Infiniti I35 2003 User Manual

Page 1

EDITION: AUGUST 2002 REVISION: APRIL 2004 PUBLICATION NO. SM3E-1C33U3

QUICK REFERENCE INDEX

All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan Motor Company Ltd., Tokyo, Japan.

Page 2

FOREWORD

This manual contains maintenance and repair procedures for the 2003 INFINITI I35.

In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.

All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by INFINITI must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.

Page 3

PLEASE HELP MAKE THIS SERVICE MANUAL BETTER!

I N F I N I T I

Your comments are important to INFINITI and will help us to improve our Service Manuals.

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SERVICE MANUAL: Model: Year:

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Page 4

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 5

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.

These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be dis-

played on the GST screen.

SRT item Self-diagnostic test item DTC

Three way catalyst function (Bank 1)

CATALYST

Three way catalyst function (Bank 2)

EVAP control system (Small leak) P0442 05H 03H Max.

EVAP SYSTEM

HO2S

HO2S HTR

EVAP control system purge flow monitoring P0441 06H 83H Min. 20mV

EVAP control system (Very small leak)

Heated oxygen sensor 1 (Bank 1)

Heated oxygen sensor 1 (Bank 2)

Heated oxygen sensor 2 (Bank 1)

Heated oxygen sensor 2 (Bank 2)

Heated oxygen sensor 1 heater (Bank 1)

Heated oxygen sensor 1 heater (Bank 2)

Heated oxygen sensor 2 heater (Bank 1)

Heated oxygen sensor 2 heater (Bank 2)

Attachment No.32

Test value

(GST display)

TID CID

P0420 01H 01H Max. 1/128

P0420 02H 81H Min. 1

P0430 03H 02H Max. 1/128

P0430 04H 82H Min. 1

P0456 07H 03H Max.

P1456 07H 03H Max.

P0133 09H 04H Max. 16ms

P1143 0AH 84H Min. 10mV

P1144 0BH 04H Max. 10mV

P0132 0CH 04H Max. 10mV

P0134 0DH 04H Max. 1s

P0153 11H 05H Max. 16ms

P1163 12H 85H Min. 10mV

P1164 13H 05H Max. 10mV

P0152 14H 05H Max. 10mV

P0154 15H 05H Max. 1s

P0139 19H 86H Min. 10mV/500ms

P1147 1AH 86H Min. 10mV

P1146 1BH 06H Max. 10mV

P0138 1CH 06H Max. 10mV

P0159 21H 87H Min. 10mV/500ms

P1167 22H 87H Min. 10mV

P1166 23H 07H Max. 10mV

P0158 24H 07H Max. 10mV

P0032 29H 08H Max. 20mV

P0031 2AH 88H Min. 20mV

P0052 2BH 09H Max. 20mV

P0051 2CH 89H Min. 20mV

P0038 2DH 0AH Max. 20mV

P0037 2EH 8AH Min. 20mV

P0058 2FH 0BH Max. 20mV

P0057 30H 8BH Min. 20mV

Test limit

Conversion

1/128mm

Page 6

FRONT & REAR SUSPENSION

CONTENTS

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

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

PRECAUTIONS

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

SPECIAL SERVICE TOOLS COMMERCIAL SERVICE TOOLS

Noise, Vibration and Harshness (NVH)

Troubleshooting ...........................................................4

NVH TROUBLESHOOTING CHART

Components.................................................................5

On-vehicle Service.......................................................6

FRONT SUSPENSION PARTS FRONT WHEEL ALIGNMENT

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

COMPONENTS REMOVAL AND INSTALLATION DISASSEMBLY INSPECTION ASSEMBLY

Stabilizer Bar .............................................................11

REMOVAL AND INSTALLATION

Transverse Link and Lower Ball Joint .......................12

REMOVAL AND INSTALLATION INSPECTION

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

GENERAL SPECIFICATIONS (FRONT) FRONT WHEEL ALIGNMENT (UNLADEN*1) LOWER BALL JOINT

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SECTION

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

REMOVAL AND INSTALLATION DISASSEMBLY INSPECTION ASSEMBLY

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

DISASSEMBLY INSPECTION ASSEMBLY

Service Data and Specifications (SDS).....................26

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

IDX

Page 7

Precautions

SBR686C

FRONT SUSPENSION

Precautions

PRECAUTIONS

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

ried out under unladen condition* with tires on ground. Oil will shorten the life of rubber bushes. Be sure to wipe off any spilled oil. *: 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

tubes.

! Always torque brake lines when installing. ! Lock nuts are unreusable parts; always use new ones.

When replacing, do not wipe the oil off the new lock nut before tightening.

NHSU0001

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

HT72520000 (J25730-A) Ball joint remover

COMMERCIAL SERVICE TOOLS

Tool name Description

Attachment Wheel alignment

1 Flare nut crowfoot 2 Torque wrench

Description

Removing tie-rod outer end and lower ball joint

NT146

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)

NT148

Removing and installing each brake piping

a: 10 mm (0.39 in)

NHSU0002

NHSU0003

NT360

SU-2

Page 8

Tool name Description

FRONT SUSPENSION

Preparation (Cont’d)

Spring compressor

Removing and installing coil spring

NT717

IDX

SU-3

Page 9

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.

=NHSU0004

NHSU0004S01

Reference page

SU-5, 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, 23

Shock absorber deformation,

damage or deflection

Bushing or mounting deterioration

—

Parts interference

Spring fatigue

SU-6

SU-9, 21

Suspension looseness

Incorrect wheel alignment

SU-6

SU-11

Stabilizer bar fatigue

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

××××××××××

×××××××××

×××××××

SU-4

Page 10

FRONT SUSPENSION

Components

NHSU0005

1. Front suspension member

2. Stabilizer bar

3. Transverse link

4. Rebound stopper

5. Knuckle

6. Strut assembly

7. Coil spring

SSU042

IDX

SU-5

Page 11

On-vehicle Service

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-5.

