Nissan Cube 2011 Workshop Manual

Page 1

Edition: October 2010 Revision: December 2011 Publication No. SM1E-1Z12U1

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, recording or otherwise, without the prior written permission of NISSAN MOTOR CO., LTD.

QUICK REFERENCE INDEX

GENERAL INFORMATION

B ENGINE

C ELECTRIC POWER TRAIN

D TRANSMISSION & DRIVELINE

E SUSPENSION

F BRAKES

G STEERING

H RESTRAINTS

I VENTILA TIO N, HEA T ER & AIR

CONDITIONER

J BODY INTERIOR

K BODY EXTERIOR, DOORS,

ROOF & VEHICLE SECURITY

L DRIVER CONTROLS

M ELECTRICAL & POWER CON-

TROL

N DRIVER INFORMATION &

MULTIMEDIA

O CRUISE CONTROL &

DRIVER ASSISTANCE

P MAINTENANCE

General Information

Engine Mechanical

Engine Lubrication System

Engine Cooling System

Engine Control System

Fuel System

Exhaust System

STR

Starting System

ACC

Accelerator Control System

HBC

Hybrid Control System

HBB

Hybrid Battery System

HBR

Hybrid Brake System

EVC

EV Control System

TMS

Traction Motor System

EVB

EV Battery System

Vehicle Charging System

HCO

High Voltage Cooling System

Clutch

Transaxle & Transmission

DLN

Driveline

FAX

Front Axle

RAX

Rear Axle

FSU

Front Suspension

RSU

Rear Suspension

SCS

Suspension Control System

Road Wheels & Tires

Brake System

Parking Brake System

BRC

Brake Control System

Steering System

STC

Steering Control System

Seat Belt

SBC

Seat Belt Control System

SRS Airbag

SRC

SRS Airbag Control System

VTL

Ventilation System

Heater & Air Conditioning System

HAC

Heater & Air Conditioning Control System

INT

Interior

Instrument Panel

Seat

ADP

Automatic Drive Positioner

DLK

Door & Lock

SEC

Security Control System

Glass & Window System

PWC

Power Window Control System

Roof

Hood

EXT

Exterior

BRM

Body Repair

MIR

Mirrors

EXL

Exterior Lighting System

INL

Interior Lighting System

Wiper & Washer

DEF

Defogger

HRN

Horn

VSP

Approaching Vehicle Sound for Pedestrians (VSP)

PWO

Power Outlet

BCS

Body Control System

LAN

LAN System

PCS

Power Control System

CHG

Charging System

Power Supply, Ground & Circuit Elements

MWI

Meter, Warning Lamp & Indicator

WCS

Warning Chime System

Sonar System

Audio, Visual & Navigation System

CCS

Cruise Control System

DAS

Driver Assistance System

DMS

Drive Mode System

Maintenance

A B

Page 2

FOREWORD

This manual contains maintenance and repair procedure for the 2011 NISSAN CUBE.

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 pa rts which are not specifically recommended by NISSAN must first be completely sat isfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service

method selected.

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PLEASE HELP MAKE THIS SERVICE MANUAL BETTER!

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

Use this form to report any issues or comments you may have regarding our Service Manuals.

Please print this form and type or write your comments below. Mail or fax to:

Nissan North America, Inc. Technical Service Information 39001 Sunrise Drive, P.O. Box 9200 Farmington Hills, MI USA 48331 FAX: (248) 488-3880

SERVICE MANUAL: Model: Year:

PUBLICATION NO. (Refer to Quick Reference Index ):

Please describe any Service Manual issues or problems in detail:

Page number(s)

Note: Please include a copy of each page, marked with your comments.

Are the trouble diagnosis procedures logical and easy to use? (circle your answer) YES NO

If no, what page number(s)?

Note: Please include a copy of each page, marked with your comments.

Please describe the issue or problem in detail:

Is the organization of the manual clear and easy to follow? (circle your answer) YES NO

Please comment:

What information should be included in NISSAN Service Manuals to better support you in servicing or repairing customer vehicles?

DATE: YOUR NAME: POSITION:

DEALER: DEALER NO.: ADDRESS:

CITY: STATE/PROV./COUNTRY: ZIP/POSTAL CODE:

Page 4

QUICK REFERENCE CHART CUBE

2011

QUICK REFERENCE CHART CUBE PFP:00000

ENGINE TUNE-UP DATA (MR18DE) ELS0003W

Engine model MR18DE Firing order 1-3-4-2

, psi)

rpm

700 ± 50

13° ± 5°

98 (1.0, 14)

Idle speed CVT (In “P or N” position) M/T (In Neutral position)

Ignition timing (BTDC at idle speed)

Tensions of drive belt Auto adjustment by auto tensione r Radiater cap relief pressure

Standard 78 - 98 (0.8 - 1.0, 11 - 14) Limit 59 (0.6, 9)

Cooling system leakage testing pressure

kPa (kg/cm

Compression pressure

Spark plug (Iridium-tipped type)

kPa (kg/cm Standard 1,500 (15.3, 217.5) Minimum 1,200 (12.2, 174) Differential limit between cylinders 100 (1.0, 14.5) Make DENSO Standard type FXE20HR11 Gap (Nominal) mm (in)

Standard 1.1 (0.043) Limit 1.4 (0.055)

, psi)/250 rpm

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QUICK REFERENCE CHART CUBE

2011

FRONT WHEEL ALIGNMENT

Minimum –0° 55′ (–0.92°)

Camber Degree minute (Decimal degree)

Caster Degree minute (Decimal degree)

Kingpin inclination Degree minute (Decimal degree)

Total toe-in Distance

Toe-in

Toe angle (left wheel or right wheel) Degree minute (Decimal degree)

Measure value under unladen* conditions. *: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

Nominal –0° 10′ (–0.17°) Maximum 0° 35′ (0.58°) Left and right difference 0° 45′ (0.75°) Minimum 3° 55′ (3.92°) Nominal 4° 40′ (4.67°) Maximum 5° 25′ (5.41°) Left and right difference 0° 45′ (0.75°) Minimum 9° 10′ (9.17°) Nominal 9° 55′ (9.92°) Maximum 10° 40′ (10.66°) Minimum 0 mm (0 in) Nominal In 1.0 mm (0.05 in) Maximum In 2.0 mm (0.07 in) Minimum 0° 00′ (0.00°) Nominal In 0° 03 Maximum In 0° 06′ (0.10°)

ELS0003X

′ (0.05°)

REAR WHEEL ALIGNMENT ELS0003Y

Minimum –2° 00′ (–2.01°) Camber Degree minute (Decimal degree)

Total toe-in Distance

Toe-in

Toe angle (left wheel or right wheel) Degree minute (Decimal degre e)

Measure value under unladen* conditions. *: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

Nominal –1° 31′ (–1.51°)

Maximum –1° 01′ (–1.01°)

Minimum Out 1.0 mm (Out 0.039 in)

Nominal In 3.0 mm (In 0.118 in)

Maximum In 7.0 mm (In 0.275 in)

Minimum Out 0° 02′ (Out 0.04°)

Nominal In 0° 08′ (In 0.14°)

Maximum In 0° 19′ (In 0.32°)

BRAKE PEDAL

Unit: mm (in.)

Depressed brake pedal height (H1)

Brake pedal reserve height (H [Depressing 490 N (50 kg, 110 lb) while turning the engine ON]

M/T 162.3 - 172.3 (6.39 - 6.78)

CVT 172.4 - 182.4 (6.79 - 7.18)

M/T 80 (3.15) or more

CVT 85 (3.35) or more

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QUICK REFERENCE CHART CUBE

2011

FRONT DISC BRAKE

Unit: mm (in.)

Item Limit Brake pad Wear thickness 2.0 (0.079) Disc rotor Wear thickness 22.0 (0.866)

REAR DRUM BRAKE

Unit: mm (in.)

Item Limit Brake lining Wear thickness 1.5 (0.059) Brake drum Wear inner diameter 230.0 (9.06)

REFILL CAPACITIES ELS00040

UNIT Liter US measure Imp measure Fuel tank 50.0 13-1/4 gal 11 gal

Engine coolant capacity (With reservoir tank at “MAX” level)

Engine oil

Transmission

Air conditioning system

CVT models 7.1 7-1/2 qt 6-1/4 qt M/T models 6.8 7-1/4 qt 6 qt Drain and refill

With oil filter change 4.1 4-3/8 qt 3-5/8 qt

Without oil filter change 3.8 4 qt 3-3/8 qt Dry engine (Overhaul) 4.9 5-1/8 qt 4-3/8 qt CVT 7.4 7-7/8 qt 6-1/2 qt M/T 2.0 4-1/4 pt 3-1/2 pt Compressor oil 0.12 4.1 fl oz 4.2 fl oz Refrigerant 0.45 kg 1.0 lb 1.0 lb

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GI-1

GENERAL INFORMATION

SECTION GI

CONTENTS

GENERAL INFORMATION

REGULAR GRADE

HOW TO USE THIS MANUAL ......................3

HOW TO USE THIS MANUAL ............................3

Description ................................................................3

Terms ........................................................................3

Units ..........................................................................3

Contents .......................... ..........................................3

Relation between Illustrations and Descriptions .......4

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

HOW TO FOLLOW TROUBLE DIAGNOSES .....6

Description ................................................................6

How to Follow Test Groups in Trouble Diagnosis ......6

Key to Symbols Signifying Measurements or Pro-

cedures .....................................................................

HOW TO READ WIRING DIAGRAMS ................9

Connector Symbols ...................................................9

Sample/Wiring Diagram -Example- .........................10

Connector Information .............................................12

ABBREVIATIONS ..............................................14

Abbreviation List ......................................................14

TIGHTENING TORQUE OF STANDARD

BOLTS ................................................................

Description ..............................................................19

Tightening Torque Table (New Standard Includ-

ed) ...........................................................................

RECOMMENDED CHEMICAL PRODUCTS

AND SEALANTS ................................................

Recommended Chemical Products and Sealants ....22

VEHICLE INFORMATION ............................23

IDENTIFICATION INFORMATION .....................23

Model Variation .......................................................23

Information About Identification or Model Code ......23

Dimensions .............................................................27

Wheels & Tires ........................................................27

PRECAUTION ..............................................28

PRECAUTIONS .................................................28

Description .......................... ....... ...... ... ....... ...... ........28

Precaution for Supplemental Restraint Syste m (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-

SIONER" .................................................................

Precaution for Procedure without Cowl Top Cove r ....28

Cautions in Removing Battery Terminal and AV

Control Unit (Models with AV Control Unit) .............

General Precautions ................................................29

Three Way Catalyst .................................................30

Multiport Fuel Injection System or Engine Control

System ................................ ....... ...... ... ....... ...... ........

Hoses ......................................................................31

Engine Oils ..............................................................31

Air Conditioning .......................................................32

Fuel .................................. ... ... ..................................32

LIFTING POINT .................................................33

Commercial Service Tools .......................................33

Garage Jack and Safety Stand and 2-Pole Lift .......33

Board-On Lift ...........................................................34

TOW TRUCK TOWING .....................................35

Tow Truck Towing ...................................................35

Vehicle Recovery (Freeing a Stuck Vehicle) ...........35

BASIC INSPECTION ...................................37

SERVICE INFORMATION FOR ELECTRICAL

INCIDENT ..........................................................

Work Flow ................................................................37

Control Units and Electrical Parts ....................... .....37

How to Check Terminal ...........................................38

Intermittent Incident .................................................41

Circuit Inspection .....................................................44

CONSULT-III/GST CHECKING SYSTEM .........49

Description .......................... ....... ...... ... ....... ...... ........49

Revision: 2011 December 2011 CUBE

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GI-2

CONSULT-III Function and System Application*1 ... 49 CONSULT-III/GST Data Link Connector (DLC)

Circuit .....................................................................

Wiring Diagram - CONSULT-III/GST CHECKING

SYSTEM - ...............................................................

INSPECTION AND ADJUSTMENT ...................54

ADDITIONAL SERVICE WHEN REMOVING BAT-

TERY NEGATIVE TERMINAL ..................................

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Required

Procedure After Battery Disconnection ............ ......

Krom

VEHICLE INFORMATION ..........................

DIMENSIONS AND WEIGHTS .......................... 55

Dimensions and Weights ........................................ 55

PRECAUTION ............................................ 56

LIFTING POINT ................................................. 56

Lifting Point ............................................................. 56

TOW TRUCK TOWING ..................................... 57

Tow Truck Towing ...................................................57

Vehicle Recovery (Freeing a Stuck Vehicle) ........... 57

Revision: 2011 December 2011 CUBE

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HOW TO USE THIS MANUAL

GI-3

< HOW TO USE THIS MANUAL >

[REGULAR GRADE]

HOW TO USE THIS MANUAL

Description INFOID:0000000006506925

This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”.

Terms INFOID:0000000006506926

• The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle.

WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.

Standard value: Tolerance at inspection and adjustment. Limit value: The maximum or minimum limit value that should not be exceeded at inspection and adjustment.

Units INFOID:0000000006506927

• The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about the standard tightening torque.

“Example”

Range

Standard

Contents INFOID:0000000006506928

• A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by matching it to the section's black tab.

• THE CONTENTS are listed on the first page of each section.

• THE TITLE is indicated on the upper portion of each page and shows the part or system.

• THE PAGE NUMBER of each section consists of two or three letters which designate the particular section and a number (e.g. “BR-5”).

• THE SMALL ILLUSTRATIONS show the import ant steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary.

