Nissan Maxima 2004 User Manual
I BODY
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SECTION
CONTENTS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Rest raint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions .............................................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
SQUEAK AND RATTLE TROUBLE DIAGNOSIS ...... 5
Work Flow ................................................................ 5
CUSTOMER INTERVIEW ..................................... 5
DUPLICATE THE NOISE AND TEST DRIVE ....... 6
CHECK RELATED SERVICE BULLETINS .. ......... 6
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 6
REP AIR THE CAUSE ........................................... 6
CONFIRM THE REPAIR ....................................... 7
Generic Squeak and Rattle Troubleshooting ........... 7
INSTRUMENT PANEL .......................................... 7
CENTER CONSOLE ............................................. 7
DOORS .............................. ................................... 7
TRUNK ............................... ................................... 8
SUNROOF/HEADLINER .......... ............. ................ 8
SEATS ................................................................... 8
UNDERHOOD .................... ............. ............. ......... 8
Diagnostic Worksheet .............................................. 9
CLIP AND FASTENER ..............................................11
Description ..............................................................11
FRONT BUMPER ..................................................... 14
Removal and Installation ........................................ 14
REAR BUMPER ....................................................... 16
Removal and Installation ........................................ 16
FRONT GRILLE ........................................................ 18
Removal and Installation ........................................ 18
COWL TOP ............................................................... 19
Removal and Installation ........................................ 19
FRONT FENDER ...................................................... 20
Removal and Installation ........................................ 20
EXTERIOR & INTERIOR
FRONT FENDER PROTECTOR ............................... 21
Removal and Installation ........................................ 21
FRONT ................................................................ 21
REAR ..................................................................22
MUDGUARD ............................................................. 23
Removal and Installation ........................................ 23
LICENSE LAMP FINISHER ...................................... 24
Removal and Installation ........................................ 24
REAR AIR SPOILER ................................................ 25
Removal and Installation ........................................ 25
ROOF SIDE MOLDING .............................................26
Removal and Installation ........................................ 26
REAR PILLAR FINISHER .........................................27
Removal and Installation ........................................ 27
DOOR OUTSIDE MOLDING ..................................... 28
Removal and Installation ........................................ 28
FRONT DOOR OUTSIDE MOLDING .................. 28
REAR DOOR OUTSIDE MOLDING ... ...... ....... ....28
SIDE GUARD MOLDING .......................................... 29
Removal and Installation ........................................ 29
REMOVAL ...................... ..................................... 29
INSTALLATION ........................... ........................29
DOOR FINISHER ...................................................... 30
Removal and Installation ........................................ 30
FRONT DOOR .................................................... 30
REAR DOOR ..... ....... ...... ....... ...... ....... ...... ....... ....31
BODY SIDE TRIM ..................................................... 32
Removal and Installation ........................................ 32
CENTER PILLAR LOWER GARNISH ................. 33
CENTER PILLAR UPPER GARNISH .................. 33
REAR PILLAR FINISHER ................................... 33
DASH SIDE FINISHER .......................................33
REAR PARCEL SHELF FINISHER ..........................34
Removal and Installation ........................................ 34
SUNSHADE .............................................................. 35
Component Parts and Harness Connector Location ...35
Wiring Diagram —SHADE— ..................................36
Removal and Installation ........................................ 38
FLOOR TRIM ............................................................ 39
Removal and Installation ........................................ 39
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HEADLINING ............................................................ 40
Removal and Installation ........................................40
TRUNK ROOM TRIM & TRUNK LID FINISHER .......42
Removal and Installation .........................................42
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PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
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The Supplemental Re straint 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 st age 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 and SB section of this Service Manual.
WARNING:
● To avoid rendering the SRS inopera tive, whi ch could incr ease the risk of pe rsonal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, inc luding incorrect removal and installation of the SRS, can lead to per-
sonal injury ca use d by unintentional ac tiv atio n o f the system. For remo va l of Spiral Cable and Air
Bag Module, see the SRS sec tion.
● Do not use electrical test equ ipment o n any circu it related to the SRS unless in structed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connectors.