! 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.

NHSU0006

SFA392B

SFA818AA

SSU010

! 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 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)

f) If ball joint movement is beyond specifications, remove and

replace it.

FRONT WHEEL ALIGNMENT

NHSU0007

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.

SU-6

Page 12

FRONT SUSPENSION

On-vehicle Service (Cont’d)

SFA975B

SRA096A

AFA050

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 wheel and mount wheel 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).

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 damaged 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.

NHSU0007S01

NHSU0007S02

NHSU0007S03

IDX

SFA234AC

SU-7

Page 13

On-vehicle Service (Cont’d)

FRONT SUSPENSION

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-30, “SDS”.

c. Tighten lock nuts to specified torque.

Lock nut tightening torque:

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

SFA486A

Front Wheel Turning Angle

1. Set wheels in straight-ahead position. Then move vehicle forward until front wheels rest on turning radius gauge properly.

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

Do not hold the steering wheel on full lock for more than 15 seconds.

Wheel turning angle (Full turn):

Refer to SDS, SU-15.

NHSU0007S04

SFA439BA

SSU023

3. Check stopper bolt head to see whether it contacts stopper bracket at specified outside wheel angle. If not, adjust stopper bolt to contact stopper bracket at the correct angle. Adjust protrusion of stopper bolt before placing stopper bolt cap. Apply grease to face of stopper bracket that bolt touches.

Tighten stopper bolt lock nut.

: 54 - 72 N·m (5.5 - 7.3 kg-m, 40 - 53 ft-lb)

SU-8

Page 14

FRONT SUSPENSION

Coil Spring and Shock Absorber

COMPONENTS

Coil Spring and Shock Absorber

=NHSU0008

1. Strut spacer

2. Strut mount insulator

3. Strut mount bracket

4. Strut mount bearing

5. Spring upper seat

6. Spring rubber seat

7. Bound bumper rubber

8. Coil spring

9. Shock absorber

10. Suspension member

11. Rebound stopper

12. Wheel hub and steering knuckle

13. Cotter pin

14. Bush link pin

15. Transverse link

16. Stabilizer

17. Connecting rod

18. Stabilizer clamp

19. Bushing

SSU056

IDX

SU-9

Page 15

Coil Spring and Shock Absorber (Cont’d)

FRONT SUSPENSION

SFA956A

SSU002

REMOVAL AND INSTALLATION

=NHSU0009

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

DISASSEMBLY

NHSU0010

1. Set shock absorber on vise, then loosen piston rod lock nut.

! Do not remove piston rod lock nut at this time.

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. Remove piston rod lock nut.

SSU003

INSPECTION Shock Absorber Assembly

NHSU0011

NHSU0011S01

! 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

NHSU0011S02

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

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

Thrust Bearing

NHSU0011S06

! Check thrust bearing parts for abnormal noise or excessive

rattle in axial direction.

! Replace if necessary.

Coil Spring

NHSU0011S03

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

necessary.

SU-10

Page 16

FRONT SUSPENSION

Coil Spring and Shock Absorber (Cont’d)

SFA508A

SFA664A

ASSEMBLY

! When installing coil spring on strut, it must be positioned as

shown in the figure at left.

! Install upper spring seat with its cutout facing the outer side of

vehicle.

NHSU0012

Stabilizer Bar

REMOVAL AND INSTALLATION

! Remove power steering gear. Refer to ST-16, “POWER

STEERING GEAR AND LINKAGE”.

! Remove stabilizer bar.

NHSU0017

SSU027

SSU026

! When installing stabilizer, make sure that band and clamp face

in their correct directions.

! Make sure that slit in bushing is in the position shown in the

figure.

IDX

SFA604B

SU-11

Page 17

Stabilizer Bar (Cont’d)

FRONT SUSPENSION

! Install stabilizer bar with ball joint socket properly placed.

SFA449BB

! Check stabilizer for deformation or cracks. Replace if neces-

sary.

! Check rubber bushings for deterioration or cracks. Replace if

necessary.

! Check ball joint can rotate in all directions. If movement is not

smooth and free, replace stabilizer bar connecting rod.

ARA027

SFA651A

SFA113A

Transverse Link and Lower Ball Joint

REMOVAL AND INSTALLATION

1. Remove wheel bearing lock nut.

2. Remove tie-rod ball joint.

3. Remove strut lower bracket fixing bolts and nuts.

4. Separate drive shaft from knuckle by slightly tapping drive shaft end.

Cover boots with shop towel so as not to damage them when removing drive shaft.

5. Separate lower ball joint stud from knuckle with suitable tool. Refer to AX-5, “FRONT AXLE — Wheel Hub and Knuckle”.

6. Remove fixing bolts.

7. Remove transverse link and lower ball joint.

8. Install fixing bolts in order of number.

Tightening torque:

Refer to “FRONT SUSPENSION”, SU-6.

9. During installation, final tightening must be carried out at curb weight with tires on the ground.

10. After installation, check wheel alignment. Refer to “ON-VEHICLE SERVICE — Front Wheel Alignment”, SU-6.

NHSU0018

SSU012

SU-12

Page 18

FRONT SUSPENSION

Transverse Link and Lower Ball Joint (Cont’d)

SFA858A

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.

Lower Ball Joint

! Check ball joint for play. Replace transverse link assembly if

any of the following cases occur. Ball stud is worn, play in axial direction is excessive or joint is hard to swing. 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):

7.8 - 77.5 N (0.8 - 7.9 kg, 1.8 - 17.4 lb)

Turning torque “B”:

0.50 - 4.90 N·m (5.1 - 50 kg-cm, 4.4 - 43.4 in-lb)

Vertical end play “C”:

0 mm (0 in)

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

necessary.