Outer Socket Lock Nut : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)

Drive Shaft Installation Bolt : 44.3 N·m (4.5 kg-m, 33 ft-lb)

Revision: 2011 December 2011 CUBE

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GI-4

< HOW TO USE THIS MANUAL >

[REGULAR GRADE]

HOW TO USE THIS MANUAL

Relation between Illustrations and Descriptions

INFOID:0000000006506929

The following sample explains the relationship between the part description in an illustration, the part name in the text and the service procedures.

Components INFOID:0000000006506930

• THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration.

SAIA0519E

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HOW TO USE THIS MANUAL

GI-5

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[REGULAR GRADE]

SYMBOLS

1. Union bolt 2. Copper washer 3. Brake hose

4. Cap 5. Bleed valve 6. Sliding pin bolt

7. Piston seal 8. Piston 9. Piston boot

10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt

13. Washer 14. Sliding pin boot 15. Bushing

16. Torqu e member 17. Inner shim cover 18. Inner shim

19. Inner pad 20. Pad retainer 21. Pad wear se nsor

22. Outer pad 23. Outer shim 24. Outer shim cover 1: PBC (Poly Butyl Cuprysil) grease

or silicone-based grease

2: Rubber grease : Brake fluid

Refer to GI section for additional symbol definitions.

SFIA2959E

SAIA0749E

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GI-6

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[REGULAR GRADE]

HOW TO FOLLOW TROUBLE DIAGNOSES

Description INFOID:0000000006506931

NOTICE:

Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing.

• Before performing trouble diagnoses, read the “Work Flow” in each section.

• After repairs, re-check that the problem has been completely eliminated.

• Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors.

• When checking circuit continuity, ignition switch should be OFF.

• Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identification of harness connectors.

• Before checking voltage at connectors, check battery voltage.

• After accomplishing the Diagnosis Procedures and Electrical Components Inspection, check that all harness connectors are reconnected as they were.

How to Follow Test Groups in Trouble Diagnosis INFOID:0000000006506932

1. Test group number and test group title

• Test group number and test group title are shown in the upper portion of each test group.

2. Work and diagnosis procedure

• Start to diagnose a problem using procedures indicated in enclosed test groups.

3. Questions and results

• Questions and required results are indicated in test group.

4. Action

• Next action for each test group is indicated based on result of each question.

JPAIA0021GB

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HOW TO FOLLOW TROUBLE DIAGNOSES

GI-7

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[REGULAR GRADE]

Key to Symbols Signifying Measurements or Procedures INFOID:0000000006506933

JPAIA0397GB

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GI-8

< HOW TO USE THIS MANUAL >

[REGULAR GRADE]

HOW TO FOLLOW TROUBLE DIAGNOSES

JPAIA0398GB

Revision: 2011 December 2011 CUBE

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HOW TO READ WIRING DIAGRAMS

GI-9

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[REGULAR GRADE]

HOW TO READ WIRING DIAGRAMS

Connector Symbols INFOID:0000000006506934

Most of connector symbols in wiring diagrams are shown from the terminal side.

• Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark.

• Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark.

• Certain systems and components, especially those related to OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to PG section, “Description”, “HARNESS CONNECTOR”.

• Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

SAIA0257E

SGI363

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GI-10

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[REGULAR GRADE]

HOW TO READ WIRING DIAGRAMS

Sample/Wiring Diagram -Example-

INFOID:0000000006506935

Each section includes wiring diagrams.

Description

JCAWA0150GB

Number Item Description

1 Power supply • This means the power supply of fusible link or fuse. 2 Fuse • “/” means the fuse.

Current rating of fusible link/fuse

• This means the current rating of the fusible link or fuse.

Number of fusible link/ fuse

• This means the number of fusible link or fuse location. 5 Fusible link • “X” means the fusible link. 6 Connector number

• Alphabetic characters show to which harness the connector is placed.

• Numeric characters show the identification number of connectors. 7Switch

• This shows that continuity exists between terminals 1 and 2 when the switch is in the A posi-

tion. Continuity exists between terminals 1 and 3 when the switch is in the B positio n.

8 Circuit (Wiring) • This means the wiring.

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HOW TO READ WIRING DIAGRAMS

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[REGULAR GRADE]

SWITCH POSITIONS

Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when:

• ignition switch is “OFF”

• doors, hood and trunk lid/back door are closed

• pedals are not depressed

• parking brake is released

MULTIPLE SWITCH

The continuity of multiple switch is described in two ways as shown below.

• The switch chart is used in schematic diagrams.

9 Shielded line • The line enclosed by broken line circle shows shield wire.

10 Connectors • This means that a transmission line bypasse s two connectors or more. 11 Option abbreviation

• This means the vehicle specifications which layouts the circuit between “ ”.

12 Relay • This shows an internal representation of the relay. 13 Optional splice • The open circle shows that the splice is optional depending on vehicle application.

14 Splice

• The shaded circle “ ” means the splice.

15 System branch • This shows that the circuit is branched to other systems. 16 Page crossing • This circuit continues to an adjacent page. 17 Component name • This shows the name of a component. 18 Terminal number • This means the terminal number of a connector. 19 Ground (GND) • This shows the ground connection.

Explation of option description

• This shows a explanation of the option abbreviation used on the same page.

Number Item Description

SGI860

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GI-12

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[REGULAR GRADE]

HOW TO READ WIRING DIAGRAMS

• The switch diagram is used in wiring diagrams.

Connector Information INFOID:0000000006506936

Description

JSAIA0017GB

Number Item Description

1 Connector number

• Alphabetic characters show to which harness the connector is placed.

• Numeric characters show the identification number of connectors. 2 Connector type • This means the connector number. Refer to PG-79, "

How To Read Harness Layout".

3 Terminal number • This means the terminal number of a connector.

JCAWA0152GB

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HOW TO READ WIRING DIAGRAMS

GI-13

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[REGULAR GRADE]

4Wire color

• This shows a code for the color of the wire.

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green BG = Beige

BR = Brown OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green

• When the wire color is striped, the base color is given first, followed by the stripe color as

shown below: Example: L/W = Blue with White Stripe

5 Connector

• This means the connector information.

• This unit-sid e is de sc rib ed by the connector symbols.

Number Item Description

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GI-14

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[REGULAR GRADE]

ABBREVIATIONS

Abbreviation List INFOID:0000000006928342

The following ABBREVIATIONS are used:

ABBREVIATION DESCRIPTION

A/C Air conditioner A/C Air conditioning

A/F sensor Air fuel ratio sensor

A/T Automatic transaxle/transmission

ABS Anti-lock braking system

ACCS Advance climate control system

ACL Air cleaner

AP Accelerator pedal

APP Accelerator pedal position

ATF Automatic transmission fluid

AV Audio visual

AWD All wheel drive

ABBREVIATION DESCRIPTION

BARO Barometric pressure

BCM Body control module

BLSD Brake limited slip differential

BPP Brake pedal position

BSW Blind spot warning

ABBREVIATION DESCRIPTION

CKP Crankshaft position

CL Closed loop

CMP Camshaft position

CPP Clutch pedal position CTP Closed throttle position CVT Continuously variable transaxle/transmission

ABBREVIATION DESCRIPTION

1 Drive range first gear

2 Drive range second gear

3 Drive range third gear

4 Drive range fourth gear

DCA Distance control assist DDS Downhill drive support

DFI Direct fuel injection system DLC Data link connector DTC Diagnostic trouble code

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ABBREVIATIONS

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[REGULAR GRADE]

ABBREVIATION DESCRIPTION

E/T Exhaust temperature

EBD Electric brake force distribution

EC Engine control

ECL Engine coolant level

ECM Engine control module

ECT Engine coolant temperature ECV Electrical control valve

EEPROM Electrically erasable programmable read only memory

EFT Engine fuel temperature EGR Exhaust gas reci rcu la tio n

EGRT Exhaust gas recirculation temperature

EGT Exhaust gas temperature EOP Engine oil pressure

EP Exhaust pressure EPR Exhaust pressure regulator EPS Electronically controlled power steering ESP Electronic stability program system

EVAP canister Evaporative emission canister

EVSE Electric vehicle supply equipment

EXC Exhaust control

ABBREVIATION DESCRIPTION

FC Fan control

FCW Forward collision warning

FIC Fuel injector control

FP Fuel pump

FR Front FRP Fuel rail pressure FRT Fuel rail temperature

FTP Fuel tank pressure FTT Fuel tank temperature

ABBREVIATION DESCRIPTION

GND Ground

GPS Global positioning system GST Generic scan tool

ABBREVIATION DESCRIPTION

HBMC Hydraulic body-motion control system

HDD Hard disk drive

HO2S Heated oxygen sensor

HOC Heated oxidation catalyst

HPCM Hybrid power train control module

Revision: 2011 December 2011 CUBE

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GI-16

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[REGULAR GRADE]

ABBREVIATIONS

ABBREVIATION DESCRIPTION

I/M Inspection and maintenance

IA Intake air

IAC Idle air control

IAT Intake air temperature

IBA Intelligent brake assist

IC Ignition control

ICC Intelligent cruise control

ICM Ignition control module

IPDM E/R Intelligent power distribution module engine room

ISC Idle speed control ISS Input shaft speed

ABBREVIATION DESCRIPTION

KS Knock sensor

ABBREVIATION DESCRIPTION

LBC Li-ion battery controller LCD Liquid crystal display LCU Local control unit LDP Lane departure prevention

LDW Lane departure warning

LED Light emitting diode

LH Left-hand

LIN Local interconnect network

ABBREVIATION DESCRIPTION

M/T Manual transaxle/transmission

MAF Mass airflow

MAP Manifold absolute pressure MDU Multi display unit

MI Malfunction indicator

MIL Malfunction indicator lamp

ABBREVIATION DESCRIPTION

NOX Nitrogen oxides

ABBREVIATION DESCRIPTION

O2 Oxygen O2S Oxygen sensor

OBD On board diagnostic

OC Oxidation catalytic converter

OD Overdrive

OL Open loop OSS Output shaft speed

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ABBREVIATIONS

GI-17

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[REGULAR GRADE]

ABBREVIATION DESCRIPTION

P/S Power steering PBR Potentio balance resistor PCV Positive crankcase ventilation PNP Park/Neutral positi on PSP Power steering pressure PTC Positive temperature coefficient PTO Power takeoff

PWM Pulse width modulation

ABBREVIATION DESCRIPTION

RAM Random access memory

RAS Rear active steer

RH Right-hand ROM Read only memory RPM Engine speed

RR Rear

ABBREVIATION DESCRIPTION

SAE Society of Automotive Engineers, Inc. SCK Serial clock SDS Service Data and Specifications SRT System readiness test SST Special Service Tools

ABBREVIATION DESCRIPTION

TC Turbocharger

TCM Transmission control module TCS Traction control sy stem TCU Telematics communication unit

TP Throttle position

TPMS Tire pressure monitoring system

TSS Turbine shaft speed

TWC Three way catalytic converter

ABBREVIATION DESCRIPTION

USS Uphill start support

ABBREVIATION DESCRIPTION

VCM Vehicle control module

VDC Vehicle dynamics control system

VIN Vehicle identification number

VSS Vehicle speed sensor

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GI-18

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[REGULAR GRADE]

ABBREVIATIONS

ABBREVIATION DESCRIPTION

WOT Wide open throttle

ABBREVIATION DESCRIPTION

1 1st range first gear

2 1st range second gear

1GR First gear

ABBREVIATION DESCRIPTION

1 2nd range first gear

2 2nd range second gear

2GR Second gear

2WD 2-wheel drive

ABBREVIATION DESCRIPTION

3GR Third gear

ABBREVIATION DESCRIPTION

4GR Fourth gear

4WAS Four wheel active steer

4WD Four wheel drive

ABBREVIATION DESCRIPTION

5GR Fifth gear

ABBREVIATION DESCRIPTION

6GR Sixth gear

ABBREVIATION DESCRIPTION

7GR Seventh gear

Revision: 2011 December 2011 CUBE

Page 25

TIGHTENING TORQUE OF STANDARD BOLTS

GI-19

< HOW TO USE THIS MANUAL >

[REGULAR GRADE]

TIGHTENING TORQUE OF STANDARD BOLTS

Description INFOID:0000000006506938

This vehicle has both new standard based on ISO* and previous standard bolts/nuts. There are some differences between these two types of bolts/ nuts; shape of the head, grade of strength, hexagonal width across flats and the standard tightening torque.

• For guidance in discriminating, refer to GI-19, "

Tightening Torque Table (New Standard Included)".

• The new standard machine screws and tapping screws have a head of ISO standard torx recess.

• If the tightening torque is not described in the description or figure, refer to GI-19, "

Tightening Torque Table

(New Standard Included)".

*ISO: International Organization for Standardization

Tightening Torque Table (New Standard Included) INFOID:0000000006506939

CAUTION:

• The special parts are excluded.

• The bolts/nuts in these tables have a strength (discrimination) number/symbol assigned to the head or the like. As to the relation between the strength grade in these tables and the strength (discrimination) number/symbol, refer to “DISCRIMINATION OF BOLTS AND NUTS”.

