2009 NISSAN MAXIMA Service Repair Manual by 163215

QUICK REFERENCE INDEX Edition: June 2008 A GENERAL INFORMATION Revision:October 2008 Publication No. SM9E-1A35U0 B ENGINE

C HYBRID

D TRANSMISSION & DRIVELINE

E SUSPENSION

F BRAKES

G STEERING H RESTRAINTS

VENTILATION, HEATER & AIR CONDITIONER

J BODY INTERIOR

K BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

L DRIVER CONTROLS

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.

M ELECTRICAL & POWER CONTROL

N DRIVER INFORMATION & MULTIMEDIA

O CRUISE CONTROL P MAINTENANCE

GI EM LU CO EC FL EX STR ACC HBC HBB HBR CL TM DLN FAX RAX FSU RSU SCS WT BR PB BRC ST STC SB SBC SR SRC VTL HA HAC INT IP SE ADP DLK SEC GW PWC RF EXT BRM MIR EXL INL WW DEF HRN PWO BCS LAN PCS CHG PG MWI WCS SN AV CCS MA

General Information Engine Mechanical Engine Lubrication System Engine Cooling System Engine Control System Fuel System Exhaust System Starting System Accelerator Control System Hybrid Control System Hybrid Battery System Hybrid Brake System Clutch System Transaxle & Transmission Driveline Front Axle Rear Axle Front Suspension Rear Suspension Suspension Control System Road Wheels & Tires Brake System Parking Brake System Brake Control System Steering System Steering Control System Seat Belt Seat Belt Control System SRS Airbag SRS Airbag Control System Ventilation System Heater & Air Conditioning System Heater & Air Conditioning Control System Interior Instrument Panel Seat Automatic Drive Positioner Door & Lock Security Control System Glass & Window System Power Window Control System Roof Exterior Body Repair Manual Mirrors Exterior Lighting System Interior Lighting System Wiper & Washer Defogger Horn Power Outlet Body Control System LAN System Power Control System Charging System Power Supply, Ground & Circuit Elements Meter, Warning Lamp & Indicator Warning Chime System Sonar System Audio, Visual & Navigation System Cruise Control System Maintenance

A B C D E F G H I J K L M N O P

FOREWORD This manual contains maintenance and repair procedure for the 2009 NISSAN Maxima. 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.

QUICK REFERENCE CHART: MAXIMA 2009

QUICK REFERENCE CHART: MAXIMA Engine Tune-up Data

INFOID:0000000004455940

GENERAL SPECIFICATIONS Cylinder arrangement

V-6

3,498 (213.45)

Displacement cm (cu in) Bore and stroke

mm (in)

95.5 x 81.4 (3.760 x 3.205)

Valve arrangement

DOHC

Firing order

1-2-3-4-5-6

Number of piston rings

Compression

Oil

Number of main bearings

Compression ratio

10.3:1

Compression pressure kPa (kg/cm2, psi)/300 rpm

Standard

1,275 (13.0, 185)

Minimum

981 (10.0, 142)

Differential limit between cylinders

98 (1.0, 14)

Cylinder number

SEM713A

Valve timing (Valve timing control - “OFF”)

PBIC0187E

Unit: degree a

240

−10

50 INFOID:0000000004455941

DRIVE BELT Tension of drive belt

Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

QUICK REFERENCE CHART: MAXIMA 2009 INFOID:0000000004455942

SPARK PLUG Unit: mm (in)

Make

DENSO

Standard type

FXE22HR11

Gap

Standard

1.1 (0.043)

Limit

1.4 (0.055)

Front Wheel Alignment (Unladen*)

INFOID:0000000004455943

Market

USA/Canada

Tire size Camber Degree minute (Decimal degree)

245/45R18

245/40R19

Minimum

-1°5’ (-1.10°)

-1°10’ (-1.15°)

-0°55’ (-0.95°)

Nominal

-0°20’ (-0.35°)

-0°40’ (-0.65°)

-0°10’ (-0.20°)

Maximum

0°25’ (0.40°)

0°20’ (0.35°)

0°35’ (0.55°)

-1°20’ (-1.35°)

-1°25’ (-1.40°)

-1°10’ (-1.20°)

-0°35’ (-0.60°)

-0°40’ (-0.65°)

-0°25’ (-0.45°)

0°10’ (0.15°)

0°05’ (0.10°)

0°20’ (0.30°)

-0°15’ ±° 0°33’ (-0.25°± 0.55°)

Minimum

4°10’ (4.20°)

4°15’ (4.25°)

3°45’ (3.75°)

Nominal

4°55’ (4.95°)

5°00’ (5.00°)

4°30’ (4.50°)

Maximum

5°40’ (5.70°)

5°45’ (5.75°)

5°15’ (5.25°)

Maximum left and right difference

0°33’ (0.55°)

Minimum

13°40’ (13.65°)

13°20’ (13.35°)

Nominal

14°25’ (14.40°)

14°05’ (14.10°)

Maximum

15°10’ (15.15°)

14°50’ (14.85°)

SFA234AC

Total toe-in Distance (A B)

245/40R19

Nominal

Maximum left and right difference

Kingpin offset Degree minute (Decimal degree)

245/45R18

Minimum

Maximum

Caster Degree minute (Decimal degree) Against ground surface

Mexico

Minimum

0 mm

Nominal

1 mm

Maximum

2 mm

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

QUICK REFERENCE CHART: MAXIMA 2009

Rear Wheel Alignment (Unladen*) Market

Camber Degree minute (Decimal degree)

INFOID:0000000004455945

USA*1

USA*2

Canada*1

Canada*2

Mexico

Minimum

−0° 55′ (− 0.92°)

-1° 02′ (1.03°)

−0° 52′ (− 0.87°)

−1° 02′ (− 1.03°)

−0° 10′ (− 0.17°)

Nominal

−0° 25′ (− 0.42°)

-0° 32′ (0.53°)

−0° 22′ (− 0.37°)

−0° 32′ (− 0.53°)

0° 20′ (0.33°)

0° 05′ (0.08°)

-0° 02′ (0.03°)

0° 8′ (0.13°)

-0° 02′ (0.03°)

0° 50′ (0.83°)

Minimum

-0.4 (0.02)

0 (0)

-0.4 (0.02)

0 (0)

Nominal

1.2 (0.05)

1.6 (0.06)

1.2 (0.05)

1.6 (0.06)

Maximum

2.8 (0.11)

3.2 (0.13)

2.8 (0.11)

3.2 (0.13)

Maximum

SFA234AC

Distance (A - B) mm (in)

Total toe-in

Distance difference between RH or LH side mm (in) Angle (left or right) Degree minute (decimal degree)

Minimum

-2 (-0.08)

Nominal

0 (0)

Maximum

2 (0.08)

Minimum

-0° 1' (-0.02°)

0° 0' (0.00°)

-0° 1' (-0.02°)

0° 0' (0.00°)

Nominal

0° 3' (0.05°)

0° 4' (0.07°)

0° 3' (0.05°)

0° 4' (0.07°)

Maximum

0° 7' (0.12°)

0° 8' (0.13°)

0° 7' (0.12°)

0° 8' (0.13°)

*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *1: 18" tire. *2: 19" tire.

Wheelarch Height (Unladen*1)

INFOID:0000000004455944

Unit: mm (in)

SFA818A

Market

USA/Canada

Mexico

Tire size

P245/45R18 *2

P245/45R18 *3

P245/40R19

P245/45R18

P245/40R19

Front (Hf)

721 (28.39)

724 (28.50)

730 (28.74)

733 (28.86)

Rear (Hr)

736 (28.98)

734 (28.90)

736 (28.98)

754 (29.68)

757 (29.80)

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

QUICK REFERENCE CHART: MAXIMA 2009 *2: Without top load sunroof *3: With top load sunroof

Brake Specifications

INFOID:0000000004455946

Unit: mm (in)

Brake model

Kiriu

Wheel size

457 (18)

483 (19)

Cylinder bore diameter Front brake

57.15 (2.250)

Pad length × width × thickness Rotor outer diameter × thickness

123.6 × 47.5 × 11 (4.866 × 1.870 × 0.433) 320 × 28 (12.598 × 1.102)

Brake model Rear brake

Kiriu

Cylinder bore diameter Pad length × width × thickness Rotor outer diameter × thickness

Master cylinder

Cylinder bore diameter

Control valve

Valve model

Brake booster

Booster model

TBD

34.93 (1.375) 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335) 308 × 16 (12.126 × 0.630) 23.81 (0.937) Electric brake force distribution Bosch

Recommended brake fluid

DOT 3

Front Disc Brake

INFOID:0000000004455947

Unit: mm (in)

Brake model

Kiriu

Wheel size Brake pad

Disc rotor

457 (18)

483 (19)

Standard thickness (new)

11.0 (0.433)

Repair limit thickness

2.0 (0.079)

Standard thickness (new)

28.0 (1.102)

Repair limit thickness

26.0 (1.024)

Thickness variation (measured at 8 positions)

0.015 (0.0006)

Maximum runout (with it attached to the vehicle)

0.035 (0.0014)

Rear Disc Brake

INFOID:0000000004455948

Unit: mm (in)

Brake model

Kiriu

Wheel size Brake pad

Disc rotor

457 (18)

483 (19)

Standard thickness (new)

8.5 (0.335)

Repair limit thickness

1.0 (0.039)

Standard thickness (new)

16.0 (0.630)

Repair limit thickness

14.0 (0.551)

Thickness variation (measured at 8 positions) Maximum runout (with it attached to the vehicle)

0.015 (0.0006) 0.05 (0.002)

QUICK REFERENCE CHART: MAXIMA 2009

Brake Pedal

INFOID:0000000004455949

Unit: mm (in)

AWFIA0433ZZ

Brake pedal free height (H)

190.7 - 202.7 (7.51 - 7.98)

Brake pedal full stroke (S)

130.0 (5.12)

Clearance between brake pedal bracket and threaded end of stop lamp switch and ASCD cancel switch (C1) or (C2)

0.74 - 1.96 (0.0291 - 0.0772)

Fluids and Lubricants - US and Canada Description

INFOID:0000000004455950

Capacity (Approximate)

Recommended Fluids/Lubricants

US measure

Imp measure

Liter

20 gal

16-5/8 gal

75.6

With oil filter change

4-7/8 qt

4 qt

4.6

Without oil filter change

4-1/2 qt

3-3/4 qt

4.3

Dry engine (Overhaul)

5-1/4 qt

4-3/8 qt

5.0

Cooling system with reservoir tank

2-1/8 gal

1-3/4 gal

8.2

CVT fluid

10-3/4 qt

9 qt

10.2

Power steering fluid (PSF)

1-1/8 qt

7/8 qt

1.0

Genuine NISSAN PSF or equivalent*4

Brake fluid

—

Genuine NISSAN Super Heavy Duty Brake Fluid*4 or equivalent DOT 3 (US FMVSS No. 116)

Brake grease

—

PBC (poly butyl cuprysil)

Brake pad plate grease

—

Molykote AS880N grease or equivalent

Multi-purpose grease

—

NLGI No. 2 (Lithium soap base)

1.21 ± 0.055 lb

—

0.55 ± 0.025 kg

Fuel

Engine oil Drain and refill

Air conditioning system refrigerant

Unleaded gasoline with an octane rating of at least 91 AKI (RON 96)

• Engine oil with API Certification Mark *1*2 • Viscosity SAE 5W-30 *2

Genuine NISSAN Long Life Antifreeze/ Coolant or equivalent Genuine NISSAN CVT Fluid NS-2 *3

HFC-134a (R-134a) *5

QUICK REFERENCE CHART: MAXIMA 2009 Description

Capacity (Approximate) US measure

Imp measure

5.03 fl oz

5.3 fl oz

—

Air conditioning system oil

Windshield washer fluid

Recommended Fluids/Lubricants

Liter

NISSAN A/C System Oil Type S or equivalent *5

150 m

Genuine NISSAN Windshield Washer Concentrate Cleaner & Antifreeze or equivalent

—

*1: For further details, see “Engine Oil Recommendation”. *2: NISSAN recommends Genuine NISSAN Ester Engine Oil available at your NISSAN dealer. *3: Using automatic transmission fluid other than Genuine NISSAN CVT Fluid NS-2 will damage the CVT, which is not covered by the NISSAN new vehicle limited warranty. *4: DEXRONTM VI type ATF or Canada NISSAN Automatic Transmission Fluid may also be used. *5: For further details, see "Air conditioning specification label".

Fluids and Lubricants - Mexico

INFOID:0000000004455951

Capacity (Approximate)

Recommended Fluids/Lubricants

Liter

Imp measure

With oil filter change

4.6

4 qt

Without oil filter change

4.3

3-3/4 qt

API grade SL or SM*1

Dry engine (engine overhaul)

5.4

4-3/4 qt

ILSAC grade GF-2, GF-3 or GF-4*1 Viscosity SAE 10W-30

Cooling system (with reservoir)

8.2

1-3/4 gal

CVT fluid

10.2

9 qt

Brake fluid

—

Power steering fluid

1.0

7/8 qt

Multi-purpose grease

—

Engine oil Drain and refill

Genuine NISSAN engine oil*1

Genuine NISSAN Engine Coolant or equivalent in its quality*2 Genuine NISSAN CVT fluid NS-2*3 DOT 3 (US FMVSS No. 116) Genuine NISSAN PSF or equivalent *4 NLGI No. 2 (Lithium soap base)

*1: For further details, see “SAE Viscosity Number”. *2: Use Genuine NISSAN Engine Coolant or equivalent in its quality, in order to avoid possible aluminum corrosion within the engine cooling system caused by the use of non-genuine engine coolant. Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be covered by the warranty even if such incidents occurred during the warranty period. *3:Using transmission fluid other than Genuine NISSAN CVT fluid NS-2 will damage the CVT, which is not covered by the warranty. *4: DEXTRON™ VI type ATF may also be used.

GENERAL INFORMATION

SECTION

GENERAL INFORMATION

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

CVT Number ............................................................22 Dimensions ..............................................................23 Wheels & Tires ........................................................23

HOW TO USE THIS MANUAL ............................ 3 Description ................................................................ 3 Terms ........................................................................ 3 Units .......................................................................... 3 Contents .................................................................... 3 Relation between Illustrations and Descriptions ...... 4 Components .............................................................. 4

PRECAUTION .............................................. 24 Description ...............................................................24 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" .....................24 Precautions Necessary for Steering Wheel Rotation after Battery Disconnect ...................................24 Procedures without Cowl Top Cover .......................25 General Precautions ................................................25 Three Way Catalyst .................................................26 Fuel (Unleaded Premium Gasoline Required) VQ35DE ..................................................................27 Multiport Fuel Injection System or Engine Control System .....................................................................27 Hoses ......................................................................27 Engine Oils ..............................................................28 Air Conditioning .......................................................29

Description ................................................................ 6 How to Follow Test Groups in Trouble Diagnosis...... 6 Key to Symbols Signifying Measurements or Procedures ..................................................................... 7

HOW TO READ WIRING DIAGRAMS ................ 9 Connector symbols ................................................... 9 Sample/wiring diagram -example- ........................... 10 Description .............................................................. 11

ABBREVIATIONS ..............................................13 Abbreviation List ...................................................... 13

LIFTING POINT ................................................. 30 Special Service Tool ................................................30 Garage Jack and Safety Stand ................................30 2-Pole Lift ................................................................31 Board-on Lift ............................................................32

Tightening Torque Table ......................................... 14

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ................................................15 Recommended Chemical Products and Sealants.... 15

TOW TRUCK TOWING ..................................... 33 Tow Truck Towing ...................................................33 Vehicle Recovery (Freeing a Stuck Vehicle) ...........33

TERMINOLOGY .................................................16 SAE J1930 Terminology List ................................... 16

BASIC INSPECTION ................................... 35

FEATURES OF NEW MODEL ..................... 20

SERVICE INFORMATION FOR ELECTRICAL INCIDENT .......................................................... 35

IDENTIFICATION INFORMATION .....................20

PRECAUTIONS ................................................. 24

HOW TO FOLLOW TROUBLE DIAGNOSES ..... 6

TIGHTENING TORQUE OF STANDARD BOLTS ................................................................14

Model Variation ....................................................... 20 Identification Number .............................................. 21 Identification Plate ................................................... 22 Engine Serial Number ............................................. 22

GI-1

Work Flow ................................................................35 Control Units and Electrical Parts ............................35 How to Check Terminal ...........................................36 Intermittent Incident .................................................39 Circuit Inspection .....................................................42

CONSULT-III CHECKING SYSTEM .................. 47 Description .............................................................. 47 Function and System Application ........................... 47

GI-2

CONSULT-III Data Link Connector (DLC) Circuit ... 48 Wiring Diagram ....................................................... 49

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL Description

INFOID:0000000003891696

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

Terms

INFOID:0000000003891697

• The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information. Standard value: Tolerance at inspection and adjustment. Limit value: The maximum or minimum limit value that should not be exceeded at inspection and adjustment.

Units

INFOID:0000000003891698

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

“Example” Range I

Outer Socket Lock Nut

: 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb) J

Standard Drive Shaft Installation Bolt

: 44.3 N·m (4.5 kg-m, 33 ft-lb) K

Contents

INFOID:0000000003891699

• A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by matching it to the section's black tab. • THE CONTENTS are listed on the first page of each section. • THE TITLE is indicated on the upper portion of each page and shows the part or system. • THE PAGE NUMBER of each section consists of two or three letters which designate the particular section and a number (e.g. “BR-5”). • THE SMALL ILLUSTRATIONS show the 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.

GI-3

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >

Relation between Illustrations and Descriptions

INFOID:0000000003891700

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

SAIA0519E

Components

INFOID:0000000003891701

â&#x20AC;˘ THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration.

GI-4

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL > GI

SFIA2959E

Union bolt

Copper washer

Brake hose

Cap

Bleed valve

Sliding pin bolt

Piston seal

Piston

Piston boot

10. Cylinder body

11.

Sliding pin

12.

Torque member mounting bolt

13. Washer

14.

Sliding pin boot

15.

Bushing

16. Torque member

17.

Inner shim cover

18.

Inner shim

19. Inner pad

20.

Pad retainer

21.

Pad wear sensor

22. Outer pad

23.

Outer shim

24.

1: PBC (Poly Butyl Cuprysil) grease or silicone-based grease

2: Rubber grease

Outer shim cover

: Brake fluid

Refer to GI section for additional symbol definitions.

SYMBOLS K

SAIA0749E

GI-5

HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL >

HOW TO FOLLOW TROUBLE DIAGNOSES Description

INFOID:0000000003891702

NOTICE: Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. • Before performing trouble diagnoses, read the “Work Flow” in each section. • After repairs, re-check that the problem has been completely eliminated. • Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. • When checking circuit continuity, ignition switch should be OFF. • Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identification of harness connectors. • Before checking voltage at connectors, check battery voltage. • After accomplishing the Diagnosis Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

How to Follow Test Groups in Trouble Diagnosis

INFOID:0000000003891703

JPAIA0021GB

1. 2. 3. 4.

Test group number and test group title • Test group number and test group title are shown in the upper portion of each test group. Work and diagnosis procedure • Start to diagnose a problem using procedures indicated in enclosed test groups. Questions and results • Questions and required results are indicated in test group. Action • Next action for each test group is indicated based on result of each question.

GI-6

HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL >

Key to Symbols Signifying Measurements or Procedures

INFOID:0000000003891704

I SAIA1539E

GI-7

HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL >

SAIA1540E

GI-8

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

HOW TO READ WIRING DIAGRAMS Connector symbols

GI INFOID:0000000003891705

Most connector symbols in wiring diagrams are shown from the terminal side. • Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. • Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. • Certain systems and components, especially those related to OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to PG section, “Description”, “HARNESS CONNECTOR”.

H SAIA0257E

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

SGI363

GI-9

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

Sample/wiring diagram -example-

INFOID:0000000003891706

â&#x20AC;¢ For detail, refer to following GI-11, "Description".

JCAWA0005GB

GI-10

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

Description

INFOID:0000000003891707

GI Number

Item

Description

Power supply

• This means the power supply of fusible link or fuse.

Fusible link

• “X” means the fusible link.

Number of fusible link/ fuse

• This means the number of fusible link or fuse location.

Fuse

• “/” means the fuse.

Current rating of fusible link/fuse

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

Optional splice

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

Connector number

• The letter shows which harness the connector is located in. • Example “M”: main harness. For detail and to locate the connector, refer to PG-53, "Electrical Units Location", PG-34, "Harness Layout".

Splice

• The shaded circle “

Page crossing

• This circuit continues to an adjacent page.

Option abbreviation

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

Relay

• This shows an internal representation of the relay.

Option description

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

Switch

• 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.

Circuit (Wiring)

• This means the wiring.

System branch

• This shows that the circuit is branched to other systems.

Shielded line

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

Component name

• This shows the name of a component.

Ground (GND)

• This shows the ground connection.

Connector

• This means the connector information. • This unit-side is described by the connector symbols.

Connectors

• This means that a transmission line bypasses two connectors or more.

” means the splice.

F ”.

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

Wire color

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

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light 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 22

Terminal number

• This means the terminal number of a connector.

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

GI-11

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL > • ignition switch is “OFF”, • doors, hood and trunk lid/back door are closed, • pedals are not depressed, and • parking brake is released.

SGI860

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

JSAIA0017GB

GI-12

ABBREVIATIONS < HOW TO USE THIS MANUAL >

ABBREVIATIONS

Abbreviation List

INFOID:0000000003891708

The following ABBREVIATIONS are used:

ABBREVIATION

DESCRIPTION

A/C

Air Conditioner

ATF

Automatic Transmission Fluid

CVT

Continuously variable transmission

Drive range 1st gear

Drive range 2nd gear

Drive range 3rd gear

Drive range 4th gear

FR, RR

Front, Rear

LH, RH

Left-Hand, Right-Hand

M/T

Manual Transaxle/Transmission

Overdrive

P/S

Power Steering

SAE

Society of Automotive Engineers, Inc.

SDS

Service Data and Specifications

SST

Special Service Tools

2WD

2-Wheel Drive

2nd range 2nd gear

2nd range 1st gear

1st range 2nd gear

1st range 1st gear

GI-13

TIGHTENING TORQUE OF STANDARD BOLTS < HOW TO USE THIS MANUAL >

TIGHTENING TORQUE OF STANDARD BOLTS Tightening Torque Table

Grade

Bolt size

Bolt diameter * mm

INFOID:0000000003891709

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

6.0

8.0

M10

10.0

M12

12.0

1.25

M14

14.0

1.5

6.0

1.0

8.0

M10

10.0

M12

12.0

M14

kg-m

Hexagon flange bolt

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

1.0

5.5

0.56

0.71

1.25

13.5

1.4

—

1.7

—

1.0

13.5

1.4

—

1.7

—

1.5

2.9

—

3.6

—

1.25

2.9

—

3.6

—

1.75

4.6

—

5.6

—

4.6

—

6.6

—

8.2

—

100

—

0.92

1.1

1.25

2.2

—

2.9

—

1.0

2.2

—

2.9

—

1.5

4.6

—

5.6

—

1.25

4.6

—

5.6

—

1.75

8.2

—

100

—

1.25

8.2

—

100

—

14.0

1.5

130

—

170

125

—

6.0

1.0

1.1

—

13.5

1.4

—

8.0

1.25

2.9

—

3.6

—

1.0

2.9

—

3.6

—

M10

10.0

1.5

5.6

—

8.2

—

1.25

5.6

—

8.2

—

M12

12.0

1.75

100

—

130

—

1.25

100

—

130

—

M14

14.0

1.5

170

125

—

210

155

—

*: Nominal diameter 1.

Special parts are excluded.

This standard is applicable to bolts having the following marks embossed on the bolt head.

MGI044A

GI-14

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS < HOW TO USE THIS MANUAL >

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS Recommended Chemical Products and Sealants

GI INFOID:0000000003891710

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

Product Description

Purpose

Rear View Mirror Adhesive

Used to permanently remount rear view mirrors to windows.

Anaerobic Liquid Gasket

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

High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.) • Do not use on plastic.

Gasket Maker 4

Nissan North America Part No. (USA) 999MP-AM000P

99998-50505

Medium Strength Thread Locking Sealant (Blue)

Threadlocker

Threadlocker (service tool removable)

Permatex 81844

D 999MP-AM001P

99998-50503

Permatex 51813 and 51817

F 999MP-AM002P

999MP-AM002P

Permatex 56521

999MP-AM003P (Ultra Grey)

99998-50506 (Ultra Grey)

Silicone RTV

High Temperature, High Strength Thread Locking Sealant (Red)

Aftermarket Crossreference Part Nos.

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

Nissan Canada Part No. (Canada)

–

999MP-AM004P

999MP-AM005P

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

Three Bond 1281B or exact equivalent in its quality

999MP-AM004P

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

999MP-AM005P

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

–

GI-15

TERMINOLOGY < HOW TO USE THIS MANUAL >

TERMINOLOGY SAE J1930 Terminology List

INFOID:0000000003891711

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. NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Air cleaner

ACL

Air cleaner

Barometric pressure

BARO

***

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

***

Data link connector for CONSULT-III

DLC for CONSULT-III

Diagnostic connector for CONSULT-III

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

Erasable programmable read only memory

EPROM

***

Evaporative emission canister

EVAP canister

Canister

Evaporative emission system

EVAP system

Canister control solenoid valve

Exhaust gas recirculation valve

EGR valve

GI-16

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

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

EGR 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 pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

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

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

GI-17

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

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

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

***

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

GI-18

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

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 system

WU-OC system

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter sysWU-TWC system tem

***

Wide open throttle position switch

Full switch

WOTP switch

***: Not applicable

GI-19

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL >

FEATURES OF NEW MODEL IDENTIFICATION INFORMATION Model Variation

Body

Engine

Sedan

VQ35DE

INFOID:0000000003891712

Grade

Transmission

3.5 S 3.5 SV

Destination USA

Canada

Mexico

CVT

BLJALQZ-EUA

BLJALQZ-ENA

â&#x20AC;&#x201D;-

CVT

BLJALFZ-EUA

BLJALFZ-ENA

BLJALFZ-EJA

Prefix and suffix designations: Position

Character

Body type

B: 4-Door

Engine

LJ: VQ35DE

Axle

A: 2WD

Drive

L: LH

Grade

Transmission

Z: CVT

A35

Model

A35: Maxima Sedan

Intake

E: EGI

Zone

2 3

Qualifier

Definition

Q: 3.5 S F: 3.5 SV

8 9 10

J: Mexico N: Canada U: 50 state emission 13

Equipment

A: Standard

Option Codes

14 15 16

XXXXX

17 18

GI-20

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL >

Identification Number

INFOID:0000000003891714

ALAIA0008ZZ

I 1.

Vehicle identification number (under carpet on cross member)

Emission control information label

Air Conditioner specification label

Vehicle identification number plate

Tire placard

Certification label

Vehicle Identification Number Arrangement K Position

Character

Qualifier

Definition

1 2

1N4

Manufacturer

1N4: USA produced passenger vehicle

3 4

Engine type

A: VQ35DE

Vehicle line

A: NISSAN Maxima

Model change

(0-9)

Body type

1: 4-door sedan

Restraint system

E: Driver and front passenger SRS air bags, SRS side and curtain air bags & 3- point manual seat belts

Check digit

(0 to 9 or X) The code for the check digit is determined by a mathematical computation.

Model year

2009

Manufacturing plant

C: Smyrna, Tennessee

GI-21

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL > Position

Character

Qualifier

XXXXX

Vehicle serial number

Definition

12 13 14 15

Chassis number

16 17

Identification Plate

INFOID:0000000003891716

LAIA0027E

Engine Serial Number

INFOID:0000000003891717

LAIA0026E

CVT Number

INFOID:0000000003891718

LAIA0074E

GI-22

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL >

Dimensions

INFOID:0000000003891720

GI Unit:mm (in)

Overall length

4843 (190.6)

Overall width

1,860 (73.2)

Overall height

1,467 (57.8)

Front tread

1,545 (62.4)

Rear tread

1,545 (62.4)

Wheelbase

2,775 (109.3)

Wheels & Tires

INFOID:0000000003891722

Conventional

Spare

Road wheel/offset mm (in)

18 X 8J Cast Aluminum/50 (1.97) 19 X 8J Cast Aluminum/50 (1.97)

17 X 4t

Tire size

P245/45R18 P245/40R19

T145/80D17

GI-23

PRECAUTIONS < PRECAUTION >

PRECAUTION PRECAUTIONS Description

INFOID:0000000003891723

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

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

INFOID:0000000003891724

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SR and SB section of this Service Manual. WARNING: • To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. • Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SR section. • Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

Precautions Necessary for Steering Wheel Rotation after Battery Disconnect INFOID:0000000004392597

NOTE: • Before removing and installing any control units, first turn the push-button ignition switch to the LOCK position, then disconnect both battery cables. • After finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. • Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results. This vehicle is equipped with a push-button ignition switch and a steering lock unit. If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure below before starting the repair operation.

OPERATION PROCEDURE 1.

2. 3. 4. 5.

Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. Carry the Intelligent Key or insert it to the key slot and turn the push-button ignition switch to ACC position. (At this time, the steering lock will be released.) Disconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. Perform the necessary repair operation. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) Perform self-diagnosis check of all control units using CONSULT-III.

GI-24

PRECAUTIONS < PRECAUTION >

Procedures without Cowl Top Cover

INFOID:0000000003891726

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

D PIIB3706J

General Precautions

INFOID:0000000003891727

• 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.

H SGI285

• Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle. These operations should be done on a level surface. • When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.

L SGI231

• Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery terminal. • If the battery terminals are disconnected, recorded memory of radio and each control unit is erased.

SEF289H

GI-25

PRECAUTIONS < PRECAUTION > • To prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot. • Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. • Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire. • Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. • Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. • Replace inner and outer races of tapered roller bearings and needle bearings as a set. • Arrange the disassembled parts in accordance with their assembled locations and sequence. • Do not touch the terminals of electrical components which use microcomputers (such as ECM). Static electricity may damage internal electronic components. • After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. • Use only the fluids and lubricants specified in this manual. • Use approved bonding agent, sealants or their equivalents when required. • Use hand tools, power tools (disassembly only) and recommended special tools where specified for safe and efficient service repairs. • When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.

SGI233

PBIC0190E

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

SGI234

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 TM sections.

Three Way Catalyst

INFOID:0000000003891728

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions. • Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. • When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. • Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the catalyst.

GI-26

PRECAUTIONS < PRECAUTION > Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst. GI

Fuel (Unleaded Premium Gasoline Required) VQ35DE

INFOID:0000000003891730

Use unleaded premium gasoline with an octane rating of at least 91 AKI (Anti-Knock Index) number (Research octane number 96).

If unleaded premium gasoline is not available, unleaded regular gasoline with an octane rating of at least 87 AKI number (Research octane number 91) can be used, but only under the following precautions: • Have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gasoline as soon as possible. • Avoid full throttle driving and abrupt acceleration. However, for maximum vehicle performance, the use of unleaded premium gasoline is recommended.

CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

Multiport Fuel Injection System or Engine Control System

INFOID:0000000003891731

• 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.

J SGI787

Hoses

INFOID:0000000003891732

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

N SMA019D

GI-27

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

SMA020D

HOSE CLAMPING • If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position. • Discard old clamps; replace with new ones.

SMA021D

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

SMA022D

Engine Oils

INFOID:0000000003891733

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 • • • • • • • • • • • •

Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. First aid treatment should be obtained immediately for open cuts and wounds. Use barrier creams, applying them before each work period, to help the removal of oil from the skin. Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advice without delay. Where practical, degrease components prior to handling. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

ENVIRONMENTAL PROTECTION PRECAUTIONS

GI-28

PRECAUTIONS < PRECAUTION > 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 GI facilities. It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources. The regulations concerning pollution vary between regions.

Air Conditioning

INFOID:0000000003891734

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA-34, "Collection and Charge".

GI-29

LIFTING POINT < PRECAUTION >

LIFTING POINT Special Service Tool

INFOID:0000000003891735

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description

LM4086-0200 ( - ) Board on attachment

S-NT001

LM4519-0000 ( - ) Safety stand attachment

S-NT002

CAUTION: • Every time the vehicle is lifted up, maintain the complete vehicle curb condition. • Since the vehicle's center of gravity changes when removing main parts on the front side (engine, transmission, suspension etc.), support a jack up point on the rear side garage jack with a transmission jack or equivalent. • Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle, suspension, etc.), support a jack up point on the front side garage jack with a transmission jack or equivalent. • Be careful not to smash or do anything that would affect piping parts.

Garage Jack and Safety Stand

INFOID:0000000003891736

WARNING: • Park the vehicle on a level surface when using the jack. Make sure to avoid damaging pipes, tubes, etc. under the vehicle. • Never get under the vehicle while it is supported only by the jack. Always use safety stands when you have to get under the vehicle. • Place wheel chocks at both front and back of the wheels on the ground.

GI-30

LIFTING POINT < PRECAUTION > â&#x20AC;¢ Lift at reinforced area of front suspension member where lower control arm attaches, staying in center line of wheels. GI

H WAIA0035E

2-Pole Lift

INFOID:0000000003891737

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.

GI-31

LIFTING POINT < PRECAUTION > When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, fuel lines and sill spoiler.

LAIA0018E

Board-on Lift

INFOID:0000000003891738

CAUTION: Make sure vehicle is empty when lifting. • 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. • Position attachments at front and rear ends of board-on lift.

AGI016

GI-32

TOW TRUCK TOWING < PRECAUTION >

TOW TRUCK TOWING

Tow Truck Towing

INFOID:0000000003891739

CAUTION: • Never tow a CVT 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. • Never tow a CVT model from the rear (that is, backward) with four wheels on the ground. This may cause serious and expensive damage to the transaxle. NISSAN recommends that the vehicle be towed with the driving (front) wheels off the ground. CAUTION: • Always release the parking brake when towing the vehicle with the front wheels raised with the rear wheels on the ground. • When the battery of a vehicle equipped with the Intelligent Key system is discharged, the vehicle should be towed with the front wheels on towing dollies or place the vehicle on a flat bed truck.

J SGI986

Vehicle Recovery (Freeing a Stuck Vehicle)

INFOID:0000000003891740

FRONT Securely install the vehicle recovery hook stored with jacking tools. Make sure that the hook is properly secured in the storage place after use. WARNING: • Stand clear of a stuck vehicle. • Do not spin your tires at high speed. This could cause them to explode and result in serious injury. Parts of your vehicle could also overheat and be damaged. CAUTION: • Tow chains or cables must be attached only to the vehicle recovery hooks or main structural members of the vehicle. Otherwise, the vehicle body will be damaged. • Do not use the vehicle tie downs to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehicle using the vehicle tie downs or recovery hooks. • Always pull the cable straight out from the front of the vehicle. Never pull on the hook at an angle. • Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or cooling systems. • Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or recovery.

CVT To tow a vehicle equipped with a CVT, an appropriate vehicle dolly MUST be placed under the towed vehicle's drive wheels. Always follow the dolly manufacture's recommendations when using their product. If the vehicle is stuck in sand, snow, mud, etc., use the following procedure: 1. Turn off the Vehicle Dynamic Control System.

GI-33

TOW TRUCK TOWING < PRECAUTION > 2. Make sure the area in front and behind the vehicle is clear of obstructions. 3. Turn the steering wheel right and left to clear an area around the front tires. 4. Slowly rock the vehicle forward and backward. Shift back and forth between R (Reverse) and D (Drive). Apply the accelerator as little as possible to maintain the rocking motion. Release the accelerator pedal before shifting between R (Reverse) and D (Drive). Do not spin the tires above 35 MPH (55 km/h). 5. If the vehicle can not be freed after a few tries, contact a professional towing service to remove the vehicle.

GI-34

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

BASIC INSPECTION

SERVICE INFORMATION FOR ELECTRICAL INCIDENT Work Flow

INFOID:0000000003891741

WORK FLOW C

SGI838

STEP

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:

STEP 1

WHAT

Vehicle Model, Engine, Transmission/Transaxle and the System (i.e., Radio).

WHEN

Date, Time of Day, Weather Conditions, Frequency.

WHERE

Road Conditions, Altitude and Traffic Situation.

HOW

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

STEP 2

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

STEP 3

Get the proper diagnosis materials together including: • Power Supply Routing • System Operation Descriptions • Applicable Service Manual Sections • Check for any Service Bulletins Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.

STEP 4

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

STEP 5

Repair or replace the incident circuit or component.

STEP 6

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

Control Units and Electrical Parts

INFOID:0000000003891742

Never reverse polarity of battery terminals. Install only parts specified for a vehicle. Before replacing the control unit, check the input and output and functions of the component parts. Do not apply excessive force when disconnecting a connector.

GI-35

PRECAUTIONS • • • •

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • Do not apply excessive shock to the control unit by dropping or hitting it. • Be careful to prevent condensation in the control unit due to rapid temperature changes and do not let water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle. • Be careful not to let oil to get on the control unit connector. • Avoid cleaning the control unit with volatile oil. • Do not disassemble the control unit, and do not remove the upper and lower covers. SAIA0255E

• When using a DMM, be careful not to let test probes get close to each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting. • When checking input and output signals of the control unit, use the specified check adapter.

SEF348N

How to Check Terminal

INFOID:0000000003891743

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

GI-36

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > Tool number (Kent-Moore No.) Tool name (J38751-95NI) Connector and terminal pin kit (NISSAN) (J38751-95INF) Connector and terminal pin kit (INFINITI) (J42992-98KIT) OBD and terminal repair kit (J42992-2000UPD) OBD-II Connector Kit Update

GI Description

E WAIA0004E

WAIA0005E

HOW TO PROBE CONNECTORS • Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks. • The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact, grasp the “T” pin using an alligator clip. Probing from Harness Side Standard type (not waterproof type) connector should be probed from harness side with “T” pin. • If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal. • Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.

K SGI841

Probing from Terminal Side FEMALE TERMINAL

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

SEL265V

GI-37

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • 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. CAUTION: Dot not bend terminal.

SEL267V

How to Check Enlarged Contact Spring of Terminal • An enlarged contact spring of a terminal may create intermittent signals in the circuit. • If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal. 1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire. NOTE: Use a male terminal which matches the female terminal. 2. Disconnect the suspected faulty connector and hold it terminal side up.

SEL270V

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

SEL271V

GI-38

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > 4. While moving the connector, check whether the male terminal can be easily inserted or not.

C SEL272V

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

G SEL273V

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

RUBBER SEAL INSPECTION

• Most waterproof connectors are provided with a rubber seal between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications. • The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector.

WIRE SEAL INSPECTION

• The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly. L SEL275V

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

SEL330V

Intermittent Incident

INFOID:0000000003891744

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

GI-39

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident. The section is broken into the six following topics:

• Vehicle vibration • Heat sensitive • Freezing • Water intrusion • Electrical load • Cold or hot start up Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem.

VEHICLE VIBRATION The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration. Connector & Harness Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This test may indicate a loose or poor electrical connection. Hint Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. Sensor & Relay Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay.

SGI839

Engine Compartment There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: • Connectors not fully seated. • Wiring harness not long enough and is being stressed due to engine vibrations or rocking. • Wires laying across brackets or moving components. • Loose, dirty or corroded ground wires. • Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground Inspection described later.) First check that the system is properly grounded. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity. Behind the Instrument Panel An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw. Under Seating Areas

GI-40

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > 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 GI pinching.

HEAT SENSITIVE B

• The customer's concern may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. • To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. CAUTION: Do not heat components above 60°C (140°). • If incident occurs while heating the unit, either replace or properly insulate the component.

SGI842

FREEZING • The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. • There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. Make sure it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. • The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

SGI843

WATER INTRUSION The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash. CAUTION: Do not spray water directly on any electrical components.

SGI844

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

P SGI845

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

GI-41

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

Circuit Inspection

INFOID:0000000003891745

DESCRIPTION • In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning, it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure. • You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this. OPEN

A circuit is open when there is no continuity through a section of the circuit. There are two types of shorts.

SHORT

• SHORT CIRCUIT

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

• SHORT TO GROUND

When a circuit contacts a ground source and grounds the circuit.

NOTE: Refer to GI-36, "How to Check Terminal" to probe or check terminal.

TESTING FOR “OPENS” IN THE CIRCUIT Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

SGI846-A

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 previous schematic. • Disconnect the battery negative cable. • Start at one end of the circuit and work your way to the other end. (At the fuse block in this example.) • Connect one probe of the DMM to the fuse block terminal on the load side. • Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A) • Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B) • Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C) Any circuit can be diagnosed using the approach in the previous example. Voltage Check Method To help in understanding the diagnosis of open circuits, please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function. • Connect one probe of the DMM to a known good ground. • Begin probing at one end of the circuit and work your way to the other end. • With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1.

GI-42

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > no voltage; open is between fuse block and SW1 (point A). • Close SW1 and probe at relay. voltage; open is further down the circuit than the relay. no voltage; open is between SW1 and relay (point B). • Close the relay and probe at the solenoid. voltage; open is further down the circuit than the solenoid. no voltage; open is between relay and solenoid (point C). Any powered circuit can be diagnosed using the approach in the previous example.

TESTING FOR “SHORTS” IN THE CIRCUIT To simplify the discussion of shorts in the system, please refer to the following schematic.

F SGI847-A

Resistance Check Method • Disconnect the battery negative cable and remove the blown fuse. • Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. • Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known good ground. • With SW1 open, check for continuity. continuity; short is between fuse terminal and SW1 (point A). no continuity; short is further down the circuit than SW1. • Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between SW1 and the relay (point B). no continuity; short is further down the circuit than the relay. • Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between relay and solenoid (point C). no continuity; check solenoid, retrace steps. Voltage Check Method • Remove the blown fuse and disconnect all loads (i.e., SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. • Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). • With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage; short is between fuse block and SW1 (point A). no voltage; short is further down the circuit than SW1. • With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for voltage. voltage; short is between SW1 and the relay (point B). no voltage; short is further down the circuit than the relay. • With SW1 closed, relay contacts jumped with fused jumper wire, check for voltage. voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage; retrace steps and check power to fuse block.

GROUND INSPECTION • Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. • Electronically-controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically-controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface.

GI-43

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • When inspecting a ground connection follow these rules: - Remove the ground bolt or screw. - Inspect all mating surfaces for tarnish, dirt, rust, etc. - Clean as required to assure good contact. - Reinstall bolt or screw securely. - Inspect for “add-on” accessories which may be interfering with the ground circuit. - If several wires are crimped into one ground eyelet terminal, check for proper crimps. 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. • For detailed ground distribution information, refer to “Ground Distribution” in PG section.

SGI853

VOLTAGE DROP TESTS • Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation. • Check the wire in the illustration. When measuring resistance with a DMM, contact by a single strand of wire will give reading of 0 ohm. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop. • Unwanted resistance can be caused by many situations as follows: - Undersized wiring (single strand example) - Corrosion on switch contacts - Loose wire connections or splices • If repairs are needed always use wire that is of the same or larger gauge. Measuring Voltage Drop — Accumulated Method • Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the DMM should be closer to power and the negative lead closer to ground. • Operate the circuit. • The DMM will indicate how many volts are being used to “push” current through that part of the circuit.

GI-44

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb. GI

SGI974

Measuring Voltage Drop — Steb-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.

M SAIA0258E

CONTROL UNIT CIRCUIT TEST System Description • When the switch is ON, the control unit lights up the lamp.

CASE 1 P

MGI034A

GI-45

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > INPUT-OUTPUT VOLTAGE CHART

Terminal No. +

−

Description Signal name

Body ground

Switch

Body ground

Lamp

Value (Approx.)

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

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF

Switch ON

Battery voltage

Switch OFF

Condition

Input/ Output Input

Output

Approx. 0 Approx. 0 (Inoperative lamp) Approx. 0

• 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.

CASE 2

MGI035A

INPUT-OUTPUT VOLTAGE CHART

Terminal No. +

−

Description Signal name

Condition

Input/ Output

Body ground

Lamp

Output

Body ground

Switch

Input

Value (Approx.)

Switch ON

Switch OFF

Battery voltage

In case of high resistance such as single strand (V) * Battery voltage (Inoperative lamp) Battery voltage

Switch ON

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

• 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. 0 V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.

GI-46

CONSULT-III CHECKING SYSTEM < BASIC INSPECTION >

CONSULT-III CHECKING SYSTEM

Description

INFOID:0000000003891746

• When CONSULT-III is connected with a data link connector equipped on the vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various kinds of diagnostic tests. 1

: Hood release handle

: Data link connector

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

ALBIA0047ZZ

Function and System Application

INFOID:0000000003891747

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

Trouble diagnostic record

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

Data monitor

Input/Output data in the ECU can be read.

CAN diagnosis

The condition of CAN communication line can be indicated by a topology.

CAN diagnosis support monitor

The condition of CAN communication line can be read.

Active test

Diagnostic Test Mode in which CONSULT-III drives some actuators apart from the ECUs and also shifts some parameters in a specified range.

DTC & SRT confirmation

The results of SRT (System Readiness Test) and the self-diagnosis status/result can be confirmed.

DTC work support

The operating condition to confirm Diagnosis Trouble Codes can be selected.

ECU identification

ECU part number can be read.

Special function

This mode can show results of self-diagnosis of ECU with either 'OK' or 'NG'. For engines, more practical tests regarding sensors/switches and/or actuators are available.

Configuration

Function to READ/WRITE vehicle configuration on BCM.

Steering lock release*2

The condition of steering lock release solenoid.

This mode shows the BCM-specific 5-digit code.

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

PIN read

Control unit initialization*2 x: Applicable

*1: With automatic drive positioner *2: With CONSULT-III security card inserted

GI-47

HVAC

IPDM E/R

MULTI AV

ABS

BCM

This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-III.

Function

METER/M&A

AIR BAG

Work support

Diagnostic test mode

ENGINE

TRANSMISSION

AUTO DRIVE POS.*1

CONSULT-III CHECKING SYSTEM < BASIC INSPECTION >

CONSULT-III Data Link Connector (DLC) Circuit

INFOID:0000000003891748

INSPECTION PROCEDURE If the CONSULT-III cannot diagnose the system properly, check the following items. Symptom

Check item

CONSULT-III cannot access any system.

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

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

• Power supply and ground circuit for the control unit of the system. (For detailed circuit, refer to wiring diagram for each system.) • Open or short circuit between the system and CONSULT-III DLC. (For detailed circuit, refer to wiring diagram for each system.) • Open or short circuit CAN communication line. Refer to LAN-15, "Trouble Diagnosis Flow Chart".

NOTE: The DDL2 circuits and CAN communication lines from DLC pins 6, 7 and 14 may be connected to more than one system. A short in a DDL circuit or CAN lines connected to a control unit in one system may affect CONSULT-III access to other systems. For a complete DDL circuit layout, refer to GI-49, "Wiring Diagram". For a complete CAN line layout, refer to LAN-28, "Wiring Diagram - CAN SYSTEM -".

GI-48

CONSULT-III CHECKING SYSTEM < BASIC INSPECTION >

Wiring Diagram

INFOID:0000000003891750

ABAWA0009GB

GI-49

ENGINE

SECTION

ENGINE MECHANICAL

CONTENTS PRECAUTION ............................................... 3 PRECAUTIONS ................................................... 3

Removal and Installation of Drive Belt Auto-tensioner .......................................................................15

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................... 3 Precautions Necessary for Steering Wheel Rotation after Battery Disconnect ..................................... 3 Precaution for Drain Coolant ..................................... 3 Precaution for Disconnecting Fuel Piping ................. 4 Precaution for Removal and Disassembly ................ 4 Precaution for Inspection, Repair and Replacement .......................................................................... 4 Precaution for Assembly and Installation .................. 4 Parts Requiring Angular Tightening .......................... 4 Precaution for Liquid Gasket ..................................... 4

AIR CLEANER FILTER ..................................... 16

PREPARATION ............................................ 6

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

PREPARATION ................................................... 6

INTAKE MANIFOLD COLLECTOR .................. 24

Special Service Tool ................................................. 6 Commercial Service Tool .......................................... 8

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

Removal and Installation .........................................16 Valve Clearance ......................................................17

COMPRESSION PRESSURE ........................... 21 On-Vehicle Service ..................................................21

ON-VEHICLE REPAIR ................................. 22 ENGINE COVER ............................................... 22 Removal and Installation .........................................22

AIR CLEANER AND AIR DUCT ....................... 23 K

INTAKE MANIFOLD ......................................... 27 Removal and Installation .........................................27

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING ............................10

EXHAUST MANIFOLD AND THREE WAY CATALYST ........................................................ 30

ON-VEHICLE MAINTENANCE .................... 12

CAMSHAFT VALVE CLEARANCE .................. 17

FUNCTION DIAGNOSIS .............................. 10

NVH Troubleshooting - Engine Noise ..................... 10 Use the Chart Below to Help You Find the Cause of the Symptom ....................................................... 11

Removal and Installation .........................................30

OIL PAN AND OIL STRAINER ......................... 33 Removal and Installation .........................................33

IGNITION COIL ................................................. 39

Exploded View ........................................................ 12 Removal and Installation ......................................... 12

Exploded View .........................................................39 Removal and Installation LH ....................................39 Removal and Installation RH ...................................39

DRIVE BELTS ....................................................14

FUEL INJECTOR AND FUEL TUBE ................ 40

SPARK PLUG ....................................................12

Checking Drive Belts ............................................... 14 Tension Adjustment ................................................ 14 Removal and Installation ......................................... 14

EM-1

Exploded View .........................................................40 Removal and Installation .........................................40 Inspection ................................................................44

ROCKER COVER .............................................. 45

REMOVAL AND INSTALLATION .............. 96

Exploded View ........................................................ 45 Removal and Installation LH ................................... 45 Removal and Installation RH .................................. 46

ENGINE ASSEMBLY ........................................ 96

FRONT TIMING CHAIN CASE .......................... 49

DISASSEMBLY AND ASSEMBLY ........... 100

Removal and Installation ........................................ 49

TIMING CHAIN .................................................. 57 Component ............................................................. 57 Removal ................................................................. 57 Inspection ............................................................... 60 Installation .............................................................. 60

REAR TIMING CHAIN CASE ............................ 66 Component ............................................................. 66 Removal and Installation ........................................ 66

CAMSHAFT ....................................................... 71 Removal and Installation ........................................ 71 Inspection after Installation ..................................... 79

OIL SEAL ........................................................... 81 Removal and Installation of Valve Oil Seal ............. 81 Removal and Installation of Front Oil Seal ............. 81 Removal and Installation of Rear Oil Seal .............. 83

CYLINDER HEAD .............................................. 85 Removal and Installation ........................................ 85 Disassembly and Assembly .................................... 89 Inspection After Disassembly ................................. 91

Removal and Installation ......................................... 96

CYLINDER BLOCK .......................................... 100 Disassembly and Assembly .................................. 100 Inspection .............................................................. 109 Dowel Pin Alignment ............................................. 119

SERVICE DATA AND SPECIFICATIONS (SDS) ......................................................... 121 SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................ 121 General Specification ........................................... 121 Drive Belt .............................................................. 121 Spark Plug ............................................................ 122 Intake Manifold ...................................................... 122 Exhaust Manifold .................................................. 122 Camshaft ............................................................... 122 Cylinder Head ...................................................... 124 Cylinder Block ...................................................... 127 Main Bearing ........................................................ 130 Connecting Rod Bearing ..................................... 131 Drive Plate ............................................................ 132

EM-2

PRECAUTIONS < PRECAUTION >

PRECAUTION

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

INFOID:0000000004173747

Precautions Necessary for Steering Wheel Rotation after Battery Disconnect

INFOID:0000000004394023

2. 3. 4. 5.

OPERATION PROCEDURE 1.

Precaution for Drain Coolant

INFOID:0000000004173748

• Drain coolant when engine is cooled.

EM-3

PRECAUTIONS < PRECAUTION >

Precaution for Disconnecting Fuel Piping

INFOID:0000000004173749

• Before starting work, make sure no fire or spark producing items are in the work area. • Release fuel pressure before disassembly. • After disconnecting pipes, plug openings to stop fuel leakage.

Precaution for Removal and Disassembly

INFOID:0000000004173750

• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. • Exercise maximum care to avoid damage to mating or sliding surfaces. • Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. • Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly. • When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used where noted in the step.

Precaution for Inspection, Repair and Replacement

INFOID:0000000004173751

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

Precaution for Assembly and Installation

INFOID:0000000004173752

• Use torque wrench to tighten bolts or nuts to specification. • When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified. • Replace with new gasket, packing, oil seal or O-ring. • Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage. • Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. • Release air within route after draining coolant. • Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure that there are no leaks at fuel line connections. • After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage.

Parts Requiring Angular Tightening

INFOID:0000000004173753

• -

Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Main bearing cap bolts Connecting rod cap nuts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening) • Do not use a torque value for final tightening. • The torque value for these parts are for a preliminary step. • Ensure thread and seat surfaces are clean and coated with engine oil.

Precaution for Liquid Gasket

INFOID:0000000004173754

REMOVAL OF LIQUID GASKET SEALING

EM-4

PRECAUTIONS < PRECAUTION > • After removing the bolts and nuts, separate the mating surface and remove the sealant using Tool. Tool number

: KV10111100 (J-37228)

CAUTION: Be careful not to damage the mating surfaces. • In areas where the cutter is difficult to use, use a plastic hammer to lightly tap (1) the cutter where the RTV Silicone Sealant is applied. Use a plastic hammer to slide the cutter (2) by tapping on the side. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces.

C WBIA0566E

LIQUID GASKET APPLICATION PROCEDURE 1.

Using a scraper, remove the old Silicone RTV Sealant adhering to the gasket application surface and the mating surface. • Remove the sealant completely from the groove of the gasket application surface, bolts, and bolt holes. Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture, grease and foreign materials. Attach the sealant tube to the tube presser. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-15, "Recommended Chemical Products and Sealants".

H PBIC0003E

Apply the sealant using Tool without breaks to the specified location. Tube presser

WS39930000 (

–

)

• If there is a groove for the sealant application, apply the sealant to the groove. K

WBIA0567E

• As for the bolt holes, normally apply the sealant inside the holes. If specified, it should be applied outside the holes. Make sure to read the text of this manual. • Within five minutes of the sealant application, install the mating component. • If the sealant protrudes, wipe it off immediately. • Do not retighten after the installation. • After 30 minutes or more have passed from the installation, fill the engine with the specified oil and coolant. Refer to MA-17, "FOR NORTH AMERICA : Fluids and Lubricants" (United States and Canada) or MA-18, "FOR MEXICO : Fluids and Lubricants" (Mexico). CAUTION: Follow all specific instructions in this manual.

EM-5

O SEM159F

PREPARATION < PREPARATION >

PREPARATION PREPARATION Special Service Tool

INFOID:0000000004173755

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

Tool number (Kent-Moore No.) Tool name

Description

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

Disassembling and assembling

NT042

Removal engine and transmission assembly

KV101J0010 (J-47242) Engine support table

WBIA0658E

KV10116200 (J-26336-A) Valve spring compressor 1. KV10115900 (J-26336-20) Attachment 2. KV10109220 ( — ) Adapter

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

PBIC1650E

Removing valve oil seal

KV10107902 (J-38959) Valve oil seal puller

S-NT011

Installing valve oil seal

— (J-39386) Valve oil seal drift

NT024

Removing crankshaft pilot bushing

ST16610001 (J-23907) Pilot bushing puller

NT045

EM-6

PREPARATION < PREPARATION > Tool number (Kent-Moore No.) Tool name

Description

KV10111100 (J-37228) Seal cutter

Removing steel oil pan and rear timing chain case

C NT046

WS39930000 ( — Tube presser

Pressing the tube of liquid gasket

)

NT052

Tightening bolts for bearing cap, cylinder head, etc.

KV10112100 (BT-8653-A) Angle wrench

H NT014

Loosening or tightening air fuel ratio A/F sensor a: 22 mm (0.87 in)

— (J-44626) Air fuel sensor Socket

LBIA0444E

K Loosening or tightening rear heated oxygen sensor a: 22 mm (0.87 in)

KV10114400 (J-38365) Heated oxygen sensor wrench

M NT636

Removing and installing crankshaft pulley

KV10117700 (J-44716) Ring gear stopper

O NT822

Holding pulley position a: 68 mm (2.68 in) b: 8 mm (0.31 in)

KV10109300 ( — ) Pulley holder

NT628

EM-7

PREPARATION < PREPARATION >

Commercial Service Tool

INFOID:0000000004173756

(Kent-Moore No.) Tool name

Description

(BT-3373-F) Belt tension gauge

Checking drive belt tension

AMA126

Power tool

Loosening bolts and nuts

PBIC0190E

Spark plug wrench

Removing and installing spark plug

PBIC2982E

Valve seat cutter set

Finishing valve seat dimensions

NT048

Piston ring expander

Removing and installing piston ring

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

EM-8

PREPARATION < PREPARATION > (Kent-Moore No.) Tool name

Description

Valve guide reamer

Reaming valve guide 1 or hole for oversize valve guide 2 Intake & Exhaust: d1: 6.0 mm (0.236 in) dia. d2: 10.2 mm (0.402 in) dia.

C NT016

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

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

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

H AEM489

T55 TorxÂŽ Plus Bit

Removing and installing M/T flywheel bolts

J PBIC1113E

EM-9

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING < FUNCTION DIAGNOSIS >

FUNCTION DIAGNOSIS NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting - Engine Noise

INFOID:0000000004173757

AWBIA0022ZZ

Camshaft bearing noise

Piston pin noise

Main bearing noise

Connecting rod bearing noise 6.

Drive belt noise (Sticking/Slipping)

Drive belt noise (Slipping) 8.

Water pump noise

Timing chain and chain tensioner noise

EM-10

3. 9.

Piston slap noise

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING < FUNCTION DIAGNOSIS > 10. Tappet noise

Valve

Valve mechanism

Drive belt

Timing chain

Rotation mechanism

Use the Chart Below to Help You Find the Cause of the Symptom

INFOID:0000000004173758

1. 2. 3. 4.

Locate the area where noise occurs. Confirm the type of noise. Specify the operating condition of engine. Check specified noise source. Repair or replace the identified part as necessary.

Operating condition of engine Location of noise

Type of noise

Top of engine Rocker cover Cylinder head

Ticking or clicking

—

Rattle

—

Slap or knock

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Before warmup

—

Slap or rap

Knock

Knock Front of engine Timing chain cover

Front of engine

Tapping or ticking

After warmup

—

When starting

—

When idling

When racing

While driving

Source of noise

Check item

—

Tappet noise

Valve clearance

EM-17

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-71

—

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

EM-21

Piston slap noise

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

EM-100

Connecting rod bearing noise

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

EM-100

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-100

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-57

Drive belts (Sticking or slipping)

Drive belts deflection

Squeaking or fizzing

Creaking

Drive belts (Slipping)

Idler pulley bearing operation

Squall Creak

—

Water pump noise

Water pump operation

A: Closely related B: Related

—

C: Sometimes related

—

—: Not related

EM-11

Reference page

N EM-14

O CO-17

SPARK PLUG < ON-VEHICLE MAINTENANCE >

ON-VEHICLE MAINTENANCE SPARK PLUG Exploded View

INFOID:0000000004335581

AWBIA0203GB

Ignition coil

Rocker cover LH

Spark plug

Removal and Installation

Rocker cover RH

INFOID:0000000004399675

REMOVAL 1. 2.

Remove the ignition coil. Refer to EM-39, "Removal and Installation LH" and EM-39, "Removal and Installation RH". Remove the spark plug with a suitable spark plug wrench.

PBIC2982E

INSPECTION AFTER REMOVAL

EM-12

SPARK PLUG < ON-VEHICLE MAINTENANCE > • Do not use a wire brush for cleaning the spark plugs. Replace as necessary.

C SMA773C

• If plug is covered with carbon, a spark plug cleaner may be used. Cleaner air pressure Cleaning time

: less than 588 kPa (6 kg/cm2, 85 psi) : less than 20 seconds

• Checking and adjusting plug gap is not required between change intervals. If the gap is out of specification, replace the spark plug.

SMA806CA

INSTALLATION Installation is in the reverse order of removal. J Make

DENSO

Standard type

FXE22HR11

Gap (nominal)

1.1 mm (0.043 in)

EM-13

DRIVE BELTS < ON-VEHICLE MAINTENANCE >

DRIVE BELTS Checking Drive Belts

INFOID:0000000004173760

AWBIA0707ZZ

Power steering pump

Drive belt auto-tensioner

Crankshaft

Idler pulley

A/C compressor pulley

Generator pulley

Idler pulley

Drive belt

Indicator

Possible use range (for new belt) C.

Belt replacement

WARNING: Inspect and check the drive belts with the engine off. 1. Inspect belt for cracks, fraying, wear or oil adhesion. If necessary, replace with a new one. 2. Rotate the crankshaft pulley two times then check the belt tension using Tool. Tool Number

: — (BT-3373-F)

NOTE: • Inspect drive belt tension when engine is cold.

Tension Adjustment

INFOID:0000000004173761

• Belt tension is not manually adjustable, it is automatically adjusted by the drive belt auto-tensioner.

Removal and Installation

INFOID:0000000004173762

REMOVAL 1. 2.

Remove the front RH side cover. While securely holding the hexagonal part in pulley center of drive belt auto-tensioner, move in the direction of arrow (loosening direction of tensioner) using suitable tool. WARNING: • Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. CAUTION: • Do not loosen the auto-tensioner pulley bolt. (Do not turn it counterclockwise. If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley.) Insert a rod approximately 6 mm (0.24 in) in diameter through the rear of tensioner into retaining boss to lock tensioner pulley. • Leave tensioner pulley arm locked until belt is installed again.

EM-14

ALBIA0223ZZ

DRIVE BELTS < ON-VEHICLE MAINTENANCE > 4. Loosen auxiliary drive belt from water pump pulley and then remove it from the other pulleys. A

INSTALLATION

1. Install the drive belt onto all of the pulleys. CAUTION: EM Confirm belts are completely set on the pulleys. 2. Release tensioner, and apply tensions to belt. WARNING: C • Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. CAUTION: • Do not loosen the auto-tensioner pulley bolt. (Don't turn it counterclockwise. If turned counter- D clockwise, the complete auto-tensioner must be replaced as a unit, including pulley.) 3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley. 4. Confirm tensions of belt at indicator is within the allowable use range. Refer to EM-14, "Checking Drive E Belts".

Removal and Installation of Drive Belt Auto-tensioner

INFOID:0000000004173763

K ALBIA0222GB

L 1. Drive belt auto-tensioner

2. Idler pulley

3. A/C idler pulley

REMOVAL CAUTION: The complete auto-tensioner must be replaced as a unit, including the pulley. 1. Remove the front RH side cover. 2. Remove the drive belt. Refer to EM-14, "Removal and Installation". • Insert a rod approximately 6 mm (0.24 in) in diameter through the rear of tensioner into the retaining boss to lock tensioner pulley. 3. Remove the drive belt auto-tensioner, with power tool. CAUTION: Do not loosen the auto-tensioner pulley bolt. (Don't turn it counterclockwise. If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley).

INSTALLATION Installation is in the reverse order of removal. CAUTION: • If there is damage greater than peeled paint, replace drive belt auto-tensioner units. • Do not swap the pulley between the new and old auto-tensioner units.

EM-15

AIR CLEANER FILTER < ON-VEHICLE MAINTENANCE >

AIR CLEANER FILTER Removal and Installation

INFOID:0000000004173764

AWBIA0679ZZ

Air duct hose

Front air duct

Grommets

Air cleaner case mounting bracket 6.

Bracket

Air cleaner filter

Air cleaner case (upper)

Mass air flow sensor

To electronic throttle control actuator

Air cleaner case side clips

Air cleaner case (lower)

CHANGING THE AIR CLEANER FILTER CAUTION: It is not necessary to remove the front air duct to replace the air cleaner filter. 1. Unhook the air cleaner case side clips. 2. Remove the air cleaner filter. 3. Install a new air cleaner filter. 4. Lock the air cleaner case side clips.

EM-16

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE >

CAMSHAFT VALVE CLEARANCE

Valve Clearance

INFOID:0000000004173765

CHECKING

• Perform inspection as follows after removal, installation or replacement of camshaft or valve related parts, or if there are unusual engine conditions regarding valve clearance. Check valve clearance while engine is cold and not running. 1. Remove the air duct with air cleaner case, collectors, hoses, wires, harnesses, and connectors. 2. Remove the intake manifold collectors. 3. Remove the ignition coils and spark plugs. 4. Remove the rocker covers.

E SEM713A

Set No.1 cylinder at TDC on its compression stroke. • Align pointer with TDC mark on crankshaft pulley.

I JMBIA1135GB

• Check that the valve lifters on No.1 cylinder are loose and valve lifters on No.4 are tight. If not, turn the crankshaft one full revolution (360°) and align as shown.

SEM418G

EM-17

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > 6. Check only the valves as shown. Crank Position

Valve No. 1

Valve No. 2

Valve No. 3

Valve No. 6

No. 1 TDC

Intake

Exhaust

Intake

SEM893E

• Using a feeler gauge, measure the clearance between the valve lifter and camshaft. • Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement lifter size. Valve Clearance for Checking (cold) Intake Exhaust

: 0.26 - 0.34 mm (0.010 - 0.013 in) : 0.29 - 0.37 mm (0.011 - 0.015 in)

SEM139D

KBIA0185E

7. 8.

Turn crankshaft 240°. Set No.3 cylinder at TDC on its compression stroke.

EM-18

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > 9. Check only those valves as shown. A Crank Position

Valve No. 2

Valve No. 3

Valve No. 4

Valve No. 5

No. 3 TDC

Intake

Exhaust

G SEM894E

10. Turn the crankshaft 240° and align as above. 11. Set No.5 cylinder at TDC on its compression stroke. 12. Check only those valves as shown.

I Crank Position

Valve No. 1

Valve No. 4

Valve No. 5

Valve No. 6

No. 5 TDC

Exhaust

Intake

Exhaust

O SEM958E

13. If all valve clearances are within specification, install the following components. If the valve clearances are out of specification, adjust the valve clearances. • Intake manifold collectors • Rocker covers • All spark plugs • All ignition coils

VALVE ADJUSTING

EM-19

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > CAUTION: Adjust valve clearance while engine is cold. NOTE: • Perform adjustment by selecting the correct head thickness of the valve lifter (adjusting shims are not used). • The specified valve lifter thickness is the dimension at normal temperatures. Ignore dimensional differences caused by temperature. Use specifications for hot engine condition to confirm valve clearances. 1. Remove the camshaft. 2. Remove the valve lifter that was measured as being outside the standard specifications. 3. Measure the center thickness of the removed lifter with a micrometer, as shown.

SEM754G

5. 6. 7. 8. 9.

Use the equation below to calculate the replacement valve lifter thickness. Valve lifter thickness calculation equation: t = t1 + (C1 - C2) t = thickness of the replacement lifter t1 = thickness of the removed lifter C1 = measured valve clearance C2 = standard valve clearance • The thickness of the new valve lifter can be identified by the stamp mark on the reverse side (inside the lifter). • Available thickness of the valve lifter (factory setting): 7.88 - 8.40 mm (0.3102 - 0.3307 in), in 0.02 mm (0.0008 in) SEM755G increments, in 27 sizes (intake/exhaust). Refer to EM-124, "Cylinder Head". Install the selected replacement valve lifter. Install the camshaft. Rotate the crankshaft a few turns by hand. Confirm that the valve clearances are within specification. After the engine has been run to full operating temperature, confirm that the valve clearances are within specification.

Standard Valve Clearance

Cold

Hot* (reference data)

Intake

0.26 - 0.34 mm (0.010 - 0.013 in)

0.304 - 0.416 mm (0.012 - 0.016 in)

Exhaust

0.29 - 0.37 mm (0.011 - 0.015 in)

0.308 - 0.432 mm (0.012 - 0.017 in)

* Approximately 80°C (176°F)

EM-20

COMPRESSION PRESSURE < ON-VEHICLE MAINTENANCE >

COMPRESSION PRESSURE

On-Vehicle Service

INFOID:0000000004173766

CHECKING COMPRESSION PRESSURE 1. 2. 3. 4. 5. 6.

7. 8.

Run the engine until it reaches normal operating temperature. Turn the ignition switch to OFF. Release fuel pressure and leave the fuel pump electrically disconnected. Refer to EC-559, "Inspection". Remove all six spark plugs. Refer to EM-12, "Removal and Installation". Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep the electric throttle control actuator butterfly-valve wide open to maximize air intake flow. Crank the engine and record the highest gauge indication. Repeat the measurement on each cylinder (steps 5 - 7). • Always use a fully-charged battery to obtain specified engine speed.

Unit: kPa (kg/cm2, psi)/rpm

Standard

Minimum

Difference limit between cylinders

1,275 (13.0, 185)/300

981 (10.0, 142)/300

98 (1.0, 14)/300

SEM387C

9. If compression in one or more cylinders is low: a. Pour a small amount of engine oil into cylinders through the spark plug holes. b. Retest compression (steps 5 - 8). • If adding oil helps raise compression pressure, then the piston rings may be worn or damaged. If so, replace piston rings after checking piston. • If the pressure stays low, a valve may be sticking or is seating improperly. Inspect and repair the valve and/or valve seat. Refer to EM-124, "Cylinder Head". If the valve and/or valve seat is damaged excessively, replace as necessary. • If compression stays low in two or more cylinders that are next to each other: - The cylinder head gasket may be leaking. - Both cylinders may have valve component damage. Inspect and repair as necessary.

EM-21

ENGINE COVER < ON-VEHICLE REPAIR >

ON-VEHICLE REPAIR ENGINE COVER Removal and Installation

INFOID:0000000004393999

REMOVAL â&#x20AC;¢ Remove the engine room cover bolts and engine room cover. CAUTION: Do not damage or scratch engine room cover when installing or removing.

AWBIA0718ZZ

INSTALLATION Installation is in the reverse order of removal.

EM-22

AIR CLEANER AND AIR DUCT < ON-VEHICLE REPAIR >

AIR CLEANER AND AIR DUCT

Removal and Installation

INFOID:0000000004173767

AWBIA0679ZZ

Air duct hose

Front air duct

Grommets

Air cleaner case mounting bracket 6.

Bracket

Air cleaner filter

Air cleaner case (upper)

Mass air flow sensor

To electronic throttle control actuator

Air cleaner case side clips

Air cleaner case (lower)

REMOVAL

1. 2. 3. 4. 5.

Remove front air duct. Disconnect the tube clamp at the electronic throttle control actuator and at the air duct hose. Remove air duct hose. Disconnect mass air flow sensor. Remove mass air flow sensor from air cleaner assembly, as necessary. CAUTION: Handle mass air flow sensor with care. • Do not shock it. • Do not disassemble it. • Do not touch its sensor. Remove air cleaner assembly.

INSTALLATION Installation is in the reverse order of removal.

EM-23

INTAKE MANIFOLD COLLECTOR < ON-VEHICLE REPAIR >

INTAKE MANIFOLD COLLECTOR Removal and Installation

INFOID:0000000004173768

AWBIA0713GB

Intake manifold collector

Gasket

Electric throttle control actuator

NOTE: Do not remove power valves.

REMOVAL WARNING: â&#x20AC;˘ To avoid the danger of being scalded, never drain the coolant when the engine is hot. â&#x20AC;˘ The gasket for intake manifold collector (upper) is secured together with intake manifold collector (lower) bolt. Thus, when replacing only the upper gasket the lower gasket must also be replaced. 1. Remove the cowl top. Refer to EXT-18, "Removal and Installation". 2. Remove the engine cover, using power tool. 3. Remove air cleaner assembly and fresh air intake tube as an assembly. Refer to EM-23, "Removal and Installation".

EM-24

INTAKE MANIFOLD COLLECTOR < ON-VEHICLE REPAIR > 4. Remove the electric throttle control actuator bolts in the reverse order as shown and remove the electric throttle control actuator. CAUTION: • Handle carefully to avoid any shock to the electric throttle control actuator. • Do not disassemble.

C SEM711G

6. 7.

Disconnect the following: • Power brake booster vacuum hose • Fuel injector electrical connectors • PCV hose • Electric throttle control actuator electrical connector • EVAP canister purge hose CAUTION: • Cover any engine openings to avoid the entry of any foreign material. Remove the EVAP canister purge volume solenoid valve bracket bolt. Position the valve aside. Loosen the intake manifold collector bolts in the order as shown using power tool, and remove the intake manifold collector and gasket.

ALBIA0228ZZ

If necessary remove the following components: • VIAS control solenoid valve • EVAP canister purge volume control solenoid valve

INSTALLATION Installation is in the reverse order of removal. • Tighten intake manifold collector bolts in the order as shown.

O ALBIA0240ZZ

EM-25

INTAKE MANIFOLD COLLECTOR < ON-VEHICLE REPAIR > • Tighten electric throttle control actuator bolts in the order shown.

SEM711G

NOTE: After installation, it is necessary to re-calibrate the electric throttle control actuator as follows: 1. Perform the ″Throttle Valve Closed Position Learning″ when harness connector of the electric throttle control actuator is disconnected. Refer to EC-18, "THROTTLE VALVE CLOSED POSITION LEARNING : Special Repair Requirement". 2. Perform the ″Idle Air Volume Learning″ when the electric throttle control actuator is replaced. Refer to EC19, "IDLE AIR VOLUME LEARNING : Special Repair Requirement".

EM-26

INTAKE MANIFOLD < ON-VEHICLE REPAIR >

INTAKE MANIFOLD

Removal and Installation

INFOID:0000000004173769

ALBIA0231ZZ

Intake manifold

Gasket

Follow installation procedure

REMOVAL

WARNING: To avoid the danger of being scalded, never drain the coolant when the engine is hot. 1. Remove the engine cover with power tool. 2. Release the fuel pressure. Refer to EC-559, "Inspection". 3. Remove intake manifold collector. Refer to EM-24, "Removal and Installation". 4. Disconnect fuel tube quick connector at vehicle piping side. 5. To remove the quick connector cap, hold the sides of the connector, push in the tabs and pull out the tube. CAUTION: • The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. • Do not use any tools to remove the quick connector. • Keep the resin tube away from heat. Be especially careful when welding near the tube. • Prevent acid liquids such as battery electrolyte, etc. from getting on the resin tube. • Do not bend or twist the tube during removal or installation. • Do not remove the remaining retainer on the tube. • When the tube is replaced, also replace the retainer with a new one.

EM-27

SFE562A

INTAKE MANIFOLD < ON-VEHICLE REPAIR > • To keep the connecting portion clean and to avoid damage and foreign materials entering, cover the ends of the fuel tubes with plastic bags or something similar. NOTE: If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling. 6. Remove the fuel rail with the fuel injectors attached, from the intake manifold. Remove the fuel injector O-rings and use new O-rings for installation. PBIC0163E

Loosen the bolts in the order as shown, and remove the intake manifold with power tool.

ALBIA0232ZZ

INSPECTION AFTER REMOVAL Surface Distortion • Using straightedge and feeler gauge, inspect the surface distortion of the intake manifold. Inspect the surface distortion of the intake manifold collector. Refer to EM-24, "Removal and Installation". Standard

: 0.1 mm (0.004 in)

WBIA0052E

INSTALLATION Installation is in the reverse order of removal. Follow the procedure below for specific tightening sequences and procedures. • Install intake manifold bolts in two steps in the numerical order as shown. Step 1 Step 2

: 7.3 N·m (0.74 kg-m, 65 in-lb) : 25 N·m (2.6 kg-m, 19 ft-lb)

ALBIA0233ZZ

NOTE: After installation, it is necessary to re-calibrate the electric throttle control actuator as follows: 1. Perform the "Throttle Valve Closed Position Learning" when harness connector of the electric throttle control actuator is disconnected. Refer to EC-18, "THROTTLE VALVE CLOSED POSITION LEARNING : Special Repair Requirement". 2. Perform the "Idle Air Volume Learning" when the electric throttle control actuator is replaced. Refer to EC19, "IDLE AIR VOLUME LEARNING : Special Repair Requirement".

EM-28

INTAKE MANIFOLD < ON-VEHICLE REPAIR > â&#x20AC;˘ Install the quick connector as follows: - Make sure no foreign substances are deposited in and around the fuel tube and quick connector and that A there is no damage. - Align the center to insert the quick connector straight onto the fuel tube. - Insert the fuel tube until a click is heard. EM - Install the quick connector cap on the quick connector joint. Align the arrow mark on the quick connector cap to the upper side. - Install the fuel hose into the hose clamp. C

E PBIC0662E

INSPECTION AFTER INSTALLATION Make sure there is no fuel leakage at connections as follows: 1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections. 2. Start the engine and rev it up and check for fuel leaks at connections. CAUTION: Do not touch engine immediately after stopping as engine is extremely hot. NOTE: Use mirrors for checking on connections out of the direct line of sight.

EM-29

EXHAUST MANIFOLD AND THREE WAY CATALYST < ON-VEHICLE REPAIR >

EXHAUST MANIFOLD AND THREE WAY CATALYST Removal and Installation

INFOID:0000000004173770

AWBIA0744GB

Exhaust manifold heat shield (RH)

Gaskets

Heated oxygen sensor 2 (bank 1)

Three way catalyst (manifold) (bank 1)

Three way catalyst (manifold) (bank 2) 8.

Heated oxygen sensor 2 (bank 2)

Exhaust manifold (LH)

10. Air fuel ratio (A/F) sensor 1 (bank 2)

11.

Air fuel ratio (A/F) sensor 1 (bank 1)

Exhaust manifold heat shield (LH)

REMOVAL WARNING:

EM-30

Exhaust manifold (RH)

EXHAUST MANIFOLD AND THREE WAY CATALYST < ON-VEHICLE REPAIR > • Perform the work when the exhaust and cooling system have completely cooled down. • When removing the front and rear engine mounting through bolts and nuts, lift the engine up slightly A for safety. For engine slingers, refer to EM-96, "Removal and Installation". 1. Remove engine and CVT assembly. Refer to EM-96, "Removal and Installation". 2. Remove the RH and LH three way catalyst supports. EM 3. Remove heated oxygen sensor 2 (bank 1), heated oxygen sensor 2 (bank 2), air fuel ratio (A/F) sensor 1 (bank 1) and air fuel ratio (A/F) sensor 1 (bank 2). a. Remove harness connector of each sensor, and disconnect the harness from the bracket and middle C clamp. b. Remove both heated oxygen sensors and air fuel ratio (A/F) sensors using Tool. D

Tool numbers

4. 5. 6.

: KV10114400 (J-38365) : — (J-44626)

CAUTION: • Be careful not to damage heated oxygen sensors or air fuel ratio (A/F) sensors. • Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor. Remove exhaust manifold and three way catalyst heat shields with power tool. Remove the three way catalyst (manifold) (bank 1) and three way catalyst (manifold) (bank 2) by loosening the bolts first and then removing the nuts and through bolts. Remove the exhaust manifolds RH (A) and LH (B). Loosen the exhaust manifold nuts in the order as shown.

: Front I

J ALBIA0235ZZ

ALBIA0236ZZ

INSPECTION AFTER REMOVAL Surface Distortion • Use a reliable straightedge and feeler gauge to check the flatness of the exhaust manifold mating surfaces. Limit

: 0.3 mm (0.012 in)

PBIC1173E

EM-31

EXHAUST MANIFOLD AND THREE WAY CATALYST < ON-VEHICLE REPAIR > INSTALLATION Installation is in the reverse order of removal. • Install the exhaust manifold nuts in the order as shown RH (A) and LH (B). : Front

ALBIA0237ZZ

ALBIA0238ZZ

CAUTION: • Before installing a heated oxygen sensor or air fuel ratio (A/F) sensor, clean the exhaust manifold threads using the oxygen sensor thread cleaner tool, and apply anti-seize lubricant. Tool numbers

: :

— —

(J-43897-18) (J-43897-12)

• Do not over-tighten the air fuel ratio (A/F) sensor or heated oxygen sensors. Doing so may cause damage. Tool numbers

: KV10114400 (J-38365) : — (J-44626)

EM-32

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR >

OIL PAN AND OIL STRAINER

Removal and Installation

INFOID:0000000004173771

AWBIA0577GB

Oil pan baffle

O-ring

Oil pressure switch

Oil cooler gasket

Oil cooler

Oil cooler connection

Oil filter

Lower oil pan

10. Oil strainer

11. Rear plate cover

Gasket

12. Upper oil pan

REMOVAL

WARNING: â&#x20AC;˘ You should not remove the oil pan until the exhaust system and cooling system have completely cooled off. â&#x20AC;˘ When removing the front and rear engine through bolts and nuts, lift the engine up slightly for safety. For engine slingers, refer to EM-96, "Removal and Installation". CAUTION: When removing the upper oil pan from the engine, first remove the crankshaft position sensor (POS). Be careful not to damage sensor edges or signal plate teeth. 1. Remove the front RH wheel and tire using power tool. 2. Disconnect the battery negative terminal. 3. Remove the oil dipstick. 4. Drain the engine coolant. Refer to CO-10, "Changing Engine Coolant". 5. Remove the engine undercover. 6. Remove the RH inner fender splash shield. 7. Remove the drive belt. Refer to EM-14, "Removal and Installation". 8. Remove the front exhaust tube. Refer to EX-5, "Removal and Installation". 9. Remove coolant pipe bolts. 10. Remove the A/C compressor with piping attached, and position it out of the way securely with wire. CAUTION: Do not pull on or crimp the A/C lines and hoses. 11. Disconnect the coolant lines from the engine oil cooler and plug them to prevent coolant loss.

EM-33

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > 12. Remove the oil filter and engine oil cooler from the upper oil pan. 13. Remove the oil pressure switch/sensor, and the crankshaft position sensor (POS) from the upper oil pan. 14. Remove the front drive shaft (RH). Refer to FAX-11, "Removal and Installation (Right Side)". 15. Disconnect the heated oxygen sensors and air flow ratio (A/F) sensors and remove the two catalytic convertors from the exhaust manifolds using power tool. Refer to EM-30, "Removal and Installation". 16. Remove the rear cover plate from the upper oil pan.

SEM717G

17. Loosen the lower oil pan bolts using power tool in order as shown. Remove the lower oil pan.

WBIA0258E

Insert Tool between the lower oil pan and the upper oil pan. Tool number

: KV10111100 (J-37228)

â&#x20AC;˘ Be careful not to damage the mating surface. â&#x20AC;˘ Do not insert a screwdriver, this will damage the mating surfaces. Slide (2) the Tool by tapping (1) its side with a hammer to remove the lower oil pan from the upper oil pan. WBIA0566E

18. Remove the four upper oil pan to transaxle bolts.

SEM469G

EM-34

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > 19. Remove the upper oil pan. a. Loosen the bolts in the order as shown, using power tool.

C LBIA0358E

b. c.

Insert an appropriate size tool into the notch (1) of the upper oil pan as shown. Pry off the upper oil pan by moving the tool up and down (2) as shown.

G SEM155F

20. Remove the O-ring seals from the bottom of the cylinder block and oil pump housing. Use new O-rings for installation.

WBIA0327E

21. Remove front cover gasket and rear oil seal retainer gasket. 22. Remove the oil strainer.

N WBIA0328E

EM-35

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > 23. If re-installing the original oil pan, remove the old sealant from the mating surfaces using a scraper. • Also remove the old sealant from mating surface of the cylinder block. • Remove the old sealant from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off the old sealant.

MEM108A

INSPECTION AFTER REMOVAL Clean oil strainer if any object is attached.

INSTALLATION CAUTION: Wait at least 30 minutes before refilling the engine with oil. 1. Install oil strainer and tighten bolt to specified torque. Refer to EM-33, "Removal and Installation". 2.

Apply Genuine Silicone RTV Sealant or equivalent, to the front cover gasket and the rear oil seal retainer gasket as shown. Refer to GI-15, "Recommended Chemical Products and Sealants".

SEM964E

Install the front cover gasket and rear oil seal retainer gasket as shown.

WBIA0328E

Apply a bead of sealant to the cylinder block mating surface of the upper oil pan to a limited portion as shown. • Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI15, "Recommended Chemical Products and Sealants". • Be sure the sealant is applied to a limited portion as shown, and the sealant is 4.0 - 5.0 mm (0.157 - 0.197 in) or 4.5 - 5.5 mm (0.177 - 0.217 in) wide. • Attaching should be done within 5 minutes after coating.

SEM185FA

EM-36

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > A

C SEM159F

Install new O-rings on the cylinder block and oil pump body. E

G WBIA0327E

Install the upper oil pan. • Tighten upper oil pan bolts in the order as shown. • Wait at least 30 minutes before refilling the engine with oil.

LBIA0359E

Install the four upper oil pan to transaxle bolts. L

N SEM469G

Apply a continuous bead of sealant to the lower oil pan. • Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI15, "Recommended Chemical Products and Sealants". • Be sure the sealant is 4.5 - 5.5 mm (0.177 - 0.217 in) wide. • Installation must be done within 5 minutes after applying sealant.

SEM159F

EM-37

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > 9.

Install the lower oil pan. Tighten the lower oil pan bolts in order as shown. • Wait at least 30 minutes before refilling the engine with oil.

WBIA0261E

10. Install rear cover plate.

SEM717G

11. Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION • Start the engine and check for leaks. Refer to LU-7, "Inspection". • Inspect the engine oil level. Refer to LU-7, "Inspection".

EM-38

IGNITION COIL < ON-VEHICLE REPAIR >

IGNITION COIL

Exploded View

INFOID:0000000004335586

I AWBIA0203GB

Ignition coil

Rocker cover (LH)

Spark plug

Rocker cover (RH)

Removal and Installation LH

INFOID:0000000004173772

REMOVAL 1. 2. 3.

Remove engine room cover. Disconnect ignition coil connector. Remove the ignition coil. CAUTION: Never shock ignition coil.

INSTALLATION Installation is in the reverse order of removal.

Removal and Installation RH

INFOID:0000000004335585

REMOVAL 1. 2. 3.

Remove the intake manifold collector. Refer to EM-24, "Removal and Installation". Disconnect ignition coil connector. Remove the ignition coil. CAUTION: Never shock ignition coil.

INSTALLATION Installation is in the reverse order of removal.

EM-39

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR >

FUEL INJECTOR AND FUEL TUBE Exploded View

INFOID:0000000004363698

JPBIA2526GB

Fuel feed hose

Quick connector cap

Fuel tube

O-ring

Fuel damper

Fuel damper cap

Clip

O-ring (black)

Fuel injector

10. O-ring (green) A.

Refer to installation

CAUTION: Never remove or disassemble parts unless instructed.

Removal and Installation

INFOID:0000000004363699

REMOVAL WARNING: • Put a “CAUTION: FLAMMABLE” sign in the workshop. • Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. • Never smoke while servicing fuel system. Keep open flames and sparks away from the work area. • To avoid the danger of being scalded, never drain engine coolant when engine is hot. 1. Remove engine cover. 2. Release the fuel pressure. Refer to EC-559, "Inspection". 3. Remove front wiper arm and extension cowl top. Refer to WW-92, "Exploded View" and EXT-17, "Exploded View".

EM-40

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > 4. Remove the electric throttle control actuator bolts in the reverse order as shown and remove the electric throttle control actuator. CAUTION: • Handle carefully to avoid any shock to the electric throttle control actuator. • Do not disassemble.

C SEM711G

5. 6. a. b.

i. ii.

Remove intake manifold collector. Refer to EM-24, "Removal and Installation". When separating fuel feed hose and fuel tube connection, disconnect quick connector as follows: Remove quick connector cap from quick connector. Disconnect quick connector from fuel tube as follows: CAUTION: Disconnect quick connector by using the quick connector release (commercial service tool: J45488), not by picking out retainer tabs. With the sleeve side of quick connector release facing to quick connector, install the quick connector release onto fuel tube. Insert the quick connector release (A) into quick connector (2) until sleeve (B) contacts and goes no further. Hold quick connector release on that position. C

: Insert and retain

CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. iii. Draw and pull out quick connector straight from fuel tube (1). JPBIA0033ZZ CAUTION: • Pull quick connector (E) holding position (D) as shown in the figure. • Never pull with lateral force applied. O-ring inside quick connector may be damaged. • Prepare container and cloth beforehand as fuel will leakage out. • Avoid fire and sparks. • Keep parts away from heat source. Especially, be careful when welding is performed around them. • Never expose parts to battery electrolyte or other acids. • Never bend or twist connection between quick connector and fuel feed hose (with damper) during installation/removal. • To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or something similar.

P JPBIA0035ZZ

Disconnect harness connector from fuel injector.

EM-41

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > 8. Loosen bolts in reverse order as shown, and remove fuel tube and fuel injector assembly. : Engine front

CAUTION: Never tilt fuel tube, or remaining fuel in pipes may flow out from pipes.

JPBIA1715ZZ

9. a.

Remove fuel injector from fuel tube as follows: Open and remove clip (1). 3

: O-ring (green)

: O-ring (black)

: Installed condition

: Clip groove

Remove fuel injector (2) from fuel tube (5) by pulling straight. CAUTION: • Be careful with remaining fuel that may go out from fuel tube. • Be careful not to damage injector nozzle during removal. • Never bump or drop fuel injector. • Never disassemble fuel injector. 10. Remove fuel damper from fuel tube.

JPBIA1958ZZ

INSTALLATION 1. a.

b. c.

Install fuel damper as follows: Install new O-ring (2) to fuel tube (1) as shown. When handling new O-ring, be careful of the following caution: CAUTION: • Handle O-ring with bare hands. Never wear gloves. • Lubricate O-ring with new engine oil. • Never clean O-ring with solvent. • Check that O-ring and its mating part are free of foreign material. • When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube. • Insert new O-ring straight into fuel tube. Never twist it. Install spacer (3) to fuel damper (4). Insert fuel damper straight into fuel tube. CAUTION: • Insert straight, checking that the axis is lined up. • Never pressure-fit with excessive force. Reference value

: 130 N (13.3 kg, 29.2 lb)

• Insert fuel damper until (B) is touching (A) of fuel tube. Tighten bolts evenly in turn. • After tightening bolts, check that there is no gap between fuel damper cap (5) and fuel tube. Install new O-rings to fuel injector paying attention to the following. CAUTION: • Upper and lower O-ring are different. Be careful not to confuse them.

EM-42

JPBIA0316ZZ

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > Fuel tube side Nozzle side

: Black : Green

• • • • •

3. a.

Handle O-ring with bare hands. Never wear gloves. EM Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Check that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to C twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube. • Insert O-ring straight into fuel injector. Never decenter or twist it. D Install fuel injector to fuel tube as follows: Insert clip (3) into clip groove (F) on fuel injector (5). 2

: O-ring (black)

: O-ring (green)

• Insert clip so that protrusion (E) of fuel injector matches cutout (C) of clip. CAUTION: • Never reuse clip. Replace it with new one. • Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube (1) with clip attached. • Insert it while matching it to the axial center. • Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip. • Check that fuel tube flange (G) is securely fixed in flange fixing groove (D) on clip. Check that installation is complete by checking that fuel injector does not rotate or come off. • Check that protrusions of fuel injectors and fuel tubes are aligned with cutouts of clips after installation.

JPBIA1959ZZ

Install fuel tube and fuel injector assembly to intake manifold. CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts. • Tighten bolts in two steps in numerical order as shown in the figure.

: Engine front

1st step 2nd step

: 10.1 N·m (1.0 kg-m, 7 ft-lb) : 22.0 N·m (2.2 kg-m, 16 ft-lb)

O JPBIA1715ZZ

5. 6. 7. a. b. c.

Connect fuel injector harness. Install intake manifold collector. Refer to EM-24, "Removal and Installation". Connect quick connector between fuel feed hose and fuel tube connection with the following procedure: Check no foreign substances are deposited in and around fuel tube and quick connector, and no damage on them. Thinly apply new engine oil around fuel tube from tip end to spool end. Align center to insert quick connector straightly into fuel tube.

EM-43

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > • Insert quick connector (1) to fuel tube until top spool (2) is completely inside quick connector, and 2nd level spool (3) exposes right below quick connector. B

: Fitted condition : Upright insertion

d. e.

f. 8.

CAUTION: • Hold (A) position as shown in the figure when inserting fuel tube into quick connector. • Carefully align center to avoid inclined insertion to preJPBIA0275ZZ vent damage to O-ring inside quick connector. • Insert until you hear a “click” sound and actually feel the engagement. • To avoid misidentification of engagement with a similar sound, be sure to perform the next step. Pull quick connector by hand holding position. Check it is completely engaged (connected) so that it does not come out from fuel tube. Install quick connector cap (3) to quick connector. 1

: Fuel feed hose

: Fuel tube

: Upper view

• Install quick connector cap with arrow (A) on surface facing in direction of quick connector (fuel feed hose side). CAUTION: If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again. Secure fuel feed hose to clamp of quick connector cap. Installation is in the reverse order of removal.

Inspection

JPBIA0039ZZ

INFOID:0000000004363700

INSPECTION AFTER INSTALLATION Check on Fuel Leakage

Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there are no fuel leakage at connection points. NOTE: Use mirrors for checking at points out of clear sight. Start the engine. With engine speed increased, check again that there are no fuel leakage at connection points. CAUTION: Never touch the engine immediately after stopped, as the engine becomes extremely hot.

EM-44

ROCKER COVER < ON-VEHICLE REPAIR >

ROCKER COVER

Exploded View

INFOID:0000000004335631

AWBIA0217ZZ

Rocker cover (RH)

Rocker cover gasket (RH)

Rocker cover (LH)

Follow installation procedure

Rocker cover gasket (LH) Front

Removal and Installation LH

INFOID:0000000004173774

REMOVAL

1. 2. 3. 4.

Remove the engine cover, using power tool. Remove front air duct. Remove blow by hose from rocker cover. Remove camshaft position sensor. CAUTION: • Handle carefully to avoid dropping and shocks. • Do not disassemble. • Do not allow metal powder to adhere to magnetic part at sensor tip (A). • Do not place sensors in a location where they are exposed to magnetism.

O ALBIA0258ZZ

5. 6.

Disconnect the ignition coil connectors. Remove the ignition coils. Refer to EM-39, "Removal and Installation LH". CAUTION: Never shock ignition coils.

EM-45

ROCKER COVER < ON-VEHICLE REPAIR > 7. Remove LH rocker cover bolts from cylinder head as shown. : Front

AWBIA0702ZZ

INSTALLATION Installation is in the reverse order of removal. • Apply sealant to the areas on the front corners using Tool. • Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-15, "Recommended Chemical Products and Sealants". Tool number

: WS39930000 (

—

)

PBIC2474E

• Tighten the rocker cover bolts in two steps in the order as shown. : Front Rocker cover bolts Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb) Step 2 : 8.33 N·m (0.85 kg-m, 74 in-lb) AWBIA0703ZZ

Removal and Installation RH

INFOID:0000000004335632

REMOVAL 1. 2. 3.

Remove the engine cover, using power tool. Disconnect the mass air flow sensor electrical connector and remove the air cleaner assembly and air intake tubes. Refer to EM-23, "Removal and Installation". Remove the intake manifold collector using power tool. Remove gasket and the electric throttle control actuator. Refer to EM-27, "Removal and Installation".

EM-46

ROCKER COVER < ON-VEHICLE REPAIR > 4. Remove ignition coils. Refer to EM-39, "Removal and Installation RH". CAUTION: Never shock ignition coils. 5. Remove camshaft position sensor. CAUTION: • Handle carefully to avoid dropping and shocks. • Do not disassemble. • Do not allow metal powder to adhere to magnetic part at sensor tip (A). • Do not place sensors in a location where they are exposed to magnetism.

D ALBIA0258ZZ

Remove RH rocker cover bolts from cylinder head as shown. : Front

H AWBIA0704ZZ

INSTALLATION I

Installation is in the reverse order of removal. • Apply sealant to the areas on the front corners using Tool. • Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-15, "Recommended Chemical Products and Sealants". Tool number

: WS39930000 (

—

) K

PBIC2474E

• Tighten the rocker cover bolts in two steps in the order as shown.

EM-47

ROCKER COVER < ON-VEHICLE REPAIR > : Front Rocker cover bolts Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb) Step 2 : 8.33 N·m (0.85 kg-m, 74 in-lb)

AWBIA0705ZZ

EM-48

FRONT TIMING CHAIN CASE < ON-VEHICLE REPAIR >

FRONT TIMING CHAIN CASE

Removal and Installation

INFOID:0000000004173775

I AWBIA0674GB

Gasket LH

Gasket RH

IVT control valve cover RH (bank 1)

IVT valve RH

IVT valve LH

Water pump cover

IVT control valve cover LH (bank 2)

Crankshaft pulley

Front oil seal

Follow installation procedure

10. Front timing chain case

NOTE: • This section describes procedures for removal/installation procedure of the front timing chain case and timing chain related parts without removing the oil pan (upper) from the vehicle. • When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain related parts, and rear timing chain case in this order, and install in reverse order of removal. Refer to EM-57. • Refer to EM-57 for component parts location.

4. 5. 6. 7. 8. 9.

REMOVAL 1. 2. 3.

Remove engine cover using power tool. Release fuel pressure. Refer to EC-559, "Inspection". Remove the air cleaner case, mass air flow sensor and air cleaner to electric throttle control actuator tube. Refer to EM-23, "Removal and Installation". Remove the engine coolant reservoir. Refer to CO-13, "Removal and Installation". Remove the cowl top and cowl top extension. Refer to EXT-18, "Removal and Installation". Remove the front RH wheel and tire using power tool. Remove the engine undercover. Remove the RH inner fender splash shield. Remove the drive belt, idler pulley and drive belt auto-tensioner. Refer to EM-14, "Removal and Installation" and EM-15, "Removal and Installation of Drive Belt Auto-tensioner".

EM-49

FRONT TIMING CHAIN CASE < ON-VEHICLE REPAIR > 10. Recover the A/C system R134a and remove the A/C compressor. Refer to HA-34, "Collection and Charge". 11. Remove engine oil cooler pipe bolts. 12. Remove the power steering oil pump and reservoir tank with lines attached and position them aside. Refer to ST-25, "Removal and Installation" 13. Remove the generator. Refer to CHG-21, "Removal and Installation". 14. Disconnect the engine harness and position aside. 15. Remove the A/C low-pressure flexible hose. Refer to HA-48, "LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation for Low-Pressure Flexible Hose". 16. Support the engine and remove the RH engine insulator, mount and bracket. Refer to EM-96, "Removal and Installation". 17. Remove the water pump cover, using Tool. Tool number

: KV10111100 (J-37228)

ALBIA0248ZZ

18. 19. 20. 21. a.

Remove the starter motor. Refer to STR-15, "Removal and Installation". Disconnect valve timing control harness connector. Remove the intake manifold collector. Refer to EM-24, "Removal and Installation". Remove the Bank 1 (RH) (A) and Bank 2 (LH) (B) IVT covers. Loosen the IVT cover bolts in the reverse order as shown. CAUTION: The shaft in the cover is inserted into the center hole of the intake camshaft sprocket. Remove the cover by pulling straight out until the cover disengages from the camshaft sprocket. • A: Bank 1 (Conventional RH bank) • B: Bank 2 (Conventional LH bank) • C: Dowel pin hole

AWBIA0720ZZ

Shaft is engaged with intake side camshaft sprocket center hole on inside. Pull straight out so as not to tilt until the joint is disengaged.

EM-50

FRONT TIMING CHAIN CASE < ON-VEHICLE REPAIR > • The mating surface of magnet retarder (2) may be fitted with the exhaust side camshaft sprocket via engine oil. Open valve A timing control cover (1) carefully. • If the mating surface of the magnet retarder is fitted with the camshaft sprocket, open the cover within the range that the EM load is not applied to the harness. Remove it so as to prevent magnet retarder from dropping. CAUTION: • Be careful not to damage magnet retarder. C • When carrying valve timing control cover, face the magnet retarder side up to prevent the cover from falling from JPBIA0042ZZ magnet retarder. D • Never remove magnet retarder from valve timing control cover. (Disassembly prohibited) 22. Remove the rocker covers as necessary. Refer to EM-45, "Removal and Installation LH" orEM-46, "Removal and Installation RH". E NOTE: Necessary only when removing secondary timing chains. 23. Obtain compression TDC of No. 1 cylinder as follows: a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.

JMBIA1135GB

Check that intake and exhaust camshaft lobes on No. 1 cylinder (right bank of engine) are located as shown. • If not, turn the crankshaft one revolution (360°) and align as shown.

L SEM418G

24. Lock the drive plate (CVT), using Tool attached to the starter bolt hole. : KV10117700 (J-44716)

CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting the Tool.

Tool number

P WBIA0580E

EM-51

FRONT TIMING CHAIN CASE < ON-VEHICLE REPAIR > 25. Remove the crankshaft pulley as follows: a. Loosen crankshaft pulley bolt using Tool and locate bolt seating surface at 10 mm (0.39 in) from its original position. Tool number

: KV10109300

WBIA0386E

Position a pulley puller at recess hole of crankshaft pulley to remove crankshaft pulley. CAUTION: Do not use a puller claw on crankshaft pulley periphery.

EMQ0477D

26. Remove the lower oil pan. Loosen the lower oil pan bolts using power tool in order as shown.

WBIA0258E

Insert Tool between the lower oil pan and the upper oil pan. Tool number

: KV10111100 (J-37228)

• Be careful not to damage the mating surface. • Do not insert a screwdriver, this will damage the mating surfaces. Slide (2) the Tool by tapping (1) its side with a hammer to remove the lower oil pan from the upper oil pan. WBIA0566E

27. Remove upper oil pan bolts as shown.

WBIA0259E

EM-52

FRONT TIMING CHAIN CASE < ON-VEHICLE REPAIR > 28. 29. 30. a.

Temporarily install lower oil pan. Support front of engine with a suitable jack. Remove the front timing chain case. Loosen the front timing chain case bolts in the order as shown.

D ALBIA0250ZZ

b. c.

Insert the appropriate size tool into the notch (A) at the top of the front timing chain case as shown. Pry off the case by moving the suitable tool (B) as shown. • Cut liquid gasket for removal using Tool. CAUTION: • Do not use a screwdriver or similar tool. • After removal, handle carefully so it does not bend, or warp under a load.

H ALBIA0251ZZ

31. Remove the front oil seal from the front timing chain case using a suitable tool. CAUTION: Do not damage the front cover.

SEM829E

32. Use a scraper to remove all of the old Silicone RTV Sealant from the front timing chain case and opposite mating surfaces. CAUTION: Do not damage the mating surfaces.

O SEM428G

INSTALLATION

EM-53

FRONT TIMING CHAIN CASE < ON-VEHICLE REPAIR > 1. Install dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.

PBIC1101E

Install the new front oil seal on the front timing chain case. Apply new engine oil to the oil seal edges. NOTE: Install it so that each seal lip is oriented as shown.

SEM715A

Install the new front oil seal so that it becomes flush with the face with front timing chain case using suitable drift. CAUTION: Press fit straight and avoid causing burrs or tilting the oil seal. NOTE: Make sure the garter spring is in position and seal lip is not inverted.

PBIC0790E

Apply Silicone RTV Sealant to front timing chain case as shown. • Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI15, "Recommended Chemical Products and Sealants". • Before installation, wipe off the protruding sealant. • C: 2.6 - 3.6 mm (0.102 - 0.142 in) dia.

ALBIA0252ZZ

EM-54

FRONT TIMING CHAIN CASE < ON-VEHICLE REPAIR > 4.

Install dowel pin on the rear timing chain case into dowel pin hole in front timing chain case. A

Loosely install the front timing chain case bolts. EM

Bolt position Bolt diameter 1, 2 : 8 mm (0.31 in) 3 – 22 : 6 mm (0.24 in) 6.

Tighten the front timing chain case bolts in the order as shown. • Retighten the front timing chain case bolts in the order as shown. Bolt position Tightening specification 1, 2 : 28.5 N·m (2.9 kg-m, 21 ft-lb) 3 – 22 : 12.8 N·m (1.3 kg-m, 9 ft-lb)

7. 8. 9. 10. a.

D AWBIA0708ZZ

Remove lower oil pan. Install upper oil pan bolts. Refer to EM-33, "Removal and Installation". Install lower oil pan. Refer to EM-33, "Removal and Installation". Install IVT control valve covers. Install new seal rings (1) in shaft grooves. CAUTION: When replacing seal rings, replace all rings with new ones on both RH and LH IVT control valve covers.

J JPBIA0060ZZ

To check the joint between dowel pins and dowel pin holes, check the looseness in the axle direction by pushing the circumferential looseness (between dowel pins and dowel holes) by twisting in the circumferential direction. • A :Mating surface of magnet retarded • B :Moves slightly • C :Not shaken CAUTION: Always perform this procedure when removing because the gap between dowel pins and dowel pin holes may not be caused on purpose. Install IVT covers with a new gasket to front timing chain case. • 1: Valve timing control cover • 2: Magnet retarder CAUTION: • Never face magnet retarder side down to prevent magnet retarder from dropping. • Check the mating surface of the magnet retarder and the drum of the exhaust side camshaft sprocket for foreign materials. • Align center of both shaft holes of the shaft and the intake side of the intake camshaft sprocket, and then insert them. • Be careful not to drop the seal ring from the shaft groove.

EM-55

JPBIA0062ZZ

JPBIA0042ZZ

FRONT TIMING CHAIN CASE < ON-VEHICLE REPAIR > • When setting the valve timing control cover in position by hand, if valve timing control cover is not centered with the valve timing case, the dowel pin of the magnet retarder may not be aligned with the dowel pin holes of the cover. In this case, return to step "b". d. e.

Being careful not to move seal ring from the installation groove, align the dowel pins on the front timing chain case with the holes to install valve timing control covers. Tighten bolts in the numerical order as shown. IVT cover torque

11.3 N·m (1.2 kg-m, 8 ft-lb)

• A: Bank 1 (Conventional RH bank) • B: Bank 2 (Conventional LH bank) • C: Dowel pin hole

AWBIA0720ZZ

11. Apply liquid gasket and install the water pump cover. • Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-15, "Recommended Chemical Products and Sealants". 12. Install crankshaft pulley and tighten the bolt in two steps. • Lubricate thread and seat surface of the bolt with new engine oil. • Apply a paint mark for the second step of angle tightening. Step 1 Step 2

: 44 N·m (4.5 kg-m, 32 ft-lb) : 84° - 90° degrees clockwise

Tool Number

: KV10112100 (BT-8653-A) SEM531G

13. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly. 14. Installation of the remaining components is in reverse order of removal.

EM-56

TIMING CHAIN < ON-VEHICLE REPAIR >

TIMING CHAIN

Component

INFOID:0000000004173776

I AWBIA0676GB

Timing chain tensioner

Internal chain guide

Timing chain tensioner

Camshaft sprocket (EXH)

Timing chain (secondary)

Timing chain (primary)

Camshaft sprocket (INT)

Timing chain (secondary)

10. Camshaft sprocket (EXH)

11. Slack guide

12. Crankshaft sprocket

13. Rear timing chain case

14. Tension guide

15. O-ring

• Refer to EM-4, "Precaution for Liquid Gasket". • Before installation, wipe off any protruding sealant. CAUTION: • After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons. • When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. • Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets, camshaft brackets, and crankshaft pulley. • Before disconnecting fuel hose, release fuel pressure. Refer to EC-559, "Inspection". • Before removing the upper oil pan, remove the crankshaft position sensor (POS). • Be careful not to damage sensor edges. • Do not spill engine oil or coolant on drive belts.

Removal

INFOID:0000000004173777

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

Remove front timing chain cover. Refer to EM-49, "Removal and Installation". Disconnect the power brake booster vacuum hose. Disconnect the electric throttle control actuator. Disconnect the coolant hoses at the electric throttle control actuator. Disconnect the PCV hose. Disconnect the EVAP canister purge volume control solenoid vacuum hose.

EM-57

TIMING CHAIN < ON-VEHICLE REPAIR > 7. Remove the engine oil dipstick. 8. Remove the rocker covers. Refer to EM-45, "Removal and Installation LH". 9.

Place paint marks on the timing chain and sprockets to indicate the correct position of the components for installation. 10. Remove the internal chain guide (1), and slack guide (2).

JPBIA0086ZZ

11. Remove the timing chain tensioner. a. Pull lever down and release plunger stopper tab. Plunger stopper tab can be pushed up to release (coaxial structure with lever).

SEM732G

Insert stopper pin into tensioner body hole to hold lever, and keep the tab released. An Allen wrench [1.2 mm (0.047 in)] is used for a stopper pin as an example. c. Insert plunger into tensioner body by pressing the slack side chain guide. d. Keep the slack side chain guide pressed and hold it by pushing the stopper pin through the lever hole and body hole. e. Remove the bolts and remove the timing chain tensioner. 12. Remove primary timing chain and crankshaft sprocket. CAUTION: After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons.

EM-58

SEM733G

TIMING CHAIN < ON-VEHICLE REPAIR > 13. Attach a suitable stopper pin (2) to the right and left camshaft chain tensioners (1) (for secondary timing chains). • A: Bank 1 • B: Bank 2 a. Insert metal or resin plate [0.5 mm (0.020 in)] into guide between timing chain and chain tensioner plunger. Remove cam sprocket and secondary timing chain with timing chain removed from guide groove. CAUTION: Chain tensioner plunger can move while stopper pin is inserted in tensioner. Plunger can come out of tensioner when timing chain is removed. Use caution during removal. • Handle the camshaft sprockets as assemblies. 14. Remove the intake and exhaust camshaft sprocket bolts. • Apply paint to the timing chain and camshaft sprockets for alignment during installation. • Secure the hexagonal portion of the camshaft using a wrench to loosen the bolts.

C JPBIA0087ZZ

G KBIA4379J

CAUTION: • Avoid impact or dropping the camshaft sprockets. Do not disassemble the camshaft sprockets (never loosen bolts (A) and (B) as shown).

JPBIA0096ZZ

15. Remove the chain tension guide. 16. Remove the rear timing chain case, if necessary. Refer to EM-66, "Removal and Installation". 17. Use a scraper to remove all of the old Silicone RTV Sealant from the front timing chain case and opposite mating surfaces. CAUTION: Do not damage the mating surfaces.

P SEM428G

EM-59

TIMING CHAIN < ON-VEHICLE REPAIR > 18. Remove all old Silicone RTV Sealant from all the bolt holes and bolts. CAUTION: Do not damage the threads or mating surfaces.

SEM161F

19. Remove the front oil seal from the front timing chain case using a suitable tool. CAUTION: Do not damage the front cover.

SEM829E

Inspection

INFOID:0000000004173778

Check for cracks and any excessive wear of the timing chain. Replace the timing chain as necessary.

Installation

INFOID:0000000004173779

NOTE: The figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, the components installed.

WBIA0280E

EM-60

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