NHSU0019

NHSU0019S01

NHSU0019S02

IDX

SU-13

Page 19

FRONT SUSPENSION

Service Data and Specifications (SDS)

GENERAL SPECIFICATIONS (FRONT)

Suspension type Independent MacPherson strut

Shock absorber type Double-acting hydraulic

Stabilizer bar Standard equipment

=NHSU0020

SU-14

Page 20

FRONT SUSPENSION

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

FRONT WHEEL ALIGNMENT (UNLADEN*1)

Tire size P225/50R17 P215/55R17

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 −1°00′ (−1.00°)

Nominal −0°15′ (−0.25°)

Maximum 0°30′ (0.50°)

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

Minimum 2°00′ (2.00°)

Nominal 2°45′ (2.75°)

Maximum 3°30′ (3.50°)

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

Minimum 13°30′ (13.50°)

Nominal 14°15′ (14.25°)

Maximum 15°00′ (15.00°)

Minimum 0 (0)

Nominal 1 (0.04)

Maximum 2 (0.08)

Minimum 0′ (0.00°)

Nominal 6′ (0.10°)

Maximum 12′ (0.20°)

Minimum 29°30′ (29.50°)

Nominal 33°00′ (33.0°)

Maximum 34°00′ (34.0°)

Nominal 28°30′ (28.50°)

=NHSU0021

*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) 0.50 - 4.90 (5.1 - 50.0, 4.4 - 43.4)

Vertical end play “C” mm (in) 0 (0)

7.8 - 77.5 (0.8 - 7.9, 1.8 - 17.4)

NHSU0022

IDX

SU-15

Page 21

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

FRONT SUSPENSION

WHEELARCH HEIGHT (UNLADEN*)

Applied model Models with 225/50R17 tire Models with P215/55R17 tire

Front (Hf) mm (in) 707 (27.83) 712 (28.03)

Rear (Hr) mm (in) 694 (27.32) 704 (27.72)

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

WHEEL RUNOUT

Steel wheel

Wheel type Aluminum

Inside Outside

Radial runout limit mm (in) 0.3 (0.012) 0.8 (0.031) or less 0.4 (0.016) or less

Lateral runout limit mm (in) 0.3 (0.012) 1.0 (0.039) or less 0.9 (0.035) or less

=NHSU0041

SFA818A

NHSU0023

SU-16

Page 22

SBR686C

REAR SUSPENSION

Precautions

PRECAUTIONS

! When installing each rubber part, final tightening must be

carried out under unladen condition* with tires on ground. Oil will shorten the life of rubber bushes. Be sure to wipe off any spilled oil. *: 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. ! Lock nuts are unreusable parts; always use new ones.

When replacing, do not wipe the oil off of the new lock nut before tightening.

NHSU0024

COMMERCIAL SERVICE TOOLS

Tool name Description

Equivalent to GG94310000 1 Flare nut crowfoot 2 Torque wrench

NT360

Spring compressor

NT717

Preparation

NHSU0026

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-4.

NHSU0027

IDX

SU-17

Page 23

Components

REAR SUSPENSION

Components

NHSU0028

1. Shock absorber mounting seal

2. Coil spring

3. Shock absorber

4. Suspension member

5. Control rod

SU-18

SSU013

6. Lateral link

7. Torsion beam

Page 24

SMA525A

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.

! Retighten all nuts and bolts to the specified torque.

Tightening torque:

Refer to “REAR SUSPENSION”, SU-18.

NHSU0029

SSU014

SMA113

SFA975B

! Check shock absorber for oil leakage or other damage. ! Check wheelarch height. Refer to “On-vehicle Service”,

“FRONT SUSPENSION PARTS”, SU-6.

REAR WHEEL ALIGNMENT

Before checking rear 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

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 wheel and mount wheel 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.

NHSU0030

NHSU0030S01

IDX

SU-19

Page 25

On-vehicle Service (Cont’d)

REAR SUSPENSION

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).

SFA948A

SFA614B

SFA234AC

Camber

NHSU0030S02

Camber is preset at factory and cannot be adjusted.

Camber:

Refer to SDS, SU-26.

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

any damaged or worn rear suspension parts.

Toe-in

NHSU0030S03

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: A − B

Refer to SDS, SU-26.

SU-20

Page 26

REAR SUSPENSION

Removal and Installation

NHSU0031

1. Washer

2. Bushing

3. Shock absorber mounting seal

4. Shock absorber mounting bracket

5. Distance tube

6. Bushing

7. Bound bumper cover

8. Bound bumper

9. Coil spring

10. Shock absorber

11. Torsion beam

12. Control rod

13. Lateral link

14. ABS sensor

15. Suspension member

SSU015

IDX

SU-21

Page 27

Removal and Installation (Cont’d)

REAR SUSPENSION

SSU016

SSU017

REMOVAL

NHSU0031S01

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. Remove tires, then remove brake hose lock plate.

2. 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.

3. 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.

4. Lower transmission jack, and remove suspension.

5. Remove trunk room trim. Refer to BT-40, “Trunk Room Trim”.

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

INSTALLATION

NHSU0031S02

! Install suspension assembly.

CAUTION:

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

1. Install suspension member.

a. Temporarily tighten bolt 5. b. Tighten all bolts in numerical order shown in the figure.

Tightening torque:

Refer to SU-21.

SSU020

SSU018

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

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

SU-22

Page 28

REAR SUSPENSION

4. 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.

SSU019

5. Tighten lateral link at suspension member.

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

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

Removal and Installation (Cont’d)

SSU021

SRA806A

Coil Spring and Shock Absorber

REMOVAL AND INSTALLATION

Remove shock absorber upper and lower fixing nuts.

Do not remove piston rod lock nut on vehicle.

DISASSEMBLY

1. Set shock absorber in vise, then loosen piston rod lock nut. Do not remove piston rod lock nut at this time.

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. Remove piston rod lock nut.

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.

NHSU0032

NHSU0033

NHSU0034

NHSU0034S01

IDX

Upper Rubber Seat and Bushing

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

SU-23

NHSU0034S02

Page 29

Coil Spring and Shock Absorber (Cont’d)

REAR SUSPENSION

SRA699A

Coil Spring

NHSU0034S03

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

ASSEMBLY

NHSU0035

! Locate upper spring seat as shown.

