Nissan teana j32 esm tai lieu sua chua phan 3

Tài liệu hướng dẫn sửa chữa xe Nissan teana j32 esm tai lieu sua chua phan 3 . Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, sưa chữa nhanh chóng, chính xác, kịp thời, hợp lý

VENTILATION, HEATER & AIR CONDITIONER SECTION HA HEATER & AIR CONDITIONING SYSTEM A B C D E CONTENTS MR20DE COMPRESSOR 22 BASIC INSPECTION General Precautions 22 LEAK DETECTION DYE 23 DIAGNOSIS AND REPAIR WORK FLOW Work Flow FUNCTION DIAGNOSIS F General Precautions 23 G PREPARATION 24 H PREPARATION 24 REFRIGERATION SYSTEM Special Service Tool 24 Commercial Service Tools .25 Sealant or/and Lubricant 26 System Diagram System Description Component Parts Location Component Description ON-VEHICLE MAINTENANCE 28 SYMPTOM DIAGNOSIS REFRIGERANT 28 HA J Collection and Charge .28 REFRIGERATION SYSTEM SYMPTOMS Trouble Diagnosis For Unusual Pressure Symptom Table LUBRICANT 32 K Maintenance of Lubricant Quantity 32 Lubricant Adjusting Procedure for Components Replacement Except Compressor 32 Lubricant Adjusting Procedure for Compressor Replacement 33 L REFRIGERATION SYSTEM 34 M COMPRESSOR SYSTEM SYMPTOMS .12 Symptom Table 12 PRECAUTION 13 PRECAUTIONS 13 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 13 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect 13 Precaution for Procedure without Cowl Top Cover 14 Working with HFC-134a (R-134a) 14 General Refrigerant Precaution 14 LHD MODELS 14 LHD MODELS : Refrigerant Connection 15 RHD MODELS 17 RHD MODELS : Refrigerant Connection 17 Service Equipment 19 Revision: 2008 December Inspection 34 Performance Chart 34 Refrigerant Leakages 35 N FLUORESCENT LEAK DETECTOR 36 Inspection 36 O ELECTRICAL LEAK DETECTOR 37 LHD MODELS 37 LHD MODELS : Inspection 37 RHD MODELS 39 RHD MODELS : Inspection .39 ON-VEHICLE REPAIR 43 HA-1 J32 P COMPRESSOR 43 Exploded View 43 Removal and Installation 43 Inspection 44 COOLER PIPE AND HOSE 45 Exploded View 45 LOW-PRESSURE FLEXIBLE HOSE 46 LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation 46 HIGH-PRESSURE FLEXIBLE HOSE 47 HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation 47 LOW-PRESSURE PIPE 47 LOW-PRESSURE PIPE : Removal and Installation (LHD models) 47 LOW-PRESSURE PIPE : Removal and Installation (RHD models) 48 SERVICE DATA AND SPECIFICATIONS (SDS) 63 SERVICE DATA AND SPECIFICATIONS (SDS) 63 Compressor 63 Lubricant 63 Refrigerant 63 Engine Idling Speed 63 Belt Tension 63 VQ25DE, VQ35DE BASIC INSPECTION 64 DIAGNOSIS AND REPAIR WORK FLOW 64 Work Flow 64 FUNCTION DIAGNOSIS 66 REFRIGERATION SYSTEM 66 System Diagram 66 System Description 66 Component Parts Location 67 Component Description 68 HIGH-PRESSURE PIPE 49 HIGH-PRESSURE PIPE : Removal and Installation (LHD models) 49 HIGH-PRESSURE PIPE : Removal and Installation (RHD models) 50 SYMPTOM DIAGNOSIS 69 CONDENSER 52 REFRIGERATION SYSTEM SYMPTOMS 69 Exploded View 52 Trouble Diagnosis For Unusual Pressure 69 Symptom Table 69 CONDENSER 52 CONDENSER : Removal and Installation 52 COMPRESSOR SYSTEM SYMPTOMS 72 CONDENSER PIPE ASSEMBLY 53 CONDENSER PIPE ASSEMBLY : Removal and Installation 53 LIQUID TANK 53 LIQUID TANK : Removal and Installation 53 REFRIGERANT PRESSURE SENSOR 54 REFRIGERANT PRESSURE SENSOR : Removal and Installation 54 HEATER & COOLING UNIT ASSEMBLY 55 Exploded View 55 HEATER & COOLING UNIT ASSEMBLY 57 HEATER & COOLING UNIT ASSEMBLY : Removal and Installation 57 HEATER CORE 59 HEATER CORE : Removal and Installation 59 Symptom Table 72 PRECAUTION 73 PRECAUTIONS 73 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 73 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect 73 Precaution for Procedure without Cowl Top Cover 74 Working with HFC-134a (R-134a) 74 General Refrigerant Precaution 74 LHD MODELS 74 LHD MODELS : Refrigerant Connection 75 RHD MODELS 77 RHD MODELS : Refrigerant Connection 77 Service Equipment 79 EVAPORATOR 60 EVAPORATOR : Removal and Installation 60 COMPRESSOR 82 EVAPORATOR PIPE ASSEMBLY 60 EVAPORATOR PIPE ASSEMBLY : Removal and Installation 60 LEAK DETECTION DYE 83 EXPANSION VALVE 61 EXPANSION VALVE : Removal and Installation 62 Revision: 2008 December General Precautions 82 General Precautions 83 PREPARATION 84 PREPARATION 84 HA-2 J32 Special Service Tool 84 Commercial Service Tools 85 Sealant or/and Lubricant 86 ON-VEHICLE MAINTENANCE 88 HIGH-PRESSURE PIPE 