Precautions
● When removing or disassembling any part, be careful not to damage or deform it. Protect parts which may
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get in the way with cloth.
● When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape.
● Keep removed parts protected with cloth.
● If a clip is deformed or damaged, replace it.
● If an unreusable part is removed, replace it with a new one.
● Tighten bolts and nuts firmly to the specified torque.
● After re-assembly has been completed, make sure each part functions correctly.
● Remove stains in the following way.
– Water-soluble stains:
Dip a cloth in warm water, and squeeze tightly. After wiping the stain, wipe with a soft dry cloth.
– Oil stain:
Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the
stain with the c loth. Nex t, dip the soft clo th in fres h water, and then sq ueeze it tightly. Then clean off the
detergent completely. Then wipe the area with a soft dry cloth.
● Do not use any organic solvent, such as thinne r or benzine.
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PREPARATION
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
SBT839
(J-43980)
NISSAN Squeak and Rattle kit
Description
Locating the noise
Repairing the cause of noise
PFP:00002
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SBT840
Commercial Service Tools
Tool name Description
Engine ear Locating the noise
SIIA0995E
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SQUEAK AND RATTLE TROUBLE DIAGNOSIS
SQUEAK AND RATTLE TROUBLE DIAGNOSIS PFP:00000
Work Flow
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CUSTOMER INTERVIEW
Interview th e cust omer, if possi ble, t o dete rmi ne th e condit ion s that exis t when the no ise oc curs . Us e the Di agnostic Worksheet during the interview to docume nt the facts and conditions w hen the noise occurs and an y
customer's comments; refer to EI-9, "
conditions that exist when the noise occurs.
● 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).
● 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.
● After ident if yi ng th e t y pe of no is e, i so lat e th e no is e in t er ms o f i t s c ha r ac te ris t ic s. T he n oi se c ha ract e ris ti cs
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.
– Squeak — (Like tennis shoes on a clean floor)
Squeak charact eristics include the lig ht contact/fast movement/ brought on by road condi tions/hard surfaces = higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping
– 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.
– Rattle — (Like shaking a baby rattle)
Rattle charact eristics inclu de the f ast repe ated co ntact/vibra tion or similar mov ement/l oose parts/mi ssing
clip or fastener/incorrect clearance.
– Knock — (Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.
– Tick — (Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action or road co nditions.
– Thump — (Heavy, muffled knock noise)
Thump characteristics include softer knock/d ead sound often brought on by activity.
– Buzz — (Like a bumblebee)
Buzz characteristics include high freque ncy rattle/firm contact.
● Often the de gree of acceptable nois e level will vary d epending upon the person. A noise that you may
judge as acceptable may be very irritating to the custome r.
● Weather conditions, especially humidit y and temperature, may have a great effect on noise level.
Diagnostic Worksheet" . This information is necessary to duplicat e the
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SQUEAK AND RATTLE TROUBLE DIAGNOSIS
DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the con ditions or location of the noise. This inform ation 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 doin g one or all of the following:
● Close a door.
● Ta p or push/pull a round the area where the noise appears to be coming from.
● Rev the engine.
● Use a floor jack to recreate vehicle “twist”.
● At idle, apply engine load (electrical load, half-clutch on M/T mode l, drive position on A/T model).
● Raise the vehicle on a hoist and hit a tire with a rubber hammer.
● Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.
● If it is difficult to duplicate the nois e, drive th e vehic le slowly on an und ulating or ro ugh road t o stress the
vehicle body.
CHECK RELATED SERVICE BULLETINS
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 pr ocedure to repair the nois e.
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the nois e to a general area. To help pinpoint the source of the noise, use a lis tening 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:
● Removing the components in t he area that you su spect the noise is coming from.
Do not use too much force when removing c lips and fasteners, otherwise cl ips and fasteners
can be broken or lost during the repair, resulting in the creation of new noise.
● Tapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull t he compone nt with excess ive force, othe rwise the noise will be elimi nated only temporarily.
● Feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing
the noise.
● Placing a piec e of paper between components that you suspect are causing the noise.
● Looking for loose components and contact marks.
Refer to EI-7, "
Generic Sque ak and Rattle Troubles hooting" .
