Infiniti G20 2001 User Manual

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Page 1

EDITION: JUNE 2000 REVISION: DECEMBER 2000

QUICK REFERENCE INDEX

Page 2

INCH TO METRIC CONVERSION TABLE

(Rounded-off for automotive use)

inches mm inches mm

.100 2.54 .610 15.49 .110 2.79 .620 15.75 .120 3.05 .630 16.00 .130 3.30 .640 16.26 .140 3.56 .650 16.51 .150 3.81 .660 16.76 .160 4.06 .670 17.02 .170 4.32 .680 17.27 .180 4.57 .690 17.53 .190 4.83 .700 17.78 .200 5.08 .710 18.03 .210 5.33 .720 18.29 .220 5.59 .730 18.54 .230 5.84 .740 18.80 .240 6.10 .750 19.05 .250 6.35 .760 19.30 .260 6.60 .770 19.56 .270 6.86 .780 19.81 .280 7.11 .790 20.07 .290 7.37 .800 20.32 .300 7.62 .810 20.57 .310 7.87 .820 20.83 .320 8.13 .830 21.08 .330 8.38 .840 21.34 .340 8.64 .850 21.59 .350 8.89 .860 21.84 .360 9.14 .870 22.10 .370 9.40 .880 22.35 .380 9.65 .890 22.61 .390 9.91 .900 22.86 .400 10.16 .910 23.11 .410 10.41 .920 23.37 .420 10.67 .930 23.62 .430 10.92 .940 23.88 .440 11.18 .950 24.13 .450 11.43 .960 24.38 .460 11.68 .970 24.64 .470 11.94 .980 24.89 .480 12.19 .990 25.15 .490 12.45 1.000 25.40 .500 12.70 2.000 50.80 .510 12.95 3.000 76.20 .520 13.21 4.000 101.60 .530 13.46 5.000 127.00 .540 13.72 6.000 152.40 .550 13.97 7.000 177.80 .560 14.22 8.000 203.20 .570 14.48 9.000 228.60 .580 14.73 10.000 254.00 .590 14.99 20.000 508.00 .600 15.24

METRIC TO INCH CONVERSION TABLE

(Rounded-off for automotive use)

mm inches mm inches

1 .0394 51 2.008 2 .079 52 2.047 3 .118 53 2.087 4 .157 54 2.126 5 .197 55 2.165 6 .236 56 2.205 7 .276 57 2.244 8 .315 58 2.283

9 .354 59 2.323 10 .394 60 2.362 11 .433 61 2.402 12 .472 62 2.441 13 .512 63 2.480 14 .551 64 2.520 15 .591 65 2.559 16 .630 66 2.598 17 .669 67 2.638 18 .709 68 2.677 19 .748 69 2.717 20 .787 70 2.756 21 .827 71 2.795 22 .866 72 2.835 23 .906 73 2.874 24 .945 74 2.913 25 .984 75 2.953 26 1.024 76 2.992 27 1.063 77 3.031 28 1.102 78 3.071 29 1.142 79 3.110 30 1.181 80 3.150 31 1.220 81 3.189 32 1.260 82 3.228 33 1.299 83 3.268 34 1.339 84 3.307 35 1.378 85 3.346 36 1.417 86 3.386 37 1.457 87 3.425 38 1.496 88 3.465 39 1.535 89 3.504 40 1.575 90 3.543 41 1.614 91 3.583 42 1.654 92 3.622 43 1.693 93 3.661 44 1.732 94 3.701 45 1.772 95 3.740 46 1.811 96 3.780 47 1.850 97 3.819 48 1.890 98 3.858 49 1.929 99 3.898 50 1.969 100 3.937

Page 3

Attachment No.11

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)

The following is the information specified in Mode 6 of SAE J1979. The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG” while

being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored. Items for which these data (test value and test limit) are displayed are the same as SRT code items. These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen.

SRT item Self-diagnostic test item DTC

CATALYST Three way catalyst function

EVAP SYSTEM

HO2S

HO2S HTR

EGR SYSTEM EGR function

EVAP control system (Small leak)

EVAP control system purge flow monitoring P1447 06H 83H Min. X mV

Heated oxygen sensor 1

Heated oxygen sensor 2

Heated oxygen sensor 1 heater

Heated oxygen sensor 2 heater

Test value

(GST display)

Te s t limit Application Unit

TID CID

P0420 01H 01H Max. X P0420 02H 81H Min. X P0440 05H 03H Max. X P1440 05H 03H Max. X -

P0133 09H 04H Max. X ms P0131 0AH 84H Min. X mV P0130 0BH 04H Max. X mV P0132 0CH 04H Max. X mV P0134 0DH 04H Max. X s P0139 19H 86H Min. X mV/500ms P0137 1AH 86H Min. X mV P0140 1BH 06H Max. X mV P0138 1CH 06H Max. X mV P0135 29H 08H Max. X mV P0135 2AH 88H Min. X mV P0141 2DH 0AH Max. X mV P0141 2EH 8AH Min. X mV P0400 31H 8CH Min. X ℃ P0400 32H 8CH Min. X ℃ P0400 33H 8CH Min. X ℃ P0400 34H 8CH Min. X ℃ P1402 35H 0CH Max. X ℃

Applicable ･: Not applicable

Page 4

FRONT & REAR SUSPENSION

CONTENTS

FRONT SUSPENSION ....................................................2

Precautions ..................................................................2

PRECAUTIONS

Preparation ..................................................................2

SPECIAL SERVICE TOOLS COMMERCIAL SERVICE TOOLS

Noise, Vibration and Harshness (NVH)

Troubleshooting ...........................................................3

NVH TROUBLESHOOTING CHART

Components.................................................................4

On-vehicle Service.......................................................5

FRONT SUSPENSION PARTS FRONT WHEEL ALIGNMENT

Coil Spring and Shock Absorber .................................9

COMPONENTS REMOVAL DISASSEMBLY INSPECTION ASSEMBLY

Third Link and Upper Link ......................................... 11

REMOVAL INSTALLATION DISASSEMBLY ASSEMBLY

Stabilizer Bar .............................................................13

REMOVAL AND INSTALLATION

Transverse Link and Lower Ball Joint .......................14

REMOVAL AND INSTALLATION INSPECTION

Service Data and Specifications (SDS).....................14

GENERAL SPECIFICATIONS (FRONT)

.........................................................2

........................................2

................................2

............................3

...................................5

.....................................6

.........................................................9

...............................................................10

........................................................10

...........................................................10

.............................................................11

...............................................................11

........................................................11

........................................................12

.............................................................12

...............................13

...............................14

...........................................................14

.....................14

SECTION

FRONT WHEEL ALIGNMENT (UNLADEN*1) LOWER BALL JOINT WHEELARCH HEIGHT (UNLADEN*) WHEEL RUNOUT

REAR SUSPENSION.....................................................17

Precautions ................................................................17

PRECAUTIONS

Preparation ................................................................17

COMMERCIAL SERVICE TOOLS

Noise, Vibration and Harshness (NVH)

Troubleshooting .........................................................17

Components...............................................................18

On-vehicle Service.....................................................19

REAR SUSPENSION PARTS REAR WHEEL ALIGNMENT

Removal and Installation ...........................................21

REMOVAL INSTALLATION

Coil Spring and Shock Absorber ...............................22

REMOVAL DISASSEMBLY INSPECTION ASSEMBLY

Torsion Beam, Lateral Link and Control Rod ............24

DISASSEMBLY INSPECTION ASSEMBLY

Service Data and Specifications (SDS).....................25

GENERAL SPECIFICATIONS (REAR) REAR WHEEL ALIGNMENT (UNLADEN*)

....................................................16

.......................................................17

...............................................................22

........................................................22

...............................................................22

........................................................23

...........................................................23

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.............15

...............................................15

.........................16

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...................................19

.....................................19

.......................25

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IDX

Page 5

FRONT SUSPENSION

Precautions

PRECAUTIONS

! When installing rubber parts, final tightening must be car-

ried out under unladen condition* with tires on ground. *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

! After installing removed suspension parts, check wheel

alignment and adjust if necessary.

! Use flare nut wrench when removing or installing brake

SBR686C

tubes.

! Always torque brake lines when installing.

Preparation

SPECIAL SERVICE TOOLS

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

Tool number (Kent-Moore No.) Tool name

Description

NCSU0001

NCSU0002

HT72520000 (J25730-B) Ball joint remover

NT146

COMMERCIAL SERVICE TOOLS

Tool name Description

Attachment Wheel alignment

NT148

1 Flare nut crowfoot 2 Torque wrench

NT360

Spring compressor

Removing tie-rod outer end and lower ball joint

NCSU0003

Measure wheel alignment

a: Screw M24 x 1.5 pitch b: 35 mm (1.38 in) dia. c: 65 mm (2.56 in) dia. d: 56 mm (2.20 in) e: 12 mm (0.47 in)

Removing and installing each brake piping

a: 10 mm (0.39 in)

Removing and installing coil spring

NT717

SU-2

Page 6

FRONT SUSPENSION

Noise, Vibration and Harshness (NVH) Troubleshooting

NVH TROUBLESHOOTING CHART

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

=NCSU0004

NCSU0004S01

Reference page

SU-4, 18

Possible Cause and SUSPECTED PARTS

Improper installation, looseness

Noise ЧЧЧЧЧЧ ×× × ×××

Shake ×××× × ×× × ×××

Vibration ЧЧЧЧЧ ×× × ×

Shimmy ×××× × × × ×××

Judder ××× × × ×××

SUSPENSION

Poor quality ride or handling

ЧЧЧЧЧ ×× × × ×

—

SU-10, 22

Shock absorber deformation,

damage or deflection

Bushing or mounting deterioration

—

SU-9, 21

Parts interference

Spring fatigue

Suspension looseness

SU-6

SU-13

Incorrect wheel alignment

Stabilizer bar fatigue

—

SU-6

Out-of-round

—

Imbalance

Incorrect air pressure

—

Uneven tire wear

—

Deformation or damage

Non-uniformity

—

Incorrect tire size

AX-3

DRIVE SHAFT

AXLE

—

SUSPENSION

TIRES

—

BR-6

ROAD WHEEL

BRAKES

ST-5

STEERING

Noise ×××××××××××××

Shake ×××××××××××××

Vibration ××××× ×

Shimmy ×××××××××××××

Symptom

TIRES

Judder ××××××××××××

Poor quality ride or handling

Noise ××××××××××

Shake ××××××××××

Shimmy, Judder

Poor quality

ROAD WHEEL

ride or handling

×: Applicable

××××××××××

×××××××××

×××××××

IDX

SU-3

Page 7

Components

FRONT SUSPENSION

Components

NCSU0005

1. Front suspension member

2. Shock absorber mounting insulator

3. Coil spring

4. Upper link bracket

5. Upper link

6. Third link

7. Knuckle

8. Transverse link

SU-4

SFA808BA

9. Stabilizer bar

10. Drive shaft

11. Shock absorber

Page 8

SMA525A

FRONT SUSPENSION

On-vehicle Service

FRONT SUSPENSION PARTS

Check front axle and front suspension parts for excessive play, cracks, wear or other damage.

! Shake each front wheel to check for excessive play. ! Make sure that cotter pin is inserted. ! Retighten all axle and suspension nuts and bolts to the speci-

fied torque.

Tightening torque:

Refer to “FRONT SUSPENSION”, SU-4.

! Check strut (shock absorber) for oil leakage or other damage. ! Check suspension ball joint for grease leakage and ball joint

dust cover for cracks or other damage. If ball joint dust cover is cracked or damaged, replace transverse link.

NCSU0006

SFA392B

SFA818AA

SFA121B

! Check spring height from top of wheelarch to the ground. a) Vehicle must be unladen*, parked on a level surface, and tires

checked for proper inflation and wear (tread wear indicator must not be showing). *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

b) Bounce vehicle up and down several times before measuring.

Standard height: Refer to SDS (SU-16).

c) Spring height is not adjustable. If out of specification, check for

worn springs or suspension parts.

! Check upper link free play. a) Jack up front of vehicle and set stands. b) Set steering wheel in straight-forward direction and lock it

using key lock.

c) Remove front wheels. d) On axle side

Install dial gauge. i) Install magnet stand on third link. ii) Set dial gauge in position.

Set dial gauge spindle in contact with flat surface of upper link.

Set at 140 mm (5.51 in) from center of upper link retaining bolt

on the third link side. (Reset dial gauge.)

SU-5

IDX

Page 9

On-vehicle Service (Cont’d)

FRONT SUSPENSION

e) Hold flanges of third link with both hands. Twist third link fully

to the right and read dial gauge indication. Similarly, twist third

link to the left and read dial gauge indication.

Free play = (Gauge indication when third link is fully twisted to

the right) + (Gauge indication when third link is fully twisted to

the left)

Allowable free play range:

7.0 mm (0.276 in), max.

SFA446B

On body side

a) Install dial gauge. i) Install magnet stand on front suspension mount member. ii) Set dial gauge in position.

Set dial gauge spindle in contact with flat surface of upper link.

Set at 140 mm (5.51 in) from center of retaining bolt on bracket

side. (Reset dial gauge.) b) Measure free play in the same manner as on axle side.

