2001 nissan sentra service repair manual by 163048

Edition: July 2000 Revision: November 2001 Publication No. SM1E-1B15U2

ÂŠ 2001 NISSAN NORTH AMERICA, INC. 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, photo-copying, recording or otherwise, without the prior written permission of Nissan North America, Inc., Gardena, California.

QUICK REFERENCE INDEX

FOREWORD This manual contains maintenance and repair procedures for the 2001 NISSAN SENTRA. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicleâ&#x20AC;&#x2122;s safety will be jeopardized by the service method selected.

NISSAN NORTH AMERICA, INC. Technical Publications Department Gardena, California

NOTES

Attachment No.13

QG18DE (Except CALIF. CA)

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II) The following is the information specified in Mode 6 of SAE J1979. The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG” while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored. Items for which these data (test value and test limit) are displayed are the same as SRT code items. These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen.

SRT item

Self-diagnostic test item Three way catalyst function (Bank 1)

CATALYST Three way catalyst function (Bank 2) EVAP control system (Small leak) EVAP SYSTEM

EVAP control system purge flow monitoring EVAP control system (Very small leak)

Heated oxygen sensor 1 (Bank 1)

Heated oxygen sensor 1 (Bank 2) HO2S

Heated oxygen sensor 2 (Bank 1)

Heated oxygen sensor 2 (Bank 2)

Heated oxygen sensor 1 heater (Bank 1) Heated oxygen sensor 1 heater (Bank 2) HO2S HTR Heated oxygen sensor 2 heater (Bank 1) Heated oxygen sensor 2 heater (Bank 2)

EGR SYSTEM

EGR function

DTC P0420 P0420 P0430 P0430 P0440 P1440 P1447 P1441 P0133 P0131 P0130 P0132 P0134 P0153 P0151 P0150 P0152 P0154 P0139 P0137 P0140 P0138 P0159 P0157 P0160 P0158 P0135 P0135 P0155 P0155 P0141 P0141 P0161 P0161 P0400 P0400 P0400 P0400 P1402

Test value (GST display) TID CID 01H 02H 03H 04H 05H 05H 06H 07H 09H 0AH 0BH 0CH 0DH 11H 12H 13H 14H 15H 19H 1AH 1BH 1CH 21H 22H 23H 24H 29H 2AH 2BH 2CH 2DH 2EH 2FH 30H 31H 32H 33H 34H 35H

01H 81H 02H 82H 03H 03H 83H 03H 04H 84H 04H 04H 04H 05H 85H 05H 05H 05H 86H 86H 06H 06H 87H 87H 07H 07H 08H 88H 09H 89H 0AH 8AH 0BH 8BH 8CH 8CH 8CH 8CH 0CH

Test limit

Conversion

Max. Min. Max. Min. Max. Max. Min. Max. Max. Min. Max. Max. Max. Max. Min. Max. Max. Max. Min. Min. Max. Max. Min. Min. Max. Max. Max. Min. Max. Min. Max. Min. Max. Min. Min. Min. Min. Min. Max.

1/128 1 1/128 1 1/128mm2 1/128mm2 20mV 1/128mm2 16ms 10mV 10mV 10mV 1s 16ms 10mV 10mV 10mV 1s 10mV/500ms 10mV 10mV 10mV 10mV/500ms 10mV 10mV 10mV 20mV 20mV 20mV 20mV 20mV 20mV 20mV 20mV 1 1 1 1 1

Attachment No.14

QG18DE (CALIF. CA)

SRT item

Self-diagnostic test item

CATALYST

Three way catalyst function

EVAP SYSTEM

EVAP control system (Small leak) EVAP control system purge flow monitoring A/F sensor 1

HO2S

Heated oxygen sensor 2

Heated oxygen sensor 3

A/F sensor 1 heater HO2S HTR

Heated oxygen sensor 2 heater Heated oxygen sensor 3 heater

EGR SYSTEM

EGR function

DTC P0420 P0420 P0440 P1440 P1447 P1273 P1274 P1275 P0139 P0137 P0140 P0138 P0145 P0144 P0143 P0146 P1277 P1277 P0141 P0141 P0147 P0147 P0400 P0400 P0400 P0400 P1402

Test value (GST display) TID CID 01H 02H 05H 05H 06H 43H 44H 45H 19H 1AH 1BH 1CH 61H 62H 63H 64H 57H 58H 2DH 2EH 71H 72H 31H 32H 33H 34H 35H

01H 81H 03H 03H 83H 0EH 8EH 8EH 86H 86H 06H 06H 92H 92H 12H 12H 04H 04H 0AH 8AH 14H 94H 8CH 8CH 8CH 8CH 0CH

Test limit

Conversion

Max. Max. Max. Max. Min. Max. Min. Min. Min. Min. Max. Max. Min. Min. Max. Max. Max. Min. Max. Min. Max. Min. Min. Min. Min. Min. Max.

1/128 1 1/128mm2 1/128mm2 20mV 0.002 0.002 0.004 10mV/500ms 10mV 10mV 10mV 10mV/500ms 10mV 10mV 10mV 5mV 5mV 20mV 20mV 20mV 20mV 1 1 1 1 1

Attachment No.15

SR20DE

SRT item

Self-diagnostic test item

CATALYST

Three way catalyst function

EVAP SYSTEM

EVAP control system (Small leak) EVAP control system purge flow monitoring

Heated oxygen sensor 1 HO2S

Heated oxygen sensor 2

Heated oxygen sensor 1 heater HO2S HTR Heated oxygen sensor 2 heater

EGR SYSTEM

EGR function

DTC P0420 P0420 P0440 P1440 P1447 P0133 P0131 P0130 P0132 P0134 P0139 P0137 P0140 P0138 P0135 P0135 P0141 P0141 P0400 P0400 P0400 P0400 P1402

Test value (GST display) TID CID 01H 02H 05H 05H 06H 09H 0AH 0BH 0CH 0DH 19H 1AH 1BH 1CH 29H 2AH 2DH 2EH 31H 32H 33H 34H 35H

01H 81H 03H 03H 83H 04H 84H 04H 04H 04H 86H 86H 06H 06H 08H 88H 0AH 8AH 8CH 8CH 8CH 8CH 0CH

Test limit

Conversion

Max. Min. Max. Max. Min. Max. Min. Max. Max. Max. Min. Min. Max. Max. Max. Min. Max. Min. Min. Min. Min. Min. Max.

1/128 1 1/128mm2 1/128mm2 20mV 16ms 10mV 10mV 10mV 1s 10mV/500ms 10mV 10mV 10mV 20mV 20mV 20mV 20mV 1 1 1 1 1

GENERAL INFORMATION SECTION

MA EM LC EC

CONTENTS PRECAUTIONS ...............................................................3 Precautions ..................................................................3 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ ........3 PRECAUTIONS FOR NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM - NATS) (IF SO EQUIPPED) ...............................................................3 GENERAL PRECAUTIONS .........................................4 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM ...................................................................6 PRECAUTIONS FOR THREE WAY CATALYST ...........6 PRECAUTIONS FOR HOSES .....................................6 PRECAUTIONS FOR ENGINE OILS ...........................7 PRECAUTIONS FOR FUEL ........................................8 PRECAUTIONS FOR AIR CONDITIONING ..................8

HOW TO USE THIS MANUAL........................................9 HOW TO READ WIRING DIAGRAMS..........................11 Sample/Wiring Diagram - EXAMPL - ........................11 OPTIONAL SPLICE..................................................12 CONTROL UNIT TERMINALS AND REFERENCE VALUE CHART ........................................................13

Description .................................................................14 CONNECTOR SYMBOLS .........................................16 SWITCH POSITIONS ...............................................17 DETECTABLE LINES AND NON-DETECTABLE LINES .....................................................................17 MULTIPLE SWITCH .................................................18 REFERENCE AREA .................................................19

HOW TO CHECK TERMINAL .......................................21 Connector and Terminal Pin Kit.................................21 How to Probe Connectors .........................................21 PROBING FROM HARNESS SIDE ............................21 PROBING FROM TERMINAL SIDE ...........................21 How to Check Enlarged Contact Spring of Terminal .....................................................................22 Waterproof Connector Inspection ..............................23 RUBBER SEAL INSPECTION ...................................23 WIRE SEAL INSPECTION ........................................23 Terminal Lock Inspection ...........................................23

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT ...............................24 Work Flow..................................................................24 Incident Simulation Tests...........................................25 INTRODUCTION ......................................................25 VEHICLE VIBRATION ..............................................25 HEAT SENSITIVE ....................................................26 FREEZING ..............................................................26 WATER INTRUSION ................................................27 ELECTRICAL LOAD .................................................27 COLD OR HOT START UP.......................................27 Circuit Inspection .......................................................27 INTRODUCTION ......................................................27 TESTING FOR ″OPENS″ IN THE CIRCUIT ................28 TESTING FOR ″SHORTS″ IN THE CIRCUIT ..............29 GROUND INSPECTION ...........................................30 VOLTAGE DROP TESTS ..........................................30 CONTROL UNIT CIRCUIT TEST ...............................32 HOW TO FOLLOW TROUBLE DIAGNOSES...............34 How to Follow Test Groups in Trouble Diagnoses....35 Harness Wire Color and Connector Number Identification...............................................................36 TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION........................................................36 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT ........37

Key to Symbols Signifying Measurements or Procedures.................................................................37 CONSULT-II CHECKING SYSTEM ...............................40 Function and System Application ..............................40 Nickel Metal Hydride Battery Replacement...............41 Checking Equipment..................................................42 CONSULT-II Data Link Connector (DLC) Circuit ......43 INSPECTION PROCEDURE .....................................43 IDENTIFICATION INFORMATION ................................44 Model Variation ..........................................................44 Identification Number.................................................45 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT .....................................................45

FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

CONTENTS

(Contâ&#x20AC;&#x2122;d)

F.M.V.S.S. CERTIFICATION LABEL ...........................46 ENGINE SERIAL NUMBER.......................................46 AUTOMATIC TRANSAXLE NUMBER ........................47 MANUAL TRANSAXLE NUMBER ..............................47

Garage Jack and Safety Stand .................................49 2-pole Lift ...................................................................50 Tow Truck Towing ......................................................51

Dimensions ................................................................47 Wheels & Tires ..........................................................47 LIFTING POINTS AND TOW TRUCK TOWING ...........48 Preparation ................................................................48 SPECIAL SERVICE TOOLS ......................................48 Board-on Lift ..............................................................48

TIGHTENING TORQUE OF STANDARD BOLTS ........52 SAE J1930 TERMINOLOGY LIST ................................53 SAE J1930 Terminology List .....................................53

VEHICLE RECOVERY (FREEING A STUCK VEHICLE)................................................................51

GI-2

PRECAUTIONS Precautions

Precautions

NIGI0001

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

MA EM LC SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER” NIGI0001S01

SGI646

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL B15 is as follows: 쐌 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), front seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. 쐌 For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), side air bag (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: 쐌 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. 쐌 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 the RS section. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER) covered with yellow insulation either just before the harness connectors or for the complete harness are related to the SRS.

EC FE CL MT AT AX SU BR ST RS BT HA SC

PRECAUTIONS FOR NVIS (NISSAN VEHICLE EL IMMOBILIZER SYSTEM — NATS) (IF SO EQUIPPED) NIGI0001S10 NVIS (NATS) will immobilize the engine if someone tries to start it without the registered NVIS (NATS) key. Both of the originally supplied ignition key IDs are NVIS (NATS) registered.