! 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.

CAUTION:

Do not reuse piston rod lock nut.

SFA436B

SSU025

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.

INSPECTION

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

essary.

Standard length:

A 206.5 - 208.5 mm (8.13 - 8.21 in) B 393.5 - 395.5 mm (15.49 - 15.57 in) C 600 - 604 mm (23.62 - 23.78 in) D 106 - 108 mm (4.17 - 4.25 in)

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

Replace if necessary.

NHSU0036

NHSU0037

SU-24

Page 30

REAR SUSPENSION

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

SRA793A

ASSEMBLY

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.

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

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

NHSU0038

SSU022

SSU024

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.

IDX

SU-25

Page 31

REAR SUSPENSION

Service Data and Specifications (SDS)

GENERAL SPECIFICATIONS (REAR)

Suspension type Multi-link beam suspension

Shock absorber type Double-acting hydraulic

=NHSU0039

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 −1°45′ (−1.75°)

Nominal −1°00′ (−1.00°)

Maximum −0°15′ (−0.25°)

Minimum −3 (−0.12)

Nominal 1 (0.04)

Maximum 5 (0.20)

Minimum −16′ (−0.27°)

Nominal 5′30′′ (0.09°)

Maximum 26′ (0.43°)

NHSU0040

SU-26

Page 32

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 Tool.............................................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.........................................9

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

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

BOOT

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

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

Assembly ...................................................................20

Adjustment .................................................................23

POWER STEERING OIL PUMP....................................25

Components...............................................................25

Pre-disassembly Inspection .......................................25

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

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

Assembly ...................................................................27

SERVICE DATA AND SPECIFICATIONS (SDS) .........29

General Specifications ...............................................29

Steering Wheel .......................................................... 29

Steering Column ........................................................29

Steering Gear and Linkage .......................................30

Power Steering .......................................................... 31

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

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

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

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

IDX

Page 33

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. The SRS system composition which is available to INFINITI I35 is as follows (The composition varies according to optional equipment.):

! 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, crash zone sensor, warning lamp, wiring harness and spiral cable.

! For a side collision

The Supplemental Restraint System consists of front 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 should 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. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors).

NHST0001

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 power steering fluid* 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. *: Genuine Nissan PSF II or equivalent. Refer to MA-11, “Fluids and Lubricants”.

NHST0003

ST-2

Page 34

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

KV48102500 (J33914) Pressure gauge adapter

ST27180001 (J25726-A) Steering wheel puller

Description

Measuring pinion rotating torque

NT169

Measuring oil pressure

NT542

Removing steering wheel

NHST0004

HT72520000 (J25730-B) Ball joint remover

KV48103500 (J26357 and J26357-

10) Pressure gauge

KV48104400 (—) Rack seal ring reformer

NT544

NT546

NT547

NT550

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

Reforming teflon ring

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

IDX

ST-3

Page 35

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

Oil pump attachment

NT541

LST024

LST025

Measuring turning torque

Measuring steering wheel turning force

Measuring rack sliding force

Commercial Service Tool

Disassembling and assembling oil pump Unit: mm (in)

NHST0005

NT774

ST-4

Page 36

×: 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-4

BR-6

NVH Troubleshooting Chart

NHST0006S01

NHST0006

IDX

Page 37

Checking Steering Wheel Play

ON-VEHICLE SERVICE

SST489B

SST490BA

Checking Steering Wheel Play

NHST0007

! 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

NHST0008

NHST0008S01

! 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

NHST0008S02

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

SST849C

Front Wheel Turning Angle

NHST0009

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-30.

Checking Gear Housing Movement

NHST0010

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 38

ON-VEHICLE SERVICE

Checking and Adjusting Drive Belts

SST850C

SST851C

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. Refer to MA-11, “Fluids and Lubricants”.

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-25.

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

NHST0011

NHST0012

NHST0013

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.

NHST0014

ST-7

IDX

Page 39

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

NHST0015

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:

216 - 284 N (22 - 29 kg, 49 - 64 lb)

Maximum force deviation:

98 N (10 kg, 22 lb)

d. Check sliding force outside the above range at rack speed of

40 mm (1.75 in)/s.

Rack sliding force:

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

Maximum force deviation:

147 N (15 kg, 33 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.

ST-8

Page 40

ON-VEHICLE SERVICE

Checking Hydraulic System

SST834-F

Checking Hydraulic System

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).

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-25.

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)

NHST0016

ST-9

IDX

Page 41

Components

STEERING WHEEL AND STEERING COLUMN

Components

NHST0017

1. Air bag module

2. Damper

3. Steering wheel

4. Spiral cable

5. Column cover

6. Combination switch

7. Steering column assembly

8. Boot

9. Clip

10. Lower joint

CAUTION:

! The rotation of the spiral cable (SRS “Air bag” component

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-21, “Removal — Air Bag Module and Spiral Cable”.

SST852C

NHST0018

NHST0018S01

SBF812E

ST-10

Page 42

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

SST853C

SST329C

! Remove damper for steering wheel. ! Remove steering wheel with Tool.

STEERING COLUMN

! Remove key interlock cable.

! 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.

NHST0018S02

IDX

SST800A

ST-11

Page 43

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 44

STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly

=NHST0019

1. Combination switch

2. Lock nut

3. Jacket tube assembly

4. Tilt lever

5. Tilt lever stopper

6. Steering column mounting bracket

7. Spring

8. Adjust bolt

9. Adjust bolt stopper

! When disassembling and assembling, unlock steering lock

with key.

! Remove combination switch. ! Install lock nut on steering column shaft and tighten the nut.

10. Nut

11. Column shaft assembly

12. Steering column lower cover

13. Lower joint

SST854CA

IDX

SST490C

ST-13

Page 45

STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly (Cont’d)

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

tool.

SST741A

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

type screw heads.