110 HIGH-PRESSURE PIPE : Removal and Installation (LHD models) 110 HIGH-PRESSURE PIPE : Removal and Installation (RHD models) 111 REFRIGERANT 88 CONDENSER 113 Collection and Charge 88 Exploded View 113 LUBRICANT .92 CONDENSER 113 CONDENSER : Removal and Installation 113 Maintenance of Lubricant Quantity 92 Lubricant Adjusting Procedure for Components Replacement Except Compressor 92 Lubricant Adjusting Procedure for Compressor Replacement 93 REFRIGERATION SYSTEM 94 Inspection 94 Performance Chart 94 Refrigerant Leakages 95 CONDENSER PIPE ASSEMBLY 114 CONDENSER PIPE ASSEMBLY : Removal and Installation 114 LIQUID TANK 114 LIQUID TANK : Removal and Installation 114 A B C D E F FLUORESCENT LEAK DETECTOR 96 REFRIGERANT PRESSURE SENSOR 115 REFRIGERANT PRESSURE SENSOR : Removal and Installation 115 Inspection 96 HEATER & COOLING UNIT ASSEMBLY 116 G ELECTRICAL LEAK DETECTOR 97 Exploded View 116 LHD MODELS 97 LHD MODELS : Inspection 97 HEATER & COOLING UNIT ASSEMBLY 118 HEATER & COOLING UNIT ASSEMBLY : Removal and Installation 118 H HEATER CORE 120 HEATER CORE : Removal and Installation 120 HA RHD MODELS 99 RHD MODELS : Inspection 99 ON-VEHICLE REPAIR 103 COMPRESSOR 103 EVAPORATOR 121 EVAPORATOR : Removal and Installation 121 J Exploded View 103 Removal and Installation 103 Inspection 104 EVAPORATOR PIPE ASSEMBLY 121 EVAPORATOR PIPE ASSEMBLY : Removal and Installation 121 K COOLER PIPE AND HOSE 105 Exploded View 105 EXPANSION VALVE 122 EXPANSION VALVE : Removal and Installation 123 L LOW-PRESSURE FLEXIBLE HOSE 106 LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation 106 SERVICE DATA AND SPECIFICATIONS (SDS) 124 M HIGH-PRESSURE FLEXIBLE HOSE 107 HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation 107 SERVICE DATA AND SPECIFICATIONS (SDS) 124 LOW-PRESSURE PIPE 108 LOW-PRESSURE PIPE : Removal and Installation (LHD models) 108 LOW-PRESSURE PIPE : Removal and Installation (RHD models) 109 Revision: 2008 December HA-3 Compressor 124 Lubricant 124 Refrigerant 124 Engine Idling Speed 124 Belt Tension 124 N O P J32 DIAGNOSIS AND REPAIR WORK FLOW [MR20DE] < BASIC INSPECTION > BASIC INSPECTION DIAGNOSIS AND REPAIR WORK FLOW Work Flow INFOID:0000000004280954 OVERALL SEQUENCE JPLIA0313GB DETAILED FLOW 1.INTERVIEW FOR MALFUNCTION Interview the symptom to the customer Revision: 2008 December HA-4 J32 DIAGNOSIS AND REPAIR WORK FLOW [MR20DE] < BASIC INSPECTION > >> GO TO 2.SYMPTOM CHECK A Check the symptom from the customer's information B >> GO TO 3.BASIC INSPECTION C Check the operation of each part Check that any symptom occurs other than the interviewed symptom >> GO TO D 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 E F 5.TROUBLE DIAGNOSIS BY DTC Perform the trouble diagnosis for the detected DTC Specify the malfunctioning part G >> GO TO 6.FAIL-SAFE ACTIVATION CHECK H Check that the symptom is applied to the fail-safe activation Does the fail-safe activate? YES >> GO TO NO >> GO TO HA 7.SYSTEM DIAGNOSIS J Perform the system diagnosis for the system that the fail-safe activates Specify the malfunctioning part >> GO TO K 8.SYMPTOM DIAGNOSIS Perform the symptom diagnosis Specify the malfunctioning part L >> GO TO 9.MALFUNCTION PART REPAIR M Repair or replace the malfunctioning part N >> 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 HA-5 J32 O P REFRIGERATION SYSTEM [MR20DE] < FUNCTION DIAGNOSIS > FUNCTION DIAGNOSIS REFRIGERATION SYSTEM System Diagram INFOID:0000000003839501 RJIA1552E System Description INFOID:0000000003839502 REFRIGERANT CYCLE Refrigerant Flow The refrigerant flows from the compressor, through the condenser with a liquid tank, through the evaporator, and then back to the compressor The refrigerant evaporation in the evaporator is controlled by an externally equalized expansion valve Freeze Protection To prevent the evaporator from freezing up, the evaporator air temperature is monitored, and the voltage signal to the A/C auto amp turns the A/C relay OFF and stops the compressor REFRIGERANT SYSTEM PROTECTION Refrigerant Pressure Sensor The refrigerant system is protected against excessively high or low-pressures by the refrigerant pressure sensor, located on the liquid tank The refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM if the system pressure rises above, or falls below the specifications ECM turns the A/C relay OFF