GI-3

IDX

PRECAUTIONS Precautions (Cont’d)

The security indicator is located on the instrument panel. The indicator blinks when the ignition switch is in the “OFF” or “ACC” position. Therefore, NVIS (NATS) warns outsiders that the vehicle is equipped with the anti-theft system. 쐌 When NVIS (NATS) detects a malfunction, the security indicator lamp lights up while ignition switch is in “ON” position. This indicates that the system is not functioning, and prompt service is required. 쐌 When servicing NVIS (NATS) (trouble diagnoses, system initialization and additional registration of other NVIS (NATS) ignition key IDs), CONSULT-II hardware and CONSULT-II NVIS (NATS) software is necessary. Refer to CONSULT-II operation manual, NVIS (NATS) for the procedures of NVIS (NATS) initialization and NVIS (NATS) ignition key ID registration. The CONSULT-II NVIS (NATS) software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function. 쐌 When servicing NVIS (NATS) (trouble diagnoses, system initialization and additional registration of other NVIS (NATS) ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to receive all keys from the vehicle owner. A maximum of five key IDs can be registered into NVIS (NATS). 쐌 If the engine fails to start the first time using the NVIS (NATS) key, start as follows. a) Leave the ignition key in “ON” position for approximately 5 seconds. b) Turn ignition key to “OFF” or “LOCK” position and wait approximately 5 seconds. c) Repeat step a and b again. d) Restart the engine while keeping the key separate from any others on key-chain.

GENERAL PRECAUTIONS

NIGI0001S03

쐌

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.

쐌

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, 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.

SGI285

쐌

SGI231

GI-4

PRECAUTIONS Precautions (Cont’d)

쐌

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

MA EM LC

SEF289H

쐌

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

EC FE CL MT

SGI233

쐌

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

AT AX SU BR

SGI234

쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

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 ECMs). Static electricity may damage internal electronic components. 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 tools 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 leaks. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.

GI-5

ST RS BT HA SC EL IDX

PRECAUTIONS Precautions (Cont’d)

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. WARNING: To prevent ECM from storing the diagnostic trouble codes, do not 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 AT sections.

PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM NIGI0001S04 쐌

쐌 쐌 SGI787

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.

PRECAUTIONS FOR THREE WAY CATALYST

NIGI0001S05

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions below: 쐌 Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. 쐌 When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. 쐌 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.

PRECAUTIONS FOR HOSES Hose Removal and Installation 쐌

NIGI0001S06 NIGI0001S0601

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

SMA019D

GI-6

PRECAUTIONS Precautions (Cont’d)

쐌

To reinstall the rubber hose securely, make sure of hose insertion length and clamp orientation. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

MA EM LC

SMA020D

Hose Clamping 쐌

쐌

NIGI0001S0602

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.

EC FE CL MT

SMA021D

쐌

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

AT AX SU BR

SMA022D

PRECAUTIONS FOR ENGINE OILS

NIGI0001S07

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 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌

NIGI0001S0701

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 underclothing, 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.

GI-7

ST RS BT HA SC EL IDX

PRECAUTIONS Precautions (Cont’d)

쐌 쐌 쐌 쐌

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 practicable, 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

NIGI0001S0702

Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. The heating system must meet the requirements of HM Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt, check with the appropriate local authority and/or manufacturer of the approved appliance. 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 courses. The regulations concerning the pollution vary between regions.

PRECAUTIONS FOR FUEL

NIGI0001S08

Use unleaded gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (research octane number 91). CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

PRECAUTIONS FOR AIR CONDITIONING

NIGI0001S09

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA-61, “HFC-134a (R-134a) Service Procedure” for specific instructions.

GI-8

NIGI0002

HOW TO USE THIS MANUAL 쐌 쐌 쐌 쐌 쐌 쐌

ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and page you are searching for. 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 letters which designate the particular section and a number (e.g. “BR-5”). THE LARGE ILLUSTRATIONS are exploded views (See below.) 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.

MA EM LC EC FE CL MT AT AX SU BR ST RS

SBR364AC

쐌

쐌 쐌 쐌

THE SMALL ILLUSTRATIONS show the important 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. 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. “Example” Tightening torque: 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb) TROUBLE DIAGNOSES are included in sections dealing with complicated components. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. The following SYMBOLS AND ABBREVIATIONS are used:

GI-9

BT HA SC EL IDX

HOW TO USE THIS MANUAL SYMBOL

ABBREVIATION

SYMBOL

Tightening torque

ABBREVIATION 2-Wheel Drive

2WD

Should be lubricated with grease. Unless otherwise indicated, use recommended multipurpose grease

A/C

Should be lubricated with oil

P/S

Power Steering

Sealing point

SST

Special Service Tools

Checking point

SAE

Society of Automotive Engineers, Inc.

Always replace after every disassembly

ATF

Automatic Transmission Fluid

Apply petroleum jelly

Air Conditioner

쎻 P

Drive range 1st gear

Apply ATF

Drive range 2nd gear

★

Select with proper thickness

Drive range 3rd gear

✩

Adjustment is required

Drive range 4th gear

Service Data and Specifications

Overdrive

LH, RH

Left-hand, Right-hand

2nd range 2nd gear

FR, RR

Front, Rear

2nd range 1st gear

M/T

Manual Transaxle/Transmission

1st range 2nd gear

A/T

Automatic Transaxle/Transmission

1st range 1st gear

SDS

GI-10

NIGI0003

HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL —

Sample/Wiring Diagram — EXAMPL — 쐌

NIGI0003S01

Refer to “Description”, GI-14.

MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

SGI091A

GI-11

HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL — (Cont’d)

OPTIONAL SPLICE

NIGI0003S0101

SGI942

GI-12

HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL — (Cont’d)

CONTROL UNIT TERMINALS AND REFERENCE VALUE CHART NIGI0003S0102

MA EM LC EC FE CL MT AT AX SGI095A

SU BR ST RS BT HA SC EL IDX

GI-13

HOW TO READ WIRING DIAGRAMS Description

Description Number

Item

=NIGI0003S02

Description

Power condition

쐌 This shows the condition when the system receives battery positive voltage (can be operated).

Fusible link

쐌 The double line shows that this is a fusible link. 쐌 The open circle shows current flow in, and the shaded circle shows current flow out.

Fusible link/fuse location

쐌 This shows the location of the fusible link or fuse in the fusible link or fuse box. For arrangement, refer to EL-9, “POWER SUPPLY ROUTING”.

Fuse

쐌 The single line shows that this is a fuse. 쐌 The open circle shows current flow in, and the shaded circle shows current flow out.

Current rating

쐌 This shows the current rating of the fusible link or fuse.

Connectors

쐌 This shows that connector E3 is female and connector M1 is male. 쐌 The G/R wire is located in the 1A terminal of both connectors. 쐌 Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connector. Refer to “REFERENCE AREA”, GI-19.

Optional splice

쐌 The open circle shows that the splice is optional depending on vehicle application.

Splice

쐌 The shaded circle shows that the splice is always on the vehicle.

Page crossing

쐌 This arrow shows that the circuit continues to an adjacent page. 쐌 The A will match with the A on the preceding or next page.

Common connector

쐌 The dotted lines between terminals show that these terminals are part of the same connector.

Option abbreviation

쐌 This shows that the circuit is optional depending on vehicle application.

Relay

쐌 This shows an internal representation of the relay. For details, refer to EL-7, “STANDARDIZED RELAY”.

Connectors

쐌 This shows that the connector is connected to the body or a terminal with bolt or nut. 쐌 This shows a code for the color of the wire.

Wire color

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

BR = Brown OR = Orange P = Pink PU = Purple GY = 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 15

Option description

쐌 This shows a description of the option abbreviation used on the page.

Switch

쐌 This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position.

Assembly parts

쐌 Connector terminal in component shows that it is a harness incorporated assembly.

Cell code

쐌 This identifies each page of the wiring diagram by section, system and wiring diagram page number.

Current flow arrow

쐌 Arrow indicates electric current flow, especially where the direction of standard flow (vertically downward or horizontally from left to right) is difficult to follow. ” shows that current can flow in either direction depending on cir쐌 A double arrow “ cuit operation.

GI-14

HOW TO READ WIRING DIAGRAMS Description (Cont’d) Number

Item

Description

System branch

쐌 This shows that the system branches to another system identified by cell code (section and system).

Page crossing

쐌 This arrow shows that the circuit continues to another page identified by cell code. 쐌 The C will match with the C on another page within the system other than the next or preceding pages.

Shielded line

쐌 The line enclosed by broken line circle shows shield wire.

Component box in wave line

쐌 This shows that another part of the component is also shown on another page (indicated by wave line) within the system.

Component name

쐌 This shows the name of a component.

Connector number

쐌 This shows the connector number. 쐌 The letter shows which harness the connector is located in. Example: M: main harness. For detail and to locate the connector, refer to EL-324, “How to Read Harness Layout”. A coordinate grid is included for complex harnesses to aid in locating connectors.

MA EM LC EC FE

Ground (GND)

쐌 The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector.

Ground (GND)

쐌 This shows the ground connection. For detailed ground distribution information, refer to EL-20, “Ground Distribution”.

Connector views

쐌 This area shows the connector faces of the components in the wiring diagram on the page.

Common component

쐌 Connectors enclosed in broken line show that these connectors belong to the same component.

Connector color

쐌 This shows a code for the color of the connector. For code meaning, refer to wire color codes, Number 14 of this chart.

Fuse box and fusible link

쐌 This shows the arrangement of fuse(s) and fusible link(s), used for connector views of the power supply routing. Refer to EL-9, “POWER SUPPLY ROUTING”. The open square shows current flow in, and the shaded square shows current flow out.

Reference area

쐌 This shows that more information on the Super Multiple Junction (SMJ), Electrical Units, exists at the end of the manual. Refer to “REFERENCE AREA”, GI-19 for details.

CL MT AT

ST RS BT HA SC EL IDX

GI-15

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

CONNECTOR SYMBOLS

=NIGI0003S0201

Most of connector symbols in wiring diagrams are shown from the terminal side. 쐌 Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. 쐌 Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. 쐌 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 EL-5, “Description”.

SGI364

쐌

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

SGI363

GI-16

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

SWITCH POSITIONS

NIGI0003S0204

Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when: 쐌 ignition switch is “OFF”, 쐌 doors, hood and trunk lid/back door are closed, 쐌 pedals are not depressed, and 쐌 parking brake is released.

MA EM LC EC FE CL MT

SGI860

DETECTABLE LINES AND NON-DETECTABLE LINES NIGI0003S0205 In some wiring diagrams, two kinds of lines, representing wires, with different weight are used. 쐌 A line with regular weight (wider line) represents a “detectable line for DTC (Diagnostic Trouble Code)”. A “detectable line for DTC” is a circuit in which ECM can detect its malfunctions with the on-board diagnostic system. 쐌 A line with less weight (thinner line) represents a “non-detectable line for DTC”. A “non-detectable line for DTC” is a circuit in which ECM cannot detect its malfunctions with the on-board diagnostic system.

AT AX SU BR ST RS BT HA

AGI095

SC EL IDX

GI-17

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

MULTIPLE SWITCH

=NIGI0003S0206

The continuity of multiple switch is described in two ways as shown below. 쐌 The switch chart is used in schematic diagrams. 쐌 The switch diagram is used in wiring diagrams.

