Nissan Maxima 2002 User Manual

BODY & TRIM

CONTENTS

PRECAUTIONS ...............................................................3

Service Notice..............................................................3

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″...............3

PREPARATION ...............................................................4

Special Service Tools..................................................4

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

SQUEAK AND RATTLE TROUBLE DIAGNOSES.........5

Work Flow....................................................................5

CUSTOMER INTERVIEW DUPLICATE THE NOISE AND TEST DRIVE CHECK RELATED SERVICE BULLETINS LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE REPAIR THE CAUSE CONFIRM THE REPAIR

Generic Squeak and Rattle Troubleshooting..............7

INSTRUMENT PANEL CENTER CONSOLE DOORS TRUNK SUNROOF/HEADLINER SEATS UNDERHOOD

Diagnostic Worksheet..................................................9

CLIP AND FASTENER..................................................11

Description.................................................................11

BODY FRONT END.......................................................13

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

FRONT BUMPER ASSEMBLY

BODY REAR END AND OPENER................................16

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

REAR BUMPER ASSEMBLY TRUNK LID INSIDE RELEASE HANDLE

DOOR.............................................................................20

Adjustment.................................................................20

STRIKER ADJUSTMENT

Front Door Glass.......................................................21

FRONT DOOR GLASS AND REGULATOR

Front Door Limit Switch Reset ..................................22

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

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

.....................................................................8

......................................................................8

...........................................................8

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

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

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

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

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

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

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

.............................................8

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

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

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

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

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

SECTION

RESET CONDITIONS RESET PROCEDURES

Rear Door Glass........................................................23

REAR DOOR GLASS AND REGULATOR

Front Door Lock.........................................................25

BELL CRANK ADJUSTMENT OUTSIDE HANDLE ROD ADJUSTMENT REMOVAL

Rear Door Lock .........................................................27

OUTSIDE HANDLE ROD ADJUSTMENT REMOVAL

INSTRUMENT PANEL ASSEMBLY .............................29

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

SIDE AND FLOOR TRIM...............................................34

Removal and Installation...........................................34

DOOR TRIM...................................................................37

Removal and Installation...........................................37

ROOF TRIM...................................................................39

Removal and Installation...........................................39

TRUNK ROOM TRIM.....................................................41

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

EXTERIOR.....................................................................42

Removal and Installation...........................................42

FRONT SEAT ................................................................48

Removal and Installation...........................................48

POWER SEAT MANUAL SEAT HEATED SEAT

Active Head Restraint................................................51

OPERATION OUTLINE

REAR SEAT...................................................................52

Removal and Installation...........................................52

SUNROOF......................................................................53

Adjustment.................................................................53

Removal.....................................................................53

Trouble Diagnoses.....................................................57

DIAGNOSTIC TABLE WIND DEFLECTOR ADJUSTMENT DRAIN HOSES

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

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

.........................................................49

........................................................50

........................................................51

.........................................................58

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

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

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

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

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

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

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

............................................51

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

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

IDX

CONTENTS (Cont’d)

WEATHERSTRIP LINK AND WIRE ASSEMBLY

WINDSHIELD AND WINDOWS ....................................61

Removal and Installation...........................................61

REMOVAL INSTALLATION WINDSHIELD

DOOR MIRROR.............................................................63

Removal and Installation...........................................63

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

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

...............................................................61

........................................................61

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

REAR VIEW MIRROR...................................................64

Removal and Installation...........................................64

REMOVAL INSTALLATION

BODY (ALIGNMENT)....................................................65

Alignment...................................................................65

ENGINE COMPARTMENT UNDERBODY

...............................................................64

........................................................64

........................................66

..........................................................68

BT-2

PRECAUTIONS

Service Notice

I When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent

scratches.

I Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soil

or damage them.

I Apply sealing compound where necessary when installing parts. I When applying sealing compound, be careful that the sealing compound does not protrude from parts. I When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust pre-

vention measures.

NFBT0001

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

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELTPRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL A33 is as follows (The composition varies according to optional equipment.):

I For a frontal collision

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

I For a side collision

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

Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING:

I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death

in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.

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

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

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

Service Manual. SRS wiring harnesses can be identified by yellow harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors).