PREVIOUS STANDARD

CAUTION:

Grade

(Strength

grade)

Bolt size

Bolt diameter

Hexagonal

width

across flats

Pitch

Tightening torque (Without lubricant)

Hexagon head bolt Hexagon flange bolt

N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb

M66.0 10 1.05.50.564 49 70.715 62

M8 8.0 12

1.25 13.5 1.4 10 — 17 1.7 13 —

1.0 13.5 1.4 10 — 17 1.7 13 —

M10 10.0 14

1.5282.921 —353.626 —

1.25 28 2.9 21 — 35 3.6 26 —

M12 12.0 17

1.75 45 4.6 33 — 55 5.6 41 —

1.25 45 4.6 33 — 65 6.6 48 —

M14 14.0 19 1.5 80 8.2 59 — 100 10 74 —

M6 6.0 10 1.0 9 0.92 7 80 11 1.1 8 97

M8 8.0 12

1.25 22 2.2 16 — 28 2.9 21 —

1.0222.216 —282.921 —

M10 10.0 14

1.5454.633 —555.641 —

1.25 45 4.6 33 — 55 5.6 41 —

M12 12.0 17

1.75 80 8.2 59 — 100 10 74 —

1.25 80 8.2 59 — 100 10 74 —

M1414.0 19 1.513013 96 —17017125—

M6 6.0 10 1.0 11 1.1 8 — 13.5 1.4 10 —

M8 8.0 12

1.25 28 2.9 21 — 35 3.6 26 —

1.0282.921 —353.626 —

M10 10.0 14

1.5555.641 —808.259 —

1.25 55 5.6 41 — 80 8.2 59 —

M12 12.0 17

1.75 100 10 74 — 130 13 96 —

1.25 100 10 74 — 130 13 96 —

M14 14.0 19 1.5 170 17 125 — 210 21 155 —

Revision: 2011 December 2011 CUBE

Page 26

GI-20

< HOW TO USE THIS MANUAL >

[REGULAR GRADE]

TIGHTENING TORQUE OF STANDARD BOLTS

The parts with aluminum or the cast iron washer surface/thread surface are excluded.

NEW STANDARD BASED ON ISO

CAUTION:

1. Use tightening torque with lubricant for the new standard bolts/nuts in principle. Friction coefficient stabilizer is applied to the new standard bolts/nuts.

2. However, use tightening torque without lubricant for the following cases. Friction coefficient st abilizer is not applied to the following bolts/nuts.

- Grade 4.8, M6 size bolt, Conical spring washer installed

- Paint removing nut (Size M6 and M8) for fixing with weld bolt

Grade

(Strength

grade)

Bolt size

Bolt diameter

Hexagonal

width

across flats

Pitch

Tightening torque

Hexagon head bolt Hexagon flange bolt

N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb

4.8 (Without lubricant)

M6 6.0 10 1.0 5.5 0.56 4 49 7 0.71 5 62

M8 8.0 13

1.25 13.5 1.4 10 — 17 1.7 13 —

1.0 13.5 1.4 10 — 17 1.7 13 —

M10 10.0 16

1.5282.921— 353.626 —

1.25 28 2.9 21 — 35 3.6 26 —

M12 12.0 18

1.75 45 4.6 33 — 55 5.6 41 —

1.25 45 4.6 33 — 65 6.6 48 —

M14 14.0 21 1.5 80 8.2 59 — 100 10 74 —

4.8 (With lubricant)

M6 6.0 10 1.0 4 0.41 3 35 5.5 0.56 4 49

M8 8.0 13

1.25 11 1.1 8 — 13.5 1.4 10 —

1.0 11 1.1 8 — 13.5 1.4 10 —

M10 10.0 16

1.5222.216— 282.921 —

1.25 22 2.2 16 — 28 2.9 21 —

M12 12.0 18

1.75 35 3.6 26 — 45 4.6 33 —

1.25 35 3.6 26 — 45 4.6 33 —

M14 14.0 21 1.5 65 6.6 48 — 80 8.2 59 —

8.8 (With lubricant)

M6 6.0 10 1.0 8 0.82 6 71 10 1.0 7 89

M8 8.0 13

1.25 21 2.1 15 — 25 2.6 18 —

1.0212.115— 252.618 —

M10 10.0 16

1.5404.130— 505.137 —

1.25 40 4.1 30 — 50 5.1 37 —

M12 12.0 18

1.75 70 7.1 52 — 85 8.7 63 —

1.25 70 7.1 52 — 85 8.7 63 —

M14 14.0 21 1.5 120 12 89 — 140 14 103 —

10.9 (With lubricant)

M6 6.0 10 1.0 10 1.0 7 89 12 1.2 9 106

M8 8.0 13

1.25 27 2.8 20 — 32 3.3 24 —

1.0272.820— 323.324 —

M10 10.0 16

1.5555.641— 656.648 —

1.25 55 5.6 41 — 65 6.6 48 —

M12 12.0 18

1.75 95 9.7 70 — 110 11 81 —

1.25 95 9.7 70 — 110 11 81 —

M14 14.0 21 1.5 160 16 118 — 180 18 133 —

Revision: 2011 December 2011 CUBE

Page 27

TIGHTENING TORQUE OF STANDARD BOLTS

GI-21

< HOW TO USE THIS MANUAL >

[REGULAR GRADE]

DISCRIMINATION OF BOLTS AND NUTS

SAIA0453E

Revision: 2011 December 2011 CUBE

Page 28

GI-22

< HOW TO USE THIS MANUAL >

[REGULAR GRADE]

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS

Recommended Chemical Products and Sealants INFOID:0000000006506940

Refer to the following chart for help in selecting the appropriate chemical product or sealant.

Product Description Purpose

Nissan North America

Part No. (USA)

Nissan Canada Part

No. (Canada)

Aftermarket Cross-

reference Part Nos.

Rear View Mirror Adhesive

Used to permanently remount rear view mirrors to windows.

999MP-AM000P 99998-50505 P ermatex 81844

Anaerobic Liquid Gasket

For metal-to-metal flange sealing. Can fill a 0.38 mm (0.015 inch) gap and provide instant sealing for most powertrain applications.

999MP-AM001P 99998-50503

Permatex 51813 and 51817

High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.)

• Do not use on plastic.

999MP-AM002P 999MP-AM002P P erm ate x 56 52 1

4 Silicone RTV

Gasket Maker

999MP-AM003P (Ultra Grey)

99998-50506 (Ultra Grey)

Permatex Ultra Grey 82194: Three Bond 1207,1215, 1216, 1217F, 1217G and 1217H Nissan RTV Part No. 999MP-A7007

Gasket Maker for Maxima/ Quest 5-speed automatic transmission (RE5F22A)

––

Three Bond 1281B or exact equivalent in its quality

High Temperature, High Strength Thread Locking Sealant (Red)

Threadlocker 999MP-AM004P 999MP-AM004P

Permatex 27200: Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388 Loctite 648

Medium Strength Thread Locking Sealant (Blue)

Threadlocker (service tool removable)

999MP-AM005P 999MP-AM005P

Permatex 24200, 24206, 24240, 24283 and 09178: Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374

Revision: 2011 December 2011 CUBE

Page 29

IDENTIFICATION INFORMATION

GI-23

< VEHICLE INFORMATION >

[REGULAR GRADE]

VEHICLE INFORMATION

IDENTIFICATION INFORMATION

Model Variation INFOID:0000000006506941

Model variation code (Prefix and suffix designations)

Information About Identification or Model Code INFOID:0000000006506942

IDENTIFICATION NUMBER

Destination Body Engine Axle Handle Transmission Grade Model

USA

(Except for California)

4−door wagon MR18DE 2WD LH drive

6M/T

STD TDSALCY-EUA

MID

TDSALDY-EUA

CVT

TDSALDZ-EUA

UPPER TDSALGZ-EUA

California

6M/T

STD TDSALCY-EVA

MID

TDSALDY-EVA

CVT

TDSALDZ-EVA

UPPER TDSALGZ-EVA

Canada

6M/T

MID

TDSALDY-ENA

CVT

TDSALDZ-ENA

UPPER TDSALGZ-ENA

JPAIA0969GB

Revision: 2011 December 2011 CUBE

Page 30

GI-24

< VEHICLE INFORMATION >

[REGULAR GRADE]

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

CERTIFICATION LABEL

FMVSS certification label (For USA)

1. Vehicle identification number plate 2. Vehicle identification number (Chassis number)

3. Vehicle identification plate

4. Air conditioner specification label 5. Emission control information label 6. Tire and loading information label

7. FMVSS certification label (For USA)

CMVSS certification label (For Canada)

JPAIA0970ZZ

JPAIA0971GB

Revision: 2011 December 2011 CUBE

Page 31

IDENTIFICATION INFORMATION

GI-25

< VEHICLE INFORMATION >

[REGULAR GRADE]

CMVSS certification label (For Canada)

IDENTIFICATION PLATE

1. MFR Month/Year 2. Gross vehicle weight rating 3. Gross axle weight rating (Front)

4. Tire size 5. Wheel size 6. Tire inflation pressure

7. Gross axle weight rating (Rear) 8. Vehicle identification number 9. Verification model code

10. Body color number 11. Trim color number 12. Transmission type

13. Axle type 14. Engine type 15. Engine displacement

16. Vin bar code

JSAIA1700ZZ

1. MFR Month/Year 2. Gross vehicle weight rating 3. Gross axle weight rating (Front)

4. Tire size 5. Wheel size 6. Tire inflation pressure

7. Gross axle weight rating (Rear) 8. Vehicle identification number 9. Verification model code

10. Body color number 11. Trim color number 12. Transmission type

13. Axle type 14. Engine type 15. Engine displacement

16. Vin bar code

JSAIA1701ZZ

Revision: 2011 December 2011 CUBE

Page 32

GI-26

< VEHICLE INFORMATION >

[REGULAR GRADE]

IDENTIFICATION INFORMATION

ENGINE SERIAL NUMBER

AUTOMATIC TRANSMISSION SERIAL NUMBER

MANUAL TRANSAXLE SERIAL NUMBER

JPAIA0672ZZ

1. Type 2. Vehicle identification number (Chassis number) 3. Model variation code

4. Body color code 5. Trim color code 6. Engine model

7. Engine displacement 8. Transmission model 9. Axle model

10. Manufacturing Plant

: Vehicle front

SAIA1341E

: Vehicle front

JPAIA0448ZZ

: Vehicle front

SAIA1338E

Revision: 2011 December 2011 CUBE

Page 33

IDENTIFICATION INFORMATION

GI-27

< VEHICLE INFORMATION >

[REGULAR GRADE]

Dimensions INFOID:0000000006506943

Unit: mm (in)

*1: With front license plate bracket *2: Without front license plate bracket

Wheels & Tires INFOID:0000000006928311

Overall length

3,980 (156.7)

3,975 (156.5)

Overall width 1,695 (66.7) Overall height 1,680 (66.1) Front tread 1,475 (58.1) Rear tread 1,480 (58.3) Wheelbase 2,530 (99.6)

Conventional

15 inch

Tire P195/60R15 87H Road wheel

(Steel)

Size 15 × 6J Offset 42 mm (1.65 in)

16 inch

Tire P195/55R16 86V Road wheel

(Aluminum)

Size 16 × 6J Offset 42 mm (1.65 in)

Spare 15 inch

Tire T125/70D15 95M Road wheel

(Steel)

Size 15 × 4T Offset 35 mm (1.38 in)

Revision: 2011 December 2011 CUBE

Page 34

GI-28

< PRECAUTION >

[REGULAR GRADE]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Description INFOID:0000000006506945

Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.

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

INFOID:0000000006928305

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front 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. Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this Service Manual.

WARNING:

Always observe the following items for preventing accidental activation.

• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision that would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.

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

• Never 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 harnesses or harness connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

Always observe the following items for preventing accidental activation.

• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury.

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

Precaution for Procedure without Cowl Top Cover INFOID:0000000006928308

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

Cautions in Removing Battery Terminal and AV Control Unit (Models with AV Control Unit)

INFOID:0000000006928309

CAUTION:

Remove battery terminal and AV control unit after a lapse of 30 seconds or more after turning the ignition switch OFF.

PIIB3706J

Revision: 2011 December 2011 CUBE

Page 35

PRECAUTIONS

GI-29

< PRECAUTION >

[REGULAR GRADE]

NOTE:

After the ignition switch is turned OFF, the AV control unit continues operating for approximately 30 seconds. Therefore, data corruption may occur if battery voltage is cut off within 30 seconds.

General Precautions INFOID:0000000006506949

• Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle.

• Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle. These operations should be done on a level surface.

• When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.

• Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery terminal.

• If the battery terminals are disconnected, recorded memory of radio and each control unit is erased.

• T o prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot.

• Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.

• Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire.

• Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly.

• Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones.

• Replace inner and outer races of tapered roller bearings and needle bearings as a set.

• Arrange the disassembled parts in accordance with their assembled locations and sequence.

• Do not touch the terminals of electrical components which use microcomputers (such as ECM). Static electricity may damage internal electronic components.

SGI285

SGI231

SEF289H

SGI233

Revision: 2011 December 2011 CUBE

Page 36

GI-30

< PRECAUTION >

[REGULAR GRADE]

PRECAUTIONS

• After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.

• Use only the fluids and lubricants specified in this manual.

• Use approved bonding agent, sealants or their equivalents when required.

• Use hand tools, power tools (disassembly only) and recommended special tools where specified for safe and efficient service repairs.

• When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leakage.

• Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint.

WARNING:

To prevent ECM from storing the diagnostic trouble codes, never carelessly disconnect the harness connectors which are related to the engine control system and TCM (transmission control module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and TM sections.

Three Way Catalyst INFOID:0000000006506950

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions.

• Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.

• When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary.

• Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the catalyst.

Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst.