SST742A

SST855C

Inspection

NHST0020

! 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”.

Steering column length “L”:

542 - 544 mm (21.34 - 21.42 in)

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

SST582B

TILT MECHANISM

NHST0020S01

! After installing steering column, check tilt mechanism opera-

tion.

ST-14

Page 46

POWER STEERING GEAR AND LINKAGE

Components

NHST0021

1. Rear cover cap

2. Gear sub-assembly

3. O-ring

4. Shim

5. Lock nut

6. Adjusting screw

7. Spring

8. Diaphragm spring

9. Washer

10. Spring seat

11. Retainer

12. Gear housing

13. Center bushing

14. Rack oil seal

15. Rack assembly

16. Rack seal ring

17. O-ring

18. Rack oil seal

19. End cover assembly

20. Boot band

21. Dust boot

22. Boot band

23. Spacer ring

24. Lock plate

25. Tie-rod inner socket

26. Tie-rod outer socket

27. Cotter pin

28. Gear housing tube

SST856C

IDX

ST-15

Page 47

Removal and Installation

POWER STEERING GEAR AND LINKAGE

Removal and Installation

NHST0022

1. Lower joint

2. Hole cover

3. Insulator bracket

4. Clamp

5. Rear cover cap

6. Gear and linkage assembly

7. Rack mounting insulator

SST857C

8. Gear housing mounting bracket

9. Cotter pin

10. Heat insulator

ST-16

Page 48

POWER STEERING GEAR AND LINKAGE

Removal and Installation (Cont’d)

CAUTION:

! The rotation of the spiral cable (SRS “Air bag” component

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.

1. Remove front exhaust tube. Refer to FE-9, “Removal and

SFA455BC

Installation”.

2. Set a suitable transmission jack under transaxle.

3. Remove center member and rear engine mounting. Refer to EM-70, “Removal”.

4. Remove front stabilizer bar. Refer to SU-11, “Removal and Installation”.

5. Remove steering gear assembly.

SST858C

SST859C

! 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)

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

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

! 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).

IDX

SST824A

ST-17

Page 49

POWER STEERING GEAR AND LINKAGE

Removal and Installation (Cont’d)

! 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.

SST860C

! Tighten gear housing mounting bracket bolts in the order

shown.

SST861C

SST862C

SST051C

Disassembly

NHST0023

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 gear sub-assembly, O-ring and shim.

Gear sub-assembly cannot be disassembled. If it is faulty, replace with a new one.

3. Remove tie-rod outer sockets and boots.

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

5. Remove retainer.

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

7. Remove end cover assembly with a suitable tool.

8. Draw out rack assembly.

9. 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

ST-18

Page 50

POWER STEERING GEAR AND LINKAGE

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

Do not scratch inner surfaces of pinion housing.

SST472A

Disassembly (Cont’d)

SST468C

Inspection

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

BOOT

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

RACK

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

GEAR SUB-ASSEMBLY

! Check pinion gear. If it is worn or damaged, replace as a gear

sub-assembly.

! Manually spin bearing. If torque variations or free play are

noted, replace as a gear sub-assembly.

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-30.

! Check ball joint for rotating torque.

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

Refer to SDS, ST-30.

! Check ball joints for axial end play.

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

Refer to SDS, ST-30.

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

outer tie-rod.

NHST0024

NHST0024S01

NHST0024S02

NHST0024S03

NHST0024S04

NHST0024S05

IDX

ST-19

Page 51

Assembly

POWER STEERING GEAR AND LINKAGE

SST083B

SST885BB

Assembly

NHST0025

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.

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

SST863C

SST321B

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

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

ST-20

Page 52

POWER STEERING GEAR AND LINKAGE

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

SST073B

7. Set rack gear in neutral position.

Rack stroke “S”:

Refer to SDS, ST-30.

Assembly (Cont’d)

SST086BA

SST864C

SST865C

8. Install adjustment shims and O-rings to gear sub-assembly.

! Install the same number of adjustment shims as before,

regardless of whether or not gear sub-assembly is replaced.

! Discard old O-rings; replace with new ones.

9. Tighten gear subassembly securing bolts to specified tightening torque.

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

11. 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.

12. Install spring seat retainer spring and adjusting screw temporarily.

IDX

SST087B

ST-21

Page 53

Assembly (Cont’d)

POWER STEERING GEAR AND LINKAGE

13. Install lock plate to rack.

a. Temporarily install spacer ring to rack.

Discard old spacer ring; replace with a new one.

b. Install lock plate to inner socket.

Discard old lock plate; replace with a new one.

c. Apply a coat of locking sealant to inner socket threads. Screw

inner socket into rack and tighten to specified torque.

d. Clinch lock plate at rack groove location (at two points). e. Install spacer ring to lock plate as shown in the Figure at left.

SST866C

Be careful not to damage spacer ring during installation

14. Tighten outer socket lock nut.

Tie-rod length “L”:

Refer to SDS, ST-30.

SST867C

SST086BA

SST967A

15. Measure rack stroke.

Rack stroke “S”:

Refer to SDS, ST-30.

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

17. Install boot bands.

! Securely install boot band to boot groove and clinch the root

section of the trapezoidal area.

! Make sure that there is a clearance of 3.5 mm (0.138 in) or less

at the clinched section of the boot band. Refer to the Figure at left.

SST868C

ST-22

Page 54

POWER STEERING GEAR AND LINKAGE

! After installing gear in vehicle, make sure that the clinched

section of boot band is positioned toward the rear of vehicle (to prevent interference with adjacent parts).

SST869C

Assembly (Cont’d)

SST719C

SST862C

Adjustment

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 60° to 80°.

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

NHST0026

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.

ST-23

IDX

Page 55

Adjustment (Cont’d)

POWER STEERING GEAR AND LINKAGE

Average rack sliding force:

216 - 284 N (22 - 29 kg, 49 - 64 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)

! 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.