REPAIR THE CAUSE
● If the cause is a loose component, tighten the component secur ely.
● 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 ure-
thane 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 informat ion.
The following materials are contained in the NISSAN Squeak 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.
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SQUEAK AND RATTLE TROUBLE DIAGNOSIS
73982-9E000: 45 mm (1. 7 7 in) t hick , 5 0 x 5 0 mm (1. 97 x 1.97 in ) /739 82 -50 Y 00 : 10 mm ( 0.39 in ) th ic k, 50 x 50
mm (1.97 x 1.97 in)
INSULATOR (Light foam block)
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 instrum ent panel applications.
68370-4B000: 15 x 25 mm (0.59 x 0.98 in) pad/6 8239-13E00: 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 greas e cannot be applied.
DUCT TAPE
Use to elimin ate movement.
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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.
Generic Squeak and Rattle Troubleshooting
Refer to Table of Contents for specific component removal and installation information.
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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 hous ing
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 co mponents while drivi ng to s top the noise. Most of th es e in c ide nts c an be re paired by applying felt cloth tape or silicone spray (in hard to reach are as) . Ur et ha ne pads ca n be use d to in su la te wiring harness.
CAUTION:
Do not use silicone s pray to isolate a sq ueak or rattle. If you saturate the area with silicone, you w ill
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 upper/lower clus ter lid C
3. Wiring harnes se s be hin d audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
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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
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SQUEAK AND RATTLE TROUBLE DIAGNOSIS
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of thes e incidents. You can usuall y insulat e the areas with fel t cloth tape o r insula tor foam bl ocks from
the NISSAN Squeak and Rattle Kit (J-43980) to repair the noise.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trun k by the owner.
In addition look for:
1. T runk lid bumpers out of adjustment
2. T runk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose l icense plate or b racket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or compo nent(s) causing the noise.
SUNROOF/HEADLINER
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 windshiel d 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
When isolatin g seat noises it is important to n ote the positio n the seat is in and the load pl aced on the se at
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 wh ic h th e n ois e oc cu rs. Most of these inci dents can be repaired by rep os iti oning the compone nt
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noises may be cause d by compon ents under the ho od or on the eng ine wall. Th e noise is th en
transmitted into the passenger compartment.
Causes of transmitted underhood noises inc lude:
1. Any component mounted to the engine wall
2. Compon ents that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator moun tin g pi ns
5. Hood bumpers out of adjus tm e nt
6. Hood striker out of adjustment
These noises can be difficu lt to isol ate sin ce the y cann ot be rea ched from the inter ior of the ve hi cle. The best
method is to sec ure, mov e or insul ate one com ponen t at a time and test drive the vehicle . Also , engine RPM
or load can be cha nged to isol ate the noise. Repairs can usu ally be made by moving, adj usting, securing, or
insulating the component causing the noise.
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SQUEAK AND RATTLE TROUBLE DIAGNOSIS
Diagnostic Worksheet
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SBT843
SQUEAK AND RATTLE TROUBLE DIAGNOSIS
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SBT844
CLIP AND FASTENER
CLIP AND FASTENER PFP:76906
Description
● Clips and fasteners in EI section correspond to the following numbers and symbols.
● Replace any clips and/or fasteners which are damaged during r emoval or installation.
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Symbol
No.
C101
C103
C203
Shapes Removal & Installation
SBF302H SBF367BA
SBT095 SBF423H
SBF258G SBF708E
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C205
C206
CE103
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MBT080A SBF638CA
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MBF519B MBF520B
SBF104B SBF147B
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CLIP AND FASTENER
Symbol
No.
CE107
CE117
CF110
Shapes Removal & Installation
SBF411H SBF767B
SBF174D SBF175DA
SBF648B SBF649B
CF118
CG101
CS101
SBF151D SBF259G
SBF145B SBF085B
SBF078B SBF992G
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CLIP AND FASTENER
Symbol
No.
CR103
Metal Clip
Shapes Removal & Installation
SBF768B SBF770B
WBT072 WBT073
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FRONT BUMPER
FRONT BUMPER
Removal and Installation
PFP:F2022
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WIIA0164E
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