Allowable free play range: 5.0 mm (0.197 in), max.

SFA123B

SFA504A

c) If free play exceeds specifications, replace upper link assem-

bly. ! Check suspension ball joint end play. a) Jack up front of vehicle and set the stands. b) Clamp dial indicator onto transverse link and place indicator tip

on lower edge of brake caliper. c) Make sure front wheels are straight and brake pedal is

depressed. d) Place a pry bar between transverse link and inner rim of road

wheel. e) While raising and releasing pry bar, observe maximum dial

indicator value.

Vertical end play:

0 mm (0 in)

If ball joint vertical end play exists, remove transverse link and

recheck the ball joint. Refer to SU-14.

SFA975B

FRONT WHEEL ALIGNMENT

NCSU0007

Before checking front wheel alignment, be sure to make a preliminary inspection (Unladen*). *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

Preliminary Inspection

NCSU0007S01

1. Check tires for wear and improper inflation.

2. Check wheels for deformation, cracks and other damage. If

deformed, remove wheel and check wheel runout. a. Remove tire from aluminum wheel and mount on a tire balance

machine. b. Set dial indicator as shown in the illustration.

Wheel runout (Dial indicator value):

Refer to SDS, SU-16.

3. Check front wheel bearings for looseness.

SU-6

Page 10

SRA096A

AFA050

SFA234AC

FRONT SUSPENSION

On-vehicle Service (Cont’d)

4. Check front suspension for looseness.

5. Check steering linkage for looseness.

6. Check that front shock absorbers work properly.

7. Check vehicle posture (Unladen).

Camber, Caster and Kingpin Inclination

Camber, caster and kingpin inclination are preset at factory and cannot be adjusted.

1. Measure camber, caster and kingpin inclination of both right

and left wheels with a suitable alignment gauge.

Camber, caster and kingpin inclination:

Refer to SDS, SU-15.

2. If camber, caster or kingpin inclination is not within

specification, inspect front suspension parts. Replace dam-

aged or worn out parts.

Toe-in

Measure toe-in using the following procedure.

WARNING:

! Always perform the following procedure on a flat surface. ! Make sure that no person is in front of the vehicle before

pushing it.

1. Bounce front of vehicle up and down to stabilize the posture.

2. Push the vehicle straight ahead about 5 m (16 ft).

3. Put a mark on base line of tread (rear side) of both tires at the

same height as hub center. These are measuring points.

4. Measure distance “A” (rear side).

5. Push the vehicle slowly ahead to rotate the wheels 180

degrees (1/2 turn).

If the wheels have rotated more than 180 degrees (1/2 turn), try the above procedure again from the beginning. Never push vehicle backward.

6. Measure distance “B” (front side).

Total toe-in:

Refer to SDS, SU-15.

7. Adjust toe-in by varying the length of steering tie-rods. a. Loosen lock nuts. b. Adjust toe-in by screwing tie-rods in and out.

Standard length “L”:

Refer to ST-32, “SDS”.

c. Tighten lock nuts to specified torque.

Lock nut tightening torque:

Refer to ST-15, “POWER STEERING GEAR AND LINKAGE”.

NCSU0007S02

NCSU0007S03

IDX

SFA486A

SU-7

Page 11

On-vehicle Service (Cont’d)

FRONT SUSPENSION

SFA439BA

Front Wheel Turning Angle

NCSU0007S04

1. Set wheels in straight-ahead position. Then move vehicle for-

ward until front wheels rest on turning radius gauge properly.

2. Rotate steering wheel all the way right and left; measure turn-

ing angle.

Wheel turning angle (Full turn):

Refer to SDS, SU-15.

SU-8

Page 12

FRONT SUSPENSION

Coil Spring and Shock Absorber

COMPONENTS

Coil Spring and Shock Absorber

=NCSU0008

SFA810BA

1. Gasket

2. Shock absorber mounting insulator

3. Upper rubber seat

4. Shock absorber bushing

5. Dust cover

6. Bound bumper rubber

7. Coil spring

8. Shock absorber

9. Third link

10. Cap

11. Wheel hub and steering knuckle assembly

12. Cotter pin

13. Transverse link

14. Connecting rod

15. Stabilizer bar

SU-9

16. Gusset pin

17. Cotter pin

18. Drive shaft

19. Upper link bracket

20. Upper link

21. Bushing

22. Washer

IDX

Page 13

Coil Spring and Shock Absorber (Cont’d)

FRONT SUSPENSION

SSU028

REMOVAL

=NCSU0009

! Remove shock absorber fixing bolt and nut (to hoodledge). ! Do not remove piston rod lock nut on vehicle.

DISASSEMBLY

NCSU0010

1. Set shock absorber on vise.

2. Compress spring with Tool so that shock absorber mounting insulator can be turned by hand.

WARNING:

Make sure that the pawls of the two spring compressors are firmly hooked on the spring. The spring compressors must be tightened alternately so as not to tilt the spring.

3. While holding the piston rod as shown in the left figure, remove the piston rod lock nut.

! Be sure to loosen the piston rod lock nut after compress-

ing the spring. If it is loosened before the spring is compressed, the piston valve nut inside the shock absorber may be loosened.

SSU029

INSPECTION Shock Absorber Assembly

NCSU0011

NCSU0011S01

! Check for smooth operation through a full stroke, both com-

pression and extension.

! Check for oil leakage on welded or gland packing portions. ! Check piston rod for cracks, deformation or other damage.

Replace if necessary.

Mounting Insulator and Rubber Parts

NCSU0011S02

! Check cemented rubber-to-metal portion for separation or

cracks. Check rubber parts for deterioration. Replace if necessary.

Coil Spring

NCSU0011S03

! Check for cracks, deformation or other damage. Replace if

necessary.

SU-10

Page 14

FRONT SUSPENSION

Coil Spring and Shock Absorber (Cont’d)

SFA448B

ASSEMBLY

! Install shock absorber so that arrow A faces rearward on LH

and forward on RH sides.

! Install upper mounting insulator with its cutout facing the inside

of the vehicle.

NCSU0012

Third Link and Upper Link

REMOVAL

CAUTION:

Kingpin bearing usually does not require maintenance. If any of the following symptoms are noted, replace kingpin bearing assembly.

! Growling noise is emitted from kingpin bearing during

operation.

! Kingpin bearing drags or turns roughly when steering

knuckle is turned by hand.

1. Remove cap and kingpin nut.

2. Remove shock absorber fixing nut and upper link fixing bolts.

3. Remove stabilizer connecting rod.

4. Remove third link and upper link.

NCSU0013

SFA922A

SFA727A

INSTALLATION Third Link

! Pack kingpin housing and cap with multi-purpose grease

before installing third link and cap.

Grease capacity:

Kingpin housing 4 g (0.14 oz) Cap 10 g (0.35 oz)

Upper Link

! Upper link has “L” or “R” stamped on it as shown.

Upper link bushings cannot be disassembled.

! When installing upper link, make sure that parts are in their

correct positions.

NCSU0014

NCSU0014S01

NCSU0014S02

IDX

SFA924A

SU-11

Page 15

Third Link and Upper Link (Cont’d)

FRONT SUSPENSION

SFA721A

SFA722A

DISASSEMBLY

1. Remove upper bearing (inner race and ball).

2. Remove kingpin grease seal.

3. Remove lower bearing (inner race and ball).

4. Remove upper and lower outer race.

! Be careful not to damage kingpin housing.

NCSU0015

SFA723A

SFA724A

SFA725A

ASSEMBLY

1. Install lower bearing.

2. Install upper bearing.

NCSU0016

SU-12

Page 16

FRONT SUSPENSION

Third Link and Upper Link (Cont’d)

3. Install kingpin grease seal.

4. Apply multi-purpose grease to oil seal lip.

SFA726A

SFA806B

SFA714BA

Stabilizer Bar

REMOVAL AND INSTALLATION

! Remove stabilizer bar.

! When installing stabilizer bar, make sure that paint mark and

clamp face in their correct directions.

! When removing and installing stabilizer bar, fix portion A.

NCSU0017

SFA926A

SFA449BA

! Install stabilizer bar with ball joint socket properly placed.

SU-13

IDX

Page 17

Transverse Link and Lower Ball Joint

FRONT SUSPENSION

Transverse Link and Lower Ball Joint

REMOVAL AND INSTALLATION

! Remove ball joint and transverse link assembly. ! During installation, final tightening must be carried out at curb

weight with tires on ground.

! After installation, check wheel alignment.

Refer to “FRONT WHEEL ALIGNMENT”, “On-vehicle Service”, SU-6.

SFA807B

INSPECTION Transverse Link

! Check transverse link for damage, cracks or deformation.

Replace it if necessary.

! Check rubber bushing for damage, cracks and deformation.

Replace transverse link if necessary.

NCSU0018

NCSU0019

NCSU0019S01

Lower Ball Joint

! Check ball joint for excessive play. Replace transverse link

assembly if any of the following exists:

! Ball stud is worn. ! Joint is hard to swing. ! Play in axial direction is excessive.

Before checking, turn ball joint at least 10 revolutions so that ball joint is properly broken in.

Swinging force “A”: (measuring point: cotter pin hole of ball stud)

SFA858A

7.8 - 54.9 N (0.8 - 5.6 kg, 1.8 - 12.3 lb)

Turning torque “B”:

0.49 - 3.43 N·m (5.0 - 35.0 kg-cm, 4.3 - 30.4 in-lb)

Vertical end play “C”:

0 mm (0 in)

! Check dust cover for damage. Replace it and cover clamp if

necessary.

Service Data and Specifications (SDS)

GENERAL SPECIFICATIONS (FRONT)

Suspension type Independent multi-link with coil spring

Shock absorber type Double-acting hydraulic

Stabilizer bar Standard equipment

NCSU0019S02

NCSU0020

SU-14

Page 18

FRONT SUSPENSION

Service Data and Specifications (SDS) (Cont’d)

FRONT WHEEL ALIGNMENT (UNLADEN*1)

Camber Degree minute (Decimal degree)

Caster Degree minute (Decimal degree)

Kingpin inclination Degree minute (Decimal degree)

Total toe-in

Distance (A − B) mm (in)

Angle (left plus right) Degree minute (Decimal degree)

Wheel turning angle Full turn*2

Inside Degree minute (Decimal degree)

Outside Degree minute (Decimal degree)

Minimum −0°45′ (−0.75°)

Nominal 0°00′ (0.00°)

Maximum 0°45′ (0.75°)

Left and right difference 45′ (0.75°) or less

Minimum 1°10′ (1.17°)

Nominal 1°55′ (1.92°)

Maximum 2°40′ (2.67°)

Left and right difference 45′ (0.75°) or less

Minimum 13°45′ (13.75°)

Nominal 14°30′ (14.50°)

Maximum 15°15′ (15.25°)

Minimum 0 (0)

Nominal 1 (0.04)

Maximum 2 (0.08)

Minimum 0′ (0.00°)

Nominal 6′ (0.10°)

Maximum 12′ (0.20°)

Minimum 31°00′ (31.00°)

Nominal 34°00′ (34.00°)

Maximum 35°00′ (35.00°)

Nominal 29°00′ (29.00°)

NCSU0021

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with

engine idle.

LOWER BALL JOINT

Swinging force “A” (Measuring point: cotter pin hole of ball stud) N (kg, lb)

Turning torque “B” N·m (kg-cm, in-lb) 0.49 - 3.43 (5.0 - 35.0, 4.3 - 30.4)

Vertical end play “C” mm (in) 0 (0)

7.8 - 54.9 (0.8 - 5.6, 1.8 - 12.3)

NCSU0022

IDX

SU-15

Page 19

Service Data and Specifications (SDS) (Cont’d)

FRONT SUSPENSION

WHEELARCH HEIGHT (UNLADEN*)

Applied model 195/60 R15 tire 195/65 R15 tire

Front (Hf) mm (in) 666 (26.22) 671 (26.42)

Rear (Hr) mm (in) 653 (25.71) 658 (25.91)

*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

WHEEL RUNOUT

Wheel type Aluminum

Radial runout limit mm (in) 0.3 (0.012)

Lateral runout limit mm (in) 0.3 (0.012)

=NCSU0041

SFA818A

NCSU0023

SU-16

Page 20

SBR686C

REAR SUSPENSION

Precautions

PRECAUTIONS

! When installing each rubber part, final tightening must be

carried out under unladen condition* with tires on ground. *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

! Use flare nut wrench when removing or installing brake

tubes.

! After installing removed suspension parts, check wheel

alignment.

! Do not jack up at the trailing arm and lateral link. ! Always torque brake lines when installing.

NCSU0024

COMMERCIAL SERVICE TOOLS

Tool name Description

Equivalent to GG94310000 1 Flare nut crowfoot 2 Torque wrench

NT360

Spring compressor

NT717

Preparation

NCSU0026

Removing and installing brake piping

a: 10 mm (0.39 in)

Removing and installing coil spring

Noise, Vibration and Harshness (NVH) Troubleshooting

Refer to “Noise, Vibration and Harshness (NVH) Troubleshooting”, “FRONT SUSPENSION”, SU-3.