ST-24

Page 56

POWER STEERING OIL PUMP

Components

NHST0027

1. Pulley

2. Snap ring

3. Drive shaft

4. Oil seal

5. Bracket

6. Front housing

7. O-ring

8. O-ring

9. Front side plate

10. Vane

11. Rotor

12. Pin

13. Cam ring

14. Gasket

15. Rear housing

16. O-ring

17. Suction pipe

18. Spring

19. Flow control valve

20. Washer

21. Joint

22. Connector

23. Washer

24. Hose

25. Connector bolt

26. Adjusting bracket

27. Adjusting bolt

28. Lock bolt

Pre-disassembly Inspection

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

SST870C

NHST0028

IDX

SST984A

ST-25

Page 57

Disassembly

POWER STEERING OIL PUMP

Disassembly

NHST0029

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.

! Remove snap ring, then draw drive shaft out.

Be careful not to drop drive shaft.

SST010B

SST034A

SST036A

! Remove oil seal.

Be careful not to damage front housing.

! Remove connector and flow control valve with spring.

Be careful not to drop flow control valve. Do not disassemble flow control valve.

ST-26

Page 58

POWER STEERING OIL PUMP

Inspection

SST038A

Inspection

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

seal.

! If serration on pulley or pulley shaft is deformed or worn,

replace it.

Assembly

Assemble oil pump, noting the following instructions.

! Make sure O-rings and oil seal are properly installed. ! Always install new O-rings and oil seal. ! Be careful of oil seal direction. ! Cam ring, rotor and vanes must be replaced as a set if neces-

sary.

! Coat each part with Genuine Nissan PSF II or equivalent when

assembling.

! Pay attention to the direction of rotor.

NHST0030

NHST0031

SST289A

SST843A

! When assembling vanes to rotor, rounded surfaces of vanes

must face cam ring side.

IDX

ST-27

Page 59

Assembly (Cont’d)

POWER STEERING OIL PUMP

! Insert pin 2 into pin groove 1 of front housing and front side

plate. Then install cam ring 3 as shown at left.

Cam ring:

D1is less than D2.

SST472C

ST-28

Page 60

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

Power steering

Steering model

17 inch tire

Steering gear type PR26AD

Steering overall gear ratio 16.6

Turns of steering wheel (Lock to lock) 2.6

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) 542 - 544 (21.34 - 21.42)

NHST0032

NHST0033

NHST0034

SST855C

IDX

ST-29

Page 61

Steering Gear and Linkage

SERVICE DATA AND SPECIFICATIONS (SDS)

Steering Gear and Linkage

Applied model All

Steering gear type PR26AD

Swinging force at cotter pin hole: “A” N (kg, lb) 6.5 - 65.7 (0.66 - 6.59, 1.5 - 14.8)

Tie-rod outer ball joint

Tie-rod inner ball joint

Tie-rod standard length “L” mm (in) 193.2 (7.606)

*: Measuring point [!: 172 mm (6.77 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) 0.4 (0.016) or less

Swinging force*: “A” N (kg, lb) 5.7 - 45.6 (0.58 - 4.65, 1.3 - 10.3)

Axial end play: “C” mm (in) 0.2 (0.008) or less

NHST0035

SST867C

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 PR26AD

Rack stroke “S” mm (in) 63.0 (2.480)

in-lb)

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

Returning angle degree 60° - 80°

0.2 (2, 1.7)

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

SST086BA

ST-30

Page 62

SERVICE DATA AND SPECIFICATIONS (SDS)

Power Steering

Applied model All

Steering gear type PR26AD

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) 1.0 (1-1/8, 7/8)

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 216 - 284 (22 - 29, 49 - 64)

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)

NHST0036

IDX

ST-31

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

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

Trouble Diagnoses with Battery/Starting/Charging

System Tester ............................................................12

DIAGNOSTIC RESULT ITEM CHART WORK FLOW DIAGNOSTIC PROCEDURE 1 DIAGNOSTIC PROCEDURE 2 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE

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

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

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

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

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

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

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

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

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

......4

SECTION

Construction...............................................................18

Removal and Installation ...........................................18

REMOVAL INSTALLATION

Pinion/Clutch Check ..................................................19

CHARGING SYSTEM ....................................................20

System Description ....................................................20

Wiring Diagram - CHARGE -.....................................21

Trouble Diagnoses with Battery/Starting/Charging

System Tester ............................................................22

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

Construction...............................................................29

Removal and Installation ...........................................29

REMOVAL INSTALLATION

SERVICE DATA AND SPECIFICATIONS (SDS) .........30

Battery........................................................................30

Starter ........................................................................30

Alternator ...................................................................30

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

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

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

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

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

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

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

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

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

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

IDX

Page 65

PRECAUTIONS

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

! 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 should 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. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors).

NHSC0001

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the following:

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

When you perform trouble diagnosis, refer to the following:

! GI-36, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” ! GI-25, “HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT”

NHSC0002

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

NHSC0017

IDX

SC-3

Page 67

How to Handle Battery

BATTERY

MEL040F

How to Handle Battery

NHSC0003

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

NHSC0003S01

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

NHSC0003S02

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

MEL043F

SEL709EA

BATTERY

How to Handle Battery (Cont’d)

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

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.

NHSC0003S0201

NHSC0003S03

MEL042FA

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

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

NHSC0003S0301

IDX

32 (90) 0.004

27 (80) 0

21 (70) −0.004

16 (60) −0.008

10 (50) −0.012

SC-5

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

NHSC0003S04

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 55°C (131°F),

stop charging. Always charge battery at a temperature below 55°C (131°F).

Charging Rates

Amps Time

50 1 hour

25 2 hours

10 5 hours

5 10 hours

NHSC0003S0401

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 headlamps 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.

NHSC0018

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.

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

IDX

SEL405X

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-12.

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”.

NHSC0018S01

IDX

SC-9

Page 73

System Description

STARTING SYSTEM

System Description

Power is supplied at all times

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

With the ignition switch in the ON or START position, power is supplied

! through 15A fuse [No. 20, 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 5.

