Infiniti G20 P11 (2002) Service Manual – STEERING SYSTEM

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STEERING SYSTEM

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

CONTENTS

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

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

TILT MECHANISM

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

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

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

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

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

BOOT 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

SECTION

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

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

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

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

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

IDX

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:

I 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.

I 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 ofcomponents 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:

I 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.

I 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.

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

Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified by yellow harness connector.

NCST0001

Precautions for Steering System

I Before disassembly, thoroughly clean the outside of the unit. I 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.

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

interfere with their operation.

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

solvent.

I 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.

I 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

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

NT542

ST27180001 (J41777) Steering wheel puller

HT72520000 (J25730-B) Ball joint remover

KV48103500 (J26357 and J26357-

10) Pressure gauge

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

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

NT063

NT179

Installing rear oil seal

a: 28 mm (1.10 in) dia.

Installing pinion oil seal

a: 35 mm (1.38 in) dia.

Disassembling and assembling oil pump Unit: mm (in)

ST-4

×: Applicable

Judder × × ЧЧЧЧЧ

Symptom STEERING

Vibration ЧЧЧЧЧ ××××

Shimmy ××× × ЧЧЧЧЧ

Noise ЧЧЧЧЧЧЧЧЧ ЧЧЧЧЧЧ

Shake ××× ЧЧЧЧЧЧ

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

Possible cause and

SUSPECTED PARTS

Reference page

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-7 ST-19 ST-19 ST-19

ST-7

ST-6

ST-8

MA-13

—

ST-10

ST-6 ST-14 ST-13 ST-15

AX-3

SU-3 SU-3 SU-3 BR-6

NVH Troubleshooting Chart

NCST0006S01

NCST0006

IDX

Checking Steering Wheel Play

ON-VEHICLE SERVICE

SST489B

SST490BA

Checking Steering Wheel Play

NCST0007

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

play.

Steering wheel play:

35 mm (1.38 in) or less

I 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

I Make sure that wheel alignment is correct.

Wheel alignment:

Refer to SU-15, SDS.

I 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 isnot in the neutral position, remove the steeringwheel 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.

I 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:

±2mm(±0.08 in) or less

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

ST-6

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:

I Do not overfill. I 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.

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

this happens, bleed air again.

NCST0014

ST-7

IDX

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

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 leftand 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

I If pressure reaches maximum operating pressure, system is

OK.

I 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.

I If pressure increases to maximum operating pressure, gear is

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

I 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

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:

I 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.

I Remove the steering wheel before removing the steering

lower joint to avoid damaging the SRS spiral cable.

Removal and Installation

STEERING WHEEL

I Remove air bag module and spiral cable.

Refer to RS-19, “Removal —Air BagModuleand Spiral Cable”.

SST819C

NCST0018

NCST0018S01

SBF812E

ST-10

STEERING WHEEL AND STEERING COLUMN

Removal and Installation (Cont’d)

I 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

I Remove steering wheel with Tool.

STEERING COLUMN

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

I When installing steering column, fingertighten all lower bracket

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

I When attaching coupling joint, be sure tightening bolt faces

cutout portion.

NCST0018S02

SST800A

IDX

ST-11

STEERING WHEEL AND STEERING COLUMN

Removal and Installation (Cont’d)

I 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

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

I When disassembling and assembling, unlock steering lock

with key.

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

ing when snap ring is installed.

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

I Steering lock

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

tool.

SST741A

IDX

ST-13

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

I 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.

I 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

I After installing steering column, check tilt mechanism opera-

tion.

SST582B

ST-14