Multiport Fuel Injection System or Engine Control System INFOID:0000000006506951

• Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM: Turn ignition switch to “OFF” position. Disconnect negative battery terminal. Otherwise, there may be damage to ECM.

• Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure.

• Be careful not to jar components such as ECM and mass air flow sensor.

JPAIA0335ZZ

SGI234

SGI787

Revision: 2011 December 2011 CUBE

Page 37

PRECAUTIONS

GI-31

< PRECAUTION >

[REGULAR GRADE]

Hoses INFOID:0000000006506952

HOSE REMOVAL AND INSTALLATION

• To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

• To reinstall the rubber hose securely, check that hose insertion length and orientation is correct. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

HOSE CLAMPING

• If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position.

• Discard old clamps; replace with new ones.

• After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around.

Engine Oils INFOID:0000000006506953

Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

HEALTH PROTECTION PRECAUTIONS

SMA019D

SMA020D

SMA021D

SMA022D

Revision: 2011 December 2011 CUBE

Page 38

GI-32

< PRECAUTION >

[REGULAR GRADE]

PRECAUTIONS

• Avoid prolonged and repeated contact with oils, particularly used engine oils.

• Wear protective clothing, including impervious gloves where practicable.

• Do not put oily rags in pockets.

• Avoid contaminating clothes, particularly underpants, with oil.

• Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.

• First aid treatment should be obtained immediately for open cuts and wounds.

• Use barrier creams, applying them before each work period, to help the removal of oil from the skin.

• Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed.

• Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.

• If skin disorders develop, obtain medical advice without delay.

• Where practical, degrease components prior to handling.

• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

ENVIRONMENTAL PROTECTION PRECAUTIONS

Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal facilities. It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources. The regulations concerning pollution vary between regions.

Air Conditioning INFOID:0000000006506954

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA section “REFRIGERANT” for specific instructions.

Fuel INFOID:0000000006506955

Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research octane number 91).

CAUTION:

• Using a fuel other than that specified could adversely affect the emission control system, and may also affect warranty coverage.

• Under no circumstances should a leaded gasoline be used, because this will damage the three-way catalyst.

• Do not use E-85 fuel in the vehic le. The vehicle is not designed to run on E-85 fuel. Using E-85 fuel can damage the fuel system components and is not covered by the NISSAN new vehicle limited warranty.

Revision: 2011 December 2011 CUBE

Page 39

LIFTING POINT

GI-33

< PRECAUTION >

[REGULAR GRADE]

LIFTING POINT

Commercial Service Tools INFOID:0000000006506956

CAUTION:

• Every time the vehicle is lifted up, maintain the complete vehicle curb condition.

• Since the vehicle's center of gravity changes when removing main parts on the front side (engine, transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission jack or equivalent.

• Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle, suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equivalent.

• Be careful not to smash or never do anything that would affect piping parts.

Garage Jack and Safety Stand and 2-Pole Lift INFOID:0000000006506957

WARNING:

• Park the vehicle on a level surface when using the jack. Check to avoid damaging pipes, tubes, etc. under the vehicle.

• Never get under the vehicle while it is supported only by the jack. Always use safety stands when you have to get under the vehicle.

• Place wheel chocks at both front and back of the wheels on the ground.

• When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced.

• When setting the lift arm, never allow the arm to contact the brake tubes, brake cable, fuel lines and sill spoiler.

Tool name Description

Board on attachment

Safety stand attachment

S-NT001

S-NT002

Revision: 2011 December 2011 CUBE

Page 40

GI-34

< PRECAUTION >

[REGULAR GRADE]

LIFTING POINT

CAUTION:

There is canister just behind Garage jack point rear . Jack up carefully.

Board-On Lift INFOID:0000000006506958

CAUTION:

Check vehicle is empty when lifting.

• The board-on lift attachment (A) set at front end of vehicle should be set on the front of the sill under the front door opening.

• Position attachments at front and rear ends of board-on lift.

1. Safety stand point and lift up point (front) 2. Safety stand point and lift up point (rear)

3. Garage jack point (front)

4. Garage jack point (rear)

JMAIA0220ZZ

: Vehicle front

JMAIA0004ZZ

Revision: 2011 December 2011 CUBE

Page 41

TOW TRUCK TOWING

GI-35

< PRECAUTION >

[REGULAR GRADE]

TOW TRUCK TOWING

Tow Truck Towing INFOID:0000000006506959

CAUTION:

• All applicable state or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed.

• It is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing is in accordance with Towing Procedure Manual at dealer.

• Always attach safety chains before towing.

• When towing, check that the transmission, steering system and powertrain are in good order. If any unit is damaged, dollies must be used.

• Never tow a CVT model from the rear (that is backward) with four wheels on the ground. This may cause serious and expensive damage to the transmission.

2WD MODELS

NISSAN recommends that vehicle be towed with the driving (front) wheels off the ground or that a dolly be used as illustrated.

CAUTION:

• Never tow CVT models with the front wheels on the ground or four wheels on the ground (forward or backward), as this may cause serious and expensive damage to the transmission. If it is necessary to tow the vehicle with the rear wheels raised, always use towing dollies under the front wheels.

• When towing CVT models with the front wheels on towing dollies:

- Turn the ignition switch to the OFF position, and secure the steering wheel in a straight ahead position with a rope or similar device. Never secure the steering wheel by turning the ignition switch to the LOCK position. This may damage the steering lock mechanism.

- M ove the selector lever to the N (Neutral) position.

• When the battery of vehicle equipped with the Intelligent Key system is discharged, your vehicle should be towed with the front wheels on towing dollies or place the vehicle on a flat bed truck.

• When tow ing two w heel drive CV T model with th e rear wheels on the ground (if you do not use towing dollies): Always release the parking brake.

Vehicle Recovery (Freeing a Stuck Vehicle) INFOID:0000000006506960

FRONT

JMAIA0068ZZ

Revision: 2011 December 2011 CUBE

Page 42

GI-36

< PRECAUTION >

[REGULAR GRADE]

TOW TRUCK TOWING

Securely install the vehicle recovery hook stored with jacking tools. Check that the hook is properly secured in the stored place after use.

WARNING:

• Stand clear of a stuck vehicle.

• Never spin your tires at high speed. This could cause them to explode and result in serious injury. Parts of your vehicle could also overheat and be damaged.

CAUTION:

• Tow chains or cables must be attached only to the vehicle recovery hooks or main structural members of the vehicle. Otherwise, the vehicle body will be damaged.

• Never use the vehicle tie downs to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehicle using the vehicle tie downs or recovery hooks.

• Always pull the cable straight out from the front of the vehicle. Never pull on the hook at an angle.

• Pulling devices should be routed so they never touch any part of the suspension, steering, brake or cooling systems.

• Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or recovery.

REAR

WARNING:

• Rear hook is not available.

AUTOMATIC TRANSMISSION

To tow a vehicle equipped with an automatic transmission, an appropriate vehicle dolly MUST be placed under the towed vehicle's drive wheels. Always follow the dolly manufacture's recommendations when using their product. If the vehicle is stuck in sand, snow, mud, etc., use the following procedure:

1. Turn off the Vehicle Dynamic Control System.

2. Check the area in front and behind the vehicle is clear of obstructions.

3. Turn the steering wheel right and left to clear an area around the front tires.

4. Slowly rock the vehicle forward and backward.

Shift back and forth between R (reverse) and D (drive). Apply the accelerator as little as possible to maintain the rocking motion. Release the accelerator pedal before shifting between R and D. Do not spin the tires above 35 mph (55 km/h).

5. If the vehicle can not be freed after a few tries, contact a professional towing service to remove the vehi-

cle.

JMAIA0137ZZ

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GI-37

< BASIC INSPECTION >

[REGULAR GRADE]

BASIC INSPECTION

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

Work Flow INFOID:0000000006506961

WORK FLOW

Control Units and Electrical Parts INFOID:0000000006506962

PRECAUTIONS

• Never reverse polarity of battery terminals.

• Install only parts specified for a vehicle.

• Before replacing the control unit, check the input and output and functions of the component parts.

• Do not apply excessive force when disconnecting a connector.

SGI838

STEP DESCRIPTION

STEP 1

Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis:

WHAT Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio). WHEN Date, Time of Day, Weather Conditions, Frequency. WHERE Road Conditions, Altitude and Traffic Situation.

HOW

System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed.

STEP 2

Operate the system, road test if necessary. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulation Tests”.

STEP 3

Get the proper diagnosis materials together including:

• Power Supply Routing

• System Operation Descriptions

• Applicable Service Manual Sections

• Check for any Service Bulletins Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.

STEP 4

Inspect the system for mechanical binding, loose connectors or wiring damage. Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Layouts.

STEP 5 Repair or replace the incident circuit or component. STEP 6

Operate the system in all modes. Verify the system works properly under all conditions. Check you have not inadvertently created a new incident during your diagnosis or repair steps.

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GI-38

< BASIC INSPECTION >

[REGULAR GRADE]

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

• Do not apply excessive shock to the control unit by dropping or hitting it.

• Be careful to prevent condensation in the control unit due to rapid temperature changes and do not let water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle.

• Be careful not to let oil to get on the control unit connector.

• Avoid cleaning the control unit with volatile oil.

• Do not disassemble the control unit, and do not remove the upper and lower covers.

• When using a DMM, be careful not to let test probes get close to each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting.

• When checking input and output signals of the control unit, use the specified check adapter.

How to Check Terminal INFOID:0000000006506963

CONNECTOR AND TERMINAL PIN KIT

• Use the connector and terminal pin kits listed below when replacing connectors or terminals.

• The connector and terminal pin kits contain some of the most commonly used NISSAN/INFINITI connectors and terminals. For detailed connector and terminal pin replacement procedures, refer to the latest NISSAN/ INFINITI CONNECTOR AND TERMINAL PIN SERVICE MANUAL.

SAIA0255E

SEF348N

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GI-39

< BASIC INSPECTION >

[REGULAR GRADE]

HOW TO PROBE CONNECTORS

• Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks.

• The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip.

Probing from Harness Side

Standard type (not waterproof type) connector should be probed from harness side with “T” pin.

• If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal.

• Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.

Probing from Terminal Side

FEMALE TERMINAL

• There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch. Do not insert any object other than the same type male terminal into female terminal.

Tool number

(Kent-Moore No.)

Tool na me

Description

(J38751-95NI) Connector and terminal pin kit (NISSAN)

(J38751-95INF) Connector and terminal pin kit (INFINITI)

(J42992-98KIT) OBD and terminal repair kit

(J42992-2000UPD) OBD-II Connector Kit Update

WAIA0004E WAIA0005E

SGI841

SEL265V

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GI-40

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[REGULAR GRADE]

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

• Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.

MALE TERMINAL

• Carefully probe the contact surface of each terminal using a “T” pin.

CAUTION:

Never bend terminal.

How to Check Enlarged Contact Spring of Terminal

• An enlarged contact spring of a terminal may create intermittent signals in the circuit.

• If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal.

1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire.

NOTE: Use a male terminal which matches the female terminal.

2. Disconnect the suspected faulty connector and hold it terminal

side up.

3. While holding the wire of the male terminal, try to insert the male

terminal into the female terminal.

CAUTION:

Never force the male terminal into the female terminal with your hands.

SEL266V

SEL267V

SEL270V

SEL271V

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

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< BASIC INSPECTION >

[REGULAR GRADE]

4. While moving the connector, check whether the male terminal can be easily inserted or not.

• If the male terminal can be easily inserted into the female ter-

minal, replace the female terminal.

Waterproof Connector Inspection

If water enters the connector, it can short interior circuits. This may lead to intermittent problems. Check the following items to maintain the original waterproof characteristics.

RUBBER SEAL INSPECTION

• Most waterproof connectors are provided with a rubber seal

between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications.

• The rubber seal may come off when connectors are disconnected.

Whenever connectors are reconnected, check the rubber seal is properly installed on either side of male or female connector.

WIRE SEAL INSPECTION

• The wire seal must be installed on the wire insertion area of a

waterproof connector. Be sure that the seal is installed properly.

Terminal Lock Inspection

Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.

Intermittent Incident INFOID:0000000006506964

DESCRIPTION

Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditions present at the time of the incident. Doing so may help avoid a No T rouble Found Di agnosis. The fol-

SEL272V

SEL273V

SEL275V

SEL330V

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GI-42

< BASIC INSPECTION >

[REGULAR GRADE]

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident.

The section is broken into the six following topics:

• Vehicle vibration

• Heat sensitive

• Freezing

• Water intrusion

• Electrical load

• Cold or hot start up Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem.

VEHICLE VIBRATION

The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration.

Connector & Harness

Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This test may indicate a loose or poor electrical connection.

Hint

Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system.

Sensor & Relay

Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay.

Engine Compartment

There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are:

• Connectors not fully seated.

• Wiring harness not long enough and is being stressed due to engine vibrations or rocking.

• Wires laying across brackets or moving components.

• Loose, dirty or corroded ground wires.

• Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground Inspection described later.) First check that the system is properly grounded. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity.

Behind the Instrument Panel

An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw.

Under Seating Areas

SGI839

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GI-43

< BASIC INSPECTION >

[REGULAR GRADE]

An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or pinching.

HEAT SENSITIVE

• The customer's concern may occur during hot weather or after car

has sat for a short time. In such cases you will want to check for a heat sensitive condition.

• To determine if an electrical component is heat sensitive, heat the

component with a heat gun or equivalent.

CAUTION:

Never heat components above 60°C (140°F).

• If incident occurs while heating the unit, either replace or properly

insulate the component.

FREEZING

• The customer may indicate the incident goes away after the car

warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system.

• There are two methods to check for this. The first is to arrange for

the owner to leave his car overnight. Check it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected.

• The second method is to put the suspect component into a freezer

long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

WATER INTRUSION

The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash.

CAUTION:

Never spray water directly on any electrical components.

ELECTRICAL LOAD

The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.

COLD OR HOT START UP

On some occasions an electrical incident may occur only when the car is started cold, or it may occur when the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis.

JPAIA0733GB

SGI843

SGI844

SGI845

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[REGULAR GRADE]

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

Circuit Inspection

INFOID:0000000006506965

DESCRIPTION

• In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure.

• You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this.

NOTE:

Refer to GI-38, "

How to Check Terminal" to probe or check terminal.

TESTING FOR “OPENS” IN THE CIRCUIT

Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

Continuity Check Method

The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Check to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits, please refer to the previous schematic.

• Disconnect the battery negative cable.

• Start at one end of the circuit and work your way to the other end. (At the fuse block in this example)

• Connect one probe of the DMM to the fuse block terminal on the load side.

• Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A)

• Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity . If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B)

• Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C)

Any circuit can be diagnosed using the approach in the previous example.

Voltage Check Method

To help in understanding the diagnosis of open circuits please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function.

• Connect one probe of the DMM to a known good ground.

• Begin probing at one end of the circuit and work your way to the other end.

• With SW1 open, probe at SW1 to check for voltage. voltage: open is further down the circuit than SW1.

OPEN A circuit is open when there is no continuity through a section of the circuit.

SHORT

There are two types of shorts.

• SHORT CIRCUIT

When a circuit contacts another circuit and causes the normal resistance to change.

• SHORT TO GROUND When a circuit contacts a ground source and grounds the circuit.

SGI846-A

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[REGULAR GRADE]

no voltage: open is between fuse block and SW1 (point A).

• Close SW1 and probe at relay. voltage: open is further down the circuit than the relay. no voltage: open is between SW1 and relay (point B).

• Close the relay and probe at the solenoid. voltage: open is further down the circuit than the solenoid. no voltage: open is between relay and solenoid (point C).

Any powered circuit can be diagnosed using the approach in the previous example.

TESTING FOR “SHORTS” IN THE CIRCUIT

To simplify the discussion of shorts in the system, please refer to the following schematic.

Resistance Check Method

• Disconnect the battery negative cable and remove the blown fuse.

• Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.

• Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known good ground.

• With SW1 open, check for continuity. continuity: short is between fuse terminal and SW1 (point A). no continuity: short is further down the circuit than SW1.

• Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity: short is between SW1 and the relay (point B). no continuity: short is further down the circuit than the relay.

• Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity: short is between relay and solenoid (point C). no continuity: check solenoid, retrace steps.

Voltage Check Method

• Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse.

• Turn the ignition switch to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground).

• With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage: short is between fuse block and SW1 (point A). no voltage: short is further down the circuit than SW1.

• With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for voltage. voltage: short is between SW1 and the relay (point B). no voltage: short is further down the circuit than the relay.

• With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage: short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage: retrace steps and check power to fuse block.

GROUND INSPECTION

• Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works.

• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface.

SGI847-A

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GI-46

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[REGULAR GRADE]

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

• When inspecting a ground connection follow these rules:

- Remove the ground bolt or screw.

- Inspect all mating surfaces for tarnish, dirt, rust, etc.

- Clean as required to assure good contact.

- Reinstall bolt or screw securely.

- Inspect for “add-on” accessories which may be interfering with the ground circuit.

- If several wires are crimped into one ground eyelet terminal, check for proper crimps. Check all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet check no ground wires have excess wire insulation.

• For detailed ground distribution information, refer to “Ground Distribution” in PG section.

VOLTAGE DROP TESTS

• Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation.

• Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop.

• Unwanted resistance can be caused by many situations as follows:

- Undersized wiring (single strand example)

- Corrosion on switch contacts

- Loose wire connections or splices.

• If repairs are needed always use wire that is of the same or larger gauge.

Measuring Voltage Drop — Accumulated Method

• Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the DMM should be closer to power and the negative lead closer to ground.

• Operate the circuit.

• The DMM will indicate how many volts are being used to “push” current through that part of the circuit.

SGI853

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GI-47

< BASIC INSPECTION >

[REGULAR GRADE]

Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

Measuring Voltage Drop — Step-by-Step

• The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”).

• Circuits in the “Computer Controlled System” operate on very low amperage.

• The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the system. Such resistance variation may be caused by poor connection, improper installation, improper wire gauge or corrosion.

• The step by step voltage drop test can identify a component or wire with too much resistance.

CONTROL UNIT CIRCUIT TEST

System Description

• When the switch is ON, the control unit lights up the lamp.

CASE 1

SGI974

SAIA0258E

MGI034A

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GI-48

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[REGULAR GRADE]

SERVICE INFORMATION FOR ELECTRICAL INCIDENT

INPUT-OUTPUT VOLTAGE CHART

• The voltage value is based on the body ground.

• *: If high resistance exists in the switch side circui t (cau se d by a singl e stra nd), termi na l 1 doe s not d et ect batt ery voltage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp.

CASE 2

INPUT-OUTPUT VOLTAGE CHART

• The voltage value is based on the body ground.

• *: If high resistance exists in the switch side circuit (caused by a singl e strand), terminal 2 does not detect ap prox. 0 V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.

Terminal No. Description

Condition Value (Approx.)

In case of high resistance such as single strand (V) *

+ − Signal name

Input/

Output

Body ground

Switch Input

Switch ON Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF 0 V Approx. 0

Body ground

Lamp Output

Switch ON Battery voltage Approx. 0 (Inoperative lamp) Switch OFF 0 V Approx. 0

Terminal No. Description

Condition Value (Approx.)

In case of high resistance such as single strand (V) *

+ − Signal name

Input/

Output

Body ground

Lamp Output

Switch ON 0 V Battery voltage (Inoperative lamp) Switch OFF Battery voltage Battery voltage

Body ground

Switch Input

Switch ON 0 V Higher than 0 Approx. 4 (Example) Switch OFF 5 V Approx. 5

MGI035A

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CONSULT-III/GST CHECKING SYSTEM

GI-49

< BASIC INSPECTION >

[REGULAR GRADE]

CONSULT-III/GST CHECKING SYSTEM

Description INFOID:0000000006506966

• When CONSULT-III/GST is connected with a data link connector (A) equipped on the vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various kinds of diagnostic tests.

• Refer to “CONSULT-III Software Operation Manual” for more information.

CONSULT-III Function and System Application*1 INFOID:0000000006928329

FUNCTION

SYSTEM APPLICATION

1 : Instrument lower panel LH

JPAIA0582ZZ

Mode Function All DTC Reading Display all DTCs or diagnostic items that all ECUs are recording and judging. Work Support This mode enables a technician to adjust some devices faster and more accurately. Self Diagnostic Results Retrieve DTC from ECU and display diagnostic items. Data Monitor Monit or the in pu t/ou tp ut si gna l of t he cont rol unit in rea l time . CAN Diagnosis This mode displays a network diagnosis result about CAN by diagram. CAN Diagnosis Support Monitor It monitors the status of CAN communication. Active Test Send the drive signal from CONSULT-III to the actuator. The operation check can be performed. DTC & SRT confirmation The status of system monitoring tests and the self-diagnosis status/result can be confirmed. ECU Identification Display the ECU identification number (part number etc.) of the selected system.

Function Test

This mode can show results of s elf-diagnosis of ECU with either “OK” or “N G”. For engines, more

practical tests regarding sensors/switches and/or actuators are available. Configuration Function to READ/WRITE vehicle configuration. Special Function Other results or histories, etc. that are recorded in ECU are displayed.

System

All DTC Reading

Work Support

Self Diagnostic Results

Data Monitor

CAN Diagnosis

CAN Diagnosis Support Monitor

Active Test

DTC & SRT confirmation

ECU Identification

Function Test

Configuration

Special Function

ENGINE xxxxxxxxxx-TRANSMISSION xxxxxx--xx-x AIR BAG x - x - x - - - x x - x METER / M&A x-xxxx-----x BCM xxxxxxx-x-xABS xxxxxxx-xx--

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GI-50

< BASIC INSPECTION >

[REGULAR GRADE]

CONSULT-III/GST CHECKING SYSTEM

x: Applicable *1: If GST application is equipped, functions in accordance with SAE J1979 and ISO 15031-5 can be used.

CONSULT-III/GST Data Link Connector (DLC) Circuit INFOID:0000000006506968

INSPECTION PROCEDURE

If the CONSULT-III/GST cannot diagnose the system properly, check the following items.

NOTE:

The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system. A short in a DDL circuit connected to a control unit in one system may affect CONSULT-III access to other systems. If the GST cannot operate properly, check the circuit based on the information of SAE J1962 and ISO 15031-

IPDM E/R x-xxxxx-x--EPS x-xxxx--x---

System

All DTC Reading

Work Support

Self Diagnostic Results

Data Monitor

CAN Diagnosis

CAN Diagnosis Support Monitor

Active Test

DTC & SRT confirmation

ECU Identification

Function Test

Configuration

Special Function

Symptom Check item

CONSULT-III/GST cannot access any system.

• CONSULT-III/GST DLC power supply circuit (Terminal 8 and 16) and ground circuit (Terminal 4 and

CONSULT-III cannot access individual system. (Other systems can be accessed.)

• Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.)

• Open or short circuit between the system and CONSULT-III DLC (For detailed circuit, refer to wiring diagram for each system.)

• Open or short circuit CAN communication line. Refer to LAN-13, "

Trouble Diagnosis Flow Chart".

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CONSULT-III/GST CHECKING SYSTEM

GI-51

< BASIC INSPECTION >

[REGULAR GRADE]

Wiring Diagram - CONSULT-III/GST CHECKING SYSTEM - INFOID:0000000006506969

JCAWM0471GB

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GI-52

< BASIC INSPECTION >

[REGULAR GRADE]

CONSULT-III/GST CHECKING SYSTEM

JCAWM0472GB

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CONSULT-III/GST CHECKING SYSTEM

GI-53

< BASIC INSPECTION >

[REGULAR GRADE]

JCAWM0473GB

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GI-54

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[REGULAR GRADE]

INSPECTION AND ADJUSTMENT

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Required Procedure After Battery Disconnection

INFOID:0000000006506970

*: Not equipped.

SYSTEM ITEM REFERENCE

Automatic air conditioning system

Temperature setting trimmer HAC-10, "

Temperature Setting Trimmer"

Foot position setting trimmer* — Inlet port memory function HAC-11, "

Inlet Port Memory Function"

Inlet port memory function (FRE)* — Inlet port memory function (REC)* — Gas sensor sensitivity adjustment function* — Auto intake switch interlocking movement change* — Clean switch interlocking movement change* —

Automatic drive positioner* Automatic drive positioner system —

Power window control Power window control system

PWC-5, "

ADDITIONAL SERVICE WHEN RE-

MOVING BATTER Y NEGATIVE TERMINAL :

Description"

Sunroof system* Sunroof system — Sunshade system* Sunshade system —

Rear view monitor

Rear view monitor predictive course line center position adjustment

—

Around view monitor* Predictive course line center position adjustment — Automatic back door system* Automatic back door system — Engine oil level read* Engine oil level read —

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DIMENSIONS AND WEIGHTS

GI-55

< VEHICLE INFORMATION >

[Krom]

VEHICLE INFORMATION

DIMENSIONS AND WEIGHTS

Dimensions and Weights INFOID:0000000006506971

*1: With front license plate bracket *2: Without front license plate bracket

Vehicle body Krom

Overall length in (mm)

157.8 (4,010)

157.5 (4,000)

Overall width in (mm) 66.7 (1,695) Overall height in (mm) 65.0 (1,650) Front tread in (mm) 58.1 (1,475) Rear tread in (mm) 58.3 (1,480) Wheel base in (mm) 99.6 (2,530) Gross vehicle weight rating (GVWR) lb (kg)

See the F.M.V.S.S. or C.M.V . S.S. certification label on the driver′s side lock piller.

Gross axle weight rating (GAWR) lb (kg) Front lb (kg) Rear lb (kg)

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GI-56

< PRECAUTION >

[Krom]

LIFTING POINT

PRECAUTION

LIFTING POINT

Lifting Point INFOID:0000000006506972

Lift-up points are located behind the side sill extensions. When using an on-board lift, use some attachments as shown in the figure. Using unsuitable Lift may damage the side sill extensions.

JKAIA0001GB

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TOW TRUCK TOWING

GI-57

< PRECAUTION >

[Krom]

TOW TRUCK TOWING

Tow Truck Towing INFOID:0000000006506973

CAUTION:

Place the vehicle only on a flat bed type truck. Other towing methods may damage the front bumper or rear bumper.

Place the vehicle on a flat bed truck as shown in the figure. Towing the vehicle with a sling type tow truck may damage the front bumper or rear bumper.

CAUTION:

Since the approach angle and the departure angle of the vehicle are smaller, front bumper fascia and rear bumper fascia may interfere in the road surface when entering and exiting from a parking lot or the steep slope. Therefore, be sure to reduce the speed sufficiently and drive carefully.

Vehicle Recovery (Freeing a Stuck Vehicle) INFOID:0000000006506974

For complete information regarding vehicle recovery, see “Vehicle recovery (Freeing a stuck vehicle)” in the “In case of emergency” section of the Owner's Manual. Use the recovery hook by installing it in the front of the vehicle. (The rear has no towing points.)

REMOVING THE TOE HOOK COVER

1. To remove the cover, insert a tapered tool (ex. flat-blade screwdriver) into the cover groove in parallel with the ground.

2. While pushing the cover downward (direction 1), pull (direction

2) it to disengage.

CAUTION:

Use a cloth for the tool during the removal to prevent damage to the vehicle.

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GI-58

< PRECAUTION >

[Krom]

TOW TRUCK TOWING

INSTALLING THE TOE HOOK COVER

1. Fit the toe hook cover at an angle in the position shown by the arrow (1) in the figure.

2. Push the toe hook cover downward (2) by sliding the diagonallyshaded area of the cover along the inner side of the housing.

3. Push the toe hook cover in by pushing the top of the cover downward.

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EM-1

ENGINE

SECTION EM

CONTENTS

ENGINE MECHANICAL

SYMPTOM DIAGNOSIS ...............................3

NOISE, VIBRATION AND HARSHNESS

(NVH) TROUBLESHOOTING .............................

NVH troubleshooting Chart .......................................3

PRECAUTION ...............................................5

PRECAUTIONS ...................................................5

Precaution for Procedure without Cowl Top Cover ......5

Precautions Necessary for Steering Wheel Rota-

tion After Battery Disconnection ................................

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-

SIONER" ...................................................................

Draining Engine Coolant ................. .... ......................6

Disconnecting Fuel Piping .........................................6

Removal and Disassembly . .... ... ................................6

Inspection, Repair and Replacement ........................6

Assembly and Installation .........................................6

Parts Requiring Angle Tightening .............................7

Liquid Gasket ............................................................7

PREPARATION ............................................9

PREPARATION ...................................................9

Special Service Tools ................................................9

Commercial Service Tools ......................................10

PERIODIC MAINTENANCE .........................13

DRIVE BELT .......................................................13

Exploded View ........................................................13

Checking .................................................................13

Tension Adjustment ................................................13

Removal and Installation ........... ... ...........................13

AIR CLEANER FILTER ......................................15

Removal and Installation ........... ... ...........................15

SPARK PLUG ....................................................16

Exploded View ........................................................16

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

Inspection ................................................................17

CAMSHAFT VALVE CLEARANCE ..................18

Inspection and Adjustment ......................................18

COMPRESSION PRESSURE ...........................21

Inspection ................................................................21

REMOVAL AND INSTALLATION ...............22

ENGINE COVER ...............................................22

Exploded View .........................................................22

Removal and Installation .........................................22

DRIVE BELT AUTO TENSIONER AND IDLER

PULLEY .............................................................

Exploded View .........................................................23

Removal and Installation .........................................23

AIR CLEANER AND AIR DUCT .......................24

Exploded View .........................................................24

Removal and Installation .........................................24

Inspection ................................................................25

INTAKE MANIFOLD .........................................26

Exploded View .........................................................26

Removal and Installation .........................................27

EXHAUST MANIFOLD ......................................30

Exploded View .........................................................30

Removal and Installation .........................................31

Inspection ................................................................32

OIL PAN (LOWER) ...........................................33

Exploded View .........................................................33

Removal and Installation .........................................33

Inspection ................................................................35

FUEL INJECTOR AND FUEL TUBE ................36

Exploded View .........................................................36

Removal and Installation .........................................36

Inspection ................................................................39

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EM-2

IGNITION COIL, SPARK PLUG AND ROCK-

ER COVER .........................................................

Exploded View ........... ... ... ... .... ................................ 41

Removal and Installation ........................................ 41

TIMING CHAIN .................................................. 43

Exploded View ........... ... ... ... .... ................................ 43

Removal and Installation ........................................ 44

Inspection ............................................................... 52

CAMSHAFT .......................................................54

Exploded View ........... ... ... ... .... ................................ 54

Removal and Installation ........................................ 54

Inspection ............................................................... 58

OIL SEAL ........................................................... 63

VALVE OIL SEAL ..................................................... 63

VALVE OIL SEAL : Removal and Installation ......... 63

FRONT OIL SEAL ..................................................... 63

FRONT OIL SEAL : Removal and Installation ........ 64

REAR OIL SEAL ....................................................... 64

REAR OIL SEAL : Removal and Installation .......... 64

CYLINDER HEAD .............................................. 66

Exploded View ........... ... ... ... .... ................................ 66

Removal and Installation ........................................ 67

Disassembly and Assembly .................................... 68

Inspection ............................................................... 72

UNIT REMOVAL AND INSTALLATION ..... 75

ENGINE ASSEMBLY ......................................... 75

Exploded View ........... ... ... ... .... ................................ 75

Removal and Installation ........................................ 75

Inspection ............................................................... 78

UNIT DISASSEMBLY AND ASSEMBLY .... 80

ENGINE STAND SETTING ............................... 80

Setting ........................... .......................................... 80

ENGINE UNIT .................................................... 82

Disassembly ........................ ................ ................ .... 82

Assembly ................................................................ 82

OIL PAN (UPPER) ............................................. 83

Exploded View ........................................................ 83

Removal and Installation .. ... .................................... 83

Inspection ............................ ................ ............. ....... 86

CYLINDER BLOCK ........................................... 87

Exploded View ........................................................ 87

Disassembly and Assembly .................................... 88

Inspection ............................ ................ ............. ....... 96

HOW TO SELECT PISTON AND BEARING ...107

Description ............................................................ 107

Piston ............................... ..................................... 107

Connecting Rod Bearing ..................................... 108

Main Bearing ........................................................ 110

SERVICE DATA AND SPECIFICATIONS

(SDS) .........................................................

114

SERVICE DATA AND SPECIFICATIONS

(SDS) ................................................................

114

General Specification ............................................ 114

Drive Belt .............................................................. 114

Spark Plug ....... .......................................... ... ... ..... 114

Exhaust Manifold .................................................. 115

Camshaft .......................... ................ ................ ..... 115

Cylinder Head ....................................................... 117

Cylinder Block ....................................................... 119

Connecting Rod Bearing ....................................... 123

Main Bearing ......................................................... 123

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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

EM-3

< SYMPTOM DIAGNOSIS >

SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH troubleshooting Chart INFOID:0000000006503495

1. Locate the area where noise occurs.

2. Confirm the type of noise.

3. Specify the operating condition of engine.

PBIC3932E

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EM-4

< SYMPTOM DIAGNOSIS >

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

4. Check specified noise source.

If necessary, repair or replace these parts.

A: Closely related B: Related C: Sometimes related —: Not related

Location

of noise

Type of

noise

Operating condition of engine

Source of

noise

Check item

Refer-

ence page

Before warm-

After

warm-

When

start-

ing

When

idling

When racing

While

driving

Top of engine Rocker cover Cylinder head

Ticking or clicking

CA—AB—

Tappet noise

Valve clearance EM-18

Rattle C A — A B C

Camshaft bearing noise

Camshaft journal oil clearance Camshaft runout

EM-115

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Slap or knock

—A—BB—

Piston pin noise

Piston to piston pin oil clearance Connecting rod bushing oil clearance

EM-119

Slap or rap

A——BBA

Piston slap noise

Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion

EM-119

Knock A B C B B B

Connecting rod bearing noise

Connecting rod bushing oil clearance Connecting rod bearing oil clearance

EM-119 EM-123

Knock A B — A B C

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-123 EM-119

Front of engine Front cover

T apping or ticking

AA—BBB

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-52 EM-43

Front of engine

Squeaking or fizzing

AB—B—C

Drive belt (Sticking or slipping)

Drive belt deflection

EM-13

Creaking A B A B A B

Drive belt (Slipping)

Idler pulley bearing operation

Squall Creak

AB—BAB

Water pump noise

Water pump operation

CO-20,

"Exploded

View"

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PRECAUTIONS

EM-5

< PRECAUTION >

PRECAUTION

PRECAUTIONS

Precaution for Procedure without Cowl Top Cover INFOID:0000000006503496

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

Precautions Necessary for Steering Wheel Rotation After Battery Disconnection

INFOID:0000000006503497

CAUTION:

Comply with the following cautions to prevent any error and malfunction.

• Before removing and installing any control units, first turn the ignition switch to the LOCK position, then disconnect both battery cables.

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

• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.

For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. If turning the steering wheel is required with the battery disconnected or discharged, follow the operation procedure below before starting the repair operation.

OPERATION PROCEDURE

1. Connect both battery cables.

NOTE:

Supply power using jumper cables if battery is discharged.

2. Turn the ignition switch to ACC position.

(At this time, the steering lock will be released.)

3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-

nected and the steering wheel can be turned.

4. Perform the necessary repair operation.

5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn

the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the ignition switch is turned to LOCK position.)

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

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

INFOID:0000000006503498

WARNING:

Always observe the following items for preventing accidental activation.

PIIB3706J

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EM-6

< PRECAUTION >

PRECAUTIONS

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

Always observe the following items for preventing accidental activation.

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

Draining Engine Coolant INFOID:0000000006503499

Drain engine coolant and engine oil when the engine is cooled.

Disconnecting Fuel Piping INFOID:0000000006503500

• Before starting work, check no fire or spark producing items are in the work area.

• Release fuel pressure before disconnecting and disassembly.

• After disconnecting pipes, plug openings to stop fuel leakage.

Removal and Disassembly INFOID:0000000006503501

• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.

• Exercise maximum care to avoid damage to mating or sliding surfaces.

• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins, check that dowel pins are installed in the original position.

• Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.

• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.

• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used in the step.

Inspection, Repair and Replacement INFOID:0000000006503502

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

Assembly and Installation INFOID:0000000006503503

• Use torque wrench to tighten bolts or nuts to specification.

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and out side diagonally in this order. If the order of tightening is specified, do exactly as specified.

• Replace with new gasket, packing, oil seal or O-ring.

• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.

• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.

• Release air within route when refilling after draining engine coolant.

• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

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PRECAUTIONS

EM-7

< PRECAUTION >

Parts Requiring Angle Tightening INFOID:0000000006503504

• Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts:

- Camshaft sprocket (INT) bolt

- Cylinder head bolts

- M ain bearing cap bolts

- Connecting rod cap bolts

- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle tightening)

• Do not use a torque value for final tightening.

• The torque value for these parts are for a preliminary step.

• Ensure thread and seat surfaces are clean and coated with engine oil.

Liquid Gasket INFOID:0000000006503505

REMOVAL OF LIQUID GASKET SEALING

• After removing mounting nuts and bolts, separate the mating surface using the seal cutter [SST: KV10111100 (J-37228)] (A) and remove old liquid gasket sealing.

CAUTION:

Be careful not to damage the mating surfaces.

• Tap the seal cutter [SST: KV10111100 (J-37228)] to insert it (B), and then slide it (C) by tapping on the side as shown in the figure.

• In areas where the seal cutter [SST: KV10111100 (J-37228)] is difficult to use, lightly tap the parts using a plastic hammer to remove it.

CAUTION:

If for some unavoidable reason tool such as a screwdriver is used, be careful not to damage the mating surfaces.

LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper (A), remove old liquid gasket adhering to the liq-

uid gasket application surface and the mating surface.

• Remove liquid gasket completely from the groove of the liquid gasket application surface, mounting bolts, and bolt holes.

2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials.

3. Attach liquid gasket tube to the tube presser (commercial service tool).

Use Genuine RTV Silicon Sealant or equivalent. Refer to GI-

22, "Recommended Chemical Products and Sealants".

4. Apply liquid gasket without gaps to the specified location according to the specified dimensions.

• If there is a groove for liquid gasket application, apply liquid

gasket to the groove.

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EM-8

< PRECAUTION >

PRECAUTIONS

• As for bolt holes (B), normally apply liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Check to read the text of this manual.

• Within five minutes of liquid gasket application, install the mating component.

• If liquid gasket protrudes, wipe it off immediately.

• Do not retighten mounting bolts or nuts after the installation.

• After 30 minutes or more have passed from the installation, fill engine oil and engine coolant.

CAUTION:

If there are specific instructions in this manual, observe them.

A: Groove

: Inside

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PREPARATION

EM-9

< PREPARATION >

PREPARATION

Sp ecial Service Tools INFOID:0000000006503506

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

Tool nu mb er (Kent-Moore No.) Tool na me

Description

KV10111100 (J-37228) Seal cutter

Removing oil pan (upper and lower) etc.

KV10116200 (J-26336-A) Valve spring compressor

1. KV10115900 (J-26336-20) Attachment

2. KV10109220 (—) Adapter

Disassembling and assembling valve mechanism Part (1) is a component of KV10116200 (J26336-A), but Part (2) is not so.

KV10112100 (BT8653-A) Angle wrench

Tightening bolts for main bearing cap, cylinder head, etc.