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

! to park/neutral position relay terminal 2 ! through park/neutral position switch ! from body grounds F41 and F39.

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

! from park/neutral position relay terminal 3 ! to starter motor terminal 2 windings.

The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The starter motor is grounded to the cylinder block. With power and ground supplied, the starter motor operates.

NHSC0021

SC-10

Page 74

STARTING SYSTEM

Wiring Diagram — START —

NHSC0005

IDX

SC-11

MEL585Q

Page 75

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.

NHSC0019

SEL408X

SEL409X

SEL410X

4. Start the engine.

5. Diagnosis result is displayed on the tester. Refer to “DIAGNOSTIC RESULT ITEM CHART”, SC-13.

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-12

Page 76

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-14.

CRANKING VOLTAGE LOW Go to “WORK FLOW”, SC-14.

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.

NHSC0019S01

IDX

SC-13

Page 77

STARTING SYSTEM

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

WORK FLOW

NHSC0019S02

*1 SC-7 *2 SC-18

SEL411XA

*3 SC-15 *4 SC-17

SC-14

Page 78

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 switch OFF.

4. Check that the starter motor B terminal E202 terminal 1 (B/R) connection is clean and tight.

5. Check voltage between starter motor B terminal E202 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.

NHSC0019S03

NHSC0019S0301

SEL961XA

2 CHECK BATTERY CABLE CONNECTION QUALITY (VOLTAGE DROP TEST)

1. Check voltage between starter motor B terminal E202 terminal 1 (B/R) and battery positive terminal using a digital circuit tester.

SEL962XA

OK or NG

OK ! GO TO 3.

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

IDX

SC-15

Page 79

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.

OK or NG

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

FLOW”, SC-14.

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

SEL947X

SC-16

Page 80

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 switch OFF.

4. Disconnect starter motor connector.

5. Check voltage between starter motor connector E201 terminal 2 (B/R) and ground using a digital circuit tester.

OK or NG

OK ! GO TO 2.

NG ! Check the following.

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

=NHSC0019S04

NHSC0019S0401

SEL948X

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

1. Connect starter motor connector.

2. Check voltage between starter motor connector E201 terminal 2 (B/R) and battery positive terminal using a digital circuit tester.

SEL949X

OK or NG

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

FLOW”, SC-14.

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

IDX

SC-17

Page 81

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

−30°C to −20°C (−22°F to −4°F) 8.2

−19°C to −10°C (−2°F to 14°F) 8.7

−9°C to 0°C (16°F to 32°F) 9.1

More than 1°C (More than 34°F) 9.4

NHSC0019S05

Construction

NHSC0006

SEL457TB

Removal and Installation

REMOVAL

1. Remove air duct assembly.

2. Remove harness protector from engine room harness.

3. Disconnect starter motor harness.

4. Remove starter motor mounting bolts (two).

5. Remove starter motor.

SC-18

MEL209O

NHSC0007

NHSC0007S01

Page 82

STARTING SYSTEM

Removal and Installation (Cont’d)

SEL934Y

INSTALLATION

To install, reverse the removal procedure.

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.

NHSC0007S02

NHSC0008

IDX

SC-19

Page 83

System Description

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 3 (S) through:

! 120A fusible link (letter A, located in the fusible link box), and ! 10A fuse (No. 70, 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 3 (S) detecting the input voltage. The charging circuit is protected by the 120A 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. 30, located in the fuse block (J/B)] ! to combination meter terminal 66 for the charge warning lamp.

Ground is supplied to terminal 68 of the combination meter through terminal 2 (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 malfunction is indicated.

NHSC0009

SC-20

Page 84

CHARGING SYSTEM

Wiring Diagram — CHARGE —

NHSC0010

IDX

SC-21

MEL586Q

Page 85

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.

NHSC0020

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-22

Page 86

SEL420X

CHARGING SYSTEM

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

9. Press “ENTER” to continue.

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-24.

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-23

IDX

Page 87

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-25.

LOW CHARGING VOLTAGE Go to “WORK FLOW”, SC-25.

HIGH CHARGING VOLTAGE Go to “WORK FLOW”, SC-25.

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-25.

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

NHSC0020S01

SC-24

Page 88

CHARGING SYSTEM

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

WORK FLOW

NHSC0020S02

IDX

SC-25

SEL423X

Page 89

CHARGING SYSTEM

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

DIAGNOSTIC PROCEDURE 1 Check “L” Terminal Circuit

NHSC0020S03

NHSC0020S0301

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 A2 terminal 2 (BR) with the ignition switch in the ON position.

SEL966X

OK or NG

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

system test.

NG ! Check the following.

! 10A fuse [No. 30, 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-26

Page 90

CHARGING SYSTEM

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

DIAGNOSTIC PROCEDURE 2 Check “B” Terminal Circuit

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 B terminal E46 terminal 1 (B/R) and ground using a digital circuit tester.

OK or NG

OK ! GO TO 3.

NG ! Check the following.

! 120A fusible link (letter A, located in fusible link box) ! Harness for open or short between alternator and fusible link

=NHSC0020S04

NHSC0020S0401

SEL967XA

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

Check voltage between alternator B terminal E46 terminal 1 (B/R) and battery positive terminal using a digital circuit tester.

SEL968XA

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.

IDX

SC-27

Page 91

CHARGING SYSTEM

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

DIAGNOSTIC PROCEDURE 3 Check “S” Terminal Circuit

=NHSC0020S05

NHSC0020S0501

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 A2 terminal 3 (B/R) and ground using a digital circuit tester.

SEL969X

OK or NG

OK ! GO TO 3.

NG ! Check the following.

! 10A fuse (No. 70, located in fuse and fusible link box) ! Harness for open or short between alternator and fuse

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

Check voltage between alternator connector A2 terminal 3 (B/R) and battery positive terminal using a digital circuit tester.

SEL970X

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

NHSC0020S06

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.