SGI875

GI-18

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

REFERENCE AREA

=NIGI0003S0207

The Reference Area of the wiring diagram contains references to additional electrical reference pages at the end of the manual. If connector numbers and titles are shown in the Reference Area of the wiring diagram, these connector symbols are not shown in the Connector Area.

MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA SC

SGI092A

Super Multiple Junction (SMJ) In a wiring diagram, the SMJ connectors include a letter of the alphabet in the terminal number. SMJ connector numbers are shown in the Reference Area of the wiring diagram. SMJ terminal arrangement can be found on the electrical reference pages at the end of the manual. For terminal arrangement of these connectors, refer to the “SUPER MULTIPLE JUNCTION (SMJ)” electrical reference page at the end of the

GI-19

EL IDX

HOW TO READ WIRING DIAGRAMS Description (Cont’d)

manual. Fuse block — Junction Box (J/B) Fuse block — Junction Box (J/B) connector number is shown in the Reference Area of the wiring diagram. For connector terminal and fuse arrangement, refer to the “FUSE BLOCK — Junction Box (J/B)” electrical reference page at the end of the manual. Fuse and fusible link box For fuse arrangement in the fuse and fusible link box, refer to the “FUSE AND FUSIBLE LINK BOX” electrical reference page at the end of the manual. Electrical units Electrical unit connector symbols are shown in the Connector Area of the wiring diagram. However, when there is not enough space to show the connector terminal arrangement in the Connector Area of the wiring diagram, the electrical unit connector number is shown in the Reference Area of the wiring diagram. For electrical unit connector terminal arrangement, refer to the “ELECTRICAL UNITS” electrical reference page at the end of the manual. Most of the electrical unit connectors on this page are shown from the harness side of the connector. Joint connector Joint connector symbols are shown in the connector area of the wiring diagram. For connector internal wiring layout and joint connector terminal arrangement, refer to the “JOINT CONNECTOR” electrical reference page at the end of the manual.

GI-20

NIGI0004

HOW TO CHECK TERMINAL Connector and Terminal Pin Kit

Connector and Terminal Pin Kit

NIGI0004S01

Use the connector and terminal pin kit listed below when replacing connectors or terminals. The connector and terminal pin kit contains some of the most commonly used NISSAN connectors and terminals. Tool number (Kent-Moore No.) Tool name

Description

— (J38751-95NI) Connector and terminal pin kit — (J42992-98KIT) OBD Terminal Repair Kit

LC EC FE CL

AGI121

How to Probe Connectors

NIGI0004S02

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.

AT AX SU BR

PROBING FROM HARNESS SIDE

NIGI0004S0201

Standard type (not waterproof type) connector should be probed from harness side with “T” pin. 쐌 If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal. 쐌 Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.

ST RS BT HA

SGI841

PROBING FROM TERMINAL SIDE

NIGI0004S0202

Female terminal 쐌 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.

SEL265V

GI-21

SC EL IDX

HOW TO CHECK TERMINAL How to Probe Connectors (Cont’d)

쐌

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

SEL266V

Male terminal Carefully probe the contact surface of each terminal using a “T” pin. Do not bend terminal.

SEL267V

How to Check Enlarged Contact Spring of Terminal

NIGI0004S03

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. 2.

Assemble a male terminal and approx. 10 cm (3.9 in) of wire. Use a male terminal which matches the female terminal. Disconnect the suspected faulty connector and hold it terminal side up.

SEL270V

While holding the wire of the male terminal, try to insert the male terminal into the female terminal. Do not force the male terminal into the female terminal with your hands.

SEL271V

GI-22

HOW TO CHECK TERMINAL How to Check Enlarged Contact Spring of Terminal (Cont’d)

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

MA EM LC

SEL272V

쐌

If the male terminal can be easily inserted into the female terminal, replace the female terminal.

EC FE CL MT

SEL273V

Waterproof Connector Inspection

NIGI0004S04

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 쐌

SEL275V

쐌

NIGI0004S0401

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, make sure the rubber seal is properly installed on either side of male or female connector.

WIRE SEAL INSPECTION

AT AX SU BR ST RS

NIGI0004S0402

The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly.

BT HA

Terminal Lock Inspection

NIGI0004S05

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

SC EL IDX

SEL330V

GI-23

NIGI0005

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Work Flow

Work Flow

NIGI0005S01

SGI838

STEP STEP 1

DESCRIPTION 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 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 aftermarket accessories have been installed.

STEP 2

Operate the system, road test if necessary. Verify the parameter of the incident. If the problem can not be duplicated, refer to â&#x20AC;&#x153;Incident Simulation Testsâ&#x20AC;?, GI-25.

STEP 3

Get the proper diagnosis materials together including: POWER SUPPLY ROUTING System Operation Descriptions Applicable Service Manual Sections Check for any Service Bulletin. 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. Make sure you have not inadvertently created a new incident during your diagnosis or repair steps.

GI-24

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Incident Simulation Tests

Incident Simulation Tests INTRODUCTION

NIGI0005S02 NIGI0005S0201

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 Trouble Found Diagnosis. The following 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: 쐌 Vehicle vibration 쐌 Heat sensitive 쐌 Freezing 쐌 Water intrusion 쐌 Electrical load 쐌 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

NIGI0005S0202

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 illustration below. Connectors & 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. Sensors & Relays 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.

MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA SC

SGI839

EL IDX

GI-25

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d)

Engine Compartment There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: 쐌 Connectors not fully seated. 쐌 Wiring harness not long enough and is being stressed due to engine vibrations or rocking. 쐌 Wires laying across brackets or moving components. 쐌 Loose, dirty or corroded ground wires. 쐌 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”, GI-30. 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 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

NIGI0005S0203

The owner’s problem 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. Do not heat components above 60°C (140°F). If incident occurs while heating the unit, either replace or properly insulate the component. SGI842

FREEZING

NIGI0005S0204

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 the car overnight. Make sure it will get cold enough to demonstrate the complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. SGI843

GI-26

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d)

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.

MA EM LC WATER INTRUSION

NIGI0005S0205

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. Do not spray water directly on any electrical components.

EC FE CL MT

SGI844

ELECTRICAL LOAD

NIGI0005S0206

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

AT AX

NIGI0005S0207

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.

SU BR

SGI845

Circuit Inspection

NIGI0005S03

INTRODUCTION

NIGI0005S0301

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.

RS BT HA

OPEN

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

SHORT

There are two types of shorts.

쐌 SHORT CIRCUIT

쐌 SHORT TO GROUND

GI-27

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

IDX

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

NOTE: Refer to “HOW TO CHECK TERMINAL”, GI-21 to probe or check terminal.

TESTING FOR “OPENS” IN THE CIRCUIT

NIGI0005S0302

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.

SGI846

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). Make sure to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits please refer to the schematic above. 1) Disconnect the battery negative cable. 2) Start at one end of the circuit and work your way to the other end. (At the fuse block in this example) 3) Connect one probe of the DMM to the fuse block terminal on the load side. 4) 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) 5) 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) 6) 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 above 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. 1) Connect one probe of the DMM to a known good ground. 2) Begin probing at one end of the circuit and work your way to the other end. 3) With SW1 open, probe at SW1 to check for voltage.

GI-28

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

Voltage: open is further down the circuit than SW1. No voltage: open is between fuse block and SW1 (point A). 4) 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). 5) 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 above example.

TESTING FOR “SHORTS” IN THE CIRCUIT

NIGI0005S0303

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

EC FE CL MT

SGI847

Resistance Check Method 1) Disconnect the battery negative cable and remove the blown fuse. 2) Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. 3) Connect one probe of the ohmmeter to the load side of the fuse terminal. Connect the other probe to a known good ground. 4) 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. 5) 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. 6) 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 1) Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. 2) Turn the ignition key to the ON or START position. Verify battery voltage at the B + side of the fuse terminal (one lead on the B + terminal side of the fuse block and one lead on a known good ground). 3) 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.

GI-29

AT AX SU BR ST RS BT HA SC EL IDX

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

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

NIGI0005S0304

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. When inspecting a ground connection follow these rules: 1) Remove the ground bolt or screw. 2) Inspect all mating surfaces for tarnish, dirt, rust, etc. 3) Clean as required to assure good contact. 4) Reinstall bolt or screw securely. 5) Inspect for “add-on” accessories which may be interfering with the ground circuit. 6) If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation.

SGI853

VOLTAGE DROP TESTS

NIGI0005S0305

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

GI-30

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d)

ohmmeter, 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: 쐌 Undersized wiring (single strand example) 쐌 Corrosion on switch contacts 쐌 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 1) Connect the voltmeter across the connector or part of the circuit you want to check. The positive lead of the voltmeter should be closer to power and the negative lead closer to ground. 2) Operate the circuit. 3) The voltmeter will indicate how many volts are being used to “push” current through that part of the circuit. Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

MA EM LC EC FE CL MT AT AX SU BR ST RS

SGI974

BT 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.

GI-31

HA SC EL IDX

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Circuit Inspection (Contâ&#x20AC;&#x2122;d)

SGI854

CONTROL UNIT CIRCUIT TEST

NIGI0005S0306

System Description: When the switch is ON, the control unit lights up the lamp.

MGI034A

Input-output voltage chart Pin No.

Item

Condition

Voltage value V

In case of high resistance such as single strand V*

Switch

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF

Approx. 0

Switch ON

Battery voltage

Approx. 0 (Inoperative lamp)

Switch OFF

Approx. 0

Lamp

The voltage value is based on the body ground. * : If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery 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.

GI-32

HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT Circuit Inspection (Contâ&#x20AC;&#x2122;d)

MA EM MGI035A

Input-output voltage chart Pin No.

Item

Condition

Voltage value V

In case of high resistance such as single strand V*

Lamp

Switch ON

Approx. 0

Battery voltage (Inoperative lamp)

Switch OFF

Battery voltage

Switch ON

Approx. 0

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

Switch

The voltage value is based on the body ground. * : If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. 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.

EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

GI-33

NIGI0006

HOW TO FOLLOW TROUBLE DIAGNOSES NOTICE: Trouble diagnoses indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the “Work Flow”. 2) After repairs, re-check that the problem has been completely eliminated. 3) Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. 4) 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 EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be OFF. 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

GI-34

HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses

How to Follow Test Groups in Trouble Diagnoses

NIGI0006S01

MA EM LC EC FE CL MT AT AX SU WGI027

Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups. Questions and required results. Questions and required results are indicated in bold type in test group. The meaning of are as follows: a. Battery voltage → 11 - 14V or approximately 12V b. Voltage: Approximately 0V → Less than 1V Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Refer to “CONNECTOR SYMBOLS”, GI-16 and “Key to Symbols Signifying Measurements or Procedures”, GI-37. Action items Next action for each test group is indicated based on result of each question. Test group number is shown in the left upper portion of each test group.

GI-35

BR ST RS BT HA SC EL IDX

HOW TO FOLLOW TROUBLE DIAGNOSES Harness Wire Color and Connector Number Identification

Harness Wire Color and Connector Number Identification

NIGI0006S03

There are two types of harness wire color and connector number indication.

TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION NIGI0006S0301 쐌 쐌 쐌

Letter designations next to test meter probe indicate harness wire color. Connector numbers in a single circle (e.g. M33) indicate harness connectors. Connector numbers in a double circle (e.g. F221) indicate component connectors.

AGI070

GI-36

HOW TO FOLLOW TROUBLE DIAGNOSES Harness Wire Color and Connector Number Identification (Contâ&#x20AC;&#x2122;d)

TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT =NIGI0006S0302

MA EM LC EC FE CL MT AT AX SU BR ST RS SGI144A

BT HA

Key to Symbols Signifying Measurements or Procedures

NIGI0006S02

Symbol

Symbol explanation

Symbol

Symbol explanation

Check after disconnecting the connector to be measured.

Procedure with Generic Scan Tool (GST, OBD-II scan tool)

Check after connecting the connector to be measured.

Procedure without CONSULT-II or GST

GI-37

EL IDX

HOW TO FOLLOW TROUBLE DIAGNOSES Key to Symbols Signifying Measurements or Procedures (Cont’d) Symbol

Symbol explanation

Symbol

Symbol explanation

Insert key into ignition switch.

A/C switch is “OFF”.

Remove key from ignition switch.

A/C switch is “ON”.

Turn ignition switch to “OFF” position.

REC switch is “ON”.

Turn ignition switch to “ON” position.

REC switch is “OFF”.

Turn ignition switch to “START” position.

Fan switch is “ON”. (At any position except for “OFF” position)

Turn ignition switch from “OFF” to “ACC” position.

Fan switch is “OFF”.

Turn ignition switch from “ACC” to “OFF” position.

Apply positive voltage from battery with fuse directly to components.

Turn ignition switch from “OFF” to “ON” position.

Drive vehicle.

Turn ignition switch from “ON” to “OFF” position.

Disconnect battery negative cable.

Do not start engine, or check with engine stopped.

Depress brake pedal.

Start engine, or check with engine running.

Release brake pedal.

Apply parking brake.

Depress accelerator pedal.

Release parking brake.

Release accelerator pedal.

GI-38

HOW TO FOLLOW TROUBLE DIAGNOSES Key to Symbols Signifying Measurements or Procedures (Contâ&#x20AC;&#x2122;d) Symbol

Symbol explanation

Symbol

Check after engine is warmed up sufficiently. Voltage should be measured with a voltmeter. Circuit resistance should be measured with an ohmmeter.

Symbol explanation Pin terminal check for SMJ type ECM and TCM connectors. For details regarding the terminal arrangement, refer to the foldout page.

MA EM LC

Current should be measured with an ammeter.

Procedure with CONSULT-II

FE Procedure without CONSULT-II

CL MT AT AX SU BR ST RS BT HA SC EL IDX

GI-39

NIGI0007

CONSULT-II CHECKING SYSTEM Function and System Application

Function and System Application Diagnostic test mode

Work support

Self-diagnostic results

Function This mode enables a technician to adjust some devices faster and more accurate by following the indications on CONSULT-II. Self-diagnostic results can be read and erased quickly.

NIGI0007S01

ENGINE

A/T

ABS

AIR BAG

SMART ENTRANCE

NVIS (NATS)*

—

Trouble diagnostic record

Current self-diagnostic results and all trouble diagnostic records previously stored can be read.

—

ECU discriminated No.

Classification number of a replacement ECU can be read to prevent an incorrect ECU from being installed.

—

Data monitor

Input/Output data in the ECU (ECM) can be read.

—

DTC work support

This mode enables a technician to set operating conditions to confirm self-diagnosis status/results.

—

Data monitor (Spec.)

The specified values will be displayed when an OK/NG judgement is difficult for the DATA MONITOR items by Bar Chart and Line Graph.

—

Active test

Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECU (ECM) and also shifts some parameters in a specified range.

—

The results of SRT (System SRT & DTC Readiness Test) and the selfconfirmation diagnosis status/results can be confirmed.

—

A maximum of four IDs (identifications) can be registered in the memory using the remote controller. These IDs can also be confirmed and erased.

—

ECU (ECM) ECU (ECM) part number can part number be read. Control unit initialization

REMO CONT ID SET UP

All registered ignition key IDs in NATS components can be initialized and new IDs can be registered.

x: Applicable *: NVIS (NATS) [Nissan Vehicle Immobilizer System (Nissan Anti-Theft System)]

GI-40

CONSULT-II CHECKING SYSTEM Nickel Metal Hydride Battery Replacement

Nickel Metal Hydride Battery Replacement

=NIGI0007S04

CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following: WARNING: Replace the nickel metal hydride battery with genuine CONSULT-II battery only. Use of another battery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if mistreated. Do not recharge, disassemble of dispose of in fire. Keep the battery out of reach of children and discard used battery conforming to the local regulations.

MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

GI-41

CONSULT-II CHECKING SYSTEM Checking Equipment

Checking Equipment When ordering the below equipment, contact your NISSAN distributor. Tool name

Description

NISSAN CONSULT-II (J-44200) 쎻 1 CONSULT-II unit (Tester internal soft: Resident version 3.2.0) and accessories 쎻 2 Program card AED00A–1 (Version 4.11) and AEN00A (For NVIS Version 2.0) For details, refer to CONSULT-II Operation Manual.

SGI100A

NOTE: 쐌 The CONSULT-II must be used in conjunction with a program card. CONSULT-II does not require loading (Initialization) procedure. 쐌 Be sure the CONSULT-II is turned off before installing or removing a program card.

GI-42

=NIGI0007S02

CONSULT-II CHECKING SYSTEM CONSULT-II Data Link Connector (DLC) Circuit

CONSULT-II Data Link Connector (DLC) Circuit

=NIGI0007S03

MA EM LC SGI122A

INSPECTION PROCEDURE

NIGI0007S0301

If the CONSULT-II cannot diagnose the system properly, check the following items. Symptom

Check item

CONSULT-II cannot access any system.

쐌 CONSULT-II DLC power supply circuit (Terminal 8) and ground circuit (Terminal 4) (For detailed circuit, refer to EC-697 [QG18DE (except Calif. CA Model)], EC-1358 [QG18DE (Calif. CA Model)], or EC-1942 (SR20DE), “MIL & DATA LINK CONNECTORS”.) 쐌 CONSULT-II DDL cable

CONSULT-II cannot access indi- 쐌 CONSULT-II program card (Check the appropriate CONSULT-II program card for the system. vidual system. (Other systems Refer to “Checking Equipment”, GI-42.) can be accessed.) 쐌 Power supply and ground circuit for the control unit of the system Refer to “Function and System (For detailed circuit, refer to wiring diagram for each system.) Application”, GI-40 for the sys쐌 Open or short circuit between the system and CONSULT-II DLC tems supported by CONSULT-II. (For detailed circuit, refer to wiring diagram for each system.)

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-II access to other systems.

MT AT AX SU BR ST RS BT HA SC EL IDX

GI-43

NIGI0012

IDENTIFICATION INFORMATION Model Variation

Model Variation

NIGI0012S01

Destination Body

Engine

Transmission

Grade

Non-California, USA

California, USA

Canada

DATALCF-EUA

—

DATALCF-ENA

GXE

DATALEF-EUA

—

DATALEF-ENA

DATALCA-EUA

—

DATALCA-ENA

GXE

DATALEA-EUA

—

DATALEA-ENA

Calif. CA

—

DATALBA-EVA

—

RS5F70A RS5F70V

DBYALUF-EUA

—

DBYALUF-ENA

RE4F03B

DBYALUA-EUA

—

DBYALUA-ENA

RS5F70A QG18DE RE4F03B

Sedan

SR20DE

Prefix and suffix designations:

WGI010

GI-44

IDENTIFICATION INFORMATION Identification Number

Identification Number

NIGI0012S02

MA EM LC EC FE CL LGI007

MT VEHICLE IDENTIFICATION NUMBER ARRANGEMENT NIGI0012S0201 AT AX SU BR ST RS BT HA SC WGI024

EL IDX

GI-45

IDENTIFICATION INFORMATION Identification Number (Contâ&#x20AC;&#x2122;d)

F.M.V.S.S. CERTIFICATION LABEL

NIGI0012S0202

LGI013

ENGINE SERIAL NUMBER

WGI012

GI-46

NIGI0012S0203

IDENTIFICATION INFORMATION Identification Number (Cont’d)

AUTOMATIC TRANSAXLE NUMBER

NIGI0012S0204

MA EM LC

SGI060A

MANUAL TRANSAXLE NUMBER

NIGI0012S0205

EC FE CL MT

SGI061A

Dimensions

NIGI0012S03

Unit: mm (in) Overall length

4,505 (177.4)

Overall width

1,710 (67.3)

Overall height

1,410 (55.5)

Front tread 14 inch 15/16 inch

1,480 (58.3) 1,470 (57.9)

Rear tread 14 inch 15/16 inch

1,460 (57.5) 1,450 (57.1)

Wheelbase

2,535 (99.8)

AT AX SU BR ST RS

Gross vehicle weight rating kg (lb)

Gross axle weight rating

Front kg (lb)

See the “F.M.V.S.S. certification label” on the driver’s side lock pillar.

Rear kg (lb)

Wheels & Tires

NIGI0012S04

14 × 6JJ (steel) 40 (1.57)

15 × 6JJ (aluminum) 45 (1.77)

16 × 6JJ (aluminum) 45 (1.77)

Conventional tire

P185/65R14

P195/60R15

P195/55R16

Spare tire

T115/70*14

T125/70*15

Road wheel Offset mm (in)

*: D or R, depending on manufacturer.

GI-47

SC EL IDX

NIGI0009

LIFTING POINTS AND TOW TRUCK TOWING Preparation

Preparation SPECIAL SERVICE TOOLS

NIGI0009S01 NIGI0009S0101

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore number) Tool name

Description

LM4086-0200 ( — ) Board-on attachment

NT001

LM4519-0000 ( — ) Safety stand attachment

NT002

Board-on Lift

NIGI0009S02

CAUTION: Make sure vehicle is empty when lifting. 쐌 The board-on lift attachment (LM4086-0200) set at front end of vehicle should be set on the front of the sill under the front door opening. 쐌 Position attachments at front and rear ends of board-on lift.

AGI016

GI-48

LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand

Garage Jack and Safety Stand

=NIGI0009S03

WARNING: 쐌 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. 쐌 Place wheel chocks at both front and back of the wheels on the ground.

MA EM LC EC FE CL MT AT AX SU BR

LGI008

ST RS BT HA SC EL IDX

GI-49

LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift

2-pole Lift

=NIGI0009S04

WARNING: 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, do not allow the arm to contact the brake tubes, brake cable, fuel lines and sill spoiler.

LGI009

GI-50

LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing

Tow Truck Towing

SGI986

NIGI0009S05

CAUTION: 쐌 All applicable state or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. 쐌 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. 쐌 Always attach safety chains before towing. 쐌 When towing, make sure that the transmission, steering system and power train are in good order. If any unit is damaged, dollies must be used. NISSAN recommends that the vehicle be towed with the driving (front) wheels off the ground as illustrated. CAUTION: 쐌 Always release the parking brake when towing the vehicle with the front wheels raised with the rear wheels on the ground. 쐌 When towing manual transaxle models with the front wheels on the ground (if a towing dolly is not used), turn the ignition key to the OFF position, and secure the steering wheel in the straight-ahead position with a rope or similar device. Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism. Move the shift lever to the N (Neutral) position. 쐌 Never tow an automatic transaxle model with the rear wheels raised and the front wheels on the ground. This may cause serious and expensive damage to the transaxle. If it is necessary to tow the vehicle with the rear wheels raised, always use towing dollies under the front wheels. 쐌 Never tow an automatic transaxle model from the rear (that is backward) with four wheels on the ground. This may cause serious and expensive damage to the transaxle.

MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA

SGI987

VEHICLE RECOVERY (FREEING A STUCK VEHICLE) SC NIGI0009S0501 쐌 쐌 쐌 쐌

Tow chains or cables must be attached only to the main structural members of the vehicle. Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or cooling systems. Always pull the cable straight out from the front of the vehicle. Never pull on the vehicle at an angle. Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or recovery.

LGI014

GI-51

EL IDX

NIGI0010

TIGHTENING TORQUE OF STANDARD BOLTS

Grade

Pitch mm

6.0

8.0

Bolt size

M10

M12

Hexagon head bolt

Hexagon flange bolt

N·m

kg-m

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

1.0

5.1

0.52

3.8

45.1

6.1

0.62

4.5

53.8

1.25

1.3

—

1.5

—

1.0

1.3

—

1.6

—

1.5

2.5

—

3.0

—

1.25

2.6

—

3.1

—

1.75

4.3

—

5.2

—

1.25

4.7

—

5.7

—

10.0

12.0

M14

14.0

1.5

7.5

—

9.0

—

6.0

1.0

8.4

0.86

6.2

74.6

1.0

1.25

2.1

—

2.5

—

8.0 1.0

2.2

—

2.7

—

1.5

4.2

—

4.9

—

1.25

4.4

—

5.2

—

1.75

7.2

—

8.6

—

1.25

7.9

—

9.4

—

M10

M12

Tightening torque (Without lubricant)

Bolt diameter * mm

10.0

12.0

M14

14.0

1.5

127

13.0

—

147

15.0

108

—

6.0

1.0

1.2

—

1.5

—

1.25

3.0

—

3.6

—

8.0 1.0

3.2

—

3.8

—

1.5

6.0

—

7.1

—

1.25

6.3

—

7.5

—

1.75

10.0

—

118

12.0

—

1.25

108

11.0

—

137

14.0

101

—

1.5

177

18.0

130

—

206

21.0

152

—

M10

M12 M14

10.0

12.0 14.0

*: Nominal diameter 1) Special parts are excluded. 2) This standard is applicable to bolts having the following marks embossed on the bolt head.

MGI044A

GI-52

NIGI0011

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List

SAE J1930 Terminology List

NIGI0011S01

All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart. ***: Not applicable NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Air cleaner

ACL

Air cleaner

Barometric pressure sensor

BARO sensor

***

Barometric pressure sensor-BCDD

BAROS-BCDD

BCDD

Camshaft position

CMP

***

Camshaft position sensor

CMPS

Crank angle sensor

Canister

***

Canister

Carburetor

CARB

Carburetor

Charge air cooler

CAC

Intercooler

Closed loop

Closed throttle position switch

CTP switch

Idle switch

Clutch pedal position switch

CPP switch

Clutch switch

Continuous fuel injection system

CFI system

***

Continuous trap oxidizer system

CTOX system

***

Crankshaft position

CKP

***

Crankshaft position sensor

CKPS

***

Data link connector

DLC

***

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic test mode selector

DTM selector

Diagnostic mode selector

Diagnostic test mode I

DTM I

Mode I

Diagnostic test mode II

DTM II

Mode II

Diagnostic trouble code

DTC

Malfunction code

Direct fuel injection system

DFI system

***

Distributor ignition system

DI system

Ignition timing control

Early fuel evaporation-mixture heater

EFE-mixture heater

Mixture heater

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmable read only memory

EEPROM

***

Electronic ignition system

EI system

Ignition timing control

Engine control

***

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

***

Engine speed

RPM

Engine speed

GI-53

MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Contâ&#x20AC;&#x2122;d) NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Erasable programmable read only memory

EPROM

***

Evaporative emission canister

EVAP canister

Canister

Evaporative emission system

EVAP system

Evaporative emission control system

Exhaust gas recirculation valve

EGR valve

Exhaust gas recirculation control-BPT valve

EGRC-BPT valve

BPT valve

Exhaust gas recirculation control-solenoid valve

EGRC-solenoid valve

EGR control solenoid valve

Exhaust gas recirculation temperature sensor

EGRT sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable read only memory

FEEPROM

***

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel level sensor

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

Fuel tank temperature sensor

FTT sensor

Tank fuel temperature sensor

Fuel trim

***

Heated oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air regulator

Idle air control valve-auxiliary air control valve

IACV-AAC valve

Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve

IACV-FICD solenoid valve

FICD solenoid valve

Idle air control valve-idle up control solenoid valve

IACV-idle up control solenoid valve

Idle up control solenoid valve

Idle speed control-FI pot

ISC-FI pot

FI pot

Idle speed control system

ISC system

***

Ignition control

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

Air

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

Detonation sensor

EGR temperature sensor

GI-54

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Contâ&#x20AC;&#x2122;d) NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Malfunction indicator lamp

MIL

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

Manifold differential pressure sensor

MDPS

***

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection system

MFI system

Fuel injection control

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

Oxidation catalyst

Catalyst

Oxidation catalytic converter system

OC system

***

Oxygen sensor

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch Inhibitor switch Neutral position switch

MA EM LC EC FE CL MT AT AX SU BR

Periodic trap oxidizer system

PTOX system

***

Positive crankcase ventilation

PCV

Positive crankcase ventilation

Positive crankcase ventilation valve

PCV valve

Powertrain control module

PCM

***

Programmable read only memory

PROM

***

Pulsed secondary air injection control solenoid valve

PAIRC solenoid valve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Air induction valve (AIV) control

Pulsed secondary air injection valve

PAIR valve

Air induction valve

Random access memory

RAM

***

Read only memory

ROM

***

Scan tool

***

Secondary air injection pump

AIR pump

***

Secondary air injection system

AIR system

***

Sequential multiport fuel injection system

SFI system

Sequential fuel injection

Service reminder indicator

SRI

***

GI-55

ST RS

SC EL IDX

SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Contâ&#x20AC;&#x2122;d) NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Simultaneous multiport fuel injection system

***

Simultaneous fuel injection

Smoke puff limiter system

SPL system

***

Supercharger

***

Supercharger bypass

SCB

***

System readiness test

SRT

***

Thermal vacuum valve

TVV

Thermal vacuum valve

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

***

Three way + oxidation catalyst

TWC + OC

Catalyst

Three way + oxidation catalytic converter system

TWC + OC system

***

Throttle body

Throttle chamber SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

Throttle position sensor

TPS

Throttle sensor

Throttle position switch

TP switch

Throttle switch

Torque converter clutch solenoid valve

TCC solenoid valve

Lock-up cancel solenoid Lock-up solenoid

Transmission control module

TCM

A/T control unit

Turbocharger

Vehicle speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAFS

Air flow meter

Warm up oxidation catalyst

WU-OC

Catalyst

Warm up oxidation catalytic converter sys- WU-OC system tem

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter system

WU-TWC system

***

Wide open throttle position switch

WOTP switch

Full switch

GI-56

ENGINE MECHANICAL SECTION

GI MA

LC EC

CONTENTS QG18DE PRECAUTIONS ...............................................................4 Parts Requiring Angular Tightening.............................4 Liquid Gasket Application Procedure ..........................4 PREPARATION ...............................................................5 Special Service Tools ..................................................5 Commercial Service Tools ...........................................7 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................10 NVH Troubleshooting - Engine Noise .......................10 OUTER COMPONENT PARTS .....................................12 Removal and Installation ...........................................12 QG18DE (EXCEPT CALIF. CA MODEL) ....................14 QG18DE (CALIF. CA MODEL) ..................................15 MEASUREMENT OF COMPRESSION PRESSURE ....16 OIL PAN.........................................................................17 Components...............................................................17 Removal.....................................................................17 Installation..................................................................18 TIMING CHAIN ..............................................................20 Components...............................................................20 Removal.....................................................................21 Inspection...................................................................24 Installation..................................................................24 OIL SEAL.......................................................................29 Replacement..............................................................29 VALVE OIL SEAL .....................................................29 FRONT OIL SEAL ....................................................29 REAR OIL SEAL ......................................................30 CYLINDER HEAD..........................................................31 Components...............................................................31 Removal.....................................................................32 Disassembly...............................................................34 Inspection...................................................................34 CYLINDER HEAD DISTORTION ...............................34 CAMSHAFT VISUAL CHECK ....................................35 CAMSHAFT RUNOUT ..............................................35 CAMSHAFT CAM HEIGHT .......................................35 CAMSHAFT JOURNAL CLEARANCE ........................36

CAMSHAFT END PLAY............................................36 CAMSHAFT SPROCKET RUNOUT ...........................37 VALVE GUIDE CLEARANCE ....................................37 VALVE GUIDE REPLACEMENT ................................37 VALVE SEATS .........................................................38 REPLACING VALVE SEAT FOR SERVICE PARTS ....39 VALVE DIMENSIONS ...............................................40 VALVE SPRING .......................................................40 VALVE LIFTER AND VALVE SHIM ............................40

Assembly ...................................................................41 Installation..................................................................41 Valve Clearance.........................................................45 CHECKING .............................................................45 ADJUSTING ............................................................46 ENGINE ASSEMBLY.....................................................49 Removal and Installation ...........................................49 REMOVAL ...............................................................50 INSTALLATION........................................................52 CYLINDER BLOCK .......................................................53 Components...............................................................53 Removal and Installation ...........................................54 Disassembly...............................................................54 PISTON AND CRANKSHAFT ....................................54 Inspection...................................................................55 PISTON AND PISTON PIN CLEARANCE ..................55 PISTON RING SIDE CLEARANCE ............................56 PISTON RING END GAP..........................................56 CONNECTING ROD BEND AND TORSION ...............56 CYLINDER BLOCK DISTORTION AND WEAR ...........57 PISTON-TO-BORE CLEARANCE ..............................57 CRANKSHAFT.........................................................58 BEARING CLEARANCE ...........................................59 CONNECTING ROD BUSHING CLEARANCE (SMALL END) ..........................................................61 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) ..........................................61 FLYWHEEL/DRIVE PLATE RUNOUT ........................62

Assembly ...................................................................62 PISTON ..................................................................62 CRANKSHAFT.........................................................63 SERVICE DATA AND SPECIFICATIONS (SDS) .........66

FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

CONTENTS General Specifications...............................................66 Compression Pressure ..............................................66 Cylinder Head ............................................................66 Valve ..........................................................................67 VALVE ....................................................................67 VALVE SPRING .......................................................67 VALVE LIFTER ........................................................67 VALVE CLEARANCE................................................67 VALVE GUIDE .........................................................68 AVAILABLE SHIMS ..................................................68 VALVE SEAT ...........................................................71 VALVE SEAT RESURFACE LIMIT.............................71 Camshaft and Camshaft Bearing ..............................72 Cylinder Block............................................................73 Piston, Piston Ring and Piston Pin ...........................73 PISTON ..................................................................73 PISTON RING .........................................................74 PISTON PIN ............................................................74 Connecting Rod .........................................................74 Crankshaft..................................................................75 Main Bearing..............................................................76 STANDARD .............................................................76 UNDERSIZE ............................................................76 Connecting Rod Bearing ...........................................76 STANDARD SIZE ....................................................76 UNDERSIZE ............................................................76 Bearing Clearance .....................................................76 Miscellaneous Components.......................................76 SR20DE PRECAUTIONS .............................................................77 Parts Requiring Angular Tightening...........................77 Liquid Gasket Application Procedure ........................77 PREPARATION .............................................................78 Special Service Tools ................................................78 Commercial Service Tools .........................................80 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................82 NVH Troubleshooting - Engine Noise .......................83 OUTER COMPONENT PARTS .....................................84 Removal and Installation ...........................................84 MEASUREMENT OF COMPRESSION PRESSURE ....88 OIL PAN.........................................................................89 Components...............................................................89 Removal.....................................................................89 Installation..................................................................91 TIMING CHAIN ..............................................................94 Components...............................................................94 Removal.....................................................................95 Inspection...................................................................98 Installation..................................................................98 OIL SEAL.....................................................................102 Replacement............................................................102

(Contâ&#x20AC;&#x2122;d) VALVE OIL SEAL ...................................................102 FRONT OIL SEAL ..................................................103 REAR OIL SEAL ....................................................103

CYLINDER HEAD........................................................105 Components.............................................................105 Removal...................................................................106 Disassembly.............................................................109 Inspection.................................................................110 CYLINDER HEAD DISTORTION .............................110 CAMSHAFT VISUAL CHECK .................................. 111 CAMSHAFT RUNOUT ............................................ 111 CAMSHAFT CAM HEIGHT ..................................... 111 CAMSHAFT JOURNAL CLEARANCE ...................... 111 CAMSHAFT END PLAY..........................................112 CAMSHAFT SPROCKET RUNOUT .........................112 VALVE GUIDE CLEARANCE ..................................112 VALVE GUIDE REPLACEMENT ..............................113 VALVE SEATS .......................................................114 REPLACING VALVE SEAT FOR SERVICE PARTS ..114 VALVE DIMENSIONS .............................................115 VALVE SPRING .....................................................115 HYDRAULIC LASH ADJUSTER ..............................116 ROCKER ARM, SHIM AND ROCKER ARM GUIDE...116 Assembly .................................................................117 Installation................................................................120 ENGINE ASSEMBLY...................................................127 Removal and Installation .........................................127 REMOVAL .............................................................128 INSTALLATION......................................................129 CYLINDER BLOCK .....................................................130 Components.............................................................130 Removal and Installation .........................................131 Disassembly.............................................................131 PISTON AND CRANKSHAFT ..................................131 Inspection.................................................................132 PISTON AND PISTON PIN CLEARANCE ................132 PISTON RING SIDE CLEARANCE ..........................132 PISTON RING END GAP........................................133 CONNECTING ROD BEND AND TORSION .............133 CYLINDER BLOCK DISTORTION AND WEAR .........133 PISTON-TO-BORE CLEARANCE ............................134 CRANKSHAFT.......................................................135 BEARING CLEARANCE .........................................135 CONNECTING ROD BUSHING CLEARANCE (SMALL END) ........................................................138 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) ........................................138 REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)......................................138 FLYWHEEL/DRIVE PLATE RUNOUT ......................139

Assembly .................................................................139 PISTON ................................................................139 CRANKSHAFT.......................................................140 SERVICE DATA AND SPECIFICATIONS (SDS) .......143 General Specifications.............................................143

EM-2

CONTENTS Compression Pressure ............................................143 Cylinder Head ..........................................................143 Valve ........................................................................144 VALVE ..................................................................144 VALVE SPRING .....................................................144 HYDRAULIC LASH ADJUSTER (HLA) .....................144 VALVE GUIDE .......................................................145 VALVE SHIM CLEARANCE ADJUSTMENT ..............145 AVAILABLE SHIM ..................................................146 VALVE SEAT .........................................................147 VALVE SEAT RESURFACE LIMIT...........................148 Camshaft and Camshaft Bearing ............................148 Cylinder Block..........................................................149 Piston, Piston Ring and Piston pin..........................150

(Contâ&#x20AC;&#x2122;d) PISTON ................................................................150 PISTON RING .......................................................150 PISTON PIN ..........................................................150

Connecting Rod .......................................................151 Crankshaft................................................................152 Main Bearing............................................................153 STANDARD ...........................................................153 UNDERSIZE ..........................................................153 Connecting Rod Bearing .........................................153 STANDARD SIZE ..................................................153 UNDERSIZE ..........................................................153 Bearing Clearance ...................................................153 Miscellaneous Components.....................................153

GI MA

LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

EM-3

PRECAUTIONS

QG18DE

Parts Requiring Angular Tightening

Parts Requiring Angular Tightening 쐌 a) b) c) 쐌 쐌 쐌

Liquid Gasket Application Procedure 1.

2. 쐌 쐌 SEM164F

3. 4. 5.

NIEM0041

Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Main bearing cap bolts Connecting rod cap nuts 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. NIEM0042

Use a scraper to remove old RTV silicone sealant from mating surfaces and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of RTV silicone sealant to mating surfaces. (Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent). For oil pan, be sure RTV silicone sealant diameter is 3.5 to 4.5 mm (0.138 to 0.177 in). For areas except oil pan, be sure RTV silicone sealant diameter is 2.0 to 3.0 mm (0.079 to 0.118 in). Apply RTV silicone sealant around the inner side of bolt holes (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant.

AEM080

EM-4

PREPARATION

QG18DE Special Service Tools

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

NIEM0043

Description

ST0501S000 ( — ) Engine stand assembly 1 ST05011000 ( — ) Engine stand 2 ST05012000 ( — ) Base

Disassembling and assembling

LC EC NT042

Overhauling engine

Engine attachment assembly 1 KV10106500 ( — ) Engine attachment 2 KV10113300 ( — ) Sub-attachment

FE CL MT AT

NT029

Loosening and tightening cylinder head bolt a: 13 mm (0.51 in) dia. b: 12 mm (0.47 in) c: 10 mm (0.39 in)

ST10120000 (J24239-O1) Cylinder head bolt wrench

AX SU BR

NT583

KV10116200 (J26336-B) Valve spring compressor 1 KV10115900 (J26336-20) Attachment 2 KV10109220 ( — ) Adapter

Disassembling valve mechanism

ST RS BT WEM044

Installing valve oil seal

KV10115600 (J38958) Valve oil seal drift

HA SC

NT024

Displacement valve lip seal

KV10107902 (J-36467) Valve oil seal puller

EL IDX

NT011

EM-5

PREPARATION

QG18DE

Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

KV101151S0 (J38972) Lifter stopper set 1 KV10115110 Camshaft pliers 2 KV10115120 Lifter stopper

Changing shims

NT041

Installing piston assembly into cylinder bore

EM03470000 (J8037) Piston ring compressor

NT044

KV10107400 (J26365-12, J26365-A) Piston pin press stand 1 KV10107310 ( — ) Center shaft 2 ST13040020 ( — ) Stand 3 ST13040030 ( — ) Spring 4 KV10107320 ( — ) Cap 5 ST13040050 ( — ) Drift

Disassembling and assembling piston pin

NT013

Removing oil pan

KV10111100 (J37228) Seal cutter

NT046

Pressing the tube of liquid gasket

WS39930000 ( — ) Tube presser

NT052

Tightening bolts for bearing cap, cylinder head, etc.

KV10112100 (BT-8653-A) Angle wrench

NT014

EM-6

PREPARATION

QG18DE Special Service Tools (Cont’d)

Tool number (Kent-Moore No.) Tool name

Description

ST16610001 (J23907) Pilot bushing puller

Removing pilot bushing

NT045

Loosening or tightening heated oxygen sensor with 22 m (0.87 in) hexagon nut

(J36471-A) Front (heated) oxygen sensor wrench

LC EC FE

NT379

Loosening or tightening air fuel ratio (A/F) sensor 1

(J44626) Air fuel ratio (A/F) sensor wrench

CL MT AT

LEM054

Preventing crankshaft from rotating

KV101056S0 ( — ) Rear gear stopper 1 KV10105620 ( — ) Adapter 2 KV10105610 ( — ) Plate assembly

AX SU BR ST RS

NT773

Commercial Service Tools Tool number (Kent-Moore No.) Tool name

Description

NIEM0044

BT HA

Spark plug wrench

Removing and installing spark plug

SC EL NT047

IDX

EM-7

PREPARATION

QG18DE

Commercial Service Tools (Contâ&#x20AC;&#x2122;d) Tool number (Kent-Moore No.) Tool name

Description

Valve seat cutter set

Finishing valve seat dimensions

NT048

Removing and installing piston ring

Piston ring expander

NT030

Valve guide drift

Removing and installing valve guide Intake & Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.5 mm (0.217 in) dia. NT015

Reaming valve guide 1 or hole for oversize valve guide 2 Intake & Exhaust: d1: 5.5 mm (0.217 in) dia. d2: 9.685 mm (0.3813 in) dia.

Valve guide reamer

NT016

Front oil seal drift

Installing front oil seal a: 52 mm (2.05 in) dia. b: 40 mm (1.57 in) dia.

NT049

Installing rear oil seal a: 103 mm (4.06 in) dia. b: 84 mm (3.31 in) dia.

Rear oil seal drift

NT049

Reconditioning the exhaust system threads before installing a new oxygen sensor (Use with anti-seize lubricant shown below.) a: J-43897-18 [18 mm dia.] for zirconia oxygen sensor b: J-43897-12 [12 mm dia.] for titania oxygen sensor

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

AEM488

EM-8

PREPARATION

QG18DE Commercial Service Tools (Contâ&#x20AC;&#x2122;d)

Tool number (Kent-Moore No.) Tool name

Description

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

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

LC AEM489

EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

EM-9

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NIEM0045

QG18DE

NVH Troubleshooting — Engine Noise

NIEM0045S01

Use the chart below to help you find the cause of the symptom. 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. Operating condition of engine Location of noise

Top of Engine Rocker Cover Cylinder Head

Type of noise

Before After When warm- warm- startup up ing

When When idling racing

While driving

Source of noise

Check item

Reference page

Ticking or C click

—

Tappet noise Valve clearance

EM-45

Rattle

—

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-36, EM-35

Slap or knock

—

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

EM-55, 61

Slap or rap

—

Piston slap noise

EM-57, 56, Piston-to-bore clearance Piston ring side clearance 56, 56, Piston ring end gap Connecting rod bend and torsion

Knock

Connecting rod bearing noise

Connecting rod bearing clearance (Big end) Connecting rod bushing clearance (Small end)

Knock

—

Main bearing Main bearing oil clearnoise ance Crankshaft runout

EM-58, EM-59

Front of Engine Timing Chain Cover

Tapping or ticking

—

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-24

Front of Engine

Squeak or fizzing

—

Other drive belts (sticking or slipping)

Drive belts deflection

MA-16, “Checking Drive Belts”

Creaking

Other drive belts (slipping)

Idler pulley bearing operation

Squall or creak

—

Water pump noise

Water pump operation

Crankshaft Pulley Cylinder Block (Side of Engine) Oil pan

A: Closely related

B: Related

C: Sometimes related —: Not related

EM-10

EM-60, 61

LC-13, “INSPECTION”

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

QG18DE

NVH Troubleshooting — Engine Noise (Cont’d)

GI MA

LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX SEM937F

EM-11

OUTER COMPONENT PARTS

QG18DE

Removal and Installation

NIEM0046

WEM089

EM-12

OUTER COMPONENT PARTS

QG18DE Removal and Installation (Contâ&#x20AC;&#x2122;d)

1. 2. 3. 4. 5. 6.

Oil pressure switch EGR valve EGR guide tube Air relief plug Intake manifold Intake manifold upper support

7. 8. 9. 10. 11.

Intake manifold rear supports Oil filter Thermostat Water pump Water pump pulley

12. 13. 14. 15. 16.

EGR tube EGR temperature sensor Support container Transmission gusset Component bracket

GI MA

LC EC FE CL MT AT AX SU BR ST RS BT HA SC WEM061

1. 2. 3. 4.

Throttle position sensor IACV-AAC valve Throttle body Injector

5. 6. 7. 8.

Injector tube Pressure regulator Intake manifold Canister purge control valve

EM-13

9. 10. 11. 12.

Throttle opener One way valve Vacuum tank Swirl control solenoid valve

EL IDX

OUTER COMPONENT PARTS

QG18DE

Removal and Installation (Contâ&#x20AC;&#x2122;d)

QG18DE (EXCEPT CALIF. CA MODEL)

NIEM0046S02

WEM090

1. 2. 3. 4.

Crankshaft pulley Engine coolant temperature sensor Gasket Exhaust manifold

5. 6. 7. 8.

Exhaust manifold cover Thermal transmitter Water drain plug Heated oxygen sensor

EM-14

9. 10. 11. 12.

TWC (manifold) Converter cover Ignition coil Spark plug

OUTER COMPONENT PARTS

QG18DE Removal and Installation (Cont’d)

QG18DE (CALIF. CA MODEL)

=NIEM0046S03

CAUTION: If the Calif. CA Model’s TWC (manifold three way catalyst) or ADS-TWC (adsorber pre-catalyst) replacement is necessary, always replace the TWC together with the ADS-TWC. Never replace these catalysts individually. The TWC and the ADS-TWC are only available together as a kit.

GI MA

LC EC FE CL MT AT AX SU BR ST RS BT HA WEM091

1. 2. 3. 4. 5.

Crankshaft pulley Engine coolant temperature sensor Gasket TWC (manifold) TWC manifold cover

6. 7. 8. 9. 10.

Air fuel ratio sensor cover Sensor wire bracket TWC cover Heated oxygen sensor 1 (front) Air fuel ratio (A/F) sensor 1

EM-15

11. 12. 13. 14.

Water drain plug Spark plug Ignition coil Thermal transmitter

SC EL IDX

NIEM0047

MEASUREMENT OF COMPRESSION PRESSURE 1. 2. 3.

4. 5. 쐌

Warm up engine. Turn ignition switch OFF. Release fuel pressure. Refer to EC-67 [QG18DE (except Calif. CA Model)] or EC-743 [QG18DE (Calif. CA Model)], “Fuel Pressure Release”. Remove ignition coils. Remove spark plugs. Clean area around plug with compressed air before removing the spark plug.

6. 7.

SEM973E

SEM387C

QG18DE

Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. 쐌 Always use a fully-charged battery to obtain specified engine speed. Compression pressure: kPa (bar, kg/cm2, psi)/rpm Standard 1,324 (13.24, 13.5, 192)/350 Minimum 1,157 (11.57, 11.5, 168)/350 Maximum allowable difference between cylinders 98 (0.98, 1.0, 14)/350 10. If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and retest compression. 쐌 If adding oil improves cylinder compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. 쐌 If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. Refer to “VALVE”, EM-67 and “VALVE SEAT”, EM-71. If valve or valve seat is damaged excessively, replace them. 쐌 If compression in any two adjacent cylinders is low and if adding oil does not improve compression, there is leakage past the gasket surface. If so, replace cylinder head gasket. 11. Install spark plugs, ignition coils and fuel pump fuse. 12. Erase DTC if any DTC appears. Refer to EC-98 [QG18DE (except Calif. CAModel)] or EC-769 [QG18DE (Calif. CAModel)], “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.

EM-16

OIL PAN

QG18DE Components

Components

NIEM0048

GI MA

LC EC FE CL MT AT

WEM124

AX SU BR

Removal 1. 2. 3. 4.

Remove engine RH side undercover splash shield. Drain engine oil. Remove front exhaust tube. Refer to FE-15, “Removal and Installation”. Remove the exhaust manifold support.

NIEM0049

ST RS BT HA SC EL IDX

EM-17

OIL PAN

QG18DE

Removal (Cont’d)

5. 6.

Remove the engine gusset. Remove rear plate cover (A/T models).

7. a. 쐌

Remove oil pan. Insert Tool between cylinder block and oil pan. Be careful not to damage aluminum mating face. Do not insert screwdriver, or oil pan flange will be damaged. Slide Tool by tapping on the side of the Tool with a hammer.

WEM049

SEM110G

SEM365E

Installation 1. 쐌

NIEM0050

Use a scraper to remove old RTV silicone sealant from mating surface of oil pan. Also remove old RTV silicone sealant from mating surface of cylinder block.

SEM295C

2. 쐌 쐌 쐌

Apply a continuous bead of RTV silicone sealant to mating surface of oil pan. Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent. Apply to groove on mating surface. Allow 7 mm (0.28 in) clearance around bolt holes.

SEM015E

EM-18

OIL PAN

QG18DE Installation (Cont’d)

쐌 쐌

Be sure RTV silicone sealant diameter is 3.5 to 4.5 mm (0.138 to 0.177 in). Attaching should be done within 5 minutes after coating.

GI MA

SEM296CA

3. 쐌 쐌 4.

Install oil pan. Tighten oil pan nuts and bolts in the numerical order. Wait at least 30 minutes before refilling engine oil. Install parts in reverse order of removal.

EC FE CL MT

SEM072F

AT AX SU BR ST RS BT HA SC EL IDX

EM-19

TIMING CHAIN

QG18DE

Components

NIEM0051

WEM026

1. 2. 3. 4. 5.

Chain tensioner Camshaft sprocket (Intake) Camshaft sprocket (Exhaust) O-ring Slack side timing chain guide

6. 7. 8. 9. 10.

Timing chain tension guide Timing chain Crankshaft sprocket Oil pump drive spacer Front cover

EM-20

11. 12. 13. 14. 15.

O-ring Oil seal Crankshaft pulley Cylinder head front cover Camshaft position sensor (PHASE)

TIMING CHAIN

QG18DE Components (Cont’d)

CAUTION: 쐌 After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. 쐌 When installing chain tensioner, oil seats, or other sliding parts, lubricate contacting surfaces with new engine oil. 쐌 Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprocket and crankshaft pulley. 쐌 When removing oil pump assembly, remove camshaft position sensor (PHASE), then remove timing chain from engine. 쐌 Be careful not to damage sensor edges.

Removal 1.

SEM869F

2. 쐌 쐌 3. 4. 5. 6. 쐌 쐌 쐌

GI MA

NIEM0052

Drain engine coolant from radiator and cylinder block. Be careful not to spill coolant on drive belts. Remove the following belts. Power steering pump drive belt Alternator drive belt Remove front RH wheel. Remove front/right-side splash undercover. Remove front exhaust tube. Disconnect vacuum hoses for: EVAP canister Brake power booster Fuel pressure regulator

EC FE CL MT AT AX SU BR

7. 8.

Remove ignition coils. Remove spark plugs.

ST RS BT HA

SEM870F

Remove rocker cover bolts in numerical order as shown in the figure.

SC EL IDX

SEM871F

EM-21

TIMING CHAIN

QG18DE

Removal (Cont’d)

10. Set No. 1 piston at TDC on its compression stroke.

SEM872F

쐌

Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure at left.

SEM873F

11. Remove camshaft position sensor (PHASE). 쐌 Do not allow any magnetic materials to contact the camshaft position sensor (PHASE). 쐌 Be careful not to damage sensor. 12. Remove cylinder head front cover.

SEM889F

13. Remove timing chain guide from camshaft bracket. 14. Attach a suitable stopper pin to chain tensioner. 15. Remove chain tensioner.

SEM875F

16. Remove camshaft sprocket bolts. 쐌 Apply paint to timing chain and cam sprockets for alignment during installation. 17. Remove camshaft sprockets.

SEM876F

EM-22

TIMING CHAIN

QG18DE Removal (Cont’d)

18. Remove cylinder head bolts at engine front side as shown. 19. Remove oil pan. Refer to “Removal”, EM-17.

GI MA

SEM008G

20. Remove starter motor, and set ring gear stopper using mounting bolt holes.

EC FE CL MT

WEM031

21. Remove crankshaft pulley bolt. 22. Remove crankshaft pulley with a suitable puller. 23. Support engine with a suitable hoist or jack.

AT AX SU BR

SEM881F

24. Remove RH engine mounting.

ST RS BT HA

SEM103G

25. Remove RH engine mounting bracket. 26. Remove idler pulley and bracket.

SC EL IDX

WEM019

EM-23

TIMING CHAIN

QG18DE

Removal (Cont’d)

27. Remove water pump pulley and water pump. 28. Remove front cover bolts and front cover as shown. ★1: Located on water pump ★2: Located on power steering pump adjusting bar, remove the bar 쐌 Inspect for oil leakage at front oil seal. Replace seal if oil leak is present.

SEM883F

29. 30. 31. 32.

Remove Remove Remove Remove

timing chain. oil pump drive spacer. chain guides. crankshaft sprocket.

SEM884F

33. Remove O-rings from cylinder block and front cover.

SEM897F

Inspection

NIEM0053

Check for cracks and excessive wear at roller links. Replace if necessary.

SEM885F

Installation 1. 쐌

NIEM0054

Install crankshaft sprocket on crankshaft. Make sure mating marks on crankshaft sprocket face front of engine.

LEM119

EM-24

TIMING CHAIN

QG18DE Installation (Cont’d)

Position crankshaft so that No. 1 piston is at TDC and crankshaft key is at 12 o’clock.

GI MA

SEM890F

Install slack side timing chain guide and timing chain tension guide.

EC FE CL MT

SEM891F

4. 쐌 쐌

Install timing chain on crankshaft sprocket. Set timing chain by aligning its mating mark with that on the crankshaft sprocket. Make sure sprocket’s mating mark faces engine front.

AT AX SU BR

LEM120

5. 쐌

Install camshaft sprockets. Set timing chain by aligning mating marks with those of camshaft sprockets.

ST RS BT HA

SEM905F

6. 쐌

Install camshaft sprocket bolts to correct torque. Apply new engine oil to bolt threads and seat surface.

SC EL IDX

SEM906F

EM-25

TIMING CHAIN

QG18DE

Installation (Cont’d)

7. 쐌 쐌 8.

Install chain tensioner. Before installing chain tensioner, insert a suitable pin into pin hole of chain tensioner. After installing chain tensioner, remove the pin. Install timing chain guide.

Install O-rings to cylinder block.

SEM907F

SEM893F

10. Before installing front cover, remove all traces of RTV silicone sealant from mating surface using a scraper. 쐌 Also remove traces of RTV silicone sealant from mating surface of cylinder block.

SEM894F

11. Apply a continuous bead of Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent to mating surface of front cover. 쐌 Check alignment of mating marks on chain and crankshaft sprocket. 쐌 Align oil drive spacer with oil pump. 쐌 Place timing chain to the side of chain guide. This prevents the chain from making contact with water seal area of front cover. SEM895F

12. Install front cover. Bolt No.

SEM896F

Tightening torque

N·m (kg-m, in-lb)

“ ”

mm (in)

6.9 - 9.5 (0.70 - 0.97, 61 - 84)

20 (0.79)

6.9 - 9.5 (0.70 - 0.97, 61 - 84)

40 (1.57)

17 - 24 (1.7 - 2.4, 148 - 208*)

70 (2.76)

6.9 - 9.5 (0.70 - 0.97, 61 - 84)

72.8 (2.866)

6.9 - 9.5 (0.70 - 0.97, 61 - 84)

12 (0.47)

*: 12 - 17 ft-lb

EM-26

TIMING CHAIN

QG18DE Installation (Cont’d)

쐌 쐌

Make sure two O-rings are present. Be careful not to damage oil seal when installing front cover.

GI MA

SEM897F

13. Install cylinder head bolts at engine front side as shown. 쐌 Tightening procedure Tighten bolts (1 - 4) to 6.3 to 8.3 N·m (0.64 to 0.85 kg-m, 55.8 to 73.5 in-lb).

EC FE CL MT

SEM009G

14. Install oil pump drive spacer. 15. Install water pump and water pump pulley. Refer to LC-12, “Removal and Installation”. 16. Install idler pulley and bracket.

AT AX SU BR

SEM945F

17. 18. 19. 20. 21. 22.

Install RH engine mounting bracket. Install RH engine mounting. Install oil pan. Refer to “Installation”, EM-18. Install crankshaft pulley. Remove ring gear stopper. Install starter motor.

ST RS BT HA

WEM019

23. Install cylinder head front cover. 쐌 Apply RTV silicone sealant to cylinder head front cover. 쐌 Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent.

SC EL IDX

SEM887F

EM-27

TIMING CHAIN

QG18DE

Installation (Cont’d)

24. Install camshaft position sensor (PHASE).

SEM889F

25. Before installing rocker cover, apply a bead of Genuine RTV silicone sealant Part No. 999MP-A7007 to mating surface of cylinder head as shown. 26. Install rocker cover gasket into rocker cover.

SEM888F

SEM908F

27. Install rocker cover and tighten in numerical order as shown in the figure. 28. Install spark plugs. 29. Install ignition coils. 30. Install front exhaust tube. 31. Install front/right-side splash undercover. 32. Install front RH wheel. 33. Install drive belts. For adjusting drive belt deflection, refer to MA-16, “Checking Drive Belts”. 34. Reinstall parts in reverse order of removal.

EM-28

OIL SEAL

QG18DE Replacement

Replacement VALVE OIL SEAL

NIEM0055 NIEM0055S01

1. Remove rocker cover. 2. Remove camshaft. 3. Remove valve spring. Refer to “Components”, EM-31. 4. Remove valve oil seal with Tool. Piston concerned should be set at TDC to prevent valve from falling.

GI MA

WEM032

Apply new engine oil to new valve oil seal and install it with Tool.

EC FE CL MT

WEM033

FRONT OIL SEAL 1. 쐌 쐌 쐌 쐌 2. 쐌

NIEM0055S02

Remove the following parts: Engine under cover RH engine side cover Generator and power steering drive belts Crankshaft pulley Remove front oil seal from front cover. Be careful not to scratch front cover.

AT AX SU BR

SEM911F

3. 쐌

Apply new engine oil to new oil seal and install it using a suitable tool. Install new oil seal in the direction shown.

ST RS BT HA

SEM715A

SC EL IDX

SEM912F

EM-29

OIL SEAL

QG18DE

Replacement (Cont’d)

REAR OIL SEAL 1.

=NIEM0055S03

Remove transaxle. Refer to MT-12, “Removal” or AT-274, “Removal”. Remove flywheel or drive plate.

3. 쐌

Remove rear oil seal. Be careful not to scratch rear oil seal retainer.

Apply new engine oil to new oil seal and install it using a suitable tool. Install new oil seal in the direction shown.

SEM096F

쐌

SEM715A

SEM097F

EM-30

CYLINDER HEAD

QG18DE Components

Components

NIEM0056

GI MA

LC EC FE CL MT AT AX SU BR ST RS BT WEM028

1. 2. 3. 4. 5. 6. 7.

Oil filler cap Rocker cover Rocker cover gasket Intake valve timing control solenoid Camshaft bracket Intake camshaft Exhaust camshaft

8. 9. 10. 11. 12. 13. 14.

Timing chain guide Cylinder head bolt Shim Valve lifter Valve cotter Valve spring retainer Valve spring

15. 16. 17. 18. 19. 20. 21.

Valve spring seat Valve oil seal Valve guide Cylinder head Cylinder head gasket Valve seat Valve

HA SC EL IDX

EM-31

CYLINDER HEAD

QG18DE

Components (Cont’d)

CAUTION: 쐌 When installing camshaft and oil seal, lubricate contacting surfaces with new engine oil. 쐌 When tightening cylinder head bolts, camshaft sprocket bolts and camshaft bracket bolts, lubricate bolt threads and seat surfaces with new engine oil. 쐌 Attach tags to valve lifters so as not to mix them up.

Removal 1. 2.

SEM869F

3. 4. 5. 6. 7. 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 8. 9.

NIEM0057

Drain engine coolant from radiator and cylinder block. Be careful not to spill coolant on drive belts. Release fuel pressure. Refer to EC-67 [QG18DE (except Calif. CA Model)], or EC-743 [QG18DE (Calif. CA Model)], “Fuel Pressure Release”. Remove air duct to intake manifold collector. Remove engine drive belts. Remove front splash undercovers. Remove front exhaust tube. Before removing intake manifold collector from engine, the following parts should be disconnected to remove intake manifold collector: EGR tube Fuel injector connectors Ground harness Breather pipe Harness connectors for: IACV-AAC valve Throttle position sensor Throttle position switch EGR temperature sensor Water hoses from collector Heater hoses PCV hose Vacuum hoses for: EVAP canister Power brake booster Fuel pressure regulator Remove intake manifold rear supports. Remove exhaust manifold.

10. Remove ignition coils. 11. Remove spark plugs.

SEM870F

EM-32

CYLINDER HEAD

QG18DE Removal (Cont’d)

12. Remove rocker cover bolts in numerical order as shown in the figure.

GI MA

SEM871F

13. Set No. 1 piston at TDC on its compression stroke.

EC FE CL MT

SEM872F

쐌

Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure at left.

AT AX SU BR

SEM905F

14. Remove camshaft position sensor (PHASE). 쐌 Do not allow any magnetic materials to contact the camshaft position sensor (PHASE). 쐌 Be careful not to damage sensor. 15. Remove intake valve timing control solenoid. 16. Remove cylinder head front cover.

ST RS BT HA

SEM889F

17. Remove timing chain guide from camshaft bracket. 18. Attach a suitable stopper pin to chain tensioner. 19. Remove chain tensioner.

SC EL IDX

SEM875F

EM-33

CYLINDER HEAD

QG18DE

Removal (Cont’d)

20. Remove camshaft sprocket bolts. 쐌 Apply paint to timing chain and cam sprockets for alignment during installation. 21. Remove camshaft sprockets.

SEM876F

22. Remove camshaft brackets and camshafts. 쐌 Apply I.D. marks to brackets to ensure correct reassembly. 쐌 Bolts should be loosened in two or three steps.

SEM877F

23. Remove cylinder head bolts. 24. Remove cylinder head with intake manifold. 쐌 Head warpage or cracking could result from removing in incorrect order. 쐌 Cylinder head bolts should be loosened in two or three steps.

SEM878F

Disassembly 1. 2.

NIEM0058

Remove valve components with Tool. Remove valve oil seal with a suitable tool.

SEM914F

Inspection CYLINDER HEAD DISTORTION 쐌 쐌 쐌

NIEM0059 NIEM0059S01

Clean surface of cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head mating surface. Check along six positions shown in figure. Head surface flatness: Standard: Less than 0.03 mm (0.0012 in) Limit: 0.1 mm (0.004 in)

SEM915F

EM-34

CYLINDER HEAD

QG18DE Inspection (Cont’d)

If beyond the specified limit, replace or resurface it. Resurfacing limit: The limit for cylinder head resurfacing is determined by the amount of cylinder block resurfacing. Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, replace cylinder head. Nominal cylinder head height: 117.8 - 118.0 mm (4.638 - 4.646 in)

CAMSHAFT VISUAL CHECK

NIEM0059S02

Check camshaft for scratches, seizure and wear.

GI MA

LC EC FE CL MT

CAMSHAFT RUNOUT 1.

NIEM0059S03

Measure camshaft runout at the center journal. Runout (Total indicator reading): Standard Less than 0.02 mm (0.0008 in) Limit 0.1 mm (0.004 in) If it exceeds the limit, replace camshaft.

AT AX SU BR

SEM154D

CAMSHAFT CAM HEIGHT 1.

SEM916F

Measure camshaft cam height. Standard cam height: Intake: 40.565 - 40.755 mm (1.5970 - 1.6045 in) Exhaust: 40.056 - 40.246 mm (1.5770 - 1.5845 in) Cam wear limit: 0.20 mm (0.0079 in) If wear is beyond the limit, replace camshaft.

NIEM0059S04

ST RS BT HA SC EL IDX

EM-35

CYLINDER HEAD

QG18DE

Inspection (Cont’d)

CAMSHAFT JOURNAL CLEARANCE 1. 2.

SEM917F

SEM156D

Measure outer diameter of camshaft journal. Standard outer diameter: No. 1 journal 27.935 - 27.955 mm (1.0998 - 1.1006 in) No. 2 to No. 5 journals 23.935 - 23.955 mm (0.9423 - 0.9431 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance: Standard Intake: 0.030 - 0.071 mm (0.0012 - 0.0028 in) Exhaust: 0.045 - 0.086 mm (0.0018 - 0.0034 in) Limit Intake: 0.135 mm (0.0053 in) Exhaust: 0.150 mm (0.0059 in)

CAMSHAFT END PLAY 1. 2.

SEM918F

3. 쐌

=NIEM0059S05

Install camshaft bracket and tighten bolts to the specified torque. Measure inner diameter of camshaft bearing. Standard inner diameter: No. 1 bearing 28.000 - 28.021 mm (1.1024 - 1.1032 in) No. 2 to No. 5 bearings Intake: 23.985 – 24.006 mm (0.9443 – 0.9451 in) Exhaust: 24.000 - 24.021 mm (0.9449 - 0.9457 in)

NIEM0059S06

Install camshaft in cylinder head. Refer to “Inspection”, EM-24. Measure camshaft end play. Camshaft end play: Standard 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit 0.20 mm (0.0079 in) If limit is exceeded, replace camshaft and remeasure end play. If limit is still exceeded after replacing camshaft, replace cylinder head.

EM-36

CYLINDER HEAD

QG18DE Inspection (Cont’d)

CAMSHAFT SPROCKET RUNOUT 1. 2.

NIEM0059S07

Install sprocket on camshaft. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket.

GI MA

SEM919F

VALVE GUIDE CLEARANCE 1.

NIEM0059S08

Measure valve deflection as shown in figure. (Valve and valve guide wear the most in this direction.) Valve deflection limit (Dial gauge reading): Intake & Exhaust 0.2 mm (0.008 in)

EC FE CL MT

SEM345D

2. a. b.

If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Calculate valve to valve guide clearance. Valve stem to valve guide clearance = valve guide inner diameter − valve stem diameter. Check that clearance is within specification. Unit: mm (in)

AT AX SU

Standard

Limit

Intake

0.020 - 0.050 (0.0008 0.0020)

0.1 (0.004)

Exhaust

0.040 - 0.070 (0.0016 0.0028)

0.1 (0.004)

SEM938C

쐌 쐌

If it exceeds the limit, replace valve and remeasure clearance. If limit is still exceeded after replacing valve, replace valve guide.

RS BT HA

VALVE GUIDE REPLACEMENT 1.

NIEM0059S09

To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F).

SC EL IDX

SEM008A

EM-37

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