE

AN

D F

RO

NT

SU

SP

EN

SIO

N

FR

ON

T A

XLE

TIR

E

RO

AD

WH

EE

L

DR

IVE

SH

AF

T

BR

AK

E

ST

EE

RIN

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Symptom

DRIVE SHAFT

Noise × × × × × × × × ×

Shake × × × × × × × × ×

FRONT AXLE

Noise × × × × × × × × ×

Shake × × × × × × × × ×

Vibration × × × × × × ×

Shimmy × × × × × × ×

Judder × × × × × ×

Poor quality ride or handling × × × × ×


[AWD]PRECAUTIONS

< PRECAUTION >





















PRECAUTIONS[AWD]

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< PRECAUTION >

F

5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turnthe push-button ignition switch from ACC position to ON position, then to LOCK position. (The steeringwheel will lock when the push-button ignition switch is turned to LOCK position.)




Precautions for Drive Shaft INFOID:0000000004670028

• Observe the following precautions when disassembling and assembling drive shaft.• Never disassemble joint sub-assembly because it is non-overhaul parts.• Perform work in a location which is as dust-free as possible.• Clean the parts, before disassembling and assembling.• Prevent the entry of foreign objects during disassembly of the service location.• Reassemble disassembled parts carefully in the correct order. If work is interrupted, a clean cover must be

placed over parts.• Use paper waste. Fabric shop cloths must not be used because of the danger of lint adhering to parts.• Clean disassembled parts (except for rubber parts) with kerosene which shall be removed by blowing with

air or wiping with paper waste.

PIIB3706J


[AWD]PREPARATION

< PREPARATION >




Tool number (Kent-Moore No.)Tool name

Description

KV40107300( − )Boot band crimping tool

Installing boot band

KV40107500( − )Drive shaft attachment

Removing drive shaft

KV38107900( − )Protectora: 32 mm (1.26 in) dia.

Installing drive shaft

KV38100500( − )Drifta: 80 mm (3.15 in) dia.b: 60 mm (2.36 in) dia.

Installing drive shaft plug

KV38102200( − )Drifta: 90 mm (3.54 in) dia.b: 31 mm (1.22 in) dia.

Installing drive shaft plug

ZZA1229D

ZZA1230D

PDIA1183J

ZZA0701D

ZZA0920D


PREPARATION[AWD]

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< PREPARATION >

F




PBIC0190E


[AWD]FRONT WHEEL HUB AND KNUCKLE


PERIODIC MAINTENANCEFRONT WHEEL HUB AND KNUCKLE


MOUNTING INSPECTIONMake sure that the mounting conditions (looseness, backlash) of each component and component conditions(wear, damage) are normal.

WHEEL BEARING INSPECTION• Move wheel hub and bearing assembly in the axial direction by hand. Make sure there is no looseness of

wheel bearing.

• Rotate wheel hub and bearing assembly and make sure that is no unusual noise or other irregular condi-tions. If there is any of irregular conditions, replace wheel hub and bearing assembly.

StandardAxial end play : Refer to FAX-28, "Wheel Bearing".


FRONT DRIVE SHAFT[AWD]

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FRONT DRIVE SHAFT


• Check drive shaft mounting point and joint for looseness and other damage.• Check boot for cracks and other damage.

CAUTION:Replace entire drive shaft assembly when noise or vibration occurs from drive shaft.


[AWD]FRONT WHEEL HUB AND KNUCKLE


REMOVAL AND INSTALLATIONFRONT WHEEL HUB AND KNUCKLE



REMOVAL

Wheel Hub and Bearing Assembly

1. Remove tires with power tool.2. Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View".


3. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work. Refer toBR-49, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Exploded View".CAUTION:Never depress brake pedal while brake caliper is removed.

4. Remove disc rotor. Refer to BR-50, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal andInstallation".

5. Remove cotter pin, then loosen wheel hub lock nut with power tool.6. Patch wheel hub lock nut with a piece of wood. Hammer the wood to disengage wheel hub and bearing

assembly from drive shaft. Take out the wheel hub lock nut.CAUTION:• Never place drive shaft joint at an extreme angle. Also be careful not to overextend slide joint.• Never allow drive shaft to hang down without support for housing (or joint sub-assembly), shaft

and the other parts.NOTE:Use a suitable puller, if wheel hub and bearing assembly and drive shaft cannot be separated even afterperforming the above procedure.

7. Remove wheel hub and bearing assembly mounting bolts, and then remove splash guard and wheel huband bearing assembly from steering knuckle.

Steering Knuckle

1. Steering knuckle 2. Ball seat 3. Cotter pin

4. Splash guard 5. Wheel hub and bearing assembly 6. Wheel hub lock nut


JPDIF0221GB


FRONT WHEEL HUB AND KNUCKLE[AWD]

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1. Remove wheel hub and bearing assembly, and then remove splash guard.2. Remove brake hose bracket. Refer to BR-21, "FRONT : Exploded View".3. Remove cotter pin (1) of steering outer socket, and then loosen

the nut.4. Remove steering outer socket (2) from steering knuckle (3) so

as not to damage ball joint boot (4) using the ball joint remover.CAUTION:Temporarily tighten the nut to prevent damage to threadsand to prevent the ball joint remover from suddenly comingoff.


6. Separate upper link from steering knuckle.7. Separate transverse link from steering knuckle so as not to damage ball joint boot using the ball joint

remover.CAUTION:Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint removerfrom suddenly coming off.

8. Remove steering knuckle form vehicle.

INSTALLATIONNote the following, and install in the reverse order of the removal.• Perform the final tightening of each of parts under unladen conditions, which were removed when removing

wheel hub and bearing assembly and steering knuckle.• Never reuse cotter pin.


INSPECTION AFTER REMOVALCheck components for deformation, cracks, and other damage. Replace if necessary.

Ball Joint InspectionCheck boots of transverse link and steering outer socket ball joint for breakage, axial play, and torque. Refer toFSU-37, "Inspection" and ST-46, "AWD : Inspection".

INSPECTION AFTER INSTALLATION1. Check the wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View".2. Check the wheel alignment. Refer to FSU-30, "Inspection".3. Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE


SGIA1183E


[AWD]FRONT DRIVE SHAFT BOOT


FRONT DRIVE SHAFT BOOT


Replacement INFOID:0000000004670037

WHEEL SIDE1. Remove tires with power tool.2. Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View".


3. Remove brake hose bracket. Refer to BR-21, "FRONT : Exploded View".4. Remove caliper assembly. Hang caliper assembly a place where it will not interfere with work. Refer to

BR-49, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Exploded View".CAUTION:Never depress brake pedal while brake caliper is removed.

5. Remove disc rotor. Refer to BR-50, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal andInstallation".

6. Remove cotter pin, then loosen wheel hub lock nut with a power tool.7. Patch wheel hub lock nut with a piece of wood. Hammer the wood to disengage wheel hub and bearing

assembly from drive shaft. Take out the wheel hub lock nut.CAUTION:• Never place drive shaft joint at an extreme angle. Also be careful not to overextend slide joint.• Never allow drive shaft to hang down without support for housing (or joint sub-assembly), shaft

and the other parts.NOTE:Use a suitable puller if wheel hub and bearing assembly and drive shaft cannot be separated even afterperforming the above procedure.

1. Joint sub-assembly 2. Circular clip 3. Boot band

4. Boot 5. Shaft 6. Spider assembly

7. Snap ring 8. Housing 9. Plug

10. Dust shield

A. Left side B. Right side

: Wheel side

: NISSAN genuine grease or an equivalent.

Refer to GI-4, "Components" for symbols not described on the above.

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FRONT DRIVE SHAFT BOOT[AWD]

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8. Remove cotter pin (1) of steering outer socket, and then loosenthe nut.

9. Remove steering outer socket (2) from steering knuckle (3) soas not to damage ball joint boot (4) using the ball joint remover.CAUTION:Temporarily tighten the nut to prevent damage to threadsand to prevent the ball joint remover from suddenly comingoff.


11. Separate transverse link from steering knuckle so as not to dam-age ball joint boot using the ball joint remover.CAUTION:Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint removerfrom suddenly coming off.

12. Remove drive shaft from wheel hub and bearing assembly.13. Remove boot bands, and then remove boot from joint sub-assembly.14. Screw a drive shaft puller (A) into joint sub-assembly screw part

to a length of 30 mm (1.18 in) or more. Support drive shaft withone hand and pull out joint sub-assembly with a sliding hammer(B) from shaft.CAUTION:• Align a sliding hammer and drive shaft and remove them

by pulling firmly and uniformly.• If joint sub-assembly cannot be pulled out, try after

removing drive shaft from vehicle.

15. Remove the circular clip (1) from shaft.16. Remove boot from shaft.17. Clean the old grease on joint sub-assembly with paper waste.18. Fill serration slot joint sub-assembly with NISSAN genuine

grease or equivalent until the serration slot and ball groovebecome full to the brim.CAUTION:After applying grease, use a paper waste to wipe off oldgrease that has oozed out.

19. Install boot and boot bands to shaft.CAUTION:• Wrap serration on shaft with tape to protect the boot from damage.• Never reuse boot and boot band.

20. Remove the tape wrapped around the serration on shaft.21. Position circular clip on groove at the shaft edge.

CAUTION:Never reuse circular clip.NOTE:Drive joint inserter is recommended when installing circular clip.

22. Align both center axles of the shaft edge and joint sub-assembly. Then assemble shaft with circular clipjoint sub-assembly.

SGIA1183E

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[AWD]FRONT DRIVE SHAFT BOOT

< REMOVAL AND INSTALLATION >23. Install joint sub-assembly (1) to shaft using plastic hammer.

CAUTION:Confirm that joint sub-assembly is correctly engaged whilerotating drive shaft.

24. Apply the balance of the specified amount of grease into theboot inside from large diameter side of boot.

25. Install the boot securely into grooves (indicated by “*” marks)shown in the figure.CAUTION:If grease adheres to the boot mounting surface (with “*”mark) on the shaft or joint sub-assembly, boot may comeoff. Remove all grease from the surface.

26. To prevent the deformation of the boot, adjust the boot installa-tion length (L) to the specified value shown below by insertingthe suitable tool into inside of the boot from the large diameterside of the boot and discharging the inside air.

CAUTION:• If the boot installation length is outside the standard, it may cause breakage of boot.• Be careful not to touch the inside of the boot with a tip of tool.

27. Secure the large and small ends of the boot with boot bandsusing the boot band crimping tool (A) [SST: KV40107300 ( −

)].

NOTE:Secure boot band so that dimension (M) meets the specificationas shown in the figure.

28. Secure joint sub-assembly and shaft, and then make sure thatthey are in the correct position when rotating boot. Install themwith boot band when boot installation positions become incor-rect.

29. Insert drive shaft to wheel hub and bearing assembly, and thentemporarily tighten wheel hub lock nut.CAUTION:• The drive shaft is press-fit. When assembling the shaft, never press it, but pull it until fully

seated by tightening the wheel hub lock nut.• Check that anticorrosive oil is applied to the thread of the drive shaft. If not, apply appropriate oil

such as engine oil.

StandardGrease amount : Refer to FAX-28, "Drive Shaft".

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StandardBoots installed length (L)

: Refer to FAX-28, "Drive Shaft".

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Dimension (M) : 2.0 – 3.0 mm (0.079 – 0.118 in)

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• If sufficient oil is not applied to the thread of the drive shaft, the wheel hub lock nut may beseized and the tightening torque reaches the specified limit prematurely. It may cause loosenessor abnormal noises.

30. Install transverse link to steering knuckle. Refer to FAX-16, "Exploded View".31. Install steering outer socket to steering knuckle. Refer to ST-37, "AWD : Exploded View".32. Install disc rotor. Refer to BR-50, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal and Instal-

lation".33. Install caliper assembly to steering knuckle. Refer to BR-49, "BRAKE CALIPER ASSEMBLY (2 PISTON

TYPE) : Exploded View".34. Install brake hose bracket to steering knuckle. Refer to BR-21, "FRONT : Exploded View".35. Install wheel sensor to steering knuckle. Refer to BRC-100, "Exploded View".36. Tighten the wheel hub lock nut to the specified torque. Refer to FAX-16, "Exploded View".37. Install cotter pin.

CAUTION:• Never reuse cotter pin.• Bend it at the root sufficiently to prevent any looseness.


[AWD]FRONT DRIVE SHAFT


FRONT DRIVE SHAFT


REMOVAL

DISASSEMBLY

1. Drive shaft (right side) 2. Drive shaft (left side) 3. Cotter pin

Refer to GI section for symbols in the figure.

SDIA3042J

1. Joint sub-assembly 2. Circular clip 3. Boot band

4. Boot 5. Shaft 6. Spider assembly

7. Snap ring 8. Housing 9. Plug

10. Dust shield

A. Left side B. Right side

: Wheel side

: NISSAN genuine grease or an equivalent.

Refer to GI-4, "Components" for symbols not described on the above.

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REMOVAL

Left Side

1. Refer to the procedure from 1 to 12 in FAX-18, "Replacement".2. Remove shock absorber from transverse link with power tool. Refer to FSU-31, "Exploded View".3. Remove fixing bolts and nuts, and then remove drive shaft from vehicle.

Right Side

1. Refer to the procedure from 1 to 12 in FAX-18, "Replacement".2. Remove shock absorber from transverse link with power tool. Refer to FSU-31, "Exploded View".3. Remove drive shaft from front final drive.

• Remove drive shaft from front final drive using the drive shaftattachment (A) [SST:KV40107500 ( − )] and a sliding ham-mer (B) while inserting tip of the drive shaft attachmentbetween housing and front final drive.CAUTION:Never place drive shaft joint at an extreme angle whenremoving drive shaft. Also be careful not to overextendslide joint.

INSTALLATION

Left SideInstall in the reverse order of removal.

Right SideNote the following, and install in the reverse order of removal.CAUTION:Always replace front final drive oil seal with new one when installing drive shaft. Refer to DLN-117,"RIGHT SIDE : Exploded View". • Place the protector (A) [SST:KV38107900 ( − )] onto front final

drive to prevent damage to the oil seal while inserting drive shaft.Slide drive shaft sliding joint and tap with a hammer to installsecurely.


DISASSEMBLY

Front Final Drive Side

1. Fix shaft with a vise.CAUTION:Protect shaft when fixing with a vise using aluminum or copper plates.

2. Remove boot bands, and then remove boot from housing.3. Put matching marks on housing and shaft, and then pull out housing from shaft.

CAUTION:Use paint or similar substance for matching marks. Never scratch the surfaces.

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< REMOVAL AND INSTALLATION >4. Put matching marks (A) on the spider assembly and shaft.

CAUTION:Use paint or similar substance for matching marks. Neverscratch the surfaces.

5. Remove snap ring (1), and then remove spider assembly fromthe shaft.

6. Remove boot from the shaft.7. Remove dust shield from housing. (right side)8. If plug needs to be removed, move boot to wheel side, and take

it out with a plastic hammer. (left side)

Wheel Side

1. Fix shaft with a vise.CAUTION:Protect shaft when fixing with a vise using aluminum or copper plates.

2. Remove boot bands, and then remove boot from joint sub-assembly.3. Screw the drive shaft puller (A) 30 mm (1.18 in) or more into the

thread of joint sub-assembly, and pull joint sub-assembly with asliding hammer (B) from shaft.CAUTION:• If joint sub-assembly cannot be removed after five or

more unsuccessful attempts, replace shaft and joint subassembly as a set.

• Align sliding hammer and drive shaft and remove them bypulling directory.

4. Remove circular clip from shaft.5. Remove boot from shaft.6. Clean old grease on joint sub-assembly with paper waste while

rotating ball cage.

ASSEMBLY

Front Final Drive Side

1. Clean old grease on housing with paper waste.2. If plug (1) has been removed, use a drift to press in a new one.

(left side): Press

3. Install new boot and boot bands to shaft.CAUTION:• Wrap serration on shaft with tape to protect boot from

damage.

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A: Drift [SST: KV38100500 ( − )]

B: Drift [SST: KV38102200 ( − )]

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• Never reuse boot and boot band. 4. Remove the tape wrapped around the serration on shaft.5. To install the spider assembly (1), align it with the matching

marks (A) on the shaft (2) during the removal, and direct the ser-ration mounting surface (B) to the shaft.

6. Secure spider assembly onto shaft with snap ring (1).7. Apply the appropriate amount of grease to spider assembly and

sliding surface.8. Assemble the housing onto spider assembly, and apply the bal-

ance of the specified amount grease.

9. Align matching marks painted when housing was removed.10. Install boot securely into grooves (indicated by “*” marks) shown

in the figure.CAUTION:If grease adheres to the boot mounting surface (with “*” mark) on shaft or housing, boot maycome off. Remove all grease from the surface.

11. To prevent the deformation of the boot, adjust the boot installation length (L) to the value shown below byinserting the suitable tool into the inside of boot from the large diameter side of boot and discharginginside air.

CAUTION:• If the boot installation length is outside the standard, it may cause breakage of boot.• Be careful not to touch the inside of the boot with the tip of tool.

12. Install new larger and smaller boot bands securely.

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StandardGrease amount : Refer to FAX-28, "Drive Shaft".

Right side Left side

StandardBoots installed length (L) : Refer to FAX-28, "Drive Shaft".

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< REMOVAL AND INSTALLATION >a. For one-touch clamp bandi. Secure the large and small ends of a boot with new boot bands

as shown in the figure.

b. For low profile type bandi. Put boot band in the groove on drive shaft boot. Then fit pawls

( ) into holes to temporary installation.NOTE:For the large diameter side, fit projection (A) and guide slit (B) atfirst.

ii. Pinch projection on the band with suitable pliers to tighten band.iii. Insert tip of band below end of the pawl.13. Secure housing and shaft, and then make sure that they are in

the correct position when rotating boot. Install them with newboot band when the mounting positions become incorrect.

14. Install dust cover to housing. (right side)CAUTION:Never reuse dust cover.

Wheel SideFor further details on the installation procedure, refer to the installation procedure of “Replacement” for thedrive shaft boot.


INSPECTION AFTER REMOVAL• Move joint up/down, left/right, and in the axial directions. Check for motion that is not smooth and for signifi-

cant looseness.• Check boot for cracks, damage, and leakage of grease.• Disassemble drive shaft and exchange malfunctioning part if there

is a non-standard condition.


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ShaftCheck shaft for runout, cracks, or other damage. Replace if necessary.

Joint Sub-Assembly (Wheel Side)Check the following:• Joint sub-assembly for rough rotation and excessive axial looseness.• The inside of the joint sub-assembly for entry of foreign material.• Joint sub-assembly for compression scars, cracks, and fractures inside of joint sub-assembly.Replace joint sub-assembly if there are any non-standard conditions of components.

Housing and Spider assembly (Front Final Drive side)Replace housing and spider assembly if there is scratching or wear of housing roller contact surface or spiderroller contact surface.NOTE:Housing and spider assembly are used in a set.


[AWD]SERVICE DATA AND SPECIFICATIONS (SDS)



Wheel Bearing INFOID:0000000004670042

Drive Shaft INFOID:0000000004670043

Item Standard

Axial end play 0.05 mm (0.002 in) or less

Item Standard

Joint Wheel side Front final drive side

Grease quantityLeft side

77 – 97 g (2.72 – 3.42 oz)95 – 105 g (3.36 – 3.70 oz)

Right side 113 – 123 g (3.99 – 4.33 oz)

Boots installed lengthLeft side

136 mm (5.35 in)152 mm (5.98 in)

Right side 158.6 mm (6.24 in)


ENGINE

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SECTION FLA

FL

FUEL SYSTEM

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CONTENTS

PRECAUTION ............................................... 2

PRECAUTIONS ................................................... 2Precaution for Battery Service ..................................2General Precautions .................................................2

PREPARATION ............................................ 3

PREPARATION ................................................... 3Commercial Service Tools ........................................3


FUEL SYSTEM .................................................... 4Inspection ..................................................................4Quick Connector .......................................................4


FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY .......................... 5

Exploded View ..........................................................5Removal and Installation ...........................................5

Inspection ................................................................. 9

FUEL TANK ......................................................10Exploded View .........................................................10Removal and Installation .........................................10Inspection ................................................................12

UNIT DISASSEMBLY AND ASSEMBLY ....13

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY ........................13

Exploded View .........................................................13Disassembly ............................................................13Assembly .................................................................13


SERVICE DATA AND SPECIFICATIONS (SDS) .................................................................15

Fuel Tank .................................................................15

FL-1Revision: 2009 October 2009 G37 Coupe

PRECAUTIONS
< PRECAUTION >




WARNING:When replacing fuel line parts, be sure to observe the following.• Put a “CAUTION: FLAMMABLE” sign in the workshop.• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. • Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.CAUTION:• Use gasoline required by the regulations for octane number. Refer to GI-31, "Fuel".• Before removing fuel line parts, perform out the following procedures:- Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in

safe area.- Release fuel pressure from the fuel lines. Refer to EC-614, "Inspection".- Disconnect the battery cable from the negative terminal. • Always replace O-ring and clamps with new ones.• Never kink or twist tubes when they are being installed.• Never tighten hose clamps excessively to avoid damaging hoses. • After installing tubes, check there is no fuel leakage at connections in the following steps.- Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check

for fuel leakage at connections.- Start engine and rev it up and check for fuel leakage at connections.• Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the

“MIL” may come on.• For servicing “Evaporative Emission System” parts, refer to EC-86, "Component Parts Location".• For servicing “On Board Refueling Vapor Recovery (ORVR)” parts, refer to EC-513, "Description".


PREPARATION

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Power tool Loosening nuts and bolts

PBIC0190E


FUEL SYSTEM
PERIODIC MAINTENANCEFUEL SYSTEM


Inspect fuel lines, fuel filler cap and fuel tank for improper attach-ment, leakage, cracks, damage, loose connections, chafing or dete-rioration.

If necessary, repair or replace damaged parts.

Quick Connector INFOID:0000000004251099

CAUTION:• After connecting fuel tube quick connectors, check quick con-

nectors are secure.

• Ensure that connector and resin tube never contact any adja-cent parts.

A : Engine

B : Fuel line

C : Fuel tank

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1 : Quick connector

2 : Retainer

A : Hard tube (or the equivalent)

B : Connection (cross-section)

C : Resin tube

D : To under floor fuel line

E : To fuel tank

F : Tab

G : Disconnection

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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

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REMOVAL AND INSTALLATIONFUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY



WARNING:Read “General Precautions” when working on the fuel system. Refer to GI-28, "General Precautions".

REMOVAL1. Check fuel level on fuel gauge. If fuel gauge indicates more than

the level as shown in the figure (full or almost full), drain fuelfrom fuel tank until fuel gauge indicates level as shown in the fig-ure or below.NOTE:Because fuel will be spilled when removing main and sub fuellevel sensor units for the top of the fuel is above the main andsub fuel level sensor units installation surface. • As a guide, fuel level becomes the position as shown in the

figure or below when approximately 20 (5-1/4 US gal, 4-3/8Imp gal) of fuel are drained from fuel tank.

• In a case that fuel pump does not operate, perform the follow-ing procedure.

1. Retainer 2.Main fuel level sensor unit, fuel filter and fuel pump assembly

3. O-ring

4. Sub fuel level sensor unit

A. Right side B. Left side


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< REMOVAL AND INSTALLATION >a. Insert hose of less than 22 mm (0.87 in) in diameter into fuel filler tube through fuel filler opening to draw
fuel from fuel filler tube.b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-10, "Exploded View".c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.2. Release the fuel pressure from the fuel lines. Refer to EC-614, "Inspection".3. Open fuel filler lid.4. Open filler cap and release the pressure inside fuel tank.5. Remove rear seat cushion. Refer to SE-192, "Exploded View".6. Peel off floor carpet, then remove inspection hole cover (1) units

by turning clips (2) clockwise by 90 degrees.

7. Disconnect harness connector (3) and fuel feed tube (2).

Disconnect quick connector as follows:• Hold the sides of connector, push in tabs and pull out fuel feed

tube.

• If quick connector sticks to tube of main fuel level sensor unit,push and pull quick connector several times until they start tomove.Then disconnect them by pulling.

CAUTION:

A : Direction mark

b : 90°

: Vehicle front

Right side : Main fuel level sensor unit, fuel filter and fuel pump assembly

Left side : Sub fuel level sensor unit JPBIA0132ZZ

1 : Quick connector

: Vehicle front

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A : Pull

B : Push in tabs

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• Quick connector (1) can be disconnected when the tabs(F) are completely depressed. Never twist it more thannecessary.

• Never use any tools to disconnected quick connector.• Keep resin tube (C) away from heat. Be especially careful

when welding near the resin tube.• Prevent acid liquid such as battery electrolyte, etc. from

getting on resin tube.• Never bend or twist resin tube during installation and dis-

connection. • Never remove the remaining retainer (2) on hard tube (or

the equivalent) (A) except when resin tube or retainer isreplaced.

• When resin tube or hard tube (or the equivalent) isreplaced, also replace retainer with new one.

• To keep the connecting portion clean and to avoid dam-age and foreign materials, cover them completely withplastic bags (A) or something similar.

8. Remove main fuel level sensor unit, fuel filter and fuel pump assembly, and sub fuel level sensor unit asfollows:CAUTION:• Never bend float arm during removal.• Avoid impacts such as falling when handling components.

a. Removal of main fuel level sensor unit, fuel filter and fuel pump assembly:i. Remove retainer.ii. Raise main fuel level sensor unit, fuel filter and fuel pump assembly, and disconnect quick connector as

follows:• Push in tabs (1) and pull out fuel tube (2).

b. Removal of sub fuel level sensor unit:i. Remove retainer.ii. Raise and release sub fuel level sensor unit to remove.


B : Connection (Cross-section)

D : To under floor fuel line

E : To fuel tank

G : Disconnection

Retainer color : NaturalJPBIA0130ZZ

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< REMOVAL AND INSTALLATION >Fuel hose• When installing fuel hose connector (1), refer to “Quick Connec-
tor”.

Main and Sub Fuel Level Sensor Unit• Face main and sub fuel level sensor units as shown in the figure,

and install them with the knock pin (C) on back aligned with pinhole on fuel tank.

• Install retainer so that its notch becomes parallel with the notch onfuel tank.

• Tighten retainer mounting bolts evenly.

Quick Connector• Connect quick connector as follows:1. Check the connection for damage or any foreign materials.2. Align the connector with the tube, then insert the connector straight into the tube until a click sound is

heard.3. After connecting, check that the connection is secure by following method.

• Pull the tube and the connector to check they are securelyconnected.

• Visually confirm that the two retainer tabs are connected to theconnector.

2 : Retainer

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A : Right side

B : Left side

: Vehicle front

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A : Align notches

: Vehicle front

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A : Pull

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INSPECTION AFTER INSTALLATIONUse the following procedure to check for fuel leakage.1. Turn ignition switch “ON” (with engine stopped), then check connections for leakage by applying fuel pres-

sure to fuel piping.2. Start engine and let it idle and check there are no fuel leakage at the fuel system connections.


FUEL TANK
FUEL TANK



WARNING:Be sure to read “General Precautions” when working on the fuel system. Refer to GI-28, "General Pre-cautions".

REMOVAL• Drain fuel from fuel tank if necessary. Refer to FL-10, "Exploded View".• Perform work on level place.1. Perform steps 2 to 7 of “REMOVAL” in “ FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP

ASSEMBLY” on main and sub fuel level sensor units. Refer to FL-5, "Exploded View".2. Remove exhaust front tube, center muffler, and main muffler. Refer to EX-5, "Exploded View".3. Remove propeller shaft. Refer to DLN-90, "Exploded View" (M/T models) or DLN-97, "Exploded View" (A/

T models).4. Remove parking rear brake cables. Refer to PB-6, "PEDAL TYPE : Exploded View" (PEDAL TYPE) or

PB-7, "LEVER TYPE : Exploded View" (LEVER TYPE).

1. Fuel filler cap 2. Grommet 3. Fuel filler tube

4. Clamp 5. Vent hose 6. Vent tube

7. Vent hose 8. EVAP hose 9. Clamp

10. Clamp 11. Fuel filler hose 12. Fuel tank mounting band

13. Fuel tank protector 14. Insulator 15. Fuel tank

Refer to GI-4, "Components" for to symbols in the figure.

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FUEL TANK

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5. Remove rear suspension assembly. Refer to RSU-23, "Exploded View".NOTE:For this service, drive shaft, final drive, and rear suspension member are required not to be separate oneanother during removal.

6. Disconnect fuel filler hose (1), vent hose (2), and EVAP hoses(3) at fuel tank side.

7. Remove fuel tank protector.8. Support the lower part of fuel tank (1) with transmission jack (A).

CAUTION:Support the position that fuel tank mounting bands neverengage.

9. Remove fuel tank mounting bands.10. Supporting with hands, descend transmission jack carefully, and remove fuel tank.

CAUTION:• Check that all connection points have been disconnected.• Confirm there is no interference with vehicle.

11. Remove fuel filler tube if necessary.

INSTALLATIONNote the following, and install in the reverse order of removal.• Surely clamp fuel hoses and insert hose to the length below.

• Be sure hose clamp is not placed on swelled area of fuel tube.• Tighten the clamp hand with the top mark (A) until the mark is on

the bolt head flange.

• To connect quick connector, refer to FL-4, "Quick Connector".

4 : Fuel tank protector

: Vehicle front

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Fuel filler hose : 35 mm (1.38 in)The other hoses : 25 mm (0.98 in)

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FUEL TANK

INSPECTION AFTER INSTALLATIONUse the following procedure to check for fuel leakage.1. Turn ignition switch “ON” (with engine stopped), and check connections for leakage by applying fuel pres-

sure to fuel piping.2. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-

tions.• After removing/installing rear suspension assembly, check to adjust wheel alignment and then, adjust neutral

position of steering angle sensor. Refer to RSU-6, "Inspection" and STC-28, "4WAS FRONT ACTUATORNEUTRAL POSITION ADJUSTMENT : Description".



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UNIT DISASSEMBLY AND ASSEMBLYFUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY


Disassembly INFOID:0000000004496643

CAUTION:Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.Remove main fuel level sensor unit as follows:1. Disconnect harness connector (A).a. Hold connector by fingers and push stopper release tab.b. Pull it out connector.

2. Remove main fuel level sensor unit (1) from fuel filter and fuelpump assembly (2) as follows:

a. Push in tab (A) to release the lock.b. After fixing tabs are disengaged, slide main fuel level sensor unit

out in direction shown by the arrow (B).CAUTION:• Be careful not to damage the main fuel level sensor unit.• Never disassemble fuel filter and fuel pump assembly.

Assembly INFOID:0000000004496644

CAUTION:Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.1. Check for damage of main fuel level sensor unit installation position on the side of fuel filter and fuel pump

assembly.2. Slide main fuel level sensor unit until it aligns to installation groove, then insert it until it stops.

• After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.

1. Fuel filter and fuel pump assembly 2. Main fuel level sensor unit

A. Fuel temp sensor

JPBIA2585ZZ

JPBIA2586ZZ

JPBIA2587ZZ


< UNIT DISASSEMBLY AND ASSEMBLY >3. Connect the white (A), black (B), and red (C) harnesses so that
they are in the positions shown in the figure.• Securely insert harness connector until it stops.

JPBIA2588ZZ



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Fuel Tank INFOID:0000000004251109

Standard and Limit

Fuel tank capacity Approx. 75.6 (20 US gal, 16-5/8 Imp gal)

Fuel recommendation Refer to GI-31


SUSPENSION

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FRONT SUSPENSION

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CONTENTS

2WD




PRECAUTION ............................................... 4

PRECAUTIONS ................................................... 4Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" ...................................................................4Precaution Necessary for Steering Wheel Rota-tion after Battery Disconnect .....................................4Precaution for Procedure without Cowl Top Cover ......5Precautions for Suspension ......................................5

PREPARATION ............................................ 6

PREPARATION ................................................... 6Special Service Tool .................................................6Commercial Service Tool ..........................................6


FRONT SUSPENSION ASSEMBLY ................... 7Inspection ..................................................................7

WHEEL ALIGNMENT .......................................... 8Inspection ..................................................................8


FRONT COIL SPRING AND SHOCK AB-SORBER .............................................................. 9

Exploded View ..........................................................9Removal and Installation .........................................10Disassembly and Assembly ....................................10Inspection ................................................................12

TRANSVERSE LINK .........................................14Exploded View .........................................................14Removal and Installation .........................................15Inspection ................................................................15

UPPER LINK .....................................................17Exploded View .........................................................17Removal and Installation .........................................18Inspection ................................................................18

FRONT STABILIZER ........................................19Exploded View .........................................................19Removal and Installation .........................................20Inspection ................................................................20

UNIT REMOVAL AND INSTALLATION ......21

FRONT SUSPENSION MEMBER .....................21Exploded View .........................................................21Removal and Installation .........................................22Inspection ................................................................22


SERVICE DATA AND SPECIFICATIONS (SDS) .................................................................23

Wheel Alignment .....................................................23Ball Joint ..................................................................23Wheelarch Height ....................................................23

AWD

SYMPTOM DIAGNOSIS ..............................25

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...........................25

NVH Troubleshooting Chart ....................................25

PRECAUTION ..............................................26

PRECAUTIONS .................................................26

FSU-1Revision: 2009 October 2009 G37 Coupe

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" ................................................................. 26Precaution Necessary for Steering Wheel Rota-tion after Battery Disconnect .................................. 26Precaution for Procedure without Cowl Top Cover ... 27Precautions for Suspension .................................... 27

PREPARATION ........................................... 28

PREPARATION ................................................. 28Special Service Tool ............................................... 28Commercial Service Tool ....................................... 28

PERIODIC MAINTENANCE ........................ 29

FRONT SUSPENSION ASSEMBLY ................. 29Inspection ............................................................... 29

WHEEL ALIGNMENT ........................................ 30Inspection ............................................................... 30

REMOVAL AND INSTALLATION ............... 31

FRONT COIL SPRING AND SHOCK AB-SORBER ............................................................ 31

Exploded View ........................................................ 31Removal and Installation ........................................ 32Disassembly and Assembly .................................... 32Inspection ............................................................... 34

TRANSVERSE LINK ......................................... 36Exploded View ........................................................ 36Removal and Installation ......................................... 37Inspection ................................................................ 37

UPPER LINK ..................................................... 39Exploded View ........................................................ 39Removal and Installation ......................................... 40Inspection ................................................................ 40

FRONT STABILIZER ......................................... 41Exploded View ........................................................ 41Removal and Installation ......................................... 42Inspection ................................................................ 42

UNIT REMOVAL AND INSTALLATION .... 43

FRONT SUSPENSION MEMBER ..................... 43Exploded View ........................................................ 43Removal and Installation ......................................... 44Inspection ................................................................ 44

SERVICE DATA AND SPECIFICATIONS (SDS) .......................................................... 45

SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................. 45

Wheel Alignment ..................................................... 45Ball Joint ................................................................. 45Wheelarch Height ................................................... 45


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING[2WD]

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×: Applicable

Reference page

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Symptom FRONT SUSPENSION

Noise × × × × × × × × × × ×

Shake × × × × × × × × × ×

Vibration × × × × × × × ×

Shimmy × × × × × × × × ×

Judder × × × × × × ×

Poor quality ride or handling × × × × × × × × ×


[2WD]PRECAUTIONS

< PRECAUTION >





















PRECAUTIONS[2WD]

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< PRECAUTION >

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Precautions for Suspension INFOID:0000000004670202

• When installing rubber bushings, the final tightening must be carried out under unladen conditions with tireson ground. Spilled oil might shorten the life of rubber bushings. Be sure to wipe off any spilled oil.