and stops the compressor when pressure on the high-pressure side detected by the refrigerant pressure sensor is over approximately 3,119 kPa (31.19 bar, 31.8 kg/cm2, 452 psi) or below approximately 118 kPa (1.18 bar, 1.2 kg/cm2, 17 psi) Pressure Relief Valve The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor The release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere when the pressure of the refrigerant in the system increases to an unusual level [more than 3,600 kPa (36.0 bar, 36.7 kg/cm2, 522 psi)] Revision: 2008 December HA-6 J32 REFRIGERATION SYSTEM [MR20DE] < FUNCTION DIAGNOSIS > Component Parts Location INFOID:0000000003839503 A B C D E F G H HA J K JPIIA0990ZZ L Compressor Refrigerant pressure sensor Condenser Liquid tank M N O P Revision: 2008 December HA-7 J32 REFRIGERATION SYSTEM [MR20DE] < FUNCTION DIAGNOSIS > JPIIA1000ZZ Evaporator Expansion valve Blower motor Component Description INFOID:0000000003839504 Component Description Compressor Intakes, compresses, and discharges refrigerant, to circulate refrigerant inside the refrigerant cycle Condenser Cools refrigerant discharged from compressor, and transforms it to liquid refrigerant Liquid tank Eliminates foreign material in refrigerant, and temporarily stores liquid refrigerant Refrigerant pressure sensor Refer to EC-312, "Description" (MR TYPE 1) or EC-606, "Description" (MR TYPE 2) Evaporator The mist form liquid refrigerant transforms to gas through evaporation by the air conveyed from the blower motor The air is cooled by the heat from evaporation Expansion valve Transforms high-pressure liquid refrigerant to mist form from low-pressure liquid refrigerant by the drawing function Blower motor Takes in air from the vehicle or fresh outside air, provides it forcedly pushes it into to the air conditioner, and circulates it inside the vehicle Revision: 2008 December HA-8 J32 REFRIGERATION SYSTEM SYMPTOMS [MR20DE] < SYMPTOM DIAGNOSIS > SYMPTOM DIAGNOSIS A REFRIGERATION SYSTEM SYMPTOMS Trouble Diagnosis For Unusual Pressure INFOID:0000000003839505 Diagnose using a manifold gauge whenever the system’s high and/or low side pressure(s) is/are unusual The marker above the gauge scale in the following tables indicates the standard pressure range Refer to the above table (Ambient air temperature-to-operating pressure table) since the standard pressure, however, differs from vehicle to vehicle Symptom Table INFOID:0000000003839506 Gauge indication Both high- and low-pressure sides are too high AC359A Refrigerant cycle Probable cause Air suction by cooling fan is insufficient Insufficient condenser cooling performance ↓ Condenser fins are clogged Improper fan rotation of cooling fan • Clean condenser • Check and repair cooling fan if necessary Poor heat exchange in condenser (After compressor operation stops, high-pressure decreases too slowly) ↓ Air in refrigeration cycle Evacuate repeatedly and recharge system Engine cooling systems malfunction Check and repair each engine cooling system Engine tends to overheat D E Excessive refrigerant charge in refrigeration cycle (1.96 bar, kg/cm2, 28 psi) It then decreases gradually thereafter C Corrective action The pressure returns to normal and is reduced soon after water is splashed on condenser • Low-pressure pipe is not cold • When the compressor is stopped the high-pressure reading quickly drops by approximately 196 kPa B Reduce refrigerant until specified pressure is obtained F • Excessive liquid refrigerant on low-pressure side • Excessive refrigerant dis• An area of the low-pressure charge flow pipe is colder than areas • Expansion valve is slightly near the evaporator outlet open compared with the • Low-pressure pipe is somespecification times covered with frost ↓ Improper expansion valve adjustment G H HA J K L Replace expansion valve M N High-pressure side is too high and low-pressure side is too low Upper side of condenser and high-pressure side are hot, however, the liquid tank is not very hot High-pressure tube or parts located between compressor and condenser are clogged or crushed • Check and repair or replace malfunctioning parts • Check lubricant for contamination AC360A Revision: 2008 December HA-9 J32 O P REFRIGERATION SYSTEM SYMPTOMS [MR20DE] < SYMPTOM DIAGNOSIS > Gauge indication High-pressure side is too low and low-pressure side is too high Refrigerant cycle Probable cause High- and low-pressure sides become equal soon after compressor operation stops Compressor pressure operation is improper ↓ Damaged inside compressor packings Replace compressor No temperature difference between high- and low-pressure sides Compressor pressure operation is improper ↓ Damaged inside compressor packings Replace compressor • There is a big temperature difference between the liquid tank outlet and inlet Outlet temperature is extremely low • Liquid tank inlet and expansion valve are frosted Liquid tank inside is slightly clogged • Replace liquid tank • Check lubricant for contamination • Expansion valve inlet temperature is extremely low compared with areas near the liquid tank • Expansion valve inlet is frosted • Temperature difference occurs somewhere in highpressure side High-pressure pipe located between liquid tank and expansion valve is clogged • Check and repair malfunctioning parts • Check lubricant for contamination Expansion valve and liquid tank are warm or slightly cool when touched Low refrigerant charge ↓ Leaking fittings or components Check refrigerant for leakages Refer to HA-35, "Refrigerant Leakages" There is a big temperature difference between the expansion valve inlet and outlet while the valve itself is frosted Expansion valve slightly closes compared with the specification ↓ Improper expansion valve adjustment Malfunctioning expansion valve Outlet and inlet may be clogged • Remove foreign materials by using compressed air • Replace expansion valve • Check lubricant for contamination An area of the low-pressure pipe is colder than areas near the evaporator outlet Low-pressure pipe is clogged or crushed • Check and repair malfunctioning parts • Check lubricant for contamination Evaporator is frozen • Check intake sensor circuit Refer to HAC-55, "Diagnosis Procedure" • Replace compressor • Repair evaporator fins • Replace evaporator • Check blower motor circuit Refer to HAC-75, "Diagnosis Procedure" AC356A Both high and low-pressure sides are too low AC353A Air flow volume is not sufficient or is too low Revision: 2008 December Corrective action HA-10 J32 WINDSHIELD GLASS < ON-VEHICLE REPAIR > • The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes Never let them come in contact with skin or eyes • Use in an open, well ventilated location Never breathe the vapors They may be harmful if inhaled Move immediately to an area with fresh air if affected by vapor inhalation • Driving the vehicle before the urethane adhesive is completely cured may affect the performance of the windshield in case of an accident CAUTION: • Perform adjustment of front wiper arms stop location Refer to WW-112, "Adjustment" • Never use an adhesive which is past its usable term Shelf life of this product is limited to six months after the date of manufacture Carefully adhere to the expiration or manufacture date printed on the box • Keep primers and adhesive in a cool, dry place Ideally, they should be stored in a refrigerator • Never leave primers or adhesive cartridge unattended with their caps open or off • Never drive the vehicle within 24 hours or until the urethane adhesive is completely cured Curing time varies depending on temperature and humidity The curing time increases under lower temperature and lower humidity Inspection A B C D E INFOID:0000000003896376 F REPAIRING WATER LEAKAGE FOR WINDSHIELD Leakage can be repaired without removing the glass Determine the extent of leakage if water is leaking between the urethane adhesive material and body or glass This can be done by applying water to the windshield area while pushing glass outward Apply primer (if necessary) and then urethane adhesive to the leakage point to stop the leakage G H I J GW L M N O P Revision: 2008 December GW-13 J32 SIDE WINDOW GLASS < ON-VEHICLE REPAIR > SIDE WINDOW GLASS Exploded View INFOID:0000000003896377 JMKIA3031GB Side window glass assembly Primer Body side outer Clip Unit : mm (in) Adhesive Refer to GI-4, "Components" for symbols in the figure Removal and Installation INFOID:0000000003896378 REMOVAL Remove rear seatback and rear seat cushion Refer to SE-113, "Removal and Installation" Remove rear pillar finisher Refer to INT-39, "Removal and Installation" Apply protective tape around the side window to