NFBT0002

BT-3

IDX

Special Service Tools

PREPARATION

Special Service Tools

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

Tool number (Kent-Moore No.) Tool name

— (J-39570) Chassis ear

— (J-43980) Nissan Squeak and Rattle kit

Description

Locating the noise

SBT839

Repairing the cause of noise

NFBT0027

SBT840

Tool name Description Engine ear

SBT841

Commercial Service Tools

Locating the noise

NFBT0028

BT-4

SQUEAK AND RATTLE TROUBLE DIAGNOSES

Work Flow

CUSTOMER INTERVIEW

Interview the customer, if possible, to determine the conditions that exist when the noise occurs. Use the Diagnostic Worksheet during the interview to document the facts and conditions when the noise occurs and any customer’s comments; refer to BT-9. This information is necessary to duplicate the conditions that exist when the noise occurs.

I The customer may not be able to provide a detailed description or the location of the noise. Attempt to

obtain all the facts and conditions that exist when the noise occurs (or does not occur).

I If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer

is concerned about. This can be accomplished by test driving the vehicle with the customer.

I After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteris-

tics are provided so the customer,service adviser andtechnician are all speaking the same language when defining the noise.

I Squeak — (Like tennis shoes on a clean floor)

Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard surfaces = higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping

I Creak — (Like walking on an old wooden floor)

Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch dependent on materials/often brought on by activity.

I Rattle — (Like shaking a baby rattle)

Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing clip or fastener/incorrect clearance.

I Knock — (Like a knock on a door)

Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.

I Tick — (Like a clock second hand)

Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver action or road conditions.

I Thump — (Heavy, muffled knock noise)

Thump characteristics include softer knock/dead sound often brought on by activity.

I Buzz — (Like a bumble bee)

Buzz characteristics include high frequency rattle/firm contact.

I Often the degreeof acceptable noiselevel will varydepending upon the person.Anoisethat you mayjudge

as acceptable may be very irritating to the customer.

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

NFBT0029

SBT842

NFBT0029S01

IDX

BT-5

Work Flow (Cont’d)

SQUEAK AND RATTLE TROUBLE DIAGNOSES

DUPLICATE THE NOISE AND TEST DRIVE

NFBT0029S02

If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to duplicate the same conditions when you confirm the repair. If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to duplicate the noise with the vehicle stopped by doing one or all of the following:

1) Close a door.

2) Tap or push/pull around the area where the noise appears to be coming from.

3) Rev the engine.

4) Use a floor jack to recreate vehicle “twist”.

5) At idle, apply engine load (electrical load, half-clutch on M/T model, drive position on A/T model).

6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.

I Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs. I If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the

vehicle body.

CHECK RELATED SERVICE BULLETINS

NFBT0029S03

After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related to that concern or symptom. If a TSB relates to the symptom, follow the procedure to repair the noise.

LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE

NFBT0029S04

1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool (Chassis Ear: J-39570, Engine Ear: J-39565 and mechanics stethoscope).

2. Narrow down the noise to a more specific area and identify the cause of the noise by:

I removing the components in the area that you suspect the noise is coming from.

Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be broken or lost during the repair, resulting in the creation of new noise.

I tapping or pushing/pulling the component that you suspect is causing the noise.

Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only temporarily.

I feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the

noise.

I placing a piece of paper between components that you suspect are causing the noise. I looking for loose components and contact marks.

Refer to “Generic Squeak and Rattle Troubleshooting”, BT-7.

REPAIR THE CAUSE

NFBT0029S05

I If the cause is a loose component, tighten the component securely. I If the cause is insufficient clearance between components:

− separate components by repositioning or loosening and retightening the component, if possible.

− insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or urethane tape. A Nissan Squeak and Rattle Kit (J-43980) is available through your authorized Nissan Parts Department.

CAUTION:

Do not use excessive force as many components are constructed of plastic and may be damaged. Always check with the Parts Department for the latest parts information.

The following materials are contained in the NissanSqueak and Rattle Kit (J-43980). Each item can be ordered separately as needed. URETHANE PADS [1.5 mm (0.059 in) thick] Insulates connectors, harness, etc. 76268-9E005: 100 x 135 mm (3.94 x 5.31 in)/76884-71L01: 60 x 85 mm (2.36 x 3.35 in)/76884-71L02: 15 x 25 mm (0.59 x 0.98 in) INSULATOR (Foam blocks) Insulates components from contact. Can be used to fill space behind a panel. 73982-9E000: 45 mm (1.77 in) thick, 50 x 50 mm (1.97 x 1.97 in)/73982-50Y00: 10 mm (0.39 in) thick, 50 x 50 mm (1.97 x 1.97 in) INSULATOR (Light foam block)

BT-6

SQUEAK AND RATTLE TROUBLE DIAGNOSES

Work Flow (Cont’d)

80845-71L00: 30 mm (1.18 in) thick, 30 x 50 mm (1.18 x 1.97 in) FELT CLOTH TAPE Used to insulate where movement does not occur. Ideal for instrument panel applications. 68370-4B000: 15 x 25 mm (0.59 x 0.98 in) pad/68239-13E00: 5 mm (0.20 in) wide tape roll The following materials, not found in the kit, can also be used to repair squeaks and rattles. UHMW (TEFLON) TAPE Insulates where slight movement is present. Ideal for instrument panel applications. SILICONE GREASE Used in place of UHMW tape that will be visible or not fit. Note: Will only last a few months. SILICONE SPRAY Use when grease cannot be applied. DUCT TAPE Use to eliminate movement.

