PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" ron mantrene
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. Information necessary to service the system safely is included in the “SRS AIR BAG" and
“SEAT BELT" of this Service Manual
WARNING:
Always observe the following items for preventing accidental activation.
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSANJINFINITI 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 “SRS AIR BAG”.
+ Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
+ When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
fn ON oF ene |, Never use ait of electric power tools or strike near the sensor(s) with
a hammer, Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
+ When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
CAUTION:
‘Comply with the following cautions to prevent any error and malfunction.
+ Before removing and installing any control units, first turn the ignition power source and accessory
power source to the OFF, then disconnect both battery cables,
+ After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
+ Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, ifthe battery is disconnected or discharged, the steering wheel will lock and
cannot be tumed,
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation
OPERATION PROCEDURE
1, Connect both battery cables.
NOTE:
‘Supply power using jumper cables if battery is discharged,
2, Open driver door,
3, Turn the ignition switch to the ON position.
(At this time, the steering lock will be released.)
4, Turn the ignition switch to OFF position with driver door open.
5, Wait for 3 minutes or longer with driver door open.
NOTE:
+ Do not close driver door because the steering wheel locks when driver door is closed.
EXT-3 PRECAUTIONS
< PRECAUTION >
* The auto ace function is adapted to this vehicle. For this reason, even when the ignition switch is tured
to OFF position, the accessory power source does not turned OFF and continues to be supplied for a
certain amount of time.
6. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned,
7. Perform the necessary repair operation.
8, When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from OFF position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
9. Perform self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover
‘When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
‘windshield.
Precautions for Removing Battery Terminal rooasn oe
+ With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time,
‘When disconnecting the 12V battery terminal, turn off the ACC ‘
te
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occu.
For vehicles with the 2-batteries, be sure tconnéct the main bat-
tery and the sub battery before turning Gi the igaition switch
NOTE: -
If the ignition switch is turned ON with any ene of the terminals of
main battery and sub battery disconnected; tien DYC may be detected
+ After installing the 12V battery, always check "Self Diagnosis Result” of all ECUs ayxd erase DTC.
NOTE: '
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
INSTRUCTION 4
1. Open the hood.
2, Tum key switch to the OFF position with the driver side door opened.
3. Get out of the vehicle and close the driver side door.
4
‘Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
4D engine: 20 minutes
HRA2DOT — : 12 minutes.
EXT PRECAUTIONS.
< PRECAUTION >
Kekengine = éminutes
NOR engine -4 minutes
RoM engine: 4 minutes
Vex engine: minutes
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5. Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
1, Unlock the door with intelligent key or remote keyless entry.
NoTi
A this moment, ACC power is supplied.
‘Open the driver side door.
‘Open the hood,
Close the driver side door.
Wait at least 3 minutes.
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
6. Remove 12V battery terminal
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
oaen
EXT-5 PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
Commercial Service Tools
Toone Descrstion
Engine ear 2 Locates the noise
EXT-6 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Work Flow strometenaerss
————
‘Check Fined Service Bullen
‘Govivn Rapa
To«
CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any of
the customer's comments; refer to EXT-11 "Diagnostic Worksheet”, This information is necessary to duplicate
the conditions that exist when the noise occurs.
+ The customer may not be able to provide a detailed description or the location of the noise. Attempt to obtain
all the facts and conditions that exist when the noise occurs (or does not occur)
+ If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer is
concemed about. This can be accomplished by a test drive with the customer.
After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics ca
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.
Squeak - (Like tennis shoes on a clean floor)
‘Squeak characteristics include the light contactfast movement/brought on by road conditions/hard surfaces
igher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping
+ Creak — (Like walking on an old wooden floor)
Creak characteristics include fim contact/slow movementitwisting with a rotational movementipitch depen-
dent on materials/often brought on by activity.
+ Rattle — (Like shaking a baby rattle)
Rattle characteristics include the fast repeated contact/vibration or similar movementiloose parts/missing
clip or fastenerlincorrect clearance
+ Knock — (Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action
+ Tick ~ (Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action of road conditions,
+ Thump — (Heavy, muffied knock noise)
‘Thump characteristics include softer knock/dead sound often brought on by activity.
+ Buzz — (Like a bumbie bee)
Buzz characteristics include high frequency rattle/firm contact
+ Often the degree of acceptable noise level will vary depending upon the person. A noise that @ technician
may judge as acceptable may be very irritating to the customer.
+ Weather conditions, especially humidity and temperature, may have a great effect on noise level.
DUPLICATE THE NOISE AND TEST DRIVE
EXT-7 SQUEAK AND RATTLE TROUBLE DIAGNOSES:
< SYMPTOM DIAGNOSIS >
if possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions vihen the repair is reconfirmed.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all ofthe following:
1) Close a door.
2) Tap or push/pull around the area where the noise appears to be coming from.
3) Rev the engine.
4) Use a floor jack to recreate vehicle “twist
5) At idle, apply engine load (electrical load, hatf-clutch on MT model, drive position on A/T model).
6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.
+ Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise ocours.
+ If itis dificult to duplicate the noise, drive the vehicle slovdy on an undulating or rough road to stress the
vehicle body,
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening too!
Engine Ear or mechanics stethoscope).
2. Narrow down the noise to a more specific area and identify the cause of the noise by:
+ Removing the components in the area that is are suspected to be the cause of the noise.
Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be broken
oF lost during the repair, resulting in the creation of new noise.
+ Tapping or pushing/pulling the component that is are suspected to be the cause of the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only tem-
porarily.
+ Feeling for a vibration by hand by touching the component(s) that is are suspected to be the cause of the
noise.
+ Placing a piece of paper between components that is are suspected to be the cause of the noise,
+ Looking for loose components and contact marks.
Refer to EXT-S, "Inspection Procedure".
REPAIR THE CAUSE
+ Ifthe cause is a loose component, tighten the component securely,
* Ifthe cause is insufficient clearance between components:
= Separate components by repositioning or loosening and retightening the component, it possible.
- Insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure~
thane tape, These insulators are available through the authorized Nissan Parts Department.
CAUTION:
Never use excessive force as many components are constructed of plastic and may be damaged.
NOTE:
+ URETHANE PADS
Insulates connectors, hamess, etc.
+ INSULATOR (Foam blocks)
insulates components from contact. Can be used to fill space behind a panel.
+ INSULATOR (Light foam block)
+ FELT CLOTHTAPE
Used to insulate vihere movement does not occur, Ideal for instrument panel applications.
The following materials, not available through NISSAN Parts Department, can also be used to repair
squeaks and rattles.
+ UHMW(TEFLON) TAPE
Insulates where slight movement is present. Ideal for instrument panel applications.
+ SILICONE GREASE
Used in place of UHMW tape that is be visible or does not fit.
‘Note: Will only last a few months.
+ SILICONE SPRAY
Used when grease cannot be applied.
+ DUCT TAPE
Used to eliminate movement.
CONFIRM THE REPAIR
EXT-8 SQUEAK AND RATTLE TROUBLE DIAGNOSES:
< SYMPTOM DIAGNOSIS >
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally ocourred. Refer to the notes on the Diagnostic Worksheet
Inspection Procedure wroemowanererit
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1, Cluster lid A and instrument panel
Acrylic lens and combination meter housing
Instrument panel to front pillar garnish
Instrument panel to windshield
Instrument panel mounting pins
Wiring harnesses behind the combination meter,
7. AC defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-
ing felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
‘CAUTION:
Never use silicone spray to isolate a squeak or rattle. if the area is saturated with si
of repair becomes impossible.
CENTER CONSOLE
Components to pay attention to include:
1, Shifter assembly cover to finisher
2, AIC control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console,
DOORS
Pay attention to the following:
1, Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. The areas can usually be insulated with felt cloth tape or insulator foam blocks to
repair the noise.
TRUNK
‘Trunk noises are often caused by a loose jack or loose items put into the trunk by the customer.
In addition look for the following:
4. Trunk fid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3, Trunk lid torsion bars knocking together
4, A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or components) caus~
ing the noise,
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1, Sunroof ld, ral, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
oanen
‘one, the recheck
EXT-9 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
‘Again, pressing on the components to stop the noise while duplicating the conditions
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS,
When isolating seat noise it is important to note the position the seat is in and the load placed on the seat
when the noise occurs. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A-squeak between the seat pad cushion and frame
3. Rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
of applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the en:
‘Components that pass through the engine wall
Engine wall mounts and connectors
Loose radiator mounting pins
Hood bumpers out of adjustment
6. Hood striker out of adjustment
‘These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
isolate most of these
EXT-10 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
Diagnostic Worksheet oocwnereorerss
SQUEAK & RATTLE
DIAGNOSTIC WORKSHEET
Dear Nissan Customer:
We are concerned about your satisfaction with your Nissan vehicle. Repairing a squeak
or rattle sometimes can be very difficult. To help us fix your Nissan right the first time,
please take a moment to note the area of the vehicle where the squeak or rattle occurs
and under what conditions. You may be asked to take a test drive with a service advisor
or technician to ensure we confirm the noise you are hearing.
|. WHERE DOES THE NOISE COME FROM? (circle the area of the vehicle)
The illustrations are for reference only, and may not reflect the actual configuration of
your vehicle.
occurs.
EXT-11 SQUEAK AND RATTLE TROUBLE DIAGNOSES
< SYMPTOM DIAGNOSIS >
‘SQUEAK & RATTLE DIAGNOSTIC WORKSHEET - page
Briefly describe the location where the noise occurs:
IL WHEN DOES IT OCCUR? (please check the boxes that apply)
anytime ater siting ut inthe rain
1 tsttime in the moming 1 when itis raining or wet
1 only when itis cold outside 1 aty or dusty conditions
1 only when itis hot outside Oi other:
I WHEN DRIVING: IV. WHAT TYPE OF NOISE
C1 through driveways 1 squeat (tke tennis shoes on a clean flor)
1 over rough roads 1 creak tike-weiking on an old wooden floor)
Ci over speed bumps 1 ate (ike shaking a baby rattle)
Ci only about__mph knock (like krivek atthe door)
Ti on acceleration tick (ike @ clock second hand)
Ti coming to stop 1 thump (heavy, mutled knock noise)
Con tums: left right or either (circle) buzz (like a bumble bee)
CO with passengers or cargo
O other:
Cater criving miles or minutes
‘TO BE COMPLETED BY DEALERSHIP PERSONNEL
Test Drive Notes:
YES NO _ Initials of person
performing
Vehicle test driven with customer a a
~ Noise verified on test drive a a
- Noise source located and repaired a a
- Follow up test drive performed to confirm repair ao a
VIN: (Customer Name:
Woe ate:
‘This form must be attached to Work Order
oo BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION >
VEHICLE INFORMATION
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color
Taorcade BEAN | BEAR | BG] BAGS | BKAD | BOAB | BRAG
Deseapton | Rea | %ROFT orange | sick | swer | Gray | wnie | Dar
Component
Paint type" | 2S 2PM 2PM 2 | aM 2M 3p 2M
Hard eer ]
@] Doormirercover | Bedyccior | BANS | BEAN | BEAR | Ge | GK23 | BKAD | BOAB | BRAG
hremium
| Fronile oe ef ale] elelala| e
Sect — fare a oe | fer
@® Filet moiging Material color | — = ia 3 = a 2
@| Pomrousaenanse | Sremm | cr | ce | ce | ew | | |e |
@| Rear spoiler (Side) | Black or | Gor | Gor | Gor | oor | Gor | cor | cor
“© | Rearspoier(Uppet) | Body coir | BAX6 | BEAN | BEAR | BG4 | BK23 | BKAD | BOAB | BRAG
@| Backccormaner [SRO [cr | er foe | @ | @ | @ | a | oe
| Back door Body color | axe | BEAN | BEAR BGai | BK2 | BKAD | BOAE | BRAG
| Sileover watratcoor| - | - | - | - | - | -|- |=
Material calor L - Pron
NOTE:
+ 2M: 2-Coat Metalic
+ 2P: 2.Coat pear
+ 28:2-Goat solid
+ 3P:3-Coat peart
+ 2PM: 2-Coat Pearl metalic
EXT-13 FRONT BUMPER
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
FRONT BUMPER
Exploded View
‘SEC. 263-620
Se iS
pe
@
é
Pyz0120.15)
@ Front bumper side bracket RH @)_Front umper stay RH @ Front bumper reinforcement
@ Front impor shernyabeoiber(@_“Hoadarmpvashercoveri, qian bumoer feb
(thout front fog fam)
Front bumper finisher RH Front bumper finisher LH
® ein ront og ime) 3B) Front aged sole: ® Goth tront og imp
EXT-14 FRONT BUMPER
< REMOVAL AND INSTALLATION >
Front bumper finisher LH
kPa @ Bumper bracket cover @ Headlamp washer cover LH
@ Front bumper fascia @ Front fog lamp LH ® Apron bracket
@ Front bumper side bracket LH @_Front bumper stay LH @ Front fog lamp RH
@ Front bumper nile
fy Paw
FD nmgigm, ti)
©, 4. ¥, @ indicates that te partis connected at poins wth same eymbal in actual vehicle
Removal and Installation wroesunev ant
CAUTIOI
Bumper fascia is made of resin. Never apply strong force to it, and be careful to prevent contact with
oil
REMOVAL
1. Fully open hood assembly.
2, Remove front grille. Refer to EXT-22, “Removal and Installation”.
3. Remove front bumper fascia fixing clips ® of bumper upper
side
4, Remove engine under cover fixing clips @ of bumper lower side.
<2 Vehicle front
5. Remove front spoiler. Refer to EXT-25. "Removal ang Installation”.
6. Remove front bumper fascia fixing screws @ lower side of the
bumper both end.
<2: Vehicle front
7, Remove front side of front filet molding (LH and RH). Refer to EXT-32, "i
Removal and Installation
EXT-15 FRONT BUMPER
< REMOVAL AND INSTALLATION >
@ Remove grommet @ front side of fender protector (LH and RH).
<2 Vehicte front
9. Remove front bumper fascia fixing screws @ (LH and RH),
<2 Vehicle front
10. Apply protective tapes (A) on the part to protect it from damage.
11. Pull bumper fascia side toward the vehicle side to disengage the
fiting of bumper side bracket and bumper fascia side according
to the numerical order 1-32 as shown by the arrows in the fig-
ure.
e ae
CAUTION: c ee
When removing bumper fascia assembly, 2 workers are 4
required so as to prevent it from dropping.
Paw
12. Disconnect front fog lamp harness connectors (LH and RH). (if equipped)
13. Disconnect front sonar sensor harness connectors (LH and RH). (if equipped)
14, Disconnect headlamp washer tube connector, and then remove headlamp washer tube from washer
pump. (if equipped)
1. Remove front bumper fascia assembly.
CAUTION:
When removing bumper fascia assembly, 2 workers are required so as to prevent it from dropping.
16. Remove the following parts after removing front bumper fascia assembly,
+ Front fog lamp. Refer to the following. (if equipped)
- LED HAEDLAMP: Refer to EXL-193, "Removal and Installation’,
- HALOGEN HEADLAMP: Refer to EX(-379, “Removal and Installation’,
EXT-16 FRONT BUMPER
< REMOVAL AND INSTALLATION >
~ Front sonar sensor. Refer to the following. (irequipped)
+ WITH PARK ASSIST: Refer to SN-299, “FRONT Removal and Installation’,
- WITHOUT PARK ASSIST: Refer to SN-113. "FRONT Removal and Installation’.
+ Headlamp washer tube. Refer to Wiv-107. "WASHER TUBE Removal and Installation’. (if equipped)
+ Headlamp washer nozzle, Refer to WW-105. "WASHER NOZZLE | Removal and Installation’. (if
equipped)
+ Front bumper side bracket (LH and RH).
+ Front bumper finisher (LH and RH).
+ Front bumper grille.
+ Front bumper molding
+ Bumper bracket cover.
17. Remove front bumper energy absorber.
18. Remove apron bracket mounting nuts and fixing clips, and then remove apron bracket,
19. Remove front bumper reinforcement
a. Remove harness clip.
b. Disengage ambient sensor fixing pawl.
c, Remove intelligent key warning buzzer mounting bolt. (with intelligent key system)
1d. Remove distance radar mounting bolts. (if equipped)
e. Remove front bumper reinforcement mounting nuts, and then remove front bumper reinforcement.
20. Remove front bumper stay mounting bolts, and then remove front bumper stay (LH and RH)
INSTALLATION
Note the folowing Heme, and then instal nthe reverse order of removal
* The following table shows the specified values for checking normal installation status.
+ Fitting adjustment cannot be performed
combination lamp (0.004 — 0.118 in)
Front bumperfascia-Front | @ _ 0.1-4.0 mm
fender panel (0.004 — 0.039 in)
(0.3) —(#4.7) mm
[(-0.012) - (+0.067) in}
Portion Clearance | Surface height difference
5 01-30mm | o
(0.004-0.118 in) |
Front bumper fascia ~ front grille
5 0.4-3.0mm =
(0.004 0.118 in)
Front bumper fascia — Front " 04-30 mm
EXT-17 REAR BUMPER
< REMOVAL AND INSTALLATION >
REAR BUMPER
Exploded View ee
SEC. 265-850
W)z0(21.95)
Bi2002,19
e021)
@ Rearbumper side bracketLH--@_ Grommet @ Rear bumper stay LH
@ Rear bumper fascia © Reflex reflector LH @ _ Rear tog amp (it equipped)
Rear bumper riser
alent © Reflex efector RH @ Rear bumper rinforcoment
@ Rear bumper stay RH @ Rear bumper sie bracket RH
Ey Paw
(9) Nm Gorm. ine)
©) tem hm, by
©, 4. ¥. © 0 insicates thatthe partis connected at points with same symbol in actual vehicle.
Removal and Installation roca ors
CAUTION:
Bumper fascia is made of resin. Never apply strong force to it, and be careful to prevent contact with
EXT-18 REAR BUMPER
< REMOVAL AND INSTALLATION >
REMOVAL
4. Fully open back door.
2. Remove back side of rear fillet molding (LH and RH). Refer to "
‘Removal and Installation",
3. Remove rear bumper fascia fixing screws @ of bumper upper
side
4. Remove rear bumper fascia fixing clips @ of bumper lower side.
5. Remove rear bumper fascia mounting bolt @ and fixing clip
lower side of bumper both end.
<2: Vehicle front
6. Remove rear bumper fascia mounting bolt @ (LH and RH)
EXT-19 REAR BUMPER
< REMOVAL AND INSTALLATION >
7. Apply protective tape (A) on the part to protect it from damage.
8. Pull rear bumper fascia side toward the vehicle side to disen-
gage the fitting of rear bumper side bracket and rear bumper
fascia side according to the numerical order 123 as shown by
the arrows in the figure.
CAUTION:
When removing bumper fascia, 2 workers are required so
as to prevent it from dropping.
Pawi
9. Disconnect rear fog lamp hamess connector. (if equipped)
10. Disconnect rear sonar sensor harness connector. (if equipped)
11, Remove rear bumper fascia assembly.
CAUTION:
When removing bumper fascia, 2 workers are required so as to prevent it from dropping.
12, Remove the following parts after removing rear bumper fascia assembly.
+ Rear fog lamp, Refer othe folowing. (f equipped)
~ LED HEADLAMP: Refer to
«HALOGEN HEADLAMP: Refer o
+ Rear sonar sensor. Refer to the following re aeaeey
- WITH PARK ASSIST: Refer to
- WITHOUT PARK ASSIST: Refer to SN-114, "REAR - Removal and Installation’,
+ Reflex reflector. Refer to EXL-212, "Removal and Installation’.
+ Rear bumper finisher. (if equipped)
13. Remove rear bumper reinforcement mounting nuts, and then remove rear bumper reinforcement,
14. Remove reat bumper stay mounting bolts, and then remove rear bumper stay (LH and RH),
INSTALLATION
Note the following items, and then install in the reverse order of removal
NOTE:
+ The following table shows the specified values for checking normal installation status.
+ Fitting adjustment cannot be performed.
EXT-20 < REMOVAL AND INSTALLATION >
REAR BUMPER
Portion Clearance ‘Surface height difference
5.5-9.5mm
6-6 , €
Rear bumper fascia—Back door |®~®| (0.217 -0.374.in)
panel 3.0-7.0mm (1.8) - (#2.4) mm
(0.118 — 0.276 in) {(-0.071) — (+0.094) in]
Rear bumper fascia — Rear fender 0.1-1.0 mm (-0.3) — (+1.7) mm_
panel
(0.004 — 0.039 in)
[(-0.012) - (+0.087) in]
EXT-21 FRONT GRILLE
< REMOVAL AND INSTALLATION >
FRONT GRILLE
Exploded View
SEC. 260623
© Tum fastoner ® Grommet @ Front emblem
® Front grile © Front camera (if equlppes)
© slip
Paw
Removal and Installation
REMOVAL
1. Fully open hood assembly.
EXT-22 FRONT GRILLE
< REMOVAL AND INSTALLATION >
2 Remove front grille fixing clips @ of front grille upper side.
<2 Vehicle tront
3. Todisengage fasteners, locate the service holes top position of front grille. Insert a flat-biaded screwdriver
(A) into the service hole on vehicle left side and rotate turn fastener counterclockwise. Insert the flat-
bladed screwdriver into the service hole on vehicle right side and rotate turn fastener clockwise
4, Disengage front grille fixing clips and pawis from back side while
Pulling front grille toward vehicle front
O ete
5. Disconnect front camera hamess connector. (if equipped)
6. Remove front grille.
7. Remove the following parts after removing front grille.
+ Front camera. Refer to AV-269, "Removal lation’. (if equipped)
+ Front emblem.
INSTALLATION
Note the following item, and then install in the reverse order of removal.
CAUTION:
When installing front grille, install turn fastener to back of front grille, and then install front grille.
EXT-23 COWL TOP
< REMOVAL AND INSTALLATION >
COWL TOP
Exploded View reco cewoncrereee2
‘SEC. 660
® Cow top seat ® Com top cover ® Coultop gile ip
@ Cow top cover cap © Cowl top extension @ EPT seal ft 100mm 0.384 in}
EXT-24 COWL TOP
< REMOVAL AND INSTALLATION >
@_EPTseal[t 3.0mm (0.118in))
© Clip
A: Paw
<2: Vehicle front
#54 Always replace after every disassembly.
Removal and Installation er
REMOVAL
1. Remove front wiper arm (LH and RH). Refer to WWit82. “WIPER ARM _ Removal and Installalion*
2. Remove fender cover (LH and RH). Refer to DLK.272 "FENDER COVER | Removal and Installation’
3. Remove cow! top insulator fixing clips @, and then remove cow!
top insulator (REM engine models anly)
4. Remove cowl top grille clip using a remover tool (A) according to
the numerical order 12 as shown by the arrows in the figure.
5. Cover cowl top cover @ and upper side of front fender panel
with a shop cloth (A) to prevent damage.
EXT-25 COWL TOP
< REMOVAL AND INSTALLATION >
6. Disengage cow! fop cover @ using a remover tool (A) fram wind-
shield glass lower molding @.
® : Windshield glass
7. Remove joint of front washer tube.
Remove cowl top cover.
9. Remove the following parts after removing cow! top cover.
+ EPT seal
+ Cow top seal.
+ Cowl top cover cap.
+ Front washer tube. Refer to WW-101, FRONT WASHER TUBE : Removal and Installation’.
+ Front washer nozzle, Refer to i !
10. Remove front wiper drive assembly, Refer to W\-85. "WIPER DRIVE ASSEMBLY» Removal and installa
tion’.
‘11. Remove cow! top extension mounting bolts and nut, and then remove cowl top extension
12. Remove EPT seal after removing cowl top extension,
INSTALLATION
‘Note the following items, and then install in the reverse order of removal
CAUTION:
* Clean the joint between the cowl top cover and the windshield, and then install them.
* Replace the EPT seal on the back surface with new EPT seal when reusing the cowl top cover
+ When installing cow! top cover ®, always match perfectly the
portion @ of cowl top extension @ with the portion @) of cowl
top cover.
SH
EXT-26 COWL TOP
< REMOVAL AND INSTALLATION >
+ When installing cow! top cover @, always engage perfectly the portion @ of cowl top cover with the
\dshield glass lower molding @, so that the surface height difference between the cowl top cover
and windshield glass () becomes “0”.
+ Never wash the vehicle within 24 hours after installing so as to keep adhesive.
+ After installing, perform adjustment of front wiper arms. Refer to WW-83. “WIPER ARM : Adjust-
ment’.
+ After installing, perform adjustment of front washer nozzle. Refer to WW-98. "FRONT WASHER NO2Z-
LE: Inspection and Adjustment".
EXT-27 FRONT SPOILER
< REMOVAL AND INSTALLATION >
FRONT SPOILER
Exploded View roo eoraeea3811
‘SEC. 960,
@® Front spoiler ® Spring nut
MUDGUARD
Exploded View
MUDGUARD
‘SEC. 630-760
@ Front mudguard
<5 Vehicle front
FRONT MUDGUARD
® Spring rut
EXT-29
@ Rear mudguard MUDGUARD
< REMOVAL AND INSTALLATION >
FRONT MUDGUARD : Removal and Installation
REMOVAL
Remove front mudguard fixing screws, and then remove front mudguard.
INSTALLATION
Install in the reverse order of removal.
REAR MUDGUARD
REAR MUDGUARD : Removal and Installation
REMOVAL
Remove rear mudguard fixing screws, and then remove rear mudguard.
INSTALLATION
Install in the reverse order of removal.
EXT-30 FILLET MOLDING
< REMOVAL AND INSTALLATION >
FILLET MOLDING
Exploded View occwnoreorertr
‘SEC. 767
@® Grommet ® Serew grommet @ Front fet molding
@ Rear filet molding
EXT-31 FILLET MOLDING
< REMOVAL AND INSTALLATION >
Clip
<= Veniale ont
FRONT FILLET MOLDING
FRONT FILLET MOLDING : Removal and Installation nrc oatrareae
REMOVAL
1. Remove front mudguard. Refer to EXT-30, "FRONT MUDGUARD Removal and _lostallation’. (if
equipped)
2. Remove front fillet molding fixing screws @ and clip ©.
<5 Vehicte front
3. Remove front filet molding fixing clips of front side according to
the numerical order 1-2 as shown in the figure.
2 elie
4. Apply protective tapes (A) on the part to protect it from damage.
<2 Vehicle front
5. Remove front fillet molding fixing clips using a remover tool (A),
and then remove front fillet molding,
© Clip
<> Vehicle font
6. Remove the following parts after removing front fillet molding,
EXT-32 FILLET MOLDING
< REMOVAL AND INSTALLATION >
+ Grommet
+ Screw grommet.
INSTALLATION
Note the following items, and then install in the reverse order of removal
CAUTION:
+ When installing front fillet molding, visually check the clips, then replace them with new parts if they
are damaged.
+ When installing front fillet molding, check that clips are securely fitted in fender panel holes, and
then press them in.
REAR FILLET MOLDING.
REAR FILLET MOLDING : Removal and Installation roo cir ares
REMOVAL
1. Remove rear mudguard. Refer to EXT-30, " DGUAR! ioval and Installation’. (if equipped)
2, Remove rear fillet molding fixing screws @),
<2 Vehicle front
3. Remove rear fillet molding fixing clips of rear side according to
the numerical order 12 as shown in the figure.
4. Apply protective tapes (A) on the part to protect it from damage.
<3 Vehicle front
EXT-33 FILLET MOLDING
< REMOVAL AND INSTALLATION >
5. Remove rear filet molding fixing clips using a remover tool (A),
and then remove rear filet molding
<3 Vehicle front
6. Remove the following parts after removing rear filet molding.
+ Grommet.
+ Screw grommet.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
+ When installing rear fillet molding, visually check the clips, then replace them with new parts if they
are damaged.
+ When installing rear fillet molding, check that clips are securely fitted in panel holes on body, and
then press them in.
EXT-34 FENDER PROTECTOR
< REMOVAL AND INSTALLATION >
FENDER PROTECTOR
FENDER PROTECTOR
FENDER PROTECTOR : Exploded View neocons
SEC. 630
® Front fender protector ® Oli rut @ Splash guard
@® Fender cio
<3 : Vehicle front
FENDER PROTECTOR : Removal and Installation woeaoncnceres:
REMOVAL
1. Remove front spoiler. Refer to £XT-28, “Removal and installation".
2. Remove front fillet molding. Refer to £XT-32, "FRONT FILLET MOLDING Removal and Installation’.
3, Remove splash guard fixing clips and then remove splash guard
EXT-35 FENDER PROTECTOR
< REMOVAL AND INSTALLATION >
4 Remove front fender protector fixing screws @ of front fender
protector front side.
REAR WHEEL HOUSE PROTECTOR : Exploded View
SEC. 767
@ Rearwheel house protector LH @) Sill cover LH ® Spring rut
@ Silcover RH © Rear whee! house protector RH
<2: Vehicle front
EXT-37 FENDER PROTECTOR
< REMOVAL AND INSTALLATION >
REAR WHEEL HOUSE PROTECTOR : Removal and Installation
REMOVAL
1. Remove rear fillet molding. Refer to EXT-33. "REAR FILLET MOLDIN(
2. Remove sill cover fixing clip @ of rear wheel house protector
front side,
faland Installation’.
3. Remove rear wheel house protector fixing clips of rear wheel house protector back side
4. Remove rear wheel house protector mounting bolt @ of rear
bumper fascia lower side
<2 = Vehicle front
5. Remove rear wheel house protector fixing clips, and then remove rear wheel house protector.
INSTALLATION
Install in the reverse order of removal
EXT-38 FLOOR SIDE FAIRING
< REMOVAL AND INSTALLATION >
FLOOR SIDE FAIRING
ENGINE UNDER COVER
ENGINE UNDER COVER : Exploded View
WITH R9M ENGINE MODELS
\
i
Vo
oly
® Engine under cover
WITHOUT R9M ENGINE MODELS
EXT-39 FLOOR SIDE FAIRING
< REMOVAL AND INSTALLATION >
‘SEC. 747
® Engine under cover
ENGINE UNDER COVER : Removal and Installation roe wrcroreness
REMOVAL
Remove engine under cover fixing clips, and then remove engine under cover.
INSTALLATION
Install in the reverse order of removal.
FLOOR UNDER COVER
EXT-40 FLOOR SIDE FAIRING
< REMOVAL AND INSTALLATION >
FLOOR UNDER COVER : Exploded View aro ionenarrs6
SEC. 747,
® Floor under cover RH © Sering push nut @ Floor under cover LH
FLOOR UNDER COVER : Removal and Installation
REMOVAL
Remove floor under cover fixing clips and spring push nut, and then remove floor under cover.
INSTALLATION
Install in the reverse order of removal.
EXT-41 ROOF RAIL
< REMOVAL AND INSTALLATION >
ROOF RAIL
Expieded View
SEC. 730
x
Phssis.10
|
Phrsc4.19) __ :
[ — T
il
oO
oe !
|
i
—
a
i
1 |
if = =
Za \ >
LEANN
~A NN
® Front roof rail cover @ Fook ra?
® Back door hinge cover @ Rear root ral cover,
1 em fp, to)
Removal and Installation
REMOVAL
EXT-42
® Root side molding ROOF RAIL
< REMOVAL AND INSTALLATION >
7. Apply protective tapes (A) on body to protect the painted surface
from damage.
2. Disengage front roof rail cover fixing pawis using a remover tool
A).
2 Paul
3. Remove front roof rail cover according to the numerical ord
1-32 as shown in the figure.
<2 Vehicle front
4. Apply protective tapes (A) on body to protect the painted surface
from damage.
5. Disengage rear roof rail cover fixing pawis using a remover tool
(A).
Pawi
EXT-43 < REMOVAL AND INSTALLATION >
6. Remove rear roof rail cover according to ‘tie tiumerical order
132 as shown in the figure.
<2 Vehicle front
7. Remove roof rail mounting bolts, and then remove roof rail
INSTALLATION
Install in the reverse order of removal.
EXT-44
tee Qigua, ROOF SIDE MOLDING
< REMOVAL AND INSTALLATION >
ROOF SIDE MOLDING
Exploded View vevonanaei
WITH ROOF RAIL
SEC. 730
@ Root ral assembly @® Root side molding ® Rook side molding clip
® Back door hinge cover
©) see
6&4: Aways replace after every disassembly
WITHOUT ROOF RAIL. ROOF SIDE MOLDING
‘SEC. 730
@ Root side molding cover @ Root side moicing @® Root side molding clip,
® Front roof side bracket © Rear root side bracket ® Back doorhinge cover
Olle
Ey iPam
2p + Aays replace after every disassembly
Removal and Installation nraswamcoaroett
REMOVAL
1, Remove roof rail, Refer to EXT-42, "Removal and Installation". (with roof rail)
2. Apply protective tape (A) on around the back door hinge cover
@ to protect it from damage.
EXT-46 ROOF SIDE MOLDING
< REMOVAL AND INSTALLATION >
3. Remove back door hinge cover fixing clip © using @ remover
tool (A).
4. Disengage back door hinge cover fixing pawl, and then while
‘escape part ® of back door hinge cover according to numerical
order 132 as shown in the figure, pull up back door hinge cover.
Paw!
5. Remive'Back door hinge cover as shown by the arrow in the fig-
ure.
6. Apply protective tape (A) on the part to protect it from damage.
<2 Vehicle front
7. Disengage roof side molding fixing clip using a remover tool (A),
and then remove roof side molding,
Clip
EXT-47 ROOF SIDE MOLDING
< REMOVAL AND INSTALLATION >
8. Remove front roof side bracket mounting bolts, and then remove front roof side bracket. (without roof rail)
8. Remove rear roof side bracket mounting bolts, and then remove rear roof side bracket. (without roof rail)
10. Remove roof side molding clip.
NOTE:
Grind the head of rivet @ with a drill (B) [bit of 64.7 — 4.9 mm
(00.185 - 0.193 in)]
INSTALLATION
Note the following item, and then install in the reverse order of removal.
NOTE:
Securely crimp roof side molding extension with a hand riveter (A).
Roof side molding
95.0 65.4 mm
(00.197 ~ 90.243 in)
Used rivethead diameter | _ 46.6 mm (90.256 in)
Prepared hole diameter
EXT-48 DOOR SASH MOLDING
< REMOVAL AND INSTALLATION >
DOOR SASH MOLDING
Exploded View wocownciroorerees
SEC. 800+820
@ Front door sash mong @ Rear door sash molcing @ Front doer panel
@® esr door pane
2. Remove front door glass run upper side. Refer to
Installation”.
3. Remove front door weather-strip upper side, Refer to LK
Installation”.
4, Remove front door sash molding fixing screw @ of front door
sash molding front side.
5. Apply protective tapes (A) on body to protact the painted surface
from damage.
6. Insert a remover tool (A) between front door panel and front door
sash molding, and then disengage front door sash molding as
shown by the arrows in the figure.
CAUTION:
Never use a material for remover tool which could damage
door panel.
7. Remove front door sash molding.
INSTALLATION
Install in the reverse order of removal
REAR DOOR SASH MOLDING
REAR DOOR SASH MOLDING : Removal and Installation snrooceswarearDe
REMOVAL
1. Fully open rear door glass.
2. Remove rear door glass run upper side. Refer to GW-55. "REAI R_GLASS RUN © Removal an
Aostallation”.
3. Remove rear door weather-strip upper side. Refer to DLK-287, ‘DOOR WEATHER-STRIP Removal and
Installation’.
4. Insert a remover tool to rear door sash molding center portion, and then disengage with rear door panel
and slide the rear and front of the vehicle, and then remove rear door sash mokding
INSTALLATION
Install in the reverse order of removal,
EXT-50 DOOR SASH TAPE
< REMOVAL AND INSTALLATION >
DOOR SASH TAPE
Exploded View wocownirooreres
‘SEC. 800820
re
(5p Always replace after every disassembly
FRONT DOOR SASH TAPE
FRONT DOOR SASH TAPE : Removal and Installation oeeomccrooriats
REMOVAL
CAUTION:
Never damage painted surface of front door panel.
1, Remove front door sash molding. Refer to EXT-49. "FRONT DOOR SASH MOLDING | Removal and
installation’.
2. Heat front door sash tape surface using a dryer, and then peel front door sash tape.
INSTALLATION
E:
Refer to the figure for front door sash tape position and overlap distance between the front door sash tape
EXT-51 DOOR SASH TAPE
< REMOVAL AND INSTALLATION >
® Front doar panel @® Front door sash tape
@ Rend
<3 Vehicle front
B 3.5 mm (0.138 in)
© 3.5mm (0.138 in)
CAUTION:
+ Degrease front door panel mounting surface for front door sash tape.
+ Paint grain or dust on mounting surface of front door sash tape may spoil exterior appearance if it
remains. Clean the mounting surface and check that no paint grain or dust remains, before starting
the operation.
+ Never reuse front door sash tape.
1. Affix front door sash tape @ to front door panel @ by applying pressure using a squeegee (A) while peel-
ing off release coated paper ©.
o_
o—/
NOTE:
+ Peel release coated paper at distance of 10 20 mm (0.384 — 0.787 in) ahead (B) of squeegee and affix
front door sash tape.
+ To prevent any bubbles from forming, slightly lif the portion, not yet affixed using squeegee. so that por-
tion dose not contact with panel surface.
* Apply pressure and affix at a low and constant speed using squeegee tilted at 40 - 50° angle (pushing
direction) (C) or 30 ~ 45° angle (pulling direction) (D)
EXT-52 DOOR SASH TAPE
< REMOVAL AND INSTALLATION >
2 For small radius portion of hemming part, gradually apply pres-
sure and affix front door sash tape @ using squeegee (A) in j 4
4-3 steps. id 2
CAUTION:
Never wash the vehicle with in 24 hours so as to keep adhe-
sive.
REAR DOOR SASH TAPE
REAR DOOR SASH TAPE : Removal and Installation nea cwnenoaris
REMOVAL
CAUTION:
Never damage painted surface of rear door panel.
1. Remove rear door glass. Refer to GVV-51, "REAR DOOR GLASS : Removal and Installation’.
2. Remove rear door sash molding. Refer to EXT-S0. "REAR DOOR SASH MOLDING - Removal and instal
tation’.
3, Remove rear door outside molding. Refer to EXT-56, "REAR DOOR OUTSIDE MOLDING : Removal and
{ostallation”.
4, Heat rear door sash tape surface using a dryer, and then peel rear door sash tape.
INSTALLATION
NOTE:
Refer to the figure for rear door sash tape position and overlap distance the rear door sash tape.
® Rear door panel ® Rear door sash tape front @ Rear door sash tape rear
EXT-53 DOOR SASH TAPE
< REMOVAL AND INSTALLATION >
® Rend
<2 * Vehicle front
© 3.0mm (0.118 in)
D 3.5mm (0.138 in)
E 3.5mm (0.138 in)
F 3.0. mm (0.118 in)
CAUTION
* Degrease rear door panel mounting surface for rear door sash tape.
+ Paint grain or dust on mounting surface of rear door sash tape may spoil exterior appearance if it
remains. Clean the mounting surface and check that no paint grain or dust remains, before starting
the operation.
+ Never reuse rear door sash tape.
1. Affix rear door sash tape @ to rear door panel @ by applying pressure using a squeegee (A) while peeling
off release coated paper @,
re 4
& .
NOTE:
+ Peel release coated paper at distance of 10 - 20 mm (0,394 —0.787 in) ahead (B) of squeegee and affix
rear door sash tape.
+ To prevent any bubbles from forming, slightly lit the portion, not yet affixed using squeegee, so that por-
tion dose not contact with panel surface.
+ Apply pressure and affix at a low and constant speed using squeegee tilted at 40 ~ 50° angle (pushing
direction) (C) or 30 — 45° angle (pulling direction) (D)
2. For small radius portion of hemming part, gradually apply pres-
sure and affix rear door sash tape @ using squeegee (A) in 13
steps.
CAUTION:
Never wash the vehicle with in 24 hours so as to keep adhe-
sive. —
EXT-54 DOOR OUTSIDE MOLDING
< REMOVAL AND INSTALLATION >
DOOR OUTSIDE MOLDING
Exploded View
‘SEC. 600+820
® Rear door panel ® Front door panel @ Front door outside molding
@ Rear door outside molding
Ay: Paw
2. Apply protective tape (A) on the part to protect it from damage.
3. Disengage rear end of front door outside molding fixing paw!
using remover tool (A) and (B).
CAUTION:
Never lift front door outside molding with excessive force to
prevent damage to the part.
Paw!
4. Twist front door outside molding toward the direction of the
arrow in the figure, and then lift up and remove it.
INSTALLATION
Install in the reverse order of removal,
REAR DOOR OUTSIDE MOLDING
REAR DOOR OUTSIDE MOLDING : Removal and Installation
REMOVAL
1. Remove rear door glass. Refer to GW-51 "REAR
2. Apply protective tape (A) on the part to protect it from damage.
EXT-56 DOOR OUTSIDE MOLDING
< REMOVAL AND INSTALLATION >
‘3 Disengage fixing paw! of rear door outside molding front and
rear end, using remover tool (A) and (B).
CAUTION:
Never lift rear door outside molding with excessive force to
prevent damage to the part.
Paw
4. Twist rear door outside molding toward the direction of the arrow
inthe figure, and then lift up and remove it,
INSTALLATION
Install in the reverse order of removal.
EXT-57 SIDE GUARD MOLDING
< REMOVAL AND INSTALLATION >
SIDE GUARD MOLDING
Exploded View
SEC. 768
oo Yo
@ Front door panel @® Front side guard molding @ Rear side guard molding
Double-sied tape
a Sener ie ® pwramm(o.oe7iny
1p
<2. Vehicle rat
24 Always repiace after every disassembly
FRONT SIDE GUARD MOLDING
FRONT SIDE GUARD MOLDING : Removal and Installation
REMOVAL
CAUTION:
EXT-58 SIDE GUARD MOLDING
< REMOVAL AND INSTALLATION >
Never damage the front door panel.
1. Apply a protective tape (A) on the door panel to protect the
painted surface from damage.
2. Cut double-sided tape using a cutter (A)
3. Disengage front side guard molding fixing clips using a remover
{00} (A), and then remove front side quard molding,
© clo
INSTALLATION
Note the following items, and then install in the reverse order of removal
CAUTION:
+ Always replace double-sided tape with a new one, if front side guard molding is reused.
+ Remove double-sided tape remaining on front door panel and back of front side guard molding with
a double-sided tape remover, after removing front side guard molding.
+ When installing front side guard molding, visually check the clips, then replace them with new parts
if they are damaged.
+ When installing front side guard molding, check that clips are securely in door panel holes, and
press them in.
+ Never wash the vehicle within 24 hours after installing so as to keep adhesive.
REAR SIDE GUARD MOLDING
REAR SIDE GUARD MOLDING : Removal and Installation eco onaneesorener)
REMOVAL
CAUTION:
Never damage the rear door panel.
EXT-59 SIDE GUARD MOLDING
< REMOVAL AND INSTALLATION >
7. Apply a protective tape (A) on the door panel to protect the
painted surface from damage.
2. Cut double-sided tape using a cutter (A).
3. Disengage rear side guard molding fixing clips using a remover
tool (A), and then remove rear side guard molding.
INSTALLATION
Note the following items, and then install in the reverse order of removal
CAUTION:
* Always replace double-sided tape with a new one, if rear side guard molding is reused,
+ Remove double-sided tape remaining on rear door panel and back of rear side guard molding with a
double-sided tape remover, after removing rear side guard molding.
+ When installing rear side guard molding, visually check the clips, then replace them with new parts if
they are damaged.
+ When installing rear side guard molding, check that clips are securely in door panel holes, and press
them in.
+ Never wash the vehicle within 24 hours after installing so as to keep adhesive.
EXT-60 SILL COVER
< REMOVAL AND INSTALLATION >
SILL COVER .
Exploded View rvonenarsr
SEC. 767 Je
@ Sitcover @ Grommet
©) Cp
<< Veil rent
EXT-61 SILL COVER
< REMOVAL AND INSTALLATION >
Removal and Installation oo commoners
REMOVAL
1, Remove front filet molding. Refer to EXT-32, "FRONT FILLET MOLDII al and installation”.
2. Remove rear fillet molding. Refer to EXT-33 "REAR F|
IG
3. Remove sill cover fixing screws @ of sill cover front side. )
\ \t J
\
[
4, Remove sill cover fixing clip @ of sill cover back side.
5. Remove sill cover mounting bolts of sill cover lower side.
6. Apply protective tape (A) on body to protect the painted surface from damage.
<5 Vehicle tront
EXT-62 SILL COVER
< REMOVAL AND INSTALLATION >
7. Disengage sill cover fixing clips, using @ remover tool (A), and
then remove sill cover Ny
etn
<3 Vehicle front
INSTALLATION
Note the following items, install in the reverse order of removal
CAUTION
+ When installing sill cover, visually check the clips, then replace them with new parts if they are dam-
aged.
‘+ When installing sill cover, check that clips are securely in door panel holes, and press them in.
EXT-63 REAR SPOILER
< REMOVAL AND INSTALLATION >
REAR SPOILER
Exploded View eco cewenrereere
SEC. 960
@ Rear spoiler LH @ Rear spoiler RH
lp
Removal and Installation nrooeeomanseroaT
REMOVAL
1, Fully open back door.
2. Remove rear spoiler mounting bolts @.
EXT-64 REAR SPOILER
< REMOVAL AND INSTALLATION >
3. Apply protective tapes (A) on body to protect the painted surface
from damage.
4, Disengage rear spoiler fixing clips using a remover tool (A)
according to the numerical order 1-3 as shown in the figure,
and then remove rear spoiler.
ote
INSTALLATION
Note the following items, and then install in the reverse order of removal
CAUTION:
+ Never damage the body panel.
+ When installing rear spoiler, visually check the rear spoiler and the cli
parts if they are damaged.
+ When installing rear spoiler, check that clips are securely in body panel holes, and press them in.
, then replace them with new
EXT-65 BACK DOOR FINISHER
< REMOVAL AND INSTALLATION >
BACK DOOR FINISHER
Exploded View
‘SEC. 251-253-266-280-000
Rear camerafRear view camera
(ifequipped)
ee
} +lp
Paw
Removal and Installation
REMOVAL
1. Remove back door inner finisher. Refer to
2. Remove cap cover @.
Hands free sensor © Back door fisher cap
@ Back oor opener switch assembly @_ License pate lamp
© Back door finisher
7_ "Removal and instaltatian'
EXT-66 BACK DOOR FINISHER
< REMOVAL AND INSTALLATION >
3, Remove back door finisher mounting nuts
4. Apply protective tape (A) on body to protect the painted surface
from damage.
5. Disengage back door finisher fixing clips using a remover tool
(A), and then remove back door finisher.
2 Gi
INSTALLATION fm
Note the following items, and then install in the reverse order of removal.
CAUTION:
+ Never damage the back door panel.
+ When installing back door finisher, visually check the back door finisher and the olips, then replace
them with new parts if they are damaged.
+ When installing back door finisher, check that clips are securely in back door panel holes, and press
them in.
EXT-67 TRANSMISSION & DRIVELINE
SECTION
FRONT AXLE
CONTENTS
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" 3
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect
Precautions for Removing Battery Terminal
Precautions for Drive Shaft
PREPARATION
PREPARATION
Special Service Tool
Commercial Service Tool
Lubricant orfand Sealant
SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ..
NVH Troubleshooting Chart a
PERIODIC MAINTENANCE
FRONT WHEEL HUB AND KNUCKLE
Inspection
FRONT DRIVE SHAFT
Inspection
REMOVAL AND INSTALLATION
FRONT WHEEL HUB AND KNUCKLE «.jnscautt
Exploded View 1"
Removal and Installation 1"
Inspection 6
FRONT DRIVE SHAFT BOOT
6
8
8
7
MR20DD errs
MR20DD ° Expladed View
MR20DD : Removal and Installation
MR20D0 : Inspection
ROM
ROM : Exploded View
ROM : Removal and Installation
ROM : Inspection
7
19
25
FRONT DRIVE SHAFT .
MR20DD errsessensstsnansnnnnnnne
MR20DD Exploded View
MR20DD : Removal and installation
MR20D0 : Disassembly and Assembly
MR20DD : Inspection
ROM sntsneseunmenenimnsnenmnannnsensennnennnnAT
ROM : Exploded View 48
ROM : Removal and Installation 50
ROM : Disassembly and Assembly 56
ROM : Inspection 60
SERVICE DATA AND SPECIFICATIONS
(sD8) ..
SERVICE DATA AND SPECIFICATIONS
(SDS)
Whet
Drive Shaft
162
4WD
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONE! 64
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect 64
Precautions for Removing Battery Terminal 65
FAX-1 Precautions for Drive Shaft 68
PREPARATION ..
PREPARATION
Special Service Tool
‘Commercial Service Tool
Lubricant orfand Sealant
SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
PERIODIC MAINTENANCE
FRONT WHEEL HUB AND KNUCKLE ..
Inspection
FRONT DRIVE SHAFT
Inspection
REMOVAL AND INSTALLATION ..
FRONT WHEEL HUB AND KNUCKLE ..sssuu 72
Exploded View 2
Removal and Installation R
Inspection 7
FRONT DRIVE SHAFT BOOT .. 78
jew 78
MR20DD | Removal and Installation 79
MR20DD : Inspection
QR25DE
‘QR25DE ; Exploded View
QR25DE | Removal and Installation
QR25DE : Inspection
ROM...
ROM - Exploded View
REM. Removal and Installation
ROM: Inspection
FRONT DRIVE SHAFT csscsssnsnentsnenesenees 400
‘MR20DD
MR20DD
MR20DD
MR200D
MR20DD
QR25DE
‘QR2501
QR25DE
QR25DE
QR25DE
ROM
ROM
ROM
ROM
ROM
Base See
Exploded View
Removal and installation tot
Disassembly and Assembly
Inspection m1
Removal and Installation
Disassembly and Assembly
inspection
Expioded View
Removal and installation
Disassembly and Assembly 131
Inspection
‘SERVICE DATA AND SPECIFICATIONS
se 1
(SDS) ..
SERVICE DATA AND SPECIFICATIONS
(SDs)
Wheel Bearing
Drive Shaft
FAX-2 PRECAUTIONS
< PRECAUTION > [wo]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" eron mance
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. Information necessary to service the system safely is included in the “SRS AIR BAG" and
“SEAT BELT" of this Service Manual
WARNING:
Always observe the following items for preventing accidental activation.
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSANJINFINITI 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 “SRS AIR BAG”.
+ Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
+ When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
fn ON oF ene |, Never use ait of electric power tools or strike near the sensor(s) with
a hammer, Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
+ When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
CAUTION:
‘Comply with the following cautions to prevent any error and malfunction.
+ Before removing and installing any control units, first turn the ignition power source and accessory
power source to the OFF, then disconnect both battery cables,
+ After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
+ Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, ifthe battery is disconnected or discharged, the steering wheel will lock and
cannot be tumed,
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation
OPERATION PROCEDURE
1, Connect both battery cables.
NOTE:
‘Supply power using jumper cables if battery is discharged,
2, Open driver door,
3, Turn the ignition switch to the ON position.
(At this time, the steering lock will be released.)
4, Turn the ignition switch to OFF position with driver door open.
5, Wait for 3 minutes or longer with driver door open.
NOTE:
+ Do not close driver door because the steering wheel locks when driver door is closed.
FAX-3 PRECAUTIONS
< PRECAUTION > [2wo]
* The auto ace function is adapted to this vehicle. For this reason, even when the ignition switch is tumed
to OFF position, the accessory power source does not turned OFF and continues to be supplied for a
certain amount of time.
6. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
ected and the steering wheel can be turned.
7. Perform the necessary repair operation
8. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from OFF position to ON position, then to LOCK position. (The steering wheel will lock
‘when the ignition switch is turned to LOCK position.)
9. Perform self-diagnosis check of all control units using CONSULT.
Precautions for Removing Battery Terminal aaprainnat
+ With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. in addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time,
+ When disconnecting the 12V battery terminal, turn off the ACC
\ EZ)
po
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch,
NOTE:
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected
After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF. refer to Instruction 2.
INSTRUCTION 1
1. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened
3. Get out of the vehicle and close the driver side door.
4
Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time,
4D engine = 20 minutes
HRA2DDT 12 minutos
Kok engine <4 minutes
MGR engine = 4 minutes
Roll engine =A minutes
Vox engine 4 minutos
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5, Remove 12V battery terminal
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
1, Unlock the door with intelligent key or remote keyless entry.
FAX-4, PRECAUTIONS
< PRECAUTION > [2wo]
NOTE:
Al this moment, ACC power is supplied.
Open the driver side door
Open the hood,
Close the driver side door.
Wait at least 3 minutes.
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
6. Remove 12V battory terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
Precautions for Drive Shaft ro eonosnmact4
waen
CAUTION:
Note the following precautions when disassembling and assembling drive shaft.
+ Joint sub-assembly does not disassemble because it is non-overhaul parts.
+ Perform work in a dust-free location.
+ Before disassembling and assembling, clean the parts.
+ Prevent the entry of foreign objects during disassembly of the service location.
+ Disassembled parts must be carefully reassembled in the correct order. If work is interrupted, a
clean cover must be placed over parts.
+ Paper waste must be used. Fabric shop cloths must not be used because of the danger of lint adher-
ing to parts.
+ Disassembled parts (except for rubber parts) should be cleaned with kerosene which shall be
removed by blowing with air or wiping with paper waste.
FAX-5 PREPARATION
< PREPARATION > [ewo]
PREPARATION
PREPARATION
Special Service Tool roe conwecoromtt
Tool umber ]
Tool name
vao704000 Removing and Instaling wheel hub lock nut
Hub lack nut wrench |
2: B5 mm (3.38 in)
Description
b asm 26)
“evanto7300 ] ttn oatbone
Beat band pinot |
wvavio750 | Remora ave shat
Dive shaft attachment |
ievser07800
Pratector
232mm (1.28 in) da,
Tnstaling dive shaft
Commercial Service Tool ‘nroconrrcra?
Tool name Desenpton
Dive shat puller ] Rarioving dive chat oink sub Sasarbly
&6
FAX-6 PREPARATION
< PREPARATION > [2wo)
‘Siang ammer Removing drive shat
Ball oint remover Removing hub bolt
QB
—__#
= FAX
A A
a
Removing and instaling steering knuckle and
strut assembly
—— SSS ‘A: 16 ~ 32 mm (0.63 -1.26 in)
Chisel 8: 10mm (0.39 in) or more
al] Is | c 40-70mm (1.87 -278 in)
L 1: 220 mm (7.87 in) ores
S:t4mm (055 in) ormore
Lubricant or/and Sealant
Name
Fil NISSAN Genuine grease or equivalent
‘Apply paste [service parts 440037S000))
FAX-7
Desciston
~ Joint sub-assembly inside
+ Housing inside
+ Joint sub-assembly NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart aemmes
Use chart below to find the cause of the symptom. If necessary, repair or replace these parts.
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illest
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§
: 5
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Possible cause and SUSPECTED PARTS ele| |£| |slé
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BElE(2 (R/£ (2 (2/2 [2 [8 [8 [5
pave [Nese BE =] = =l=[ =] [=]
sHarT —_[sreke fah ojala bel =e) eel els
Weise =Te=t=t et)
ane Shake xtx[ p=] =) = Pete
rout | Warton ze ell beh ber 1s
AXLE: ‘Shimmy x [x x x] x xx
“baer x EE x
oor ally nde orhanding xLeL pL bebe
hepatic
FAX-8 FRONT WHEEL HUB AND KNUCKLE
< PERIODIC MAINTENANCE > [wo]
PERIODIC MAINTENANCE
FRONT WHEEL HUB AND KNUCKLE
Inspection
COMPONENT PART
Make sure that the mounting conditions (looseness, backlash) of each component and component conditions
(wear, damage) are normal,
WHEEL HUB ASSEMBLY (BEARING-INTEGRATED TYPE)
Check the folowing kets, and replace the pat nscesary Za
+ Move wheel hub and bearing assembly in the axial direction by hand. Check there is no looseness of wheel
bearing.
Axial end play + Refer to FAX-62, “Wheel Bearing”.
+ Rotate wheel hub and make sure there is no unusual noise or other iegular conditions. If there is any of
iegular conditions, replace wheel hub and bearing assembly.
FAX-9 FRONT DRIVE SHAFT
< PERIODIC MAINTENANCE > [2wo]
FRONT DRIVE SHAFT
Inspection
FRONT DRIVE SHAFT INSPECTION
Check the following items, and replace the part if necessary.
* Check drive shaft mounting point and joint for looseness and other damage.
CAUTION:
Replace entire drive shaft assembly when noise or vibration occur from drive shaft.
+ Check boo! for cracks and other damage.
FAX-10 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION > [2wo]
REMOVAL AND INSTALLATION
FRONT WHEEL HUB AND KNUCKLE
Exploded View roeownero nears
SEC. 400
BOM o0 192,00
@ Sieering knuckle @ Splash guar @ uv bot
@® Wheet hub and bearing assembly @ Disc otor © Wheel hub took nut
@ Adjusting cap ® Cotter pin
Nim thom, ta)
(24: Always replace ater every sisassemby
Removal and Installation wroweenecoranesis
REMOVAL
1. Remove tires. Refer to WWT-61. "Removal and Installation”.
2. Remove front wheel sensor from steering kunckle. Refer to BRC-212, "FRONT WHEEL SENSOR
Removal and instalation”
3. Remove lock plate @ from strut assembly.
* LHD: Refer to BR-24. "FRONT: Exploded View".
+ RHD: Refer to BREA "FRONT Exploded View"
FAX-11 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION > [2wo]
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) | Removal
and installation’.
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal
and installation’.
+ RHD (1 PISTON TYPE): Refer to BR-111," PI yu
and installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116."
and Installation’,
CAUTION:
Never depress brake pedal while brake caliper is removed.
5. Remove disc rotor.
CAUTION:
+ Put matching marks @ on the wheel hub and bearing
assembly and the disc rotor before removing the disc
rotor.
+ Never drop disc rotor.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000)
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NOTE:
Use suitable puller, if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure,
8, Remove wheel hub lock nut.
9. Remove wheel hub and bearing assembly
10. Remove splash guard.
11, Remove transverse link from steering knuckle and front suspension member. Refer to FSU-17, "Removal
and Installation’
12. Separate steering outer socket from steering knuckle. Refer to ST-22, "Removal and Installation’.
13. Separate the connection of strut assembly and steering knuckle as follows.
CAUTION:
FAX-12 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION >
[2wo)
Be sure to keep the following procedure because steering knuckle may be damaged when you
enlarge the gap of steering knuckle too much.
‘a. Remove strut mounting bolts from steering knuckle.
b. Measure the gap (A) of the steering knuckle. And then mark the
enlarged limit (B) to the chisel
© Merking
Enlarged limit (B) = gap (A) + 2.5 mm (0.098 in)
NOTE:
Standard of gap: 6.9 + 0.5 mm (2.56 + 0.02 in)
c._ Enlarge the gap of the steering knuckle with the chisel (A) (com-
mercial service tool) not to surpass a limit as shown in the figure.
CAUTION:
+ Never enlarge the gap more than 2.5mm (0.098in).
+ Be careful not to damage the projection @ and strut
assembly @ with the chisel.
G. Separate the connection of strut assembly and steering knuckle
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
+ Never allow drive shaft to hang down without support for joint sub-assembly, shaft and the other
parts,
+ Be sure to remove lubricants if lubricant has been used to separate the connection of strut
assembly and steering knuckle.
FAX-13 FRONT WHEEL HUB AND KN!
< REMOVAL AND INSTALLATION >
JUCKLE
[2wo}
14. Remove hub bolts @ from wheel hub and bearing assembly,
using the ball joint remover (A) (commercial service tool).
CAUTION:
+ Remove hub bolt only when necessary.
+ Never hammer the hub bolt to avoid impact to the wheel
hub and bearing assembly.
+ Pull out the hub bolt in a direction perpendicular to the
wheel hub and bearing assembly.
15. Perform inspection after removal. Refer to FAX-16, "Inspection",
INSTALLATION
Note the following, and install in the reverse order of the removal
Hub Bolts
+ Place a washer ® as shown in the figure to install the hub bolts
by using the tightening force of the nut ®.
CAUTION:
+ Check that there is no clearance between wheel hub and
bearing assembly, and hub bolt.
+ Never reuse hub bolt.
Drive shaft
+ Clean the matching surface of wheel hub lock nut and wheel hub an:
CAUTION:
Never apply lubricating oil to these matching surface.
+ Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000))
to surface @ of joint sub-assembly of drive shaft,
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste = 4.03.0. (0.04-0.10 oz)
\d bearing assembly.
CAUTION:
Tighten the wheel hub lock nut to the specified torque. Refer to FAX-11. "Exoloded View"
+ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
FAX-14 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION > [2wo]
+ When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles.
CAUTION:
Never reuse cotter pin.
Disc rotor
CAUTION:
+ Align the matching marks @ made during removal when reus-
ing the disc rotor.
+ Never drop disc rotor.
Strut Assembly and Steering Knuckle Connection
CAUTION:
Be sure to remove lubricants if lubricant has been used to separate the connection of strut assembly
and steering knuckle.
+ Install the steering knuckle to strut assembly as follows.
1. Set suitable jack under steering knuckle.
2. Align the gap @ of steering knuckle to the projection part @ of
strut.
3. Tighten the mounting bolt with pushing up the steering knuckle
© until contacts stopper bracket @) end face, using @ suitable
jack
‘CAUTION:
Check the stable condition when using a jack.
+ Perform inspection after installation. Refer to FAX-16, “inspection”.
FAX-15 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION > [2wo]
Inspection nronemmnm ened
INSPECTION AFTER REMOVAL
Check the following items, and replace the part if necessary.
+ Check components for deformation, cracks, and other damage.
+ Check boots of transverse link and steering outer socket ball joint for breakage, axial end play, and swing
torque.
~ Transverse link: Refer to ESU-18. “Inspection”.
~ Steering outer socket: Refer to ST-26.."
INSPECTION AFTER INSTALLATION
1, Check wheel sensor harness for proper connection. Refer to BRC-212, "FRONT WHEEL SENSOR :
Exploded View".
2. Check the wheel alignment. Refer to FSU-8, “Inspection”.
3. Adjust neutral position of steering angle sensor. Refer to BRC-99, "Work Procedure".
FAX-16 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [2wo]
FRONT DRIVE SHAFT BOOT
MR20DD
MR20DD : Exploded View arooanmacrrat
LEFT SIDE
(SEC. 391
® Chrevtar clip ® dust shieta @ Housing
® Snap ring © Spider assembly © Stopper ring
@ Boot band ® Boot @ Shaft
@ Damper band @® Dynamic damper @® Joint sub-assembly
@ Dustshieis
<3: Wheel side
1: Fill NISSAN Genuine grease or equivalent.
2: Apply paste farce pats (4400875000)]
(29: Always replace ater every isassembsy
FAX-17 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
= RIGHT SIDE (CVT)
[2wo)
SEC.391
Pes (29,35)
Pys8 4.9, 05)
@
1A, 98>
6 YG,
oo
2 po 2 8
@ Spider assembly @® Snap ring @
8 ee & em ®
oe sna
@ see
IEG 1: FIINISSAN Genuine grease or equivalent
Aoply paste [service parts (440037S000)}
BL nm team, to)
(£9: Aways replace ater every sisassembly
FAX-18
Circular clip
Shaft
Stopper ring
Housing
Retainer FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
[2wo)
RIGHT SIDE (MT)
[sec.s91
Fae (a.9, 25)
Dust shield
Boot band
Damper band ®
Spider assembly @
Dust shield @
ee
‘Support bearing bracket
Wheel sige
§@GO969
Joint sub-assembly
Boot
‘Dynamic damper
‘Snap ring
‘Support bearing
EGB 1: Fill NISSAN Genuine grease or equivalent.
PA Nim thom, te)
(24 Always replace ater every sisassombly
Apply paste [service parts (4400378000)
MR20DD : Removal and Installation
REMOVAL
Wheel Side
1, Remove tires. Refer to
Circular ap
‘hat
‘Stopper ring
Housing
Retainer
WI-61. "Removal and Installation”.
2, Remove wheel sensor from steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR : Removal
s
FAX-19 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24. "FRONT - Exploded View",
+ RHD: Refer to BR-88. "FRONT ; Exploded View"
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMI ‘ON TYPE} | Re
:
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBL\ a E) : Removal
and Installation”
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON ov
and Installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116.""
lation",
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-11, "Removal and Installation’.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000),
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NoTt
Use suitable puller if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8. Remove wheel hub lock nut
9. Remove transverse link from steering knuckle and front suspension member. Refer to ESU-17, "Removal
10. Separate steering outer socket from steering knuckle, Refer to S1-22. "Removal and Installation’.
FAX-20 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
71. Remove drive shaft from wheel hub and bearing assembly
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove boot bands, and then separate boot from joint sub-assembly.
43. Screw drive shaft puller (A) (commercial service tool) into joint
sub-assembly screw part to a length of 30 mm (1.18 in) or more.
Support drive shaft with one hand and pull out joint sub-assem-
bly from shaft
‘CAUTION:
* Align sliding hammer and drive shaft and remove them by
pulling directory.
+ If joint sub-assembly cannot be pulled out, try after
removing drive shaft from vehicle. Refer to FAX-42,
14, Remove circular clip @ from shaft
15. Remove boot from shaft
Transaxle Side
Remove boot after removing drive shatt
+ Remove: Refer to FAX-36_"MR20DD _ Removal and installation”.
* Disassembly: Refer to FAX-42. "MR200D | Disassembly and Assembly’.
INSTALLATION
Wheel Side
1. Clean the old grease on joint sub-assembly with paper waste.
2. Fill serration slot joint sub-assembly @ with NISSAN genuine
grease or equivalent until the serration slot and ball groove
become full to the brim
‘CAUTION:
After applying grease, use a shop cloth to wipe off old
grease that has aozed out.
FAX-21 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
[2wo]
3. Install boot and boot bands to shaft.
CAUTION:
+ Never reuse boot and boot band.
+ Wrap serration on shaft with tape @ to protect the boot
from damage.
4. Remove the tape wrapped around the serration on shaft
5. Position the circular clip © on groove at the shaft edge.
CAUTION:
Never reuse circular clip.
NOTE:
Drive joint inserter is recommended when installing circular clip
@.
6. Align both center axles of the shaft edge and joint sub-assembly, Then assemble shaft with joint sub-
assembly holding circular clip.
7. Install joint sub-assembly @ to shaff using plastic hammer.
CAUTION:
* Check circular clip is properly positioned on groove of the
joint sub-assembly.
+ Confirm that joint sub-assembly is correctly engaged
while rotating drive shaft.
8. Fill into the boot inside with the specified amount of grease from large diameter side of boot,
Grease amount __; Refer to FAX-62, “Drive Shaft”.
FAX-22 FRONT DRIVE SHAFT BOOT
<= REMOVAL AND INSTALLATION > wo]
9. Install the boot securely into grooves (indicated by” marks)
shown in the figure
‘CAUTION
If grease adheres to the boot mounting surface (indicated *
by “*” mark) on the shaft or joint subassembly. boot may be
removed. Remove all grease from the boot mounting sur-
face.
10,,To prevent the deformation of the boot, adjust the boot installa-
tion length (L) to the specified value shown below by inserting
the Suitable too! into the inside of the boot from the large diame- S
{er sidé of the boot and discharging the inside air ry
L + Refer to FAX-62, “Drive Shaft”.
CAUTION:
+ If the boot mounting length exceeds the standard, it may cause breakage in the boot.
+ Be careful not to touch the inside of the boot with a tip of tool.
11. Secure the large and small ends of the boot with boot bands
using the boot band crimping tool (A) (SST: KV40107300),
CAUTION:
Never reuse boot band.
NOTE:
‘Secure boot band so that dimension (M) meets the specification as shown in the figure.
M :1,0- 4,0 mm (0.039 - 0.187 in)
12, Check that displacement does not occur when boot is rotated with the joint sub-assembly and shaft fixed.
CAUTION:
+ Reinstall them using boot bands when boot installation positions become incorrect.
+ Never reuse boot band.
13, Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly.
CAUTION:
Never apply lubricating oil to these matching surface.
FAX-23 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [2wo)
14, Clean the matching surface of drive shaft and wheel hub and
bearing assembly. And then apply paste [service parts
(440037S000)] to surface ® of joint sub-assembly of drive shaft.
CAUTION:
Apply paste to cover entire flat surface of joint sub-assem-
bly of drive shaft.
Amount paste: 1.0 - 3.09 (0.04- 0.10 02)
15. Insert drive shaft to wheel hub and bearing assembly, and then temporarily tighten wheel hub lock nut.
CAUTION:
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
16. Install transverse link to steering knuckle and front suspention member. Refer to FSU-17, "Exploded
ey
17. Install steering outer socket to steering knuckle.
+ LHD: Refer to ST-20, "LHD | Exploded View".
+ RHD: Refer to ST-21, "RHD : Exploded View!
18. Tighten the wheel hub lock nut to the specified torque. Refer to FAX-11, "Exploded View"
CAUTION:
+ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
19. When installing a cotter pin @® and adjusting cap @, securely
bend the basal portion to prevent rattles,
CAUTION:
Never reuse cotter pin.
20. Install disc rotor. Refer to FAX-11, "Removal and Installation”.
21. Install caliper assembly to steering knuckle.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 Pi
and Installation".
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal
.
and installation”.
+ RHD (1 PISTON TYPE): Refer to BR-
and Installation’.
+ RHD (2 PISTON TYPE): Refer to BR-56."t q
and Installation”.
22. Install lock plate to strut assembly.
+ LHD: Refer to BR-24, "FRONT ; Exploded View".
+ RHD: Refer to BR-88, "FRONT : Exploded View",
23. Install wheel sensor to steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR | Removal and
5
24. Install tires to vehicle. Refer to W1-61, "Removal and installation".
25. Perform inspection after installation. Refer to FAX.25, "MR20DD : Inspection".
Transaxle Side
* Installation: Refer to FAX-36, "MR20DD ; Removal and installation"
FAX-24 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
[2w0)
~ Assembly: Refer to FAX-42, "MIR2ODD _ Disassembly and Assembly
MR20DD : Inspection
INSPECTION AFTER REMOVAL
Check the following items, and replace the part if necessary.
+ Check components for deformation, cracks, and other damage.
+ Check boots of transverse link and steering outer socket ball joint for breakage, axial
torque.
~ Transverse link: Refer to FSU-18. "Inspection’.
~ Steering outer socket: Refer to ST-26. “inspection”.
INSPECTION AFTER INSTALLATION
4, Check wheel
Exploded View".
2. Check the wheel alignment. Refer to FSU-8, "Inspection!
3. Adjust neutral position of steering angle sensor. Refer to BRC-99, "Work Procedure"
ROM
R9M : Exploded View
end play, and swing
'sor harness for proper connection. Refer to BRC-212, "FRONT WHEEL SENSOR
LEFT SIDE
oon P — = a6
a,
Ray _Pe
= ZA
pad — (90
/
/
S ®
& hoe
Je x]
oe
© Craterip © Denson @ Hors
@ site © Spier seat © Stepper ting
ey poate es o oa
39 ange a GF esis © Bin wean
1 het sice
1: Fl NISSAN Genuine grease or equivalent.
2: Apply paste [service parts (4400375000)
(29: Aways replace ater every dsassemby
FAX-25 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
[2wo)
@
®
@
@
@
@
a
RIGHT SIDE (CVT)
SEC. 391
Gig P2502 6,10)
A yo Mow
Dust shield
Boot band
Damper band
Spider assembly
Dust shila
Support bearing bracket
Wheel side
@SSOe8
Joint sub-assembly ® Cireuier clip
Boot ® shat
Dynamic damper ® Stopper ring
Snap ring ® Housing
Support bearing ® Retainer
Heat insulator
IEG 1: FIINISSAN Genuine grease or equivalent
BL nm team, to)
(£9: Aways replace ater every sisassembly
Aoply paste [service parts (440037S000)}
FAX-26 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [2wo]
RIGHT SIDE (MMT)
‘SEC. 391 TPss0 28,18)
, a Pieos.s9
Fisvesiw oe Z
ay Sy
8 \
@ Dust shieid @ Joint sub-assembly @ Circular ip
@ Boot band @ Boot @ shat
® Stopper ting ® Spider assembly @ Snap rng
® Housing @ Dust shiets ® Support bearing
@ Retainer @ Support bearing bracket @ Heatinsulator
<3: Wheel side
+ FI NISSAN Genuine grease or equivalent
2: Apply paste [service parts (440087000),
Fn kam, toby
(Always repace ater every aisassembiy
R9M : Removal and Installation aro coor ores
REMOVAL
Whee! Side
1, Remove tires. Refer to WWI-61. “Removal and Installation”.
2. Remove wheel
nsor from steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR Removal
FAX-27 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24. "FRONT - Exploded View",
+ RHD: Refer to BR-88. "FRONT ; Exploded View"
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMI ‘ON TYPE} | Re
:
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBL\ a E) : Removal
and Installation”
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON ov
and Installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116.""
lation",
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-11, "Removal and Installation’.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000),
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NoTt
Use suitable puller if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8. Remove wheel hub lock nut
9. Remove transverse link from steering knuckle and front suspension member. Refer to ESU-17, "Removal
10. Separate steering outer socket from steering knuckle, Refer to S1-22. "Removal and Installation’.
FAX-28 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
71. Remove drive shaft rom wheel hub and bearing assembly
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove boot bands, and then separate boot from joint sub-assembly.
43. Screw drive shaft puller (A) (commercial service too!) into joint
sub-assembly screw part to a length of 30 mm (1.18 in) or more.
Support drive shaft with one hand and pull out joint sub-assem-
bly from shaft
‘CAUTION:
+ Align sliding hammer and drive shaft and remove them by
pulling directory.
+ If joint sub-assembly cannot be pulled out, try after
removing drive shaft from vehicle. Refer to FAX-55, "R9M :
Disassembly and Assembly".
14, Remove circular clip @ from shaft.
15. Remove boot from shaft
Transaxle Side
Remove boot after removing drive shaft.
+ Remove: Refer to FAX.50_"R9M - Removal and Installation”.
* Disassembly: Refer to FAX-56. "ROM : Disassembly and Assembly"
INSTALLATION
Wheel Side
1, Clean the old grease on joint sub-assembly with paper waste.
2. Fill serration slot joint sub-assembly @ with NISSAN genuine
grease or equivalent until the serration slot and ball groove
become full to the brim
CAUTION:
After applying grease, use a shop cloth to wipe off old
grease that has aozed out.
FAX-29 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
[2wo]
3. Install boot and boot bands to shaft.
CAUTION:
+ Never reuse boot and boot band.
+ Wrap serration on shaft with tape @ to protect the boot
from damage.
4. Remove the tape wrapped around the serration on shaft
5. Position the circular clip © on groove at the shaft edge.
CAUTION:
Never reuse circular clip.
NOTE:
Drive joint inserter is recommended when installing circular clip
@.
6. Align both center axles of the shaft edge and joint sub-assembly, Then assemble shaft with joint sub-
assembly holding circular clip.
7. Install joint sub-assembly @ to shaff using plastic hammer.
CAUTION:
* Check circular clip is properly positioned on groove of the
joint sub-assembly.
+ Confirm that joint sub-assembly is correctly engaged
while rotating drive shaft.
8. Fill into the boot inside with the specified amount of grease from large diameter side of boot,
Grease amount _; Refer to FAX-62, “Drive Shaft”.
FAX-30 FRONT DRIVE SHAFT BOOT
<= REMOVAL AND INSTALLATION > wo]
9. Install the boot securely into grooves (indicated by” marks)
shown in the figure
‘CAUTION
If grease adheres to the boot mounting surface (indicated *
by “*” mark) on the shaft or joint subassembly. boot may be
removed. Remove all grease from the boot mounting sur-
face.
10,,To prevent the deformation of the boot, adjust the boot installa-
tion length (L) to the specified value shown below by inserting
the Suitable too! into the inside of the boot from the large diame- S
{er sidé of the boot and discharging the inside air ry
L + Refer to FAX-62, “Drive Shaft”.
CAUTION:
+ If the boot mounting length exceeds the standard, it may cause breakage in the boot.
+ Be careful not to touch the inside of the boot with a tip of tool.
11. Secure the large and small ends of the boot with boot bands
using the boot band crimping tool (A) (SST: KV40107300),
CAUTION:
Never reuse boot band.
NOTE:
‘Secure boot band so that dimension (M) meets the specification as shown in the figure.
M :1,0- 4,0 mm (0.039 - 0.187 in)
12, Check that displacement does not occur when boot is rotated with the joint sub-assembly and shaft fixed.
CAUTION:
+ Reinstall them using boot bands when boot installation positions become incorrect.
+ Never reuse boot band.
13, Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly.
CAUTION:
Never apply lubricating oil to these matching surface.
FAX-31 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [2wo)
14, Clean the matching surface of drive shaft and wheel hub and
bearing assembly. And then apply paste [service parts
(440037S000)] to surface ® of joint sub-assembly of drive shaft.
CAUTION:
Apply paste to cover entire flat surface of joint sub-assem-
bly of drive shaft.
Amount paste: 1.0- 3.09 (0.04-0.10 02)
15. Insert drive shaft to wheel hub and bearing assembly, and then temporarily tighten wheel hub lock nut.
CAUTION:
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
16. Install transverse link to steering knuckle and front suspention member. Refer to FSU-17, "Exploded
ey
17. Install steering outer socket to steering knuckle.
+ LHD: Refer to ST-20, "LHD | Exploded View".
+ RHD: Refer to ST-21, "RHD : Exploded View!
18. Tighten the wheel hub lock nut to the specified torque. Refer to FAX-11, "Exploded View"
CAUTION:
+ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
19. When installing a cotter pin @® and adjusting cap @, securely
bend the basal portion to prevent rattles,
CAUTION:
Never reuse cotter pin.
20. Install disc rotor. Refer to FAX-11, "Removal and Installation”.
21. Install caliper assembly to steering knuckle.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 Pi
and Installation".
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal
.
and installation”.
+ RHD (1 PISTON TYPE): Refer to BR-
and Installation’.
+ RHD (2 PISTON TYPE): Refer to BR-56."f q
and Installation”.
22. Install lock plate to strut assembly.
+ LHD: Refer to BR-24, "FRONT : Exploded View".
+ RHD: Refer to BR-88, "FRONT : Exploded View",
23. Install wheel sensor to steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR | Removal and
5
24. Install tires to vehicle. Refer to W1-61, "Removal and installation".
25. Perform inspection after installation. Refer to FAX-33, "R9M - Inspection’.
Transaxle Side
+ Installation: Refer to FAX-50. "ROM : Removal and Installation’
FAX-32 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [wo]
* Assembly: Refer to FAX-56, "ROM : Disassembly and Assembly".
ROM : Inspection
INSPECTION AFTER REMOVAL
Check the following items, and teplace the patt if necessary
* Check components for deformation, cracks, and other damage.
* Check boots of transverse link and steering outer socket ball joint for breakage, axial end play, and swing
torque.
- Transverse link: Refer to
3 ESU-18. “Inspection”.
= Steering outer socket: Refer to ST:26, “Inspection” =
INSPECTION AFTER INSTALLATION
1, Check wheel sensor hamess for proper connection. Refer to BRC-212, "FRONT WHEEL SENSOR ;
Exploded View".
2. Cheok the whee! alignment. Refer to FSU-8, “Inspection”
3. Adjust neutral position of steering angle sensor. Refer to 8RC-99, "Work Procedure”
FAX-33 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [2wo)
FRONT DRIVE SHAFT
MR20DD
MR20DD : Exploded View sroocommceeei?
LEFT SIDE
[SEC.391 nm ® o
@ Cireviar ep @ Dust siela @ Housing
@® Snap ring © Spider assembly @© Stopper ing
@ Boot bane @ Boot @ Shaft
@ Damper band ® Dynamic damper @® Joint sub-assembly
@ Dust shiela
Fill NISSAN Genuine grease or equivalent
Apply paste [service parts (440037S000)]
(29: Aways replace ater every cisassembly
FAX-34 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
[2wo)
RIGHT SIDE (CVT)
‘SEC.391
h Feo us,5
Phes i. 55)
@ dustshieis © soint sub-assembly @ Circular ap
@® Boot band © Boot @© shat
@® Damper band ® dynamic damper © Sepper ting
@ Spider assembly @ Snap sing ® Housing
@® oustshieis @® Suppor nearing @ Retainer
® Suppor bearing bracket
<3: Wheel side
1: Fil NISSAN Genuine grease or equivalent
HEEB 2 Apply paste [service parts (4400378000),
Dh nm thom, ta)
(29: Aiways replace ater every isassembsy
FAX-35 FRONT DRIVE SHAFT
[2wo)
RIGHT SIDE (Mi)
‘sec.as1
hse 49,35)
Pesce. « ;
1
@
@ Dust shits @® soint sub-assembly @ Croulr cp
@ Bootband ® Boot @ shat
@ Damperband ® Dynamic damper @® stopper rng
@ Spider assembly @® Snap ring ® Housing
@ Dust shield ® Support bearing @ Retainer
{Support bearing bracket
Whee! side
HEEB: FIINISSAN Genuine grease or equivalent
HEEB? Apaly paste (service parts (4400878000)}
Lm gam, tio)
(24: Aways replace after every disassembly
MR20DD : Removal and Installation ero comwacoreeeser
REMOVAL
Lef Side
1. Remove tires. Refer to WW1-61. "Removal and \nstaliation”.
2, Remove wheel sensor from steering knuckle. Refer to BRO-212 “FRONT WHEEL SENSOR - Removal
FAX-36 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24. "FRONT - Exploded View"
+ RHD: Refer to * (
4, Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Rer
and installation”.
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE Cal ASSEMBLY (2 PISTON TYPE) : Removal
and Installation”.
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE! H
and installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116. "
t -
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-11, "Removal and Installation’.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000)
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NOTE:
Use suitable puller, if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8 Remove wheel hub lock nut.
9. Remove transverse link from steering knuckle and front suspension member. Refer to £SU-17, "Removal
and Installation”
10. Separate steering outer socket from steering knuckle. Refer to ST-22. "Removal and Installation”.
FAX-37 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
"7. Remove drive shaft from wheel hub and bearing assembly.
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove drive shaft from transaxle assembly.
+ Use the drive shaft attachment (A) (SST: KV40107500) and a
sliding hammer (B) (commercial service tool) while inserting
tip of the drive shaft attachment between housing and tran-
saxle assembly.
CAUTION:
+ Never place drive shaft joint at an extreme angle when
removing drive shaft. Also be careful not to overextend
slide joint.
+ Confirm that the circular clip is attached to the drive
shaft.
Right Side
1. Remove tires. Refer to WT-61, "Removal and Installation’.
2. Remove wheel sensor from steering knuckle. Refer to BRC-
and Installation”.
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24, "FRONT ; Exploded View",
+ RHD: Refer to BR-88, "FRONT : Exploded View’.
4, Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51. [PER ASSEMBLY (1 PI TYPE) “ Removal
and Installation’.
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal
‘and Installation’.
+ RHD (1 PISTON TYPE): Refer to BR-111,"
and Installation’
+ RHD (2 PISTON TYPE): Refer to BR-56. " CALI
and Installation’
CAUTION:
Never depress brake pedal while brake caliper is removed.
5. Remove disc rotor. Refer to FAX-11_ "Removal and Installation’.
FAX-38 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [2wo}
© Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000).
7, Patch wheel hub lock nut with a piece of wood. Hammer the
‘wood to disengage wheel hub and bearing assembly from drive
shaft.
NOTE:
Use suitable puller, if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8. Remove whee! hub lock nut.
9. Remove transverse link from steering knuckle and front suspension member. Refer to ESU-17, ‘Removal
and Installation’.
10. Separate steering outer socket from steering knuckle. Refer to
‘11. Remove drive shaft from wheel hub and bearing assembly.
‘CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove retainer mounting bolts and retainer.
13. Remove drive shaft from transaxle assembly.
+ Use the drive shaft attachment (SST: KV40107500) and a sliding hammer while inserting tip of the drive
shaft attachment between housing and transaxle assembly.
CAUTION:
Never place drive shaft joint at an extreme angle when removing drive shaft. Also be careful not
to overextend slide joint.
14. If necessary, remove the support bearing bracket mounting bolts and the support bearing bracket,
INSTALLATION
Left Side
Note the following, and install in the reverse order of removal
CAUTION:
Always replace differential side oil seal with new one when installing drive shaft.
+ MIT: Refer to TM-38. “Removal and Installation”.
+ CVT: Refer to TM-429. "Removal and Installation”.
FAX-39 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
[2wo]
* Place the protector (A) (SST: KV38107900) onto transaxle assem-
bly to prevent damage to the differential side oil seal while inserting
drive shaft. Slide drive shaft sliding joint and tap with a hammer to
install securely.
CAUTION:
+ Check that circular clip is completely engaged.
+ Never reuse differential side oil seal.
Clean the matching surface of whee! hub lock nut and wheel hub an:
CAUTION:
Never apply lubricating oil to these matching surface.
+ Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @ of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste: 1.03.0 g (0.04-0.10 oz)
CAUTION:
+ Since the drive shaft is assembled by press-fitting, use the ti
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
+ When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles.
CAUTION:
Never reuse cotter pin.
Tighten the wheel hub lock nut to the specified torque. Refer to FAX-11. “Exploded View",
tightening torque range for the wheel
+ Perform inspection after installation. Refer to FAX-46, "MR20DD - Inspection"
Right Side
Note the following, and install in the reverse order of removal.
CAUTION:
Always replace differential side oil seal with new one when installing drive shaft.
+ MIT: Refer to
* CVT: Refer to TM-429. "Removal and Installation”.
FAX-40 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
* Place the protector (A) (SST. KV38107900) onto transaxle assem-
bly to prevent damage to the differential side oil seal while inserting
drive shaft. Slide drive shaft sliding joint and tap with a hammer to
install securely,
~ CAUTION:
Never reuse differential side oil seal.
+ When installing support bearing bracket tighten the mounting bolt with the following procedure.
CVT models
~ To install support bearing bracket @ and mounting bolts, tempo-
rarily tighten the bolts before tightening to the specified torque,
referring to the tightening method and the numerical order shown
below:
“Temporary tightening 142
Final tightening (Specified torque) 34
~ Set plate @ so thet the notch part @ becomes upper side.
CAUTION:
Never reuse plate.
~ Temporarily tighten the bolts before tightening to the specified
torque, referring to the tightening method and the numerical order
shown below:
‘Temporary tightening 536
Final tightening (Specified torque) 738
(MIT models
= To install support bearing bracket @ and mounting bolts, tempo-
rary tighten the bolts before tightening to the specified torque,
referring to the tightening method and the numerical order shown
below:
‘Temporary tightening 192
Final tightening (Speciied torque) aaa
Set plate @ so thet the notch part @ becomes upper side.
CAUTION:
Never reuse plate.
= Temporarily tighten the bolts before tightening to the specified
torque, referring to the tightening method and the numerical order
shown below:
“Temporary tightening 556
Final tightening (Specitied torque) 738
CAUTION:
Never apply lubricating oil to these matching surface.
FAX-41
Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly. FRONT DRIVE SHAFT
<= REMOVAL AND INSTALLATION > [2wo]
* Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @) of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste: 1.0- 3.09 (0.04-0.10 02)
Tighten the wheel hub lock nut to the specified torque. Refer to EAX-1
CAUTION:
« Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
+ When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles.
CAUTION:
Never reuse cotter pin.
* Perform inspection after i
MR20DD : Disassembly and Assembly nrowowwearonsce#
DISASSEMBLY
Transaxle Assembly Side
1. Fix shaft with a vise
CAUTION:
Protect shaft using aluminum or copper plates when fixing with a vise.
2. Remove boot bands, and then remove boot from housing,
Remove stopper ring,
4, Put matching marks on housing and shaft, and then pull out housing from shaft.
CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surfaces.
5. Putmatching marks @ on the spider assembly and shaft
CAUTION:
Use paint or an equivalent for matching marks. Never
scratch the surfaces.
FAX-42 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
6. Remove snap ring @, and then remove spider assembly from
shaft
Remove boot from shaft
Remove circular clip from housing (left side)
Remove dust shield from housing,
(0. Clean old grease on housing with paper waste
zoen
‘Support Bearing
1, Remove dust shield from housing
rf
2, Remove snap ring @,
3. Press out support bearing from housing
4, Remove dust shield
Dynamic Damper
Remove damper bands, then remove dynamic damper from shaft
Wheel Side
4. Fix shaft with a vise
um or copper plates when fixing with a vise.
2, Remove boot bands, and then remove boot from joint sub-assembly.
FAX-43 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [2wo]
3. Screw drive shaft puller (A) (commercial service tool) into joint
sub-assembly Screw part to a length of 30 mm (1.18 in) or more.
Support drive shaft with one hand and pull out joint sub-assem-
bly from shaft.
CAUTION:
+ If joint sub-assembly cannot be removed after five or
‘more unsuccessful attempts, replace shaft and joint sub
assembly as a set.
+ Align sliding hammer and drive shaft and remove them by
Pulling directory.
4. Remove circular clip from shaft
5. Remove boot from shaft
6. Clean old grease on joint sub-assembly with paper towels while rotating ball cage.
ASSEMBLY
Transaxle Assembly Side
1. Wiap serration on shaft with tape @ to protect boot from dam-
age. Install new boot and boot bands to shaft.
CAUTION:
Never reuse boot and boot band.
2. Remove the tape wrapped around the serration on shaft.
3. To install the spider assembly (D, align it with the matching
marks @ on the shaft @ put during the removal, and direct the
serration mounting surface @ to the shaft
4. Secure spider assembly onto shaft with snap ring @.
CAUTION:
Never reuse snap ring.
5. Apply the appropriate amount of grease to spider assembly and
sliding surface.
6. Assemble the housing onto spider assembly, and apply the bal-
ance of the specified amount grease.
Grease amount _; Refer to FAX-62, “Drive Shaft”,
7. Align matching marks put during the removal of housing : rors
8. Install stopper ring,
CAUTION:
Never reuse stopper ring.
FAX-44 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
f2wo}
a.
10.
1
12.
13,
14.
Install boot securely into grooves (indicated by ™” marks) shown
in the figure,
CAUTION:
If grease adheres to the boot mounting surface (indicated
by “*” mark) on shaft or housing, boot may be removed.
Remove all grease from the surface.
‘To prevent from deformation of the boot, adjust the boot installa-
tion length to the value shown below (L) by inserting the suitable
tool into the inside of boot from the large diameter side of boot
and discharging inside air.
L + Refer to FAX-62, “Drive Shaft’
CAUTION:
+ If the boot installation length exceeds the standard, it may cause breakage in boot.
tool.
* Be careful not to touch the inside of the boot with the tip of
Install new boot bands securely
CAUTION:
Never reuse boot band.
Put boot band in the groove on drive shaft boot. Then fit pawis
(4a) into holes to temporary installation.
NOTE:
For the large diameter side, fit projection @ and guide slit © at
first
Pinch projection on the band with suitable pliers to tighten band.
Insert tip of band below end of the pawl.
Secure housing and shaft, and then make sure that they are in the correct position when rotating boot
Install them with new boot band when the mounting positions become incorrect.
Install dust shield (left side)
CAUTION:
Never reuse dust shield.
Install circular clip to housing (left side).
CAUTION:
Never reuse circular
‘Support Bearing
1
Install dust shield on housing,
CAUTION:
Never reuse dust shield.
FAX-45 FRONT DRIVE SHAFT
<= REMOVAL AND INSTALLATION > [ewo]
2. Press support bearing @ onto housing to using the suitable tool
@
3. Install snap ring.
CAUTION:
Never reuse snap ring.
4. Install dust shields,
CAUTION:
Never reuse dust shields.
Dynamic Damper
+ Install damper bands securely as shown in the figure.
+ Secure dynamic damper with bands in the following specified posi-
tion when removing
CAUTION:
Never reuse bands.
Demission ? Refer to FAX-62, "Drive Shaft”.
‘Wheel Side
For further details, refer to the installation procedure of "EAX-19. "M2000 + Removal and Installation”” for the
drive shaft boot
MR2O0DD : Inspection rocco
INSPECTION AFTER REMOVAL
+ Move joint up/down, leftright, and in the axial directions. Check for motion that is not smooth and for signifi-
cant looseness.
FAX-46 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > Ewo)
* Check boot for cracks, damage, and leakage of grease.
* Disassemble drive shaft and exchange malfunctioning part if there
is a non-standard condition,
INSPECTION AFTER DISASSEMBLY
Shaft
Check shaft for runout, cracks, or other damage. Replace if there are:
Dynamic Damper
Check damper for cracks or wear. Replace if necessary,
Joint Sub-Assembly (Wheel Side)
Check the following:
+ Joint sub-assembly for rough rotation and excessive axial looseness
+ The inside of the joint sub-assembly for entry of foreign material
+ Joint sub-assembly for compression scars, cracks, and fractures inside of joint sub-assembly
Replace joint sub-assembly if there are any non-standard conditions of components.
Housing and Spider assembly (Transaxle Side)
Replace housing and spider assembly if there is scratching or wear of housing roller contact surface or spider
roller contact surface,
NOTE:
Housing and spider assembly are used in a set.
‘Support Bearing (Right Side)
Make sure wheel bearing rolls freely and is free from noise, cracks, pitting or wear. Replace support bearing if
there are any non-standard conditions,
‘Support Bearing Bracket (Right Side)
Check for bending, cracks, or damage. Replace support bearing bracket if there are any non-standard condi-
tions.
INSPECTION AFTER INSTALLATION
1. Check wheel sensor harness for proper connection. Refer to BRC-212. "FRONT WHEEL SENSOR _
2. Check the wheel alignment, Refer to FSU-8. "Insnection’
3. Adjust neutral position of steering angle sensor. Refer to SIRC-99. "Work Procedure"
ROM
FAX-47 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [2wo)
ROM : Exploded View
LEFT SIDE
SEC. 391
® Circular cip @ Dust shies @ Housing
® Snap rng © Spider assembly ® Swopper rng
@ Beotbana @ Boot @ shen
@ Damperband ® Dynamic damper ® soint sub-assembly
@ Dust shietd
[2wo]
RIGHT SIDE (CVT)
‘SEC. 291
125.026, 16)
S Bhse0 (49.55)
@ dustshieis © soint sub-assembly @ Circular ap
@® Boot band © Boot @© shat
@® Damper band ® dynamic damper © Sepper ting
@ Spider assembly @ Snap sing ® Housing
@® oustshieis @® Suppor nearing @ Retainer
® Suppor bearing bracket @ Heat insulator
<3: Wheel side
1: Fil NISSAN Genuine grease or equivalent
HEEB 2 Apply paste [service parts (4400378000),
Dh nm thom, ta)
(29: Aiways replace ater every isassembsy
FAX-49 FRONT DRIVE SHAFT
[2wo)
RIGHT SIDE (Mi)
SEC. 391 ee
250 25,18)
oes
@ Dust shits @® soint sub-assembly @ Croulr cp
@ Bootband ® Boot @® shat
® Stopper eng @® Spider assemby @® Snap ring
@ Housing @ Dust shield ® Support bearing
@ Retainer ® Support bearing bracket @ Heat insulator
<1 Whee! side
EB FILNISSAN Genuine grease or equivalent.
2: Apply paste service parts (440037S000)]
Bh vm cam, toe)
Ep: Aivays replace ater every cisassembly
R9M : Removal and Installation oo cwmimamere
REMOVAL
Left Side
1. Remove tires. Refer to W1-61, "Removal and installation”.
2, Remove wheel sensor from steering knuckle. Refer to BRC-212. “FRONT WHEEL SENSOR - Removal
FAX-50 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24. "FRONT - Exploded View"
+ RHD: Refer to * (
4, Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Rer
and installation”.
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE Cal ASSEMBLY (2 PISTON TYPE) : Removal
and Installation”.
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE! H
and installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116. "
t -
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-11, "Removal and Installation’.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000)
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NOTE:
Use suitable puller, if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8 Remove wheel hub lock nut.
9. Remove transverse link from steering knuckle and front suspension member. Refer to £SU-17, "Removal
and Installation”
10. Separate steering outer socket from steering knuckle. Refer to ST-22. "Removal and Installation”.
FAX-51 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
"7. Remove drive shaft from wheel hub and bearing assembly.
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove drive shaft from transaxle assembly.
+ Use the drive shaft attachment (A) (SST: KV40107500) and a
sliding hammer (B) (commercial service tool) while inserting
tip of the drive shaft attachment between housing and tran-
saxle assembly.
CAUTION:
+ Never place drive shaft joint at an extreme angle when
removing drive shaft. Also be careful not to overextend
slide joint.
+ Confirm that the circular clip is attached to the drive
shaft.
Right Side
1. Remove tires. Refer to WT-61, "Removal and Installation’.
2. Remove wheel sensor from steering knuckle. Refer to BRC-
and Installation”.
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24, "FRONT ; Exploded View",
+ RHD: Refer to BR-88, "FRONT : Exploded View’.
4, Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51. [PER ASSEMBLY (1 PI TYPE) “ Removal
and Installation’.
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal
‘and Installation’.
+ RHD (1 PISTON TYPE): Refer to BR-111,"
and Installation’
+ RHD (2 PISTON TYPE): Refer to BR-56. " CALI
and Installation’
CAUTION:
Never depress brake pedal while brake caliper is removed.
5. Remove disc rotor. Refer to FAX-11_ "Removal and Installation’.
FAX-52 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [2wo}
© Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000).
7, Patch wheel hub lock nut with a piece of wood. Hammer the
‘wood to disengage wheel hub and bearing assembly from drive
shaft.
NOTE:
Use suitable puller, if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8. Remove wheel hub lock nut.
9, Remove transverse link from steering knuckle and front suspension member. Refer to FSU-I7. ‘Removal
and Installation’.
10. Separate steering outer socket from steering knuckle. Refer to ST-22. and | "
11, Remove drive shaft from wheel hub and bearing assembly,
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove retainer mounting bolts and retainer.
13. Remove drive shaft from transaxle assembly.
+ Use the drive shaft attachment (SST: KV40107500) and a sliding hammer while inserting tip of the drive
shaft attachment between housing and transaxle assembly.
CAUTION:
Never place drive shaft joint at an extreme angle when removing drive shaft. Also be careful not
to overextend slide joint.
14. If necessary, remove the support bearing bracket mounting bolts, support bearing bracket and the heat
insulator.
INSTALLATION
Left Side
Note the following, and install in the reverse order of removal
CAUTION:
Always replace differential side oil seal with new one when installing drive shaft.
+ MIT: Refer to TM-118. "Removal and Installation".
+ CVT: Refer to TM-690. “Removal and Installation".
FAX-53 FRONT DRIVE SHAFT
<= REMOVAL AND INSTALLATION > [2wo]
* Place the protector (A) (SST: KV38107900) onto transaxle assem-
bly to prevent damage to the differential side oil seal while inserting
drive shaft. Slide drive shaft sliding joint and tap with a hammer to
install securely.
CAUTION:
+ Check that circular clip is completely engaged.
+ Never reuse differential side oil seal.
+ Clean the matching surface of whee! hub lock nut and wheel hub and bearing assembly.
CAUTION:
Never apply lubricating oil to these matching surface.
* Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste: 1.0-3.0g (0.04 -0.10 02)
Tighten the wheel hub lock nut to the specified torque. Refer to FAX-11. "Explodad View",
CAUTION:
«Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
+ When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles.
CAUTION:
Never reuse cotter pin.
+ Perform inspection after installation. Refer to FAX.60. "R9M _ Inspection’.
Right Side
Note the following, and install in the reverse order of removal
CAUTION:
Always replace differential side oil seal with new one when installing drive shaft.
+ MIT: Refer to TM-118, "Removal and Installation”,
oO ‘efer to TM-690, "Removal and Installation”.
FAX-54 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
* Place the protector (A) (SST: KV38107900) onto transaxle assem-
bly to prevent damage to the differential side oil seal while inserting
drive shaft. Slide drive shaft sliding joint and tap with a hammer to
install securely,
CAUTION:
Never reuse differential side oil seal.
AY
[
I.
+ When installing support bearing bracket tighten the mounting bolt with the followi
~ To install support bearing bracket ( and mounting bolts, tempo-
rary tighten the bolts before tightening to the specified torque,
referring to the tightening method and the numerical order shown
below:
‘Temporary tightening 192
Final tightening (Specified torque) 344
~ Set plate @ so thet the notch part @ becomes upper side.
CAUTION:
Never reuse plate.
~ Temporarily tighten the bolts before tightening to the specified
ing procedure.
1.3
57
torque, referring to the tightening method and the numerical order
shown below:
“Temporary tightening 556
Final tightening (Speciid torque) 738
+ Instal the heat insulator @ to touch a projection @ of the bracket @
‘as shown in figure.
+ Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly
CAUTION:
Never apply lubricating oil to these matching surface.
+ Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @) of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste: 1.0~3.0.g (0.04 - 0.10 oz)
FAX-55 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [2wo]
+ Tighten the wheel hub lock nut to the specified torque. Refer to FAX-11, exploded View"
CAUTION:
+ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
+ When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles
CAUTION:
Never reuse cotter pin.
+ Perform inspection after installation. Refer to FAX-60. "ROM _ inspection’.
ROM : Disassembly and Assembly riser
DISASSEMBLY
Transaxle Assembly Side
1. Fix shaft with a vise.
CAUTION:
Protect shaft using aluminum or copper plates when fixing with a vise.
2, Remove boot bands, and then remove boot from housing
Remove stopper ring
4. Put matching marks on housing and shaft, and then pull out housing from shaft.
CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surfaces.
5. Putmatching marks @ on the spider assembly and shaft
CAUTION:
Use paint or an eq
scratch the surfaces.
lent for matching marks. Never
6. Remove snap ring @, and then remove spider assembly from
shaft.
Remove boot from shaft.
Remove circular clip from housing (left side)
Remove dust shield from housing.
0. Clean old grease on housing with paper waste.
‘Support Bearing
FAX-56 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
7
2.
3
4
Remove dust shield from housing
f2wo}
4
Remove snap ring (.
Press out support bearing from housing,
Remove dust shield
Dynamic Damper (If equipped)
Remove damper bands, then remove dynamic damper from shaft.
Wheel Side
4
4
5.
6.
Fix shaft with a vise
CAUTION:
Protect shaft using aluminum or copper plates when fixing with a vise.
Remove boot bands, and then remove boot from joint sub-assembly.
Screw drive shaft puller (A) (commercial service tool) into joint
sub-assembly screw part to a length of 30 mm (1.18 in) or more,
‘Support drive shaft with one hand and pull out joint sub-assem-
bly from shaft.
CAUTION:
+ If joint sub-assembly cannot be removed after five or
more unsuccessful attempts, replace shaft and joint sub
assembly as a set.
+ Align sliding hammer and drive shaft and remove them by
pulling directory.
Remove circular clip from shaft
Remove boot from shaft
Clean old grease on joint sub-assembly with paper towels while rotating ball cage.
ASSEMBLY
FAX-57 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [2wo]
Transaxle Assembly Side
1. Wrap serration on shaft with tape @ to protect boot from dam-
age. Install new boot and boot bands to shaft.
CAUTION:
Never reuse boot and boot band.
2, Remove the tape wrapped around the serration on shaft
3. To install the spider assembly (, align it with the matching
marks @) on the shaft @) put during the removal, and direct the
serration mounting surface @ to the shaft
4. Secure spider assembly onto shaft with snap ring @.
CAUTION:
Never reuse snap ring.
5. Apply the appropriate amount of grease to spider assembly and
sliding surface.
6. Assemble the housing onto spider assembly, and apply the bal-
ance of the specified amount grease.
Grease amount tefer to FAX-62, “Drive Shaft”.
7. Align matching marks put during the removal of housing. roves
8. Install stopper ring
CAUTION:
Never reuse stopper ring.
9. Install boot securely into grooves (indicated by “*" marks) shown
in the figure.
CAUTION:
If grease adheres to the boot mounting surface (indicated
by “*" mark) on shaft or housing, boot may be removed.
Remove all grease from the surface.
10. To prevent from deformation of the boot, adjust the boot installa
tion length to the value shown below (L) by inserting the suitable
tool into the inside of boot from the large diameter side of boot
and discharging inside air.
L
CAUTION:
+ If the boot installation length exceeds the standard, it may cause breakage in boot.
+ Be careful not to touch the inside of the boot with the tip of tool.
11. Install new boot bands securely.
CAUTION:
Never reuse boot band.
tefer to FAX-62. "Drive Shaft”.
FAX-58 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
f2wo}
‘@. Put boot band in the groove on drive shaft boot. Then fit pawis
(4a) into holes to temporary installation,
NOTE:
For the large diameter side, fit projection ® and guide sit @ at
first
Pinch projection on the band with suitable pliers to tighten band.
Insert tip of band below end of the paw!
SSS
12, Secure housing and shaft, and then make sure that they are in the correct position when rotating boot.
Install them with new boot band when the mounting positions become incorrect
13. Install dust shield (left side)
CAUTION:
Never reuse dust shield.
14. Install circular clip to housing (left side).
CAUTION:
Never reuse circular
‘Support Bearing
1. Install dust shield on housing,
CAUTION:
Never reuse dust shield.
2. Press support bearing @ onto housing to using the suitable tool
(A).
3. Install snap ring
CAUTION:
Never reuse snap ring.
FAX-59 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [2wo]
4, Install dust shields.
CAUTION:
Never reuse dust shields.
Dynamic Damper (If equipped)
+ Put boot band in the groove on drive shaft boot. Then fit paws (4m
into holes to temporary installation.
NOTE:
For the large diameter side, ft projection @ and guide sit @ at
rst
+ Pinch projection on the band with suitable pliers to tighten band.
+ Insert tip of band below end of the pawl.
+ Secure dynamic damper with bands in the following specified posi-
tion when removing,
CAUTION:
Never reuse bands.
Demission + Refer to FAX-62, "Drive Shaft".
Wheel Side
For further details, refer to the installation procedure of "FAX.27. 'RSM Removal and Installation” for the
drive shaft boot
ROM : Inspection nrcicemencom2¥6
INSPECTION AFTER REMOVAL
+ Move joint up/down, leftright, and in the axial directions. Check for motion that is not smooth and for signifi-
cant looseness.
FAX-60 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > Ewo)
* Check boot for cracks, damage, and leakage of grease.
* Disassemble drive shaft and exchange malfunctioning part if there
is anon-standard condition,
INSPECTION AFTER DISASSEMBLY fra
Shaft
Check shaft for runout, cracks, or other damage. Replace if there are
Dynamic Damper (If equipped)
‘Check damper for cracks or wear. Replace if necessary,
Joint Sub-Assembly (Wheel Side)
Check the following:
+ Joint sub-assembly for rough rotation and excessive axial looseness
+ The inside of the joint sub-assembly for entry of foreign material
+ Joint sub-assembly for compression scars, cracks, and fractures inside of joint sub-assembly
Replace joint sub-assembly if there are any non-standard conditions of components.
Housing and Spider assembly (Transaxle Side)
Replace housing and spider assembly if there is scratching or wear of housing roller contact surface or spider
roller contact surface,
NOTE:
Housing and spider assembly are used in a set.
‘Support Bearing (Right Side)
Make sure wheel bearing rolls freely and is free from noise, cracks, pitting or wear. Replace support bearing if
there are any non-standard conditions,
‘Support Bearing Bracket (Right Side)
Check for bending, cracks, or damage. Replace support bearing bracket if there are any non-standard condi-
tions.
INSPECTION AFTER INSTALLATION
1. Check wheel sensor harness for proper connection. Refer to BRC-212. "FRONT WHEEL SENSOR _
Exploded View".
2. Check the wheel alignment, Refer to FSU-5. "Insnection’
3. Adjust neutral position of steering angle sensor. Refer to SIRC-99. "Work Procedure"
FAX-61 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [wo],
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Wheel Bearing aime
Tavalend pay ‘a6 mm [0.002 hy ores
Drive Shaft wrioommwnny sins
MR20DD
cur
Sendard
‘tem
Tataice Right sce
Wheel sie T1S= 1959 (608-4762)
‘Grease quentiy
Transaxle side 75105 g (818-687 ez)
5 wheel se 1415 mm GS7Iny
Sere es Transane side 198.9mm (775i) 108: mm (7-48 in}
[A 273—279 mm (10.75 — 10.9819) 243248 mm (@57 -8.80 In)
Dimension of namic camper” | iam EE
*: For measuring position. Refer to FAX-42, "MR20DD : Disassembly and Assembly".
wr
Sendra
tem
Tatace Rint se
Weal se Ti6— 135 9 (408 ATE oz)
(Grease quantity
Transaxle side 175106 9 (618-687 02)
A Wheel side 4415 mm (667 in)
Bole ea ae Transaxle side 202.1 mm (79819) 188.8 mm (7-44in)
a 213-27 mm(10.75-1098in) | 243-249 mm (@67—9.80 in)
Dimension of dynamic damper’ | eit
= For measuring postion, Refer fo 7 Z
ROM
cur
Biendard
tem
Tetisie Renae
Wheel ste T45— 165 g(5 1158202)
‘Grease quantity
Transaie side 265 — 286 g (836 - 1005 c2)
C Wheel se 145mm (871m)
insta
ae Transanie side 198.1 mm (772i) 1841 mm (7.25in)
ae a 255-261 mm {10.04-1028in) | 205-211 mm (6.07 -8.31 in)
Dimension of dynamic dam
rension of namic damper” | aie Guat
*: For measuring position. Refer to FAX-56. "ROM ; Disassembly and Assembly".
Mr
FAX-62 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [wo]
= Standard
Tetsae Right se
Wheel ae TAS 105 g(6.11 58202)
Grease quantty
“Transaxie side 265 286 g (036 — 10.05 02)
; Wheel side 145mm (ET in)
ee Transexe side 198. mm (TIBI etm (725m)
[A 207-218 mn (8.15 —8.39n) =
Dimension of namie damper” ATR ISH —
*: For measuring position. Refer to FAX-55, "ROM; Disassembly anid AssombI
FAX-63 PRECAUTIONS
< PRECAUTION > fawo]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" wporcomeno0 censor
‘The Supplemental Restraint System such as "AIR BAG” and “SEAT BELT PRE-TENSIONER’, used along
vith a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG" and
“SEAT BELT” of this Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
+ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that 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 “SRS AIR BAG”.
+ Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring hamesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
+ When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
+ When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
+ Before removing and installing any control units, first turn the ignition power source and accessory
power source to the OFF, then disconnect both battery cables,
+ After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
+ Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehiole with steering lock unit, if the battery is disconnected or discharged, the steering whee! will lock and
cannot be tumed.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
‘Supply power using jumper cables if battery is discharged,
2. Open driver door.
3. Turn the ignition switch to the ON position.
(At this time, the steering lock will be released.)
4, Tum the ignition switch to OFF position with driver door open.
5. Wait for 3 minutes or longer with driver door open.
NOTE:
+ Do not close driver door because the steering wheel locks when driver door is closed.
FAX-64 PRECAUTIONS
< PRECAUTION > [ao]
= The auto aco function is adapted to this vehicle. For this reason, even when the ignition switch is turned
to OFF position, the accessory power source does not turned OFF and continues to be supplied for a
certain amount of time.
6. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
7. Perform the necessary repair operation.
8. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from OFF position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
9. Perform self-diagnosis check of all control units using CONSULT.
Precautions for Removing Battery Terminal sei
+ With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
of remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is tuned to the OFF position, i.e. ACC power is supplied for a certain fixed time
+ When disconnecting the 12V battery terminal, turn off the ACC.
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
‘Some ECUs operate for a certain fixed time even after ignition
switch is tured OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch
NOTE:
If the ignition switch is turned ON with any one of the terminals of
‘main battery and sub battery disconnected, then DTC may be detected,
‘After installing the 12V battery, always check "Self Diagnosis Result’ of all ECUs and erase DTC.
NOTE:
‘The removal of 12V battery may cause a DTC detection error,
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
INSTRUCTION 1
1, Open the hood.
2. Tum key switch to the OFF position with the driver side door opened.
3. Get out of the vehicle and close the driver side door.
4.
Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
DéDengine 20 minutes
HRAZDDT 12 minutos
Kok engine 4 minutes
MOR engine 4 minutes
ROM engine 4 minutes
Vox engine 4 minutes
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5. Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
1. Unlock the door with intelligent key or remote keyless entry.
FAX-65 PRECAUTIONS
< PRECAUTION > fawo]
NO
At this moment, ACC power is supplied
‘Open the driver side door.
‘Open the hood.
Close the driver side door.
Wait at least 3 minutes,
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function,
6. Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
Precautions for Drive Shaft wreioemenseco4o9
CAUTION:
Note the following precautions when disassembling and assembling drive shaft.
+ Joint sub-assembly does not disassemble because it is non-overhaul parts.
+ Perform work in a dust-free location.
+ Before disassembling and assembling, clean the parts.
+ Prevent the entry of foreign objects during disassembly of the Service location.
+ Disassemble parts must be carefully reassembled in the correct order. If work is interrupted, a
clean cover must be placed over parts.
+ Paper waste must be used. Fabric shop cloths must not be used because of the danger of lint adher-
ing to parts.
+ Disassembled parts (except for rubber parts) should be cleaned with kerosene which shall be
removed by blowing with air or wiping with paper waste.
FAX-66 PREPARATION
<= PREPARATION >
[awn]
PREPARATION
PREPARATION
Special Service Tool
Tool number T
Fee Description
Kv40104000 |” Removing and Instaling wheel hub lock nut
Hub lock nut wrench
2: 85 mm (3.35 in)
b. 85 mm (2.58 in)
v40107300
Boot band crimping tool
| instating boot bend
Kvao107800 Fmaving drive shat
Drive shaft attachment
KV36107800 Instaling drive shaft
Protector
2 32 mm (1.2 in) ala,
Commercial Service Tool
Teolname
‘Description
Drive shat puller
——
Romaving drive shaft joint sub assembly
FAX-67 < PREPARATION >
PREPARATION
[awp}
Siding hammer
Ball joint remover
Chisel
a
eP
SS
—S
Ranoving drive shat
Removing hub bolt
Removing and instaliing steering knuckle and
strut assembly
‘A: 16 ~32 mm (0.63 - 1.26 in)
B: 10 mm (0.39 in) or more
©: 40-70 mm (1.87 2.76 in)
220 mm (7.87 in) or less,
S:14 mm (0.55 in) or more
Lubricant or/and Sealant
Name Description
huine grease or equivale ~ Joint sub-assembly inside
Fill NISSAN Genuine gt equivalent ease
‘Apply paste [service parts (440087S000)] + Joint sub-assembly
FAX-68 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [4wp]
SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart rN,
Use chart below to find the cause of the symptom. If necessary, repair or replace these parts.
ale :
2/8 ]8]8]e] es] se
Reference ' (ays (dle lz ee] 2 [5 |
Z Zlslzlz lf lzlz
| alse le lz ls|s
= [= |2|2|8|2
|g 3
5
% 5
g 5
i 5
Possible cause and SUSPECTED PARTS ele! [2] |sle
* Flo
Fe! ere l2/2|] fale
ere eleleigie| [Elz] le
Slelblalelzlele] [2/4 lyle
Plelalele iglesia lal lS le
&/SlelFls ls lelele|2|8| S|
oe Lee aE xl =p=l = =|
sur [anise ee
Noise ep tettet=t
= Shake Ec
Symptom
Front | Wbraon xl el >see pel
AXLE [Shimmy *[ x % ¥ | ™] x
(Huser x eel els
oor quality rae orhanding xleL_l*L Lele
Thppleable
FAX-69 FRONT WHEEL HUB AND KNUCKLE
< PERIODIC MAINTENANCE > fawo]
PERIODIC MAINTENANCE
FRONT WHEEL HUB AND KNUCKLE
Inspection seo
COMPONENT PART
Make sure that the mounting conditions (looseness, backlash) of each component and component conditions
(wear, damage) are normal,
WHEEL HUB ASSEMBLY (BEARING-INTEGRATED TYPE)
Check the following items, and replace the part if necessary.
* Move wheel hub and bearing asseriby in he axial direction by hand, Check there is no looseness of wheel
earing
Axial end play + Refer to FAX-137, "Wheel Bearing”,
+ Rotate wheel hub and make sure there is no unusual noise or other irregular conditions. If there is any of
irregular conditions, replace wheel hub and bearing assembly,
FAX-70 FRONT DRIVE SHAFT
< PERIODIC MAINTENANCE > [4wp]
FRONT DRIVE SHAFT
Inspection oo cowrccees
FRONT DRIVE SHAFT INSPECTION
Check the following items, and replace the part if necessary.
* Check drive shaft mounting point and joint for looseness and other damage.
CAUTION:
Replace entire drive shaft assembly when noise or vibration occur from drive shaft.
* Check boot for cracks and other damage.
FAX-71 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION > [4wp)
REMOVAL AND INSTALLATION
FRONT WHEEL HUB AND KNUCKLE
Exploded View inroocmenco ensue?
‘SEC. 400
BOP 02.00
@ Steering knuckle @ Splash guars @ Hub batt
@® Whee! hub and bearing assembly @)_ Disc rotor © Whes! hub lock nut
@ Adjusting cap ® Cotter pin
BL sem team, ro)
(£4: Atways replace ater every sisassembly
Removal and Installation nvopmmmnanuct
REMOVAL
1. Remove tires. Refer to W1-61, "Removal and installation”,
2. Remove front wheel sensor from steering kunckle. Refer to SRC-212. "FRONT WHEEL SENSOR
Re and In: r.
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to 8R-24, "FRONT : Exploded View’.
+ RHD: Refer to BR-88. "FRONT - Exploded View".
FAX-72 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION > [awo]
a
10.
“
12,
13,
Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work
* LHD (1 PISTON TYPE): Refer to BR-51. "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE): Removal
and Installation”.
+ LHD (2 PISTON TYPE): Refer to BR:56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) ; Removal
"i
+ RHD (1 PISTON TYPE): Refer to BR-111" ¥
and Installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116."
and Installation’.
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor.
CAUTION:
+ Put matching marks @® on the wheel hub and bearing
assembly and the disc rotor before removing the disc
rotor.
+ Never drop disc rotor.
Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000),
Patch wheel hub lock nut with a piece of wood, Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NOTE:
Use suitable puller, if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
Remove wheel hub lock nut
Remove wheel hub and bearing assembly.
Remove splash guard.
Remove transverse link from steering knuckle and front suspension member. Refer to FSU-i7, ‘Removal
and Installation”.
Separate steering outer socket from steering knuckle. Refer to ST-22, "Removal and Installation”.
‘Separate the connection of strut assembly and steering knuckle as follows.
CAUTION:
FAX-73 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION >
[4wD]
Be sure to keep the following procedure because steering knuckle may be damaged when you
enlarge the gap of steering knuckle too much.
‘a. Remove strut mounting bolts from steering knuckle.
b. Measure the gap (A) of the steering knuckle. And then mark the
enlarged limit (B) to the chisel
© Marking
Enlarged limit (B) = gap (A) + 2.5 mm (0.098 in)
NoTr
Standard of gap: 6.9 + 0.5 mm (2.56 + 0.02 in)
c. Enlarge the gap of the steering knuckle with the chisel (A) (com-
mercial service tool) not to surpass a limit as shown in the figure.
CAUTION:
+ Never enlarge the gap more than 2.5mm (0.098in).
* Be careful not to damage the projection @ and strut
assembly @ with the chisel.
d. Separate the connection of strut assembly and steering knuckle.
CAUTION:
+ Never place drive shaft joint at an extreme angle.
* Be careful not to overextend slide joint.
+ Never allow drive shaft to hang down without support for joint sub-assembly, shaft and the other
parts.
+ Be sure to remove lubricants if lubricant has been used to separate the connection of strut
assembly and steering knuckle.
FAX-74 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION >
74, Remove hub bolts @ from wheel hub and bearing assembly,
using the ball joint remover (A) (commercial service tool)
CAUTION:
+ Remove hub bolt only when necessary.
+ Never hammer the hub bolt to avoid impact to the wheel
hub and bearing assembly.
+ Pull out the hub bolt in a direction perpendicular to the
wheel hub and bearing assembly.
15. Perform inspection after removal. Refer to FAX-77, *insoection
INSTALLATION
Note the following, and install in the reverse order of the removal
Hub Bolts
+ Place a washer @) as shown in the figure to install the hub bolts ©
by using the tightening force of the nut 6)
CAUTION:
* Check that there is no clearance between wheel hub and
bearing assembly, and hub bolt.
+ Never reuse hub bolt.
Drive shaft
* Clean the matching surface of wheel hub lock nut and wheel hub an«
CAUTION:
Never apply lubricating oil to these matching surface.
* Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @ of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste: 4.0-3.0.g (0.04- 0.10 oz)
\d bearing assembly.
CAUTION:
* Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut,
+ Be sure to use torque wrench to tighten the wheel hub lock ni
+ Never reuse wheel hub lock nut.
FAX-75
Tighten the wheel hub lock nut to the specified torque. Refer to EAX.72. "Exploded View"
ut. Never use a power tool. FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION > [4wo]
+ When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rates.
‘CAUTION:
Never reuse cotter pin.
Disc rotor
CAUTION:
* Align the matching marks @® made during removal when reus-
ing the disc rotor.
+ Never drop disc rotor.
Strut Assembly and Steering Knuckle Connection
CAUTION:
Be sure to remove lubricants if lubricant has been used to separate the connection of strut assembly
and steering knuckle.
+ Install the steering knuckle to strut assembly as follows,
1. Set suitable jack under steering knuckle,
2. Align the gap @ of steering knuckle to the projection part ® of A
ms \
u eal
3. Tighten the mounting bolt with pushing up the steering knuckle
© until contacts stopper bracket @ end face, using a suitable Ar
jack Ny
CAUTION: aS &
Check the stable condition when using a jack. Ds
Le
PA veniaancz
+ Perform inspection after installation. Refer to FAX-77. “inspection”.
FAX-76 FRONT WHEEL HUB AND KNUCKLE
< REMOVAL AND INSTALLATION > [4wo]
Tnspection
INSPECTION AFTER REMOVAL
Check the following items, and teplace the part if necessary
* Check components for deformation, cracks, and other damage.
* Check boots of transverse link and steering outer socket ball joint for breakage, axial end play, and swing
torque.
- Transverse link: Refer to FSU-18, “Inspection”,
- Steering outer socket: Refer to ST-26. " r.
INSPECTION AFTER INSTALLATION
1, Check wheel sensor harness for proper connection. Refer to BRC-212, "FRONT WHEEL SENSOR :
Exploded View".
2. Cheok the wheel alignment. Refer to ESU-8. “Inspection”
3. Adjust neutral position of steering angle sensor. Refer to BRC-99, "Work Procedure”
FAX-77 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [4wo)
FRONT DRIVE SHAFT BOOT
MR20DD
MR20DD : Exploded View sonoma
LEFT SIDE
(SEC. 391
@ Circular cp ® dust shield @ Housing
@® Snap cing ® Spider assembly © Stopper ring
@ Boot bang ® Boot @ Shan
@ Damper band @ Dinamic damper @® Joint sub-assembly
@ Dust shieta
Wheel side
Fill NISSAN Genuine grease or equivalent
Apply paste [service parts (4400378000)
(29: Aways replace ater every cisassembly
FAX-78 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [4wo]
RIGHT SIDE
‘SEC.a9
\ Pee (2, 35)
&®
Fassc2s's0 B.
//
Phe 40.05)
oN
© dust shiis © sont sub-assembly @ Cicuiaretip
@ Beet band @ Boot © Stat
@ Damper vane ® dynamic damper @® Stopper rg
@ Sviderassembiy ® Snap sing @ Housing
@ Dustshieie @ Supportdearng @ Fetaner
® _Soppon bearing bracket
<3: Whe side
EB 1: FI NISSAN Genuine grease or eauivalent.
‘Apply paste service pats 440037000)
PA Nim thom, te)
(8$: Always replace ater every cisassembiy,
MR20DD : Removal and Installation swooumeiren
REMOVAL
Whee! Side
1, Remove tires. Refer to WT-61. "Removal and Installation”.
2, Remove wheel sensor from steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR « Removal
and Installation’.
FAX-79 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24. "FRONT - Exploded View",
+ RHD: Refer to BR-88. "FRONT ; Exploded View"
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMI ‘ON TYPE} | Re
:
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBL\ a E) : Removal
and Installation”
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON ov
and Installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116.""
lation"
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-72, "Removal and installation’.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000).
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NoTt
Use suitable puller if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8. Remove wheel hub lock nut
9. Remove transverse link from steering knuckle and front suspension member. Refer to ESU-17, "Removal
10. Separate steering outer socket from steering knuckle, Refer to S1-22. "Removal and Installation’.
FAX-80 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
71. Remove drive shaft from wheel hub and bearing assembly
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove boot bands, and then separate boot from joint sub-assembly.
43. Screw drive shaft puller (A) (commercial service tool) into joint
sub-assembly screw part to a length of 30 mm (1.18 in) or more.
Support drive shaft with one hand and pull out joint sub-assem-
bly from shaft
‘CAUTION:
* Align sliding hammer and drive shaft and remove them by
pulling directory.
+ If joint sub-assembly cannot be pulled out, try after
removing drive shaft from vehicle. Refer to FAX-42,
14, Remove circular clip @ from shaft
15. Remove boot from shaft.
Transaxle Side
Remove boot after removing drive shaft.
+ Remove: Refer to EAX-401. "MR200D _ Removal and installation”
+ Disassembly: Refer to FAX-107, “MR20DD * Disassembly and Assembly"
INSTALLATION
Wheel Side
1. Clean the old grease on joint sub-assembly with paper waste.
2. Fill serration slot joint sub-assembly @ with NISSAN genuine
grease or equivalent until the serration slot and ball groove
become full to the brim
‘CAUTION:
After applying grease, use a shop cloth to wipe off old
grease that has aozed out.
FAX-81 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
[4wo)
3. Install boot and boot bands to shaft.
CAUTION:
+ Never reuse boot and boot band.
+ Wrap serration on shaft with tape @ to protect the boot
from damage.
4. Remove the tape wrapped around the serration on shaft
5. Position the circular clip © on groove at the shaft edge.
CAUTION:
Never reuse circular clip.
NOTE:
Drive joint inserter is recommended when installing circular clip
@.
6. Align both center axles of the shaft edge and joint sub-assembly, Then assemble shaft with joint sub-
assembly holding circular clip.
7. Install joint sub-assembly @ to shaff using plastic hammer.
CAUTION:
* Check circular clip is properly positioned on groove of the
joint sub-assembly.
+ Confirm that joint sub-assembly is correctly engaged
while rotating drive shaft.
8. Fill into the boot inside with the specified amount of grease from large diameter side of boot,
Grease amount
+ Refer to FAX-137, “Drive Shaft”.
FAX-82 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [awo]
9. Install the boot securely into grooves (Indicated by” marks)
shown in the figure
CAUTION
If grease adheres to the boot mounting surface (indicated *
by “*” mark) on the shaft or joint subassembly. boot may be
removed. Remove all grease from the boot mounting sur-
face.
10,,To prevent the deformation of the boot, adjust the boot instalia-
tion length (L) to the specified value shown below by inserting
the suitable too! into the inside of the boot from the large diame- Ss
ter side of the boot and discharging the inside air. ceasaia:
rd
L : Refer to FAX-137, “Drive Shaft".
CAUTION:
+ If the boot mounting length exceeds the standard, it may cause breakage in the boot.
+ Be careful not to touch the inside of the boot with a tip of tool.
11. Secure the large and small ends of the boot with boot bands
using the boot band crimping tool (A) (SST: KV40107300),
CAUTION:
Never reuse boot band.
NOTE:
‘Secure boot band so that dimension (M) meets the specification as shown in the figure.
M :1.0~ 4.0 mm (0.039 - 0.157 in)
12. Check that displacement does not occur when boot is rotated with the joint sub-assembly and shaft fixed.
CAUTION:
+ Reinstall them using boot bands when boot installation positions become incorrect.
+ Never reuse boot band.
13, Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly.
CAUTION:
Never apply lubricating oil to these matching surface.
FAX-83 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [4wo]
14, Clean the matching surface of drive shaft and wheel hub and
bearing assembly. And then apply paste [service parts
(440037S000)] to surface ® of joint sub-assembly of drive shaft.
CAUTION:
Apply paste to cover entire flat surface of joint sub-assem-
bly of drive shaft.
Amount paste: 1.0-3.0g (0.04-0.10 02)
15. Insert drive shaft to wheel hub and bearing assembly, and then temporarily tighten wheel hub lock nut.
CAUTION:
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
16. Install transverse link to steering knuckle and front suspention member. Refer to FSU-17, "Exploded
ey
17. Install steering outer socket to steering knuckle.
+ LHD: Refer to ST-20, "LHD | Exploded View".
+ RHD: Refer to ST-21."RHD : Exploded View!
18. Tighten the wheel hub lock nut to the specified torque. Refer to FAX-72, "Exploded View’.
CAUTION:
+ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
19. When installing a cotter pin @® and adjusting cap @, securely
bend the basal portion to prevent rattles
CAUTION:
Never reuse cotter pin.
20. Install disc rotor. Refer to FAX-72, "Removal and installation"
21. Install caliper assembly to steering knuckle.
+ LHD (1 PISTON TYPE): Refer fo 8-51, "BRAKE CALIPER ASSEMBLY (1 PI
and Installation".
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal
f .
and Installation”.
+ RHD (1 PISTON TYPE): Refer to BR-
and Installation’.
+ RHD (2 PISTON TYPE): Refer to BR-56. q
and Installation”.
22. Install lock plate to strut assembly.
+ LHD: Refer to BR-24, "FRONT : Exploded View".
+ RHD: Refer to BR-88, "FRONT : Exploded View",
23. Install wheel sensor to steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR | Removal and
5
24. Install tires to vehicle. Refer to W1-61, "Removal and installation".
25. Perform inspection after installation. Refer to FAX-85, "MR20DD : Inspection".
Transaxle Side
* Installation: Refer to FAX-101, "MR20DD ; Removal and Installation’.
FAX-84 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [4wo]
~ Assembly: Refer to FAX-107, "NIRZODD Disassembly and Assembly"
MR2O0DD : Inspection nrceewencoect'2
INSPECTION AFTER REMOVAL
Check the following items, and replace the part if necessary.
+ Check components for deformation, cracks, and other damage.
+ Check boots of transverse link and steering outer socket ball joint for breakage, axial end play, and swing
torque.
~ Transverse link: Refer to FSU-18. "Inspection’.
~ Steering outer socket: Refer to ST-26. “inspection”.
INSPECTION AFTER INSTALLATION fra
4, Check wheel sensor harness for proper connection. Refer to BRC-212, "FRONT WHEEL SENSOR.
Exploded View".
2. Check the wheel alignment. Refer to FSU-8, "Inspection!
3. Adjust neutral position of steering angle sensor. Refer to BRC-99, "Work Procedure"
QR25DE
QR25DE : Exploded View eroweommereanee'y
LEFT SIDE
[Sec.391
Dust shield
Spider assembly
Boot
Circular clip
‘Snap ring
Boot band
Housing
‘Stopper ring
Shatt
Se@e@e8
8SeG6e
Damper band
Dust shield
[4wo)
RIGHT SIDE
(SEC. 391
@ dust she @ soi aivassemby @ Cheuareip
@ Boot band @ oat © sun
@ Damper band © dynamic camper © sepperog
@ Spider assembly ® Snap ring ® Housing
@ Dustane @ Support beara @ Retainer
Suppor besrr bracket
©: Whee ste
EEG 1: Fill NISSAN Genuine grease or equivalent.
HEEB 2: Anply paste (service parts (440037S000))
Dn tam, n)
#54: Always replace ater every disassembly
QR25DE : Removal and Installation incon
REMOVAL
Wheel Side
1. Remove tires. Refer to WW1-61. "Removal and Installation”.
2, Remove wheel sensor from steering knuckle. Refer to BRO-212 “FRONT WHEEL SENSOR - Removal
FAX-86 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
3. Remove lock plate @ from strut assembly.
+ LHD; Refer to BR-24. "FRONT - Exploded View".
+ RHD: Refer to * 3
4, Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Rer
and installation”.
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE Cal ASSEMBLY (2 PISTON TYPE) : Removal
and Installation”.
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE M
and installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116. "
‘and Installation”.
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-72, "Removal and Installation"
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000)
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NOTE:
Use suitable puller, if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8 Remove wheel hub lock nut.
9. Remove transverse link from steering knuckle and front suspension member. Refer to £SU-17, "Removal
and Installation”
10. Separate steering outer socket from steering knuckle. Refer to ST-22. "Removal and Installation’.
FAX-87 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
77. Remove drive shaft from wheel hub and bearing assembly
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove boot bands, and then separate boot from joint sub-assembly.
13. Screw drive shaft puller (A) (commercial service tool) into joint
sub-assembly screw part to a length of 30 mm (1.18 in) or more.
Support drive shaft with one hand and pull out joint sub-assem-
bly from shaft.
CAUTION:
+ Align sliding hammer and drive shaft and remove them by
pulling directory.
+ If joint sub-assembly cannot be pulled out, try after
removing drive shaft from vehicle. Refer to FAX-119,
14. Remove circular clip @ from shaft.
15. Remove boot from shat.
‘Transaxle Side
Remove boot after removing drive shaft.
+ Remove: Refer to FAX-113. "QR25DE - Removal and Installation”
+ Disassembly: Refer to FAXTI9 "QR25DE Disassembly and Assembly"
INSTALLATION
Wheel Side
1. Clean the old grease on joint sub-assembly with paper waste.
2. Fill serration slot joint sub-assembly @ with NISSAN genuine
grease or equivalent until the serration slot and ball groove
become full to the brim.
CAUTION:
After applying grease, use a shop cloth to wipe off old
grease that has oozed out.
FAX-88 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
[4wb)
3. _ Install boot and boot bands to shaft.
CAUTION:
+ Never reuse boot and boot band.
+ Wrap serration on shaft with tape @ to protect the boot
from damage. PO
( re
4. Remove the tape wrapped around the serration on shaft
5. Position the circular clip @ on groove at the shaft edge
CAUTION:
Never reuse circular clip.
NOTE:
Drive joint inserter is recommended when installing circular clip
6. Align both center axles of the shaft edge and joint sub-assembly, Then assemble shaft with joint sub-
assembly holding circular clip.
7. Install joint sub-assembly @ to shaft using plastic hammer.
CAUTION:
* Check circular clip is properly positioned on groove of the
joint sub-assembly.
+ Confirm that joint sub-assembly is correctly engaged
while rotating drive shaft.
8, Fill into the boot inside with the specified amount of grease from large diameter side of boot.
Grease amount
+ Refer to FAX-137, "Drive Shaft”.
FAX-89 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [awo]
3, Install the boot securely into grooves (Indicated by" marks)
shown in the figure.
CAUTION
If grease adheres to the boot mounting surface (indicated
by “*” mark) on the shaft or joint subassembly. boot may be \
removed. Remove all grease from the boot mounting sur-
face.
10. To prevent the deformation of the boot, adjust the boot installa-
tion length (L) to the specified value shown below by inserting
the suitable tool into the inside of the boot from the large diame-
ter side of the boot and discharging the inside air. siicaas
fs Refer to FAX-137, "Drive Shaft”.
CAUTION:
+ Ifthe boot mounting length exceeds the standard, it may cause breakage in the boot.
+ Be careful not to touch the inside of the boot with a tip of tool.
11. Secure the large and small ends of the boot with boot bands
using the boot band crimping tool (4) (SST: KV40107300).
CAUTION: A |
Never reuse boot band.
NOTE:
‘Secure boot band so that dimension (M) meets the specification as shown in the figure.
u £4.04. mm (0.039 - 0.187 in)
12. Check that displacement does not occur when boot is rotated with the joint sub-assembly and shaft fixed.
CAUTION:
+ Reinstall them using boot bands when boot installation positions become incorrect.
+ Never reuse boot band.
13. Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly.
CAUTION:
Never apply lubricating oil to these matching surface.
FAX-90 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [4wo]
14
15,
16
17,
18.
19,
20.
2
22,
23.
24,
25.
lean the matching surface of drive shaft and wheel hub and
bearing assembly, And then apply paste [service parts
(4400378000) to surface @) of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assem-
bly of drive shaft.
Amount paste: 1.0- 3.0 g (0.04 - 0.10 oz)
Insert drive shaft to wheel hub and bearing assembly, and then temporarily tighten wheel hub lock nut
CAUTION:
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
Install transverse link to steering knuckle and front suspention member. Refer to FSU-17, "Exploded
View".
Install steering outer socket to steering knuckle.
+ LHD: Refer te S20 WHO Exploded View".
+ RHD: Refer to ST-21.”
Tighten the wheel hub lock nut to i specified torque. Refer to FAX-72, "Exploded View",
CAUTION:
* Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
When installing a cotter pin @ and adjusting cap @, securely
bend the basal portion to prevent rattles.
CAUTION: FB
Never reuse cotter pi
Install disc rotor. Refer to FAX-72, "Removal and Installation”.
Install caliper assembly to steering knuckle
+ LHD (1 PISTON TYPE): Refer to BR-51. "BRAKE CA\ Y (1 PISTON TYPE) : Removal
and Installation’.
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE): Removal
and Installation’.
+ RHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal
i a
Install lock plate to strut assembly.
+ LHD: Refer to BR-24, "FRONT : Exploded View’.
+ RHD: Refer to BR-86. "FRONT: Exploded View"
Install wheel sensor to steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR « Removal and
<
Install tires to vehicle Refer to VWT-61. "Removal and Installation’.
Perform inspection after installation. Refer to FAX-92, "QR25DE - Inspection’
Transaxle Side
* Installation: Refer to FAX-113, "QR25DE : Removal and Installation’.
FAX-91 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [4wp)
‘Assembly: Refer to FAX-119, "QR25DE_ Dissssembiy and Assembi™
QR25DE : Inspection nrocenancronss
INSPECTION AFTER REMOVAL
Check the following items, and replace the part if necessary.
+ Check components for deformation, cracks, and other damage.
+ Check boots of transverse link and steering outer socket ball joint for breakage, axial end play, and swing
torque.
~ Transverse link: Refer to FSU-18. "inspection"
~ Steering outer socket: Refer to ST-25. "inspection"
INSPECTION AFTER INSTALLATION
1. Check wheel sensor hamess for proper connection, Refer to 8RC-212, "FRONT WHEEL SENSOR
Exploded View"
2. Check the wheel alignment. Refer to FSU-8, "Inspection’.
3. Adjust neutral position of steering angle sensor. Refer to BRC-99. "Work Procedure".
ROM
ROM : Exploded View ‘eroecummoresr
LEFT SIDE
SEC. 391
© Ciesla @® dust iets @ Housing
® Snap ing © Spider assembly @ Stopper rng
@ Boot bend @ Boot @ shor
@ Damper band ® Dynamic damper ® Joint sub-assembly
@ Dust shield
wee! sige
EB 1: FILNISSAN Genuine grease or equvelent.
EGR 2 Asal pate [service parts (4400378000)]
(24: Aways replace ator every clsassembly
FAX-92 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [4wo]
RIGHT SIDE
‘SEC. 391 ey 0,
Sr 2 (49.25)
Ay (42.99)
Haven)
@ Dust shieid @ Joint sub-assembly @ Circular ip
@ Boot band @ Boot @ shat
® Stopper ting ® Spider assembly @ Snap rng
® Housing @ Dust shiets ® Support bearing
@ Retainer @ Support bearing bracket @ Heatinsulator
<3: Wheel side
+ FI NISSAN Genuine grease or equivalent
2: Apply paste [service parts (440087000),
Fn kam, toby
(Always replace ater every disassembly
R9M ; Removal and Installation wrote
REMOVAL
Whee! Side
1, Remove tires. Refer to WI-61, “Removal and Installation”.
2. Remove wheel
nsor from steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR Removal
FAX-93 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24. "FRONT - Exploded View",
+ RHD: Refer to BR-88. "FRONT ; Exploded View"
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMI ‘ON TYPE} | Re
:
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBL\ a E) : Removal
and Installation”
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON ov
and Installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116.""
lation"
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-72, "Removal and installation’.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000).
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NoTt
Use suitable puller if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8. Remove wheel hub lock nut
9. Remove transverse link from steering knuckle and front suspension member. Refer to ESU-17, "Removal
10. Separate steering outer socket from steering knuckle, Refer to S1-22. "Removal and Installation’.
FAX-94 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
71. Remove drive shaft rom wheel hub and bearing assembly
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove boot bands, and then separate boot from joint sub-assembly.
43. Screw drive shaft puller (A) (commercial service too!) into joint
sub-assembly screw part to a length of 30 mm (1.18 in) or more.
Support drive shaft with one hand and pull out joint sub-assem-
bly from shaft
‘CAUTION:
* Align sliding hammer and drive shaft and remove them by
pulling directory.
+ If joint sub-assembly cannot be pulled out, try after
removing drive shaft from vehicle. Refer to FAX-131, "RM
iDisassembly and Assembly”.
14, Remove circular clip @ from shaft.
15. Remove boot from shaft
Transaxle Side
Remove boot after removing drive shaft.
+ Remove: Refer to FAX-125, "RSM _ Removal and Installation"
+ Disassembly: Refer to FAX-131. "ROM | Disassembly and Assembly"
INSTALLATION
Wheel Side
1, Clean the old grease on joint sub-assembly with paper waste.
2. Fill serration slot joint sub-assembly @ with NISSAN genuine
grease or equivalent until the serration slot and ball groove
become full to the brim
CAUTION:
After applying grease, use a shop cloth to wipe off old
grease that has aozed out.
FAX-95 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION >
[4wo)
3. Install boot and boot bands to shaft.
CAUTION:
+ Never reuse boot and boot band.
+ Wrap serration on shaft with tape @ to protect the boot
from damage.
4. Remove the tape wrapped around the serration on shaft
5. Position the circular clip © on groove at the shaft edge.
CAUTION:
Never reuse circular clip.
NOTE:
Drive joint inserter is recommended when installing circular clip
@.
6. Align both center axles of the shaft edge and joint sub-assembly, Then assemble shaft with joint sub-
assembly holding circular clip.
7. Install joint sub-assembly @ to shaff using plastic hammer.
CAUTION:
* Check circular clip is properly positioned on groove of the
joint sub-assembly.
+ Confirm that joint sub-assembly is correctly engaged
while rotating drive shaft.
8. Fill into the boot inside with the specified amount of grease from large diameter side of boot,
Grease amount
+ Refer to FAX-137, “Drive Shaft”.
FAX-96 FRONT DRIVE SHAFT BOOT
<= REMOVAL AND INSTALLATION > [awo]
9. Install the boot securely into grooves (indicated by” marks)
shown in the figure
‘CAUTION
If grease adheres to the boot mounting surface (indicated *
by “*” mark) on the shaft or joint subassembly. boot may be
removed. Remove all grease from the boot mounting sur-
face.
10,,To prevent the deformation of the boot, adjust the boot instalia-
tion length (L) to the specified value shown below by inserting
the suitable too! into the inside of the boot from the large diame- Ss
ter side of the boot and discharging the inside air. ceasaia:
rd
L : Refer to FAX-137, “Drive Shaft".
CAUTION:
+ If the boot mounting length exceeds the standard, it may cause breakage in the boot.
+ Be careful not to touch the inside of the boot with a tip of tool.
11. Secure the large and small ends of the boot with boot bands
using the boot band crimping tool (A) (SST: KV40107300),
CAUTION:
Never reuse boot band.
NOTE:
‘Secure boot band so that dimension (M) meets the specification as shown in the figure.
M :1,0- 4,0 mm (0.039 - 0.187 in)
12, Check that displacement does not occur when boot is rotated with the joint sub-assembly and shaft fixed.
CAUTION:
+ Reinstall them using boot bands when boot installation positions become incorrect.
+ Never reuse boot band.
13, Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly.
CAUTION:
Never apply lubricating oil to these matching surface.
FAX-97 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [4wo]
14. Clean the matching surface of drive shaft and wheel hub and
bearing assembly. And then apply paste [service parts
(440037S000)] to surface @ of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assem-
bly of drive shaft.
Amount paste: 1.0- 3.09 (0.04-0.10 02)
15. Insert drive shaft to wheel hub and bearing assembly, and then temporarily tighten wheel hub lock nut.
CAUTION:
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
16. Install transverse link to steering knuckle and front suspention member. Refer to FSU-17, "Exploded
Nheahe
17. Install steering outer socket to steering knuckle.
+ LHD: Refer to ST-20, "LHD | Exploded View".
+ RHD: Refer to ST-21."RHD : Exploded View"
18. Tighten the wheel hub lock nut to the specified torque. Refer to FAX-72. " i
CAUTION:
+ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
19. When installing a cotter pin @ and adjusting cap @, securely
bend the basal portion to prevent rattles
CAUTION:
Never reuse cotter pin.
20. Install disc rotor, Refer to FAX-72, "Removal and Installation".
21. Install caliper assembly to steering knuckle.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 PE) : Rem
and Installation".
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal
.
and installation”.
+ RHD (1 PISTON TYPE): Refer to BR-
and Installation’.
+ RHD (2 PISTON TYPE): Refer to BR-56. q
and Installation”.
22. Install lock plate to strut assembly.
+ LHD: Refer to BR-24, “FRONT : Exploded View".
+ RHD: Refer to BR-88, "FRONT : Exploded View",
23. Install wheel sensor to steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR | Removal and
4
24. Install tires to vehicle. Refer to WWI-61, "Removal and installation".
25. Perform inspection after installation. Refer to FAX.99. "R9M - Inspection"
Transaxle Side
* Installation: Refer to FAX-125, "R9M : Removal and Installation’.
FAX-98 FRONT DRIVE SHAFT BOOT
< REMOVAL AND INSTALLATION > [4wo]
+ Assembly: Refer to FAX-131, "ROM : Disassembly and Assembly".
ROM : Inspection
INSPECTION AFTER REMOVAL
Check the following items, and teplace the patt if necessary
* Check components for deformation, cracks, and other damage.
* Check boots of transverse link and steering outer socket ball joint for breakage, axial end play, and swing
torque.
- Transverse link: Refer to
3 ESU-18. “Inspection”.
= Steering outer socket: Refer to ST:26, “Inspection” =
INSPECTION AFTER INSTALLATION
1, Check wheel sensor hamess for proper connection. Refer to BRC-212, "FRONT WHEEL SENSOR ;
Exploded View".
2. Cheok the whee! alignment. Refer to FSU-8, “Inspection”
3. Adjust neutral position of steering angle sensor. Refer to 8RC-99, "Work Procedure”
FAX-99 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo)
FRONT DRIVE SHAFT
MR20DD
MR20DD : Exploded View nrovamaane
LEFT SIDE
[SEC.391
@ Circular cp ® dust shield @ Housing
@® Snap cing ® Spider assembly © Stopper ring
@ Boot bang ® Boot @ Shan
@ Damper band @ Dinamic damper @® Joint sub-assembly
@ Dust shieta
Wheel side
Fill NISSAN Genuine grease or equivalent
Aoply paste [service parts (440037$000))
(69: Aways replace ater every dlsassembiy
FAX-100 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
RIGHT SIDE
‘SEC.39
Pies ceo. 10)
P0149, 05)
Phae 40.05)
© dust shies ® sont sub-assembly @ Cicuiaretip
@ Bock band ® Boot © Stat
@ Damper vane ® dynamic damper @® Stopper rg
@ Seiderassembiy ® Snap sing @ Housing
@ Dustshieie @ Suppordearng @ Fetaner
® _Soppor bearing bracket
<3 Whe sige
EER: FI NISSAN Genuine grease or equivalent
2: Apply paste [eric pats (4400378000)
Nim thom, te)
(8$: Always replace ater every cisassembiy,
MR20DD : Removal and Installation erooucenesi?
REMOVAL
Left Side
1. Remove tires. Refer to WT-61. "Removal and Installation”.
2, Remove wheel sensor from steering knuckle. Refer to BRC-212, "FRONT WHEEL SENSOR : Removal
and Installation.
FAX-101 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24. "FRONT - Exploded View",
* RHD: Refer to BR-88. "FRONT : Exploded View".
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMI ‘ON TYPE} | Re
:
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBL\ a E) : Removal
and Installation”
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON ov
and Installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116.""
lation"
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-72, "Removal and installation’.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000).
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NoTt
Use suitable puller if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8. Remove wheel hub lock nut
9. Remove transverse link from steering knuckle and front suspension member. Refer to ESU-17, "Removal
10. Separate steering outer socket from steering knuckle, Refer to S1-22. "Removal and Installation’.
FAX-102 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
71. Remove drive shaft from wheel hub and bearing assembly
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove drive shaft from transaxle assembly.
+ Use the drive shaft attachment (A) (SST: KV40107500) and a
sliding hammer (B) (commercial service tool) while inserting
tip of the drive shaft attachment between housing and tran-
saxle assembly,
CAUTION:
+ Never place drive shaft joint at an extreme angle when
removing drive shaft. Also be careful not to overextend
slide joint.
* Confirm that the circular clip is attached to the drive
shaft.
Right Side
1. Remove tires. Refer to WI:61. "Removal and Installation’.
2. Remove wheel sensor from steering knuckle, Refer to BRC-!
and Installation’.
3. Remove lock plate @ from strut assembly.
* LHD: Refer to BR-24, "FRONT - Exploded View".
+ RHD: Refer to BR-68, "FRONT ; Exploded View",
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) . Removal
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) . Removal
and Installation".
+ RHD (1 PISTON TYPE): Refer to BR-111, " A IN a
and installation".
+ RHD (2 PISTON TYPE): Refer to BR-116, "BRA\ Pr Y (2 PISTON TYPE) : Rer
sand Installatio
CAUTION:
Never depress brake pedal while brake caliper is removed.
5. Remove disc rotor. Refer to F
FAX-103 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
6 Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000)
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NOTE:
Use suitable puller, if whee! hub and bearing assembly and drive
shaft cannot be separated even afier performing the above pro-
cedure,
8. Remove wheel hub lock nut.
9, Remove transverse link from steering knuckle and front suspension member, Refer to FSU-17. "Removal
and installation’,
10. Separate steering outer socket from steering knuckle, Refer to ST-22. "i installation’.
‘11. Remove drive shaft from wheel hub and bearing assembly.
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12, Remove retainer mounting bolts and retainer.
13. Remove drive shaft from transfer assembly.
+ Use the drive shaft attachment (SST: KV40107500) and a sliding hammer while inserting tip of the drive
shaft attachment between housing and transfer assembly.
CAUTION:
Never place drive shaft joint at an extreme angle when removing drive shaft. Also be careful not
to overextend slide joint.
14. If necessary, remove the support bearing bracket mounting bolts and the support bearing bracket
INSTALLATION
Left Side
Note the following, and install in the reverse order of removal
CAUTION:
Iways replace differential side oil seal with new one when installing drive shaft. Refer to TN-429.
“Removal and Installation”.
FAX-104 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
[4wo]
* Place the protector (A) (SST: KV38107900) onto transaxle assem-
bly to prevent damage to the differential side oil seal while inserting
drive shaft. Slide drive shaft sliding joint and tap with a hammer to
install securely.
CAUTION:
+ Check that circular clip is completely engaged.
+ Never reuse differential side oil seal.
Clean the matching surface of wheel hub lock nut and wheel hub an
CAUTION:
Never apply lubricating oil to these matching surface.
Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @ of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste: 1.0- 3.0 g (0.04- 0.10 oz)
Tighten the wheel hub lock nut to the specified torque. Refer to £
CAUTION:
* Since the drive shaft is assembled by press-fitting, use the ti
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub fock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles
CAUTION:
Never reuse cotter pin.
72."
ightening torque range for the wheel
+ Perform inspection after installation. Refer to FAX-111, "MR200D - Inspection"
Right Side
Note the following, and install in the reverse order of removal
CAUTION:
Always replace transfer cover oil seal (inner) and transfer cove
installing drive shaft. Refer to DLN-78. "
FAX-105
F oil seal (outer) with new one when FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
* Place the protector (A) (SST. KV38107900) onto transfer assembly
to prevent damage to the transfer cover oil seal (inner) and transfer
cover oil seal (outer) while inserting drive shaft. Slide drive shaft
sliding joint and tap with a hammer to install securely.
CAUTION: Li
Never reuse transfer cover oil seal (inner) and transfer cover
oil seal (outer).
+ When installing support bearing bracket tighten the mounting bolt with the following procedure.
~ To install support bearing bracket @ and mounting bolts, tempo- [— 7. =
rarily tighten the bolts before tightening to the specified torque, |")
referring to the tightening method and the numerical order shown
below’
Temporary tahtening 492
Final tightening (Specied torque) 344
~ Set plate @ so thet the notch part @ becomes upper side.
CAUTION:
Never reuse plate.
~ Temporarily tighten the bolts before tightening to the specified poise
torque, referring to the tightening method and the numerical order
shown below:
Temporary tightening 546
Final tightening (Specified torave) 198
+ Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly.
CAUTION:
Never apply lubricating oil to these matchi
1g surface.
+ Clean the matching surface of drive shaft and whee! hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @ of joint sub-assembly of drive shaft.
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft,
Amount paste: 1.0 - 3.0g (0.04-0.10 oz)
+ Tighten the wheel hub lock nut to the specified torque. Refer to FAX-72. "Exploded View".
CAUTION:
+ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
FAX-106 FRONT DRIVE SHAFT
<= REMOVAL AND INSTALLATION > [awo]
* When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles.
CAUTION:
Never reuse cotter pin.
@®
vos |
+ Perform inspection after installation. Refer to EAX-111, "82000 - inspection"
MR20DD : Disassembly and Assembly wcwomncnoae'®
DISASSEMBLY
Transaxle Assembly Side
4. Fixshaft with a vise
CAUTION:
Protect shaft using aluminum or copper plates when fixing with a vise.
2. Remove boot bands, and then remove boot from housing.
Remove stopper ring
4. Put matching marks on housing and shaft, and then pull out housing from shaft.
CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surfaces.
5. Put matching marks @ on the spider assembly and shaft.
CAUTION:
Use paint or an equivalent for matching marks. Never
scratch the surfaces.
6. Remove snap ring @, and then remove spider assembly from
shaft
7. Remove boot from shaft
8. Remove circular clip from housing (eft side).
9. Remove dust shield from housing,
10. Clean old grease on housing with paper waste
‘Support Bearing
FAX-107 FRONT DRIVE SHAFT
(awo]
1. Remove dust shield from housing.
2. Remove snap ring @.
3. Press out support bearing from housing,
4. Remove dust shield
Dynamic Damper
Remove damper bands, then remove dynamic damper from shaft.
Wheel Side
1. Fix shaft with a vise,
CAUTION:
art
Protect shaft using aluminum or copper plates when fixing with a vise.
2, Remove boot bands, and then remove boot from joint sub-assembly.
3. Sorew drive shaft puller (A) (commercial service tool) into joint
sub-assembly screw part fo a length of 30 mm (1.18 in) or more,
Support drive shaft with one hand and pull out joint sub-assem-
bly from sha.
CAUTION:
+ If joint sub-assembly cannot be removed after five or
more unsuccessful attempts, replace shaft and joint sub
assembly as a set.
+ Align sliding hammer and drive shaft and remove them by
Pulling directory.
4. Remove circular clip from shaft
5. Remove boot from shaft
UE,
6. Clean old grease on joint sub-assembly with paper towels while rotating ball cage.
ASSEMBLY
FAX-108 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
Transaxle Assembly Side
1. Wrap serration on shaft with tape @ to protect boot from dam-
age. Install new boot and boot bands to shaft
CAUTION:
Never reuse boot and boot band.
2. Remove the tape wrapped around the serration on shaft.
3. To install the spider assembly @, align it with the matching
marks @ on the shaft @ put during the removal, and direct the
serration mounting surface ® to the shaft
4. Secure spider assembly onto shaft with snap ring @.
CAUTION:
Never reuse snap ring.
5. Apply the appropriate amount of grease to spider assembly and
sliding surface.
6. Assemble the housing onto spider assembly, and apply the bal
ance of the specified amount grease.
Grease amount __: Refer to FAX-137. “Drive Shaft”.
7. Align matching marks put during the removal of housing. " rowuiee
8. Install stopper ring.
CAUTION:
Never reuse stopper ring.
9. Install boot securely into grooves (indicated by “*” marks) shown
inthe figure.
CAUTION: vf
If grease adheres to the boot mounting surface (indicated
by “*” mark) on shaft or housing, boot may be removed. |
Remove all grease from the surface. |
10. To prevent from deformation of the boot, adjust the boot installa~ U
tion length to the value shown below (L) by inserting the suitable
tool into the inside of boot from the large diameter side of boot
and discharging inside air. Ss
it : Refer to FAX-137, "Drive Shaft’. =
CAUTION:
+ If the boot installation length exceeds the standard, it may cause breakage in boot.
+ Be careful not to touch the inside of the boot with the tip of tool.
11, Install new boot bands securely.
CAUTION:
Never reuse boot band.
FAX-109 FRONT DRIVE SHAFT
(awo}
@. Put boot band in the groove on drive shaft boot. Then fit pawls
(4) into holes to temporary installation,
NOTE:
For the large diameter side, fit projection @ and guide slit @ at
first.
Pinch projection on the band with suitable pliers to tighten band,
Insert tip of band below end of the paw!
12
Ss
Secure housing and shaft, and then make sure that they are in the correct position when rotating boot.
Install them with new boot band when the mounting positions become incorrect.
13. Install dust shield (left side),
CAUTION:
Never reuse dust shield.
Install circular clip to housing (left side),
CAUTION:
Never reuse circular clip.
‘Support Bearing
1. Install dust shield on housing
CAUTION:
Never reuse dust shield.
Press support bearing @ onto housing to using the suitable tool
(a)
Install snap ring.
CAUTION:
Never reuse snap ring.
14
FAX-110 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
4, Install dust shields.
CAUTION:
Never reuse dust shields.
Dynamic Damper
+ Install damper bands securely as shown in the figure,
+ Secure dynamic damper with bands in the following specified posi-
tion when removing,
CAUTION:
Never reuse bands.
Demission + Refer to FAX-137. "Drive Shaft”.
Wheel Side
[4wo]
For further details, refer to the installation procedure of "EAX-79. "MR20DD Removal and installation” for the
drive shaft boot
MR20DD : Inspection
INSPECTION AFTER REMOVAL
+ Move joint up/down, leftright, and in the axial directions. Check for motion that is not smooth and for signifi-
cant looseness.
* Check boot for cracks, damage, and leakage of grease.
+ Disassemble drive shaft and exchange malfunctioning part if there
is a non-standard condition,
ae
INSPECTION AFTER DISASSEMBLY
FAX-111 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo}
Shaft
Check shaff for runout, cracks, or other damage. Replace if there are
Dynamic Damper
Check damper for cracks or wear. Replace if necessary.
Joint Sub-Assembly (Wheel Side)
Check the following
+ Joint sub-assembly for rough rotation and excessive axial looseness.
+ The inside of the joint sub-assembly for entry of foreign material
+ Joint sub-assembly for compression scars, cracks. and fractures inside of joint sub-assembly
Replace joint sub-assembly if there are any non-standard conditions of components,
Housing and Spider assembly (Transaxle Side)
Replace housing and spider assembly if there is scratching or wear of housing roller contact surface or spider
roller contact surface.
NOTE:
Housing and spider assembly are used in a set.
‘Support Bearing (Right Side)
‘Make sure wheel bearing rolls freely and is free from noise, cracks, pitting or wear. Replace support bearing if
there are any non-standard conditions.
‘Support Bearing Bracket (Right Side)
Check for bending, cracks, or damage. Replace support bearing bracket if there are any non-standard condi-
tions.
INSPECTION AFTER INSTALLATION
4. Check wheel sensor harness for proper connection, Refer to BRC-212, "FRONT WHEEL SENSOR.
Exploded Vie
2. Check the wheel alignment, Refer to ESU-6, "Inspection",
3. Adjust neutral position of steering angle sensor. Refer to BRC-99, ‘Wark Procedure
QR25DE
QR25DE : Exploded View erveenewecremuas
LEFT SIDE
[sEC.391
® Ciruar ef ® dustshiers @ Housing
@ Snap cing ® Spider assembly ® Stopper sing
@® Bootband ® Boot @ shat
@ _Damperband @® Dynamic damper ® soint sub-assembly
FAX-112 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
[4wp)
@ Dostshis
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24. "FRONT - Exploded View",
* RHD: Refer to BR-88. "FRONT : Exploded View".
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMI ‘ON TYPE} | Re
:
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBL\ a E) : Removal
and Installation”
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON ov
and Installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116.""
lation"
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-72, "Removal and installation’.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000).
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NoTt
Use suitable puller if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8. Remove wheel hub lock nut
9. Remove transverse link from steering knuckle and front suspension member. Refer to ESU-17, "Removal
10. Separate steering outer socket from steering knuckle, Refer to S1-22. "Removal and Installation’.
FAX-114 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
71. Remove drive shaft from wheel hub and bearing assembly
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove drive shaft from transaxle assembly.
+ Use the drive shaft attachment (A) (SST: KV40107500) and a
sliding hammer (B) (commercial service tool) while inserting
tip of the drive shaft attachment between housing and tran-
saxle assembly,
CAUTION:
+ Never place drive shaft joint at an extreme angle when
removing drive shaft. Also be careful not to overextend
slide joint.
* Confirm that the circular clip is attached to the drive
shaft.
Right Side
1. Remove tires. Refer to WI:61. "Removal and Installation’.
2. Remove wheel sensor from steering knuckle, Refer to BRC-!
and Installation’.
3. Remove lock plate @ from strut assembly.
* LHD: Refer to BR-24, "FRONT - Exploded View".
+ RHD: Refer to BR-68, "FRONT ; Exploded View",
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) . Removal
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) . Removal
and Installation".
+ RHD (1 PISTON TYPE): Refer to BR-111, " A IN a
and installation".
+ RHD (2 PISTON TYPE): Refer to BR-116, "BRA\ Pr Y (2 PISTON TYPE) : Rer
sand Installatio
CAUTION:
Never depress brake pedal while brake caliper is removed.
5. Remove disc rotor. Refer to F
FAX-115 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
6 Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000)
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NOTE:
Use suitable puller, if whee! hub and bearing assembly and drive
shaft cannot be separated even afier performing the above pro-
cedure,
8. Remove wheel hub lock nut.
9, Remove transverse link from steering knuckle and front suspension member, Refer to FSU-17. "Removal
and installation’,
10. Separate steering outer socket from steering knuckle, Refer to ST-22. "i installation’.
‘11. Remove drive shaft from wheel hub and bearing assembly.
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12, Remove retainer mounting bolts and retainer.
13. Remove drive shaft from transfer assembly.
+ Use the drive shaft attachment (SST: KV40107500) and a sliding hammer while inserting tip of the drive
shaft attachment between housing and transfer assembly.
CAUTION:
Never place drive shaft joint at an extreme angle when removing drive shaft. Also be careful not
to overextend slide joint.
14. If necessary, remove the support bearing bracket mounting bolts and the support bearing bracket
INSTALLATION
Left Side
Note the following, and install in the reverse order of removal
CAUTION:
Iways replace differential side oil seal with new one when installing drive shaft. Refer to TN-429.
“Removal and Installation”.
FAX-116 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
[4wo]
* Place the protector (A) (SST: KV38107900) onto transaxle assem-
bly to prevent damage to the differential side oil seal while inserting
drive shaft. Slide drive shaft sliding joint and tap with a hammer to
install securely.
CAUTION:
+ Check that circular clip is completely engaged.
+ Never reuse differential side oil seal.
Clean the matching surface of wheel hub lock nut and wheel hub an
CAUTION:
Never apply lubricating oil to these matching surface.
Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @ of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste: 1.0- 3.0 g (0.04- 0.10 oz)
Tighten the wheel hub lock nut to the specified torque. Refer to £
CAUTION:
* Since the drive shaft is assembled by press-fitting, use the ti
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub fock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles
CAUTION:
Never reuse cotter pin.
72."
ightening torque range for the wheel
+ Perform inspection after installation. Refer to FAX-123, "QR25DE : Inspection”.
Right Side
Note the following, and install in the reverse order of removal
CAUTION:
Always replace transfer cover oil seal (inner) and transfer cove
installing drive shaft. Refer to DLN-79." ft
FAX-117
F oll seal (outer) with new one when FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
* Place the protector (A) (SST. KV38107900) onto transfer assembly
to prevent damage to the transfer cover oil seal (inner) and transfer
cover oil seal (outer) while inserting drive shaft. Slide drive shaft ry
sliding joint and tap with a hammer to install securely.
CAUTION: Li
Never reuse transfer cover oil seal (inner) and transfer cover
il seal (outer).
+ When installing support bearing bracket tighten the mounting bolt with the following procedure.
~ To install support bearing bracket @ and mounting bolts, tempo-
rarily tighten the bolts before tightening to the specified torque,
referring to the tightening method and the numerical order shown
below’
Temporary tahtening 492
Final tightening (Specied torque) 3944549657
~ Set plate @ so thet the notch part @ becomes upper side.
CAUTION:
Never reuse plate.
- Temporarily tighten the bolts before tightening to the specified
torque, referring to the tightening method and the numerical order
shown below:
Temporary tightening Bae
Final tightening (Specified torque) 04
+ Clean the matching surface of wheel hub lock nut and wheel hub and bearing assembly.
CAUTION:
Never apply lubricating oil to these matchi
ig surface.
+ Clean the matching surface of drive shaft and whee! hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @ of joint sub-assembly of drive shaft.
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft,
Amount paste: 1.0 - 3.0g (0.04-0.10 oz)
* Tighten the wheel hub lock nut to the specified torque. Refer to FAX-72 "Exploded View".
‘CAUTION:
+ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
FAX-118 FRONT DRIVE SHAFT
<= REMOVAL AND INSTALLATION > [awo]
* When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles.
CAUTION:
Never reuse cotter pin.
@
vo |
* Perform inspection after installation. Refer to EAX-123, “QR25DE _ Inspection’,
QR25DE : Disassembly and Assembly wcwowareo ess
DISASSEMBLY
Transaxle Assembly Side
4. Fixshaft with a vise
CAUTION:
Protect shaft using aluminum or copper plates when fixing with a vise.
2. Remove boot bands, and then remove boot from housing.
Remove stopper ring
4. Put matching marks on housing and shaft, and then pull out housing from shaft.
CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surfaces.
5. Put matching marks @ on the spider assembly and shaft.
CAUTION:
Use paint or an equivalent for matching marks. Never
scratch the surfaces.
6. Remove snap ring @, and then remove spider assembly from
shaft
7. Remove boot from shaft
8. Remove circular clip from housing (eft side).
9. Remove dust shield from housing,
10. Clean old grease on housing with paper waste
‘Support Bearing
FAX-119 FRONT DRIVE SHAFT
(awo]
1. Remove dust shield from housing.
2. Remove snap ring @.
3. Press out support bearing from housing,
4. Remove dust shield
Dynamic Damper
Remove damper bands, then remove dynamic damper from shaft.
Wheel Side
1. Fix shaft with a vise,
CAUTION:
art
Protect shaft using aluminum or copper plates when fixing with a vise.
2, Remove boot bands, and then remove boot from joint sub-assembly.
3. Sorew drive shaft puller (A) (commercial service tool) into joint
sub-assembly screw part fo a length of 30 mm (1.18 in) or more,
Support drive shaft with one hand and pull out joint sub-assem-
bly from sha.
CAUTION:
+ If joint sub-assembly cannot be removed after five or
more unsuccessful attempts, replace shaft and joint sub
assembly as a set.
+ Align sliding hammer and drive shaft and remove them by
Pulling directory.
4. Remove circular clip from shaft
5. Remove boot from shaft
UE,
6. Clean old grease on joint sub-assembly with paper towels while rotating ball cage.
ASSEMBLY
FAX-120 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
Transaxle Assembly Side
1. Wrap serration on shaft with tape @ to protect boot from dam-
age. Install new boot and boot bands to shaft
CAUTION:
Never reuse boot and boot band.
2. Remove the tape wrapped around the serration on shaft.
3. To install the spider assembly @, align it with the matching
marks @ on the shaft @ put during the removal, and direct the
serration mounting surface ® to the shaft
4. Secure spider assembly onto shaft with snap ring @.
CAUTION:
Never reuse snap ring.
5. Apply the appropriate amount of grease to spider assembly and
sliding surface.
6. Assemble the housing onto spider assembly, and apply the bal
ance of the specified amount grease.
Grease amount __: Refer to FAX-137. “Drive Shaft”.
7. Align matching marks put during the removal of housing. " rowuiee
8. Install stopper ring.
CAUTION:
Never reuse stopper ring.
9. Install boot securely into grooves (indicated by “*” marks) shown
inthe figure.
CAUTION: vf
If grease adheres to the boot mounting surface (indicated
by “*” mark) on shaft or housing, boot may be removed. |
Remove all grease from the surface. |
10. To prevent from deformation of the boot, adjust the boot installa~ U
tion length to the value shown below (L) by inserting the suitable
tool into the inside of boot from the large diameter side of boot
and discharging inside air. Ss
it : Refer to FAX-137, "Drive Shaft’. =
CAUTION:
+ If the boot installation length exceeds the standard, it may cause breakage in boot.
+ Be careful not to touch the inside of the boot with the tip of tool.
11, Install new boot bands securely.
CAUTION:
Never reuse boot band.
FAX-121 FRONT DRIVE SHAFT
(awo}
@. Put boot band in the groove on drive shaft boot. Then fit pawls
(4) into holes to temporary installation,
NOTE:
For the large diameter side, fit projection @ and guide slit @ at
first.
Pinch projection on the band with suitable pliers to tighten band,
Insert tip of band below end of the paw!
12
Ss
Secure housing and shaft, and then make sure that they are in the correct position when rotating boot.
Install them with new boot band when the mounting positions become incorrect.
13. Install dust shield (left side),
CAUTION:
Never reuse dust shield.
Install circular clip to housing (left side),
CAUTION:
Never reuse circular clip.
‘Support Bearing
1. Install dust shield on housing
CAUTION:
Never reuse dust shield.
Press support bearing @ onto housing to using the suitable tool
(a)
Install snap ring.
CAUTION:
Never reuse snap ring.
14
FAX-122 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
4, Install dust shields.
CAUTION:
Never reuse dust shields.
Dynamic Damper
+ Install damper bands securely as shown in the figure,
+ Secure dynamic damper with bands in the following specified posi-
tion when removing,
CAUTION:
Never reuse bands.
Demission + Refer to FAX-137. "Drive Shaft”.
Wheel Side
[4wo]
For further details, refer to the installation procedure of "FAX-86. "OR25DE - Removal and installation" for the
drive shaft boot
QR25DE : Inspection
INSPECTION AFTER REMOVAL
+ Move joint up/down, leftright, and in the axial directions. Check for motion that is not smooth and for signifi-
cant looseness.
* Check boot for cracks, damage, and leakage of grease.
+ Disassemble drive shaft and exchange malfunctioning part if there
is a non-standard condition,
ae
INSPECTION AFTER DISASSEMBLY
FAX-123 FRONT DRIVE SHAFT
<= REMOVAL AND INSTALLATION > [4wp)
Shat
Check shaff for runout, cracks, or other damage. Replace if there are
Dynamic Damper
Check damper for cracks or wear. Replace if necessary.
Joint Sub-Assembly (Wheel Side)
Check the following
+ Joint sub-assembly for rough rotation and excessive axial looseness.
+ The inside of the joint sub-assembly for entty of foreign material
+ Joint sub-assembly for compression scars, cracks. and fractures inside of joint sub-assembly
Replace joint sub-assembly if there are any non-standard conditions of components,
Housing and Spider assembly (Transaxle Side)
Replace housing and spider assembly if there is scratching or wear of housing roller contact surface or spider
roller contact surface.
NOTE:
Housing and spider assembly are used in a set.
‘Support Bearing (Right Side)
‘Make sure wheel bearing rolls freely and is free from noise, cracks, pitting or wear. Replace support bearing if
there are any non-standard conditions.
‘Support Bearing Bracket (Right Side)
Check for bending, cracks, or damage. Replace support bearing bracket if there are any non-standard condi-
tions.
INSPECTION AFTER INSTALLATION
1 snsor harness for proper connection, Refer to BRC-212, "FRONT WHEEL SENSOR
2. Check the wheel alignment. Refer to FSU-8, "Inspection".
3. Adjust neutral position of steering angle sensor. Refer to BRC-99, ‘Wark Procedure
ROM
ROM : Exploded View roeeneecoente|
LEFT SIDE
SEC. 391
® Circular of ® dust shies @ Housing
@ Snap cing ® Spider assembly ® Stopper sing
@® Bootbana ® Boot @ shat
@ Damper band @® Dynamic damper @® soint sub-assembly
FAX-124 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
@ Dust shieis
<3 Wheel side
EBS + FI NISSAN Genuine grease or equivalent
‘Apply paste [service pats (440087S000)]
(2h Always replace ater every cisassembly
RIGHT SIDE
SEC. 391 aI)
| &@
@® dust shies ® Joint sub-assembly @ Crreviar ap
® Bootband © Boot @ shah
@ Seppe ring @© Spider assembly @ snap ting
@ Housing @ Oustshietd ® Support bearing
@ Retainer @ Suppor bearing bracket @ Heat insulator
<3 Wheel side
Fill NISSAN Genuine grease or equivalent
Apply paste [service parts (440037S000))
Ph. vm thom, tb)
(Gs: Alnaysrepace ater every isassembiy
R9M : Removal and Installation sro cmnmenots
REMOVAL
Left Side
1. Remove tires. Refer to WI-61, "Removal and Installation’,
2. Remove wheel sensor from steering knuckle. Refer to BRO-212. 'FRONT WHEEL SENSOR * Removal
and Installation"
FAX-125 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
3. Remove lock plate @ from strut assembly.
+ LHD: Refer to BR-24. "FRONT - Exploded View",
* RHD: Refer to BR-88. "FRONT : Exploded View".
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work.
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMI ‘ON TYPE} | Re
:
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBL\ a E) : Removal
and Installation”
+ RHD (1 PISTON TYPE): Refer to BR-111, "BRAKE CALIPER ASSEMBLY (1 PISTON ov
and Installation”.
+ RHD (2 PISTON TYPE): Refer to BR-116.""
lation"
CAUTION:
Never depress brake pedal while brake caliper is removed.
Remove disc rotor. Refer to FAX-72, "Removal and installation’.
6. Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000).
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NoTt
Use suitable puller if wheel hub and bearing assembly and drive
shaft cannot be separated even after performing the above pro-
cedure.
8. Remove wheel hub lock nut
9. Remove transverse link from steering knuckle and front suspension member. Refer to ESU-17, "Removal
10. Separate steering outer socket from steering knuckle, Refer to S1-22. "Removal and Installation’.
FAX-126 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
71. Remove drive shaft from wheel hub and bearing assembly
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12. Remove drive shaft from transaxle assembly.
+ Use the drive shaft attachment (A) (SST: KV40107500) and a
sliding hammer (B) (commercial service tool) while inserting
tip of the drive shaft attachment between housing and tran-
saxle assembly,
CAUTION:
+ Never place drive shaft joint at an extreme angle when
removing drive shaft. Also be careful not to overextend
slide joint.
* Confirm that the circular clip is attached to the drive
shaft.
Right Side
1. Remove tires. Refer to WI:61. "Removal and Installation’.
2. Remove wheel sensor from steering knuckle, Refer to BRC-!
and Installation’.
3. Remove lock plate @ from strut assembly.
* LHD: Refer to BR-24, "FRONT - Exploded View".
+ RHD: Refer to BR-68, "FRONT ; Exploded View",
4. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work
+ LHD (1 PISTON TYPE): Refer to BR-51, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) . Removal
+ LHD (2 PISTON TYPE): Refer to BR-56, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) . Removal
and Installation".
+ RHD (1 PISTON TYPE): Refer to BR-111, " A IN a
and installation".
+ RHD (2 PISTON TYPE): Refer to BR-116, "BRA\ Pr Y (2 PISTON TYPE) : Rer
sand Installatio
CAUTION:
Never depress brake pedal while brake caliper is removed.
5. Remove disc rotor. Refer to F
FAX-127 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
6 Remove cotter pin, adjusting cap and then loosen wheel hub
lock nut, using a hub lock nut wrench (A) (SST: KV40104000)
7. Patch wheel hub lock nut with a piece of wood. Hammer the
wood to disengage wheel hub and bearing assembly from drive
shaft
NOTE:
Use suitable puller, if whee! hub and bearing assembly and drive
shaft cannot be separated even afier performing the above pro-
cedure,
8. Remove wheel hub lock nut.
9, Remove transverse link from steering knuckle and front suspension member, Refer to FSU-17. "Removal
and installation’,
10. Separate steering outer socket from steering knuckle, Refer to ST-22. "i installation’.
‘11. Remove drive shaft from wheel hub and bearing assembly.
CAUTION:
+ Never place drive shaft joint at an extreme angle.
+ Be careful not to overextend slide joint.
12, Remove retainer mounting bolts and retainer.
13. Remove drive shaft from transaxle assembly.
+ Use the drive shaft attachment (SST: KV40107500) and a sliding hammer while inserting tip of the drive
shaft attachment between housing and transaxle assembly
CAUTION:
Never place drive shaft joint at an extreme angle when removing drive shaft. Also be careful not
to overextend slide joint.
14. If necessary, remove the support bearing bracket mounting bolts, support bearing bracket and the heat
insulator.
INSTALLATION
Left Side
Note the following, and install in the reverse order of removal
CAUTION:
Always replace differential side oll seal with new one when installing drive shaft. Refer to TM-119,
“Removal and Installation”.
FAX-128 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
[4wo]
* Place the protector (A) (SST: KV38107900) onto transaxle assem-
bly to prevent damage to the differential side oil seal while inserting
drive shaft. Slide drive shaft sliding joint and tap with a hammer to
install securely.
CAUTION:
+ Check that circular clip is completely engaged.
+ Never reuse differential side oil seal.
Clean the matching surface of wheel hub lock nut and wheel hub an
CAUTION:
Never apply lubricating oil to these matching surface.
Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @ of joint sub-assembly of drive shaft
CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste: 1.0- 3.0 g (0.04- 0.10 oz)
Tighten the wheel hub lock nut to the specified torque. Refer to £
CAUTION:
* Since the drive shaft is assembled by press-fitting, use the ti
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub fock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
When installing a cotter pin @ and adjusting cap @, securely bend
the basal portion to prevent rattles
CAUTION:
Never reuse cotter pin.
72."
ightening torque range for the wheel
+ Perform inspection after installation. Refer to FAX-135, "ROM : Inspection’
Right Side
Note the following, and install in the reverse order of removal.
CAUTION:
Always replace differential side oil seal with new one when installing drive shaft. Refer to TM-118,
“Removal and Installation”.
FAX-129 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
[4wD]
+ Place the protector (A) (SST: KV38107900) onto transaxle assem-
bly to prevent damage to the differential side oll seal while inserting
drive shaft. Slide drive shaft sliding joint and tap with @ hammer to
install securely,
CAUTION:
Never reuse differential side oil seal.
+ When installing support bearing bracket tighten the mounting bolt with the following procedure.
- To install support bearing bracket @ and mounting bolts, tempo-
rarily tighten the bolts before tightening to the specified torque,
referring to the tightening method and the numerical order shown
below:
142
344
Temporary tanning
Final tightening (Specied torave)
~ Set plate @ so thet the notch part @) becomes upper side.
‘CAUTION:
Never reuse plate.
ey 1a
- Temporarily tighten the bolts before tightening to the specified
torque, referring to the tightening method and the numerical order
shown below:
536
7398
Temporary tightening
Final tightening (Specifed torave)
+ Instal the heat insulator @ to touch a projection @ of the bracket @
‘as shown in figure.
+ Clean the matching surface of wheel hub lock nut and wheel hub an:
CAUTION:
Never apply lubricating oil to these matching surface.
+ Clean the matching surface of drive shaft and wheel hub and bear-
ing assembly. And then apply paste [service parts (440037S000)]
to surface @) of joint sub-assembly of drive shaft.
‘CAUTION:
Apply paste to cover entire flat surface of joint sub-assembly
of drive shaft.
Amount paste: 1.0-3.0.g (0.04 0.10 oz)
\d bearing assembly
FAX-130 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [awo]
= Tighten the wheel hub lock nut to the specified torque. Refer to FAX-72, "Exploded View
CAUTION:
+ Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel
hub lock nut.
+ Be sure to use torque wrench to tighten the wheel hub lock nut. Never use a power tool.
+ Never reuse wheel hub lock nut.
When installing a cotter pin @ and adjusting cap ®, securely bend
the basal portion to prevent rattles.
CAUTION:
Never reuse cotter pin.
+ Perform inspection after installation. Refer to FAX-135. "! ection”.
ROM : Disassembly and Assembly wei
DISASSEMBLY
Transaxle Assembly Side
1. Fix shaft with a vise.
CAUTION:
Protect shaft using aluminum or copper plates when fixing with a vise.
2, Remove boot bands, and then remove boot from housing
Remove stopper ring
4. Put matching marks on housing and shaft, and then pull out housing from shaft
CAUTION:
Use paint or an equivalent for matching marks. Never scratch the surface:
5. Put matching marks @ on the spider assembly and shaft
CAUTION:
Use paint or an eqt
scratch the surfaces.
lent for matching marks. Never
6. Remove snap ring @, and then remove spider assembly from
shaft.
Remove boot from shaft.
Remove circular clip from housing (left side),
Remove dust shield from housing,
0, Clean old grease on housing with paper waste
‘Support Bearing
FAX-131 FRONT DRIVE SHAFT
(awo]
1. Remove dust shield from housing.
2. Remove snap ring @.
3. Press out support bearing from housing,
4. Remove dust shield
Dynamic Damper (if equipped)
Remove damper bands, then remove dynamic damper from shaft.
Wheel Side
1. Fix shaft with a vise,
CAUTION:
art
Protect shaft using aluminum or copper plates when fixing with a vise.
2, Remove boot bands, and then remove boot from joint sub-assembly.
3. Sorew drive shaft puller (A) (commercial service tool) into joint
sub-assembly screw part fo a length of 30 mm (1.18 in) or more,
Support drive shaft with one hand and pull out joint sub-assem-
bly from sha.
CAUTION:
+ If joint sub-assembly cannot be removed after five or
more unsuccessful attempts, replace shaft and joint sub
assembly as a set.
+ Align sliding hammer and drive shaft and remove them by
Pulling directory.
4. Remove circular clip from shaft
5. Remove boot from shaft
UE,
6. Clean old grease on joint sub-assembly with paper towels while rotating ball cage.
ASSEMBLY
FAX-132 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [4wo]
Transaxle Assembly Side
1. Wrap serration on shaft with tape @ to protect boot from dam-
age. Install new boot and boot bands to shaft
CAUTION:
Never reuse boot and boot band.
2. Remove the tape wrapped around the serration on shaft.
3. To install the spider assembly @, align it with the matching
marks @ on the shaft @ put during the removal, and direct the
serration mounting surface ® to the shaft
4. Secure spider assembly onto shaft with snap ring @.
CAUTION:
Never reuse snap ring.
5. Apply the appropriate amount of grease to spider assembly and
sliding surface.
6. Assemble the housing onto spider assembly, and apply the bal
ance of the specified amount grease.
Grease amount __: Refer to FAX-137. “Drive Shaft”.
7. Align matching marks put during the removal of housing. " rowuiee
8. Install stopper ring.
CAUTION:
Never reuse stopper ring.
9. Install boot securely into grooves (indicated by “*” marks) shown
inthe figure.
CAUTION: vf
If grease adheres to the boot mounting surface (indicated
by “*” mark) on shaft or housing, boot may be removed. |
Remove all grease from the surface. |
10. To prevent from deformation of the boot, adjust the boot installa~ U
tion length to the value shown below (L) by inserting the suitable
tool into the inside of boot from the large diameter side of boot
and discharging inside air. Ss
it : Refer to FAX-137, "Drive Shaft’. =
CAUTION:
+ If the boot installation length exceeds the standard, it may cause breakage in boot.
+ Be careful not to touch the inside of the boot with the tip of tool.
11, Install new boot bands securely.
CAUTION:
Never reuse boot band.
FAX-133 FRONT DRIVE SHAFT
(awo}
@. Put boot band in the groove on drive shaft boot. Then fit pawls
(4) into holes to temporary installation,
NOTE:
For the large diameter side, fit projection @ and guide slit @ at
first.
Pinch projection on the band with suitable pliers to tighten band,
Insert tip of band below end of the paw!
12
Ss
Secure housing and shaft, and then make sure that they are in the correct position when rotating boot.
Install them with new boot band when the mounting positions become incorrect.
13. Install dust shield (left side),
CAUTION:
Never reuse dust shield.
Install circular clip to housing (left side),
CAUTION:
Never reuse circular clip.
‘Support Bearing
1. Install dust shield on housing
CAUTION:
Never reuse dust shield.
Press support bearing @ onto housing to using the suitable tool
(a)
Install snap ring.
CAUTION:
Never reuse snap ring.
14
FAX-134 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION >
[4wo]
4, Install dust shields.
CAUTION:
Never reuse dust shields.
Dynamic Damper (tf equipped )
+ Put boot band in the groove on drive shaft boot, Then fit pawis (4
into holes to temporary installation,
Nort
For the large diameter side, fit projection @ and guide slit @ at
first
+ Pinch projection on the band with suitable pliers to tighten band.
+ Insert tip of band below end of the pawl
* Secure dynamic damper with bands in the following specified posi-
tion when removing
CAUTION:
Never reuse bands.
Demission + Refer to FAX-137. "Drive Shaft".
Wheel Side
For further details, refer o the installation procedure of “EAX-86, "QR25DE - Removal and Installallon™ for the
drive shaft boot,
ROM : Inspection
INSPECTION AFTER REMOVAL
* Move joint up/down, leftright, and in the axial directions. Check for motion that is not smooth and for signifi-
cant looseness.
FAX-135 FRONT DRIVE SHAFT
< REMOVAL AND INSTALLATION > [awn]
* Check boot for cracks, damage, and leakage of grease.
* Disassemble drive shaft and exchange malfunctioning part if there
is a non-standard condition.
INSPECTION AFTER DISASSEMBLY
Shaft
Check shaft for runout, cracks, or other damage. Replace if there are.
Dynamic Damper (If equipped)
Check damper for cracks or wear, Replace if necessary.
Joint Sub-Assembly (Wheel Side)
Check the following:
+ Joint sub-assembly for rough rotation and excessive axial looseness
+ The inside of the joint sub-assembly for entry of foreign material
+ Joint sub-assembly for compression scars, cracks, and fractures inside of joint sub-assembly
Replace joint sub-assembly if there are any non-standard conditions of components
Housing and Spider assembly (Transaxle Side)
Replace housing and spider assembly if there is scratching or wear of housing roller contact surface or spider
roller contact surface.
NOTE:
Housing and spider assembly are used in a set.
Support Bearing (Right Side)
Make sure wheel bearing rolls freely and is free from noise, cracks, pitting or wear. Replace support bearing if
there are any non-standard conditions.
‘Support Bearing Bracket (Right Side}
Check for bending, cracks, or damage. Replace support bearing bracket if there are any non-standard condi-
tions.
INSPECTION AFTER INSTALLATION
1. Check wheel sensor hamess for proper connection. Refer to BRC-212. "FRONT WHEEL SENSOR =
2. Check the wheel alignment. Refer to FSU-8, inspection’.
3. Adjust neutral position of steering angle sensor. Refer to BRC-99. "Work Procedure!’
FAX-136 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [aw]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Wheel Bearing eT
Talend pay DoS mm OOO Mores
Drive Shaft phn
oe ex
T Sandee
ter poser cure weer
Tete Rint ece
Wheel ade | TE= 105g (ADS- A TOO
Grease quantty
Transane se W75~ 195g (18-687 oz)
= ~ | nee! sae 144.5 mm (657 im)
insta length
Bose peed fet ‘Transaxle side 196.9 mm (7.75 in) 188.9 mm (7.44 in)
[a F3—7ramm (10 75= 1086) | 24S =249mm (857 -8.60in)
Dimension of namic camper | = - aa
: For measuring position. Refer to FAX-107, "MR20DD ° Disassembly and Assembly".
QR25DE
T Sandee
tem fe
I Tete Tignes
Wheels FE= 1g ADS A TORT
Grease quanly
Transaie se T75~ 1889 (618-6870)
Whee ide TAS mm ATI)
instaed | _ " =
Biota a, ‘Transaxle side 196.9 mm (7.75 in) 188.9 mm {7.44 in}
[a 240— 246 mm (945 9.66 in)
Parenmornat iheamle dariper’ 5: 70 mm (2.76 in) ‘60 mm (1.97 In)
*: For measuring position. Refer to FAX-119. "QR25DE : Disassembly and Assembly".
ROM
Sandee
tem
Tete Rint
Wheel ade) WS WISH aR
Grease quentty
Transaie side 765 = 285 g (935 10.08 az)
: Whee aide 145 mm (B7AIn)
instaled — ae ae Ets a oe
Boots installed length rareasatail in Teh. mm (725)
[a 207 =279 mm (6.15 - 6.391) =
mension of namic camper’ | * tae =
*: For measuring position. Refer to FAX-131, "ROM ; Disassembly and Assembly".
FAX-137 ENGINE
sconow F~ LI
FUEL SYSTEM
CONTENTS
GASOLINE ENGINE MODEL
PRECAUTION
PRECAUTIONS
Precautions for Removing Battery Terminal 3
General Precautions 4
PREPARATION
PREPARATION
‘Special Service Tools
SYSTEM DESCRIPTION
SYSTEM
WARNING/INDICATOR (ON INFORMATION DIS-
PLAY)
‘WARNING/INDICATOR (ON INFORMATION
DISPLAY) : Low fuel warning 6
WARNINGIINDICATORICHIME LIST
WARNINGIINDICATOR/CHIME LIST : Warning’
Indicator (On information Display) 7
PERIODIC MAINTENANCE ..
FUEL SYSTEM
Hydraulic Layout
Inspection
Quick Connector
REMOVAL AND INSTALLATION ...
FUEL LEVEL SENSOR UNIT, FUEL FILTER
AND FUEL PUMP ASSEMBLY
Exploded View
Removal and Installation
Disassembly and Assembly
Inspection
FUEL TANK ..
8
8
9
9
Exploded View 24
Removal and Installation 21
Inspection 2
EVAP CANISTER
Hydraulic Layout
Removal and Installation
Inspection
SERVICE DATA AND SPECIFICATIONS
(sDs)
‘SERVICE DATA AND SPECIFICATIONS,
(SDS)
Fuel Tank.
DIESEL ENGINE MODEL
PRECAUTION ...
PRECAUTIONS
Precautions far Remaving Battery Terminal
General Precautions
PREPARATION ...
PREPARATION ..
Special Service Tools
SYSTEM DESCRIPTION ...
COMPONENT PARTS ..
Fuel Filter Sensor
STRUCTURE AND OPERATION
FUEL TRANSPORTATION IN FUEL TANK
FUEL TRANSPORTATION IN FUEL TAN}
tem Description
SYSTEM ..
WARNING/INDICATOR (ON INFORMATION DIS-
PLAY)
FLA WARNING/INDICATOR (ON INFORMATION
DISPLAY) : Low fuel warning
WARNING/INDICATOR/CHIME LIST sn
WARNING/INDICATORICHIME LIST : Wet
lamps/Indicator lamps
WARNING/INDICATORICHIME LIST : Werning!
Indicator (On Information Display)
PERIODIC MAINTENANCE
FUEL SYSTEM
Hydraulic Layout
Inspection
Air Bleeding
(Quick Connector
FUEL FILTER
Exploded View
Removal and instalation
Draining Water from Fuel Filter
Inspection
io
Ss8Ses RaBes FB BBE
REMOVAL AND INSTALLATION .
FUEL LEVEL SENSOR UNIT, FUEL FILTER
AND FUEL PUMP ASSEMBLY
Exploded View
Removal and installation
Disassembly and Assembly
Inspection
FUEL TANK ....
Exploded View
Removal and Installation
Inspection
SERVICE DATA AND SPECIFICATIONS
(SDS) ..
‘SERVICE DATA AND SPECIFICATIONS
(sDs) 54
Fuel Tank st
51
FL-2 PRECAUTIONS.
< PRECAUTION > = [GASOLINE ENGINE MODEL]
PRECAUTION a
PRECAUTIONS
Precautions for Removing Battery Terminal wocooneicorser [ae
* With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
of remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, ie. ACC power is supplied for a certain fixed time.
+ When disconnecting the 12V battery terminal, tum off the ACC
. EZ)
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
* For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch
NOTE:
If the ignition switeit is turned ON with any one of the terminals of
‘main battery and sub battery disconnected, then DTC may be detected
* After installing the 12V battery, always check "Self Diagnosis Result’ of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 o Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2
INSTRUCTION 4
4. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened.
3. Get out of the vehicle and close the driver side door.
4.
Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse.
of the specified time.
DéDengine 20 minutes
HRA2ODT 12 minutes
KoK engine :4 minutes
MOR engine 4 minutes
ROM engine © 4 minutes
9x engine: 4 minutes
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5. Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
4. Unlock the door with intelligent key or remote keyless entry,
NOT!
Atthis moment, ACC power is supplied
Open the driver side door
Open the hood,
Close the driver side door.
Walt at least 3 minutes.
wRoN
FL-3 PRECAUTIONS
< PRECAUTION > [GASOLINE ENGINE MODEL]
‘CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
6. Remove 12V battery terminal
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC,
General Precautions rocco
WARNING:
When replacing fuel line parts, be sure to observe the following.
+ Put a “CAUTION: FLAMMABLE” sign in the workshop.
+ Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
+ Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:
+ Use gasoline required by the regulations for octane number. Refer to Gi-30, “Fuel”.
+ Before removing fuel line parts, perform out the following procedures:
~ Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
~ Release fuel pressure from the fuel lines. Refer to EC-152, "Work Procedure" (MR20DD) or EC-558,
"Work Procedure” (QR25DE).
Disconnect the battery cable from the negative terminal.
* Always replace O-ring and clamps with new ones.
+ Never kink or twist tubes when they are being installed.
+ Never tighten hose clamps excessively to avoid damaging hoses.
+ After installing tubes, check there is no fuel leakage at connections in the following steps.
~ Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check
for fuel leakage at connections.
- Start engine and rev it up and check for fuel leakage at connections.
+ Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the
“MIL” may come on.
FL-4 < PREPARATION >
PREPARATION
PREPARATION
Special Service Tools
Tool number
Tool name
KVi01207S0
Unifie fuel look sing wrench
PREPARATION
[GASOLINE ENGINE MODEL]
——
Removing and installing lock ring
Description SYSTEM
< SYSTEM DESCRIPTION > [GASOLINE ENGINE MODEL]
SYSTEM DESCRIPTION
SYSTEM
WARNING/INDICATOR (ON INFORMATION DISPLAY)
WARNING/INDICATOR (ON INFORMATION DISPLAY) : Low fuel warning wrscavwassrns
DESIGN/PURPOSE
This warns the driver that the fuel level is low.
OPERATION AT COMBINATION METER CAN COMMUNICATION CUT-OFF OR UNUSUAL SIG-
NAL
For the operation for CAN communications blackout or abnormal signal reception, refer to MWI-19. "METER
‘SYSTEM : Fail-Safe".
SYSTEM DIAGRAM
SIGNAL PATH
The combination meter receives fuel level sensor signal (resistance value) from the fuel level sensor unit and
indicates low fuel level warning on the vehicle information display when fuel level sensor signal (resistance
value) is less than the specified value.
LIGHTING CONDITION
When all of the following conditions are satisfied:
+ After a lapse of 15 seconds after the ignition switch is turned ON,
+ Fuel level is lower than the specified level.
jevel waming indication timing (Vehicle Parked on the level)
Approx. 10.8 2-3/8 imp gal) or less
(fuel tank dead amount included)
Fuel level
Fuel tank dead amount AprOX. 2.8.0 (2-48 Imp at)
SHUTOFF CONDITION
When any of the following conditions was satisfied:
+ Ignition switch is OFF.
+ Fuel level is the specified level or more.
WARNING/INDICATOR/CHIME LIST
FL SYSTEM
< SYSTEM DESCRIPTION > [GASOLINE ENGINE MODEL]
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)
cae = amare
FL-7 FUEL SYSTEM
< PERIODIC MAINTENANCE > [GASOLINE ENGINE MODEL]
PERIODIC MAINTENANCE
FUEL SYSTEM
Hydraulic Layout “nme cesconrm
MR20DD models
EVAP canister purge volume contr
é VAP line (Fuel tank to EVAP canis-
solenoid valve
Fuel feed line a
@
Fue! level sensor unit, uel fter and
fue! pump assembly Grae
@
@ Svbtuelevesensorassemby — ®
®
VAP line (EVAP canister to EVAP
@ Fus' ier tube EVAP canister ® canister purge volume control sole-
noid valve)
® View i)
CAUTION:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.
FLS FUEL SYSTEM
< PERIODIC MAINTENANCE > [GASOLINE ENGINE MODEL}
GR25DE models
VAP canister purge volume control
VAP tne (Fuel tank to EVAP canis-
© ‘solenoid vave
@ Foci eed tine
©
ter)
Fuel level sensor unit uel iter and.
@ Subuelievel sensor assembly —@) iam seer @ Fuel tank
EVAP line (EVAP canister to EVAP
@® Feel filer tube @ EVAP canister @ canister purge volume control sole-
noid vai)
View
CAUTION:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.
Inspection alma
Inspect fuel lines, fuel filler cap, and fuel tank for improper attach-
ment, leakage, cracks, damage, loose connections, chafing or dete-
Fioration
® Engine
@ | Fueltine
© Fueltank
If necessary, repair or replace damaged parts.
Quick Connector trocawercnorees
CAUTION:
FL-9 FUEL SYSTEM
< PERIODIC MAINTENANCE > [GASOLINE ENGINE MODEL]
+ After connecting fuel tube quick connectors, check quick con-
nectors are secure.
Quick connector
Retainer
Hard tube (or the equivalent)
Connection (cross-section)
Resin tube
To underfloor fuel ine
®80e8880
To fuel tank
Tab
o@
Disconnection
+ Ensure that connector and resin tube never contact any adja-
cent parts.
FL-10 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [GASOLINE ENGINE MODEL}
REMOVAL AND INSTALLATION
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Exploded View felonies
REMOVAL
SEC. 172
@ Lock ring @ Subuel level sensor assembly @_O-ring
Fue! level sensor uit, fuel fiter and
Gy Fost. © uel pump assemoiy
<3: Vehicle front
9 : Aways replace ater every disassembly
DISASSEMBLY
FL-11 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
[GASOLINE ENGINE MODEL]
SEC. 172
© Fuel er and fuel urn aesembly @ Fuel level sensor unit
Removal and Installation ciara
WARNING:
Read “General Precautions” when working on the fuel system. Refer to FL-4. "General Precautions".
REMOVAL
CAUTION:
Perform the operation with vehicle on level ground.
1, Release fuel pressure, Refer to EC-152, "Work Procedure” (MR20DD) or EC-558_ “Work Procedure"
(QR2508)
2. Check fuel level on a level ground. If the fuel level is 7/8 of the fuel tank (full or nearly full), draw appropri-
ate amount of fuel from the fuel tank,
Guideline: Draw approximately 10 liters (2-1/4 Imp gal) from a full-tank condition.
+ In the event of maifunction in fuel pump, insert a hose measuring 20 mm (0.79 in) in diameter into the
filler opening to draw approximately 10 liters (2-1/4 Imp gal) fuel.
Open fuel filler tid
Open the fuel filer cap and release the pressure inside the fuel tank.
Remove rear seat cushion. Refer to SE-52, "Exploded View".
Remove inspection hole cover.
+ Using a screwdriver, remove it by turning clips clockwise by 90 degrees.
Disconnect hamess connector @ and quick connector ®.
oa
~
@ Fst feed tube
@® Fuel evel sensor unt uel iter and fuel pump assembly
<2 Vehicle ont
Disconnect auick connector as follows:
FL-12 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
[GASOLINE ENGINE MODEL]
+ Hold the sides of connector, push in tabs @ and pull out fuel
feed tube.
® Pu
+ If quick connector sticks to tube of fuel level sensor unit, fuel
filter and fuel pump assembly, push and pull quick connector
several times until they start to move. Then disconnect them
by pulling,
CAUTION:
Quick connector can be disconnected when the tabs ©
are completely depressed. Never twist it more than neces-
sary.
® - Connection cross-section)
© Tounder Foor fuel ine
© ‘Tote tank
@ : Disconnection
+ Never use any tools to disconnected quick connector.
+ Keep resin tube © away from heat. Be especially careful
when welding near the resin tube.
+ Prevent acid liquid such as battery electrolyte, etc. from
getting on resin tube.
+ Never bend or twist resin tube during installation and dis-
connection.
+ Never remove the remaining retainer @ on hard tube (or
the equivalent) @® except when resin tube or retainer Is,
replaced.
+ When resin tube or hard tube (or the equivalent) is
replaced, also replace retainer with new one.
+ To keep the connecting portion clean and to avoid dam-
age and foreign materials, cover them completely with
plastic bags @) or something
B. Remove lock ring according to the following instructions:
FL-13 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
[GASOLINE ENGINE MODEL]
10.
install pawl (B) of unified fuel lock ring wrench [SST
10120750] (A) to the position shown in the figure.
Temporarily tighten mounting bolt (B) of the paw! according to
the measurement (R) from the center of unified fuel lock ring
wrench [SST: KV101207S0] (A) to the end of pawl (C).
R :82mm (3.23 in)
Set unified fuel lock ring wrench [SST KV101207S0) (A) to lock
pawl,
Remove lock ring
CAUTION
+ To prevent lock ring wrench from being detached,
securely hold down spinner handle (B) by hand.
+ To reduce impact caused by removal operation, use long
spinner handle [handle length: 60 cm (23.62 in) or more]
and slowly turn it counterclockwise.
Raise fuel level sensor unit, fuel fiter and fuel pump assembly.
CAUTION:
* Never bend float arm during removal.
‘ing and tighten the mounting bolt of the
+ Never pollute the inside by residue fuel. Draw out avoiding inclination by supporting with a
cloth.
+ Never cause impacts such by dropping when handling components.
Separate fuel tube 25 per the following steps to remove fuel level sensor unit, fuel filter and fuel pump
assembly,
+ Pinch quick connector @) square-part with your fingers, and
pull out the quick connector by hand.
+ If quick connector and tube on sender unit are stuck, push
several times until they move, and pull out.
NOTE:
‘When separating the fuel tube, tle a gasoline-resistance rope
to the tip of the fuel tube and leave the rope on the fuel tank
side to easily pull the fuel tube for installation,
FL44 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
* Disconnect harness connector ®,
Sub Fuel Level Sensor Assembly
1. Remove fuel level sensor unit, fuel filter and fuel pump assembly.
2, Remove lock ring according to the following instructions:
a. Install pawi (B) of unified fuel lock ring wrench [SST:
KV101207S0] (A) to the position shown in the figure
b. Temporarily tighten mounting bolt (B) of the pawl according to
the measurement (R) from the center of unified fuel lock ring
wrench [SST: KV101207S0] (A) to the end of pawl (C).
R :82mm (3.23 in)
[GASOLINE ENGINE MODEL]
Vm Ya \ Le.
¢.
©. Set unified fuel lock ring wrench [SST: KV101207S0] (A) to lock ring and tighten the mounting bolt of the
aw
4. Remove lock ring.
CAUTION;
To prevent lock ring wrench from being detached,
securely hold down spinner handle (B) by hand,
+ To reduce impact caused by removal operation, use long
spinner handle [handle length: 60 cm (23.62 in) or more]
and slowly turn it counterclockwise.
FL-15 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
<= REMOVAL AND INSTALLATION > [GASOLINE ENGINE MODEL]
3. Remove sub fuel level sensor assembly ©.
CAUTION:
+ Never disassemble a fuel tube @ from sub fuel sensor
assembly.
+ Never bend float arm during removal
+ Never pollute the inside by residue fuel. Draw out avoid-
1g inclination by supporting with a cloth.
+ Never cause impacts such by dropping when handling
components.
NOTE:
Tie a gasoline-resistance rope to a tip of the tube, Draw and r dina
leave the rope to the fuel tank side so that the rope can be the
guide for installation,
INSTALLATION
Note to the following, and install in the reverse order of removal.
‘Sub Fuel Level Sensor Assembly
1. Install new O-ring to fuel tank without any twist
CAUTION:
Do not reuse O-rings.
2. Using the rope left on the fuel tank side at removal, run the fuel tube inside the fuel tank to install the sub
fuel level sensor assembly to the fuel tank.
CAUTION:
+ Never bend float arm during installation.
+ To install, fuel tube @ must run to the front (<) of the vehicle to avoid the interference with the
float arm @, as shown in the figure.
3. Install the sub fuel level sensor assembly on the fuel tank with
the sub fuel level sensor assembly top surface @ faced the front
of the vehicle
[GASOLINE ENGINE MODEL]
Install lock ring for sub fuel level sensor assembly with unified
fuel lock ring wrench [SST:KV101207S0] by turning clockwise.
‘CAUTION
+ Install lock ring horizontally.
+ Turn the lock ring @ until it is engaged in the fuel tank
side ® as shown in the figure.
Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
41, Install new O-ring to fuel tank without any twist.
CAUTION:
Do not reuse O-rings.
2. Connect the fuel tube as per the following steps.
* Insert the quick connector @ straight to the fuel level sensor
unit, fue! filter and fuel pump assembly.
+ Judge a good fit from connecting sound and tactile feedback.
+ Pull the fuel tube by hand to check a secure fit
3. Connect harness connector ®)
FL-17 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION >
[GASOLINE ENGINE MODEL)
a
install the fuel level sensor unit, fuel fiter and fuel pump assem=
bly on the fuel tank with the fue! level sensor unit, fuel filter and
fuel pump assembly top surface @ faced the front of the vehicle.
<2 Vehiale front
CAUTION
+ Never allow seal packing to drop.
+ Never bend float arm during installing.
+ To install, fuel tube © must run to the front (<) of the
vehicle to avoid the interference with the float arm @, as
shown in the figure.
Install lock ring for fuel level sensor unit, fuel filter and fuel pump
assembly with unified fuel lock ring wrench [SST:KV101207S0]
by turing clockwise.
CAUTION:
+ Install lock ring horizontally.
+ Turn the lock ring @ until it is engaged in the fuel tank
side © as shown in the figure.
Connect quick connector of fuel feed tube as per following pro-
cedures,
Check the connection for damage or any foreign materials.
Align the connector with the tube, then insert the connector
straight into the tube until a “click” sound is heard.
After connecting, check that the connection is secured with fol-
lowing procedures,
+ Visually confirm that the two tabs are connected to the con-
nector.
FL-18 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [GASOLINE ENGINE MODEL]
* Pull @ the tube and the connector to check that they are
securely connected.
7. Connect hamess connector.
Inspection Hole Gover
+ Before installing inspection hole cover, check that the connecting part has no fuel leakage. Refer to FL-20.
inspection’
1. Install inspection hole covers with the front mark (arrow) facing front of vehicle.
2. Lock clips by turing counterclockwise
Disassembly and Assembly heme
DISASSEMBLY
1, Disconnect fuel level sensor harness connector @).
2. Remove fuel level sensor from fuel fiter and fuel pump assembly, according to the following steps.
@. Remove fuel level sensor harness from fuel filter and fuel pump assembly
b. Press into paw! @ of fuel level sensor mounting area Tl
©. With the fuel level sensor unlocked, slide it in the direction ®.
CAUTION:
+ Be careful not to damage the fuel level sensor.
+ Never disassemble fuel filter and fuel pump assembly.
FL-19 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< REMOVAL AND INSTALLATION > [GASOLINE ENGINE MODEL]
ASSEMBLY
1, Install fuel level sensor all the way. Tactually and aurally check the fit
2. Connect fuel level sensor harness connector ®.
3. Install fuel level sensor harness to fuel fitier and fuel pump
assembly.
Inspection esos
INSPECTION AFTER INSTALLATION
Use: following procedure to check for fuel leakage
1. Turn ignition switch “ON” (with engine stopped), then check connections:ar #akage by applying fuel pres-
sure to fuel piping be
2. Start engine and let it idle and check there are no fuel leakage at the fuel sysiem connections.
FL-20 FUEL TANK
= REMOVAL AND INSTALLATION > [GASOLINE ENGINE MODEL)
FUEL TANK
Exploded View eto
SEC.172
\e
5.0051, 4)
@ Ful tank band (RH) @ Fuel tank band (LH) @ Protector
@ Fueltank @ Clamp @ Venthose
@ Clamp ® Fusifilerhose @ Fuel fer tube
@ Grommet @ Fuel flercap
BL vm tig-m, )
Nem (kam, nt)
Removal and Installation aaa
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL4, “General Pre-
cautions”,
REMOVAL
4. Perform the steps 1 to 7 of “REMOVAL in“ FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL
PUMP ASSEMBLY". Refer to FL-12, "Removal and installation’
2. Drain fuel from fuel tank if necessary. Refer to FL-12, "Removal and installation”
CAUTION:
+ Because fuel tank forwardly inclines and becomes unstable when installing/removing, fuel
should be drained if found the remaining quantity.
+ Situate vehicle on a flat and solid surface.
3. Remove main muffler. Refer to EX.6. "Exoloded View" (MR20DD) or EX-12. "Exploded View" (QR25DE),
4, Remove rear propeller shaft. Refer to DLN-214. "Exploded View". (4WD models)
5. Remove protector from fuel tank.
FL-21 FUEL TANK
< REMOVAL AND INSTALLATION > [GASOLINE ENGINE MODEL]
6. Disconnect vent hose @, EVAP tube @, and fuel filler hose @ at
rear side of fuel tank
<2 Vehicle front
Instruction for quick connector @ of EVAP tube, Refer to FL-
12. "Removal and Installation".
7. Remove suspension bar. Refer to RSU-13, "Exploded View". (4WD models)
8. Support the lower part of fuel tank @ with transmission jack (A)
‘CAUTION:
Support the position that fuel tank mounting bands nev-
erengage.
Remove fuel tank band (RH and LH).
10. Lower transmission jack carefully to remove fuel tank while holding it by hand.
CAUTION:
Fuel tank may be in an unstable condition because of the shape of fuel tank bottom. Never rely on
jack too much. Be sure to hold tank securely.
INSTALLATION
Note the following, and install in the reverse order of removal.
+ Surely clamp fuel hoses and insert hose to the length below.
Fuel filler hose £35 mm (1.38 in)
The other hoses £25 mm (0.98 i
+ Be sure hose clamp is not placed on swelled area of fuel tube.
+ Tighten fuel filler hose clamp
Remaining length of screw thread Specified torque
Fuel filler tube side 7 - 11 mm (0.28 - 0.43 in) 2.5 Nem (0.26 kg-m, 22 in-Ib)
Fuel tank side 5-8 mm (0.20 - 0.36 in) 2.5 Nem (0.26 kg-m, 22 in-Ib)
+ To connect quick connector, refer to FL-12, "Remo!
Inspection Pee em
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leakage.
1. Turn ignition switch “ON” (with engine stopped), and check connections for leakage by applying fuel pres-
sure to fuel piping
2. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connec-
tions,
FL-22 EVAP CANISTER
< REMOVAL AND INSTALLATION > [GASOLINE ENGINE MODEL}
EVAP CANISTER
Hydraulic Layout weooeneronreer
MR20DD models
EEVAP canister purge volume contol EVAP tine (Fuel tank to EVAP canis~
© solenoid vee @ Fuel feed tne o
© Subtelievelsensorassenby _@ fiellevel senso unite Mer 99d Fue ang
VAP tine (EVAP canister to EVAP.
@® Fuel filer woe @® EVAP canister @ canister purge volume contol sole-
noid vaive)
8) | View i)
CAUTION:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.
FL-23 EVAP CANISTER
<= REMOVAL AND INSTALLATION > [GASOLINE ENGINE MODEL]
‘QR25DE models
EEVAP canister purge volume contiel EVAP ne (Fuel tank fo EVAP canis-
© Stood ate D Fed waive @ we
Fuel evel sensor uit, fel fier and
@ ‘Subtueileve sensor assemaly jaipur newer
@® Foeltank
EVAP line (EVAP canister to EVAP
@ Fuel filertube ® EVAP canister ® canister purge volume control soe
noid valve)
B view
CAUTION:
Do not use soapy water or any type of solvent while installing vacuum hose or purge ho:
Removal and Installation ‘srooconmnorran
REMOVAL
2
@ — :EVAP canister
Remove EVAP canister, slide it upward.
INSTALLATION
Install in the reverse order of removal,
FL-24 EVAP CANISTER
< REMOVAL AND INSTALLATION > [GASOLINE ENGINE MODEL]
‘CAUTION:
Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses.
Inspection 00 coca.
Check EVAP canister. Refer to EC-428, "Inspection" (MR20DD) or EC-804, “inspection” (@R25DE).
FL-25 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [GASOLINE ENGINE MODEL]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel Tank
Standard and Limit
Fuel tank capacity ‘Approx. 60 @ (13-218 imp gal)
Refer to GIO Fue
Fuel recommendation
FL-26 PRECAUTIONS
< PRECAUTION > [DIESEL ENGINE MODEL]
PRECAUTION i
PRECAUTIONS
Precautions for Removing Battery Terminal wooooseccoreer: [aE
* With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
of remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, ie. ACC power is supplied for a certain fixed time.
+ When disconnecting the 12V battery terminal, tum off the ACC
. EZ)
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
* For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch
NOTE:
If the ignition switeit is turned ON with any one of the terminals of
‘main battery and sub battery disconnected, then DTC may be detected
* After installing the 12V battery, always check "Self Diagnosis Result’ of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 o Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2
INSTRUCTION 4
4. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened.
3. Get out of the vehicle and close the driver side door.
4.
Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse.
of the specified time.
DéDengine 20 minutes
HRA2ODT 12 minutes
KoK engine :4 minutes
MOR engine 4 minutes
ROM engine © 4 minutes
9x engine: 4 minutes
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5. Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
4. Unlock the door with intelligent key or remote keyless entry,
NOT!
Atthis moment, ACC power is supplied
Open the driver side door
Open the hood,
Close the driver side door.
Walt at least 3 minutes.
wRoN
FL-27 PRECAUTIONS
< PRECAUTION > [DIESEL ENGINE MODEL]
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
6. Remove 12V battery terminal
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
General Precautions ‘nr cma 0r08
WARNING:
When replacing fuel line parts, be sure to observe the following.
+ Put a “CAUTION: FLAMMABLE” sign in the workshop.
+ Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
+ Never smoke while servicing fuel system. Keep open flames and sparks away from the work area,
CAUTION:
* Use diesel fuel required by the regulations for cetane number. Refer to Gi-30, "Fuel".
* Before removing fuel line parts, perform out the following procedures:
- Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
- Disconnect the battery cable from the negative terminal.
+ Always replace O-ring and clamps with new ones.
+ Never kink or twist tubes when they are being installed.
+ Never tighten hose clamps excessively to avoid damaging hoses.
+ After installing tubes, check there is no fuel leakage at connections in the following steps.
- Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check
for fuel leakage at connections.
- Start engine and rev it up and check for fuel leakage at connections.
* Drain water from fuel filter, when the water-in-fuel-filter warn-
ing lamp turns ON (with fuel filter warning). Refer to EL-38,
“Draining Water from Fuel Filter”.
Teg
4
FL-28 < PREPARATION >
PREPARATION
PREPARATION
Special Service Tools
Tool number
Tool name
KVi01207S0
Unifie fuel look sing wrench
PREPARATION
[DIESEL ENGINE MODEL]
bunntomas
Removing and installing lock ring
Description
FL-29 < SYSTEM DESCRIPTION >
SYSTEM DESCRIPTI
COMPONENT PARTS
Fuel Filter Sensor
+ Fuel filter sensor @ is integrated in the fUel filer and detects the
water in the fuel filter.
® :Drainplug
+ When the water-infuelfilter waming lamp tums ON, drain water
from fuel fiter. Refer to £1-38, "Draining Water from Fuel Filter’
NOTE:
COMPONENT PARTS.
ION
[DIESEL ENGINE MODEL]
TT
Ifthe fuel filter warning lamp turns ON after draining water from fuel filter, perform the following,
+ Disconnect fuel filter sensor connector.
+ Check condition of the water-in-fuel-fiter warning lamp.
‘MWL-106, “Wiring Diagram”
- If the warning lamp is OFF, replace the
fuel filter sensor.
FL-30
If the waming lamp is ON, check the hamess between combination meter and fuel filter sensor. Refer to STRUCTURE AND GPERATION
< SYSTEM DESCRIPTION > [DIESEL ENGINE MODEL]
STRUCTURE AND OPERATION
FUEL TRANSPORTATION IN FUEL TANK
FUEL TRANSPORTATION IN FUEL TANK : System Description roe anon 836
i
The electric fuel pump and the transfer jet pump are integrated with the main fuel level sensor unit, fuel filter
and fue! pump assembly. This is installed to the fuel tank.
‘The transfer jet pumps draw up fuel using a flow of return fuel. The transfer jet pump (sub side) transfers fuel
from the sub side to inside of the fuel pump assembly. The transfer jet pump (main side) transfers fuel from the
main side to inside of the fuel pump assembly. The fuel sent to fuel pump assembly is supplied to the engine
by an electric fuel pump.
NOTE:
Fuel on the sub side is consumed first
LZ ~ elf
A NY Ss [BIT
{ {= “9 NX SE |
é ©
@ Suh hel vet sensor unt © Maint ier sencr nt WEE Fue mernese
@ sweie © wanace © Feetine
© eum ie © “Tereteretpurp ab se) ®Eecitel up
@ Tanserlotpunp nan se) Trantor ube
FL-31 SYSTEM
< SYSTEM DESCRIPTION > [DIESEL ENGINE MODEL]
SYSTEM
WARNING/INDICATOR (ON INFORMATION DISPLAY)
WARNING/INDICATOR (ON INFORMATION DISPLAY) : Low fuel warning sroewnrn
DESIGN/PURPOSE
This wams the driver that the fuel level is low.
OPERATION AT COMBINATION METER CAN COMMUNICATION CUT-OFF OR UNUSUAL SIG-
NAL
For the operation for CAN communications blackout or abnormal signal reception, refer to MWLI02, "Fail
Sale’.
SYSTEM DIAGRAM
=
el sane sgral
Fustovet onsor
SIGNAL PATH
‘The combination meter receives fuel level sensor signal (resistance value) from the fuel level sensor unit and
indicates low fuel level warning on the vehicle information display when fuel level sensor signal (resistance
value) is less than the specified value.
LIGHTING CONDITION
When all of the following conditions are satisfied
+ After a lapse of 15 seconds after the ignition switch is turned ON.
+ Fuel level is lower than the specified level
Fuel evel warning indlation tiring (Vehioe: Parked on the level)
‘Approx. 10.80 2-3/8 Imp gab or less
Fuel level
; (fe tank dead aevount included)
“Fueltank dead amount | Approx 280(2-4/8mpa)
SHUTOFF CONDITION
When any of the following conditions was satisfied:
+ Ignition switch is OFF
+ Fuel level is the specified level or more
WARNING/INDICATOR/CHIME LIST
FL-32 < SYSTEM DESCRIPTION >
WARNING/INDICATOR/CHIME LIST : Warning lamps/Indicator lamps
SYSTEM
[DIESEL ENGINE MODEL]
Name Design Tarangemeniruncbon
Regarding ihe arangement.Refer‘o MiNi METERSYSTE il
Fuel er warning lamp a
ding the function
WARNING/INDICATORICHIME LIST : Warning/Indicator (On Information Display)
Name
Desion
‘ArangementFuncton
Low fuel warning
"i
Regarding he arrangement. Refer o MiN-i0 “MEIER SYST:
Bessa
Regarding the function. Refer to FL-32.“WARNING/INDIGATOR (ON.
INFORMATION DISPLAY) Low fuel waming®
FL-33 FUEL SYSTEM
< PERIODIC MAINTENANCE > [DIESEL ENGINE MODEL]
PERIODIC MAINTENANCE
FUEL SYSTEM
Hydraulic Layout “nrmo ceewron armas
MIT models
@ Fuel ter @® Fuel pressure sensor
® Fueltecd tube @® Fuel retum tube
@ Subfuellovel sensor assembly @)_ Ful tank
Mal fue level sensor. el iter and
fuel pump assembly
@® Fuel pump
® Fuel cooling tube
@® Fuel er tube FUEL SYSTEM
< PERIODIC MAINTENANCE > [DIESEL ENGINE MODEL]
CVT models
® Fuel titer ® Fuel pressure sensor @ Fuel pump
@® Fustfeed tube © Fuelretum tube © Fuel cooling tube
@ Subiuel level sensor assembly @_ Fuel tank @ Feel ilertube
Main fuel level sensor, fue iter and
® ‘fuel pump assembly
Inspection [DIESEL ENGINE MODEL]
+ After connecting fuel tube quick connectors, check quick con-
nectors are secure.
Quick connector
Retainer
Har tube (or the equivalent)
Connection (cross-section)
Resin tube
“To under floor fuel tne
To fuel tank
3@SOGGHO
Tab
®
Disconnection
+ Ensure that connector and resin tube never contact any adja-
cent parts.
FL-36 FUEL FILTER
< PERIODIC MAINTENANCE > = IDIESEL ENGINE MODEL}
FUEL FILTER ~
Exploded View wooowceronrness
peer Ph2soce, 19) —_
2
WL
——,
a
@ Fuel ter protector @ Fuel ter bracket @ Fuelretum hose
@ Brecket © Fuel feed hose © Fuel feed hose
@ Fuel pressure sensor @ Fuel ter @ Fuel return ube
@ Fuelteca uve
@ Tohuettank © Tolvel woe © Totus! pump
19) Nem Ke, rs)
Ne kom.)
© A -Incicates thatthe pais connected at points with same symbol in actual vehicle
Removal and Installation erin
REMOVAL
WARNING:
Be careful of the following when replacing fuel system parts:
+ Display “CAUTION: flammable material”.
+ Keep away from flames, and work in a well-ventilated area.
+ Keep a fire extinguisher handy.
+ Keep drained fuel in a safe place.
CAUTION:
+ Perform the operation with vehicle on level ground.
+ Do not bend and twist hose and tube.
1. Remove fuel fiter protector.
2. Disconnect fuel feed hoses and fuel return hose from fuel filter.
CAUTION:
Plug the pipe to prevent fuel from draining.
FL-37