protect the painted surface from damage Remove side window glass using piano wire Revision: 2008 December GW-14 J32 SIDE WINDOW GLASS < ON-VEHICLE REPAIR > WARNING: Always wear safety glasses and heavy gloves to prevent injury CAUTION: • Be careful not to scratch the glass when removing • Never set or stand the glass on its edge Small chips may develop into cracks A B INSTALLATION • Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions provided with it • Open a door window while the urethane adhesive is curing This prevents the glass from being forced out by passenger room air pressure when all door windows are closed • The molding must be installed securely so that it is in position and leaves no clearance • Inform the customer that the vehicle should remain stationary until the urethane adhesive is completely cured (approximately 24 hours) Curing time varies with temperature and humidity WARNING: • Keep heat and open flames away as primers and adhesive are flammable • The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes Never let them come in contact with skin or eyes • Use in an open, well ventilated location Never breathe the vapors They may be harmful if inhaled Move immediately to an area with fresh air if affected by vapor inhalation • Driving the vehicle before the urethane adhesive is completely cured may affect the performance of the side window in case of an accident CAUTION: • Never use an adhesive which is past its usable term Shelf life of this product is limited to six months after the date of manufacture Carefully adhere to the expiration or manufacture date printed on the box • Keep primers and adhesive in a cool, dry place Ideally, they should be stored in a refrigerator • Never leave primers or adhesive cartridge unattended with their caps open or off • Never drive the vehicle within 24 hours or until the urethane adhesive is completely cured Curing time varies depending on temperature and humidity The curing time will increase under lower temperature and lower humidity Inspection INFOID:0000000003896379 C D E F G H I J Repairing Water Leakage for side window glass Leakage can be repaired without removing glass GW Determine the extent of leakage if water is leaking between the urethane adhesive material and body or glass This can be done by applying water to the side window glass area while pushing glass outward Apply primer (if necessary) and then urethane adhesive to the leakage point to stop the leakage L M N O P Revision: 2008 December GW-15 J32 REAR WINDOW GLASS < ON-VEHICLE REPAIR > REAR WINDOW GLASS Exploded View INFOID:0000000003896380 JMKIA2307GB Rear window glass Dam sealant rubber Spacer Roof Primer Adhesive Body side outer Parcel shelf Headlining assembly 10 Rear pillar finisher 11 Trunk lid outer Unit : mm (in) 12 Rear parcel shelf finisher Refer to GI-4, "Components" for symbols in the figure Removal and Installation INFOID:0000000003896381 REMOVAL Remove rear seatback and rear seat cushion Refer to SE-113, "Removal and Installation" Remove rear pillar finisher (LH/RH) Refer to INT-39, "Removal and Installation" Revision: 2008 December GW-16 J32 REAR WINDOW GLASS < ON-VEHICLE REPAIR > Remove rear parcel shelf finisher Refer to INT-43, "Removal and Installation" Remove partially the headlining assembly (rear edge) Refer to the following • For the normal roof Refer to INT-50, "NORMAL ROOF : Removal and Installation" • For sunroof (TYPE A) Refer to INT-54, "SUNROOF (TYPE A) : Removal and Installation" • For sunroof (TYPE B) Refer to INT-58, "SUNROOF (TYPE B) : Removal and Installation" Remove connectors and ground from the rear window defogger Remove glass using piano wire or power cutting tool (A) and an inflatable pump bag (B) after removing molding using pliers A B C D E PIIB5779E F NOTE: Mark the body and the glass with matching marks if the rear window glass is reused WARNING: Always wear safety glasses and heavy gloves to prevent injury CAUTION: • Never use a cutting knife or power cutting tool when the rear window glass is reused • Be careful not to scratch the glass when removing • Never set or stand the glass on its edge Small chips may develop into cracks G H INSTALLATION I • The dam sealant rubber should be installed in position • Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions provided with it • Open a door window while the urethane adhesive is curing This prevents the glass from being forced out by J passenger compartment air pressure when all door windows are closed • Inform the customer that the vehicle should remain stationary until the urethane adhesive is completely cured (approximately 24 hours) Curing time varies with temperature and humidity GW WARNING: • Keep heat and open flames away as primers and adhesive are flammable • The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes Never L let them come in contact with skin or eyes • Use in an open, well ventilated location Never breathe the vapors They may be harmful if inhaled Move immediately to an area with fresh air if affected by vapor inhalation • Driving the vehicle before the urethane adhesive is completely cured may affect the performance M of the rear window in case of an accident CAUTION: • Never use an adhesive which is past its usable term Shelf life of this product is limited to six months after the date of manufacture Carefully adhere to the expiration or manufacture date N printed on the box • Keep primers and adhesive in a cool, dry place Ideally, they should be stored in a refrigerator • Never leave primers or adhesive cartridge unattended with their caps open or off O • Never drive the vehicle within 24 hours or until the urethane adhesive is completely cured Curing time varies depending on temperature and humidity The curing time increases under lower temperature and lower humidity P Inspection INFOID:0000000003896382 REPAIRING WATER LEAKAGE FOR REAR WINDOW GLASS Leakage can be repaired without removing the glass Determine the extent of leakage if water is leaking between the urethane adhesive material and body or glass This can be done by applying water to the back door window glass area while pushing glass outward Apply primer (if necessary) and then urethane adhesive to the leakage point to stop the leakage Revision: 2008 December GW-17 J32 FRONT DOOR GLASS < ON-VEHICLE REPAIR > FRONT DOOR GLASS Exploded View INFOID:0000000003896383 JMKIA2309ZZ Front door glass run Front door glass Module base Power window motor Regulator assembly Front door inside seal Corner cover Front door panel : Clip : Vehicle front Removal and Installation INFOID:0000000003896384 REMOVAL Remove front door finisher • Driver side Refer to INT-30, "DRIVER SIDE : Removal and Installation" • Passenger side Refer to INT-33, "PASSENGER SIDE : Removal and Installation" Remove front door corner cover Refer to MIR-21, "DOOR MIRROR ASSEMBLY : Removal and Installation" Remove front door inside seal Remove both seals (A) as shown in the figure JMKIA2310ZZ Revision: 2008 December GW-18 J32 FRONT DOOR GLASS < ON-VEHICLE REPAIR > Reconnect the power window main switch and then operate the power window main switch to raise or lower the door window until the glass mounting bolts can be seen Remove the front door glass mounting bolts A B : Bolt C JMKIA2311ZZ Hold securely the front door glass and pull it out of the sash to remove the door glass D E F G JMKIA0626ZZ H INSTALLATION Install in the reverse order of removal Inspection and Adjustment INFOID:0000000003896385 I SYSTEM INITIALIZATION J Initialize the system if any of the following work has been done • Electric power supply to power window switch or motor is interrupted by blown fuse or disconnecting battery cable, etc • Removal and installation of the regulator assembly GW • Removal and installation of the motor from the regulator assembly • Removal and installation of the harness connector of the power window switch • Removal and installation of the door glass L • Removal and installation of the front door glass run • Disconnection and connection of the minus terminal of the battery Initialization Follow the steps below after installing each component to the vehicle Disconnect the minus terminal of battery or disconnect power window switch harness connector temporarily Then reconnect after at least minute Turn ignition switch ON Operate power window switch to open the window full width Draw fully the power window switch in the up direction (auto close position) and hold Continue holding the switch even when window is completely closed and then release after more than seconds Inspect the anti-pinch system function NOTE: Initialization may be cancelled