EC-1296
< PRECAUTION >[K9K]
PRECAUTIONS
Cylinder NO.1 is at the flywheel end.
-1: Crankshaft pulley
ENGINE RUNNING
No work should be carried out on the hydraulic system while engine is running.
Remember that fuel pressure values in hydraulic circuit can reach up to 1,600 bar.
Keep hands or face (particularly eyes) out of any high pressure leak.
Recall that fuel is dangerous for health.
FUEL RAIL PRESSURE SENSOR
Under warranty, do not remove the fuel rail pressure sensor from the rail.
Do not try to measure the resistance of the fuel rail pressure sensor. This test is destructive for the
internal components.
FUEL INJECTOR
Fuel injectors are driven by over 100V.
FUEL injector electronics are polarised. In case of intervention on wiring harness, do not
invertwires. It is destructive for the piezo components.
Do not drive the fuel injectors if their body is not connected to the battery ground (risk ofelectro-
static discharge). For instance, fuel injector body have to be in contact with cylinder.
Piezo fuel injector connector must not be unplugged while engine is running. Risk of majordamage
to the engine (fuel injector could stay opened).
CleanlinessINFOID:0000000001162747
Cleanliness
RISKS ASSOCIATED WITH CONTAMINATION
The high pressure direct injection system is highly sensitive to contamination. The risks associated withcon-
tamination are:
damage to or destruction of the high pressure injection system,
components jamming,
components losing seal integrity.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (par-
ticles a few microns in size) should have entered the system during dismantling.
The cleanliness principle must be applied from the filter to the fuel injectors.
What are the sources of contamination?
metal or plastic chips,
paint,
fibres:
- from cardboard,
- from brushes,
- from paper,
- from clothing,
- from cloths,
foreign bodies such as hair,
ambient air
etc.
NOTE:
Cleaning the engine using a high pressure washer is prohibited because of the risk of damaging connections.
In addition, moisture may collect in the connectors and create electrical connection malfunction.
INSTRUCTIONS TO BE FOLLOWED BEFORE CARRYING OUT ANY WORK
JMBIA0432ZZ
PRECAUTIONS
EM-7
< PRECAUTION >[HR16DE]
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PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"
INFOID:0000000001527642
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 SR and SB section of
this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
Precaution for Procedure without Cowl Top CoverINFOID:0000000001527633
When performing the procedure after removing cowl top cover, cover
the lower end of windshield.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000001527634
NOTE:
This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS-
TEM).
Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work.
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
PIIB3706J
EM-90
< REMOVAL AND INSTALLATION >[HR16DE]
ENGINE ASSEMBLY
If items or work required are not covered by the engine section, follow the procedures in the applica-
ble sections.
Always use the support point specified for lifting.
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
For supporting points for lifting and jacking point at rear axle, refer to GI-48, "
Garage Jack and
Safety Stand and 2-Pole Lift".
REMOVAL
Outline
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
Preparation
1. Remove the hood assembly. Refer to DLK-214, "Removal and Installation".
2. Remove the cowl top cover and cowl top extension assembly. Refer to EXT-20, "
Removal and Installa-
tion".
3. Release fuel pressure. Refer to EC-377, "
Inspection" (EURO-OBD), EC-681, "Inspection" (WITHOUT
EURO-OBD).
4. Drain engine coolant from radiator. Refer to CO-11, "
Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
Never spill engine coolant on drive belt.
5. Drain the transmission fluid. Refer to TM-628, "
Draining" (M/T models), TM-171, "Changing A/T Fluid" (A/
T models).
6. Remove the following parts.
Engine undercover
Front road wheels and tires: Refer to WT-6, "
Rotation".
Front fender protector (RH and LH): Refer to EXT-22, "
Removal and Installation".
Battery and battery tray: Refer to PG-6, "
Removal and Installation".
Drive belt: Refer to EM-16, "
Removal and Installation".
Air duct and air cleaner case assembly: Refer to EM-27, "
Exploded View".
Radiator hose (upper and lower): Refer to CO-16, "
Component".
Disconnect cooling fan controller wiring harness.
Remove coolant reservoir tank.
Remove fan shroud and cooling fan assembly. Refer to CO-16, "
Component".
Engine Room LH
1. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then tem-
porarily secure the engine harness into the engine side.
CAUTION:
Protect connectors using a resin bag against foreign materials.
2. Remove ground cable at transaxle side.
3. Disconnect fuel feed hose at engine side. Refer to EM-35, "
Exploded View".
4. Disconnect EVAP purge hose and brake booster vacuum hose.
5. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-24,
"Exploded View".
6. Disconnect control linkage from transaxle. Refer to TM-189, "
Exploded View" (A/T), TM-630, "Exploded
View" (M/T).
7. Disconnect the clutch tube at transmission side. Refer to CL-12, "
Removal and Installation".
Engine Room RH
1. Remove ground cable between front cover and vehicle.
2. Remove generator and generator bracket; Refer to CHG-15, "
Removal and Installation".
3. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. (with A/C models) Refer to HA-34, "
Removal and Installation of
Compressor - HR16DE".
EM-134
< PRECAUTION >[MR18DE]
PRECAUTIONS
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"
INFOID:0000000001527643
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 SR and SB section of
this Service Manual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
Precaution for Procedure without Cowl Top CoverINFOID:0000000001337763
When performing the procedure after removing cowl top cover, cover
the lower end of windshield.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000001337764
NOTE:
This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS-
TEM).
Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work.
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
PIIB3706J
PRECAUTIONS
EM-251
< PRECAUTION >[K9K]
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PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"
INFOID:0000000001516580
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 SR and SB section of
this Service Manual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
Precaution for Procedure without Cowl Top CoverINFOID:0000000001527630
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000001527631
NOTE:
This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS-
TEM).
Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
PIIB3706J
EM-256
< PRECAUTION >[K9K]
PRECAUTIONS
SPECIAL FEATURES
CAUTION:
The engine must not operate with:
- Diesel engine fuel containing more than 10% diester,
- Petrol, even in tiny quantities.
The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out
any work, check that the injector rail is not under pressure and that the fuel temperature is not too
high.
You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the fuel tem-
perature sensor and the venturi can be replaced.
For safety reasons, it is strictly forbidden to slacken a injection tube union when the engine is run-
ning.
It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the pressure sensor fails, the pressure sensor, the rail and the five
injection tubes must be replaced.
It is strictly forbidden to remove any high pressure supply pump pulley marked number 070 575. If
the pump is being replaced, the pulley must be replaced.
It is forbidden to repair the wiring connecting the knock sensor (accelerometer) and the CKP sensor
(engine speed sensor). If the wiring should fail, it has to be replaced with new wiring.
Applying 12 volts directly to any component in the system is prohibited.
Ultrasonic carbon removal and cleaning are prohibited.
Never start the engine without the battery being connected correctly.
It is essential to replace all the disconnected air inlet plastic pipes.
INSTRUCTIONS FOR INJECTION TUBES
CAUTION:
All the injection tube removed must be systematically replaced along with the clips.
TIGHTENING THE INJECTION TUBES
NOTE:
fit the pump/rail pipe before the rail/injector pipes.
Rail-pump pipe
Undo the rail,
Grease the threads of the injection tube nuts,
Insert the injection tube olive into the taper of the high pressure pump outlet,
Insert the injection tube olive into the taper of the high pressure rail inlet.
Move the nut into position by hand, on the rail side then the pump side,
Tighten the rail,
Tighten the injection tube nuts on the rail side then on the pump side.
Rail/injector pipes
Undo the rail,
Grease the threads of the injection tube nuts,
Insert the injection tube olive into the taper of the high pressure injector inlet,
Insert the injection tube olive into the taper of the high pressure rail outlet,
Move the nuts into position by hand, on the injector side then the rail side,
Tighten the rail,
Ensure that the new clip, supplied with the new injection tube, is fitted,
Tighten the nuts of the injection tubes on the injector side first and then on the fuel rail side.
NOTE:
Before fitting a new injection tube, move back the nuts on the pipe then lightly lubricate the nut
threads with the oil from the sachet provided in the parts kit.
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there are no diesel leaks.
Reprime the circuit using the priming pump.
Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks.
Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
Once the engine coolant temperature is above 50°C and provided there are no malfunctions present, carry
out a road test, taking the engine speed up to 4000 rpm at least once to check that there are no leaks.
Perform a visual inspection after the road test to make sure that there are no high pressure leaks.
Clean off the tracing fluid.
EXL-2
FLASHER : CONSULT-III Function (BCM -
FLASHER) ..............................................................
27
COMB SW .................................................................28
COMB SW : CONSULT-III Function (BCM -
COMB SW) .............................................................
28
BATTERY SAVER ....................................................28
BATTERY SAVER : CONSULT-III Function (BCM
- BATTERY SAVER) ..............................................
28
DIAGNOSIS SYSTEM (IPDM E/R) ....................30
CONSULT - III Function (IPDM E/R) ......................30
DIAGNOSIS SYSTEM (HEADLAMP LEVEL-
IZER) ..................................................................
31
CONSULT-III Function ...........................................31
COMPONENT DIAGNOSIS ........................32
POWER SUPPLY AND GROUND CIRCUIT .....32
BCM (BODY CONTROL MODULE) .........................32
BCM (BODY CONTROL MODULE) : Diagnosis
Procedure ...............................................................
32
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) .............................
32
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) : Diagnosis Pro-
cedure .....................................................................
32
HEADLAMP (HI) CIRCUIT ................................33
HEADLAMP (HALOGEN) .........................................33
HEADLAMP (HALOGEN) : Description ..................33
HEADLAMP (HALOGEN) : Component Function
Check .....................................................................
33
HEADLAMP (HALOGEN) : Diagnosis Procedure ...33
HEADLAMP (XENON) ..............................................34
HEADLAMP (XENON) : Description .......................34
HEADLAMP (XENON) : Component Function
Check .....................................................................
34
HEADLAMP (XENON) : Diagnosis Procedure .......35
HEADLAMP (LO) CIRCUIT ...............................37
HEADLAMP (HALOGEN) .........................................37
HEADLAMP (HALOGEN) : Description ..................37
HEADLAMP (HALOGEN) : Component Function
Check .....................................................................
37
HEADLAMP (HALOGEN) : Diagnosis Procedure ...37
HEADLAMP (XENON) ..............................................38
HEADLAMP (XENON) : Description .......................38
HEADLAMP (XENON) : Component Function
Check .....................................................................
38
HEADLAMP (XENON) : Diagnosis Procedure .......39
FRONT FOG LAMP CIRCUIT ...........................41
Description ..............................................................41
Component Function Check ...................................41
Diagnosis Procedure ...............................................41
REAR FOG LAMP CIRCUIT .............................43
Description ..............................................................43
Component Function Check ...................................43
Diagnosis Procedure ...............................................43
PARKING LAMP CIRCUIT ................................46
WITH DAYTIME LIGHT SYSTEM .............................46
WITH DAYTIME LIGHT SYSTEM : Description .....46
WITH DAYTIME LIGHT SYSTEM : Component
Function Check .......................................................
46
WITH DAYTIME LIGHT SYSTEM : Diagnosis Pro-
cedure .....................................................................
46
WITHOUT DAYTIME LIGHT SYSTEM .....................48
WITHOUT DAYTIME LIGHT SYSTEM : Descrip-
tion ..........................................................................
48
WITHOUT DAYTIME LIGHT SYSTEM : Compo-
nent Function Check ...............................................
48
WITHOUT DAYTIME LIGHT SYSTEM : Diagno-
sis Procedure ..........................................................
49
TURN SIGNAL LAMP CIRCUIT ........................52
Description ..............................................................52
Component Function Check ...................................52
Diagnosis Procedure ...............................................52
LIGHT & RAIN SENSOR ...................................55
Description ..............................................................55
Component Function Check ...................................55
Diagnosis Procedure ...............................................55
HEADLAMP AIMER SWITCH ...........................57
Description ..............................................................57
Diagnosis Procedure ...............................................57
HEADLAMP (HALOGEN) .................................58
Wiring Diagram .......................................................58
HEADLAMP (XENON) .......................................59
Wiring Diagram .......................................................59
AUTO LIGHT SYSTEM .....................................60
Wiring Diagram .......................................................60
HEADLAMP AIMING SYSTEM (MANUAL) ......61
Wiring Diagram .......................................................61
HEADLAMP AIMING SYSTEM (AUTOMAT-
IC) ......................................................................
62
Wiring Diagram .......................................................62
DAYTIME LIGHT SYSTEM ...............................63
Wiring Diagram .......................................................63
FRONT FOG LAMP ...........................................64
Wiring Diagram .......................................................64
REAR FOG LAMP .............................................65
Wiring Diagram .......................................................65
EXL-3
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TURN SIGNAL AND HAZARD WARNING
LAMPS ...............................................................
66
Wiring Diagram .......................................................66
PARKING, LICENSE PLATE AND TAIL
LAMPS ...............................................................
67
WITH DAYTIME LIGHT SYSTEM .............................67
WITH DAYTIME LIGHT SYSTEM : Wiring Dia-
gram ........................................................................
67
WITHOUT DAYTIME LIGHT SYSTEM ......................67
WITHOUT DAYTIME LIGHT SYSTEM : Wiring Di-
agram ......................................................................
68
STOP LAMP .......................................................69
Wiring Diagram .......................................................69
BACK-UP LAMP ................................................70
Wiring Diagram .......................................................70
ECU DIAGNOSIS .........................................71
BCM (BODY CONTROL MODULE) ...................71
Description ..............................................................71
IPDM E/R (INTELLIGENT POWER DISTRI-
BUTION MODULE ENGINE ROOM) .................
72
Description ..............................................................72
SYMPTOM DIAGNOSIS ..............................73
EXTERIOR LIGHTING SYSTEM SYMPTOMS ....73
Symptom Table .......................................................73
NORMAL OPERATING CONDITION .................75
Description ..............................................................75
BOTH SIDE HEADLAMPS DO NOT SWITCH
TO HIGH BEAM .................................................
76
Description ..............................................................76
Diagnosis Procedure ...............................................76
BOTH SIDE HEADLAMPS (LO) ARE NOT
TURNED ON .......................................................
77
Description ..............................................................77
Diagnosis Procedure ...............................................77
PARKING, LICENSE PLATE AND TAIL
LAMPS ARE NOT TURNED ON ........................
78
Description ..............................................................78
Diagnosis Procedure ...............................................78
BOTH SIDE FRONT FOG LAMPS ARE NOT
TURNED ON .......................................................
79
Description ..............................................................79
Diagnosis Procedure ...............................................79
PRECAUTION ..............................................80
PRECAUTIONS ..................................................80
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
80
ON-VEHICLE MAINTENANCE ....................81
HEADLAMP ......................................................81
Aiming Adjustment ...................................................81
FRONT FOG LAMP ..........................................83
Aiming Adjustment ...................................................83
ON-VEHICLE REPAIR .................................84
HEADLAMP ......................................................84
Bulb Replacement ...................................................84
Removal and Installation .........................................84
Disassembly and Assembly - Halogen ....................85
Disassembly and Assembly - Xenon .......................86
FRONT FOG LAMP ..........................................87
Bulb Replacement ...................................................87
Removal and Installation .........................................87
HEADLAMP AIMING CONTROL ......................88
Removal and Installation of Headlamp Aiming
Switch ......................................................................
88
Removal and Installation of Height Sensor .............89
AUTO LIGHT SYSTEM .....................................91
Removal and Installation of Light and Rain Sensor
....
91
SIDE TURN SIGNAL LAMP ..............................92
Bulb Replacement ...................................................92
Removal and Installation .........................................92
REAR COMBINATION LAMP ...........................93
Bulb Replacement ...................................................93
Removal and Installation .........................................93
Disassembly and Assembly .....................................93
HIGH-MOUNTED STOP LAMP ........................96
Bulb Replacement ...................................................96
Removal and Installation .........................................96
LICENSE PLATE LAMP ...................................98
Bulb Replacement ...................................................98
Removal and Installation .........................................98
REAR FOG LAMP ...........................................100
Bulb Replacement .................................................100
Removal and Installation .......................................100
LIGHTING & TURN SIGNAL SWITCH ...........101
Removal and Installation .......................................101
HAZARD SWITCH ..........................................102
Removal and Installation .......................................102
SERVICE DATA AND SPECIFICATIONS
(SDS) ..........................................................
103