KV10117100 (J-3647-A) Heated oxygen sensor wrench

Loosening or tightening air fuel ratio sensor 1

For 22 mm (0.87 in) width hexagon nut

KV10107902 (J-38959) Valve oil seal puller

Removing valve oil seal

KV10115600 (J-38958) Valve oil seal drift

Installing valve oil seal

Use side A (G). a: 20 (0.79) dia. d: 8 (0.31) dia. b: 13 (0.51) dia. e: 10.7 (0.421) c: 10.3 (0.406) dia. f: 5 (0.20) H: Side B

Unit: mm (in)

S-NT046

PBIC1650E

S-NT014

NT379

NT011

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EM-10

< PREPARATION >

PREPARATION

Commercial Service Tools

INFOID:0000000006503507

EM03470000 (J-8037) Piston ring compressor

Installing piston assembly into cylinder bore

ST16610001 (J-23907) Pilot bushing puller

Removing pilot converter

KV11103000 (—) Pulley puller

Removing crankshaft pulley

KV11105210 (J-44716) Stopper plate

Fixing drive plate

Tool number (Kent-Moore No.) Tool name

Description

S-NT044

S-NT045

NT676

ZZA0009D

(Kent-Moore No.) Tool name

Description

(J-45488) Quick connector release

Removing fuel tube quick connectors in engine room

(—) Spark plug wrench

Removing and installing spark plug a: 14 mm (0.55 in)

PBIC0198E

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PREPARATION

EM-11

< PREPARATION >

(—) Pulley holder

Crankshaft pulley removing and installing

(—) Valve seat cutter set

Finishing valve seat dimensions

(—) Piston ring expander

Removing and installing piston ring

(—) Valve guide drift

Removing and installing valve guide

(—) V alve guide reamer

1: Reaming valve guide inner hole 2: Reaming hole for oversize valve guide

(J-43897-18) (J-43897-12) Oxygen sensor thread cleaner

Reconditioning the exhaust system threads before installing a new air fuel ratio sensor (Use with anti-seize lubricant shown below.)

A: J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor B: J-43897-12 [12 mm (0.47 in) dia.] for tit ania heated oxygen sensor

C: Mating surface shave cylinder D: Flutes

(—) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust sy stem threads

(Kent-Moore No.) Tool na me

Description

ZZA1010D

S-NT048

S-NT030

PBIC4012E

PBIC4013E

JPBIA0238ZZ

AEM489

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EM-12

< PREPARATION >

PREPARATION

(—) Manual lift table caddy

Removing and installing engine

(—) Tube presser

Pressing the tube of liquid gasket

(Kent-Moore No.) Tool name

Description

ZZA1210D

S-NT052

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DRIVE BELT

EM-13

< PERIODIC MAINTENANCE >

PERIODIC MAINTENANCE

DRIVE BELT

Exploded View INFOID:0000000006503508

Checking INFOID:0000000006503509

WARNING:

Perform this step when engine is stopped.

• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range (A) in the figure.

NOTE:

• Check the drive belt auto-tensioner indication when the engine is cold.

• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the fig-

ure.

• Visually check entire drive belt for wear, damage or cracks.

• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.

Tension Adjustment INFOID:0000000006503510

Removal and Installation INFOID:0000000006503511

REMOVAL

1. Remove front wheel and tire (RH).

2. Remove front fender protector (RH). Refer to EXT-22, "

FENDER PROTECTOR : Exploded View".

3. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with

a wrench securely. Then move the wrench handle in the direction of arrow (loosening direction of tensioner).

CAUTION:

Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off.

4. Insert a rod approximately 6 mm (0.24 in) in diameter such as

short-length screwdriver into the hole (B) of the retaining boss to fix drive belt auto-tensioner.

• Keep drive belt auto-tensioner pulley arm locked after drive belt is removed.

5. Remove drive belt.

1. Alternator 2. Drive belt auto-tensioner 3. Crankshaft pulley

A/C compressor (models with A/C) Idler pulley (models without A/C)

5. Water pump 6. Drive belt

A. Possible use range B.

Range when new drive belt is installed

C. Indicator

PBIC3137J

Refer to : EM-114, "Drive Belt".

PBIC3936E

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EM-14

< PERIODIC MAINTENANCE >

DRIVE BELT

INSTALLATION

1. Install drive belt.

CAUTION:

• Confirm drive belt is completely set to pulleys.

• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each pulley groove.

2. Release drive belt auto-tensioner, and apply tension to drive belt.

3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.

4. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to

EM-13, "

Exploded View".

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AIR CLEANER FILTER

EM-15

< PERIODIC MAINTENANCE >

AIR CLEANER FILTER

Removal and Installation INFOID:0000000006503512

REMOVAL

1. Push the tabs (A) of both ends of the air cleaner cover (1) into the inside (B).

2. Pull up the air cleaner cover forward (C) and remove it.

3. Remove the air cleaner filter (1) and holder (2) assembly from the air cleaner case.

4. Remove the air cleaner filter from the holder.

INSTALLATION

Note the following, and install in the reverse order of removal.

• Install the air cleaner cover (1) in the direction as shown in the fig-

ure.

PBIC3557J

PBIC3558J

2 : Air cleaner filter 3: Holder

PBIC3559J

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EM-16

< PERIODIC MAINTENANCE >

SPARK PLUG

Exploded View INFOID:0000000006503513

Removal and Installation INFOID:0000000006503514

REMOVAL

1. Remove ignition coil. Refer to EM-41, "Exploded View".

2. Remove spark plug with a spark plug wrench (commercial service tool).

CAUTION:

Never drop or shock spark plug.

INSTALLATION

1. PCV hose 2. Rocker cover 3. Spark plug

4. Ignition coil 5. PCV hose 6. PCV valve

7. O-ring 8. Rocker cove r gask e t A. To air duct assembly B.

Comply with the assembly procedure when tightening. Refer to EM-41

C. To intake manifold

Refer to GI-4, "

Components" for symbols in the figure.

PBIC4366J

a : 14 mm (0.55 in)

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SPARK PLUG

EM-17

< PERIODIC MAINTENANCE >

Install in the reverse order of removal.

Inspection INFOID:0000000006503515

INSPECTION AFTER REMOVAL

Use the standard type spark plug for normal condition.

CAUTION:

• Never drop or shock spark plug.

• Never use a wire brush for cleaning.

• If plug tip is covered with carbon, spark plug cleaner may be used.

• Spark plug gap adjustment is not required between replacement intervals.

• Measure spark plug gap. when it exceeds the limit, replace spark plug even if it is with in the specified replacement mileage. Refer to EM-114, "

Spark Plug".

Spark plug (Standard type) : Refer to EM-114, "

Spark Plug".

Cleaner air pressure

: Less than 588 kPa (6 kg/cm

85 psi)

Cleaning time : Less than 20 seconds

SMA773C

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EM-18

< PERIODIC MAINTENANCE >

CAMSHAFT VALVE CLEARANCE

Inspection and Adjustment INFOID:0000000006503516

INSPECTION

Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if there is unusual engine conditions regarding valve clearance.

1. Remove rocker cover. Refer to EM-41, "

Exploded View".

2. Measure the valve clearance with the following procedure: a. Set No. 1 cylinder at TDC of its compression stroke.

• Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover.

• At the same time, check that both intake and exhaust cam noses of No. 1 cylinder face inside ( ) as shown in the figure.

• If they do not face inside, rotate crankshaft pulley once more (360 degrees) and align as shown in the figure.

b. Use a feeler gauge, measure the clearance between valve lifter

and camshaft.

• By referring to the figure, measure the valve clearances at locations marked “×” as shown in the table below [locations

indicated with black arrow ( ) in the figure] with a feeler gauge.

C : White paint mark (Not use for service)

PBIC3960E

1 : Camshaft (INT) 2 : Camshaft (EXH)

: Engine front

PBIC3359J

Valve clearance : Refer to EM-115, "Camshaft".

PBIC3192J

A : Exhaust side B : No. 1 cylinder C : No. 2 cylinder D : No. 3 cylinder E : No. 4 cylinder

PBIC3193J

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CAMSHAFT VALVE CLEARANCE

EM-19

< PERIODIC MAINTENANCE >

c. Set No. 4 cylinder at TDC of its compression stroke.

• Rotate crankshaft pulley (1) one revolution (360 degrees) and align TDC mark (no paint) (B) to timing indicator (A) on front cover.

• By referring to the figure, measure the valve clearance at locations marked “×” as shown in the table below [locations indi-

cated with black arrow ( ) in the figure] with a feeler gauge.

3. If out of standard, perform adjustment. Refer to “ADJUSTMENT”.

ADJUSTMENT

• Perform adjustment depending on selected head thickness of valve lifter.

1. Remove camshaft. Refer to EM-54, "

Exploded View".

2. Remove valve lifters at the locations that are out of the standard.

3. Measure the center thickness of the removed valve lifters with a micrometer (A).

4. Use the equation below to calculate valve lifter thickness for replacement.

F : Intake side

: Engine front

Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.

No. 1 cylinder at compression TDC

EXH ××

INT ××

C : White paint mark (Not use for service)

PBIC3960E

A : Exhaust side B : No. 1 cylinder C : No. 2 cylinder D : No. 3 cylinder E : No. 4 cylinder F : Intake side

: Engine front

PBIC3194J

Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.

No. 4 cylinder at compression TDC

EXH ××

INT ××

PBIC3195J

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Page 84

EM-20

< PERIODIC MAINTENANCE >

CAMSHAFT VALVE CLEARANCE

• Thickness of new valve lifter (B) can be identified by stamp mark (A) on the reverse side (inside the cylinder).

• Stamp mark “302” indicates 3.02 mm (0.1189 in) in thickness.

NOTE:

Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-115, "

Camshaft".

5. Install the selected valve lifter.

6. Install camshaft. Refer to EM-54, "

Exploded View".

7. Install timing chain and related parts. Refer to EM-43, "

Exploded View".

8. Manually rotate crankshaft pulley a few rotations.

9. Check that the valve clearances is within the standard. Refer to “INSPECTION”.

10. Install remaining parts in the reverse order of removal.

11. Warm up the engine, and check for unusual noise and vibration.

Valve lifter thickness calculation: t = t

1 + (C1 – C2)

t = Valve lifter thickness to be replaced t

1 = Removed valve lifter thickness

1 = Measured valve clearance

2 = Standard valve clearance:

Intake : 0.30 mm (0.012 in) Exhaust : 0.33 mm (0.013 in)

PBIC3196J

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Page 85

COMPRESSION PRESSURE

EM-21

< PERIODIC MAINTENANCE >

COMPRESSION PRESSURE

Inspection INFOID:0000000006503517

1. Warm up engine thoroughly. Then, stop it.

2. Release fuel pressure. Refer to EC-487, "

Inspection".

3. Remove ignition coil and spark plug from each cylinder . Refer to EM-41, "

Exploded View".

4. Connect engine tachometer (not required in use of CONSULT- III).

5. Install compression gauge (B) with an adapter (A) (commercial service tool) onto spark plug hole.

• Use the adapter whose picking up end inserted to spark plug

hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.

6. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each cylinder.

CAUTION:

Always use a fully charged battery to obtain the specified engine speed.

• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the

engine speed again with normal battery gravity.

• If compression pressure is below minimum value, check valve clearances, and parts associated with

combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, and cylinder head gasket). After the checking, measure compression pressure again.

• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole

of the cylinder to recheck it for compression.

- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-

ton rings and replace if necessary.

- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-

functioning. Check valves for damage. Replace valve or valve seat accordingly.

• If two adjacent cylinders have respectively low compression pressure and their compression remains

low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cylinder head gaskets.

7. After inspection is completed, install removed parts.

8. Start the engine, and check that the engine runs smoothly.

9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-126, "

Description".

PBIC3541J

a : 20 mm (0.79 in)

JPBIA0171ZZ

Compression pressure : Refer to EM-114, "General Specification".

Revision: 2011 December 2011 CUBE

Page 86

EM-22

< REMOVAL AND INSTALLATION >

ENGINE COVER

REMOVAL AND INSTALLATION

ENGINE COVER

Exploded View INFOID:0000000006503518

Removal and Installation INFOID:0000000006503519

REMOVAL

Remove engine cover.

CAUTION:

Never damage or scratch engine cover when installing or removing.

INSTALLATION

Install in the reverse order of removal.

1. Engine cover Refer to GI-4, "

Components" for symbols in the figure.

JPBIA2354GB

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DRIVE BELT AUTO TENSIONER AND IDLER PULLEY

EM-23

< REMOVAL AND INSTALLATION >

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY

Exploded View INFOID:0000000006503520

Removal and Installation INFOID:0000000006503521

Removal

1. Remove the following parts.

• Engine cover: Refer to EM-22, "

Exploded View".

• Cowl top cover and extension cowl top: Refer to EXT-20, "

Exploded View".

• Vacuum lines: Refer to BR-31, "

Exploded View".

• Air duct: Refer to EM-24, "

Exploded View".

• Front fender protector (RH): Refer to EXT-22, "

FENDER PROTECTOR : Exploded View".

• Ground cable (between front cover and radiator core support)

2. Remove drive belt. Refer to EM-13, "

Removal and Installation".

• Keep drive belt auto-tensioner pulley arm locked after drive belt are removed.

3. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting bracket (RH) and the engine mounting insulator (RH). Refer to EM-75, "

Exploded View".

CAUTION:

Never damage or scratch oil pan (lower) when supporting.

4. Loosen mounting bolt and remove drive belt auto-tensioner.

• Lift the front side of the engine with a jack sustaining engine base to remove mounting bolt.

Installation

Install in the reverse order of removal.

CAUTION:

When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.

1. Front cover 2. Drive belt auto-tensioner 3. Idler pulley (models without A/C)

Idler pulley bracket (models without A/C)

5. Shaft (models without A/C)

Refer to GI-4, "

Components" for symbols in the figure.

JPBIA2908GB

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Page 88

EM-24

< REMOVAL AND INSTALLATION >

AIR CLEANER AND AIR DUCT

Exploded View INFOID:0000000006503522

Removal and Installation INFOID:0000000006503523

REMOVAL

NOTE:

Mass air flow sensor is removable under the car-mounted condition.

