AT-252
ON-VEHICLE SERVICE
Revision: 2006 January2006 M35/M45
Installation
CAUTION:
After completing installation, check A/T fluid leakage, A/T fluid level and A/T position. Refer to AT- 1 3 ,
"Checking A/T Fluid" , AT- 2 2 8 , "Checking of A/T Position" .
1. As shown in the figure, use a drift to drive rear oil seal into the
rear extension until it is flush.
CAUTION:
Apply ATF to rear oil seal.
Do not reuse rear oil seal.
2. Install return spring (1) to parking pawl (2).
3. Install parking pawl (with return spring) and pawl shaft to rear
extension.
4. Install parking actuator support to rear extension.
SCIA5311E
SCIA6180J
SCIA3424E
SCIA3423E
AT-260
ON-VEHICLE SERVICE
Revision: 2006 January2006 M35/M45
Rear Oil Seal (VQ35DE Models Only)NCS001QV
REMOVAL AND INSTALLATION
Removal
1. Remove rear propeller shaft. Refer to PR-8, "Removal and
Installation" .
2. Remove transfer assembly from A/T assembly (AWD models).
Refer to TF-44, "
Removal and Installation" .
3. Remove rear oil seal using a flat-bladed screwdriver.
CAUTION:
Be careful not to scratch rear extension assembly (2WD
models) or adapter case assembly (AWD models).
Installation
CAUTION:
After completing installation, check for A/T fluid leakage and A/T fluid level. Refer to AT- 1 3 , "
Checking
A/T Fluid" .
1. As shown in the figure, use the drift to drive rear oil seal into rear
extension assembly (2WD models) or adapter case assembly
(AWD models) until it is flush.
CAUTION:
Apply ATF to rear oil seal.
Do not reuse rear oil seal.
2. Install transfer assembly to A/T assembly (AWD models). Refer
to TF-44, "
Removal and Installation" .
3. Install rear propeller shaft. Refer to PR-8, "
Removal and Installa-
tion" .
SCIA5410E
SCIA5411E
ATC-18
PREPARATION
Revision: 2006 January2006 M35/M45
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220)
UV lamp and UV safety goggles
(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottle
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872)
Refrigerant dye cleanerPower supply:
DC 12 V (Battery terminal)
(J-42220)
UV lamp and UV safety gogglesPower supply:
DC 12 V (Battery terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system
Includes:
UV lamp and UV safety goggles
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)Application:
For HFC-134a (R-134a) PAG oil
Container:
1/4 ounce (7.4 cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.)
(J-41459)
HFC-134a (R-134a) dye injector
Use with J-41447, 1/4 ounce
bottleFor injecting 1/4 ounce of fluorescent
leak detection dye into A/C system
(J-43872)
Refrigerant dye cleanerFor cleaning dye spills
(J-39183)
Manifold gauge set (with hoses
and couplers)Identification:
The gauge face indicates HFC-134a
(R-134a).
Fitting size: Thread size
1/2 -16 ACME Tool number
(Kent-Moore No.)
Tool nameDescription
ZHA200H
SHA438F
SHA439F
SHA440F
SHA441F
RJIA0196E
PREPARATION
ATC-19
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AT C
Revision: 2006 January2006 M35/M45
Commercial Service ToolsNJS000FY
Service hoses
High-pressure side hose
(J-39501-72)
Low-pressure side hose
(J-39502-72)
Utility hose
(J-39476-72)Hose color:
Low hose: Blue with black stripe
High hose: Red with black stripe
Utility hose: Yellow with black stripe
or green with black stripe
Hose fitting to gauge:
1/2 -16 ACME
Service couplers
High-pressure side coupler
(J-39500-20)
Low-pressure side coupler
(J-39500-24)Hose fitting to service hose:
M14 x 1.5 fitting is optional or
permanently attached.
(J-39650)
Refrigerant weight scaleFor measuring of refrigerant
Fitting size: Thread size
1/2
-16 ACME
(J-39649)
Vacuum pump
(Including the isolator valve)Capacity:
Air displacement: 4 CFM
Micron rating: 20 microns
Oil capacity: 482 g (17 oz.)
Fitting size: Thread size
1/2 -16 ACME Tool number
(Kent-Moore No.)
Tool nameDescription
S-NT201
S-NT202
S-NT200
S-NT203
Tool nameDescription
Refrigerant identifier equipmentChecking for refrigerant purity and
system contamination
Power toolFor loosening bolts and nuts
RJIA0197E
PBIC0190E
ATC-170
REFRIGERANT LINES
Revision: 2006 January2006 M35/M45
Checking for Refrigerant LeaksNJS000HY
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electrical leak detector or fluorescent dye leak
detector (SST: J-42220).
If dye is observed, confirm the leak with an electrical leak detector. It is possible a prior leak was repaired and
not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electrical leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electrical leak detector probe slower and closer to the suspected leak area will improve the
chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorNJS000HZ
1. Check A/C system for leaks using the UV lamp and safety goggles (SST: J-42220) in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open-
ing indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (SST: J-43872) to prevent future
misdiagnosis.
4. Perform a system performance check and verify the leak repair with an approved electrical leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionNJS000I0
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm
2 , 50 psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (SST: J-41459).
3. Connect the injector tool to the A/C low-pressure side service valve.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool (SST: J-41459) (refer to the manufacture’s
operating instructions).
6. With the engine still running, disconnect the injector tool from the service valve.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
8. Attach a blue label as necessary.
BR-10
BRAKE FLUID
Revision: 2006 January2006 M35/M45
BRAKE FLUIDPFP:KN100
On-Board Inspection NFS000OU
CHECKING BRAKE FLUID LEVEL
Make sure that a brake fluid level in reservoir tank is within the
standard (between MAX and MIN lines).
Visually check around reservoir tank for fluid leakage.
If the level is excessively low, check brake system for leakage.
Release parking brake pedal and see if brake warning lamp
goes off. If not, check brake system for fluid leakage.
Checking Brake LineNFS000OV
CAUTION:
If leakage occurs around joints, retighten or, if necessary, replace damaged parts.
1. Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged
parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
Drain and RefillNFS000OW
CAUTION:
Refill with new brake fluid “DOT 3”.
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
Before working, disconnect connectors of ABS actuator and electric unit (control unit) or battery
cable from the negative terminal.
1. Connect a vinyl tube to bleed valve.
2. Depress brake pedal, loosen bleed valve, and gradually remove
brake fluid.
SFIA2484E
SBR389C
BRA0007D
CO-16
[VQ35DE]
RADIATOR
Revision: 2006 January2006 M35/M45
Minimize the lift of A/C condenser to prevent load from being applied to A/C piping.
e. After removing the radiator, place the A/C condenser on the radiator core support to prevent load from
being applied to piping. And then, temporarily secure them using a rope to prevent them from being
dropped.
INSTALLATION
Installation is the reverse order of removal.
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant using the radiator cap tester adapter [SST: EG17650301 (J33984-A)]
and the radiator cap tester (commercial service tool). Refer to CO-11, "
LEAK CHECK" .
Start and warm up the engine. Visually make sure that there is no leaks of engine coolant and A/T fluid.
Checking Radiator CapNBS004QU
Check valve seat of radiator cap.
–Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
–Check if valve seat has no soil and damage.
Pull negative-pressure valve to open it, and make sure that it
close completely when released.
–Make sure that there is no dirt or damage on the valve seat of
radiator cap negative-pressure valve.
–Make sure that there are no unusualness in the opening and
closing conditions of negative-pressure valve.
Check radiator cap relief pressure.
–When connecting radiator cap to the radiator cap tester (com-
mercial service tool) and the radiator cap tester adapter (SST),
apply engine coolant to the cap seal surface.
Replace radiator cap if there is an unusualness related to the above three.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
Checking RadiatorNBS004QV
Check radiator for mud or clogging. If necessary, clean radiator as follows.
Be careful not to bend or damage radiator fins.
PBIC2816E
SMA967B
Standard:
78 - 98 kPa (0.8 - 1.0 kg/cm
2 , 11 - 14 psi)
Limit:
59 kPa (0.6 kg/cm
2 , 9 psi)
SLC755A
RADIATOR
CO-45
[VK45DE]
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Revision: 2006 January2006 M35/M45
INSTALLATION
Installation is the reverse order of removal.
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant using radiator cap tester adapter [SST: EG17650301 (J33984-A)] and
radiator cap tester (commercial service tool). Refer to CO-40, "
LEAK CHECK" .
Start and warm up engine. Visually Check if there is no leaks of engine coolant and A/T fluid.
Checking Radiator CapNBS004RI
Check valve seat of radiator cap.
–Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
–Check if valve seat has no soil and damage.
Pull negative-pressure valve to open it, and make sure that it
close completely when released.
–Make sure that there is no dirt or damage on the valve seat of
radiator cap negative-pressure valve.
–Make sure that there are no unusualness in the opening and
closing conditions of negative-pressure valve.
Check radiator cap relief pressure.
–When connecting radiator cap to the radiator cap tester adapter
(SST) and the radiator cap tester (Commercial service tool),
apply engine coolant to the cap seal surface.
Replace radiator cap if there is an unusualness.
CAUTION:
When installing a radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
Checking RadiatorNBS004RJ
Check radiator for mud or clogging. If necessary, clean radiator as follows:
Be careful not to bend or damage the radiator fins.
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape the harness and electrical connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surface once per minute.
PBIC2816E
SMA967B
Standard : 78 - 98 kPa (0.8 - 1.0 kg/cm2 , 11 - 14 psi)
Limit : 59 kPa (0.6 kg/cm
2 , 9 psi)
SLC755A