- Unladen conditions mean that fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools andmats are in designated positions.

• After servicing suspension parts, be sure to check wheel alignment.• Self-lock nuts are not reusable. Always use new ones when installing. Since new self-lock nuts are pre-oiled,

tighten as they are.

PIIB3706J


[2WD]PREPARATION

< PREPARATION >






Description

ST35652000( – )Shock absorber attachment

Disassembling and assembling shock absorber

ST3127S000(J-25765-A)Preload gauge

Measuring rotating torque of ball joint

ZZA0807D

ZZA0806D



Spring compressor Removing and installing coil spring

PBIC0190E

S-NT717


FRONT SUSPENSION ASSEMBLY[2WD]

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PERIODIC MAINTENANCEFRONT SUSPENSION ASSEMBLY


MOUNTING INSPECTIONMake sure the mounting conditions (looseness, backlash) of each component and component conditions(wear, damage) are normal.

BALL JOINT AXIAL END PLAY1. Set front wheels in a straight-ahead position.

CAUTION:Never depress brake pedal.

2. Place an iron bar or equivalent between transverse link or upper link and steering knuckle.3. Measure axial end play by prying it up and down.

CAUTION:Be careful not to damage ball joint boot. never damage the installation position by applying exces-sive force.

SHOCK ABSORBERCheck for oil leakage, damage and replace if malfunction is detected.

StandardAxial end play : Refer to FSU-23, "Ball Joint".


[2WD]WHEEL ALIGNMENT


WHEEL ALIGNMENT


DESCRIPTIONCAUTION:• Camber, caster, kingpin inclination angles cannot be adjusted.• If camber, caster, or kingpin inclination angle is outside the standard, check front suspension parts

for wear and damage. Replace suspect parts if a malfunction is detected.• Kingpin inclination angle is reference value, no inspection is required.• Measure wheel alignment under unladen conditions. NOTE:“Unladen conditions” means that fuel, engine coolant, and lubricant are full. Spare tire, jack, hand tools andmats are in designated positions.

GENENRAL INFORMATION AND RECOMMENDATIONS• A four-wheel thrust alignment should be performed.- This type of alignment is recommended for any NISSAN/INFINITI vehicle.- The four-wheel “thrust” process helps ensure that the vehicle is properly aligned and the steering wheel is

centered.- The alignment rack itself should be capable of accepting any NISSAN/INFINITI vehicle.- The rack should be checked to ensure that it is level.• Make sure the machine is properly calibrated.- Your alignment equipment should be regularly calibrated in order to give correct information.- Check with the manufacturer of your specific equipment for their recommended Service/Calibration Sched-

ule.

ALIGNMENT PROCESSIMPORTANT:Use only the alignment specifications listed in this Service Manual.• When displaying the alignment settings, many alignment machines use “indicators”: (Green/red, plus or

minus, Go/No Go). Never use these indicators.- The alignment specifications programmed into your machine that operate these indicators may not be cor-

rect.- This may result in an ERROR.• Some newer alignment machines are equipped with an “optional Rolling Compensation” method to “com-

pensate” the sensors (alignment targets or head units). Never use this “Rolling Compensation” method.- Use the “Jacking Compensation Method”. After installing the alignment targets or head units, raise the vehi-

cle and rotate the wheels 1/2 turn both ways.- See Instructions in the alignment machine you're using for more information on this.

PRELIMINARY CHECKCheck the following:• Tires for improper air pressure and wear.• Road wheels for runout. Refer to WT-95, "Inspection".• Wheel bearing axial end play. Refer to FAX-5, "Inspection".• Transverse link or upper link ball joint axial end play. Refer to FSU-23, "Ball Joint", FSU-18, "Inspection".• Shock absorber operation.• Each mounting part of axle and suspension for looseness and deformation.• Each of suspension member, shock absorber, upper link and transverse link for cracks, deformation and

other damage.• Vehicle height (posture).


FRONT COIL SPRING AND SHOCK ABSORBER[2WD]

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REMOVAL AND INSTALLATIONFRONT COIL SPRING AND SHOCK ABSORBER


JPEIA0174GB


[2WD]FRONT COIL SPRING AND SHOCK ABSORBER



REMOVAL1. Remove tires with power tool.2. Remove harness of the wheel sensor from shock absorber. Refer to BRC-100, "Exploded View".


3. Remove brake hose bracket. Refer to BR-21, "FRONT : Exploded View".4. Remove stabilizer connecting rod mounting nuts (lower side) with power tool.5. Remove stabilizer connecting rod mounting nuts (upper side) with power tool, and then remove stabilizer

connecting rod from transverse link.6. Separate upper link from steering knuckle.7. Remove mounting nuts of shock absorber mounting bracket, then remove shock absorber assembly.

INSTALLATIONNote the following, and install in the reverse order of removal.• Never tap on the ball joint cap of the stabilizer connecting rod with a hammer or a similar item when inserting

the stabilizer connecting rod into the transverse link.• Perform final tightening of bolts and nuts at the shock absorber lower side (rubber bushing), under unladen

conditions with tires on level ground.


DISASSEMBLYCAUTION:Never damage shock absorber piston rod when removing components from shock absorber.1. Install shock absorber attachment (A) [SST: ST35652000 ( –

)] to shock absorber and secure it in a vise.CAUTION:When installing the shock absorber attachment to shockabsorber, wrap a shop cloth around shock absorber to pro-tect it from damage.

1. Piston rod lock nut 2. Mounting seal 3. Shock absorber mounting bracket

4. Bound bumper 5. Rubber seat 6. Coil spring

7. Transverse link 8. Front suspension member 9. Suspension member stay

10. Stabilizer clamp 11. Stabilizer bushing 12. Stabilizer connecting rod

13. Stabilizer bar 14. Cotter pin 15. Steering knuckle

16. Upper link 17. Stopper rubber 18. Shock absorber


JPEIA0006ZZ



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2. Using a spring compressor (A) (commercial service tool), com-press coil spring between rubber seat and shock absorber untilcoil spring with a spring compressor is free.CAUTION:Be sure a spring compressor is securely attached coilspring. Compress coil spring.

3. Make sure coil spring with a spring compressor between rubberseat and shock absorber is free and then remove piston rod locknut while securing the piston rod tip so that piston rod does notturn.

4. Remove mounting seal, shock absorber mounting bracket, rub-ber seat, bound bumper from shock absorber.

5. Remove coil spring with a spring compressor, and then gradually release a spring compressor.CAUTION:Loosen while making sure coil spring attachment position does not move.

6. Remove the shock absorber attachment from shock absorber.

ASSEMBLY1. Install shock absorber attachment (A) [SST: ST35652000 ( – )] to shock absorber and secure it in a

vise.CAUTION:When installing the shock absorber attachment to shock absorber, wrap a shop cloth aroundshock absorber to protect it from damage.

2. Compress coil spring using a spring compressor (commercial service tool), and install it onto shockabsorber.

CAUTION:• Install with the large-diameter side (A) facing up and the

small-diameter side (B) facing down.• Be sure a spring compress or is securely attached to coil

spring. Compress coil spring.

3. Install the shock absorber mounting bracket and rubber seat.CAUTION:Align the paint mark (A) to the stud bolt (1) position whenassembling.

4. Apply soapy water to bound bumper. CAUTION:Never use machine oil.

JPEIA0168ZZ

PEIA0108E

JPEIA0009ZZ


[2WD]FRONT COIL SPRING AND SHOCK ABSORBER

< REMOVAL AND INSTALLATION >5. Insert bound bumper into shock absorber mounting bracket, and then install it to shock absorber together

with rubber seat.

• Install the shock absorber mounting bracket as shown in the figure.

• Check that the lower end of the coil spring is positioned at the spring lower seat of the shock absorber.6. Secure piston rod tip so that piston rod does not turn, then tighten piston rod lock nut with specified

torque.7. Gradually release a spring compressor, and remove coil spring.

CAUTION:Loosen while making sure coil spring attachment position does not move.

8. Remove the shock absorber attachment from shock absorber.9. Install the mounting seal to shock absorber mounting bracket.



Shock AbsorberCheck the following items, and replace the part if necessary.• Shock absorber for deformation, cracks or damage. • Piston rod for damage, uneven wear or distortion.• Oil leakage.

Shock Absorber Mounting Bracket and Rubber Parts InspectionCheck shock absorber mounting bracket for cracks and rubber parts for wear. Replace it if necessary.

Coil SpringCheck coil spring for cracks, wear or damage, and replace it if necessary.

1. Shock absorber mounting bracket

A. Right side B. Left side C. Coil spring lower end position

: Vehicle front

Angle (a) : 35.4°

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INSPECTION AFTER INSTALLATION• Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View".• Check wheel alignment. Refer to FSU-8, "Inspection".• Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE



[2WD]TRANSVERSE LINK


TRANSVERSE LINK





JPEIA0174GB


TRANSVERSE LINK[2WD]

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REMOVAL1. Remove tires with power tool.2. Remove under cover with power tool.3. Remove shock absorber. Refer to FSU-9, "Exploded View".4. Remove steering outer socket from steering knuckle. Refer to ST-30, "2WD : Exploded View".5. Remove transverse link from steering knuckle.6. Set suitable jack under transverse link.7. Remove mounting bolts and nuts, and then remove transverse link.


the stabilizer connecting rod into the transverse link.• Perform final tightening of bolts and nuts at the front suspension member installation and shock absorber

lower side (rubber bushing), under unladen conditions with tires on level ground. • Never reuse cotter pin.



AppearanceCheck the following items, and replace the part if necessary.• Transverse link and bushing for deformation, cracks or damage.• Ball joint boot for cracks or other damage, and also for grease leakage.

Ball Joint InspectionManually move ball stud to confirm it moves smoothly with no binding.

Swing Torque InspectionNOTE:Before measurement, move ball stud at least ten times by hand to check for smooth movement.• Hook a spring balance (A) at cotter pin mounting hole. Confirm

spring balance measurement value is within specifications whenball stud begins moving.

- If it is outside the specified range, replace transverse link assem-bly.

Rotating Torque Inspection





StandardSwing toque : Refer to FSU-23, "Ball

Joint".

JPEIA0005ZZ


[2WD]TRANSVERSE LINK

< REMOVAL AND INSTALLATION >• Attach mounting nut to ball stud. Make sure that rotating torque is

within specifications with a preload gauge (A) [SST: ST3127S000(J-25765-A)].


Axial End Play Inspection• Move tip of ball stud in axial direction to check for looseness.

- If it is outside the specified range, replace transverse link assembly.

INSPECTION AFTER INSTALLATION• Check wheel sensor harness for proper connection. Refer to BR-21, "FRONT : Exploded View".• Check wheel alignment. Refer to FSU-8, "Inspection".• Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE


StandardRotating toque : Refer to FSU-23, "Ball

Joint".

PDIA1258E

StandardAxial end play : Refer to FSU-23, "Ball

Joint".


UPPER LINK[2WD]

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UPPER LINK





JPEIA0174GB


[2WD]UPPER LINK



REMOVAL1. Remove tires with power tool.2. Remove shock absorber. Refer to FSU-9, "Exploded View".3. Remove mounting bolts and nuts with power tool, and then remove upper link from steering knuckle.4. Remove mounting bolts and nuts, and then remove upper link and stopper rubber.

INSTALLATIONNote the following, and install in the reverse order of removal.• Perform final tightening of bolts and nuts at the vehicle installation position (rubber bushing), under unladen




AppearanceCheck the following items, and replace the part if necessary.• Upper link and bushing for deformation, cracks or damage.• Ball joint boot for cracks or other damage, and also for grease leakage.


Swing Torque InspectionNOTE:Before measurement, move ball stud at least ten times by hand to check for smooth movement.• Hook a spring balance (A) at cutout on ball stud. Confirm spring

balance measurement value is within specifications when ball studbegins moving.

- If it is outside the specified range, replace upper link assembly.



INSPECTION AFTER INSTALLATION• Check wheel sensor harness for proper connection. Refer to BR-21, "FRONT : Exploded View".• Check wheel alignment. Refer to FSU-8, "Inspection".• Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE






StandardSwing torque : Refer to FSU-23, "Ball Joint".

JPEIA0005ZZ



FRONT STABILIZER[2WD]

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FRONT STABILIZER





JPEIA0174GB


[2WD]FRONT STABILIZER



REMOVAL1. Remove tires with power tool.2. Remove under cover with power tool.3. Remove stabilizer connecting rod.

CAUTION:Apply a matching mark to identify the installation position.

4. Remove the stabilizer clamp and stabilizer bushing.5. Remove stabilizer bar.

INSTALLATIONNote the following, and install in the reverse order of removal.• Check the mounting mark when installing.• Tighten the mounting nut to the specified torque while holding a hexagonal part of stabilizer connecting rod

side.


INSPECTION AFTER REMOVALCheck stabilizer bar, stabilizer connecting rod, stabilizer bushing and stabilizer clamp for deformation, cracksor damage. Replace it if a malfunction is detected.






FRONT SUSPENSION MEMBER[2WD]

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UNIT REMOVAL AND INSTALLATIONFRONT SUSPENSION MEMBER


JPEIA0174GB


[2WD]FRONT SUSPENSION MEMBER



REMOVAL1. Remove tire with power tool.2. Remove under cover with power tool.3. Remove suspension member stay with power tool.4. Separate steering gear assembly and lower joint. Refer to ST-24, "WITHOUT 4WAS : Exploded View"

(without 4WAS), ST-25, "WITH 4WAS : Exploded View" (with 4WAS).5. Remove steering outer socket from steering knuckle. Refer to ST-30, "2WD : Exploded View".6. Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View".7. Remove stabilizer connecting rod from transverse link. Refer to FSU-19, "Exploded View".8. Remove front stabilizer. Refer to FSU-19, "Exploded View".9. Install engine slinger, and then hoist engine. Refer to EM-69, "2WD : Removal and Installation".10. Remove transverse link from front suspension member. Refer to FSU-14, "Exploded View".11. Remove steering hydraulic piping bracket and steering gear from front suspension member. Refer to ST-

59, "2WD : Exploded View".12. Set suitable jack front suspension member.13. Remove mounting nuts between engine mounting insulator and from suspension member. Refer to EM-

69, "2WD : Exploded View".14. Remove mounting bolts and nuts of front suspension member with power tool.15. Gradually lower jack to remove front suspension assembly from vehicle.

INSTALLATIONNote the following, and install in the reverse order of removal.• Perform final tightening of installation position between front suspension member and transverse links (rub-

ber bushing) under unladen condition with tires on level ground.


INSPECTION AFTER REMOVALCheck the front suspension member for significant deformation, cracks, or damages. Replace if necessary.

INSPECTION AFTER INSTALLATION• Check wheel sensor harness for proper connection. Refer to BR-21, "FRONT : Exploded View".• Check wheel alignment. Refer to FSU-8, "Inspection".• Adjust the neutral position of the steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING

ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".









SERVICE DATA AND SPECIFICATIONS (SDS)[2WD]

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Wheel Alignment INFOID:0000000004257338

Measure value under unladen* conditions.

*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

Ball Joint INFOID:0000000004257339

Wheelarch Height INFOID:0000000004257340

Item Standard

CamberDegree minute (Decimal degree)

Minimum –1° 10′ (–1.17°)

Nominal –0° 25′ (–0.42°)

Maximum 0° 20′ (0.33°)

Left and right difference 0° 33′ (0.55°) or less

CasterDegree minute (Decimal degree)

Minimum 4° 05′ (4.08°)

Nominal 4° 50′ (4.83°)

Maximum 5° 35′ (5.58°)


Kingpin inclinationDegree minute (Decimal degree)

Minimum 6° 40′ (6.67°)

Nominal 7° 25′ (7.42°)

Maximum 8° 10′ (8.16°)

Toe-in

Total toe-inDistance

Minimum 0 mm (0 in)

Nominal In 1 mm (0.04 in)

Maximum In 2 mm (0.08 in)

Toe angle (left wheel or right wheel)Degree minute (Decimal degree)

Minimum 0° 00′ (0.00°)

Nominal In 0° 02′ 30″ (0.04°)

Maximum In 0° 05′ (0.08°)

Item Standard

Swing torqueTransverse link 0.5 – 3.6 N·m (0.06 – 0.36 kg-m, 5 – 31 in-lb)

Upper link 0 – 2.0 N·m (0 – 0.2 kg-m, 0 – 17 in-lb)

Measurement on spring balanceTransverse link 7.8 – 56.3 N (0.8 – 5.7 kg, 1.8 – 12.7 lb)

Upper link 0 – 61.5 N (0 – 6.3 kg, 0 – 13.8 lb)

Rotating torque Transverse link 0.5 – 3.9 N·m (0.06 – 0.39 kg-m, 5 – 34 in-lb)

Axial end play 0 mm (0 in)

Item Standard

Applied model Except for sports models For sports models

Wheel size 18 inch 19 inch

Front (Hf) 712 mm (28.03 in) 715 mm (28.15 in) 716 mm (28.19 in)


[2WD]SERVICE DATA AND SPECIFICATIONS (SDS)


Measure value under unladen* conditions


Rear (Hr) 702 mm (27.64 in) 705 mm (27.76 in) 706 mm (27.80 in)

Item Standard

Applied model Except for sports models For sports models

Wheel size 18 inch 19 inch

SFA818A


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING[AWD]

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Reference page

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Symptom FRONT SUSPENSION

Noise × × × × × × × × × × × × × ×

Shake × × × × × × × × × × × ×

Vibration × × × × × × × × × ×

Shimmy × × × × × × × × × ×

Judder × × × × × × × ×

Poor quality ride or handling

× × × × × × × × × ×


[AWD]PRECAUTIONS

< PRECAUTION >





















PRECAUTIONS[AWD]

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F





Precautions for Suspension INFOID:0000000004670177

• When installing rubber bushings, the final tightening must be carried out under unladen conditions with tireson ground. Spilled oil might shorten the life of rubber bushings. Be sure to wipe off any spilled oil.

- Unladen conditions mean that fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools andmats are in designated positions.

• After servicing suspension parts, be sure to check wheel alignment.• Self-lock nuts are not reusable. Always use new ones when installing. Since new self-lock nuts are pre-oiled,

tighten as they are.

PIIB3706J


[AWD]PREPARATION

< PREPARATION >






Description

ST35652000( – )Shock absorber attachment

Disassembling and assembling shock absorber

ST3127S000(J-25765-A)Preload gauge

Measuring rotating torque of ball joint

ZZA0807D

ZZA0806D



Spring compressor Removing and installing coil spring

PBIC0190E

S-NT717


FRONT SUSPENSION ASSEMBLY[AWD]

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PERIODIC MAINTENANCEFRONT SUSPENSION ASSEMBLY


MOUNTING INSPECTIONMake sure the mounting conditions (looseness, backlash) of each component and component conditions(wear, damage) are normal.

BALL JOINT AXIAL END PLAY1. Set front wheels in a straight-ahead position.

CAUTION:Never depress brake pedal.

2. Place an iron bar or equivalent between transverse link or upper link and steering knuckle.3. Measure axial end play by prying it up and down.

CAUTION:Be careful not to damage ball joint boot. never damage the installation position by applying exces-sive force.

SHOCK ABSORBERCheck for oil leakage, damage and replace if malfunction is detected.



[AWD]WHEEL ALIGNMENT


WHEEL ALIGNMENT


DESCRIPTIONCAUTION:• Camber, caster, kingpin inclination angles cannot be adjusted.• If camber, caster, or kingpin inclination angle is outside the standard, check front suspension parts

for wear and damage. Replace suspect parts if a malfunction is detected.• Kingpin inclination angle is reference value, no inspection is required.• Measure wheel alignment under unladen conditions. NOTE:“Unladen conditions” means that fuel, engine coolant, and lubricant are full. Spare tire, jack, hand tools andmats are in designated positions.

GENENRAL INFORMATION AND RECOMMENDATIONS• A four-wheel thrust alignment should be performed.- This type of alignment is recommended for any NISSAN/INFINITI vehicle.- The four-wheel “thrust” process helps ensure that the vehicle is properly aligned and the steering wheel is

centered.- The alignment rack itself should be capable of accepting any NISSAN/INFINITI vehicle.- The rack should be checked to ensure that it is level.• Make sure the machine is properly calibrated.- Your alignment equipment should be regularly calibrated in order to give correct information.- Check with the manufacturer of your specific equipment for their recommended Service/Calibration Sched-

ule.

ALIGNMENT PROCESSIMPORTANT:Use only the alignment specifications listed in this Service Manual.• When displaying the alignment settings, many alignment machines use “indicators”: (Green/red, plus or

minus, Go/No Go). Never use these indicators.- The alignment specifications programmed into your machine that operate these indicators may not be cor-

rect.- This may result in an ERROR.• Some newer alignment machines are equipped with an optional “Rolling Compensation” method to “com-

pensate” the sensors (alignment targets or head units). Never use this “Rolling Compensation” method.- Use the “Jacking Compensation Method”. After installing the alignment targets or head units, raise the vehi-

cle and rotate the wheels 1/2 turn both ways.- See Instructions in the alignment machine you're using for more information on this.

PRELIMINARY CHECKCheck the following:• Tires for improper air pressure and wear.• Road wheels for runout. Refer to WT-95, "Inspection".• Wheel bearing axial end play. Refer to FAX-17, "Inspection".• Transverse link or upper link ball joint axial end play. Refer to FSU-37, "Inspection", FSU-40, "Inspection".• Shock absorber operation.• Each mounting part of axle and suspension for looseness and deformation.• Each of suspension member, shock absorber, upper link and transverse link for cracks, deformation and

other damage.• Vehicle height (posture).


FRONT COIL SPRING AND SHOCK ABSORBER[AWD]

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REMOVAL AND INSTALLATIONFRONT COIL SPRING AND SHOCK ABSORBER


JPEIA0139GB


[AWD]FRONT COIL SPRING AND SHOCK ABSORBER



REMOVAL1. Remove tires with power tool.2. Remove stabilizer connecting rod mounting nuts (upper side) with power tool, and then remove stabilizer

connecting rod from transverse link.3. Remove shock absorber mounting bolts and nuts (lower side) with power tool, and then remove shock

absorber from transverse link.4. Remove drive shaft. Refer to FAX-22, "Exploded View".5. Separate upper link from steering knuckle.6. Remove the mounting nuts of shock absorber mounting bracket, then remove shock absorber assembly.

INSTALLATIONNote the following, and install in the reverse order of removal.CAUTION:Never tap on the ball joint cap of the stabilizer connecting rod with a hammer or a similar item wheninserting the stabilizer connecting rod into the transverse link.• Perform final tightening of bolts and nuts at the shock absorber lower side (rubber bushing), under unladen



DISASSEMBLYCAUTION:Never damage shock absorber piston rod when removing components from shock absorber.1. Install shock absorber attachment (A) [SST: ST35652000 ( –

)] to shock absorber and secure it in a vise.CAUTION:When installing the shock absorbershock absorber attach-ment to shock absorber, wrap a shop cloth around shockabsorber to protect it from damage.



7. Shock absorber 8. Stopper rubber 9. Upper link

10. Steering knuckle 11. Cotter pin 12. Insulator

13. Transverse link 14. Stabilizer bar 15. Stabilizer connecting rod

16. Stabilizer bushing 17. Stabilizer clamp 18. Front cross bar

19. Front suspension member


JPEIA0006ZZ



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2. Using a spring compressor (A) (commercial service tool), com-press coil spring between rubber seat and shock absorber untilcoil spring with a spring compressor is free.CAUTION:Be sure a spring compressor is securely attached coilspring. Compress coil spring

3. Make sure coil spring with a spring compressor between rubberseat and shock absorber is free and then remove piston rod locknut while securing the piston rod tip so that piston rod does notturn.

4. Remove mounting seal, shock absorber mounting bracket, rub-ber seat, bound bumper from shock absorber.

5. Remove coil spring with a spring compressor, and then gradually release a spring compressor.CAUTION:Loosen while making sure coil spring attachment position does not move.

6. Remove the shock absorber attachment from shock absorber.

ASSEMBLY1. Install shock absorber attachment (A) [SST: ST35652000 ( − )] to shock absorber and secure it in a

vise.CAUTION:When installing the shock absorber attachment to shock absorber, wrap a shop cloth aroundshock absorber to protect it from damage.

2. Compress coil spring using a spring compressor (commercial service tool), and install it onto shockabsorber.

CAUTION:• Install with the large-diameter side (A) facing up and the

small-diameter side (B) facing down.• Be sure a spring compress or is securely attached to coil

spring. Compress coil spring.

3. Install the shock absorber mounting bracket and rubber seat.CAUTION:Align the paint mark (A) to the stud bolt (1) position whenassembling.

4. Apply soapy water to bound bumper. CAUTION:Never use machine oil.

JPEIA0168ZZ

PEIA0108E

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[AWD]FRONT COIL SPRING AND SHOCK ABSORBER

< REMOVAL AND INSTALLATION >5. Insert bound bumper into shock absorber mounting bracket, and then install it to shock absorber together

with rubber seat.

• Install the shock absorber mounting bracket as shown in the figure.

• Check that the lower end of the coil spring is positioned at the spring lower seat of the shock absorber.6. Secure piston rod tip so that piston rod does not turn, then tighten piston rod lock nut with specified

torque.7. Gradually release a spring compressor, and remove coil spring.

CAUTION:Loosen while making sure coil spring attachment position does not move.

8. Remove the shock absorber attachment from shock absorber.9. Install the mounting seal to shock absorber mounting bracket.



Shock AbsorberCheck the following items, and replace the part if necessary.• Shock absorber for deformation, cracks or damage.• Piston rod for damage, uneven wear or distortion.• Oil leakage.

Shock Absorber Mounting Bracket and Rubber Parts InspectionCheck shock absorber mounting bracket for cracks and rubber parts for wear. Replace it if necessary.

Coil SpringCheck coil spring for cracks, wear or damage, and replace it if necessary.

1. Shock absorber mounting bracket

A. Right side B. Left side C. Coil spring lower end position

: Vehicle front

Angle (a) : 35.4°

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INSPECTION AFTER INSTALLATION1. Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View".2. Check wheel alignment. Refer to FSU-30, "Inspection".3. Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE



[AWD]TRANSVERSE LINK


TRANSVERSE LINK





JPEIA0139GB


TRANSVERSE LINK[AWD]

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REMOVAL1. Remove tires with power tool.2. Remove under cover with power tool.3. Remove shock absorber. Refer to FSU-31, "Exploded View".4. Remove front crossbar.5. Remove steering outer socket from steering knuckle. Refer to ST-37, "AWD : Exploded View".6. Remove transverse link from steering knuckle.7. Set suitable jack under transverse link.8. Remove mounting bolts and nuts, and then remove transverse link.


the stabilizer connecting rod into the transverse link.• Perform final tightening of bolts and nuts at the front suspension member installation and shock absorber

lower side (rubber bushing), under unladen conditions with tires on level ground.



AppearanceCheck the following items, and replace the part if necessary.• Transverse link and bushing for deformation, cracks or damage.• Ball joint boot for cracks or other damage, and also for grease leakage.


Swing Torque InspectionNOTE:Before measurement, move ball stud at least ten times by hand to check for smooth movement.• Hook a spring balance (A) at cotter pin mounting hole. Confirm

spring balance measurement value is within specifications whenball stud begins moving.


Rotating Torque Inspection






StandardSwing toque :Refer to FSU-45, "Ball Joint".

JPEIA0005ZZ


[AWD]TRANSVERSE LINK

< REMOVAL AND INSTALLATION >• Attach mounting nut to ball stud. Make sure that rotating torque is

within specifications with a preload gauge (A) [SST: 3127S000 (J-25765-A)].



- If it is outside the specified range, replace transverse link assembly.



StandardRotating toque : Refer to FSU-45, "Ball Joint".

PDIA1258E

StandardAxial end play :Refer to FSU-45, "Ball Joint".


UPPER LINK[AWD]

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UPPER LINK





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[AWD]UPPER LINK



REMOVAL1. Remove tires from with power tool.2. Remove shock absorber. Refer to FSU-31, "Exploded View".3. Remove mounting bolts and nuts with power tool, and then remove upper link from steering knuckle.4. Remove mounting bolts and nuts, and then remove upper link and stopper rubber.

INSTALLATIONNote the following, and install in the reverse order of removal.• Perform final tightening of bolts and nuts at the vehicle installation position (rubber bushing), under unladen




AppearanceCheck the following items, and replace the part if necessary.• Upper link and bushing for deformation, cracks or damage.• Ball joint boot for cracks or other damage, and also for grease leakage.


Swing Torque InspectionNOTE:Before measurement, move ball stud at least ten times by hand to check for smooth movement.• Hook a spring balance (A) at cutout on ball stud. Confirm spring

balance measurement value is within specifications when ball studbegins moving.











StandardSwing torque : Refer to FSU-45, "Ball Joint".

JPEIA0005ZZ



FRONT STABILIZER[AWD]

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FRONT STABILIZER





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[AWD]FRONT STABILIZER



REMOVAL1. Remove tires with power tool.2. Remove under cover with power tool.3. Remove stabilizer connecting rod.

CAUTION:Apply a matching mark to identify the installation position.

4. Remove the stabilizer clamp and stabilizer bushing.5. Remove stabilizer bar.

INSTALLATIONNote the following, and install in the reverse order of removal.• Check the mounting mark when installing.• Tighten the mounting nut to the specified torque while holding a hexagonal part of stabilizer connecting rod

side.


INSPECTION AFTER REMOVALCheck stabilizer bar, stabilizer connecting rod, stabilizer bushing and stabilizer clamp for deformation, cracksor damage. Replace it if necessary.







FRONT SUSPENSION MEMBER[AWD]

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UNIT REMOVAL AND INSTALLATIONFRONT SUSPENSION MEMBER


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[AWD]FRONT SUSPENSION MEMBER



REMOVAL1. Remove tire with power tool.2. Remove under cover with power tool.3. Remove front cross bar.4. Separate steering gear assembly and lower joint. Refer to ST-24, "WITHOUT 4WAS : Exploded View".5. Remove steering outer socket from steering knuckle. Refer to ST-37, "AWD : Exploded View".6. Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View".7. Remove shock absorber. Refer to FSU-31, "Exploded View".8. Remove front stabilizer. Refer to FSU-41, "Exploded View".9. Install engine slinger, and then hoist engine. Refer to EM-74, "AWD : Removal and Installation".10. Remove transverse link from front suspension member with power tool. Refer to FSU-36, "Exploded

View".11. Remove steering hydraulic piping bracket and steering gear from front suspension member. Refer to ST-

61, "AWD : Exploded View".12. Set suitable jack front suspension member.13. Remove mounting nuts between engine mounting insulator and from suspension member. Refer to EM-

73, "AWD : Exploded View". 14. Remove mounting bolts and nuts of front suspension member with power tool.15. Gradually lower jack to remove front suspension assembly from vehicle.

INSTALLATIONNote the following, and install in the reverse order of removal.• Perform final tightening of installation position between front suspension member and transverse links (rub-

ber bushing) under unladen condition with tires on level ground.


INSPECTION AFTER REMOVALCheck the front suspension member for significant deformation, cracks, or damages. Replace if necessary.

INSPECTION AFER INSTALLATION1. Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View".2. Check wheel alignment. Refer to FSU-30, "Inspection".3. Adjust the neutral position of the steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING

ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".










SERVICE DATA AND SPECIFICATIONS (SDS)[AWD]

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Wheel Alignment INFOID:0000000004499007


*Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

Ball Joint INFOID:0000000004499008

Wheelarch Height INFOID:0000000004499009

Item Standard


Minimum –1° 10′ (–1.17°)

Nominal –0° 25′ (–0.42°)

Maximum 0° 20′ (0.33°)



Minimum 3° 30′ (3.50°)

Nominal 4° 15′ (4.25°)

Maximum 5° 00′ (5.00°)



Minimum 6° 40′ (6.67°)

Nominal 7° 25′ (7.42°)

Maximum 8° 10′ (8.16°)

Toe-in

Total toe-inDistance

Minimum 0 mm (0 in)



Toe angle (left wheel or right wheel)Degree minute (Decimal degree)

Minimum 0° 00′ (0.00°)

Nominal In 0° 02′ 30″ (0.04°)

Maximum In 0° 05′ (0.08°)

Item Standard

Swing torqueTransverse link 0.5 – 3.6 N·m (0.06 – 0.36 kg-m, 5 – 31 in-lb)

Upper link 0 – 2.0 N·m (0 – 0.2 kg-m, 0 – 17 in-lb)

Measurement on spring balanceTransverse link 7.8 – 56.3 N (0.8 – 5.7 kg, 1.8 – 12.5 lb)

Upper link 0 – 61.5 N (0 – 6.3 kg, 0 – 13.8 lb)

Rotating torque Transverse link 0.5 – 3.9 N·m (0.06 – 0.39 kg-m, 5 – 34 in-lb)

Axial end play 0 mm (0 in)

Item Standard

Front (Hf) 726 mm (28.58 in)


[AWD]SERVICE DATA AND SPECIFICATIONS (SDS)




Rear (Hr) 718 mm (28.27 in)

Item Standard

SFA818A


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QUICK REFERENCE INDEX A GENERAL INFORMATION GI General InformationB ENGINE EM Engine Mechanical

LU Engine Lubrication SystemCO Engine Cooling SystemEC Engine Control SystemFL Fuel SystemEX Exhaust System

STR Starting SystemACC Accelerator Control System

C HYBRID HBB Hybrid Battery System

HBR Hybrid Brake SystemD TRANSMISSION & DRIVE-

LINECL ClutchTM Transaxle & Transmission

DLN DrivelineFAX Front AxleRAX Rear Axle

E SUSPENSION FSU Front SuspensionRSU Rear SuspensionSCS Suspension Control SystemWT Road Wheels & Tires

F BRAKES BR Brake SystemPB Parking Brake System

BRC Brake Control SystemG STEERING ST Steering System

STC Steering Control SystemH RESTRAINTS SB Seat Belt

SBC Seat Belt Control SystemSR SRS Airbag

SRC SRS Airbag Control SystemI VENTILATION, HEATER &

AIR CONDITIONERVTL Ventilation SystemHA Heater & Air Conditioning System

HAC Heater & Air Conditioning Control SystemJ BODY INTERIOR INT Interior

IP Instrument PanelSE Seat

ADP Automatic Drive PositionerK BODY EXTERIOR,

DOORS, ROOF & VEHICLE SECURITY

DLK Door & LockSEC Security Control SystemGW Glass & Window System

PWC Power Window Control SystemRF Roof

EXT ExteriorBRM Body Repair

L DRIVER CONTROLS MIR MirrorsEXL Exterior Lighting SystemINL Interior Lighting SystemWW Wiper & WasherDEF DefoggerHRN Horn

M ELECTRICAL & POWER CONTROL

PWO Power OutletBCS Body Control SystemLAN LAN SystemPCS Power Control SystemCHG Charging SystemPG Power Supply, Ground & Circuit Elements

N DRIVER INFORMATION & MULTIMEDIA

MWI Meter, Warning Lamp & IndicatorWCS Warning Chime SystemSN Sonar SystemAV Audio, Visual & Navigation System

O CRUISE CONTROL CCS Cruise Control SystemP MAINTENANCE MA Maintenance

All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmit-ted in any form, or by any means, electronic, mechani-cal, recording or otherwise, without the prior written per-mission of NISSAN MOTOR CO., LTD.

Edition: September 2008Revison: October 2009Publication No. SM9E-1C36U1

FOREWORDThis manual contains maintenance and repair procedure for the 2009 INFINITI G37 Coupe.

In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.

All information in this manual is based on the latest product informationat the time of publication. The right is reserved to make changes in specifi-cations and methods at any time without notice.

IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety ofthe technician and the efficient functioning of the vehicle.The service methods in this Service Manual are described in such amanner that the service may be performed safely and accurately.Service varies with the procedures used, the skills of the technicianand the tools and parts available. Accordingly, anyone using serviceprocedures, tools or parts which are not specifically recommendedby NISSAN must first be completely satisfied that neither personalsafety nor the vehicle’s safety will be jeopardized by the servicemethod selected.

QUICK REFERENCE CHART G37 COUPE

QUICK REFERENCE CHART G37 COUPE PFP:00000

ENGINE TUNE-UP DATA (VQ37VHR) ELS0003W

Engine model VQ37VHR

Firing order 1-2-3-4-5-6

Idle speedA/T (In “P or N” position)M/T (In Neutral position)

rpm650 ± 50

Ignition timing(BTDC at idle speed)

10° ± 5°

CO% at idle 0.7 - 9.9 % and engine runs smoothly

Tensions of drive belt Belt tension is not necessary, as it is automatically

adjusted by drive belt auto-tensioner.

Radiater cap relief pressure kPa (kg/cm2, psi)

Standard 122.3 - 151.7 (1.2 - 1.5, 18 - 22)

Limit 107 (1.1, 16)

Cooling system leakage testing pressure kPa (kg/cm2, psi)157 (1.6, 23)

Compression pressure kPa (kg/cm2, psi)/200 rpm

Standard 1,667 - 2,354 (17 - 24, 242 - 341)

Minimum 1,226 (12.5, 178)

Differential limit between cylinders 98 (1.0, 14)

Spark plug(Iridium-tipped type)

Make DENSO

Standard type FXE24HR11

Gap (Nominal) mm (in) 1.1 (0.043)

2009


FRONT WHEEL ALIGNMENT ELS0003X

Measure value under unladen* conditions.*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

REAR WHEEL ALIGNMENT ELS0003Y

Measure value under unladen* conditions.*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

BRAKE PEDALUnit: mm (in)

Applied model 2WD AWD


Minimum –1° 10′ (–1.17°)

Nominal –0° 25′ (–0.42°)

Maximum 0° 20′ (0.33°)



Minimum 4° 05′ (4.08°) 3° 30′ (3.50°)

Nominal 4° 50′ (4.83°) 4° 15′ (4.25°)

Maximum 5° 35′ (5.58°) 5° 00′ (5.00°)



Minimum 6° 40′ (6.67°)

Nominal 7° 25′ (7.42°)

Maximum 8° 10′ (8.16°)

Total toe-in

Distance

Minimum 0 mm (0 in)



Angle (Left wheel or right wheel)Degree minute (Decimal degree)

Minimum 0° 00′ (0.00°)

Nominal In 0° 02′ 30″ (0.04°)

Maximum In 0° 05′ (0.08°)


Minimum –1° 45′ (–1.75°)

Nominal –1° 15′ (–1.25°)

Maximum –0° 45′ (–0.75°)

Total toe-in

Distance

Minimum 0 mm (0 in)

Nominal In 2.8 mm (0.110 in)

Maximum In 5.6 mm (0.220 in)

Angle (Left wheel or right wheel)Degree minute (Decimal degree)

Minimum 0° 00′ (0.00°)

Nominal In 0° 07′ (0.12°)

Maximum In 0° 14′ (0.23°)

Brake pedal height (H1) 171.5 - 181.5 (6.75 - 7.15)

Depressed brake pedal height (H2)[Depressing 490 N (50 kg, 110 lb) while turning the engine ON]

124.0 (4.88) or more

2009


FRONT DISK BRAKE 1 Piston Type

Unit: mm (in)

2 Piston TypeUnit: mm (in)


REAR DISK BRAKE 1 Piston (Front 1 Piston) Type

Unit: mm (in)

1 Piston (Front 2 Piston) TypeUnit: mm (in)


Item Limit

Brake pad Wear thickness 2.0 (0.079)

Disc rotor

Wear thickness 30.0 (1.181)

Thickness variation (measured at 8 positions) 0.015 (0.0006)

Runout (with it attached to the vehicle) 0.035 (0.0014)

Item Limit


Disc rotor




Item Limit


Disc rotor




Item Limit


Disc rotor




Item Limit


Disc rotor




Item Limit


Disc rotor




2009


REFILL CAPACITIES ELS00040

UNIT Liter US measure

Fuel tank 75.6 20 gal

Engine Coolant (With reservoir tank) at MAX level

A/T models 8.5 9 qt

M/T models 8.6 9-1/8 qt

Engine oil

Drain and refill

With oil filter change 4.9 5-1/8 qt

Without oil filter change 4.6 4-7/8 qt

Dry engine (Overhaul) 5.7 6 qt

Transmission

A/T 9.2 9-3/4 qt

M/T

VIN: UP to JNKCV64E09M605016

2.93 6-1/4 pt

VIN: From JNKCV64E09M605017

2.83 6 pt

Transfer 1.0 2-1/8 pt

Final driveFront 0.65 1-3/8 pt

Rear 1.4 3 pt

Power steering system 1.0 1-1/8 qt

Air conditioning systemCompressor oil 0.15 5.07 fl oz

Refrigerant 0.55 kg 1.21 lb

2009

GENERAL INFORMATION

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SECTION GI
GENERAL INFORMATION
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CONTENTS

HOW TO USE THIS MANUAL ...................... 3

HOW TO USE THIS MANUAL ............................ 3Description ................................................................3Terms ........................................................................3Units ..........................................................................3Contents ....................................................................3Relation between Illustrations and Descriptions .......4Components ..............................................................4

HOW TO FOLLOW TROUBLE DIAGNOSES ..... 6Description ................................................................6How to Follow Test Groups in Trouble Diagnosis ......6Key to Symbols Signifying Measurements or Pro-cedures .....................................................................7

HOW TO READ WIRING DIAGRAMS ................ 9Connector Symbols ...................................................9Sample/Wiring Diagram -Example- .........................10Description ..............................................................11

ABBREVIATIONS ..............................................13Abbreviation List ......................................................13

TIGHTENING TORQUE OF STANDARD BOLTS ................................................................14

Description ..............................................................14Tightening Torque Table (New Standard Includ-ed) ...........................................................................14

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ................................................17

Recommended Chemical Products and Sealants ....17

TERMINOLOGY .................................................18SAE J1930 Terminology List ...................................18

VEHICLE INFORMATION ............................22

IDENTIFICATION INFORMATION .....................22Model Variation .......................................................22Information About Identification or Model Code ......23

Dimensions ..............................................................25Wheels & Tires ........................................................25

PRECAUTION ..............................................26

PRECAUTIONS .................................................26Description ...............................................................26Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" .................................................................26Precautions For Xenon Headlamp Service .............26Precaution Necessary for Steering Wheel Rota-tion after Battery Disconnect ...................................27Precaution for Battery Service .................................27Precaution for Procedure without Cowl Top Cover ....27General Precautions ................................................28Three Way Catalyst .................................................29Multiport Fuel Injection System or Engine Control System .....................................................................29Hoses ......................................................................29Engine Oils ..............................................................30Air Conditioning .......................................................31Fuel ..........................................................................31

LIFTING POINT .................................................32Commercial Service Tools .......................................32Garage Jack and Safety Stand and 2-Pole Lift .......32Board-On Lift ...........................................................33

TOW TRUCK TOWING .....................................34Tow Truck Towing ...................................................34Vehicle Recovery (Freeing a Stuck Vehicle) ...........35

BASIC INSPECTION ...................................37

SERVICE INFORMATION FOR ELECTRICAL INCIDENT ..........................................................37

Work Flow ................................................................37Control Units and Electrical Parts ............................37How to Check Terminal ...........................................38Intermittent Incident .................................................41Circuit Inspection .....................................................44

GI-1Revision: 2009 October 2009 G37 Coupe

CONSULT-III/GST CHECKING SYSTEM ......... 49Description .............................................................. 49CONSULT-III Function and System Application*1 ... 49CONSULT-III/GST Data Link Connector (DLC) Circuit ..................................................................... 50Wiring Diagram - CONSULT-III/GST CHECKING SYSTEM - ............................................................... 51

INSPECTION AND ADJUSTMENT ................... 56

ADDITIONAL SERVICE WHEN REMOVING BAT-TERY NEGATIVE TERMINAL .................................. 56

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Required Procedure After Battery Disconnection ................... 56


HOW TO USE THIS MANUAL

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< HOW TO USE THIS MANUAL >

GHOW TO USE THIS MANUALHOW TO USE THIS MANUAL


This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diag-noses”.

Terms INFOID:0000000004257245

• The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injuryand/or damage to some part of the vehicle.WARNING indicates the possibility of personal injury if instructions are not followed.CAUTION indicates the possibility of component damage if instructions are not followed.BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.Standard value: Tolerance at inspection and adjustment.Limit value: The maximum or minimum limit value that should not be exceeded at inspection and adjust-ment.

Units INFOID:0000000004257246

• The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), andalternatively expressed in the metric system and in the yard/pound system.Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about thestandard tightening torque.

“Example”Range

Standard

Contents INFOID:0000000004257247

• A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find thefirst page of each section by matching it to the section's black tab.

• THE CONTENTS are listed on the first page of each section.• THE TITLE is indicated on the upper portion of each page and shows the part or system.• THE PAGE NUMBER of each section consists of two or three letters which designate the particular section

and a number (e.g. “BR-5”).• THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of

work and hidden or tricky steps which are not shown in the previous large illustrations.Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxleor transmission, etc. are presented in a step-by-step format where necessary.

Outer Socket Lock Nut : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)

Drive Shaft Installation Bolt : 44.3 N·m (4.5 kg-m, 33 ft-lb)


Relation between Illustrations and Descriptions INFOID:0000000004257248

The following sample explains the relationship between the part description in an illustration, the part name inthe text and the service procedures.

Components INFOID:0000000004257249

• THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubri-cation points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary toperform repairs.The illustrations should be used in reference to service matters only. When ordering parts, refer to the appro-priate PARTS CATALOG.Components shown in an illustration may be identified by a circled number. When this style of illustration isused, the text description of the components will follow the illustration.

SAIA0519E



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SYMBOLS

1. Union bolt 2. Copper washer 3. Brake hose

4. Cap 5. Bleed valve 6. Sliding pin bolt

7. Piston seal 8. Piston 9. Piston boot

10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt

13. Washer 14. Sliding pin boot 15. Bushing

16. Torque member 17. Inner shim cover 18. Inner shim

19. Inner pad 20. Pad retainer 21. Pad wear sensor

22. Outer pad 23. Outer shim 24. Outer shim cover

1: PBC (Poly Butyl Cuprysil) grease or silicone-based grease

2: Rubber grease : Brake fluid

Refer to GI section for additional symbol definitions.

SFIA2959E

SAIA0749E


HOW TO FOLLOW TROUBLE DIAGNOSES


NOTICE:Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the followinginstructions before diagnosing.• Before performing trouble diagnoses, read the “Work Flow” in each section.• After repairs, re-check that the problem has been completely eliminated.• Refer to Component Parts and Harness Connector Location for the Systems described in each section for

identification/location of components and harness connectors.• When checking circuit continuity, ignition switch should be OFF.• Refer to the Circuit Diagram for quick pinpoint check.

If you need to check circuit continuity between harness connectors in more detail, such as when a sub-har-ness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identi-fication of harness connectors.

• Before checking voltage at connectors, check battery voltage.• After accomplishing the Diagnosis Procedures and Electrical Components Inspection, make sure that all

harness connectors are reconnected as they were.

How to Follow Test Groups in Trouble Diagnosis INFOID:0000000004257251

1. Test group number and test group title• Test group number and test group title are shown in the upper portion of each test group.

2. Work and diagnosis procedure• Start to diagnose a problem using procedures indicated in enclosed test groups.

3. Questions and results• Questions and required results are indicated in test group.

4. Action• Next action for each test group is indicated based on result of each question.

JPAIA0021GB



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JPAIA0397GB


JPAIA0398GB


HOW TO READ WIRING DIAGRAMS

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GHOW TO READ WIRING DIAGRAMS

Connector Symbols INFOID:0000000004257253

Most of connector symbols in wiring diagrams are shown from the terminal side.• Connector symbols shown from the terminal side are enclosed by

a single line and followed by the direction mark.• Connector symbols shown from the harness side are enclosed by

a double line and followed by the direction mark.• Certain systems and components, especially those related to

OBD, may use a new style slide-locking type harness connector.For description and how to disconnect, refer to PG section,“Description”, “HARNESS CONNECTOR”.

• Male and female terminalsConnector guides for male terminals are shown in black andfemale terminals in white in wiring diagrams.

SAIA0257E

SGI363


Sample/Wiring Diagram -Example- INFOID:0000000004257254

• For detail, refer to following GI-11, "Description".

JCAWA0005GB



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GDescription INFOID:0000000004257255

SWITCH POSITIONS Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition.A vehicle is in the “normal” condition when:

Number Item Description

1 Power supply • This means the power supply of fusible link or fuse.

2 Fusible link • “X” means the fusible link.

3Number of fusible link/fuse

• This means the number of fusible link or fuse location.

4 Fuse • “/” means the fuse.

5Current rating of fus-ible link/fuse

• This means the current rating of the fusible link or fuse.

6 Optional splice • The open circle shows that the splice is optional depending on vehicle application.

7 Connector number• The letter shows which harness the connector is located in.• Example “M”: main harness. For detail and to locate the connector, refer to PG-77, "How

To Read Harness Layout", PG-79, "Main Harness".

8 Splice • The shaded circle “ ” means the splice.

9 Page crossing • This circuit continues to an adjacent page.

10 Option abbreviation • This means the vehicle specifications which layouts the circuit between “ ”.

11 Relay • This shows an internal representation of the relay.

12 Option description • This shows a description of the option abbreviation used on the page.

13 Switch• This shows that continuity exists between terminals 1 and 2 when the switch is in the A

position. Continuity exists between terminals 1 and 3 when the switch is in the B position.

14 Circuit (Wiring) • This means the wiring.

15 System branch • This shows that the circuit is branched to other systems.

16 Shielded line • The line enclosed by broken line circle shows shield wire.

17 Component name • This shows the name of a component.

18 Ground (GND) • This shows the ground connection.

19 Connector• This means the connector information.• This unit-side is described by the connector symbols.

20 Connectors • This means that a transmission line bypasses two connectors or more.

21 Wire color

• This shows a code for the color of the wire.

B = BlackW = WhiteR = RedG = GreenL = BlueY = YellowLG = Light Green

BR = BrownOR or O = OrangeP = PinkPU or V (Violet) = PurpleGY or GR = GraySB = Sky BlueCH = Dark BrownDG = Dark Green

• When the wire color is striped, the base color is given first, followed by the stripe color as shown below:Example: L/W = Blue with White Stripe

22 Terminal number • This means the terminal number of a connector.


< HOW TO USE THIS MANUAL >• ignition switch is “OFF”,• doors, hood and trunk lid/back door are closed,• pedals are not depressed, and• parking brake is released.
MULTIPLE SWITCHThe continuity of multiple switch is described in two ways as shown below.• The switch chart is used in schematic diagrams.• The switch diagram is used in wiring diagrams.

SGI860

JSAIA0017GB


ABBREVIATIONS

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GABBREVIATIONS

Abbreviation List INFOID:0000000005195961

The following ABBREVIATIONS are used:

ABBREVIATION DESCRIPTION

A/C Air Conditioner

A/T Automatic Transaxle/Transmission

ATF Automatic Transmission Fluid

D1 Drive range first gear

D2 Drive range second gear

D3 Drive range third gear

D4 Drive range fourth gear

FR, RR Front, Rear

LH, RH Left-Hand, Right-Hand

M/T Manual Transaxle/Transmission

OD Overdrive

P/S Power Steering

SAE Society of Automotive Engineers, Inc.

SDS Service Data and Specifications

SST Special Service Tools

2WD 2-Wheel Drive

22 2nd range second gear

21 2nd range first gear

12 1st range second gear

11 1st range first gear


TIGHTENING TORQUE OF STANDARD BOLTS


This vehicle has both new standard based on ISO* and previous standard bolts/nuts. There are some differ-ences between these two types of bolts/ nuts; shape of the head, grade of strength, hexagonal width acrossflats and the standard tightening torque.• For guidance in discriminating, refer to GI-14, "Tightening Torque Table (New Standard Included)".• The new standard machine screws and tapping screws have a head of ISO standard torx recess.• If the tightening torque is not described in the description or figure, refer to GI-14, "Tightening Torque Table

(New Standard Included)".*ISO: International Organization for Standardization

Tightening Torque Table (New Standard Included) INFOID:0000000004655570

CAUTION:• The special parts are excluded.• The bolts/nuts in these tables have a strength (discrimination) number/symbol assigned to the head

or the like. As to the relation between the strength grade in these tables and the strength (discrimi-nation) number/symbol, refer to “DISCRIMINATION OF BOLTS AND NUTS”.

PREVIOUS STANDARD

CAUTION:

Grade (Strength

grade)

Bolt size

Bolt di-ameter

mm

Hexagonal width

across flatsmm

Pitchmm

Tightening torque (Without lubricant)

Hexagon head bolt Hexagon flange bolt

N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb

4T

M6 6.0 10 1.0 5.5 0.56 4 49 7 0.71 5 62

M8 8.0 121.25 13.5 1.4 10 — 17 1.7 13 —

1.0 13.5 1.4 10 — 17 1.7 13 —

M10 10.0 141.5 28 2.9 21 — 35 3.6 26 —

1.25 28 2.9 21 — 35 3.6 26 —

M12 12.0 171.75 45 4.6 33 — 55 5.6 41 —

1.25 45 4.6 33 — 65 6.6 48 —

M14 14.0 19 1.5 80 8.2 59 — 100 10 74 —

7T

M6 6.0 10 1.0 9 0.92 7 80 11 1.1 8 97

M8 8.0 121.25 22 2.2 16 — 28 2.9 21 —

1.0 22 2.2 16 — 28 2.9 21 —

M10 10.0 141.5 45 4.6 33 — 55 5.6 41 —

1.25 45 4.6 33 — 55 5.6 41 —

M12 12.0 171.75 80 8.2 59 — 100 10 74 —

1.25 80 8.2 59 — 100 10 74 —

M14 14.0 19 1.5 130 13 96 — 170 17 125 —

9T

M6 6.0 10 1.0 11 1.1 8 — 13.5 1.4 10 —

M8 8.0 121.25 28 2.9 21 — 35 3.6 26 —

1.0 28 2.9 21 — 35 3.6 26 —

M10 10.0 141.5 55 5.6 41 — 80 8.2 59 —

1.25 55 5.6 41 — 80 8.2 59 —

M12 12.0 171.75 100 10 74 — 130 13 96 —

1.25 100 10 74 — 130 13 96 —

M14 14.0 19 1.5 170 17 125 — 210 21 155 —



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GThe parts with aluminum or the cast iron washer surface/thread surface are excluded.

NEW STANDARD BASED ON ISO

CAUTION:1. Use tightening torque with lubricant for the new standard bolts/nuts in principle. Friction coeffi-

cient stabilizer is applied to the new standard bolts/nuts.2. However, use tightening torque without lubricant for the following cases. Friction coefficient stabi-

lizer is not applied to the following bolts/nuts.- Grade 4.8, M6 size bolt, Conical spring washer installed- Paint removing nut (Size M6 and M8) for fixing with weld bolt

Grade (Strength

grade)

Bolt size

Bolt di-ameter

mm

Hexagonal width

across flatsmm

Pitchmm

Tightening torque

Hexagon head bolt Hexagon flange bolt

N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb

4.8(Without lubricant)

M6 6.0 10 1.0 5.5 0.56 4 49 7 0.71 5 62

M8 8.0 131.25 13.5 1.4 10 — 17 1.7 13 —

1.0 13.5 1.4 10 — 17 1.7 13 —

M10 10.0 161.5 28 2.9 21 — 35 3.6 26 —

1.25 28 2.9 21 — 35 3.6 26 —

M12 12.0 181.75 45 4.6 33 — 55 5.6 41 —

1.25 45 4.6 33 — 65 6.6 48 —

M14 14.0 21 1.5 80 8.2 59 — 100 10 74 —

4.8(With lu-bricant)

M6 6.0 10 1.0 4 0.41 3 35 5.5 0.56 4 49

M8 8.0 131.25 11 1.1 8 — 13.5 1.4 10 —

1.0 11 1.1 8 — 13.5 1.4 10 —

M10 10.0 161.5 22 2.2 16 — 28 2.9 21 —

1.25 22 2.2 16 — 28 2.9 21 —

M12 12.0 181.75 35 3.6 26 — 45 4.6 33 —

1.25 35 3.6 26 — 45 4.6 33 —

M14 14.0 21 1.5 65 6.6 48 — 80 8.2 59 —


M6 6.0 10 1.0 8 0.82 6 71 10 1.0 7 89

M8 8.0 131.25 21 2.1 15 — 25 2.6 18 —

1.0 21 2.1 15 — 25 2.6 18 —

M10 10.0 161.5 40 4.1 30 — 50 5.1 37 —

1.25 40 4.1 30 — 50 5.1 37 —

M12 12.0 181.75 70 7.1 52 — 85 8.7 63 —

1.25 70 7.1 52 — 85 8.7 63 —

M14 14.0 21 1.5 120 12 89 — 140 14 103 —


M6 6.0 10 1.0 10 1.0 7 89 12 1.2 9 106

M8 8.0 131.25 27 2.8 20 — 32 3.3 24 —

1.0 27 2.8 20 — 32 3.3 24 —

M10 10.0 161.5 55 5.6 41 — 65 6.6 48 —

1.25 55 5.6 41 — 65 6.6 48 —

M12 12.0 181.75 95 9.7 70 — 110 11 81 —

1.25 95 9.7 70 — 110 11 81 —

M14 14.0 21 1.5 160 16 118 — 180 18 133 —


DISCRIMINATION OF BOLTS AND NUTS

SAIA0453E


RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS

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GRECOMMENDED CHEMICAL PRODUCTS AND SEALANTS

Recommended Chemical Products and Sealants INFOID:0000000004257258

Refer to the following chart for help in selecting the appropriate chemical product or sealant.

Product Description PurposeNissan North America

Part No. (USA)Nissan Canada Part

No. (Canada)Aftermarket Cross-reference Part Nos.

1Rear View Mirror Adhe-sive

Used to permanently re-mount rear view mirrors to windows.

999MP-AM000P 99998-50505 Permatex 81844

2Anaerobic Liquid Gas-ket

For metal-to-metal flange sealing.Can fill a 0.38 mm (0.015 inch) gap and provide in-stant sealing for most pow-ertrain applications.

999MP-AM001P 99998-50503Permatex 51813 and 51817

3High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.)• Do not use on plastic.

999MP-AM002P 999MP-AM002P Permatex 56521

4 Silicone RTV

Gasket Maker999MP-AM003P(Ultra Grey)

99998-50506(Ultra Grey)

Permatex Ultra Grey 82194;Three Bond 1207,1215, 1216, 1217F, 1217G and 1217HNissan RTV Part No. 999MP-A7007

Gasket Maker for Maxima/Quest 5-speed automatic transmission(RE5F22A)

– –Three Bond 1281B or exact equivalent in its quality

5High Temperature, High Strength Thread Locking Sealant (Red)

Threadlocker 999MP-AM004P 999MP-AM004P

Permatex 27200;Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388Loctite 648

6Medium Strength Thread Locking Seal-ant (Blue)

Threadlocker (service tool removable)

999MP-AM005P 999MP-AM005P

Permatex 24200, 24206, 24240, 24283 and 09178;Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374


TERMINOLOGY
TERMINOLOGY

SAE J1930 Terminology List INFOID:0000000005195962

All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, newterms, new acronyms/abbreviations and old terms are listed in the following chart.

NEW TERMNEW ACRONYM /ABBREVIATION

OLD TERM

Air cleaner ACL Air cleaner

Barometric pressure BARO ***

Barometric pressure sensor-BCDD BAROS-BCDD BCDD

Camshaft position CMP ***

Camshaft position sensor CMPS Crank angle sensor

Canister *** Canister

Carburetor CARB Carburetor

Charge air cooler CAC Intercooler

Closed loop CL Closed loop

Closed throttle position switch CTP switch Idle switch

Clutch pedal position switch CPP switch Clutch switch

Continuous fuel injection system CFI system ***

Continuous trap oxidizer system CTOX system ***

Crankshaft position CKP ***

Crankshaft position sensor CKPS ***

Data link connector DLC ***

Diagnostic test mode DTM Diagnostic mode

Diagnostic test mode selector DTM selector Diagnostic mode selector

Diagnostic test mode I DTM I Mode I

Diagnostic test mode II DTM II Mode II

Diagnostic trouble code DTC Malfunction code

Direct fuel injection system DFI system ***

Distributor ignition system DI system Ignition timing control

Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater

Early fuel evaporation system EFE system Mixture heater control

Electrically erasable programmable read only memory

EEPROM ***

Electronic ignition system EI system Ignition timing control

Engine control EC ***

Engine control module ECM ECCS control unit

Engine coolant temperature ECT Engine temperature

Engine coolant temperature sensor ECTS Engine temperature sensor

Engine modification EM ***

Engine speed RPM Engine speed

Erasable programmable read only memory EPROM ***

Evaporative emission canister EVAP canister Canister

Evaporative emission system EVAP system Canister control solenoid valve

Exhaust gas recirculation valve EGR valve EGR valve


TERMINOLOGY

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Exhaust gas recirculation control-BPT valve

EGRC-BPT valve BPT valve

Exhaust gas recirculation control-solenoid valve

EGRC-solenoid valve EGR control solenoid valve

Exhaust gas recirculation temperature sen-sor EGRT sensor Exhaust gas temperature sensor

EGR temperature sensor

Flash electrically erasable programmable read only memory

FEEPROM ***

Flash erasable programmable read only memory

FEPROM ***

Flexible fuel sensor FFS ***

Flexible fuel system FF system ***

Fuel pressure regulator *** Pressure regulator

Fuel pressure regulator control solenoid valve

*** PRVR control solenoid valve

Fuel trim FT ***

Heated Oxygen sensor HO2S Exhaust gas sensor

Idle air control system IAC system Idle speed control

Idle air control valve-air regulator IACV-air regulator Air regulator

Idle air control valve-auxiliary air control valve

IACV-AAC valve Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve

Idle air control valve-idle up control sole-noid valve

IACV-idle up control solenoid valve Idle up control solenoid valve

Idle speed control-FI pot ISC-FI pot FI pot

Idle speed control system ISC system ***

Ignition control IC ***

Ignition control module ICM ***

Indirect fuel injection system IFI system ***

Intake air IA Air

Intake air temperature sensor IAT sensor Air temperature sensor

Knock *** Detonation

Knock sensor KS Detonation sensor

Malfunction indicator lamp MIL Check engine light

Manifold absolute pressure MAP ***

Manifold absolute pressure sensor MAPS ***

Manifold differential pressure MDP ***

Manifold differential pressure sensor MDPS ***

Manifold surface temperature MST ***

Manifold surface temperature sensor MSTS ***

Manifold vacuum zone MVZ ***

Manifold vacuum zone sensor MVZS ***

Mass air flow sensor MAFS Air flow meter

Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve

Multiport fuel injection system MFI system Fuel injection control


OLD TERM


TERMINOLOGY
Nonvolatile random access memory NVRAM ***

On board diagnostic system OBD system Self-diagnosis

Open loop OL Open loop

Oxidation catalyst OC Catalyst

Oxidation catalytic converter system OC system ***

Oxygen sensor O2S Exhaust gas sensor

Park position switch *** Park switch

Park/neutral position switch PNP switchPark/neutral switchNeutral position switch

Periodic trap oxidizer system PTOX system ***

Positive crankcase ventilation PCV Positive crankcase ventilation

Positive crankcase ventilation valve PCV valve PCV valve

Powertrain control module PCM ***

Programmable read only memory PROM ***

Pulsed secondary air injection control sole-noid valve

PAIRC solenoid valve AIV control solenoid valve

Pulsed secondary air injection system PAIR system Air induction valve (AIV) control

Pulsed secondary air injection valve PAIR valve Air induction valve

Random access memory RAM ***

Read only memory ROM ***

Scan tool ST ***

Secondary air injection pump AIR pump ***

Secondary air injection system AIR system ***

Sequential multiport fuel injection system SFI system Sequential fuel injection

Service reminder indicator SRI ***

Simultaneous multiport fuel injection sys-tem

*** Simultaneous fuel injection

Smoke puff limiter system SPL system ***

Supercharger SC ***

Supercharger bypass SCB ***

System readiness test SRT ***

Thermal vacuum valve TVV Thermal vacuum valve

Three way catalyst TWC Catalyst

Three way catalytic converter system TWC system ***

Three way + oxidation catalyst TWC + OC Catalyst

Three way + oxidation catalytic converter system

TWC + OC system ***

Throttle body TBThrottle chamberSPI body

Throttle body fuel injection system TBI system Fuel injection control

Throttle position TP Throttle position

Throttle position sensor TPS Throttle sensor

Throttle position switch TP switch Throttle switch

Torque converter clutch solenoid valve TCC solenoid valveLock-up cancel solenoidLock-up solenoid

Transmission control module TCM A/T control unit


OLD TERM


TERMINOLOGY

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***: Not applicable

Turbocharger TC Turbocharger

Vehicle speed sensor VSS Vehicle speed sensor

Volume air flow sensor VAFS Air flow meter

Warm up oxidation catalyst WU-OC Catalyst

Warm up oxidation catalytic converter sys-tem

WU-OC system ***

Warm up three way catalyst WU-TWC Catalyst

Warm up three way catalytic converter sys-tem

WU-TWC system ***

Wide open throttle position switch WOTP switch Full switch


OLD TERM


IDENTIFICATION INFORMATION
< VEHICLE INFORMATION >
VEHICLE INFORMATIONIDENTIFICATION INFORMATION

Model Variation INFOID:0000000004257260

Destination Body Transmission Engine Axle Grade Model

USA

Coupe

7AT

VQ37VHR

2WD

Standard GLSALQL-EUA

Journey GLSALSL-EUA

Journey + Premium GLSALTL-EUA

SportGLSALVL-EUA

6MT GLSALVY-EUA

7AT

Sport + Premium

GLSALWL-EUA

6MT GLSALWY-EUA

7AT4WAS

GLSBLWL-EUA

6MT GLSBLWY-EUA

7AT

AWD

Journey GLSNLSL-EUA

Journey + Premium GLSNLTL-EUA

Sport GLSNLVL-EUA

Sport + Premium GLSNLWL-EUA

Canada

2WD

Journey + Premium GLSALTL-ENA

Sport + Premium

GLSALWL-ENA

6MT GLSALWY-ENA

7AT4WAS

GLSBLWL-ENA

6MT GLSBLWY-ENA

7AT AWDJourney + Premium GLSNLTL-ENA

Sport + Premium GLSNLWL-ENA



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GModel variation code (Prefix and suffix designations)

Information About Identification or Model Code INFOID:0000000004257261

IDENTIFICATION NUMBER

JPAIA0451GB

JPAIA0143GB

1. Vehicle identification plate 2. Emission control information label 3.Vehicle identification number (Chassis number)

4. Vehicle identification number plate 5. Air conditioner specification label 6. Tire and loading information label

7. FMVSS certification label


VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

IDENTIFICATION PLATE

ENGINE SERIAL NUMBER

AUTOMATIC TRANSMISSION NUMBER

JPAIA0452GB

JPAIA0004ZZ

1. Type 2. Vehicle identification number (Chassis number) 3. Model variation code

4. Body color code 5. Trim color code 6. Engine model

7. Engine displacement 8. Transmission model 9. Axle model

: Vehicle front

JPAIA0005ZZ



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MANUAL TRANSMISSION NUMBER

Dimensions INFOID:0000000004257262

Unit: mm (in)

*1: 2WD 18-in tire models

*2: 2WD 19-in tire models

*3: AWD models

Wheels & Tires INFOID:0000000004257263

: Vehicle front

JPAIA0334ZZ

PAIA0068E

Overall length 4,650 (183.1)

Overall width 1,823 (71.8)

Overall height 1,393 (54.8)*1, 1,395 (54.9)*2, 1,406 (55.4)*3

Front tread 1,545 (60.8)

Rear tread 1,560 (61.4)

Wheelbase 2,850 (112.2)

Conventional Spare

Road wheel/offset mm (in)

18 × 8J Aluminum/43 (1.69)17 × 4T Aluminum/30 (1.18)18 × 4T Aluminum/0 (0)Front: 19 × 8-1/2J Aluminum/43 (1.69)

Rear: 19 × 9J Aluminum/45 (1.77)

Tire size

P225/50R18 94VT145/80D17 107MT145/70R18 107MFront: 225/45R19 92W

Rear: 245/40R19 94W


PRECAUTIONS
< PRECAUTION >


Observe the following precautions to ensure safe and proper servicing. These precautions are notdescribed in each individual section.









Precautions For Xenon Headlamp Service INFOID:0000000004257266

WARNING:Comply with the following warnings to prevent any serious accident.• Disconnect the battery cable (negative terminal) or the power supply fuse before installing, remov-

ing, or touching the xenon headlamp (bulb included). The xenon headlamp contains high-voltagegenerated parts.

• Never work with wet hands.• Check the xenon headlamp ON-OFF status after assembling it to the vehicle. Never turn the xenon

headlamp ON in other conditions. Connect the power supply to the vehicle-side connector.(Turning it ON outside the lamp case may cause fire or visual impairments.)

• Never touch the bulb glass immediately after turning it OFF. It is extremely hot. CAUTION:Comply with the following cautions to prevent any error and malfunction.• Install the xenon bulb securely. (Insufficient bulb socket installation may melt the bulb, the connec-

tor, the housing, etc. by high-voltage leakage or corona discharge.)• Never perform HID circuit inspection with a tester.• Never touch the xenon bulb glass with hands. Never put oil and grease on it.• Dispose of the used xenon bulb after packing it in thick vinyl without breaking it. • Never wipe out dirt and contamination with organic solvent (thinner, gasoline, etc.).


PRECAUTIONS

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< PRECAUTION >

GPrecaution Necessary for Steering Wheel Rotation after Battery Disconnect

INFOID:0000000004684854









4. Perform the necessary repair operation.5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn







PIIB3706J


PRECAUTIONS
< PRECAUTION >

• Do not operate the engine for an extended period of time withoutproper exhaust ventilation.Keep the work area well ventilated and free of any inflammablematerials. Special care should be taken when handling any inflam-mable or poisonous materials, such as gasoline, refrigerant gas,etc. When working in a pit or other enclosed area, be sure to prop-erly ventilate the area before working with hazardous materials.Do not smoke while working on the vehicle.

• Before jacking up the vehicle, apply wheel chocks or other tireblocks to the wheels to prevent the vehicle from moving. After jack-ing up the vehicle, support the vehicle weight with safety stands atthe points designated for proper lifting before working on the vehi-cle.These operations should be done on a level surface.

• When removing a heavy component such as the engine or tran-saxle/transmission, be careful not to lose your balance and dropthem. Also, do not allow them to strike adjacent parts, especiallythe brake tubes and master cylinder.

• Before starting repairs which do not require battery power:Turn off ignition switch.Disconnect the negative battery terminal.

• If the battery terminals are disconnected, recorded memory ofradio and each control unit is erased.

• To prevent serious burns:Avoid contact with hot metal parts.Do not remove the radiator cap when the engine is hot.

• Dispose of drained oil or the solvent used for cleaning parts in anappropriate manner.

• Do not attempt to top off the fuel tank after the fuel pump nozzleshuts off automatically.Continued refueling may cause fuel overflow, resulting in fuel sprayand possibly a fire.

• Clean all disassembled parts in the designated liquid or solventprior to inspection or assembly.

• Replace oil seals, gaskets, packings, O-rings, locking washers,cotter pins, self-locking nuts, etc. with new ones.

• Replace inner and outer races of tapered roller bearings and needle bearings as a set.• Arrange the disassembled parts in accordance with their assembled locations and sequence.• Do not touch the terminals of electrical components which use microcomputers (such as ECM).

Static electricity may damage internal electronic components.• After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.• Use only the fluids and lubricants specified in this manual.• Use approved bonding agent, sealants or their equivalents when required.

SGI285

SGI231

SEF289H

SGI233


PRECAUTIONS

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< PRECAUTION >

G• Use hand tools, power tools (disassembly only) and recommended

special tools where specified for safe and efficient service repairs.• When repairing the fuel, oil, water, vacuum or exhaust systems,

check all affected lines for leaks.

• Before servicing the vehicle:Protect fenders, upholstery and carpeting with appropriate covers.Take caution that keys, buckles or buttons do not scratch paint.

WARNING:To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harnessconnectors which are related to the engine control system and TCM (transmission control module)system. The connectors should be disconnected only when working according to the WORK FLOW ofTROUBLE DIAGNOSES in EC and AT sections.

Three Way Catalyst INFOID:0000000004257271

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. Toprevent this, follow the instructions.• Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.• When checking for ignition spark or measuring engine compression, make tests quickly and only when nec-

essary.• Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the

catalyst.Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the threeway catalyst.

Multiport Fuel Injection System or Engine Control System INFOID:0000000004257272

• Before connecting or disconnecting any harness connector for themultiport fuel injection system or ECM:Turn ignition switch to “OFF” position.Disconnect negative battery terminal.Otherwise, there may be damage to ECM.

• Before disconnecting pressurized fuel line from fuel pump to injec-tors, be sure to release fuel pressure.

• Be careful not to jar components such as ECM and mass air flowsensor.

Hoses INFOID:0000000004257273

HOSE REMOVAL AND INSTALLATION

JPAIA0335ZZ

SGI234

SGI787


PRECAUTIONS
< PRECAUTION >• To prevent damage to rubber hose, do not pry off rubber hose with
tapered tool or screwdriver.

• To reinstall the rubber hose securely, make sure that hose insertionlength and orientation is correct. (If tube is equipped with hosestopper, insert rubber hose into tube until it butts up against hosestopper.)

HOSE CLAMPING• If old rubber hose is re-used, install hose clamp in its original posi-

tion (at the indentation where the old clamp was). If there is a traceof tube bulging left on the old rubber hose, align rubber hose atthat position.

• Discard old clamps; replace with new ones.

• After installing plate clamps, apply force to them in the direction ofthe arrow, tightening rubber hose equally all around.

Engine Oils INFOID:0000000004257274

Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contactwith used oil.If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

HEALTH PROTECTION PRECAUTIONS • Avoid prolonged and repeated contact with oils, particularly used engine oils.• Wear protective clothing, including impervious gloves where practicable.• Do not put oily rags in pockets.• Avoid contaminating clothes, particularly underpants, with oil.

SMA019D

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SMA021D

SMA022D


PRECAUTIONS

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< PRECAUTION >

G• Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regu-

larly.• First aid treatment should be obtained immediately for open cuts and wounds.• Use barrier creams, applying them before each work period, to help the removal of oil from the skin.• Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Prepara-

tions containing lanolin replace the natural skin oils which have been removed.• Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.• If skin disorders develop, obtain medical advice without delay.• Where practical, degrease components prior to handling.• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face

shields; in addition an eye wash facility should be provided.

ENVIRONMENTAL PROTECTION PRECAUTIONS Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste dis-posal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposalfacilities.It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources.The regulations concerning pollution vary between regions.

Air Conditioning INFOID:0000000004257275

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer toHA section “REFRIGERANT” for specific instructions.

Fuel INFOID:0000000004257276

INFINITI recommends the use of unleaded premium gasoline with an octane rating of at least 91 AKI (Anti-Knock Index) number (Research octane number 96).

If unleaded premium gasoline is not available, unleaded regular gasoline with an octane rating of at least 87AKI number (Research octane number 91), may be temporarily used, but only under the following precautions:• Have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gas-

oline as soon as possible.• Avoid full throttle driving and abrupt acceleration.However, for maximum vehicle performance, the use of unleaded premium gasoline is recommended.

CAUTION:Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel(i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affectthe emission control devices and systems, and could also affect the warranty coverage validity.


LIFTING POINT
< PRECAUTION >
LIFTING POINT


CAUTION:• Every time the vehicle is lifted up, maintain the complete vehicle curb condition.• Since the vehicle's center of gravity changes when removing main parts on the front side (engine,

transmission, suspension etc.), support a jack up point on the rear side garage jack with a missionjack or equivalent.

• Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle,suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equiv-alent.

• Be careful not to smash or do not do anything that would affect piping parts.

Garage Jack and Safety Stand and 2-Pole Lift INFOID:0000000004257278

WARNING:• Park the vehicle on a level surface when using the jack. Make sure to avoid damaging pipes, tubes,

etc. under the vehicle.• Never get under the vehicle while it is supported only by the jack. Always use safety stands when

you have to get under the vehicle.• Place wheel chocks at both front and back of the wheels on the ground.• When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of

the vehicle are well balanced.• When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, fuel lines and

sill spoiler.


Board on attachment

Safety stand attachment

S-NT001

S-NT002


LIFTING POINT

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< PRECAUTION >

G

CAUTION:There is canister just behind Garage jack point rear. Jack up be carefully.

Board-On Lift INFOID:0000000004257279

CAUTION:Make sure vehicle is empty when lifting.

• The board-on lift attachment (A) set at front end of vehicleshould be set on the front of the sill under the front dooropening.

• Position attachments at front and rear ends of board-on lift.

1. Safety stand point and lift up point (front) 2. Safety stand point and lift up point (rear)

3. Garage jack point (front)

4. Garage jack point (rear)

JMAIA0060ZZ

: Vehicle front

JMAIA0004ZZ


TOW TRUCK TOWING
< PRECAUTION >
TOW TRUCK TOWING

Tow Truck Towing INFOID:0000000004257280

CAUTION:• All applicable state or Provincial laws and local laws regarding the towing operation must be

obeyed.• It is necessary to use proper towing equipment to avoid possible damage to the vehicle during tow-

ing operation. Towing is in accordance with Towing Procedure Manual at dealer.• Always attach safety chains before towing.• When towing, make sure that the transmission, steering system and powertrain are in good order. If

any unit is damaged, dollies must be used.• Never tow an automatic transmission model from the rear (that is backward) with four wheels on the

ground. This may cause serious and expensive damage to the transmission.

2WD MODELS

INFINITI recommends that vehicle be towed with the driving (rear) wheels off the ground or that a dolly beused as illustrated.CAUTION:• Never tow automatic transmission models with the rear wheels on the ground or four wheels on the

ground (forward or backward), as this may cause serious and expensive damage to the transmis-sion.If it is necessary to tow the vehicle with the front wheels raised, always use towing dollies under therear wheels.

• When towing rear wheel drive models with the front wheels on the ground or on towing dollies:- Turn the ignition key to the OFF position, and secure the steering wheel in a straight ahead position

with a rope or similar device.Never secure the steering wheel by turning the ignition key to the LOCKposition. This may damage the steering lock mechanism.

- Move the selector lever to the N (Neutral) position.• When the battery of vehicle equipped with the Intelligent Key system is discharged, your vehicle

should be towed with the front wheels on towing dollies or place the vehicle on a flat bed truck.

If the speed or distance must necessarily be greater, remove the propeller shaft before towing to prevent dam-age to the transmission.

PIIB6402E


TOW TRUCK TOWING

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< PRECAUTION >

GAWD MODELS

INFINITI recommends that a dolly be used as illustrated when towing AWD models.CAUTION:Never tow AWD models with any of the wheels on the ground as this may cause serious and expen-sive damage to the powertrain.

Vehicle Recovery (Freeing a Stuck Vehicle) INFOID:0000000004257281

FRONTSecurely install the vehicle recovery hook stored with jacking tools.Make sure that the hook is properly secured in the stored place afteruse.WARNING:• Stand clear of a stuck vehicle.• Do not spin your tires at high speed. This could cause them to

explode and result in serious injury. Parts of your vehiclecould also overheat and be damaged.

CAUTION:• Tow chains or cables must be attached only to the vehicle

recovery hooks or main structural members of the vehicle.Otherwise, the vehicle body will be damaged.

• Do not use the vehicle tie downs to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehi-cle using the vehicle tie downs or recovery hooks.

• Always pull the cable straight out from the front of the vehicle. Never pull on the hook at an angle.• Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or

cooling systems.• Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or

recovery.

REARWARNING:• Rear hook is not available.

AUTOMATIC TRANSMISSION

To tow a vehicle equipped with an automatic transmission, an appropriate vehicle dolly MUST be placed underthe towed vehicle's drive wheels. Always follow the dolly manufacture's recommendations when using theirproduct.If the vehicle is stuck in sand, snow, mud, etc., use the following procedure:1. Turn off the Vehicle Dynamic Control System.2. Make sure the area in front and behind the vehicle is clear of obstructions.

PIIB6403E

JMAIA0049ZZ


TOW TRUCK TOWING
< PRECAUTION >3. Turn the steering wheel right and left to clear an area around the front tires.4. Slowly rock the vehicle forward and backward.
Shift back and forth between R (reverse) and D (drive).Apply the accelerator as little as possible to maintain the rocking motion.Release the accelerator pedal before shifting between R and D.Do not spin the tires above 35 mph (55 km/h).

5. If the vehicle can not be freed after a few tries, contact a professional towing service to remove the vehi-cle.


SERVICE INFORMATION FOR ELECTRICAL INCIDENT

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GBASIC INSPECTIONSERVICE INFORMATION FOR ELECTRICAL INCIDENT


WORK FLOW

Control Units and Electrical Parts INFOID:0000000004257283

PRECAUTIONS• Never reverse polarity of battery terminals.• Install only parts specified for a vehicle.• Before replacing the control unit, check the input and output and functions of the component parts. • Do not apply excessive force when disconnecting a connector.

SGI838

STEP DESCRIPTION

STEP 1

Get detailed information about the conditions and the environment when the incident occurred.The following are key pieces of information required to make a good analysis:

WHAT Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio).

WHEN Date, Time of Day, Weather Conditions, Frequency.

WHERE Road Conditions, Altitude and Traffic Situation.

HOWSystem Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed.

STEP 2Operate the system, road test if necessary.Verify the parameter of the incident.If the problem cannot be duplicated, refer to “Incident Simulation Tests”.

STEP 3

Get the proper diagnosis materials together including:• Power Supply Routing• System Operation Descriptions• Applicable Service Manual Sections• Check for any Service BulletinsIdentify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.

STEP 4Inspect the system for mechanical binding, loose connectors or wiring damage.Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Lay-outs.

STEP 5 Repair or replace the incident circuit or component.

STEP 6Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inad-vertently created a new incident during your diagnosis or repair steps.


< BASIC INSPECTION >• Do not apply excessive shock to the control unit by dropping or hit-
ting it.• Be careful to prevent condensation in the control unit due to rapid

temperature changes and do not let water or rain get on it. If wateris found in the control unit, dry it fully and then install it in the vehi-cle.

• Be careful not to let oil to get on the control unit connector.• Avoid cleaning the control unit with volatile oil.• Do not disassemble the control unit, and do not remove the upper

and lower covers.

• When using a DMM, be careful not to let test probes get close toeach other to prevent the power transistor in the control unit fromdamaging battery voltage because of short circuiting.

• When checking input and output signals of the control unit, use thespecified check adapter.

How to Check Terminal INFOID:0000000004257284

CONNECTOR AND TERMINAL PIN KIT• Use the connector and terminal pin kits listed below when replacing connectors or terminals.• The connector and terminal pin kits contain some of the most commonly used NISSAN/INFINITI connectors

and terminals. For detailed connector and terminal pin replacement procedures, refer to the latest NISSAN/INFINITI CONNECTOR AND TERMINAL PIN SERVICE MANUAL.

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HOW TO PROBE CONNECTORS• Connector damage and an intermittent connection can result from improperly probing of the connector dur-

ing circuit checks.• The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the

connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alliga-tor clip.

Probing from Harness Side Standard type (not waterproof type) connector should be probedfrom harness side with “T” pin.• If the connector has a rear cover such as a ECM connector,

remove the rear cover before probing the terminal.• Do not probe waterproof connector from harness side. Damage to

the seal between wire and connector may result.

Probing from Terminal Side

FEMALE TERMINAL• There is a small notch above each female terminal. Probe each

terminal with the “T” pin through the notch.Do not insert any object other than the same type male terminalinto female terminal.



-(J38751-95NI)Connector and terminal pin kit (NISSAN)-(J38751-95INF)Connector and terminal pin kit (INFINITI) -(J42992-98KIT)OBD and terminal repair kit-(J42992-2000UPD)OBD-II Connector Kit Up-date

WAIA0004E WAIA0005E

SGI841

SEL265V


< BASIC INSPECTION >• Some connectors do not have a notch above each terminal. To
probe each terminal, remove the connector retainer to make con-tact space for probing.

MALE TERMINAL• Carefully probe the contact surface of each terminal using a “T”

pin.CAUTION:Dot not bend terminal.

How to Check Enlarged Contact Spring of Terminal• An enlarged contact spring of a terminal may create intermittent signals in the circuit.• If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged con-

tact spring of female terminal.1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire.

NOTE:Use a male terminal which matches the female terminal.

2. Disconnect the suspected faulty connector and hold it terminalside up.

3. While holding the wire of the male terminal, try to insert the maleterminal into the female terminal.CAUTION:Do not force the male terminal into the female terminal withyour hands.

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G4. While moving the connector, check whether the male terminal

can be easily inserted or not.

• If the male terminal can be easily inserted into the female ter-minal, replace the female terminal.

Waterproof Connector Inspection If water enters the connector, it can short interior circuits. This may lead to intermittent problems.Check the following items to maintain the original waterproof characteristics.

RUBBER SEAL INSPECTION• Most waterproof connectors are provided with a rubber seal

between the male and female connectors. If the seal is missing,the waterproof performance may not meet specifications.

• The rubber seal may come off when connectors are disconnected.Whenever connectors are reconnected, make sure the rubber sealis properly installed on either side of male or female connector.

WIRE SEAL INSPECTION• The wire seal must be installed on the wire insertion area of a

waterproof connector. Be sure that the seal is installed properly.

Terminal Lock Inspection Check for unlocked terminals by pulling wire at the end of connector.An unlocked terminal may create intermittent signals in the circuit.

Intermittent Incident INFOID:0000000004257285

DESCRIPTIONSometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create theconditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The fol-

SEL272V

SEL273V

SEL275V

SEL330V


< BASIC INSPECTION >lowing section illustrates ways to simulate the conditions/environment under which the owner experiences anelectrical incident.
The section is broken into the six following topics:• Vehicle vibration• Heat sensitive• Freezing• Water intrusion• Electrical load• Cold or hot start upGet a thorough description of the incident from the customer. It is important for simulating the conditions of theproblem.

VEHICLE VIBRATIONThe problem may occur or become worse while driving on a rough road or when engine is vibrating (idle withA/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustra-tion.

Connector & HarnessDetermine which connectors and wiring harness would affect the electrical system you are inspecting. Gentlyshake each connector and harness while monitoring the system for the incident you are trying to duplicate.This test may indicate a loose or poor electrical connection.

HintConnectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector termi-nals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs inter-mittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean theterminals on related connectors in the system.

Sensor & RelayGently apply a slight vibration to sensors and relays in the system you are inspecting.This test may indicate a loose or poorly mounted sensor or relay.

Engine CompartmentThere are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of thethings to check for are:• Connectors not fully seated.• Wiring harness not long enough and is being stressed due to engine vibrations or rocking.• Wires laying across brackets or moving components.• Loose, dirty or corroded ground wires.• Wires routed too close to hot components.To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to GroundInspection described later.) First check that the system is properly grounded. Then check for loose connectionby gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect thewiring for continuity.

Behind the Instrument PanelAn improperly routed or improperly clamped harness can become pinched during accessory installation. Vehi-cle vibration can aggravate a harness which is routed along a bracket or near a screw.

Under Seating Areas

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GAn unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides)during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage orpinching.

HEAT SENSITIVE• The customer's concern may occur during hot weather or after car

has sat for a short time. In such cases you will want to check for aheat sensitive condition.

• To determine if an electrical component is heat sensitive, heat thecomponent with a heat gun or equivalent.CAUTION:Do not heat components above 60°C (140°).

• If incident occurs while heating the unit, either replace or properlyinsulate the component.

FREEZING • The customer may indicate the incident goes away after the car

warms up (winter time). The cause could be related to water freez-ing somewhere in the wiring/electrical system.

• There are two methods to check for this. The first is to arrange forthe owner to leave his car overnight. Make sure it will get coldenough to demonstrate his complaint. Leave the car parked out-side overnight. In the morning, do a quick and thorough diagnosisof those electrical components which could be affected.

• The second method is to put the suspect component into a freezerlong enough for any water to freeze. Reinstall the part into the carand check for the reoccurrence of the incident. If it occurs, repair orreplace the component.

WATER INTRUSIONThe incident may occur only during high humidity or in rainy/snowyweather. In such cases the incident could be caused by water intru-sion on an electrical part. This can be simulated by soaking the caror running it through a car wash.CAUTION:Do not spray water directly on any electrical components.

ELECTRICAL LOAD The incident may be electrical load sensitive. Perform diagnosis withall accessories (including A/C, rear window defogger, radio, foglamps) turned on.

COLD OR HOT START UP On some occasions an electrical incident may occur only when the car is started cold, or it may occur whenthe car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight tomake a proper diagnosis.

SGI842

SGI843

SGI844

SGI845


Circuit Inspection INFOID:0000000004257286

DESCRIPTION • In general, testing electrical circuits is an easy task if it is approached in a logical and organized method.

Before beginning it is important to have all available information on the system to be tested. Also, get a thor-ough understanding of system operation. Then you will be able to use the appropriate equipment and followthe correct test procedure.

• You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiringharness or electrical component to do this.

NOTE:Refer to GI-38, "How to Check Terminal" to probe or check terminal.

TESTING FOR “OPENS” IN THE CIRCUITBefore you begin to diagnose and test the system, you should rough sketch a schematic of the system. Thiswill help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your work-ing knowledge of the system.

Continuity Check MethodThe continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistancefunction will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always startwith the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits, please refer to the previous schematic.• Disconnect the battery negative cable.• Start at one end of the circuit and work your way to the other end. (At the fuse block in this example)• Connect one probe of the DMM to the fuse block terminal on the load side.• Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that por-

tion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an overlimit or infinite resistance condition. (point A)

• Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuithas good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resis-tance condition. (point B)

• Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of thecircuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infi-nite resistance condition. (point C)

Any circuit can be diagnosed using the approach in the previous example.

Voltage Check MethodTo help in understanding the diagnosis of open circuits please refer to the previous schematic.In any powered circuit, an open can be found by methodically checking the system for the presence of voltage.This is done by switching the DMM to the voltage function.• Connect one probe of the DMM to a known good ground.• Begin probing at one end of the circuit and work your way to the other end.• With SW1 open, probe at SW1 to check for voltage.

voltage; open is further down the circuit than SW1.

OPEN A circuit is open when there is no continuity through a section of the circuit.

SHORT

There are two types of shorts.

• SHORT CIRCUITWhen a circuit contacts another circuit and causes the normal resistance to change.

• SHORT TO GROUND When a circuit contacts a ground source and grounds the circuit.

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Gno voltage; open is between fuse block and SW1 (point A).

• Close SW1 and probe at relay.voltage; open is further down the circuit than the relay.no voltage; open is between SW1 and relay (point B).

• Close the relay and probe at the solenoid.voltage; open is further down the circuit than the solenoid.no voltage; open is between relay and solenoid (point C).

Any powered circuit can be diagnosed using the approach in the previous example.

TESTING FOR “SHORTS” IN THE CIRCUITTo simplify the discussion of shorts in the system, please refer to the following schematic.

Resistance Check Method• Disconnect the battery negative cable and remove the blown fuse.• Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.• Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known

good ground.• With SW1 open, check for continuity.

continuity; short is between fuse terminal and SW1 (point A).no continuity; short is further down the circuit than SW1.

• Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground.Then, check for continuity.continuity; short is between SW1 and the relay (point B).no continuity; short is further down the circuit than the relay.

• Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and aknown good ground. Then, check for continuity.continuity; short is between relay and solenoid (point C).no continuity; check solenoid, retrace steps.

Voltage Check Method• Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid discon-

nected) powered through the fuse.• Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse ter-

minal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground).• With SW1 open and the DMM leads across both fuse terminals, check for voltage.

voltage; short is between fuse block and SW1 (point A).no voltage; short is further down the circuit than SW1.

• With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check forvoltage.voltage; short is between SW1 and the relay (point B).no voltage; short is further down the circuit than the relay.

• With SW1 closed, relay contacts jumped with fused jumper wire check for voltage.voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C).no voltage; retrace steps and check power to fuse block.

GROUND INSPECTION • Ground connections are very important to the proper operation of electrical and electronic circuits. Ground

connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) canbecome an unwanted resistance. This unwanted resistance can change the way a circuit works.

• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground candrastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit.Even when the ground connection looks clean, there can be a thin film of rust on the surface.

SGI847-A


< BASIC INSPECTION >• When inspecting a ground connection follow these rules:- Remove the ground bolt or screw.- Inspect all mating surfaces for tarnish, dirt, rust, etc.- Clean as required to assure good contact.- Reinstall bolt or screw securely.- Inspect for “add-on” accessories which may be interfering with the ground circuit.- If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eye-let make sure no ground wires have excess wire insulation.

• For detailed ground distribution information, refer to “Ground Distribution” in PG section.

VOLTAGE DROP TESTS • Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage

drop in a circuit is caused by a resistance when the circuit is in operation.• Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire

will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strandof wire is not able to carry the current. The single strand will have a high resistance to the current. This willbe picked up as a slight voltage drop.

• Unwanted resistance can be caused by many situations as follows:- Undersized wiring (single strand example)- Corrosion on switch contacts- Loose wire connections or splices.• If repairs are needed always use wire that is of the same or larger gauge.

Measuring Voltage Drop — Accumulated Method• Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the

DMM should be closer to power and the negative lead closer to ground.• Operate the circuit.• The DMM will indicate how many volts are being used to “push” current through that part of the circuit.

SGI853



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GNote in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

Measuring Voltage Drop — Step-by-Step• The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those

in “Computer Controlled Systems”).• Circuits in the “Computer Controlled System” operate on very low amperage.• The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the

system. Such resistance variation may be caused by poor connection, improper installation, improper wiregauge or corrosion.

• The step by step voltage drop test can identify a component or wire with too much resistance.

CONTROL UNIT CIRCUIT TEST System Description• When the switch is ON, the control unit lights up the lamp.

CASE 1

SGI974

SAIA0258E

MGI034A


< BASIC INSPECTION >INPUT-OUTPUT VOLTAGE CHART
• The voltage value is based on the body ground.

• *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unitdoes not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up thelamp.

CASE 2

INPUT-OUTPUT VOLTAGE CHART

• The voltage value is based on the body ground.

• *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unitdoes not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up thelamp.

Terminal No. Description

Condition Value (Approx.)In case of high resistance such as single strand (V) *+ − Signal name

Input/Output

1Body ground

Switch InputSwitch ON Battery voltage

Lower than battery voltage Approx. 8 (Ex-ample)

Switch OFF 0 V Approx. 0

2Body ground

Lamp OutputSwitch ON Battery voltage Approx. 0 (Inoperative lamp)


Terminal No. Description

Condition Value (Approx.)In case of high resistance such as single strand (V) *+ − Signal name

Input/Output

1Body ground

Lamp OutputSwitch ON 0V Battery voltage (Inoperative lamp)

Switch OFF Battery voltage Battery voltage

2Body ground

Switch InputSwitch ON 0 V Higher than 0 Approx. 4 (Example)


MGI035A


CONSULT-III/GST CHECKING SYSTEM

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GCONSULT-III/GST CHECKING SYSTEM


• When CONSULT-III/GST is connected with a data link connector(A) equipped on the vehicle side, it will communicate with the con-trol unit equipped in the vehicle and then enable various kinds ofdiagnostic tests.

• Refer to “CONSULT-III Software Operation Manual” for more infor-mation.

CONSULT-III Function and System Application*1 INFOID:0000000004257288

x: Applicable

*1: If GST application is equipped, functions in accordance with SAE J1979 and ISO 15031-5 can be used.

1 : Instrument driver lower panel

JPAIA0024ZZ

Diagnostic test mode

Function

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ION

AIR

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R/M

&A

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IPD

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ICC

4WA

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FR

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S (

MA

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/HIC

AS

)

AD

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IGH

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LTI A

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D/4

WD

Work SupportThis mode enables a technician to adjust some devices faster and more accurately.

x - - - x x x - x - - x - - x -

Self-Diagnostic Results

Retrieve DTC from ECU and display diag-nostic items.

x x x x x x x x x x x x x x x x

Data MonitorMonitor the input/output signal of the con-trol unit in real time.

x x - x x x x x x x x x x x x x

CAN DiagnosisThis mode displays a network diagnosis re-sult about CAN by a diagram.

x x x x x x x x x - x x x x - x

CAN Diagnosis Support Monitor

It monitors the status of CAN communica-tion.

x x - x x x x x x x x x x x - x

Active TestSend the drive signal from CONSULT-III to the actuator. The operation check can be performed.

x - - - x x x x x x x x - - x x

DTC & SRT confirmation

The status of system monitoring tests and the self-diagnosis status/result can be con-firmed.

x x - - - - - - - - - - - - - -

ECU Identifica-tion

Display the ECU identification number (part number etc.) of the selected system.

x x - x x x x x x x x x x x - x

Function Test

This mode can show results of self-diagno-sis of ECU with either “OK” or “NG”. For en-gine, more practical tests regarding sensors/switches and/or actuators are available.

x x x - - - x - - - - - - - - -

ConfigurationFunction to READ/WRITE vehicle configu-ration.

- - - - x - - - - - - - - - - -

Special Func-tion

Other results or histories, etc. that are re-corded in ECU are displayed.

- x x - - - - - - - - - - - - -


CONSULT-III/GST Data Link Connector (DLC) Circuit INFOID:0000000004257289

INSPECTION PROCEDUREIf the CONSULT-III/GST cannot diagnose the system properly, check the following items.

NOTE:The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system. Ashort in a DDL circuit connected to a control unit in one system may affect CONSULT-III access to other sys-tems.If the GST cannot operate properly, check the circuit based on the information of SAE J1962 and ISO 15031-3.

Symptom Check item

CONSULT-III/GST cannot ac-cess any system.

• CONSULT-III/GST DLC power supply circuit (Terminal 8 and 16) and ground circuit (Terminal 4 and 5)

CONSULT-III cannot access in-dividual system. (Other sys-tems can be accessed.)

• Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.)

• Open or short circuit between the system and CONSULT-III DLC (For detailed circuit, refer to wiring diagram for each system.)

• Open or short circuit CAN communication line. Refer to LAN-18, "Trouble Diagnosis Flow Chart".



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GWiring Diagram - CONSULT-III/GST CHECKING SYSTEM - INFOID:0000000004257290

JCAWM0134GB


JCAWM0135GB



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JCAWM0136GB


JCAWM0137GB



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JCAWM0138GB


INSPECTION AND ADJUSTMENT
INSPECTION AND ADJUSTMENTADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Re-quired Procedure After Battery Disconnection INFOID:0000000004257291

*: Not equipped.

SYSTEM ITEM REFERENCE

Automatic temperature control

Temperature setting trimmer HAC-7, "Temperature Setting Trimmer"

Foot position setting trimmer HAC-9, "Foot Position Setting Trimmer"

Inlet port memory function HAC-10, "Inlet Port Memory Function"

Inlet port memory function (FRE)* —

Inlet port memory function (REC)* —

Gas sensor sensitivity adjustment function* —

Auto intake switch Interlocking movement change* —

Clean switch interlocking movement change* —

Automatic drive positioner Automatic drive positioner systemADP-9, "ADDITIONAL SERVICE WHEN RE-MOVING BATTERY NEGATIVE TERMINAL :

Description"

Power window control Power window control systemPWC-5, "ADDITIONAL SERVICE WHEN RE-MOVING BATTERY NEGATIVE TERMINAL :

Description"

Sunroof system* Sunroof system —

Sunshade system* Sunshade system —

Rear view monitorRear view monitor possible route line center position adjustment

AV-374, "ADDITIONAL SERVICE WHEN RE-MOVING BATTERY NEGATIVE TERMINAL :

Description"

Around view monitor* Predicted course line center position adjustment —

Automatic back door system* Automatic back door system —

Engine oil level read* Engine oil level read —


infiniti g37-09-coupe4

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