SC-28

Page 92

CHARGING SYSTEM

Construction

NHSC0012

SEL460T

Removal and Installation

REMOVAL

1. Remove engine undercover RH.

2. Remove side inspection cover RH.

3. Loosen belt idler pulley.

4. Remove drive belt.

5. Remove A/C compressor mounting bolts (four).

6. Slide A/C compressor forward.

7. Disconnect alternator harness connector.

8. Remove alternator upper bolt and lower bolt.

INSTALLATION

To install, reverse the removal procedure.

SEL974Y

NHSC0013

NHSC0013S01

NHSC0013S02

IDX

SEL935Y

SC-29

Page 93

Battery

SERVICE DATA AND SPECIFICATIONS (SDS)

Battery

Type 80D26L

Capacity 12V - 55AH

Cold cranking current (For reference value)

582A

Starter

M0T87181

Type

Applied model A/T

System voltage 12V

Terminal voltage 11.0V

No-load

Minimum diameter of commutator 28.8 mm (1.134 in)

Minimum length of brush 7.0 mm (0.276 in)

Brush spring tension 18.3 - 24.8 N (18.3 - 2.53 kg, 4.11 - 5.58 lb)

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

Clearance between pinion front edge and pinion stopper 0.5 - 2.0 mm (0.020 - 0.079 in)

Current Less than 90A

Revolution More than 2,800 rpm

MITSUBISHI make

Reduction gear type

NHSC0014

NHSC0015

Alternator

Type

Nominal rating 12V - 110A

Ground polarity Negative

Minimum revolution under no-load (When 13.5 volts is applied) Less than 1,100 rpm

Hot output current (When 13.5 volts is applied)

Regulated output voltage 14.1 - 14.7V

Minimum length of brush More than 6.00 mm (0.2362 in)

Brush spring pressure 1.000 - 3.432 N (102 - 350 g, 3.60 - 12.34 oz)

Slip ring minimum outer diameter More than 26.0 mm (1.024 in)

Rotor (Field coil) resistance 2.16 - 2.46Ω

LR1110-723V

HITACHI make

(More than 35A/1,300 rpm)

More than 70A/1,800 rpm More than 91A/2,500 rpm

More than 110A/5,000 rpm

NHSC0016

SC-30

Page 94

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

Isofix Child Restraint Anchorage ...............................13

REMOVAL AND INSTALLATION

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .........14

Precautions ................................................................14

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

SPECIAL SERVICE TOOLS

SRS Configuration .....................................................16

Seat Belt Pre-tensioner with Load Limiter.................17

Side Air Bag...............................................................17

SRS Component Parts Location ...............................18

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

REMOVAL AND INSTALLATION

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

REMOVAL AND INSTALLATION

Crash Zone Sensor ...................................................19

REMOVAL AND INSTALLATION

Satellite Sensor..........................................................20

REMOVAL AND INSTALLATION

Driver Air Bag Module and Spiral Cable ...................21

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

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

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

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

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

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

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

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

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

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

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

........3

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

.......10

.....10

......14

.....14

SECTION

REMOVAL AND INSTALLATION REMOVAL INSTALLATION

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

REMOVAL INSTALLATION

Side Air Bag Module..................................................25

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

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

INFORMATION FROM CUSTOMER PRELIMINARY CHECK WORK FLOW

Schematic ..................................................................38

Wiring Diagram - SRS -.............................................39

SRS Operation Check ...............................................42

DIAGNOSTIC PROCEDURE 1

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

DIAGNOSTIC PROCEDURE 2 DIAGNOSTIC PROCEDURE 3

...............................................................21

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

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

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

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

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

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

HOW TO CHANGE SELF-DIAGNOSIS MODE

..........................................................37

...............................21

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

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

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

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

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

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

...................................................34

............................................34

.........35

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

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

..................................42

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

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

IDX

Page 95

CONTENTS (Cont’d)

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

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 .....................................................60

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

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

..................................57

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

......................59

DIAGNOSTIC PROCEDURE 9

Trouble Diagnoses: ″AIR BAG″ Warning Lamp

Does Not Turn On .....................................................62

DIAGNOSTIC PROCEDURE 10

Collision Diagnosis ....................................................63

FOR FRONTAL COLLISION FOR SIDE COLLISION

..................................60

................................62

.....................................63

.............................................65

RS-2

Page 96

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. The SRS composition which is available to INFINITI I35 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 should 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

Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector.

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 “SRS Operation Check” for details. (RS-42)

! 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.)

NHRS0001

NHRS0002

NHRS0002S01

IDX

RS-3

Page 97

SEAT BELTS

Precautions (Cont’d)

! 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.

! 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 98

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 front and rear kicking plate, then remove center pillar upper and lower garnish. Refer to BT-33, “SIDE AND FLOOR TRIM” for details.

7. Disconnect seat belt pre-tensioner connector.

8. Remove the screw securing seat belt pre-tensioner retractor, then remove seat belt and seat belt pre-tensioner retractor.

9. Remove bolts securing seat belt adjuster, then remove seat belt adjuster.

=NHRS0003

SRS977

RS-5

IDX

Page 99

Front Seat Belt (Cont’d)

SEAT BELTS

RS-6

SRS016A

Page 100

SEAT BELTS

Rear Seat Belt

REMOVAL AND INSTALLATION

1. Remove rear seat. Refer to BT-50, “REAR SEAT” for details.

2. Remove outer and floor anchor bolt.

3. Remove rear seatback. Refer to “REAR SEAT” for details.

4. Remove rear side garnish. Refer to BT-33, “SIDE AND FLOOR TRIM” for details.

5. Remove rear parcel shelf finisher. Refer to BT-33, “SIDE AND FLOOR TRIM” for details.

6. Remove bolts securing rear seat belt retractor, then remove seat belt and seat belt retractor.

Rear Seat Belt

=NHRS0004

RS-7

IDX

SRS008A

Infiniti I35 2003 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual