Tài liệu hướng dẫn sửa chữa xe Nissan teana j32 esm tai lieu sua chua phan 2 . Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xác, hiệu quả, hợp lý
DRIVER CONTROLS SECTION EXL EXTERIOR LIGHTING SYSTEM A B C D E CONTENTS XENON TYPE BASIC INSPECTION DIAGNOSIS AND REPAIR WORKFLOW Work Flow INSPECTION AND ADJUSTMENT 11 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT 11 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description 11 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Requirement (ADAPTIVE LIGHT) 11 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description 11 ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Requirement (HEADLAMP LEVELIZER) 11 LEVELIZER ADJUSTMENT 11 LEVELIZER ADJUSTMENT : Description 11 LEVELIZER ADJUSTMENT : Special Repair Requirement (ADAPTIVE LIGHT) 11 CONFIGURATION (HEADLAMP LEVELIZER) 12 CONFIGURATION (HEADLAMP LEVELIZER) : Description 12 CONFIGURATION (HEADLAMP LEVELIZER) : Special Repair Requirement (HEADLAMP LEVELIZER) 12 WITH AFS 14 WITH AFS : System Diagram 14 WITH AFS : System Description .14 WITH AFS : Component Parts Location 15 WITH AFS : Component Description 16 WITHOUT AFS 16 WITHOUT AFS : System Diagram 16 WITHOUT AFS : System Description 16 WITHOUT AFS : Component Parts Location 17 WITHOUT AFS : Component Description 17 G H I AUTO LIGHT SYSTEM 18 System Diagram 18 System Description 18 Component Parts Location 19 Component Description 19 ACTIVE ADAPTIVE FRONT-LIGHTING SYSTEM 20 System Diagram 20 System Description 20 Component Parts Location 22 Component Description 22 J K EXL M HEADLAMP AIMING CONTROL SYSTEM (AUTO) 24 System Diagram 24 System Description 24 Component Parts Location 25 Component Description 25 N O FRONT FOG LAMP SYSTEM 26 SENSOR INITIALIZE 12 SENSOR INITIALIZE : Description 12 SENSOR INITIALIZE : Special Repair Requirement (HEADLAMP LEVELIZER) 13 System Diagram 26 System Description 26 Component Parts Location 27 Component Description 27 FUNCTION DIAGNOSIS 14 TURN SIGNAL AND HAZARD WARNING LAMP SYSTEM 28 HEADLAMP SYSTEM 14 System Diagram 28 System Description 28 Revision: 2008 December F EXL-1 J32 P WITH AFS 28 WITH AFS : Component Parts Location 29 Description 56 DTC Logic 56 Diagnosis Procedure 56 Component Inspection 58 WITHOUT AFS 29 WITHOUT AFS : Component Parts Location 30 Component Description 30 B2516 SHIFT SIGNAL [P, R] 59 PARKING, LICENSE PLATE AND TAIL LAMPS SYSTEM 31 Description 59 DTC Logic 59 Diagnosis Procedure 59 System Diagram 31 System Description 31 Component Parts Location 32 Component Description 32 REAR FOG LAMP SYSTEM 33 B2517 VEHICLE SPEED SIGNAL 60 Description 60 DTC Logic 60 Diagnosis Procedure 60 System Diagram 33 System Description 33 Component Parts Location 34 Component Description 34 B2519 LEVELIZER CALIBRATION 61 EXTERIOR LAMP BATTERY SAVER SYSTEM 35 B2521 ECU CIRCUIT 62 System Diagram 35 System Description 35 Component Parts Location 36 Component Description 36 DIAGNOSIS SYSTEM (BCM) 37 COMMON ITEM 37 COMMON ITEM : CONSULT-III Function (BCM COMMON ITEM) 37 HEADLAMP 38 HEADLAMP : CONSULT-III Function (BCM HEAD LAMP) 38 FLASHER 40 FLASHER : CONSULT-III Function (BCM FLASHER) 40 DIAGNOSIS SYSTEM (IPDM E/R) 42 Diagnosis Description 42 CONSULT-III Function (IPDM E/R) 44 DIAGNOSIS SYSTEM (AFS) 47 CONSULT-III Function (ADAPTIVE LIGHT) 47 DIAGNOSIS SYSTEM (HEADLAMP LEVELIZER) 49 CONSULT-III Functions (HEADLAMP LEVELIZER) 49 COMPONENT DIAGNOSIS 50 B2503, B2504 SWIVEL ACTUATOR 50 Description 50 DTC Logic 50 Diagnosis Procedure 51 Component Inspection 54 B2514 HEIGHT SENSOR UNUSUAL [RR] 56 Revision: 2008 December Description 61 DTC Logic 61 Diagnosis Procedure 61 Description 62 DTC Logic 62 Diagnosis Procedure 62 C0126 STEERING ANGLE SENSOR SIGNAL 65 Description 65 DTC Logic 65 Diagnosis Procedure 65 C0428 STEERING ANGLE SENSOR CALIBRATION 66 Description 66 DTC Logic 66 Diagnosis Procedure 66 U1000 CAN COMM CIRCUIT 67 Description 67 DTC Logic 67 Diagnosis Procedure 67 U1010 CONTROL UNIT (CAN) 68 DTC Logic 68 Diagnosis Procedure 68 B2080 ECU TROUBLE 69 Description 69 DTC Logic 69 Diagnosis Procedure 69 B2081 INITIAL NOT DONE 70 DTC Logic 70 Diagnosis Procedure 70 B2082 SENSOR OUT OF RANGE 71 DTC Logic 71 Diagnosis Procedure 71 B2083 SEN SIG NOT PLAUSIBLE 72 DTC Logic 72 Diagnosis Procedure 72 EXL-2 J32 B2084 VOLTAGE UNDER LIMIT .73 DTC Logic 73 Diagnosis Procedure 73 B2085 LOWBEAM SIG OPEN LINE 74 Description 74 DTC Logic 74 Diagnosis Procedure 74 B2086 FRQ OVER LIMIT 76 Description 76 DTC Logic 76 Diagnosis Procedure 76 B2087 SHORT TO GROUND .78 DTC Logic 78 Diagnosis Procedure 78 B2088 SHORT TO BATTERY 79 DTC Logic 79 Diagnosis Procedure 79 B208A PARA NOT PROG 80 DTC Logic 80 Diagnosis Procedure 80 POWER SUPPLY AND GROUND CIRCUIT 81 WITH AFS : Description 90 WITH AFS : Component Function Check 90 WITH AFS : Diagnosis Procedure 90 A WITHOUT AFS 91 WITHOUT AFS : Component Function Check 91 WITHOUT AFS : Diagnosis Procedure 92 B XENON HEADLAMP 94 C Description .94 Diagnosis Procedure .94 HEADLAMP LEVELIZER CIRCUIT 96 D WITH AFS 96 WITH AFS : Description 96 WITH AFS : Component Function Check 96 WITH AFS : Diagnosis Procedure 96 E WITHOUT AFS 97 WITHOUT AFS : Description 97 WITHOUT AFS : Component Function Check 97 WITHOUT AFS : Diagnosis Procedure 97 G FRONT FOG LAMP CIRCUIT 100 Component Function Check 100 Diagnosis Procedure 100 BCM (BODY CONTROL MODULE) 81 BCM (BODY CONTROL MODULE) : Diagnosis Procedure 81 PARKING LAMP CIRCUIT 102 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 81 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) : Diagnosis Procedure 81 TURN SIGNAL LAMP CIRCUIT 105 AFS CONTROL UNIT 82 AFS CONTROL UNIT : Diagnosis Procedure 82 F Component Function Check 102 Diagnosis Procedure 102 LHD 105 LHD : Description 105 LHD : Component Function Check 105 LHD : Diagnosis Procedure 105 H I J K RHD 108 RHD : Description 108 RHD : Component Function Check 108 RHD : Diagnosis Procedure 108 EXL OPTICAL SENSOR 112 M Description 85 Diagnosis Procedure 85 Description 112 Component Function Check 112 Diagnosis Procedure 112 N HEADLAMP (HI) CIRCUIT 86 HAZARD SWITCH 115 AUTO LEVELIZER CONTROL UNIT 83 AUTO LEVELIZER CONTROL UNIT : Diagnosis Procedure 83 EXTERIOR LAMP FUSE 85 Component Function Check 115 Diagnosis Procedure 115 WITH AFS 86 WITH AFS : Description 86 WITH AFS : Component Function Check 86 WITH AFS : Diagnosis Procedure 86 TAIL LAMP CIRCUIT 117 WITHOUT AFS 88 WITHOUT AFS : Component Function Check 88 WITHOUT AFS : Diagnosis Procedure 88 LICENSE PLATE LAMP CIRCUIT 119 HEADLAMP (LO) CIRCUIT 90 WITH AFS 90 Revision: 2008 December Component Function Check 117 Diagnosis Procedure 117 Component Function Check 119 Diagnosis Procedure 119 REAR FOG LAMP CIRCUIT 121 Component Function Check 121 EXL-3 J32 O P Diagnosis Procedure .121 HEADLAMP SYSTEM 123 Wiring Diagram - HEADLAMP - .123 AUTO LIGHT SYSTEM 128 LHD 128 LHD : Wiring Diagram - AUTO LIGHT SYSTEM - 128 AUTO LEVELIZER CONTROL UNIT 234 Reference Value 234 Wiring Diagram - HEADLAMP AIMING CONTROL SYSTEM - 236 Fail-safe 239 DTC Inspection Priority Chart 240 DTC Index 241 SYMPTOM DIAGNOSIS 242 RHD 131 RHD : Wiring Diagram - AUTO LIGHT SYSTEM - 132 EXTERIOR LIGHTING SYSTEM SYMPTOMS 242 FRONT FOG LAMP SYSTEM 136 Wiring Diagram - FRONT FOG LAMP - 136 WITH AFS 242 WITH AFS : Symptom Table 242 TURN SIGNAL AND HAZARD WARNING LAMP SYSTEM 139 WITHOUT AFS 244 WITHOUT AFS : Symptom Table 244 LHD 139 LHD : Wiring Diagram - TURN AND HAZARD WARNING LAMPS - 139 RHD 143 RHD : Wiring Diagram - TURN AND HAZARD WARNING LAMPS - 144 PARKING, LICENSE PLATE AND TAIL LAMPS SYSTEM 149 Wiring Diagram - PARKING, LICENSE PLATE AND TAIL LAMPS - .149 STOP LAMP 155 Wiring Diagram - STOP LAMP - 155 BACK-UP LAMP 159 NORMAL OPERATING CONDITION 247 Description 247 BOTH SIDE HEADLAMPS DO NOT SWITCH TO HIGH BEAM 248 WITH AFS 248 WITH AFS : Description 248 WITH AFS : Diagnosis Procedure 248 BOTH SIDE HEADLAMPS (HI) ARE NOT TURNED ON 249 WITHOUT AFS 249 WITHOUT AFS : Description 249 WITHOUT AFS : Diagnosis Procedure 249 Wiring Diagram - BACK-UP LAMP - 159 BOTH SIDE HEADLAMPS (LO) ARE NOT TURNED ON 250 REAR FOG LAMP SYSTEM 163 Description 250 Diagnosis Procedure 250 Wiring Diagram - REAR FOG LAMP - 163 ECU DIAGNOSIS 167 PARKING, LICENSE PLATE AND TAIL LAMPS ARE NOT TURNED ON 251 BCM (BODY CONTROL MODULE) 167 Description 251 Diagnosis Procedure 251 Reference Value 167 Wiring Diagram - BCM - 191 Fail-safe 204 DTC Inspection Priority Chart .206 DTC Index .207 BOTH SIDE FRONT FOG LAMPS ARE NOT TURNED ON 252 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 209 PRECAUTION 253 Reference Value 209 Wiring Diagram - IPDM E/R - 217 Fail-safe 220 DTC Index .222 AFS CONTROL UNIT 223 Reference Value 223 Wiring Diagram - ACTIVE AFS - 226 Fail-Safe 232 DTC Inspection Priority Chart 232 DTC Index .233 Revision: 2008 December Description 252 Diagnosis Procedure 252 PRECAUTIONS 253 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 253 Precautions For Xenon Headlamp Service 253 ON-VEHICLE MAINTENANCE 254 HEADLAMP AIMING ADJUSTMENT 254 WITH AFS 254 EXL-4 J32 WITH AFS : Description 254 WITH AFS : Aiming Adjustment Procedure 255 LHD 256 LHD : Description 256 LHD : Aiming Adjustment Procedure (Low Beam) 258 LHD : Aiming Adjustment Procedure (High Beam) 259 RHD 260 RHD : Description 260 RHD : Aiming Adjustment Procedure (Low Beam) 262 RHD : Aiming Adjustment Procedure (High Beam) 263 FRONT FOG LAMP AIMING ADJUSTMENT 265 Description 265 Aiming Adjustment Procedure 265 ON-VEHICLE REPAIR 267 FRONT COMBINATION LAMP 267 Removal and Installation 280 HEIGHT SENSOR 282 Exploded View 282 Removal and Installation 282 A B AUTO LEVELIZER CONTROL UNIT 283 Exploded View 283 Removal and Installation 283 C REAR COMBINATION LAMP 284 Exploded View 284 Removal and Installation 284 Replacement 285 D HIGH-MOUNTED STOP LAMP 286 E Exploded View 286 Removal and Installation 286 REAR FOG LAMP 287 F Exploded View 287 Removal and Installation 287 Replacement 287 G WITH AFS 267 WITH AFS : Exploded View 267 WITH AFS : Removal and Installation 268 WITH AFS : Replacement 268 WITH AFS : Disassembly and Assembly 268 LICENSE PLATE LAMP 288 H WITHOUT AFS 269 WITHOUT AFS : Exploded View 269 WITHOUT AFS : Removal and Installation 270 WITHOUT AFS : Replacement 270 WITHOUT AFS : Disassembly and Assembly 271 Exploded View 288 Removal and Installation 288 Replacement 288 SERVICE DATA AND SPECIFICATIONS (SDS) 290 I SERVICE DATA AND SPECIFICATIONS (SDS) 290 J FRONT FOG LAMP 272 Exploded View 272 Removal and Installation 272 Replacement 272 WITH AFS 290 WITH AFS : Bulb Specifications 290 OPTICAL SENSOR 274 WITHOUT AFS 290 WITHOUT AFS : Bulb Specifications 290 Exploded View 274 Removal and Installation 274 LIGHTING & TURN SIGNAL SWITCH 275 Exploded View 275 HAZARD SWITCH 276 Exploded View 276 Removal and Installation 276 AFS CONTROL UNIT 277 Exploded View 277 Removal and Installation 277 STEERING ANGLE SENSOR 278 EXL HALOGEN TYPE BASIC INSPECTION 291 DIAGNOSIS AND REPAIR WORKFLOW 291 FUNCTION DIAGNOSIS 293 System Diagram 293 System Description 293 Component Parts Location 294 Component Description 294 AFS OFF SWITCH 279 System Diagram 295 System Description 295 Component Parts Location 296 Component Description 296 Exploded View 280 Revision: 2008 December N HEADLAMP SYSTEM 293 AUTO LIGHT SYSTEM 295 SIDE TURN SIGNAL LAMP 280 M Work Flow 291 Removal and Installation 278 Exploded View 279 Removal and Installation 279 K FRONT FOG LAMP SYSTEM 297 EXL-5 J32 O P System Diagram 297 System Description 297 Component Parts Location 298 Component Description 298 TURN SIGNAL AND HAZARD WARNING LAMP SYSTEM 299 System Diagram 299 System Description 299 Component Parts Location 300 Component Description 300 PARKING, LICENSE PLATE AND TAIL LAMPS SYSTEM 301 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) : Diagnosis Procedure 317 EXTERIOR LAMP FUSE 319 Description 319 Diagnosis Procedure 319 HEADLAMP (HI) CIRCUIT 320 Component Function Check 320 Diagnosis Procedure 320 HEADLAMP (LO) CIRCUIT 322 Component Function Check 322 Diagnosis Procedure 322 System Diagram 301 System Description 301 Component Parts Location 302 Component Description 302 FRONT FOG LAMP CIRCUIT 324 REAR FOG LAMP SYSTEM 303 PARKING LAMP CIRCUIT 326 System Diagram 303 System Description 303 Component Parts Location 304 Component Description 304 EXTERIOR LAMP BATTERY SAVER SYSTEM 305 System Diagram 305 System Description 305 Component Parts Location 306 Component Description 306 DIAGNOSIS SYSTEM (BCM) 307 COMMON ITEM .307 COMMON ITEM : CONSULT-III Function (BCM COMMON ITEM) 307 HEADLAMP .308 HEADLAMP : CONSULT-III Function (BCM HEAD LAMP) 308 Component Function Check 324 Diagnosis Procedure 324 Component Function Check 326 Diagnosis Procedure 326 TURN SIGNAL LAMP CIRCUIT 328 LHD 328 LHD : Description 328 LHD : Component Function Check 328 LHD : Diagnosis Procedure 328 RHD 331 RHD : Description 331 RHD : Component Function Check 331 RHD : Diagnosis Procedure 331 OPTICAL SENSOR 335 Description 335 Component Function Check 335 Diagnosis Procedure 335 HAZARD SWITCH 338 Component Function Check 338 Diagnosis Procedure 338 FLASHER 310 FLASHER : CONSULT-III Function (BCM FLASHER) .310 TAIL LAMP CIRCUIT 340 DIAGNOSIS SYSTEM (IPDM E/R) 312 Component Function Check 340 Diagnosis Procedure 340 Diagnosis Description 312 CONSULT-III Function (IPDM E/R) .314 LICENSE PLATE LAMP CIRCUIT 342 COMPONENT DIAGNOSIS 317 Component Function Check 342 Diagnosis Procedure 342 POWER SUPPLY AND GROUND CIRCUIT 317 REAR FOG LAMP CIRCUIT 344 BCM (BODY CONTROL MODULE) 317 BCM (BODY CONTROL MODULE) : Diagnosis Procedure 317 Component Function Check 344 Diagnosis Procedure 344 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 317 HEADLAMP SYSTEM 346 Wiring Diagram - HEADLAMP - 346 AUTO LIGHT SYSTEM 350 LHD 350 Revision: 2008 December EXL-6 J32 LHD : Wiring Diagram - AUTO LIGHT SYSTEM - 350 RHD 353 RHD : Wiring Diagram - AUTO LIGHT SYSTEM - 354 HEADLAMP AIMING CONTROL SYSTEM (MANUAL) 358 Description 358 Wiring Diagram - HEADLAMP AIMING CONTROL SYSTEM (MANUAL) - 358 Component Inspection 359 FRONT FOG LAMP SYSTEM 361 Wiring Diagram - FRONT FOG LAMP - 361 TURN SIGNAL AND HAZARD WARNING LAMP SYSTEM 364 LHD 364 LHD : Wiring Diagram - TURN AND HAZARD WARNING LAMPS - 364 RHD 368 RHD : Wiring Diagram - TURN AND HAZARD WARNING LAMPS - 369 PARKING, LICENSE PLATE AND TAIL LAMPS SYSTEM 374 Wiring Diagram - PARKING, LICENSE PLATE AND TAIL LAMPS - 374 STOP LAMP 380 Wiring Diagram - STOP LAMP - 380 BACK-UP LAMP 384 Wiring Diagram - BACK-UP LAMP - 384 REAR FOG LAMP SYSTEM 388 Wiring Diagram - REAR FOG LAMP - 388 ECU DIAGNOSIS 392 BCM (BODY CONTROL MODULE) 392 BOTH SIDE HEADLAMPS (HI) ARE NOT TURNED ON 451 BOTH SIDE HEADLAMPS (LO) ARE NOT TURNED ON 452 C PARKING, LICENSE PLATE AND TAIL LAMPS ARE NOT TURNED ON 453 D Description 453 Diagnosis Procedure 453 BOTH SIDE FRONT FOG LAMPS ARE NOT TURNED ON 454 Description 454 Diagnosis Procedure 454 G Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 455 H ON-VEHICLE MAINTENANCE 456 HEADLAMP AIMING ADJUSTMENT 456 I LHD 456 LHD : Description 456 LHD : Aiming Adjustment Procedure (Low Beam) 457 LHD : Aiming Adjustment Procedure (High Beam) 458 J RHD 460 RHD : Description 460 RHD : Aiming Adjustment Procedure (Low Beam) 462 RHD : Aiming Adjustment Procedure (High Beam) 463 FRONT COMBINATION LAMP 467 Symptom Table 448 Description 465 Aiming Adjustment Procedure 465 ON-VEHICLE REPAIR 467 Exploded View 467 Removal and Installation 467 Replacement 468 Disassembly and Assembly 468 FRONT FOG LAMP 470 Exploded View 470 Removal and Installation 470 Replacement 470 OPTICAL SENSOR 472 Exploded View 472 Removal and Installation 472 Revision: 2008 December F PRECAUTIONS 455 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 434 EXTERIOR LIGHTING SYSTEM SYMPTOMS 448 E PRECAUTION 455 FRONT FOG LAMP AIMING ADJUSTMENT 465 SYMPTOM DIAGNOSIS 448 B Description 452 Diagnosis Procedure 452 Reference Value 392 Wiring Diagram - BCM - 416 Fail-safe 429 DTC Inspection Priority Chart 431 DTC Index 432 Reference Value 434 Wiring Diagram - IPDM E/R - 442 Fail-safe 445 DTC Index 447 A Description 451 Diagnosis Procedure 451 EXL-7 J32 K EXL M N O P LIGHTING & TURN SIGNAL SWITCH 473 HIGH-MOUNTED STOP LAMP 480 Exploded View .473 Exploded View 480 Removal and Installation 480 HEADLAMP AIMING SWITCH 474 Exploded View .474 Removal and Installation .474 HAZARD SWITCH 475 Exploded View .475 Removal and Installation .475 SIDE TURN SIGNAL LAMP 476 Exploded View .476 Removal and Installation .476 REAR COMBINATION LAMP 478 Exploded View .478 Removal and Installation .478 Replacement 479 REAR FOG LAMP 481 Exploded View 481 Removal and Installation 481 Replacement 481 LICENSE PLATE LAMP 482 Exploded View 482 Removal and Installation 482 Replacement 482 SERVICE DATA AND SPECIFICATIONS (SDS) 484 SERVICE DATA AND SPECIFICATIONS (SDS) 484 Bulb Specifications 484 Revision: 2008 December EXL-8 J32 DIAGNOSIS AND REPAIR WORKFLOW [XENON TYPE] < BASIC INSPECTION > BASIC INSPECTION A DIAGNOSIS AND REPAIR WORKFLOW Work Flow INFOID:0000000003839190 B OVERALL SEQUENCE C D E F G H I J K EXL M N O P JPLIA0313GB DETAILED FLOW 1.INTERVIEW FOR MALFUNCTION Interview the symptom to the customer Revision: 2008 December EXL-9 J32 DIAGNOSIS AND REPAIR WORKFLOW [XENON TYPE] < BASIC INSPECTION > >> GO TO 2.SYMPTOM CHECK Check the symptom from the customer's information >> GO TO 3.BASIC INSPECTION Check the operation of each part Check that any symptom occurs other than the interviewed symptom >> GO TO 4.SELF-DIAGNOSIS WITH CONSULT-III Perform the self-diagnosis with CONSULT-III Check that any DTC is detected Is any DTC detected? YES >> GO TO NO >> GO TO 5.TROUBLE DIAGNOSIS BY DTC Perform the trouble diagnosis for the detected DTC Specify the malfunctioning part >> GO TO 6.FAIL-SAFE ACTIVATION CHECK Check that the symptom is applied to the fail-safe activation Does the fail-safe activate? YES >> GO TO NO >> GO TO 7.SYSTEM DIAGNOSIS Perform the system diagnosis for the system that the fail-safe activates Specify the malfunctioning part >> GO TO 8.SYMPTOM DIAGNOSIS Perform the symptom diagnosis Specify the malfunctioning part >> GO TO 9.MALFUNCTION PART REPAIR Repair or replace the malfunctioning part >> GO TO 10 10.REPAIR CHECK (SELF-DIAGNOSIS WITH CONSULT-III) Perform the self-diagnosis with CONSULT-III Check that any DTC is not detected Erase DTC if DTC is detected before the repair Check that DTC is not detected again Is any DTC detected? YES >> GO TO NO >> GO TO 11 11.REPAIR CHECK (OPERATION CHECK) Check the operation of each part Does it operate normally? YES >> INSPECTION END NO >> GO TO Revision: 2008 December EXL-10 J32 SERVICE DATA AND SPECIFICATIONS (SDS) [VQ25DE, VQ35DE] < SERVICE DATA AND SPECIFICATIONS (SDS) Unit: mm (in) A EM C D SEM645 SBIA0535E Engine Main journal diameter “Dm” grade Pin journal diameter “Dp” grade VQ25DE Standard Standard Center distance “r” Taper (Difference between “A” and “B”) Out-of-round (Difference between “X” and “Y”) Crankshaft runout [TIR*] Crankshaft end play VQ35DE E 59.975 - 59.974 (2.3612 - 2.3612) 59.974 - 59.973 (2.3612 - 2.3611) 59.973 - 59.972 (2.3611 - 2.3611) 59.972 - 59.971 (2.3611 - 2.3611) 59.971 - 59.970 (2.3611 - 2.3610) 59.970 - 59.969 (2.3610 - 2.3610) 59.969 - 59.968 (2.3610 - 2.3609) 59.968 - 59.967 (2.3609 - 2.3609) 59.967 - 59.966 (2.3609 - 2.3609) 59.966 - 59.965 (2.3609 - 2.3608) 59.965 - 59.964 (2.3608 - 2.3608) 59.964 - 59.963 (2.3608 - 2.3607) 59.963 - 59.962 (2.3607 - 2.3607) 59.962 - 59.961 (2.3607 - 2.3607) 59.961 - 59.960 (2.3607 - 2.3606) 59.960 - 59.959 (2.3606 - 2.3606) 59.959 - 59.958 (2.3606 - 2.3605) 59.958 - 59.957 (2.3605 - 2.3605) 59.957 - 59.956 (2.3605 - 2.3605) 59.956 - 59.955 (2.3605 - 2.3604) 59.955 - 59.954 (2.3604 - 2.3604) 59.954 - 59.953 (2.3604 - 2.3603) 59.953 - 59.952 (2.3603 - 2.3603) 59.952 - 59.951 (2.3603 - 2.3603) Grade No A Grade No B Grade No C Grade No D Grade No E Grade No F Grade No G Grade No H Grade No J Grade No K Grade No L Grade No M Grade No N Grade No P Grade No R Grade No S Grade No T Grade No U Grade No V Grade No W Grade No X Grade No Y Grade No Grade No F G H I J K Grade No 44.968 - 44.974 (1.7704 - 1.7706) 51.968 - 51.974 (2.0460 - 2.0462) Grade No 44.962 - 44.968 (1.7702 - 1.7704) 51.962 - 51.968 (2.0457 - 2.0460) Grade No 44.956 - 44.962 (1.7699 - 1.7702) 51.956 - 51.962 (2.0455 - 2.0457) 36.61 - 36.69 (1.4413 - 1.4445) 40.66 - 40.74 (1.6008 - 1.6039) M 0.002 (0.0001) Limit 0.002 (0.0001) Standard N Less than 0.05 (0.0020) Limit 0.10 (0.0039) Standard O 0.10 - 0.25 (0.0039 - 0.0098) Limit 0.30 (0.0118) P *: Total indicator reading Main Bearing INFOID:0000000003802400 MAIN BEARING Revision: 2008 December L EM-271 J32 SERVICE DATA AND SPECIFICATIONS (SDS) [VQ25DE, VQ35DE] < SERVICE DATA AND SPECIFICATIONS (SDS) Unit: mm (in) PBIC2619E Grade number Thickness 2.000 - 2.003 (0.0787 - 0.0789) Black 2.003 - 2.006 (0.0789 - 0.0790) Brown 2.006 - 2.009 (0.0790 - 0.0791) Green 2.009 - 2.012 (0.0791 - 0.0792) Yellow 2.012 - 2.015 (0.0792 - 0.0793) Blue 2.015 - 2.018 (0.0793 - 0.0794) Pink 2.018 - 2.021 (0.0794 - 0.0796) Purple 01 12 23 34 45 56 67 Width Identification color 2.021 - 2.024 (0.0796 - 0.0797) White UPR 2.003 - 2.006 (0.0789 - 0.0790) Brown LWR 2.000 - 2.003 (0.0787 - 0.0789) Black UPR 2.006 - 2.009 (0.0790 - 0.0791) LWR 2.003 - 2.006 (0.0789 - 0.0790) UPR 2.009 - 2.012 (0.0791 - 0.0792) Yellow LWR 2.006 - 2.009 (0.0790 - 0.0791) Green UPR 2.012 - 2.015 (0.0792 - 0.0793) Blue LWR 2.009 - 2.012 (0.0791 - 0.0792) Yellow UPR 2.015 - 2.018 (0.0793 - 0.0794) Pink LWR 2.012 - 2.015 (0.0792 - 0.0793) Blue UPR 2.018 - 2.021 (0.0794 - 0.0796) Purple LWR 2.015 - 2.018 (0.0793 - 0.0794) Pink UPR 2.021 - 2.024 (0.0796 - 0.0797) White LWR 2.018 - 2.021 (0.0794 - 0.0796) Purple 19.9 - 20.1 (0.783 - 0.791) Remarks Grade is the same for upper and lower bearings Green Brown Grade and color are different for upper and lower bearings UNDERSIZE Unit: mm (in) Items Thickness Main journal diameter 0.25 (0.0098) 2.132 - 2.140 (0.0839 - 0.0843) Grind so that bearing clearance is the specified value MAIN BEARING OIL CLEARANCE Unit: mm (in) Items Main bearing oil clearance Standard Limit 0.035 - 0.045 (0.0014 - 0.0018)* 0.065 (0.0026) *: Actual clearance Connecting Rod Bearing INFOID:0000000003802401 CONNECTING ROD BEARING Revision: 2008 December EM-272 J32 SERVICE DATA AND SPECIFICATIONS (SDS) [VQ25DE, VQ35DE] < SERVICE DATA AND SPECIFICATIONS (SDS) Unit: mm (in) Grade number Thickness Identification color (mark) 1.500 - 1.503 (0.0591 - 0.0592) Black 1.503 - 1.506 (0.0592 - 0.0593) Brown 1.506 - 1.509 (0.0593 - 0.0594) Green A EM UNDERSIZE Unit: mm (in) Items Thickness 0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643) C Crank pin journal diameter Grind so that bearing clearance is the specified value D CONNECTING ROD BEARING OIL CLEARANCE Unit: mm (in) Items Connecting rod bearing oil clearance Standard Limit 0.020 - 0.045 (0.0008 - 0.0018)* 0.070 (0.0028) E *: Actual clearance F G H I J K L M N O P Revision: 2008 December EM-273 J32 ENGINE SECTION EX EXHAUST SYSTEM A EX C D E CONTENTS F MR20DE VQ25DE, VQ35DE PRECAUTION PRECAUTION PRECAUTIONS PRECAUTIONS Removal and Installation Removal and Installation PREPARATION PREPARATION PREPARATION PREPARATION Special Service Tools Commercial Service Tools Commercial Service Tool ON-VEHICLE MAINTENANCE ON-VEHICLE REPAIR H I ON-VEHICLE MAINTENANCE 10 EXHAUST SYSTEM 10 EXHAUST SYSTEM Inspection G J Inspection 10 ON-VEHICLE REPAIR 11 K EXHAUST SYSTEM 11 EXHAUST SYSTEM Exploded View Removal and Installation Inspection Exploded View 11 Removal and Installation 11 Inspection 12 L M N O P Revision: 2008 December EX-1 J32 PRECAUTIONS [MR20DE] < PRECAUTION > PRECAUTION PRECAUTIONS Removal and Installation INFOID:0000000003801902 CAUTION: • Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape • Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops • Be careful not to cut your hand on the heat insulator edge Revision: 2008 December EX-2 J32 PREPARATION [MR20DE] < PREPARATION > PREPARATION A PREPARATION Special Service Tools INFOID:0000000003801903 Tool number Tool name KV10114400 Heated oxygen sensor wrench EX Description C Loosening or tightening heated oxygen sensor a: For 22 mm (0.87 in) width hexagon nut D E S-NT636 Commercial Service Tools INFOID:0000000003801904 Tool name Description Power tool Loosening nuts and bolts F G H I PBIC0190E Heated oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a: 18 mm (0.71 in) dia for zirconia heated oxygen sensor b: 12 mm (0.47 in) dia for titania heated oxygen sensor J K AEM488 Lubricating heated oxygen sensor thread cleaner when reconditioning exhaust system threads Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) L M N AEM489 O P Revision: 2008 December EX-3 J32 EXHAUST SYSTEM [MR20DE] < ON-VEHICLE MAINTENANCE > ON-VEHICLE MAINTENANCE EXHAUST SYSTEM Inspection INFOID:0000000003801905 Check exhaust pipes, muffler, and mounting for improper attachment, leakage, cracks, damage or deterioration • If anything is found, repair or replace damaged parts SMA211A Revision: 2008 December EX-4 J32 EXHAUST SYSTEM [MR20DE] < ON-VEHICLE REPAIR > ON-VEHICLE REPAIR A EXHAUST SYSTEM Exploded View INFOID:0000000003801906 EX C D E F G H I J K JPBIA2217GB Main muffler (RH) Mounting rubber Heated oxygen sensor Exhaust front tube Seal bearing Stud bolt Spring Mounting rubber Mounting rubber bracket (RH) 10 Seal bearing 11 Spring 12 Bolt 13 Mounting rubber bracket (LH) 14 Mounting rubber 15 Main muffler (LH) 16 Ring gasket 17 Mounting rubber 18 Center muffler L M Refer to GI-4, "Components" for symbols in the figure N Removal and Installation INFOID:0000000003801907 REMOVAL O • Disconnect each joint and mounting • Remove heated oxygen sensor with following procedure P Revision: 2008 December EX-5 J32 EXHAUST SYSTEM < ON-VEHICLE REPAIR > - Using heated oxygen sensor wrench [SST: KV10114400] (A), removal heated oxygen sensor (1) CAUTION: Be careful not to damage heated oxygen sensor [MR20DE] JPBIA0460ZZ INSTALLATION Note the following, and install in the reverse order of removal CAUTION: • Always replace seal bearings with new ones when reassembling • Discard any heated oxygen sensor which has been dropped onto a hard surface such as a concrete floor Use a new one • Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxygen sensor thread cleaner and apply anti-seize lubricant (commercial service tool) • Never over torque heated oxygen sensor Doing so may cause damage to the heated oxygen sensor 2, resulting in the “MIL” coming on • If heat insulator is badly deformed, repair or replace it If deposits such as mud pile up on the heat insulator, remove them • When installing heat insulator avoid large gaps or interference between heat insulator and each exhaust pipe • Remove deposits from the sealing surface of each connection Connect them securely to avoid gas leakage • When installing each mounting rubber, use silicon oil to avoid twisting • Temporarily tighten mounting nuts and bolts Check each part for unusual interference and mounting rubber interference, and then tighten them to the specified torque • When installing each mounting rubber, avoid twisting or unusual extension in up/down, front/rear and right/left directions Exhaust Manifold to Exhaust Front Tube Securely insert seal bearing (2) into exhaust manifold (1) side in the direction shown in the figure 3 : Spring : Nut : Stud bolt : Exhaust front tube CAUTION: Be careful not to damage seal bearing surface when installing JPBIA2372ZZ With spring, tighten nut CAUTION: • Fasten stud bolts to the flange of exhaust manifold side to the specified torque before fastening mounting nuts • Ensure springs are seated correctly on the flange and not sitting on (A) • Be careful that stud bolt does not interfere with mounting hole of exhaust front tube ( ) After installing, check that stud bolt does not interfere with mounting hole of exhaust front tube Exhaust Front Tube to Center Muffler Revision: 2008 December EX-6 J32 EXHAUST SYSTEM < ON-VEHICLE REPAIR > Securely insert seal bearing (2) into exhaust front tube (1) side in the direction shown in the figure 3 : Spring : Bolt : Center muffler [MR20DE] A EX CAUTION: Be careful not to damage seal bearing surface when installing With spring, tighten bolt CAUTION: • Ensure springs are seated correctly on the flange and not sitting on (A) • Be careful that bolt does not interfere with mounting hole of center muffler ( ) After installing, check that bolt does not interfere with mounting hole of center muffler Inspection C JPBIA2174ZZ D E INFOID:0000000003801908 INSPECTION AFTER INSTALLATION F • Check clearance between tail tube and rear bumper is even • With engine running, check exhaust tube joints for gas leakage and unusual noises • Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue stress Improper installation could result in excessive noise and vibration G H I J K L M N O P Revision: 2008 December EX-7 J32 PRECAUTIONS [VQ25DE, VQ35DE] < PRECAUTION > PRECAUTION PRECAUTIONS Removal and Installation INFOID:0000000003801909 CAUTION: • Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape • Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops • Be careful not to cut your hand on the heat insulator edge Revision: 2008 December EX-8 J32 PREPARATION [VQ25DE, VQ35DE] < PREPARATION > PREPARATION A PREPARATION Commercial Service Tool INFOID:0000000003801910 Tool name Description Power tool Loosening nuts and bolts EX C D E PBIC0190E F G H I J K L M N O P Revision: 2008 December EX-9 J32 EXHAUST SYSTEM [VQ25DE, VQ35DE] < ON-VEHICLE MAINTENANCE > ON-VEHICLE MAINTENANCE EXHAUST SYSTEM Inspection INFOID:0000000003801911 Check exhaust pipes, muffler, and mounting for improper attachment, leakage, cracks, damage or deterioration • If anything is found, repair or replace damaged parts SMA211A Revision: 2008 December EX-10 J32 EXHAUST SYSTEM [VQ25DE, VQ35DE] < ON-VEHICLE REPAIR > ON-VEHICLE REPAIR A EXHAUST SYSTEM Exploded View INFOID:0000000003801912 EX C D E F G H I J K L M JPBIA2498GB Main muffler (RH) Exhaust front tube Bracket (for China) Mounting rubber Gasket Ring gasket Mounting rubber Mounting rubber Center muffler 10 Mounting rubber 11 Main muffler (LH) 13 Mounting rubber 14 Dynamic damper A N 12 Ring gasket O Premium grade models (for China) Refer to GI-4, "Components" for symbols in the figure Removal and Installation INFOID:0000000003801913 REMOVAL Disconnect each joint and mounting using power tool INSTALLATION Note the following, and install in the reverse order of removal • If exhaust front tube stud bolts were removed, and install them and tighten to the specified torque below Revision: 2008 December EX-11 J32 P EXHAUST SYSTEM [VQ25DE, VQ35DE] < ON-VEHICLE REPAIR > : 14.7 N·m (1.5 kg-m, 11 ft-lb) CAUTION: • Always replace exhaust tube gaskets with new ones when reassembling • If heat insulator is badly deformed, repair or replace exhaust front tube/center muffler If deposits such as mud pile up on the heat insulator, remove them • Remove deposits from the sealing surface of each connection Connect them securely to avoid gases leakage • When installing each mounting rubber, use silicon oil to avoid twisting • Temporarily tighten mounting nuts and bolts Check each part for unusual interference, and then tighten them to the specified torque • When installing each mounting rubber, avoid twisting or unusual extension in up/down, front/rear and right/left directions Inspection INFOID:0000000003801914 INSPECTION AFTER INSTALLATION • Check clearance between tail tube and rear bumper is even • With engine running, check exhaust tube joints for gas leakage and unusual noises • Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue stress Improper installation could result in excessive noise and vibration Revision: 2008 December EX-12 J32