1. Remove air duct (inlet) and resonator assembly.

2. Remove engine cover. Refer to EM-22, "

Exploded View".

3. Remove the air cleaner filter from the air cleaner case.

4. Remove air duct [between air duct (inlet) and air cleaner case] from the air cleaner case.

5. Disconnect PCV hose.

6. Remove the air duct (between air cleaner case and electric throttle control actuator).

• Add matching marks if necessary for easier installation.

7. Remove air cleaner case with the following procedure. a. Remove battery. Refer to PG-103, "

Exploded View".

b. Disconnect mass air flow sensor harness connector. c. Remove the air cleaner case.

8. Remove mass air flow sensor from air cleaner case, if necessary.

1. Air cleaner filter 2. Mass air flow sensor 3. O-ring

4. Holder 5. Cleaner cover 6. Clamp

7. Air duct 8. PCV hose 9. Air duct (inlet)

10. Air duct 11. Resonator 12. Grommet

13. Grommet 14. Air cleaner case A. To electric throttle control actuator B. To rocker cover Refer to GI-4, "

Components" for symbols in the figure.

JPBIA2909GB

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Page 89

AIR CLEANER AND AIR DUCT

EM-25

< REMOVAL AND INSTALLATION >

CAUTION:

Handle the mass air flow sensor with following cares.

• Never shock the mass air flow sensor.

• Never disassemble the mass air flow sensor.

• Never touch the sensor of the mass air flow sensor.

INSTALLATION

CAUTION:

Do not reuse O-rings.

Note the following, and install in the reverse order of removal.

• Align marks. Attach each joint. Screw clamps firmly.

Inspection INFOID:0000000006503524

INSPECTION AFTER REMOVAL

Inspect air duct and resonator assembly for crack or tear.

• If anything found, replace air duct and resonator assembly.

Revision: 2011 December 2011 CUBE

Page 90

EM-26

< REMOVAL AND INSTALLATION >

INTAKE MANIFOLD

Exploded View INFOID:0000000006503525

Except for California

JPBIA2910GB

1. Clamp 2. Harness bracket 3. Clamp

4. PCV hose 5. Gasket 6. Vacuum hose

7. Clamp 8. Intake manifold 9. Bracket

10. Clamp 11. EVAP hose 12. O-ring

13.

EVAP cani ster purge volume control solenoid valve

14. EVAP vacuum tank 15. Clamp

16. EVAP hose 17. EVAP service port 18. EVAP hose

19. Clamp 20. Water hose 21. Water hose

22. Elec tric thrott le co ntro l ac tuator 23. Gasket A. To brake booster B. To centrali zed under-floor piping C. To water outlet Refer to GI-4, "

Components" for symbols in the figure.

Revision: 2011 December 2011 CUBE

Page 91

INTAKE MANIFOLD

EM-27

< REMOVAL AND INSTALLATION >

For California

Removal and Installation INFOID:0000000006503526

REMOVAL

1. Remove engine cover. Refer to EM-22, "Exploded View".

2. Pull out oil level gauge.

CAUTION:

Cover the oil level gauge guide openings to avoid entry of foreign materials.

3. Disconnect PCV hose from intake manifold and rocker cover.

4. Remove air duct (inlet), resonator and air duct assembly. Refer to EM-24, "

Exploded View".

5. Disconnect vacuum hose from intake manifold.

6. Disconnect water hoses from electric throttle control actuator as follows:

• Drain engine coolant from radiator or attach plug to prevent engine coolant leakage when engine coolant is not drained. Refer to CO-9, "

Draining".

CAUTION:

Perform this step when the engine is cold.

7. Remove electric throttle control actuator.

CAUTION:

• Handle carefully to avoid any shock to electric throttle control actuator.

• Never disassemble electric throttle control actuator.

JSBIA1206GB

1. PCV hose 2. Intake manifold 3. Gasket

4. Intake manifold adapter 5. Gasket 6. Cylinder head

7. Gasket 8. Electric throttle control actuator A. To water outlet B. View B Refer to GI-4, "

Components" for symbols in the figure.

Revision: 2011 December 2011 CUBE

Page 92

EM-28

< REMOVAL AND INSTALLATION >

INTAKE MANIFOLD

8. Remove intake manifold (1) with the following procedure:

a. Loosen and remove intake manifold mounting bolts (A) and (B). b. Remove harness clip from intake manifold side. c. Disconnect EVAP hose from intake manifold. d. Disconnect harness connector from EVAP canister purge vol-

ume control valve.

e. Loosen mounting bolts in reverse order as shown in the figure.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

9. Remove intake manifold adapter (for California).

10. Remove brackets from intake manifold, if necessary.

11. Remove engine cover bracket, if necessary.

12. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.

INSTALLATION

CAUTION:

Do not reuse O-rings.

Note the following, and install in the reverse order of removal.

Intake Manifold

1. Check if gasket is not dropped from the installation groove of intake manifold.

2. Install intake manifold with the following procedure:

: Engine front

PBIC3939E

: Engine front

PBIC3527J

Revision: 2011 December 2011 CUBE

Page 93

INTAKE MANIFOLD

EM-29

< REMOVAL AND INSTALLATION >

a. Tighten in numerical order as shown in the figure.

b. Tighten No. 1 bolt again.

c. Tighten intake manifold mounting bolt (A). Then tighten intake

manifold mounting bolt (B).

Electric Throttle Control Actuator

• Tighten bolts of electric throttle control actuator equally and diagonally in several steps.

• Perform “Throttle Valve Closed Position Learning” after rep air when removing harness connector of the electric throttle control actuator. Refer to EC-24, "

THROTTLE VALVE CLOSED POSITION LEARNING : Special Repair Requirement" (except for CALIFORNIA) or EC-502, "THROTTLE VALVE CLOSED POSITION LEARNING : Special Repair Requirement" (for CALIFORNIA).

• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing electric throttle control actuator. Refer to following table.

: Engine front

PBIC3527J

1 : Intake manifold

: Engine front

PBIC3939E

Item Except for CALIFORNIA For CALIFORNIA

Throttle Valve Closed Position Learning EC-24

EC-502

Idle Air Volume Learning EC-25 EC-503

Revision: 2011 December 2011 CUBE

Page 94

EM-30

< REMOVAL AND INSTALLATION >

EXHAUST MANIFOLD

Exploded View INFOID:0000000006503527

Except for CALIFORNIA

PBIC4735E

1. Exhaust manifold cover 2. Exhaust manifold 3. Gasket

4. Stud bolt 5. Harness bracket 6. Air fuel ratio sensor 1

7. Exhaust manifold stay

Refer to GI-4, "

Components" for symbols in the figure.

Revision: 2011 December 2011 CUBE

Page 95

EXHAUST MANIFOLD

EM-31

< REMOVAL AND INSTALLATION >

For CALIFORNIA

Removal and Installation INFOID:0000000006503528

REMOVAL

1. Remove exhaust front tube. Refer to EX-5, "Exploded View".

2. Remove exhaust manifold cover.

3. Remove the air fuel ratio sensor 1.

• Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], remove air fuel ratio sensor 1.

CAUTION:

Handle air fuel ratio sensor 1 carefully and avoid impacts. NOTE:

The exhaust manifold can be removed and installed without removing the air fuel ratio sensor 1 (Disassembly of harness connector is necessary).

4. Remove exhaust manifold stay.

5. Remove exhaust manifold.

• Loosen nuts in reverse order as shown in the figure.

NOTE:

• The figure shows except for CALIFORNIA as an example.

• Disregard No. 6 to 8 when loosening.

JSBIA1270GB

1. Harness bracket 2. Air fuel ratio sensor 1 3. Exhaust manifold cover

4. Exhaust manifold 5. Gasket 6. Cy lin de r head

7. Exhaust manifold stay 8. Oil pan (upper) Refer to GI-4, "

Components" for symbols in the figure.

: Engine front

JPBIA2356ZZ

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Page 96

EM-32

< REMOVAL AND INSTALLATION >

EXHAUST MANIFOLD

6. Remove gasket.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

INSTALLATION

1. Install gasket to cylinder head as shown in the figure.

2. Install exhaust manifold with the following procedure: a. Tighten nuts in numerical order as shown in the figure.

NOTE:

• The figure shows except for CALIFORNIA as an example.

• No. 6 to 8 mean double tightening of nuts No. 1 to 3.

b. Install exhaust manifold stay (2) in the direction as shown in the

figure.

NOTE:

The figure shows except for CALIFORNIA as an example.

3. Install remaining parts in the reverse order of removal.

Inspection INFOID:0000000006503529

INSPECTION AFTER REMOVAL

Surface Distortion

• Using feeler gauge (A) and straightedge (B), check the surface distortion of exhaust manifold mating surface in each exhaust port and entire part.

• If it exceeds the limit, replace exhaust manifold.

: Engine front

PBIC3943E

: Engine front

JPBIA2356ZZ

1 : Exhaust manifold 3 : Drive shaft support be arin g bra cket A : Upper mark

: Vehicle front

PBIC3255J

Limit : Refer to EM-115, "Exhaust Manifold".

PBIC3530J

Revision: 2011 December 2011 CUBE

Page 97

OIL PAN (LOWER)

EM-33

< REMOVAL AND INSTALLATION >

OIL PAN (LOWER)

Exploded View INFOID:0000000006503530

Removal and Installation INFOID:0000000006503531

REMOVAL

1. Drain engine oil. Refer to LU-8, "Draining".

2. Remove oil pan (lower) with the following procedure:

1. Oil level gauge 2. Oil level gauge guide 3. Rear oil seal

4. O-ring 5. Oil pan (upper) 6. Oil pump drive chain

7. Crankshaft sprocket 8. Oil pump sprocket 9. Oil pump chain tensioner

10. Oil pump 11. Drain plug 12. Drain plug washer

13. Oil pan (lower) 14. Oil filter 15. Connector bolt

16. O-ring A. Refer to LU-10

B. Oil pan side

Refer to GI-4, "

Components" for symbols in the figure.

PBIC4463J

Revision: 2011 December 2011 CUBE

Page 98

EM-34

< REMOVAL AND INSTALLATION >

OIL PAN (LOWER)

a. Loosen mounting bolts in reverse order as shown in the figure.

b. Insert seal cutter [SST: KV10111100 (J-37228)] (A) between oil

pan (upper) and oil pan (lower).

CAUTION:

• Be careful not to damage the mating surface.

• Never insert a screwdriver. This damages the mating surfaces.

c. Slide the seal cutter [SST: KV10111100 (J-37228)] by tapping on

the side of tool with a hammer.

d. Remove oil pan (lower).

INSTALLATION

CAUTION:

Do not reuse drain plug washer.

1. Install oil pan (lower) as follows: a. Use a scraper (A) to remove old liquid gasket from mating sur-

faces.

• Also remove old liquid gasket from mating surface of oil pan (upper).

• Remove old liquid gasket from the bolt holes and threads.

CAUTION:

Never scratch or damage the mating surface when cleaning off old liquid gasket.

: Engine front

PBIC3146J

JPBIA0276ZZ

PBIC3953E

Revision: 2011 December 2011 CUBE

Page 99

OIL PAN (LOWER)

EM-35

< REMOVAL AND INSTALLATION >

b. Apply a continuous bead of liquid gasket (A) with a tube presser

(commercial service tool) as shown in the figure.

Use Genuine RTV Silicon Sealant or equivalent. Refer to GI-

22, "Recommended Chemical Products and Sealants".

CAUTION:

Attaching should be done within 5 minutes after liquid gasket application.

c. Tighten bolts in numerical order as shown in the figure.

2. Install oil pan drain plug.

CAUTION:

Do not reuse drain plug washer.

• Refer to the figure of components of former page for installation direction of drain plug washer. Refer to

EM-33, "

Exploded View".

3. Install in the reverse order of removal after this step.

Inspection INFOID:0000000006503532

INSPECTION AFTER REMOVAL

Clean oil strainer if any object attached.

INSPECTION AFTER INSTALLATION

1. Check the engine oil level and adjust engine oil. Refer to LU-7, "Inspection".

2. Start engine, and check there is no leakage of engine oil.

3. Stop engine and wait for 10 minutes.

4. Check the engine oil level again. Refer to LU-7, "

Inspection".

1 : Oil pan (lower)

: Engine outside

PBIC4590E

: Engine front

PBIC3146J

Revision: 2011 December 2011 CUBE

Page 100

EM-36

< REMOVAL AND INSTALLATION >

FUEL INJECTOR AND FUEL TUBE

Exploded View INFOID:0000000006503533

CAUTION:

Never remove or disassemble parts unless instructed as shown in the figure.

Removal and Installation INFOID:0000000006503534

WARNING:

• Put a “CAUTION: FLAMMABLE” sign in the workshop.

• Be sure to work in a well ventilated area and furnish workshop with a CO

2 fire extinguisher.

• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.

REMOVAL

1. Release the fuel pressure. Refer to EC-487, "Inspection".

2. Remove intake manifold. Refer to EM-26, "

Exploded View".

1. Fuel feed tube 2. Bracket 3. Quick connector cap

4. Fuel tube 5. O-ring (black) 6. Clip

7. Injector 8. O-ring (green) A. To centralized under-floor piping Refer to GI-4, "

Components" for symbols in the figure.

PBIC3537J

Revision: 2011 December 2011 CUBE

Nissan Cube 2011 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual