2009 NISSAN TITAN Service Repair Manual by 163215

QUICK REFERENCE INDEX Edition: May 2008 A GENERAL INFORMATION Revision: November 2008 Publication No. SM9E-1A60U0 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 TM DLN FAX RAX FSU RSU SCS WT BR PB BRC ST STC SB SBC SR SRC VTL HA HAC INT IP SE ADP AP 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 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 Postioner Adjustable Pedal 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

This manual contains maintenance and repair procedure for the 2009 NISSAN TITAN. 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: TITAN

2009

QUICK REFERENCE CHART: TITAN Engine Tune-up Data

INFOID:0000000001711124

GENERAL SPECIFICATIONS Cylinder arrangement 3

V-8 3

5,552 (338.80)

Displacement cm (in ) Bore and stroke

mm (in)

98 x 92 (3.86 x 3.62)

Valve arrangement

DOHC

Firing order

1-8-7-3-6-5-4-2

Number of piston rings

Compression

Oil

Number of main bearings

Compression ratio

9.8:1

Compression pressure

kPa

(kg/cm2, psi)/rpm

Standard

1,520 (15.5, 220)/200

Minimum

1,324 (13.5, 192)/200

Differential limit between cylinders

98 (1.0, 14)/200

Cylinder number

SEM957C

Valve timing

PBIC0187E

Unit: degree a

244°

232°

-8°

60°

10°

54°

QUICK REFERENCE CHART: TITAN

2009

Front Wheel Alignment (Unladen*1)

INFOID:0000000001711125

Drive type

Camber Degree minute (decimal degree)

2WD

4WD

Minimum

-0° 57′ (-0.95°)

-0° 27′ (-0.45°)

Nominal

-0° 12′ (-0.20°)

0° 18′ (0.30°)

0° 33′ (0.55°)

1° 03′ (1.05°)

0° 45′ (0.75°) or less

Minimum

2° 15′ (2.25°)

1° 27′ (1.45°)

Nominal

3° 0′ (3.00°)

2° 12′ (2.20°)

Maximum

3° 45′ (3.75°)

2° 57′ (2.95°)

0° 45′ (0.75°) or less

13° 33′ (13.55°)

13° 0′ (13.00°)

Minimum

1.8 mm (0.07 in)

Nominal

2.8 mm (0.11 in)

Maximum

3.8 mm (0.15 in)

Minimum

0° 3′ (0.05°)

Nominal

0° 5′ (0.08°)

Maximum

0° 7′ (0.12°)

Maximum Cross camber

Caster Degree minute (decimal degree)

Cross caster Kingpin inclination (reference only) Degree minute (decimal degree)

SFA234AC

Distance (A − B) Total toe-in Angle (left plus right) Degree minute (decimal degree)

Wheel turning angle (full turn)

0° 7′ (0.12°)

Inside Degree minute (decimal degree)

34° 30′ – 38° 30′ * (34.50° – 38.50°)

34° 56′ – 38° 56′ *4 (34.93° – 38.93°)

Outside Degree minute (decimal degree)

30° 58′ – 34° 58′ *3 (30.97° – 34.97°)

31° 01′ – 35° 01′ *5 (31.02° – 35.02°)

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Target value 37° 30′ (37.50°) *3: Target value 33° 58′ (33.97°) *4: Target value 37° 56′ (37.93°) *5: Target value 34° 01′ (34.02°)

General Specification (Rear) Suspension type Shock absorber type

INFOID:0000000001711127

Rigid axle with semi-elliptic leaf spring Double-acting hydraulic

QUICK REFERENCE CHART: TITAN

2009

Wheelarch Height (Unladen*1)

INFOID:0000000001711126

Unit: mm (in)

LEIA0085E

Drive type

2WD

Wheel base

Short

Rear wheel arch height (Hr)

Long

Short

4WD*3 Long

Short

Long

King Cab

Crew Cab

King Cab

Crew Cab

King Cab*2

Crew Cab*2

King Cab*2

Crew Cab*2

King Cab*2

Crew Cab*2

King Cab*2

Crew Cab*2

P265/ 70R18

912 (35.91)

914 (35.98)

912 (35.91)

914 (35.98)

949 (37.36)

951 (37.44)

949 (37.36)

951 (37.44)

949 (37.36)

951 (37.44)

949 (37.36)

951 (37.44)

P275/ 70R18

922 (36.30)

925 (36.42)

922 (36.30)

925 (36.42)

960 (37.80)

962 (37.87)

959 (37.76)

962 (37.87)

960 (37.80)

962 (37.87)

959 (37.76)

962 (37.87)

P275/ 60R20

917 (36.10)

919 (36.18)

917 (36.10)

920 (36.22)

955 (37.60)

957 (37.68)

954 (37.56)

957 (37.68)

955 (37.60)

957 (37.68)

954 (37.56)

957 (37.68)

P265/ 70R18

952 (3748)

954 (37.56)

950 (37.40)

951 (37.44)

991 (39.02)

994 (39.13)

989 (38.94)

991 (39.02)

993 (39.09)

989 (38.94)

991 (39.02)

P275/ 70R18

962 (37.87)

965 (37.99)

960 (37.80)

962 (37.87)

1002 (39.45)

1004 (39.53)

1000 (39.37)

1002 (39.45)

1001 (39.41)

1004 (39.53)

1000 (39.37)

1002 (39.45)

P275/ 60R20

957 (37.68)

959 (37.76)

955 (37.60)

956 (37.64)

996 (39.21)

999 (39.33)

995 (39.17)

996 (39.21)

998 (39.29)

995 (39.17)

996 (39.21)

Body Front wheel arch height (Hf)

4WD*2

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Without tow package. *3: With tow package.

Brake Specification

INFOID:0000000001711128

Unit: mm (in)

Front brake

Brake model Rotor outer diameter × thickness

Rear brake

CLZ31VC 350 × 30 (13.8 × 1.2)

Pad Length × width × thickness

111.0 × 73.5 × 11.88 (4.73 × 2.894 × 0.374)

Cylinder bore diameter (each)

51 (2.01)

Brake model

AD14VE

Rotor outer diameter × thickness Pad Length × width × thickness Cylinder bore diameter Control valve

Valve model

Brake booster

Booster model Diaphragm diameter

320 × 14 (12.6 × 0.6) 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335) 48 (1.89) Electric brake force distribution C215T 215 (8.46)

QUICK REFERENCE CHART: TITAN

2009

Brake Pedal

INFOID:0000000001711129

Brake pedal height (from dash panel top surface)

182.3 − 192.3 mm (7.18 − 7.57 in)

Depressed pedal height [under a force of 490 N (50 kg-f, 110 lb-f) with engine running]

More than 90.3 mm (3.55 in)

Clearance between stopper rubber and the threaded end of stop lamp switch and ASCD cancel switch

0.74 − 1.96 mm (0.029 − 0.077 in)

Pedal play

3 − 11 mm (0.12 − 0.43 in)

When equipped with adjustable pedal, the pedal must be in the forward most (closest to the floor) position for pedal height measurement.

Front Disc Brake

INFOID:0000000001711130

Brake model

CLZ31VC Standard thickness (new)

Brake pad

Disc rotor

11.88 mm (0.468 in)

Repair limit thickness

1.0 mm (0.039 in)

Standard thickness (new)

26.0 mm (1.024 in)

Repair limit thickness

24.5 mm (0.965 in)

Maximum uneven wear (measured at 8 positions) Runout limit (with it attached to the vehicle)

0.015mm (0.0006 in) 0.03 mm (0.001 in)

Rear Disc Brake

INFOID:0000000001711131

Brake model Brake pad

Disc rotor

AD14VE Standard thickness (new)

12.13 mm (0.478 in)

Repair limit thickness

1.0 mm (0.039 in)

Standard thickness (new)

14.0 mm (0.551 in)

Repair limit thickness

12.0 mm (0.472 in)

Maximum uneven wear (measured at 8 positions) Runout limit (with it attached to the vehicle)

0.015 mm (0.0006 in) 0.07 mm (0.003 in)

Fluids and Lubricants

INFOID:0000000001711132

Capacity (Approximate)

Description

Metric

US measure

Imp measure

Short wheelbase

105.8

28 gal

23 1/4 gal

Long wheelbase

140

37 gal

30 gal

With oil filter change

6.2

6 1/2 qt

5 1/2 qt

Without oil filter change

5.9

6 1/4 qt

5 1/4 qt

7.6

8 qt

6 3/4 qt

12.2

3 1/4 gal

2 5/8 gal

Automatic transmission fluid (ATF)

10.6

11 1/4 qt

9 3/8 qt

Rear final drive oil

2.01

4 1/4 pt

3 1/2 pt

Transfer fluid

2.0

2 1/8 qt

1 3/4 qt

Front final drive oil

1.6

3 3/8 pt

2 7/8 pt

Fuel

Engine oil Drain and refill

Dry engine (engine overhaul) Cooling system

With reservoir at MAX level

QUICK REFERENCE CHART: TITAN Description Power steering fluid (PSF)

2009

Capacity (Approximate) Metric 1.0

US measure

Imp measure

2 1/8 pt

1 3/4 pt

Brake fluid

—

Multi-purpose grease

—

Brake grease

—

1 1/4 gal

1 gal

1.54 ± 0.11 lb

6.8 fl oz

7.0 fl oz

Windshield washer fluid Air conditioning system refrigerant Air conditioning system oil

4.5 0.70 ± 0.05 kg 200 m

GENERAL INFORMATION

SECTION

GENERAL INFORMATION

CONTENTS

HOW TO USE THIS MANUAL ...................... 2

PRECAUTION .............................................. 25

HOW TO USE THIS MANUAL ............................ 2

PRECAUTIONS ................................................. 25

Description ................................................................ 2 Terms ........................................................................ 2 Units .......................................................................... 2 Contents .................................................................... 2 Relation between Illustrations and Descriptions ...... 3 Components .............................................................. 3

Description ...............................................................25 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" .....................25 Procedures without Cowl Top Cover .......................25 General Precautions ................................................25 Three Way Catalyst .................................................27 Precaution for Fuel (Unleaded Regular Gasoline Recommended) .......................................................27 Multiport Fuel Injection System or Engine Control System .....................................................................27 Hoses ......................................................................27 Engine Oils ..............................................................28 Air Conditioning .......................................................29

LIFTING POINT ................................................. 30

Pantograph Jack ......................................................30 Garage Jack and Safety Stand ................................30 2-Pole Lift ................................................................30

HOW TO FOLLOW TROUBLE DIAGNOSES ..... 5 Description ................................................................ 5 How to Follow Test Groups in Trouble Diagnosis...... 5 Key to Symbols Signifying Measurements or Procedures ..................................................................... 6

HOW TO READ WIRING DIAGRAMS ................ 8 Connector symbols ................................................... 8 Sample/wiring diagram -example- ............................. 9 Description .............................................................. 10

ABBREVIATIONS ..............................................12 Abbreviation List ...................................................... 12

TOW TRUCK TOWING ..................................... 32

TIGHTENING TORQUE OF STANDARD BOLTS ................................................................13

Tow Truck Towing ...................................................32 Vehicle Recovery (Freeing a stuck vehicle) ............33

Tightening Torque Table ......................................... 13

BASIC INSPECTION ................................... 34

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ................................................14

SERVICE INFORMATION FOR ELECTRICAL INCIDENT .......................................................... 34

Recommended Chemical Products and Sealants.... 14

FEATURES OF NEW MODEL ..................... 19

Work Flow ................................................................34 Control Units and Electrical Parts ............................34 How to Check Terminal ...........................................35 Intermittent Incident .................................................38 Circuit Inspection .....................................................41

IDENTIFICATION INFORMATION .....................19

CONSULT-III CHECKING SYSTEM ................. 46

TERMINOLOGY .................................................15 SAE J1930 Terminology List ................................... 15

Model Variation ....................................................... 19 Identification Number .............................................. 21 Dimensions ............................................................. 23 Wheels & Tires ........................................................ 24 Revision: November 2008

GI-1

Description ...............................................................46 Function and System Application ............................46 CONSULT-III Data Link Connector (DLC) Circuit....47 Wiring Diagram ........................................................48

2009 Titan

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

HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL Description

INFOID:0000000003788784

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

Terms

INFOID:0000000003788785

• 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:0000000003788786

• 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 Outer Socket Lock Nut

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

Standard Drive Shaft Installation Bolt

: 44.3 N·m (4.5 kg-m, 33 ft-lb)

Contents

INFOID:0000000003788787

• 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.

Revision: November 2008

GI-2

2009 Titan

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

Relation between Illustrations and Descriptions

INFOID:0000000003788788

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

SAIA0519E

Components

INFOID:0000000003788789

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.

Revision: November 2008

GI-3

2009 Titan

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

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. Outer shim cover

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

2: Rubber grease

: Brake fluid

Refer to GI section for additional symbol definitions.

SYMBOLS

SAIA0749E

Revision: November 2008

GI-4

2009 Titan

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

HOW TO FOLLOW TROUBLE DIAGNOSES

Description

INFOID:0000000003788790

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:0000000003788791

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.

Revision: November 2008

GI-5

2009 Titan

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

Key to Symbols Signifying Measurements or Procedures

INFOID:0000000003788792

SAIA1539E

Revision: November 2008

GI-6

2009 Titan

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

N SAIA1540E

Revision: November 2008

GI-7

2009 Titan

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

HOW TO READ WIRING DIAGRAMS Connector symbols

INFOID:0000000003788793

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

SAIA0257E

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

SGI363

Revision: November 2008

GI-8

2009 Titan

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

Sample/wiring diagram -example-

INFOID:0000000003788794

â&#x20AC;¢ For detail, refer to following GI-10, "Description". B

P JCAWA0005GB

Revision: November 2008

GI-9

2009 Titan

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

Description Number

INFOID:0000000003788795

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-65, "Electrical Units Location", PG-38, "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.

”.

• 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:

Revision: November 2008

GI-10

2009 Titan

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.

G 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

Revision: November 2008

GI-11

2009 Titan

ABBREVIATIONS < HOW TO USE THIS MANUAL >

ABBREVIATIONS Abbreviation List

INFOID:0000000003788796

The following ABBREVIATIONS are used: ABBREVIATION

DESCRIPTION

A/C

Air Conditioner

A/T

Automatic Transaxle/Transmission

ATF

Automatic Transmission Fluid

AWD

All wheel drive

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

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

Revision: November 2008

GI-12

2009 Titan

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:0000000003788797

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

kg-m

ft-lb

Hexagon flange bolt in-lb

6.0

8.0

M10

10.0

M12

12.0

1.25

4.6

—

M14

14.0

1.5

8.2

—

6.0

1.0

0.92

8.0

1.25

2.2

1.0

2.2

M10

10.0

1.5

1.25

M12

12.0

M14

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

—

6.6

—

100

—

1.1

—

2.9

—

2.9

—

4.6

—

5.6

—

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

Special parts are excluded.

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

P MGI044A

Revision: November 2008

GI-13

2009 Titan

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

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS Recommended Chemical Products and Sealants

INFOID:0000000003788798

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

Aftermarket Crossreference Part Nos.

Rear View Mirror Adhesive

Used to permanently remount rear view mirrors to windows.

999MP-AM000P

99998-50505

Permatex 81844

Anaerobic Liquid Gasket

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

999MP-AM001P

99998-50503

Permatex 51813 and 51817

High Performance Thread Sealant

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

999MP-AM002P

Permatex 56521

99998-50506 (Ultra Grey)

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

999MP-AM003P (Ultra Grey)

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

Nissan Canada Part No. (Canada)

Purpose

Gasket Maker 4

Nissan North America Part No. (USA)

Product Description

High Temperature, High Strength Thread Locking Sealant (Red)

Medium Strength Thread Locking Sealant (Blue)

Revision: November 2008

Threadlocker

Threadlocker (service tool removable)

–

999MP-AM004P

999MP-AM005P

GI-14

–

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

2009 Titan

TERMINOLOGY < HOW TO USE THIS MANUAL >

TERMINOLOGY

SAE J1930 Terminology List

INFOID:0000000003788799

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

Revision: November 2008

GI-15

2009 Titan

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

EGRT sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable read only memory

FEEPROM

***

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel 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

***

Exhaust gas recirculation temperature sensor EGR temperature sensor

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

Revision: November 2008

GI-16

2009 Titan

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

Revision: November 2008

GI-17

2009 Titan

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 system

WU-TWC system

***

Wide open throttle position switch

WOTP switch

Full switch

***: Not applicable

Revision: November 2008

GI-18

2009 Titan

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL >

FEATURES OF NEW MODEL

IDENTIFICATION INFORMATION Model Variation

INFOID:0000000003788800

Prefix and suffix designations: C Position

Character

2 3

Qualifier Body type

Definition B: King Cab

C: Crew Cab Engine

PK: VK56DE

A: 2WD SWB 4

G: 2WD LWB

Axle

N: 4WD SWB U: 4WD LWB

Drive

L: LH

R: XE 6

T: SE

Grade

U: OR (PRO-4X) V: LE

Transmission

N: RE5R05A (5A/T)

Model

P85: 2009 Titan

8 9

P85

10 11

E: EGI

Intake

M: FFV

N: Canada

Zone

Equipment

A: Standard

Option Codes

U: USA and Mexico

14 15 16

XXXXX

18 2WD Model

Body

Engine

Transmission

Destination

50-State VK56DE

RE5R05A (5A/T)

King Cab (SWB)

Canada

VK56DE FFV

Revision: November 2008

RE5R05A (5A/T)

50-State

GI-19

Grade

Model

BPKALRN-EUA

BPKALTN-EUA

BPKALVN-EUA

BPKALRN-ENA

BPKALTN-ENA

BPKALRN-MUA

BPKALTN-MUA

BPKALVN-MUA

2009 Titan

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL > Body

Engine

Transmission

Destination

50-State VK56DE

RE5R05A (5A/T)

Crew Cab (SWB)

Mexico

VK56DE FFV

RE5R05A (5A/T)

50-State

Grade

Model

CPKALRN-EUA

CPKALTN-EUA

CPKALVN-EUA

CPKALRN-EUA

CPKALTN-EUA

CPKALRN-MUA

CPKALTN-MUA

CPKALVN-MUA

Grade

Model

BPKNLRN-EUA

BPKNLTN-EUA

OR (PRO-4X)

BPKNLUN-EUA

BPKNLVN-EUA

BPKNLRN-ENA

BPKNLTN-ENA

OR (PRO-4X)

BPKNLUN-ENA

BPKNLVN-ENA

BPKNLRN-MUA

BPKNLTN-MUA

OR (PRO-4X)

BPKNLUN-MUA

BPKNLVN-MUA

CPKNLRN-EUA

4WD Model

Body

Engine

Transmission

Destination

50-State

VK56DE

RE5R05A (5A/T)

King Cab (SWB)

Canada

VK56DE FFV

RE5R05A (5A/T)

50-State

VK56DE

RE5R05A (5A/T)

Crew Cab (SWB)

Canada

Mexico

VK56DE FFV

RE5R05A (5A/T)

50-State

CPKNLTN-EUA

OR (PRO-4X)

CPKNLUN-EUA

CPKNLVN-EUA

CPKNLRN-ENA

CPKNLTN-ENA

OR (PRO-4X)

CPKNLUN-ENA

CPKNLVN-ENA

CPKNLVL-EUA

CPKNLRN-MUA

CPKNLTN-MUA

OR (PRO-4X)

CPKNLUN-MUA

CPKNLVN-MUA

2WD Model

Body

Engine

Transmission

Destination

VK56DE

RE5R05A (5A/T)

50-State

VK56DE FFV

RE5R05A (5A/T)

50-State

King Cab (LWB)

Revision: November 2008

GI-20

Grade

Model

BPKGLRN-EUA

BPKGLTN-EUA

BPKGLRN-MUA

BPKGLTN-MUA

2009 Titan

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL > Body

Engine

VK56DE

Transmission

RE5R05A (5A/T)

Destination

Grade

Model

CPKGLRN-EUA

CPKGLTN-EUA

CPKGLVN-EUA

CPKGLRN-MUA

CPKGLTN-MUA

CPKGLVN-MUA

Grade

Model

BPKULRN-EUA

BPKULTN-EUA

BPKULTN-ENA

BPKULRN-MUA

BPKULTN-MUA

CPKULRN-EUA

CPKULTN-EUA

OR (PRO-4X)

CPKULUN-EUA

50-State

Crew Cab (LWB) VK56DE FFV

RE5R05A (5A/T)

50-State

4WD Model

Body

Engine

VK56DE

Transmission

RE5R05A (5A/T)

King Cab (LWB)

Destination 50-State Canada

VK56DE FFV

RE5R05A (5A/T)

50-State

50-State VK56DE

CPKULVN-EUA

CPKULRN-ENA

CPKULTN-ENA

CPKULVN-ENA

CPKULRN-MUA

CPKULTN-MUA

OR (PRO-4X)

CPKULUN-MUA

CPKULVN-MUA

RE5R05A (5A/T)

Crew Cab (LWB)

Canada

VK56DE FFV

RE5R05A (5A/T)

50-State

Identification Number

INFOID:0000000003788801

P LAIA0047E

Emission control information label

Vacuum hose diagram

FMVSS certification label

Vehicle identification number plate

Tire placard

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT Revision: November 2008

GI-21

2009 Titan

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL > Position

Character

Qualifier

Definition

1 2

1N6

Manufacturer

1N6: USA produced multi-purpose vehicle

3 A: VK56DE

Engine type

Vehicle line

A: NISSAN Titan

Model change

(0-9)

Body type

B; VK56DE (Flexible fuel vehicle)

6: Truck (King Cab) 7: Truck (Crew Cab) A: 2WD SWB, 4-wheel ABS, Class E C: 4WD SWB, 4-wheel ABS, Class F

Gross vehicle weight rating

D: 2WD SWB, 4-wheel ABS, Class F E: 2WD LWB, 4-wheel ABS, Class E F: 4WD LWB, 4-wheel ABS, Class F G: 2WD LWB, 4-wheel ABS, Class F

Check digit

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

Model year

2009

Manufacturing plant

N: Canton Mississippi

Vehicle serial number

Chassis number

11 12 13 14 15

XXXXXX

16 17

ENGINE SERIAL NUMBER

LAIA0044E

TRANSFER SERIAL NUMBER

AGI108

Revision: November 2008

GI-22

2009 Titan

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL >

AUTOMATIC TRANSMISSION NUMBER

PAIA0054E

Dimensions

INFOID:0000000003788802

E Unit: mm (in)

Drive type

2WD

4WD

Overall length (Short Bed)

5704 (224.6)

Overall length (Long Bed)

6204 (244.2)

Overall width

2021 (79.6)

Overall height King Cab

1907.0 (75.1)

1946.0 (76.6)

Overall height Crew Cab

1916.0 (75.4)

1954.0 (76.9)

Front tread width

Rear tread width

18 inch tire with off road package

1725 (67.9)

18 inch tire

1725 (67.9)

20 inch tire with alloy wheels

1729 (68.1)

18 inch tire with off road package

1725 (67.9)

18 inch tire

1725 (67.9)

20 inch tire with alloy wheels

1729 (68.1)

Wheelbase (Short Bed)

3550 (139.8)

Wheelbase (Long Bed)

4050 (159.4)

Revision: November 2008

GI-23

2009 Titan

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL > Unit: mm (in)

Grade

Drive type

2WD

SE 4WD

OR (PRO-4X)

2WD

4WD

LE 2WD

4WD

King Cab at rear axle

Minimum running ground clearance measurement

SWB

260 (10.2)

271 (10.7)

265 (10.4)

LWB

259 (10.2)

270 (10.6)

265 (10.4)

with skid plates *1

SWB

280 (11.0)

288 (11.3)

286 (11.3)

LWB

281 (11.1)

288 (11.3)

286 (11.3)

without skid plates *1

SWB

280 (11.0)

—

286 (11.3)

LWB

281 (11.1)

—

286 (11.3)

Crew Cab SWB

263 (10.4)

273 (10.7)

268 (10.6)

LWB

261 (10.3)

272 (10.7)

266 (10.5)

with skid plates *1

SWB

282 (11.1)

290 (11.4)

288 (11.3)

LWB

283 (11.1)

291 (11.5)

289 (11.4)

without skid plates *1

SWB

282 (11.1)

—

288 (11.3)

LWB

283 (11.1)

—

289 (11.4)

at rear axle

*1 measured at front suspension

Wheels & Tires Drive Type

INFOID:0000000003788803

Grade XE

4x2

4x4

LE PRO-4X

Revision: November 2008

Road wheel

Tire

Spare tire size

18X8JJ Steel

P265/70R18

18X8JJ Alloy

P265/70R18

18X8JJ Alloy

P265/70R18

18X8JJ Chrome Clad Alloy

P265/70R18

20X8JJ Alloy

P275/60R20

20X8JJ Chrome Clad Alloy

P275/60R20

18X8JJ Steel

P265/70R18

18X8JJ Alloy

P265/70R18

18X8JJ Alloy

P265/70R18

18X8JJ Chrome Clad Alloy

P265/70R18

20X8JJ Alloy

P275/60R20

20X8JJ Chrome Clad Alloy

P275/60R20

18X8JJ Alloy

P275/70R18

GI-24

2009 Titan

PRECAUTIONS < PRECAUTION >

PRECAUTION

PRECAUTIONS Description

INFOID:0000000003788804

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:0000000003788805

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.

Procedures without Cowl Top Cover

INFOID:0000000003788807

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

PIIB3706J

General Precautions

INFOID:0000000003788808

• 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.

SGI285

Revision: November 2008

GI-25

2009 Titan

PRECAUTIONS < PRECAUTION > • 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. 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

• 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

Revision: November 2008

GI-26

2009 Titan

PRECAUTIONS < PRECAUTION > • 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:0000000003788809

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

Precaution for Fuel (Unleaded Regular Gasoline Recommended)

INFOID:0000000004221420

Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research octane number 91). E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) may only be used in vehicles specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models.) 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:0000000003788810

• 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.

P SGI787

Hoses

INFOID:0000000003788811

HOSE REMOVAL AND INSTALLATION

Revision: November 2008

GI-27

2009 Titan

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

SMA019D

• 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:0000000003788812

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.

Revision: November 2008

GI-28

2009 Titan

PRECAUTIONS < PRECAUTION > • Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. GI • 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). PreparaB tions 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. C • Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

ENVIRONMENTAL PROTECTION PRECAUTIONS

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

Air Conditioning

INFOID:0000000003788813

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

Revision: November 2008

GI-29

2009 Titan

LIFTING POINT < PRECAUTION >

LIFTING POINT Pantograph Jack

INFOID:0000000003788814

WAIA0041E

Garage Jack and Safety Stand

INFOID:0000000003788815

CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.

WAIA0042E

2-Pole Lift

INFOID:0000000003788816

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.

Revision: November 2008

GI-30

2009 Titan

LIFTING POINT < PRECAUTION > â&#x20AC;¢ When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, or fuel lines. GI

WAIA0043E

Revision: November 2008

GI-31

2009 Titan

TOW TRUCK TOWING < PRECAUTION >

TOW TRUCK TOWING Tow Truck Towing

INFOID:0000000003788817

WARNING: • Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. • Place wheel chocks at both front and back of the wheels on the ground. CAUTION: • All applicable State or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. • It is necessary to use proper towing equipment to avoid possible damage during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. • Always attach safety chains before towing. • When towing, make sure that the transmission, steering system and power train are in good order. If any unit is damaged, dollies must be used. • Never tow an automatic transmission model from the rear (i.e., backward) with four wheels on the ground as this may cause serious and expensive damage to the transmission.

AGI077

2WD MODEL NISSAN does not recommend towing automatic transmission equipped vehicles with the drive wheels on the ground. CAUTION: • When towing with the front wheels on the ground: Turn the ignition key to the OFF position and move the transmission shift lever to the neutral position. On automatic transmission models, to move the selector lever to N (neutral) position, turn the ignition key to OFF position and secure the steering wheel in a straight ahead position with a rope or similar device. Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism. • When towing manual transmission models with the rear wheels on the ground (if you do not use a towing dollies): Always release the parking brake and move the transmission shift lever to the neutral position.

SGI976

Revision: November 2008

GI-32

2009 Titan

TOW TRUCK TOWING < PRECAUTION > Towing Point GI

WAIA0045E

CAUTION: Never tow the vehicle using only the towing points. To avoid damaging the vehicle body, use proper towing equipment when towing.

4WD MODEL NISSAN does not recommend towing automatic transmission equipped vehicles with the drive wheels on the ground. CAUTION: • Never tow 4WD models with any of the tires on the ground as this may cause serious and expensive damage to the transfer case and transmission.

SGI973

Vehicle Recovery (Freeing a stuck vehicle)

INFOID:0000000003788818

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

Revision: November 2008

GI-33

2009 Titan

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

BASIC INSPECTION SERVICE INFORMATION FOR ELECTRICAL INCIDENT Work Flow

INFOID:0000000003788819

WORK FLOW

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 After Market Accessories have been installed.

STEP 2

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

STEP 3

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

STEP 4

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

STEP 5

Repair or replace the incident circuit or component.

STEP 6

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

Control Units and Electrical Parts

INFOID:0000000003788820

PRECAUTIONS • • • •

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

Revision: November 2008

GI-34

2009 Titan

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.

C 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:0000000003788821

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.

Revision: November 2008

GI-35

2009 Titan

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

Description

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.

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

Revision: November 2008

GI-36

2009 Titan

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.

C SEL266V

D MALE TERMINAL

• Carefully probe the contact surface of each terminal using a “T” pin. CAUTION: Dot not bend terminal.

G 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.

L 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

Revision: November 2008

GI-37

2009 Titan

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

SEL272V

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

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. 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:0000000003788822

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-

Revision: November 2008

GI-38

2009 Titan

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident. GI 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.

L 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

Revision: November 2008

GI-39

2009 Titan

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 pinching.

HEAT SENSITIVE • The customer's concern may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. • To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. CAUTION: 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.

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. Revision: November 2008

GI-40

2009 Titan

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

Circuit Inspection

INFOID:0000000003788823

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-35, "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.

J 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. Revision: November 2008

GI-41

2009 Titan

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.

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. Revision: November 2008

GI-42

2009 Titan

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • When inspecting a ground connection follow these rules: - Remove the ground bolt or screw. GI - Inspect all mating surfaces for tarnish, dirt, rust, etc. - Clean as required to assure good contact. - Reinstall bolt or screw securely. B - 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. C • For detailed ground distribution information, refer to “Ground Distribution” in PG section. D

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

Revision: November 2008

GI-43

2009 Titan

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.

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.

SAIA0258E

CONTROL UNIT CIRCUIT TEST System Description • When the switch is ON, the control unit lights up the lamp. CASE 1

MGI034A

Revision: November 2008

GI-44

2009 Titan

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.)

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

Battery voltage (Inoperative lamp)

Switch ON

Switch OFF

Battery voltage

Switch ON

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

Battery voltage

• The voltage value is based on the body ground. • *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.

Revision: November 2008

GI-45

2009 Titan

CONSULT-III CHECKING SYSTEM < BASIC INSPECTION >

CONSULT-III CHECKING SYSTEM Description

INFOID:0000000003788824

• 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

ENGINE

ABS

AIR BAG

IPDM E/R

BCM

METER/M&A

AUTO DRIVE POS.*1

ALL MODE AWD/4WD*2

Work support

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

Self-diagnostic

Self-diagnostic can be performed quickly.

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 ECM can be read.

Data monitor (spec)

Data monitor specification can be read.

CAN diagnosis

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

CAN diagnosis support monitor

The communication condition of CAN communication line can be read.

Active test

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

Function test

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.

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.

ECM/ECU part number

ECM/ECU part number can be read.

ECU discriminated No.

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

Passenger Airbag

Displays the STATUS (readiness) of the front passenger air bag.

Configuration

Sets control module parameters to match vehicle options.

Diagnostic test mode

Revision: November 2008

GI-46

DIFF LOCK*3 HVAC

Function

TRANSMISSION

INFOID:0000000003788825

2009 Titan

CONSULT-III CHECKING SYSTEM

GI DIFF LOCK*3 HVAC

ALL MODE AWD/4WD*2

AUTO DRIVE POS.*1

BCM

METER/M&A

IPDM E/R

ABS

Function

AIR BAG

ENGINE

Diagnostic test mode

TRANSMISSION

< BASIC INSPECTION >

PIN read

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

Control unit initialization*4

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

x : Applicable *1:With automatic drive positioner

*2: With 4-wheel drive *3: With electronic locking rear differential *4: With security card installed

CONSULT-III Data Link Connector (DLC) Circuit

INFOID:0000000003788826

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-14, "Trouble Diagnosis Flow Chart".

NOTE: The CAN and DDL2 circuits from DLC pins 6, 7 and 14 may be connected to more than one system. A short in any circuit connected to a control unit in one system may affect CONSULT-III access to other systems.

Revision: November 2008

GI-47

2009 Titan

CONSULT-III CHECKING SYSTEM < BASIC INSPECTION >

Wiring Diagram

INFOID:0000000003788827

ABAWA0003GB

Revision: November 2008

GI-48

2009 Titan

ENGINE

SECTION

ENGINE MECHANICAL

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

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

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

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

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

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

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

Valve Clearance ......................................................18 Checking Compression Pressure ............................23

ON-VEHICLE REPAIR ................................. 24 ENGINE ROOM COVER ................................... 24 Removal and Installation .........................................24 Exploded View .........................................................25 Removal and Installation .........................................25

INTAKE MANIFOLD ......................................... 26 Exploded View .........................................................26 Removal and Installation .........................................26

EXHAUST MANIFOLD AND THREE WAY CATALYST ........................................................ 30 Exploded View .........................................................30 Removal and Installation .........................................30

ON-VEHICLE MAINTENANCE .................... 13

IGNITION COIL ................................................. 37

DRIVE BELTS ....................................................13

Exploded View .........................................................37 Removal and Installation .........................................37

Exploded View ........................................................ 15 Removal and Installation (Viscous paper type) ....... 15

SPARK PLUG ....................................................16 Exploded View ........................................................ 16 Revision: November 2008

AIR CLEANER AND AIR DUCT ....................... 25

OIL PAN AND OIL STRAINER ......................... 33

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

COMPRESSION PRESSURE ........................... 23

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

Checking Drive Belts ............................................... 13 Removal and Installation ......................................... 13 Drive Belt Auto Tensioner and Idler Pulley ............. 14

Exploded View .........................................................33 Removal and Installation .........................................33

ROCKER COVER ............................................. 38 Exploded View .........................................................38 Removal and Installation .........................................38

FUEL INJECTOR AND FUEL TUBE ................ 40 Exploded View .........................................................40 Removal and Installation .........................................40

TIMING CHAIN .................................................. 44

EM-1

2009 Titan

Exploded View ........................................................ 44 Removal and Installation ........................................ 45

CAMSHAFT ....................................................... 53 Exploded View ........................................................ 53 Removal and Installation ........................................ 53 Inspection after Installation ..................................... 62

OIL SEAL ........................................................... 64 Removal and Installation of Valve Oil Seal ............. 64 Removal and Installation of Front Oil Seal ............. 64 Removal and Installation of Rear Oil Seal .............. 65

CYLINDER HEAD .............................................. 68 Exploded View ........................................................ 68 Removal and Installation ........................................ 68 Exploded View ........................................................ 70 Disassembly and Assembly .................................... 70 Inspection After Disassembly ................................. 72

REMOVAL AND INSTALLATION ............... 78

Revision: November 2008

ENGINE ASSEMBLY ........................................ 78 Exploded View ........................................................ 78 Removal and Installation ......................................... 78

DISASSEMBLY AND ASSEMBLY ............ 82 ENGINE UNIT .................................................... 82 Exploded View ........................................................ 82 Disassembly and Assembly .................................... 83 Inspection After Disassembly .................................. 90

HOW TO SELECT PISTON AND BEARING .. 101 How to Select Piston and Bearing ........................ 101

SERVICE DATA AND SPECIFICATIONS (SDS) ......................................................... 108 SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................ 108 Standard and Limit ................................................ 108

EM-2

2009 Titan

PRECAUTIONS < PRECAUTION >

PRECAUTION

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

INFOID:0000000003787007

Precaution for Drain Engine Coolant

INFOID:0000000003787008

Drain engine coolant when engine is cooled.

Precaution for Disconnecting Fuel Piping

INFOID:0000000003787009

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

Precaution for Removal and Disassembly

J INFOID:0000000003787010

• 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:0000000003787011

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

Precaution for Assembly and Installation

O INFOID:0000000003787012

• 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 engine oil or engine coolant passages for any restriction and blockage. • Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. Revision: November 2008

EM-3

2009 Titan

PRECAUTIONS < PRECAUTION > • Release air within route when refilling after draining engine 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 engine coolant, fuel, oil, and exhaust systems for leakage.

Parts Requiring Angular Tightening

INFOID:0000000003787013

• For final tightening of the following engine parts use Tool: Tool number

: KV10112100 (BT-8653-A)

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

Precaution for Liquid Gasket

INFOID:0000000003787014

REMOVAL OF LIQUID GASKET SEALING • After removing the bolts and nuts, separate the mating surface and remove the old liquid gasket sealing using Tool. Tool number

: KV10111100 (J-37228)

CAUTION: Do not damage the mating surfaces. • Tap the seal cutter to insert it (1). • In areas where the Tool is difficult to use, lightly tap to slide it (2). WBIA0566E

LIQUID GASKET APPLICATION PROCEDURE 1.

Remove the old liquid gasket adhering to the gasket application surface and the mating surface using suitable tool. • Remove the liquid gasket completely from the groove of the liquid gasket application surface, bolts, and bolt holes. Thoroughly clean the mating surfaces and remove adhering moisture, grease and foreign material.

PBIC0003E

Attach the liquid gasket tube to the Tool. Tool number

: WS39930000 (

—

)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". Apply the liquid gasket without breaks to the specified location with the specified dimensions.

WBIA0567E

Revision: November 2008

EM-4

2009 Titan

PRECAUTIONS < PRECAUTION > • If there is a groove for the liquid gasket application, apply the liquid gasket to the groove. • As for the bolt holes, normally apply the liquid gasket inside the holes. If specified in the procedure, it should also be applied outside the holes. • Within five minutes of liquid gasket application, install the mating component. • If the liquid gasket protrudes, wipe it off immediately. • Do not retighten after the installation. • Wait 30 minutes or more after installation before refilling the engine with engine oil and engine coolant. CAUTION: If there are specific instructions in this manual, observe them.

C SEM159F

Revision: November 2008

EM-5

2009 Titan

PREPARATION < PREPARATION >

PREPARATION PREPARATION Special Service Tool

INFOID:0000000003787015

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

KV10111100 (J-37228) Seal cutter

Removing steel oil pan and rear timing chain case

S-NT046

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

— (J-44626) Air fuel sensor Socket

LBIA0444E

Inspecting compression pressure

EG15050500 (J-45402) Compression gauge adapter

ZZA1225D

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 26336-A), but part (2) is not.

(J-

PBIC1650E

Tightening bolts for cylinder head, main bearing cap and connecting rod cap

KV10112100 (BT-8653-A) Angle wrench

S-NT014

Removing valve oil seal

KV10107902 (J-38959) Valve oil seal puller

S-NT011

Revision: November 2008

EM-6

2009 Titan

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

Description

KV10115600 (J-38958) Valve oil seal drift

Installing valve oil seal Use side A. a: 20 (0.79) dia. d: 8 (0.31) dia. b: 13 (0.51) dia. e: 10.7 (0.421) dia. c: 10.3 (0.406) dia. f: 5 (0.20) dia. Unit: mm (in)

S-NT603

Installing piston assembly into cylinder bore

EM03470000 (J-8037) Piston ring compressor

S-NT044

Removing crankshaft pilot bushing

ST16610001 (J-23907) Pilot bushing puller

H S-NT045

Pressing the tube of liquid gasket

WS39930000 ( — ) Tube presser

S-NT052

Removing and installing crankshaft pulley

— (J-47245) Ring gear stopper

M LBIA0451E

Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210)

16441 6N210 (J-45488) Quick connector release

O PBIC0198E

Releasing drive belt tension

— (J-46535) Drive belt tension releaser

WBIA0536E

Revision: November 2008

EM-7

2009 Titan

PREPARATION < PREPARATION >

Commercial Service Tool

INFOID:0000000003787016

(Kent-Moore No.) Tool name

Description

Power tool

Loosening bolts and nuts

PBIC0190E

Spark plug wrench

Removing and installing spark plug

S-NT047

Loosening and tightening cylinder head bolt, and use with angle wrench [SST: KV10112100 (BT-8653-A)] a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in)

(J-24239-01) Cylinder head bolt wrench

NT583

Valve seat cutter set

Finishing valve seat dimensions

S-NT048

Pulley puller

Removing crankshaft pulley

ZZA0010D

Piston ring expander

Removing and installing piston ring

S-NT030

Revision: November 2008

EM-8

2009 Titan

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

Description

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.

C S-NT015

Valve guide reamer

1: Reaming valve guide hole 2: Reaming hole for oversize valve guide Intake & Exhaust: d1: 6.0 mm (0.236 in) dia. d2: 10.175 - 10.196 mm (0.4006 - 0.4014 in) dia. S-NT016

Front oil seal drift

Installing front oil seal

H ZZA0012D

Rear oil seal drift

Installing rear oil seal

J ZZA0025D

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

AEM488

Reconditioning the exhaust system threads before installing a new A/F sensor and heated oxygen sensor (Use with anti-seize lubricant shown below.) a: J-43897-18 (18 mm dia.) (0.71 in) for zirconia heated oxygen sensor b: J-43897-12 (12 mm dia.) (0.55 in) for titania heated oxygen sensor Lubricating A/F sensors and heated oxygen sensor thread cleaning tool when reconditioning exhaust system threads

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

O AEM489

Revision: November 2008

EM-9

2009 Titan

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

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

INFOID:0000000003787017

AWBIA0149ZZ

Revision: November 2008

EM-10

2009 Titan

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING < FUNCTION DIAGNOSIS > 1.

Timing chain

Intake valve

Exhaust valve

Drive belt

Water pump

VTC noise

Tappet noise

Camshaft bearing noise

Valve mechanism

Rotation mechanism

Piston pin noise

Piston slap noise

Main bearing noise

Connecting rod bearing noise

Drive belt noise (slipping)

Drive belt noise (stick/slipping)

Water pump noise

Timing chain and chain tensioner noise

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

INFOID:0000000003787018

1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts.

Operating condition of engine Location of noise

Top of engine Rocker cover Cylinder head

Type of noise

Ticking or clicking Rattle

Slap or knock

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Front of engine Chain case cover Front cover

Slap or rap

Before warmup

After warmup

When starting

When idling

When racing

While driving

Source of noise

—

Tappet noise

Valve clearance

EM-18

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-53 EM-53

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

EM-90 EM-90

Piston slap noise

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

EM-90 EM-90 EM-90 EM-90

EM-90 EM-90

—

Check item

Reference page

Knock

Connecting rod bearing noise

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

Knock

—

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-90 EM-90

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-45 EM-45

Tapping or ticking

Revision: November 2008

—

EM-11

2009 Titan

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING < FUNCTION DIAGNOSIS > Operating condition of engine Location of noise

Type of noise

Squeaking or fizzing Front of engine

Before warmup

After warmup

When starting

When idling

When racing

While driving

—

Drive belts (Sticking or slipping)

Drive belts deflection Idler pulley bearing operation

Source of noise

Check item

Reference page

EM-13

Creaking

Drive belts (Slipping)

Squall Creaking

—

Water pump noise

Water pump operation

CO-20

Rattle

—

VTC

VTC lock pin clearance

EM-62

A: Closely related B: Related C: Sometimes related

Revision: November 2008

—: Not related

EM-12

2009 Titan

DRIVE BELTS < ON-VEHICLE MAINTENANCE >

ON-VEHICLE MAINTENANCE

DRIVE BELTS Checking Drive Belts

INFOID:0000000003787019

G LBIA0391E

Drive belt

Power steering pump pulley

Generator pulley

Crankshaft pulley

A/C compressor

Idler pulley

Cooling fan pulley

Water pump pulley

Drive belt auto tensioner

Allowable working range

WARNING: Be sure to perform when the engine is stopped. 1. Remove air duct and resonator assembly when inspecting drive belt. 2. Make sure that indicator (single line notch) of each auto tensioner is within the allowable working range (between three line notches). NOTE: â&#x20AC;˘ Check the drive belt auto tensioner indication when the engine is cold. â&#x20AC;˘ The indicator notch is located on the moving side of the drive belt auto tensioner. 3. Visually check entire belt for wear, damage or cracks. 4. If the indicator is out of allowable working range or belt is damaged, replace the belt. Refer to EM-13.

DRIVE BELT TENSION There is no manual drive belt tension adjustment. The drive belt tension is automatically adjusted by the drive belt auto tensioner.

Removal and Installation

INFOID:0000000003787020

REMOVAL 1.

Remove the air duct and resonator assembly. Refer to EM-25, "Removal and Installation". P

Revision: November 2008

EM-13

2009 Titan

DRIVE BELTS < ON-VEHICLE MAINTENANCE > 2. Install Tool on drive belt auto tensioner pulley bolt, move in the direction of arrow (loosening direction of tensioner) as shown. Tool number

—

(J-46535)

CAUTION: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. Remove the drive belt. WBIA0537E

INSTALLATION Installation is in the reverse order of removal. CAUTION: Make sure belt is securely installed around all pulleys. • Rotate the crankshaft pulley several turns clockwise to equalize belt tension between pulleys. • Make sure belt tension is within the allowable working range, using the indicator notch on the drive belt auto tensioner. Refer to EM-13, "Checking Drive Belts".

Drive Belt Auto Tensioner and Idler Pulley

INFOID:0000000003787021

WBIA0607E

Drive belt auto tensioner

Idler pulley

REMOVAL 1. 2. 3.

Remove the air duct and resonator assembly. Refer to EM-25, "Removal and Installation". Remove the drive belt. Refer to EM-13, "Removal and Installation". Remove the drive belt auto tensioner and idler pulley using power tool.

INSTALLATION Installation is in the reverse order of removal.

Revision: November 2008

EM-14

2009 Titan

AIR CLEANER FILTER < ON-VEHICLE MAINTENANCE >

AIR CLEANER FILTER

Exploded View

INFOID:0000000003787022

G ALBIA0413GB

Air cleaner case (lower)

Air cleaner filter

Air duct and resonator assembly

⇐

Front

Removal and Installation (Viscous paper type)

Air cleaner case (upper)

INFOID:0000000003787023

REMOVAL NOTE: • The viscous paper type filter does not need cleaning between replacement intervals. • Replace the air filter as necessary for periodic maintenance. Refer to MA-6, "Introduction of Periodic Maintenance". 1. Remove the air duct and resonator assembly. 2. Remove the air cleaner case (upper). 3. Remove the air cleaner filter from the air cleaner case (lower).

INSTALLATION 1. 2. 3.

Install the new air cleaner filter in the air cleaner case (lower). Install the air cleaner case (upper). Install the air duct and resonator assembly (inlet).

Revision: November 2008

EM-15

2009 Titan

SPARK PLUG < ON-VEHICLE MAINTENANCE >

SPARK PLUG Exploded View

INFOID:0000000003787024

WBIA0796E

Ignition coil

Spark plug

Removal and Installation

INFOID:0000000003787025

REMOVAL 1. 2. 3.

Remove engine room cover using power tool. Refer to EM-24, "Removal and Installation". Remove ignition coil. Refer to EM-37, "Removal and Installation". Remove spark plug using suitable tool.

SEM294A

INSPECTION AFTER REMOVAL • Do not use a wire brush for cleaning. • If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (5.9 bar, 6 kg/cm2 , 85 psi) Cleaning time: Less than 20 seconds

SMA773C

Revision: November 2008

EM-16

2009 Titan

SPARK PLUG < ON-VEHICLE MAINTENANCE > â&#x20AC;¢ Checking and adjusting plug gap is not required between change intervals.

C SMA806CA

INSTALLATION Installation is in the reverse order of removal. Spark Plug Types

Make

NGK

Model

Standard model

FFV model

Standard type

DILFR5A-11

DILFR5A-11D

Gap (Nominal)

1.1 mm (0.043 in)

1.1 mm (0.043)

CAUTION: Do not drop or shock spark plug.

Revision: November 2008

EM-17

2009 Titan

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE >

CAMSHAFT VALVE CLEARANCE Valve Clearance

INFOID:0000000003787026

INSPECTION NOTE: Perform the following inspection after removal, installation or replacement of camshaft or valve-related parts, or if there are unusual engine conditions due to changes in valve clearance over time (starting, idling, and/or noise). 1. Warm up the engine. Then stop the engine. 2. Remove the engine room cover. Refer to EM-24, "Removal and Installation". 3. Remove the air cleaner and air duct assembly. Refer to EM-25, "Removal and Installation". 4. Remove the RH bank and LH bank rocker covers using power tool. Refer to EM-38, "Removal and Installation". 5. Turn the crankshaft pulley in the normal direction (clockwise when viewed from engine front) to align TDC identification notch (without paint mark) with timing indicator.

KBIA2476E

At this time, make sure both the intake and exhaust cam noses of No. 1 cylinder (top front on LH bank) face outside. â&#x20AC;˘ If they do not face outside, turn crankshaft pulley once more.

KBIA0400J

Revision: November 2008

EM-18

2009 Titan

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > 7. Measure valve clearances at the locations marked “×” as shown in the table below (locations indicated with black arrow). • : Engine front • (black): Measurable at No.1 cylinder compression top dead center • (white): Measurable at No. 3 cylinder compression top dead center • A: RH • B: LH • C: Exhaust • D: Intake NOTE: Firing order 1-8-7-3-6-5-4-2 • No. 1 cylinder compression TDC Measuring position (RH bank) No. 1 cylinder at TDC

No. 4 cyl (F)

No. 1 cyl (J)

No. 3 cyl (K)

No. 6 cyl (G)

INT

No. 8 cyl (H) ×

EXH

Measuring position (LH bank) No. 1 cylinder at TDC

No. 2 cyl (E)

INT

EXH

No. 5 cyl (L)

No. 7 cyl (M)

G WBIA0713E

• Measure valve clearance using suitable tool. Refer to EM-108, "Standard and Limit". CAUTION: If the inspection was carried out with a cold engine, make sure the values with a fully warmed up engine are still within specifications.

K KBIA0185E

Turn the crankshaft pulley clockwise 270° from the position of No. 1 cylinder compression TDC to obtain No. 3 cylinder compression TDC.

Revision: November 2008

EM-19

2009 Titan

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > 9. Measure valve clearances at the locations marked “×” as shown in the table below (locations indicated with white arrow). • : Engine front • (black): Measurable at No.1 cylinder compression top dead center • (white): Measurable at No. 3 cylinder compression top dead center • A: RH • B: LH • C: Exhaust • D: Intake NOTE: Firing order 1-8-7-3-6-5-4-2 • No. 3 cylinder compression TDC Measuring position (RH bank) No. 3 cylinder at TDC

No. 4 cyl (F)

No. 6 cyl (G)

No. 8 cyl (H)

EXH

INT

Measuring position (LH bank) No. 3 cylinder at TDC

No. 2 cyl (E)

No. 1 cyl (J)

No. 3 cyl (K)

INT

EXH

No. 5 cyl (L)

No. 7 cyl (M) ×

WBIA0713E

KBIA0185E

Revision: November 2008

EM-20

2009 Titan

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > 10. Turn the crankshaft pulley clockwise 90° from the position of No. 3 cylinder compression TDC (clockwise by 360° from the position of No. 1 cylinder compression TDC) to measure the intake and exhaust valve clearances of No. 6 cylinder (G) and the exhaust valve clearance of No. 2 cylinder (E). • : Engine front • A: RH • B: LH • C: Exhaust • D: Intake • E: No. 2 cylinder • F: No. 4 cylinder • G: No. 6 cylinder • H: No. 8 cylinder • J: No. 1 cylinder • K: No. 3 cylinder • L: No. 5 cylinder • M: No. 7 cylinder

G WBIA0713E

11. If out of specifications, adjust as necessary.

ADJUSTMENT NOTE: • Perform adjustment depending on the selected head thickness of the valve lifter. • The specified valve lifter thickness is the dimension at normal temperatures. Ignore dimensional differences caused by temperature. Use the specifications for hot engine condition to adjust. 1. Remove the camshaft. Refer to EM-53, "Removal and Installation". 2. Remove the valve lifters at the locations that are out of specification. 3. Measure the center thickness of the removed valve lifters using suitable tool. 4. Use the equation below to calculate the valve lifter thickness for replacement. • Valve lifter thickness calculation: Thickness of replacement valve lifter = t1+ (C1 - C2) t1 = Thickness of removed valve lifter C1 = Measured valve clearance C2= Standard valve clearance: KBIA0057E

• Thickness of a new valve lifter can be identified by stamp marks on the reverse side (inside the cylinder). Stamp mark N788 indicates 7.88 mm (0.3102 in) in thickness. • Available thickness of valve lifter: 25 sizes with range 7.88 to 8.36 mm (0.3102 to 0.3291 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-108, "Standard and Limit".

EM-21

Install the selected valve lifter.

Revision: November 2008

KBIA0119E

2009 Titan

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > 6. Install the camshaft. 7. Manually turn the crankshaft pulley a few turns. 8. Make sure the valve clearances for a cold engine are within specifications. Refer to EM-108, "Standard and Limit". 9. After completing the repair, check the valve clearances again with the specifications for a warmed engine. Make sure the values are within specifications. Refer to EM-108, "Standard and Limit".

Revision: November 2008

EM-22

2009 Titan

COMPRESSION PRESSURE < ON-VEHICLE MAINTENANCE >

COMPRESSION PRESSURE

Checking Compression Pressure 1. 2.

3. 4. 5.

Warm up the engine thoroughly. Then stop the engine. EM Release the fuel pressure. Refer to EC-481, "Fuel Pressure Check". CAUTION: If CONSULT-III is not used to release fuel pressure leave the fuel pump fuse disconnected until C step 7. Remove the spark plug from each cylinder. Refer to EM-16, "Removal and Installation". Connect the engine tachometer (not required in use of CONSULT-III). D Install the compression tester with Tool into the spark plug hole. Tool number

INFOID:0000000003787027

: EG15050500 (J-45402)

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

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

Standard 1,520 (15.5, 220) / 200

7. 8. 9.

Minimum 1,324 (13.5, 192) / 200

Deference limit between cylinders

G WBIA0605E

98 (1.0, 14) / 200

CAUTION: Always use a fully charged battery to obtain specified engine speed. • If the engine speed is out of the specified range, check the battery liquid for proper gravity. Check the engine speed again with normal battery gravity. • If the compression pressure is below the minimum value, check the valve clearances and parts associated with the combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After checking, measure the compression pressure again. • If some cylinders have low compression pressure, pour a small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. - If the added engine oil improves the compression, the piston rings may be worn out or damaged. Check the piston rings and replace if necessary. - If the compression pressure remains at a low level despite the addition of engine oil, the valves may be malfunctioning. Check the valves for damage. Replace the valve or valve seat accordingly. • If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, the gaskets may be leaking, or a valve in adjacent cylinders may be damaged. Inspect and repair as required. Install the components in the reverse order of removal. Start the engine and confirm that it runs smoothly. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-40, "System Description".

Revision: November 2008

EM-23

2009 Titan

ENGINE ROOM COVER < ON-VEHICLE REPAIR >

ON-VEHICLE REPAIR ENGINE ROOM COVER Removal and Installation

INFOID:0000000003787028

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.

WBIA0795E

INSTALLATION Installation is in the reverse order of removal.

Revision: November 2008

EM-24

2009 Titan

AIR CLEANER AND AIR DUCT < ON-VEHICLE REPAIR >

AIR CLEANER AND AIR DUCT

Exploded View

INFOID:0000000003787029

G ALBIA0413GB

Air cleaner case (lower)

Air cleaner filter

Air duct and resonator assembly

⇐

Front

Removal and Installation

Air cleaner case (upper)

INFOID:0000000003787030

REMOVAL 1. Remove the engine room cover using power tool. Refer to EM-24, "Removal and Installation". 2. Disconnect the harness connector from air cleaner case (upper). 3. Remove the air duct and resonator assembly and air cleaner case. 4. Remove air cleaner filter and air cleaner case (lower) • Add marks as necessary for easier installation.

INSTALLATION Installation is in the reverse order of removal.

Revision: November 2008

EM-25

2009 Titan

INTAKE MANIFOLD < ON-VEHICLE REPAIR >

INTAKE MANIFOLD Exploded View

INFOID:0000000003787031

KBIA2461E

Intake manifold

PCV hose

Gasket

Electric throttle control actuator

Water hose

PCV hose

EVAP hose

EVAP canister purge control solenoid valve

10.

Bracket

11.

Gasket

Removal and Installation

INFOID:0000000003787032

REMOVAL 1.

2. 3. 4. 5.

Partially drain the engine coolant. Refer to CO-11, "Changing Engine Coolant". WARNING: To avoid the danger of being scalded, never drain the engine coolant when the engine is hot. Remove the engine room cover using power tool. Refer to EM-24, "Removal and Installation". Release the fuel pressure. Refer to EC-481, "Fuel Pressure Check". Remove the air duct and resonator assembly. Refer to EM-25, "Removal and Installation". Disconnect the fuel tube quick connector on the engine side.

LBIA0395E

Revision: November 2008

EM-26

2009 Titan

INTAKE MANIFOLD < ON-VEHICLE REPAIR > • Perform the following steps to disconnect the quick connector using Tool. Tool number a.

: 16441 6N210 (J-45488) EM

Remove quick connector cap (engine side only).

C SBIA0354E

With the sleeve side of Tool facing quick connector, install Tool onto fuel tube. c. Insert Tool into quick connector until sleeve contacts and goes no further. Hold the Tool in that position. CAUTION: Inserting the Tool hard will not disconnect quick connector. Hold Tool where it contacts and goes no further. d. Draw and pull out quick connector straight from fuel tube. CAUTION: • Pull quick connector holding "A" position in illustration. WBIA0604E • Do not pull with lateral force applied. O-ring inside quick connector may be damaged. • Prepare container and cloth beforehand as fuel will leak out. • Avoid fire and sparks. • Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of foreign materials. 6. Remove or disconnect harnesses, brackets, vacuum hose, vacuum gallery and PCV hose and tube from intake manifold. 7. Remove electric throttle control actuator by loosening bolts diagonally. CAUTION: • Handle carefully to avoid any damage to the electric throttle control actuator. • Do not disassemble. 8. Remove the fuel injectors and fuel tube assembly. Refer to EM-40, "Removal and Installation". 9. Loosen the bolts in reverse order shown using power tool. 10. Remove the intake manifold. CAUTION: Cover engine openings to avoid entry of foreign materials. • Clean all gasket mating surfaces, do not reuse gaskets.

N KBIA2462E

INSTALLATION

Installation is in the reverse order of removal.

Revision: November 2008

EM-27

2009 Titan

INTAKE MANIFOLD < ON-VEHICLE REPAIR > • Tighten the intake manifold bolts in numerical order as shown.

KBIA2462E

• Install the EVAP canister purge control solenoid valve connector with it facing front of engine. • Tighten the electronic throttle control actuator bolts of the electric throttle control actuator equally and diagonally in several steps. • After installation perform inspection after installation. • Install the water hose so that its overlap width for connection is between 27 mm (1.06 in) and 32 mm (1.26 in) (target: 27 mm 1.06 in). Connecting Quick Connector of Fuel Tube Install quick connector as follows (the steps are the same for quick connectors on both engine side and vehicle side except for the quick connector cap). 1. Make sure no foreign substances are deposited in and around tube and quick connector, and they are not damaged. 2. Thinly apply new engine oil around the fuel tube from tip end to the spool end. 3. Align center to insert quick connector straight into fuel tube. • Insert until the paint mark for engagement identification (white) goes completely inside quick connector so that you cannot see it from the straight side of the connected part. Use a mirror to check this where it is not possible to view directly from the straight side, such as quick connector on vehicle side.

PBIC0017E

• Insert fuel tube into quick connector until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector on engine side. CAUTION: • Hold "A" position in illustration when inserting fuel tube into quick connector. • Carefully align center to avoid inclined insertion to prevent 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 KBIA0272E sound, be sure to perform the next step. Pull quick connector by hand holding "A" position. Make sure it is completely engaged (connected) so that it does not come out from fuel tube. NOTE: Recommended pulling force is 50 N (5.1 kg, 11.2 lb).

Revision: November 2008

EM-28

2009 Titan

INTAKE MANIFOLD < ON-VEHICLE REPAIR > 5. Install the quick connector cap on the quick connector joint (on engine side only). 6. Install the fuel hose and tube to hose clamps. 7. Refill the engine coolant. Refer to CO-11, "Changing Engine Coolant".

C SBIA0354E

INSPECTION AFTER INSTALLATION • After installing fuel tubes, make sure there is no fuel leakage at connections in the following steps. - Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections. - Start the engine and rev it up and check for fuel leaks at the connections. • Perform procedures for “Throttle Valve Closed Position Learning” after finishing repairs. Refer to EC-22, "Throttle Valve Closed Position Learning". • If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after finishing repairs. Refer to EC-23, "Idle Air Volume Learning".

Revision: November 2008

EM-29

2009 Titan

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

EXHAUST MANIFOLD AND THREE WAY CATALYST Exploded View

INFOID:0000000003787033

AWBIA0453GB

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

Exhaust manifold cover (bank 2)

Exhaust manifold (bank 2)

Gaskets

Exhaust manifold (bank 1)

Exhaust manifold cover (bank 1)

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

Coated face

Manifold side

Up mark

â&#x2021;?

Front

Removal and Installation

INFOID:0000000003787034

REMOVAL WARNING: Perform the work when the exhaust and cooling system have cooled sufficiently. 1. Remove the air duct and resonator assembly. Refer to EM-25, "Removal and Installation". 2. Drain the engine coolant from the radiator. Refer to CO-11, "Changing Engine Coolant". 3. Remove the engine undercover using power tool. 4. Remove the radiator and radiator hoses. Refer to CO-15, "Removal and Installation". 5. Remove the drive belts. Refer to EM-13, "Removal and Installation". 6. Remove the air fuel ratio A/F sensors (bank 1, bank 2). â&#x20AC;˘ Follow steps below to remove each air fuel ratio A/F sensor. a. Remove the harness connector of each air fuel ratio A/F sensor, and harness from bracket and middle clamp.

Revision: November 2008

EM-30

2009 Titan

EXHAUST MANIFOLD AND THREE WAY CATALYST < ON-VEHICLE REPAIR > b. Remove the air fuel ratio A/F sensors from both left and right exhaust manifolds using Tool. Tool number

—

(J-44626) EM

CAUTION: • Do not damage the air fuel ratio A/F sensors • Discard any air fuel ratio A/F sensor which has been dropped from a height of more than 0.5m (19.7 in) onto a hard surface such as a concrete floor. Replace it with a new one.

C WBIA0630E

7. 8.

a. b. c. d. 9. a. b. c. d. e.

Remove the front cross bar. Remove the exhaust manifold (LH) (A) following the steps below. • : Front Remove the exhaust front tube. Refer to EX-6, "Removal and Installation". Remove the exhaust manifold cover. Loosen the nuts in reverse order of illustration (A) using power tool. Remove the exhaust studs from positions 2, 4, 6, 8 and remove exhaust manifold (LH). Remove the exhaust manifold (RH) (B) following the steps below. Remove the exhaust front tube. Refer to EX-6, "Removal and Installation". Remove the oil level gauge guide. Refer to EM-83. Remove the exhaust manifold cover. Loosen the nuts in reverse order of illustration (B) using power tool. Remove the exhaust studs from positions 2, 4, 6, 8 and remove exhaust manifold (RH).

G WBIA0696E

INSPECTION AFTER REMOVAL Surface Distortion • Check the flatness of each exhaust manifold flange surface using suitable tools.

Flatness limit

: 0.3 mm (0.012 in)

• If measurement exceeds the limit, replace the exhaust manifold. M

N KBIA2504E

INSTALLATION

Installation is in the reverse order of removal.

Revision: November 2008

EM-31

2009 Titan

EXHAUST MANIFOLD AND THREE WAY CATALYST < ON-VEHICLE REPAIR > • Install new exhaust manifold gasket with the top of the triangular up mark on it facing up and its coated face (gray side) toward the exhaust manifold side.

KBIA2553E

• Tighten the exhaust manifold nuts in the numerical order shown. Then recheck the torque of the nuts both (A) and (B). - A: Exhaust manifold LH - B: Exhaust manifold RH : Front

WBIA0696E

• Before installing new air fuel ration A/F sensors, clean the exhaust system threads using Tool and apply antiseize lubricant. Tool number

: — : —

(J-43879-12) (J-43897-18)

CAUTION: • Do not over tighten the air fuel ratio A/F sensors. Doing so may cause damage to the sensor, resulting in the MIL coming on.

Revision: November 2008

EM-32

2009 Titan

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR >

OIL PAN AND OIL STRAINER

Exploded View

INFOID:0000000003787035

J KBIA2465E

Oil pan (upper)

O-ring

O-ring (with collar)

Oil level gauge guide

Oil level gauge

O-ring

Connector bolt

10.

Oil filter

11. Oil cooler

12. Relief valve

13.

Oil pressure switch

14. Gasket

15. Drain plug

16.

Oil pan (lower)

17. Oil strainer

Removal and Installation

M INFOID:0000000003787036

REMOVAL

WARNING: To avoid the danger of being scalded, never drain the engine oil when the engine is hot. 1. Remove the engine. Refer to EM-78, "Removal and Installation". 2. Remove the oil pan (lower) using the following steps.

Revision: November 2008

EM-33

2009 Titan

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > a. Remove the oil pan (lower) bolts using power tool.

KBIA2466E

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

: KV10111100 (J-37228)

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

3. 4. a.

Remove the oil strainer from the oil pan (upper). Remove the oil pan (upper) using the following steps. Remove the oil pan (upper) bolts as shown.

KBIA2467E

Remove the oil pan (upper) from the cylinder block by prying it at the points shown, using suitable tool. CAUTION: Do not damage mating surface.

KBIA2468E

Revision: November 2008

EM-34

2009 Titan

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > 5. Remove the O-rings from the oil pump and front cover. NOTE: Do not reuse O-rings.

C KBIA2469E

INSPECTION AFTER REMOVAL Clean the oil strainer.

INSTALLATION 1. a.

Install the oil pan (upper) using the following steps. Apply liquid gasket thoroughly as shown. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI14, "Recommended Chemical Products and Sealants". CAUTION: Apply liquid gasket to outside of bolt hole for the hole shown by .

H KBIA2470E

Install new O-rings to the oil pump and front cover side.

KBIA2469E

Tighten the bolts in numerical order as shown. M6 × 30 mm (1.18 in) M8 × 25 mm (0.98in) M8 × 45 mm (1.77 in) M8 × 123 mm (4.84in)

: No. 15, 16 : No. 1, 3, 5, 7, 11, 13 : No. 2, 4, 6, 8, 10, 14 : No. 9, 12

Install the oil strainer to the oil pan (upper).

O PBIC2553E

Revision: November 2008

EM-35

2009 Titan

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > 3. Install the oil pan (lower). a. Apply liquid gasket thoroughly as shown. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants".

KBIA2471E

Tighten the oil pan (lower) bolts in numerical order as shown.

PBIC2595E

4. 5.

Install the oil pan drain plug. Install engine assembly. Refer to EM-78, "Removal and Installation". â&#x20AC;˘ Do not fill the engine oil for at least 30 minutes after oil pan is installed.

INSPECTION AFTER INSTALLATION 1. 2. 3. 4.

Check engine oil level and add engine oil if necessary. Refer to LU-8, "Inspection". Start the engine, and check for leaks of engine oil. Stop engine and wait for 10 minutes. Check engine oil level again.

Revision: November 2008

EM-36

2009 Titan

IGNITION COIL < ON-VEHICLE REPAIR >

IGNITION COIL

Exploded View

INFOID:0000000003787037

G WBIA0796E

Ignition coil

Spark plug

Removal and Installation

INFOID:0000000003787038

REMOVAL

1. 2. 3.

Remove the engine room cover using power tool. Refer to EM-24, "Removal and Installation". Disconnect the harness connector from the ignition coil. Remove the ignition coil. CAUTION: Do not shock ignition coil.

INSTALLATION Installation is in the reverse order of removal.

Revision: November 2008

EM-37

2009 Titan

ROCKER COVER < ON-VEHICLE REPAIR >

ROCKER COVER Exploded View

INFOID:0000000003787039

KBIA2508E

Rocker cover (LH)

PCV control valve

O-ring

Rocker cover gasket (LH)

Rocker cover (RH)

PCV control valve

O-ring

Oil filler cap

Rocker cover gasket (RH)

Removal and Installation

INFOID:0000000003787040

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

Remove the engine room cover using power tool. Refer to EM-24, "Removal and Installation". Remove the air duct and resonator assembly. Refer to EM-25, "Removal and Installation" (for LH only). Move the harness on the upper rocker cover and its peripheral aside. Remove the electric throttle control actuator, loosening the bolts diagonally (for LH only). Remove the ignition coils. Refer to EM-37, "Removal and Installation". Remove the PCV hose from the PCV control valves. Loosen the rocker cover bolts in reverse order as shown using power tool. CAUTION: Do not hold the rocker cover (RH) (B) by the oil filler neck. • : Engine front • A: Rocker cover LH • B: Rocker cover RH Remove the rocker cover.

WBIA0697E

INSTALLATION Revision: November 2008

EM-38

2009 Titan

ROCKER COVER < ON-VEHICLE REPAIR > 1. Apply liquid gasket to the joint part of the cylinder head and camshaft bracket following the steps below. NOTE: Illustration shows an example of (LH) side (zoomed in shows No.1 camshaft bracket). a. Use illustration ″a″ to apply liquid gasket to the joint part of No.1 camshaft bracket and cylinder head. b. Use illustration ″b″ to apply liquid gasket 90° to illustration ″a″. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants".

G KBIA2510E

Install the rocker cover and tighten the bolts in two steps in the order shown. • A: Rocker cover LH • B: Rocker cover RH • : Engine front 1st step 2nd step

: 2.0 N·m (0.2 kg-m, 18 in-lb) : 8.3 N·m (0.85 kg-m, 73 in-lb)

CAUTION: • Do not hold the rocker cover (RH) (B) by the oil filler neck. • Make sure the new rocker cover gasket is installed in the groove of the rocker cover. 3.

WBIA0697E

Install the PCV hoses. NOTE: • Remove foreign materials from inside the hose using compressed air. • The inserted length is within 25 - 30 mm (0.98 - 1.18 in) [Target: 25 mm (0.98 in)]. Installation of the remaining components is in the reverse order of removal.

Revision: November 2008

EM-39

2009 Titan

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR >

FUEL INJECTOR AND FUEL TUBE Exploded View

INFOID:0000000003787041

KBIA2472E

Fuel tube (RH bank)

Cap

Fuel damper

O-ring

O-ring (Standard model: Blue) (FFV model: Black)

Fuel injector

Clip

O-ring (Standard model: Brown) (FFV model: Green)

O-ring

10. Fuel hose assembly

11. Fuel tube (LH bank)

Removal and Installation

INFOID:0000000003787042

CAUTION: Do not remove or disassemble parts unless instructed as shown.

REMOVAL 1. 2. 3. 4. 5.

Remove engine room cover using power tool. Refer to EM-24, "Removal and Installation". Release fuel pressure. Refer to EC-481, "Fuel Pressure Check". Disconnect the negative battery terminal. Disconnect fuel injector harness connectors. Disconnect fuel hose assembly from fuel tube (RH bank and LH bank). CAUTION: • While hoses are disconnected, plug them to prevent fuel from draining. • Do not separate fuel connector and fuel hose. Remove fuel injectors with fuel tube assembly.

Revision: November 2008

EM-40

2009 Titan

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > 7. Remove fuel injector from fuel tube. a. Spread open to remove clip. b. Remove fuel injector from the fuel tube by pulling straight out. CAUTION: • Be careful with remaining fuel that may leak out from fuel tube. • Do not damage injector nozzles during removal. • Do not bump or drop fuel injectors. • Do not disassemble fuel injectors.

G KBIA2506E

Remove fuel damper from each fuel tube.

INSTALLATION 1. a.

Install fuel damper to each fuel tube. Apply engine oil to O-ring and set it into the fuel tube. CAUTION: • Handle O-ring with bare hands. Never wear gloves. • Lubricate O-ring with new engine oil. • Do not clean O-ring with solvent. • Make sure 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. Make sure that backup spacer is in the O-ring connecting surface of fuel damper. NOTE: Backup spacer is fuel damper assembly part. Insert fuel damper until it seats on fuel tube. CAUTION: • Insert straight, making sure that the axis is lined up. • Do not pressure-fit with excessive force. Reference value

d. 2.

K KBIA2473E

:130 N (13.3 kg, 29.2 lb)

Install cap, and then tighten bolts evenly by turns. • After tightening bolts, make sure that there is no gap between cap and fuel tube. Install O-rings to fuel injector paying attention to the items below. CAUTION: • Upper and lower O-rings are different. Standard model Fuel tube side Nozzle side

Revision: November 2008

: Blue : Brown

EM-41

2009 Titan

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

: Black : Green

• • • • •

3. a.

Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure 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, do not insert it quickly into fuel tube. • Insert O-ring straight into fuel tube. Do not angle or twist it. Install fuel injector to fuel tube. Insert clip into clip mounting groove on fuel injector. • Insert clip so that lug “A” of fuel injector matches notch “A” of the clip. CAUTION: • Do not reuse clip. Replace it with a new one. • Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube with clip attached. • Insert it while matching it to the axial center. • Insert fuel injector so that lug “B” of fuel tube matches notch “B” of the clip. • Make sure that fuel tube flange is securely fixed in flange fixing groove on clip. Make sure that installation is complete by checking that fuel injector does not rotate or come off. • Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.

KBIA2507E

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 fuel tube assembly bolts “a” to “b” in illustration and in two steps. 1st step 2nd step

: 12.8 N·m (1.3 kg-m, 9 ft-lb) : 24.5 N·m (2.5 kg-m, 18 ft-lb)

KBIA2474E

Install fuel hose assembly. • Follow precautions for fuel injector when handling O-ring. • Insert connectors straight, making sure that the axis is lined up with fuel tube side to prevent O-ring from being damaged. • Tighten bolts evenly in several steps. • Make sure that there is no gap between flange and fuel tube after tightening bolts. Installation of the remaining components is in the reverse order of removal.

Revision: November 2008

EM-42

2009 Titan

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > INSPECTION AFTER INSTALLATION A After installing fuel tubes, make sure there are no fuel leaks at connections using the following steps. 1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections. EM 2. Start the engine and rev it up and check for fuel leaks at connections. WARNING: Do not touch the engine immediately after stopping, as engine becomes extremely hot. NOTE: C Use mirrors for checking on hidden points. D

Revision: November 2008

EM-43

2009 Titan

TIMING CHAIN < ON-VEHICLE REPAIR >

TIMING CHAIN Exploded View

INFOID:0000000003787043

AWBIA0100GB

Revision: November 2008

EM-44

2009 Titan

TIMING CHAIN < ON-VEHICLE REPAIR > 1.

Camshaft sprocket LH bank EXH

Camshaft sprocket LH bank INT (VTC)

Camshaft sprocket RH bank INT (VTC)

Camshaft sprocket RH bank EXH

Front cover

Intake valve timing control solenoid valve (RH)

Intake valve timing control solenoid valve cover (RH)

Intake valve timing control position sensor (RH)

Intake valve timing control position sensor (LH)

10. Intake valve timing control solenoid valve cover (LH)

11.

Camshaft position sensor (PHASE)

Crankshaft pulley bolt

13. Crankshaft pulley

14.

Chain tensioner cover

15.

Front oil seal

16. Intake valve timing control solenoid valve (RH)

17.

O-ring

18.

Timing chain tension guide RH bank

19. Timing chain slack guide (RH)

20.

Timing chain RH bank

21.

Timing chain LH bank

22. Chain tensioner (RH)

23.

Timing chain slack guide LH bank

24.

Timing chain tension guide LH bank

25. Chain tensioner (LH)

26.

O-ring

27.

Bracket

28. Oil pump drive spacer

29.

Oil pump assembly

30.

Crankshaft sprocket

To crankshaft

To camshaft LH bank EXH

To camshaft LH bank INT (VTC)

To camshaft RH bank INT (VTC)

To camshaft RH bank EXH

Apply sealant to mating side

Refer to EM-45

Removal and Installation

INFOID:0000000003787044

NOTE: • To remove timing chain and associated parts, start with those on the LH bank. The procedure for removing parts on the RH bank is omitted because it is the same as that for removal on the LH bank. • To install timing chain and associated parts, start with those on the RH bank. The procedure for installing parts on the LH bank is omitted because it is the same as that for installation on the RH bank.

REMOVAL

1. 2.

3. a. b.

Remove the engine assembly from the vehicle. Refer to EM-78, "Removal and Installation". Remove the following components and related parts: • Drive belt auto tensioner and idler pulley. Refer to EM-13, "Removal and Installation". • Thermostat housing and water hose. Refer to CO-22, "Removal and Installation". • Power steering oil pump bracket. Refer to ST-20, "Removal and Installation". • Oil pan (lower), (upper) and oil strainer. Refer to EM-33, "Removal and Installation". • Ignition coil. Refer to EM-37, "Removal and Installation". • Rocker cover. Refer to EM-38, "Removal and Installation". Remove the Intake valve timing control solenoid valve cover (RH) (A) and Intake valve timing control solenoid valve cover (LH) (B) as follows: Loosen and remove the bolts as shown. Cut the liquid gasket and remove the covers using Tool. Tool number

: KV10111100 (J-37228)

CAUTION: Do not damage mating surfaces. WBIA0798E

Revision: November 2008

EM-45

2009 Titan

TIMING CHAIN < ON-VEHICLE REPAIR > 4. Obtain compression TDC of No. 1 cylinder as follows: a. Turn the crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with the timing indicator on the front cover.

KBIA2476E

At this time, make sure both intake and exhaust cam lobes of No. 1 cylinder (top front on LH bank) point outside. â&#x20AC;˘ If they do not point outside, turn crankshaft pulley once more.

KBIA0400J

5. a.

Remove the crankshaft pulley. Loosen the crankshaft pulley bolts using a hammer handle to secure the crankshaft.

PBIC0053E

Remove the crankshaft pulley from the crankshaft using tool. â&#x20AC;˘ Remove the crankshaft pulley using suitable tool. Set the bolts in the two bolt holes [M6 x 1.0 mm (0.04 in)] on the front surface. NOTE: The dimension between the centers of the two bolt holes is 61 mm (2.40 in).

KBIA2477E

6. a. b.

Remove the front cover. Loosen and remove the bolts in the reverse of order shown. Cut the liquid gasket and remove the covers using Tool. Tool number

: KV10111100 (J-37228)

CAUTION: Do not damage mating surfaces. Remove the front oil seal using suitable tool. CAUTION: Do not damage front cover.

Revision: November 2008

KBIA2478E

EM-46

2009 Titan

TIMING CHAIN < ON-VEHICLE REPAIR > 8.

Remove the oil pump drive spacer. • Hold and remove the flat space of the oil pump drive spacer by pulling it forward.

C KBIA2512E

9. Remove the oil pump. Refer to LU-14, "Removal and Installation". 10. Remove the chain tensioner on the LH bank using the following steps. NOTE: To remove the timing chain and associated parts, start with those on the LH bank. The procedure for removing parts on the RH bank is omitted because it is the same as that for the LH bank. a. Squeeze the return-proof clip ends using suitable tool and push the plunger into the tensioner body. b. Secure the plunger using stopper pin. • Stopper pin is made from hard wire approximately 1 mm (0.04 in) in diameter. c. Remove the bolts and chain tensioner. WARNING: Plunger, spring, and spring seat pop out when (squeezing) return-proof clip without holding plunger head. It may cause serious injuries. Always hold plunger head when KBIA2479E removing. NOTE: • Stop the plunger in the fully extended position by using the return-proof clip (1) if the stopper pin is removed. • Push the plunger (2) into the tensioner body while squeezing the return-proof clip (1). Secure it using stopper pin (3).

KBIA2483E

11. Remove the timing chain tension guide and timing chain slack guide. 12. Remove the timing chain and crankshaft sprocket. 13. Loosen the camshaft sprocket bolts as shown and remove the camshaft sprocket. • A: Camshaft holding location CAUTION: To avoid interference between valves and pistons, do not turn crankshaft or camshaft when timing chain is disconnected. 14. Repeat the same procedure to remove the RH timing chain and associated parts.

WBIA0799E

INSPECTION AFTER REMOVAL Revision: November 2008

EM-47

2009 Titan

TIMING CHAIN < ON-VEHICLE REPAIR > Check for cracks and any excessive wear at link plates. Replace chain if necessary. • In the same way as for the LH bank, inspect the timing chain and associated parts on the RH bank.

PBIC0282E

INSTALLATION

AWBIA0150ZZ

Camshaft sprocket RH bank INT (VTC)

Camshaft sprocket RH bank EXH

Camshaft dowel pin RH bank

Timing chain RH bank

Timing chain slack guide RH bank

Chain tensioner (RH)

Crankshaft sprocket

Crankshaft key

Timing chain tension guide LH bank

10. Timing chain LH bank

11. Camshaft dowel pin LH bank

12. Camshaft sprocket LH bank EXH

13. Camshaft sprocket LH bank INT (VTC)

14. Chain tensioner LH

15. Timing chain tension guide RH bank

16. Timing chain slack guide LH bank

LH bank

RH bank

Alignment mark (Link color: blue)

Alignment mark (Identification mark)

Alignment mark for LH bank (Notch) G.

Alignment mark for LH bank (Link color: copper)

Alignment mark for RH bank (Link color: copper)

Alignment mark (Link color: blue)

Alignment mark (Identification mark) L.

Alignment mark (Link color: blue)

Alignment mark (Identification mark)

NOTE: • The above figure shows the relationship between the mating mark on each timing chain and that of the corresponding sprocket, with the components installed. • To install the timing chain and associated parts, start with those on the RH bank. The procedure for installing parts on the LH bank is omitted because it is the same as that for installation on the RH bank.

Revision: November 2008

EM-48

2009 Titan

TIMING CHAIN < ON-VEHICLE REPAIR > 1. Make sure the crankshaft key and camshaft dowel pin RH bank and camshaft dowel pin LH bank are facing in the direction shown.

C SBIA0356E

Install the camshaft sprockets. • Install the camshaft sprocket INT (VTC) (A) and camshaft sprockets EXH (B) by selectively using the groove of the dowel pin according to the bank. (Common part used for both exhaust banks.) NOTE: Use the groove marked "R" for RH bank and "L" for LH bank. • Lock the hexagonal part of the camshaft in the same way as for removal, and tighten the bolts.

G AWBIA0151ZZ

Install the crankshaft sprockets for both banks. • Install LH bank crankshaft sprocket (B) and RH bank crankshaft sprocket (C) so that their flange side (A) (the larger diameter side without teeth) faces in the direction shown. NOTE: The same parts are used but facing directions are different.

WBIA0701E

5. 6.

Install the timing chains and associated parts. • Align the alignment mark on each sprocket and the timing chain for installation. CAUTION: • Before installing timing chain tensioner, it is possible to change the position of alignment mark on timing chain and each sprocket. After the alignment marks are aligned, keep them aligned by holding them by hand. • Install the slack guides and tension guides onto the correct side by checking the identification mark on the surface. • Install the chain tensioner with the plunger locked in with the stopper pin. CAUTION: • Before and after the installation of the chain tensioner, make sure that the alignment mark on the timing chain is not out of alignment. • After installing the chain tensioner, remove the stopper pin to release the chain tensioner. Make sure the chain tensioner is released. • To avoid chain-link skipping of the timing chain, do not move crankshaft or camshafts until the front cover is installed. In the same way as for the RH bank, install the timing chain and associated parts on the LH bank. Install the oil pump.

Revision: November 2008

EM-49

2009 Titan

TIMING CHAIN < ON-VEHICLE REPAIR > 7. Install the oil pump drive spacer as follows: • Install so that the front mark on the front edge of the oil pump drive spacer faces the front of the engine. • Insert the oil pump drive spacer according to the directions of the crankshaft key and the two flat surfaces of the oil pump inner rotor. • If the positional relationship does not allow the insertion, rotate the oil pump inner rotor to allow the oil pump drive spacer to be inserted. KBIA2490E

Install the front oil seal using suitable tool. CAUTION: Do not scratch or make burrs on the circumference of the oil seal.

PBIC0059E

Install the chain tensioner cover. • Apply liquid gasket as shown. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants".

KBIA2547E

10. Install the front cover as follows: a. Install a new O-ring on the cylinder block.

KBIA2516E

Revision: November 2008

EM-50

2009 Titan

TIMING CHAIN < ON-VEHICLE REPAIR > b. Apply liquid gasket as shown. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". c. Check again that the timing alignment marks on the timing chain and on each sprocket are aligned. Then install the front cover.

C KBIA2517E

M6 × 50 mm (1.97 in) M6 × 80 mm (3.15 in) M6 × 20 mm (0.79 in) e.

Install the bolts in the numerical order shown. : No. 1, 20, 25, 26, 27 : No. 4, 5, 7 : Except the above

After tightening, re-tighten to the specified torque. CAUTION: Be sure to wipe off any excessive liquid gasket leaking onto surface mating with oil pan.

G KBIA2478E

11. Install the Intake valve timing control solenoid valve cover (RH) (A) and Intake valve timing control solenoid valve cover (LH) (B) as follows: a. Apply liquid gasket (D) as shown. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". CAUTION: The start and end of the application of the liquid gasket should be crossed at position (C) that cannot be seen after attaching the Intake valve timing control solenoid valve cover.

WBIA0800E

D : 2.6 - 3.6 mm (0.102 - 0.142 in) dia. b.

Install the bolts and tighten them to specification in the numerical order shown. • A: Intake valve timing control solenoid valve cover (RH) • B: Intake valve timing control solenoid valve cover (LH)

WBIA0798E

12. Install the crankshaft pulley. • Install the key of the crankshaft. • Insert the pulley by lightly tapping it. CAUTION: Do not tap pulley on the side surface where the belt is installed (outer circumference). 13. Tighten the crankshaft pulley bolt. • Lock the crankshaft using suitable tool, then tighten the bolt. • Perform the following steps for angular tightening: a. Apply engine oil onto the threaded parts of the bolt and seating area. Revision: November 2008

EM-51

2009 Titan

TIMING CHAIN < ON-VEHICLE REPAIR > b. Select the one most visible notch of the four on the bolt flange. Corresponding to the selected notch, put a alignment mark (such as paint) on the crankshaft pulley. Crankshaft pulley bolt torque Step 1 : 93.1 N·m (9.5 kg-m, 69 ft-lb) Step 2 : additional 90° (angle tightening) 14. Rotate the crankshaft pulley in normal direction (clockwise when viewed from engine front) to check for parts interference. 15. Installation of the remaining components is in the reverse of order of removal.

KBIA2519E

INSPECTION AFTER INSTALLATION • Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are lower than required quantity, fill to the specified level. Refer to MA-10, "Fluids and Lubricants". • Use procedure below to check for fuel leakage. • Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel leakage at the connection points. • Start engine. With engine speed increased, check again for fuel leakage at connection points. • Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises. • Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant. • Bleed air from passages in lines and hoses, such as in cooling system. • After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level if necessary. • Summary of the inspection items: Item

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluids*

Level

Leakage

Level

Leakage

—

Leakage

—

Fuel Exhaust gas

*Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

Revision: November 2008

EM-52

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR >

CAMSHAFT

Exploded View

INFOID:0000000003787045

J AWBIA0101GB

Cylinder head RH bank

Camshaft bracket (No. 2, 3, 4, 5)

Valve lifter

Camshaft bracket (No. 1)

Seal washer

Camshaft RH bank EXH

Camshaft RH bank INT

Camshaft LH bank INT

Camshaft LH bank EXH

10. Camshaft sprocket RH bank EXH

11. Camshaft sprocket RH bank INT (VTC)

12. Camshaft sprocket LH bank INT (VTC)

13. Camshaft sprocket LH bank EXH

14. Camshaft position sensor (PHASE)

15. O-ring

16. Cylinder head LH bank

Refer to EM-53

Removal and Installation

INFOID:0000000003787046

NOTE: Do not remove the engine assembly to perform this procedure.

REMOVAL 1.

Remove the RH bank and LH bank rocker covers. Refer to EM-38, "Removal and Installation". P

Revision: November 2008

EM-53

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > 2. Obtain compression TDC of No. 1 cylinder as follows: a. Turn the crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with the timing indicator on the front cover.

KBIA2476E

At this time, make sure both intake and exhaust cam lobes of No. 1 cylinder (top front on LH bank) point outside. â&#x20AC;˘ If they do not point outside, turn crankshaft pulley once more.

KBIA0400J

3. a. b.

Remove the intake valve timing control solenoid valve cover (RH) (A) and intake valve timing control solenoid valve cover (LH) (B) as follows: Loosen and remove the bolts as shown. Cut the liquid gasket and remove the covers using Tool. Tool number

: KV10111100 (J-37228)

CAUTION: Do not damage mating surfaces. WBIA0798E

Paint alignment marks on the RH bank (A) timing chain links (C) and LH bank (B) timing chain links (D) and align with the camshaft sprocket alignment marks (E) and (F).

AWBIA0154ZZ

Remove the chain tensioner (LH) using the following steps. WARNING: Plunger, spring, and spring seat pop out when squeezing return-proof clip without holding plunger head. It may cause serious injuries. Always hold plunger head when removing.

Revision: November 2008

EM-54

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > a. Squeeze return-proof clip ends using suitable tool and push the plunger into the tensioner body. b. Secure plunger using stopper pin. • Stopper pin is made from hard wire approximately 1 mm (0.04 in) in diameter. c. Remove the bolts and the chain tensioner.

C KBIA2479E

NOTE: • Stop plunger in the fully extended position using return-proof clip (1) if stopper pin is removed. • Push the plunger (2) into the chain tensioner body while squeezing the return-proof clip (1). Secure it using stopper pin (3).

G KBIA2483E

Remove the chain tensioner cover from the front cover using Tool. Tool number

: KV10111100 (J-37228)

CAUTION: Do not damage mating surfaces.

K KBIA2521E

a. b.

Remove the chain tensioner (RH) using the following steps. WARNING: Plunger, spring, and spring seat pop out when squeezing return-proof clip without holding plunger head. It may cause serious injuries. Always hold plunger head when removing. Squeeze return-proof clip ends using suitable tool and push the plunger into the chain tensioner body. Secure plunger using stopper pin. • Stopper pin is made from hard wire approximately 1 mm (0.04 in) in diameter.

P KBIA2479E

Revision: November 2008

EM-55

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > c. Remove the bolts and the chain tensioner (RH) (A). NOTE: If it is difficult to push plunger on chain tensioner (RH) (A), remove the plunger under extended condition.

WBIA0705E

Loosen camshaft sprocket bolts as shown and remove camshaft sprockets. CAUTION: To avoid interference between valves and pistons, do not turn crankshaft or camshaft with timing chain disconnected.

KBIA2485E

Remove the RH (A) front cover bolts and the LH (B) front cover bolts.

WBIA0706E

10. Remove RH (A) camshaft bracket bolts and LH (C) camshaft bracket bolts in the reverse of order shown to remove camshaft brackets. • Remove No. 1 camshaft bracket. NOTE: The bottom and front surface of bracket will be stuck because of liquid gasket. • ⇐: Engine front • B: Exhaust side • D: Intake side

WBIA0707E

Revision: November 2008

EM-56

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > 11. Remove the camshaft. 12. Remove the valve lifters if necessary. • Correctly identify location where each part is removed from. Keep parts organized to avoid mixing them up.

INSPECTION AFTER REMOVAL Camshaft Runout

1. 2. 3.

Put V block on precise flat work bench, and support No. 1 and No. 5 journals of the camshaft. Set dial indicator vertically to No. 3 journal. Turn the camshaft to one direction, and measure the camshaft runout on dial indicator (total indicator reading). Camshaft runout

: Less than 0.02 mm (0.0008 in)

• If measurement exceeds specification, replace the camshaft. EMK0641D

Camshaft Cam Height • Measure the camshaft cam height. G

Standard cam height (intake) Standard cam height (exhaust) Cam wear limit (intake & exhaust)

: 44.865 - 45.055 mm (1.7663 - 1.7738 in) : 45.075 - 45.265 mm (1.7746 - 1.7821 in) : 0.02 mm (0.0008 in)

• If measurement is not within the specifications, replace the camshaft.

I PBIC0039E

Camshaft Journal Clearance Camshaft Journal Diameter

• Measure the diameter of the camshaft journal. Standard diameter

: 25.950 - 25.970 mm (1.0217 - 1.0224 in)

PBIC0040E

Camshaft Bracket Inner Diameter

• Tighten the camshaft bracket bolt to the specified torque. • Measure the inner diameter (A) of the camshaft bracket. Standard

: 26.000 - 26.021 mm (1.0236 - 1.0244 in)

Calculation of Camshaft Journal Clearance (Journal clearance) = (camshaft bracket inner diameter) – (camshaft journal diameter) Standard

: 0.030 - 0.071 mm (0.0012 - 0.0028 in)

• If measurement is not within specification, replace either or both camshaft and cylinder head. Revision: November 2008

EM-57

PBIC1645E

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > NOTE: The inner diameter of the camshaft bracket is manufactured together with the cylinder head. Replace the whole cylinder head as an assembly. Camshaft End Play • Install dial gauge in the thrust direction on the front end of the camshaft. Measure the end play when the camshaft is moved forward/ backward (in direction to axis).

Standard

: 0.115 - 0.188 mm (0.0045 - 0.0074 in)

• If measurement is out of the specified range, replace the camshaft and measure again. • If measurement is still out of the specified range, replace the cylinder head. PBIC0042E

• Measure the following parts if end play is outside the specified value. - Dimension ″A″ for camshaft No. 1 journal Standard

: 30.500 - 30.548 mm (1.2008-1.2027 in)

- Dimension ″B″ for cylinder head No. 1 journal Standard

: 30.360 - 30.385 mm (1.1953-1.1963 in)

• If measurements are not within specification, replace the camshaft and/or cylinder head.

KBIA2426J

Camshaft Sprocket Runout

1. 2. 3.

Install the camshaft in the cylinder head. Install the camshaft sprocket to the camshaft. Measure the camshaft sprocket runout. Runout

: Less than 0.15 mm (0.0059 in)

• If measurement exceeds the specification, replace the camshaft sprocket.

KBIA0181J

Valve Lifter Check if the surface of the valve lifter has any wear or cracks. • If any damage is found, replace the valve lifter. • Select the thickness of the head so that the valve clearance is within the standard when replacing. Refer to EM-18, "Valve Clearance".

KBIA0182E

Valve Lifter Clearance Valve Lifter Diameter

Revision: November 2008

EM-58

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > • Measure the diameter of the valve lifter. A

Standard

: 33.977 - 33.987 mm (1.3377 - 1.3381 in) EM

C JEM798G

D Valve Lifter Hole Diameter

• Measure the diameter of the valve lifter hole of the cylinder head, using suitable tool. Standard

: 34.000 - 34.016 mm (1.3386 - 1.3392 in)

Calculation of Valve Lifter Clearance (Valve lifter clearance) = (valve lifter hole diameter) – (valve lifter diameter) Standard

: 0.013 - 0.039 mm (0.0005 - 0.0015 in)

• If the measurement is not within specification, referring to each specification of the valve lifter diameter and hole diameter, replace either or both the valve lifter and cylinder head.

PBIC0043E

INSTALLATION 1. 2.

Install the valve lifters if removed. • Install removed parts in their original locations. Install the camshafts. Use the table below for identification of the RH and LH, and intake and exhaust. Bank RH

INT EXH

Identification paint (front)

Identification paint (rear)

Identification rib

INT

Pink

—

Yes

EXH

—

Orange

Yes

INT

Pink

—

EXH

—

Orange

L KBIA2523E

• Install so that the RH bank (B) dowel pins (A) and LH bank (C) dowel pins (A) at the front of the camshaft face are in the direction shown.

P WBIA0708E

Revision: November 2008

EM-59

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > 3. Install the RH bank (B) and LH bank (D) camshaft brackets (A). • Install by referring to the installation location mark (E) on the upper surface. • Install so that the installation location mark (E) can be correctly read when viewed from the intake manifold side (C). ⇐

: Front

AWBIA0164ZZ

• • • -

Install No. 1 camshaft bracket using the following procedure: C:11 mm (0.43 in) D: 2.0 - 3.0 mm (0.079 - 0.118 in) dia. Apply liquid gasket to No. 1 camshaft bracket (A) and (B) as shown. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". CAUTION: • After installation, be sure to wipe off any excessive liquid gasket outside of application (C) and (D) both on RH and LH sides. • Remove completely any excess of liquid gasket inside bracket.

WBIA0710E

- Apply liquid gasket (C) to the back side of the LH (A) bank front cover and RH (B) bank front cover as shown. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". C:2.6 - 3.6 mm (0.102 - 0.142 in) dia.

WBIA0711E

Revision: November 2008

EM-60

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > - Position No. 1 camshaft bracket close to the mounting position, and then install it to prevent from touching liquid gasket applied to each surface.

C SBIA0259E

- Temporarily tighten the RH (A) and LH (B) front cover bolts (4 for each bank) as shown. E

G WBIA0706E

Tighten the camshaft bracket bolts as follows:

Camshaft bracket bolts Step 1 (bolts 9 - 12) : 2.0 N·m (0.2 kg-m, 17 in-lb) Step 2 (bolts 1 - 8) : 2.0 N·m (0.2 kg-m, 17 in-lb) Step 3 (all bolts) : 5.9 N·m (0.6 kg-m, 52 in-lb) Step 4 (all bolts) : 10.4 N·m (1.1 kg-m, 92 in-lb)

CAUTION: After tightening the camshaft bracket bolts, be sure to wipe off excessive liquid gasket from the parts listed below. • Mating surface of rocker cover • Mating surface of front cover • A: RH bank • B: Exhaust side • C: LH bank • D: Intake side • ⇐: Front

N WBIA0707E

Tighten the RH (A) and LH (B) front cover bolts (4 for each bank) as shown to the specified torque. Front cover bolts

: 11.0 N·m (1.1 kg-m, 8 ft-lb)

WBIA0706E

Revision: November 2008

EM-61

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > 5. a.

Install the camshaft sprockets using the following procedure: • A: LH bank shown Install the camshaft sprockets aligning them with the matching marks painted on the timing chain (B) and the camshaft sprockets (C) before removal. Align the camshaft sprocket key groove with the dowel pin on the camshaft front edge at the same time. Then temporarily tighten camshaft sprocket bolts.

AWBIA0152ZZ

b. c.

• Install the intake (VTC) (A) and exhaust (B) side camshaft sprockets by selectively using the groove of the dowel pin according to the bank for the exhaust (B) side camshaft sprockets. (Common part used for both exhaust banks.) NOTE: Use the groove marked "R" for RH bank and "L" for LH bank. Lock the hexagonal part of the camshaft in the same way as for removal, and tighten the camshaft sprocket bolts. Check again that the timing alignment mark on the timing chain and on each sprocket are aligned. AWBIA0151ZZ

6. a.

Install the chain tensioner using the following procedure: NOTE: LH is shown. Install the chain tensioner. • Compress the plunger and hold it using a stopper pin when installing. • Loosen the slack guide side timing chain by rotating the camshaft hexagonal part if mounting space is small. Chain tensioner bolts

b. c.

Remove the stopper pin and release the plunger, and then apply tension to the timing chain. Install the chain tensioner cover onto the front cover. • Apply liquid gasket as shown. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". Chain tensioner cover bolts

7. 8.

: 6.9 N·m (0.70 kg-m, 61 in-lb) KBIA2479E

: 9.0 N·m (0.92 kg-m, 80 in-lb)

Check and adjust valve clearances. Refer to EM-18, "Valve Clearance". Installation of the remaining components is in the reverse order of removal.

Inspection after Installation

KBIA2547E

INFOID:0000000003787047

INSPECTION OF CAMSHAFT SPROCKET (INT) OIL GROOVE WARNING: Check when engine is cold so as to prevent burns from any splashing engine oil. CAUTION:

Revision: November 2008

EM-62

2009 Titan

CAMSHAFT < ON-VEHICLE REPAIR > Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT III and it is directed according to inspection procedure of EC section. Refer to EC-92, "On Board Diagnosis A Logic". 1. Check engine oil level. Refer to LU-8, "Inspection". 2. Perform the following procedure so as to prevent the engine from being unintentionally started while EM checking. a. Release fuel pressure. Refer to EC-481, "Fuel Pressure Check". C b. Disconnect ignition coil and injector harness connectors if practical. 3. Remove IVT control solenoid valve. 4. Crank engine, and then make sure that engine oil comes out from IVT control cover oil hole. End cranking D after checking. WARNING: Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.). CAUTION: E • Engine oil may squirt from IVT control solenoid valve installation hole during cranking. Use a shop cloth to prevent engine oil from splashing on worker, engine components and vehicle. • Do not allow engine oil to get on rubber components such as drive belts or engine mount insulaF tors. Immediately wipe off any splashed engine oil. 5. Clean oil groove between oil strainer and IVT control solenoid valve if engine oil does not come out from IVT control valve cover oil hole. Refer to LU-7, "Schematic". G 6. Remove components between IVT control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. • Clean oil groove if necessary. H 7. After inspection, installation of the remaining components is in the reverse order of removal. I

Revision: November 2008

EM-63

2009 Titan

OIL SEAL < ON-VEHICLE REPAIR >

OIL SEAL Removal and Installation of Valve Oil Seal

INFOID:0000000003787048

REMOVAL 1. 2. 3. 4.

Remove the camshaft relating to the valve oil seal to be removed. Refer to EM-53, "Removal and Installation". Remove the valve lifters. Refer to EM-70, "Exploded View". • Correctly identify the location where each part is removed from. Keep parts organized to avoid mixing them up. Turn the crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent the valve from dropping into the cylinder. Remove the valve collet using Tool. Tool number

: KV10116200 (J-26336-A) : KV10115900 (J-26336-20) : KV10109220 ( — )

CAUTION: Do not damage the valve lifter holes. Remove the valve spring retainer and valve spring. CAUTION: Do not remove the valve spring seat from the valve spring.

WBIA0578E

Remove the valve oil seal using Tool. Tool number

: KV10107902 (J-38959)

WBIA0478E

INSTALLATION Installation is in the reverse order of removal. • Install the valve oil seal using Tool. Tool number

: KV10115600 (J-38958)

• Apply new engine oil on the new valve oil seal joint and seal lip. • Install the valve oil seal to the specified height "H". Height "H" (without valve spring installed) Intake and exhaust : 14.300 - 14.900 mm (0.5630 0.5870 in) WBIA0490E

Removal and Installation of Front Oil Seal

INFOID:0000000003787049

REMOVAL 1. 2.

Remove the engine. Refer to EM-78, "Removal and Installation". Remove the crankshaft pulley. Refer to EM-45, "Removal and Installation".

Revision: November 2008

EM-64

2009 Titan

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