with continuous opening and closing operation In this case, initialize the system INSPECT THE FUNCTION OF THE ANTI-PINCH SYSTEM Fully open the door glass Place a wooden piece (wooden hammer handle, etc.) at near fully closed position Perform fully closing operation with auto up switch Revision: 2008 December GW-19 J32 M N O P FRONT DOOR GLASS < ON-VEHICLE REPAIR > • Check that the glass reverses without pinching the wooden piece, is lowered approximately 150 mm (5.906 in) or for more than seconds and then stops • The glass should not be raised with power window main switch operated while it is reversing or lowering CAUTION: • Be careful not to be pinched • When performing the inspection after the system initialization, check that the auto up function is normal Then, start the inspection FITTING INSPECTION • Check that the glass is fit securely into the sash groove • Lower the glass slightly [approximately 10 to 20 mm (0.394 to 0.787 in)], and check that the clearance to the sash is parallel Loosen the regulator mounting bolts, guide rail mounting bolts, and glass and guide rail mounting bolts to correct the glass position if the clearance between the glass and sash is not parallel Revision: 2008 December GW-20 J32 FRONT REGULATOR < ON-VEHICLE REPAIR > FRONT REGULATOR A Exploded View INFOID:0000000003896386 B C D E F G H I JMKIA2309ZZ Front door glass run Front door glass Module base Power window motor Regulator assembly Front door inside seal Corner cover Front door panel J : Clip GW : Vehicle front Removal and Installation INFOID:0000000003896387 L REMOVAL M Remove front door glass Refer to GW-18, "Removal and Installation" Disconnect the power window motor harness connector (1) and remove the bolts from the module assembly N : Bolt O P JMKIA2312ZZ Revision: 2008 December GW-21 J32 FRONT REGULATOR < ON-VEHICLE REPAIR > Remove the harnesses fixing clips shown by the arrows in the figure with a tool from the module assembly (2) Disconnect the regulator motor harness connector (1) : Clip JMKIA2313ZZ Remove the door module assembly from door panel Remove front door glass run INSTALLATION Install in the reverse order of removal Disassembly and Assembly INFOID:0000000003896388 DISASSEMBLY Remove the power window motor from the module assembly Remove the regulator assembly mounting bolts, then remove the regulator assembly ASSEMBLY Assemble in the reverse order of disassembly Inspection and Adjustment INFOID:0000000003896389 Inspection after Removal Check the regulator assembly for the following items Replace it if a malfunction is detected • Wire wear • Regulator deformation SYSTEM INITIALIZATION Initialize the system if any of the following work has been done • Electric power supply to power window switch or motor is interrupted by blown fuse or disconnecting battery cable, etc • Removal and installation of the regulator assembly • Removal and installation of the motor from the regulator assembly • Removal and installation of the harness connector of the power window switch • Removal and installation of the door glass • Removal and installation of the front door glass run • Disconnection and connection of the minus terminal of battery Initialization Follow the steps below after installing each component to the vehicle Disconnect the minus terminal of battery or disconnect power window switch harness connector temporarily Then reconnect after at least minute Turn ignition switch ON Operate power window switch to open the window full width Draw fully the power window switch in the up direction (auto close position) and hold Continue holding the switch even when window is completely closed and then release after more than seconds Inspect the anti-pinch system function NOTE: Initialization may be cancelled with continuous opening and closing operation In this case, initialize the system INSPECT THE FUNCTION OF THE ANTI-PINCH SYSTEM Fully open the door glass Revision: 2008 December GW-22 J32 FRONT REGULATOR < ON-VEHICLE REPAIR > Place a wooden piece (wooden hammer handle, etc.) at near fully closed position Perform fully closing operation with auto up switch • Check that the glass reverses without pinching the wooden piece, is lowered approximately 150 mm (5.906 in) or for more than seconds and then stops • The glass should not be raised with power window main switch operated while it is reversing or lowering CAUTION: • Be careful not to be pinched • When performing the inspection after the system initialization, check that the auto up function is normal Then, start the inspection FITTING INSPECTION • Check that the glass is fit securely into the sash groove • Lower the glass slightly [approximately 10 to 20 mm (0.394 to 0.787 in)], and check that the clearance to the sash is parallel Loosen the regulator mounting bolts, guide rail mounting bolts, and glass and guide rail mounting bolts to correct the glass position if the clearance between the glass and sash is not parallel A B C D E F G H I J GW L M N O P Revision: 2008 December GW-23 J32 REAR DOOR GLASS < ON-VEHICLE REPAIR > REAR DOOR GLASS Exploded View INFOID:0000000003896390 JMKIA2315ZZ Rear door glass run Corner piece assembly Power window motor Regulator assembly Rear door glass Rear door inside seal Sealing screen Rear door panel : Vehicle front Removal and Installation INFOID:0000000003896391 REMOVAL Remove rear door finisher Refer to INT-36, "Removal and Installation" Remove rear door inside seal Remove partially the sealing screen (1) with a cutter knife NOTE: Cut the butyl-tape so that no parts of the butyl-tape remain on the sealing screen, if the sealing screen is reused JMKIA2316ZZ Revision: 2008 December GW-24 J32 REAR DOOR GLASS < ON-VEHICLE REPAIR > Remove the bolt fixing the corner piece assembly lower side to the door panel as shown in the figure A : Bolt B C JMKIA2317ZZ D Remove partially the door side weather strip, then remove both screws fixing the corner piece assembly (1) upper side to the door panel as shown in the figure with a screwdriver (A) E : Screw F G JMKIA1952ZZ Remove the corner piece assembly from the glass upper side Reconnect the rear door power window switch Operate the power window switch to raise or lower the door window until the glass mounting bolts can be seen Remove the rear door glass mounting bolts H I : Bolt J GW JMKIA1789ZZ L 10 Remove the rear door glass from inside or outside of door panel M N JMKIA0640ZZ O INSTALLATION Install in the reverse order of removal P Inspection and Adjustment INFOID:0000000003896392 FITTING INSPECTION • Check that the glass is fit securely into the sash groove • Lower the glass slightly [approximately 10 to 20 mm (0.394 to 0.787 in)], and check that the clearance to the sash is parallel Loosen the regulator mounting bolts, guide rail mounting bolts, and glass and carrier plate mounting bolts to correct the glass position if the clearance between the glass and sash is not parallel Revision: 2008 December GW-25 J32 REAR REGULATOR < ON-VEHICLE REPAIR > REAR REGULATOR Exploded View INFOID:0000000003896393 JMKIA2315ZZ Rear door glass run Corner piece assembly Power window motor Regulator assembly Rear door glass Rear door inside seal Sealing screen Rear door panel : Vehicle front Removal and Installation INFOID:0000000003896394 REMOVAL Remove rear door glass Refer to GW-24, "Removal and Installation" Remove the regulator mounting bolts (B), the nuts (A), disconnect the power window motor harness connector (C) and then remove the regulator assembly from the door panel JMKIA2989ZZ Remove the rear door glass run Revision: 2008 December GW-26 J32 REAR REGULATOR < ON-VEHICLE REPAIR > INSTALLATION Install in the reverse order of removal A Disassembly and Assembly INFOID:0000000003896395 B DISASSEMBLY Remove power window motor from regulator assembly ASSEMBLY C Assemble in the reverse order of disassembly Inspection and Adjustment INFOID:0000000003896396 D Inspection after Removal Check the regulator assembly for the following items Replace or grease it if a malfunction is detected • Wire wear • Regulator deformation The arrows in the figure show the application points of the multi-purpose grease E F : Grease application point G H JMKIA2318ZZ I FITTING INSPECTION • Check that the glass is fit securely into the sash groove • Lower the glass slightly [approximately 10 to 20 mm (0.394 to 0.787 in)], and check that the clearance to the sash is parallel Loosen the regulator mounting bolts, guide rail mounting bolts, and glass and carrier plate mounting bolts to correct the glass position if the clearance between the glass and sash is not parallel J GW L M N O P Revision: 2008 December GW-27 J32