CONFIRM THE REPAIR

Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.

NFBT0029S06

Generic Squeak and Rattle Troubleshooting

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

INSTRUMENT PANEL

Most incidents are caused by contact and movement between:

1. The cluster lid A and instrument panel

2. Acrylic lens and combination meter housing

3. Instrument panel to front pillar garnish

4. Instrument panel to windshield

5. Instrument panel mounting pins

6. Wiring harnesses behind the combination meter

7. A/C defroster duct and duct joint

These incidents can usually be located by tapping or moving the components to duplicate the noise or by pressing on the components while driving to stop the noise. Most of these incidents can be repaired by applying felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring harness.

CAUTION:

Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will not be able to recheck the repair.

CENTER CONSOLE

Components to pay attention to include:

1. Shifter assembly cover to finisher

2. A/C control unit and cluster lid C

3. Wiring harnesses behind audio and A/C control unit

The instrument panel repair and isolation procedures also apply to the center console.

DOORS

Pay attention to the:

1. Finisher and inner panel making a slapping noise

2. Inside handle escutcheon to door finisher

3. Wiring harnesses tapping

4. Door striker out of alignment causing a popping noise on starts and stops

Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks from the Nissan Squeak and Rattle Kit (J-43980) to repair the noise.

NFBT0030

NFBT0030S01

NFBT0030S02

NFBT0030S03

IDX

BT-7

SQUEAK AND RATTLE TROUBLE DIAGNOSES

Generic Squeak and Rattle Troubleshooting (Cont’d)

TRUNK

=NFBT0030S04

Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner. In addition look for:

1. Trunk lid bumpers out of adjustment

2. Trunk lid striker out of adjustment

3. The trunk lid torsion bars knocking together

4. A loose license plate or bracket

Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) causing the noise.

SUNROOF/HEADLINER

NFBT0030S05

Noises in the sunroof/headliner area can often be traced to one of the following:

1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise

2. Sunvisor shaft shaking in the holder

3. Front or rear windshield touching headliner and squeaking

Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these incidents. Repairs usually consist of insulating with felt cloth tape.

SEATS

NFBT0030S06

When isolating seat noises it’s important to note the position the seat is in and the load placed on the seat when the noise is present. These conditions should be duplicated when verifying and isolating the cause of the noise. Cause of seat noise include:

1. Headrest rods and holders

2. A squeak between the seat pad cushion and frame

3. The rear seat back lock and bracket

These noises can be isolated by moving or pressing on the suspected components while duplicating the conditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component or applying urethane tape to the contact area.

UNDERHOOD

NFBT0030S07

Some interior noises may be caused by components under the hood or on the engine wall. The noise is then transmitted into the passenger compartment. Causes of transmitted underhood noises include:

1. Any component mounted to the engine wall

2. Components that pass through the engine wall

3. Engine wall mounts and connectors

4. Loose radiator mounting pins

5. Hood bumpers out of adjustment

6. Hood striker out of adjustment

These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or insulating the component causing the noise.

BT-8

SQUEAK AND RATTLE TROUBLE DIAGNOSES

Diagnostic Worksheet

NFBT0031

BT-9

IDX

SBT843

SQUEAK AND RATTLE TROUBLE DIAGNOSES

Diagnostic Worksheet (Cont’d)

BT-10

SBT844

CLIP AND FASTENER

Description

I Clips and fasteners in BT section correspond to the following numbers and symbols. I Replace any clips and/or fasteners which are damaged during removal or installation.

Symbol No. Shapes Removal & Installation

C101

SBF302H

C103

SBT095

NFBT0003

SBF367BA

SBF423H

C205

C206

CE103

MBT080A

MBF519B

SBF638CA

MBF520B

BT-11

IDX

SBF104B

SBF147B

CLIP AND FASTENER

Description (Cont’d)

Symbol No. Shapes Removal & Installation

CF110

SBF648B

CF118

SBF649B

CR103

CS101

SBF151D

SBF768B

SBF078B

SBF259G

SBF770B

SBF992G

BT-12

BODY FRONT END

Removal and Installation

I When removing or installing hood, place a cloth or other padding on hood. This prevents vehicle body from

being scratched.

I Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it. I Hood adjustment: Adjust at hinge portion. I Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood

locks engaging mechanism.

I Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood.

WARNING:

I Be careful not to scratch hood stay when installing hood. A scratched stay may cause gas leak-

age.

I The contents of the hood stay are under pressure. Do not take apart, puncture, apply heat or allow

fire near it.

FRONT BUMPER ASSEMBLY

1. Remove clips securing engine undercover from front side.

2. Remove clip and bolt securing left and right sides of front fender protectors.

3. Remove screws securing left and right sides of front fender protectors.

4. Remove clips securing left and right sides of front fender protectors in wheelhouse.

5. Remove screws securing left and right front fenders to bumper fascia.

6. Remove clips and protector securing bumper fascia.

7. Extract bumper fascia assembly, then disconnect fog lamp and side marker lamp harness connectors.

8. Remove energy absorber.

9. Remove bolts, hook and pawl securing headlamp assembly, then disconnect harness connectors.

10. Remove bolt and nuts securing bumper upper retainer.

11. Remove bolts and nuts securing bumper bracket.

12. Remove nuts securing bumper reinforcement to left and right bumper stays.

13. Extract bumper reinforcement.

14. Remove bolts and nut securing bumper stays, then remove the bumper stays.

Fog lamp assembly

15. Remove bolt securing fog lamp assembly.

16. Extract fog lamp assembly.

NFBT0004

NFBT0004S01

BT-13

IDX

SBT765

Removal and Installation (Cont’d)

BODY FRONT END

BT-14

SBT766

BODY FRONT END

Removal and Installation (Cont’d)

BT-15

IDX

SBT767

Removal and Installation

BODY REAR END AND OPENER

Removal and Installation

NFBT0005

I When removing or installing trunk lid, place a cloth or other padding on trunk lid. This prevents vehicle

body from being scratched.

I Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it. I Trunk lid adjustment: Adjust at hinge-trunk lid portion for proper trunk lid fit. I Trunklid lock system adjustment: Adjust striker so that it is in the center of the lock. After adjustment,check

trunk lid lock operation.

I After installation, make sure that trunk lid and fuel filler lid open smoothly.

★ For Wiring Diagram, refer to EL-203, “TRUNK LID AND FUEL FILLER LID OPENER”.

REAR BUMPER ASSEMBLY

NFBT0005S01

1. Remove screws securing left and right rear fenders to bumper fascia.

2. Remove screws securing left and right rear fenders to bumper fascia lower side.

3. Remove trunk room trim. Refer to “TRUNK ROOM TRIM” for details, BT-41.

4. Working from inside trunk, remove jack then remove nuts securing jack bracket.

5. Working from inside trunk, remove bolts securing left and right rear fenders to bumper fascia.

6. Working from inside trunk, remove nuts securing rear panel to bumper fascia.

7. Extract bumper fascia assembly after removing the clamps securing it.

8. Remove energy absorber.

9. Remove nuts securing bumper reinforcement to left and right bumper stays.

10. Extract bumper reinforcement.

11. Remove nuts securing bumper stays, then remove the bumper stays.

BT-16

SBT084A

BODY REAR END AND OPENER

Removal and Installation (Cont’d)

BT-17

IDX

SBT085A

Removal and Installation (Cont’d)

BODY REAR END AND OPENER

BT-18

SBT770

BODY REAR END AND OPENER

Removal and Installation (Cont’d)

TRUNK LID INSIDE RELEASE HANDLE

NFBT0005S02

SBT253AA

BT-19

IDX

Adjustment

DOOR

Adjustment

NFBT0006

SBT772

SBT771

STRIKER ADJUSTMENT

NFBT0006S01

Adjust striker so that it is parallel with advancing direction of door lock.

BT-20

DOOR

Front Door Glass

I Make sure that door glass is positioned in glass run groove. I Make sure that there is no abnormality when door glass is

raised or lowered.

FRONT DOOR GLASS AND REGULATOR

=NFBT0007

NFBT0007S01

SBT773

I For removal of front door trim, refer to “DOOR TRIM”, BT-37. I For removal of door mirror, refer to “DOOR MIRROR”, BT-63. I For removal of door outside molding, refer to “EXTERIOR”,

BT-42.

I Remove sealing screen.

1. Using power window main switch, raise or lower door glass until carrier plate securing bolts are visible.

2. Remove bolts securing carrier plate.

SBT774

IDX

BT-21

+ 49 hidden pages