NCSU0027

SU-17

IDX

Page 21

Components

REAR SUSPENSION

Components

NCSU0028

1. Gasket

2. Coil spring

3. Shock absorber

4. Torsion beam

SU-18

SRA788AB

5. Lateral link

6. Control rod

Page 22

REAR SUSPENSION

On-vehicle Service

REAR SUSPENSION PARTS

Check axle and suspension parts for excessive play, wear or damage.

! Shake each rear wheel to check for excessive play.

NCSU0029

SMA525A

SRA789A

SMA113

SFA975B

! Retighten all nuts and bolts to the specified torque.

Tightening torque:

Refer to “REAR SUSPENSION”, SU-18.

! Check shock absorber for oil leakage or other damage. ! Check wheelarch height. Refer to SU-5 (“FRONT SUSPEN-

SION PARTS”, “On-vehicle Service”).

REAR WHEEL ALIGNMENT Preliminary Inspection

1. Check tires for wear and improper inflation.

2. Check wheels for deformation, cracks and other damage. If deformed, remove wheel and check wheel runout.

a. Remove tire from aluminum wheel and mount on a tire balance

machine.

b. Set dial indicator as shown in the illustration.

Wheel runout (Dial indicator value):

Refer to SDS, SU-16.

3. Check front wheel bearings for looseness.

4. Check front suspension for looseness.

5. Check steering linkage for looseness.

6. Check that front shock absorbers work properly.

7. Check vehicle posture (Unladen).

NCSU0030

NCSU0030S01

SU-19

IDX

Page 23

On-vehicle Service (Cont’d)

REAR SUSPENSION

SFA948A

SFA614B

SFA234AC

Camber

NCSU0030S02

Camber is preset at factory and cannot be adjusted.

Camber:

Refer to SDS, SU-25.

! If the camber is not within specification, inspect and replace

any damaged or worn rear suspension parts.

Toe-in

NCSU0030S03

Toe-in is preset at factory and cannot be adjusted. Measure toe-in using following procedure. If out of specification, inspect and replace any damaged or worn rear suspension parts.

WARNING:

! Perform following procedure always on a flat surface. ! Make sure that no person is in front of the vehicle before

pushing it.

1. Bounce rear of vehicle up and down to stabilize the posture.

2. Push the vehicle straight ahead about 5 m (16 ft).

3. Put a mark on base line of the tread (rear side) of both tires at the same height of hub center. This mark is a measuring point.

4. Measure distance “A” (rear side).

5. Push the vehicle slowly ahead to rotate the wheels 180 degrees (1/2 turn).

If the wheels have rotated more than 180 degrees (1/2 turn), try the above procedure again from the beginning. Never push vehicle backward.

6. Measure distance “B” (front side).

Total toe-in:

Refer to SDS, SU-25.

SU-20

Page 24

REAR SUSPENSION

Removal and Installation

NCSU0031

1. Washer

2. Bushing

3. Shock absorber mounting seal

4. Shock absorber mounting bracket

5. Upper spring seat rubber

6. Bushing

7. Bound bumper cover

8. Bound bumper

9. Coil spring

10. Shock absorber

11. Torsion beam

12. Lateral link

13. Control rod

14. ABS sensor

SRA791AB

SU-21

IDX

Page 25

Removal and Installation (Cont’d)

REAR SUSPENSION

SRA695A

SRA792A

REMOVAL

NCSU0031S01

CAUTION:

! Before removing the rear suspension assembly, discon-

nect the ABS wheel sensor from the assembly. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative.

! Remove suspension assembly.

1. Disconnect parking brake cable from caliper and remove brake caliper and rotor.

Suspend caliper assembly with wire so as not to stretch brake hose. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted.

2. Using a transmission jack, raise torsion beam a little, and remove nuts and bolts from the trailing arm, shock absorber assembly (lower side) and lateral link.

3. Lower transmission jack, and remove suspension.

4. Remove trunk room trim. Refer to BT-32, “Trunk Room”.

5. Remove strut securing nuts (upper side). Then pull out strut assembly.

INSTALLATION

NCSU0031S02

! Install suspension assembly.

CAUTION:

Refill with new brake fluid “DOT 3”. Never reuse drained brake fluid.

1. Attach control rod to lateral link. Do not tighten bolts at this time.

2. Attach lateral link, control rod and torsion beam to vehicle. Do not tighten bolts at this time.

SRA697A

SRA698A

3. Using a transmission jack to lift the torsion beam, place lateral link and control rod horizontally against torsion beam. Tighten bolts and nuts to specified torque.

4. Attach shock absorber assembly to vehicle. Then tighten the upper side of shock absorber assembly.

5. Remove transmission jack and lower torsion beam so that the shock absorber assembly reaches full extension. Tighten torsion beam at trailing arm and lower side of shock absorber assembly to specified torque.

Coil Spring and Shock Absorber

REMOVAL

Remove shock absorber upper and lower fixing nuts.

Do not remove piston rod lock nut on vehicle.

NCSU0032

SU-22

Page 26

REAR SUSPENSION

Coil Spring and Shock Absorber (Cont’d)

SSU028

SSU029

DISASSEMBLY

1. Set shock absorber in vise.

2. Compress spring with Tool so that the shock absorber upper spring seat can be turned by hand.

WARNING:

Make sure that the pawls of the two spring compressors are firmly hooked on the spring. The spring compressors must be tightened alternately so as not to tilt the spring.

3. While holding the piston rod as shown in the left figure, remove the piston rod lock nut.

! Be sure to loosen the piston rod lock nut after compress-

ing the spring. If it is loosened before the spring is compressed, the piston valve nut inside the shock absorber may be loosened.

INSPECTION Shock Absorber Assembly

! Check for smooth operation through a full stroke, both com-

pression and extension.

! Check for oil leakage on welded or gland packing portions. ! Check piston rod for cracks, deformation or other damage.

Replace if necessary.

NCSU0033

NCSU0034

NCSU0034S01

Upper Rubber Seat and Bushing

Check rubber parts for deterioration or cracks. Replace if necessary.

Coil Spring

Check for cracks, deformation or other damage. Replace if necessary.

ASSEMBLY

! Locate upper spring seat as shown.

NCSU0034S02

NCSU0034S03

NCSU0035

IDX

SRA699A

SU-23

Page 27

Coil Spring and Shock Absorber (Cont’d)

SFA436B

REAR SUSPENSION

! When installing coil spring, be careful not to reverse top and

bottom direction. (Top end is flat.)

! When installing coil spring on shock absorber, it must be posi-

tioned as shown in figure at left.

Torsion Beam, Lateral Link and Control Rod

DISASSEMBLY

! Remove torsion beam assembly. Refer to “Removal and

Installation”, “REAR SUSPENSION”, SU-22.

! Remove lateral link and control rod from torsion beam.

NCSU0036

SRA794A

INSPECTION

NCSU0037

! Check for cracks, distortion or other damage. Replace if nec-

essary.

Standard length:

A 207 - 208 mm (8.15 - 8.19 in) B 394 - 395 mm (15.51 - 15.55 in) C 601 - 603 mm (23.66 - 23.74 in) D 106 - 108 mm (4.17 - 4.25 in)

! Check all rubber parts for wear, cracks or deformation.

Replace if necessary.

ASSEMBLY

NCSU0038

1. Temporarily assemble lateral link and control rod.

! When installing the control rod, connect the bush with the

smaller inner diameter to the lateral link.

SRA793A

SU-24

Page 28

REAR SUSPENSION

Torsion Beam, Lateral Link and Control Rod (Cont’d)

2. Temporarily install lateral link and control rod on torsion beam.

! When installing, place lateral link with the arrow topside.

SRA701A

3. Place lateral link and control rod horizontally against torsion beam, and tighten to the specified torque.

4. Install torsion beam assembly. Refer to “Removal and Installation”, “REAR SUSPENSION”, SU-22.

SRA702A

Service Data and Specifications (SDS)

GENERAL SPECIFICATIONS (REAR)

Suspension type Multi-link beam suspension

Shock absorber type Double-acting hydraulic

REAR WHEEL ALIGNMENT (UNLADEN*)

Camber Degree minute (Decimal degree)

Total toe-in Distance (A − B)

mm (in)

Angle (left plus right) Degree minute (Decimal degree)

*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

Minimum −2°03′ (−2.05°)

Nominal −1°18′ (−1.30°)

Maximum −0°33′ (−0.55°)

Minimum 0 (0)

Nominal 4 (0.16)

Maximum 8 (0.31)

Minimum 0′ (0.00°)

Nominal 24′ (0.40°)

Maximum 48′ (0.80°)

NCSU0039

NCSU0040

SU-25

IDX

Page 29

NOTES

Page 30

STEERING SYSTEM

CONTENTS

PRECAUTIONS ...............................................................2

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″ ...............2

Precautions for Steering System.................................2

PREPARATION ...............................................................3

Special Service Tools ..................................................3

Commercial Service Tools ...........................................4

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING.....................................................5

NVH Troubleshooting Chart.........................................5

ON-VEHICLE SERVICE ..................................................6

Checking Steering Wheel Play....................................6

Checking Neutral Position on Steering Wheel ............6

PRE-CHECKING CHECKING

Front Wheel Turning Angle..........................................6

Checking Gear Housing Movement ............................6

Checking and Adjusting Drive Belts ............................7

Checking Fluid Level ...................................................7

Checking Fluid Leakage ..............................................7

Bleeding Hydraulic System..........................................7

Checking Steering Wheel Turning Force ....................8

Checking Hydraulic System.........................................8

STEERING WHEEL AND STEERING COLUMN .........10

Components...............................................................10

Removal and Installation ...........................................10

STEERING WHEEL STEERING COLUMN

........................................................6

...............................................................6

.................................................10

...............................................11

SECTION

Disassembly and Assembly .......................................13

Inspection...................................................................14

TILT MECHANISM

POWER STEERING GEAR AND LINKAGE ................15

Components...............................................................15

Removal and Installation ...........................................16

Disassembly...............................................................18

Inspection...................................................................18

.....................................................................18

BOOT

.....................................................................18

RACK PINION ASSEMBLY GEAR HOUSING CYLINDER TIE-ROD OUTER AND INNER SOCKETS

Assembly ...................................................................19

Adjustment .................................................................24

POWER STEERING OIL PUMP....................................26

Components...............................................................26

Pre-disassembly Inspection.......................................26

Disassembly...............................................................26

Inspection...................................................................27

Assembly ...................................................................28

SERVICE DATA AND SPECIFICATIONS (SDS) .........31

General Specifications...............................................31

Steering Wheel ..........................................................31

Steering Column ........................................................31

Steering Gear and Linkage .......................................32

Power Steering ..........................................................33

...................................................14

.................................................19

....................................19

..................19

IDX

Page 31

PRECAUTIONS

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

The supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to INFINITI G20 is as follows:

! For a frontal collision

The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.

! For a side collision

The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).

Information necessary to service the system safely is included in the RS section of this Service 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 by an authorized INFINITI dealer.

! Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-

sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section.

! Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

Service Manual. Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) covered with yellow insulation tape either just before the harness connectors or for the complete harness are related to the SRS.

NCST0001

Precautions for Steering System

! Before disassembly, thoroughly clean the outside of the unit. ! Disassembly should be done in a clean work area. It is important to prevent the internal parts from

becoming contaminated by dirt or other foreign matter.

! Place disassembled parts in order, on a parts rack, for easier and proper assembly. ! Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might

interfere with their operation.

! Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable

solvent.

! Before assembly, apply a coat of recommended Genuine Nissan PSF-II or equivalent to hydraulic

parts. Vaseline may be applied to O-rings and seals. Do not use any grease.

! Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during instal-

lation. Perform functional tests whenever designated.

NCST0003

ST-2

Page 32

PREPARATION

Special Service Tools

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

Tool number (Kent-Moore No.) Tool name

KV48100700 (J26364) Torque adapter

ST35300000 (—) Drift

KV48102500 (J33914) Pressure gauge adapter

Description

Measuring pinion rotating torque

NT169

Installing power steering oil pump oil seal

a: 59 mm (2.32 in) dia. b: 45 mm (1.77 in) dia.

NT073

Measuring oil pressure

NCST0004

ST27180001 (J41777) Steering wheel puller

HT72520000 (J25730-B) Ball joint remover

KV48103500 (J26357 and J26357-

10) Pressure gauge

NT542

NT544

NT546

Removing steering wheel

Removing ball joint

a: 33 mm (1.30 in) b: 50 mm (1.97 in) r: R11.5 mm (0.453 in)

Measuring oil pressure

KV48104400 (—) Rack seal ring reformer

NT547

NT550

ST-3

Reforming teflon ring

a: 50 mm (1.97 in) dia. b: 36 mm (1.42 in) dia. c: 100 mm (3.94 in)

IDX

Page 33

Special Service Tools (Cont’d)

Tool number (Kent-Moore No.) Tool name

Description

PREPARATION

ST3127S000 1 GG91030000 (See J25765-A) Torque wrench 2 HT62940000 (—) Socket adapter 3 HT62900000 (—) Socket adapter

(J-44372) Spring gauge

(J-44183-A) Spring gauge

Tool number Description

NT541

NT127

Measuring turning torque

Measuring steering wheel turning force

Measuring rack sliding force

Commercial Service Tools

NCST0005

Rear oil seal drift

Pinion oil seal drift

Oil pump attachment

Installing rear oil seal

a: 28 mm (1.10 in) dia.

NT063

Installing pinion oil seal

a: 35 mm (1.38 in) dia.

NT063

Disassembling and assembling oil pump Unit: mm (in)

NT179

ST-4

Page 34

×: Applicable

Judder ×××××××

Symptom STEERING

Noise ЧЧЧЧЧЧЧЧЧ ЧЧЧЧЧЧ

Shake ××× ЧЧЧЧЧЧ

Vibration ЧЧЧЧЧ ××××

Shimmy ××× × ЧЧЧЧЧ

SUSPECTED PARTS

Possible cause and

Reference page

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

ST-5

Fluid level

Air in hydraulic system

Tie-rod ball joint swinging force

Tie-rod ball joint rotating torque

Tie-rod ball joint end play

Steering gear fluid leakage

Steering wheel play

Steering gear rack sliding force

Drive belt looseness

Improper steering wheel

Improper installation or looseness or tilt lock lever

Mounting rubber deterioration

Steering column deformation or damage

Improper installation or looseness of steering column

Steering linkage looseness

DRIVE SHAFT

AXLE

SUSPENSION

TIRES

ROAD WHEEL

BRAKES

ST-7

ST-19

ST-7

ST-6

ST-8

MA-13

—

ST-10

ST-6

ST-14

ST-13

ST-15

AX-3

SU-3

BR-6

NVH Troubleshooting Chart

NCST0006S01

NCST0006

IDX

Page 35

Checking Steering Wheel Play

ON-VEHICLE SERVICE

SST489B

SST490BA

Checking Steering Wheel Play

NCST0007

! With wheels in a straight-ahead position, check steering wheel

play.

Steering wheel play:

35 mm (1.38 in) or less

! If it is not within specification, check the following for loose or

worn components.

Steering gear assembly Steering column Front suspension and axle

Checking Neutral Position on Steering Wheel

PRE-CHECKING

NCST0008

NCST0008S01

! Make sure that wheel alignment is correct.

Wheel alignment:

Refer to SU-15, SDS.

! Verify that the steering gear is centered before removing the

steering wheel.

CHECKING

NCST0008S02

1. Check that the steering wheel is in the neutral position when driving straight ahead.

2. If it is not in the neutral position, remove the steering wheel and reinstall it correctly.

3. If the neutral position is between two teeth, loosen tie-rod lock nuts. Turn the tie-rods by the same amount in opposite directions on both left and right sides.

SMA127

SST663B

Front Wheel Turning Angle

NCST0009

1. Rotate steering wheel all the way right and left; measure turning angle.

Turning angle of full turns:

Refer to SU-15, SDS.

2. If it is not within specification, check rack stroke.

Rack stroke “S”:

Refer to SDS, ST-32.

Checking Gear Housing Movement

NCST0010

1. Check the movement of steering gear housing during stationary steering on a dry paved surface.

! Apply a force of 49 N (5 kg, 11 lb) to steering wheel to check

the gear housing movement. Turn off ignition key while checking.

Movement of gear housing:

±2 mm (±0.08 in) or less

2. If movement exceeds the limit, replace mount insulator after confirming proper installation of gear housing clamps.

ST-6

Page 36

ON-VEHICLE SERVICE

Checking and Adjusting Drive Belts

SST476C

SST477C

Checking and Adjusting Drive Belts

Refer to MA-13, “Checking Drive Belts”.

Checking Fluid Level

Check fluid level, referring to the scale on reservoir tank. Use “HOT” range for fluid temperatures of 50 to 80°C (122 to 176°F). Use “COLD” range for fluid temperatures of 0 to 30°C (32 to 86°F).

CAUTION:

! Do not overfill. ! Recommended fluid is Genuine Nissan PSF-II or equiva-

lent.

Checking Fluid Leakage

Check the lines for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration.

1. Run engine between idle speed and 1,000 rpm.

Make sure temperature of fluid in oil tank rises to 60 to 80°C (140 to 176°F).

2. Turn steering wheel right-to-left several times.

3. Hold steering wheel at each “lock” position for five seconds and carefully check for fluid leakage.

CAUTION:

Do not hold the steering wheel in a locked position for more than 15 seconds.

4. If fluid leakage at connectors is noticed, loosen flare nut and then retighten.

Do not overtighten connector as this can damage O-ring, washer and connector.

5. If fluid leakage from power steering pump is noticed, check power steering pump. Refer to ST-26.

6. Check rack boots for accumulation of power steering fluid.

NCST0011

NCST0012

NCST0013

Bleeding Hydraulic System

1. Raise front end of vehicle until wheels are clear of the ground.

2. Add fluid into oil tank to specified level. Then quickly turn steering wheel fully to right and left and lightly touch steering stoppers. Repeat steering wheel operation until fluid level no longer decreases.

3. Start engine. Repeat step 2. above.

! Incomplete air bleeding will cause the following to occur. When

this happens, bleed air again.

NCST0014

ST-7

IDX

Page 37

Bleeding Hydraulic System (Cont’d)

ON-VEHICLE SERVICE

a) Air bubbles in reservoir tank b) Clicking noise in oil pump c) Excessive buzzing in oil pump Fluid noise may occur in the valve or oil pump. This is common

when the vehicle is stationary or while turning the steering wheel slowly. This does not affect the performance or durability of the system.

SST491B

SST090B

Checking Steering Wheel Turning Force

NCST0015

1. Park vehicle on a level, dry surface and set parking brake.

2. Start engine.

3. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is approximately 60 to 80°C (140 to 176°F).]

Tires need to be inflated to normal pressure.

4. Check steering wheel turning force when steering wheel has been turned 360° from the neutral position.

Steering wheel turning force:

39 N (4 kg, 9 lb) or less

5. If steering wheel turning force is out of specification, check rack sliding force.

a. Disconnect steering column lower joint and knuckle arms from

the gear.

b. Start and run engine at idle to make sure steering fluid has

reached normal operating temperature.

c. Pull tie-rod slowly to move it from neutral position to ±11.5 mm

(±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack sliding force is within specification.

Average rack sliding force:

167 - 226 N (17 - 23 kg, 37 - 51 lb)

Maximum force deviation:

98 N (10 kg, 22 lb)

d. Check sliding force outside the above range.

Rack sliding force:

Not more than 294 N (30 kg, 66 lb)

6. If rack sliding force is not within specification, overhaul steering gear assembly.

7. If rack sliding force is OK, inspect steering column. Refer to ST-13.

SST834-F

Checking Hydraulic System

NCST0016

Before starting, check belt tension, driving pulley and tire pressure.

1. Set Tool. Open shut-off valve. Then bleed air. Refer to “Bleeding Hydraulic System”, ST-7.

2. Run engine at idle speed or 1,000 rpm.

Make sure temperature of fluid in tank rises to 60 to 80°C (140 to 176°F).

ST-8

Page 38

ON-VEHICLE SERVICE

Checking Hydraulic System (Cont’d)

WARNING:

Warm up engine with shut-off valve fully opened. If engine is started with shut-off valve closed, fluid pressure in oil pump increases to maximum. This will raise oil temperature abnormally.

3. Check pressure with steering wheel fully turned to left and right positions with engine idling at 1,000 rpm.

CAUTION:

Do not hold the steering wheel in a locked position for more than 15 seconds.

Oil pump maximum standard pressure:

8,140 - 8,728 kPa (83 - 89 kg/cm

! If pressure reaches maximum operating pressure, system is

OK.

! If pressure increases above maximum operating pressure,

check power steering pump flow control valve. Refer to ST-26.

4. If power steering pressure is below the maximum operating pressure, slowly close shut-off valve and check pressure again.

CAUTION:

Do not close shut-off valve for more than 15 seconds.

! If pressure increases to maximum operating pressure, gear is

damaged. Refer to “Removal and Installation”, ST-16.

! If pressure remains below maximum operating pressure, pump

is damaged. Refer to “Disassembly”, ST-26.

5. After checking hydraulic system, remove Tool and add fluid as necessary. Then completely bleed air out of system. Refer to ST-7.

, 1,180 - 1,266 psi)

IDX

ST-9

Page 39

Components

STEERING WHEEL AND STEERING COLUMN

Components

NCST0017

1. Air bag module

2. Steering wheel

3. Spiral cable

4. Column cover

5. Combination switch

6. Steering column assembly

7. Lower joint

8. Boot

9. Clip

CAUTION:

! The rotation of the spiral cable (SRS “AIR BAG” compo-

nent part) is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed.

! Remove the steering wheel before removing the steering

lower joint to avoid damaging the SRS spiral cable.

Removal and Installation

STEERING WHEEL

! Remove air bag module and spiral cable.

Refer to RS-20, “Removal — Air Bag Module and Spiral Cable”.

SST819C

NCST0018

NCST0018S01

SBF812E

ST-10

Page 40

STEERING WHEEL AND STEERING COLUMN

Removal and Installation (Cont’d)

! Align spiral cable correctly when installing steering wheel. a) Set the front wheels in the straight-ahead position. b) Make sure that the spiral cable is in the neutral position.

The neutral position is detected by turning left 2.5 revolutions from the right end position. Align the two marks (

CAUTION:

The spiral cable may snap due to steering operation if the cable is installed in an improper position. Also, with the steering linkage disconnected, the cable may snap by turning the steering wheel beyond the limited number of turns. (The spiral cable can be turned up to 2.5 turns from the neutral position to both the right and left.)

SRS266

SST818C

SST329C

! Remove steering wheel with Tool.

STEERING COLUMN

! Remove key interlock cable (A/T models).

! When installing steering column, fingertighten all lower bracket

and clamp retaining bolts; then tighten them securely. Do not apply undue stress to steering column.

! When attaching coupling joint, be sure tightening bolt faces

cutout portion.

NCST0018S02

SST800A

IDX

ST-11

Page 41

STEERING WHEEL AND STEERING COLUMN

Removal and Installation (Cont’d)

! Align slit of lower joint with projection on dust cover. Insert joint

until surface A contacts surface B.

CAUTION:

After installation, turn steering wheel to make sure it moves smoothly. Ensure the number of turns are the same from the straight forward position to left and right locks. Be sure that the steering wheel is in a neutral position when driving straight ahead.

SST491C

ST-12

Page 42

STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly

1. Combination switch

2. Snap ring

3. Washer

Disassembly and Assembly

4. O-ring

5. Jacket tube assembly

6. Spring

SST698C

7. Steering column lower cover

8. Column shaft assembly

=NCST0019

SST670B

! When disassembling and assembling, unlock steering lock

with key.

! Remove combination switch. ! Ensure that rounded surface of snap ring faces toward bear-

ing when snap ring is installed.

! Install snap ring on upper shaft with a suitable tool.

! Steering lock

a) Break self-shear type screws with a drill or other appropriate

tool.

SST741A

IDX

ST-13

Page 43

STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly (Cont’d)

b) Install new self-shear type screws and then cut off self-shear

type screw heads.

SST742A

SST334C

Inspection

NCST0020

! When steering wheel does not turn smoothly, check the steer-

ing column as follows and replace damaged parts.

a) Check column bearings for damage or unevenness. Lubricate

with recommended multi-purpose grease or replace steering column as an assembly, if necessary.

b) Check jacket tube for deformation or breakage. Replace if

necessary.

! When the vehicle comes into a light collision, check length “L”.

Column length “L”:

535.9 - 538.1 mm (21.10 - 21.18 in)

If out of the specifications, replace steering column as an assembly.

TILT MECHANISM

NCST0020S01

! After installing steering column, check tilt mechanism opera-

tion.

SST582B

ST-14

Page 44

POWER STEERING GEAR AND LINKAGE

Components

NCST0021

1. Rear cover cap

2. Rear housing assembly

3. Pinion seal ring

4. Pinion assembly

5. O-ring

6. Shim

7. Pinion oil seal

8. Lock nut

9. Adjusting screw

10. Spring

11. Spring disc

12. Washer

13. Spring seat

14. Retainer

15. Gear housing

16. Center bushing

17. Rack oil seal

18. Rack assembly

19. Rack seal ring

20. O-ring

21. Rack oil seal

22. End cover assembly

23. Boot clamp

24. Dust boot

25. Boot band

26. Lock plate

27. Tie-rod inner socket

28. Tie-rod outer socket

29. Cotter pin

30. Gear housing tube

31. Spacer

SST820CA

IDX

ST-15

Page 45

Removal and Installation

POWER STEERING GEAR AND LINKAGE

Removal and Installation

NCST0022

1. Lower joint

2. Hole cover

3. Insulator bracket

4. Rear cover cap

5. Gear and linkage assembly

6. Rack mounting insulator

CAUTION:

! The rotation of the spiral cable (SRS “AIR BAG” compo-

nent part) is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed.

! Remove the steering wheel before removing the steering

lower joint to avoid damaging the SRS spiral cable.

! Detach tie-rod outer sockets from knuckle arms with Tool. ! When disconnecting steering shaft lower joint, follow the pro-

SFA455BC

cedure shown below.

1. Remove nuts for fitting the hole cover.

2. Disconnect the lower joint while shifting the hole cover.

SST835C

7. Gear housing mounting bracket

8. Cotter pin

9. Clamp

ST-16

Page 46

POWER STEERING GEAR AND LINKAGE

Removal and Installation (Cont’d)

! Install pipe connector. ! Observe specified tightening torque when tightening high-pres-

sure and low-pressure pipe connectors. Excessive tightening will damage threads of connector or O-ring.

Connector tightening torque:

1 Low-pressure side

27 - 39 N·m (2.8 - 4.0 kg-m, 20 - 29 ft-lb)

2 High-pressure side

15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb)

SST710CA

! The O-ring in low-pressure pipe connector is larger than that

in high-pressure connector. Take care to install the proper O-ring.

SST824A

SST819A

! Initially, tighten nut on tie-rod outer socket and knuckle arm to

29 to 39 N·m (3 to 4 kg-m, 22 to 29 ft-lb). Then tighten further to align nut groove with first pin hole so that cotter pin can be installed.

CAUTION:

Tightening torque must not exceed 49 N·m (5 kg-m, 36 ft-lb).

! Before removing lower joint from gear, set gear in neutral

(wheels in straight-ahead position). After removing lower joint, put matching mark on pinion shaft and pinion housing to record neutral position.

! To install, set left and right dust boots to equal deflection.

Attach lower joint by aligning matching marks of pinion shaft and pinion housing.

! Tighten gear housing mounting bracket bolts in the order

shown.

SST677B

IDX

ST-17

Page 47

Disassembly

POWER STEERING GEAR AND LINKAGE

SST718CB

SST051C

Disassembly

NCST0023

1. Prior to disassembling, measure pinion rotating torque. Record the pinion rotating torque as a reference.

! Before measuring, disconnect gear housing tube and

drain fluid.

! Use soft jaws when holding steering gear housing. Handle

gear housing carefully, as it is made of aluminum. Do not grip cylinder in a vise.

2. Remove pinion gear.

Be careful not to damage pinion gear when removing pinion seal ring.

3. Remove tie-rod outer sockets and boots.

4. Loosen tie-rod inner socket by prying up staked portion, and remove socket.

5. Remove retainer.

6. Remove pinion assembly.

7. Use a 2 to 2.5 mm (0.079 to 0.098 in) diameter drill to completely remove staked portion of gear housing end.

8. Remove end cover assembly with a suitable tool.

9. Draw out rack assembly.

10. Remove rack seal ring.

! Using a heat gun, heat rack seal to approximately 40°C

(104°F).

! Remove rack seal ring.

Be careful not to damage rack.

SST052C

SST472A

11. Remove center bushing and rack oil seal using tape wrapped socket and extension bar.

Do not scratch inner surfaces of pinion housing.

Inspection

NCST0024

Thoroughly clean all parts in cleaning solvent or Genuine Nissan PSF-II or equivalent. Blow dry with compressed air, if available.

BOOT

NCST0024S01

! Check condition of boot. If cracked excessively, replace it. ! Check boots for accumulation of power steering fluid.

RACK

NCST0024S02

Thoroughly examine rack gear. If damaged, cracked or worn, replace it.

ST-18

Page 48

POWER STEERING GEAR AND LINKAGE

Inspection (Cont’d)

SST468C

PINION ASSEMBLY

! Thoroughly examine pinion gear. If pinion gear is damaged,

cracked or worn, replace it.

! Check that all bearings roll freely. Ensure that balls, rollers and

races are not cracked, pitted or worn. Replace if necessary.

GEAR HOUSING CYLINDER

Check gear housing cylinder bore for scratches or other damage. Replace if necessary.

TIE-ROD OUTER AND INNER SOCKETS

! Check ball joints for swinging force.

Tie-rod outer and inner ball joints swinging force “A”:

Refer to SDS, ST-32.

! Check ball joint for rotating torque.

Tie-rod outer ball joint rotating torque “B”:

Refer to SDS, ST-32.

! Check ball joints for axial end play.

Tie-rod outer and inner ball joints axial end play “C”:

Refer to SDS, ST-32.

! Check condition of dust cover. If cracked excessively, replace

outer tie-rod.

NCST0024S03

NCST0024S04

NCST0024S05

SST083B

Assembly

1. Using a heat gun, heat new teflon rack seal ring to approximately 40°C (104°F). Then place it onto rack.

2. Using Tool, compress rack seal ring securely onto rack.

Always insert Tool from the rack gear side.

NCST0025

SST885BB

IDX

ST-19

Page 49

Assembly (Cont’d)

POWER STEERING GEAR AND LINKAGE

3. Insert new rack oil seal.

! Place plastic film into rack oil seal to prevent damage by

rack teeth.

! Do not forget to remove plastic film after rack oil seal is

positioned properly.

! Make sure lips of rack oil seal face each other.

SST201A

4. Install center bushing and rack oil seal with rack assembly.

SST830A

SST321B

SST073B

5. Insert rack oil seal and end cover assembly to rack. Then tighten end cover assembly.

6. Fasten end cover assembly to gear housing by staking.

7. Set rack gear in neutral position.

Rack stroke “S”:

Refer to SDS, ST-32.

SST086BA

ST-20

Page 50

POWER STEERING GEAR AND LINKAGE

8. Coat seal lip of new pinion oil seal with multi-purpose grease. Install it into pinion housing of gear with a suitable tool.

Make sure lip of oil seal faces up when installed.

Assembly (Cont’d)

SST381A

SST074B

SST085B

9. Install pinion bearing adjusting shim(s).

! Whenever pinion assembly, gear housing and rear housing are

disassembled, replace shim(s) with new ones. Always use the same number of shim(s) when replacing.

10. Install new pinion seal ring (made of Teflon) on pinion gear assembly.

! Using a heat gun, heat pinion seal ring to approximately 40°C

(104°F) before installing it onto pinion gear assembly.

! Make sure pinion seal ring is properly settled in valve groove.

11. Apply a coat of multi-purpose grease to needle bearing roller and oil seal lip.

SST075B

SST552

12. Install pinion assembly to rear housing.

Be careful not to damage pinion oil seal.

ST-21

IDX

Page 51

Assembly (Cont’d)

POWER STEERING GEAR AND LINKAGE

13. Apply a coat of multi-purpose grease to new rear oil seal lip before installing rear housing.

SST133C

14. Ensure that the rack is centered. Install rear cover cap so that its protrusion is positioned as shown in figure.

Be careful not to damage worm ring and oil seal.

SST507C

SST087B

SST327BA

15. Install diaphragm spring into gear housing.

! Always install retainer, spring washer and diaphragm spring in

that order.

! Make sure convex end (painted white) of diaphragm spring

faces outward when installing.

16. Install retainer spring and adjusting screw temporarily.

17. Install new lock plate.

a. Attach lock plate 2 to side rod inner socket 1. b. Insert steering gear spacer 5 to rack 4. c. Apply locking sealant to inner socket threads 3.

Screw inner socket into rack 4 and tighten to specified torque.

d. Stake lock plate at two places.

CAUTION:

! To prevent scratching the boot, remove burrs from lock

plate.

! Ensure steering gear spacer is installed with rubber side

facing rack.

18. Tighten outer socket lock nut.

Tie-rod length “L”:

Refer to SDS, ST-32.

SST093B

ST-22

Page 52

POWER STEERING GEAR AND LINKAGE

19. Measure rack stroke.

Rack stroke “S”:

Refer to SDS, ST-32.

Assembly (Cont’d)

SST086BA

SST967A

SST440A

20. Before installing boot, coat the contact surfaces between boot and tie-rod with grease.

21. Install boot clamps.

! To install, wrap boot clamp around boot groove twice. To

tighten clamp, place a screwdriver through both rings. Twist rings 4 to 4-1/2 turns while pulling with a force of approx. 98 N (10 kg, 22 lb).

! Twist boot clamp in the direction shown in figure at left.

! Locate twisted end of boot clamp in the range shown. (This will

prevent interference with other parts.)

SST509C

SST126B

! After twisting boot clamp, bend twisted and diagonally so it

does not contact boot.

ST-23

IDX

Page 53

Adjustment

POWER STEERING GEAR AND LINKAGE

SST719C

SST718CB

Adjustment

NCST0026

Adjust pinion rotating torque as follows:

1. Set rack to the neutral position without fluid in the gear.

2. Coat the adjusting screw with locking sealant and screw it in.

3. Lightly tighten lock nut.

4. Tighten adjusting screw to a torque of 4.9 to 5.9 N·m (50 to 60 kg-cm, 43 to 52 in-lb).

5. Loosen adjusting screw, then retighten it to 0.2 N·m (2 kg-cm,

1.7 in-lb).

6. Move rack over its entire stroke several times.

7. Measure pinion rotating torque within the range of 180° from neutral position. Stop the gear at the point of maximum torque.

8. Loosen adjusting screw, then retighten it to 4.9 N·m (50 kg-cm, 43 in-lb).

9. Loosen adjusting screw by 70° to 110°.

10. Prevent adjusting screw from turning, and tighten lock nut to specified torque.

SST713C

SST090B

11. Check rack sliding force on vehicle as follows:

a. Install steering gear onto vehicle, but do not connect tie-rod to

knuckle arm.

b. Connect all piping and fill with steering fluid. c. Start engine and bleed air completely. d. Disconnect steering column lower joint from the gear. e. Keep engine at idle and make sure steering fluid has reached

normal operating temperature.

f. Pull tie-rod slowly to move it from neutral position to ±11.5 mm

(±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack sliding force is within specification.

Average rack sliding force:

167 - 226 N (17 - 23 kg, 37 - 51 lb)

Maximum force deviation:

98 N (10 kg, 22 lb)

g. Check sliding force outside above range at rack speed of 40

mm (1.57 in)/s.

Maximum rack sliding force:

294 N (30 kg, 66 lb)

Maximum force deviation:

147 N (15 kg, 33 lb)

ST-24

Page 54

POWER STEERING GEAR AND LINKAGE

! If rack sliding force is not within specification, readjust by

repeating adjustment procedure from the beginning.

! If rack sliding force is still out of specification after

readjustment, gear assembly needs to be replaced.

Adjustment (Cont’d)

ST-25

IDX

Page 55

Components

POWER STEERING OIL PUMP

1. Pulley

2. Front bracket

3. Oil seal

4. Suction pipe

5. O-ring

6. Casing

7. Flow control valve spring

Components

8. Flow control A valve

9. Dowel pin

10. Flow control B valve assembly

11. Side plate (Front)

12. Cam ring

13. Rotor

14. Vane

NCST0037

JST938E

15. Snap ring

16. Side plate (Rear)

17. Side plate inner seal

18. Side plate outer seal

19. O-ring

20. Rear cover

SST925C

Pre-disassembly Inspection

NCST0038

Disassemble the power steering oil pump only if the following items are found.

! Oil leak from any point shown in the figure. ! Deformed or damaged pulley. ! Poor performance.

Disassembly

NCST0039

CAUTION:

! Parts which can be disassembled are strictly limited.

Never disassemble parts other than those specified.

! Disassemble in as clean a place as possible. ! Clean your hands before disassembly. ! Do not use rags; use nylon cloths or paper towels. ! Follow the procedures and cautions in the Service

Manual.

! When disassembling and reassembling, do not let foreign

matter enter or contact the parts.

ST-26

Page 56

POWER STEERING OIL PUMP

1. Fix power steering pump to vise.

CAUTION:

When fixing the pump to vise, use an aluminum plate or such to avoid damaging the fitting plane of the steering pump.

2. Remove the front bracket mounting bolt, and remove the front bracket from the casing.

3. Remove the rear cover mounting bolt, and remove the rear cover from the casing.

4. Remove the O-ring from the casing.

5. Remove side plate (rear side) from cam ring, then remove side plate inner/outer seals from side plate (rear side).

6. Remove rotor snap ring using snap ring pliers, and remove pulley from casing.

CAUTION:

Do not damage pulley shaft when removing rotor snap ring.

Disassembly (Cont’d)

SST926C

SST928C

7. Remove the followings from casing.

! Cam ring ! Rotor ! Vane ! Side plate (front side) ! Flow control A valve ! Flow control valve spring ! Flow control B valve assembly

CAUTION:

Be careful not to drop flow control valve.

8. Remove inlet connector mounting bolt, and remove inlet connector from casing.

9. Remove inlet connector seal from inlet connector.

10. Remove drive shaft seal from casing with a screwdriver.

CAUTION:

Do not damage casing surface with the screwdriver.

Inspection

! If pulley is cracked or deformed, replace it. ! If an oil leak is found around pulley shaft oil seal, replace the

seal.

! Check the casing and the inside of the rear body for damage.

If damages are found in the rear body, replace the entire rear body. If the casing is damaged, replace the entire power steering pump as an assembly.

! Check the cam ring for damage. If damage is found, replace

the cam ring, rotor and vane as a set.

! Check the side plates (front and rear) for damage. If damage

NCST0040

ST-27

IDX

Page 57

Inspection (Cont’d)

POWER STEERING OIL PUMP

is found, replace the side plates as a set (front and rear).

SST934C

SST928C

Assembly

NCST0041

1. Apply grease to the lip of the drive shaft seal, and attach the casing.

CAUTION:

The drive shaft seal cannot be reused. Always replace after every disassembly.

2. When removing the dowel pin, if it is difficult to insert with your hands, insert into the casing by tapping lightly with a hammer or similar tool.

3. Attach the flow control A valve, flow control valve spring, and the flow control B valve assembly to the locations indicated in the drawing left.

4. Match the dowel pin A on the flow control A valve side with the notch B of the side plate (front), and attach the side plate (front) to the casing.

SST929C

SST930C

5. Face the cam ring side with fewer pores towards the casing, and attach the cam ring on top of the side plate (front).

6. Attach the pulley to the casing.

CAUTION:

Attach with care so as not to damage the drive shaft seal.

ST-28

Page 58

POWER STEERING OIL PUMP

7. Face the side of the rotor with the punch mark towards the casing, and attach the rotor to the pulley shaft.

Assembly (Cont’d)

SST289A

SST843A

SST931C

8. Attach the vane to the rotor so that the vane’s arc touches the cam ring.

9. Use a hammer or suitable tool to insert the rotor snap ring into the pulley shaft channel.

CAUTION:

! The rotor snap ring cannot be reused. Always replace after

every disassembly.

! Insert with care so as not to damage the rotor or the pul-

ley shaft.

! If the rotor is damaged, replace the power steering as an

assembly.

10. Match the dowel pin A on the flow control A valve side with the notch B of the side plate (rear), and attach the side plate (rear) to the cam ring.

11. Apply Genuine Nissan PSF II or equivalent to O-ring and attach to the casing.

CAUTION:

The O-ring cannot be reused. Always replace after every disassembly.

SST932C

SST933C

12. Attach a side plate inner seal and side plate outer seal with Genuine Nissan PSF II or equivalent applied, to the side plate (rear).

CAUTION:

The side plate inner seal and outer seal cannot be reused. Always replace after every disassembly.

13. Set the power steering pump on the vice.

CAUTION:

When securing to the vice, use an aluminum plate or other material to protect the installation surface of the power steering pump from damage.

ST-29

IDX

Page 59

Assembly (Cont’d)

POWER STEERING OIL PUMP

14. Attach the rear body to the casing, and secure the bolts (4 bolts) in a diagonal order to the specified torque.

15. Attach the front bracket to the casing, and secure the bolts (2 bolts) to the specified torque.

16. Attach the inlet collector seal to the grooves of the inlet collector, and attach the inlet collector to the casing with attachment bolts.

CAUTION:

The inlet collector seal cannot be reused. Always replace after every disassembly.

ST-30

Page 60

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

Steering model Power steering

Steering gear type PR24AC

Steering overall gear ratio 17.7

Turns of steering wheel (Lock to lock) 2.84

Steering column type Collapsible, tilt

Steering Wheel

Steering wheel axial play mm (in) 0 (0)

Steering wheel play mm (in) 35 (1.38) or less

Movement of gear housing mm (in) ±2(±0.08) or less

Steering Column

Applied model All

Steering column length “L” mm (in) 535.9 - 538.1 (21.10 - 21.18)

NCST0032

NCST0033

NCST0034

SST334C

ST-31

IDX

Page 61

Steering Gear and Linkage

SERVICE DATA AND SPECIFICATIONS (SDS)

Steering Gear and Linkage

Applied model All

Steering gear type PR24AC

Swinging force at cotter pin hole: “A” N (kg, lb) 6.9 - 65.7 (0.7 - 6.7, 1.5 - 14.8)

Tie-rod outer ball joint

Tie-rod inner ball joint

Tie-rod standard length “L” mm (in) 158.6 (6.24)

*: Measuring point [!: 170 mm (6.69 in)]

Rotating torque: “B” N·m (kg-cm, in-lb) 0.29 - 2.94 (3.0 - 30.0, 2.6 - 26.0)

Axial end play: “C” mm (in) 0.5 (0.020) or less

Swinging force*: “A” N (kg, lb) 5.9 - 46.1 (0.6 - 4.7, 1.3 - 10.4)

Axial end play: “C” mm (in) 0.2 (0.004) or less

NCST0035

Initial tightening torque N·m (kg-cm, in-lb) 4.9 - 5.9 (50 - 60, 43 - 52)

Retightening torque after loosening N·m (kg-cm,

Retainer adjustment Adjusting screw

Steering gear type PR24AC

Rack stroke “S” mm (in) 66.0 (2.60)

in-lb)

Tightening torque after gear has settled N·m (kg-cm, in-lb)

Returning angle degree 40° - 60°

0.2 (2, 1.7)

4.9 - 5.9 (50 - 60, 43 - 52)

SST488C

SST086BA

ST-32

Page 62

SERVICE DATA AND SPECIFICATIONS (SDS)

Power Steering

Applied model All

Steering gear type PR24AC

Range within ±11.5 mm (±0.453 in)

Rack sliding force N (kg, lb) Under normal operating oil pressure

Steering wheel turning force (Measured at one full turn from the neutral position) N (kg, lb)

Fluid capacity (Approximate) ! (US qt, Imp qt) 0.9 (1, 3/4)

Oil pump maximum pressure kPa (kg/cm

from the neutral position at rack speed of 3.5 mm (0.138 in)/s

Except for the above range

, psi)

Average force 167 - 226 (17 - 23, 37 - 51)

Maximum force deviation 98 (10, 22)

Maximum sliding force 294 (30, 66)

Maximum force deviation 147 (15, 33)

39 (4, 9) or less

8,140 - 8,728 (83 - 89, 1,180 -

1,266)

NCST0036

ST-33

IDX

Page 63

NOTES

Page 64

STARTING & CHARGING SYSTEM

CONTENTS

PRECAUTIONS ...............................................................2

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″ ...............2

Wiring Diagrams and Trouble Diagnosis.....................2

PREPARATION ...............................................................3

Special Service Tool ....................................................3

BATTERY.........................................................................4

How to Handle Battery ................................................4

METHODS OF PREVENTING OVER-DISCHARGE CHECKING ELECTROLYTE LEVEL SPECIFIC GRAVITY CHECK CHARGING THE BATTERY

Trouble Diagnoses with Battery/Starting/Charging

System Tester ..............................................................7

DIAGNOSTIC RESULT ITEM CHART

STARTING SYSTEM .....................................................10

System Description....................................................10

M/T MODELS A/T MODELS

Wiring Diagram - START -......................................... 11

M/T MODELS A/T MODELS

Trouble Diagnoses with Battery/Starting/Charging

System Tester ............................................................13

DIAGNOSTIC RESULT ITEM CHART WORK FLOW

..........................................................10

...........................................................10

..........................................................11

...........................................................12

..........................................................15

........................................6

............................4

......................................5

..........................9

........................14

......4

SECTION

DIAGNOSTIC PROCEDURE 1 DIAGNOSTIC PROCEDURE 2 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE

Construction...............................................................19

Removal and Installation ...........................................19

Pinion/Clutch Check ..................................................20

CHARGING SYSTEM ....................................................21

System Description....................................................21

Wiring Diagram - CHARGE -.....................................22

Trouble Diagnoses with Battery/Starting/Charging

System Tester ............................................................23

DIAGNOSTIC RESULT ITEM CHART WORK FLOW DIAGNOSTIC PROCEDURE 1 DIAGNOSTIC PROCEDURE 2 DIAGNOSTIC PROCEDURE 3 MALFUNCTION INDICATOR

Construction...............................................................30

Removal and Installation ...........................................30

SERVICE DATA AND SPECIFICATIONS (SDS) .........31

Battery........................................................................31

Starter ........................................................................31

Alternator ...................................................................31

......................................................19

..........................................................26

..................................16

..................................18

........................25

..................................27

..................................28

..................................29

....................................29

IDX

Page 65

PRECAUTIONS

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to INFINITI G20 is as follows:

! For a frontal collision

! For a side collision

Information necessary to service the system safely is included in the RS section of this Service 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 by an authorized INFINITI dealer.

! Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-

sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section.

! Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

NCSC0001

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the following:

! GI-11, “HOW TO READ WIRING DIAGRAMS” ! EL-9, “POWER SUPPLY ROUTING” for power distribution circuit

When you perform trouble diagnosis, refer to the following:

! GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” ! GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”

NCSC0002

SC-2

Page 66

PREPARATION

Special Service Tool

Tool number Tool name

J-44373 Model 620 Battery/Starting/Charging system tester

Description

SEL403X

Special Service Tool

NCSC0017

SC-3

IDX

Page 67

How to Handle Battery

BATTERY

MEL040F

How to Handle Battery

NCSC0003

CAUTION:

! If it becomes necessary to start the engine with a booster

battery and jumper cables, use a 12-volt booster battery.

! After connecting battery cables, ensure that they are

tightly clamped to battery terminals for good contact.

! Never add distilled water through the hole used to check

specific gravity.

METHODS OF PREVENTING OVER-DISCHARGE

NCSC0003S01

The following precautions must be taken to prevent over-discharging a battery.

! The battery surface (particularly its top) should always be kept

clean and dry.

! The terminal connections should be clean and tight. ! At every routine maintenance, check the electrolyte level.

This also applies to batteries designated as “low maintenance” and “maintenance-free”.

! When the vehicle is not going to be used over a long period of

time, disconnect the negative battery terminal. (If the vehicle has an extended storage switch, turn it off.)

MEL041F

MEL042F

! Check the charge condition of the battery.

Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent over-discharge.

CHECKING ELECTROLYTE LEVEL

NCSC0003S02

WARNING:

Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touching a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid contacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.

SC-4

Page 68

BATTERY

How to Handle Battery (Cont’d)

! Remove the cell plug using a suitable tool. ! Add distilled water up to the MAX level.

MEL043F

SEL709E

MEL042FA

Sulphation

A battery will be completely discharged if it is left unattended for a long time and the specific gravity will become less than

1.100. This may result in sulphation on the cell plates.

To determine if a battery has been “sulphated”, note its voltage and current when charging it. As shown in the figure, less current and higher voltage are observed in the initial stage of charging sulphated batteries. A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test.

SPECIFIC GRAVITY CHECK

1. Read hydrometer and thermometer indications at eye level.

2. Use the chart below to correct your hydrometer reading according to electrolyte temperature.

NCSC0003S0201

NCSC0003S03

Hydrometer Temperature Correction

Battery electrolyte temperature °C (°F) Add to specific gravity reading

71 (160) 0.032

66 (150) 0.028

60 (140) 0.024

54 (130) 0.020

49 (120) 0.016

43 (110) 0.012

38 (100) 0.008

32 (90) 0.004

27 (80) 0

21 (70) −0.004

16 (60) −0.008

10 (50) −0.012

NCSC0003S0301

SC-5

IDX

Page 69

How to Handle Battery (Cont’d)

BATTERY

Battery electrolyte temperature °C (°F) Add to specific gravity reading

4 (40) −0.016

−1 (30) −0.020

−7 (20) −0.024

−12 (10) −0.028

−18 (0) −0.032

Corrected specific gravity Approximate charge condition

1.260 - 1.280 Fully charged

1.230 - 1.250 3/4 charged

1.200 - 1.220 1/2 charged

1.170 - 1.190 1/4 charged

1.140 - 1.160 Almost discharged

1.110 - 1.130 Completely discharged

CHARGING THE BATTERY

NCSC0003S04

CAUTION:

! Do not “quick charge” a fully discharged battery. ! Keep the battery away from open flame while it is being

charged.

! When connecting the charger, connect the leads first, then

turn on the charger. Do not turn on the charger first, as this may cause a spark.

! If battery electrolyte temperature rises above 60°C (140°F),

stop charging. Always charge battery at a temperature below 60°C (140°F).

Charging Rates

Amps Time

50 1 hour

25 2 hours

10 5 hours

5 10 hours

NCSC0003S0401

Do not charge at more than 50 ampere rate. NOTE:

The ammeter reading on your battery charger will automatically decrease as the battery charges. This indicates that the voltage of the battery is increasing normally as the state of charge improves. The charging amps indicated above refer to initial charge rate.

! If, after charging, the specific gravity of any two cells varies

more than .050, the battery should be replaced.

SC-6

Page 70

BATTERY

Trouble Diagnoses with Battery/Starting/Charging System Tester

CAUTION:

When working with batteries, always wear appropriate eye protection.

NOTE:

! To ensure a complete and thorough diagnosis, the battery,

starter and alternator test segments must be done as a set from start to finish.

! If battery surface charge is detected while testing, the tester

will prompt you to turn on the headlights to remove the surface charge.

! If necessary, the tester will prompt you to determine if the bat-

tery temperature is above or below 0°C (32°F). Choose the appropriate selection by pressing the up or down arrow button, then press “ENTER” to make the selection.

NCSC0018

SEL404X

1. Turn off all loads on the vehicle electrical system. Clean or repair as necessary.

2. Visually inspect the battery, battery terminals and cable ends with ignition switch in “OFF” position.

NOTE:

The contact surface between the battery terminals, cable ends and tester leads must be clean for a valid test. A poor connection will prevent testing and a “CHECK CONNECTION” message will appear during the test procedures. If this occurs, clean the battery post and terminals, reconnect them and restart the test.

3. Connect the red tester lead clamp to the positive battery terminal, and the black to the negative terminal.

SEL405X

4. The tester will turn on automatically. Using the arrow keys, select “IN VEHICLE” on the tester and then press the “ENTER” key.

IDX

SC-7

Page 71

BATTERY

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

5. Locate the battery type and rating stamped or written on the top case of the battery to be tested.

NOTE:

The battery type and rating will have either of the following.

CCA: Cold Cranking Amps (490 CCA, 550 CCA, etc.) JIS: Japanese Industrial Standard.

Battery is stamped with a number such as: 80D26L: 80 (rank of output), D (physical size-depth), 26 (width in cm). The last character L (post configuration) is not input into the tester.

SEL406X

The tester requires the rating for the battery be entered exactly as it is written or stamped on the battery. Do not attempt a CCA conversion for JIS stamped batteries. JIS must be input directly.

6. Using the arrow and “ENTER” keys alternately, select the battery type and rating.

NOTE:

The tester lists five choices; CCA, JIS, IEC, DIN, and EN. Only use CCA or JIS.

SEL407X

SEL576X

7. Press “ENTER” to begin the test. Diagnosis results are displayed on the tester. Refer to “DIAGNOSTIC RESULT ITEM CHART” SC-9.

8. Press “ENTER”, then test output code is displayed. Record the test output code on the repair order.

9. Toggle back to the “DIAGNOSTIC SCREEN” for test results.

NOTE:

! If necessary, the tester will ask the user to determine if the

battery has just been charged. Choose the appropriate selection by pressing the up or down arrow button and then press the “ENTER” button to make the selection.

! When testing a battery installed in a vehicle that has recently

been driven, select “BEFORE CHANGE”.

! If the battery has just been slow charged due to a “CHARGE

& RETEST” decision by the tester, and the tester asks the user “BEFORE CHARGE/AFTER CHARGE”, select “AFTER CHARGE”.

SC-8

Page 72

BATTERY

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC RESULT ITEM CHART

Diagnostic item Service procedure

GOOD BATTERY Battery is OK, go to “Trouble Diagnoses”, “STARTING SYSTEM”. Refer to SC-13.

Replace battery.

REPLACE BATTERY

BAD CELL-REPLACE

GOOD-RECHARGE

CHARGE & RETEST

Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. If second test result is “Replace Battery”, then do so. Perform battery test again to confirm repair.

Replace the battery. Perform battery test again with Battery/Starting/Charging system tester to confirm repair.

Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester.

Perform the slow battery charging. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester to confirm repair.

NOTE: If the tester asks the user “BEFORE CHARGE/AFTER CHARGE”, select “AFTER CHARGE”.

NCSC0018S01

SC-9

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Page 73

System Description

STARTING SYSTEM

System Description

M/T MODELS

NCSC0004

NCSC0004S01

Power is supplied at all times

! to ignition switch terminal 1 ! through 40A fusible link (letter g, located in the fuse and fusible link box).

With the ignition switch in the START position, power is supplied through 10A fuse [No. 26, located in the fuse block (J/B)]

! to park/neutral position relay terminal 1. Also, with the ignition switch in the START position, power is supplied

! from ignition switch terminal 5 ! to park/neutral position relay terminal 3.

When the clutch pedal is depressed, ground is supplied

! to park/neutral position relay terminal 2 through the clutch interlock switch ! from body grounds M15, M71 and M76.

Then park/neutral position relay is energized and power is supplied

! from park/neutral position relay terminal 5 ! to starter motor harness connector terminal 2.

The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine starts.

A/T MODELS

NCSC0004S02

Power is supplied at all times

! to ignition switch terminal 1 ! through 40A fusible link (letter g, located in the fuse and fusible link box).

With the ignition switch in the ON or START position, power is supplied through 10A fuse [No. 16, located in the fuse block (J/B)]

! to park/neutral position relay terminal 1. Also, with the ignition switch in the START position, power is supplied

! from ignition switch terminal 5 ! to park/neutral position relay terminal 6.

With the selector lever in the P or N position, ground is supplied

! to park/neutral position relay terminal 2 through the park/neutral position switch ! from body grounds, E28 and E9.

Then park/neutral position relay is energized and power is supplied

! from park/neutral position relay terminal 7 ! to starter motor harness connector terminal 2.

SC-10

Page 74

STARTING SYSTEM

Wiring Diagram — START —

M/T MODELS

Wiring Diagram — START —

NCSC0005

NCSC0005S01

SC-11

IDX

TSC004

Page 75

Wiring Diagram — START — (Cont’d)

STARTING SYSTEM

A/T MODELS

NCSC0005S02

SC-12

TSC005

Page 76

STARTING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester

NOTE:

To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be done as a set from start to finish.

1. Turn off all loads on the vehicle electrical system.

2. Perform battery test with Battery/Starting/Charging system tester. Refer to SC-7.

3. Press “ENTER” to begin the starting system test.

NCSC0019

SEL408X

SEL409X

SEL410X

4. Start the engine.

5. Diagnosis result is displayed on the tester. Refer to “DIAGNOSTIC RESULT ITEM CHART”, SC-14.

NOTE:

! If the starter performs normally but the engine does not start,

perform engine diagnosis.

! For intermittent “NO CRANK” or “NO STARTER OPERATION”

incidents, go to DIAGNOSTIC PROCEDURE 2.

SC-13

IDX

Page 77

STARTING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC RESULT ITEM CHART

Diagnostic item Service procedure

CRANKING VOLTAGE NORMAL Go to “WORK FLOW”, SC-15.

CRANKING VOLTAGE LOW Go to “WORK FLOW”, SC-15.

CHARGE BATTERY

REPLACE BATTERY

Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester. Refer to SC-7.

Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. Refer to SC-7. If second test result is “REPLACE BATTERY”, then do so. Perform battery test again to confirm repair.

NCSC0019S01

SC-14

Page 78

STARTING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

WORK FLOW

NCSC0019S02

*1 SC-7 *2 SC-19

*3 SC-16 *4 SC-18

SC-15

SEL411X

IDX

Page 79

STARTING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 1 Check “B” Terminal Circuit

1 CHECK POWER SUPPLY FOR STARTER MOTOR “B” TERMINAL

1. Remove the fuel pump fuse.

2. Crank or start the engine (where possible) until the fuel pressure is released.

3. Turn the ignition OFF.

4. Check that the starter motor connector E117 terminal 1 (B/R) connection is clean and tight.

5. Check voltage between starter motor connector E117 terminal 1 (B/R) and ground using a digital circuit tester.

OK or NG

OK ! GO TO 2.

NG ! Check harness between the battery and the starter motor for open circuit.

NCSC0019S03

NCSC0019S0301

SEL945X

2 CHECK BATTERY CABLE CONNECTION QUALITY (VOLTAGE DROP TEST)

1. Check voltage between starter motor connector E117 terminal 1 (B/R) and battery positive terminal using a digital circuit tester.

SEL946X

OK or NG

OK ! GO TO 3.

NG ! Check harness between the battery and the starter motor for poor continuity.

SC-16

Page 80

STARTING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

3 CHECK STARTER MOTOR GROUND CIRCUIT (VOLTAGE DROP TEST)

1. Check voltage between starter motor case and battery negative terminal using a digital circuit tester.

SEL947X

OK or NG

OK ! Starter motor “B” terminal circuit is OK. Further inspection necessary. Refer to “WORK

FLOW”, SC-15.

NG ! Check the starter motor case and ground for poor continuity.

SC-17

IDX

Page 81

STARTING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 2 Check “S” Terminal Circuit

1 CHECK POWER SUPPLY FOR STARTER MOTOR “S” TERMINAL

1. Remove the fuel pump fuse.

2. Crank or start the engine (where possible) until the fuel pressure is released.

3. Turn the ignition OFF.

4. Disconnect starter motor connector.

5. Check voltage between starter motor connector E118 terminal 2 (B/W for M/T models or B/Y for A/T models) and ground using a digital circuit tester.

OK or NG

OK ! GO TO 2.

NG ! Check the following.

! 40A fusible link (letter g, located in fuse and fusible link box) ! Park/neutral position relay ! Harness for open or short

=NCSC0019S04

NCSC0019S0401

SEL948X

2 CHECK “S” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

1. Connect starter motor connector.

2. Check voltage between starter motor connector E118 terminal 2 (B/W for M/T models or B/Y for A/T models) and battery positive terminal using a digital tester.

SEL949X

OK or NG

OK ! Starter motor “S” terminal circuit is OK. Further inspection necessary. Refer to “WORK

FLOW”, SC-15.

NG ! Check harness between the battery and the starter motor “S” terminal for poor continuity.

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Page 82

STARTING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE

Engine coolant temperature Voltage V

NCSC0019S05

−30°C to −20°C (−22°F to −4°F) 8.0

−19°C to −10°C (−2°F to 14°F) 8.8

−9°C to 0°C (16°F to 32°F) 9.1

More than 1°C (More than 34°F) 9.3

Construction

NCSC0006

Removal and Installation

MEL645K

NCSC0007

IDX

MEL646K

SC-19

Page 83

Pinion/Clutch Check

STARTING SYSTEM

Pinion/Clutch Check

1. Inspect pinion teeth. ! Replace pinion if teeth are worn or damaged. (Also check

condition of ring gear teeth.)

2. Inspect reduction gear teeth. ! Replace reduction gear if teeth are worn or damaged. (Also

check condition of armature shaft gear teeth.)

3. Check to see if pinion locks in one direction and rotates smoothly in the opposite direction.

! If it locks or rotates in both directions, or unusual resistance is

evident, replace.

NCSC0008

SC-20

Page 84

CHARGING SYSTEM

System Description

The alternator provides DC voltage to operate the vehicle’s electrical system and to keep the battery charged. The voltage output is controlled by the IC regulator. Power is supplied at all times to alternator terminal 4 (S) through:

! 100A fusible link (letter e, located in the fuse and fusible link box), and ! 7.5A fuse (No. 37, located in the fuse and fusible link box).

Terminal B supplies power to charge the battery and operate the vehicle’s electrical system. Output voltage is controlled by the IC regulator at terminal 4 (S) detecting the input voltage. The charging circuit is protected by the 100A fusible link. The alternator is grounded to the engine block. With the ignition switch in the ON or START position, power is supplied

! through 10A fuse [No. 11, located in the fuse block (J/B)] ! to combination meter terminal 37 for the charge warning lamp.

Ground is supplied to terminal 38 of the combination meter through terminal 3 (L) of the alternator. With power and ground supplied, the charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened and the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a fault is indicated.

NCSC0009

SC-21

IDX

Page 85

Wiring Diagram — CHARGE —

CHARGING SYSTEM

Wiring Diagram — CHARGE —

NCSC0010

SC-22

TSC006

Page 86

CHARGING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester

NOTE:

To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be done as a set from start to finish.

1. Turn off all loads on the vehicle electrical system.

2. Perform battery and starting system test with Battery/Starting/ Charging system tester.

3. Press “ENTER” to begin the charging system test.

4. Start engine.

NCSC0020

SEL417X

SEL418X

5. Press “ENTER” until “LOADS OFF REV ENGINE 5 SEC” is displayed.

6. Raise and hold the engine speed at 1,500 to 2,000 rpm for about 5 seconds, then return to the engine to idle. Once the increase in engine rpm is detected, press “ENTER” to continue.

NOTE:

! If after 30 seconds an increase in engine idle speed is not

detected, “RPM NOT DETECTED” will display.

! Some engines may have a higher idle initially after starting,

particularly when the engine is cold. The tester may detect this without any other action being taken. If this occurs, continue on with the testing process. The final results will not be affected.

SEL419X

7. The tester now checks the engine at idle and performs the DIODE/RIPPLE check.

8. When complete, the tester will prompt you to turn on the following electrical loads.

! Heater fun set to highest. Do not run the A/C or windshield

defroster.

! Headlamp high beam ! Rear window defogger

NOTE:

Do not run the windshield wipers or any other cyclical loads.

SC-23

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Page 87

CHARGING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

9. Press “ENTER” to continue.

SEL420X

10. Raise and hold the engine speed at 1,500 to 2,000 rpm for about 5 seconds, then return the engine to idle. Once the increase in engine rpm is detected, press “ENTER” to continue.

NOTE:

If after 30 seconds an increase in engine idle speed is not detected, “RPM NOT DETECTED” will be displayed. Press “ENTER” to restart the test.

SEL421X

SEL422X

SEL577X

11. Diagnostic result is displayed on the tester. Refer to “DIAGNOSTIC RESULT ITEM CHART”, SC-25.

12. Press “ENTER” then test output code is displayed. Record the test output code on the repair order.

13. Toggle back to the “DIAGNOSTIC SCREEN” for test results.

SC-24

Page 88

CHARGING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC RESULT ITEM CHART

Diagnostic item Service procedure

CHARGING SYSTEM NORMAL Charging system is normal and will also show DIODE RIPPLE test result.

NO CHARGING VOLTAGE Go to “WORK FLOW”, SC-26.

LOW CHARGING VOLTAGE Go to “WORK FLOW”, SC-26.

HIGH CHARGING VOLTAGE Go to “WORK FLOW”, SC-26.

DIODE RIPPLE NORMAL Diode ripple is OK and will also show CHARGING VOLTAGE test result.

EXCESS RIPPLE DETECTED

DIODE RIPPLE NOT DETECTED Go to “WORK FLOW”, SC-26.

Replace the alternator. Perform “DIODE RIPPLE” test again using Battery/Starting/ Charging system tester to confirm repair.

NCSC0020S01

SC-25

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Page 89

CHARGING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

WORK FLOW

NCSC0020S02

SC-26

SEL423X

Page 90

CHARGING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 1 Check “L” Terminal Circuit

1 CHECK “L” TERMINAL CONNECTION

Check to see if “L” terminal is clean and tight.

OK or NG

OK ! GO TO 2.

NG ! Repair “L” terminal connection. Confirm repair by performing complete Battery/Starting/

Charging system test.

2 CHECK “L” TERMINAL CIRCUIT

1. Disconnect alternator connector.

2. Apply ground to alternator connector E106 terminal 3 (Y/R) with the ignition switch in the ON position.

NCSC0020S03

NCSC0020S0301

SEL950X

OK or NG

OK ! Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging

system test.

NG ! Check the following.

! 10A fuse [No. 11, located in fuse block (J/B)] ! CHARGE lamp ! Harness for open or short between combination meter and fuse ! Harness for open or short between combination meter and alternator

SC-27

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Page 91

CHARGING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 2 Check “B” Terminal Circuit

=NCSC0020S04

NCSC0020S0401

1 CHECK “B” TERMINAL CONNECTION

Check to see if “B” terminal is clean and tight.

OK or NG

OK ! GO TO 2. Confirm repair by performing complete Battery/Starting/Charging system test.

NG ! Repair “B” terminal connection.

2 CHECK ALTERNATOR “B” TERMINAL CIRCUIT

Check voltage between alternator connector E107 terminal B (W) and ground using a digital circuit tester.

SEL951X

OK or NG

OK ! GO TO 3.

NG ! Check the following.

! 100A fusible link (letter e, located in fuse and fusible link box) ! Harness for open or short between alternator and fusible link

3 CHECK “B” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

Check voltage between alternator connector E107 terminal B (W) and battery positive terminal using a digital tester.

SEL952X

OK or NG

OK ! Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging

system test.

NG ! Check harness between the battery and the alternator for poor continuity.

SC-28

Page 92

CHARGING SYSTEM

Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d)

DIAGNOSTIC PROCEDURE 3 Check “S” Terminal Circuit

1 CHECK “S” TERMINAL CONNECTION

Check to see if “S” terminal is clean and tight.

OK or NG

OK ! GO TO 2.

NG ! Repair “S” terminal connection. Confirm repair by performing complete Battery/Starting/

Charging system test.

2 CHECK ALTERNATOR “S” TERMINAL CIRCUIT

Check voltage between alternator connector E106 terminal 4 (W) and ground using a digital circuit tester.

OK or NG

OK ! GO TO 3.

NG ! Check the following.

! 7.5A fuse (No. 37, located in fuse and fusible link box) ! Harness for open or short between alternator and fuse

=NCSC0020S05

NCSC0020S0501

SEL953X

3 CHECK “S” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST)

Check voltage between alternator connector E106 terminal 4 (W) and battery positive terminal using a digital tester.

SEL954X

OK or NG

OK ! Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging

system test.

NG ! Check harness between the battery and the alternator for poor continuity.

MALFUNCTION INDICATOR

The IC regulator warning function activates to illuminate “CHARGE” warning lamp, if any of the following symptoms occur while alternator is operating:

! Excessive voltage is produced. ! No voltage is produced.

NCSC0020S06

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SC-29

Page 93

Construction

CHARGING SYSTEM

Construction

NCSC0012

MEL161JA

MEL965N

Removal and Installation

NCSC0013

1. Remove A/C compressor assembly fixing bolt and move the compressor assembly under the vehicle.

2. Remove alternator adjusting bar.

3. Remove alternator bracket with alternator.

4. Pull out alternator assembly under the vehicle.

5. Remove alternator pivot bolt from bracket.

6. Install in the reverse order of removal.

SC-30

Page 94

SERVICE DATA AND SPECIFICATIONS (SDS)

Battery

Type 80D26L

Capacity V-AH 12-55

Cold cranking current A (For reference value)

582

Starter

S114–831

Type

System voltage 12V

Terminal voltage 11.0V

No-load

Minimum diameter of commutator 28.0 mm (1.102 in)

Minimum length of brush 10.5 mm (0.413 in)

Brush spring tension 16.2 N (1.65 kg, 3.64 lb)

Clearance between bearing metal and armature shaft Less than 0.2 mm (0.008 in)

Clearance between pinion front edge and pinion stopper 0.3 - 2.5 mm (0.012 - 0.098 in)

Current Less than 90A

Revolution More than 2,700 rpm

HITACHI make

Reduction gear type

NCSC0014

NCSC0015

Alternator

Type

Nominal rating 12V-90A

Ground polarity Negative

Minimum revolution under no-load (When 13.5 volts is applied) Less than 1,300 rpm

Hot output current (When 13.5 volts is applied)

Regulated output voltage 14.1 - 14.7V

Minimum length of brush 5.0 mm (0.197 in)

Brush spring pressure 4.8 - 6.0 N (490 - 610 g, 17.28 - 21.51 oz)

Slip ring minimum outer diameter 22.1 mm (0.870 in)

Rotor (Field coil) resistance 1.8 - 2.1Ω

A2TB0491A

MITSUBISHI make

More than 25A/1,300 rpm More than 67A/2,500 rpm

NCSC0016

SC-31

IDX

Page 95

NOTES

Page 96

RESTRAINT SYSTEM

CONTENTS

SEAT BELTS ...................................................................3

Precautions ..................................................................3

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ PRECAUTION FOR SEAT BELT SERVICE

Front Seat Belt.............................................................5

REMOVAL AND INSTALLATION

Rear Seat Belt .............................................................7

REMOVAL AND INSTALLATION

Seat Belt Inspection.....................................................9

AFTER A COLLISION PRELIMINARY CHECKS SEAT BELT RETRACTOR ON-VEHICLE CHECK SEAT BELT RETRACTOR OFF-VEHICLE CHECK

Tether Anchor Plate ...................................................12

REMOVAL AND INSTALLATION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .........13

Precautions ................................................................13

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ PRECAUTIONS FOR SRS ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ SERVICE WIRING DIAGRAMS AND TROUBLE DIAGNOSIS

Preparation ................................................................14

SPECIAL SERVICE TOOLS

SRS Configuration .....................................................15

Seat Belt Pre-tensioner with Load Limiter.................16

Built-in Type Side Air Bag..........................................16

SRS Component Parts Location ...............................17

Maintenance Items ....................................................17

Diagnosis Sensor Unit ...............................................18

REMOVAL AND INSTALLATION

Seat Belt Pre-tensioner .............................................19

REMOVAL AND INSTALLATION

Satellite Sensor..........................................................19

REMOVAL AND INSTALLATION

Driver Air Bag Module and Spiral Cable ...................20

REMOVAL AND INSTALLATION REMOVAL INSTALLATION

...............................................................20

.................................................9

........................................................22

.................................5

.................................7

............................................9

...............................12

...........................13

......................................14

...............................18

...............................19

...............................20

........3

..................3

.......10

.....10

......13

.....13

SECTION

Front Passenger Air Bag Module ..............................23

REMOVAL INSTALLATION

Side Air Bag Module ..................................................24

REMOVAL INSTALLATION

Disposal of Air Bag Module and Seat Belt Pre-

tensioner ....................................................................26

CHECKING DEPLOYMENT TOOL DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE) DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER (OUTSIDE OF VEHICLE) DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER

Trouble Diagnoses Introduction.................................32

DIAGNOSIS FUNCTION DIAGNOSIS MODE FOR CONSULT-II

WITH CONSULT-II

WITHOUT CONSULT-II HOW TO ERASE SELF-DIAGNOSIS RESULTS

How to Perform Trouble Diagnoses for Quick

and Accurate Repair ..................................................35

INFORMATION FROM CUSTOMER PRELIMINARY CHECK WORK FLOW

Schematic ..................................................................37

Wiring Diagram - SRS -.............................................38

SRS Operation Check ...............................................41

DIAGNOSTIC PROCEDURE 1

Trouble Diagnoses with CONSULT-II...................43

DIAGNOSTIC PROCEDURE 2 DIAGNOSTIC PROCEDURE 3 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) DIAGNOSTIC PROCEDURE 5

...............................................................23

........................................................23

...............................................................24

........................................................25

.................................................................30

HOW TO CHANGE SELF-DIAGNOSIS MODE

..........................................................36

.............................26

...........................27

..............30

...........................................31

...........................................32

.......................32

...................................................33

............................................33

.........33

..........................35

............................................35

..................................41

..................................43

..................................46

......................48

..................................48

IDX

Page 97

CONTENTS (Cont’d)

Trouble Diagnoses without CONSULT-II..............52

DIAGNOSTIC PROCEDURE 6 DIAGNOSTIC PROCEDURE 7 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6)

Trouble Diagnoses: ″AIR BAG″ Warning Lamp

Does Not Turn Off .....................................................58

DIAGNOSTIC PROCEDURE 9

Trouble Diagnoses: ″AIR BAG″ Warning Lamp

Does Not Turn On .....................................................60

DIAGNOSTIC PROCEDURE 10

Trouble Diagnoses: SRS Does Not Enter

Diagnosis Mode Using Door Switch..........................61

..................................52

..................................55

......................57

..................................58

................................60

DIAGNOSTIC PROCEDURE 11

Trouble Diagnoses: ″SEAT BELT″ Warning Lamp

Does Not Turn Off .....................................................62

DIAGNOSTIC PROCEDURE 12

Trouble Diagnoses: ″SEAT BELT″ Warning Lamp

Does Not Turn On .....................................................64

DIAGNOSTIC PROCEDURE 13

Collision Diagnosis ....................................................65

FOR FRONTAL COLLISION FOR SIDE COLLISION

.............................................67

................................61

................................62

................................64

.....................................65

RS-2

Page 98

SEAT BELTS

Precautions

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER”

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to INFINITI G20 is as follows:

! For a frontal collision

! For a side collision

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 by an authorized INFINITI dealer.

! Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-

sonal injury caused by unintentional activation of the system.

! Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

PRECAUTION FOR SEAT BELT SERVICE

CAUTION:

! Before removing the seat belt pre-tensioner assembly, turn the ignition switch off, disconnect both

battery cables and wait at least 3 minutes.

! Do not use electrical test equipment for seat belt pre-tensioner connector. ! After replacing or reinstalling seat belt pre-tensioner assembly, or reconnecting seat belt pre-ten-

sioner connector, check the system function. Refer to “Checking Seat Belt Pre-tensioner Operation by Using “SEAT BELT” Warning Lamp — User Mode”, “SRS Operation Check” (RS-42) for details.

! Do not use disassemble buckle or seat belt assembly. ! Replace anchor bolts if they are deformed or worn out. ! Never oil tongue and buckle. ! If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt

assembly.

! If webbing is cut, frayed, or damaged, replace seat belt assembly. ! When replacing seat belt assembly, use a genuine seat belt assembly.

After A Collision

WARNING:

Inspect all seat belt assemblies including retractors and attaching hardware after any collision. NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the collision was minor and the belts show no damage and continue to operate properly. Failure to do so could result in serious personal injury in an accident. Seat belt assemblies not in use during a collision should also be replaced if either damage or improper operation is noted. Seat belt pre-tensioner should be replaced even if the seat belts are not in use during a frontal collision in which the air bags are deployed.

Replace any seat belt assembly (including anchor bolts) if: ! The seat belt was in use at the time of a collision (except for minor collisions and the belts, retractors and

buckles show no damage and continue to operate properly).

! The seat belt was damaged in an accident. (i.e. torn webbing, bent retractor or guide, etc.) ! The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for dam-

age or distortion and repair as necessary before installing a new seat belt assembly.

NCRS0001

NCRS0002

NCRS0002S01

IDX

RS-3

Page 99

SEAT BELTS

Precautions (Cont’d)

! Anchor bolts are deformed or worn out. ! The seat belt pre-tensioner should be replaced even if the seat belts are not in use during the collision in

which the air bags are deployed.

RS-4

Page 100

SEAT BELTS

Front Seat Belt

REMOVAL AND INSTALLATION

1. Slide the seat all the way forward and tilt the seatback toward the front.

2. Remove adjuster cover.

3. Slide floor anchor cover.

4. Remove floor anchor bolt.

5. Remove shoulder anchor bolt.

6. Remove center pillar upper and lower garnish. Refer to BT-26, “SIDE AND FLOOR TRIM” for details.

7. Disconnect seat belt pre-tensioner connector.

8. Remove second sash guide.

9. Remove the screw securing seat belt pre-tensioner retractor, then remove seat belt and seat belt pre-tensioner retractor.

10. Remove bolts securing seat belt adjuster, then remove seat belt adjuster.

=NCRS0003

SRS556-A

RS-5

IDX

Infiniti G20 2001 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual